Qa/Qc Policies And Procedures Manual

Issue: Issue: 002-01 002-01 Issue Date: November 19, 2010

QA/QC POLICIES AND PROCEDURES PROCEDURES MANUAL MANUA L

ISSUED TO:_______________________________________ CONTROLL CONTROLL ED COPY NO.:____________________ NO.:___________________________ _______

QA/QC POLICIES AND PROCEDURES MANUAL

Issue: 002-01 Issue Date: November 19,

2010

TABLE OF CONTENTS Page Revision Introduction

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Management Statement of Commitment

5

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1. QC Organiza Organization tion and Responsibil ities

6

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10

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16

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4. Au 4. Audi di ts

21

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5. Mechanical Mechanical Projects

24

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6. Piping/Welding Piping/Welding Projects

29

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38

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40

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Organization Chart

2. Material Control    

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Procurement Control and Storage Vendor Surveillance Customer Supplied Materials

3. Document Management       

   

QA/QC Policies and Procedures Manual Quality Control Manual (Code Work) Drawing Drawings, s, Designs, Specificati pecifications ons and Revision R evisions s P roject Document Documentation ation and Package P ackage Development Development Documentation Responsibility Flow Chart Inspection/Test Plans Archive Storage

WPS / PQRs PQR s WPQs – Welder Testing PWHT Test Testiing

7. Nondestructiv e Examination Examination   

Classification of NDT personnel Trai Train ning ing rd 3 Party NDE Contractor

8. Pressure Pressure Testing Testing



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Page Revision 9. Calibr Calibr ation of Inspection/Test Inspection/Test Equipm ent

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10. Field Erection and Equipment

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11. Paint Paint and Insulation

45

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12. Civil/Structural Projects

50

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13. Instrument and Electrical Projects

57

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14. Subcontractor Selection Selection and Quality Quality Requirements Requirements

58

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15. Non-conformances

59

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ATTACHMENTS: A. Weld ers Respon Resp onsi si bi li ty Form For m B. Rod Slips C. Welders perfo rmanc e Qualif Qualif icati on Test



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INTRODUCTION

Thi This QA/ QA/QC QC Poli Policies cies and Proce Proced dures Ma Manual has be been cre created in order to esta stablish lish a Quality Control System for all service lines in the Plant Performance Services LLC or Inc. This manual manual is to be utilize utilized d on all mechanical, mechanical, welding, welding, Electrical E lectrical & Instr Instrum ument entation, ation, Civil and Structu tructural ral projects. projects. In using these these guidelines, guidelines, P 2S can can assure that all service lines are adhering to the same QA/QC standards, policies and procedures and in doing so, can ensure that our corporate policy of quality and customer satisfaction are fundamental in the completion of all projects. Thi This QA/ QA/QC QC Polic Policiies an and Proce Proced dures Ma Manual is to to be utili ilized zed in con conjunctio ction n with ith, and not in lieu of, the the existing existing P 2S Quality Quality Control ontrol Manual. Manual. The P2S P2S Quality Quality Control ontrol Manual dictates policies and procedures, in relation to A.S.M.E. and N.B.I.C. ju jurisd isdict iction ional fabrica ication ion and repairs. This This QA/QC QA/QC Polic Policiies an and Proce Proced dures Ma Manual is to be used to reference the requirements for projects in regard to quality control for all projects and sets standards for material procurement, installation procedures, documentation documentation requirements, requirements, non-destructive non-destructive examination examination procedures, final final Projec P rojectt Data Package P ackage requirement requirements s and Project P roject Data Package P ackage routing routing requirement requirements. s.

November 19, 2010



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1. QC ORGANIZATION/RESPONSIBILITIES

This procedure applies to the organization of those departments of P2S, which provide services or perform activities related to the implementation and completion of projects for all service lines. NOTE: This manual does not supersede any requirements for ASME Boiler and

Pressure Vessel Code work. The P2S "Quality Control Manual for Boiler and Pressure Vessel Code Work" shall be utilized for any ASME and/or NBIC Code Work that requires certification and stamping by P2S. General

This manual describes the Quality requirements and responsibilities for all service lines within Plant Performance Services (P2S) which shall include LLC. or Inc, as applicable. It includes organization, assignment of QA/QC responsibilities, and methods for accomplishing quality-related activities. The Company’s Quality Assurance/Control personnel have the responsibility, authority, and organizational freedom to identify quality-related problems and initiate remedial actions. President and General Manager

The President of P2S is ultimately responsible for the continued success of the company and for all phases of company operations. He directs the organization and has made the Regional President responsible for the operating aspects of construction, maintenance and installation projects. The Vice President has also directed the Corporate QC Director to implement and maintain a Quality Assurance Program to cover all activities of Plant Performance Services. Corporate QC Director

The Corporate QC Director formulates company-wide quality assurance policies, obtains approval of these policies by P2S management, and measures their implementation and effectiveness. He has delegated responsibility for quality assurance at the job site to the Regional QC Managers and/or Lead Inspectors. The responsibilities of the Corporate Quality Assurance Director include: 

Control of this QA/QC Manual.

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Monitoring of all upper class code activities that are the responsibility of P2S.

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Supervision of the Regional QC Managers.

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Performance of periodic project audits in order to ensure that the requirements of this manual are being complied with.

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Indoctrinating the Regional Vice Presidents, Director of Operations, and Regional QC Managers in the P2S QA/QC System requirements.



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Identifying quality assurance problems, initiating actions which result in solutions; verifying the implementation of solutions, and controlling further processing; ensure that installation of non-conformance items, deficiencies or unsatisfactory conditions are properly remedied and recorded.

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Defining and measuring the overall effectiveness of P2S QA/QC System.

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Reviewing and approving written procedures that implement this QA/QC System.

Regional Vice President

The Regional Vice President is responsible for all the operating aspects of construction, maintenance and installation projects within his region. The Regional Vice President is responsible for: 

Organizing the P2S staff.

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Planning and conducting operations.

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Administrative activities.

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Resolution of problems concerning QA/QC.

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Successful completion of projects.

Director of Operations

The Director of Operations is responsible for the overall planning and conduct of site installation, fabrication, and erection activities. He organizes and directs the staff, assures the availability of suitable manpower and skills, and coordinates company and subcontractor resources to perform the work and assure that the work is accomplished as required by contract. The Director of Operations shall be responsible for implementing the requirements of this manual and shall coordinate with the Regional QC Manager on all matters that affect quality activities. Project Manager / Superintendent

The Project Manager / Superintendent or his/her designee is responsible for supervising the receipt and storage of material to be used for the work, planning fabrication activities, obtaining required manpower thru Human Resources and skills to perform the work, and directing the project personnel. He is also responsible for monitoring work activities to meet QA/QC requirements with site QC, safety requirements and productivity targets, as well as notifying the Site Lead QC Inspector of any quality related questions or concerns Regional QC Manager

The Regional QC Manager for each service region shall be responsible for coordinating the activities of the Site Inspection Staff under his/her direction. This includes the assignment of Site Lead QC Inspectors for each project, assuring compliance of P2S and customer QA/QC policies by the Site Lead QC Inspectors,



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assuring compliance with State and/or governing agency laws and regulations and the review and archiving of completed Project Data Packages. The Regional QC Manager is responsible for developing and implementing the training programs for project management, supervision, craft and QC personnel that assure execution of the assigned work to the customer specifications. The Regional QC Manager, or his/her/her designee, is responsible for insuring a project specific QC Plan or Quality Execution Plan is developed and submitted to the client prior to starting work. Site Lead QC Inspector

The Site Lead QC Inspector shall develop, implement, administer, and maintains the Quality Control activities at the site. He or She tailors the site QA/QC program to encompass regulatory and customer requirements, construction codes and standards and P2S quality control standards. The responsibilities of the Site Lead QC Inspector include: 

Verifying that the requirements of this QA/QC Program are implemented.

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Contacting the QA/QC Regional Manager on the interpretation of corporate policy and directives.

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Maintaining liaisons with the P2S Project Manager and his/her staff as well as the customer Inspector or representative.

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Assuring and certifying that the project has been accomplished in accordance with the applicable specifications.

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Transmitting the final Data Package to the customer or his/her designee and to the P2S Regional office for archiving.

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Scheduling inspections and examinations with sub-contractors and the customer Representative.

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Identifying quality assurance problems, initiating action, which results in solutions, verifying the implementation of solutions and ensuring that nonconforming items or unsatisfactory conditions are properly remedied and recorded.

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Receipt inspection of all materials.

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Inspections and examinations of fabrication and installation processes to ensure that activities conform to the applicable Code and the Design Specifications and Drawings and completing the applicable forms which verify these activities.

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Reviewing control drawings and assigning inspection hold points.



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QUALITY ORGANIZATIONAL STRUCTURE CHART

QA/QC Director (P2S)

QC Manager Western Region (P2S)

QC Manager Eastern Region (P2S)

QC Manager Fabrication (P2S)

QC Manager Central R egion (P2S)

QC Manager Power Services (P2S)

Site QC Lead (P2S)

Site QC Lead (P2S)

Site QC Lead (P2S)

Site QC Lead (P2S)

Site QC Lead (P2S)

QC Inspectors (P2S)

QC Inspectors (P2S)

QC Inspectors (P2S)

QC Inspectors (P2S)

QC Inspectors (P2S)

2. MATERIAL CONTROL Procurement Scope

This procedure covers the ordering, receiving, identification, storage and distribution of materials. General

Materials for all projects will be purchased in accordance with the P2S and/or customer drawings, customer specifications, the terms of the contract or the applicable code Material Purchasing

Material shall be purchased using a Purchase Order/Materials Requisition and a copy shall be supplied to the Site Lead QC Inspector and retained. All materials shall be purchased in accordance with the requirements of the applicable Bill of Materials and/or customer specifications. Material substitution is not allowed without the approval of the Site Lead QC Inspector and concurrence of the customer.



