240K-C2-OT-05-002-Rev.00

W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc

SOCIEDAD MINERA CERRO VERDE S.A.A. CERRO VERDE PRODUCTION UNIT EXPANSION

PROJECT NO. A6CV

SITE QUALITY MANUAL

DOCUMENT NO. 240K-C2-OT-05-002 REV. 0

19 JUNE 2013

W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc

Sociedad Minera Cerro Verde S.A.A. Document No. 240K-C2-OT-05-002 Cerro Verde Production Unit Expansion Revision 0 Project No. A6CV

SITE QUALITY MANUAL

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Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 0000 Project No. A6CV Revision 0, 10 June 2103

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TABLE OF CONTENTS / DATE REVISION PAGE

Administrative Procedure No.

Title Revision Date

000 509 0000 Table of Contents / Date Revision Page 10 June 13 000 509 0010 Foreword 10 June 13 000 509 0020 Manual Preparation and Maintenance 10 June 13 000 509 0040 Organization and Responsibilities 10 June 13 000 509 0050 Document Control 10 June 13 000 509 0090 Process Control 10 June 13 000 509 0110 Inspection, Measuring and Test Equipment 10 June 13 000 509 0130 Control of Nonconformances 10 June 13 000 509 0140 Corrective Action 10 June 13 000 509 0150 Preventive Action 10 June 13 000 509 0160 Quality Records 10 June 13 000 509 0170 Quality Audits 10 June 13 000 509 0180 Personnel Training and Qualification 10 June 13 000 509 0200 Site Subcontractor Qualification 10 June 13 000 509 0210 Contractor Quality Requirements 10 June 13 000 509 0220 Surveillance of Construction Activities 10 June 13 000 509 0230 Field Receiving Inspection 10 June 13 000 509 0240 Turnover 10 June 13 000 509 0250 Material & Equipment Storage & Maintenance 10 June 13 000 509 5100 Activity Plan for Construction 10 June 13

Inspection and Test Procedure

No. Title Revision Date

000 509 7000 Inspection and Testing 10 June 13 000 509 7010 Soils 10 June 13 000 509 7020 Bituminous Concrete Paving 10 June 13 000 509 7030 Pilling - Steel H - Piles 10 June 13 000 509 7040 Piling – Pre-Cast Concrete Piles 10 June 13 000 509 7050 Piling - Timber Piles VOID 000 509 7060 Piling - Closed End Concrete Filled Pipe Piles VOID 000 509 7070 Piling - Concrete Filled Thin Shell Pipe Piles VOID 000 509 7080 Drilled Caissons VOID 000 509 7090 Augered Cast-In-Place Piles 10 June 13 000 509 7100 Concrete and Grout 10 June 13 000 509 7200 Structural Steel 10 June 13 000 509 7300 Buildings 10 June 13 000 509 7310 Heating Ventilating and Air Conditioning 10 June 13 000 509 7320 Roofing Inspection 10 June 13 000 509 7400 Equipment 10 June 13


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Inspection and Test Procedure

No. Title Revision Date

000 509 7410 Field Fabricated Tanks 10 June 13 000 509 7420 Cooling Tower VOID 000 509 7430 Refractory Concrete VOID 000 509 7440 Gas Turbine/Generator VOID 000 509 7460 Steam Turbine/Generator VOID 000 509 7470 Generator Testing VOID 000 509 7500 Underground Piping 10 June 13 000 509 7510 Aboveground Piping 10 June 13 000 509 7520 Pressure Testing 10 June 13 000 509 7550 Hygienic Tubing VOID 000 509 7560 Chemical Cleaning of Pipe 10 June 13 000 509 7570 Steam Tracing for Pipe and Equipment VOID 000 509 7600 Electrical Inspection 10 June 13 000 509 7610 Electrical Testing 10 June 13 000 509 7620 Electrical Equipment 10 June 13 000 509 7640 Electrical Heat Tracing VOID 000 509 7700 Control Systems Instrumentation 10 June 13 000 509 7710 Control System Calibration 10 June 13 000 509 7800 Coatings and Linings 10 June 13 000 509 7810 Insulation 10 June 13 000 509 7820 Fireproofing Inspection 10 June 13 000 509 7830 Cathodic Protection 10 June 13 000 509 7910 Welding Inspection 10 June 13 000 509 7920 Nondestructive Examination 10 June 13 000 509 7930 Positive Material Identification 10 June 13 000 509 7950 Hardness Testing 10 June 13 000 509 F0000 Quality Control Forms 10 June 13 The Fluor Site Quality Program for this Project is described and documented in this Site Quality Manual.

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality ManualCerro Verde Production Unit Expansion 000 509 F0000Project No. A6CV Revision 0, 10 June 2013

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FORMS INDEX

Form Number Form Title Revision Date

000.509.F00501 Request For Information 10 June 13

000.509.F00502 Request For Information Log 10 June 13

10 June 13

000.509.F01101 Calibration Assignment Log and Record 10 June 13

000.509.F01102 I.M.T.E. Sign In/Out History of Use Log 10 June 13

000.509.F01103 Calibrations Tickler File 10 June 13

000.509.F01104 Calibration Data Sheet 10 June 13

10 June 13

000.509.F01301 Nonconformance Report 10 June 13

000.509.F01302 Nonconformance Report Log 10 June 13

000.509.F01303 Hold Tag/Sticker 10 June 13

10 June 13

000.509.F01401 Corrective Action Report 10 June 13

000.509.F01402 Corrective Action Status Log 10 June 13

10 June 13

000.509.F01501 Preventive Action Log 10 June 13

10 June 13

000.509.F01601 Quality Records Control 10 June 13

10 June 13

000.509.F01701 Audit Finding 10 June 13

000.509.F01702 Audit Summary 10 June 13

10 June 13

000.509.F01801 Project Specific Quality Training 10 June 13

10 June 13

000.509.F02001 Site Subcontractor Qualification 10 June 13

000.509.F02002 Soil Testing Laboratory Evaluation Record 10 June 13

000.509.F02003 Asphalt Testing Laboratory Evaluation Record 10 June 13

000.509.F02004 Concrete Batch Plant Evaluation Record 10 June 13

000.509.F02005 Concrete Testing Laboratory Evaluation Record 10 June 13

000.509.F02006 NDE Subcontractor Evaluation Record 10 June 13

10 June 13

000.509.F02201 Surveillance Report 10 June 13

000.509.F02202 Surveillance Report Log 10 June 13

10 June 13

000.509.F02301 Receiving Inspection Checklist 10 June 13

10 June 13

000.509.F02401 Transfer of Care, Custody and Control (Turnover Notice) 10 June 13

000.509.F02402 System Walkdown Notice 10 June 13

000.509.F02403 Mechanical Completion Civil Checklist 10 June 13

000.509.F02404 Mechanical Completion Electrical/Instrumentation Checklist 10 June 13

000.509.F02405 Mechanical Completion/Mechanical Checklist 10 June 13



FORMS INDEX


000.509.F02406 Mechanical Completion/Quality Control Checklist 10 June 13

000.509.F02407 Master Punch List Record 10 June 13

000.509.F02408 Interim Turnover Notice 10 June 13

000.509.F02409 Mechanical Completion Certificate 10 June 13

10 June 13

000.509.F02501 Storage Inspection Checklist 10 June 13

000.509.F02502 Equipment Protection Preservation and Inspection Record 10 June 13

000.509.F70001 Inspection and Test Plan 10 June 13

000.509.F70002 Inspection and Test Plan 10 June 13

000.509.F70101 Soil Inspection Checklist 10 June 13

000.509.F70102 Field Compaction Test Record 10 June 13

000.509.F70103 Density of Soil Place by the Sand-Cone Method ASTM D-1566 AASHTO-T-191

10 June 13

000.509.F70104 Nuclear Moisture-Density Test Report 10 June 13

000.509.F70105 Soil Density Test Log 10 June 13

10 June 13

000.509.F70201 Bituminous Concrete Paving Inspection Checklist 10 June 13

000.509.F70202 Bulk Specific Gravity 10 June 13

000.509.F70204 Nuclear Density Test Report – Bituminous Concrete 10 June 13

10 June 13

000.509.F70301 Pile Driving Inspection Record 10 June 13

000.509.F70302 Pile Driving Record 10 June 13

000.509.F70303 Record of Pile Driving 10 June 13

000.509.F70801 Caisson Inspection Record VOID

000.509.F70901 Augered Cast-In-Place Pile Record 10 June 13

000.509.F71001 Pre-Concrete Inspection Checklist 10 June 13

000.509.F71002 Concrete Inspection Record VOID

000.509.F71003 Concrete Pour Card 10 June 13

000.509.F71004 Cementitious Grout Inspection Record 10 June 13

000.509.F71005 Cementitious Grout Testing Record 10 June 13

000.509.F71006 Epoxy Resin Grout Inspection Record 10 June 13

000.509.F71007 Concrete Compression Strength Test Record 10 June 13

000.509.F71008 Concrete Placement Log 10 June 13

000.509.F71009 Grout Placement Log 10 June 13

000.509.F71010 Concrete Batch Plant Inspection Record 10 June 13



FORMS INDEX


000.509.F72002 Structural Steel Inspection 10 June 13

000.509.F72003 Torque Wrench Calibration Log 10 June 13

000.509.F73001 Building Inspection and Test Checklist 10 June 13

000.509.F73002 Final Building Inspection Summary 10 June 13

000.509.F73003 Carpentry Checklist 10 June 13

000.509.F73004 Painting Checklist 10 June 13

000.509.F73005 Plumbing Checklist 10 June 13

000.509.F73006 Ceramic Tile Checklist 10 June 13

000.509.F73007 Concrete Checklist 10 June 13

000.509.F73008 Structural Steel Checklist 10 June 13

000.509.F73009 Masonry (Brickwork) Checklist 10 June 13

000.509.F73010 Plaster Checklist 10 June 13

000.509.F73011 Doors, Windows, Hardware, Glazing Checklist 10 June 13

000.509.F73012 Computer (Raised) Floors Checklist 10 June 13

000.509.F73013 Prefab Wall Element Systems Checklist 10 June 13

000.509.F73014 Building Metal Siding And Roofing Checklist 10 June 13

000.509.F73015 Buildings Water Proofing And Damp Proofing Checklist 10 June 13

000.509.F73016 Suspended Ceiling Checklist 10 June 13

000.509.F73101 HVAC Inspection Record 10 June 13

000.509.F73102 Buildings Air Conditioning Checklist 10 June 13

000.509.F73201 Roofing Inspection Checklist 10 June 13

000.509.F74001 Equipment Installation Checklist 10 June 13

000.509.F74002 Heat Exchangers & Reboilers Installation Record VOID

000.509.F74003 Electrostatic Precipitator Checklist VOID

000.509.F74004 Inspection Record Static Equipment 10 June 13

000.509.F74005 Tray Installation Inspection Record 10 June 13

000.509.F74006 Air Cooled Heat Exchanger Inspection Checklist VOID

000.509.F74007 Air Cooler Run In Test Report VOID

000.509.F74008 Reciprocating Compressor Inspection Record 10 June 13

000.509.F74009 Fan Installation Inspection Checklist 10 June 13

000.509.F74010 Furnaces Inspection Record VOID

000.509.F74011 Fuel Gas Steam Generator Inspection Checklist VOID

000.509.F74012 Steam Turbine Inspection Checklist VOID

000.509.F74013 Agitators/Mixers Inspection Checklist 10 June 13

000.509.F74014 Equipment/Piping Strain and Alignment Inspection Form 10 June 13

000.509.F74015 Installation Checklist Travelling Cranes 10 June 13

000.509.F74016 Package Equipment Installation Checklist 10 June 13



FORMS INDEX


000.509.F74017 Desuperheaters/Ejectors Inspection Checklist VOID

000.509.F74018 Filters/Strainers Installation Record 10 June 13

000.509.F74019 Centrifugal Compressor Inspection Record 10 June 13

000.509.F74020 Rotating Equipment Inspection Record 10 June 13

000.509.F74021 Rotating Equipment Alignment Record 10 June 13

000.509.F74022 Belt Driven Equipment Alignment Record 10 June 13

000.509.F74024 Inspection Record For Draw Off Tray Leak Test Report 10 June 13

000.509.F74025 Inspection Record For Air Coolers 10 June 13

000.509.F74026 Final Closing Authorization Record 10 June 13

000.509.F74027 API 686 Baseplate Installation Checklist (Prior to Grouting) 10 June 13

000.509.F74028 API 686 Equipment Grouting Checklist 10 June 13

000.509.F74029 API 686 Alignment Check Sheet 10 June 13

000.509.F74030 Baseplate Leveling Record 10 June 13

000.509.F74031 Reverse Dial Alignment Record 10 June 13

000.509.F74032 Piping Alignment Data Sheet 10 June 13

000.509.F74033 Rotating Equipment (Face-Rim) Alignment Record 10 June 13

000.509.F74101 Tank Elevation Tolerances Record 10 June 13

000.509.F74102 Inspection Record Field Erected Tank 10 June 13

000.509.F74103 Tank Plate Dimensional Control Record Field Erected Tank 10 June 13

000.509.F74104 Water Filling And Settlement Record Field Erected Tank 10 June 13

000.509.F74105 Tank Leak Test Record 10 June 13

000.509.F74106 Tank Test Certificate 10 June 13

000.509.F74201 Inspection Record Cooling Tower VOID

000.509.F74301 Field Installed Refactory Record VOID

000.509.F74401 Gas Turbine/Generator Gear Inspection Checklist VOID

000.509.F74402 Gas Turbine Inspection Record VOID

000.509.F74405 Shop-Fabricated Field-Erected Stack Inspection Record VOID

000.509.F74406 Heat Recovery Steam Generator Inspection Record VOID

000.509.F74407 Breeching And Duct Work Inspection Record VOID

000.509.F74408 Equipment Protection Activities Record – Gas Turbines VOID

000.509.F74601 Site Daily Activities Log VOID

000.509.F74602 Stg Foundation Settlement Record VOID

000.509.F74603 Stg Fixators VOID

000.509.F74604 Stg Sole Plates VOID

000.509.F74605 Stg Front Standard Base Plate Assembly VOID

000.509.F74606 Exhaust Hood Horizontal Joint Levelness VOID



FORMS INDEX


000.509.F74607 Stg Shell/Casing Load Test VOID

000.509.F74608 Stg Piping Attachment VOID

000.509.F74609 Stg Foundation Top of Concrete Elevations VOID

000.509.F74701 Generator Test Checklist VOID

000.509.F74702 Generator Cold Resistance Test Record VOID

000.509.F75001 Underground Pipe Inspection Record 10 June 13

000.509.F75002 Insulation Resistance (Insulated Flanges-Underground Piping) Test Record

10 June 13

000.509.F75003 Holiday (Spark) Test Record 10 June 13

000.509.F75101 Aboveground Pipe Inspection Record 10 June 13

000.509.F75102 Visual Inspection of Flanges, Gaskets and Bolting 10 June 13

000.509.F75103 Weld Map Record 10 June 13

000.509.F75201 Pressure Test Report 10 June 13

000.509.F75501 Hygienic Drawing Revision Log VOID

000.509.F75502 Hygienic Material Receiving Log VOID

000.509.F75503 Hygienic Valve Receiving Inspection Report VOID

000.509.F75504 Hygienic Vessel Nozzle Receiving Inspection Report VOID

000.509.F75505 Hygienic Tube/Fitting Receiving Inspection Report VOID

000.509.F75506 Hygienic Pre-weld Inspection Checklist VOID

000.509.F75507 Hygienic Welder Qualification Report VOID

000.509.F75508 Hygienic Orbital Weld Log VOID

000.509.F75509 Hygienic Post Installation Checklist VOID

000.509.F75601 Pipe Cleaning and Verification Checklist 10 June 13

000.509.F75701 Mechanical Heat Tracing Inspection Record VOID

000.509.F76001 Conduit And Cable Tray Checklist 10 June 13

000.509.F76002 Electrical Manhole Inspection Checklist 10 June 13

000.509.F76003 Medium & High Voltage Underground Cable Splice Inspection Record

10 June 13

000.509.F76004 Medium and High Voltage Cable Termination Checklist 10 June 13

000.509.F76005 Cable Pulling Inspection Checklist 10 June 13

000.509.F76006 Fan/Speed Reducer/Motor Inspection Checklist 10 June 13

000.509.F76007 Switch House Inspection Checklist 10 June 13

000.509.F76008 Lighting Receptacle, Instrument Distribution Panels Inspection Checklist

10 June 13



FORMS INDEX


000.509.F76009 Electrical Motor Inspection Checklist 10 June 13

000.509.F76010 Aboveground Conduit Inspection Checklist 10 June 13

000.509.F76011 Lighting Panelboard Inspection Record 10 June 13

000.509.F76012 Underground Conduit (Duct Bank) Inspection 10 June 13

000.509.F76013 Grounding/Earthing System (Grid or Loop) Inspection Record 10 June 13

000.509.F76014 Cable Termination Checklist 10 June 13

10 June 13

000.509.F76101

Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record

10 June 13

000.509.F76102 Insulation Resistance (Power, Control Wire And Cable) Test Record

10 June 13

000.509.F76103 Insulation Resistance (Instrument Wire And Cable) Test Record 10 June 13

000.509.F76104 DC High Potential Test (Medium Voltage Cable) Record 10 June 13

000.509.F76105 Current Transformer (And Ammeter) Test Record 10 June 13

000.509.F76106 LV Over-current And Earth/Ground-Fault Protection Relay Test 10 June 13

000.509.F76107 Over-current/Ground Fault Protection Relay (Induction Type) Test 10 June 13

000.509.F76108 Over-current/Ground Fault Protection Relay (Thermal Type) Test 10 June 13

000.509.F76109 Switching Units HV Switchgear Inspection And Test Record 10 June 13

000.509.F76110 Ground Electrode Resistance Inspection Test Record 10 June 13

000.509.F76111 Ground Fault Protection Relay Induction Inspection and Test Record

10 June 13

000.509.F76112 Grounding Continuity Inspection and Test Record 10 June 13

000.509.F76113 Grounding Rod Inspection and Test Record 10 June 13

000.509.F76114 Bus Bar Assemblies LV Switchgear Test Record 10 June 13

000.509.F76115 Neutral Grounding/Earthing Resistor Test Record 10 June 13

000.509.F76116 Ground Continuity (Non Electrical) Equipment/Structures Test Record

10 June 13

000.509.F76117 Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record

10 June 13

000.509.F76118 Insulation Resistance (Equipment) Test Record 10 June 13

000.509.F76119 Insulation Resistance (Transformer) Test Record 10 June 13

000.509.F76120 Liquid Dielectric Strength Test Record 10 June 13

000.509.F76121 DC Proof Test Record for Motors 10 June 13

000.509.F76122 Feeder Breaker (480V MCC) Test Record 10 June 13

000.509.F76123 Breaker/Contractor (480V MCC) Test Record 10 June 13

000.509.F76124 460V Motor Circuit (480V MCC) Test Record 10 June 13

000.509.F76125 Medium Voltage Motor Circuit Test Record 10 June 13

000.509.F76126 Equipment Absorption Ration and Polarization Index Test Record (Megger)

10 June 13

000.509.F76127 Insulation Resistance (Medium Voltage Power Cables) Test Record

10 June 13

000.509.F76128 Bus Throat Insulation and Ductor Reports 10 June 13

000.509.F76129 Circuit Breaker Contract Timing Test Report 10 June 13



FORMS INDEX


000.509.F76130 Vacuum Circuit Breaker Ductor Insulation Report 10 June 13

000.509.F76131 Drawout Vacuum Breaker Inspection Test 10 June 13

000.509.F76132 Main Bus Insulation and Ductor Report 10 June 13

000.509.F76133 Electric Motor Run-In Test Record 10 June 13

000.509.F76134 Drawout Air Circuit Breaker Inspection Record 10 June 13

000.509.F76135 Insulation Resistance (Rotating Equipment) Test Record 10 June 13

000.509.F76201 Emergency Generators Inspection Checklist 10 June 13

000.509.F76202

Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units)

10 June 13

000.509.F76203 Inspection LV Switchgear (Including Incoming and Sectionalizer Units)

10 June 13

000.509.F76204 Inspection of Outgoing – LV Switchgear 10 June 13

000.509.F76205 Inspection of Static Supply Unit (UPS) 10 June 13

000.509.F76206 Motor Control Centers Inspection Checklist 10 June 13

000.509.F76207 Motor Control Centers (Motors and Starters) Inspection Record 10 June 13

000.509.F76208 High Voltage Motors and Starters 10 June 13

000.509.F76209 Motors Checklist 10 June 13

000.509.F76210 Control and Relay Panels Inspection Checklist 10 June 13

000.509.F76211 Electronic Equipment Inspection Checklist 10 June 13

000.509.F76212 Power Panel Inspection Checklist 10 June 13

000.509.F76213 Switchgear Inspection Checklist 10 June 13

000.509.F76214 Low Voltage Feeders Inspection Record 10 June 13

000.509.F76215 High Voltage Cable Inspection and Test Record 10 June 13

000.509.F76216 Electrical Equipment Inspection Record 10 June 13

000.509.F76217 Control Scheme Inspection Checklist 10 June 13

000.509.F76218 Power Transformer Inspection Checklist 10 June 13

000.509.F76219 Switching Units – HV Switchgear Inspection and Test Record 10 June 13

000.509.F76220 Switching Units – HV Switchgear Inspection Checklist 10 June 13

000.509.F76221 Liquid – Filled Transformer Inspection Record 10 June 13

000.509.F76222 Busway Inspection Record 10 June 13

000.509.F76223 Switchgear Inspection Record 10 June 13

000.509.F76224 Motor Control Center Inspection Record 10 June 13

000.509.F76225 Battery and Battery Charger Inspection Record 10 June 13

000.509.F76226 Liquid Immersed Medium Voltage Disconnect Switch Inspection Record

10 June 13

000.509.F76227 Electric Motor – Electrical Activities Inspection Record 10 June 13

000.509.F76228 Electric Motor – Mechanical Activities Inspection Record 10 June 13

000.509.F76229 Electric Motor for Compressor Installation Checklist 10 June 13

000.509.F76230 Compressor Vibration Checklist 10 June 13

000.509.F76231 Vibration Probe Record 10 June 13



FORMS INDEX


000.509.F76232 Dry Type Lighting, Receptacle & Instrument Transformers Checklist

10 June 13

000.509.F76233 Instrument Wire and Cables Continuity Checks >50VDC 10 June 13

000.509.F76401 Heat Trace Test Log VOID

000.509.F76402 Electrical Heat Trace Inspection Record VOID

000.509.F77001 Instrumentation Inspection Checklist 10 June 13

000.509.F77002 Instrument Loop Checklist Inspection 10 June 13

000.509.F77003 Impulse Line Pressure Test Sheet 10 June 13

000.509.F77004 Instrument Grounding System Check Sheet 10 June 13

000.509.F77005 Installation Check Sheet (Local Instruments) 10 June 13

000.509.F77006 Orifice Plate Specification Check Report 10 June 13

000.509.F77007 Control Systems Quality 10 June 13

000.509.F77008 Loop Check Record 10 June 13

000.509.F77101 Instrument Calibration Sheet 10 June 13

000.509.F77102 Safety Valve Tracking Sheet 10 June 13

000.509.F77103 Relief Valve Inspection and Final Acceptance 10 June 13

000.509.F77104 Switch Calibration Data Record 10 June 13

000.509.F77105 Valve Calibration Data Record 10 June 13

000.509.F77106 Control System Test Equipment Calibration Log 10 June 13

000.509.F77107 Loop Mechanical Completions & Acceptance Record 10 June 13

000.509.F78001 Coating Inspection Record 10 June 13

000.509.F78002 Lining Inspection Record 10 June 13

000.509.F78101 Equipment Thermal Insulation Inspection 10 June 13

000.509.F78102 Piping Thermal Insulation Record 10 June 13

000.509.F78201 Release For Application/Inspection Of Fireproofing Checklist 10 June 13

000.509.F78202 Fireproofing Inspection Preconstruction Checklist 10 June 13

000.509.F78301 Cathodic Protection Inspection Report 10 June 13

000.509.F79001 Daily Welding Report 10 June 13

000.509.F79002 Post Weld Heat Treatment Log 10 June 13

000.509.F79201 Welder B31.3 Random Radiography Control Log 10 June 13

000.509.F79202 Nondestructive Examination Request/Record 10 June 13

000.509.F79203 Radiographic Rejectable Defects Statistics 10 June 13



FORMS INDEX


000.509.F79204 Welding/NDE Status Log 10 June 13

000.509.F79205 Ferrite Test Report 10 June 13

000.509.F79206 Welding/NDE Double Joints Status Log 10 June 13

000.509.F79301 PMI Inspection Record 10 June 13

000.509.F79302 Bulk Material Positive Material Identification Record 10 June 13

000.509.F79303 Pipe Spool Positive Material Identification Record “Point” Sheet 10 June 13

000.509.F79304 Weekly PMI Log 10 June 13

000.509.F79501 Verification Of Training For Hardness Testing 10 June 13

000.509.F79502 Report Of Vision Test 10 June 13

000.509.F79503 Hardness Testing Report 10 June 13



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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.


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The Project Procedures Manual (PPM), 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.

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 0020 Project No. A6CV Revision 0 , 10 June 2013

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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 000.509.0200and 000.509.0210). 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.

- Table of Contents / Date Revision Page (0000); Under "Procedure Number" and "Title"

change to include only those procedures used in the project manual.

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 0020 Project No. A6CV Revision 0 , 10 June 2013

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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.


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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 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. 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



Quality Responsibility Matrix

Section 1 - CIVIL

1.1 Construction Surveying RESPONSIBILITY

ACTIVITY Construction QA/QC

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 RESPONSIBILITY


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 RESPONSIBILITY


Qualify 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

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



1.4 Asphalt RESPONSIBILITY


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 RESPONSIBILITY


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 RESPONSIBILITY


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 placement procedures and documentation requirement.

X

Conduct grout testing at site TEST LAB S




Section 2 - STRUCTURAL STEEL

2.1 Structural Steel RESPONSIBILITY


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 RESPONSIBILITY


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 building 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




Section 4 - EQUIPMENT

4.1 Equipment RESPONSIBILITY

ACTIVITY Construction QA/QC 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. Site requirements. X

Monitor the Contractor's quality control activities to verify conformance to inspection, testing and documentation requirements.

X

4.2 Field Fabricated Tanks RESPONSIBILITY


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 inspection, testing and documentation requirements.

X

Witness hydrostatic testing S X




Section 5 - PIPING

5.1 Underground Piping RESPONSIBILITY


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 RESPONSIBILITY


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




5.3 Aboveground Piping Erection RESPONSIBILITY


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 RESPONSIBILITY


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




5.5 Pressure Testing of Piping RESPONSIBILITY


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 RESPONSIBILITY


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




Section 6 - ELECTRICAL

6.1 Underground Electrical RESPONSIBILITY


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, i.e,. 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 RESPONSIBILITY

ACTIVITY Construction QA/QC Monitor in-process installation of electrical conduit and cable tray, including welding of supports.

X

Witness initial testing of shielded cable, i.e., 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, i.e., 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


X S





6.3 Electrical Equipment RESPONSIBILITY


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


X S


Section 7-CONTROL SYSTEMS

7.1 Control Systems Site Shop Operations RESPONSIBILITY


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 RESPONSIBILITY


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

Monitor the Contractor's quality control activities. S X

Verify documentation procedures are being followed. X S




Section 8 - COATINGS, LININGS, INSULATION AND CATHODIC PROTECTION

8.1 Coatings RESPONSIBILITY


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


Verify the Contractor has prepared the QC documentation. S X

Audit coating documentation. X

8.2 Insulation RESPONSIBILITY


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 RESPONSIBILITY


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


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 Monitor surface preparation to ensure mounting studs and reinforcements are correctly installed.

X S

Ensure that test plates,cubes,etc,from refractory applications are taken at the required frequencies

X S




8.4 Cathodic Protection - Underground Structures. RESPONSIBILITY


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 RESPONSIBILITY


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 RESPONSIBILITY


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



9.2 Structural and Reinforcing Steel Welding RESPONSIBILITY


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 Nondestructive Examination (NDE) RESPONSIBILITY


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 NDE CONTRACTOR 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




9.4 Pipe hardness Testing RESPONSIBILITY


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) RESPONSIBILITY


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 RESPONSIBILITY


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




10.3 Positive Material Identification (PMI) RESPONSIBILITY


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 RESPONSIBILITY


Monitor equipment and material preservation in storage and document. MM S

11.2 Equipment and Material Protection (Contractor) RESPONSIBILITY

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 RESPONSIBILITY


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 drawings and specifications

X



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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.F00501, 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.F00502. 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.



- The Construction Engineer shall describe the condition or design change requested in terms

that can be easily understood by those who review it, including appropriate references, specific drawings and specifications to illustrate the recommended change.

- To minimize delay in construction, authority for deviation from specifications and drawings may

be acquired by direct communication with the Design Engineer and the Client pending processing of the RFI. A copy of the Record of Telephone Conversation will accompany the RFI transmitted to the Design Engineer and the Client. Approval of the Client’s construction site representative should be acquired, if possible.

- The Design Engineer and the Client portion of the RFI indicate approval or disapproval of the

field recommended change or recommends alternatives. The signed original will be returned to the Site Manager for disposition or authority to proceed.

- The Construction Engineering Manager shall maintain a file that contains a full history of the

action and data supporting the approval of each Request For Information. Subcontractor Documents

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

- Subcontractor prepared field sketches and "as-built" drawings originating at the construction

site shall be documented and controlled in accordance with the Request For Information (RFI) requirements described in this procedure.

Submittals - Field Contracts

- Submittals are reviewed under the direction of the Construction Engineering Manager. Subcontractor technical submittals are forwarded to Construction Engineering Manager. A submittals list shall be maintained reflecting the specification reference, description, date received, and the status of acceptance through Construction Engineering approval. The Site 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.



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.

esamohod

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RECEIPT AND DISTRIBUTION OF DOCUMENTS Construction Engineering Manager

- Establish document control log system for receipt of documents and provided standard distribution as indicated on the Distribution Matrix System.

Document Control - Drawings (design, vendor and field sketch), specifications

- Review receipt transmittal and enter date received in the Electronic Tracking System.

- Review distribution list and reproduce copies as required.

- Prepare distribution transmittals and distribute documents accordingly. Document Control - Manuals

- Based on input from Site Manager, determine distribution for each type manual. Maintain a "Master" manual in Document Control and reproduce copies as required.

- Assign individuals numbered manuals, prepare distribution transmittals and distribute

accordingly. Document Recipient

- Sign transmittal acknowledging receipt of documents and return signed transmittal Document Control within 10 days.

- Replace superseded documents as required with the new documents. Destroy or return the

superseded documents (except for inspection or historical record) to Document Control. The document recipient is responsible for maintaining documents current.

Document Control

- Destroy returned superseded documents. REPRODUCTION AND ISSUE OF REQUESTED DOCUMENTS Requester

- Fill out document request form and present to Document Control.

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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.



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



Attachment 1 – 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.

Originated By: The person originating the request and provided recommended action.

Title: List the current position of the originator on the project.

Date: The date the request is submitted for approval.

Originator’s Company Name List Company name of the originator

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

Title: List the current position of the approver.

Date: The date the request is approved for submission

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



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

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

Title: List the current position of the Approver on the project.

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

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

Title: List the current position of the Approver on the project.

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

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

Cost Impact? Indicate using the checkbox if the RFI response has a cost impact that will

require an estimate or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor.

Schedule Impact? Indicate using the checkbox if the RFI response has a schedule impact that will

require an adjustment in the contract schedule or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor

Closed RFI and Date Verified: Inter the name and date the RFI was closed and verified. Distribution: List all parties requiring a copy of the completed request once the response has

been received.

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 F00501 Project No. A6CV Revision 0, 10 June 2013

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REQUEST FOR INFORMATION (RFI)

PROJECT NAME PROJECT # DATE RFI #

WBS (Work Breakdown Structure) WORK PACKAGE TURNOVER/STARTUP SYSTEM DISCIPLINE

REQUEST TO (RESPONDENT): RESPONDENT’S COMPANY/LOCATION PHONE/EMAIL

SUBJECT:

SPECIFICATIONS/DOCUMENTS/DWGS REFERENCED OR IMPACTED:

QUESTIONS/DESCRIPTION OF CONFLICT:

ORIGINATOR’S RECOMMENDED SOLUTION:

ORIGINATOR (Sign) TITLE DATE APPROVED (Sign) TITLE DATE

ORIGINATOR’S (SUB) CONTRACTOR COMPANY NAME: ORIGINATOR’S (SUB) CONTRACT #:

REPLY REQUIRED BY:

RESPONSE:

RESPONDENT (Sign) TITLE DATE APPROVED (Sign) TITLE DATE

ARE THE QUESTION AND RESPONSE ADEQUATE FOR CLOSURE

OF THIS RFI? YES NO

IS THERE A COST IMPACT DUE TO THIS RFI? YES NO

IF YES, SITE INSTRUCTION TO BE ISSUED

IS THERE A SCHEDULE IMPACT DUE TO THIS RFI? YES NO

IF YES, SITE INSTRUCTION TO BE ISSUED

THE WORK WAS COMPLETED AS NOTED ON THIS CLOSED

RFI AND VERIFIED BY DATE:

DISTRIBUTION:

The response to this RFI is NOT an authorization to perform a change to the contract. Work may proceed in accord with the response only if such work involves NO change in cost or schedule. If the response involves change in cost or schedule, a Site Instruction or similar document must be received before the response can be executed. Where no Site Instruction is indicated, action must be taken in accordance with Article 15.0 of Part III, Section 15.2 and subject work must not proceed in accordance with Section 15.3 or 15.4 of Part III, General Terms of the Fluor Standard Contract.


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REQUEST FOR INFORMATION LOG ID A00502A

RFI No. Date

Opened Originator Discipline

Date Closed

Description Of Request


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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 as determined by Project Management.

Special processes identified must be accomplished and documented under controlled conditions

by appropriately qualified personnel using approved procedures and equipment in accordance with the governing specifications and the associated referenced codes and standards.


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PROCEDURE

Site Quality Manager

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


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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 re-verification. 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 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.



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.



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



Attachment 1 Criteria for the Selection of Inspection, Measuring and Test 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.



Attachment 2 - 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.



Attachment 3 - IM & TE Calibration Requirements List

END USER DESCRIPTION FREQUENCY PROCEDURE TOLERANCES

Surveyor Chain Initial Conformance Visual* ±1/8” (0.32cm) (2)

Surveyor Level 6 Months Per Procedure

Surveyor Transit 6 Months Per Procedure

Surveyor Tape Initial Conformance Visual* ±1/8” (0.32cm) (2)

Surveyor Distamat 6 Months Per Procedure

Mechanical Pressure Gauges 6 Months ±5% (2)

Mechanical Torque Wrenches 6 Months ±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 6 Months ±5°F (15°C) (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.





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CALIBRATION ASSIGNMENT LOG AND RECORD ID A01101

Equipment/Instrument Identification No.

Item Description Size-Range

Manufacturer Model No.

Manufacturer Serial No Calibration Frequency Calibration Tolerance Date

Calibrated Calibration Due Date


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I M T E SIGN IN/OUT HISTORY OF USE LOG ID A01102

I M T E Description: I M T E No.:

Name Badge No. Date Out Date In Area/System/PKG No.


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CALIBRATIONS TICKLER FILE ID A01103

Month Year

Sunday Monday Tuesday Wednesday Thursday Friday Saturday





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CALIBRATION DATA SHEET ID A01104

Area/Location Unit No. Project Job No.

Tag No. Manufacturer Description

Model No. Serial No. Type Action

Direct Reserve Size Fail Position

Calibration Range

Calibration Procedure

As Found Calibration

Input Output Input Output

0% 0%

25% 25%

75% 75%

100% 100%

Mounted Accessories

Remarks

Calibrated By Date


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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



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.



• 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.



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 or Fluor Subcontractors or subtier subcontractor

initiating NCR's that require Project Design Engineer approval should send a copy of the approved NCR to the Fluor Site Quality Manager (prior to performing the actions specified in the NCR disposition, if possible).

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

• Obtain other required approvals as required.

DOCUMENTATION The Site Quality Manager shall retain all NCR’s and the NCR log in the Quality Files.

FORMS Quality Forms: 000.509.F01301 - Nonconformance Report 000.509.F01302 - Nonconformance Report Log 000.509.F01303 - Hold Tag/Sticker Attachment Attachment 1 - Instruction for completion of Non-Conformance Report Attachment 2 - Nonconformance Routing Chart



Attachment 1 - Instruction for completion of 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 - select from below C08a Not Aware of Procedure (includes not trained) C08b Ignored Procedure (includes no time / low priority / not important) C08c Misapplied Procedure (includes not understood / thought not to apply) C08d Not Effective (needs update / improvement / is inappropriate) / incorrect C08e Incorrect Reference to Procedure (includes incorrectly specified) C08f Procedure Not in Native Language 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.

Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code. 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.

Requires approval from design engineer and may require approval of client.

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.



Attachment 2 - 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 NCR’s on Activities within Regulating Authority Scope, they need to Review/Accept

NonconformanceDiscovered

NCRInitiated

Site QualityManager

Review/Confirms/Signs

Lead Field EngineerRecommended Disposition/

Signature

Site QualityManager

for Routing

Site QualityManager

Assigns Number

CorrectiveAction

CorrectiveAction

Approved

ApplicableDesign Authority

Review DispositionApprove or Disapprove

NOTE 2

QualityManagerVerifies

QualityManagerClosesNCR

Quality ManagerDistributes

Closed NCR

Execution ofCorrective Action

NOTE 1

Corrective Action:

1) Remove/Replace Rework to Full Design Intent

2) Repair

3) Use As Is

Distribution:

Reject

Accepts


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NONCONFORMANCE REPORT ID A01301A

Tag Description: Tag No.:

P. O. No.: Inspection Classification Turnover System:

Subcontractor: Subcontractor Client Sub – System:

Fluor Other Location:

Initiated by: Date: Hold Tag Yes No

NCR No.

Area/Location Unit/Equip No. Discipline/Responsibility:

DWG. No./Rev. Spec./Rev. Audit No. (If Applicable)

DESCRIPTION OF NONCONFORMANCE

ROOT CAUSE CAUSE CODE(S)

DISPOSITION Use as is Rework Repair Other

DISPOSITION BY Design Eng. Approval Req.

Construction Engineer Date

Yes No DISPOSITION COMPLETED BY

Contractor Date

Design Engineer Date

ACTION VERIFIED AND NON-CONFORMANCE CLOSED

VERIFICATION METHOD DOC REVIEW INSPECTION OTHER

FLUOR INSPECTOR DATE

FLUOR-VERIFIED DISPOSITION AND RECOMMENDED CLOSURE OF NCR FLUOR SITE QUALITY MANAGER DATE





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NONCONFORMANCE REPORT LOG ID A01302

Page _______of _______

NCR No. Discipline Hold Tag

Date Opened Date Closed Description of Nonconformance


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HOLD TAG/STICKER ID A01303

(Recommended Color: Red with Green Letters)

HOLD

Hold Tag No._____________________

DO NOT USE

NCR Number_____________________

(DO NOT REMOVE THIS TAG)





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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 nonconformitynonconformity. 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 nonconformitynonconformity 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). This may also include where a trend is noted (ie the same nonconforming condition occurs three or more times).

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.



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 nonconformity 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.



DOCUMENTATION The Corrective Action Report and associated attachments shall be retained in the Quality Control Files by the Site Quality Manager. The status of open CAR’s will be reviewed with Site Management on a periodic basis to ensure timely close out of the CAR’s. REFERENCES Quality Control Forms: 000.509.F01401 - Corrective Action Report 000.509.F01402 - Corrective Action Report Log ATTACHMENTS Attachment 1 - Corrective Action Response Instructions



Attachment 1 - 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 and state when the action has been or will be completed. Identify other work affected and if additional actions or controls are needed.

CAR Section 4 – Corrective Action Section

In addition to correcting the nonconformity, the Responsible Person needs to assess it’s severity/impact to see if further analysis is warranted (i.e. determine the root cause and develop a plan to prevent recurrence). When evaluating the severity of the nonconformity consideration should be given to its impact on project cost, schedule or quality issues (e.g. resulting in excessive rework). This decision is indicated by marking yes or no in Section 4 or the CAR. Root Cause: The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s) including an explanation will be stated.


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 - select from below

C08a Not Aware of Procedure (includes not trained)

C08b Ignored Procedure (includes no time / low priority / not important)

C08c Misapplied Procedure (includes not understood / thought not to apply)

C08d Not Effective (needs update / improvement / is inappropriate) / incorrect

C08e Incorrect Reference to Procedure (includes incorrectly specified)




C08f Procedure Not in Native Language

C09 People Driven

C10 Systems Driven

C11 Work Environment

C99 Other

Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code 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 and 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 CAR’s (Section 5 Completed) are to be copied to the Construction Technology Quality Manager.





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CORRECTIVE ACTION REPORT ID A01401A

1 - Identification Supplier Name: Contract/P.O. No.: Date:

CAR Number: Originator:

Personnel contracted: Discipline:

2 - Nonconformity Reference:

Requirement:

Description:

Contributing Cause(s): [List code number(s) see Att. 1 of 000 509 0140]

3 – Correction of Nonconformity (By Responsible Person) Plan to address the Nonconformity (e.g. correct/repair/waiver) Estimated Completion Date:

4 – Corrective Action Section (By Responsible Person) In the judgement of the Responsible Person, is an analysis of the root cause(s) of this nonconformity required (including determining a plan to prevent recurrence) in light of the magnitude of the problem and the risk involved? (If Yes, continue: if no, mark N/A below). Yes / No Root Cause(s): List code number(s) see 000.509.0140.att. 1, and explain underlying reason why nonconformity occurred

Plan to Prevent Recurrence: Estimated Completion Date:

Responsible Person: Date:

5 – Closeout Verification Correction of Nonconformity:

Verifier: Date:

Corrective Action Implemented and Effective: (only completed when a root cause was determined see 4 above)

Evaluator: Date:


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CORRECTIVE ACTION STATUS LOG ID A01402A

CAR No. Date

Initiated Description of CAR Contractor/Supplier Contract/P.O. No. Responsible Person

Response Received Date

Date Closed


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

GENERAL Definitions

Preventive Action: The action taken to eliminate the cause of potential nonconformities. Preventive action will be appropriate to the magnitude of the potential nonconformity and commensurate with the potential risks that may be encountered. Nonconformities: The non-fulfillment of specified requirements.

Preventive action involves the detection and elimination or modification of work performance conditions (or circumstances) which have a potential to cause nonconformities. Each employee should continually evaluate his/her work process to identify potential nonconformities.

PROCEDURE Project Personnel

Review appropriate sources of information that may be used to identify potential nonconformities such as:

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

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



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 - select from below C08a Not Aware of Procedure (includes not trained) C08b Ignored Procedure (includes no time / low priority / not important) C08c Misapplied Procedure (includes not understood / thought not to apply) C08d Not Effective (needs update / improvement / is inappropriate) / incorrect C08e Incorrect Reference to Procedure (includes incorrectly specified) C08f Procedure Not in Native Language C09 People Driven C10 Systems Driven C11 Work Environment C99 Other

Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code



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

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






PREVENTIVE ACTION LOG

Project Number: Project Name:

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





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SURVEILLANCE REPORT ID A02201

Location Subcontractor/Activity Date Completed Work Yes No

Report No.

Inspection Checklist, Specification, Or Drawing Used As Reference:

RESULTS: Follow-up Required Satisfactory

Description Of Item/Work Inspected/Observed:

Observations/Deficiency:

Surveillance Personnel/Date Site Quality Manger/Date

Person Notified Of Deficiency Name Title

Recommended Corrective Action:

Corrective Actions Implemented/Accepted:

Surveillance Personnel/Date Site Quality Manager/Date





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PREVENTIVE ACTION LOG ID A01501A

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


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AUDIT FINDING ID A01701

1) Project/Contract Number: Finding Number:

Project Name: Audit Date:

Auditor(s):

Auditee Personnel Contacted:

2) A. Reference:

B. Requirement:

Continued on back

3) Deficiency:

Continued on back 4) Proposed Disposition:

Expected Completion Date:

5) Corrective Action Evaluation, and Response:

Disposition (Action taken to correct deficiency) Completion Date:

6) Auditee Signature: Date:

7) Auditor Concurrence with disposition: Date: Continued on back

8) Auditor Follow-up and Close-out Verification:

Auditor Signature: Date Deficiency closed:


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AUDIT SUMMARY ID A01702

Project: Construction Audit Number:

Client: Audit Dates:

Project Number: Report Date:

Audit Location:

Audit Scope:

Summary of Audit Results:

Entry Meeting Date: Exit Meeting Date:

The entry & exit meeting were conducted with:

A summary of the audit results is as follows:

Quality Manual Principles assessed. Quality Manual Principles found to be satisfactory.

Deficiencies reported. Observations for improvement.

Previous Findings and Action Follow-up:

Finding Number Status – (Open or Closed) Date Closed

Lead Auditor Signature: Date:





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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 arestaff is 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.



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.



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.



