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20.0 CONSTRUCTION QUALITY ASSURANCE/CONTROL MANUAL

20.1 INTRODUCTION

This Construction Quality Assurance/Control Manual has been developed toserve as a guide in facilitating the Contractors development of their own QCprogram for this project. The procedures do not attempt to be instructional innature. They do not describe how something is to be inspected or tested. Theydo, however, define what is to be inspected and tested, who is to inspect andtest, and how the program is to be executed. Where reference is made to theobligations of a Contractor, they shall equally apply to sub-contractors, approvedtesting agencies or authorities and the like employed by the Contractor.

The following procedures have been divided into disciplines so that the applicableprocedures for the contract can be included. These procedures were developedbased on the most common scenarios thus far encountered. The proceduresdeveloped are as follows:

PROCEDURE PROC.NUM.

PROCEDURE PROC.NUM.

Soils Testing QCC1.2

Pressure Piping QCC5.1

Surveying QCC

1.3

Electrical QCC

6.0

Concrete QCC1.4

Control Systems QCC7.0

Grouting QCC1.5

Insulation QCC8.0

StructuralSteel

QCC2.0

Coatings andLinings

QCC8.1

Buildings QCC

3.0

Material

Receiving

QCC

10.0

Equipment QCC4.1

EquipmentProtection

QCC11.0

UndergroundPiping

QCC5.0

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Soils Testing (QCC 1.2)

This procedure is based on the contractor being a creditable licensed testingagency.

Surveying (QCC 1.3)

This procedure is based on the contractor being an accredited licensed surveyingcompany and that they will coordinate and locate the site survey bench marks.

Concrete (QCC 1.4)

This procedure is based on the contractor performing surveying to ensure properlocations and elevations of foundations, installing rebar, placing concrete and

bush hammering the cured surface for grouting.

The concrete testing agency is to be contracted by the Contractor

Grouting (QCC 1.5)

This procedure is based on the contractor performing all phases of grouting work.

Structural Steel (QCC 2.0)

This procedure is based on the contractor performing surveying to ensure correct,plumb and alignment, erection of steel, bolt tensioning and welding.

Buildings (QCC 3.0)

This procedure is based on the contractor supplying and erecting the buildingstructural steel.

Equipment (QCC 4.1)

This procedure is based on the erection of presses, vessels, exchangers, firedheaters, rotating equipment and specialty equipment. It also addresses traywork, painting, surveying, grouting, and equipment protection. NOTE: Theapplicable equipment inspection procedure will have to be added as required for

the Scope of Work.

Underground Piping (QCC 5.0)

This procedure is based on the contractor performing location surveying,excavation, compaction of soil below and above the piping, welding, wrapping,holiday testing, non-destructive testing and pressure testing.

Pressure Piping (QCC 5.1)

This procedure is based on the contractor performing erection of pipe, welding,pressure testing, stress relieving and installing steam/glycol tracing.

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It is assumed that the pipe work and materials will be supplied by the mechanicalcontractor.

Electrical (QCC 6.0)

This procedure is based on the contractor performing one or more of:underground electrical, above-ground electrical equipment or electric heat tracing.

It is assumed that electrical equipment and material will be supplied perspecifications and drawings.

Control Systems (QCC 7.0)

This procedure is based on the contractor installing, calibrating and testinginstruments at site.

Insulation (QCC 8.0)

This procedure is based on the contractor supplying and installing the insulation.

Coatings and Lin ings (QCC 8.1)

This procedure is based on the contractor performing the surface preparation andapplying the required thickness of coatings or linings.

Material Receiv ing (QCC 10.0)

This procedure is based on the contractor purchasing and receiving material atsite.

Equipment Protection (QCC 11.0)

This procedure has been developed in two sections: One, where the contractoris responsible for initial preservation upon receipt at a site facility; the other,where the contractor performs standard preservation operations on equipmentissued to the field forces for installation.

Documentation

Exhibits for documenting the work are referenced throughout the procedures. Alist of all exhibits for a procedure is listed on the last page of each procedure.

20.2 SOIL TESTING PROCEDURE QCC 1.2

20.2.1 Scope

This procedure has been developed to detail quality control requirements fortesting laboratories performing soils testing at field site locations managed bySavant but paid for by the Contractor.

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20.2.2 Responsibilities

The testing laboratory is responsible for the quality of testing work performed atsite and shall perform the following:

Ensure that soils tests are performed in accordance with the contract Scope ofWork, project specifications and applicable codes. These tests include areas ofsite grading, proof rolling, backfill, trenching, structural backfill for foundations andunderground piping. The quality and suitability of backfill material shall also bemonitored.

Document all test results on company letterhead forms, a copy of which shall beforwarded to Savant. The testing laboratory shall ensure that the necessarytesting data is recorded on the Field Compaction Test Record (Exhibit 20-1) andthat each report details the location of the sample. Where samples are takenfrom foundation bases, the foundation location number shall be recorded on thereport. Where samples are taken from pipelines, the line number shall berecorded on the report. In all cases, the survey coordinates or reference to afixed point, location, or stationing shall be included on the reports. The elevationof the sample location may reference a relative elevation such as top of concrete,bottom of pipe, final grade, etc. A sketch may also be used to identify testlocation.

20.2.3 Exhibits

20-1 Field Compaction Test Record

20.3 SURVEYING PROCEDURE QCC 1.3

20.3.1 SCOPE

This procedure has been developed to detail quality control of surveying workperformed by Savant, the Employer and the Contractors independent surveyor.


The Employers Independent Surveyor

The independent surveyor will be contracted by Savant. The independent

surveyor shall perform the following:

The independent surveyor shall establish permanent monuments and verifyproperty limits. Provide layout control plan documenting monuments, boundaries,and existing utilities.

Savant, at its discretion, may have the Contractor's grades, measurements, orlevels checked and verified by the independent surveyor. If they are found to beoutside of allowable tolerance, the contractor shall pay all costs related to thechecking, verification and correction if necessary.

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The independent surveyor shall, with input from the contractors surveyor,prepare certified survey data for location of all above-ground and underground

structures and underground utilities.

Trade Contractor's Surveyor

The trade contractor shall employ services of a competent licensed surveyor.The trade contractor's surveyor shall exercise proper precaution to verify figuresshown on drawings before laying out work, and be held responsible for any errorresulting from its failure to exercise such precautions.

The trade contractor's surveyor shall monitor the placement of all structuralfoundations, structural steel and concrete columns, walls and elevated floor slabsand shall produce a separate certification for the foundations, ground slab andelevated floor deck in conjunction with the corresponding perimeter walls,columns and floors to ensure verticality and dimensional compliance with theInterior Survey Verification Plans and all other contract documents.

Ensure that instruments, tapes, staffs and other tools used are kept in a neat andtidy manner. Instruments shall be calibrated at least once per month and recordsof calibrations recorded and documented. Damaged instruments are to beimmediately removed from site.

Verify that daily diaries of assignments are maintained in a logical and orderlymanner. All records shall include the following information:

J ob title

Date

Weather information

Equipment used

Relevant benchmarks and monuments

Description of points located or surveyed

Sketch of area including N (North) arrow

Drawing number

Foundation, line or equipment tag number

Ensure that completed survey records are submitted to Savant at the completionof assignments.

E. The trade contractor's surveyor shall provide horizontal and vertical controlfor all disciplines involved in the construction process as set out below.

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Control Survey the Contractor shall establish and continuously protect existingand all other horizontal and vertical control points necessary to perform the work

in accordance with the contract documents.