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Welding Consumable Purchasing

All weld material, including fluxes, shall be purchased by the Project Manager or his/her designee and shall meet the requirements of this manual, ASME Section II, Part C and/or the customer requirements. “Unspecified” materials shall meet the requirements stated in the customer specification. Welding consumables shall be inspected upon receipt by the Project Manager or his/her designee and by the Site Lead QC Inspector, and checked against the original purchase documents to verify the material received is the same as the material ordered. All welding material, if accepted, shall be stored under proper environmental conditions, and protected from damage. Welding materials received in damaged containers, or whose containers become damaged later, shall be returned to the supplier or discarded. All welding material shall be purchased, received and stored per the requirements set forth in the Code (ASME Section II, Part C), this manual and the documentation shall be retained. Material Control and Storage Scope

To establish material storage and handling procedures in order to avoid damage, deterioration and misplacement. General

All material will be received and shall be segregated pending receiving inspection by the Project Manager or his/her designee and/or Site Lead QC Inspector. Receiving Inspection

The Site Lead QC Inspector, using the jobsite copy of the Purchase Order/Material Requisition documents, shall examine all material for basic dimensions, Code and/or Specification required markings, physical condition, and quantity. For all products requiring evidence of their chemical and physical characteristics by the referencing customer specification (Normally Plate), the Site Lead QC Inspector shall review the Material Test Reports (MTR) to ensure they meet the requirements listed in the customer specification and/or ASME Section II for the respective material specification, prior to use. When the received material is deemed acceptable, the Site Lead QC Inspector shall sign and date the MTR or other supplied documentation and retains copies of said documentation. The material is then released for fabrication or stock inventory, as applicable. If the Material that does not meet all the Purchase Order/Material Requisition requirements it shall be paint marked or tagged "Do Not Use". This material shall be handled as a nonconformance and a NCR will be written per the requirements of this manual. The Project Manager or his/her designee and the Site Lead QC Inspector shall be responsible to ensure that only material that has gone through the proper receiving inspection, and has been found acceptable, is released.



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Material Storage

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 as 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



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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, airborne 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, weather tight,

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



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with uniform heating and temperature control, or its equivalent, to prevent condensation and corrosion. Minimum temperature shall be 40F and maximum shall be 140F or less if so stipulated by the manufacturer. Level C - Items shall be stored indoors, or equivalent, with all provisions and

requirements as set forth in Level B items except that heat and temperature control is not required. Level D - Items may be stored outdoors in well-drained areas marked and

designated for storage, preferable gravel-covered or paved, and reasonable removed from the actual construction and traffic so that possibility of damage from construction equipment is minimized. Items shall be stored on 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.

Welding Consumable Storage

All welding consumables shall be segregated by using the ASME Section II, Part C or proprietary classification (E7018, ER70S-2, etc.) and will be stored in areas protected from moisture. The Project Manager or his/her designee is responsible for storage and issuance of the correct filler material to welders. All welding consumables are to be controlled and distributed by authorized personnel only.



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Welding materials shall be stored, in the original sealed containers, in a dry storage space designated for that purpose. All opened containers of Low Hydrogen type welding electrodes are to be kept in a heated rod oven. Low hydrogen type weld electrodes, when issued, shall be placed in portable heated ovens. The temperature in these ovens shall be maintained in accordance with the electrode manufactures recommendations or ASME Section II, Part C. Unconsumed low hydrogen electrodes shall remain in heated storage at all times or shall be discarded. In lieu, of discarding the rod it may be segregated and designated for "Non-Critical" use. Vendor Surveillance

In order to ensure compliance with P2S standards and customer specifications, as well as the requirements of the applicable code, vendors will be monitored on an “as required” basis. The Site Lead QC Inspector will be notified by the Project Manager or his/her designee, preferably before order placement or sub-contract issuance. All subcontractors must be qualified in advance through Procurement/Contracts. The Site Lead QC Inspector in coordination with the client will make the determination as to the necessity and/or the extent of vendor surveillance requirements. Customer Supplied Material

When materials and/or welding consumables are supplied by the customer, all necessary steps are to be taken to ensure that they are identified and verified as to material type to comply with the appropriate customer specification. Upon receipt from the customer, materials and welding consumables are to be stored and distributed in accordance with the requirements of this manual. 3. DOCUMENT MANAGEMENT QC Manual Scope

This procedure describes the preparation, review, approval and distribution of this manual and any revisions as required. It defines the system established to transmit, distribute and control the QA/QC Policies and Procedures Manual and any subsequent revisions in order to ensure that the latest revision is used at the location where the activity is performed. General

Preparation, review, approval and implementation of this manual shall be the responsibility of the Corporate QC Director. Procedure

All QC Manuals shall be identified on the title page as "Controlled Copy" or "Uncontrolled Copy”. Only controlled copies shall be issued to employees and shall



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be numbered for identification and control purposes. Uncontrolled copies are for issue to personnel outside this organization, such as current and potential customers. Any “Uncontrolled Copy” manuals shall be current at the time of issue, but will not be updated thereafter without a written request from the manual holder. A record of the manual number, name of the recipient, and the date of issue of all “Controlled Copy” manuals will be maintained. Revisions to the QA/QC Manual are prepared, approved, distributed and controlled in the same manner as the original issue QA/QC Manual. Revision to this manual shall be by complete sections, except for forms and attachments, which may be done individually. The next revision level, with effective date, shall be recorded on the “Table of Contents” page and each page of the revised section(s) or form(s). The latest revised paragraph(s) shall be identified with a vertical line in the right margin of the page for easy identification of the revised requirement(s). At the option of the QA/QC Director, this QA/QC Manual may be advanced to the next edition level, as indicated on the Cover Page, and the revision level of all sections and exhibits may be returned to "0", whenever there are substantial changes made to the overall manual content or structure. Drawings , Designs and Specifi cations Scope

This procedure applies to customer supplied drawings, specifications, work orders and other associated documents, procedures and instructions as well as any subtier vendor documents. It defines the system established to transmit, distribute and control documents and subsequent revisions in order to ensure that the latest revision of these documents are used at the location where the activity is performed General

The Project Manager or his/her designee will be responsible for controlling all document distribution. Procedure

Documents shall be distributed as a minimum to the Site Lead QC Inspector and others as determined by the Project Manager. Revisions to controlled documents will be distributed to The Project Manager or his designee. The superseded document shall be destroyed or returned. The Site Lead QC Inspector shall maintain a Document Log showing the document name, latest revision and date received.



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Records Scope

This procedure applies to the generation, storage and maintenance of jobsite records that are generated for and/or by P2S. Records which shall also include all Quality Records that are documented evidence that construction conformed to requirements of the Design Specifications, Code and/or jurisdictional requirements. General

Designated P2S Site QC Inspection staff will be responsible for the preparation of jobsite records and are responsible for maintenance and storage of these jobsite records. Records that are identified as “Confidential” in any confidentiality agreement shall be controlled in accordance with specific procedures established by that agreement. Quality Records are documented evidence that construction conformed to requirements of the Design Specifications, Code and/or jurisdictional requirements. Quality Records shall include: 

Test and inspection reports

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Radiographs

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Material and equipment certificates required by specification

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Equipment maintenance/preservation records

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As-built drawings

Procedure Site Lead QC Inspector

In coordination with the Project Manager and any other group manager who receives and/or generates quality records, identify the quality records that will be retained during construction and identify the record custodian that will be responsible. A Record Retention Schedule should be developed prior to the start of construction to meet the requirements of that project. The Site Lead QC Inspector in coordination with the Project Manager or his/her designee will identify all Quality Records (or copies of records) that will be retained for storage in Archives. Identify this on a Quality Records Control form.



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Maintain the Quality Records Control form current and, if possible, before records are received on site or generated. Site Records Custodian

Establish and maintain a filing system for inspection, testing, and other jobsite/QC 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 a Quality Records Control Form. Prior to filing the record the custodian shall review the documents to verify the following: 

Documents are appropriate

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Documents are complete

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Entries are correct

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Documents are legible

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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 P2S P urchasing 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. Record Turnover

Maintain the jobsite records until they are requested for project turnover and/or sent to Archives. NOTE: Any subcontractors that are used will retain their records until they are

requested by P2S. The Site Lead QC Inspector 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 completion/system turnover will be retained by P2S until system acceptance by customer. After system acceptance by customer, this documentation will be transferred to customer under separate correspondence. A copy of this supporting documentation will also be sent to the



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P2S Regional QC office for storage. Completed QC job files will be stored per the company record retention requirements. Due to the fact that there is a minimum of documentation requirements for all projects, the following matrix (Exhibit 5A) should be referenced in order to determine the personnel responsible for this documentation in the event that there is not a Q.C. representative on the project. The P2S representative will be responsible for compiling the documentation and ensuring that all parties required receive their copies of the “Data Package”. The “Data Package” requirements are outlined in the specific service line sections of this manual. In the case of code repairs a Q.C. representative will be required on the project. As outlined in the Quality Control Manual for boiler and pressure vessel code work.

Project Documentation Responsibi lity Flow Chart Quality Control Representative

Project Manager

Project Superintendent

General Foreman

Foreman

Craftsmen

Exhibit 5A

Inspection/Test Plans

Normally Inspection/Test Plans are provided by the client to P2S to develop work scopes and NDE requirements. In the event that Inspection/Test Plans are not provided by the client and are requested by the client, P 2S QC will develop this document and receive written concurrence of approval from the client.



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Inspection/Test Plans do not necessarily have to be developed for every work scope item, unless requested by the client. They can be developed for a group of items such as vessels, piping, exchangers, etc. It is necessary to have the client review and acquire written approval of all Inspection/Test P lans prior to starting work. Ar chive Storage

The original of the Inspection/NDE records (Data Package) for a project needs to be sent to the respective P2S Regional QC Manager for storage. A copy(s) of the records should be given to the client unless they request the original. Records should be filed neatly in an appropriate shipping container. Each container shall be labeled with the job number, client name, location and month/year of project. A CD of the weld log shall be sent to the respective Regional QC Manager for storage. The CD shall be labeled as the box. Inspection/NDE records (Data Package) will be kept for a period of 5 years unless specified otherwise by the client, Code or jurisdictional requirements. 4. AUDITS Scope

This procedure describes the responsibilities and activities for quality audits of P2S quality-impacting activities. Audits are performed to determine the effectiveness of the P2S Site Quality Manual implementation. General

An audit is a planned and documented activity performed to determine, by evaluation of objective evidence, compliance with the established Site Quality Manual. Project/Job Audits (PA)

The Regional P2S QC Manager is responsible for performing project/job Quality 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 Regional QC Manager. Project/job audits will be performed by onsite QC personnel with periodic audits being performed by the Regional QC Manager or his/her designee.