Attachment 1 - Sample of Site Specific Quality Records Control Form

Record Identification Custodian System

Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code

Form # Title Job Title or Sub Name

Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F00501 Request For Information CEM N

000 509 F00502 Request For Information Log CEM N

000 509 F01101 Calibration Assignment Log and Record CEM N

000 509 F01102 I.M.T.E. Sign In/Out History of Use Log CEM N

000 509 F01103 Calibrations Tickler File CEM N

000 509 F01104 Calibration Data Sheet CEM N

000 509 F01301 Nonconformance Report SQM N

000 509 F01302 Nonconformance Report Log SQM N

000 509 F01303 Hold Tag/Sticker SQM N

000 509 F01401 Corrective Action Report SQM N

000 509 F01402 Corrective Action Status Log SQM N

000 509 F01501 Preventive Action Log SQM N

000 509 F01601 Quality Records Control SQM N

000 509 F01701 Audit Finding SQM N

000 509 F01702 Audit Summary SQM N

000 509 F01801 Project Specific Quality Training SQM N

000 509 F02001 Site Subcontractor Qualification SQM N

000 509 F02002 Soil Testing Laboratory Evaluation Record SQM N

000 509 F02003 Asphalt Testing Laboratory Evaluation Record SQM N

000 509 F02004 Concrete Batch Plant Evaluation Record SQM N

000 509 F02005 Concrete Testing Laboratory Evaluation Record SQM N

000 509 F02006 NDE Subcontractor Evaluation Record SQM N

000 509 F02201 Surveillance Report SQM N

000 509 F02202 Surveillance Report Log SQM N

000 509 F02301 Receiving Inspection Checklist SQM N

000 509 F02401 Transfer of Care, Custody and Control (Turnover Notice)

COMM Y

000 509 F02402 System Walkdown Notice CEM Y

000 509 F02403 Mechanical Completion Civil Checklist CEM Y

000 509 F02404 Mechanical Completion Electrical/Instrumentation Checklist

CEM Y

000 509 F02405 Mechanical Completion/Mechanical Checklist CEM Y

000 509 F02406 Mechanical Completion/Quality Control Checklist CEM Y

000 509 F02407 Master Punch List Record CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F02408 Interim Turnover Notice CEM Y

000 509 F02409 Mechanical Completion Certificate CEM Y

000 509 F02501 Storage Inspection Checklist MM Y

000 509 F02502 Equipment Protection Preservation and Inspection Record

MM Y

000 509 F70001 Inspection and Test Plan SQM N

000 509 F70002 Inspection and Test Plan SQM N

000 509 F70101 Soil Inspection Checklist CEM Y

000 509 F70102 Field Compaction Test Record CEM Y

000 509 F70103 Density of Soil Place by the Sand-Cone Method ASTM D-1566 AASHTO-T-191

CEM Y

000 509 F70104 Nuclear Moisture-Density Test Report CEM Y

000 509 F70105 Soil Density Test Log CEM Y

000 509 F70201 Bituminous Concrete Paving Inspection Checklist CEM Y

000 509 F70202 Bulk Specific Gravity CEM Y

000 509 F70204000 509

F70203

Nuclear Density Test Report – Bituminous ConcreteBituminous Concrete Compaction

CEM Y

000 509 F70301000 509

F70204

Pile Driving Inspection RecordNuclear Density Test Report – Bituminous Concrete

CEM Y

000 509 F70302000 509

F70301 Pile Driving RecordPile Driving Inspection Record CEM Y

000 509 F70303000 509

F70302 Record of Pile DrivingPile Driving Record CEM Y

000 509 F70801000 509

F70303 Caisson Inspection RecordRecord of Pile Driving

000 509 F70901000 509

F70801

Augered Cast-In-Place Pile RecordCaisson Inspection Record

CEM Y

000 509 F71001000 509

F70901

Pre-Concrete Inspection ChecklistAugered Cast-In-Place Pile Record

CEM Y

000 509 F71002000 509

F71001

Concrete Inspection RecordPre-Concrete Inspection Checklist

000 509 F71003000 509

F71002 Concrete Pour CardConcrete Inspection Record CEM

Y

000 509 F71004000 509

F71003

Cementitious Grout Inspection RecordConcrete Pour Card

CEM Y

000 509 F71005000 509

F71004

Cementitious Grout Testing RecordCementitious Grout Inspection Record

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F71006000 509

F71005

Epoxy Resin Grout Inspection RecordCementitious Grout Testing Record

CEM Y

000 509 F71007000 509

F71006

Concrete Compression Strength Test RecordEpoxy Resin Grout Inspection Record

CEM Y

000 509 F71008000 509

F71007

Concrete Placement LogConcrete Compression Strength Test Record

CEM Y

000 509 F71009000 509

F71008 Grout Placement LogConcrete Placement Log CEM

Y

000 509 F71010000 509

F71009

Concrete Batch Plant Inspection RecordGrout Placement Log

SQM N

000 509 F72002000 509

F71010

Structural Steel InspectionConcrete Batch Plant Inspection Record

CEM Y

000 509 F72003000 509

F72002

Torque Wrench Calibration LogStructural Steel Inspection

CEM Y

000 509 F73001000 509

F72003

Building Inspection and Test ChecklistTorque Wrench Calibration Log

CEM Y

000 509 F73002000 509

F73001

Final Building Inspection SummaryBuilding Inspection and Test Checklist

CEM Y

000 509 F73003000 509

F73002

Carpentry ChecklistFinal Building Inspection Summary

CEM Y

000 509 F73004000 509

F73003 Painting ChecklistCarpentry Checklist CEM Y

000 509 F73005000 509

F73004 Plumbing ChecklistPainting Checklist CEM Y

000 509 F73006000 509

F73005 Ceramic Tile ChecklistPlumbing Checklist CEM Y

000 509 F73007000 509

F73006 Concrete ChecklistCeramic Tile Checklist CEM Y

000 509 F73008000 509

F73007 Structural Steel ChecklistConcrete Checklist CEM Y

000 509 F73009000 509

F73008

Masonry (Brickwork) ChecklistStructural Steel Checklist

CEM Y

000 509 F73010000 509

F73009 Plaster ChecklistMasonry (Brickwork) Checklist CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F73011000 509

F73010

Doors, Windows, Hardware, Glazing ChecklistPlaster Checklist

CEM Y

000 509 F73012000 509

F73011

Computer (Raised) Floors ChecklistDoors, Windows, Hardware, Glazing Checklist

CEM Y

000 509 F73013000 509

F73012

Prefab Wall Element Systems ChecklistComputer (Raised) Floors Checklist

CEM Y

000 509 F73014000 509

F73013

Building Metal Siding And Roofing ChecklistPrefab Wall Element Systems Checklist

CEM Y

000 509 F73015000 509

F73014

Buildings Water Proofing And Damp Proofing ChecklistBuilding Metal Siding And Roofing Checklist

CEM Y

000 509 F73016000 509

F73015

Suspended Ceiling ChecklistBuildings Water Proofing And Damp Proofing Checklist

CEM Y

000 509 F73101000 509

F73016

HVAC Inspection RecordSuspended Ceiling Checklist

CEM Y

000 509 F73102000 509

F73101

Buildings Air Conditioning ChecklistHVAC Inspection Record

CEM Y

000 509 F73201000 509

F73102

Roofing Inspection ChecklistBuildings Air Conditioning Checklist

CEM Y

000 509 F74001000 509

F73201

Equipment Installation ChecklistRoofing Inspection Checklist

CEM Y

000 509 F74002000 509

F74001

Heat Exchangers & Reboilers Installation RecordEquipment Installation Checklist

000 509 F74003000 509

F74002

Electrostatic Precipitator ChecklistHeat Exchangers & Reboilers Installation Record

000 509 F74004000 509

F74003

Inspection Record Static EquipmentElectrostatic Precipitator Checklist

CEM Y

000 509 F74005000 509

F74004

Tray Installation Inspection RecordInspection Record Static Equipment

CEM Y

000 509 F74006000 509

F74005

Air Cooled Heat Exchanger Inspection ChecklistTray Installation Inspection Record

000 509 F74007000 509

F74006

Air Cooler Run In Test ReportAir Cooled Heat Exchanger Inspection Checklist

000 509 F74008000 509

F74007

Reciprocating Compressor Inspection RecordAir Cooler Run In Test Report

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F74009000 509

F74008

Fan Installation Inspection ChecklistReciprocating Compressor Inspection Record

CEM Y

000 509 F74010000 509

F74009

Furnaces Inspection RecordFan Installation Inspection Checklist

000 509 F74011000 509

F74010

Fuel Gas Steam Generator Inspection ChecklistFurnaces Inspection Record

000 509 F74012000 509

F74011

Steam Turbine Inspection ChecklistFuel Gas Steam Generator Inspection Checklist

000 509 F74013000 509

F74012

Agitators/Mixers Inspection ChecklistSteam Turbine Inspection Checklist

CEM Y

000 509 F74014000 509

F74013

Equipment/Piping Strain and Alignment Inspection FormAgitators/Mixers Inspection Checklist

CEM Y

000 509 F74015000 509

F74014

Installation Checklist Travelling CranesEquipment/Piping Strain and Alignment Inspection Form

CEM Y

000 509 F74016000 509

F74015

Package Equipment Installation ChecklistInstallation Checklist Travelling Cranes

CEM Y

000 509 F74017000 509

F74016

Desuperheaters/Ejectors Inspection ChecklistPackage Equipment Installation Checklist

000 509 F74018000 509

F74017

Filters/Strainers Installation RecordDesuperheaters/Ejectors Inspection Checklist

CEM Y

000 509 F74019000 509

F74018

Centrifugal Compressor Inspection RecordFilters/Strainers Installation Record

CEM Y

000 509 F74020000 509

F74019

Rotating Equipment Inspection RecordCentrifugal Compressor Inspection Record

CEM Y

000 509 F74021000 509

F74020

Rotating Equipment Alignment RecordRotating Equipment Inspection Record

CEM Y

000 509 F74022000 509

F74021

Belt Driven Equipment Alignment RecordRotating Equipment Alignment Record

CEM Y

000 509 F74024000 509

F74022

Inspection Record For Draw Off Tray Leak Test ReportBelt Driven Equipment Alignment Record

CEM Y

000 509 F74025000 509

F74024

Inspection Record For Air CoolersInspection Record For Draw Off Tray Leak Test Report

CEM Y

000 509 F74026000 509

F74025

Final Closing Authorization RecordInspection Record For Air Coolers

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F74027000 509

F74026

API 686 Baseplate Installation Checklist (Prior to Grouting)Final Closing Authorization Record

CEM Y

000 509 F74028000 509

F74027

API 686 Equipment Grouting ChecklistAPI 686 Baseplate Installation Checklist (Prior to Grouting)

CEM Y

000 509 F74029000 509

F74028

API 686 Alignment Check SheetAPI 686 Equipment Grouting Checklist

CEM Y

000 509 F74030000 509

F74029

Baseplate Leveling RecordAPI 686 Alignment Check Sheet

CEM Y

000 509 F74031000 509

F74030

Reverse Dial Alignment RecordBaseplate Leveling Record

CEM Y

000 509 F74032000 509

F74031

Piping Alignment Data SheetReverse Dial Alignment Record

CEM Y

000 509 F74033000 509

F74032

Rotating Equipment (Face-Rim) Alignment RecordPiping Alignment Data Sheet

CEM Y

000 509 F74101000 509

F74033

Tank Elevation Tolerances RecordRotating Equipment (Face-Rim) Alignment Record

CEM Y

000 509 F74102000 509

F74101

Inspection Record Field Erected TankTank Elevation Tolerances Record

CEM Y

000 509 F74103000 509

F74102

Tank Plate Dimensional Control Record Field Erected TankInspection Record Field Erected Tank

CEM Y

000 509 F74104000 509

F74103

Water Filling And Settlement Record Field Erected TankTank Plate Dimensional Control Record Field Erected Tank

CEM Y

000 509 F74105000 509

F74104

Tank Leak Test RecordWater Filling And Settlement Record Field Erected Tank

CEM Y

000 509 F74106000 509

F74105 Tank Test CertificateTank Leak Test Record CEM Y

000 509 F74201000 509

F74106

Inspection Record Cooling TowerTank Test Certificate

000 509 F74301000 509

F74201

Field Installed Refactory RecordInspection Record Cooling Tower

000 509 F74401000 509

F74301

Gas Turbine/Generator Gear Inspection ChecklistField Installed Refactory Record

000 509 F74402000 509

F74401

Gas Turbine Inspection RecordGas Turbine/Generator Gear Inspection Checklist




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F74405000 509

F74402

Shop-Fabricated Field-Erected Stack Inspection RecordGas Turbine Inspection Record

000 509 F74406000 509

F74405

Heat Recovery Steam Generator Inspection RecordShop-Fabricated Field-Erected Stack Inspection Record

000 509 F74407000 509

F74406

Breeching And Duct Work Inspection RecordHeat Recovery Steam Generator Inspection Record

000 509F74408000

509 F74407

Equipment Protection Activities Record – Gas TurbinesBreeching And Duct Work Inspection Record

000 509 F74601000 509F74408

Site Daily Activities LogEquipment Protection Activities Record – Gas Turbines

000 509 F74602000 509

F74601

Stg Foundation Settlement RecordSite Daily Activities Log

000 509 F74603000 509

F74602 Stg FixatorsStg Foundation Settlement Record

000 509 F74604000 509

F74603 Stg Sole PlatesStg Fixators

000 509 F74605000 509

F74604

Stg Front Standard Base Plate AssemblyStg Sole Plates

000 509 F74606000 509

F74605

Exhaust Hood Horizontal Joint LevelnessStg Front Standard Base Plate Assembly

000 509 F74607000 509

F74606

Stg Shell/Casing Load TestExhaust Hood Horizontal Joint Levelness

000 509 F74608000 509

F74607 Stg Piping AttachmentStg Shell/Casing Load Test

000 509 F74609000 509

F74608

Stg Foundation Top of Concrete ElevationsStg Piping Attachment

000 509 F74701000 509

F74609

Generator Test ChecklistStg Foundation Top of Concrete Elevations

000 509 F74702000 509

F74701

Generator Cold Resistance Test RecordGenerator Test Checklist

000 509 F75001000 509

F74702

Underground Pipe Inspection RecordGenerator Cold Resistance Test Record

CEM Y

000 509 F75002000 509

F75001

Insulation Resistance (Insulated Flanges-Underground Piping) Test RecordUnderground Pipe Inspection Record

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F75003000 509

F75002

Holiday (Spark) Test RecordInsulation Resistance (Insulated Flanges-Underground Piping) Test Record

CEM Y

000 509 F75101000 509

F75003

Aboveground Pipe Inspection RecordHoliday (Spark) Test Record

CEM Y

000 509 F75102000 509

F75101

Visual Inspection of Flanges, Gaskets and BoltingAboveground Pipe Inspection Record

CEM Y

000 509 F75103000 509

F75102

Weld Map RecordVisual Inspection of Flanges, Gaskets and Bolting

CEM Y

000 509 F75201000 509

F75103 Pressure Test ReportWeld Map Record CEM Y

000 509 F75501000 509

F75201

Hygienic Drawing Revision LogPressure Test Report

000 509 F75502000 509

F75501

Hygienic Material Receiving LogHygienic Drawing Revision Log

000 509 F75503000 509

F75502

Hygienic Valve Receiving Inspection ReportHygienic Material Receiving Log

000 509 F75504000 509

F75503

Hygienic Vessel Nozzle Receiving Inspection ReportHygienic Valve Receiving Inspection Report

000 509 F75505000 509

F75504

Hygienic Tube/Fitting Receiving Inspection ReportHygienic Vessel Nozzle Receiving Inspection Report

000 509 F75506000 509

F75505

Hygienic Pre-weld Inspection ChecklistHygienic Tube/Fitting Receiving Inspection Report

000 509 F75507000 509

F75506

Hygienic Welder Qualification ReportHygienic Pre-weld Inspection Checklist

000 509 F75508000 509

F75507

Hygienic Orbital Weld LogHygienic Welder Qualification Report

000 509 F75509000 509

F75508

Hygienic Post Installation ChecklistHygienic Orbital Weld Log

000 509 F75601000 509

F75509

Pipe Cleaning and Verification ChecklistHygienic Post Installation Checklist

CEM Y

000 509 F75701000 509

F75601

Mechanical Heat Tracing Inspection RecordPipe Cleaning and Verification Checklist

000 509 F76001000 509

F75701

Conduit And Cable Tray ChecklistMechanical Heat Tracing Inspection Record

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F76002000 509

F76001

Electrical Manhole Inspection ChecklistConduit And Cable Tray Checklist

CEM Y

000 509 F76003000 509

F76002

Medium & High Voltage Underground Cable Splice Inspection RecordElectrical Manhole Inspection Checklist

CEM Y

000 509 F76004000 509

F76003

Medium and High Voltage Cable Termination ChecklistMedium & High Voltage Underground Cable Splice Inspection Record

CEM Y

000 509 F76005000 509

F76004

Cable Pulling Inspection ChecklistMedium and High Voltage Cable Termination Checklist

CEM Y

000 509 F76006000 509

F76005

Fan/Speed Reducer/Motor Inspection ChecklistCable Pulling Inspection Checklist

CEM Y

000 509 F76007000 509

F76006

Switch House Inspection ChecklistFan/Speed Reducer/Motor Inspection Checklist

CEM Y

000 509 F76008000 509

F76007

Lighting Receptacle, Instrument Distribution Panels Inspection ChecklistSwitch House Inspection Checklist

CEM Y

000 509 F76009000 509

F76008

Electrical Motor Inspection ChecklistLighting Receptacle, Instrument Distribution Panels Inspection Checklist

CEM Y

000 509 F76010000 509

F76009

Aboveground Conduit Inspection ChecklistElectrical Motor Inspection Checklist

CEM Y

000 509 F76011000 509

F76010

Lighting Panelboard Inspection RecordAboveground Conduit Inspection Checklist

CEM Y

000 509 F76012000 509

F76011

Underground Conduit (Duct Bank) InspectionLighting Panelboard Inspection Record

CEM Y

000 509 F76013000 509

F76012

Grounding/Earthing System (Grid or Loop) Inspection RecordUnderground Conduit (Duct Bank) Inspection

CEM Y

000 509 F76014000 509

F76013

Cable Termination ChecklistGrounding/Earthing System (Grid or Loop) Inspection Record

CEM Y

000 509 F76101000 509

F76014

Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test RecordCable Termination Checklist

CEM Y

000 509 F76102000 509

F76101

Insulation Resistance (Power, Control Wire And Cable) Test RecordGrounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record

CEM Y

000 509 F76103000 509

F76102

Insulation Resistance (Instrument Wire And Cable) Test RecordInsulation Resistance (Power, Control Wire And Cable) Test Record

CEM Y

000 509 F76104000 509

F76103

DC High Potential Test (Medium Voltage Cable) RecordInsulation Resistance (Instrument Wire And Cable) Test Record

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F76105000 509

F76104

Current Transformer (And Ammeter) Test RecordDC High Potential Test (Medium Voltage Cable) Record

CEM Y

000 509 F76106000 509

F76105

LV Over-current And Earth/Ground-Fault Protection Relay TestCurrent Transformer (And Ammeter) Test Record

CEM Y

000 509 F76107000 509

F76106

Over-current/Ground Fault Protection Relay (Induction Type) TestLV Over-current And Earth/Ground-Fault Protection Relay Test

CEM Y

000 509 F76108000 509

F76107

Over-current/Ground Fault Protection Relay (Thermal Type) TestOver-current/Ground Fault Protection Relay (Induction Type) Test

CEM Y

000 509 F76109000 509

F76108

Switching Units HV Switchgear Inspection And Test RecordOver-current/Ground Fault Protection Relay (Thermal Type) Test

CEM Y

000 509 F76109 Switching Units HV Switchgear Inspection And Test Record

000 509 F76110 Ground Electrode Resistance Inspection Test Record

CEM Y

000 509 F76111000 509

F76110

Ground Fault Protection Relay Induction Inspection and Test RecordGround Electrode Resistance Inspection Test Record

CEM Y

000 509 F76112000 509

F76111

Grounding Continuity Inspection and Test RecordGround Fault Protection Relay Induction Inspection and Test Record

CEM Y

000 509 F76113000 509

F76112

Grounding Rod Inspection and Test RecordGrounding Continuity Inspection and Test Record

CEM Y

000 509 F76114000 509

F76113

Bus Bar Assemblies LV Switchgear Test RecordGrounding Rod Inspection and Test Record

CEM Y

000 509 F76115000 509

F76114

Neutral Grounding/Earthing Resistor Test RecordBus Bar Assemblies LV Switchgear Test Record

CEM Y

000 509 F76116000 509

F76115

Ground Continuity (Non Electrical) Equipment/Structures Test RecordNeutral Grounding/Earthing Resistor Test Record

CEM Y

000 509 F76117000 509

F76116

Ground Continuity (Electrical Equipment and Ground Test Bars) Test RecordGround Continuity (Non Electrical) Equipment/Structures Test Record

CEM Y

000 509 F76118000 509

F76117

Insulation Resistance (Equipment) Test RecordGround Continuity (Electrical Equipment and Ground Test Bars) Test Record

CEM Y

000 509 F76119000 509

F76118

Insulation Resistance (Transformer) Test RecordInsulation Resistance (Equipment) Test Record

CEM Y

000 509 F76120000 509

F76119

Liquid Dielectric Strength Test RecordInsulation Resistance (Transformer) Test Record

CEM Y

000 509 F76121000 509

F76120

DC Proof Test Record for MotorsLiquid Dielectric Strength Test Record

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F76122000 509

F76121

Feeder Breaker (480V MCC) Test RecordDC Proof Test Record for Motors

CEM Y

000 509 F76123000 509

F76122

Breaker/Contractor (480V MCC) Test RecordFeeder Breaker (480V MCC) Test Record

CEM Y

000 509 F76124000 509

F76123

460V Motor Circuit (480V MCC) Test RecordBreaker/Contractor (480V MCC) Test Record

CEM Y

000 509 F76125000 509

F76124

Medium Voltage Motor Circuit Test Record460V Motor Circuit (480V MCC) Test Record

CEM Y

000 509 F76126000 509

F76125

Equipment Absorption Ration and Polarization Index Test Record (Megger)Medium Voltage Motor Circuit Test Record

CEM Y

000 509 F76127000 509

F76126

Insulation Resistance (Medium Voltage Power Cables) Test RecordEquipment Absorption Ration and Polarization Index Test Record (Megger)

CEM Y

000 509 F76128000 509

F76127

Bus Throat Insulation and Ductor ReportsInsulation Resistance (Medium Voltage Power Cables) Test Record

CEM Y

000 509 F76129000 509

F76128

Circuit Breaker Contract Timing Test ReportBus Throat Insulation and Ductor Reports

CEM Y

000 509 F76130000 509

F76129

Vacuum Circuit Breaker Ductor Insulation ReportCircuit Breaker Contract Timing Test Report

CEM Y

000 509 F76131000 509

F76130

Drawout Vacuum Breaker Inspection TestVacuum Circuit Breaker Ductor Insulation Report

CEM Y

000 509 F76132000 509

F76131

Main Bus Insulation and Ductor ReportDrawout Vacuum Breaker Inspection Test

CEM Y

000 509 F76133000 509

F76132

Electric Motor Run-In Test RecordMain Bus Insulation and Ductor Report

CEM Y

000 509 F76134000 509

F76133

Drawout Air Circuit Breaker Inspection RecordElectric Motor Run-In Test Record

CEM Y

000 509 F76135000 509

F76134

Insulation Resistance (Rotating Equipment) Test RecordDrawout Air Circuit Breaker Inspection Record

CEM Y

000 509 F76201000 509

F76135

Emergency Generators Inspection ChecklistInsulation Resistance (Rotating Equipment) Test Record

CEM Y

000 509 F76202000 509

F76201

Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units)Emergency Generators Inspection Checklist

CEM Y

000 509 F76203000 509

F76202

Inspection LV Switchgear (Including Incoming and Sectionalizer Units)Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units)

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F76204000 509

F76203

Inspection of Outgoing – LV SwitchgearInspection LV Switchgear (Including Incoming and Sectionalizer Units)

CEM Y

000 509 F76205000 509

F76204

Inspection of Static Supply Unit (UPS)Inspection of Outgoing – LV Switchgear

CEM Y

000 509 F76206000 509

F76205

Motor Control Centers Inspection ChecklistInspection of Static Supply Unit (UPS)

CEM Y

000 509 F76207000 509

F76206

Motor Control Centers (Motors and Starters) Inspection RecordMotor Control Centers Inspection Checklist

CEM Y

000 509 F76208000 509

F76207

High Voltage Motors and StartersMotor Control Centers (Motors and Starters) Inspection Record

CEM Y

000 509 F76209000 509

F76208 Motors ChecklistHigh Voltage Motors and Starters CEM Y

000 509 F76210000 509

F76209

Control and Relay Panels Inspection ChecklistMotors Checklist

CEM Y

000 509 F76211000 509

F76210

Electronic Equipment Inspection ChecklistControl and Relay Panels Inspection Checklist

CEM Y

000 509 F76212000 509

F76211

Power Panel Inspection ChecklistElectronic Equipment Inspection Checklist

CEM Y

000 509 F76213000 509

F76212

Switchgear Inspection ChecklistPower Panel Inspection Checklist

CEM Y

000 509 F76214000 509

F76213

Low Voltage Feeders Inspection RecordSwitchgear Inspection Checklist

CEM Y

000 509 F76215000 509

F76214

High Voltage Cable Inspection and Test RecordLow Voltage Feeders Inspection Record

CEM Y

000 509 F76216000 509

F76215

Electrical Equipment Inspection RecordHigh Voltage Cable Inspection and Test Record

CEM Y

000 509 F76217000 509

F76216

Control Scheme Inspection ChecklistElectrical Equipment Inspection Record

CEM Y

000 509 F76218000 509

F76217

Power Transformer Inspection ChecklistControl Scheme Inspection Checklist

CEM Y

000 509 F76219000 509

F76218

Switching Units – HV Switchgear Inspection and Test RecordPower Transformer Inspection Checklist

CEM Y

000 509 F76220000 509

F76219

Switching Units – HV Switchgear Inspection ChecklistSwitching Units – HV Switchgear Inspection and Test Record

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F76221000 509

F76220

Liquid – Filled Transformer Inspection RecordSwitching Units – HV Switchgear Inspection Checklist

CEM Y

000 509 F76222000 509

F76221

Busway Inspection RecordLiquid – Filled Transformer Inspection Record

CEM Y

000 509 F76223000 509

F76222

Switchgear Inspection RecordBusway Inspection Record

CEM Y

000 509 F76224000 509

F76223

Motor Control Center Inspection RecordSwitchgear Inspection Record

CEM Y

000 509 F76225000 509

F76224

Battery and Battery Charger Inspection RecordMotor Control Center Inspection Record

CEM Y

000 509 F76226000 509

F76225

Liquid Immersed Medium Voltage Disconnect Switch Inspection RecordBattery and Battery Charger Inspection Record

CEM Y

000 509 F76227000 509

F76226

Electric Motor – Electrical Activities Inspection RecordLiquid Immersed Medium Voltage Disconnect Switch Inspection Record

CEM Y

000 509 F76228000 509

F76227

Electric Motor – Mechanical Activities Inspection RecordElectric Motor – Electrical Activities Inspection Record

CEM Y

000 509 F76229000 509

F76228

Electric Motor for Compressor Installation ChecklistElectric Motor – Mechanical Activities Inspection Record

CEM Y

000 509 F76230000 509

F76229

Compressor Vibration ChecklistElectric Motor for Compressor Installation Checklist

CEM Y

000 509 F76231000 509

F76230

Vibration Probe RecordCompressor Vibration Checklist

CEM Y

000 509 F76232000 509

F76231

Dry Type Lighting, Receptacle & Instrument Transformers ChecklistVibration Probe Record

CEM Y

000 509 F76233000 509

F76232

Instrument Wire and Cables Continuity Checks >50VDCDry Type Lighting, Receptacle & Instrument Transformers Checklist

CEM Y

000 509 F76401000 509

F76233

Heat Trace Test LogInstrument Wire and Cables Continuity Checks >50VDC

000 509 F76402000 509

F76401

Electrical Heat Trace Inspection RecordHeat Trace Test Log

000 509 F77001000 509

F76402

Instrumentation Inspection ChecklistElectrical Heat Trace Inspection Record

CEM Y

000 509 F77002000 509

F77001

Instrument Loop Checklist InspectionInstrumentation Inspection Checklist

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F77003000 509

F77002

Impulse Line Pressure Test SheetInstrument Loop Checklist Inspection

CEM Y

000 509 F77004000 509

F77003

Instrument Grounding System Check SheetImpulse Line Pressure Test Sheet

CEM Y

000 509 F77005000 509

F77004

Installation Check Sheet (Local Instruments)Instrument Grounding System Check Sheet

CEM Y

000 509 F77006000 509

F77005

Orifice Plate Specification Check ReportInstallation Check Sheet (Local Instruments)

CEM Y

000 509 F77007000 509

F77006

Control Systems Quality Control indexOrifice Plate Specification Check Report

CEM Y

000 509 F77008000 509

F77007 Loop Check RecordControl Systems Quality CEM Y

000 509 F77101000 509

F77008 Instrument Calibration SheetLoop Check Record CEM Y

000 509 F77102000 509

F77101

Safety Valve Tracking SheetInstrument Calibration Sheet

CEM Y

000 509 F77103000 509

F77102

Relief Valve Inspection and Final AcceptanceSafety Valve Tracking Sheet

CEM Y

000 509 F77104000 509

F77103

Switch Calibration Data RecordRelief Valve Inspection and Final Acceptance

CEM Y

000 509 F77105000 509

F77104

Valve Calibration Data RecordSwitch Calibration Data Record

CEM Y

000 509 F77106000 509

F77105

Control System Test Equipment Calibration LogValve Calibration Data Record

CEM Y

000 509 F77107000 509

F77106

Loop Mechanical Completions and Acceptance RecordControl System Test Equipment Calibration Log

CEM Y

000 509 F78001000 509

F77107

Coating Inspection RecordLoop Mechanical Completions and Acceptance Record

CEM Y

000 509 F78002000 509

F78001

Lining Inspection RecordCoating Inspection Record

CEM Y

000 509 F78101000 509

F78002

Equipment Thermal Insulation InspectionLining Inspection Record

CEM Y

000 509 F78102000 509

F78101

Piping Thermal Insulation RecordEquipment Thermal Insulation Inspection

CEM Y




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F78201000 509

F78102

Release For Application/Inspection Of Fireproofing ChecklistPiping Thermal Insulation Record

CEM Y

000 509 F78202000 509

F78201

Fireproofing Inspection Preconstruction ChecklistRelease For Application/Inspection Of Fireproofing Checklist

CEM Y

000 509 F78301000 509

F78202

Cathodic Protection Inspection ReportFireproofing Inspection Preconstruction Checklist

CEM Y

000 509 F79001000 509

F78301

Daily Welding ReportCathodic Protection Inspection Report

CEM Y

000 509 F79002000 509

F79001

Post Weld Heat Treatment LogDaily Welding Report

CEM Y

000 509 F79201000 509

F79002

Welder B31.3 Random Radiography Control LogPost Weld Heat Treatment Log

CEM Y

000 509 F79202000 509

F79201

Nondestructive Examination Request/RecordWelder B31.3 Random Radiography Control Log

CEM Y

000 509 F79203000 509

F79202

Radiographic Rejectable Defects StatisticsNondestructive Examination Request/Record

CEM Y

000 509 F79204000 509

F79203

Welding/NDE Status LogRadiographic Rejectable Defects Statistics

CEM Y

000 509 F79205000 509

F79204 Ferrite Test ReportWelding/NDE Status Log CEM Y

000 509 F79206000 509

F79205

Welding/NDE Double Joints Status LogFerrite Test Report

CEM Y

000 509 F79301000 509

F79206

PMI Inspection RecordWelding/NDE Double Joints Status Log

CEM Y

000 509 F79302000 509

F79301

Bulk Material Positive Material Identification RecordPMI Inspection Record

CEM Y

000 509 F79303000 509

F79302

Pipe Spool Positive Material Identification Record “Point” SheetBulk Material Positive Material Identification Record

CEM Y

000 509 F79304000 509

F79303

Weekly PMI LogPipe Spool Positive Material Identification Record “Point” Sheet

SQM N

000 509 F79501000 509

F79304

Verification Of Training For Hardness TestingWeekly PMI Log

SQM N

000 509 F79502000 509

F79501

Report Of Vision TestVerification Of Training For Hardness Testing

SQM N




Turnover Package

Records Retention

Center

Records Retention

Center File

Locator Code


Y = Yes N = No

Y = Yes N = No

Retention (Years)

000 509 F79503000 509

F79502 Hardness Testing ReportReport Of Vision Test CEM Y

000 509 F79503 Hardness Testing Report

GENERAL NOTES: Note #1 If NDE Reports contain data on more than one line, copies of the report shall be placed in each line file to which 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.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 FILE LOCATOR CODES:

R1 System No. R2 Form No. (by date of completion or alphabetical)

R3R1 Equipment No.System No. R4R2 Pour No.Form No. (by date of completion or alphabetical)

R5R3 By FCR No.Equipment No. R6R4 Drawing No.Pour No.

R7R5 Line and SheetBy FCR No. R6 Drawing No.

R7 Line and Sheet

ACRONYMS:

ACRONYMS:

CEM Construction Engineering Manager SQM Site Quality Control Manager

CACEM Contracts AdministratorConstruction Engineering Manager

DESQM

Discipline EngineerSite Quality Control Manager

NDECCA NDE CoordinatorContracts Administrator

RRCDE

Record Retention CenterDiscipline Engineer

NDEC NDE Coordinator RRC Record Retention Center





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QUALITY RECORDS CONTROL ID A01601

Record Identification Custodian Turnover Records

Retention Center File Locator

Code Form # Title Job Title or Sub Name

Y = Yes N = No

Retention Period

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 Copies of these records are to be sent to the applicable Construction Technology Welding Engineer as they are

generated. Note #4 Reference the Project File Index for Fluor Daniel files numbers. Note #5 Maintain by Equip. Tag. Number.

FILE LOCATOR CODES:

R1 = System No. R2 = Form No. (by date of completion or alphabetical) R3 = Equipment No. R4 = Pour No. R5 = By FDCR No. R6 = Drawing No. R7 = Line and Sheet

ACRONYMS:

CEM = Construction Engineering Manager CQM = Site Quality Control Manager CA = Contracts Administrator DE = Discipline Engineer NDEC = NDE Coordinator RRC = Records Retention Center


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QUALITY AUDITS

SCOPE This procedure describes the responsibilities and activities for performing quality audits of construction quality-related activities. Audits are performed to determine the effectiveness of the Fluor Site Quality Manual implementation as well as verifying compliance with established requirements.

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. This procedure requires that audits be documented and tracked using the Quality Management System (QMS) tool. This is an established program used by Fluor across the company for management of quality audits. The program is Lotus Notes based. It can be found by going in to FDNet and typing http://www.fdglobal.com/fdglobal/workgrps/qa/qms.nsf in the URL bar at the top of the screen. Projects that do not have access to FDNet or projects that are experiencing connectivity issues with the Fluor network may be allowed to use the alternative forms noted in this procedure. 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 established requirements. These requirements can include the Site Quality Manual, drawings, specifications, codes, standards, plans and procedures

PROCEDURE Site Quality Manager - Ensure, if using QMS, that at least one person has been qualified as a lead auditor. This person

will be responsible for all audits entered in to the QMS program. Qualification as a lead auditor will be in accordance with Section 2 of the QA Procedures Manual 000.042.1000 which is available in Knowledge On Line.

- Establish a schedule for conducting Quality Audits. Refer to Attachments I for schedule

examples. It is preferred that the schedule in QMS be used, however 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 re-audit schedule.

- Request a copy of the QA Project Audit schedule to see when site audits are planned from the

engineering office.



- Ensure that personnel performing audits using QMS have obtained access rights and have taken the necessary training to be able to work in QMS. Access rights can be obtained from Barry Rittberg. His e-mail address is [email protected]. His phone number is 949-349-2356. QMS and auditor training material are available and can be found in the Quality knowledge community in Knowledge On Line (KOL). The courses required to be taken for auditing are: QA020 – Training For Discipline Auditors (this is available in Fluor University) QA025 – How To Use Discipline Audit Checklists (this is available in Fluor University) Personnel who wish to become certified as lead auditors will be required to take the above training, perform three audits (as required by the QA Procedures Manual), and take a test. The test is to be coordinated with Barry Rittberg once the person has obtain certificates from Fluor University attesting that the above training courses have been successfully completed. The following training material is recommended if the above does not provide enough information to perform audits. QA004 – Using QMS (this is considered required reading) QA021 – Internal Auditing Basics (this is a video to be watched)

- Develop an audit plan by reviewing the Quality Program (contractor's and/or Fluor’s) and identifying the items to be verified. This may be done by marking up an uncontrolled copy of the procedures, development of a checklist or other methods. This audit does not need to include activities that are subjected to surveillance (reference 000 509 0220). Previous audit results should be considered. It is recommended that personnel review the on-line training class QA-031 How To Create A Project Audit Plan if they are looking for guidance on how to develop an audit plan. This class is available in the quality community in Knowledge On Line.

- Review and concur with the plan, checklist, marked up procedures or other acceptable method of

identifying items to be verified. - Provide a copy of the audit log to the regional quality manager on a monthly basis if the project is

not using QMS. Auditor - Ensure that the required QMS and auditor training, as detailed above, have been taken prior to

starting an audit. - Execute the audit in accordance with the established checklist. There is a detailed procedure

000.042.1000 in the quality knowledge community that describes the Fluor audit process. Personnel conducting construction audits are advised to review this document.

- Audit findings are to be created, issued and tracked in the QMS program.

- For projects that are not able to use QMS then a nonconformance or corrective action report (see

procedures 000.509.0130 & 000.509.0140) is to be issued when an activity or action is found to



not comply with a written requirement. Recommendations are to be treated as observations and will be noted in the narrative audit report.

- An audit summary report from QMS will summarize the audit results and can be used to manage the audit work process on the project. The audit report, and any associated findings, is to be issued to the Site Quality Manager (SQM) for processing (unless this task has been delegated by the SQM to another person)

- Projects that are not able to use QMS are to ensure that audits, nonconformances and corrective actions are logged. Sample log formats for nonconformances and corrective actions are referenced in procedures 000.509.0130 & 000.509.0140.

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 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 (and any associated audit findings)

and issue to the Site Manager. Review results of the audit with the Site Manager. A copy of the report is to be sent to the Construction Technology's Regional 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.

- Keep track of outstanding audit findings and report this to the Site Manager on a regular basis.

Frequency of reports is to be agreed between the Site Manager and the Site Quality Manager.



Site Quality Manager / Auditee - Assign responsibility for disposition of deficiency and record in QMS. Findings raised in QMS are

then e-mailed to the person responsible for correcting the finding. - For projects that are not using QMS the person responsible for disposition is to be given a copy of

the nonconformance report, along with follow-up reminders, via e-mail until the deficiency has been properly dispositioned.

Auditor Assist the Site Quality Manager with identifying any required root causes and following up on close out of findings.

DOCUMENTATION - QMS Audit summary with attached Audit Findings. Note, for projects not using QMS the audit

report and summary are to be maintained by audit number in a file system · Copy of closed audit findings - Root Cause Analysis if required

FORMS Quality Control Forms: - 000 509 F01702 - Audit Summary (if not using QMS)

ATTACHMENTS Attachment 1 - Audit Schedule (Fluor) – if not using schedule in QMS Attachment 2 -Audit Schedule (Subcontractor(s)) – if not using schedule in QMS



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.



AUDIT SCHEDULE (Subcontractors)

Subcontractors Jan. |

Feb. |

March |

April |

May |

June |

July |

Aug. |

Sept. |

Oct. |

Nov. |

Dec. |

(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.



AUDIT SUMMARY ID A01702

Project: Construction Audit Number:

Client: Audit Dates:

Project Number: Report Date:

Audit Location:

Audit Scope:

Summary of Audit Results:

Entry Meeting Date: Exit Meeting Date:

The entry & exit meeting were conducted with:

A summary of the audit results is as follows:

Quality Manual Principles assessed. Quality Manual Principles found to be satisfactory.

Deficiencies reported. Observations for improvement.

Previous Findings and Action Follow-up:

Finding Number Status – (Open or Closed) Date Closed

Lead Auditor Signature: Date:





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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.



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

- Provide for instructor, facilities and equipment support.

Note: Instructors will usually be the Site Quality Manager, the Construction Engineering Manager and/or discipline engineers.

Training needed for certification will usually be provided by Construction Technology.



• 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





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PROJECT SPECIFIC QUALITY TRAINING ID A01801

Training Subject:

Instructor(s):

Duration:

Date:

Attendees Member Number Job Title

Note: Attach Training Outline Instructor Signature:


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SITE SUBCONTRACTOR QUALIFICATION

SCOPE This procedure describes the initial qualification of site subcontractors. This procedure does not apply to subcontractors that have been previously approved by Fluor or the Owner.

GENERAL When qualifications of site subcontractors include an evaluation of the Quality capabilities of the subcontractor, the evaluation shall be done in accordance with this procedure.

PROCEDURE • Qualification of Subcontractors • Contracts Administrator

- Upon selection of a proposed subcontractor, the Contracts Administrator shall notify the Site Quality Manager and request a subcontractor qualification be performed. When construction has designated someone to technically supervise the proposed subcontractor, he shall also be notified.

NOTE: The Contracts Administrator shall contact the subcontractor relative to the

obtaining of documents, arranging of communication or establishment of meetings and/or visits.


- Upon notification (including receipt of subcontractor quality programs), review the qualifications of the proposed subcontractor based upon the quality requirements to be included in the Fluor subcontract. This review may include meetings and/or visits with the subcontractor candidate. The Site Quality Manager may use the "Site Subcontractor Qualification" guidelines (Form 000.509.F02001); however, this guide does not necessarily represent the quality requirements to the subcontractor and therefore should be used only as an aid to the evaluation. The Technical Supervisor should use the applicable "Evaluation Record" (Forms 000.509.F02002 and 000.509.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):

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.


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

If the subcontractor is "conditionally" qualified, complete and forward the "Site

Subcontractor Qualification" form as above, however include the specific limitations and/or actions that will be required.


- Process contractor qualification documents in accordance with the Document Control Section in the SPM and procedure 000.509.0160 (Quality Records).

FORMS Quality Control Forms: 000.509.F02001 - Site Subcontractor Qualification 000.509.F02002 - Soil Testing Laboratory Evaluation Record 000.509.F02003 - Asphalt Testing Laboratory Evaluation Record 000.509.F02004 - Concrete Batch Plant Evaluation Record 000.509.F02005 - Concrete Testing Laboratory Evaluation Record 000.509.F02006 - NDE Subcontractor Evaluation Record


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SITE SUBCONTRACTOR QUALIFICATION ID A02001

Project Name Project Number

Subcontractor RFP Number

Address

City, State, Zip PO Number

Scope of subcontracted work

Subcontractor Quality Representative (1st in charge)

Title Phone

Email

Subcontractor Quality Representative (2nd in charge)

Title Phone

Email

Quality Management Reports To Title

Qualification Approval

Approved “Conditionally” Approved Not Approved Required additional actions

Explain “Conditional Approval” here. Consider especially the additional cost if the subcontractor will need assistance in operation of the quality program.

Site Quality Manager Date Site Contracts Administrator Date



1.0 Organization

1.1 Does the subcontractor have a quality control organization:

1.2 Is an organization chart available:

1.3 Does inspection have sufficient authority within the overall organization?

1.4 Is inspection adequately organized and staffed to exercise its responsibilities:

1.5 Are inspection reporting channels adequate:

2.0 Quality Program

2.1 Does the subcontractor have a quality manual?

2.2 Is the quality manual approved and signed by management? 2.3 Does the subcontractor’s management periodically review their Quality program for effectiveness?

2.4 Are the written procedures or instructions other than the Quality Manual? 2.5 Does the subcontractor have an established and adequate training program for their personnel?

2.6 Is the program compliant with international quality standards?

3.0 Design Control

3.1 Does the subcontractor have a design plan or procedure that:

1. Provides for consideration of the design criteria and requirements?

2. Lists all design document required, e.g., drawings and specifications?

3. Identifies design responsibilities?

4. Provides for the inclusion of acceptance criteria? 3.2 Does the subcontractor have a procedure for the review and control of design documents that:

1. Designates responsibility for design review?

2. Provides a method of design change control? 3. Provides for the review of design changes and field changes by responsible personnel?

3.3 Is design reviewed for suitability of material and processes?

3.4 Are the current revisions of the design documents known and available to engineering? 3.5 Is the results of the design verification resolved according to a controlled and operative plan? 3.6 Do design changes and corresponding document changes receive an adequate design verification. 3.7 Is there a mechanism to incorporate field operations and requirement changes into the design documents? 3.8 Is the design document release to purchasing and/or construction/manufacturing, controlled and adequate?

3.9 Are required subcontractor documents clearly identified?

3.10 Is the review of required subcontractor documents formalized as a procedure?



4.0 Procurement Document Control 4.1 Does the subcontractor have an adequate procedure in use for Procurement Document Control?

4.2 Is each procurement document reviewed for the following:

1. Subcontractor’s Quality requirements to their vendors?

2. Customer’s Quality requirements to contractor’s vendors?

3. A check for latest revision of drawings, specification, codes, etc.?

4. Special packaging and preservation requirements?

5. Special tests or certifications?

6. Provisions for audits by subcontractor and/or customer?

7. A check for the inclusion of design criteria of basis?

8. Source Inspection requirements?

5.0 Instructions, Procedures and Drawings

5.1 Does subcontractor have a documented system of instructions, procedures and drawings? 5.2 Do instructions, procedures and drawings identify all documents necessary to perform the work, i.e., codes, standards, etc.?

5.3 What is the approval plan for deviations? Describe

5.4 Do instructions and procedures provide hold points where the documentation of conformance is provided?

5.5 Do instructions, procedures and drawings exist at work locations?

6.0 Document Control

6.1 Does subcontractor have a procedure for approval and issue?

6.2 Does document control include:

1. Drawings?

2. Specifications?

3. Instructions?

4. Procedures?

6.3 Is distribution of documents controlled by procedures?

6.4 Are revisions to documents controlled by procedures?

6.5 Are mark-up documents used?

7.0 Control or Purchased Material, Equipment and Services

7.1 Does subcontractor evaluate sub-tier suppliers? 1. Are there adequate procedures in use to define sub-tier supplier requirements?

7.2 Is a survey performed before qualifying a new supplier?

7.3 Does the system provide for audits of supplier’s inspection program?



7.4 Is there an approved supplier’s list? 7.5 Does subcontractor require his sub-tier suppliers to furnish material certification and/or inspection reports?

7.6 Does subcontractor perform receiving inspection activity?

8.0 Identification and Control of Materials, Parts and Components 8.1 Does the subcontractor have procedures for identification of materials, parts and components?

8.2 Does the program provide controls to prevent mix of materials? 8.3 Are materials in process traceable to manufacturer’s heat treatment number, lot number or other material where required?

8.4 Does the program provide for specific traceability to piece, part or component?

8.5 Is the inspection status of material, part of component easily identified?

9.0 Control or Special Processes 9.1 Does subcontractor have an adequate procedure in use to control qualification of special processes? 9.2 Are procedures available and adequate for the qualification of special process personnel? 9.3 Do procedures identify methods by which measurements will be made, e.g., current, temperature, etc.?

9.4 Do procedures provide for documentation of parameters?

9.5 Are the procedures available at work locations for special processes?

10.0 Inspection

10.1 Does subcontractor have general procedures written for:

1. Receiving Inspection?

2. In-Process Inspection?

3. Final Inspection?

10.2 Do written inspection instructions provide inspection personnel with:

1. Measuring equipment required?

2. Parameters to be inspected?

3. Criteria for determining quality conformance or rejection? 4. Specification of the environment for the inspections

(E.g., temperature controlled, etc.)?

5. Identification of inspection holds points?

10.3 Are purchase orders, drawings, specifications, etc. available to inspection personnel?

10.4 Is inspection documented by work order, shop traveler, history record, etc.? 10.5 Is nonconforming material properly identified and segregated to prevent unauthorized use?

10.6 Are provisions adequate to permit the customer to designate hold points for inspections? 10.7 Do source and receiving inspection procedures provide for the proper handling, storage and preservation of materials and equipment?



10.8 Is adequate inspection and test equipment available? 10.9 Are inspection procedures and/or instructions reviewed and approved by higher authority than initiator prior to release? 10.10 Are personnel performing inspections different than those that performed the activity being inspected?

11.0 Test Control

11.1 Does subcontractor have written test procedures in existence and used?

11.2 Are accept-reject criteria specified in the test procedure?

11.3 Does procedure provide a list of test instruments to be used?

11.4 Are test results documented and maintained?

11.5 Does inspection perform testing?

11.6 Are there provisions in procedures to permit customer to witness test?

12.0 Control of Measuring and Test Equipment

12.1 Does the subcontractor have a program for calibration of inspection and test instruments? 12.2 Does subcontractor have a calibration laboratory or approved source for calibration of inspection and test instruments?

12.3 Are all inspection and test instruments uniquely identified?

12.4 Are calibration dates and re-calibration due dates marked on tools and instruments?

12.5 Are tool and instrument record cards maintained?

12.6 Are calibration standards traceable to the N.I.S.T.? 12.7 Does the program assure removal from service of equipment that has exceeded calibration period?

12.8 Are inspection equipment and calibration standards properly handled and protected?

13.0 Handling Storage and Shipping

13.1 Does subcontractor have written procedures that describe proper handling of material?

13.2 Are their written procedures that describe proper storage of materials? 1. Do the procedures specify preservation and environmental conditions to be maintained during storage?

2. Are materials stored in such a manner as to prevent damage?

3. Are storage facilities adequate for the type of materials stored? 4. Is material, having service life, properly dated, stored and rotated in stock for control of shelf life? 5. Are obsolete items purged from the stock area periodically? 6. Are corrosive, toxic or flammable materials properly stored and segregated?

13.3 Is their adequate procedure in use, which controls shipping activity?

14.0 Inspection and Test Status

14.1 Does subcontractor have controls that permit determination of inspection and test status? 14.2 Are shop travelers or tags used to show status of inspection or tests?

14.3 Do shop travelers or tags have sign offs at each inspection station? 14.4 Are inspection stamps used? 14.5 Does inspection and test status information become part of final quality documentation?



15.0 Nonconforming Materials, Parts or Components 15.1 Does subcontractor have written procedure(s) available for the identification and control of nonconforming items?

15.2 Does procedure(s) specify the identification to be used on item?

15.3 Are nonconforming items segregated and adequately controlled to prevent their use? 15.4 Is there a procedure for advising customer of all nonconformances that are applicable to the customer’s orders?

16.0 Corrective Action 16.1 Does subcontractor have an adequate procedure in use for control of the corrective action program?

16.2 Are causes of deficiencies identified? 16.3 Is there approved documentation for the disposition of the item, scrap, repair acceptance, etc.?

16.4 Is there a follow-up system to assure expedient response to corrective action requests?

16.5 Are corrective action summaries reported to management?

16.6 Are records of nonconformity and approved disposition traceable to the item? 16.7 Are provisions made for the prompt action on customer’s comments resulting from inspections and audits?

17.0 Quality Records 17.1 Does subcontractor have a procedure/system identifying what records are to be maintained?

17.2 Are records maintained covering:

1. Supplier Surveys?

2. Inspection (Receiving, In-Process, Final)?

3. Material (plus certification)? 4. Audits? 5. Inspection Reports? 6. Inspection Instructions?

7. Test Records?

8. Test Logs?

9. Failure Reports?

10. Special Process Certification?

11. Procedure Qualifications?

12. Personnel Qualification (NDE, etc.)?

13. Personnel Qualification – Welding?

14. Other 17.3 Does the system provide for review of final data packages prior to shipment of equipment?

17.4 Are record locations defined?



17.5 Are retention periods defined?

17.6 Is disposition of records defined?

17.7 Does the system provide for storage of radiograph film to prevent deterioration and loss?

17.8 Is customer release obtained before Quality records are destroyed?

18.0 Audits

18.1 Does subcontractor have an adequate procedure/system defining the audit program?

18.2 Is there a planned schedule?

18.3 Is there a checklist provided for each audit?

18.4 Is there a detailed report required for each audit?

18.5 Is follow-up action prescribed (i.e., re-audit or deficient areas)?

18.6 Are there internal quality system audits of:

1. Receiving Inspection?

2. In-Process Inspections?

3. Final Inspections?

4. Quality Control Records?

5. Nonconforming Material Control?

6. Corrective Action Systems?

7. Calibration of Inspection Tools and Instruments?

8. Materials Control?

9. Drawing and Procedure Control?

10. Design Control?

11. Special Processes?

12. Packaging and Shipping Inspections?

13. Other

18.7 Does management review audit reports?





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SOIL TESTING LABORATORY EVALUATION RECORD ID A02002

INDEX

1.0 INSTRUCTIONS

2.0 EQUIPMENT FOR SOILS INSPECTION AND TESTING

2.1 LABORATORY TESTING EQUIPMENT

2.2 FIELD TESTING EQUIPMENT

3.0 MANAGEMENT SUPERVISION

4.0 CONCLUSION AND REMARKS

5.0 RECOMMENDATIONS



1.0 INSTRUCTIONS

1.1 This evaluation can only be made by the assigned Construction Engineer or others

qualified to review soil testing laboratories. 1.2 The space to the right of each statement in this document should be completed with

one, two, or three word answers, such as: Yes, No, Satisfactory, Unsatisfactory or, Does Not Apply, etc.

1.3 If any part of the testing laboratory has not been inspected, indicate to the right of the

appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual

statement. 1.5 The conclusions drawn by the Inspector should be based only upon observations and

documentation noted in the body of the report.



2.0 EQUIPMENT FOR SOILS INSPECTION AND TESTING

2.1 Laboratory Testing Equipment

2.1.1 Is equipment available to satisfy ASTM D 1140-54 "Amount of Material In Soils Finer Than The No. 200 Sieve?"

2.1.2 Is equipment available to satisfy ASTM D 1883-73 "Bearing Ratio

of Laboratory-Compacted Soils?" 2.1.3 Is equipment available to satisfy ASTM D 423-66 "Liquid Limit of

Soils?" 2.1.4 Is equipment available to satisfy ASTM D 3017-78 "Moisture

Content of Soils, and Soil Aggregate in Place By Nuclear Methods (Shallow Depth)?"

2.1.5 Is equipment available to satisfy ASTM D 2216-80 "Moisture

Content of Soil, Laboratory?" 2.1.6 Is equipment available to satisfy ASTM D 698-78 "Moisture-Density

Relations of Soils, Using 5.5 LB. (2.5kg) Rammer, and 12-inch (304.8 mm) Drop?"

2.1.7 Is equipment available to satisfy ASTM D 1557-78 "Moisture-

Density Relations of Soils Using 10-LB (4.5kg) Rammer, and 18-inch (457.8 mm) Drop?"

2.1.8 Is equipment available to satisfy ASTM D 424-59 "Plastic Limit and

Plasticity Index of Soils?"

2.1.9 Is equipment available to satisfy ASTM D 2049-69 "Relative Density of Cohesion-less Soils?"

2.1.10 Is equipment available to satisfy ASTM D 2166-66 "Unconfined

Compressive Strength of Cohesive Soils?"

2.1.11 Is there and additional equipment required for this contract?



2.0 EQUIPMENT FOR SOILS INSPECTION AND TESTING (Cont’d)

2.2 Field Testing Equipment

2.2.1 Is equipment available to satisfy ASTM D 2922-78 "Density of Soil and Soil Aggregates in Place of Nuclear Methods (Shallow Depth)?"

