Mechanical and Electrical Field Inspection Guideline

2002 Bechtel Corporation
All Rights Reserved.

No parts of this publication may be reproduced
in any form without the prior written or
expressed permission of the publisher.
Printed in the United States of America.
1997, 2001 Bechtel.qxd-6263-03/03 (old 5709-11/01)
Mechanical/Electrical
Field Inspection Guidelines
Table of Contents
Number
Construction Inspections
Construction Safety
Equipment Tag/Lockout
Receiving and Storage
Design Document Control
Material Control
Measuring and Testing Equipment
Control of Deficient Items
Records Retention
Heavy Lift Rigging

G-21
G-22
G-23
G-24
G-25
G-26
G-27
G-28
Rigging Method Selection

Rigging Performance
Movement by Transport
Mobile Cranes
Bridge Cranes
Base-Mounted Cranes
Rigging Components
Suspended Personnel Work Platforms
Field Welding
G-31
G-32
G-33
G-34
General Welding
Code Welding
Nondestructive Examination
Heat Treatment
Piping Systems
P-1
General Piping
1997, 2001 Bechtel

TOC-1
Table of Contents
Number
Title
General
G-1
G-2
G-3
G-4
G-5
G-6
G-7
G-8
G-9
P-2
P-3
P-4
P-5
P-6
P-7
P-8
Title
Large Pipe
Small Pipe
Embedded Piping
Storm and Sanitary Sewer
HDPE Piping
Valves
Hangers and Supports
Lined Piping
P-11
P-12
P-13
P-14
P-15
Plastic-Lined Pipes
Lined Pipe Gaskets
Kynar-Lined Pipe
PTFE-Lined Pipe
Lined PipeSaran or Polypropylene
Flushing, Testing, and Insulating

P-21
P-22
P-23
P-24
Flushing and Cleaning

Leak Testing
Pipe Insulation
Vibration Isolation and Control
General Mechanical Inspections

M-1
M-2
M-3
M-4
M-5
M-6
M-7
General Equipment Setting

Rotating Equipment
Coupling Alignment
Belt-Driven Equipment
Non-Rotating Equipment
Pumps
Elevated Steel Tanks
TOC-2
Table of Contents
Number
M-8
Title
Table of Contents
Number
Underground Storage Tanks
Mechanical Equipment
M-11
M-12
M-13
M-14
M-15
M-16
M-17
M-18
M-19
Boilers
Condensers
Heat Exchangers
Columns and Vessels
Steam Turbines
Combustion Gas Turbines
Diesel Engines
Furnaces and Heaters
Water Treatment Equipment
Heating, Ventilating, and Air

Conditioning
M-21
M-22
M-23
M-24
M-25
HVAC Installation
Ductwork
HVAC Fans
Air Conditioning Equipment
Forced Draft Cooling Fans
M-31
M-32
Crane and Hoist Installation

Testing Hoisting Equipment
E-7
E-8
E-9
E-10
Title
Electrical Installations (continued)
Lighting Systems
Grounding
Batteries
Cathodic Protection
Instrumentation Installations
J-1
J-2
J-3
J-4
J-5
J-6
Instrument Installation Review

Instrument Piping and Tubing
Instrument Mounting Supports
Instrumentation Cleanliness
Instrumentation Testing
Instrumentation System Release
Hoisting Systems
Electrical Installations
E-1
E-2
E-3
E-4
E-5
E-6
Embedded Rigid Conduit

Raceway
Electrical Panels and Switchgear
Electrical Equipment
Wire and Cable
Terminations
TOC-3
TOC-4
Guideline G-1
C. After Performing Inspections
A. Before Performing any Inspections
Review the contract, specifications, drawings, industry standards,

vendor requirements, and other project agreements on the work to
be inspected.
Determine what is required to be inspected.
Determine the frequency of inspection required.
Determine the method of inspection.
Determine requirements for third-party inspections.
Develop a formal plan for project inspection activities.
Check all approved design drawings including any approved
changes associated with the work to be inspected.
Review material requirements for the materials to be used and
obtain material samples for use in inspection activities where
appropriate.
Review project procedures and/or the contractor quality plan to
determine requirements before starting any inspection activities.
Identify which forms or documents must be completed to document
field inspection activities.
Guideline G-1
Immediately advise supervision and/or the contractor of any unacceptable work and the corrective action required to correct the deficiencies.
Follow up on all rejected work after corrective actions have been
implemented to ensure that the work is acceptable.
File all inspection records in the project files per procedure requirements.
B. During Inspections
Check that only approved materials have been used.