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Regional QC Audits (RA)

The Corporate P2S QC Manager is responsible for performing audits of the P2S Regional QC offices to measure compliance of those areas to corporate QC standards and practices. The procedure will follow the same format as the Project/J ob Audit methodology as applicable. Procedure Regional QC Manager (PA)/Corporate QC Manager (RA)

Establish a schedule for conducting Quality Audits. The schedule should show the audit dates or internal activities to be assessed. Performance on previous audits should influence the re-audit schedule. The Project/Job audit (PA) schedule shall be a developed at the beginning of the

project, based upon P2S Business practices and O&M Management Toolbox guidelines and or specific client requirements. Develop an audit plan by reviewing the Quality Program 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 on site surveillance. Review and concur with the plan, checklist, marked up procedures or other acceptable method of identifying items to be verified. Audi tor

Execute the audit in accordance with the established checklist. When a deficiency is found, investigate to the extent necessary to determine if the deficiency is isolated. If it is isolated and corrected during the audit no additional Non-Conformance Report (NCR) is required. If it is not isolated or cannot be corrected during the audit, complete an NCR. Document the reference, procedure number, specification number, drawing, etc. and the requirement that was not complied with. Describe and document the deficiency that was noted during the audit. During and upon completion of the audit, notify the supervisor of the audited area of all deficiencies found. Prepare an audit summary report and report finding to the Site QC Manager (PA)/Regional QC Manager (RA) for processing.



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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. 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 Lead QC Manager (PA)/Regional QC Manager (RA)

Review and, upon concurrence, sign the audit summary report, attach all "Audit Findings", and address to the Project Manager (PA)/Regional Director of Operations (RA). Review results of the audit with the Project Manager/Regional DOO. Additional distribution should be as requested by the aforementioned. Maintain files of all audits. These files should include: 1)

Audit summary with attached audit finding and checklist/marked up procedure.

2)

Copies of objective evidence obtained during the audit.

3)

Copies of Audit finding reports closed upon completion of disposition and verification and acceptance by an auditor.

Assign responsibility for disposition of deficiency and record on NCR. Sign and date NCR upon documenting or concurring with the disposition (action taken to correct the deficiency). Copies of all audit summary reports shall be forwarded to the Corporate QC Manager for review and storage. Audi tor

Sign and date NCR upon acceptance of the disposition. Sign and date NCR, upon completion and satisfactory verification of action taken to correct the deficiency.



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Generate a status report of all audit findings that have not been completed and accepted by the Site QC Manager (PA)/Regional QC Manager (RA) and address it to the Project Manager (PA)/Regional DOO (RA). A summary report of open audit findings shall be forwarded to the Corporate QC Manager. A bi-weekly review meeting will be conducted between the Regional QC Manager and the Corporate QC Manager 5. MECHANICAL PROJECTS Scope

This section provides procedures for inspection of all activities relating to mechanical projects. Procedure

Mechanical maintenance, including disassembly, cleaning, re-assembly and hydro testing for exchangers, fin fans, towers and drums, shall be inspected in accordance with the applicable code, customer specification and contract parameters. Standard turnaround practices will also be employed in providing this inspection. All P 2S personnel on the project will be cognizant of all quality aspects in order to assure quality and customer satisfaction. Preparation and Disassembly

For all pressure vessels, (exchangers, fin fans, towers and drums) the original code of construction shall be established before the commencement of any work in order to determine if the repair or required maintenance will require any special inspections or procedures. If the vessel was originally constructed to A.S.M.E. Section VIII, (“U” Stamped) refer to P2S Quality Control Manual for Code work. Documentation pertaining to work shall be retained. For Exchangers, the TEMA (Tubular Exchanger Manufacturers Association) design type shall be determined (Refer to TEMA chart), in order to effectively establish the proper work procedures to be utilized when performing maintenance on the exchanger. Documentation pertaining to work shall be retained. In order to ensure a correct re-assembly, all components will be match marked and stenciled prior to disassembly. Requirements for passivation, special washes, such as soda ash wash, or for any special testing medium such as heated water or condensate, shall be determined before beginning any disassembly activities. All isolation or test blinds shall have a gasket installed on both sides unless the client objects for safety reasons. (When working exchangers, the existing gasket



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may be used on the non-exchanger side for isolation purposes provided that the client has no objections.) Repairs and A ssembly

The Project Superintendent, or his/her designee, shall ensure that all gasket surfaces are inspected and immediately report any damage to the P2S Site Lead QC Inspector. The P2S Site Lead QC Inspector will then report the damage to the Customer Representative. The P2S Site Lead QC Inspector shall inspect all components before re-assembly to check for any damage or non-conformances. An Exchanger Sign-Off Form or a Vessel Closure Form shall be signed off by a P2S and a Customer Representative before any re-assembly can begin. All components, which were repaired or re-worked, will be inspected by the P2S Site Lead QC Inspector at the completion of the repair or re-work in order to assure compliance with the Code and customer specifications and requirements. Testing

All pressure tests (hydrostatic or pneumatic) shall be performed as required by the applicable code or the customer specification. Care must be taken to minimize the effects of adverse weather conditions such as extreme cold (freezing) or extreme heat (over pressuring). A Hydrostatic Test Form will be completed and signed off by the P2S Representative and the Customer Representative before the release of pressure. Final Bolt-Up

The Site Lead QC Inspector or Project Superintendent, or their designee, shall be responsible for the inspections to assure proper bolting sequence and also for the installation of the proper gasket. Bolts shall be torqued (if required) in accordance with the applicable customer specification or written instruction. The Project Superintendent, or his/her designee, and the Site Lead QC Inspector shall be responsible for performing the inspections for proper bolting and for the installation of the proper gaskets per the customer specification. During bolt-up of nozzles, drains, etc., the gasket must line up evenly with the inside bore of the accompanying flange with no portion of the gasket extending into its bore. When tightening the bolts, the flange faces must be kept parallel and all bolts must be tightened uniformly and in a criss-cross sequence. This criss-cross sequence starts by lightly tightening the first bolt then moving directly (180 degrees) across the circle for the second bolt, then moving ¼ (90 degrees) around the flange



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to tighten the third and directly across (180 degrees) to tighten the fourth. This sequence is to be continued until all bolts are tightened. The bolts are to be snugly tightened during the first round of the sequence, with care being taken to not over tighten. If over tightening occurs during this first round of the sequence, it is possible to tilt the flanges out of parallel with one another and cause the gasket to be pinched or otherwise damaged which can cause a leak. Upon completion of the tightening sequence, the Craft Foremen will check the flange make-up for tightness and contact the Site Lead QC Inspector. At that time the Site Lead QC Inspector will verify that the bolts are tight by means of a hammer test and will also verify the correct bolt size and length. If the bolts were torqued, the Site Lead QC Inspector will verify 10% of all nuts for verification of proper torquing. The flange will at that time be marked, either with flagging tape or paint, to indicate that the bolt-up has been completed and inspected. All of these procedures will be completed per the customer specification. The Site Lead QC Inspector will complete a sign-off sheet for all final flange makeups and include the sign-off sheet in the final Project Data Package. The customer representative will be granted the opportunity to witness all final bolt-ups. A Customer Representatives signature is required on the final bolt-up sign-off sheets. In Process Inspection

The Project Superintendent, or his/her designee, and the Site Lead QC Inspector shall: 1)

Monitor the in-progress disassembly, handling of components, cleaning, assembly and installation of the equipment in accordance with the specified requirements.

2)

Complete the required documentation, as applicable, of these inspections utilizing P2S QA/QC Forms. These documentation activities shall be performed concurrent with each phase of inspection as noted on the documents.

3)

Inspect anchor bolts for proper locations and elevations prior to setting equipment on their foundation and/or support.

4)

Inspect completed equipment when the responsible craft supervisor indicates that all required and/or associated work is complete. An equipment punch list should be completed at this time, noting any deviations and/or nonconformities found during the inspection. The punch list shall be forwarded to the responsible craft supervisor for corrective action. Upon completion of the punch list items, the punch list shall be signed by the responsible supervisor and returned to the Site Lead QC Inspector as notification to re-inspect the listed items. Upon its return to the Site Lead QC Inspector, the completed



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punch list items shall be inspected and if all are found to be satisfactory, the appropriate client representative shall be notified that the effected equipment is complete. 5)

Ensure that the Customer Representative, when required by the Purchase Order, is present to technically supervise and/or inspect any applicable work activities.