2.2.2 Is equipment available to satisfy ASTM D 2937-71 "Density of soil

in Place By The Drive-Cylinder Method?" 2.2.3 Is equipment available to satisfy ASTM D 2167-66 "Density of Soil

in Place By The Rubber Balloon Method?" 2.2.4 Is equipment available to satisfy ASTM D 1556-64 "Density of Soil

in Place By The Sand-Cone Method?" 2.2.5 Is equipment available to satisfy ASTM D 1194-72 "Bearing

Capacity of soils for Static Load on Spread Footings?"




3.1 Is the Agency under the direction of a person charged with engineering

managerial responsibility?

3.2 Does that peson have a Masters Degree in Soils from an accredited College or University, and is he/she a full time employee of the Agency?

3.3 Does he/she have at least five years of engineering experience in inspection

and testing of soils? 3.4 Does the Supervising Laboratory Technician have at least five years

experience performing tests on soils?

3.5 Does he/she demonstrate an ability to perform the tests normally required in

the manner stipulated under ASTM or other governing procedures? 3.6 Does the Supervising Field Technician have at least five years experience in

the kind of work involved on construction projects? 3.7 Does that person demonstrate either by oral or written examination, or both,

the ability to perform correctly the duties required?



4.0 CONCLUSIONS AND REMARKS

The Agency does have adequate facilities and qualified personnel to perform the work required by Fluor in accordance with contract specifications:

5.0 RECOMMENDATIONS


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ASPHALT TESTING LABORATORY EVALUATION RECORD ID A02003

INDEX

1.0 INSTRUCTIONS

2.0 EQUIPMENT FOR ASPHALT INSPECTION AND TESTING



5.0 RECOMMENDATIONS



1.0 INSTRUCTIONS


qualified to inspect Asphalt Testing Laboratories. 1.2 The space to the right of each statement in this document should be completed with








2.0 EQUIPMENT FOR ASPHALT INSPECTION AND TESTING

2.1 Is equipment available to satisfy ASTM D-5 test for penetration of

bituminous materials? 2.2 Is equipment available to satisfy ASTM D-92 test for flash and fire points

by Cleveland open cup? 2.3 Is equipment available to satisfy ASTM D-113 test for ductility of

bituminous materials? 2.4 Is equipment available to satisfy ASTM D-1754 test for effect of heat and

air on asphalt materials (thin film oven test)? 2.5 Is equipment available to satisfy ASTM D 2042 test for solubility of asphalt

materials in trichlorethylene? 2.6 Is equipment available to satisfy ASTM C-127 test for specific gravity and

absorption of coarse aggregate? 2.7 Is equipment available to satisfy ASTM C-128 test for specific gravity and

absorption of fine aggregate? 2.8 Is equipment available to satisfy ASTM C-136 test for sieve or screen

analysis of fine and coarse aggregates? 2.9 Is equipment available to satisfy ASTM D 2172 test for quantitative

extraction of bitumen form bituminous paving mixtures? 2.10 Is equipment available to satisfy ASTM D 1559 test for resistance to

plastic flow of bituminous mixture using Marshall apparatus?

2.11 Is there any additional equipment required for this contract?






3.2 Does that person a Bachelors Degree of Science or Engineering from an accredited College or University, and is he/she a full time employee of the Agency?


and testing of asphalt? 3.4 Does the Supervising Laboratory Technician have at least five years

experience performing tests on asphalt? 3.5 Does he/she demonstrate an ability to perform the tests normally required in

the manner stipulated under ASTM or other governing procedures? 3.6 Does the Supervising Field Technician have at least five years experience in

the kind of work involved on construction projects? 3.7 Does he/she demonstrate either by oral or written examination, or both, the

ability to perform correctly the duties required?





5.0 RECOMMENDATIONS





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CONCRETE BATCH PLANT EVALUATION RECORD ID A02004

INDEX

1.0 INSTRUCTIONS

2.0 MATERIALS AND STORAGE HANDLING

3.0 BATCHING EQUIPMENT

4.0 CENTRAL MIXER

5.0 TICKETING SYSTEM

6.0 DELIVERY FLEET

7.0 QUALITY CONTROL


9.0 RECOMMENDATIONS




1.0 INSTRUCTIONS


qualified to inspect Batch Plants. 1.2 The space to the right of each statement in this document should be completed with




statement. 1.5 If additional test equipment is required for a specific contract, other than that listed in

this form, add to the list. 1.6 The conclusions drawn by the Inspector should be based only upon observations and


NOTE: Is this plant certified to ASTM specification C94-80 (or equivalent international standard)?

Is the plant National Ready Mix Certified?




2.0 MATERIALS AND STORAGE HANDLING

2.1 Cement

2.1.1 Suitability of silos: water tight and constructed to allow free movement to discharge openings.

2.1.2 Are facilities adequate to provide for separation of different cement

and cementious materials required for the project.

2.2 Aggregates 2.2.1 Is the unloading of transports and the building of stockpiles

adequate to prevent segregation. 2.2.2 Will stockpile areas prevent contamination and allow for free

draining?

2.3 Water 2.3.1 Is an adequate clean supply of water available? 2.3.2 Are cold weather and hot weather facilities adequate?

2.4 Admixtures 2.4.1 Are storage and handling systems for admixtures sufficient to

prevent freezing? 2.4.2 Are the automatic measurement devices in working order?

2.4.3 Are measuring devices in plain view of the operator?




3.0 BATCHING EQUIPMENT

3.1 Scales

3.1.1 Is there a sticker on face of scales indicating date of the latest calibration?

3.1.2 Are test weights available for checking scale accuracy?

3.2 Weight Batchers 3.2.1 Are the batchers for weighing materials freely suspended from a

scale, and equipped with necessary charging and discharging mechanisms?

3.2.2 Is the cement weighed on scales or in weigh hoppers not used for

weighing other concrete materials? 3.2.3 Are batchers large enough to receive the rated load with our

making contact with the charging mechanism? 3.2.4 Are provisions made for removal of overload from batchers?

3.2.5 Are cement batchers provided with dust seals between charging

mechanism hopper? 3.2.6 Is the weigh hopper vented to permit escape of air?

3.2.7 Is the hopper self-cleaning and fitted with means to assure

complete discharge?

3.2.8 Are vibrators or other appurtenances installed in such a way as not

to affect accuracy of weighing?

3.2.9 Is wind protection sufficient to prevent interference with weighing

accuracy?




3.0 BATCHING EQUIPMENT (Cont’d)

3.3 Water Meters

3.3.1 Are the meters equipped with a cut off device capable of stopping the flow within specified tolerance?

3.3.2 Does the operator have a visual indication of the volume of water

used, at any time during the batching operation?

3.4 Dispensers for Liquid Admixture 3.4.1 Is there a separate dispenser for each liquid admixture in regular use? 3.4.2 Is the piping free of leaks and properly valved to prevent backflow or

siphoning to insure that the measured amount is discharged? 3.4.3 Is each volumetric dispenser provided with an accurately calibrated

container in which the admixture may be collected when it is desired to check the accuracy of measurement?

3.4.4 Do the volumetric admixture dispensers provide visual indication, or

interlock cut off, when liquid admixture supply is not available to the dispenser? (This is to prevent the dispensing of air instead of admixture.)

3.5 Accuracy of Plant Batching

3.5.1 Have the cement and aggregate scale been calibrated, and is the

calibration documentation on file?

3.5.2 Have the water meters been calibrated, and is the calibration documentation on file?

3.5.3 Have the admixture dispensers been calibrated, and is the calibration

documentation on file?

3.5.4 Does the producer have compensation control for the free moisture on aggregate?





3.6 Batching Systems

3.6.1 Weight Batcher Controls

3.6.1.1 Manual Control: Are the batching devices actuated by hand, hydraulic, pneumatic, or electrical power assists? (circle one)

3.6.1.2 Semiautomatic Control:: Doe the semiautomatic weigh

batcher control start the weighing operation of the material, and stop the flow automatically when the designated weight has been reached?

3.6.1.3 Does the semiautomatic interlocked weigh batcher control

start the weighing operation of the material, and stop the flow automatically when the designated mass has been reached?

3.6.1.4 Is the system interlocked to assure that the discharge

mechanism cannot be opened until the mass is within the allowable tolerance?

3.6.1.5 Automatic Control: Does the automatic weigh batcher

control start the weighing operation of cement, aggregate, water or admixture, then stop the flow automatically when the designated mass has been reached?

3.6.1.6 Is the system interlocked to assure that:

(a) The charging gate or valve cannot be opened until the

scale has returned to zero balance;

(b) The charging gate or valve cannot be opened if the discharge mechanism is open;

(c) The discharge mechanism cannot be actuated until the

mass of materials is within the allowable tolerance.





3.6 Batching Systems (Cont’d)

3.6.2 Volumetric Batching Device Controls

3.6.2.1 Manual Control: Manual volumetric control for or admixture exists when the volumetric measuring device is actuated manually with the accuracy of the measuring operation being dependent on the operator's visual observation of a volumetric indicator (such as, a digital meter display or a sight gage and his manual cut off of the flow at the desired volume.) Is the flow of water or admixture controlled by hand, pneumatic, hydraulic, or electrical power assists? (circle one)

3.6.2.2 Automatic Control: When actuated by a single starting

signal, does an automatic volumetric control start the measuring operation and stop the flow automatically when the designated volume has been reached?




3.7 Recorders

3.7.1 Are permanent records of the quantity of cement, aggregate and water

measured into a particular batch of concrete provided?

3.7.2 Are the recorders properly protected and capable of being locked?

3.7.3 Are provisions made for identifying the particular batch with the corresponding delivery ticket?

3.7.4 Do the recorders register empty balance?

3.7.5 Are the batched quantities of ingredients recorded?

3.7.6 Do the recorders register the scale readings within the limits specified by

ASTM-C 94-80?

3.7.7 Are the recorders used for all ingredients?




4.0 CENTRAL MIXER

4.1 Is the plant capable of producing uniform concrete in the mixing time

designated in ASTM specification C-94-80 for ready mixed concrete? 4.2 Is the plant equipped with timing devices that will not permit batches to be

discharged before the predetermined mixing time has elapsed?




5.0 TICKETING SYSTEM

5.1 Does the delivery ticket provide the following information?

(Attach a sample of the ticket to this report.)

5.1.1 Name of Ready Mixed Concrete Company.

5.1.2 Ready mixed plant designation if more than one plant is used.

5.1.3 Serial number of ticket.

5.1.4 Truck number of designation.

5.1.5 Name of purchaser.

5.1.6 Name and Location of job.

5.1.7 Specific class or designation of concrete in conformance with job specifications.

5.1.8 Volume of concrete.

5.1.9 Date. 5.1.10 Time when batch was loaded. 5.1.11 Extra water added at the request of the receiver of the concrete,

and his signature or initials. 5.1.12 Type and name of admixture and amount batched.




6.0 DELIVERY FLEET

6.1 Truck Mixers

6.1.1 Is the interior condition satisfactory with no appreciable accumulation of hardened concrete, or blades with excessive wear? (Blade wear shall be checked at the point of maximum drum diameter nearest to the drum head. When the height of the blade at this point, measured from the drum shell, is less than 90 percent of the original radial height, the blade is considered excessively worn. The manufacturer of the mixer will furnish original blade dimensions on request.)

6.1.2 Are the charging, discharge openings and chute is good condition;

free from appreciable accumulations of cement or concrete; with surface clean and smooth?

6.1.3 Is the drum or container of such size, that the rating as a mixer (in

volume of mixed concrete) does not exceed 63 percent of the gross volume of the mixer, disregarding blades? (This requirement is met by all mixers carrying a rating plate of the Truck Mixer Manufacturers Bureau.)

6.1.4 Is the mixer provided with a plate showing the manufacturers

recommended operating speed for mixing? (The range must not be less than four or more than 18 r/min. to operate satisfactorily at recommended speed.)

6.1.5 Is the mixer provided with a counter to indicate the number of

revolutions of the drum or blades? 6.1.6 On units equipped to batch the mixing water, is the equipment in

proper working condition with gage glasses or water meters clean and legibly graduated; water pump or injection system in good working order with nozzles unobstructed, and without leakage into mixer?




6.0 DELIVERY FLEET (Cont’d)

6.2 Summary of Fleet Conditions

Total number of units available for use:

Number of units checked and found acceptable:

Number of units checked and found unacceptable:

TRUCK NO. OR DESIGNATION OF INDIVIDUAL UNIT EXAMINED:

ACCEPTABLE UNACCEPTABLE GIVE REASON

TRUCK MIXERS UNITS

AGITATOR UNITS

NON-AGITATING UNITS




7.0 QUALITY CONTROL

7.1 Are the Quality Control personnel independent of plant line personnel, and

do they report directly to top management? 7.2 Do the Quality Control personnel have adequate experience and training to

supervise concrete production of plant being inspected? 7.3 Are the test facilities adequate to perform physical tests of cement? 7.4 Are the test facilities adequate to perform physical test of aggregates? 7.5 Has the plant and/or trucks been approved for use by any inspecting bodies

of governmental agencies or private institutions?

7.6 Are these inspection records on record?






9.0 RECOMMENDATIONS


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CONCRETE TESTING LABORATORY EVALUATION RECORD ID A02005

INDEX

1.0 INSTRUCTIONS

2.0 EQUIPMENT FOR CONCRETE INSPECTION AND TESTING

2.1 LABORATORY EQUIPMENT

2.2 FIELD INSPECTION EQUIPMENT

3.0 DOCUMENTATION OF QUALIFICATIONS



6.0 RECOMMENDATIONS




1.0 INSTRUCTIONS


qualified to inspect Concrete Testing Laboratories. 1.2 The space to the right of each statement in this document should be completed with









2.0 EQUIPMENT FOR CONCRETE INSPECTION AND TESTING

2.1 Laboratory Equipment

2.1.1 Does the compression testing machine perform to ASTM E4-79 "Verification of Testing Machines", and ASTM C39-80 "Test for Compressive Strength of Cylindrical concrete Specimens?"

2.1.2 Has the testing machine been calibrated and is the calibration

documentation on file? 2.1.3 Are the facilities for preparing concrete test specimens in accordance

with ASTM C192-81 "Making and Curing Concrete Test Specimens in the Laboratory?"

2.1.4 Are the facilities for curing concrete specimens in accordance with

ASTM C511-76. 2.1.5 Are the facilities for capping concrete specimens in accordance with

ASTM C617-76. 2.1.6 Does the equipment for testing concreting materials conforming to

the following ASTM methods?

2.1.6.1 C136-81 Test for sieve or screen analysis of fine and coarse aggregate.

2.1.6.2 C127-80 Test for specific gravity absorption of fire aggregate.

2.1.6.3 C128-79 Test for specific gravity and absorption of fine aggregate.

2.1.6.4 C566-78 Test for total moisture content aggregate by drying.

2.1.6.5 C29-78 Test for unit weight of aggregate.




2.0 EQUIPMENT FOR CONCRETE INSPECTION AND TESTING (Cont’d)

2.1 Laboratory Equipment (Cont’d)

2.1.7 Are the facilities for physical and chemical analysis of cement in accordance with ASTM C150-81?

2.1.8 Are the facilities for testing admixtures and related materials in

accordance with ASTM? 2.1.9 Is there any additional equipment required for this contract?

2.2 Field Inspection Equipment 2.2.1 Are pocket thermometers available? 2.2.2 Is the equipment required by C231-81 "Test for Air Content of

freshly Mixed Concrete by the Pressure Method," available? 2.2.3 Is the equipment required by C31-69, "Making and Curing

concrete Compressive and Flexural Strength Test Specimens, in the field"?

2.2.4 Is the equipment required by ASTM C143-78 "Sampling Fresh

Concrete," available?

2.2.5 Is the equipment required by ASTM C143-78, "Test for Slump of Portland Cement Concrete," available?

2.2.6 Is the equipment required by ASTM C138-77 "Test for Unit

Weight, Yield and Air Content of Concrete," available?

2.2.7 Is there any additional equipment required for this contract?




3.0 DOCUMENT OF QUALIFICATIONS

3.1 Has the Agency had its laboratory equipment and procedures inspected at

intervals of not more than three years by a qualified national authority, as evidence of its competence to perform the required tests?

3.2 Has the Agency had its laboratory equipment and procedures inspected at intervals of not more than three years by a local jurisdictional body as evidence of its competence to perform the required test?

3.3 Are the Field Technicians certified to ACI 301 or other acceptable international recognized standard.







4.2 Is that person a registered professional engineer and a full time employee of that Agency?


and testing of construction materials? 4.4 Does the Supervising Laboratory Technician have at least five years

experience performing tests on construction materials? (He/she shall be able to perform the tests normally required in the manner stipulated under ASTM or other governing procedures.)

4.5 Does the supervising Field Technician have at least five years inspection

experience in the kind of work involved on construction projects? (He/she shall be able to demonstrate either by written or oral examination, or both, the ability to perform correctly the duties required.)






6.0 RECOMMENDATIONS





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NDE SUBCONTRACTOR EVALUATION RECORD ID A02006

INDEX

1.0 INSTRUCTIONS

2.0 GENERAL

2.1 NDE METHODS

2.2 PERSONNEL TRAINING AND CERTIFICATION

2.3 QUALITY ASSURANCE PROGRAM

2.4 MANAGEMENT

2.5 NDE PROCEDURES

2.6 RADIOACTIVE MATERIALS LICENSE

2.7 EXPERIENCE HISTORY

3.0 SPECIFIC

3.1 NDE METHOD ____________________________________


5.0 RECOMMENDATIONS




1.0 INSTRUCTIONS 1.1 This evaluation may only be made by the site nondestructure examination

coordinator, or others qualified to review nondestructive examination contractors. 1.2 The space to the right of each statement in this document should be completed with


1.3 If any function of the NDE contractor has not been inspected, indicate to the right of

the appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual

statement. 1.5 The conclusions drawn by the examiner should be based only upon observations and





2.0 GENERAL 2.1 NDE Method Capabilities

Radiography Magnetic Particle PMI

Ultrasonics Visual (CW) Time of Flight UT

Liquid Penetrant Eddy Current Other

2.2 Personnel Training and Certification 2.2.1 Does subcontractor have a written practice for the qualification and

certification of NDE personnel? 2.2.2 Does written practice utilize SNT-TC-1A as the basis for the

program? 2.2.3 Does written practice properly address examinations required for

each level of certification? 2.2.4 Does initial experience fulfill the requirements of SNT-TC-1A? 2.2.5 Does initial training fulfill the requirements of SNT-TC-1A?




2.0 GENERAL (Cont’d) 2.3 Management

2.3.1 List key management/supervisory personnel and areas of responsibility.

2.3.2 List NDE Level III personnel certified by examination. Add

ASNT certificate number if applicable.

2.3.3 Does subcontractor have records of specific examinations

administered to level III personnel certified on the basis of ASNT examinations?




2.0 GENERAL (Cont’d) 2.4 NDE Procedures

2.4.1 Does subcontractor have written procedures for all NDE methods which he performs?

2.4.2 How does subcontractor ensure that procedures are updated to reflect the latest code requirements?

2.4.3 Do procedures allow interpretation for acceptance by Level I

personnel?

2.4.4 List codes/standards that subcontractor's procedures reference.

2.4.5 Will subcontractor agree to submit all applicable NDE procedures

and report forms to Fluor for review and authorization?




2.0 GENERAL (Cont’d) 2.5 Experience History

2.5.1 List all past and present work in NDE (include summary of methods performed).

2.5.1a Nuclear:

2.5.1b Non-Nuclear:




3.0 SPECIFIC 3.1 Indicate NDE Method:

______________________________________________

3.1.1 Indicate number of Certified Level II Personnel:_____________________

3.1.2 Indicate number of Certified Level I

Personnel:_____________________

3.1.3 List all applicable equipment (Type, MFG and QTY) used to perform examinations, obtain results and verify adequacy of test methods.




3.0 SPECIFIC (Cont’d) 3.1 NDE Method: ____________________________________________

(Cont’d)

3.1.4 Describe general condition of test equipment.

3.1.5 Additional

Comments:




4.0 CONCLUSIONS AND REMARKS The Agency does have adequate facilities and qualified personnel to perform the work required by

Fluor in accordance with contract specifications:

5.0 RECOMMENDATIONS





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CONTRACTOR QUALITY REQUIREMENTS

SCOPE This procedure establishes the quality requirements for Site Contractors and is to be used for all site contracts that involve engineering, procurement and/or construction activities.

APPLICATION This procedure is to 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. It utilizes the standard Attachment E (form 000.430.F0176) which is available in the Contract Management knowledge community in Knowledge On Line (KOL).

GENERAL Contractor is responsible for providing services and performing work in accordance with the design and quality requirements as required by their contract. Company’s approach to construction management contracting normally requires each Contractor to staff and perform the inspection activities, with Company performing surveillance over the Contractor activities. 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 for Company approval. However, since Fluor utilizes a turnover software program, it is ideal if the Contractors use Fluor’s forms. This allows for consistency between Contractors in how they document their inspection and testing activities and it makes it easier to manage the turnover completion process. In some rare instances, the Company may also elect to perform the inspection – but this is not the preferred method when dealing with a construction contractor. The Contracts Management group has a Standard Contract Attachment E - Quality Management Requirements form 000 430 F0176 that is available in Knowledge On Line. This Attachment E is to be developed so that it is scope-specific for the contract RFP package it is to be included in. It needs to be scope specific so that it excludes requirements and references to forms that are not applicable to the contractors’ scope of work. The Site Quality Manager is to contact the Project Contracts Manager to request input to the contract RFP packages. This duty can be performed by the Regional Construction Quality Manager (RCQM) if a Site Quality Manager is not yet assigned to the project. The Construction Technical Services group can advise who the RCQM is for a particular area. Contractor quality requirements are to be monitored by either performing quality audits (refer to 000 509 0170) or by performing quality surveillances (refer to 000 509 0220.


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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. This procedure requires that surveillances be documented and tracked using the Quality Management System (QMS) tool. This is an established program used by Fluor across the company for management of quality audits and surveillances. The program is Lotus Notes based. Go in to FDNet and type http://www.fdglobal.com/fdglobal/workgrps/qa/qms.nsf in the URL bar at the top of the screen to access the QMS program. Projects that do not have access to FDNet or are experiencing connectivity issues with the Fluor network may be allowed to use the alternative forms noted in this procedure. Surveillance is the monitoring by witnessing and observation of the Quality Program implementation during construction/installation work activities. This can involve verifying that a work process or procedure is being performed in accordance with a written requirement. 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 - Will assign surveillance responsibilities to inspection personnel. - Ensure that personnel performing surveillances using QMS have obtained access rights and have

taken the necessary training to be able to work in QMS. Access rights can be obtained from Barry Rittberg. His e-mail address is [email protected]. His phone number is 949-349-2356. QMS for Contractor Surveillance training is available in the Quality knowledge community in Knowledge On Line (KOL). The course required to be taken for performing surveillances is:

- QA012 – QMS For Contractor Surveillance

Reading material on using QMS is available (course QA-004) in the Quality community for those who want more information on using the QMS program.



NOTE: Scope, duration, and intensity of surveillance 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 or contractors.

Surveillance Personnel - Ensure that the required QMS training has been taken as described above. - Perform periodic surveillance of work activities.

NOTE: Surveillance personnel should refer to the applicable inspection/test plans (ITP’s) 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.

- Indicate the results of the surveillance verification activity in the QMS program. Projects that are

not able to use QMS can use Form 000 509 F02201.

Record on the Surveillance Report those areas or items monitored or reviewed. If no deficiencies are found during this surveillance, so state (satisfactory) and forward to the Site Quality Manager for his review.

NOTE: The “Inspector” may recommend a nonconformance or corrective action to be

taken to correct the condition or deficiency. Refer to procedures 000.509.0130 and 000.509.0140.

When a deficiency is found and will need a follow-up inspection to verify conformity, identify it in the QMS program. For projects that are not able to use QMS the deficiency will be noted on the Surveillance Report in the “Observation / Deficiency” section. Notify the responsible person of the deficiency and record the action being taken. For projects that are not able to use QMS the surveillance report is to be signed 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 QMS for close out. For projects that are not able to use QMS the corrective action space in the surveillance report is to have the corrective action recorded and the “Inspector” shall then sign and date to indicate acceptance / completion and the report is considered closed.

QMS will automatically log all surveillance reports raised within the QMS program. For

projects that are not able to use QMS the Surveillance Report information is to be recorded 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 or corrective action 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 by recording them within the QMS program. For projects that are not able to use QMS nonconformances are to be documented using Form 000 509 F01301.

Site Quality Manager - Review the results of the surveillance and/or verification activities recorded in QMS or on the

Surveillance Report (if project is unable to use QMS). Signify review and concurrence by signing and dating the surveillance report (only if project is unable to use QMS).

- Advise the Site Manager of serious quality problems.

DOCUMENTATION All Surveillance Reports shall be retained in the QMS program. Projects that are not able to use QMS are to retain copies in the Quality Control files.

FORMS

Quality Control Form: 000 509 F02201 – Surveillance Report (only used if project is unable to use QMS) 000 509 F02202 – Surveillance Report Log (only used if project is unable to use QMS)








Report No.














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SURVEILLANCE REPORT LOG ID A02202A

REPORT NO.

INITIATOR CONTRACTOR SUBJECT OPEN CLOSED BY /

DATE


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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

(000 509 0230) Attachment 1

As project progresses

Perform quality receipt inspection


000.509.F02301 As required by

project

Responsibilities - Subcontracted Work


Warehouse receipt of material/items

Subcontractor O, S, and D Per shipment

received Determine inspection and

storage level requirements

Subcontractor (000 509 0230) Attachment 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.



• 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



Attachment 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 EQUIPMENTPiece 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 MATERIALDimensional Checks Accessories Damage

SHOP FABRICATED TANKS & VESSELS

Refractory Corrosion

Damage SPECIALITY EQUIPMENT Item Markings Corrosion Damage INSTRUMENTSAccessories 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 COATINGSName Plate Data Accessories Damage

MACHINERY PIPE Deterioration Damage Cleanliness Shipping Prep Cap Markings Corrosion Damage WELD FILLER MATERIALAccessories 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



Attachment 2 Typical Permanent Plant Material and Equipment Inspection List 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 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:



NONCONFORMANCE REPORT ID A01301A





Initiated by: Date: Hold Tag Yes No

NCR No.

Area/Location Unit/Equip No. Discipline/Responsibility:

DWG. No./Rev. Spec./Rev. Audit No. (If Applicable)

DESCRIPTION OF NONCONFORMANCE

ROOT CAUSE CAUSE CODE(S)

DISPOSITION Use as is Rework Repair Other

DISPOSITION BY Design Eng. Approval Req.

Construction Engineer Date

Yes No DISPOSITION COMPLETED BY

Contractor Date

Design Engineer Date

ACTION VERIFIED AND NON-CONFORMANCE CLOSED

VERIFICATION METHOD DOC REVIEW INSPECTION OTHER

FLUOR INSPECTOR DATE

FLUOR-VERIFIED DISPOSITION AND RECOMMENDED CLOSURE OF NCR FLUOR SITE QUALITY MANAGER DATE






HOLD TAG/STICKER ID A01303

(Recommended Color: Red with Green Letters)

HOLD

Hold Tag No._____________________

DO NOT USE

NCR Number_____________________

(DO NOT REMOVE THIS TAG)





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RECEIVING INSPECTION CHECKLIST ID A02301

P.O. Number Supplier Date Received Project Number

Receiving Hold Tag Attached Mark No. Heat No. Material Test Reports Required Yes No Yes No Item #'S _______

Description Of Material/Equipment

Item No. Inspection Attributes* Quantity Accept Reject Hold Tag No.

Nonconformance Report Number(s)

Storage Requirements

Remarks

* Inspection Attributes are identified in Attachment 1 for certain items

Prepared By/Date Inspector/Date


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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 / Complete It Administrator

Form 000.509.F02402 Two weeks before mechanical completion date

Generate master punchlist

Turnover Coordinator / Complete It Administrator

Form 000.509.F02407 Prior to mechanical completion date

Generate exceptions list Turnover Coordinator / Complete It Administrator

Exceptions list format - site specific

Generate discipline checklist

Turnover Coordinator/ Complete It 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 / Complete It 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





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/ Complete It Administrator / Subcontractor

Form 000.509.F02402 Two weeks before mechanical date

Generate master punchlist

Subcontractor/ Turnover Coordinator / Complete It Administrator

Form 000.509.F02407 Prior to mechanical completion date

Generate discipline checklist


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


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




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). Complete It 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.



• 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.



FORMS Quality Control Forms:

000.509.F02401 Transfer of Care, Custody and Control (Turnover Notice) 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 Record 000.509.F02408 Interim Turnover Notice 000.509.F02409 Mechanical Completion Certificate





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TURNOVER NOTICE This letter is to advise you that except as set forth below all work is essentially complete as of _____________and is ready for commissioning and start-up operations on this system. The respective equipment has been tested and operation will be under supervision of your representative upon your acceptance. Upon the date of your acceptance hereof, it is provided that mechanical completion and care, custody and control of the facilities described, hereby excepting those items on the attached Exception List, will be passed to The Client. Responsibility for loss or damage, excepting those items on the attached Exceptions List, is assumed by The Client and subrogation waived against Fluor under which The Client may hereafter carry in force on the facilities herewith transferred. Nothing herein contained shall be construed as relieving Fluor of any of its guarantees under the contract covering the facilities hereby transferred, except that the guarantee period with respect to the workmanship of Fluor subject to this Transfer shall commence to run upon your signed acceptance. Kindly acknowledge your acceptance and approval of the foregoing by signing and returning two of the enclosed copies of this letter, or advise in what respect the above described facilities are not ready for commissioning and initial start-up operations. Sincerely, Fluor Site Manager Accepted by: ____________________________________ Date: ______________________ CLIENT CONSTRUCTION MANAGER Accepted by: __________________________________ _ Date: _____________________ CLIENT START-UP LEADER


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SYSTEM WALKDOWN NOTICE ID A02402A

The Client: SYSTEM NUMBER: SYSTEM DESCRIPTION:

Fluor The Client

* Participation in this system walkdown is required by these persons or their designee. The others are notified for information only.

The system is scheduled for a joint Fluor/The Client walkdown on ______________. The walkdown and punchlist must be complete within two (2) days. Punchlist items will be entered into MCPlus by designated punch entrants to produce the “Master System Punchlist” (MSP) to assist Fluor and The Client in establishing Category 2, 3, 4 & 5 items and tracing their acceptance and closure. Please notify me if your discipline can not perform the walkdown as scheduled. Systems Coordinator ____________________________________ Ext. ___________


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MECHANICAL COMPLETION CIVIL CHECKLIST ID A02403A

The Client:

SYSTEM NUMBER:

SYSTEM DESCRIPTION:

1. All paving is installed and properly sealed in accordance with the drawings and specifications.

2. All structural steel, stairs, and grating is installed in accordance with the drawings and specifications.

3. All structural steel base plates are grouted in accordance with the drawings and specifications.

4. All structural steel requiring concrete fire proofing is installed in accordance with drawings and specifications.

5. All approved gates and other safety devices are installed in accordance with drawings and specifications.

6. All bollard posts are installed in appropriate locations in accordance with drawings and specifications.

7. All construction debris are removed and the area is in a broom clean condition.

8. All architectural work, which includes but is not limited to roofing, windows, and doors, etc., is in accordance with drawings and specifications.

9. All structural steel, pipes, equipment, and other structures are painted in accordance with drawings and specifications.

10. All civil related NCR’s that affect this system have been closed.

Subcontractor Fluor Commissioning Fluor QA

Name: Name: Name:

Signature: Signature: Signature:

Date: Date: Date:


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MECHANICAL COMPLETION ELECTRICAL / INSTRUMENTATION CHECKLIST ID A02404A

The Client: Contract No.:

SYSTEM NUMBER:

SYSTEM DESCRIPTION:

1. All electrical/instrumentation installations have been installed in accordance with design and vendor documents.

2. All electrical cables have been meggered (and DC hi-pot tested if over 1000v rating)

3. All associated switchgear, breakers, transformers, relays, busway, and distribution equipment has been inspected and/or tested in accordance with project specifications.

4. All motors and air cooler fans have been meggered and bumped to check direction of rotation.

5. All associated instruments have been calibrated, function tested and/or loop tested as required by project specifications .

6. Instruments are calibrated and installed in accordance with design documents.

7. Instruments and instrumentation tubing are tested as required by code and specifications.

8. All electrical/instrumentation related NCR’s that affect his system have been closed.


Name: Name: Name:


Date: Date: Date:


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MECHANICAL COMPLETION / MECHANICAL CHECKLIST ID A02405A

The Client:

SYSTEM NUMBER:

SYSTEM DESCRIPTION:

1. Piping is installed in accordance with design documents. Hydrotests have been completed.

2. Pipe supports; hangers, guides, anchors, spring cans, etc., have been installed in accordance with design documents. Travel stops on spring hangers for water filled piping are to be removed after the applicable piping system has been filled with water. At this time "cold load setting" shall be verified. Travel stops on spring hangers for steam or gas filled piping have been removed by construction and cold load settings have been verified.

3. Rotating equipment is installed in compliance with vendor and specification requirements. Cold alignment has been performed and base plates are grouted.

4. Maintenance on applicable equipment has been performed.

5. Temporary lubricants and rust inhibitors have been removed and initial lubrication is complete .

6. All vessel internals, packing and desiccants are installed and Fluor's final closures are completed.

7. Mechanical related NCRs that affect this system have been closed.

8. Coatings; paint and insulation complete.


Name: Name: Name:


Date: Date: Date:


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MECHANICAL COMPLETION / QUALITY CONTROL CHECKLIST ID A02406A

The Client:

SYSTEM NUMBER:

SYSTEM DESCRIPTION:

1. Turnover notice and the supporting documentation has been received.

2. Hydrostatic test packages for this system are complete, accepted, and are included in this system package.

3. Quality control records for this system are complete and are included in this system package as required.

4. All NCR’s, that affect this system, are closed and are on file.


Name: Name: Name:


Date: Date: Date:


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Punch List Page: of

TO System:

TO System Description: Print Date:

Priority ‘1’ Items to be completed before handover of the Package to the next phase Priority ‘5’ Other Issues Priority ‘2’ Items may be completed anytime at the approval of Client Priority ‘3’ Items generated by the client/operations Priority ‘4’ Added scope

Groups: VE – Vendor CC – Construction CM – Commissioning SU – Start Up

PL No.

Tag/Line/Cable Raised By/On

Pri Status PL Item Description & Comments Group Resp. (Disc)

Mat Eng Req’d by Date Cleared Verified

By Date By Date


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MECHANICAL COMPLETION CERTIFICATE Project No. MCC No. Date

This documents the turnover to and acceptance by The Client for equipment and/or systems listed below as being mechanically complete in accordance with the established system boundaries.

Component, System or Subsystem Number Description

Exceptions to the above scope See Attached Punchlist

Process Consistency Check By The Client

SIGNATURES

Released By Fluor Date Accepted by The Client Date

Mechanical Coordinator


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INTERIM TURNOVER NOTICE ___________________ As The Client's Project Manager and duly authorized representative, I hereby issue in accordance with Article 19 - Completion and Acceptance - of the Principal Document, this INTERIM TURNOVER NOTICE for: _________________. Interim Turnover Package _________________

Under the terms and conditions of:

Contract Number ___________

Dated _________

Between The Client and Fluor, Inc.

and certify that Mechanical Completion of the above portion of Work was achieved on __________________. A Master Punchlist is attached indicating items which are still incomplete or known to be deficient and the dates such items are to be finished or corrected. It shall remain as Fluor's responsibility to finish and correct this work by the dates so indicated, as well as correcting any deficiencies which are uncovered during the startup operations. The issuance of this TURNOVER NOTICE does not in any way denote The Client's concurrence that the Facility, or any part thereof, fully conforms to Job Specification nor relieve Fluor from its obligations under Article 20 - Warranties and Guarantees. It does constitute The Client's assumption of care, custody, control and responsibility for the above mentioned portion of the work. Notwithstanding, all conditions and terms of Contract No. _________ (Amended) are still valid.

The Client/Date Fluor/Date


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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 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


Form: 000.509.F02501

Monthly during the life of the activity

Perform Preservation Activities


Form: 000.509.F02502

Each Item

Resolve discrepancies as appropriate


Form: 000.509.F02501

As required to resolve discrepancies

Surveillance Site Quality Manager

(*Note 1) Form:

000.509.F02501 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.F02501for a sample of the storage inspection checklist).



• 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)



Attachment 1 - Material/Equipment Storage Requirement List The requirements for storage are divided into four levels with respect to protective measures to prevent damage, deterioration or contamination of items and materials based upon important physical characteristics, the ambient conditions during construction installation and operation of the item or material. Level A - Items classified to Level A are those that are exceptionally sensitive to environmental conditions and require special measures for protection from one or more of the following effects: temperatures outside required limits; sudden temperature changes; humidity and vapors; gravitational (g) forces; physical damage and air-borne contamination (e.g., rain, snow, dust, slat spray, fumes). The following shall be used as a guide for classifying items intended for Level A classification: a. Special electronic equipment and instrumentation. b. Special materials, such as chemicals that are sensitive to environment. c. Computers Level B - Items classified to Level B are those that are sensitive to environmental conditions and require measures for protection from the damaging effects of one or more of the following: temperature extremes, humidity and vapors, gravitational forces, physical damage and airborne contamination but do not require the special protection required for Level A items. The following shall be used as a guide for classifying items intended for Level B classification: a. Instrumentation b. Electrical penetrations c. Batteries d. Welding electrode and wire e. Motor control centers, switchgear, and control panels f. Motors and generators g. Precision-machined parts h. Erection spares, such as gaskets, "O" rings i. Air-handling filters Level C - Items classified to Level C are those that require protection from exposure to the environment, air-borne contaminants, gravitational forces, and physical damage. Protection from water vapor and condensation is not so important as that for Level B items.



The following shall be used as a guide for classifying items intended for Level C classification: a. Pumps b. Valves c. Fluid Filters d. Compressors e. Turbines f. Instrument cable g. Thermal insulation h. Fans and blowers Level D - Items classified to Level D are those that are less sensitive to the environment than Level C. These items require protection against the elements, air-borne contamination, and physical damage. The following shall be used as a guide for classifying items intended for Level D classification: a. Tanks b. Heat exchangers and parts c. Accumulators d. Demineralizers e. Evaporators f. Piping g. Electrical cable h. Structural items i. Reinforcing steel



STORAGE REQUIREMENTS Items assigned a level of storage shall be maintained at this level of storage until they are removed from storage. Items removed from storage and installed, but not operating, shall have the assigned level of storage maintained.

Levels of Storage Environmental conditions for items classified as levels A, B, C, and D described in this procedure shall meet the following requirements: Level A - Items shall be stored under those conditions described for Level B items but with any additional requirements detailed by the manufacturer and/or engineering representative. Level B - Items shall be stored within a fire-resistant, tear-resistant, weathertight, and 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 40°F (4C) and maximum shall be 140F (60C) 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 (100mm) cribbing or equivalent to allow for air circulation and to avoid trapping water. Care of Stored Items Care of items in storage shall be exercised in accordance with the following: a. Items in storage shall have all covers, caps, plugs, or other closures intact. When it is necessary

to remove a cover for access purposes, it shall be immediately replaced and properly resealed thereafter.

b. Temporary preservatives shall be left intact during storage. Should reapplication of preservatives

be required at the site, only those previously approved shall be used. c. Desiccant humidity indicators shall also be monitored, and desiccants shall be changed or

reprocessed when specified. d. Instrumentation racks shall be energized as specified by the manufacturer. e. Space heaters enclosed in electrical items shall be energized.



f. Rotating electrical equipment shall be given insulation resistance tests on a scheduled basis. g. The shafts of rotating equipment shall be rotated on a periodic basis. The degree of turn shall be

1 1/4 turn so that the parts receive a coating of lubrication where applicable, and so that the shaft does not come to rest in a previous position.

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

equipment.


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STORAGE INSPECTION CHECKLIST ID A02501

Storage Area/Item Date

Storage Level

YES NO N/A

1. Are identifications and markings intact?

2. Are covers, plugs, and caps intact?

3. Are temporary preservatives and coatings intact?

4. Is desiccant saturated?

5. Any evidence of physical damage?

6. Is proper cleanliness being maintained?

7. Are instrument racks energized as specified?

8. Are space heaters energized as specified?

9. Has rotating equipment been rotated as specified?

10. Has rotating equipment been tested as specified?

11. Evidence of damage to items hit by a forklift or truck?

12. Any water damage?

13. Is dust and dirt excessive?

14. Are items and materials on cribbing as specified?

15. Any container items broken or leaking?

16. Has storage level been maintained?

Is Reinspection Required? Yes No

Discrepancies:

Remarks:

Inspector/ Date


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EQUIPMENT PROTECTION PRESERVATION AND INSPECTION RECORD ID A02502





Initial Preservation Upon Receipt: Store on free draining ground or

foundations. Inspect equipment protection by

vendor. Tag and store accessory items. Reference Section For Additional Details

Manufacturer:

Corrosion Inhibitors/Lubricants (Note Type And Where Used):

Date Performed

Initials

STD. Preservation Operations: Rotate Shaft 2-1/4 turns. Reference Section For Additional Details

Frequency Indicate One:

Days Weeks Months

Date Performed

Initials

Date Performed

Initials

STD. Preservation Operations: Storage Conditions Damage Corrosion Flange Protection Accessory Conditions Reference Section For Additional Details

Frequency Indicate One:

Days Weeks Months

Date Performed

Initials

Date Performed

Initials

Special Instruction: (Project/Spec/Vendor)

Frequency Indicate:

Days Weeks Months

Describe:

Date Performed

Initials

Date Performed

Initial

Remarks:

Subcontractor Fluor Field Engineering Fluor QA

Name: Name: Name:


Date: Date: Date:


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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 work

activity.



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

- Approved by Construction - The title of the individual responsible for approving from a construction

standpoint, that the work is accomplished and acceptable. - Approved by Project - Usually reserved for project manager review and approval that the work

performance and verification meets project and contract requirements. - Approved by Client - to be used when the work performed requires the Client’s approval (usually

specified by contract). NOTE: For subcontracted work, refer to the “Subcontractor Control” Section 1 of Appendix I for typical "Go-By". PROCEDURE AND RESPONSIBILITIES • Site Manager or Designee - Refer to Appendix I and revise as follows to develop the project specific AP - Construction. NOTE: The project specific "AP - Construction" may be developed by marking up the "AP - Construction - Reference Guide" (Appendix I) to indicate changes.

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

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

the Work Activity.

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

If a deviation to the Corporate Standard is made by project personnel, indicate the deviation

by dropping the first three zero's of the Corporate Descriptor (e.g. 509 7031).

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

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



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.

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



Appendix I - Activity Plan – Construction Client Name Project Name Project Number

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

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


Concrete Installation

000.215.03300 000.509.7100 DCE CM SQM CM N/A

Grout Installation 000.215.03600A 000.215.03600B


Structural Steel Installation

000.215.05120 000.215.05130


Coatings and Wrapping of Steel Pipe

000.285.86410 000.285.86210


Hot Insulation 000.285.86110 000.509.7810 Contract

DCE CM SQM CM N/A





WORK INSTRUCTION

BASIS OF CHECK

INTER DISCIPLINE

REVIEW INDEPENDENT VERIFICATION

PERFORMED BY

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY


Internal Linings 000.285.86310 000.509.7800 Contract

DCE CM SQM CM

Raceway and Supports Installation

000.265.65051 000.265.65052


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


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





WORK INSTRUCTION

BASIS OF CHECK

INTER DISCIPLINE


PERFORMED BY

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY


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

Subcontractor’s 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





WORK INSTRUCTION

BASIS OF CHECK

INTER DISCIPLINE


PERFORMED BY

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY


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


Field Machining Contract Contract CEM SUB SQC CM N/A Geotechnical Investigation


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



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).





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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.



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 000.509.F70002shall be used. Otherwise for processes such as concrete placement or piping installation, Inspection and Test Plans shall be documented on form 000.509.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 000.509.0130where a NCR is needed, that documentation does not need to be duplicated by a Surveillance Report.



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



Attachment 1 - Instructions for completion of the ITP form Field Name Description Activity Identify the general activity or scope of work for the ITP Description Identify the specific activity that applies to the ITP Project Name/Number Enter project name and number Client Enter Client name Contractor Enter contractor name (if subcontracted) Contract Number Enter contract or subcontract number as applicable ITP Number Uniquely Identify the ITP, ITP 509 7XXXX Issue Date/Revision Number Enter the current issue date and revision Item Number Used to identify the sequence of the quality-related activity Quality-Related Activity Enter a description of the quality-related activity Requirement and Acceptance Criteria Enter the acceptance criteria or reference to the specification or other

standard where the acceptance criteria may be found. Responsibility Enter the Fluor position primarily responsible for executing Fluor’s

participation in the activity. Use the code legend on the bottom of the ITP form to represent the entities.

Scope of Inspection Use these fields to specify the level of participation required by the various

entities. Inspection Record If an inspection record is to be used to document the inspection results,

enter the form or record number. CompleteIt Input If the activity is recorded in CompleteIt indicate with a “Yes” Completion Sign-off Indicate if Fluor and/or Client signatures are required.


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Inspection and Test Plan Activity

Description Project Name Project Location Project Number

Client Contractor Contract Number Document Number ITP 509 7XXXX Revision X

Issue Date

Item Inspection/Test Stage Requirement and

Acceptance Criteria Responsibility

Scope of Inspection Inspection Record

CompleteITInput Sub Fluor Client

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






Inspection and Test Plan Activity

Description

Project Name Project Location Project Number

Client Contractor Contract Number Document Number ITP 509 FXXXX Revision 0

Issue Date

Item Inspection/Test Stage Requirement and

Acceptance Criteria Responsibility

Scope of Inspection Inspection/Test

Record

Completion Sign-Off

Sub Fluor Client Fluor Client

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





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


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

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


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.


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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.::]N/A


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SOIL INSPECTION CHECKLIST ID C70101A





Drawing No.:

Specification No.:

Inspection Reference Subcontractor Fluor FE/QA

1. Excavation cleared of foreign and loose material.

2. Slopes shored or correctly stepped.

3. Fill Material cleans and conforms to requirements.

4. Lift thickness and compaction procedures in accordance with specifications.

5. Final elevation in accordance to drawings.

6. Moisture control acceptable.

7. Compaction Method and Equipment.

8. Soil Density Test Reports filed.

Remarks:


Name: Name: Name:


Date: Date: Date:


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FIELD COMPACTION TEST RECORD ID C70102A





Drawing No. Specification No. Test Date

Type of Subgrade Type Compactor

Type Fill Lift Thickness Min. Compaction Required: %

Laboratory Standard:

Type Date Max. Density Optimum Moisture

Field Test Equip:

Type S/N Correction Factor

Location Sketch Test No.

Elevation/Depth

Moisture %

Dry Density

Compaction %

Acc/Rej

Comments:

Tested By Approved By


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DENSITY OF SOIL IN PLACE BY THE SAND-CONE METHOD ASTM D-1566 - AASHTO-T-191

ID C70103A

Date:

Standard Sand Density ___________ kg/m³

Minimum Compaction Required (Standard Proctor) _____________%

Fill Material Identification

Location of Sample

Maximum Dry Density kg/m³

Optimum Moisture __________ % Method of Test

Original Weight Sand + Container

Final Weight Sand + Container

Total Weight Sand Used

Sand Contained in Cone

Total Sand in

Volume of Hole

Weight Wet Soil + Tare

Weight Dry Soil + Tare

Weight Water

Weight Tare

Weight Dry Soil

Moisture Content %


Weight Tare

Weight Wet Soil

Weight Dry Soil

Dry Density kg/m³

Percent Compaction

Inspector: Date:

Reviewed by: Date:





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NUCLEAR MOISTURE - DENSITY TEST REPORT ID C70104A

Test Number

Location

Average Elevation: From

To

Mode & Depth

Proctor Number

Maximum Dry Density

Optimum Moisture

Density Count

Density Count Ratio

Wet Density PCF

Moisture Count

Moisture Count Ratio

Moisture PCF

Dry Density

% Moisture

% Compaction Required Minimum Compaction

Standard Count

Machine Number Density Moisture

Remarks:

Inspector: Date:

Reviewed by: Date:





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SOIL DENSITY TEST LOG ID C70105A

DENSITY TEST NO.

DATE Comp

% W %

PLACEMENT REPRESENTED ACC REJ RE TEST RESULTS

Comp %

ACC REJ W %

ACC REC


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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.


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 F70204 (Note 1)


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): An 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.



RESPONSIBILITIES - Subcontracted Work


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)


Perform testing for paving

Subcontractor Form 000 509 F70202 and 000 509 F70204 (Note 1)


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 tests for the subgrade have been performed. b) Verify that material qualification test for the bituminous concrete paving have been

performed and approved. 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 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. 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 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.::]N/A






DENSITY OF SOIL IN PLACE BY THE SAND-CONE METHOD ASTM D-1566 - AASHTO-T-191

ID C70103A

Date:

Standard Sand Density ___________ kg/m³

Minimum Compaction Required (Standard Proctor) _____________%

Fill Material Identification

Location of Sample

Maximum Dry Density kg/m³

Optimum Moisture __________ % Method of Test

Original Weight Sand + Container

Final Weight Sand + Container

Total Weight Sand Used

Sand Contained in Cone

Total Sand in

Volume of Hole


Weight Dry Soil + Tare

Weight Water

Weight Tare

Weight Dry Soil

Moisture Content %


Weight Tare

Weight Wet Soil

Weight Dry Soil

Dry Density kg/m³

Percent Compaction

Inspector: Date:

Reviewed by: Date:






NUCLEAR MOISTURE - DENSITY TEST REPORT ID C70104A

Test Number

Location

Average Elevation: From

To

Mode & Depth

Proctor Number

Maximum Dry Density

Optimum Moisture

Density Count

Density Count Ratio

Wet Density PCF

Moisture Count

Moisture Count Ratio

Moisture PCF

Dry Density

% Moisture

% Compaction Required Minimum Compaction

Standard Count

Machine Number Density Moisture

Remarks:

Inspector: Date:

Reviewed by: Date:





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BITUMINOUS CONCRETE PAVING INSPECTION CHECKLIST ID C70201A





Subcontractor Date

Location – Sta. To

1. Subgrade acceptable

Compaction QC Inspector/Eng. Preparation Line/grade per drawing

2. Base Preparation acceptable

Equipment QC Inspector/Eng. Layer thickness/total thickness Compaction Smoothness Material

3. Paving acceptable

Weather conditions QC Inspector/Eng. Mix temperature Layer thickness/total thickness Overlaps/joints Rolling Tack coat Prime coat Repairs Finish surface smoothness Line/grade

4. Testing complete and acceptable

Const. Eng.