Site Preparation - Provide surveys of areas prior to site preparations to allowquantities to be calculated. This may include survey of borrow pit areas to allowcalculation of material used on the job.

Underground Piping - Control excavation of underground piping trenches by theuse of batter boards set to the grade of the trench and offset from the center lineof the trench by an appropriate distance to allow for the depth of the trench, sidescopes and equipment to be used. On completion of excavation of the trench,final grade stakes are to be set in the base of the trench to allow for sandbedding.

As-built details of all underground piping must be maintained on marked updrawings and submitted to Savant.

Foundations - Contractor's surveyor shall provide control for the layout offoundations by placing control lines on batter boards set up around the foundationby the carpenters. The control lines should be marked on the batter board withan accurate description and actual coordinates. It is preferable to use the mainreference line on the foundation drawing as the survey control line.

Contractor's surveyor shall check foundations prior to placing concrete fororientation, level, location and elevation of anchor bolts. This shall also includeother inserts such as conduits.

On completion of pouring and stripping of forms, the contractor's surveyor shall:

Set permanent centerlines on foundations

Establish an elevation mark on each foundation. (150 mm below top of grout andactual elevation marked)

Stencil foundation or equipment number on the foundations

Structural - Contractor's surveyor shall set shim elevations for structural steelerection and shall check completed structures for verticality.

Equipment - Contractor's surveyor shall check equipment for level and ensurethat orientation is correct as per orientation punch marks or by reference to aprinciple flange on the piece of equipment.

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Piping - Contractor's surveyor shall locate the centrelines of each pipe on theabove-ground pipe racks or decks at every other support or at each change of

direction, as required.

Permanent Reference Points - Ensure that at the completion of the job, thesurvey crew has prepared a listing of all permanent reference marks existing onsite. This record will be submitted to the Employer as a reference for anypotential future required work.

F. Survey of "As Installed" location and elevation of work.

Trade Contractor's Responsibil ities

The trade contractor(s) shall be responsible for complete, timely and accuratefield measurements as necessary for proper coordination, fabrication andinstallation of all materials and equipment within their scope of work. The tradecontractor agrees to cooperate with the other surveyors to accommodate anydiscovered variations or deviations from the contract documents andspecifications so that the progress of the work is not adversely affected.

Before ordering any material or doing any work, the Trade Contractor shall field-verify all dimensions and measurements with the contract documents. Anydifferences shall be promptly reported to the Savant. No claims for additionalcontract costs or time will be recognized for any conditions not so reported.

Actual dimensions, drawings, or notes indicating dimensions shall at all times beused instead of measurements of the drawings by scale. No scaled

measurements shall be used for dimensioning work. Figures on drawings, aswell as detailed drawings themselves are subject in every case to measurementsof adjacent or incorporated work. All such measurements necessary shall bemade before undertaking any work dependent upon such data.

20.3.3 SUBMITTALS

Survey documentation to verify accuracy of field engineering work.

Verticality and dimensional compliance certification for all foundations, slabs ongrade, elevated floor decks, perimeter walls, columns and floor openings.

Prior to substantial completion, the Contractor shall contribute information to afinal as-built property survey to be prepared by the independent surveyor showingproperty lines, retaining walls, site fencing, building lines, roads with centre lines,and significant features (real property) as a result of the construction project.

20.3.4 RECORDS

The Contractor shall maintain complete and accurate logs of control and surveywork as it progresses.

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The Contractor shall, on completion of foundations and major site improvements,including underground site utilities, prepare a certified survey showing

dimensions, locations, angles, and elevations of all construction.

20.4 CONCRETE PROCEDURE QCC 1.4

20.4.1 Scope

This procedure has been developed to detail quality control of structural concretework performed by a Contractor managed by Savant. This procedure is based onthe Contractor performing the required surveying to ensure proper locations andelevations of foundations.


The Contractor is responsible for the quality of concrete construction and shallperform his work as follows:

Ensure that foundation locations and construction are correct. Locations are tobe verified by use of proper surveying methods from established reference pointsat the site. The formwork, anchor bolt locations, elevations and orientation,reinforcing steel, and embedded items are to be inspected and documented onPre-Concrete Inspection Record Exhibit 20-2), prior to placing the concrete. Aseparate Exhibit 20-2 shall be complete for each equipment foundation. AConcrete Pour Card (Exhibit 20-3) shall be completed prior to and after each andevery concrete pour. The tag number for the equipment shall be recorded on theexhibit. Miscellaneous structural foundations in an area or unit may be

amalgamated on one exhibit, provided the unit, area or drawing number isproperly recorded.

Inspect in-process concrete work such as control of concrete trucks, concreteconveyance equipment, reinforcing, framework, inserts, and concrete finishing.

The Concrete Placement Log (Exhibit 20-4) shall be used to provide a record ofconcrete placements and test results.

Inspect post-concrete work such as concrete curing; stripping; visual examinationfor line, form and surface defects; and check anchor bolt locations.

Verify that the correct number of tests has been taken and that the required

strengths have been achieved after 28 days.

Ensure a mix design has been submitted to Savant for approval prior to orderingconcrete. The Contractor is to verify that the batch plant supplying concrete hasfacilities capable of accurately producing the approved mix design.

Verify that bush hammering has been performed so that the latent material hasbeen removed to expose a solid, clean base for future grouting operations.

20.4.3 Exhibits

20-2 Pre-Concrete Inspection Record

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Concrete Pour Card

Concrete Placing Log

20.5 GROUTING PROCEDURE QCC 1.5

20.5.1 Scope

This procedure has been developed to detail quality control of grouting workperformed by a Contractor managed by Savant.


The Contractor is responsible for the quality of grout construction and shallperform the following:

Ensure that grout materials have been purchased in accordance withspecifications. The Contractor shall store, prepare the base, mix, place, and curethe grout in accordance with the specifications and manufacturer'srecommendation. The Contractor shall procure and review the manufacturer'sdata prior to starting the work.

Inspect in-process grouting work such as base preparation, materials, paddling orworking of grout, method for mixing and protection during curing. The Contractorshall complete Cementations Grout Inspection Record (Exhibit 20.5) or EpoxyGrout Inspection Record (Exhibit 20.6), whichever is applicable. A separateExhibit shall be completed for each equipment foundation. The tag number for

the equipment or structure shall be recorded on the exhibit. Miscellaneousstructural bases may be combined on one exhibit provided the unit, area, ordrawing numbers are properly recorded.

Verify that tests for consistency (for cement grouts), temperature, and requiredcompressive strength tests have been taken by the testing laboratory.

Inspect post-grouting work such as stripping of forms and cleanup. Ensure thatthe grout blends with the sides of the foundation and that the required chamfer isin place.

20.5.3 Exhibits

20-5 Cementations Grout Inspection Record

20-6 Epoxy Resin Grout Inspection Record

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20.6 STRUCTURAL STEEL PROCEDURE QCC 2.0

20.6.1 Scope

This procedure has been developed to detail quality control of structural steelconstruction performed by a Contractor managed by Savant. This procedure isbased on the prime contractor performing the required surveying to ensurecorrect verticality and alignment, erection of steel, bolt tensioning and welding.All structural steel materials, foundations, grouting of base plates and anyrequired non-destructive examination will be supplied or performed by theContractor.


The Contractor is responsible for the quality of structural steel construction andshall perform the following:

Provide written certification and design calculations for all pre-engineered metalbuilding systems. Samples will be provided as per the specifications for review,and approval and colour selection.

Check the verticality, alignment and level of erected structural steel to ensure thatit complies with project specifications.

Check the camber of beams upon arrival at the project site and before erection.