Project Documentation and Final Project Data Package

Documentation of inspection activities shall be performed in accordance with the requirements listed above and compiled into a final P roject Data Package. Upon completion, the Site Lead QC Inspector, or his/her representative shall review the Project Data Package, in order to ensure completeness and compliance with P2S and customer requirements. Upon completion of the project, the required number of copies of the final Project Data Package shall be given to the customer. The original shall be sent to the Regional QC office of P2S for archiving. The P2S Regional QC Manager of each area is responsible for the archiving and control of these Data Packages. DOCUMENTATION REQUIREMENTS FOR MECHANICAL PROJECTS Scope

All projects completed by P2S have minimum documentation requirements, which must be completed and compiled into a final Project Data Package. The required number of copies of the final Project Data Package will be transferred to the customer, who at that time is to sign a Data Package Transmittal Form and the original Data Package is to be sent to the Regional QC office for archiving. The following is a list of minimum documentation requirements for Mechanical P rojects. If requested, customer supplied documentation may be utilized after review and will suffice in lieu of P2S forms. Copies of these forms are to be signed by a P2S representative and are to become a part of the completed Project Data Package. Mechanical Project Documentation 1)

Daily Project Logs (DPL-1)

2)

Pressure Test Reports (HY D-1)

3)

Valve Logs for Manual Valves, Control Valves and PSV’s ( MVL-1, CVL-1 & PSVL-1)

4)

Exchanger Report and Tracking Logs or Exchanger Sign-off Forms (ETL-1 or ESO-1)

5)

Tower Report and Tracking Logs or Final Closure Sign-off Forms (TRTL-1 or FCSO-1)



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6)

Drum Report and Tracking Logs or Final Closure Sign-off Forms (DRTL-1 or FCSO-1)

7)

Flange & Gasket Sign-off Forms (FGSO-1)

8)

Pre-Hydro Punch Lists (PRHP-1)

9)

Post-Hydro Punch Lists (POHP-1)

10) Mechanical Completion Forms (MCF-2) Exchanger Hydro Test Procedure Shell side Test: 1)

Isolate the exchanger except for the high point vent on shell side by blinding or closing valves as long as it can be assured no leakage will occur thru valves. Testing against closed valves must be approved by the client.

2)

Install calibrated test pressure gauge or pressure chart recorder on shell side. Pressure gauge range to be not less than 1 ½ times or more than 4 times the maximum test pressure.

3)

Remove the channel cover from at least one side.

4)

Open high point vent and fill exchanger shell with water (Chlorides <50ppm or per client specs)

5)

Allow water to flow out of vent for a minute to insure all trapped air escapes then close and plug high point vent.

6)

Pressurize the shell side to test pressure specified by the client, block-in.

7)

Pressure may have to be bumped up several times to ensure all trapped air removed.

8)

Check for leaks at tube joints in tube sheet or from tubes; monitor the test pressure.

9)

Test pressure shall be held for at least 30 min. or as specified by client. a) If repairs are required, retest after repairs are made. Tubes to be plugged must be punctured or cut past the tube sheet.

10) If a pressure gauge is used, document the initial and ending pressure reading. Tube side test: 1)

Isolate the exchanger except for the high point vent on tube side by blinding or closing valves as long as it can be assured no leakage will occur thru valves. Testing against closed valves must be approved by the client.

2)

Install calibrated test pressure gauge or pressure chart recorder on tube side. Pressure gauge range to be not less than 1 ½ times nor more than 4 times maximum test pressure.



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3)

Open low point valve on shell side of exchanger.

4)

Open high point vent on tube side and fill exchanger tube side with water (Chlorides <50ppm or per client specs)

5)

Allow water to flow out of vent for a minute to insure all trapped air escapes then close and plug high point vent.

6)

Pump tube side to test pressure specified by client, block in.

7)

Pressure may have to be bumped up several times to insure all trapped air removed.

8)

Watch for water drips from low point valve on shell side or anywhere else; monitor the test pressure.

9)

Test pressure shall be held at least 30 minutes or as specified by client.

10) If repairs are required, retest after repairs are made. *

Tubes to be plugged

must be punctured or cut past the tube sheet. 11) If a pressure gauge is used, document the initial and the ending pressure

readings. *

A shell side test may be performed to determine if leak is at tube-to-tube sheet joint or in the tube itself.

6. PIPING/WELDING PROJECTS Scope

P2S performs many different types of welding projects, all of which require different types of inspections, documentation, non-destructive testing and reporting to various jurisdictions and entities. For projects, which involve work performed to governing Codes such as; (A.S.M.E. B31.3, AWS, etc.) there are also minimum standards, which must be adhered to. The following requirements apply to all projects where welding is to be performed by P2S. Commencement and Conclusi on of Welding Projects

The following sections, below, are to be adhered to and completed before the commencement, and after the conclusion of all welding projects. Weld Procedure Specific ations

Prior to the commencement of any welding on any project, the site Quality Control representative or project supervisor is to obtain a written Weld Procedure Specification (W.P.S.) and supporting Procedure Qualification Record (P.Q.R.) from the Quality Control office. A W.P.S./P.Q.R. is to be obtained for all base materials to be welded with consideration to be given to all variables such as base material thickness, filler metal requirements, pre-heat and post-weld heat-treatment requirements and backing. These are a few of many variables to be considered



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when requesting a W.P.S./P.Q.R. These welding procedures shall be available to all welders and welding operators. Welder Perform ance Qualifi cation Records

Before any welder or welding operator can commence with any welding, a written Welder Performance Qualification record (W.P.Q.) for that individual is to be obtained from the Q.C. office. If a request has been made for these items by the customer, copies are to be presented to the customer; additionally copies are also to be preserved in a project file to be included in the completed Data Package. Before any certified welder can start welding, please have him/her read and sign the Welders Responsibility form see Attachment A. Welder Perform ance Qualifi cation Requirements Scope

Purpose is to describe an outline the requirements for Welder Performance Qualification Tests. Purpose

To maintain consistent Welder Performance Qualification testing throughout P2S, to maintain an accurate Welder Continuity Log, and satisfy all requirements of ASME Section IX. Welder Performance Qualification Tests

See Attachment C Welder Performance Updating

In order to keep our Welder Continuity Log current, all welding performed by P2S employees is to be reported utilizing the Welder Performance Update Form (P2S Form No. WPUF-1[ESM1]) at the conclusion of all projects. This form updates welding per process used for each welder. After completion of the form it is to be sent to the Sand Springs QC office. Special Requirements

Prior to the commencement of all projects the Project manager, or his/her designee, will, preferably during the pre-job “Handoff Meeting”, prepare a list of “Special Requirements” for the project. All aspects of the project will be addressed in these “Special Requirements’, however, the QC items will include, but will not be limited to: 1)

Extent and type of non-destructive testing. (R.T., P.T., P.M.I., Hardness Testing, etc.)

2)

Special hydrotest requirements. (De-mineralized water, etc.)

3)

Code related repairs, alterations, etc.



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4)

Special documentation requirements requested by the customer.

5)

Post-weld heat-treatment requirements.

Piping Systems Test Packages

Piping test packages (Hydro Packages) will be compiled prior to the start of fabrication and/or erection of piping systems. These test packages are to be utilized by the P roject Superintendent, or his/her representative, for erection purposes and by the Site Lead QC Inspector in order to ensure that all N.D.E. has been completed. Use of the test packages during the erection and testing of the piping systems, will ensure that all piping is installed correctly and completely and that the customer specifications and the applicable codes are satisfied. Upon completion of the test packages by the P2S Site Lead QC Inspector, and prior to installation of the piping, the customer shall review the packages in order to approve test boundaries, test pressures, and all other content of the packages. All test packages shall be “walked down” by the P2S Site Lead QC Inspector, P2S Project Superintendent and, if required, the customer representative. At that time, all blind points shall be identified with tags, which indicate the test package number. The correct blind and hydro-gaskets should also be wired to the blind point along with the proper bolting, if required. This tagging will serve the purpose of locating the blind points for both testing and isolation purposes. All “tie-in” points of the new piping systems shall be tagged with the “tie-in” number. For identification purposes, all piping to be demolished is to be painted with a stripe, preferably with a fluorescent, or at least, a bright color, which can be easily identified. Upon completion of the installation the test packages may be used by painters, insulators, etc. in order to verify that the piping system is completed and ready for the next phase of construction. The “Test Packages” are to consist of the following: 1)

Customer Drawings (Weld Maps)

2)

Weld Log

3)

P&ID’s (If available)

4)

N.D.E. Reports (Penetrant Testing Reports, Radiographic Reports, etc.)

5)

Pre-Hydro Punch List

6)

Hydro Sign-off Form

7)

Post-Hydro Punch List

8)

Mechanical Completion Form

9)

Non-conformance Reports



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Installation of Piping Systems

All piping will be fabricated/erected as shown on the design drawings and in accordance with applicable construction code, customer specifications and contract parameters. All P2S personnel on the project will be cognizant of all applicable aspects in order to ensure quality and customer satisfaction. All piping spools, random lengths of pipe, and associated components will be examined prior to use or installation to ensure compliance with the applicable code, design and specification. Any material or equipment that does not conform to the requirements of any of these standards will not be installed unless authorized by the customer in writing. In order to ensure that all materials remain traceable, the product specification and heat number shall be transferred to all material sections prior to any required cutting. This shall apply to all plate, pipe, fittings, etc., to be used as a pressure retaining part or an attachment to a pressure part regardless of the code of construction. A36 materials used for structural steel are exempt from this requirement. A Non-conformance Report shall be issued for any component or components associated with the fabrication and installation, which do not conform to the code or specification. Such items will be placed on “hold” and removed from the immediate work area, where reasonably possible, to prevent inadvertent use. Such items will be marked “DO NOT USE”, until the Non-conformance has been rectified. (Refer to section P2S-QC-5 of the P2S QC Manual for A.S.M.E. & N.B.I.C. projects for further details on the disposition of non-conformances.) Pipe and fitting ends will be protected from damage to the point of installation. Interiors of pipe and fittings will be checked for foreign objects and, if necessary, wiped or blown clean prior to fabrication or installation. Pipe spools pieces which have been internally or externally coated or lined, will be handled in a manner that will not damage the coated or lined surface. Connecting flange faces will be protected from damage by the use of covers to the point of installation. Bolts or studs will be installed in a manner that will not damage the flanges or coated areas near the flange face. Pipe, pipe spools, and components will be installed true and plumb. Misalignment, equipment stress, and inadequate support will be minimized where possible through proper placement and acceptable construction practices. Valves will be installed in accordance with design drawings. Valves installed by welding will remain in the open position during installation and throughout the welding process unless specified otherwise by the customer or the manufacturer’s