For materials that cannot be visually verified after installation,
establish controls to ensure that the correct materials have
been used.
Use material samples to verify that the in-place materials
match submitted samples, when appropriate.
Check key dimensional requirements including location, size, clearances, spacing, and other key dimensions for the installation.
Perform any required inspection verification testing such as slump
testing, torque verifications, and pressure test verifications.
Ensure that properly controlled and calibrated materials and
testing equipment (M&TE) devices are used for verification
testing.
When worker qualification requirements exist, ensure that qualified
personnel have performed the work.
Document all inspections per project procedure requirements.
If a formal quality control program is implemented on the project, document all inspections performed on the required form.
1997, 2001 Bechtel

G-1-1
G-1-2
Guideline G-2
Construction Safety
Construction Safety
Check that materials being used and structures, coatings, or

materials being worked on have been assessed for health
hazards.
D. Gases, Vapors, Fumes, and Mists
A. Personal Safety and General Crew Safety
Check that energy potentials such as excavations, confined

spaces, pressurized systems, electrical, chemical, physical agents
have been identified and are properly controlled.
Check that the required personal protective equipment has been
inspected and is ready for use when needed.
Is head, eye, ear, hand, foot, lung, or body protection
required?
Check that safe access is provided to the work area.
Check that required permits are issued and encompass inspection
activities.
Examples of permits include: cold work, hot work, ignition
source, lockouts, confined space entry, area entry, excavation,
hole watch, and fire watch.
Check that a colleague or supervisor is knowledgeable of area of
inspection and time duration when working alone or with energy
potentials
Check compliance with site safety and health procedures such as
completed job safety analysis, scaffold tagging, lockout/tagout,
safety eye wash/shower test, hot work containment, stand-by personnel, barricades, and signs.
B. Emergency Preparedness
Check that medical personnel are available for advice and consultation on occupational health matters and that employees understand the reporting requirements and process.
Check that equipment for prompt transportation of injured personnel to a physician or hospital is available and that a communication
system for calling an ambulance is provided.
Check that the telephone numbers for physicians, hospitals, and
ambulance service are conspicuously posted.
Check that emergency procedures are understood for medical, fire,
and natural emergencies.
Check that emergency exit routes and staging areas are clear and
unobstructed.
Check that fire protection equipment such as fire hydrants, hoses,
extinguishers, and sprinklers is readily available and serviceable.
Check that emergency eye wash and showers are available and
operational.
C. Hazardous Materials
Check that employees are knowledgeable of the hazards and control measures associated with all chemicals in use.
1997, 2001 Bechtel

G-2-1
Guideline G-2
Check that employees are not exposed to amounts in excess of

threshold limit values. Have an industrial hygienist evaluate any
concerns.
Ensure that equipment or protective measures intended to reduce
or control exposure are approved by a competent industrial hygienist and are being used properly.
E. Ventilation
Check that threshold limit values are not exceeded when fumes,
mists, or dusts are removed by ventilation.
Ensure that exhaust systems do not draw harmful substances
through work area.
Check that exhaust systems operate continually if needed and are
shut down when required.
Check that all ventilation systems for dusts, fumes, mists, vapors,
or gases are discharged to outside atmosphere and away from
intakes.
F. Flammable and Combustible Liquids
Check that only approved and properly labeled containers, portable

tanks, and metal safety cans are used for the storage and handling
of flammable liquids.
Check that temporary buildings, fire hazards, equipment, or materials are not placed where they obstruct exits.
Check that temporary buildings placed inside another building are
noncombustible or have a 1-hour fire resistant rating.
Check that outside buildings are at least 10 ft (3 m) from other
structures.
Check temporary heating devices for clearance from combustible
material.
Check that heaters on wood floors are placed on noncombustible
material, extending a minimum of 2 ft (0.5 m) on all sides.
Check that clearance between heaters and tarpaulins, canvas, or
similar coverings is at least 10 ft (3 m). Coverings must be securely fastened to prevent contact with heater.
Check that temporary heating devices are equipped with pilot and
automatic shutoff valve to prevent flow of fuel if flame goes out.
Check that fluid used in hydraulic powered tools is fire-resistant.
Check that covers are used on containers with hazardous or flammable wastes.
G-2-2
Construction Safety
Guideline G-2
G. Fire Prevention Measures

Ensure that a fire prevention and protection program is in place at
the site.
Check that combustible materials are isolated from hot work either
by distance or fire-resistant covers.
Check that slag and hot materials are properly contained.
Check that hot work permits are properly executed.
Check that scrap wood, cartons, and other combustibles are
promptly and properly disposed.
H. Welding and Cutting Operations
Check that hot work permits are being used.