Ensure that bolt-tensioning activities are performed in accordance with project

specifications. The Contractor shall provide calibration certificates if a torquewrench is utilized to check bolt-tensioning operations.

Ensure that additional holes required for field erection are produced so that theholes are round with smooth edges. Holes shall be drilled or reamed to achievethe final required size.

Provide samples of grout material for testing by the material-testing laboratory.

Verify that all welding is performed in accordance with approved weldingprocedures and AWS D1.1 standard. Welders shall be qualified in accordancewith AWS D1.1 and be in possession of a valid qualification card. The Contractor

shall maintain Welders Qualification Log - Structural (Exhibit 20-7) during thecourse of construction. Ensure that welding, which does not meet AWS D1.1 anddrawing requirements, is replaced or repaired.

Inspect the completed steel structures, including all site welding, and correct anydeficiencies before requesting Savant to perform an acceptance inspection.Document inspection results on the Structural Steel Inspection Record (Exhibit20-8).

Verify compliance with drawings, specifications, including material, welding andfabrication.

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20.6.3 Exhibits

20-7 Welders Qualifications Log (Structural)

Structural Steel Inspection Record

20.7 BUILDING CONSTRUCTION PROCEDURE QCC 3.0

20.7.1 Scope

This procedure has been developed to detail quality control of buildingconstruction performed by a Contractor managed by Savant. This procedure isbased on separate Contractor performing the building erection, electrical work,and commissioning an HVAC system.


The Contractor is responsible for the quality of building construction and shallperform work as follows:

Ensure that building materials are properly stored and protected on site

Inspect the in-process construction to verify that the work complies with thespecifications, drawings, and contract Scope of Work

Check alignment, verticality and level of structural steel to ensure it complies withproject specifications. As a minimum, the tolerances shall at least comply with

AISC Handbook of Steel Construction.

Ensure that bolt-tensioning operations are performed in accordance with projectspecifications. The Contractor shall supply a certificate of calibration if a torquewrench is utilized to check bolt-tensioning activities.

Verify that all welding to the structure is performed in accordance with approvedwelding procedures and AWS D1.1 standard. Welders shall be qualified inaccordance with AWS D1.1 and be in possession of a valid qualification card.Welders shall be listed on the Welders Qualification Log - Structural (Exhibit 20-7). Ensure that welding, which does not meet AWS D1.1 and drawingrequirements, is replaced or repaired.

Verify that all control systems have been loop checked and that the heating andventilating or HVAC system has been balanced and documented.

Inspect the completed building and correct any deficiencies before requestingsavants final acceptance inspection. Inspection shall include the structurewelding, masonry, materials, plaster, doors, windows, cladding, flashing, trim,drywall, floor coverings, carpentry, roofing, plumbing, electrical and lighting. Afunction test shall be performed on doors, windows, plumbing, electrical andlighting.

Document inspection results on the Building Inspection Record (Exhibit 20-9).

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Maintain a file of inspection and testing activities performed on the building. Aseparate file shall be maintained for each building. In addition to the inspection

and testing records, the file shall also contain:

Vendor data and drawings for equipment installed in the building

Data sheets for the equipment in the building

Balancing report(s) for HVAC system

20.7.3 Exhibits

20-7 Building Inspection Record

20.8 EQUIPMENT PROCEDURE QCC 4.1

20.8.1 Scope

This procedure has been developed to detail QC of field erected pressurevessels, exchangers, fired heaters, rotating equipment and specialty equipmentinstalled by Contractor at field sites managed by Savant. This procedure isbased on erection only and does not address welding to/on the equipment. Anyrequired welding, repairs or alterations to pressure vessels or fired heaters mustbe performed in accordance with code. The Contractor shall be in possession ofcode symbol stamps if required by the jurisdictional authorities.

This procedure is also based on the Contractor performing any tray work,

painting, surveying, grouting, refractory, and equipment protection. Refer to theapplicable discipline procedures as required by the Scope of Work.

Refer to applicable procedures if concrete, electrical, piping, instrumentation, orinsulation included in the Scope of Work.


The Contractor is responsible for the quality of his work and shall perform thefollowing:

Check the anchor bolt locations and elevations prior to setting equipment on the

foundations. Savant is to be immediately notified if anchor bolt locations orelevations are not correct.

Check the plumb, alignment, level and orientation of equipment immediately afterinstallation. This check shall be performed in accordance with the ContractScope of Work, specifications and drawings. Deficiencies shall be corrected bythe Contractor prior to grouting operations.

Ensure that any required grouting is installed in accordance with the requirementsof procedure QCC-1.5

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Ensure that any required equipment protection is performed in accordance withthe requirements of procedure QCC-11.0

Ensure that any required painting is installed in accordance with the requirementsof procedure QCC-8.1

Inspect the installed equipment and correct all deficiencies prior to requesting anacceptance inspection by Savant. The Contractor shall inspect the equipment inaccordance with the contract Scope of Work, specifications, drawings, andEquipment Inspection Reference (Exhibit 20-10). Deficiencies detected by PMCwill be recorded on a punch list and submitted to the prime contractor(s) forcorrection.

Complete and sign off Final Closing Authorization (Exhibit 20-12), when vessels,exchangers or heaters are considered complete, clean and acceptable by theContractor and Savant.

20.8.3 Rotating Equipment

Perform a preliminary alignment of equipment in accordance with thespecifications and manufacturer requirements prior to grouting operations.Perform a cold alignment after grouting is complete and the piping has beenconnected and tightened. A final alignment check shall be performed in thepresence of Savant after the piping connections to the equipment have beenloosened.

Air-cooled heat exchangers are to have alignment and settings work performed

after piping is connected.

Document each alignment on Rotating Equipment Alignment Record (Exhibit 20-13).

Cleaning of the lube/seal oil system shall be documented on Lube Oil FlushingInspection Record (Exhibit 20-14).

20.8.4 Specialty Equipment

Equipment such as conveyors, elevators, screens, feeders, etc. are to beinstalled in accordance with the specifications, drawings and contract Scope of

Work. Each alignment shall be documented on Exhibit 20-13. Deficiencies are tobe corrected prior to requesting Savants acceptance inspection.

20.8.5 Elevated Storage Tank

Elevated storage tanks are to be installed in accordance with the specifications,drawings and contract Scope of Work. Material certification is required for tankmaterials. Water tanks will be coated, which will require inspection of surfacepreparation, and verification of the dry film thickness. A water test anddisinfections is required per the specifications. Deficiencies are to be correctedprior to requesting Savants acceptance inspection.

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20.8.6 Sanitary Sewer Pump Station

Sanitary Sewer Pumping Stations are to be installed in accordance with thespecifications, drawings, and contract Scope of Work. Material certifications andperformance curves are required on the pumps and the electric sewage grinder.All pumps will be bumped and run to verify rotation. Pump motors as well asseals and cables will be hi-potted. A start-up test is required on lift station pumpsby the pump manufacturer and both a start-up test and performance test arerequired on the electric sewage grinder.

20.8.7 Detention Equipment

Detention equipment is to be installed in accordance with the specifications,drawings, and contract Scope of Work. The Contractor should conductperformance tests on each locking device and control lock to ensure that thesystem operates properly. Savant shall witness the test.