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recommendations. Valve bonnets and/or packing will be removed prior to welding, if deemed necessary. Proper support will be maintained in order to prevent damage to any portion of the valve being installed. Bolts, gaskets, and in-line components will be installed in accordance with the design drawings. Lubricants, as specified by the customer, will be applied on the threaded surfaces of studs and bolts before installation. Bolts and studs will be tightened sequentially and evenly, using a cross over technique to prevent undue stress on the flange surface and to prevent leakage in the gasket area. Pipe supports and appropriate hangers will be installed in the locations specified in the design drawings. Spring-type hangers and constant support type hangers will be erected in accordance with the manufacturers and customers instructions. Hanger pins will be left in place during hydro testing to prevent damage to hanger due to the added weight of the water. Spring type and constant support hangers will be installed and set to proper loading prior to completion of the project and turnover to the customer. Equipment and valves that require service and/or maintenance during construction and prior to start-up will be maintained and serviced in accordance with the manufacturer’s recommendations or by the directions shown in the specification. Welding Scope

The purpose of this section is to establish methods for monitoring, examining and reviewing field and shop practices related to welding and for the providing documentation for these activities Procedure

All welding will be performed in accordance with the requirements of A.S.M.E. Section IX and the referencing construction code, using welders and welding operators employed by and qualified by P2S. The Project Superintendent, or his/her representative, shall be responsible for ensuring that all shop or field construction, maintenance and turnaround personnel under his/her jurisdiction comply with the requirements of this procedure. All welding procedures will be prepared and qualified in accordance with A.S.M.E. Section IX and other applicable A.S.M.E. construction Codes. All Welding Procedure test coupons will be prepared, qualified and certified under the direct supervision of the Quality Control Manager, or his/her representative. The required testing and examinations of the test coupons will be performed by P2S. or an approved testing laboratory. The Quality Control Manager, or his/her



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representative, will review the testing and examination results and, if found acceptable, will record and certify the Procedure Qualification Record. Welders Performance Qualification testing will be under the full supervision of a Quality Control Inspector, or a Qualified company employee, at the discretion of the Quality Control Manager. Welder Performance Qualification records will be received, prepared and certified by the Quality Control Manager, or his/her representative, after the results of the tests are obtained. These records will be kept on file at the shop/field site for use by the Construction Supervisor, who is responsible for training, supervising and assigning welders. The Quality Control Manager, or his/her representative, will assign a symbol to each qualified welder for identification purposes. All tack and production welds will be made using qualified procedures and welders, who will be assigned a symbol by the Quality Control Manger, or his/her representative, for identification purposes. The welder’s symbol will be stamped adjacent to the weld or will be documented on a weld map. Tack welds made by sub-contractors and non-qualified individuals, shall be made using qualified procedures approved by the Quality Control Manager, or his/her representative, and shall be fully removed prior to completing the weld. The Site Quality Control Inspector or his/her representative will maintain a welder continuity record for each job location. The information provided by this Record shall be used by the Quality Control Manager, or his/her representative, to update the Welder Continuity Log. The Welder Performance Update Form (P2S Form No. WPUF-1) shall be used to compile this information and is to be forwarded to the Sand Springs office upon the completion of each project. The Customer Representative shall have access to all records pertaining to the welding materials, Weld Procedures and Welder Performance Records. He may require the re-qualification of any welder, welding operator or Weld Procedure at any time, if he has reason to believe that the requirements of the applicable Code or customer specification are not being met. The Quality Control Manager, or his/her assigned Site Quality Control Inspection Personnel, shall have authority to remove any welders stencil at any time, if there is reason to believe that the quality of the welders work does not meet P2S. The shop/field Supervisor, or his/her representative, shall distribute all welding consumables. No more than a (4) hour supply of Low Hydrogen type covered electrodes is to be distributed at a time, unless it is to be kept in a portable rod caddy. All unused weld materials shall be returned to the shop/field Supervisor, or his/her representative, with the Low Hydrogen type electrodes being segregated and undergoing a re-baking process, in accordance with A.S.M.E. Section II Part C,



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before returning to the holding oven. The Rod Slips shall be used when distributing welding consumables, See Attachment B. All weld material, including fluxes, shall be purchased by the Purchasing Agent, or his/her representative and shall meet the requirements Section II, P art C or the A.S.M.E. Code, or client requirements, if materials are not ASME listed. Welding consumables shall be inspected upon receipt by the Material Controller, or his/her representative, or by the Site Quality Control Inspector, and checked off of his/her copy of the purchase order. All welding material, if accepted, shall be stored under proper environmental conditions, and protected from damage. Welding materials received in damaged containers, or whose containers become damaged later, shall be returned to the supplier or discarded. Examination and Inspection

Examinations and inspections will be performed on all piping, vessels, drums, etc. and on all associated welds and ancillaries in order to ensure compliance with the specifications, P2S Policies and Procedures and the applicable codes. Customer Inspection

All piping and/or piping components will be subject to inspection by the customers inspector or representative during all phases of construction and/or installation. Visual Examination of Welds

All welds considered complete and scheduled for visual examination will be clean and suitably prepared with all required markings. The applicable supervisor will be responsible for notifying the Site Quality Control Inspector, or his/her designee, of the completed weld. All welds will be visually examined and any defects found, which are not within the parameters of the applicable code will be corrected. All socket welds and seal welds will be examined visually and completely. At a minimum, all socket welds and seal welds will be free of excessive undercut and surface irregularities. All completed butt welds will be visually examined and, at a minimum, will be free of the following indications: 1)

Cracks

2)

Lack of fusion

3)

Excessive undercut

4)

Inadequate or excessive reinforcement



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Welds determined to be unacceptable will be flagged during the examination. The applicable supervisor and welder will be informed of the defects found and instructed as to the required action prior to re-examination. Project Documentation and Final Project Data Package

Documentation of inspection activities shall be performed in accordance with the requirements listed above and compiled into a final P roject Data Package. Upon completion, the Project Data Package shall be reviewed by the Site Lead QC Inspector to ensure completeness and compliance with P2S and customer requirements. Upon completion of the project, the required number of copies of the final Project Data Package shall be given to the customer. The original shall be sent to the Regional QC office for archiving. DOCUMENTATION REQUIREMENTS FOR PIPING/WELDING PROJECTS Scope

All projects completed by P2S have minimum documentation requirements, which must be completed and compiled into a final Project Data Package. The required number of copies of the final Project Data Package will be transferred to the customer and the original will be sent to the Regional QC office for archiving. The following is a list of minimum documentation requirements for Welding Projects. If requested and upon review, certain customer supplied documentation will suffice in lieu of P2S forms. Copies of these forms are to be signed by a P2S representative and are to become a part of the completed Project Data Package. Piping/Welding Project Documentation (Other than ASME/NBIC Manual) 1)

Weld Tracking Logs / Weld Maps

2)

N.D.E. Reports

3)

Daily Project Logs (DPL-1)

4)

Copies of Weld Procedures Utilized on the Project

5)

Welder Performance Qualification Records

6)

Pressure Test Reports (HY D-1)

7)

Pre-Hydro Punch Lists (PRHP-1)

8)

Post-Hydro Punch Lists (POHP-1)

9)

Mechanical Completion Forms (MCF-1)

10) Welder Performance Update Form (WPUF-1) 11)

Non-conformance Reports



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12)

In Process Control Sheet, addressing job specifics

Piping/Welding Project Documentation (Per ASME/NBIC Manual) 1)

All data requirements in section 6 (Piping/Welding) above

2)

In Process Control Sheet (IPCSF-1 or IPCSS-1)

3)

Original Data Report (For equipment being repaired)

4)

N.B.I.C. and/or A.P.I. Repair Forms (R-1, R-2, etc.)

5)

Partial Data Reports (For new pre-fabricated parts)

6)

Original Nameplate Replication (Rubbing)

7)

Copy or Rubbing of New Nameplate

8)

Copies of Certificates of Authorization Utilized (Customer package only)

9)

M.T.R.’s (Material Test Reports)

10) Code Calculations (If required) 7. NONDESTRUCTIVE EXAMINA TION Classifi cation o f NDT personn el Scope

To establish minimum classification requirements for Quality Control Personnel for Mechanical and Welding projects for field and shop locations. Procedure

Classification of Quality Control personnel will be based on the individual certification and experience of each inspector, performance and supervisory skills. These certifications include: 1) AWS-CWI Certification 2) API 510 Certification- Pressure Vessels 3) API 570 Certification- Piping 4) API 653 Certification- Storage Tanks 5) ASNT-TC-1A Level II- Film Interpretation (RT) 6) ASNT-TC-1A Level II- Penetrant Testing (PT) 7) ASNT-TC-1A Level II- Magnetic Particle Testing (MT) 8) ASNT-TC-1A-Level II- Ultrasonic Testing (UT)



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Q.C. Classification Point System

Variable

Points

Point Scales:

AP I 653 Certification

3

12 or over

A.W.S.-C.W.I. Certification

3

7-12 points

A.P .I. 510 Certification

3

3-6 Points

A.P.I. 570 Certification SNT-TC-1A Level II (R.T.) SNT-TC-1A Level II (P.T.) SNT-TC-1A Level II (M.T.) SNT-TC-1A Level II (U.T.)

3 1 1 1 2

Each Year of Servi ce w/ P2S- Q.C. Depart ment Each Year of Servi ce w/ P2S (In any capacity) Each Year of Servi ce in Q.C. (Employers other than P2S)

Lead/ “A” Inspector “B” Inspector “C” Inspector

3 2 1

Example: Brad Weldon CWI API 510 Level II (R.T.) Level II (P.T.)

3 3 1 1

Level II (M.T.) (9) Years of Service in P2S Q.C. Dept.

1 27

Total

36 “ A” Inspector

In addition to the point system, an inspector must meet the following minimum certification requirements for each classification. Lead/ “ A” Inspector:

Must have certification in at least two (2) of the following: API 653, CWI, API 510 and/or API 570 preferably API 510 and CWI. Must be certified SNT-TC-1A Level II in VT, RT and PT.