Remarks:

Inspector/Eng.: Date:

Reviewed by: Date:


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BULK SPECIFIC GRAVITY ID C70202A





Date Type Mixture

Location of Sample Sample #

Subcontractor

PARAFFIN COATED SPECIMENS

Bulk SP gr. = A =

=

SP gr.

D-E - (D-A)

F

A = Mass of dry specimen in air, g,

D = Mass of dry specimen plus paraffin coating in air, g,

E = Mass of dry specimen plus paraffin coating in water, g,

F = Specific gravity of the paraffin at 25oC (77oF) + 2oF

Method Used: AASHTO T 166 ASTM D 1188

UNCOATED SPECIMENS

Bulk SP gr. = A = =

SP gr. B - C

A = Mass in grams of sample in air.

B = Mass in grams of surface dry specimen in air.

C = Mass in grams of sample in water.

Method Used: AASHTO T 166 ASTM D 2726

Inspector: Date:

Reviewed by: Date:


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NUCLEAR DENSITY TEST REPORT - BITUMINOUS CONCRETE ID C70204A





Test Number

Location

Drawing Number

Mode & Depth

Marshell Test Number

Maximum Density

Density Count

Density Count Ratio

Wet Density

% Compaction

Specified Minimum Compaction

Standard Count Remarks:

Machine Number Density

Draw Sketch

Inspector: Date:

Reviewed by: Date:


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STEEL H PILES

SCOPE This procedure prescribes the installation, inspection, and testing of Steel H Piles.



ACTIVITY

Monitor pile load test Civil Construction

Engineer _____ As required

Inspect in-process pile driving


000.509.F70301 000.509.F70302 000.509.F70303


Check final pile locations/installation


Survey field books As required

Surveillance QC Inspection

(Note 2) 000.509.F02201 As required



ACTIVITY Perform pile load test (See Note 1)

Subcontractor _____ As required by project specification



Inspect in-process pile driving (See Note 1)

Subcontractor 000.509.F70301 000.509.F70302 000.509.F70303


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.



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.



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.



- 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


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PILE DRIVING INSPECTION RECORD ID C70301A





Driving Formula Date

Weight Of Hammer Drop Type Of Hammer

Foundation Number

Depth in m

Blows Per m Depth in

m Blows Per

m Depth in m

Blows Per m Pile Data

1 27 53 Pile Number

2 28 54 Dia: Tip

3 29 55 Head

4 30 56 Length of

5 31 57

6 32 58

7 33 59

8 34 60

9 35 61

10 36 62

11 37 63

12 38 64

13 39 65

14 40 66 Cut Off

15 41 67 Bottom of Pile

16 42 68 Overburden

17 43 69 Design Length

18 44 70

19 45 71 Kind of Pile

20 46 72 Starting Time

21 47 73 Stopping Time

22 48 74

23 49 75

24 50 76

25 51 77

26 52 78


Name Name Name

Signature Signature Signature

Date Date Date





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PILE DRIVING RECORD ID C70302A





Project: Driver Type:

Location: Ramweight:

Pile Capacity: Freefall Height:

Pile Size: Pile Type:

Weather Condition: Pile Manufacturer:

Pile Number Length Date Driven Horizontal 7,5 cm Maximum

Point Elevation

Cut-Off Elevation

Blowcount Last m/cm

Redriven Record:

General Remarks:


Name Name Name


Date Date Date





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RECORD OF PILE DRIVING ID C70303A





Gen

eral

In

form

atio

n Job Number: Required Blows:

Pile Type: Pile Size:

Specified Capacity:

Pil

e D

ata

Pile Number

Orig. Length

Date Driven

Jetting Depth

Surface Elev.

Driving Time

Cut-Off Elev.

Tip Elevation

Cut-Off Length

Hammer Data

Pen

etra

tion

Res

ista

nce

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Make:

Model:

Stroke:

Ram Weight:

Rated Energy:

Type:

Action:

Remarks:


Name Name Name


Date Date Date





W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7040 Rev 0 Precast Concrete Piles.doc Page 1 of 4

PRECAST CONCRETE PILES

SCOPE This procedure prescribes the installation, inspection and testing of precast prestressed concrete piles.





Inspect in-process piling installation


000.509.F70301 000.509.F70302 000.509.F70303


Check final pile location/installation

Senior Field Engineer Survey Field Books As required


(Note 2) 000.509.F02201

Per Procedure 000 509 0220



ACTIVITY

Perform pile load test (See Note 1)

Subcontractor _____ As required by project specification



Inspect in-process pile driving (See Note 1)

Subcontractor 000.509.F70301 000.509.F70302 000.509.F70303


Check final pile installation


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.

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.

- 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.


- 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.


- 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 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



PILE DRIVING INSPECTION RECORD ID C70301A





Driving Formula Date

Weight Of Hammer Drop Type Of Hammer

Foundation Number

Depth in m

Blows Per m Depth in

m Blows Per

m Depth in m

Blows Per m Pile Data

1 27 53 Pile Number

2 28 54 Dia: Tip

3 29 55 Head

4 30 56 Length of

5 31 57

6 32 58

7 33 59

8 34 60

9 35 61

10 36 62

11 37 63

12 38 64

13 39 65

14 40 66 Cut Off

15 41 67 Bottom of Pile

16 42 68 Overburden

17 43 69 Design Length

18 44 70

19 45 71 Kind of Pile

20 46 72 Starting Time

21 47 73 Stopping Time

22 48 74

23 49 75

24 50 76

25 51 77

26 52 78


Name Name Name


Date Date Date






PILE DRIVING RECORD ID C70302A





Project: Driver Type:

Location: Ramweight:

Pile Capacity: Freefall Height:

Pile Size: Pile Type:

Weather Condition: Pile Manufacturer:

Pile Number Length Date Driven Horizontal 7,5 cm Maximum

Point Elevation

Cut-Off Elevation

Blowcount Last m/cm

Redriven Record:

General Remarks:


Name Name Name


Date Date Date






RECORD OF PILE DRIVING ID C70303A





Gen

eral

In

form

atio

n Job Number: Required Blows:

Pile Type: Pile Size:

Specified Capacity:

Pil

e D

ata

Pile Number

Orig. Length

Date Driven

Jetting Depth

Surface Elev.

Driving Time

Cut-Off Elev.

Tip Elevation

Cut-Off Length

Hammer Data

Pen

etra

tion

Res

ista

nce

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Depth Blows

Per cm.

Make:

Model:

Stroke:

Ram Weight:

Rated Energy:

Type:

Action:

Remarks:


Name Name Name


Date Date Date





W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7090 Rev 0 Augered Cast in Place Piles.doc Page 1 of 4

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


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 pile’s installation record.

General All Subcontractor supplied materials and proprietary items shall be subject to Fluor’s approval

and shall be installed in accordance with the Contract Documents. All chemical admixtures which contain chloride are prohibited for use on this project. Materials Portland Cement Portland cement shall conform to ASTM C 150, type of cement as specified in the Contract

Documents.



Mineral Admixture

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

Fluidifier

Fluidifier shall conform to ASTM C937

Water Water shall meet requirements of ASTM C94.

Fine Aggregates Fine aggregate shall conform to ASTM C33.

Reinforcing Bars Reinforcing bars shall conform to ASTME A615. High strength reinforcing bars shall conform to requirements of ASTM A722 Grade 150. Methods acceptable to Fluor shall be provided to facilitate proper centering of any steel cores or

tension reinforcing installed in the piles.

Grout Mixes The grout shall be a mixture of Portland cement, fine aggregate, pozzolanic material (when

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

Grout materials shall be accurately measured to meet design proportions. Grout shall be

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

Temperature of Grout oF Maximum Holding Time Hours

Less than 70 (21oC) From 70 to 90 (70-90oC) Greater than 90 (90oC)

2.5 2.0

Shall not be used

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

temperatures in accordance with ACI 305R.



Grout test cubes shall be made, cured and tested in accordance with ASTM C942. At least six

2-inch cubes shall be made for each 4 hours (or portion thereof) during which piles are placed, for each pile rig. Test each set of 6 cubes as follows: 2 cubes at 7 days, 2 cubes at 28 days and 2 cubes held in reserve.

Test the flow of grout each time cubes are made and any time inconsistencies are observed per

ASTM C939, except that the cone shall be modified to provide a ¾ - inch (19 mm) 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 (75 mm) 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 (30 cm) 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 (15 to 30 cm) and

begin grout pumping. Re-drill the auger to the previously established tip elevation before commencing auger withdrawal, after the grout pressure builds up.

Continuously maintain a grout head of a least 5 feet (1.5 m) 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 (1.5 m) 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 (1.5 m) increment of pile. If

any 5-foot (1.5 m) increment is deficient, reinstall the pile by advancing the auger 10 feet (3 m) below the deficient grout interval or to the bottom of the pile, whichever is less and re-grout pile with a reduced rate of auger withdrawal.

No pile shall be left partially completed overnight. All piles must be completely grouted and

protected at the termination of each day’s operation. Reinforcing steel shall conform to the Contract Documents, shall be placed while the grout is

still fluid and shall have centering fins, spacers or other devices to assure minimum grout cover as shown on the drawings or if not shown, at least 3 inches (7.5 cm) 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. FORMS Quality Control Forms: 000.509.F70901 Augered Cast-In-Place Pile Record 000.509.F71005 Cementitious Grout Testing Record


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AUGERED CAST-IN-PLACE PILE RECORD ID C70901A





Contract No. Pile No.

Project: Meets Specs.

Owner: Observed By:

Engineer: Date Installed:

Contractor: Weather:

Grout Truck No

Ticket No. Batch Time Arrival Time

Load (m)

Water Added On

Site (1)

Grout Sampling/Testing Grout Cube Data

Time Sampled

Time Initial

Set Flowcone

Time Made

Set No.

DWG No. Grouting Summary Re-Grouting Summary

Pile No Initial

Installation Re-

Grout Depth

Pump Strokes

Grout Factor

Pump Pres.

Depth (cm)

Pump Strokes

Grout factor

Ground Elev. (cm)

Alignment

Auger Dia. (mm)

Augering Start:

Finish:

Depth (cm)

Pile Tip Elev. (cm)

Theor. Grout Vol. (cm)

Grouting Start:

Finish:

Avg. Pump Pres. (kg/cm²)

Grout Return (cm)

Total Pump Strokes

Before:

After:


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AUGERED CAST-IN-PLACE PILE RECORD ID C70901A





DWG No.

Grouting Summary Re-Grouting Summary

Pile No Initial

Installation Re-

Grout Depth

Pump Strokes

Grout Factor

Pump Pres.

Depth (cm)

Pump Strokes

Grout factor

Total Grout Vol. (cm)

Overall Grout Factor

Tension Steel Placed

Lap Splice

Centralizers

Sonic Logging PVC

Cage Steel Piaced

Lap Splice

Centralizers:

Grout Loss Drilling

Adjacent Pile

Remarks


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CEMENTITIOUS GROUT TESTING RECORD ID C71005A





Subcontractor Fluor

FE/QA

1. Grout consistency as measured by Corps of Engineers flow cone (CRD-79) was Grout consistency is:

Fluid Flowable Plastic Stiff

2. Temperature was measured and is in accordance with manufacturer’s recommendation for materials, mixing, placing and curing.

Outside Ambient °C Mixing Water °C

Inside Ambient °C Grout Bags °C

Equipment Plates °C Foundations °C

Mixed Grout °C In-Place (1 Hr.)

3. Test cubes were sampled for this placement location. Test cubes sampled: Number

Tag No. to

Remarks


Name: Name: Name:


Date: Date: Date:





W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7100 Rev 0 Concrete and Grout.doc Page 1 of 4

CONCRETE AND GROUT

SCOPE This procedure applies to inspection and testing of structural concrete and grouting.



Supply Concrete

Supplier Batch Ticket As required

Perform Concrete Placement

Civil Superintendent

000.509.F71003 As required

Batch Plant Technical Supervision


000.509.F02004 (Concrete Batch Plant Evaluation Record) and 000.509.F71010

Initially then random

Concrete Inspection


000.509.F71001 & 000.509.F71002 for Structural Concrete 000.509.F71004 for Cementitious Grout 000.509.F71006 for Epoxy Resin Grout 000.509.F71007, 000.509.F71008 000.509.F71010 for Batch Plant

For individual placements as required by specification.

Coordination of Placement


000.509.F71003 (Concrete Pour Card)

Each placement

Test Concrete

Test Agency (Note 1)

F71007 (Note 1) (plus 000.509.F71005 for cementitiousCementitious grout)

Each set of cylinders/cubes as required by specification.


(Note 2) 000.509.F02201


NOTE 1: Approved Test Agency Reports on their letterhead is preferred over the use of Form

000.509.F71007 and 000.509.F71005 for documenting concrete tests, but it must contain at least the information provided by these forms.


inspection forms by Fluor Quality.





OF ACTIVITY

Supply Concrete

Supplier Batch Ticket As required

Perform Concrete Placement

Subcontractor 000.509.F71003 As required

Batch Plant Technical Supervision


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


000.509.F02005 Initially then random


(Note 2) 000.509.F02201




GENERAL • Concrete Inspection:

- Inspection will include the items on the applicable checklist (Forms 000.509.F71001 and 000.509.F71002, 000.509.F71004 or 000.509.F71006) depending on the type of concrete. Form 000.509.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.



- 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.F71008.

- Maintain test and/or inspection records received from the Test Agency. • 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.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 N/A [::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.::]


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CONCRETE BATCH PLANT INSPECTION RECORD ID C71010





Concrete Supplier Batch Plant Operator Class Of Concrete

To: QC Department Contract No.:

From:

Report Date: Report No.

CC: Construction Contractor(s)

Construction Manager(s) Contracts:

QC Supervisor(s)

Civil Supervisor(s) Location:

Description Remarks

1. Cement silos are watertight and adequate to provide separate types of cement.

2. Aggregate stockpiles are free draining and adequate to provide separate types of aggregates.

3. Water supply is clean and adequate for all weather conditions.

4. Admixtures storage is prevented from freezing and suitable for separate types of admixtures.

5. On batching equipment the latest calibration is indicated and calibration documents are available.

6. Batching system: Manual Control Semi-Automatic Control

Visual Control Automatic Control

7. Recording system: Manual Computer Print-Out

8. Quality control: Manual Computer Print-Out

9. Approved Material Used

10. Approved Mix Design Used

Conclusion /Recommendations:


Name Name Name


Date Date Date


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PRE-CONCRETE INSPECTION CHECKLIST ID C71001A





Concrete Structure/Location: Equipment/Structural Steel Drawing No.

Referenced Drawings: U/G Electrical Drawing No.

Concrete Rebar & Embed. Drawings No. U/G Mechanical Drawing No.

1. Forms 3. Sub-Foundation Conduits

Survey Checked Piles Ground Wire/Earthing

Orientation Compaction Water Stop

Location (Coord) Cleanliness 5. Misc.

Size Moisture Keyways

Elevation Blinding Layer Blockouts

Clean And Oiled Elevation Surface Roughened

Chamfer U/G Mech. & Elect Bonding Agent

Straight, Level, Plumb 4. Embedments Type Of Finish

Adequate Bracing Anchor Bolts (Diameter, Length, Type) Sets/Test Specimen

2. Re-Bar Anchor Bolts (Location, Projection) Per Survey Book Hot/Cold Weather Protection

Grade Anchor Bolt Sleeves Joints

Size Anchor Bolt Grounding Special Placing Equip. Required (Tremies, Pumps,

Splices Thread Projection Form Vibrators Screeds)

Spacing Weld Pads Leakage System In Place

Clearance Angle Iron Finished Slope

Cleanliness Inserts

Adequate Support Pipes 6. Order Concrete To The Following Specifications:

Mix Design Quantity Delivery Per Hour

Max. Aggregate Size No. Of Test Cylinders/Set

Slump No. Sets Required

Admixtures

Remarks

SUBCONTRACTOR Fluor Concrete Pour Release Fluor QA

Name:

Civil Superintendant Date

Name: Electrical FE Date

Signature:

Mechanical FE Date

Signature: Civil FE Date

Date: Fluor QA Date Date:


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CONCRETE POUR CARD ID C71003A





Planning Information

Originator Date

Pour Number Quantity m³

Location Elevation

Design Mix Placing Temperature

Required Finish/Curing Air Content

Special Instructions Slump

Pre Pour Release

Civil Date

Mechanical Date

Electrical Date

Survey Date

Quality Control Date

Pour

Weather

Placement Started Date Time

Placement Completed Date Time

Cu. Yards Placed

Remarks


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CEMENTITIOUS GROUT INSPECTION CHECKLIST ID C71004A





GROUTING (Indicate Type): TYPE A - Cement Based Non-shrink

Subcontractor Fluor FE/QA

1.0 PRE-GROUTING INSPECTION

1.1 Shimplates installed according to specification, not protruding baseplate.

1.2 Base concrete was cleaned, roughened and pre-saturated for __________ hours.

1.3 Baseplate Size:_____________ Vertical Clear: ____________

Horizontal Clear:___________

1.4 Vent holes in baseplates checked and are sufficient or additional holes were drilled. 1.5 Hold point for rotating equipment.

Name:__________________________________ Date:________________

Signature:____________________________________________

2.0 GROUTING INSPECTION 2.1 Specified materials did not exceed shelf life recommended by vendor.

Grout Brand:______________________________________

2.2 The mix procedure used was in accordance with the manufacturer’s recommendations.

Mixer Type:___________________________ Capacity:________________

Mix Time/Batch:_______________________

Parts of Water/Bag:_____________________ Bags/Batch:_____________

2.3 Curing according to manufacturer’s recommended _____________ hours.

2.4 Temperature measured, see manufacturer’s recommendations.

Outside ambient: ____________ °C Inside ambient:____________ °C

Mixing water: ____________ °C Mixed grout: ____________ °C

3.0 POST-GROUTING INSPECTION

3.1 Grout formwork removed.

3.2 Grout fixed to concrete base.

3.3 Grout finishing according to specification.

3.4 Grout coating applied.

REMARKS:


Name: Name: Name:


Date: Date: Date:


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CEMENTITIOUS GROUT TESTING RECORD ID C71005A





Subcontractor Fluor

FE/QA

1. Grout consistency as measured by Corps of Engineers flow cone (CRD-79) was Grout consistency is:

Fluid Flowable Plastic Stiff

2. Temperature was measured and is in accordance with manufacturer’s recommendation for materials, mixing, placing and curing.

Outside Ambient °C Mixing Water °C

Inside Ambient °C Grout Bags °C

Equipment Plates °C Foundations °C

Mixed Grout °C In-Place (1 Hr.)

3. Test cubes were sampled for this placement location. Test cubes sampled: Number

Tag No. to

Remarks


Name: Name: Name:


Date: Date: Date:




Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual

Cerro Verde Production Unit Expansion 000 509 F71006 Project No. A6CV Revision 0, 10 June 2013

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EPOXY RESIN GROUT INSPECTION RECORD ID C71006A






1. Specified materials did not exceed shelf life recommended by vendor.

2. The materials were temperature stabilized 24 hours prior to mixing, and the aggregate was dry prior to mixing. (Indicate: ) Resin brand_________________ Catalyst brand_________________

3. The mix procedure is in accordance with the manufacturer's recommendations.

4. The concrete is at least 14 days old prior to grouting.

5. The concrete bond surface is clean, roughened and dry.

6. Metal surfaces to be embedded in grout are clean.

7. Metal surfaces to be kept free of grout are caulked or covered with plastic tape.

8. Formwork sealed, watertight and coated to prevent bonding.

9. Anchor bolt holes sealed (if not to be grouted) or dried.

10. Foundation adequately protected against sunlight, rain or sudden temperature changes during grout placement.

11. Final cleaning of metal surfaces completed just prior to grouting.

12. Formwork checked for leaks during placement.

13. Placement complete within manufacturer's recommended time.

14. Foundation adequately protected against sunlight, rain or sudden temperature changes during grout curing.

15. Curing of grout was in accordance with manufacturer's recommendations.

16. The temperature was measured and is in accordance with manufacturer's recommendations for mixing, placing and curing.

Outside Ambient:

Aggregate:

Inside Ambient: Mixed Grout:

Resin: Equipment Plates:

Catalyst: Foundation:

Remarks:


Name: Name: Name:


Date: Date: Date:

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual

Cerro Verde Production Unit Expansion 000 509 F71006 Project No. A6CV Revision 0, 10 June 2013

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CONCRETE COMPRESSION STRENGTH TEST RECORD ID C71007A





Mix Design No.: Concrete Supplier:

Contractor:

Mix Proportions Identity Batch Wt. Contract No.:

Cement, brand and type Date:

Fine agg., source Weather: Air Temp.:

Course agg., source Required Strength

Water, source Unit Weight kg/m³

Admixture, brand Slump Range

Admixture, brand Air Content Range

Admixture, brand

Test Data

Specimen Identity

Location and Volume Presented Truck No.

Slump (cm)

WT. (kg)

Air %

Temp. (°C)

Test Days

Test Strength (kg/cm²)


Name Name Name


Date Date Date


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CONCRETE PLACEMENT LOG ID C71008





Date Placed

Location of Pour Represented Pour

Number 7 Day

Results 28 Day Results

Other Results

ACC. REJ. en m³ Placed

en m³ Placed To Date


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GROUT PLACEMENT LOG ID C71009





Date Placed

Placement Represented Placement Number

7 Day Results

28 Day Results

Other Results

ACC. REJ. En m³ Placed

En m³ Placed To

Date


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STRUCTURAL STEEL

SCOPE This procedure describes the functions to be performed in the inspection of the erection of structural steel.



Verify acceptability of Interface Structures


000.509.F72002 Once for each structure

Erect Structural Steel Civil Superintendent _____ _____

Inspect In-process Structural Steel Erection


000.509.F72002 Daily during life of activity

Perform Final Inspection


000.509.F72002 Once per structure



Verify acceptability of Interface Structures


000.509.F72002 Once for each structure

Erect Structural Steel Subcontractor _____ _____

Inspect In-process Structural Steel Erection


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.



• 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.



- 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





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STRUCTURAL STEEL INSPECTION CHECKLIST ID S72002A


P. O. No.: Inspection Classification Area/Unit:

Subcontractor: Subcontractor Client Turnover System:

Work Package: Fluor Other Sub – System:

Drawing No.: Specification No.:

Item Description of Check Subcontractor Fluor FE/QA

FOUNDATIONS

01 Foundation inspections and tests complete. Piles Soils Concrete

02 Leveling plate or billet plate grouting complete and checked.

ANCHOR BOLTS

03 Grade and elevation

04 Anchor bolts condition

05 Base plate condition

06 Bearings surface cleaned and protected

07 Shimming of base plates

FIT-UP

08 Correct numbers location, and size

09 Survey Group checks alignment, plumbness, spacing, and elevation for conformance to erection tolerances

10 Match of member

11 Members free of distortion

12 Mating surfaces free of paint

BOLTS

13 Correct grade

14 Correct length

15 Correct size

16 All bolts visually inspected to verify evidence of tightening

17 Connections marked indicating statues

18 Bolt tightening method used: Calibrated Wrench Turn-of-Nut Load Indicating Washers Snap-Off Fasteners

WELDING

19 Welds approved by welding inspector

20 Field coatings checked

21 Fireproofing inspections and tests complete

22 Final inspection complete


Name: Name: Name:


Date: Date: Date:


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TORQUE WRENCH CALIBRATION LOG ID S72003Ar





Minimum Fastener Tension (Kips) for:

Dia. inches A325 Bolts A490 Bolts 1/2 12.6 Kips 15.8 Kips Bolt Tightening Equipment Used: 5/8 20.0 Kips 26.2 Kips 3/4 29.4 Kips 36.8 Kips 7/8 41.0 Kips 51.5 Kips 1 53.6 Kips 67.2 Kips Calibrated Equipment Used: 1 1/8 58.8 Kips 84.0 Kips 1 1/4 74.6 Kips 107.1 Kips 1 3/8 89.3 Kips 127.1 Kips 1 1/2 108.2 Kips 165.4 Kips

Date Bolt Size

Tension Reading* Before Adjustment

Tension Reading* After Adjustment

Signature

* Each tension reading shall be the average of three bolts.


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BUILDINGS SCOPE This procedure describes the inspection and testing activities to be performed for buildings that are constructed by Fluor. RESPONSIBILITIES - Self-Perform


ACTIVITY Verify foundations

complete Civil Construction

Engineer 000.509.F73001


Review structural steel documents


_____ Prior to steel erection

Monitor in-process building construction


000.509.F02201 Daily during life of

activity

Inspect completed work Civil Construction

Engineer 000.509.F73003 -000.509.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 Inspect in-process

foundations Subcontractor 000.509.F73001 Daily during life of activity

Inspect in-process building superstructure


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


Engineer/ Site Quality Manager

000.509.F73002 As required to close open

items

Surveillance QC Inspection 000.509.F02201 Per Procedure 000.509.0220



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.



• 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



Attachment 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



Attachment 2

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 (4C)

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


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

2. Waterproof coating free of wrinkles and buckles



Attachment 3

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 (13oC)

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


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

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



Attachment 4

BUILDINGS, METAL DOORS AND WINDOWS INSPECTION REFERENCE

VERIFY THE USE OF CORRECT MATERIALS


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


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



Attachment 5

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" (30-40 cm) each side of joint and is sanded

smooth.


1. Installed gypsum board free from damage.

2. All cemented joints and nail depressions will present smooth and uniform appearance when wall is painted.



Attachment 6

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.



Attachment 7

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



Attachment 8

BUILDINGS BUILT-UP ROOFING INSPECTION REFERENCE


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 (10C) for 24 hours prior to use

5. Ambient temperature is 40F (4C) 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


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



Attachment 9

BUILDINGS CERAMIC TILE INSPECTION REFERENCE



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


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


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BUILDING INSPECTION AND TEST CHECKLIST ID B73001A





Building Description __________________________________ Bldg. No._________ Initials/Date

1. Receiving operations/inspections performed on the following building materials and/or equipment.

2. Equipment and material protection program performed on the following materials or equipment.

3. Foundation inspections and tests complete.

Piles Soils Concrete

4. Foundation checked for location, elevation and orientation prior to starting superstructure.

5. Superstructure inspections complete.

6. Building tests complete. Building tests performed for this building:

Electrical Heating Plumbing

Air Conditioning Ventilation Other

7. Final inspection complete.

Remarks


Name Name Name


Date Date Date


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FINAL BUILDING INSPECTION SUMMARY ID B73002B





Receiving: Inspection Performed (See Attached List) Subcontractor Fluor FE/QA

1. Separate completion packages:

Structural Steel Piling Electrical Civil / Concrete HVAC

2. Masonry Checklist

3. Roof Metal Sliding and Roofing Checklist

4. Plaster Checklist

5. Doors/Windows/Hardware/Glazing/Keyplan Checklist

6. Insulation Checklist

7. Ceiling Checklist

8. Plumbing Checklist

9. Ceramic Tiles Checklist

10. Computer (Raised) Floors Checklist

11. Fire-Fighting System Checklist

12. Automatic Operated Components Checklist

13. Furniture / Kitchen Checklist

14. Surface Preparation / Finish Concrete Checklist

15. Sheeting / Cladding Checklist

16. Structural Steel Checklist

17. Carpentry Checklist

18. Painting Checklist

19. Pre Fab Wall Element Systems Checklist

20. Building Inspection and Test Checklist

21. Building water proofing and damp proofing Checklist

Remarks:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73003 Rev 0 Carpentry Checklist.doc Page 1 of 2

CARPENTRY CHECKLIST ID A73003A






01 Verify correct grade of materials used for all timber.

02 Verify correct species of timber used.

03 Verify use of correct preservative treatment.

04 Verify compliance with priming requirements.

05 Inspect timber construction dimensions.

06 Inspect fabrication quality.

07 Inspect joints.

08 Inspect blocking.

09 Studs aligned.

10 Door lintels and frames per design requirements.

Notes:


Name: Name: Name:


Date: Date: Date:


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PAINTING CHECKLIST ID X73004A






Verify use of correct painting materials:

01 Trade name and manufacturer

02 Grade

03 Manufacturer's data sheets

04 Protection for applied paint

05 Guarantees

06 Pot or shelf life

07 Correct colors

Inspect painting application:

08 Surface preparation

09 Method of application

10 Number of coats

11 Thickness of dry film

Ascertain workmanship:

12 Evenness of applied coat

13 Brush marks, sags, runs, etc.

14 Cleanliness of area upon completion

Notes:


Name: Name: Name:


Date: Date: Date:


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PLUMBING CHECKLIST ID C73005A





Item Description of check Subcontractor Fluor FE/QA

Verify the use of correct plumbing materials

01 Sanitary waste and vent system

02 Acid waste and vent system

03 Potable water system

04 Instrument air system

05 Plumbing fixtures and equipment

Verify plumbing installation per design documents

06 Hangers and supports

07 Piping

08 Joints

09 Valves

10 Fixtures

11 Hydrotesting

12 Correctness to codes, regulations

Notes:


Name: Name: Name:


Date: Date: Date:


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CERAMIC TILE CHECKLIST ID A73006A






01 Type and color of tile per design documents

02 Type and color of mortar per design documents

03 Inspection of substrate

04 Proportioning of mortar mixtures per design

05 Application procedures acceptable per specifications

06 Subsurface preparation per design

07 Grout procedure, pointing acceptable per specifications

08 Tile face plumb and in place, dividing over floor and wall surface

09 Inspect for cracks, misalignment

10 Grout joints uniform

Notes:


Name: Name: Name:


Date: Date: Date:


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CONCRETE CHECKLIST ID C73007A






General:

01 Concrete test specimen reports filed

02 Concrete mix designs approved

03 Patching and repairs complete

04 Embedments in place and correct location

Verify correct floor finishes:

05 Floated

06 Trowelled

07 Floor slab hardener

Verify correct use of granolithic concrete topping:

08 Material sources

09 Material proportions

10 Application method

11 Workmanship

Notes:


Name: Name: Name:


Date: Date: Date:


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STRUCTURAL STEEL CHECKLIST ID S73008A






01 Structural elements (main structure, bulkheads, decks, platforms/ walkways, grating, roof)- installed and checked against drawings

02 Structural elements - plumb, level, aligned

03 All structural supports installed per design and all temporary aids/ brackets removed

04 All temporary aids/ brackets/ steel removed

05 Anchor bolt nuts tight

06 Column base grouted

07 Bolted connections checked

08 Welded connections checked

09 Stairs, handrails, ladders, floor plates in place and per design

10 All penetrations installed, with sleeves/ kick plates of specified size complete with drain holes as required

11 All welding and NDT work completed and cleared

12 Coatings applied, touch-up complete

Notes:


Name: Name: Name:


Date: Date: Date:


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MASONRY (BRICKWORK) CHECKLIST ID C73009A





Item Description of Check Subcontractor Fluor

FE/QA

Verify use of correct materials:

01 Engineering brick, face brick, common brick

02 Cement, fine aggregate, water

03 Wall ties, reinforcing, flashing

Inspect construction of brickwork:

04 Coursing and wythes

05 Application of mortar

06 Inserts

07 Tie-ins and anchoring


08 Alignment of bond

09 Brickwork is plumb and true

10 Mortar joints uniformly struck or tooled

11 Cleanliness upon completion

12 Pointing to masonry work

13 Expansion joints in masonry work

Notes:


Name: Name: Name:


Date: Date: Date:


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PLASTER CHECKLIST ID A73010A






Verify the correct use of plaster materials:

01 Cement

02 Lime

03 Sand

04 Water

Inspect application of plaster:

05 Proportioning of plaster mixtures per design

06 Application technique per design

07 Subsurface preparation per design

08 Thickness of application per design

09 Installations of accessories like corner beads, etc. per design


10 Plaster face plumb and in one plane

11 Plaster flush with inserts

12 Troweled surface uniform

13 No defects, such as cracks and blisters

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73011 Rev 0 Doors Windows Hardware Glazing Checklist.doc Page 1 of 2

DOORS, WINDOWS, HARDWARE, GLAZING CHECKLIST ID A73011A






01 Correct materials used for doors, door bucks

02 Correct materials used for window sash and liners

03 Correct materials used for hardware

04 Correct materials used for window glass and putty

05 Correct materials used for electrical components for power operated doors

06 Correct materials used for guides and panel sections for telescoping doors

07 Verify the general operation of the doors

08 Frames anchored plumb and level

09 Doors and sashes not inhibited or bound from normal movement

10 Hardware in good mechanical operation

11 Glass well bedded and putty neatly trimmed

12 Operation of overhead or telescoping doors (controls, smoothness and speed)

13 Telescoping door guides installed, secured and aligned

14 Installation hardware is correct

Notes:


Name: Name: Name:


Date: Date: Date:


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COMPUTER (RAISED) FLOORS CHECKLIST ID A73012A






01 Correct materials used for floor panels/elements.

02 Correct materials used for floor supports.

03 Correct materials used for floor finishing.

04 Verify completion of installation per design.

05 Verify system level and square.

06 Floor system clean and free of damage.

Notes:


Name: Name: Name:


Date: Date: Date:


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PREFAB WALL ELEMENT SYSTEMS CHECKLIST ID A73013A






Verify the use of correct materials:

01 Frames

02 Panels

03 Glass

04 Doors

Inspect per design:

05 General operation

06 Hardware

07 Installation of panels and glass

08 Wall finishing/paint system

09 Wall panels anchored in accordance with design documents


10 Systems free of damage

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73014 Rev 0 Building Metal Roofing and Siding Checklist.doc Page 1 of 2

BUILDING METAL SIDING AND ROOFING CHECKLIST ID A73014A






Verify the use of correct materials:

01 Correct siding profile

02 Correct roofing profile

03 Fasteners, flashing, closer strips and caulking

04 Wall insulation

Inspect installation of siding and roof panels per design:

05 Correct spacing of fasteners

06 Insulation

07 Supports for roof insulation

08 Placement of closer strips

09 Flashing


10 Alignment of seams and fasteners

11 Tightness of joints

12 Repair of damage to panels or finish

13 Cleanliness upon completion

14 Manufacturer’s warranty intact

15 Systems free of damage

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73015 Rev 0 Buildings Waterproofing and Dampproofing Checklist.doc Page 1 of 2

BUILDINGS WATER PROOFING AND DAMP PROOFING CHECKLIST ID A73015A






Verify use of correct asphalt material:

01 Bitumen roofing felt

02 Horizontal damp proofing

03 Mastic asphalt

04 Hot application asphalt

05 Bituminous adhesives

06 Bituminous roofing

07 Polyethylene sheet

08 Insulation material

09 Roof slope falls to roof drains

Inspect application of asphaltic materials per design:


11 Coats, laps and thickness

12 Methods of application

13 Temperature of material and surface

14 Manufacturer’s warranty intact

Notes:


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73015 Rev 0 Buildings Waterproofing and Dampproofing Checklist.doc Page 2 of 2



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SUSPENDED CEILING CHECKLIST ID A73016A






Verify correct materials per design:

01 Ceiling board

02 Joint cover strips

03 Suspension system / exposed metal "T" system

04 Timber brandering

Inspect suspended ceiling construction:

05 Completion of all work above the ceiling, prior to start of work

06 Suspension system (e.g., set level and square, prior to installation of ceiling board)

07 Ceiling board fixed correctly to timber brandering

08 Adoption for recessed lighting fixtures


09 Tightness of joints

10 Cut boards at ceiling line

11 Boards free of discoloration or damage

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7310 Rev 0 Heating, Ventilating and Air Conditioning Ductwork.doc Page 1 of 2

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


Verify ductwork configuration


000.509.F73001 000.509.F73002

Upon completion of work

Verify ductwork integrity


000.509.F73001 000.509.F73002

Prior to turnover of system

Verify leak testing performed


000.509.F73001 000.509.F73002


Verify connections to equipment

Electrical/Mechanical Engineer

000.509.F73001 000.509.F73002


Surveillance QC Inspector

(Note 1) 000.509.F02201


NOTE 1: Surveillance is not required if the Fluor quality representative is performing

inspections. RESPONSIBILITIES - Subcontracted Work


Verify ductwork configuration

Subcontractor 000.509.F73101 000.509.F73102

Upon completion of work

Verify ductwork integrity



Perform leak test Subcontractor 000.509.F73101 000.509.F73102


Connect duct to equipment



Surveillance QC Inspector 000.509.F02201 Per Procedure 000.509.0220


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7310 Rev 0 Heating, Ventilating and Air Conditioning Ductwork.doc Page 2 of 2

PROCEDURE • Verify Ductwork Configuration: - Identify the specific limits of the system/sub-system to be inspected. Obtain the latest

approved revision of the drawings of the system/sub-system for verification of the work to be inspected.

- Verify that the installed configuration of the ductwork and hangers conforms to the

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

• Verify Ductwork Integrity: - Ductwork should be checked internally by means of the access doors to assure that it is

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

- Verify that any internal field-installed accessories, such as dampers, are in place.

Inspections prior to release for testing shall verify that openings in the ductwork are closed or fitted with temporary blank-offs as required to establish the pressure boundaries for leak testing.

• Verify Leak Testing Performed: - Verify that leak testing has been performed and that leakage rates are within allowable

limits. The integrity of duct joints shall be confirmed via leak testing. After leak testing, verify that all temporary blank-offs are removed.

• Verify Connections to Equipment: - Verify that all external field-installed accessories, such as registers, grills and diffusers are

in place. Verify that any required connections to equipment are complete and in accordance with the drawings.

FORMS Quality Control Forms 000.509.F73101 - HVAC Inspection Checklist 000.509.F73102 - Buildings Air Conditioning Checklist


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73101 Rev 0 HVAC Inspection Record.doc Page 1 of 2

HVAC INSPECTION RECORD ID B73101B





Drawing No.:

Subcontractor Fluor FE/ QA

Inspection/Verification Checkpoints:

1. Materials are in accordance with Design Documents.

2. Air conditioning checklist complete.

3. Internal accessories complete.

4. Leak testing complete.

5. Temporary blank-offs removed.

6. Connections between duct and equipment complete/acceptable.

7. All Non-conformance Reports are closed.

8. Walkdown is complete.

9. Test/Performance runs according to specification:

Type of Run Date

10. Other Inspection/Verification Activities performed as follows:

Remarks


Name: Name: Name:


Date: Date: Date:





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BUILDINGS AIR CONDITIONING CHECKLIST ID B73102A






1.0 Equipment

1.1 Specified equipment installed in accordance with manufacturer’s drawings and specifications.

1.2 Coolers.

1.3 Blowers/Ventilators.

1.4 Filters.

1.5 Heaters.

1.6 Dryers.

2.0 Ductwork

2.1 Duct supports installed per specifications.

2.2 Joints airtight.

2.3 Insulation installed per drawings.

2.4 Volume extractors or balancing dampers installed.

2.5 Sheet metal closing angles installed.

2.6 Dampers installed.

2.7 Ceiling diffusers checked.

2.8 Ductwork interior clean of debris.

2.9 Check for rattles and excessive noise.

3.0 Piping

3.1 Punched and tested.

3.2 Insulation installed as per drawings and specifications.

3.3 Valve director furnished.

4.0 Control Systems

4.1 Systems checked for completeness.

4.2 Clean filters installed.

4.3 Fan rotation checked.

4.4 Balancing completed and controls systems adjusted.

4.5 Balance position of balancing dampers marked.

4.6 Test data recorded and verified.

Remarks:


Name: Name: Name:


Date: Date: Date:





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ROOFING INSPECTION SCOPE This procedure prescribes the roofing system inspection activities to be performed. RESPONSIBILITIES - Subcontracted


ACTIVITY

Install Roofing Subcontractor

Roofing Installation General

Requirements


000.509.F73201 Daily during activity

Inspect Roofing Installation of

Adhered Membrane


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 cover-up. - Coordinate manufacturer representative inspections and respond to his findings. - Notify appropriate craft supervision when his work, overhead or adjacent to roofing contractors

work, impacts the quality aspect of the roofing system. FORMS Quality Control Form: 000.509.F73201 - Roofing Daily Inspection Checklist


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ROOFING INSPECTION CHECKLIST ID C73201A

AREA: BUILDING: DATE: TIME: WEATHER: Sunny Cloudy Rainy Foggy TEMPERATURE: C DEWPOINT: C

Inspection Attribute Acceptable Remarks General Requirements

1. Decking in the field of the roof,

secured through ribs to supports at 30,5 cm on center.

Inspector Date

2. Decking at corners (0,92 m²) and perimeters (1,8 width, or two deck panels, what ever is less) secured through ribs to supports at 15,24 cm on center.

Inspector Date

3. Decking side laps attached to supports, and secured between supports at 91,4 cm on center maximum.

Inspector Date

4. All penetrating elements, nailers, parapets and curbs installed.

Inspector Date

5. All receiving surfaces free of splinters and protruberant fasteners.

Inspector Date

6. Deck is free of moisture and debris. Inspector Date

7. Verify drains are unblocked. Inspector Date

Adhered Membrane

8. Insulation boards are not crushed.

Inspector Date

9. Install tapered edge strips to form crickets.

Inspector Date

10. Insulation boards to be half width or greater.

Inspector Date 11. Insulation boards with 1,9 cm

minimum edge bearing along upper flanges of the metal deck.

Inspector Date

12. Insulation boards butted together. Inspector Date

13. Fill insulation joints greater than 0.6 cm.

Inspector Date




14. Isocyanurate boards are glass faced.

Inspector Date

15. Insulation boards are FM approved with membrane.

Inspector Date

16. Insulation fasteners installed every 0,18 m².

Inspector Date

17. Insulation fasteners through metal deck upper flanges.

Inspector Date

18. Sumps formed about drain. Inspector Date

19. Insulation fasteners driven flush to the top of the insulation without crushing or breaking the insulation surface.

Inspector Date

20. Along perimeters and corners, insulation fasteners increased by 50 percent.

Inspector Date

21. Loose lay sheet without stretching. Inspector Date

22. Sheets allowed to relax 30 minutes minimum.

Inspector Date

23. Sheet seams 10,15 cm minimum. Inspector Date

24. Temperature of liquid adhesives and sealants 15,5°C minimum.

Inspector Date

25. Fold EPDM sheet back 3 m without wrinkles or buckles.

Inspector Date 26. Bonding adhesive stirred 5 minutes

minimum (scrapping sides and bottom).

Inspector Date

27. Surfaces to be bonded are clean and dry.

Inspector Date 28. Bonding adhesives applied evenly

without globs or puddles with mechanical roller dispenser. Bonding adhesive applied to both insulation and sheet at 11,15 m² to each surface. (Do not apply to seam surfaces).

Inspector Date

29. Operation discontinued if condensation forms on adhesives.

Inspector Date

30. Roll coated sheet on to coated substrate without wrinkles.

Inspector Date




31. Bonded half of sheet brushed with a soft bristle broom.

Inspector Date

32. Fold back unbonded half of sheet and repeat bonding process.

Inspector Date 33. Install adjoining sheets in the same

manner, edges overlapped 10/15 cm minimum, and formed with the flow of water.

Inspector Date

34. Seams formed outside of sump. Inspector Date

35. Splice area cleaned by scrubbing with Sure-Seal HP splice wipe or clean natural rags saturated with Sure-Seal splice cleaner. Extra cleaning required at factory seams.

Inspector Date

36. Cleaned material solid black in color with no streaking.

Inspector Date

37. Top sheet held back during cleaning process.

Inspector Date 38. Splicing cement stirred for 5

minutes minimum, scrapping sides and bottom.

Inspector Date

39. Splicing cement applied to both mating surfaces with 11,5 cm medium nap roller. Adhesive applied smoothly, continuously, and uniformly to achieve a heavy coat. Adhesive not allowed to glob or puddle.

Inspector Date

40. At corners and angles, splicing cement applied with 1,25 cm thick paint brush to achieve a smooth surface without brush marks.

Inspector Date

41. Splicing cement applied at the rate of 9,29 m²/ per gallon.

Inspector Date 42. Splicing cement allowed to dry until

it is tacky, but will not stick or string to a dry finger touch and will not be moved when pushed with a dry finger.

Inspector Date

43. If splicing cement over dried, fresh coat of splicing cement applied at half the rate.

Inspector Date

44. Just before closing splice, bead of In-Seam Sealant between 0,3 and 0,6 cm applied a minimum of 1,2 cm from the inside edge of bottom sheet and a minimum of 5 cm from the lead edge of the top sheet.

Inspector Date




45. Sure-Seal HP splice wipes or

Natural cloths contaminated by In-Seam Sealant not reused for application of splice cleaner.

Inspector Date

46. Top sheet rolled onto mating surfaces without stretching or buckling.

Inspector Date

47. Seam wiped with hand toward edge.

Inspector Date 48. Splice immediately rolled with a 5

cm wide steel roller with positive pressure toward outer edge. Roller not run parallel to seam. In-Seam Sealant remains evident and sensitive to the touch.

Inspector Date

49. Wait two hours minimum, but before end of work day, probe seam.

Inspector Date

50. Sure-Seal HP splice wipe or clean cloth dampened with splice cleaner used to clean the dry splice edge at least 0,02 cm beyond both sides of seam edge.

Inspector Date

51. 0,7 cm bead of lap sealant applied to completely cover splice edge.

Inspector Date

52. Lap sealant feathered with Carlisle tool.

Inspector Date 53. RUSS (EPDM 0,11 cm minimum

wide reinforced 15,24 cm EPDM) installed along perimeter, sections, expansion joints, curbs, and rising walls with gaps between strips not exceeding 2,5 cm.

Inspector Date

54. RUSS fastened with Carlisle fasteners - through seam fastening plates to metal deck at 30 cm on center maximum, and pre-drilled holes in 15,2 to 22,8 cm from corners.

Inspector Date

55. RUSS cleaned in accordance with membrane splices.

Inspector Date

56. Membrane spliced to RUSS in accordance to membrane splices.

Inspector Date 57. Vertical field seams at curbs and

walls overlaid with 15,2 cm wide uncured Elastoform flashing.

Inspector Date




Remarks:


Name: Name: Name:


Date: Date: Date:





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EQUIPMENT

SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for equipment erection and installation.



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


_____ 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.





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


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


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.



• 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.



• 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.


000.509.F74001 Equipment Installation Checklist 000.509.F74002 Heat Exchangers & Reboilers Installation Record 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 Record 000.509.F74011 Fuel Gas Steam Generator Inspection Checklist 000.509.F74012 Steam Turbine Inspection Checklist 000.509.F74013 Agitators/Mixers Inspection Checklist 000.509.F74014 Equipment/Piping Strain and Alignment Inspection Form 000.509.F74015 Installation Checklist Travelling Cranes 000.509.F74016 Package Equipment Installation Checklist



000.509.F74017 Desuperheaters/Ejectors Inspection Checklist 000.509.F74018 Filters/Strainers Installation Record 000.509.F74019 Centrifugal Compressor Inspection Record 000.509.F74020 Rotating Equipment Inspection Record 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 Leveling Record 000.509.F74031 Reverse Dial Alignment Record 000.509.F74032 Piping Alignment Data Sheet 000.509.F74033 Rotating Equipment (Face-Rim) Alignment Record

ATTACHMENTS Attachment 1 - Equipment Inspection Reference



Attachment 1

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.



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.





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EQUIPMENT INSTALLATION CHECKLIST ID M74001A



Subcontractor: Subcontractor Turnover System:

Fluor Other Sub – System:

Equipment Description:

Drawing No.

Specification No.

Vendor Drawing No.


Assembly

Orientation

Elevation

Shimming and Grouting

Final Alignment and Rotation

Bolting and Anchoring

Instrumentation

Vessel Closure Permit (Attach Closure Permit)

Insulation

Rigging and Handling (Attach Rigging Plan)

Protection

Cleaning, Lubrication, Adjustment, Packings

Vessel Internals Check

Item No. Horizontal &

Plumb Tightness

All Parts Operable

Cleanliness Remarks


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74004 Rev 0 Inspection Record Static Equipment.doc Page 1 of 2

INSPECTION RECORD STATIC EQUIPMENT ID M74004A



Subcontractor: Subcontractor Sub – System:


Subject Subcontractor Fluor FE/QA

1. Verify nameplate data meets description.

2. Verify preservation integrity (if applicable).

3. Verify foundation and foundation bolts meet specified requirements.

4. Verify installation tolerances have been met.

5. Verify grouting meet specifications.

6. Verify all internals are correctly installed.

7. Verify all shipping devices have been removed.

8. Verify all vents, drains, and instruments con. etc. are installed in ACC. with equipment trim isometrics.

9. Verify alignments of piping connections are correct.

10. Verify coating system meets specified requirements.

11. Verify insulation meets specified equipment.

12. Verify prior to final closing for internal cleanliness.

13. Verify all ladders, platforms, stairways and walkways on correctly installed.

14. Orientation correct

15. Correct shimming installed

16. Tightness of anchor bolts nuts

17. Grouting completed

18. Sliding plate free (for horizontal vessels only ) & lubricated

19. Trays/down comers/support rings

20. Davits installed (Where applicable )

21. Ready for closure

22. Closure certificate signed


Name Name Name


Date Date Date


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TRAY INSTALLATION INSPECTION RECORD ID M74005AR





TRAY No.

1

1

2

2

3

3 TRAY No.

4

4

Tray No. Design Dim’s Below

Overflow Actual Dimensions

HorizontallyWorking

Value A B C D E F

Contractor Fluor Field Engineering Fluor QA

Name: Name: Name:


Date: Date: Date:

A B C

A B C

A F B E C D

A F B E C D


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RECIPROCATING COMPRESSOR INSPECTION RECORD ID M74008A






1. Receive operations/inspection complete

2. Equipment protection program instituted and documented 3. Anchor bolts checked for location, elevation and orientation, prior to

setting equipment.

4. Equipment set: checked for location, elevation and orientation

5. Nameplate data verified 6. Preliminary alignment completed and documented. (Belt sheave

alignment requires no documentation).

7. Jackscrews removed and anchor bolt nuts tightened.

8. Base grouting completed and documented 9. Lube oil system flushed. Lubricant:

10. Suction piping cleaned in accordance with specifications and documented.

11. Final cold alignment set to manufacturer’s tolerances and documented (belt sheave alignment requires no documentation).

12. Temporary suction screen installed

13. Compressor and driver checked for freedom of measurement

14. Driver activities completed and documented.

15. Pulsation dampening system checked 16. Belts installed, or coupling lubricated and closed. Lubricant:

17. Belt or coupling guard in place and secured.

18. Compressor and driver dowelled (when specified).

19. Field coatings/insulation checked. 20. Vendor representative provided service/supervision for the equipment.

Vendor reports attached to this inspection record.