20.8.8 File Retention

Records shall be retained by the Contractor for each piece of equipment. Thefiles shall be maintained by equipment tag number and shall contain all relatedrecords for that tag number, e.g.:

10-20-002 Feed Pump

This file will contain (where applicable):

Alignment records for motor to pump

Grouting records for pump base

Grounding records, if required

Electric motor run-in records

Equipment preservation records for pump and motor

coating or insulation records

records of field repairs or NDE performed on this piece of equipment

20.8.9 Exhibits

20-10 Equipment Inspection Reference

20-11 Equipment Pressure Test Record

20-12 Final Closing Authorization Record

20-13 Rotating Equipment Alignment Record

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20-14 Lube Oil Flushing Inspection Record

20.9 UNDERGROUND PIPING PROCEDURE QCC 5.0

20.9.1 Scope

This procedure has been developed to detail quality control of undergroundpiping work performed by a Contractor managed by Savant. This procedure isbased on the Contractor performing the required surveying to ensure properlocations, excavation, compaction of soil below and above the pipe, welding,wrapping, holiday testing, non-destructive testing and pressure testing.


The Contractor is responsible for the quality of underground piping construction

and shall perform his work as follows:

Ensure locations for lines are correct by proper surveying from establishedreference points at the site. Depth of excavation is to be checked as well asslope or grade.

Ensure that compaction values have been attained, before and after laying thepipe, when sand bedding is specified in the contract Scope of Work. All areaswith low compaction are to be corrected before and after laying the pipe in thetrench.

20.9.3 Coating and Wrapping

Inspect in-process coating and wrapping applications that includes surfacepreparation; coating and wrapping methods; protection and handling of wrappedpipe; and repairs to damaged coatings and wrappings. Test for holidays in thecoating and wrapping. Results shall be recorded on Coating and Lining Holiday

Test Record (Exhibit 20-15).

20.9.4 Welding

Ensure that welding is performed using qualified welders and approved weldingprocedures. Welders shall be qualified in accordance with ASME Section IX.Maintain Welder Qualification Log (Exhibit 20-16) during the course of

construction. Maintain welding consumable as specified in Consumable StorageReference. The Contractor shall visually inspect all field welds to ensurecompliance with the applicable codes. The welding inspector shall be certified asrequired by code.

20.9.5 Weld Records

Maintain a line map indicating radiography locations. Weld locations do not haveto be recorded on a weld map for underground drains, sewers and firewater lines.Weld maps, indicating weld numbers and radiography locations, shall bemaintained for underground pressure process piping (i.e., fuel gas, etc.) withinthe plant site boundaries.

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Verify that all welds are low stress stamped with the welder's symbol and markedon the pipe adjacent to the weld outside of the shrink sleeve area.

Maintain Daily Welding Report (Exhibit 20-17) on a daily basis while weldingactivities are ongoing. All welders producing butt, socket or fillet welds are tohave their work recorded. A copy of the Daily Welding Report will be submitted toSavant daily.

20.9.6 Radiography

Radiography is according to code and specifications. All required NDE must beperformed and clearance documented on Piping Pressure Test Record (Exhibit20-18) prior to pressure testing the line(s).

20.9.7 Punching

Inspect the line(s) prior to pressure testing to ensure that all work complies withthe drawings and contract Scope of Work. All deficiencies are to be correctedbefore pressure-testing activities are commenced.

20.9.8 Pressure Testing

Pressure test the line(s) in accordance with specifications and applicable code.Record the results on Exhibit 20-18, and ensure that all information has beenrecorded. Exhibit 20-18 must be signed by Savant. All sanitary systems will beair-leak tested and tested for infiltration/escape. All leaks detected duringpressure test activities must be repaired and the pressure test repeated.

20.9.9 Restoration

Perform restoration activities on the line(s) pressure tested to ensure that allwater is drained, stoppers have been removed, and that any in-line instrumentsremoved for the pressure test have been installed. Document that restoration iscomplete by signing the bottom section of Exhibit 20-18.

20.9.10 Sterilization of Water Lines

After pressure testing, all water lines will be sterilized by chlorination per AWWAC-65.

20.9.11 Drawings

Colour-code the line, indicated as pressure tested and accepted, on a copy of theunderground piping plan.

Produce as-built of the line(s) if location, depth or slope differs from theconstruction drawings.

20.9.12 Exhibits

20-15 Coating and Lining Holiday Test Record

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20-16 Welder Qualification Log (Piping)

20-17 Daily Welding Report

20-18 Piping Pressure Test Record

20-19 Hydrostatic Test Report

20.10 PRESSURE PIPING PROCEDURE QCC 5.1

20.10.1 Scope

This procedure has been developed to detail quality control of above-ground

pressure piping constructed by a contractor at a field site location managed bySavant. This procedure is based on the contractor performing erection of pipe,welding, pressure testing, installing steam/glycol tracing and stress relieving ofthe pressure piping. Refer to procedure QCC-10.0 if purchase and receiving ofmaterial is included in the contract Scope of Work. The contractor shall be inpossession of an ASME and National Board accreditation (as applicable) forcode-stamped work. If the contractor has an acceptable QC program, contractormay use his procedures with the understanding that the following procedures andExhibits are considered a minimum requirement and are mandatory. Thecontractor has the option of using his own documentation exhibits provided theycontain at least the information contained on the enclosed forms and areapproved for use by Savant.


The contractor is responsible for the quality of above-ground pressure-pipingconstruction and shall perform his work as follows:

Control piping drawings to ensure that only the latest revision is available in thefield for pipe erection.

Inspect in-process erection of each line to verify that it is being fabricated anderected in accordance with the drawings. Immediately notify Savant if erectedspools are found to have fabrication errors.

20.10.3 Welding

Verify that welding procedures have been approved and are on file at site.

Ensure that welding consumables are stored and maintained as detailed in theproject specifications.

Ensure that welders hired for the site are in possession of a current qualificationand that the welders are utilized to perform welding only within the limitations oftheir individual qualifications. (See Document welder qualifications on WeldersQualification Log (Exhibit 20-16)). The contractor shall issue low stress stamps to

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each welder and ensure that all welds are stamped by the responsible welder.When specifications do not allow hard stamping of welds, then the welder's

symbol shall be marked beside the weld using a paint stick that is free of lead,sulphur and chlorides.

20.10.4 Visual Inspection

Visually inspect in-process and completed pipe welds. The welding inspectorshall be certified as required by code. Visual inspection shall include: weldconsumables, joint preparation, fit-up, preheat, interpass temperature, weldprocedure variables, and weld condition between passes, appearance of finishedwelds and consumable control and storage. Repair all external defects, asdefined by the ANSI B31.3 Code (as applicable), prior to performing requiredradiography.

20.10.5 Radiography

Initial qualification welds radio graphed for a particular welder is not to beconsidered part of an assigned lot of welds. Firewater and drain lines do notrequire the first two welds radio graphed. If a welder starts on drain or firewaterlines, he shall have his first two welds radio graphed when he starts work on otherline classes. (see Document data for completed welds on Daily Welding Report(Exhibit 20-17)). This exhibit shall be completed by the contractor on a dailybasis to indicate his welder's daily production and a copy submitted to Savant.

Record the date welded and welder's symbol on Welding/NDE Status Log(Exhibit 20-20) on a daily basis. The information shall be taken from the Daily

Welding Report.

Arrange for radiography of pipe welds in accordance with the code andspecifications. Welds to be radio graphed for random radiography must beselected from sample lots established from Welder B31.3 Random RadiographyControl Log (Exhibit 20-21). Lots are to be established as 20 welds for 5%radiography and 10 welds for 10% radiography. The contractor shall ensure thatExhibit 20-21 is updated on a daily basis from the information recorded on Exhibit20-17. All radiographs and envelopes shall have the following informationrecorded: contract number, line number, line class, sheet number, weld number,pipe size, pipe schedule, welder's symbol and date. In addition, the interpretationreport shall detail the isotope used, the effective focal size, the class and brand

name of film used; and the NDE contractor's procedure number. The procedurenumber must be referenced in the contractor's approved written proceduremanual that will detail: the type of exposure (single or double wall), the type ofviewing (single or double wall), the number of films per cassette and the minimumsource-to-film distance.