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“ B” Inspector:

The inspector must have a certification in at least one (1) of the following: API 653, CWI, API 510 and/or API 570 preferably an API 510 or CWI. Must be certified SNT-TC-1A Level II in VT, RT and PT. “ C” Inspector:

Must be certified SNT-TC-1A Level II in PT and VT. The point system plus the certification requirements are the major factors that will determine an inspector’s classification but it is not all-inclusive. J ob performance and supervisory skills will also affect classification especially for the “A” Inspector. Ability to read drawings proficiently is a requirement for an “A” Inspector. Each Chief Inspector will be responsible for determining the classification of Inspectors used by P2S in his/her/her respective zone. Also, he/she will maintain a list of inspectors with their current classification and will update this list as necessary. Training

NDE personnel are to receive training in P2S QC procedures and documentation. As needed, training for receiving an ASNT Level II certification by P2S will be provided. P2S will support, for core personnel and if approved, outside training for certifications such as AWS CWI, API 510, API 570, etc. P2S will pay the class fees for approved personnel if they obtain approval upfront and certification is received. Contact you supervisor if you are interested in this type of training. 3rd Party NDE Contracto r

The Site Lead QC Inspector must obtain/evaluate procedures and personnel certifications for any NDE contractor P2S plans to use. Procedures and personnel certifications must meet the requirements of ASNT TC-1A. The Site Lead QC Inspector must approve a 3rd party NDE contractor we plan to use before we bring them onsite. The Site Lead QC Inspector must monitor and audit any NDE contractor activities. If the contractor is not meeting requirements, please advise the job P2S P roject Manager and the appropriate P2S Regional QC Manager. The contractor will be removed from the project if requirements cannot be met. After each job, please provide a written performance evaluation of each NDE contractor’s services to the Regional QC Manager. Contractors that continuously provide unsatisfactory service will not be used by P2S, until they can prove that changes have been made to improve service. If the 3rd party NDE contractor does not work directly for P2S, the Site Lead QC Inspector must still monitor their activities. If the contractor is not obtaining timely/accurate inspections, the Site Lead QC Inspector should contact the P2S P roject Manager. The P2S P roject Manager should advise



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the client that the NDE contractor is not meeting standards which could cause delays or improperly inspected items. 8. PRESSURE TESTING Scope

This procedure outlines engineering prerequisites and basic quality control requirements for planning and performing specific hydro testing and pneumatic tests. Procedure

Prior to the commencement of any testing activity, the piping system, vessel or fabricated component is to be walked down by the Project Superintendent, or his/her designee and the Site Quality Control Inspector for verification of compliance with all drawings, specification and Applicable codes. At that time the Site Quality Control Inspector is to complete a pre-hydro punch list. Upon completion of this punch list, the Project Superintendent, or his/her designee is to complete the items listed and re-notify the Site Quality Control Inspector of completion. Upon verification, by the Site Quality Control Inspector, that all items on the punch list have been completed, the pressure test may be started. All testing is to be performed in the presence of the Site Quality Control Inspector, or his/her representative and the Customer Representative. All required safety precautions will be in place and enforced during the testing. If deemed necessary, by the Project Superintendent and the Site Quality Control Inspector, or their representative, the test will be performed employing a gradient pressure increase to check for leaks at pressures lower than the final test pressure. A preliminary check will be made at 15 p.s.i. in order to check for any major leaks then the pressure is to be increased by either 5 p.s.i. or 10% of the test pressure, whichever is greater, until the final test pressure is achieved. Calibration of all gauges will be per Section 9 of this Manual. Hydrostatic or pneumatic test forms will be completed for each pressure test made and are to be signed by the P2S and Customer Representatives. These forms are to become a part of the final Project Data Package. PNEUMATIC TEST PROCEDURE Summary:

There are many safety and quality concerns that could arise before, during and after an air test that can be dealt with ahead of time. With proper planning of the



2010

job and strict adherence to the specification documents these concerns should and can be eliminated or controlled. Controlli ng docum ent: Pressure Testing Purpose:

To develop a procedure that will control if not eliminate all concerns that could arise during the pneumatic tests to be performed on this job. Preparation procedure: 1)

The test package will be marked up and approved prior to set up

2)

Piping system will be walked out and bought off by P2S supervision, P2S QC, and client QC for pretest acceptance prior to test.

3)

Piping Checklist and pretest communication meeting must be completed at the time the test is to be conducted

4)

Client will be notified if the set safety boundary extends into the perimeters of the process area.

5)

General PPE will be required until the perimeter barricade is erected at which point, anyone inside the barricade will have to wear face shield and monogoggles.

6)

Perimeter barricades will be erected to fit the test and will have attendees to make sure that no one enters the barricaded area.

7)

No one will be allowed in the barricade area, except for the people at the test tree while the pipe is being stepped up to the required pressure and held 5 minutes before entering to check for leaks.

8)

P2S will tape any necessary flange connections leaving one opening to test for leaks.

9)

Air compressors shall be equipped with discharge filters for removal of water, oil, and foreign matter.

10) A pressure relief device will be used, having a set pressure not to exceed the

test pressure plus 10%. Pressuri zation procedure: 1)

After all pretest walk downs are approved and the perimeter barricades have been erected, P 2S will begin the pressurization of the system according to the provisions and this procedure.

2)

STEP-1 P2S will bring the system up to 1 bar (15 psi) and hold the pressure for 5 minutes and perform the appropriate walk downs according to the engineering specification.

3)

P2S will not depressurize or remove isolations during pressurization.



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4)

After the walk down is approved P2S will begin the pressurization of the system according to the provisions and this procedure.

5)

STEP-2 The line will be brought up to 25% of the primary test pressure or (25psi) and held for 10 minutes.

6)

STEP-3 Gradually increase the pressure to 50% of the primary test pressure in 20% increments holding 2-3 minutes at each step up to allow stress and strain to equalize. Holding for 10 minutes.

7)

STEP-4 Increase pressure in increments of 10% until primary test pressure is reached and held 60 minutes.

8)

Once the test pressure has been achieved and held successfully for 60 minutes. Then bleed the pressure down to 80% of the primary test pressure and complete the final leak check.

9)

If any problems are found P2S will depressurize the system, address the issue then start over from step 1 with the pressurization procedure.

10) When the test is sold off to P2S and client QC P2S will open the bleed valves

and depressurize the system. 11) When the system is completely bled down P2S will remove the barricades. Personal Protective equipment: 1)

Hard hat

2)

Monogoggles

3)

Face shield (inside barricade)

4)

Hearing protection

5)

Gloves

Training:

All personnel involved in the pneumatic test will receive proper training on the hazards involved. 9. CALIBRATION OF INSPECTION/TEST EQUIPMENT Scope

This section of the manual refers to the calibration and certification of measurement and testing equipment. Purpose

To establish guidelines for assuring that all measurement and testing equipment is accurately calibrated, repaired and certified. The Quality Control manager, or his/her representative, shall ensure that all gauges and other measuring equipment shall be tested, either in-house or by sub-



2010

contractor, repaired as necessary, calibrated and certified at periods not to exceed one (1) year or per client specifications. If at any time if there is reason to believe that a particular piece of equipment is in error, it shall also be repaired and/or recalibrated as necessary. The Site Quality Control Inspector shall be responsible for informing the Quality Control Manager whenever calibration of equipment is necessary. All equipment shall be furnished with an initial calibration certificate showing a relationship to a national standard, where such standard exists. All measuring and test equipment shall be permanently identified with a serial number traceable to calibration records. All records of calibration shall be made available to the Customer Representative for review. All sub-contractors will be required to provide evidence of calibration certification of their equipment. (e.g.– chart recorders, UT machines, etc.) Any piece of equipment checked with a discrepant instrument shall be nonconforming until the Quality Control Manager, or his/her representative, have verified that such item meets the requirements of this Manual, or shall be rechecked with a calibrated and accurate instrument. Recommended Frequency

Manufacturing Tolerances

Level

12 Months

Manufacturing Recommendations

Transit

12 Months

Manufacturing Recommendations

6 Months

+/- ½%

3 Months

+/- 5%

Calipers

6 Months

+/- .001

Dial Indicators

6 Months

+/- .001

Micrometers

6 Months

+/- .001

Machinist Level

6 Months 12 Months

+/- .000.5

Equipment Type

Pressure Gauge Torque Wrench

Rod Ovens

+/- 25F of Specified Range

Each item calibrated will have a tag showing the date calibrated and the next calibration date.



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10. FIELD ERECTION AND EQUIPMENT

The following is a general guide for surveillance in erection and setting of columns, towers, pressure vessels, tanks, exchangers, and equipment. 1)

Verify that receiving inspection is completed and documented.

2)

If item was in temporary storage (lay down yard), verify that it was not damaged and remove temporary support attachments, as required, before erection.

3)

Internal checks:

4)

No loose miscellaneous hardware

5)

Temporary shipping supports removed, if not required, before erection.

6)

Verify engineered components are secured per drawings

7)

Verify internal coating is not damaged

8)

If silica gel is used, check for disposition and dryness

9)

Verify painting or insulation before erection

10) Verify rigging to specified lifting lugs or attachments. NOTE: For unusually large or heavy lifts, ascertain that any special lifting

calculations have been submitted and approved by P2S and client. This would include type, size, position of lifting equipment and personnel requirements. 11) Verify foundation dimensions, etc., are complete as per project specifications

and drawings. 12) Monitor transport and lifting operations 13) When in position, verify correct securing hardware 14) Verify shimming materials, thickness and position of shims 15) Verify operation of subject equipment is plumb by use of level or transit as

required 16) Verify rigging to specified lifting lugs or attachments. NOTE: Verify sliding ends of heat exchanger supports are free to slide.

Reference the installation drawings for specific dimensions, if required. If tolerances are not specified, the washer over the slotted holes should be able to be turned by hand. Mounting bolt requires a double nut and tack-weld to the mounting stud. 17) Verify electrical ground wire is connected. 18) Record date of erection and pertinent inspection information using the

appropriate form.



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Grouting

After all inspections are complete and inspected by the Site Lead QC Inspector and client, a release to grout can be issued. 11. PAINTING AND INSULATION Scope

This procedure outlines client and manufacturer’s prerequisites and basic quality control requirements for planning and performing specific Painting and Insulation of materials and equipment Standards and Specifi cations

The painting and insulation shall conform to the applicable project specifications and manufacturer’s recommendations. Surface preparation shall conform to applicable painting and insulation specifications Receiving Inspection – Painted Items and Paint 1)

Check for areas where paint may have been applied over mill scale or rust.