Ensure that fire extinguishers are present during all welding and
cutting operations.
Check that oxygen and fuel cylinders are stored at least 20 ft (6 m)
apart.
Ensure that only trained personnel operate welding and cutting
equipment.
I.
Compressed Gases
Check that cylinders are segregated in well-ventilated areas.

Ensure that smoking is prohibited in cylinder storage areas.
Check that cylinders are stored in a secure and upright position.
J. Ionizing Radiation
Check that persons using x-rays or radioactive materials are qualified or licensed where necessary.
K. Nonionizing Radiation
Check that only qualified, trained personnel operate laser equipment.

Check that laser safety goggles are provided when power exceeds
0.005 watts and that employees are not exposed to intensities over
allowable limits.
Check that areas are posted with warning signs when laser equipment is used.
Check that lasers are turned off when not in use.
Check that laser beams are not directed at employees.
Check that lasers are not used when it is raining or snowing or
when there is heavy fog or dust in the air.
Check that labels indicating power are shown on laser equipment.
Check that laser beams are used in controlled areas and/or isolated from employee contact.
L. Illumination
Check that illumination is provided and is adequate for the task

being performed. Particular attention should be given to the following areas:
Exits and egress routes
G-2-3
Construction Safety
Guideline G-2
Work areas
All walkways including, ramps, runways, corridors, and stairways
Offices, shops, and storage areas
Parking lots, security, and access points.
M. Worker Activity Checklist
Is the employee watching what he/she is doing?

Is the employee watching where he/she is going?
When ascending/descending, is the employee following three point
rule?
A combination of feet and hands adding to three at all times.
Is the employee twisting, overextending, or jerking?
Is the employee lifting correctly?
Are employee body parts positioned to avoid pinch or pinned positions?
Is the employee in the line of fire?
Can an energy source contact, strike, or hit the employee?
Do employees communicate their actions, concerns, or warnings?
Do they request assistance?
Do employees preplan their work? Do they anticipate, recognize,
evaluate, and control hazards?
Are the correct tools being used for the task? Are they being used
correctly? Are the tools in good repair?
Are walking and working surfaces free of hazards?
Are vehicles operated at safe speed and do they have appropriate
alarms?
Are employees trained to operate equipment?
N. Head, Eye, and Face Protection
Ensure that appropriate head protection is provided and used by all

employees.
Check that eye and face protection devices are provided and used.
Check that adequate eye and face protection equipment is provided to prevent injury from physical or chemical agents.
Check that eye-wash devices are properly located adjacent to hazardous chemical storage or use areas.
O. Respiratory Protection
Check that respirators are an approved type (e.g., U.S. Bureau of

Mines or other local standard) and are designed to protect for the
specific type and concentration of contaminant in the work environment.
Check that employees required to use respirators are trained in
their use and are clean shaven.
Ensure that respiratory equipment is regularly inspected and is in
good condition.
Interchanging components from different manufacturers is
prohibited.
Ensure that used respiratory equipment is cleaned and disinfected
before reissue.
G-2-4
Construction Safety
Guideline G-2
P. Safety Harnesses/Lifelines/Retractable Reels
Check that safety equipment is used for employee safety only.

Items used otherwise should be destroyed.
Check that lifeline systems (anchorage points, cable size, clamps)
and safety harnesses have a minimum breaking strength of 5,400
lbs (2,450 kg).
Check for proper safety equipment inspection and storage.
Q. Occupational Noise Exposure
Ensure that employees are provided with hearing protection when

noise levels may exceed limits.
Check that an effective hearing conservation program is administered when noise levels continuously exceed limits.
Check that devices for hearing protection are worn properly.
R. Scaffolds and Ladders
Check that portable ladders are tied, blocked, or otherwise secured