20.10.6 Maintenance of Welding Records

Maintain welding records on a daily basis during the course of construction. Allfield welds on isometrics shall be pre-numbered. Each sheet has its own set ofnumbers; so it is imperative that the line number and sheet number be recordedon Status Log. Welds in straight run pipe are to be recorded on the piping

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drawings. When straight run pipe is being double jointed on the ground and it isnot certain which line it belongs to, use the prefix "DJ " before these field welds.

Maintain a separate log of "DJ " welds that is unique to the "DJ " number usingWelding/NDE Status Log - Double J oints (Exhibit 20-22). In other words, therewill be one DJ -1 on the entire job. Ensure each "DJ " weld is marked twice at 1200intervals. Weld maps shall accurately show the final location of all "DJ " welds.

Each isometric drawing shall have Welding/NDE Status Log (Exhibit 20-20),attached over the Bill of Material section. This log must be maintained on a dailybasis as it will serve as a complete summary of all NDE performed on that portionof the line. This information is essential when the time comes to provide NDEclearance for test packages.

20.10.7 Welding/NDE Documentation

Establish and maintain welding/NDE documentation files. Line folders for eachline number shall be established. Each line folder shall contain:

Isometric drawings, piping plans or piping sketches showing the relative locationand number of each field weld for this line number.

Records of the NDE performed on this line.

Welding/NDE Status Log, Exhibit 20-20 showing the status of all welding andNDE performed on field welds on this line number.

Welding and welder records shall be maintained in the following manner:

Daily Welding Reports (Exhibit 20-17) chronologically filed in 3 ring binders.

Individual welder records containing Welder B31.3 Random Radiography ControlLog (Exhibit 20-21) for each line class requiring RT.

Welders Qualification Log (Exhibit 20-16) listing all welders and their currentqualifications supported by actual qualification records and copies of theirqualification cards.

Double J oint Welding/NDE Status Log (Exhibit 20-22) filed in 3-ring binders.

PWHT records shall be filed in chronological or numerical order.

20.10.8 Pressure Test Packages

Assemble pressure-test packages for the job. These packages are, as much aspossible, to be assembled so that they comprise a portion or all of a pipingsystem. This is required to facilitate system turnover at the end of the job. Eachpressure-test package shall contain the following:

Marked up piping drawings indicating extent of test; location of blinds; andequipment or instrumentation to be included or excluded from test. Lines beingtested are to be color-coded.

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Piping isometrics for lines included in the test. Isometrics are to indicate locationof blinds, valves open or closed, fill point, vent locations, equipment or

instrumentation excluded from test and location of additional supports if required.

A partially completed Piping Pressure Test Record (Exhibit 20-18) indicating linesto be tested (with origin and termination points), design test pressure, energylevel (if pneumatic), test medium, and test package number.

20.10.9 Inspection (Punch ing) Of Lines

Inspect completed lines using a copy of the above described pressure testpackage. Additional information such as standard drawings or specificationsshould be included to assist the contractor while inspecting (or punching) lines.Correct all deficiencies and ensure that the NDE clearance is signed off onExhibit 20-18 before submitting the package to Savant for acceptance inspection.Once a package is ready for pressure testing, issue two copies, plus the originalof Exhibit 20-18 of the pressure test package to Savant for acceptanceinspection. Deficiencies found by Savant will be recorded on a punch list andsubmitted to the contractor for correction. Once a package is consideredacceptable for testing, the release for testing portion of Exhibit 20-18 will besigned by Savant and returned to the contractor. The receipt of this signed formis notification to the contractor to proceed with pressure testing.

20.10.10 Pressure Testing

Pressure test the system and inspect the lines while under pressure. All leaksare to be repaired. Leaks which require draining of the lines are to be repaired

and the pressure test repeated. Record the actual test pressure, test mediumtemperature, start and finish times of test, pressure gauge number, calibrationdate and ambient temperature on Exhibit 20-18. Ensure that all requiredsignatures are recorded under "Piping Pressure Test Satisfactorily Completed."

20.10.11 Restoration

Drain the line(s) after successful completion of the pressure test and restore thesystem. Restoration includes removal of stoppers, installing instrumentationremoved for the test, replacing flappers in check valves and replacing plugs invents and drains. Notify Savant when restoration is complete so that anacceptance inspection can be performed. Any deficiencies found by Savant will

be recorded on a punch list and submitted to the contractor for correction.Acceptance will be documented by the sign off by Savant under "Line RestorationSatisfactorily Completed."

20.10.12 Steam Tracing

Steam and glycol tracing shall be installed in accordance with the drawings,specifications and contract Scope of Work. Any fittings which are to be left underthe insulation shall be leak tested prior to applying insulation. All leads from thesupply manifold are to be tested to verify that they run to the correctcorresponding return lead and to ensure that there are no leaks. All joints shallbe soaped while under pressure. Unless otherwise specified, the minimum test

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pressure shall be a 30 psi using either air or nitrogen. Document test results onExhibit 20-18.

Steam tracing records shall be filed by supply manifold number and area or unit.Copies of the supply manifold drawings must be attached to Exhibit 20-18.

20.10.13 Exhib its

These exhibits are to be provided at a later date.

N/A ANSI B31.3 Random Radiography Requirements Reference

N/A Radiographic Examination Marked-up Pipe Line Sketch (sample)

N/A Non-destructive Examination Marked-up Spool (sample)

20-20 Welding/NDE Status Log

20-21 Welder B31.3 Random Radiography Control Log

20-22 Welding/NDE Status Log (Double J oints)

20.11 ELECTRICAL PROCEDURE QCC 6.0

20.11.1 Scope

This procedure has been developed to detail quality control of electricalconstruction performed by a contractor at a field site location managed bySavant. This procedure has been divided into four main areas that are:Underground Electrical, Above-ground Electrical, Electrical Equipment, andElectric Heat Tracing. One or more areas may be disregarded or deleted if it isnot included in the Contract Scope of Work. Refer to the Material ReceivingProcedure if purchase and receiving of tagged electrical equipment is included inthe Contract Scope of Work.


The contractor is responsible for the quality of electrical construction work andshall perform the following:

Ensure that all electrical construction is installed, connected and tested inaccordance with the Scope of Work, project specifications, drawings andapplicable codes.

Maintain electrical files by the following methods:

Area or unit for grounding or bonding records.

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Substation or control building for power distribution and instrument cable records.

This will include the transformers, switchgear and MCC up to the MCC

distribution bus.

Equipment tag for rotating and electrical equipment. This will include the feedercable, switch and accessories from the tagged item, (i.e., lighting circuits frompanels or electric tracing circuits from panels).

Schedule inspection by governmental agencies when required by local laws.

20.11.3 Underground Electrical

Inspect in-process installation of the grounding system. This shall include:

Checking ground rods for correct type and depth

Inspecting grounding conductors and connections, as they are installed, prior tobackfilling

Colour code underground drawings, as required, to track in-progress installation

Test the resistance-to-earth for each ground rod; or designated group of rods; foreach foundation; as required by the drawings and specifications. The contractorshall record test data on Grounding System Inspection Record (Exhibit 20-23).

Inspect in-process duct bank and electrical manhole installation in accordancewith drawings, specifications and the Scope of Work

Inspect in-process installation of all underground cables. Document undergroundsplices for medium and high voltage cables on Exhibit 20-24 where allowed byspecification and code. Ensure cable pulling in underground duct banks isperformed in accordance with the specifications and Scope of Work.