21. Equipment protection program completed and documented.

22. Final inspection complete. Punch items cleared.


Name: Name: Name:


Date: Date: Date:


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FAN INSTALLATION INSPECTION CHECKLIST M74009A






01 Verify baseplate level and correctly grouted.

02 Verify jackscrews removed and anchor bolts tightened.

03 Verify temporary shipping preservatives/oils removed.

04 Verify lubrication applied (where required).

05 Verify excess piping strain alleviated.

06 Verify final alignment as per specification.

07 Verify blower driver checked for rotation.

08 Verify gear unit checked (where applicable).

09 Verify bearing lube system cleaned, flushed and operable.

10 Verify belts installed or coupling connected.

11 Verify packing installed.

12 Verify blower and driver dowelled (where applicable).

13 Verify casing drained.

14 Verify inlet vanes set correctly and operable.

15 Verify air filtration system correct.

16 Verify all controls, protection devices and auxiliary systems correct.

17 Verify all pipe supports correctly supported.

Notes:


Name: Name: Name:


Date: Date: Date:


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AGITATORS/MIXERS INSPECTION CHECKLIST ID M74013A





Item Description of Check Subcontractor Fluor FE/QA Remarks

01 Verify mounting flange level (or plumb).

02 Verify driver direction of rotation.

03 Verify shaft plumb (or level).

04 Verify shaft straightness.

05 Verify alignment of drive shafts end clearance. inch

06 Verify concentric parallel 1/4 Turn 1/2 Turn 3/4 Turn Full Turn

07 Verify mechanical seal or packing in coupling cleaned, closed and lubed.

08 Verify shaft turns freely by hand. Important: Do not start with dry mechanical seal.

09 Verify bearing house flushed and relubed.

10 Verify seal fluid system operable.

11 Verify lubricator operable.

12 Verify driver doweled in place.

13 Verify coupling guard in place.

14 Verify grounding strap installed.

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74014 Rev 0 Equipment-Pipe Strain and Alignment Inspection Form.doc Page 1 of 2

EQUIPMENT/PIPING FLANGE ALIGNMENT INSPECTION RECORD ID M74014AR





Report No.:

Flange Misalignments: Nozzle No.: Subcontractor Fluor FE/QA

Vertical bolt hole offset cm cm

Horizontal bolt hole offset cm cm

Rotational offset cm cm

Flange face parallelism cm cm

Flange face separation cm cm

Flange Misalignments: Nozzle No.: Subcontractor FluorFE/QA






Flange Misalignments: Nozzle No.: Subcontractor Fluor FE/QA






IM & TE ID:

Calibration Due Date:


Name: Name: Name:


Date: Date: Date:


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INSTALLATION CHECKLIST TRAVELLING CRANES ID M74015A






Note: * Indicate Correct One

Definition

01 Verify configuration: fixed monorail/underhung bridge/overhead bridge/other .................................. (*)

02 Verify marking safe working load: Beam

03 Verify marking safe working load: Crane

Verify type of drive

04 Hoist: manual/electric/pneumatic (*)

05 Longitudinal: manual/electric/pneumatic (*)

06 Transversal manual/electric/pneumatic (*)

Type of lift: cable/chain (*)

Verify fixed parts

07 i.e. runway beams, rails: Verify dimensions, positions, levels, fixing to structures, parallelism of rails / runway beams (if applicable), end stops, interlocks

Verify moving parts

08 i.e., bridge, end carriages, drives, hoists, etc., for conformity and correct mechanical assembly

09 Verify certification is complete, if required

Notes:


Name: Name: Name:


Date: Date: Date:


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PACKAGED EQUIPMENT INSTALLATION CHECKLIST ID M74016A






01 All shipping stops, bracing and packaging removed.

02 Unit installed according to vendor instructions, undamaged, with skid location and orientation correct, holding down arrangement complete and secure.

03 Check vibration mountings are secure and set correctly.

04 Check equipment is level and shim material is to the correct specification.

05 Nameplate details correct and in accordance with the datasheet. Nameplate securely attached, readable not obscured.

06 Purchased equipment release note available.

07 All shipped loose knocked down items re-installed in accordance with vendor’s installation instructions.

08 Where preservation materials are installed, equipment is suitably marked “PRESERVATION INSIDE”.

09 Unit clean and free from external damage and all paint work in good condition.

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74018 Rev 0 Filters Strainers Installation Record.doc Page 1 of 2

FILTERS/STRAINERS INSPECTION CHECKLIST ID M74018A






01 Nameplate details are in accordance with data sheet.

02 Check location is correct.

03 Check filter is level and supports are correct.

04 Check holding down bolts are fitted and torque settings are correct.

05 Check external condition of filter.

06 Check external fittings are correctly installed on filter.

07 Check earthing is correctly fitted and to specification.

08 Check vent / drain valves are fitted correctly.

09 Check crossover valve is fitted correctly.

10 Check balance line is fitted correctly.

11 Check filter is internally clean.

12 Check all filter elements are fitted correctly.

13 Check all filter elements condition.

14 Check all filter element types are correct.

15 Check filter access lid is fitted correctly.

16 Check access lid securing bolts are fitted and torque settings are correct.

17 Check inlet and outlet pipework supports are secured / adequate.

Notes:


Name: Name: Name:


Date: Date: Date:


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CENTRIFUGAL COMPRESSOR INSPECTION CHECKLIST ID M74019A






FE/QA

01 Verify receipt operations/inspection complete.

02 Verify equipment protection program instituted and documented.

03 Verify anchor bolts checked for location, elevation and orientation, prior to setting equipment.

04 Verify equipment set; checked for location, elevation and orientation.

05 Verify nameplate data.

06 Verify preliminary alignment completed and documented.

07 Verify jackscrews removed and anchor bolt nuts tightened.

08 Verify base plate grouting completed and documented when manufactured grouts are required.

09 Verify lube and seal oil systems flushed. Lubricant:

10 Verify suction piping cleaned in accordance with specifications and documented.

11 Verify final cold alignment set to manufacturer's tolerances and documented.

12 Verify temporary suction screen installed.

13 Verify compressor and driver checked for freedom of measurement.

14 Verify driver activities completed and documented.

15 Verify coupling lubricated and closed. Lubricant:

16 Verify coupling guard in place and secured.

17 Verify compressor and driver doweled.

18 Verify field coatings/insulation checked.

19 Verify vendor representative provided service/supervision for this equipment. Vendor reports attached to this inspection record.

20 Verify equipment protection program completed and documented.

21 Verify final inspection complete.


Name: Name: Name:


Date: Date: Date:


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ROTATING EQUIPMENT INSPECTION CHECKLIST ID M74020A






FE/QA

01 Verify nameplate data.

02 Verify preservation integrity.

03 Verify foundation and foundation bolts meet specified requirements.

04 Verify installation tolerance have been met.

05 Verify grouting meet specifications.

06 Verify all internals are correctly installed.

07 Verify all shipping devices have been removed.

08 Verify all vents, drains, instrument connections, etc., are installed in accordance with equipment trim isometrics.

09 Verify alignments of piping connections are correct.

10 Verify coating system meets specified requirements.

11 Verify insulation meets specified equipment.

12 Verify prior to final closing for internal cleanliness.

13 Verify all ladders, platforms, stairways, and walkways are correctly installed.

14 Verify all shafts for freedom of movement.

15 Verify coupling alignment and installation.

16 Verify direction of rotation.

17 Verify electric motor.

18 Verify installed coupling guard gives adequate protection.

19 Verify correct quality and quantities of lubricants have been installed.

Notes:


Name: Name: Name:


Date: Date: Date:


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ROTATING EQUIPMENT ALIGNMENT CERTIFICATE

ID M74021AR





Manual No. : Phase :

Platform : Create Date :

INFORMATION AND INSPECTION

Manufacturer Type Serial No

Test Equipment Used Type Serial No. Calibration Expiry Date

Note : Indicate contents of completed report by the deletion of either “ Y “ of “ n/a “ as applicable.

Page No. Record Sheet Description

2 of 6 Flange Alignment Data Sheet Y n/a

3 of 6 Alignment Data Sheet - Uncoupled Y n/a

4 of 6 Alignment Data Sheet - Pipework Loose Y n/a

5 of 6 Alignment Data Sheet - Pipework Tight Y n/a

6 of 6 Uncoupled / Coupled Motor Run Data Sheet Y n/a

Remarks:



ROTATING EQUIPMENT ALIGNMENT CERTIFICATE ID M74021Ar


FLANGE ALIGNMENT

Nozzle Alignment

Inner Ring

No. Description Line No. A B C Gasket Type 1 Yes No

Remarks: (1) Spiral Wound / CAF / RTJ / Graylock





COUPLING ALIGNMENT - UNCOUPLED

DRIVER DRIVEN

Fig 3

D

C

For face and periphery use clock C only.

For reverse alignment use clock C and D.

DRIVER DRIVEN

C

Fig 1

RIGID MOUNT

Fig 2

B A

A

B

B

A

A B

A

B

0 90 180 270

DRIVER DRIVEN



RORATING EQUIPMENT ALIGNMENT CERTIFICATE ID M74021Ar


COUPLING ALIGNMENT - COUPLED : PIPEWORK LOOSE

N.B. For instructions of method of alignment including completion of alignment data sheet. See section 2.9 of Code of Practice “ Mechanical Commissioning “ METHOD OF ALIGNMENT EMPLOYED ...........................................

LOOKING IN DIRECTION OF ............................................................

PIPEWORK FREE ..............................................................................

LENGH OF COUPLER SPACER .......................................................

1 RADIAL CONCENTRICITY OF EACH HALF COUPLING TO IT’S OWN SHAFT (Use for face/periphery and reverse alignment.)

2 COUPLING GAP. FACE TO FACE. (AXIAL) (Use only for face/periphery method.)

3 RADIAL CONCENTRICITY COUPLING FLANGES TO EACH OTHER (Use only for face/periphery and reverse alignment.)

3

4

DRIVER DRIVEN

61

25 7

D.B.F.F.

mm mm

mm

mm

mm mm

mm

mm

DRIVENGAUGE No. 2

DRIVERGAUGE No. 1

mm mm

mm

mm

CLOCK GAUGES 3 & 4

DRIVENGAUGE No. 6

DRIVERGAUGE No. 5

mm mm

mm

mm

mm mm

mm

mm





COUPLING ALIGNMENT - COUPLED : PIPEWORK TIGHT

N.B. For instructions of method of alignment including completion of alignment data sheet. See section 2.9 of Code of Practice “ Mechanical Commissioning “ METHOD OF ALIGNMENT EMPLOYED ...........................................

LOOKING IN DIRECTION OF ............................................................

PIPEWORK FREE ..............................................................................

LENGH OF COUPLER SPACER .......................................................

.1 RADIAL CONCENTRICITY OF EACH HALF COUPLING TO IT’S OWN SHAFT (Use for face/periphery and reverse alignment.)

2 COUPLING GAP. FACE TO FACE. (AXIAL) (Use only for face/periphery method.)

3 RADIAL CONCENTRICITY COUPLING FLANGES TO EACH OTHER. (Use only for face/periphery and reverse alignment.)

3

4

DRIVER DRIVEN

61

25 7

D.B.F.F.

mm mm

mm

mm

mm mm

mm

mm

DRIVENGAUGE No. 2

DRIVERGAUGE No. 1

mm mm

mm

mm

CLOCK GAUGES 3 & 4

DRIVENGAUGE No. 6

DRIVERGAUGE No. 5

mm mm

mm

mm

mm mm

mm

mm





UNCOUPLED / COUPLED MOTOR RUN DATA SHEET

1. Uncoupled Motor Run

Time (mins) LV 2 4 6 8 10 15 20 25 30 HV 0 30 60 90 120 150 180 210 240

Amb Temp °C

Fan Casing temp °C

Bearing temp DE °C

Bearing temp NDE °C

Vibration monitoring mm/s

Remarks :

2. Coupled Motor Run

Time (mins) LV 2 4 6 8 10 15 20 25 30 HV 0 30 60 90 120 150 180 210 240

Amb Temp °C

Fan Casing temp °C

Bearing temp DE °C

Bearing temp NDE °C

Vibration monitoring mm/s

Remarks :


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74022 Rev 0 Belt Driven Equipment Alignment Record.doc Page 1 of 2

C

BELT DRIVEN EQUIPMENT ALIGNMENT RECORD ID M74022AR





Description of Check Subcontractor Fluor FE/QA

Pulley alignment

Feeler gauge/straight edge on pulley faces.

View from top

A1..............................................… .000 cm

A2..............................................… .000 cm

A3..............................................… .000 cm

A4..............................................… .000 cm

Belt tension

Adjust C to vendor’s recommendation.

C………………………………..cm

Notes:


Name: Name: Name:


Date: Date: Date:

A1 A2 A3 A4


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74024 Rev 0 Inspection Record for Draw Off Tray Leak Test.doc Page 1 of 2

INSPECTION RECORD FOR DRAW OFF TRAY LEAK TEST REPORT ID M74024A






1.0 Number of trays to be tested

2.0 Gaskets installed

3.0 Volume of water in trays before test

Depth cm

4.0 Volume of water in trays after 30 minutes.

Depth cm

5.0 Test acceptable

General Notes:

Reason for failure:

Corrective action required:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74025 Rev 0 Inspection Record For Air Coolers.doc Page 1 of 2

INSPECTION RECORD FOR AIR COOLERS ID M74025A






1.0 Verify motor rotation

2.0 Install V-belts and adjust

3.0 Auto – variable pitch fan. Operation check:

3.1 Apply _______ psi air to diaphram & adjust blade for maximum blade angle of ________.

3.2 Adjust for minimum blade pitch angle of

3.3 Verify fan rotation

3.4 Motor amps, fan pitch under load conditions

4.0 Start fan & record motor ammeter reading: Amps

4.1 Verify vibration

5.0 4 hour test run:

5.1 Verify bearings

5.2 Retighten belts

5.3 Adjust blade pitch

6.0 Restart motor :

6.1 Verify motor amps if blade pitch changed Amps

7.0 Vibration switch test:

7.1 Trip simulation acceptable

Remarks


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74026 Rev 0 Final Closing Authorization Record.doc Page 1 of 2

FINAL CLOSING AUTHORIZATION RECORD ID M74026Ar





1. The above equipment has been supplied, erected and internally fitted in accordance with the applicable drawings, specifications and manufacturer's standard and is certified to be mechanically acceptable. Equipment has been inspected for cleanliness and is free of all debris.

Fluor/Date

2. Authorization is hereby granted to effect final closing or sealing of this equipment.

Client/Date

3. Final closing has been effected.

Fluor/Date





W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74027 Rev 0 API 686 Pre- Grout Baseplate Installation Checklist .doc Page 1 of 2

API 686 BASEPLATE INSTALLATION CHECKLIST (PRIOR TO GROUTING) ID M74027A





Reference Anchor bolts checked for: Subcont Fluor FE/QA

3.5.2 Clean and dry sleeves filled with a nonbonding moldable material such as spray foam

3.5.3 Undamaged threads wrapped with duct tape for protection during chipping and grouting operation

Foundation checked for:

3.6.2 Breaks in aggregate to show that top of foundation has been chipped off to remove low-strength, high porosity concrete (laitance)

3.6.4 Concrete grout areas clean and free of oil, dust and moisture

Baseplate (or soleplate) checked for:

3.8.2 (5 cm) minimum radiused corners

3.8.6 Sufficient grout and air vent holes in each compartment

3.8.9 Continuous welds that are free or cracks

Stencil stating underside pre-coated with an epoxy primer

Coupling guard bolts greased and installed to full depth.

Elevation adjustment checked for:

3.8.7 Adjustment nuts not used on anchor bolts

3.9.1.2 Jackscrews liberally coated with paste wax or grease

3.8.8 Jackscrews provided with stainless steel leveling pads

3.9.4.5 Anchor bolts snug tight to hold baseplate in place

3.9.4.1 Baseplate (or soleplate) raised to proper height per construction drawings

3.9.4.4 Each machined mounting pads level to within 0,002 cm and centers are within 0,005 cm separation of each other (i.e., two pads three feet apart shall be a maximum of 0,015 cm from the correct elevation). Data Sheet for level record completed

API 686 Chapter 5 paragraph number is referenced preceding each item. Proceed to ‘Baseplate Grouting Checklist’ (000 509 F74028) when all of the above items have been accepted.


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74027 Rev 0 API 686 Pre- Grout Baseplate Installation Checklist .doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74028 Rev 0 API 686 Equipment Grouting Checklist.doc Page 1 of 4

API 686 EQUIPMENT GROUTING CHECKLIST ID M74028A Tag Description: Tag No.:




4.1 MACHINERY INSTALLATION PREGROUT SETUP CHECKLIST

Reference Anchor Bolt Preparation Subcont

Fluor FE/QA

3.5.2 Anchor bolt sleeves are clean and dry and filled with a nonbonding moldable material

3.5.2 Anchor bolts are not tilted or bolt-bond and are perpendicular with respect to the bottom of the baseplate/soleplate

3.5.3 Foundation anchor bolt threads are undamaged.

3.5.3 Foundation anchor bolt threads have been wrapped with duct tape for protection.

3.5.4 All anchor bolt locations and projections have been verified.

Foundation preparation

3.6.1 An adequate weather-protective cover has been constructed over the areas to be grouted.

3.6.2 Concrete foundation is roughened up and all laitance removed for a good grout bond.

3.6.2 The minimum grout thickness under any portion of the baseplate/soleplate will be 2,5-5 cm.

3.6.2 Foundation is free of structural cracks.

3.6.3 All grout forms have been provided with 2,5 cm 45-degree chamfer strips at vertical corners and horizontal edges.

3.6.4 Concrete grout areas are clean and free of oil, dust, and moisture.

Grout Forms

3.7.1 Grout forms are of adequate strength to support the grout.

3.7.3 Inside surfaces of grout have three coats of paste wax applied.

3.7.4 Grout forms have been sealed to the foundation to prevent leaks.

3.7.5 Grout forms have 2,5 cm, 45-degree chamfer strips at all vertical corners and at the horizontal surface of the grout.

Mounting Plate Design Verification

3.8.2 Baseplate/soleplate has 5 cm minimum radiused corners.

3.8.3 Anchor bolts have 0,3 cm annular clearance in baseplate or soleplate holes.

3.8.4 All pump and other small baseplates have been provided with vertical leveling screws.

3.8.5 Baseplates have been provided with one 5 cm minimum grout filling hole in the center of each bulkhead section and one 1,25 cm vent hole.

3.8.6 Baseplates have sufficient grout and air vent holes in each compartment to allow for proper grouting.

3.8.7 Elevation adjustment nuts will not be permanently grouted.



API 686 EQUIPMENT GROUTING CHECKLIST ID M74028A

3.8.8 Baseplate leveling jackscrews have been provided with stainless steel leveling pads.

3.8.9 Baseplate welds are continuous and free of cracks.

3.8.10 All grout pour and vent holes are accessible.

Mounting Plate Preparation

3.9.1.1 Baseplate/soleplate has been blasted and all grouting surfaces prepared in accordance with the grout manufacturer’s recommendations.

3.9.1.2 Three coats of paste wax have been applied to all surfaces where grout bond is not desired. These surfaces include jackscrews, grout forms and coupling guard bolts.

3.9.1.3 All miscellaneous mounting plate holes are plugged to prevent the entrance of grout.

3.9.1.4 Equipment to be grouted is isolated and in a strain-free condition with all piping, conduit and so forth, disconnected.

Expansion Joints

3.9.2.1 Expansion joints placed on 1,2 to 1,8 meter intervals.

3.9.2.2 Expansion joints fixed into position such that they will not move when grout is poured.

Soleplate Installation and Leveling

3.9.3.1 The elevation to the top of equipment baseplate or soleplate referenced to the civil benchmark is in agreement with the construction grout drawing.

3.9.3.7 All shims used in sub soleplates are AISI Standard type 300 stainless steel.

3.9.3.9 All machined baseplate or soleplate surfaces are level in accordance with the specification and signed-off Data Sheets for level record have been completed.

3.9.4.1 All baseplate elevations set in accordance with the construction drawings.

3.9.4.2 A preliminary equipment alignment check has been made.

1.9.4.5 All baseplate surfaces are level in accordance with the specification and signed-off Data Sheets for level record have been completed.

Pregrout Setup

3.12.1 All surfaces in contact with grout are clean, dry and oil free.

3.12.2 Anchor bolt nuts have been “snugged” into position to prevent baseplate/soleplate floating.

3.12.3 Anchor bolt sleeves have been filled with flexible mastic material.

3.12.3 Top of anchor bolt sleeve has been packed with a soft moldable material.

3.12.4 Grout form elevation agrees with the construction drawings.

3.12.8 Grouting material is in clean, dry, unopened containers and has been stored at a temperature of approximately 23,8˚C for 48 hours prior to grouting.

3.12.9 All foundation and metal surfaces are within the temperature range of 18,3-32,2˚C

3.12.10 Sufficient quantity of grouting materials are on hand at the jobsite to complete the job (15-25 percent extra).

3.12.11 Clean tools, mixing equipment and safety supplies are on hand at the jobsite.

3.12.12 Material Safety Data Sheets and personnel protection requirements have been reviewed with all grouting personnel.




4.2 MACHINERY INSTALLATION GROUT PLACEMENT CHECKLIST

Ambient temperature at beginning of grout pour _______˚C .

Pre-grout meeting has been completed and all personnel understand the grout plan and individual responsibilities.

Grout Mixing

3.13.2 Resin and hardener are mixed at 200-250 rpm for the specified time and no air entrainment is indicated.

3.13.3 Full bags of aggregate are slowly added to blended resin/hardener liquid and mixed to completely wet-out the aggregate.

3.13.3 No partial units of epoxy, resins, hardener or aggregate used.

3.13.4 Grout mixed in a clean, slow-speed (15-20 r.p.m) portable mortar mixer (or in a wheelbarrow for small pours).

Mounting Plate Grouting

Grout is placed within its pot life.

Time at beginning of pour: (AM) (PM)

Time at end of pour: (AM) (PM)

3.14.2 No vibrator is used to facilitate grout placement.

3.14.2 Grout pour rate is slow enough to permit air to escape.

3.14.3 The grout volume used agrees with the estimated cavity volume.

3.14.4 No grout leaks are observed.

3.14.5 For special purpose equipment, a grout sample is obtained for each batch mixture (polystyrene cup full) for compressive strength testing. All samples are to be labeled and their batch placement location noted.

3.14.7 All grout surface air bubbles are removed.

3.14.9 Grout holes and vent holes filled with grout.

Ambient temperature at end of grout pour _______ ˚C

4.3 MACHINERY INSTALLATION POST-GROUTING CHECKLIST

3.15.1 Grout is of sufficient hardness to remove forms.

3.15.1 Grout forms remained in place after grouting for 48-36 hours.

3.15.3 Mounting plate jackscrew holes are filled with a flexible material such as RTV silicone rubber.

3.15.4 Grout is checked for “softness” with a dial indicator. Baseplate/soleplate checked for soft foot at each anchor bolt location with a magnetic base dial indicator as anchor bolts are torqued. Base movement does not exceed 0,025 mm.

3.15.5 Expansion joints sealed with elastic epoxy seam sealant.

3.15.6 Top of machinery foundation painted with a grout-compatible nonskid protective coating.




3.15.7

Lubricate all anchor bolt threads liberally and torque anchor bolts in accordance with the manufacturer’s recommendations.

Anchor bolt size:

Torque specification:

Installed torque:

3.15.8 Ensure that all anchor bolts have full penetration of the anchor bolt nut and a minimum of 2 ½ threads protrude above the anchor bolt nut.

Filling Grout Voids

3.16.1 Baseplate “sounded” for voids and all voids repaired. Indicate number of voids found, their size and their location:

3.16.2 Void areas have NPT 0,3 cm holes installed in opposite corners of void with grease fitting installed in one of the holes.

3.16.3 Grout void fill and vent holes are in “communication”.

3.16.3 Dial indicator used on mounting plate to monitor plate movement while filling grout void.

3.16.4 All spilled grout is cleaned up with manufacturer’s approved solvent.

3.16.5 Recheck baseplate to ensure that all voids are filled with grout.


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74029 Rev 0 API 686 Equipment Alignment Checklist.doc Page 1 of 2

API 686 ALIGNMENT CHECK SHEET ID M74029A





Reference Subcont Fluor

FE/QA

5.1.1 Prealignment meeting held

Roles & Responsibilities Contract and Back up Phone Numbers Alignment Table complete and available Taper Gauges available for checking piping flange alignment Shims SSTL or better material, not laminated and flat to 1/1000. At least 0,3cm

thick but not more than 1,2 cm under movable machine foot. No more than one 0,3 cm thick shim under any foot.

Sag of alignment fixture recorded (<0.8 mm/m)

Alignment Checklist

5.1.3 Equipment installed and fixed machine centered on holes

5.1.12 Fixed and movable machines shafts free to turn

Pump seal locking devices disengaged Packing or blocking material removed Lubrication provided for bearings

5.1.4 Coupling hubs runout rim and face readings is ≤0,005cm” or the manufacturer’s requirement, whichever is less.

5.1.5 Check for Bolt-Bound condition

5.1.11 All piping is disconnected

5.4.1 Movable and fixed machine rotors DBSE or coupling spacer gap length acceptable when set to running position

5.4.2.1 Minimize number of shims (Max 5 shims under any support)

5.4.2.1 Shims are full bearing where practical (use largest pre-cut shim)

5.4.4 Confirm Pump & Motor soft foot is not more than 0,005 cm”

5.5.1.1 Sag of alignment fixture recorded (<0.8 mm/m)

5.4.5 Alignment within tolerance before pipes and conduit attached

5.4.5. Pipe strain confirmed to be within 0.005 cm shaft end deflection

5.4.5 Alignment within tolerance after pipes and conduit attached


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74030 Rev 0 Baseplate Leveling Record.doc Page 1 of 2

BASEPLATE LEVELLING RECORD ID M74030A





Limits: + Each pad level to within 0,002 cm/m (record reading and note direction with arrow)

Slope between pads less than 0,005 cm/m (record reading and note direction with arrow) Z Soft foot less than 0,005 cm (record reading after grouting baseplate with equipment set) Before/After Grout (circle one)


Name Name Name


Date Date Date

Z = _ _ _ _

Z = _ _ _ _

Z = _ _ _ _

Z = _ _ _ _

Z = _ _ _ _

Z = _ _ _ _


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74031 Rev 0 Reverse Dial Alignment Record.doc Page 1 of 2

REVERSE DIAL ALIGNMENT RECORD ID M74031A






Name Name Name


Date Date Date

Movable Machine(Driver)

Movable Machine(Driver)

_ _ _ _ _ _

Fixed Machine(Driven)

_ _ _ _ _ _

A

B

Before/After Piping (circle one)

(180)

Fixed Machine(Driven)

A (0)

DBSE = _ _ _ _

(0)

(180)

B

(90)

(270)

(270)

(90)

Looking

Thermal Growth (Motor) ______ Thermal Growth (Pump) ______


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74032 Rev 0 Piping Alignment Datasheet.doc Page 1 of 2

PIPING ALIGNMENT DATA SHEET ID M74032A Tag Description: Tag No.:




Machinery Installer: Machinery Identification:

Equipment nozzle and mating flange alignment tolerances shall be within the following maximum permissible limits: a. For steam turbines and compressors other than reciprocating types, 0,4mm (1/64 in. in.) for all alignment categories listed in Subpar. b. below. [For nozzles greater than NPS 24 (600 mm) (24 in.), the machinery vendor shall supply matting flanges.] b. For centrifugal pumps and other rotating machinery:

Alignment Detail Maximum Permissible Misalignment of Flanged Joints. In.

NPS 12 NPS 22 NPS 24 1. Vertical bolt hole offset 1/8 1/16 1/64 2. Horizontal bolt hole offset 1/8 1/16 1/64 3. Rotational offset 1/8 1/16 1/64 4. Flange face parallelism (across diameter) 1/64 1/64 1/64 5. Flange face separation, plus space required for gasket 1/8 1/16 1/64

Pipe Strain Readings Note: For horizontal machinery – Dial indicator readings on coupling hub flange.

For vertical machinery – Dial indicator readings on driver-mount flange. Net Indicator Readings Inlet Flange Bolt-Up Outlet Flange Bolt-Up

Horizontal Orientation (1) = or - μm. or cm. = or - μm. or cm. Vertical Orientation (2) = or - μm. or cm. = or - μm. or cm.

(1) For vertical machinery, the horizontal orientation is perpendicular to pipe centerline when viewed from top. (2) For vertical machinery, the vertical orientation is parallel to pipe centerline when viewed from top. (3) Maximum shaft movement in either direction is 50 micrometers (0,005 cm).

Subcontractor Fluor Field Engineering Fluor QA Name Name Name


Date Date Date

_______ 7.INLET

1. _______

2. _______

3. _______

4. _______

_______ 8.

_______ 6.

_______ 5.

Top orNorth

_______ 7.OUTLET

1. _______

2. _______

3. _______

4. _______

_______ 8.

_______ 6.

_______ 5.

Top orNorth

Pipe Strain Measurement

Flange Size: ______________________ Flange Size: ______________________

Feeler Gauge Readings Between Gasket Faces


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74033 Rev 0 Rotating Equipment Face-rim Alignment Record.doc Page 1 of 2

ROTATING EQUIPMENT (FACE-RIM) ALIGNMENT RECORD ID M74033A





P P

M M

Equipment Tag No.: ______________

Piping Disconnected Piping Connected

Notes: Nominal Coupling Gap: ________________ For Face-Rim Alignment Method:

Record Readings on either driver or driven hub. Use the inner lines for face readings for that hub.

For Reverse Alignment Method: Record the rim readings on both driver and driven hubs.


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7410 Rev 0 Field Fabricated Tanks.doc Page 1 of 4

FIELD FABRICATED TANKS SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for field fabricated tanks. RESPONSIBILITIES - Self-Perform


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



RESPONSIBILITIES - Subcontracted


Verify foundation surveying

Construction Engineer Survey Field Books Prior to start of erection

Inspect foundation construction

Subcontractor 000.509.F02201 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


Periodically during life of activity

Surveillance of weld and NDE activities.

Site Quality Manager/ Subcontractor


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.



• 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.




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


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74101 Rev 0 Tank Elevations Tolerance Report.doc Page 1 of 2

TANK ELEVATION TOLERANCES RECORD ID M74101AR





+

0

-

0 + 00 1 + 00 2 + 00 3 + 00 4 + 00 5 + 00 6 + 00 7+00 8+ 00 STATIONS

Note: Show vertical scale and units. TANK FOUNDATION DESIGN ELEV.____________________________ FOUNDATION DESIGN CROWN ELEV._________________________________________________ INSTRUCTIONS TANK FOUNDATION TOLERANCE Foundation elevation tolerances in accordance with applicable specifications and drawings. Establish tank foundation tolerances and obtain tank fabricator acceptance before the start of tank erection. Starting at North Centerline with Station 0+00, and moving clockwise, establish stations at approximately half-sheet intervals around the tank. Do this by establishing the tank shell outline on the foundation and marking off the half-sheet intervals. Take level readings at each station and Senior Field Engineer Date record on this form. Unless otherwise specified by the contract, the initial tolerance of foundations shall be in accordance with API-650. Foundation elevation tolerances checked and accepted. This exhibit may also be used to record shell and roof elevation tolerances, as well as settlement data, during and after signature of the Fabricator's Representative. Area Superintendent Date Fabricator's Representative Date


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INSPECTION RECORD FIELD ERECTED TANK ID M74102A

Subject Subcontractor Fluor

FE/QA

1.0 Inspection-Bottom

1.1 Bottom annulare plates level.

2.0 Inspection-Shell

2.1 Shell diameter checked at bottom, mid-height, top.

2.2 Shell height checked.

2.3 Shell banding checked. /Shell peaking checked.

2.4 Wind girder erection checked.

2.5 Location nozzle’s, manhole and stairway checked.

3.0 Inspection-Roof

3.1 Support columns for roof in place and plumb.

3.2 Roof fittings locations checked.

3.3 Roof seals installed and checked.

3.4 Stairway and ladder locations checked.

3.5 Fire extinguishing systems installed and checked.

3.6 Internal spray and distributor piping and fittings checked.

4.0 Testing

4.1 Hydrotest water quality and temperature checked.

4.2 Operation of vents and liquid gauges checked.

4.3 Tank cleaned.

4.4 Corner weld tested.

4.5 Bottom seams vacuum tested.

5.0 Arrangement

5.1 Foundation correct

5.2 Dimension in accordance with design data

5.3 Peaking/banding/Verticality & Roundness

5.4 Nozzle Sizing, orientation & standouts

5.5 Bottom drain location correct

5.6 Arrangement traceability weld maps accepted

5.7 Temporary attachments removed


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INSPECTION RECORD FIELD ERECTED TANK ID M74102A


FE/QA

6.0 Testing

6.1 All NDE completed and verified

6.2 Floor Vacuum Test

6.3 Nozzle reinforcing pad air test

6.4 Fixed roof tightness test

6.5 Hydrostatic Test

6.6 Settlement under hydrotest recorded

7.0 Attachments

7.1 Ladders & platforms installed correctly

7.2 Foam piping installed (where applicable)

7.3 Sprinkler system installed (where applicable)

7.4 Breather valves/Air vents installed

7.5 Level gauges/ stilling wells installed

7.6 Earthing

8.0 Surface Protection

8.1 Internal coatings

8.2 External coatings

9.0 Final Acceptance

9.1 Tank calibration carried out

9.2 Nameplate data correct

9.3 Tank cleaned out & ready for closure

9.4 QC documentation reviewed & accepted

9.5 Closure certificate signed

Remarks


Name Name Name


Date Date Date


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TANK PLATE DIMENSIONAL CONTROL RECORD FIELD ERECTED TANK ID M74103AR





Type of Tank: Diameter cm. Height: cm. Volume: m3

Dimension check for: ( ) Roundness (HP) ( ) Peaking/Banding(HP) ( ) Verticality(HP)

No. Weld/Plate

No. Tolerance Difference Acceptable No.

Weld/Plate No.

Tolerance Difference Acceptable

1 11

2 12

3 13

4 14

5 15

6 16

7 17

8 18

9 19

10 20

Notes:


Name: Name: Name:


Date: Date: Date:


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WATER FILLING AND SETTLEMENT RECORD FIELD ERECTED TANK ID M74104A





Type of Tank: Diameter: cm Height: cm Volume: cm3

Water Filling

No. Increment Time

Height Rate Holding

Time Remarks

From To

1 cm cm .hrs

2 cm cm .hrs

3 cm cm .hrs

4 Full cm cm .hrs

Tank Settlement Record

No. Stage Section to be checked (degrees )

0 - 45 45 - 90 90 - 135 135 - 180 180 - 225 225 - 270 270 - 315 215 - 360 Remarks

1 Before Fill HP

2

3

4 Full HP

5 Empty HP


Name: Name: Name:


Date: Date: Date:


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TANK LEAK TEST RECORD ID M74105AR





Type of Tank: Diameter: cm Height:: cm Volume: cm3

Leak Test for: ( ) Vacuum Box (HP) ( ) Oil (HP) ( ) Air (HP)

No. Test Area /

Portion Test Date Result No.

Test Area / Portion

Test date Result

Subcontractor Fluor Client

Name: Name: Name:


Date: Date: Date:


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TANK TEST CERTIFICATE ID M74106






FE/QA Bottom - Vacuum Test Numbers

Fittings - Air Test Numbers

Roof - Vacuum Test Numbers

Shell - Hydrostatic Test Numbers


Name: Name: Name:


Date: Date: Date:


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FINAL CLOSING AUTHORIZATION RECORD ID M74026Ar





1. The above equipment has been supplied, erected and internally fitted in accordance with the applicable drawings, specifications and manufacturer's standard and is certified to be mechanically acceptable. Equipment has been inspected for cleanliness and is free of all debris.

Fluor/Date

2. Authorization is hereby granted to effect final closing or sealing of this equipment.

Client/Date

3. Final closing has been effected.

Fluor/Date








Report No.














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UNDERGROUND PIPING

SCOPE This procedure applies to the activities associated with inspection and testing of underground piping.

RESPONSIBILITY - Self-Perform Pipe Installation


ACTIVITY Request Excavation 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.F75201 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 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


Daily during life of activity.

Backfill Request/Release Subcontractor 000.509.F75001 Each backfill. Backfill Inspection Subcontractor 000.509.F75001 Each installation.

Surveillance Mechanical Supt. Not Required Daily during life of activity.

Site Quality Manager Form 000.509.F02201 Daily during life of activity.



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).



• 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" (0.8 cm) 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.



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 1 - Underground Pipe Inspection Reference



Attachment 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





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UNDERGROUND PIPE INSPECTION CHECKLIST ID P75001A





Drawing Number Sheet Drawing Number Sheet


01 Excavation releases: Construction Engineer – Mech. Mechanical Supt. Electrical Supt. Civil Supt.

02 Location and excavation inspection completed

03 Pipe fabrication and installation inspection completed

04 Cleaning of pipe completed

05 Pressure test satisfactory

06 Insulation resistance (insulated flanges-underground piping) test satisfactory

07 Coating and wrapping checked

08 Holiday test satisfactory

09 Cathodic protection completed

10 Backfill request/release(s) obtained Construction Engineer – Mech. Site Quality Manager Client

11 Backfill inspection completed

Notes:


Name: Name: Name:


Date: Date: Date:


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INSULATION RESISTANCE (INSULATED FLANGES – UNDERGROUND PIPING) TEST RECORD

ID P75002AR





Reference Drawing

Test equipment No.

Notes: 1. Use multi-volt-ohm meter tester or a gas electronics insulation checker model 601.

2. Minimum acceptable value is 10,000 ohms or a suitable reading using the gas electronics insulation checker model 601.

Line number Flange location Resistance (ohms) Date Subcontractor Fluor FE/QA


Name: Name: Name:


Date: Date: Date:


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HOLIDAY (SPARK) TEST RECORD ID P75003AR





ISO-Sheet Number Spool Number Subcontractor Fluor FE/QA

Voltage setting: kV


Name: Name: Name:


Date: Date: Date:


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PRESSURE TEST REPORT ID P75201A





Test Package No.: ___________________ Description: _____________________________________________________

Test Boundaries P. &I.D. No.(s) R P. &I.D. No.(s) R P. &I.D. No.(s) R P. &I.D. No.(s) R

ISO No.(s) Sht R ISO No.(s) Sht R ISO No.(s) Sht R

Vessels or Equipment in test boundary:

Test Conditions

Test Medium _______________________________ Chlorine Content __________________

Test Media/Metal Temp Min._____________ Max.__________________ Actual______________

Ambient Temp. Min.____________________ Actual_________________

Test Pressure Min.________________ Max.______________ Actual_____________ Relief Valve Setting_______________

Holding Time: Min. ______________ Actual_____________

Test Gage Number:

M.T.E.________ Date Last Calibrated:

______________ Test Gage Range:

Low_______ High_______

M.T.E.________ ______________ Low_______ High_______

Pre-Test Inspections/Release

Pre-Test Walkdown Complete: Pipe Field Eng Date

NDE, PWHT, PMI (if required) Complete/Accepted: QA Inspector Date

Verification of Satisfactory Test Results

QC Inspector Date

QA Inspector Date

Verification of Line Restoration

Pipe Field Engineer Date

QA Inspector Date

Remarks:

For coordinate boundaried system such as oil water sewer, test beginning and ending coordinates shall be indicated on the attached drawings.





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ABOVEGROUND PIPING

SCOPE This procedure applies to the activities associated with inspection and testing of aboveground piping.

RESPONSIBILITIES - Self-Perform Pipe Installation


ACTIVITY Welding Inspection and Testing

Per 000.509.7910 Per 000.509.7910 Per 000.509.7910

Inspect on-site pipe fabrication and installation


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 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.F75201 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 Scott Fincher, Corporate Code Specialist at 864 -281-6796.



• 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, 000.509.F75102, 000.509.F75103 and 000.509.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



Attachment 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.





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ABOVE GROUND PIPE INSPECTION CHECKLIST ID P75101A






General 01 System complies with P and ID's and isometric drawings. 02 Piping fabrication ITR complete and accepted. 03 All field weld inspection and NDE, traceability and history records complete and

accepted.

04 All NDT/stress relieving requirements performed in accordance with requirements and documented.

05 Correct bolts and gaskets are installed at all mechanical joints. (Optional: Use form P75102A)

06 All vents and drains are installed, including vents and drains for testing and are of correct pressure rating.

07 Piping of correct material, schedule and type. 08 Rating of all forged steel fittings is correct. 09 Check valve materials - (use spec ref. in piping material specification, tags and

nameplates.

10 Branch reinforcements are correct. 11 Compound on screwed connections in accordance with specifications. 12 All pressure connections as per specification. 13 Correct direction of flow through filters and strainers traps, check valves, globe

valves and control valves.

14 All instrument connections installed and any delicate instruments are isolated/ removed from test.

15 All relief valves, bursting disks, and specified control valves have been removed. 16 Check orifice valve tap orientation correct, taps and plugs have been seal

welded and unused. Tapped holes are plugged and welded.

17 Check orifice flanges have required upstream and downstream clearances, that bores have been ground and orifice plates have been removed.

18 All thermowells are installed. 19 All pipe supports installed according to drawings and specifications. 20 Gags on spring supports and expansion joints are in position.

21 Check that system is adequately supported such that no spring in pipework causes stress on pumps or vessel nozzles.

22 All chainwheels and extended spindles installed.

Notes:


Name: Name: Name:


Date: Date: Date:


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VISUAL INSPECTION OF FLANGES, GASKETS, AND BOLTING ID P75102A





Line/Drawing No. Line Class Sheet No. Rev. No.


01 Flange type and rating

02 Flange preparation and cleaning

03 Flange condition

04 Gasket type

05 Gasket condition and rating

06 Bolting type

07 Bolting size

08 Lubrication

09 Torque sequence correct

10 Torque values verified

11 Identification of torqued connection

12 Rejected items flagged

Notes:


Name: Name: Name:


Date: Date: Date:


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WELD MAP RECORD ID W75103

Iso No.:

Weld No. Date Made Welder Stencil

RT RT Report No.

PMI PWHT Weld No. Date Made Welder Stencil

RT RT Report No.

PMI PWHT ACC REJ ACC REJ


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Test Conditions






Test Gage Number:



Low_______ High_______

M.T.E.________ ______________ Low_______ High_______





QC Inspector Date

QA Inspector Date



QA Inspector Date

Remarks:






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PIPE CLEANING AND VERIFICATION CHECKLIST ID P75601A


P.O. No.: Inspection Classification Turnover System:



Piping Services Group Q.C. Remarks

Identification No. Code Class Matl. System Cleanliness Level Verified By Date


Name: Name: Name:


Date: Date: Date:





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DAILY WELDING REPORT ID W79001

Subcontractor Area

Unit Line No. Line Class

Sheet No.

Weld No. Type Weld

Size Wall

Thick. Welder Symbol

Process Fit-Up Visual

Inspected Remarks

Root Bal

Foreman

Date

Welding Inspector

Date





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PRESSURE TESTING

SCOPE This procedure applies to pressure testing of installed piping systems.



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

_____ _____

Perform Pre-Test Inspections/Release

Pipe Const. Engr. 000 509 F75201 Prior to Test Site Quality Manager 000 509 F75201 Prior to Test

Perform Test Mechanical

Superintendent _____ _____


Pipe Const. Engr. 000 509 F75201 Test Completion Site Quality Manager 000 509 F75201 Test Completion

Provide Restoration Instructions

Pipe Const. Engr. _____ _____

Verify Completion of Restoration

Pipe Const. Engr. 000 509 F75201 Each Test Site Quality Manager 000 509 F75201 Each Test

Surveillance of Testing and Restoration

Site Quality Manager 000.509.F02201 Daily



RESPONSIBILITIES - Subcontracted


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


Perform Pre-Test Inspections/Release

Subcontractor 000 509 F75201 Prior to Test Site Quality Manager 000 509 F75201 Prior to Test

Perform Test Subcontractor _____ _____


Subcontractor 000 509 F75201 Test Completion Site Quality Manager 000 509 F75201 Test Completion


Pipe Const. Engr. _____ _____


Subcontractor 000 509 F75201 Each Test 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".



- 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.

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















Test Conditions






Test Gage Number:



Low_______ High_______

M.T.E.________ ______________ Low_______ High_______





QC Inspector Date

QA Inspector Date



QA Inspector Date

Remarks:






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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


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


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PIPE CLEANING AND VERIFICATION CHECKLIST ID P75601A


P.O. No.: Inspection Classification Turnover System:



Piping Services Group Q.C. Remarks

Identification No. Code Class Matl. System Cleanliness Level Verified By Date


Name: Name: Name:


Date: Date: Date:





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ELECTRICAL INSPECTION SCOPE This procedure applies to inspection of electrical installations. Refer to procedure 000.509.7010 and 000.509.7100 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


000 509 F760XX Each installation at completion


(Note 1) 000 509 F02201

Daily during life of activity and at completion



ACTIVITY

Install electrical items Subcontractor _____

Each electrical item

Inspect in-process electrical installation



Check final electrical installation


000 509 F760XX Each installation at completion


(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.


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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 & 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 House 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 000.509.F76014 Cable Termination Checklist


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76001 Rev 0 Conduit and Cable Tray Checklist.doc Page 1 of 2

CONDUIT AND CABLE TRAY CHECKLIST ID E76001A





Drawing:


Cable Tray

Verify the following are in accordance with design documents

01 Supports

02 Grounding

03 Cable spacing

04 Cable tie down

05 Barriers

06 Splice Plates

07 Wall penetrations

08 High voltage labels

Conduits

Verify the following are in accordance with design documents

09 Workmanship

10 Supports

11 Pull joints

12 Expansion joints

13 Bonding jumpers

14 Seals and drains

15 High voltage labels

16 Fittings

Notes:


Name: Name: Name:


Date: Date: Date:


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ELECTRICAL MANHOLE INSPECTION CHECKLIST ID C76002A





Location Drawing Number

Inspection Prior to Concrete Pour or Dry Packing


01 Verify opening size and location for compliance with drawings and specifications.

02 Grounding/earthing in place and secure.

03 Pulling eyes and ladder rungs in place.

04 Verify conduit size, orientation, type, location, adequate support and plugs/caps for compliance with drawings and specifications.

05 Sump or drain provided in accordance with drawings.

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76003 Rev 0 Medium and High Voltage Underground Cable Splice Inspection Record.doc Page 1 of 2

MEDIUM AND HIGH VOLTAGE UNDERGROUND CABLE SPLICE INSPECTION RECORD

ID E76003AR





Note: This Inspection Record is for cables rated greater than 2000 volts. When this work is contracted, inspection may be documented on Contractor's detailed Inspection Record. Subcontractor Fluor FE/QA

Reference Dwg.: Splice No.: Splice Kit Manufacturer: Kit No.: Circuit No.: From: To: Cable Rated Voltage: Cable Type:

01 Coordinates (Surveyor Complete And Initial/Date At Right)

Trench Number:

A West/East: South/North

B West/East: South/North

C West/East: South/North

Manhole Number: Pull Box Number

02 Splice Make-up: A Acceptable

B Acceptable

C Acceptable

Neutral Acceptable

03 Document DC High Potential (hypot) Test on 000 509 F76008, or obtain appropriate documentation from testing contractor.

04 Sheath grounded/earthed, as required.

05 Field changes recorded on "as-built" drawings.

06 Splice markers installed, when required.


Name: Name: Name:


Date: Date: Date:


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MEDIUM AND HIGH VOLTAGE CABLE TERMINATION CHECKLIST ID E76004A





NOTE: This Inspection checklist is for terminations rated greater than 2000 Volts

Circuit Number KIT Number

Drawing Number KIT Manufacturer

Verify the following are acceptable in accordance with design documents: Subcontractor Fluor FE/QA

1. Cable size type, location, installation and routing

2. Cable bend radius IAW specifications and cable jacket free of kinks

3. Cable termination supports and support spacing IAW drawings and Specifications

4. Cable installation neat and evenly spaced

5. Cable free of surface damage

6. Termination Kit/Materials installed IAW Manufacturer’s instructions

7. Document DC High Potential Test (hypot) on 000 509 F76104

8. Cable Terminated IAW equipment manufacturer’s instructions, including torquing of bolted connections.

Torque Wrench Number:

Cal Date:

Torqued at: inch/foot lbs

9. Check phase location and marking: Left to Right Top to Bottom Front to Rear IAW Specification requirements ΦA Acceptable ΦB Acceptable ΦC Acceptable

10. Metallic Sheaths/Shields/Armor grounded/earthed IAW termination detail drawings


Name Name Name


Date Date Date


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CABLE PULLING INSPECTION CHECKLIST ID E76005A





Drawing Number:


FE/QA

Verify the applicable attributes listed below:

01 Underground conduit has been swabbed-out

02 Cable tray is free of sharp edges

03 Verify number of bends between pulling points does not exceed specification requirements

04 Verify cable reel assignment and cutting schedule

05 Verify cable voltage rating, minimum pulling temperature and type of pulling compound

06 Verify arrows on high voltage cable reels for direction of pulling off reel

07 Megger metal clad cables before pulling

08 Verify instrument cable for continuity and isolation from drain wire before pulling

09 Verify maximum permitted pulling tension not exceeded

10 Megger power and control cable after installation (Record test results on E76006A)

11 Megger instrument wire and cable after installation (Record test results on E76007A)

12 Hypot medium and high voltage cable (Record test results on E76008A)

13 Continuity check instrument wire after installation

14 Bend radius of trained cable in accordance with specifications

15 Cable is free of kinks, neat and cablelay is in accordance with drawings

16 Spacing between instrument cable and power cable in accordance with design

17 Cables identified per specification and drawings

18 Cable ends sealed after cutting

Notes:


Name: Name: Name:


Date: Date: Date:


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FAN/SPEED REDUCER/MOTOR INSPECTION CHECKLIST ID E76006A






FE/QA

Check name plates

Make Model Serial No

01 Fan

02 Speed Reducer

03 Gearbox

04 Shafts

05 Coupling

06 Motor

07 Equipment installation report completed

08 Shaft / coupling torqued to requirements

09 Coupling alignment report completed

10 Fan blades ‘U’-bolts torqued to requirements

11 Initial blade angle set correctly

12 Check linkages and freedom of rotation

13 Correct oil grade and level in speed reducer

14 Fan housing fixed

15 Installation acceptable

Notes:


Name: Name: Name:


Date: Date: Date:


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SWITCH HOUSES INSPECTION CHECKLIST ID E76007A






Tidiness and general condition of station and yard in satisfactory condition.