to prevent displacement.
Check that ladders placed in passageways, doorways, or in other
areas where they may be displaced are protected by barricades or
guards.
Check that job-made ladders providing the only means of exit for
25 or more employees are double cleated and not more than 24 ft
(7.3 m) in length.
Check that ladder cleats are inset into side rails 1/2 inches (12
mm), or filler blocks are placed between cleats.
Check that ladders have been inspected and are properly
labeled/marked.
Check that scaffold and ladders are placed or constructed on solid
foundations. Adjustable or plane bases are required for scaffold
legs.
Check that scaffolding is properly tagged.
Check that standard guard rails and toe boards are provided on all
scaffolds that are 10 ft (3 m) or more above ground or floor.
Standard guard rails shall be minimum 42 inches (1 m) high, constructed with 2 inch x 4 inch posts and rails (or equivalent), 1 inch
x 6 inch mid-rail and 4 inch high toe boards (minimum). Sizes refer
to nominal or dressed lumber dimensions.
Check that scaffolds that must be passed or worked under are provided with screen from toe board to midrail.
Check that overhead protection is provided for workers on a scaffold exposed to overhead hazards.
Check that scaffold planks extend between 6 and 12 inches (15
and 30 cm) and are of scaffold grades material.
G-2-5
Construction Safety
Guideline G-2
Check that scaffold is secured to the building every 26 ft (8 m) vertically and every 30 ft (9 m) horizontally.
Check anchorage on two point suspension scaffolds. Anchorage
must be redundant and capable of supporting 6 times the intended
load.
Check working load of suspended scaffold. A maximum of 500 lbs
(227 kg) for two workers and a maximum of 750 lbs (340 kg) for
three workers.
Check that each employee has a separate independent lifeline.
S. Excavation, Shoring, and Trenching
Check for underground structures such as gas, water, electric, and

utilities before performing any excavation.
Check excavation depth. If greater that 4 ft (1.2 m), identify competent person.
Check atmospheric testing.
Check that burden is at least 2 ft (0.6 m) from excavation and
machine loading.
Check groundwater and groundwater control.
Check adjacent structures for shoring stability.
Check adequacy of shoring or angle of repose for soil and depth
conditions.
Check support and protection of roads and sidewalks.
Check for adequate access. Ladders or stairs are required for
every 25 ft (7.6m) of lateral travel.
Check that equipment ramps are adequate and that slope is not too
steep.
T. Hoists, Cranes, and Derricks
Check cables and sheaves for excessive wear and abrasion.

Check slings, chains, hooks, and eyes for defects, excessive wear,
or damage.
Check overhead utility potentials to ensure that lines are inactivated or removed or that work is at safe distance from the lines as
required by local regulations.
Check barricades or lift area isolation.
Check lift plan and verify weights calculations.
U. Housekeeping
Make sure that general site housekeeping is up to standards.

Ensure that scrap with protruding nails such as crates and boards
are removed and properly disposed from work areas.
Check that combustible scrap and debris is removed at least once
each shift or more frequently as required.
Verify that separate labeled containers are provided for waste,
trash, and oily rags.
G-2-6
Construction Safety
Guideline G-2
Ensure that scrap with protruding nails such as crates and boards
are removed and properly disposed from work areas.
Check that combustible scrap and debris is removed at least once
each shift or more frequently as required.
Verify that separate labeled containers are provided for waste,
trash, and oily rags.
V. Safety Nets
Ensure that safety nets are provided when the work place is more
than 25 ft (7.6 m) above the ground or water and when the use of
platforms, scaffolds, ladders, temporary floors, safety lines, or body
harnesses are impractical.
Check that nets extend 8 ft (2.5 m) beyond work edge where workers are exposed.
Check that nets are installed as close as possible to the work and
no more than 25 ft (7.6 m) below working level over ground or
water.
W. Miscellaneous Safety and Health Issues
Check that covers are on hazardous or flammable waste containers.

Check that employees working over or near water use life jackets.
Check that floor openings are guarded with standard handrails. A
floor opening is a hole 12 inches (30 cm) or more in its least dimension.
Check that runways are provided with standard rails and toe boards
when they are 4 ft (1.2 m) or more above the ground.
Ensure that an entry permit is issued and that the atmosphere is
tested and found safe or forced ventilation is provided before
employees enter a manhole or nonvented vault.
Check that an employee is available in the immediate vicinity for
assistance when work is being done in a manhole or nonvented
vault.
X. Sanitation
Check that containers for drinking water are so labeled.

Check that outlets for non-potable water are labeled.
Verify that no connection exists between potable and non-potable
water supplies.
Check that toilets are adequate and in proper working order.
Check that adequate washing facilities are provided for employees
handling hazardous materials.
Check that workers do not have to work in unsanitary conditions.
G-2-7
Guideline G-3
A. Establishing A Tag/Lockout Condition
Ensure that an authorized/affected worker completes a tag/lockout

request defining work or testing to be performed.
Before the equipment is turned off, ensure that the
authorized/affected worker understands:
Type and magnitude of energy involved
The potential hazards of the energy being controlled
The method of controlling the energy
Shut down the equipment per procedures avoiding hazards to
workers and equipment as a result of the equipment stoppage.
Physically locate, tag, and lock (install and try) all boundary energy
devices that will control and isolate the equipment from all energy
source(s).
Release, disconnect, and render safe all residual or stored energy
in the equipment.
Establish a method to monitor and verify equipment isolation if
there is a potential for residual or stored energy buildup.
Continue monitoring until equipment lockout is removed or the
potential for residual or stored energy buildup no longer
exists.
B. Working in a Tag/Lockout Condition
Ensure that an authorized/affected worker verifies that isolation or