Test installed underground cable. Document mega meter testing of power,control wire and cable on Exhibit 20-25; and instrument wire and cable on Exhibit20-26. Document Hi Pot testing of medium and high voltage cable on Exhibit 20-27 (or use suitable documentation from testing subcontractor).

Inspect duct bank prior to concrete placement. Ensure concrete is placed in

accordance with the project specifications and drawings.

20.11.4 Above Ground Electr ical

Inspect the in-process installation of electrical conduit, tray and cable pulling inaccordance with the specifications, drawings, and Contract Scope of Work. Thisactivity shall also include the welding of electrical supports. Ensure that weldersare qualified in accordance with ASME Section IX or AWS D1.1.

Test installed cable. Document mega meter testing of power, control wire andcable on Exhibit 20-25; and instrument wire and cable on Exhibit 20-26.

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Document High Pot testing of medium and high voltage cable on Exhibit 20-27 (oruse suitable documentation from testing subcontractor).

Inspect conduit seals and ensure that all seals have been poured after all cableshave been pulled, tested and instrument loop checks completed. Document onExhibit 20-27.

20.11.5 Electrical Equipment

Inspect the in-process installation of electrical equipment in accordance with thespecifications, drawings and contract Scope of Work. This activity shall alsoinclude termination of medium and high voltage cable. Anchor bolt locations andelevations shall also be checked for correctness prior to placing equipment.

Test field installed equipment as follows:

Transformers - document insulation resistance on Exhibit 20-28. Document liquiddielectric strength on Exhibit 20-29.

Rotating Equipment - document insulation resistance on Exhibit 20-30.Document motor run-in tests on Exhibit 20-31. Document D.C. High Pot tests onExhibit 20-32. Document equipment absorption ratio and polarization index onExhibit 20-33 (for motors over 200 hp).

Bonding or Grounding - document bonding resistance of electrical equipment onExhibit 20-34. Document bonding resistance of non-electrical equipment onExhibit 20-35. Exhibit 20-36 may be used where applicable.

Generators - document cold resistance test on Exhibit 20-30. Document load runtest on Exhibit 20-37.

Electric Equipment (Switchgear, MCC) - Document insulation resistance onExhibit 20-38. Document switchgear neutral ground resistor test on Exhibit 20-39. Document D.C. High Pot tests on Exhibit 20-40.

Perform pre-operational checks which include:

Adjusting timing circuits

Adjusting protective relays

Adjusting circuit breaker "trip" settings

Testing operation of automatic transfer switches

Testing uninterruptible power supplies (UPS)

Document the above tests on the appropriate vendor or third party testing agencydocumentation.

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Arrange for vendor representative, as required, to visit the site during equipmentinstallation. Vendor checklists and acceptance records shall be used to

document inspection and testing activities of their equipment.

Inspect completed equipment installation in accordance with the specifications,drawings, Contract Scope of Work and manufacturer's requirements. Correctdeficiencies before requesting Savant to perform their acceptance inspection.

20.11.6 Electr ic Heat Tracing

Inspect the in-process installation of electrical heat tracing in accordance with thespecifications, drawings and Contract Scope of Work.

Perform continuity and mega meter tests of electric tracing cable. Mega metertests shall be performed prior to installation, after installation, and after insulation.Document these tests on Exhibit 20-41, Electrical Heat Tracing Test Record.

20.11.7 Exhibits

These exhibits will be provided at a later date.

Underground Electrical

6-3R Grounding/Earthing Resistance Readings Test Record

20-23 Grounding/Earthing System Inspection Record

20-24 Medium and High Voltage Underground Cable Splice Inspection Record

20-25 Insulation Resistance (Power, Control Wire) Test Record

20-26 Insulation Resistance (Instrument Wire) Test Record

20-27 D.C. High Potential Test Record

Above-ground Elec tr ical

6-14R D.C. High Potential Test Record

Electrical Equipment

20-28 Insulation Resistance (Transformer) Test Record

20-29 Liquid Dielectric Strength Test Record

20-30 Insulation Resistance (Rotating Equipment) Test Record

20-31 Electric Motor Run-In Test Record

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20-32 D.C. Proof Test (Rotating Equipment) Test Record

20-33 Equipment Absorption Ratio and Polarization Index

20-34 Bonding Resistance Readings (Electric Equipment) Test Record

20-35 Bonding Resistance Readings (Non-electric Equipment) Record

20-36 Ground Resistance Readings Test Record

20-37 Generator Load Run Test Record

20-38 Insulation Resistance (Equipment) Test Record

20-39 Neutral Grounding Resistor Test Record

20-40 D.C. High Potential (Equipment) Test Record

6-22R Generator Cold Resistance Test Record

Electric Heat Tracing

20-41 Electrical Heat Tracing Test Record

20.12 CONTROL SYSTEMS PROCEDURE QCC 7.0

20.12.1 Scope

This procedure has been developed to detail quality control of control systemsthat are tested, calibrated and installed by a contractor managed by Savant.Refer to the Materials Procedure if receiving inspection is included in the contractScope of Work.


The contractor is responsible for the quality of control systems field operationsand shall perform the following activities.

20.12.3 Testing or Calibrating Instruments

Test and/or calibrate instruments in the field shop in accordance with vendorinstructions and project specifications. Pressure tests shall be documented onInstrument Pressure Test Record (Exhibit 20-42). Calibrations shall bedocumented on:

Exhibit 20-43 for switches

Exhibit 20-44 for solenoid valves

Exhibit 20-45 for instruments except switches and solenoid valves.

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Check all test equipment used for calibration, throughout the life of the job, asrequired by specifications. Document these checks on Control Systems Test

Equipment Calibration Log (Exhibit 20-46). Place calibration stickers on theinstruments that indicate date of last calibration and the date for the nextcalibration.

20.12.4 Inspection of Work

Inspect in-process installation that shall include:

Instrument racks and panels; locations and mounting

Process piping connections

Instrument air supply tubing

Pneumatic signal tubing

Heat tracing

Inspect instrument installation (except electrical installation) when the work iscomplete. The inspection shall be performed with applicable drawings andspecifications, an instrument data sheet and Instrument Loop InstallationInspection Record (Exhibit 20-47) for that loop. Record all inspection deficiencieson the punch list for each loop. Update the punch list once the deficiencies havebeen corrected, and submit the form to Savant as notification for acceptanceinspection.

20.12.5 Coordination of Work

Coordinate activities with the electrical contractor to ensure that all instrumentelectrical installation inspections and mega meter tests are complete for theinstrument(s) being inspected. This shall include:

Electrical cable racks and supports

Electrical conduit and support

Cable pulling

Mega meter testing cables prior to termination.

20.12.6 Pressure Tests

Test the instrument piping and tubing after the instruments have been inspected,accepted and documented. Pressure tests for pipe and tubing shall bedocumented on Exhibit 20-47.

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20.12.7 Calibration of Gauges

Ensure that test gauges are calibrated at least every three months, or wheneveraccuracy is suspect, and that a sticker is affixed to each gauge which details thegauge number and calibration date.

20.12.8 Continuity Tests

Test the continuity of instrument cables, as well as the correct cable terminations,after electrical installation inspection has been completed by the electricalcontractor. Document completion of these tests on Exhibit 20-47.

20.12.9 Loop Checks

Perform loop checks in accordance with project specifications. All loop checks

shall be performed from the installed instrument to the control room panel.Complete Loop Mechanical Completion and Acceptance Record (Exhibit 20-48)and Loop Installation Inspection Record (Exhibit 20-47) for the final acceptanceand sign off of the loop. Deficiencies detected during loop-check activities shallbe corrected and the loop check repeated.