Verify the following items:

01 Station exterior: Has the station been numbered and fire fighting instructions and danger

signs been provided?

02 Is the station equipment complete with:

First aid/electrical shock treatment directions

03 Verify instructions required by local authority.

04 Key diagram of main power system

05 Single line diagrams of switchgear

06 Schematic/wiring diagrams of switchgear

07 Blackboard and/or log book

08 Sufficient caution and danger notices and spare fuses

09 If a telephone is provided:

10 Fire extinguisher State type: CO2/BCF

11 Special operating tools/grounding equipment

12 Proper operation of:

Safety locks

13 Doors, door locks and panic bars

14 Lighting, socket outlets, emergency lighting

15 H. V. A. C.

16 Verify appropriate and in operating condition.

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76008 Rev 0 Lighting Receptacle, Iinstrument Distribution Panel Checklist.doc Page 1 of 2

LIGHTING, RECEPTACLE, INSTRUMENT DISTRIBUTION PANELS INSPECTION CHECKLIST

ID E76008A






Verify the following are acceptable:

01 Ground bus in panel

02 Panel equipment ground bond

03 Wire markers (feeder)

04 Directory complete

05 Equipment number on nameplate

06 Phase meter test ABC

07 Touch-up painting complete

08 Receptacle Panel

Volt test all receptacles for standard HNG Orientation.

09 All receptacles identified by circuit number on nameplate

10 Lighting Panel

With all lights on, compare branch circuit. “Hot” amps to branch neutral amps.

11 Covers complete

12 Provide the data and complete the following:

12.1 Main breaker amps

12.2 Feeder Size

12.3 Neutral underground at panel

12.4 Ground wire size

12.5 Megger at 1000V 0-0

12.6 Megger at 1000V 0-Gnd

Notes:


Name: Name: Name:


Date: Date: Date:


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ELECTRICAL MOTOR INSPECTION CHECKLIST ID E76009A






01 Verify motors nameplate data ratings and verify against motor list.

02 Verify damage and missing parts.

03 Verify foundation and foundation bolts meet specified requirements.

04 Verify installation tolerance has been met.

05 Verify all internals are correctly installed.

06 Verify all shipping devices have been removed and check for cleanliness.

07 Verify all vents, drains, instruments connection etc., are installed in accordance with equipment trim isometrics.

08 Verify screens, guards and other personnel protective design features are correctly installed where applicable.

Verify if the location and orientation is correct.

09 Mounting

10 Baseplate

11 Level

12 Grouting

13 Junction box location

14 Verify mounting bolts for tightness.

15 Wired for proper rotation and rotation checked.

16 Couplings/pulleys installed.

17 Frame and casing sound and free of debris.

18 Paint finish checked.

19 Verify lubrication.

20 Verify vibration.

Notes:


Name: Name: Name:


Date: Date: Date:


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ABOVEGROUND CONDUIT INSPECTION CHECKLIST ID E76010A





Drawing(s):


1. Supports and spacing in accordance with specification and drawings

2. Supports adjacent to terminal fittings

3. Conduits clean, stub-ups protected, open ends plugged, damage during construction repaired

4. Field bend radius correct in accordance with specifications and codes. Bends free of deformities

5. Expansion joints as shown on drawings

6. Installation neat and evenly spaced

7. Spacing between instrument and power conduit in accordance with project specifications

8. Spacing from hot pipes and hot surfaces maintained in accordance with project specifications

9. Conduit permanently and effectively grounded, unless specifications permit otherwise. Bonding jumpers installed around expansion joints

10. Proper fittings installed with threads fully engaged, no wrench cuts, conduit ends have bushings and covers installed

11. Seals and drains installed in accordance with drawings

12. Flexible conduit installed with proper bending radius and with standard fittings

13. Junction boxes leveled and supported with proper hubs, locknuts and bushings installed, in accordance with drawings. Junction boxes properly identified.

14. Adequate number of pulling points

Conduits seals, as shown on the following drawings, poured and marked by Construction. (List drawing number or attached drawings):

Additional conduit seals, recorded on as-build drawings, poured and marked by Construction for the following: equipment, analyzer housing, local control panels, etc. (List Tag Numbers):


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76011 Rev 0 Lighting Panelboard Inspection Record.doc Page 1 of 2

LIGHTING PANELBOARD INSPECTION RECORD ID E76011A





Building: Area/Unit Panelboard Tag:


1. Receiving Operations/Inspection complete

2. Equipment Protection Program instituted and documented

3. Check assembly for any missing parts

4. Enclosure approved for area classification

5. Panelboard circuit schedule filled out

6. Correct circuit breaker, fuse size and location

7. Neutral wire correctly color coded

8. Grounding/earthing installed and connected. Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars), completed

9. Seals installed (if required)

10. Check for breather and drain

11. Check panel load balance

12. Check color coding of branch circuit conductors

13. Clean out

14. Check mounting and supports

15. Fixtures and receptacles are correct type and installed as per drawings

16. Fixtures and receptacles on correct circuit

17. Nameplate, number of circuits and panelboard location per drawing

18. Correct glands installed (i.e., flameproof glands on explosionproof enclosures)

19. Megger buses including neutral. Record results on Form: 000 509 F76035: Insulation Resistance (Equipment) Test Record. Main disconnect and outgoing circuits should be open

20. Equipment protection program completed and documented

21. Final inspection complete. Punch List Record, cleared.


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76012 Rev 0 Underground Conduit - Duct Bank Inspection Checklist.doc Page 1 of 2

UNDERGROUND CONDUIT (DUCT BANK) INSPECTION ID E76012A

Tag Description: Tag No.: P. O. No.: Inspection Classification Turnover System:



Location Drawing No.


1. Trenching checked for location, elevation and forming. Check for conflicts with other under ground construction

2. Conduit size, type and location checked for conformance to specifications and drawings, conduit sloped to drain into manholes.

3. Rigid steel elbows used for all stub-ups, including PVC runs.

4. Conduit seals installed in accordance with drawings.

5. Minimum concrete coverage will be in accordance with specifications on all sides on conduits

6. Conduit Spacing, Supports and Tie-downs correct.

7. Field bend radius correct per drawings/specifications. Bends free of deformities.

8. Pipe caps on all ends.

9. All conduit connection tightly made.

10. Reinforcing bars installed when specified.

11. All field changes recorded on as-built drawings

12. Trench/forms free of debris

13. Concrete coverage adequate; spaces not left exposed.

14. Concrete color in accordance with specifications

15. Stub-up concrete encasement correct

16. Stub-up dimensions and location checked.

17. Backfill and compaction correct

18. Conduits free of such things as stop pages and grout leakage

19. PVC conduit just above grade, plus elbow

20. Conduit blown and pull strings installed.

Remarks:


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76013 Rev 0 Grounding Earthing System Inspection Record.doc Page 1 of 2

GROUNDING/EARTHING SYSTEM (GRID OR LOOP) INSPECTION RECORD ID E76013A





Note!!! This Inspection Record is for the (Check One):

1. Main Grounding/Earthing System: Cal Date:


2. Dedicated Instrument System:

Reference Drawing:

3. Primary conductor is correct size and type in accordance with drawings

4. Ground/earthing conductor burial depth and routing per drawings and specifications

5. Thermal/compression connections checks (no cold joints or burnouts)

6. Thermal/compression connection insulation checked

7. Ground/earthing anode locations and installation per drawings

8. Ground/earthing anode connections checked

9. Location, type, size and insulation color of equipment taps per drawings and protected during construction

10. System ground/earthing anode resistance-to-earth checked and recorded on Form: 000 509 F76101. Ground/Earthing Resistance Reading (Resistance to Earth and Loop Continuity) Test Record.

11. All field Revisions recorded on as-build drawings

12. Maximum allowable system ground resistance not to exceed 1 ohm. For dedicated instrument systems (i.e. – TDC 3000), the maximum allowable ground resistance is 1 ohm

Remarks:


Name Name Name


Date Date Date


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CABLE TERMINATION CHECKLIST ID E76014A





Cable I. D. Number

Drawing Number

Verify the following are acceptable inaccordance with design documents: Subcontractor Fluor FE/QA

1. Cable length adequate

2. Cable preparation proper

3. Termination lug correct Size/type

4. Crimping tool correct

5. Permanent cable I.D. correct

6. Terminals torqued per specification

7. Wire size, type, and color correct

8. Crimping tool correct

Remarks


Name Name Name


Date Date Date


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ELECTRICAL TESTING SCOPE This procedure applies to testing of electrical installation. RESPONSIBILITIES - Self-Perform


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 F761XX Applicable Form

Test Completion


Electrical Construction Engineer

_____ Each Test Package


Site Quality Manager Electrical Supervisor

000 509 F761XX Applicable Form

Each Test



Define Test Boundaries Subcontractor _____ Each Test Package


Subcontractor _____ Each Test Package

Perform Electrical Test Subcontractor _____ Each Test Package

Verify Test Results Subcontractor/

Site Quality Manager Applicable Form Test Completion


Discipline Engineer _____ Each Test Package



_____ Each Test


(*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 • 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.


000.509.F76101 Grounding/Earthing Resistance Reading (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 Over-current And Earth/Ground-Fault Protection Relay Test 000.509.F76107 Over-current/Ground Fault Protection Relay (Induction Type) Test 000.509.F76108 Over-current/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 Assemblies 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/Contractor (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 Ration 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 Contract 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





W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76101 Rev 0 Grounding earthing Resistance Reading Test Record.doc Page 1 of 2

GROUNDING/EARTHING RESISTANCE READINGS (RESISTANCE TO EARTH AND LOOP CONTINUITY) TEST RECORD

ID E76101AR





Test Equipment: (Note 1) (Note 2) Reference Drawing: Notes: 1. Record resistance-to-earth for each rod (or group of rods) with all other conductors disconnected. When a foundation is

used for grounding/earthing, measure resistance from anchor bolt to earth. Resistance not to exceed: ohms for any single rod, designated group of rods or foundation, when tested in accordance with test method designated in specifications.

2. Check continuity from each equipment ground/earthing tap to ground/earthing loop bus or rod. If all taps between any two rods (indicate rod numbers below) or all taps connected to bus measure less than ohms, indicate check mark in "tap" column.

Rod Number Or Foundation

Resistance To Earth (Ohms)

Ambient Temp. (C-F)

Weather Taps ( ) Initials/Date


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76102 Rev 0 Insulation Resistance Power Control Wire Test Record.doc Page 1 of 2

INSULATION RESISTANCE (POWER CONTROL WIRE & CABLE) TEST RECORD

ID E76102A





Test Equipment: Test Voltage:


Ambient Temperature: C F Date

Notes: 1. Perform Insulation Resistance Test (megger) between each conductor and all other conductors and metallic sheath for cables with nonshielded conductors. Test between each conductor and shield for multiconductor cables with shielded conductors. Record lowest reading for each cable.

2. Use 500V test set for cables rated 300 to 600 volts and 2500V test set for cable rated over 600 volts.

3. Readings will vary inversely with temperature, and cable length. When Project specifies use of temperature correction factors, attach 2nd sheet with computed values. Indicate on each sheet "Measured" or "Temperature corrected".

Panel No. Circuit No. Feeder No.

Wire Tagging

Cable Rated Voltage

Wire Or Cable Insulation Resistance

(Megohms)* Initials

Quantity Size From To

*Minimum acceptable Project values Resistance For Resistance When Cable

Cable Rated Test Cable Only Cable/Wire Size Connected to Equip

Voltage Duration (Megohms) Or Amperage (Ohms)


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76103 Rev 0 Insulation Resistance Instrument Wire Test Record.doc Page 1 of 2

INSULATION RESISTANCE (INSTRUMENT WIRE AND CABLE) TEST RECORD

ID E76103AR





Test Equipment:

Ambient Temperature:

Test Voltage:

Notes: 1. Record only the lowest value.

2. MP - multi-pair cable, SP - single pair cable.

3. Megger with instruments disconnected.

4. Use 250 volt (or lower voltage, when specified) range on DC test set.

5. Readings will vary with temperature and cable length.*

Cab

le n

umbe

r or

in

stru

men

t num

ber

Indi

cate

MP

or

SP

ty

pe

(2)

Con

duct

or to

co

ndui

t (si

ngle

pai

r no

n-sh

ield

ed

cabl

es)

(meg

ohm

s)

Con

duct

or to

C

ondu

ctor

(m

egoh

ms)

(1

)

Con

duct

or to

S

hiel

d (m

egoh

ms)

(1

)

Shi

eld

to S

hiel

d (m

ultip

air

cabl

es

only

) (m

egoh

ms)

(1

)

Ove

rall

Shi

eld

to le

ad

and

arm

or

(mul

tipai

r ca

bles

onl

y)

(meg

ohm

s)

Shi

eld

to C

ondu

it (s

ingl

e pa

ir ca

bles

on

ly)

(meg

ohm

s)

Initi

als

*Minimum Acceptable Project Values


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76104 Rev 0 DC High Potential Test Record.doc Page 1 of 2

DC HIGH POTENTIAL TEST (MEDIUM VOLTAGE CABLE) RECORD ID E76104A





Circuit Number: Ref. Dwg.:

Cable Size: (SQ.MM.) (MCM) From: To:

Number Of Conductors: No. Of Splices:

Cable Length: Manufacturer:

Insulation Type: Thickness:

Jacket Material:

Weather: Temp.: C F Humidity: Date:

Test Equipment Used:

Note: 1. The test voltage shown below shall be reached in 10 equal voltage increments. 2. After each voltage increase, the leakage current shall be allowed to stabilize during a 1-minute interval. If 1-minute intervals are

insufficient to stabilize the current, the cable shall be discharged, and the test repeated with new time intervals of greater, but still equal, duration.

3. Record the stabilized leakage current, in microamps, at the end of each time interval. 4. Allow the voltage to remain constant at the full test voltage and record the leakage current for 5 minutes for unshielded cables and 15

minutes for shielded cables.* 5. Read test equipment instruction manual prior to testing cable. 6. When Project specifies the plotting of test results, attach 2ND sheet with separate plot for each phase. Note leakage current, in

microamps, on "y" axis. Note step-voltage increase on "x" axis, followed by time, in minutes, for the dielectric absorption portion of the test.

Voltage Hold Time At Each

Step: Sec.

kV kV kV kV kV kV kV kV kV kV Phase A3

Phase B3

Phase C4

(Record Leakage Current In Microampers) Time At kV

Sec 30

Min 1

Min 2

Min 3

Min 4

Min 5

Min 6

Min 7

Min 8

Min 9

Min 10

Min 11

Min 12

Min 13

Min 14

Min 15

Phase A3

Phase B3

Phase C4

*Maximum acceptable Project Values: (leakage current at end of 5 or 15 minutes). Maximum Acceptable Cable Rated Voltage Test Voltage Leakage Current (Kilovolts) (Kilovolts) (Microampers) 1All Other Phases and Shields to be grounded


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76105 Rev 0 Current Transformer Test Record.doc Page 1 of 2

CURRENT TRANSFORMER (AND AMMETER) TEST RECORD ID E76105A






Location: Switchgear No: Panel No.:

Current transformer: Function: Serial No.:

Class: Type: bar/wound

Ratio: VA rating:

1.0 Verify the following items: 1.1 Mechanical Damage 1.2 Tight Connections 1.3 Star-Point Connection and Ground Link

2.0 Insulation resistance test, secondary winding at 500 V:

phase to ground

L1-G L2-G L3-G MΩ

3.0 Resistance test secondary circuit (C) (including transformer winding and all secondary loads)

L1 L2 L3

4.0 Test CT polarity by battery flick test (C) L1 L2 L3 Ω

5.0 Ratio test (C) (to be combined with relay testing, if required)

Phase L1 L2 L3

5.1 Primary current A

5.2 Secondary current A

5.3 Ammeter reading A

Remarks


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76106 Rev 0 LV Over Current and Earth Fault Protection Relay Test.doc Page 1 of 2

LV OVERCURRENT AND EARTH/GROUND-FAULT PROTECTION RELAY TEST

ID E76106A






Location: Switchgear No.: Panel No.:

Relay: Motor protection relay

Manufacturer: Type: Contractor rating: ______ A

Trip setting range: ______A Motor FLC:_____A

1.0 Primary injection test

at selected trip setting ______ A

all three phases connected in series

2.0 Test current in % setting 300 300 120 105

Current, A

3.0 Relay Condition Cold Warm Warm Warm

Relay Time, Seconds No Trip After

4.0 Curve Time, Seconds (Supplied By Manufacturer)

______ Min

5.0 Ground-fault relay

Setting ______ A

Measured pick-up current ______ A

6.0 Relay setting after test: 6.1 Thermal relay ______ A 6.2 Earth-fault relay ______ A 6.3 Setting sealed ______

Remarks


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76106 Rev 0 LV Over Current and Earth Fault Protection Relay Test.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76107 Rev 0 Over Current & Earth FP -Indn Type- Relay Test.doc Page 1 of 2

OVERCURRENT/GROUND-FAULT PROTECTION RELAY (INDUCTION TYPE) TEST

ID E76107A






Switchgear No.: Panel No.

Relay: Overcurrent Inverse Time.

Manufacturer: Type: CT Ratio:

Current Setting Range: Selected Setting: A

Time Setting Range: Selected Setting: %

Test Setting Injection Current Trip Time Seconds Remarks

Current A Time % Is Primary A Secondary A Curve 2) Actual Phase

Secondary Injection Measure and inject S 100 1) NA NA NA Minimum relay

S 100 1.3x NA Operating current at 1)

S 100 2x NA NOTE: The trip time curve will be supplied by the manufacturer 2)

S 100 4x NA

Primary Injection

S S 1.3x For pre-commissioning

S S 2x Inspection only

Check correct reset action

Check correct trip action

Check correct flag operation

NOTES: S = preferably at selected setting NA = not applicable

Values to be filled in for each overcurrent and earth-fault element

Relay setting after test:

Instantaneous element ______________A

Current setting _______________A

Time setting _______________%

Adhesive label provided____________


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76107 Rev 0 Over Current & Earth FP -Indn Type- Relay Test.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76108 Rev 0 Over Current GFP -Thermal Type- Relay Test.doc Page 1 of 2

OVERCURRENT/GROUND-FAULT PROTECTION RELAY (THERMAL TYPE) TEST

ID E76108A





Subcontractor Fluor

FE/QA

Switchgear No.: Panel No:

Relay: Overcurrent inverse time Relay:

Manufacturer: Type: Rated current:

Trip setting range: Selected setting: %

Tap setting: Selected setting: %

Motor FLC: A CT ratio:

1.0 Secondary injection test Nominal injection current Is = tap setting x rated current = A

2.0 Injection current Operating Temperature

Trip time All three phases x ls A Curve Actual connected in series 4x cold 2x warm load to trip 4x warm setting 105% 1x warm running load indication %

3.0 Primary injection test (for pre-commissioning inspection only) Injection current = 100% FLC = A Running load indication = %

4.0 Relay setting after the test: Tap setting % Adhesive label provided Load to trip % Inst. setting x In NOTE: Trip time curve will be supplied by the manufacturer

Remarks


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76108 Rev 0 Over Current GFP -Thermal Type- Relay Test.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76109 Rev 0 Switching Units HV Switchgear Inspect & Test Records.doc Page 1 of 2

SWITCHING UNITS HV SWITCHGEAR INSPECTION AND TEST RECORD ID E76109A





Rating:

Manufacturer: Switching device: Type

Function: Panel No.:

Switchgear No.: Reference Document:


1.0 Record the reading of the operations counter

1.1 Check the following items and report any deviations/defects under remarks:

1.2 Circuit labelling correct

1.3 Operation of safety shutters

1.4 Padlocking facilities

1.5 Interlocking facilities, mechanical/electrical

1.6 Mechanical position indicators, indicating lights

1.7 Insulating bushings and barriers

1.8 Cable box and terminations

1.9 Alignment of main and auxiliary contacts

1.10 Mechanical closing and tripping

1.11 Electrical closing local/remote

1.12 Electrical tripping local/remote

1.13 Alarm indications local/remote

1.14 Anti-condensation heater

1.15 Test insulation resistance at 500 V ..............................megaohms

2.0 Secondary and auxiliary wiring

2.1 Test insulation resistance at 500 V ..............................megaohms


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76109 Rev 0 Switching Units HV Switchgear Inspect & Test Records.doc Page 2 of 2







3.0 Earthing:

3.1 Verify the conditions of earthing bar and connections

3.2 Test the earthing bar continuity ...............................microohms

3.3 Record fuse type/rating ....................

3.4 HV pressure test - circuit breaker (for pre-commissioning inspection only)

Test voltage DC Leakage Current - MA

kV A B C

kV A B C

Tester used:

4.0 Insulation resistance - circuit braker:

Test voltage V DC

Phase A B C Megaohms

Tester used:

5.0 Conductivity test - circuit braker:

Phase R S T Ohm

Ducter used:

Current transformer test completed

Sheet no.:

Protection relay test completed

Sheet no.:

Remedial action required:

Remarks


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76110 Rev 0 Ground Electrode Resistance Inspection Test Record.doc Page 1 of 2

GROUND ELECTRODE RESISTANCE INSPECTION TEST RECORD ID E76110A





Additional Information: Vendor:

Reference Document: Test Method

Tests of individual electrodes

No. Length cm Section cm2 Resistance Ohms Remarks

Test grid system


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76110 Rev 0 Ground Electrode Resistance Inspection Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76111 Rev 0 GFP Induction Relay Inspection and Test Report.doc Page 1 of 2

GROUND FAULT PROTECTION RELAY INDUCTION INSPECTION AND TEST RECORD

ID E76111A





Additional Information: Current setting range: CT ratio:

Manufacturer: Selected setting: A

Time setting range: Relay:

Selected setting:: %: Type:

Switchgear No.: Panel No.: Reference Document:

Check correct trip action

Check correct flag operation

Notes:

S = preferably at selected setting NA = Not Applicable

Values to be filled in for each overcurrent and ground/fault element

Relay setting after test:

Instantaneous element A

Current setting A

Time setting %

Adhesive label provided

Remarks:


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76111 Rev 0 GFP Induction Relay Inspection and Test Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76112 Rev 0 Grounding Continuity Inspection and Test Record.doc Page 1 of 2

GROUNDING CONTINUITY INSPECTION AND TEST RECORD ID E76112A






01 Check earth bosses installed are welded correctly.

02 Check conductor tape is jointed correctly.

03 Check and confirm all cables are correctly sized.

04 Check that the equipment is bonded to the main earth.

05 Check all cables lugs are fitted correctly.

06 Confirm maximum two cables are terminated to each earth boss.

07 Confirm all contact points are clean and greased with the approved compound.

08 Check all washers are of vibration proof type.

09 Confirm cable protective measures (kick plates) are installed.

10 For IS equipment ensure that a separate insulated earth bar has been installed and is earthed in accordance with project specifications.

11 Test earth continuity resistance from main earthing point to the final earth point of the sub-system. Maximum 1.0 ohms.

12 Ductor test across all tape joints. Maximum 1.0 ohms.

Notes:

This procedure should be used for major items of equipment (i.e., vendor’s skids, switchboards, etc.). Small power and equipment earthing will be confirmed correct on the respective check sheets.


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76112 Rev 0 Grounding Continuity Inspection and Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76113 Rev 0 Grounding Rod Inspection and Test Record.doc Page 1 of 2

GROUNDING ROD INSPECTION AND TEST RECORD ID E76113A





Drawing No.: Ground Temperature:

Earth Test Rating: Manufacturer:

1.0 Test each ground rod with the earth tester and record reading in the following table.

Ground Rod No.

Ground Resistance In

Ohms

Ground Rod No.


Ohms

Ground Rod No.


Ohms

2.0 Area Grounding Resistance (with all rods installed and connected) _____________ OHMS

Remarks:


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76113 Rev 0 Grounding Rod Inspection and Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76114 Rev 0 Busbar Assembly LV Swithcgear Test Record.doc Page 1 of 2

BUS BAR ASSEMBLIES LV SWITCHGEAR TEST RECORD ID E76114A





Manufacturer: Rating:

Reference Document: Section:

System voltage: Switchgear No.:


1.0 Insulation resistance test - bus-bar system at 500 V CC


2.0 Tester used: Cal Date:

2.1 Conductivity test - bus-bar system (C)

Spout to spout Megaohms

Unit # Incomer 1 2-3 4-5 6-7 Incomer 7

A

B

C

3.0 Ducter used: Grounding system

3.1 Check the continuity of the grounding bar and connections ....................... ohms

3.2 Measure continuity of switchboard to main ground ......................... ohms

3.3 Current transformer test (include. ammeter) completed Sheet no. ...........

3.4 After energizing

3.5 Check voltmeter reading: ............

3.6 Check phase rotation (C) .............

Remedial action completed:


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76114 Rev 0 Busbar Assembly LV Swithcgear Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76115 Rev 0 Neutral Grounding Resistor Test Record.doc Page 1 of 2

NEUTRAL GROUNDING/EARTHING REISTOR TEST RECORD ID E76115A





Test Equipment Test Voltage: Cal. Date:

Test Equipment Test Voltage: Cal. Date:

Notes!!! 1. Use 500 volt test set for 600 volt equipment and below, 2500 volt tests set for equipment rated over 600 volts. 2. Resistor must be disconnected from ground/earth and neutral during Insulation Resistance (megger) and DC Overpotential Tests. 3. Resistor must be disconnected from neutral during Cold Resistance Test. 4. Apply DC Overpotential Test between terminals and ground for the complete device. (The voltage applied between the terminals of each assembly and its grounded enclosure shall be twice the rated AC voltage plus 1000 V when rated 600 V or less, or 2.25 times the rated AC voltage plus 2000 V when rated over 600 V for 1 Minute.) This test is a Pass/Fail test based purely on withstand alone. 5. Inspect assembly for damage and missing parts. 6. Check to assure that the center tap ratio is correct, when CT is supplied with resistor. 7. Verify resistor reterminated.

Tag Number Cold Resistance

(ohms)

Insulation Resistance

(megaohms)*

Overpotential ()

CT Ratio Pri-Sec

Reterm ()


*Minimum acceptable Project Values: Voltage Class Insulation Resistance (megaohms)


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76115 Rev 0 Neutral Grounding Resistor Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76116 Rev 0 Ground Continuity Equipment-Structure Test Record.doc Page 1 of 2

GROUND CONTINUITY (NONELECTRICAL) EQUIPMENT/STRUCTURES TEST RECORD

ID E76116A





Test Equipment Used: Weather

Cal. Date:

Notes!!! 1. Vessels, tanks and structural steel bonded to the main grounding/earthing system, dedicated ground/earthing rod or

foundation, as indicated on drawings listed below. 2. Measure resistance from ground/earthing wire tap (or anchor bolt) to tagged equipment frame or structural steel.

Resistance not to exceed ohms.

Equipment Tag No. or Structure

Drawings Measured Resistance

(ohms) Subcontractor Fluor FE/QA


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76116 Rev 0 Ground Continuity Equipment-Structure Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76117 Rev 0 Ground Continuity Equipment-Grnd Test Bars Test Record.doc Page 1 of 2

GROUND CONTINUITY (ELECTRICAL EQUIPMENT AND GROUND TEST BARS) TEST RECORD

ID E76117A





Test Equipment Used: Weather

Cal. Date:

Notes!!! 1. Electrical equipment bonded to the main grounding/earthing system or dedicated ground/earthing rod, as indicated on

drawings listed below. 2. Measure resistance from ground/earthing wire tap to tagged equipment bus bars, tagged equipment enclosures, and any

other points indicated on the drawings. Resistance not to exceed _______ ohms.

Electrical Equipment Tag No.

Drawing Measured Resistance

(ohms) Subcontractor Fluor FE/QA


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76117 Rev 0 Ground Continuity Equipment-Grnd Test Bars Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76118 Rev 0 Equipment Insulation Resistance Test Record.doc Page 1 of 2

INSULATION RESISTANCE (EQUIPMENT) TEST RECORD

ID E76118A





Test Equipment: Substation:

Ambient Temperature: oC oF Ref. Spec.:

Reference Drawing:

Cal. Date:

Notes!!! 1. Use 500 Volt test set for 600 Volt equipment and below, 2500/5000 Volt test set for equipment rated over 600

volts. 2. For equipment with solid state control circuits, consult manufacturer’s literature for maximum test voltages.

Switchgear MCC (other)

Insulation Resistance (megaohms)* Rated Test Voltage

(kV)

Voltage (kV)

SubcontractorFluor

FE/QA ФA to G ФB to G ФC to G ФA to ФB ФB to ФC ФC to ФA

*Minimum acceptable Project values: Equipment Voltage Class Resistance (megaohms)


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76119 Rev 0 Transformer Insulation Resistance Test Record.doc Page 1 of 2

INSULATION RESISTANCE (TRANSFORMER)TEST RECORD ID E76119A





Substation No. Test Equipment:

Cal Date: Notes!! 1. Use 500 volt test set for 600 volt equipment and below, 2500 volt test set for equipment rated 601-5000 volts and 5000 volt test

set for equipment rated over 5000 volts

2. Test voltage to be applied for 1 minute duration and reading taken

3. Neutral must be disconnected from ground during test

4. Record temperature of insulating liquid for liquid-immersed transformers and surrounding air temperature for dry type transformers.

5. Readings will vary inversely with temperature. When Project specifies use of temperature correction factors, attach 2nd sheet with computed values. Indicate on each sheet “measured” or “temperature corrected.”

Equipment Tag No.

Insulation Resistance (megaohms)* Rated

Pri To Sec Voltage

Rating (kV) Pri-Sec Or Air

Liquid Temp. (0C/0F) Primary Secondary

ФA to G ФB to G ФC to G ФA to G ФB to G ФC to G

*Minimum acceptable Project values: Voltage Class Resistance (megaohms) Tester’s Name/Date


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76120 Rev 0 Liquid Dielectric Strength Test Record.doc Page 1 of 2

LIQUID DIELECTRIC STRENGTH TEST RECORD ID E76120A





Notes!! 1. Minimum acceptable breakdown voltage determined in accordance with the following:

ANSI standard Other:

2. Test performed: At laboratory and test results attached. In the field to test procedure:

Test equipment: Cal Date:

Equipment Tag No. Liquid Type and Spec. Minimum (kilovolts)

Actual Breakdown Voltage Reading (kilovolts)



Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76121 Rev 0 DC Proof Test Record for Motors.doc Page 1 of 2

DC PROOF TEST RECORD FOR MOTORS ID E76121A





Test Equipment: Cal Date:

Ambient Temperature: 0C 0F

Notes!! 1. Equipment must meet minimum PI (Polarization Index) values prior to conducting this test. Complete Form: 000 509 F76053

Equipment Absorption Ration and Polarization Index Test Record. 2. Isolate each phase winding, whenever practical. If not practical, test of entire winding is acceptable. 3. Increase voltage at rate indicated below, until full test voltage is reached. This test is a Pass/Fail test based purely on withstand

alone. 4. Test duration at full test voltage shall be: * minutes. 5. Read instruction manual prior to using test equipment 6. All other phases to be grounded/earthed

Tag No. PI Rated AC

Voltage (kV) Equipment Test

Voltage (kV) () OK

Subcontractor Fluor FE/ QA ФA ФB ФC

*Project requirements as follows: Equipment

Rated Voltage (kilovolts)

Minimum PI Prior

To Test DC Test Voltage

Time to Reach Test Voltage

(seonds)


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76121 Rev 0 DC Proof Test Record for Motors.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76122 Rev 0 Feeder Breaker 480 V Test Record.doc Page 1 of 2

FEEDER BREAKER (480V MCC) TEST RECORD ID E76122A





Equipment Designation:

Load Designation:

Load (kW/kVA): Voltage: F.L.A:

Circuit Breaker MFR: Rating: Setting:

Conductor Size: Power: Ground:


1. Check nameplate data of breaker against approved supplier drawings

2. Check breaker components for cleanliness

3. Check mechanical function of breaker

4. Check wiring for proper identification

5. Check conduits/cables for tagging

6. Check components for identification

7. Check equipment for conformance to area classification

8. Check installation for seals, breathers and drains

9. Verify power conductor continuity

10. Check that power cable Insulation Resistance Test (megger) is completed and that Form: 000 509 F76102: Insulation Resistance Test Record (Power, Control Wire and Cable), is on file


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76123 Rev 0 Breaker Contactor 480 V Test Record.doc Page 1 of 2

BREAKER/CONTACTOR (480V MCC) TEST RECORD ID E76123A






Load Designation:

Load (kW/kVA): Voltage: F.L.A.:

Circuit Breaker Mfr.: Rating: Setting

Contactor Mfr.: Size:

Conductor Size: Power: Control: Ground:


1. Check nameplate data of breaker, contactor fuses and relays against approved supplier drawings

2. Check main and auxiliary contacts

3. Check contactor/breaker components for cleanliness

4. Check control fuses, CPT rating and coil voltage

5. Check mechanical function of contactor and breaker

6. Check wiring for proper identification

7. Check conduits/cables for tagging

8. Check components for identification

9. Check equipment for conformance to area classification


11. Verify continuity of all power and control leads

12. Check that power cable Insulation Resistance Test (megger) is completed and that Form: 000 509 F76102

13. Complete functional operation check of the control circuit using contract drawings and approved supplier drawings. Close and open the contactor using all control devices.

Remarks:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76123 Rev 0 Breaker Contactor 480 V Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76124 Rev 0 460V Motor Circuit Test Record.doc Page 1 of 2

460 V MOTOR CIRCUIT (480V MCC) TEST RECORD ID E76124A






Motor Tag No.: Voltage: F.L.A.:

kW/HP: RPM: S.F.:

Circuit Breaker Mfr.: Rating: Setting:

Starter Mfr.: Size: O/L HTR. Size:



1. Check motor starter for cleanliness

2. Check nameplate data and tagging of motor starter components for conformance to approved supplier drawings

3. Check conduits and/or cables for correct tagging

4. Check equipment and installation for conformance to area classification


6. Check main and auxiliary contacts of breaker and contactors

7. Manual check mechanical operation of breaker, contactor, O/L relay and O/L reset device

8. Check continuity of power and control cables

9. Complete functional operations check of the motor control circuit using the contract drawings and approved supplier drawings. Close and open the starter using all control devices

10. Verify completion of activities on Form: 000 509 F76227: Electric Motor-Electrical Activities Inspection Record, and Form: 000 509 F76228: Electric Motor Mechanical Activities Inspection Record, prior to motor bump and run-in, in accordance with Form: 000 509 F76133: Electric Motor Run-in Test Record

Remarks


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76124 Rev 0 460V Motor Circuit Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76125 Rev 0 Medium Voltage Motor Circuit Test Record.doc Page 1 of 2

MEDIUM VOLTAGE MOTOR CIRCUIT TEST RECORD ID E76125A






Motor Tag No.: Serial No.:

Manufacturer: Service Factor:

KW/HP: F.L.A.: Rated Voltage:

Started Description:

Manufacturer: CT Ratio:

Contactor Rating: Type:

Rated Current: Fuse Size: Rated Voltage:

O/L Relay Setting:



1. Check motor starter for cleanliness

2. Check nameplates data and tagging of motor starter components for conformance to approved Supplier drawings

3. Check conduits and/or cables for correct tagging

4. Check equipment and installation for conformance to area classification


6. Check main and auxiliary contacts of breaker and contactors

7. Check mechanical operation of breakers, contactors and relay and O/L reset devices

8. Check continuity of power and control cables

9. Verify calibration and setting of protective relays

10. Check wiring to surge arrestors, capacitors, stator RTDs and current transformers

11. Complete functional operations check of the motor control circuit using the contract drawings and approved Supplier drawings. Check to see that motor space heaters are fuctional. Close and open the starter using all control devices.

12. Verify completion of activities on Form: 000 509 F76227: Electric Motor-Electrical Activities Inspection Record and Form: 000 509 F76228: Electric Motor Mechanical Activities Inspection Record, prior to motor bump and run-in, in accordance with Form: 000 509 F76133: Electric Motor Run-in Test Record

Comments:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76125 Rev 0 Medium Voltage Motor Circuit Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76126 Rev 0 Equipment Absortion and Polarization Test Record.doc Page 1 of 2

EQUIPMENT ABSORPTION RATIO AND POLARIZATION RATIO TEST RECORD (MEGGER)

ID E76126A





Equipment Tag No.: Test Equipment:

Test Voltage: Ambient Temperature: oC oF

Rel. Humidity: Equipment Temperature:

Notes!!! 1. Perform test as indicated on Test Records for each individual equipment type. Reference the following forms:

Transformers: 000 509 F76119 Insulation Resistance (Transformer) Test Record Equipment: 000 509 F76118 Insulation Resistance (Equipment) Test Record Motors and Generators 000 509 F76135 Insulation Resistance (Rotating Equipment) Test Record

2. Absorption Raito = 1 Min. Resistance Value 30 Sec. Resistance Value 3. Polarization Index = 10 Min. Resistance Value 1 Min. Resistance Value

Ohms to Ground 30 Sec. Reading ΦA to Ground

Ohms to Ground 1 Min. Reading ΦA to Ground

Ohms to Ground 10 Min. Reading ΦA to Ground

Dielectric Absorption

Ration

Polarization Index

Ohms to Ground 30 sec. Reading ΦB to Ground

Ohms to Ground 1 Min. Reading ΦB to Ground

Ohms to Ground 10 Min. Reading ΦB to Ground

Dielectric Absorption Ratio

Polarization Index

Ohms to Ground 30 Sec. Reading ΦC to Ground

Ohms to Ground 1 Min. Reading ΦC to Ground

Ohms to Ground 10 Min. Reading ΦC to Ground

Dielectric Absorption

Ratio

Polarization Index

Tester’s Name/Date


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76126 Rev 0 Equipment Absortion and Polarization Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76127 Rev 0 Insulation Resistance -Med V Power Cables- Test Record.doc Page 1 of 2

INSULATION RESISTANCE (MEDIUM VOLTAGE POWER CABLES) TEST RECORD

ID E76127A







Ambient Temperature: oC oF Date

Notes: 1. Perform Insulation Resistance Test (megger) between each conductor and all other conductors and metallic sheath for cables with nonshielded conductors. Test between each conductor and shield for multiconductor cables with shielded conductors. Record lowest reading for each cable.

2. Use 2500V test set for cable rated over 600 volts. 3. Reading will vary inversely with temperature and cable length. When Project specifies use of temperature correction factors,

attach 2nd sheet with computed values. Indicate on each sheet “Measured” or “Temperature corrected”. 4. For Medium Voltage cables, perform megger test after final Hi-Pot Test.

Panel No. Circuit No. Feeder No.

Wire Tagging Cable Rated

Voltage

Wire Or Cable Insulation Resistance

(Megaohms)* Initials Quantity Size From To A to Gnd B to Gnd C to Gnd

*Minimum acceptable Project values:

Cable Rated Voltage

Test

Duration

Resistance For Cable Only

(Megaohms)

Cable/Wire Size

Or Amperage

Resistance When Cable Connected to Equip

(Ohms)


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76127 Rev 0 Insulation Resistance -Med V Power Cables- Test Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76128 Rev 0 Bus Throat Insulation and Ductor Report.doc Page 1 of 2

BUS THROAT INSULATION AND DUCTOR REPORT ID E76128A





Date: Station & Transformer No.: Temperature:

By: Test Set /Manuf/Model: Humidity:

Calibration Date:

Bus: A or B

N-S-E-W

WIN#

Same as Main Bus

Insulation Resistance P-G in Megaohms

Insulation Resistance P-P in Megaohms

Ductor in Micro-ohms = < 50 minimum

Hea

ters

w

orki

ng

Insp

ect &

C

lean

Bus

Insp

ect

Insu

lati

on

Bar

rier

s

Insp

ect &

C

lean

Bus

T

hroa

t

Insp

ect &

C

lean

In

sula

tors

Pai

nt in

Goo

d C

ondi

tion

Remarks

(Condition of Equipment) A B C A-B A-C B-C A B C

Notify immediate supervisor if any readings are not within acceptable limits. Infrared bolts connection points: Yes No

Comments: Results:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76128 Rev 0 Bus Throat Insulation and Ductor Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76129 Rev 0 Circuit Breaker Contact timing Test Report.doc Page 1 of 2

CIRCUIT BREAKER CONTACT TIMING TEST REPORT ID E76129A





Date: Station:

By: Manufacturer:

Breaker WIN No. Cubicle No.: Test set mfg., model & S.N.:

Cal. Date:

Closing Time Opening Time

Accept. Max/ms Time/ms as found/as left

Delta Closing Time*

Pass/Fail Accept. Max/ms Time/ms as found/as left

Delta Closing Time *

Pass/Fail

Contact 1 / /

Contact 2 / /

Contact 3 / /

Note: Maximum acceptable time can be found in the Manufacturers instruction manual. If test fails; notify your Supervisor

*This is the biggest difference between contacts

Comments:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76129 Rev 0 Circuit Breaker Contact timing Test Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76130 Rev 0 Vacuum Circuit Breaker Ductor Insulation Report.doc Page 1 of 2

VACUUM CIRCUIT BREAKER DUCTOR INSULATION REPORT ID E76130A





Date: Station: Temperature:

By: Test Set (Model & Mtg.): Humidity:

Cal Date:

S.N. of Breaker/ Feeder#

WIN #

Counter Reading

Contact Resistance In Micro-ohms (50 maximum) *

Insulation of Breaker In Megohms Vacuum Bottle Integrity Test

Good/Bad

Tu

lip

s L

ub

rica

ted

Mec

han

ism

In

spec

ted

O

per

ated

at

leas

t 5

tim

esT

rip

od w

ith

ea

ch r

elay

Condition of Equipment (parts replaced etc.) Before After Phase-Ground Phase-Phase

A B C A B C A B C A-B A-C B-C A B C


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76130 Rev 0 Vacuum Circuit Breaker Ductor Insulation Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76131 Rev 0 Drawout Vacuum Breaker Inspection Test.doc Page 1 of 2

DRAWOUT VACUUM BREAKER INSPECTION RECORD ID E76131A





Switchgear Tag No.: Serial No.:


One at a time, insert breakers into their respective cubicles and check the following:

1. Roll breaker into TEST position. (The spring charging mechanism should operate and charge spring)

2. Withdraw breaker to DISCONNECTED position

3. Roll breaker into the TEST position. Close breaker using door switch and check indication light for operation. Close breaker from remote control station where applicable

4. Trip breaker and check indication light. Trip from door switch and remote control station

5. Trip each breaker from each protection device and check relay targets for operation. Test proper operation of lockout device in closing circuit

6. Trip each breaker with its mechanical trip device

7. Measure insulation resistance between phases and between phase-to-ground with breaker withdrawn and closed. Record below

8. Perform contract resistance test and record below

9. Perform circuit breaker contract Timing test. Record on Test Record Form: 000 509 F76129

10. Perform Ductor Tests. Record on Test Record Form: 000 509 F76130

11. Perform DC Proof Test on vacuum bottles and record below

12. Roll breaker into CONNECTED position and test operation of latch check switch, if provided

13. Verify nameplate data (such as continuous amperes, interrupting amperes, etc.) is in accordance with supplier drawings

Comments:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76131 Rev 0 Drawout Vacuum Breaker Inspection Test.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76132 Rev 0 Main Bus Insulation and Ductor Report.doc Page 1 of 2

MAIN BUS INSULATION AND DUCTOR REPORT ID E76132A





Date: Station: Temperature:

By: Test Set /Manuf/Model: Humidity:

Calibration Date:

Bus: A or B

N-S-E-W

WIN#

Insulation Resistance

P-G in Megaohms

Insulation Resistance P-P in Megaohms

Ductor in Micro-ohms = < 50

minimum

Man

ual

Tra

nsfe

r M

ade

(Bot

h W

ays)

Aut

o X

ter

mad

e w

ith

Sou

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Bre

aker

Aut

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ter

mad

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ith

Sud

den

Pre

ssur

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elay

Insp

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C

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Bus

Insp

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Insu

lati

on

Bar

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s

Insp

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C

lean

Bus

h T

hroa

t

Insp

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C

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In

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tors

PT

Lea

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Insp

ect/

Fus

e C

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Cle

an

Pai

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Goo

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ondi

tion

Remarks

(Condition of Equipment) A B C A-B A-C B-C A B C

Notify immediate supervisor if any readings are not within acceptable limits. Infrared bolts connection points: Yes No

Comments: Results:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76132 Rev 0 Main Bus Insulation and Ductor Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76133 Rev 0 Electric Motor Run-in Test Report.doc Page 1 of 2

ELECTRIC MOTOR RUN-IN TEST RECORD ID E76133A





Reference Drawing: Test Equipment:

Calibration Date: _______________________________

NOTES 1. Duration of tests to comply with project specifications. 2. Complete Form 000 509 F76227; Electric Motor – Electrical Activities Inspection Record.

Test Remarks Subcontractor Fluor FE/QA

Voltage Actual voltage measured at motor control center ______Volts

Rotation Check Bump motor to verify rotation motor must be uncoupled.

No Load Current At beginning of test: _______ AMPS. At end of test: ________ AMPS.

Temperature of Bearing Check bearing for high temperature: Before Start 15 Minutes after start 30 Minutes after start 1 Hour after start 2 Hours after start 3 Hours after start

Vibration Make visual inspection during run; test and record any unusual vibration in remarks column.

Noise Record any unusual noise in remarks column.


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76133 Rev 0 Electric Motor Run-in Test Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76134 Rev 0 Drawout Air Circuit Breaker Inspection Record.doc Page 1 of 2

DRAWOUT AIR CIRCUIT BREAKER INSPECTION RECORD ID E76134A





Switchgear Tag No.: Serial No.:


One at a time, insert breakers into their respective cubicles and check the following:

1. Roll breaker into TEST position. (The spring charging mechanism should operate and charge spring)

2. Withdraw breaker to DISCONNECTED position

3. Roll breaker into the TEST position. Close breaker using door switch and check indication light for operation. Close breaker from remote control station where applicable

4. Trip breaker and check indication light. Trip from door switch and remote control station

5. Trip each breaker from each protection device and check relay targets for operation. Test proper operation of lockout device in closing circuit

6. Trip each breaker with its mechanical trip device

7. Check contact alignment and wipe (air break only)

8. Perform Insulation Resistance Test (megger) between each phase and to ground with breaker withdrawn and closed. Record on 000 509 F76127

9. Perform Contract Resistance Test and record below

10. Perform circuit breaker contact timing tests. Record on Test Record Form: 000 509 F76129


12. Roll breaker into CONNECTED position and test operation of latch check switch, if provided

13. Verify nameplate data (such as continuous amperes, interrupting amperes, etc.) is in accordance with supplier drawings

Remarks:


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76134 Rev 0 Drawout Air Circuit Breaker Inspection Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76135 Rev 0 Insulation Resistance Rotating Equipment Test Report.doc Page 1 of 2

INSULATION RESISTANCE (ROTATING EQUIPMENT) TEST RECORD ID E76135A





Motor Tag No.:

Test Equipment: Test Voltage: Cal Date:

Ambient Temperature: oC oF Equip. Temp., If Know: oC oF

How Known: Cal. Date

Notes!!! 1. Use 500 Volt test set for 600 Volt equipment and below, 2500/5000 Volt test set for equipment rated over 600 Volts.

2. Test duration shall be 1 minute; note if otherwise: 3. Disconnect each phase winding from neutral, wherever practical. If not practical, test may be made on entire winding. 4. Document testing of low voltage and medium voltage equipment on separate sheets. 5. Reading will vary inversely with temperature. When Project specifies use of temperature correction factors, attach 2nd sheet

with computed values. Indicate on each sheet “Measured” or “Temperature Corrected”.

Equipment Tag No.

Insulation Resistance (megohms)* Equipment Rated

Voltage Subcontractor Fluor FE/QA

ФA to G ФB to G ФC to G ФA to ФB ФB to ФC ФC to ФA

*Minimum acceptable Project values: Voltage Class Resistance (megohms)


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76135 Rev 0 Insulation Resistance Rotating Equipment Test Report.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7620 Rev 0 Electrical Equipment.doc Page 1 of 4

ELECTRICAL EQUIPMENT

SCOPE This procedure applies to inspection and testing of electrical equipment.



ACTIVITY

Install Equipment Self Perform _____ _____

Inspect in-process Equipment Installation


000 509 F762XX Daily during life of

activity

Inspect/Perform Equipment Protection


000 509 F02201 Periodically

Electrical Supervisor 000 509 F02201 Periodically

Define Test Boundaries Construction Engineer _____ Each Test Package


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





_____ Each Test


(Note 1) 000.509.F02201 Each Test







ACTIVITY

Install Equipment Subcontractor _____ _____

Inspect in-process Equipment Installation


000 509 F762XX Daily during life

of activity

Inspect/Perform Equipment Protection


000 509 F02201 Periodically

Define Test Boundaries 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




Subcontractor/ Construction Engineer Site Quality Manager

_____ Each Test


(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.



• 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 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 000.509.F76232 Dry Type Lighting, Receptacle & Instrument Transformers Checklist 000.509.F76233 Instrument Wire and Cables Continuity Checks >50VDC





Report No.














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EMERGENCY GENERATORS INSPECTION CHECKLIST ID E76201A





Vendor:

Reference Document:


01 Verify nameplate date in accordance with drawings, specifications and requisitions

02 Location and orientation

03 Access and fixing correct

04 Verify diesel, generator panels and enclosure for any visible signs of damage

05 Measure insulation resistance prior to starting and record

06 Verify electrical panel labelling

07 Verify pilot lamp test

08 Verify connections are tight

09 Grounding connected and tight

10 Verify make and type of battery

11 Verify load circuit

12 Make visual inspection during test run and record any unusual vibration and unusual noise in “Notes” space

Remarks:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76202 Rev 0 Inspection of Switchgear Bus-bar Continuity.doc Page 1 of 2

INSPECTION OF SWITCHGEAR BUS-BAR CONTINUITY (INCLUDING INCOMING AND SECTIONALIZER UNITS)

ID E76202A





Circuit Designation

Busbar Conductivity, MΩ Subcontractor

Fluor FE/QA

From To L1 L2 L3 N G Ducter #

NOTES: Conductivity measurements shall be carried out between adjacent outgoers or adjacent outgoer and incomers in order to verify the entire bus-bar path including 'droppers/risers'. For identical connections the measured values shall not differ by more than 20% from each other.