de-energizing is complete before starting the work covered by the
equipment tag/lockout request.
Ensure that a test is performed on normally energized or cyclical
equipment parts exposed to the worker during the work operation
to verify that these parts are de-energized.
C. Temporary Removal of Tag/Lockout Devices for Testing

or Positioning
Inspect the work area, remove all nonessential items, and verify
that the equipment is operationally intact.
Inspect the work area and position all workers away from danger.
Notify all affected workers of the pending energization.
Remove the tag/lockout device.
Energize the equipment and proceed with testing or positioning.
Shut down the equipment per procedures avoiding hazards to
workers and equipment as a result of the equipment stoppage.
Reinstall tag/lockout devices and physically check all energy isolating devices.
Check all residual or stored energy sources to ensure that energy
has been released, disconnected, or rendered safe.
1997, 2001 Bechtel

G-3-1
Guideline G-3
Establish a method to monitor and verify equipment isolation if

there is a potential for residual or stored energy buildup.
Continue monitoring until equipment lockout is removed or the
potential for residual or stored energy buildup no longer
exists.
D. Release of a Tag/Lockout Condition
Inspect the work area, remove all nonessential items, and verify
that the equipment is operationally intact.
Inspect the work area and position all workers away from danger.
Notify all affected workers of the pending energization.
Ensure that the worker who initiated the control removes the
tag/lockout device returning tags and/or locks to the appropriate
custodian.
Energize the equipment.
Guideline G-4
Receiving and Storage

A. Receiving
Maintain a daily receiving log.

Check for loading and shipping damage to material and equipment.
Verify that items are free of damage caused by fire or high
temperatures, excessive weather exposure, environmental
damage, tie down failure, or rough handling.
Avoid contamination of the materials and components during
receipt inspection.
Check that material and equipment conform to size, type, quantity,
and configuration specified in the purchase order and on the detail
drawings.
Verify that all required supplier documentation is received with the
shipment.
Verify that Material Safety Data Sheets (MSDSs) are provided
for all chemicals.
Review supplier documentation for special identification, marking,
and tagging required by the purchase order or contract.
Make this review when the shipment is received to avoid the
added cost and schedule impacts.
Promptly identify and expedite all shortage items and initiate repair
or replacement of damaged items.
Avoid double handling by checking shipping and erection schedules.
Unload and transport directly to erection areas, where possible.
Follow manufacturer instructions and/or approved procedures
when unloading, rigging, handling, and transporting components to
and from rail cars or trucks.
B. Storage
G-3-2
Verify that good housekeeping practices are used in storage areas.

Systematize and record storage locations so that materials can be
located easily.
Provide full crane, truck, and rail access to storage areas.
Segregate and control access to damaged or rejected materials.
Provide dry indoor storage for instruments, electrical equipment,
weld rod, insulation, and other items, requiring protection from the
elements.
Provide numbered bin storage, where appropriate.
Identify and control items with a specified shelf life.
Perform user acceptance tests, where required.
Perform preventive maintenance for equipment per manufacturer
instructions.
Check that manufacturer storage and preservation requirements
are followed.
Ensure that flammable and hazardous materials are properly
stored.
G-4-1
Guideline G-5
Guideline G-6
Design Document Control
Material Control
A. Preplanning
Check that a site procedure exists to control project design documents and design document changes. This procedure must
address:
Verification of the documents received against project engineering, vendor, or subcontractor transmittals
Maintenance of document control logs (registers) listing the
current revision to each document
Control stamping of the documents
Field distribution of design documents using controlled distribution lists
Logging and transmittal of field changes such as Field
Change Requests (FCRs) and Field Change Notices (FCNs)
for approval
Receipt, control, and distribution of approved field generated
changes such as FCRs and FCNs
Check that personnel responsible for controlling and using design
documents are knowledgeable of the requirements.
Check that the central filing system is neat and well organized.
B. Central Document Control
Check that newly received documents conform to the applicable

project engineering, vendor, or subcontractor transmittal listing.
Check that the pertinent information for newly received documents
is entered into control logs or registers.
Check that newly received documents are stamped per site procedure requirements.
Check that newly received documents are distributed per the site
procedure.
Check that the document control system is regularly audited as
required by site procedures.
C. Implementation of Design Document Control
Check that documents are obtained from controlled sources per the
site procedure.
Check that the document has the appropriate stamp for the application.
Check for interim field changes to design documents per site
requirements.
A. Preplanning
Make sure that material availability and delivery are considered in

work scheduling.
Track critical procurements.
Expedite orders when required.
Establish priorities for material receipt and issue.
Check that a process/procedure is in place to control material procurement, receiving, storage, maintenance, and issue.
Define technical and quality requirements in purchase orders.
Identify and properly handle hazardous materials.
Perform receipt inspection for damage and purchase order
requirements.
Identify and implement storage and maintenance requirements.
Control material storage and issue.
Check that site personnel are knowledgeable of site material control process.
B. Implementation of Site Material Control
Check that required receipt inspection documentation is completed.