Maintain instrumentation files during the course of construction. These files areto be maintained by loop and shall contain:

The loop drawing;

Associated electrical/detention drawing;

Applicable data sheets for instruments in loop;

Vendor data for instruments in loop;

Exhibit 20-43 (if required)




Exhibit 20-47

A separate file may be kept for miscellaneous instruments that are not part of aloop.

20.12.11 Exhib its


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20-42 Instrument Pressure Test Record

20-43 Switch Calibration Data Record

20-44 Valve Calibration Data Record

20-45 Instrument Calibration Data Record (Other)

20-46 Control Systems Test Equipment Calibration Log

20-47 Instrument Loop Installation Check List

20-48 Loop Mechanical Completion and Acceptance Record

20.13 INSULATION PROCEDURE QCC 8.0

20.13.1 Scope

This procedure has been developed to detail quality control of insulation workperformed by a Contractor at a field site location managed by Savant. It isassumed that any required tests of the insulation material will be performed by acontracted testing laboratory.


The Contractor is responsible for the quality of the installed insulation and shallperform the following:

Ensure insulation materials are kept dry in the original container. Fiberglass,ceramic fiber and calcium silicate that is exposed to moisture shall be dried out atambient temperatures before being covered.

Inspect in-process installation to verify that correct type and thickness of materialis being installed in accordance with specifications. Document the results of allinspections on the Insulation Inspection Record (Exhibit 20-49). The contractorshall verify that the correct line or tag number is recorded on this exhibit.

Inspect completed work prior to notifying Savant for final acceptance inspection.Deficient work, detected by Savant, will be documented on a punch list ordeficiency report. The contractor shall correct the deficiencies and notify Savantin writing, or by returning a signed off copy of the punch list, when the work isready for re-inspection.

20.13.3 Exhibits

20-49 Insulation Inspection Record (to be provided at a later date)

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20.14 COATINGS AND LININGS PROCEDURE QCC 8.1

20.14.1 Scope

This procedure has been developed to detail quality control of coatings andlinings work performed by a contractor managed by Savant. This procedure isbased on the contractor performing the surface preparation and applying therequired thickness of coatings or linings.


The contractor is responsible for the quality of applied coatings and linings andshall perform the following:

Ensure coating and lining materials are stored and mixed in accordance with

project specifications and manufacturer requirements.

Inspect the surface preparation and compare with the SSP-1 Vis-1 standards oras required by project Specifications. Ensure that surface finish for lined vesselsmeet the requirements of NACE RP-01-78 or as required by projectspecifications.

Inspect the in-process coating or lining application to verify that the work is free ofapplication or material defects. During lining application, the contractor shallcheck the temperature and humidity prior to each day's work.

Check dry film thickness of applied coatings or linings in sufficient locations to

verify that the required thickness has been applied.

Inspect completed coating or lining application for workmanship prior to notifyingSavant to perform acceptance inspection. Test continuity of linings using aholiday detector as per project specification requirements. Rubber liners are tohave the vulcanization checked. The lining surface shall also be checked forblisters, open seams, lifted edges, surface defects, pinholes, and hardness. Alldefects shall be repaired and retested.

Document inspection of coatings on Coatings Inspection Record (Exhibit 20-50)and inspection of linings on Linings Inspection Record (Exhibit 20-51). Bothexhibits are to be completed as the work progresses. A separate exhibit shall be

completed for each equipment tag number. Lines or structure may be groupedonto one exhibit provided the items are accurately listed or that a drawing isattached that details the items inspected.

Deficiencies will be documented on either a punch list or a deficiency report. Thecontractor shall correct the deficiencies and notify Savant in writing or byreturning a signed off copy of the punch list when the work is ready for re-inspection.

20.14.3 Exhibits

20-50 Coatings Inspection Record (to be provided at a later date)

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20-51 Linings Inspection Record (to be provided at a later date)

20.15 MATERIAL RECEIVING PROCEDURE QCC 10.0

20.15.1 Scope

This procedure has been developed to detail quality control of material receivingactivities performed by a contractor at a field site location managed by Savant.

This procedure is based on the contractor purchasing and receiving fieldconstruction material.


The contractor is responsible for field material receiving activities and shallperform the following activities.

20.15.3 General Requirements

Verify that all material received meets the requirements of the purchase order.The contractor shall ensure that:

The material is correctly marked, labelled or tagged

The correct quantities and sizes of items are received

Parts, accessories or unassembled items that were shipped separately havebeen identified, tagged or collected

Shipping protection is satisfactory

Item code numbers are clearly legible (where applicable)

For materials and equipment supplied by the Employer, perform receivinginspection and acceptance in accordance with specifications, site procedures andcontract requirements. Any deficiency in material or equipment shall immediatelybe brought to the attention of Savant for resolution.

20.15.4 Receiv ing Equipment

Inspect received equipment as it arrives at site. The contractor shall open allboxed accessories to ensure that quantities, sizes, identification and condition areacceptable and comply with purchase order requirements. Inspection of receivedequipment shall also include:

Checks for damage. Any damage shall be recorded on a damage report andcorrected. Where possible, the damaged equipment shall be returned to thevendor. The vendor shall be otherwise contacted if repairs must be made in thefield.

Verify that equipment arrives properly preserved in accordance with projectspecifications. Flange faces must be covered; equipment must have been

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thoroughly drained of water after hydro-testing; proper lubricants, desiccants orpurging gases, as required, must have been installed; and corrosion protection of

exposed surfaces, as well as under base plates, must have been performed.

Mega meter test electrical equipment, (i.e., transformers, switchgear, rotatingequipment and MCCs) to ensure internals were not damaged during transport ofthe equipment, if directed by Savant. Document insulation resistance fortransformers on Exhibit 20-52; Insulation Resistance for Rotating Equipment onExhibit 20-53, and Insulation Resistance of Switchgear and MCCs on Exhibit 20-54.

20.15.5 Receiving Piping and Plate Material

Inspect piping and pressure vessel plate material as it arrives at site. Thisinspection shall include:

Verify that piping or plate material is correctly stamped or stencilled with thematerial specification, grade, schedule or thickness, size and heat number. Pipespools shall be identified with the correct line number, line class and mark piecenumber.

Match the heat number to the mill test reports (MTRs) when MTRs are requiredby the project specifications or the contract Scope of Work. The item code andpurchase order number shall be printed on the MTR. If item codes are not used,then a system for providing easy trace ability of heat numbers to MTRs shall beutilized.

Verify that the correct colour code has been applied to the material as required inthe project specifications or contract Scope of Work. Material that is received andfound to be lacking a required colour code shall have the correct colour codeapplied by the contractor. Colour codes on piping shall have a stripe, at least 1"in width, (painted) that runs along the entire length of the pipe but does not coverthe pipe identification stencilling. Paints shall be free of sulphur, lead andchlorides.

Ensure that ASME material is kept separate from the other material. ASMEmaterial must be purchased to SA or SB grade, whichever is applicable andcolour-coded red or as required by specification.

Perform positive material identification (PMI) on materials to the extent specifiedin the project specifications or the contract Scope of Work.

20.15.6 Deficiency Reports

Issue a deficiency report for materials that do not comply with the contract Scopeof Work, project specifications, purchase order or drawing requirements.Deficient material, whenever feasible, shall be replaced by the supplier or vendor.When replacement is not possible, (i.e., due to schedule demands) the deficientmaterial shall either be repaired or accepted "as is." Repairs shall only beperformed using a procedure that has been approved by the supplier vendor and

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Savant. Acceptance "as is" must be approved by Savant and the Employer priorto issuing the material to the field.