Name Name Name


Date Date Date


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INSPECTION LV SWITCHGEAR (INCLUDING INCOMING AND SECTIONALIZER UNITS)

ID E76203A





Subcontractor Fluor

FE/QA

Switchgear No.: Section:

Manufacturer:

System voltage: Rating:

1.0 Insulation resistance test - bus-bar system at 500-VTester used:

Phase L1-G ............. L2-G L3-G MΩ

Anti-condensation heaters working Test insulation resistance at 500 V MΩ

2.0 Grounding system

Check the condition of the grounding bar and connections

Measure continuity of switchboard to main earth MΩ

3.0 Current transformer test (incl. ammeter) Completed Yes No (Sheet F76012) Sheet No.

4.0 After energizing Check voltmeter reading: Check phase rotation (C):

5.0 Relay setting after the test:

Tap setting ________% Adhesive label provided

Load to trip ________%

Inst. Setting ________x In

NOTE: Trip time curve will be supplied by the manufacturer

Remarks


Name: Name: Name:


Date: Date: Date:


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INSPECTION OF OUTGOING UNIT – LV SWITCHGEAR ID E76204A






Location: Switchgear No: Function:

Manufacturer: Switching device type:

Panel No.: Rating:

1.0 Check the following items and note any deviations/defects under remarks:

1.1 Circuit labeling 1.2 Mechanical damage 1.3 Door interlock 1.4 Mechanical position indication 1.5 Electrical closing local/remote 1.6 Electrical tripping local/remote 1.7 Alarm indication local/remote 1.8 Wiring connection and marking

1.9 test insulation resistance wiring at 500 V MΩ

2.0 Grounding; Verify the condition of the grounding bus and connections

3.0 Insulation resistance test - switching device at 500 V Phase L1-E L2-E L3-E MΩ

4.0 Protection relay test (E76106) Sheet No.

5.0 Restart relay tested result: s

6.0 Verify and record the fuse: Class Rating Condition

Remarks


Name: Name: Name:


Date: Date: Date:


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INSPECTION OF OUTGOING UNIT – LV SWITCHGEAR ID E76204A





7.0 LIGHTING CIRCUITS INSULATION RESISTANCE TEST * (fittings disconnected).

Circuit Number Value MΩ Date Circuit Number Value MΩ Date

CONVENIENCE OUTLETS *

Circuit Number IR MΩ Residual Current

Device Gnd Loop Impedance

Polarity Date


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INSPECTION OF STATIC SUPPLY UNIT (UPS) ID E76205A

Subcontractor Fluor

FE/QA

Unit No.: Manufacturer

Rectifier/Inverter: Serial No.:

Battery Type: No. Of Cells/Volts:

1.0 AC/DC distribution board

1.1 Check:

Good condition – no mechanical damage

Correct labeling

Correct grounding

Insulation resistance at 500-V

1.2 Test:

Bar 1 – Ground MΩ Bar 1 - Bar 2 MΩ Bar 2 – Earth MΩ

Test ground-fault indication and detection

1.3 Record:

Fuse size: Type: Actual load:

2.0 Verify the following items:

Correct grounding Cable connections

Operating temperature Cleanliness

No abnormal noise No leaking capacitors

All parallel capacitors at same temperature

3.0 Verify correct operation of:

Forced cooling fan Interlock system

Indicating lights/meters Common alarm





4.0 Check operating set points

4.1 Rectifier:

Float charge voltage V Boost charge voltage V

(Indicate if trip or alarm function)

AC failure V S

Rectifier failure Low DC voltage V

High DC voltage V Earth fault

Rectifier output oscilloscope check at normal load

4.2 Inverter:

Inverter output voltage & frequency V Hz

Inverter in synchronism

Auto change-over:

A. From inverter to by-pass

B. From by-pass to inverter

C. Inverter output oscilloscope check at normal load

(Indicate if trip or alarm function)

Low DC input V High DC input V

Low AC output V High AC output V

Inverter fail Load on bypass

Fuse failure

5.0 Batteries

5.1 Check that all connections are tight and that anti-corrosive coating is provided

5.2 Check the liquid level of each cell

5.3 Check the cells for leakage

- Cell voltage and specific gravity tests

- Battery discharge capacity test





5.4 Battery discharge capacity test

Unit No.: Test Date:

Normal load: A

Time DC Volts DC Amps AC Volts AC Amps Hz

0 min

5 min

Test guidelines: 1. Discharge load current to be equal to normal load current +/- 10%. 2. Simulate a rectifier power failure and discharge to the point of inverter trip or the specified minimum voltage. 3. Cell voltages may be measured during battery discharge, to detect defects. 4. Upon completion of the test carry out boost charging.

5.5 Battery cell tests

Unit No.: Test Date:

Temperature: °F

Cell No. Volts S.G. Cell No. Volts S.G Cell No. Volts S.G.

Record in coupled condition: - starting time (if over 1 s) s (A)

Remarks:


Name: Name: Name:


Date: Date: Date:





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MOTOR CONTROL CENTERS INSPECTION CHECKLIST ID E76206A





Item Description of Check – Record Data on E76207Ar Subcontractor Fluor FE/QA

Verify the following are acceptable per design drawings:

01 Remote trip installed

02 Ventilation filters

03 Control PNL directory complete

04 All nameplates complete

05 Ground bus continuous

06 Ground bus tied to plant GND

07 Bus joints torqued

08 All mechanical interlocks operational

09 Unused knockouts plugged

10 Floor anchors installed

11 Grouting complete

12 Touch up painting completed

Remarks:


Name: Name: Name:


Date: Date: Date:


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MOTOR CONTROL CENTERS (MOTORS AND STARTERS) INSPECTION RECORD

ID E76207Ar





Reference E76206A

Incoming Feeder Size

In. Fdr-Conduit or Cable Bus or Bus Duct

Main Disconnect Rating

Control Transformer Kva

Cont Pnl Main Bkr or Fuse Size

Horizontal Bus Rating

Horizontal Bus Type

Vertical Bus Rating

Vertical Bus Type

Megger at 1000v

Megger at 1000v Ground

Ground Bus Type

Ground Bus Rating Remarks:


Name: Name: Name:


Date: Date: Date:





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HIGH VOLTAGE MOTORS AND STARTERS ID E76208A





Motors

Complete the Motor Checklist, Form F76209, except for electrical test data.

Starters


Verify the following are acceptable in accordance with design documents:


02 Ground bus tied to plant ground




06 Touch-up painting complete

07 Maintenance tools available

08 Conduits labeled 4160 volts

09 Control scheme check

Remarks:


Name: Name: Name:


Date: Date: Date:


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MOTORS CHECKLIST ID E76209A





Control Scheme:

1.0 Mechanical As Installed

Acceptable Acceptable 1.01 Motor Equip. No. Nameplate 1.08 Ericson Cplg. 1.02 Belt Drive 1.09 Meyers Hub 1.03 Dowel Pins 1.10 Conduit Brace 1.04 Drain Plug 1.11 Flex Conduit 1.05 Gasket-Cond. Box 1.12 Mtr Rotates Freely 1.06 Weephole-Cond. Box 1.13 Vibration 1.07 Bearing Temp. 1.14 Noise

2.0 Electrical As Installed

2.01 MCC Disc. Switch Size 2.07 Meter CT’s Ratio 2.02 Breaker Size 2.08 Feeder Cable Size 2.03 Fuse Size 2.09 Control XFMR Size 2.04 Starter Size 2.10 Grounding 2.05 OL Heater Size 2.11 Local Disc. Switch 2.06 OL CT’s Ratio 2.12 Motor Space Heater

3.0 Actual Nameplate Data

3.01 MFG 3.06 Volts 3.02 H.P. 3.07 ENCL. 3.03 F.L.A. 3.08 INS. CL. 3.04 S.F. 3.09 Temp. C

3.05 RPM 3.10 Serial No.

4.0 Electrical Test Data

4.01 Megger At 1000 V __________ Meg 4.03 No Load Amps 4.02 Rotation CW __________ CCW __________ 4.04 Two (2) Hour Run YES NO

Remarks:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76210 Rev 0 Control and Relay Panels Inspection Checklist.doc Page 1 of 2

CONTROL AND RELAY PANELS INSPECTION CHECKLIST ID E76210A





*NOTE: Control and alarm device testing to be done during control scheme and logic checks.


Verify the following are acceptable in accordance with design documentation

01 Panel ground wire installed

02 Internal cooling fan

03 Forced ventilation

04 Nameplates complete

05 Internal device labels complete

06 Terminal strips labeled

07 NEMA construction (I, 3R, etc.) of enclosure

08 Field wire markers complete


10 Convenience outlet phased

11 Internal lighting complete

12 Floor entrances sealed

13 Touch up painting completed

14 Annunciator wiring bundled and formed to allow removal of a single print wiring without shutdown. Future points are not blocked.

Remarks:


Name: Name: Name:


Date: Date: Date:


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ELECTRONIC EQUIPMENT INSPECTION CHECKLIST ID E76211A





Manufacturer: Type: Rating:

Serial No.: Model No.: Style No.:


01 Inspect for damaged and missing parts

02 Inspect for loose nuts and bolts

03 Inspect for loose wiring connections

04 Inspect for dirt and foreign materials

05 Test per manufacturer’s instructions

06 Record item number of UPS system of which above equipment is a part.* (* N/A for all components. Complete this item on from covering inverter portion of UPS as a record of the Complete System Test.)

07 Other:

Remarks:


Name: Name: Name:


Date: Date: Date:


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POWER PANEL INSPECTION CHECKLIST ID E76212A






Verify the following:

01 Remote trip installed

02 Panel directory complete


04 Ground bus installed

05 Ground bus tied to plant ground grid

06 All mechanical interlocks operational




10 Touch up painting complete

11 Provide the data and complete the following:

11.1 Incoming Feeder Size

11.2 Main Disc. or Fuse Rating

11.3 Vertical Bus Rating

11.4 Vertical Bus Type

11.5 Megger at 1000V

11.6 Megger at 1000v Ground

11.7 Feeder Fuse Type

Remarks:


Name: Name: Name:


Date: Date: Date:


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SWITCHGEAR INSPECTION CHECKLIST ID E76213A






1. Confirm that checks according to the certified equipment procedure have been performed for certified switchboards.

2. Verify name plate details against data sheet.

3. Visually inspect equipment for external damage.

4. Inspect the switchboard for alignment and secure fixings.

5. Confirm equipment is correctly located as per Switchroom layout drawings.

6. Check all cable entries are correct to design requirements.

7. Check earthing conforms to project specification. Inspect switchboard earth bar and ensure all earth terminations are correct and secure.

8. Check inside of the switchboard is clean, dry and silica gel, etc., has been removed.

9. Check all cubicle doors can be opened and are not obstructed.

10. Visually inspect the switchboard cubicles for damage.

11. Ensure that torque settings of Busbar shipping joints are in accordance with supplier requirements / specifications.

12. Check all equipment carries the correct circuit identification.

13. Ensure all Busbars are encapsulated as per specification.

14. Ensure that ducter tests are performed across all bolted shipping joints and readings are acceptable and recorded, a copy of which to be maintained within the construction dossiers.

15. On completion of all cable glanding confirm spare entries are correctly plugged.

16. Check gaskets and seals are not damaged.

17. Check all bolts are correct and none missing.

Remarks:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76214 Rev 0 Low Voltage Feeders Inspection Record.doc Page 1 of 2

LOW VOLTAGE FEEDERS INSPECTION RECORD ID E76214A





1.0 Low Voltage Switchgear to MCC

1.1 Type Installation

1.2 Feeder Size

1.3 Mechanical Installation

1.4 Ground Conductor

1.5 NEMA Standard Phasing

1.6 Megger @ 1000V 0-0

1.7 Megger @ 1000V 0-Gnd

2.0 MCC to Disconnect, Power Panel, or Packaged Equipment

2.1 MCC Disc Switch Size

2.2 Fuse Size

2.3 Fuse Type

2.4 Feeder Cable Size

2.5 Wire Markers - Both Ends

2.6 Ground Conductor

2.7 NEMA Standard Phasing

2.8 Megger @ 1000V 0-0

2.9 Megger @ 1000V 0-Gnd

Remarks:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76215 Rev 0 High Voltage Cable Inspection and Test Record.doc Page 1 of 2

HIGH VOLTAGE CABLE INSPECTION AND TEST RECORD ID E76215A





01 Cable is the correct type and size, see cable schedule.

02 Cable glands are the correct type, and correctly fitted.

03 Ensure IP sealing washers are fitted to gland, where required.

04 Check earth bonding is correct to design drawings.

05 On single core cables, ensure that cables are earthed as shown on the contract electrical drawings.

06 Confirm cable route and segregation are correct.

07 Check cable supports, cleating and banding are to specification.

08 Check bending radius is within manufacturer’s recommendations.

09 Check cable markers are correct through transits and each end.

10 Confirm protective measures (kick plates) are fitted correctly.

11 Test and confirm conductor continuity.

12 Test and confirm earth wire continuity.

13 Test and confirm drain wire continuity.

14 Measure resistance of gland body to earth. Maximum 0,1 ohms.

15 Test insulation resistance using a 5KV megger for 15 minutes.

Minimum reading Megaohms. Ɯ

16 Discharge all cores to earth for a minimum period of 15 minutes. Ɯ

17 Perform a pressure test and record current leakage. Ɯ


19 Stress cones fitted to manufacturer’s instructions. Ɯ

20 Test and record insulation resistance using a 5KV megger for 15 minutes.

Minimum reading Megaohms. Ɯ


22 Reconnect all cores.

23 Confirm all cable cores are laid correctly.

24 Confirm correct terminations and fit terminal box cover.

Notes: A Test 11 to 13 inclusive. Test results are subject to manufacturer’s permissibles and length of cable. Both must be checked to confirm acceptable reading.

Ɯ Witness points.


Name: Name: Name:


Date: Date: Date:


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ELECTRICAL EQUIPMENT INSPECTION RECORD ID E76216A





Type Of Equipment:

System Voltage: Unit No.:

Size / Rating: Registration No:

Establish And Record The Length Of Cable:


1.0 Compare nameplate information with equipment record. Note any deviations under remarks.

2.0 Establish and Record the following:

2.1 Equipment/circuit identification.

2.2 Area classification.

2.3 Type of Ex-protection/gas group/temperature class.

2.4 Degree of enclosure protection.

2.5 Electrical protection setting/rating.

2.6 Actual maximum load/amp meter reading.


3.1 Labeling correct.

3.2 No unauthorized modifications.

3.3 Enclosures and glasses satisfactory.

3.4 Seals and gaskets satisfactory.

3.5 Bolts and glands complete and tight.

3.6 No undue accumulation of dust and dirt.

3.7 No leakage of oil/compound.

3.8 No damage to aboveground part of connected cables.

3.9 Adequate protection of equipment and cables against corrosion, the weather, vibration and other adverse factors.

3.10 Motor fans and couplings not rubbing on cowls/guards.

3.11 Grounding in good condition.

3.12 Oil levels in sight glasses correct.

3.13 Padlock facilities correct.

3.14 Silica gel in breathers satisfactory.

3.15 Pressurization systems correct & tested.

4.0 Suitable for use in areas as classified: YES NO


Name: Name: Name:


Date: Date: Date:


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CONTROL SCHEME INSPECTION CHECKLIST ID E76217A





Control Scheme

Mtr. Equipment No.

Drawing No./Rev.


FE/QA

Verify the following:

01 Motor uncoupled

02 Motor leads dropped (low voltage)

03 Contractor in test position (high voltage)

04 Solenoids disconnected

05 Neutral grounded

06 Wire markers complete

Remarks:


Name: Name: Name:


Date: Date: Date:


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POWER TRANSFORMER INSPECTION CHECKLIST ID E76218A






01 Check all equipment is suitable for hazardous area.

02 Verify equipment is suitable for IP rating.

03 Verify name plate details against data sheet.

04 Visually inspect equipment for external damage and leaks.

05 Check equipment fixings and mountings are secure.

06 Check air / water cooling ventilation air inlet / outlets are clear.

07 If transformer is oil filled check level indicator shows correct level.

08 Check terminal box interior for damage, cleanliness and remove packing.

09 Ensure gland plates for outgoing single core feeders are non-magnetic.

10 Check cable boxes for compound leaks.

11 Check gaskets and seals are not damaged.

12 Check all bolts are correct and none are missing.

Remarks:


Name: Name: Name:


Date: Date: Date:


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Rating:

Manufacturer: Switching device: Type

Function: Panel No.:

Switchgear No.: Reference Document:

Subject: Subcontractor Fluor FE/QA

1.0 Record the reading of the operations counter


1.2 Circuit labelling correct

1.3 Operation of safety shutters

1.4 Padlocking facilities

1.5 Interlocking facilities, mechanical/electrical

1.6 Mechanical position indicators, indicating lights

1.7 Insulating bushings and barriers

1.8 Cable box and terminations

1.9 Alignment of main and auxiliary contacts

1.10 Mechanical closing and tripping

1.11 Electrical closing local/remote

1.12 Electrical tripping local/remote

1.13 Alarm indications local/remote

1.14 Anti-condensation heater

1.15 Test insulation resistance at 500 V ..............................Megaohms

2.0 Secondary and auxiliary wiring

2.1 Test insulation resistance at 500 V ..............................Megaohms


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3.0 Earthing:

3.1 Verify the conditions of earthing bar and connections

3.2 Test the earthing bar continuity ............................... Micro Ohm

3.3 Record fuse type/rating ....................

3.4 HV pressure test - circuit breaker (for pre-commissioning inspection only)

Test voltage DC Leakage Current - MA

kV A B C

kV A B C

Tester used:

4.0 Insulation resistance - circuit braker:

Test voltage V DC


Tester used:

5.0 Conductivity test - circuit braker:

Phase R S T Ohm

Ducter used:

Current transformer test completed

Sheet no.:

Protection relay test completed

Sheet no.:

Remedial action required:

Remarks


Name: Name: Name:


Date: Date: Date:


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76220 Rev 0 Switching Units HV Switchgear Insp Chklist.doc Page 1 of 2

SWITCHING UNITS – HV SWITCHGEAR INSPECTION CHECKLIST ID E76220A





Item Description of Check Subcontractor FluorFE/QA

01 Confirm certified equipment check sheets are complete.

02 Check all cable check sheets are complete.

03 Verify name plate details against datasheet.

04 Confirm switchboard has been correctly sited.

05 Visually inspect equipment for external damage.

06 Check equipment fixings and mountings are secure.

07 Ensure that torque settings of Busbar shipping joints are in accordance with supplier requirements / specifications.

08 Check earthing conforms to project specification.

09 Inspect switchboard earth bar and ensure all earth terminations are correct and secure.

10 Ensure gland plates for outgoing single core feeders are non-magnetic.

11 Check gaskets and seals are not damaged.

12 Check all bolts are correct and none missing.

13 Ensure that ducter tests are performed across all bolted shipping joints and readings are acceptable and recorded, a copy of which to be maintained within the construction dossiers.

14 Ensure all Busbars are encapsulated as per specification.

Remarks


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76221 Rev 0 Liquid Filled Transformer Inspection Record.doc Page 1 of 2

LIQUID-FILLED TRANSFORMER INSPECTION RECORD ID E76221A





Substation: Building: Transformer Tag No.: Subcontractor Fluor FE/QA



3. Tag number, voltage and kVA rating per plan drawings and one-line

4. Check transformer nameplate against purchase specification

5. Location, mounting and orientation per drawings 6. Visually inspect for cleanliness and no chips, cracks or other apparent damage to

bushings, radiators and tanks

7. Check lubrication and freedom of rotation of cooling fans

8. Check lubrication and freedom of motion of tap changers and other operating accessories

9. Inspect fuses, disconnect switches and surge arrestors

10. Inspect for liquid leakage around tank, radiators and accessories

11. Collect samples of insulating liquid per manufacturer’s instructions and determine dielectric strength of insulating liquid. Record on Form: 000 509 F76120: Liquid Dielectric Strength Test Record

12. Check for continuity in all windings

13. Measure cold resistance of neutral grounding/earthing resistor and perform Insulation Resistance Test (megger) and DC Overpotential Test. Record readings on Form: 000 509 F76115: Neutral Grounding/Earthing Resistor Test Record

14. Neutral wire size, insulation and color per drawings/schedule

15. Case ground/earth and grounding/earthing resistor correctly installed. Measure bonding resistance of connections and record on Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars)

16. Check that incoming feeders have had Insulation Resistance Test (megger) performed and that Form: 000 509 F76102. Insulation Resistance Test Record (Power Control Wire and Cable), is on file

17. Check that incoming feeders have had DC High Potential Test (hypot) when required by specification and that Form: 000 509 F76104: DC High Potential Test Record (Medium Voltage Cable), is on file

18. Check inert gas pressure gage (pressure should be in accordance with manufacturer’s instructions)

19. Check temperature gage for proper operations

20. Check liquid level gage for proper operation and proper level of liquid in various compartments

21. Check sudden pressure relay and relief device

22. Alarm and control circuits connected and complete


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LIQUID-FILLED TRANSFORMER INSPECTION RECORD ID E76221A

Substation: Building: Transformer Tag No.:


23. Primary/secondary cables/bus duct properly supported, insulated and protected against mechanical damage. Belted connections torqued in accordance with manufacturer’s recommendations. Torgue Wrench No. __________________ Cal. Date:_________________________

24. Check conductor size, insulation class and type

25. Check conductor phasing and identification

26. Check conduit connections

27. Perform Insulation Resistance Test (megger) of transformer primary and secondary windings and record readings on Test Form: 000 509 F76119: Insulation Resistance (Transformer) Test Record

28. Perform DC High Potential Test (hypot) when required by specification and record readings on Form: 000 509 F76104: DC High Potential Test Record

29. Perform Insulation Power Factor (Doble) tests, when required by specifications and document on Project furnished Exhibit

30. Measure primary and secondary voltages with tap changer in each position and verify that voltages ratios are per transformer nameplate. Apply construction power to primary transformer connection and measure secondary voltages. Primary voltage rating shall not be exceeded

31. Record transformer tap setting below (Set at mid-tap unless otherwise indicated in Engineering Documents.)

32. Check correct operation of control system for fans

33. Check correct rotation of cooling fans

34. Check to assure connections are tight and secure

35. Alarm trip and fans start contact operational. High winding and/or liquid temperature alarm set at 900 C, or in accordance with manufacturer’s instructions

36. Mechanical relief device is reset

37. Spare control/alarm conductors taped or capped

38. Spare hubs or knockouts plugged

39. Paint scratches refinished

40. Handhold covers tightly secured

41. Supplier Representative provided service/supervision for the equipment Supplier test reports attached to this inspection Record

42. Confirm NDE tests are done after lifting lugs are installed for any defects in laminations.

43. Equipment Protection Program completed and documented

44. Final inspection complete. Punch List Record


Name Name Name


Date Date Date


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BUSWAY INSPECTION RECORD ID E76222A





Busway Tag No.: Subcontractor Fluor FE/QA

1. Receiving Operations/Inspection Complete


3. Using supplier drawings, check entire assembly, including auxiliary equipment, for any missing parts

4. Torque the connections according to manufacturer’s recommendations. Torque Wrench Number __________________ Cal Date ______________________

5. Inspect bus insulators for damage and cleanliness

6. Drain holes unplugged

7. Vertical and horizontal support spacing in accordance with manufacturer’s instructions

8. Check for proper clearance, where visible, between busbars and between busbars and enclosure

9. Gaskets installed (if required)

10. Perform Insulation Resistance Test (megger) on bus and record on Test Record, Form: 000 509 F76118: Insulation Resistance (Equipment) Test Record

11. Busway housing grounded. Record bonding resistance on Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars)

12. Check for proper phasing after installation


14. Connect space heaters and check operability (when applicable)


16. Final inspection complete. Punch items on Punch List Record

Remarks:


Name Name Name


Date Date Date


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SWITCHGEAR INSPECTION RECORD ID E76223A





Substation: Building: Switchgear Tag No.:

Subcontractor Fluor FE/QA Note!! #1 Test with circuit breakers withdrawn and with circuit breakers in operating position and open. All circuit transformer secondaries must be shorted before testing begins and instrument potential transformers must be racked in, but with fuses removed.



3. Check phasing of buses

4. Remove shipping supports

5. Check and inspect for completeness of all components. Torque bolted joints according to manufacturer’s recommendations. Torque Wrench Number _________________________ Cal Date_____________________________

6. All devices installed such as: ground fault relays, volt meters, ammeters, breakers, fuses, etc. Location and type according to supplier drawings

7. Check control wiring (especially Field connections at shipping splits)

8. Perform Insulation Resistance Test (megger) buses and record on Test Record, Form: 000 509 F76118: DC High Potential Test (Hypot) Buses, when required by specification. Record on Form: 000 509 F76104, DC High Potential Test Record

9. Perform Insulation Resistance Test (megger) control and potential transformer primary windings and record on Test Record, Form: 000 509 F76119: Insulation Resistance (Transformer) Test Record

10. Perform Ductor Test. Record on Test Record Form: 000 509 F76130

11. Check control transformer fuses, type and size

12. Check potential transformer fuses, type and size

13. Check primary and secondary ratings of all transformers including control transformers

14. Check for proper grounding/earthing connections at both ends of assembly. Record bonding resistance on Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars)

15. Check ground/earth bus bar continuity to ensure connection has been made at shipping split points

16. Tagging correct

17. Cubicles clean, dry and dust free

18. Instruments zeroed

19. Space heaters are connected and operable

20. Insert and remove breaker of same rating in various units to ensure interchangeability

21. Check continuity of all fuses. Check size and type

22. Perform circuit breaker test


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SWITCHGEAR INSPECTION RECORD ID E76223A

23. Terminals and connections tight and secure. Torque bolted connections Torque Wrench Number: Calibration Date::

24. Mainbus and tapes (size according to supplier drawing)

25. Insulation Resistance Test (megger) the DC and AC control circuits, main and outgoing control disconnect devices open. Record results on Test Record, Form: 000 509 F76102

26. Check incoming power cables Insulation Resistance Tested (meggered) prior to connection to switchgear and that results recorded on Form: 000 509 F76102

27. Check DC High Potential Testing (hypot) of incoming power cables completed, when required by specification and recorded on Form: 000 509 F76104: DC High Potential Test Record (Medium Voltage Cable)

28. Incoming feeder terminations properly made up

29. Supplier Representative provided service/supervision for this equipment. Supplier test reports attached to this Inspection Record.



Remarks


Name Name Name


Date Date Date



MOTOR CONTROL CENTER INSPECTION RECORD ID E76224A Tag Description: Tag No.:




Substation: Building: MCC Tag No.: Subcontractor Fluor FE/QA



3. Check for missing parts using supplier drawings. Inspect each unit or cubicle for proper nameplate in accordance with approved drawings

4. Inspect main bus and bus taps to switches and potential transformers. Torque bolted joints in accordance with manufacturer’s recommendations

5. Determine that all terminal block connections are secure and properly identified (especially Field connections at shipping splits)

6. Manually operate switches and contactors. Check for freedom of all moving parts

7. Check nameplate data for switches, contactors, fuses and relays against approved supplier drawings. Verify contactor auxiliary contacts, normally open/closed according to drawing

8. Check for correct sizing of overload relay heaters in accordance with approved drawings

9. Protective grounding/earthing is correctly installed and connected to main ground/earth. Verify Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars), completed. Check main ground/earth bus for continuity between shipping sections

10. Record Insulation Resistance (megger) readings on Test Record, Form: 000 509 F76118: Insulation Resistance (Equipment) Test Record. Test with disconnect switches connected and open. Test with disconnect switches connected and closed. For the second test, ensure that neutral is disconnected at starters. Reconnect neutral after second test

11. Check that power and control cables for each cubicle Insulation Resistance Tested (megger) and that Form: 000 509 F76102: Insulation Resistance Test Record (Power Control Wire and Cable) Test Record, is on file

12. Perform DC High Potential Test (hypot) when required by specification and record on Form: 000 509 F76104: DC High Potential Test Record (Medium Voltage Cable).

13. Spot check overload relays for trip action by injecting current from relay testing equipment in accordance with relay sheets

14. Check to see that enclosure space heaters are connected and operable (when applicable), and that MOTOR space heater circuits are functional

15. Overload reset button free and functional

16. Perform functional check of contactor. Use supplier or Fluor elementary drawing. Observe all Project safety precautions

17. Check timing relays for correct type, size and time setting in accordance with drawings

18. Check control power transformers for correct size and voltage in accordance with drawings

19. Check main contact pressure, alignment and for full contact area (high voltage contactors, only)

20. Supplier Representative provided service/supervision for this equipment. Supplier test reports attached to this Inspection Record


22. Final inspection complete. Punch items on Punch List Record.


Name Name Name


Date Date Date





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BATTERY AND BATTERY CHARGER INSPECTION RECORD ID E76225A





Substation: Building: Equipment Tag No.:

Note!! When batteries are placed in service while work is still being performed around them, protection should be provided. Metal objects laid or dropped on them could cause a short or an explosion. Tarpaulin, plastic or similar material, should not be used because batteries in service require ventilation.




3. Batteries and racks installed and checked for proper mechanical installation, including connections and number of cells

4. Batteries filled with electrolyte to proper level and charged in accordance with manufacturer’s recommendations

5. Lead acid batteries checked with hydrometer for correct specific gravity, in accordance with manufacturer’s specifications

6. Grounding/earthing connection checked. Record readings on Test Record Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars)

7. Battery charger checked for proper installation, wiring complete and properly connected

8. Charger operates in accordance with manufacturer’s recommendations. Current output, voltage and operation of control components checked.

9. Check charger nameplate against approved supplier drawings

10. Accessory equipment such as hydrometer, thermometer, special wrenches and spare electrolyte accounted for

11. Batteries, battery racks and charger cleaned. Terminals and interconnectors covered with protective base

12. Test Charger for maximum rated output and correct operation, as required by Project specifications

13. Booster charge in accordance with manufacturer’s instructions

14. Set charger for float operation with adjustment of proper float voltage

15. Charger marked with float and boost charge voltage limits

16. Verify proper operations of low DC voltage relay and alarm contacts. Indicate limits

17. Verify proper operation of AC failure relays and alarm contacts

18. Verify ground detection relay or lights operate properly. Verify alarm output relays operate

19. Voltmeters checked, zeroed

20. Ammeters checked, zeroed

21. Fuses and circuit breakers in accordance with supplier drawings

22. Verify operation of charger output failure relay and alarm contacts

23. Supplier Representative provided service/supervision for this equipment. Supplier test reports attached to this inspection record




Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76226 Rev 0 Liq Immersed Med V Disconn Switch Inspn Record.doc Page 1 of 2

LIQUID IMMERSED MEDIUM VOLTAGE DISCONNECT SWITCH INSPECTION RECORD

ID E76226A






1. Receiving Operations/Inspection Complete

2. Tag Number, Voltage Rating per one line

3. Visually inspect for cleanliness and no chips or cracks or other apparent damage to bushings

4. Inspect for liquid leakage

5. Collect samples of insulating liquid and determine dielectric strength of insulation liquid. Record on Form: 000 509 F76120: Liquid Dielectric Strength Test Record.

6. Check connections and the jumpers at the terminals

7. Final inspection complete. Punch items on punch list record.

Remarks


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76227 Rev 0 Electric Motor - Elect Activities Inspection Record.doc Page 1 of 2

ELECTRIC MOTOR-ELECTRICAL ACTIVITIES INSPECTION RECORD ID E76227A





Motor Tag No.:

Subcontractor Fluor

FE/QA Note!!! Inspection of the Mechanical items related to this motor is documented on the appropriate Mechanical Exhibit for the driven equipment with similar Tag Number.


2. Nameplate data agrees with motor list, plan drawings and one-line

3. Motor type is suitable for use in area classification

4. Check the power and control cables Insulation Resistance Tested (megger) prior to connection to motor

5. For induction motors, perform the following motor test, as required by the specifications and document on the appropriate forms. For synchronous motors, test in accordance with manufacturer’s instructions

a. Form: 000 509 F76135 Insulation resistance (Rotating Equipment) Test Record (megger)

b. Form: 000 509 F76121 DC Proof Test Record

c. Form: 000 509 F76104 DC High Potential Test Record

d. Insulation Resistance Test of Pedestal (when applicable): ____________ ohms

e. Form 000 509 F76126 Equipment Absorption Ratio and Polarization Index Test Record

6. Grounding/Earthing conductors installed, connected and bonded resistance checked from motor frame to ground/earth system tap. Record resistance on form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars).

7. Motor splices and terminations complete. Spare wires (pigtails) on multiple voltage motors properly insulated

8. Motor electrical accessories are properly connected and functioning such as space heater, thermocouples and vibrations switches

9. Cable gland properly made up

10. Bonding jumper installed, when required, across flexible conduit

11. Control station nameplate installed

12. Covers are installed, bolts and nuts are tightened

13. Final inspection complete. Items Punch List Record

Remarks


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76228 Rev 0 Electric Motor - Mechl Activities- Inspection Record.doc Page 1 of 2

ELECTRIC MOTOR-MECHANICAL ACTIVITIES INSPECTION RECORD ID E76228A





Motor Tag No.:




3. Anchor bolts checked for location, elevation and orientations prior to setting equipment

4. Equipment set and checked for location, elevation and orientation

5. Preliminary alignment completed and documented

6. Jackscrews removed and anchor bolt nuts tightened

7. Baseplate grouting complete and documented when manufactured grouts are required

8. Final cold alignment set to manufacturer’s tolerance and documented

9. Motor electrical activities complete and documented on Form: 000 509 F76227: Electric Motor-Electrical Activities Inspection Record

10. Grease or oil checked to assure proper filling

11. Field coating checked

12. Verify completion of activities on Form: 000 509 F76124 460 V Motor Circuit (480 V MCC) Test Record, Form: 000 509 F76125: Medium Voltage Motor Circuit Test Record, prior to motor bump and run-in, in accordance with Form: 000 509 F76133: Electric Motor Run-in Test record


14. Final inspection complete. Mechanical punch items on Punch List

Remarks


Name Name Name


Date Date Date


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76228 Rev 0 Electric Motor - Mechl Activities- Inspection Record.doc Page 2 of 2



W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76229 Rev 0 Electric Motor for Compressor Installation Checklist.doc Page 1 of 2

ELECTRIC MOTOR FOR COMPRESSOR INSTALLATION CHECKLIST ID E76229A





MOTOR: WIN: TAG:

DRIVEN EQUIP WIN: TAG:

Initials/Date

1. Baseplate pads free of dirt and scale, and filed to remove high spots.

2. Motor feet free of dirt and scale, and filed to remove high spots.

3. Drilled and tapped holes in baseplate pads clean and threads undamaged.

4. Motor weight verified, proper rigging and crane for lifting.

5. Motor set on base, bolts snugged and motor checked for soft foot.

6. Align the motor to the driven equipment with the proper offset to allow for thermal growth.

7. Verify the coupling spacing will allow the motor to run on magnetic center when coupled.

8. Connect the inlet and outlet oil lines to the motor bearing housings. Check to see if the lines have to be insulated from the housings.

9. Commission the lube system and check for any oil leaks.

10. Install the vibration monitoring probes and calibrate to the monitor.

11. Electricians to connect the motor leads, connect the motor heaters and the winding RTD.

12. Electricians to perform the following checks:

- Set and test the protective relays and control devices

- Test wire insulation resistance of power and control circuits

- Test the motor winding insulation resistance

- Test the motor ground connections

13. Secure the motor coupling for a solo run of the motor

14. Run the motor solo for at least in hour or longer until the motor bearing temperatures, motor winding temperatures, and vibration levels stabalize. Verify the proper rotation of the motor

15. Stop the motor using the emergency shutdown. Time the coast down.

16. Couple the motor to the driven equipment and torque the coupling bolts to the prescribed value. Install the coupling guard.


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76230 Rev 0 Compressor Vibration Checklist.doc Page 1 of 2

COMPRESSOR VIBRATION CHECKLIST ID E76230B





Tim

e

VIBRATION

Motor

OB Vert

OB Horz

IB Vert

IB Horz

Gear

Active

Inactive

OB Vert

OB Horz

IB Vert

IB Horz

Pinion

OB Vert

OB Horz

IB Vert

IB Horz

Comp

Active

Inactive

OB Vert

OB Horz

IB Vert

IB Horz

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 F76230 Project No. A6CV Revision C, 28 February 2012

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Tim

e

TEMPERTURES

Motor OB

IB

Gear

Active

Inactive

OB

IB

Pinion OB

IB

Comp

Active

Inactive

OB

IB

Seals OB

IB

Temp to Brgs

Temp to Seals

Press to Brgs

DP to Seals

Suction Press

Discharge Press

Suction Temp

Discharge Temp

Motor Amps


Name: Name: Name:


Date: Date: Date:

COMPRESSOR VIBRATION CHECKLIST ID E76230B


W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76231 Rev 0 Vibration Probe Record.doc Page 1 of 2

VIBRATION PROBE RECORD ID E76231B





Bently Nevada Probe: Compressor Number:

1 2COMPRESSOR

7 8

MOTOR

3 4

5 6

GEAR

Bearing Probe

Position Type Probe

Extension Cable

Proximeter Radial

Probe Gap Voltage

Axial Probe Gap Voltage Monitor

Point Number

Against Normal Shoes

Mid Position

Against Counter Shoes

No. 1 Compressor

Outboard

Horiz.

Vert.

Axial

Key ø

No. 2 Compressor

Inboard

Horiz.

Vert.

No. 3 Gear H.S.

Horiz.

Vert.

No. 4 Gear H.S.

Horiz.

Vert.

Axial

No. 5 Gear L.S.

Horiz.

Vert.

Axial

No. 6 Gear L.S.

Horiz.

Vert.

No. 7 Motor

Inboard

Horiz.

Vert.

No. 8 Motor

Outboard

Horiz.

Vert.

Axial

Key ø


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76232 Rev 0 Dry Type Lighting Trnasformer Checklist.doc Page 1 of 2

DRY TYPE LIGHTING, RECEPTACLE & INSTRUMENT TRANSFORMERS CHECKLIST

ID E76232B





Equipment No.: System:

Location Drawing: Manufacturer:

For: No-Load Volts

Phase to Phase V

Lighting Rating

Receptacle or Volts

Instrument Tap Setting

Nameplate Insul. Class

Ship. Braces Removed Temp. Rise C

Wire Markers Compl. Windings Cu A1

Neutral Bond Size MCC Disc SW Size

Ground Conductor Size Fuse Size

Equipment Ground Yes No Fuse Type

Phase Meter Test (ABC) Yes No Fuse Type

Feeder Size

Touch-up Paint

Test Equip. Cal. Date Tester AMB. Temp.

Notes: 1) Use 500-volt test set for 600-volt equipment and below, 2500-volt test set for equipment rated over 601-5000 volts and 5000-volt test set for equipment rated over 5000 volts.

2) Test voltage to be applied for one-minute duration and reading taken. 3) Neutral must be disconnected from ground during test. 4) Record surrounding air temperature of transformers.

5) Readings will vary inversely with temperature. When project specifies use of temperature correction factors. Attach second sheet with computed values. Indicate on each sheet “Measured” or “Temperature Corrected”.

Resistance (MEGOHMS)* Pri-Sec Voltage Rating (kV)

Liquid or Air

Temp (oC – oF)

Primary Secondary Pri to

Sec A to G B to G C to G A to G B to G C to G

Comments:


Name Name Name


Date Date Date


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76233 Rev 0 Instrmt Wire & Cable Continuity Check -50VDC.doc Page 1 of 2

INSTRUMENT WIRE & CABLES CONTINUITY CHECKS >50VDC

ID E76233





Location:

Reel #: Size Type Length

Cable # Size: Type:

Tester Meter ID # Calibration Date:

RESULTS

Conductor # Continuity Conductor # Continuity Conductor # Continuity


Name Name Name


Date Date Date


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CONTROL SYSTEM INSTRUMENTATION

SCOPE This procedure applies to the inspection of installations and loop check of instrumentation.



Inspect received instruments

E & I Construction Engineer Instrument Superintendent

_____ Each Instrument

Inspect in-process instrument installation

Site Quality Manager/ E & I Construction Engineer


Inspect completed instrument installation


000 509 F770XX Each Instrument

Perform Pressure Testing of Tubing

Instrumentation Superintendent _____ Each Pressure Test Package

Verify Pressure Testing of Tubing


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



Inspect received instruments

Subcontractor _____ Each Instrument

Inspect in-process instrument installation

Subcontractor 000 509 F770XX Daily during life of activity

Inspect completed instrument installation


000 509 F770XX Each Instrument

Perform Pressure Testing on Tubing

Subcontractor _____ Each Pressure Test Package

Verify Pressure Testing of Tubing


000 509 F770XX Each Pressure Test Package

Test Instrument Cables Subcontractor _____ Each cable

Verify Instrument Cable Testing


000 509 F770XX Each cable

Perform/ Verify Loop Check

Subcontractor/ E & I Construction Engineer

Site Quality Manager 000 509 F770XX Each loop


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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 Checklist Inspection 000.509.F77003 Impulse Line Pressure Test Sheet 000.509.F77004 Instrument Grounding System Check Sheet 000.509.F77005 Installation Check Sheet (Local Instruments) 000.509.F77006 Orifice Plate Specification Check Report 000.509.F77007 Control Systems Quality 000.509.F77008 Loop Check Record 000.509.F77107 Loop Mechanical Completion and Acceptance Record


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INSTRUMENTATION INSPECTION CHECKLIST ID I77001A





Loop No.:

Drawing(s)


Verify the following attributes:

01 Instruments mounted at proper height.

02 Instrument stands secure and vibration free.

03 Correct piping/tubing materials used.

04 All tubing trays and supports per details.

05 All air supply and process tubing connected to proper parts per details.

06 All tubing fitting nuts torqued per specifications.

07 Good workmanship used in tubing installation and neat in appearance.

08 Signal/power leads have proper separation and angle of intersection.

09 Tubing/piping pressure tested prior to heat tracing or insulating.

10 Loop checked per specification.

ANY DISCREPANCIES NOTED ABOVE AS FOLLOWS:

Punch List Items from Above List Date Cleared


Name: Name: Name:


Date: Date: Date:





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INSTRUMENT LOOP INSPECTION CHECKLIST ID I77002A





Cable No.: Junction Box No.:

Cable Type: Color/Loop No.:


01 Measuring Element

Installation Correct Tappings Position Correct

Location Correct Materials Correct

02 Impulse Lines According to Hook-Up Traced

Pressure Tested Materials Correct

03 Field Instrument

Local Indicator Working Power Supply Correct

Air Supply Correct Correct Installation Weather Protected

04 Panel Instrument

Correct Installation Air Supply Correct

Power Supply Correct

05 Control Valve Correct Installation Limit SW Tested Positioner Checked

Size & Type Correct Stroke Tested I/P Transducer Checked

06 Solenoid Valve Correct Installation Size & Type Correct

Other (indicate) :________________

07 Air Supplies Correct Installation Blown Clear & Leak Tested

Other (indicate) :________________

08 Transmission Pneumatic Lines Tested Insulation Checked (C-C, C-G)

Continuity Checked

09 Temperature T/C or RTD Checked Continuity Checked

Correct Cable Loop Impedance Checked

10 General Support Correct Earthing Correct

Tagging/Marking Correct

Notes:


Name: Name: Name:


Date: Date: Date:


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IMPULSE LINE PRESSURE INSPECTION CHECKLIST ID I77003A





Item Description of Check

Instrument Tag No.

Instrument Tag No.

Instrument Tag No.

Instrument Tag No. Subcontractor

Fluor FE/QA

01 Ferrules correctly installed and crimped

02 Slope and supports correct

03 Tubing blow clear

04 Valve block seals correct

05 Test pressure bar

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77004 Rev 0 Instrument Grounding System Checksheet.doc Page 1 of 2

INSTRUMENT GROUNDING SYSTEM CHECK SHEET ID I77004A





Description of accepted items:

Grounding system

Manufacturer:

Drawings:

Items to check: Subcontractor Fluor FE/QA

1 All metal enclosures correctly grounded

2 Cable shields/screens correctly grounded

3 Safety barriers, convertors, etc. Correctly grounded

4 Dedicated ICS ground correct

5 ICS minus and ground correctly connected

6 Isolation of the three ground systems from another correct

7 Grounding cable to central point correct

8 After testing: Three grounding systems connected together correctly

9 Metal tray (trunking, conduits) correctly grounded

10 Computer floor correctly grounded

11 Frames (supports for consoles, cabinets) correctly grounded

Remarks


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77005 Rev 0 Installation Checksheet Local Instruments.doc Page 1 of 2

INSTALLATION CHECK SHEET (LOCAL INSTRUMENTS) ID I77005A





Instrument Tag No.:

Range Witness Date Instrument Tag

No.: Range Witness Date Subcontractor Fluor FE/QA

1. Verify correct instrument is installed at correct P.I.D. location, including correct tag number and model number

2. Verify integrity of process installation (no open plugs etc.)

3. Verify all instruments have been calibrated (certificates available, stickers on instruments)

4. Verify accessibility

5. Verify correct gasket materials installed


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77006 Rev 0 Orifice Plate Inspection Checklist.doc Page 1 of 2

ORIFICE PLATES INSPECTION CHECKLIST ID I77006A






01 Install orifice with sharp edge upstream

02 Bevel edge, if any, must face downstream

03 Make sure gaskets on each side of orifice do not obstruct orifice bore

04 Identification tab on square edge plates must face upstream

05 Verify correct labelling

06 Verify orientation of pressure taps per specification of process

07 Visually inspect for damage

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77007 Rev 0 Controls System Quality.doc Page 1 of 2

CONTROL SYSTEMS QUALITY CONTROL INDEX ID 77007





Tag Number

Fun

ctio

n

Typ

e

Loc

atio

n Flow Diagram

Spec Sheet

Loop Diagram Number

Installation Sign-Off

Test PressurePressure Test

Sign-Off Calibration Sign-Off

Loop Check Sign-Off

Remarks

Type Codes: E = Electrical C = Combination (E &P) Location Codes: P = Pipe R = Equipment Rack

P = Piped D = Direct or Mechanical F = Front of Main Control Panel L = Local Panel

B = Back of Main Control Panel H = Control House

Sheet of


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77008 Rev 0 Loop Check Record.doc.doc Page 1 of 2

LOOP CHECK RECORD ID I77008A





Job No./Unit No.: Loop No.:

Record Loop Component Tag No.

Comments:

System Installation Complete and Required Documents on File Control/Systems: Date: Electrical: Date:

Loop Function Test Tested By: Date: Accepted By: Date: Fluor Accepted By: Date:

Start-Up Accepted By: Date:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77107 Rev 0 Loop Mechanical Completion and Acceptance Record.doc Page 1 of 2

LOOP MECHANICAL COMPLETION AND ACCEPTANCE RECORD ID F77107





Area:

Instrument Loop Tag No.:

Loop Schematic Drawing No.:

Flow Diagram Drawing No.:

This Loop _________________________________________is mechanically complete in accordance with Drawings and Specifications.

Fluor/Date

This Loop _________________________________________has been checked within the parameters listed on the instrument loop drawing, and/or mechanical flow diagram, and is acceptable.

Fluor/Date


Name: Name: Name:


Date: Date: Date:


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CONTROL SYSTEM CALIBRATION SCOPE This procedure applies to calibration of instruments for control systems. RESPONSIBILITIES - Self-Perform


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 000.509.F77104 000.509.F77105 000.509.F77106

Each Instrument

Surveillance Test Equipment

Site Quality Manager 000.509.F02201 Periodically throughout

life of project



ACTIVITY

Inspect Instrument Subcontractor 000.509.F77001 Each Instrument

Test and Calibrate Instruments

Subcontractor

000.509.F77101 000.509.F77102 000.509.F77103 000.509.F77104 000.509.F77105 000.509.F77106

Each Instrument

Surveillance Test Equipment

Site Quality Manager 000.509.F02201 Periodically throughout life

of project


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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. • 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

000.509.F77104 – Switch Calibration Data Record 000.509.F77105 - Valve Calibration Data Record 000.509.F77106 – Control System Test Equipment Calibration Log



INSTRUMENTATION INSPECTION CHECKLIST ID I77001A





Loop No.:

Drawing(s)


Verify the following attributes:

01 Instruments mounted at proper height.

02 Instrument stands secure and vibration free.

03 Correct piping/tubing materials used.

04 All tubing trays and supports per details.

05 All air supply and process tubing connected to proper parts per details.

06 All tubing fitting nuts torqued per specifications.

07 Good workmanship used in tubing installation and neat in appearance.

08 Signal/power leads have proper separation and angle of intersection.

09 Tubing/piping pressure tested prior to heat tracing or insulating.

10 Loop checked per specification.

ANY DISCREPANCIES NOTED ABOVE AS FOLLOWS:

Punch List Items from Above List Date Cleared


Name: Name: Name:


Date: Date: Date:





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INSTRUMENT CALIBRATION SHEET ID I77101A





Instrument Calibration Sheet

Date: Technician: Area:

Tag Number: Loop Service:

Manufacturer: Model: Serial No.:

Process Range and Units: (scfm, gpm, psig, oC , etc.)

Transmitter Input Range and Units: (in H20, psig, etc.)

Transmitter Output Signal

For Flow Instruments: Chart Factor: Orifice Plate Bore: Chart Scale: (circle one)

Integrator Factor: Linear – Square Root - Combination

For Differential Pressure Instruments: Fill Fluid: For I/P Transducer Suppression: Fluid Type: Input

Elevation: Specific Gravity: Output

Test Equipment Used Serial No. Manufacturer Model No. Description Calibrated Due Date

Input Standard Output Notes Percent Input Value As Found As Left % Error

0 25 50 75

100

Percent Error Calculation: Percent Error = “As Found” Output – “Correct” Output x 100 Span Output

Remarks:

Subcontractor Acceptance: Date:

Fluor FE/QA Acceptance: Date:


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Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 FF77102 Project No. A6CV Revision 0, 10 June 2013

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SAFETY VALVE TRACKING SHEET ID I77102A





Manufacturer

Model No. Serial No.

Calibration Tag Verification Date Checked:

Pressure Setting

Calibration Date

System Status Pre-Hydrotest

Post-Hydrotest

Reinstatement Complete


Pressure Setting

Calibration Date *


Post-Hydrotest

Reinstatement Complete


Pressure Setting

Calibration Date *


Post-Hydrotest

Reinstatement Complete * Calibration date at turnover must be within 60 days of System turnover date.


Name: Name: Name:


Date: Date: Date:

Sociedad Minera Cerro Verde S.A.A. 240K-C2-05-002 Site Quality Manual Cerro Verde Production Unit Expansion 000 509 FF77102 Project No. A6CV Revision 0, 10 June 2013

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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77103 Rev 0 Relief Valve Inspection and Final Acceptance.doc Page 1 of 2

RELIEF VALVE INSPECTION AND FINAL ACCEPTANCE ID I77103A





Tag Number Orifice Size Inlet Rating Outlet Rating Set Pressure

Manufacturer Model Number Serial Number Type

Yes No N/A

Marking in accordance with API 526 and specification.