Check that material is properly handled from off loading through
installation.
Use proper handling practices.
Implement special handling requirements.
Check that material is properly stored.
Ensure that storage meets project and manufacturer requirements.
Control access to storage areas.
Maintain storage areas in a neat and orderly manner.
Ensure that materials can be easily located.
Check that material issue is controlled and documented.
Check that correct material is installed.
Material markings are correct.
Materials meet design requirements.
Material installation documentation is complete.
D. Document Turnover
Check that a project procedure exists for the turnover of records to

the client per contract requirements.
1997, 2001 Bechtel

G-5-1
G-6-1
Guideline G-8
Guideline G-7
Measuring and Testing Equipment
Control of Deficient Items
A. Preplanning
A. Preplanning
Review contract requirements, codes, standards, specifications,

drawings, procedures, and other site requirements to determine the
type, size, and range of equipment required to fall under the calibration control program.
Check that a site procedure exists to control Measuring and Testing
Equipment (M&TE) at the site. The procedure must address:
Usage control
Storage and maintenance of M&TE
M&TE labeling
Calibration expiration recall
Evaluation of M&TE that is lost, damaged, or found to be out
of calibration
Check that personnel responsible for using and controlling the
M&TE are knowledgeable of the requirements
B. Implementation of M&TE Control
Check that the M&TE appears to be functioning properly.

Check that the M&TE is labeled properly.
Check that the M&TE is not past the calibration due date.
Check that the M&TE has been properly withdrawn identifying:
Where will the M&TE is to be used
On what items the M&TE will be used
The value or range of values that the M&TE will be used to
verify
The name of the person who checked out the M&TE
Check that the M&TE is being used within the acceptable range.
Check that any required pre-usage or post-usage functional tests
are performed
Check that the required documentation is completed and that it
records:
M&TE identification
Value measured
Name of the person using the M&TE
Check that M&TE is returned to the designated storage location
1997, 2001 Bechtel

G-7-1
Check that a site procedure exists to control deficient items.

This procedure must address methods to:
Identify, document, and evaluate deficient items.
Prevent inadvertent use of deficient items.
Segregate deficient items, where necessary.
Control deficient items released for installation before the
deficiency is resolved.
Ensure that the final resolution of the deficiency is obtained.
Determine the cause of the deficiency and the appropriate
corrective action.
Notify appropriate functions of the deficiency and corrective
action.
Ensure that responsibility for review and disposition deficient items
is defined.
Verify that site personnel are knowledgeable of deficient item
control requirements.
B. Implementation of Deficiency Control
Check that deficient items are documented by the use of:

Receipt Inspection Reports
Punchlists
Deficiency Reports
Check that items released for installation before the final resolution
of the deficiency can be traced and retrieved from the installed
location.
Ensure that the deficiency is resolved before the item is turned over
or the deficiency is noted as an exception.
Check that dispositions have the required level of approval.
Check that all specified rework, repair, and verifications are performed and documented.
Check that measures are taken to prevent the inadvertent use of
rejected items by scraping, discarding, or destroying the rejected
items.
Check that the cause of the deficiency is determined and appropriate corrective action is taken.
Check that repaired or reworked items are reinspected as required.
G-8-1
1997, 2001 Bechtel
Guideline G-9
Guideline G-21
Records Retention
A. Preplanning
Check that a site procedure exists to control construction quality

records. This procedure must address:
Which construction quality records must be retained
Requirements for control of in-process construction quality
records
Requirements for filing and storage of completed construction
quality records
Appropriate fire protection
Provisions for supplementing or correcting completed records
Method for turning over completed construction records to the
client
Method of turning over completed construction records for
Bechtel archives
Check that personnel responsible for controlling construction
quality records are knowledgeable of the requirements.
B. Implementation of Construction Quality Record Retention
Check that construction quality records are complete and legible.