Maintain files by purchase order number which contain a copy of the purchaseorder, receiving reports, any damage reports, any deficiency reports, MTRs, PMIreports, and any non-destructive testing, (i.e., MT or PT) performed on thematerial. The contractor shall maintain a separate file by piping item codenumber when the specifications or Scope of Work require mill test reports formaterial. A copy of the MTRs shall be kept, by item code number, in the itemcode file so that MTRs for material can be easily located at a later date. If itemcodes are not used, then the contractor shall utilize his own system that provideseasy trace ability of heat numbers to MTRs and purchase order numbers.

20.15.8 Exhibits


20-52 Insulation Resistance (Transformer) Test Record

20-53 Insulation Resistance (Rotating Equipment) Test Record

20-54 Insulation Resistance (Equipment) Test Record

20.16 EQUIPMENT PROTECTION PROCEDURE QCC 11.0

20.16.1 Scope

This procedure has been developed to detail quality control during equipmentprotection activities performed by a contractor at a field site location managed bySavant.

This procedure has been produced in two sections: one section on initialpreservation upon receipt at the site warehousing facility, and the other sectionon standard preservation operations for equipment issued to the field forces forinstallation. It is assumed that none of the equipment was ordered with a

requirement for long-term storage.


The contractor is responsible for equipment protection activities and shall performthe operations listed below, as applicable. Preservatives such as anti-corrosives,water-replacements, desiccants or rust inhibitors shall be purchased and used bythe contractors as required by the equipment manufacturer. Preservationactivities shall be documented on Equipment Protection, Preservation andInspection Record (Exhibit 20-55).

INITIAL PRESERVATION UPON RECEIPT

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Equipment is considered to be in storage the moment it is brought on site. Eachequipment manufacturer has similar requirements for storage. The contractor

shall review and implement the manufacturer's requirements for each piece ofequipment. As a minimum, the following operations shall be performed unlessspecifically prohibited by the manufacturer.

Pumps

Check for obvious damages to pump casing, coupling and drive components.

Flanged openings are to be sealed with steel or wooden flange covers andgaskets. Pipe openings are to be protected with plastic pipe caps and tape.

Threaded openings are to be coated and plugged.

Inspect the lube oil and seal flush piping and fill the pipes and reservoir with rustpreventative oil.

If ball-type bearings are used, the bearing housings must be filled withpreservative oil.

Apply protective rust inhibiting coatings on shafts, finished parts, and otherexterior surfaces vulnerable to moisture. Internal surfaces shall be sprayed withspecified fluids through pump nozzles and/or through casing drains. Vendorrecommended materials will be used.

Plug instrument taps.

Cover the unit with 6-mil. Minimum thickness transparent polyethylene film andseal it with tape, open to bottom.

Unless the pump is installed on its foundation, it must not be stored closer than150 mm to the ground. Pump skids are to be supported full length horizontally toavoid sagging. The pump shall be stored in such a manner as to afford easyaccess and air circulation.

Rotate the shafts 2-1/4 turns every month in the direction of rotation.

Motors

Remove the shipping cover, box or crate and the polyethylene shroud, but leavethe machine mounted on its skid. Inspect for obvious damage.

Ensure that all machined surfaces have rust preventative in place and in goodcondition.

Ensure that there is a moisture barrier between the machined feet and the skids.

Cover motor with 6 mil. Polyethylene film to protect against settling dust, dirt, ordebris. Ensure that there is adequate clearance for good ventilation around themachine.

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Store in a building at or above ambient temperature.

Remove drain plugs.

Rotate the shafts 2-1/4 turns every month in the direction of rotation.

Connect space heaters, if provided, and ensure proper operation.

Compressors

Upon receiving the equipment, conduct a thorough inspection noting any brokenseals and/or damaged covers. All components shipped loose must be checkedto ensure that all storage preparations and/or fixtures, etc., are still intact and ableto effectively protect the equipment. Check the inside and outside of the machineto make sure all running parts and exposed surfaces subject to corrosion are

adequately protected. If required, spray coat machined surfaces with rustpreventive oil.

Make sure all covers are bolted tight and all openings are properly closed againstmoisture and dust.

All equipment and packing boxes must be stored in a clean, high and dryenvironment. In addition, compressor bases must be stored on a level surfacesupported the full length of the skid or frame to prevent distortion.

Equipment and packing boxes must be adequately covered with tarps andpreferably stored in an environment-controlled building.

At least once a month, remove covers and check for condensation and adequateprotection against rust.


For Liquid Filled Transformers (on arrival and at eight week intervals)

Note vacuum/pressure gauge reading and compare to manufacturersrequirements.

Take sample for dielectric testing when required.

For Switchgear, MCCs, and Similar Equipment

Remove from packing crates and store in warm, dry, well-ventilated warehouse.

Connect space heater, if provided, and ensure proper operation (check everyeight weeks).

STANDARD PRESERVATION OPERATIONS FOR EQUIPMENT TO BEINSTALLED IN THE FIELD

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This procedure addresses the contractor who has equipment to be installed in thefield (usually directly on to the foundations). The contractor shall review and

implement the manufacturer's requirements for each piece of equipment. As aminimum, the following operations shall be performed:

Pumps

The pumps are to be weather protected at all times and are to be protected fromdamages caused by other construction activities.

Rotate shafts 2-1/4 turns every month in direction of rotation.

Mechanical seals are to have preservative oil injected into the seal faces throughthe flushing connection every six months. Injection bushing or floating ring-typeseals are to be regularly inspected to be sure they are clean and dry.

Inspect internal pump surfaces by removing the flange covers and recoat withpreservative as necessary every six months.

Inspect external unpainted surfaces and recoat with preservative as necessaryevery six months.

Inspect coupling and recoat with preservative as necessary every six months, orevery week if stored outdoors.

Motors

Inspect every month for:

Physical damage

Cleanliness

Sign of condensation

Integrity of protective coatings

Condition of paint discoloration

Signs of vermin or insect activity

Integrity of all closures

Satisfactory space heater operations. It is required that an alarm system be inplace to operate on interruption of power to the space heaters. Alarms are to beresponded to immediately.

Rotate shaft 2-1/4 turns in the direction of rotation.

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Compressors

Compressors are to be weather protected at all times and shall be protected fromdamages caused by other construction activities.

Every three to four weeks:

For Reciprocating Compressors

Inspect the internal surfaces of the frame for rust and dirt.

Inspect the cylinder bores for rust.

Inspect pressure vessels and piping for internal rusting.

Inspect components shipped loose such as the pistons, piston rods, packing andvalves by removing the protective coating of paper and check for rust. Carefullyrepackage parts after inspection.

If there is any rust present, clean and recoat with preservative oil.

Rotate crankshaft 2-1/4 turns.

For Centrifugal Compressor

Inspect exposed surface for rust and dirt. Clean rust and apply rust inhibitive oil.

Rotate shaft 2-1/4 turns.

If lube oil system has been flushed, the oil pump shall be turned on once a weekfor 15 minutes.


For Switchgear, MCC and Similar Equipment

Unless immediately energized, ensure space heaters, if provided, are connectedand operating properly. (Check every 8 weeks.)

20.16.3 Exhibits


N/A Equipment Protection, Preservation and Inspection Record(Sample)

20-55 Equipment Protection, Preservation and Inspection Record

002-405-007-QA-QC MANUAL.pdf

Documents

Transcript of 002-405-007-QA-QC MANUAL.pdf