2)

Check the use of correct paint

3)

Check for damage to paint.

4)

Check for dry film thickness

5)

Paint material shall be checked for damaged containers.

Receiving Inspection – Insulated Items and Insulation

Insulated items received shall be checked against the applicable purchase order for the following: 1)

Correct thickness

2)

Correct material

3)

Damage

Insulation received, at a mini mum shall be checked for the foll owing : 1)

Water damage to insulating cements or insulation

2)

Excessive breakage of block or pre-form pipe insulation

3)

Damage to jacketing materials

4)

Conformance of material to specifications.



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Inspection Procedures - Paint

All painting must conform to the applicable approved painting specifications. Form C[ESM2] shall be used to record inspection results. The following items, at a minimum shall be checked prior to, during, and after final painting: 1)

Surface preparation per applicable drawings.

2)

Surface shall be dry and clean, free from dirt, oil, grease, water and other foreign matter.

3)

Motors, pumps and related equipment damaged due to specific cleaning process, i.e. sand blasting, per specifications shall be brought to the attention of the inspector/engineer for changes as necessary.

4)

All surfaces must be cleaned and painted the same day.

5)

Check for use of correct primer

6)

On pressure vessels and piping, any laminar areas exposed by sand-blasting shall be repaired by grinding and welding as required. Repair shall be executed by qualified welder’s using approved weld procedures. The inspection department shall be notified prior to grinding or welding.

7)

Each layer of primer, within multiple layers, each layer shall be checked by the QC Department for correct mill thickness, surface conditions and compatibility with other paint.

8)

Intermediate coats shall not be applied until the approval of the primer coat(s) has been received by the Site Lead QC Inspector.

9)

Check intermediate painting material to ensure conformance to specifications.

10) The final coat of paint shall not be applied prior to the approval of intermediate

coats by the Site Lead QC Inspector. 11) Check for use of correct paint materials of final coat. 12) Check thickness of finished product 13) Check for good workmanship; i.e., no paint runs, excessive sand which may

have blown on wet paint, scratches, etc. Some of the following items may require special procedures or paint applications and are normally found in the job specifications: 1)

Equipment and piping requiring cold insulation

2)

Equipment and piping requiring high temperature paint.

3)

Vessel skirts and structural steel requiring fireproofing.

4)

Galvanized items - when painting is required.

5)

Pressure gauges shall not be painted.



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Pump and motor parts affecting operation; i.e. seals, air filters, rotating shafts, bearings, etc., shall not be painted. All special coatings must be applied in strict accordance with approved specifications and manufacturer’s recommendations. If the information conflicts, contact the applicable engineering department for clarification. External Doping and Wrapping

All doping and wrapping material types shall meet client engineering specifications. The Site Lead QC Inspector shall inspect the pipe surface preparation prior to doping application and shall also check dope pot for specified temperatures as required. Holiday Detection (J eeping pipe) of lines shall be conducted in the presence of a P2S QC inspector and client inspector where required. This shall be performed following specified curing time. The Site Lead QC Inspector shall document the results of these tests on the Daily Inspection Form and incorporate into the Quality Control document files. Internal Coatings

Internal coatings inspection criteria shall be as specified in section 6 of this manual. Internal coating material type shall be specified by client specifications. Internal Holiday Detection or wet and dry film thickness readings shall be performed as required by client engineering standards. Inspection Procedures – Insulation General

All insulation must conform to the applicable approved project insulation specifications. The specifications shall list the approved materials for insulating equipment and piping of hot and cold services. The Site Lead QC Inspector must examine all materials used to ensure conformance to specifications. Equipment

The Site Lead QC Inspector must inspect at a minimum, the following items prior to application of insulation: 1)

Confirm the completion of all testing; i.e., hydro, pneumatic, NDE, soap test on pads, etc.

2)

Mechanical check for all insulation rings, supports, clips, ladders, platforms, etc.

3)

Confirm equipment in cold services have been painted as required.



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4)

Surface of equipment should be free of ice, snow, dirt, grease, etc.

5)

Nozzles and other protruding items normally require paint before insulation.

6)

Make certain that bull plugs or other small connections are of sufficient length to project through insulation, or make positive note of their locations so that insulation can be subsequently cut away to expose the connections. Bull plugs may be required by specifications to be seal welded before insulation.

The following is a supplemental checklist for inspection of insulation: 1)

Check for the use of proper material (foam glass, calcium silicate, kaowool).

2)

Check the thickness of insulation and jacketing.

3)

Check the distance between bands, screws, etc.

4)

Check that nameplates, couplings, Code stamps, etc., are left exposed.

5)

Where double layer insulation is used, verify there are no common joints between layers.

6)

Insulation must be kept dry until properly weatherproofed.

7)

Check insulation expansion or contraction joints when required.

8)

Check on amount of lap and use of “S” clips on jacketing.

9)

Inspect sealing and caulking around protrusions through jacketing.

10) Installation of expansion bands where specified. 11) Insulation support rings and stiffener rings are covered with insulation where

required. 12) Insulation shall be beveled at all flanged connections to allow for removal of

bolts without insulation damage. 13) Inspect the joints on cold insulated equipment to ensure that they are

completely sealed. Piping

Piping shall be checked for the following prior to insulation: 1)

Confirm the completion of all testing; i.e., hydro, pneumatic, NDE, soap tests on pads, etc.

2)

Mechanical check for completion of supports, clips, shoes, guides, stops, branch connections, line size and line number, heat treatment, etc.

3)

Piping in cold service may require special paint.

4)

Material surfaces should be free of foreign matter.

5)

Vertical piping may require insulation supports.

6)

Remove all temporary supports, brackets, etc.



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7)

Ensure steam and electric tracing systems are complete, if applicable.

The majority of the recommended inspection procedures listed in the above equipment insulation checklist apply to piping. A review of applicable piping specifications is recommended for detailed requirements. 12. CIVIL/STRUCTURAL PROJECTS Civil - General Scope

This procedure provides a general outline of functions to be performed or verified by the QC Department relative to jobsite civil work. Specific requirements will be written into the Project Execution Plan and Site Quality Control Manual. Survey

Verify that all preliminary survey work for the site has been previously completed and documented by subcontractor. 1)

Check to see that the correct control monument and benchmarks are used.

2)

Check to see that the benchmarks are adequately protected.

3)

Check to see that the permanency of the control monument is adequate.

Soil Investig ation

Soil investigation shall be contracted to independent civil consultants. The consultants may be asked to supply at a minimum the following information: 1)

Bearing ratio curves

2)

Land Fill procedures

3)

Compaction test reports

4)

Moisture density reports

The soil consultant shall determine how taking representative soil samples from various areas on the construction site can best use materials. The consultant shall determine if the material from stripping and excavating is adequate for backfill or if it is to be discarded as waste. The consultant shall recommend borrow pits for fill materials. Stockpiles of waste materials shall be by mutual agreement between the client and P2S. Site Preparation

All trees, shrubs, stumps, fences, abandoned structures, foundations, large rocks, debris, etc., shall be removed to a depth specified by the contract specifications. Any areas that may collect rainwater shall contain proper drainage.



2010

Determine that grass and other organic materials have been removed as required by the project drawings and specifications. This material shall be disposed of per contract specifications, and not stockpiled or buried where other construction operations will be interfered with. Check for location and depth of excavation to ensure conformance with approved drawing specifications. Land Fill

Any backfill materials used on the construction site shall be that which was approved by the soil consultant. If the fill material was not approved at the time of soil investigation and it is questionable, the soil consultant shall be called in for approval. Prior to placing of fill materials, the excavation shall be inspected at a minimum, for the following: 1)

The area is free of organic material; i.e., paper, wood, rags, etc.

2)

Excessive water is removed.

3)

Loose rock, dirt, etc., which will interfere with foundations has been removed.

4)

If in cold climates, fill shall not be placed over frozen soil.

5)

Check for soft spots.

Soil Proctors & Compaction

Where a controlled backfill compaction is required, the percentage of such shall be specified by engineering specification or transmitted per written document. When a controlled backfill compaction test is required, there should be a minimum of one proctor test for each specific-type backfill. The Site Lead QC Inspector shall be notified in advance of testing and shall monitor this procedure. All test reports from the lab shall be forwarded to the Regional QC Manager and shall be filed accordingly. The Site Lead QC Inspector shall notify the Civil Superintendent of acceptance or rejection of proctors. The procedure for the density test shall be in accordance with applicable engineering specifications or ASTM, D-1556. When specified, other tests shall be in accordance with: 1)

ASTM, D-1883 – Bearing Ratio of Laboratory-Compacted Soils

2)

ASTM, D-1557 – Moisture-Density Relations of Soils



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Foundations

Investigate area for existing underground facilities and assure that they have been, or are, properly recorded. When depth of excavation is great enough and conditions indicate possible ground cave-in, shoring shall be used for safety of personnel. The Site Lead QC Inspector or Survey Supervisor shall check the size, location, and elevation of the excavation. Water shall be removed from the excavation site. Pumps must be available to maintain drainage in the event seepage continues to run into the excavation. Backfill of the excavation shall be accomplished by using soil materials as described by specifications and the soil consultants. Trenching

The excavation shall be checked by the Site Lead QC Inspector as to location and elevations. Coated pipe shall lay on suitable softeners. Hard supports are not acceptable. Backfill under roads, foundations, slab, or other load-bearing areas shall be compacted in accordance with engineering specifications. Roads

Placement of the subgrade and subbase materials for roads shall be in accordance with applicable specifications and shall be checked by the Site Lead QC inspector. The soil shall be free of organic material, large rocks, debris, frozen material, excessive moisture, soft spots, in existing soil, or any other condition which would hinder compaction of the subbase. All undesirable materials shall be removed and replaced in accordance with the project specifications. When specified, the soil shall be scarified before starting the first lift of the subbase. Location and elevation of subbase shall be in agreement with approved drawings. The base materials shall be installed and compacted according to the contract drawings and specifications. Before placing the base, ensure that the subbase moisture content is as required by specifications. Asphalt and bituminous paving shall be installed over a prime coat on a base that is not frozen and is relatively dry. The temperature of the hot mix shall be checked with a thermometer at the delivery truck as specified by specifications. The lifts,