Check that records that are light, pressure, or temperature
sensitive are handled per manufacturer instructions.
Check that precautions are taken with electronic records to ensure
that only authorized personnel can access and make changes to
the records.
Check that the in-process construction quality records are stored
as required.
Check that completed quality records are filed as required.
Check for interim field changes to design per site requirements.
A. Preplanning
Preplan all heavy lifts and prepare a formal rigging plan for:
All lifts of more than 10 tons
All lifts of critical equipment or lifts over critical equipment
regardless of weight.
Obtain certified rigging engineer rigging plan review and approval
for all lifts of more than 50 tons.
B. Heavy Lift Rigging Plans
Determine configuration and dimensions of the items to be

handled.
Locate the center of gravity and determine weight using certified
vendor drawings.
Double check vessel weight with shipping scale weights.
Verify that the vessel is empty and drained of hydrostatic test water.
Determine if temporary shipping skids must be left in place for the
lift and if so, include the skid weight in the load evaluation.
Determine the method of attachment.
If attachment points are provided on the equipment, make
certain that they are intended to handle the entire weight and
not just a component.
Comply with fabricator handling requirements to prevent damage.
Determine necessity and availability of special handling devices.
Account for all rigging component weights in determining the load
to be lifted including the boom jib, wire rope, hooks and shackles,
and spreader beams.
Make appropriate crane capacity deductions per manufacturer
crane chart.
C. Work Site Evaluation
Determine the path of movement from receipt of final setting;

identify areas of restricted movement, including both lateral and
overhead clearances.
Check proximity of electrical power lines and maintain the minimum
required clearance in all transport and rigging operations.
Determine the adequacy of work areas.
Check floors, structures, and access roads for design-imposed load
restrictions.
Anticipate load distribution change during upending and other
handling operations.
1997, 2001 Bechtel

G-9-1
1997, 2001 Bechtel

G-21-1
Guideline G-21
D. Equipment Handling
Determine the proper orientation of the equipment in its final

location.
Place a matching orientation mark (e.g., plant north) on both the
equipment and the equipment support that can be matched during
setting operations.
Determine the proper handling sequence for equipment with several
components.
Determine whether wind, temperature, humidity, or rain will require
special handling restrictions.
Guideline G-22
Rigging Performance
A. Preplanning
Recheck clearance in path of lifting operations.

Check that the crane and/or equipment are on stable level ground
and that mats are used as shown on drawings.
Verify the type of crane.
Ensure that outriggers are fully extended before making the lift.
Check that the crane is positioned per the heavy lift rigging plan.
Verify that accessories, such as slings and shackles, have been
properly examined and inspected.
Verify that test certificates are available for all lifting equipment.
Verify that boom length, working radius, load line reeving are per
rigging plan.
Check that accessories are the size, capacity, and quality specified.
Check that nondestructive examination is performed on lifting lugs.
Check that softeners are placed over sharp corners and objects for
protection.
Verify that hydrostatic test water has been completely drained from
vessels before lifting operations.
Ensure that heavy lift rigging plan requirements are reviewed with
the superintendent, crane operator, ground crew, and competent
signal person(s) before making the lift.
B. Work Operations
Monitor rigging operations for compliance with the heavy lift rigging
plan.
Perform a preliminary lift by slowly raising and lowering load slightly
to ensure that all equipment is functioning properly and is
suspended at correct altitude.
Check that slings and load have equalized as required.
Ensure that walk loads are as close to the ground as possible.
Check that chain slings are not used.
Check that tag lines are used.
Hoist, traverse, and rotate the item as required for placement.
G-21-2
1997, 2001 Bechtel