Connection size and rating in accordance with specification.

Material of construction in accordance with specification.

Center – To – Face Dimension in accordance with API 526.

Set pressure in accordance with specification.

Relief valve complies with ASME code requirements.

Letter Designation of orifice is in accordance with specification.

Relief valve tagged in accordance with Client Practices.


Name: Name: Name:


Date: Date: Date:


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SWITCH CALIBRATION DATA RECORD ID F77104





Specification Sheet No.:

Purchase Order No.: Item No.:

Serial No.:

Test Equipment Model S/N

Function Specified Actual

Set No. 1

Reset No. 1

Set No. 2

Reset No. 2

Set No. 3

Reset No. 3

Set No. 4

Reset No. 4

If Additional Setpoints, use second Sheet.

Remarks:


Name: Name: Name:


Date: Date: Date:


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VALVE CALIBRATION DATA RECORD ID F77105





Specification Sheet No.:

Purchase Order No.: Item No.:

Serial No.:

Fail Position: Bench Set: Length of travel:

Test Equipment Model S/N

Positioner: Yes No

Manufacturer: Type:

Actuator* 0% 50% 100%

Input

Output (Stem Travel)

Positioner

Input

Output

Stem Travel

*Not Applicable for Double Acting Cylinders.

Limit Switch Tag No.: Open Closed

Remarks:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77106 Rev 0 Control System Test Equipment Calibration Log.doc Page 1 of 2

CONTROL SYSTEMS TEST EQUIPMENT CALIBRATION LOG ID F77106





Equipment:

Model No.: Calibration Frequency:

Last Calibration Date Signature Last Calibration Date Signature


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7800 Rev 0 Coatings and Linings.doc Page 1 of 4

COATINGS AND LININGS SCOPE This procedure describes the inspection, testing, and documentation required to be performed for coatings. RESPONSIBILITIES - Self-Perform


Inspect surface preparation

Supervisor/Construction Engineer/Site Quality Manager


Verify color/type coatings approved

Supervisor/Construction Engineer/ Site Quality Manager

000 509 F78001 As required by applications

Inspect in-process coating/lining


000 509 F78001 000.509.F78002


Check Thickness Supervisor/Construction

Engineer/Site Quality Manager 000 509 F78001

As required to verify thickness requirements

Inspect completed coatings


000 509 F78001 _____

Follow-up any deficiencies identities


_____ As required to close-out deficiencies



Inspect surface preparation

Subcontractor/Construction Engineer/Site Quality Manager


Verify color/type coatings approved


000 509 F78001 As required by applications

Inspect in-process coating/lining


000 509 F78001 000.509.F78002


Check Thickness Subcontractor/Construction Engineer/Site Quality Manager

000 509 F78001 As required to verify thickness requirements

Inspect completed coatings


000 509 F78001 _____

Follow-up any deficiencies identities


_____ As required to close-out deficiencies



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.



FORMS Quality Support Forms: 000.509.F78001 - Coating Inspection Record 000.509.F78002 - Lining Inspection Record ATTACHMENTS Attachment 1 - Example – Acceptance Criteria



Attachment 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


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COATINGS INSPECTION RECORD ID X78001AR





Type Object: Item Description of Check Subcontractor

Fluor FE/QA

Piping 01 Coating by approved manufacturer

Structural Steel 02 Surface preparation SSPC-SP value

Equipment 03 Surface dry-free from condensation

Tank Exterior 04 Paint mixed, thinned and applied in accordance with

manufacturer’s specification Tank Interior Brush Spray Roller

Object Location: 05 Primer in accordance with specification

Outdoors 06 Finish coat is acceptable

Indoors 07 Workmanship acceptable

Conditions: Mon Tues Wed Thurs Fri Sat

AM PM AM PM AM PM AM PM AM PM AM PM

Relative humidity %

Substrate Temperature

Ambient Temperature

Dew Point

Brandname Paint Batch No Coat

No FT Application Method DFT Average

A Base B Hardener

Notes:


Name: Name: Name:


Date: Date: Date:


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LININGS INSPECTION RECORD ID X78002AR





Item Description of Check Subcontractor

Fluor FE/QA

01 Pressure tests have been satisfactorily completed on equipment to be lined.

02 Internal surfaces to be lined have been visually inspected to verify that fabricated weldments are acceptable for lining application in accordance with NAC RP-01-78 or specified standard _______________________.

03 Surface preparation is complete and has been checked with the surface profile comparator in accordance with SSPC-SP5 or specified method _____________ and visually examined in accordance with SSPC VIS-1 or specified standard ____________________.

04 Temperature and humidity of lining area was checked daily with a sling hygromometer and was found to be in temperature and humidity ranges recommended by the manufacturer for application of lining.

Conditions Mon Tues Wed Thurs Fri Sat

AM PM AM PM AM PM AM PM AM PM AM PM

Relative humidity %

Substrate Temperature

Ambient Temperature

Dew Point

05 Liquid lining application has been visually inspected and accepted.

06 Sheet or rubber lining installation has been checked with an approved holiday detector and has been accepted or identified; defects have been repaired.

07 Lining thickness has been checked with a nordsen dry film thickness gage or ________________. Average lining thickness: ________________.

08 Vulcanization has been performed satisfactorily. The lining surface has been checked for blisters, open seams, lifted edges, surface defects, pinholes and hardness.

09 Completed linings have been marked in accordance with the specifications.

Notes:


Name: Name: Name:


Date: Date: Date:


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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7810 Rev 0 Insulation.doc Page 1 of 4

INSULATION SCOPE This procedure describes the inspection activities for insulation installation. RESPONSIBILITIES - Self-Perform


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


(Note 1) From 000.509.F02201


NOTE 1: Surveillance is not required if the Fluor Quality representative is performing

inspections. RESPONSIBILITIES - Subcontracted Work


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


Subcontractor Form 000.509.F78101 Each piece of equipment, line or structure


Subcontractor Form 000.509.F78101 Each piece of equipment, line or structure

Surveillance QC Inspection Form 000.509.F02201 Per Procedure 000.509.0220



PROCEDURE • Release for Insulation:

- The construction engineer will issue the "Release for Insulation" (Form 000.509.F78101) 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



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.





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EQUIPMENT THERMAL INSULATION INSPECTION CHECKLIST ID IC78101A





Release for Insulation

Engineer: Date

Inspector: Date


Insulation Materials

01 Proper materials

02 Verify insulation materials are free from damage

03 Verify insulation materials shelf-life has not expired

Hot Vessels and Equipment

04 Proper material thickness used

05 Proper application at stiffener rings

06 Nameplates left exposed

07 Proper banding and breather springs used

08 Proper use of filler and/or mastic materials

Cold Vessels and Equipment


10 Proper insulation of attachments

11 Proper contraction joint at support rings


13 Proper banding used

14 Proper use of filler, joints seals and vapor seal

Tank insulation – Hot

15 Proper spacing of welded pins for support

16 Proper banding used (insulation/jacketing)

17 Proper expansion system

18 Proper lapping vertically and horizontally

19 Proper use of “S” clips


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EQUIPMENT THERMAL INSULATION INSPECTION CHECKLIST ID IC78101A


20 Vertical support bars used on 50’ diameter and larger

21 Proper flashing used per specification details

22 Proper roof (build up) application over insulation

Weatherproofing Hot Equipment

23 Proper use of weather proofing mastic at fittings

24 Proper banding of metal jacket

25 Proper use of “S” clips on vertical runs

26 Corrugated jacketing on vessel

27 Proper lap and metal screw spacing

28 Proper main shield on vertical vessels

Weatherproofing Cold Equipment

29 Proper use of vapor barrier mastic paint jacketing

30 No use of screws on cold work except on standing seam systems

Acoustical Lagging


32 Proper application at stiffener


34 Proper banding and breather springs used


Removable Covers

36 Proper stenciling or tagging for identification

Notes:


Name: Name: Name:


Date: Date: Date:


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PIPING THERMAL INSULATION INSPECTION CHECKLIST ID IC78102A





Release for Insulation

Engineer: Date:

Inspector: Date:

**fill out applicable sections as determined by type of insulation**


Insulation Materials

01 Proper Materials

02 Verify insulation materials are free from damage

03 Verify insulation materials shelf-life has not expired

Insulating Hot Piping


05 Flanges, flanged valve bodies, bonnets and flanged fittings insulated

06 Minimum clearances between insulation and adjacent surfaces

07 45 degrees to vertical runs properly supported

08 Service over 454 °C shall be in two layers

09 Joints staggered and proper wire ties

10 Expansion joints spacing horizontal runs correct

11 Proper clearance at flange breaks

12 Tubing properly insulated


Insulation Cold Piping


15 Proper insulation of attachments

16 Contraction joints at specified intervals

17 Proper cradle diameter at supports

18 45 degrees to vertical runs properly supported

19 Proper use of joints sealer for single and multiple layer applications

20 Proper taping or banding used

21 Proper use of filler materials, sealer and/or vapor barriers


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PIPING THERMAL INSULATION INSPECTION CHECKLIST ID IC78102A


Weatherproofing Hot Piping

22 Proper use of weather proofing mastic at fittings

23 Proper banding of metal jacket

24 Proper use of “S” clips on vertical runs

25 Proper lap and metal screw spacing

26 Proper main shield on vertical vessels

Weatherproofing Cold Piping

27 Proper use of vapor barrier mastic paint jacketing

28 No use of screws on cold work except on standing seam systems

Removable Covers

29 Proper stenciling or tagging for identification

Remarks:


Name: Name: Name:


Date: Date: Date:


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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



ACTIVITY

Coordinate release for fireproofing

Construction Engineer000.509.F78201 000.509.F78202

Daily

Install fireproofing Subcontractor ----- -----


Subcontractor 000.509.F78201 Each 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




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.



• 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 (30 m) 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








Report No.














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RELEASE FOR APPLICATIONS OF FIREPROOFING AND INSPECTION CHECKLIST

ID F78201A





Release

Area Designation:

From Elevation: To Elevation

Requested By: Date

Exclusions/Remarks:

Discipline Engineering Release Date

Inspection

Drawings:

Work Inspected:


01 Protection of areas not to be fireproofed

02 Area(s) of surface(s) to be fireproofed


04 Type of fireproofing Normal Concrete Brickwork

Insulating Concrete Proprietary

05 Brand name (if applicable): Concrete grade:

06 Application method: Gunned Trowelled

(not for brickwork) Formed

07 Skirt fireproofing required: Inside Outside

08 Anchorage/reinforcement

09 Slump test performed

10 Compressive strength cylinders prepared

11 Finished/cured surface

12 Material thickness required

13 Material thickness attained

14 Sealing of joints/seams

15 Cleanliness

Subcontractor Fluor Field Engineering Fluor QA Name: Name: Name:


Date: Date: Date:


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FIREPROOFING INSPECTION PRECONSTRUCTION CHECKLIST ID F78202A





This checklist is to be filled out to document shotcrete panels made for mix design approval and subsequent panels made to qualify each application crew (i.e. nozzleman, delivery equipment operator and hoseman).

Fireproofing Material and Mix Proportions Used:

Panel Size and Description of Reinforcement:

Positions of Panel as Shot: A- Horizontal B – Vertical C - Overhead

Note: Clearly identify each panel with A, B or C, date completed, material used, nozzleman.

Panel No.

Position Nozzleman Delivery Equipment

Operator Material Used

Date Completed


Name Name Name


Date Date Date


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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.



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


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 /


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


inspection forms by Fluor Quality. NOTE 2: Surveillance is not required if the Fluor Site Quality Manager is performing inspections.



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.



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








Report No.














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CATHODIC PROTECTION INSPECTION REPORT ID F78301





Drawing No.:/P&ID No. Rev.

Tag/Line No. Sheet No.

Tank Other :

Pipe

Test Station

Origin of Inspection:

Termination of Inspection Point:

Number of Anode Ends Welded:

Test Station No.:

Operation Temperature:

Anode Type:

No. Of Anodes:

Weld Area Cleaned:

Welds Acceptable:

Is the Anode Ribbon secured to the pipe on 10 – 12 feet centers

Notes: - Zinc Ribbon Anodes shall be used for Piping systems operating at or below 140f – Low Temperature System - Magnesium Ribbon Anodes shall be used on Pipes which operate from 141f to 250f - If more than one Anode is specified, each Anode end shall be welded to the Piping. - Reference – 414000-0-SP-4-CP-1

Comments:

Date of Inspection: Witnessed by:


Name: Name: Name:


Date: Date: Date:


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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" • ASME 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”



• Fluor Welding Manual (Self perform work only) • Applicable Project Specifications



ACTIVITY Assign numbers to field pipe welds


Each piping isometric drawing

Each isometric requiring field welds

Weld Checking and Inspections (Non ASME Code)

Welder Foreman

Form 000.509.F79001 Daily Welding Report Form 000.509.F79002 Weld Heat Treatment Log

Daily

Certified Welding Inspector


Daily

Weld Checking and Inspections (ASME Code Stamped)

Welder Foreman Per Fluor "Quality Control System Manual for Boiler & Pressure Vessel Code Work" 000 510 XXXX

Daily


Daily

Surveillance Welder Foreman None Daily


Form 000.509.F02201 Form 000.509.F79002

See general section





ACTIVITY Assign numbers to field pipe welds

Subcontractor Each piping isometric drawing

Each isometric requiring field welds

Weld Checking and Inspections (Non ASME Code)

Subcontractor Welding Foreman


Daily

Subcontractor Certified Welding Inspector


Daily

Weld Checking and Inspections (ASME Code Stamped)

Subcontractor Welder Foreman

Per the subcontractor approved Quality Control System Manual for Boiler & Pressure Vessel Code Work

Daily

Subcontracor Certified Welding Inspector

Daily

Surveillance

Subcontractor Welder Foreman

None Daily

Subcontractor Certified Welding Inspector

Form 000.509.F02201 Form 000.509.F79002

Daily

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".

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.F79001) 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" 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 are 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 are 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 (000.509.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).



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.", found in the Nondestructive Examination (NDE) Manual – Fluor Enterprises, Inc., 000.511.0000

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 - ASME 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



Attachment 1 - 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 ASME B31.2 3.1 All completed welds shall have a visual examination

4.0 ASME B31.3(B31.3 (1) A. Category "D" Fluid Service Visual examination shall be performed to the extent necessary to satisfy the examiner that

components, materials, workmanship and welds conform to the requirements. B. "Normal Service Conditions" 1. Sufficient welds, materials and components shall be examined to satisfy the

examiner that they conform to specifications and are free from defects and damage.

2. At least 5% of completed welds shall be examined. Each welder's work shall be

included. 3. Examine 100% of completed longitudinal welds, except those in components made

from a listed specification (i.e., A53B welded pipe, A234 welded fillings). 4. Random examination of the assembly of threaded, bolted, and other joints for

conformance to engineering requirements. 5. Random examination of alignment, guides, supports, and cold spring. 6. Examination of erected piping for defects or deviations from engineering design.



7. When pneumatic testing is performed, all threaded, bolted, and other mechanical

joints shall be examined. C. "Severe Cyclic Conditions" Same as #B above except all fabrication shall be examined. D. "Category "M" Fluid Service Same as #B above except all fabrication shall be examined. E. High Pressure Piping Same as #B above except all fabrication shall be examined. NOTE(1): 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




8.0 ANSI/ASME B31.9 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they






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


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.



Attachment 2 Weldolet and Sockolet Fittings Attachment



Attachment 3 - ANSI B16.11 Forged Steel Fittings



Attachment 4 - ASME Section I Acceptance Criteria

1.0 ASME SECTION I 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516G70,

etc.) and per the Quality Control System Manual, B & PV Code Work (i.e; heat number).

B. Joint preparation and cleanliness shall be in accordance with the WPS. C. Check welder qualification, base material for conformance to the WPS. D. Welding filler materials shall be in accordance with the WPS. E. Preheating prior to cutting or welding (including tacking) shall be in accordance

with the WPS. F. Tack welds shall be made by qualified welders. G. Tack welds that are to be incorporated into the final weld shall be visually

examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding.

H. The backside of double welded joints shall be backgouged to sound metal and

visually examined prior to welding. I. Each weld pass shall be free of porosity, slag, cold lap, cracks and other

indications that would compromise weld quality.

J. Arc strikes shall be properly removed and areas visually examined. K. Welding end transitions shall provide for a maximum 30 degree angle across the

weld, with respect to the base metal (diameters, or plate thickness) on each side of the weld. Additionally where two thick sections taper down to the weld joint, the minimum angle formed by the O.D. of the base materials shall be 150 degrees.

L. Fit-up and alignment of butt welds shall be in accordance with the WPS and the

following where "t" is the nominal thickness of the thinner section at the joint (dimensions in inches).



ALIGNMENT TOLERANCE OF JOINT TO BE BUTT WELDED (Note 1) Direction of Joints in Cylindrical Shells

(Inches) 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.

(Millimeters) Section Thickness (mm) Longitudinal Circumferential Up to 12, incl. 1/4t 1/4t Over 12 to 19, incl. 3 1/4t Over 19 to 38, incl. 3 5 Over 38 to 50, incl. 3 1/8t Over 50 Lesser of 1/16 t or 9.5 Lesser of 1/8t or 9.5 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"

(6.3 cm). Before welding, there shall be at least 1/16" (1.5 mm) 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" (1.5 mm) 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" (2 mm).

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"

(2.4 mm) or 20% of the thinner of the sections being joined. The contour of the



concavity shall be smooth and the resulting thickness of the weld, including any outside reinforcement, shall be at least equal to the required thickness of the thinner section.

G. Any allowable off-set on a finished weld shall be faired at a 3:1 taper over the width

of the finished section. Additional weld metal may be added beyond edge of weld. H. Undercut shall not exceed 1/32" (0.8 mm) 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 (1 m).

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:

(Inches)

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



(Millimeters)

Nominal Thickness (in) Circumferential Joints in Pipe and Tubing (in)

Maximum Reinforcement (in) Other Welds

Up to 3 2.4 2.4 Over 3 to 5, incl. 3 2.4 Over 5 to 12, incl. 4 2.4 Over 12 to 25, incl. 5 2.4 Over 25 to 50, incl. 6.3 3 Over 50 to 76, incl. Note 1 4 Over 76 to 101, incl. Note 1 5.5 Over 101 to 127, incl. Note 1 6.3 Over 127 Note 1 8

Note 1: The greater of 1/4 in. (6.3 mm) or 1/8 times the width of the weld in inches.



Attachment 5 - ASME Section VIII, Division I Acceptance Criteria

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. CMTR’s 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


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.

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

(Inches) 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.

(Millimeter)

Nominal Thickness (t), mm Joint Categories A* B,C,D* Up thru 12 1/4t 1/4t Over 12 thru 19 3 1/4t Over 19 thru 38 3 5 Over 38 thru 50 3 1/8t Over 50 Lesser of 1/16t or 9.5 Lesser of 1/8t or 9.5

* 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" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm). 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.

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 (0.8 mm), 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 (1 m).

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.



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 (2.4 mm) 3/32 (2.4 mm) 1/32 (0.8 mm) 3/32" (2.4 mm) thru 3/16 5 mm) 1/8 (3 mm) 1/16 (1.5 mm) Over 3/16 (5 mm) thru ½ (12 mm) 5/32 (4 mm) 3/32 (2.4 mm) Over ½ (12 mm) thru 1 (25 mm) 3/16 (5 mm) 3/32 (2.4 mm) Over 1 thru 2 (25-50 mm) ¼ (6.3 mm) 1/8 (3 mm) Over 2 thru 3 (50-76 mm) ¼ (6.3 mm) 5/32 (4 mm) Over 3 thru 4 (76-101 mm) ¼ (6.3 mm) 7/32 (5.5 mm) Over 4 thru 5 (101-127 mm) ¼ (6.3 mm) ¼ (6.3 mm) Over 5 (127 mm) 5/16 (8 mm) 5/16 (8 mm)



Attachment 6 - ASME B31.1 Acceptance Criteria

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.


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 (1.5 mm) inch unless the piping design specifically states a different allowable misalignment, in which case, the misalignment over 1/16 inch (1.5 mm) 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


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. 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 (1.5 mm)

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" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) 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 (0.8 mm) and shall not reduce the wall

thickness below minimum wall requirements (i.e., .875 X nominal wall for schedule pipe, the minimum ordered wall thickness of minimum wall pipe, and nominal wall minimum, minus .01 inch for nominal wall ordered pipe that is made from rolled and longitudinally welded plate).

I. Any offset of outside butt welding surfaces shall be faired to a 30 degrees

maximum taper over the width of the weld (excluding reinforcement). J. 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 (3 mm) 1/16 (1.5 mm) 3/32 (2.4 mm) 3/16 (5 mm) Over 1/8 thru 3/16 (3-5 mm) 1/16 (1.5 mm) 1/8 (3 mm) 3/16 (5 mm) Over 3/16 thru ½ (5-12 mm) 1/16 (1.5 mm) 5/32 (4 mm) 3/16 (5 mm) Over 1/2 thru 1 (25-19 mm) 3/32 (2.4 mm) 3/16 (5 mm) 3/16 (5 mm) Over 1 thru 2 (25-50 mm) 1/8 (3 mm) ¼ (6.3 mm) ¼ (6.3 mm) Over 2 (50 mm) 5/32 (4 mm) 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 (1.5 mm) for the GTAW process nor 3/32 inch (2.4 mm) 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 (6.3 mm) 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.

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.



Attachment 7 - ASME B31.2 Acceptance Criteria

1.0 ASME 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.



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 (3 mm) or one-half the branch wall thickness, whichever is less.


1/4" (6.3 mm). Before welding, there shall be at least 1/16" 1.5 mm) 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. 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 (38 mm) in any 6 inches (15 cm) 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 (3 mm).

E. Branch connection weld sizes are shown in Figure A. F. Undercut shall not exceed 1/32 inch (0.8 mm). G. *Weld reinforcement shall not exceed the following:

COMPONENT REINFORCEMENT

Thickness (in.) Thickness, Max (in.) 1/2" (12 mm) and under 1/8" (3 mm) Over 1/2" thru 1" (12-25 mm) 5/32" (4 mm) Over 1" (25 mm) 3/16" (5 mm)

* For double welded joints this limitation or reinforcement shall apply to each

surface of the weld separately. H. No under filled (weld cap) areas.



FIGURE A

ASME B31.2

WELDED BRANCH DETAILS

NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown

here. tc = the smaller of 1/4" (6.3 mm) or .7 x Tb

Tr = nominal thickness of reinforcement, in. Detail (1) w = Tb + tc

tmin = the smaller of Tb or Tr Detail (2) w = Th + tc

Tb = nominal thickness of branch wall Detail (3) w = Tr + tc or Tb + tc

Th = nominal thickness of header wall Detail (4) w = Th + Tr + tc

Detail (5) w = Tb + tc

w = Governing thickness for determining Postweld Heat Treat.



Attachment 8 - ASME B31.3 Acceptance Criteria 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. CMTR’s are required for all material requiring CVN testing. CMTR’s may be required for other piping as designated in a site specification.

B. 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.












M. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) 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.



FIGURE A ASME B31.3

WELD ACCEPTANCE CRITERIA



FIGURE B

ASME B31.3

WELD ACCEPTANCE CRITERIA NOTES



FIGURE C

ASME B31.3

WELD CRITERIA NOTES AND WELD CRITERIA FOR TABLE K341.3.2A



FIGURE D

ASME B31.3


NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" (6.3 mm) or .7 x Tb









Attachment 9 - ASME B31.4 - ASME B31.8 - ASME B31.11 Acceptance Criteria

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


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.










* Shallow crater cracks located at the stopping point of weld beads, and that are

5/32 inch (4 mm) 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 (3 mm). 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 (12 mm) or, the group length in any continuous 12 inch (30 cm) length of weld exceeds 1/2 inch (12 mm) or, an individual pore within a cluster exceeds 1/16 inch (1.5 mm).

B. Incomplete penetration and incomplete fusion is unacceptable when: 1. The length of an individual indication exceeds 1 inch (25 mm). 2. The group of indications in any continuous 12 inch (30 cm) length of weld

exceeds 1 inch (25 mm). 3. The group of indications exceeds 8 percent of the weld length in any weld

less than 12 inches (30 cm) 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 (50 mm). 2. The group of indications in any continuous 12 inch (30 cm) length of weld

exceeds 3 inches (76 mm). 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 (6.3 mm) and the internal root

concavity is less than the thinnest adjacent base metal. 2. The maximum dimension exceeds the thinner of the nominal wall thickness

joined and the internal root concavity is less than the thinnest adjacent base metal.



3. If more than one burn-through is present, the sum of the maximum dimensions of separate burn-through exceeds 1/2 inch (12 mm) in any continuous 12 inch (30 cm) 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 (6 cm), if more than one burn-through is present and the internal root concavity of more than one of the burn-through exceed 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 (30 cm) length of weld exceeds 2 in. (50 mm). 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 (0.8 mm) or 12 1/2% of the pipe

wall thickness whichever is smaller. 2. Undercut depth shall not exceed 1/64 inch (0.4 mm) or 6% to 12.5% of pipe

wall thickness whichever is smaller for a maximum length of 2 inches (50 mm) in a continuous 12 inch (30 cm) 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 (30 cm) length of

weld exceeds 2 inches (50 mm). 2. The group length of indications exceeds 8 percent of the weld length. H. The weld cap (weld reinforcement) shall not exceed 1/16 inch 1.5 mm). 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 (3 mm). 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.



FIGURE A

ASME B31.4 - B31.8 - B31.11

WELD DETAILS FOR UNEQUAL WALL THICKNESS



FIGURE B

ASME B31.4 - B31.8 - B31.11

BRANCH CONNECTION DETAILS WITHOUT REINFORCEMENT



FIGURE C

ASME

B31.4 - B31.8 - B31.11



Attachment 10 - ASME/ANSI B31.5 Acceptance Criteria 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





I. The backside of double welded joints shall be back-gouged to sound metal and







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 (3 mm), 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.



FIGURE A

ASME B31.5

WELD ACCEPTANCE CRITERIA



FIGURE B

ASME B31.5

WELD ACCEPTANCE CRITERIA NOTES



FIGURE C

ASME B31.5


NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" (6.3 mm) or .7 x Tb Tr = nominal thickness of reinforcement, in. Detail (1) w = Tb + tc tmin = the smaller of Tb or Tr Detail (2) w = Th + tc Tb = nominal thickness of branch wall Detail (3) w = Tr + tc or Tb + tc Th = nominal thickness of header wall Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc w = Governing thickness for determining Postweld Heat Treat.



Attachment 11 - ANSI/ASME B31.9 Acceptance Criteria 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





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




1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting.



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 (38 mm) in any 6 inch (15 cm) 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 (3 mm).

E. Branch connection weld sizes are shown in Figure A. F. Undercut shall not exceed 1/32 inch (0.8mm) or 12 1/2% of the wall thickness

whichever is less. G. Weld reinforcement shall not exceed 3/16 inch (5 mm). H. When accessible for inspection, inside root penetration shall not exceed 1/8 inch (3

mm).



FIGURE A

ASME B31.9


NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here.

tc = the smaller of 1/4" (6.3 mm) or .7 x Tb









Attachment 12 - ASME B96.1 Acceptance Criteria 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







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 (0.8 mm).

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 (9.5 mm)or less 3/32" (2.4 mm) Greater than 3/8 inch to 3/4 inch (9.5-19 mm) 1/8" (3 mm)

Greater than 3/4 inch (19 mm) 3/16" (5 mm)



Attachment 13 - API 620 Acceptance Criteria 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 (6.3 mm) thick steel stamping shall not be used. CMTR’s 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.


with the WPS. F. Fit-up, shall be in accordance with the WPS except misalignment of butt welds

shall not exceed 1/16” (1.5 mm) for <=1/4” (6.3 mm) and 1/8” (3 mm) (or 25% plate thickness whichever is less) for plates over ¼” (6.3 mm). 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.



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

(10 cm) of length and the maximum diameter of each cluster or pore does not exceed 3/32 inch (2.4 mm).

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 (0.4 mm) for longitudinal butt joints and for welds that attach

nozzles, manholes, and clean out openings. 2. 1/32 inch (0.8 mm) for circumferential butt joints. D. No lack of fusion. E. No overlaps or abrupt ridges or valleys. F. No underfilled (weld cap) areas. G. Weld reinforcement (internal or external), where RT is not required, shall meet the

following:

PLATE THICKNESS

(INCHES)

MAXIMUM THICKNESS OF REINFORCEMENT (INCHES)

Vertical Joints Horizontal Joints 1/2 inch (12 mm) or less 3/32 (2.4 mm) 1/8 (3 mm)

Over 1/2 inch to 1 inch (12-25 mm) 1/8 (3 mm) 3/16 (5 mm) Over 1 inch (25 mm) 3/16 (5 mm) ¼ (6.3 mm)

H. Where RT is required, weld reinforcement shall not exceed 1/16” (1.5 mm) for

plates <=1/2” (12 mm), 3/32” (2.4 mm) for plates over ½” (12 mm) through 1” (25 mm), and 1/8” (3 mm) for plates over 1” (25 mm) thickness.

I. Weld repairs shall be feathered to a 4:1 taper.



Attachment 14 - API 650 Acceptance Criteria 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 CMTR’s are required by drawing or purchase order. Review drawing to determine if CVN testing is required, (if so, CMTR’s are required).

B. Joint preparation and cleanliness shall be in accordance with the WPS. Edges of

Plates to be welded shall not be manually gas cut. Vertical joints shall be staggered a minimum of five times the plate thickness.

C. 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 ½” (12 mm) 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” (16 mm) shall not exceed the lesser of 1/8” (3 mm) or 10% of the plate thickness, and shall not exceed 1/16” (1.5 mm) for plates 5/8” (16 mm) or less. For horizontal butt joints, the upper plate shall not project over the lower plate by more than the lesser of 1/8” (3 mm) or 20% of the plate thickness for plates 5/16” (8 mm) and over. For plates under 5/16” (8 mm), the projection shall not exceed 1/16” (1.5 mm). 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. 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 (0.4 mm) for vertical butt joints and for welds that attach nozzles,

manholes, clean out openings and permanent attachment. 2. 1/32 inch (0.8 mm) for horizontal butt joints. D. Surface porosity does not exceed one cluster (one or more pores) in any 4 inches

(10 cm) of length and the diameter of each cluster or pore does not exceed 3/32 inch (2.4 mm).

E. No lack of fusion. F. No under-filled (weld cap) areas. G. Weld reinforcement (internal or external) shall meet the following:

PLATE THICKNESS (INCHES)

MAXIMUM THICKNESS OF REINFORCEMENT (INCHES)

Vertical Joints Horizontal Joints 1/2 inch (12 mm) or less 3/32 (2.4 mm) 1/8 (3 mm)

Over 1/2 inch to 1 inch (12-25 mm) 1/8 (3 mm) 3/16 (5 mm) Over 1 inch (25 mm) 3/16 (5 mm) ¼ (6.3 mm)

H. Where RT is required, weld reinforcement shall not exceed 1/16” (1.5 mm) for

plates <= ½” (12 mm), 3/32” (2.4 mm) for plates over ½” (12 mm) through 1” (25 mm), and 1/8” (3 mm) for plates over 1” (25 mm) thickness.

I. Areas where temporary attachments have been removed shall be ground smooth

and visually inspected.

J. Peaking at vertical joints and banding at horizontal joints shall not exceed ½” (12 mm) when using a 36” (1 m) sweep board (for vertical joints, the sweep board must meet tank curvature).



Attachment 15 - AWWA D100 (Identical to AWS D5.2) Acceptance Criteria 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” (16 mm) shall not exceed the lesser of ¼” (6.3 mm) or 10% of the plate thickness, and shall not exceed 1/16” (1.5 mm) for plates 5/8” (16 mm) or less. For horizontal (and other secondary stress joints) butt joints for plates over 5/8” (16 mm) shall not exceed the lesser of 3/8” (9.5 mm) or 20% of the plate thickness. And shall not exceed 1/8” (3 mm) for plates 5/8” (16 mm) 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 (1.5 mm).

Where separation occurs, the weld size shall be increased by the amount of separation.






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 (0.4 mm) for vertical joints (lap or butt weld). 2. 1/32 inch (0.8 mm) 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:

Plate Thickness (Inches)

Maximum Thickness of Reinforcement (Inches)

Vertical Joints Horizontal Joints ½ inch (12 mm) and less 3/32” (2.4 mm) 1/8” (3 mm)

Over 1/2/ inch to 1 inch (12-25 mm) 1/8” (3 mm) 3/16” (5 mm) Over 1 inch (25 mm) 3/16” (5 mm) 1/4” (6.3 mm)

H. Welder’s identification shall be stamp (low stress stamps) adjacent to the weld at intervals not to exceed 3 feet (1 m)or the constructor may supply a record of welders employed on each joint.

I. Peaking at vertical joints and banding at horizontal joints shall not exceed ½” (12

mm) when using a 36” (1 m) sweep board (for vertical joints, the sweep board must meet tank curvature).



Attachment 16 - ANSI/AWS D1.1 / D1.6 Acceptance Criteria

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 (1.5 mm). 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 (1.5 mm), 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" (3 mm). In correcting misalignment, the parts shall be drawn in to a slope not greater than 1/2 inch (12 mm) in 12 inches (30 cm). 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. E. No under filled areas. F. Undercut: AWS D1.1 – For material less than 1” (25 mm) thick, undercut shall not

exceed 1/32” (0.8 mm) except a maximum of 1/16’ (1.5 mm) is permitted for an accumulated length of 2” (50 mm) in any 12” (30 cm). For material equal to or greater than 1’ (30 cm), undercut shall not exceed 1/16” (1.5 mm) for any length of weld. AWS D1.6 – For material less than 3/16” (5 mm), undercut shall not exceed



.010” (0.25 mm). For material equal to 3/16” (5 mm) and less than 1” (25 mm), undercut shall not exceed 1/32” (0.8 mm). 1/16” (1.5 mm) undercut is permitted for an accumulated length of 2” (50 mm) in any 12” (30 cm) for material greater than ½’ (15 cm) thick.

G. Butt weld reinforcement shall not exceed 1/8 inch (3 mm). H. Convexity of a fillet weld shall not exceed .07 times the actual width, plus .06 inch

(1.5 mm). 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 (1.5 mm) 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.



Attachment 17 - 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, note this in the remarks portion of the Daily Welding Report.

1.1 SOCKET WELDS, HALF COUPLINGS, WELDOLETS (UNDER 2" or 5 cm) 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" or 5 cm) 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" or 5 cm AND OVER), WELDOLETS (2" or

5 cm AND OVER) ETC. All butt welds, mitre welds, branch connections (2" or 5 cm and over), weldolets (2" or 5

cm and over) and slip-on flanges shall have a three digit weld number running consecutively throughout all lines contained in the modification. Each modification shall begin with weld 001 and numbered with the flow to the end of the line. Additional lines should continue with the next number and progress until all such welds are numbered. A log attached to the field welding isometric package should readily identify the last weld number used. If additional welds are needed, the next unused numbers will be assigned and logged. On modifications where it is not practical to pre-number the welds, the next consecutive number, as determined by the log, shall be used as the welding progresses.

1.3 ATTACHMENT WELDS Attachment welds shall be numbered using the nearest (upstream) piping weld as a part of

the weld number with the suffix "X1". In other words, a shoe welded between welds 021 and 022 will be numbered 021X1. Additional attachment welds in this area will be



numbered 021X2 and 021X3, etc. In the common case of a reinforcing pad, all welds will refer to the field weld number joining the pipe-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 an unique weld identification as required.

2.1 Double Jointed Welds - All random length piping being welded by the Site Pipe Shop into

double (or triple) lengths for ease in field erection shall be given a unique number. If the line number and line class are unknown at the time of fabrication these welds shall be given consecutive four digit weld numbers prefixed by "DJ". A log shall be maintained by the Pipe Shop Supervisor of the "DJ" weld numbers used to prevent duplication of weld numbers. All "DJ" weld numbers shall be hard stamped or etched across the weld in two locations 120 degrees apart, 60 either side of the welders stamp. These "DJ" welds shall be radiographed 100 % and stockpiled for eventual use. These welds will be tracked as "Unassigned Welds" and transferred when the actual modification, line number and class are known.

All random length piping being double (or triple) jointed in the Site Pipe Shop where the

modification number, line number and line class are known at the time of fabrication shall be given consecutive three digit shop weld numbers beginning with SW100 and numbered consecutively within that particular modification. These welds will be subject to the normal shop weld NDE requirements and welder control based on the line class requirements. These weld numbers shall be hard stamped or etched as described above with the exception of "DJ" prefix which will be "SW" in this case.



All random length piping double (or triple) jointed in the field for installation on a particular modification where the line number and line class are known shall be given consecutive field weld numbers within the modification. These numbers shall be hard stamped or etched by the Piping Supervisor for eventual location in the piping system. These welds shall be subject to the normal NDE and welder control for the line class at the time of production.

2.1.1 Piping Drawings All field welds on pressure piping (both pressure retaining and attachment welds)

shall be accurately located on the isometric drawing (or plot plan). Since other records will show the welder and the date or production (Daily Welding Report, Line Welding and NDE Record) this information is not necessary to include on the drawing.

Double joint ("DS") random length pipe welds shall be accurately shown on the

isometric, rack, or plot plan drawings in relation to the field tie-in welds.





Report No.
















Subcontractor Area


Sheet No.

Weld No. Type Weld

Size Wall



Inspected Remarks

Root Bal

Foreman

Date

Welding Inspector

Date





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POST WELD HEAT TREATMENT LOG ID W79002





Log No. Line No. Line Class Sheet No.

Mark No.

Weld No. Weld Type

Circuit No.

Completion Date

Initials

Welding Supervisor: Date:

Inspector: Date:


Name Name Name


Date Date Date





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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


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


Perform RT, UT, MT, PT, PMI, HT

Subcontractor Report as specified in the approved NDE Procedure

Per specification

Technical Supervision of NDE


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



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", found in the Nondestructive Examination (NDE) Manual – Fluor Enterprises, Inc., 000.511.0000. 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 000.509.0090and 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 000.509.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.

- 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 000.509.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 B31.3. 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.F79201and 000.509.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.

- 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.

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: (See the Nondestructive Examination (NDE) Manual – Fluor Enterprises, Inc., 000.511.0000) 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) 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

ATTACHMENTS

Attachment 1 – ASME B31.3 Random Radiography Requirements Reference



Attachment 1 – ASME B31.3 Random Radiography Requirements Reference

If ACCEPTABLE, allwelds in this welder'slot are considered to

be acceptable

Radiograph2nd Weld

If BOTH additionalwelds are acceptable,the balance of weldsin this welder's lot are

considered to beacceptable.

Radiograph3rd Weld

2nd WeldAcceptable

2nd WeldRejected

3rd WeldAcceptable

2nd WeldRejected

3rd WeldRejected

Radiograph6th Weld

Radiograph7th Weld

3rd WeldRejected

If BOTH additionalwelds are

ACCEPTABLE,consider the balanceof the welds in this lot

to be acceptable.

If EITHER of thesewelds are

REJECTED, all weldsby this welder in this

lot shall be 100%Radiographed.*

If ALL FOUR of thesewelds are

ACCEPTABLE,consider the balanceof the welds in this lot

to be acceptable.

If ANY of these fourwelds are

REJECTED, all of thewelds by this welder

in this lot shall be100%

Radiographed.*

Radiograph4th Weld

Radiograph5th Weld

Radiograph4th Weld

Radiograph5th Weld

Select weld fromwelder's lot of

welds **

Radiograph Weld

If REJECTED,select two

additional weldsfrom same lot

** Note: The first two pressure piping butt welds radiographed for eachwelder 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.





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WELDER B31.3 RANDOM RADIOGRAPHY CONTROL LOG ID W79201

Cum

ulat

ive

But

t W

elds

Dat

e W

elde

d

Weld Identification Examination Data

Defects And Disposition Drawing Number

(Line And Sheet)

Wel

d N

umbe

r

Dat

e E

xam

ined

Acc

epte

d (A

)

Rej

ecte

d (R

)

Tw

o B

31.3

Tra

cer

Wel

ds S

elec

ted

For

E

ach

Rej

ect

Defects and Disposition Symbols

B31.3 Interpretation Defects Repair Instructions

CK Crack GO Grind Out, remove area with defect

IP Incomplete Penetration GS Grind Surface

LF Lack of Fusion CW Cutout Weld, slice in weld plane

UC Undercutting R1 First Repair

P Porosity R2 Second Repair

S Slag Welder’s Name

CR Concave Root Surface Welder’s Symbol

EL Elongated Indication Prepared By:


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NONDESTRUCTIVE EXAMINATION REQUEST/RECORD ID W79202

Type Examination

Radiographic Ultrasonic Date:

Liquid Penetrant Hardness Testing Requested by:

Magnetic Partical PMI Site NDE Coordinator

Examination Data

Line No./Spool Sheet:

Location:

P No./Material:

Pipe Size/Schedule:

Acceptance criteria (code):

Location Line No/Sheet Weld No.

Welder Symbol

P No. / Material

Pipe Size/ Schedule

Date NDE

Completed

Note: The Following Identification Shall Be Plainly And Permanently Included On The Radiographic Film: Project No., Line No., Weld No., Welder Symbol, Date Of Radiography.


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RADIOGRAPHIC REJECTABLE DEFECTS STATISTICS ID W79203

Process Reporting Period From To

Rejectable Butt Welds

This Reporting Period Accumulative Job Totals

Number Of Butt Welds Radiographed

Number Of Butt Welds Rejected Percent Rejected

Number Of Butt Welds Radiographed

Number Of Butt Welds Rejected

Percent Rejected

Rejectable Defect Classification

This Reporting Period Accumulative Job Totals

Lack of Fusion Lack of Fusion

Cracks Cracks

Undercut Undercut

Incomplete Penetration Incomplete Penetration

Concave Root Concave Root

Slag Inclusions Slag Inclusions

Porosity Porosity

Elongated Indication Elongated Indication

Remarks

General Notes:

1. This exhibit is to be used to track weld quality levels as determined by butt weld radiography.

2. Keep separate records for each weld process, controlling code, random or 100% radiography.

3. Report high or increasing defect rates or repetitive defect types to the Jobsite Welding Specialist and the Construction Project Manager.


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WELDING/NDE STATUS LOG ID W79204

Line No. Line Class Sheet No. Revision

Weld No. Welder Symbol

Date Welded

RT/UT Accept Date

PT/MT Accept Date

PWHT Date

BH Date

Remarks

NDE Technician : Date:

Fluor QA Inspector: Date:


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FERRITE TEST REPORT ID W79205





Acceptable FN No.

Equipment Number or Isometric Drawing Number

Weld Number

Base Material Welder’s ID

Stamp

Location

00 900 1800 2700 AVG

Remarks

NDE Technician/Date Fluor QA Inspector/Date


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Subcontractor Area


Sheet No.

Weld No. Type Weld

Size Wall



Inspected Remarks

Root Bal

Foreman

Date

Welding Inspector

Date






POST WELD HEAT TREATMENT LOG ID W79002





Log No. Line No. Line Class Sheet No.

Mark No.

Weld No. Weld Type

Circuit No.

Completion Date

Initials

Welding Supervisor: Date:

Inspector: Date:


Name Name Name


Date Date Date





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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


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.F79301Form 000.509.F79302Form 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


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.F79301Form 000.509.F79302Form 000.509.F79304

Technically Supervise PMI

Subcontractor Quality Manager

_____ _____

Resolve Accept and Rejects

Subcontractor Quality Manager

Project Specifications Per Rejects



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

subcontractor’s own vendors/suppliers meets the requirements of the project specifications. Nonconforming items (alloys for which the required PMI has not been performed, items without the required PMI identification coding in place, and/or items without PMI documentation) shall be placed in a “Quarantine” area until such time as the nonconformance is resolved. The Subcontractor Quality Manager shall be responsible for obtaining disposition for incoming items found to be nonconforming.



• 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 manufacturer’s containers.

- Each container must have the AWS Classification, heat and lot number clearly marked. - Filler metal certification is required.



- 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 000.509.F79301, 000.509.F79302 or 000.509.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.



- 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 85012 – General Specification for Positive Material Identification (PMI)



Attachment 1 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 are not listed in Attachment 2, the alloy should be assigned a pre-determined color and included in the PMI plan as such.

(e) All PMI locations must have PMI verification color markings and the PMI Technician must apply

the markings at the time of actual PMI testing. Each component should be marked with a ½” (12 mm) 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.



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. (60 cm) diameter. 3. Manual welding---two samples from each girth seam equal to or > 24 in. (60 cm)

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 ¼” (6.3 mm) diameter paint mark on each ring

adjacent to the alloy designation of the ring gasket. 4.3 All ring joint gaskets must be checked out of the designated holding facility by the piping job

supervisor or foreman. 4.4 PMI Verification will be dependent upon the placement of the ring gasket in the flange so that

the Inspector can see the paint marking and the alloy designator for the ring. 5.0 Valves: 5.1 All alloy valves will be PMI tested in two (2) locations (Valve body and Bonnet). 5.2 The PMI Technician will mark each location with the designated verification color.



6.0 Welding Wire (Bare): 6.1 Bare wire shall be purchased in unopened manufacturer’s containers. 6.2 Each container must have the AWS Classification, heat and lot number clearly marked. 6.3 Filler metal certification is required. 6.4 The greatest of 5% or 5 pieces of welding wire shall be PMI checked from each container. 6.5 Coated electrodes do not require PMI checks prior to use. Deposited filler metal (SMAW) must

be PMI checked in the as welded condition. 7.0 Non-Conformances: 7.1 If there is a component in a PMI system that does not meet the necessary chemistry, that

component must be flagged with a color of flagging tape that does not conflict with other colors designated for NDE or PWHT. The PMI Technician must inform the Site Quality Manager immediately of any non-conformances and these must be corrected by the fabricator/erector as a matter of priority.

8.0 Verification/Audit of PMI Procedure

The Site Quality Representative must witness initial calibration/standardization of the PMI equipment at the start of each work period and observe PMI testing randomly during the work period to assure compliance with this procedure. These observations must be noted on the PMI point sheets by initialing the test points that are witnessed by the Site Quality Representative. The Site Quality Representative during the PMI operation must witness a minimum of 5% of all PMI testing. A weekly log will be maintained by the Site Quality Representative to verify the percentage of PMI testing observed.



Attachment 2 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)





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PMI INSPECTION RECORD ID W79301A





PMI Request By: Signature: Date:

Purchase Order Number: PMI Equipment Used:

PMI Performed By: Signature: Date:

PMI Performed By: Signature:

Company Performing PMI:

PMI Will Be/Was Performed At:

Examination Results/By Material Identification Item Or Tag No.

Sample Size Material Mill Cert. No. Heat Number Description

Examination Results/Analyzed Material Item Or Tag No.

Sample Size Material Mill Cert. No. Heat NumberChemical Composition Percentage

Cr Mo Ni Mn Ti V Fe Co Cu Nb W

Address Of Supplier Responsible For Rejection (s)

Additional Information

Manhours And Loss Incurred From Rejections, Etc.

PMI Supervisor

Signature/Date


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BULK MATERIAL POSITIVE MATERIAL IDENTIFICATION RECORD ID W79302A

Calibration/Standardization Witnessed:

Chemical Composition Percentage Site Quality Representative:

Cr Mo Ni MN Ti V FE Co Cu Nb W Print Name: Company: Standard Signature:

Analyzed Date:

Purchase Order Number: PMI Performed by (Print Name):

Fabricator’s Pipe Spool Drawing (s): Signature/Date:

Location Where PMI Performed PMI Analyzer Manufacturer & Model:

Item No.

QTY Line Item Description Type, Size,

Rating Material

Type Body Bonnet Stem

Material Verified PMI Remarks

Accept Reject


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PIPE SPOOL POSITIVE MATERIAL IDENTIFICATION RECORD “POINT” SHEET ID W79303A





Calibration/Standardization Witnessed:

Chemical Composition Percentage Site Quality Representative:

Cr Mo Ni MN Ti V FE Co Cu Nb W Print Name: Company: Standard Signature:

Analyzed Date:

PMI Points

Line Number and Class MK # Sheet

# Rev.

#

PMI Results PMI Technician Site Quality Representative Date

Accepted Rejected Print Signature Print Signature

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PIPE SPOOL POSITIVE MATERIAL IDENTIFICATION RECORD “POINT” SHEET ID W79303A

PMI Points

Line Number and Class MK # Sheet

# Rev.

#

PMI Results PMI Technician Site Quality Representative Date

Accepted Rejected Print Signature Print Signature

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WEEKLY PMI LOG ID W79304A

Calibration/Standardization Witnessed Start of Work Period

Date Number of Points Witnessed # of #

Job # Sketch # PMI Technician Site Quality

Representative

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HARDNESS TESTING SCOPE This procedure describes the functions to be performed in the performance of hardness testing. RESPONSIBILITIES


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

Personnel Training & Vision Test

Site Quality Manager 000.509.F79501

Yearly or each applicable.

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 (30 cm) 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.


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• 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


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VERIFICATION OF TRAINING FOR HARDNESS TESTING ID W79501

This is to verify that has been trained in the use of the Hardness

Testing Equipment described below or has successfully used this equipment within the past year.

Description of Equipment:

Site Manager/Site Quality Manager Date


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REPORT OF VISION TEST ID W79502

Employee Name: Social Security Number:

Type Chart Used:

Jaeger J1 @ 30 cm min. Jaeger J2 @ 30 cm min.

Snellen Equivalent to J1 @ cm min. Snellen Equivalent to J2 @ 30 cm min.

Near Vision Results:

Left Eye Right Eye

Passed

Failed

Corrected

Uncorrected

Remarks/Comments:

Printed Name, Signature And Title Of Test

Administrator Date Of Test

(Month (Day) (Year)


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HARDNESS TESTING REPORT ID W79503A

Project Project No. Date

Drawing No. Applicable Code/Spec Test Equipment Type/Proc. PWHT Before After

Weld No. Weld Type Material Size And

Thickness Hardness Test Results

Base Mat'l Weld Metal Reading #1 #2 #3 Ave.

BM

HAZ WM

HAZ BM

BM HAZ

WM

HAZ BM

BM HAZ

WM

HAZ BM

BM HAZ

WM

HAZ BM

BM HAZ

WM

HAZ BM

BM HAZ

WM

HAZ BM

Remarks

EQUIPMENT OPERATOR (PRINT)/DATE QC INSPECTOR (SIGN)/DATE


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