2010

width, etc., shall be in accordance with plans and specifications. Before installation of the seal coat, the pavement shall be proofed. Tank Pads

The location, size, and other design variables shall be checked by the Site Lead QC Inspector or Survey Supervisor for conformance with approved drawings and specifications. The fill material shall conform to applicable specifications. A compaction test shall be taken as described by specifications. A copy of the compaction test results on each foundation shall be filed with the Regional QC Manager. If an oiled sand base is required by specifications, it shall be mixed outside the excavation area then brought in to the base and compacted. Levees and Basins

The Site Lead QC Inspector or Survey Supervisor shall check the location, size and elevation of the levees and basins to ensure conformance with approved design drawings. The fill material shall conform to and be installed in accordance with approved drawings. The fill material must be compacted to specifications to insure that the slopes are firm and will not erode. Ditches

The Site Lead QC Inspector or Survey Supervisor shall check the location, slope, flow, and elevation to assure conformance to drawings. Check the slopes for correct compaction and uniformity if they are to receive concrete or Gunite. If hydro mulch is employed, ascertain the use of the proper type soil which will aide growth. Check that inlet and outlet structures are installed per drawings. Pilings

The Site Lead QC Inspector shall check the piling locations in all cases. Piling location shall be within the tolerances indicated on the drawings and specifications. The Site Lead QC Inspector shall check to determine that the piling itself is within specified tolerances. Should the pile be rejected, new piling shall be driven only when approved by Engineering.



2010

Records shall be maintained on all permanent piling. Concrete Scope

This procedure covers method of application for the taking of concrete samples and slump tests under field conditions. Concrete Mix Design

P2S does not assume responsibility for determining concrete mix designs for any specific project. All projects shall be furnished to P2S via engineering specifications or outlines written procedures information shall include desired slumps, percentages or air entrainment and minimum compression strength (P.S.I.) of all cylinder breaks required at each interval. Initial Pour Procedure

Prior to a pour, the Civil Superintendent shall initiate a Pour Approval Slip. He shall obtain signatures of all craft supervisors signifying all conduit, rebar, anchor bolts, underground pipe and grounds are properly installed. The Pour Approval Slip shall then be turned over to the Survey Supervisor for verification of physical layout, dimensional correctiveness, correct elevation and correct anchor bolt placement. Upon determination that all of the above items are correct, survey personnel shall initial the Pour Slip and return it to the Civil Superintendent to schedule and notify the concrete batch plant of the day and time if pour. Copies of the completed pour slips shall be turned in to the Site Lead QC Inspector for verification and subsequent filing. Concrete Tests

The Civil Superintendent or his/her craft foreman shall be responsible for preparing all slump tests and test cylinders. This information shall be documented by the Civil Superintendent on the pour approval slip (Form A). All testing shall be performed in accordance with engineering specifications, ASTM, and ACI standards. The Site Lead QC Inspector shall be notified in advance of these events and shall monitor all such activities. Slump Concrete Test Specimens

Slump test shall be taken prior to each group of test cylinders. Minimum Slump & Air Tests 1)

One test per one hundred (100) cubic yards of concrete.

2)

Additional tests to be taken per job specification, design requirements, client representative or Site Lead QC Inspector discretion.



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Mold – The test specimen shall be formed in a mold made of metal not readily

attacked by the cement paste. The metal shall not be thinner than No. 16 gauge. The mold shall be in the form of the lateral surface of the frustum of a cone, with the base 8 inches in diameter, the top 4 inches in diameter, and the height 12 inches. Individual diameters and heights shall be within +/- 1/8 inch of the prescribed dimensions. The base and the top shall be open and parallel to each other and at right angles to the axis of the cone. The interior of the mold shall be relatively smooth and freer from projections such as protruding rivets. The mold shall be free from dents. Tampin g Rod – shall be a round, straight, steel rod 5/8 inch in diameter, and

24 inches long. The tamping end is to be rounded to a hemispherical tip of the same diameter. The Sampling, and Mixing Receptacle – shall be a suitable, heavy gauge

metal pan, wheelbarrow, or a flat, clean, nonabsorbent mixing board of sufficient capacity to allow easy mixing of the entire sample by shovel or trowel. Procedure – Dampen the mold and place it on a flat, moist, nonabsorbent

(rigid) surface. It shall be held firmly in place during filling by the operator standing on two foot pieces. From the sample of concrete obtained, immediately fill the mold in three layers, each approximately one-third the volume of the mold. NOTE: One-third of the volume of the slump mold fills it to a depth of 2-5/8

inches-, two-thirds of the volume fills it to a depth of 6-1/8 inches. Rod each layer with 25 strokes of the tamping rod. Uniformly distribute the strokes over the cross section of each layer. For the bottom layer, this will necessitate inclining the rod slightly and making approximately half of the strokes near the perimeter, and them progressing with vertical strokes spiral toward the center. Rod the bottom layer throughout its depth, so that the strokes just penetrate into the underlying layer. 13. INSTRUMENT/ELECTRICAL PROJECTS Scope

P2S will be functioning as a Construction Management Organization in regards to where instrument and electrical services are required. Procedures

The Subcontractor will be responsible for all QC requirements with verification of appropriate inspections and documentation included. The Subcontractors QC Inspector will report all inspection documentation to the P2S Site QC Lead.



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14. SUBCONTRACTOR SELECTION AND QUALITY REQUIREMENTS

This procedure describes the initial qualification of site subcontractors. GENERAL

When qualifications of site subcontractors include an evaluation of the QC capabilities of the subcontractor, the evaluation shall be performed in accordance with this procedure. PROCEDURE Qualification of Subcontractors Contracts Administrator

Upon selection of a proposed subcontractor, the Contracts Administrator shall notify the Regional QC 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. Regional QC Manager

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 P2S subcontract. This review may include meetings and/or visits with the subcontractor candidate. The Regional QC Manager should use the applicable Evaluation Record Form. 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. 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.



2010

Contracts Administrator

Reconcile quality issues and exceptions prior to contract award. Obtain input as needed from the Site Lead QC Inspector. Incorporate the agreed to quality requirements into the contract. After the "Notice to Proceed", obtain the process control procedure that were made a part of the contract and provide these procedures to the Regional QC Manager and the Site Lead QC Inspector. NOTE: These procedures are to be approved by the Site Lead QC Inspector before

the Subcontractor is authorized to proceed with work within the procedure scope unless specifically approved by the Site Manager. 15. NONCONFORMANCES Scope

To provide guidelines for the recognition, verification and disposition of nonconformities in order to assure that all problems, which may arise, are reported and corrected in a manner that satisfies all code requirements and customer specifications. Procedure

Any item which does not conform to the applicable code, customer specification, customer drawing, or design requirements shall be considered a non-conformity. The non-conformity shall be marked “DO NOT USE” and no work will be permitted on that item until the non-conformity has been resolved. The Regional Quality Control Manager, or his/her representative, shall prepare the Non-conformance Report (P2S Form No. NCR-1) this form will contain a proposed solution and will be reviewed with the Project Manager, or his/her representative, and then with the Customer Representative for their concurrence. The approved disposition shall be adhered to without deviation when making the necessary repairs. Verification that the approved disposition has been carried out shall be done by the Regional Quality Control Manager, or his/her representative, and the Customer Representative, and recorded on the NCR, and placed in the Quality Control job file. A copy of the NCR will be placed in the final Project Data Package. After verification that the non-conformance has been corrected, the Regional Quality Control manager, or his/her representative, may remove the “DO NOT USE” marking.



2010

ATTACHMENT A Welders Respons ibili ty 

Before you perform any welding, it is very important to look at the ISO, and find out what type of metal you’re about to weld. Make sure you get the proper welding rods for the job.



Find out about the welding procedure and ask if the weld you’re about to do requires any NDT (non destructive test.) These tests can be UT, PT, MT, or sometimes the weld requires PT the root or something else. PLEASE ASK!



When using low hydrogen rods, keep the rod caddy plugged in at all times!



Never carry more than one type of welding rod in your rod tube.



Keep the ground close to the welding area. If you are going to be welding on any pipe that is attached to any pump. YOU MUST use a double ground clamp.



When welding chrome or carbon steel above 3/4” thick you’re required to have a temperature stick and insulation around the weld on both sides.



Do not start a weld if you cannot finish the bead and hot pass before you walk away from it.



Only bridge tack a fit that you are going to leave for the next shift.



When making a horizontal weld, a 3 bead cap or more is required.



When making a vertical weld, if the cap is going to be wider than ½” a two or three bead cap is required.



Use of fire blanket and wind break is essential, three sides of wind break are required, **USE COMMON SENSE**



When welding on small check valves with the spring inside, make sure to remove the spring before welding on it.



If the weather is below 50 degrees preheat is mandatory.



If making a weld in position, make sure you check the level and square before you put your stencil.



Perform 100% of your welds as if it were to be radiograph.



The first two welds will be production welds, if one of these welds fail on the visual or on the radiograph, it may be the cause for a Termin ation in accordance to P2S and or clients j ob standards.



If one of your two tracer welds fail on a visual or on the radiograph, it may also be the cause for a Termination in accordance to P2S and or cli ents job standards.



2010 

Do not dry wash a weld unless approved by the QA/QC Department, and never use water to quench a weld.

When you finish the weld: 

Clean and buff the weld



Inspect and fix any arc marks, undercut or dog marks



Do not ring file the weld



Put your stencil ½” away from the weld



Take pride in your job, make every weld look good!

**Please understand that we will do anythin g in o ur pow er to keep rejection rate as low as possi ble however, we depend on you for this matter. For the same reason if you are having any prob lems let us kn ow im mediately.**

Print Name

Signature

Last four digits of your SS#

Date


2010

ATTACMENT B Rod Slips


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