G-22-1
Guideline G-23
Guideline G-24
Movement by Transport
Mobile Cranes
A. Transport Vehicles
Ensure that the transport vehicle complies with local motor vehicle
regulations.
Make sure that special conditions and equipment required for safe
transport of hazardous materials are identified and planned.
Determine the combined weight of the transport vehicle and trailer.
Verify that drivers and operators are licensed, qualified, and
certified as required to operate assigned equipment.
Develop an emergency plan for the transport effort.
Ensure that the height, width, and length of the load complies with
local regulations.
Preplan requirements for escort vehicles, transport signs, and
transport hours and verify compliance with local regulations.
Inspect transport vehicle and trailer to verify working condition of
horn, back-up alarm, lights, turn signals, tires, brakes, emergency
brake, ball and hitch, safety chains, reflectors, electrical wiring and
connections, and fire extinguishers.
Ensure that adequate tie downs and chocking are provided.
B. Load Evaluation
Confirm the weight of the component(s) to be transported by checking manufacturer documents and certified scale weights when
available.
Ensure that shipping skids are included in the weight determination.
Check for water that may be trapped in the component to be
transported and may increase the transported load.
Verify that the weight of the component to be moved is within the
design capability of the transport vehicle.
Verify that configuration and structure of the transport vehicle or
trailer bed will accommodate the component(s) to be moved.
Determine the combined weight of the transported component(s)
and transport vehicle.
Plan transport vehicle load distribution to avoid exceeding axle load
limits.
A. Preplanning
Note the boom model and number of parts of load line required by
the manufacturer load chart.
Determine whether a jib is to be used.
If so, note the mode, capacity, length, and offset required for
the lift.
Determine whether the crane will remain stationary and/or level
during all phases of the operation.
If load must be walked with the crane, verify that crawler cranes are
rated at 75 percent of tip-up.
Truck cranes are normally rated at 85 percent of tip-up.
Most manufacturers do not furnish information on conditions
for use.
Charts are normally based on capacity without outriggers.
Do not overload tires and running gear.
Critical loads must be carried over rear of crane on firm level
ground.
Check slings and fittings to ensure a safety factor of 5.
To determine safety factor, consider angle of sling, efficiency
of end connections, type of hitch, and reduction due to bending around corners and small radius pins.
Verify that softeners are in place if required to protect slings around
sharp corners or to protect the surface.
If a four sling lift is to be made, verify that any two slings are
capable of handling the entire load.
Verify that the rated capacity of the spreader bar (if used) is
adequate.
Verify that hand lines are used to control the load during lift
operation, if required.
C. Travel Route Evaluation
Verify that axle loadings do not exceed floor or access road

limitations.
Verify that vehicle maneuverability is compatible with the access
route.
Determine whether assistance is required to negotiate grades.
Verify that adequate clearance is available along access route.
1997, 2001 Bechtel

G-23-1
1997, 2001 Bechtel

G-24-1
Guideline G-25
Guideline G-26
Bridge Cranes
Base-Mounted Cranes
A. Preplanning
A. Preplanning
Note: Handling construction loads with bridge cranes permits

handling up to the rated capacity of the crane within the entire
area of coverage.
Check slings and fittings to ensure that they have a safety factor
of 5.
To determine safety factor, consider angle of slings, efficiency
of end connections, type of hitch, and reductions due to bending around corners and small radius pins.
Verify that softeners are in place if required to protect slings around
sharp corners or to protect the surface.
If four slings are used, verify that any two are capable of handling
the entire load.
Verify that the rated capacity of the spreader bar is adequate.
Verify that hand lines are used to control the load during lifting
operation, if required.
When handling loads through an access hatch, complete a clearance study to determine that sufficient drift is provided with the
hook in the upper limit position.
Before a base-mounted crane is used for rigging operations, the

entire system should be inspected by the person-in-charge or the
responsible field engineer.
Verify that the total load to be lifted includes the weight of the piece
plus an allowance of 10 percent for impact.
Verify that the hoist provides adequate line pull on one drum (or
two, if simultaneously) to make the lift. Line pull decreases as the
number of wraps on the drum increases.
Check the hoist to verify that it has adequate capacity to spool the
length of rope required for the lift with no less than two wraps on
the drum at all times.
Verify that proper anchorage installation of the rope to the
drum.
Ensure that the hoist is located at a sufficient distance from the lead
sheave to provide the proper fleet angle to ensure that the rope will
spool evenly on the drum.
Verify that the hoist anchorage provides a safety factor of 2 based
on the total line pull at any time, not including the weight of the
hoist.
Check whether the angle at which the rope leaves the drum will
produce a vertical or side force on the hoist.
Anchorage must be provided to resist these forces.
Select a load line that will provide a safety factor of 31/2 for the
most heavily loaded rope based on the maximum load to be lifted
by a set of falls.
Take into account end connection and friction from sheaves.
Verify that the size of rope used is adequate for the number of
parts of line used.
Select load blocks compatible with the load line whose rated capacity is equal to or greater than the maximum load they must hoist.
Select lead sheaves compatible with the load line and with a rated
capacity equal to or greater than the resultant of the load line entering and leaving the sheave.
The resultant is the bisector of the angle between the two
lines.
B. In-Process Inspections
Verify that the lead sheave is free to move its loaded position without interference and make provisions to prevent movement along
the member to which it is anchored.
Wire rope used to anchor lead sheaves must provide a safety
factor of 3.
Verify that load lines enter and leave sheaves squarely and not at
an angle that would cause the rope to bear on the lip of the sheave.
G-25-1
G-26-1
Base-Mounted Cranes
Guideline G-26
Verify that suspended from structural steel supporting the upper

load block is designed per AISC or other applicable design code.
Verify that the slings and spreader bars used to attach the load
block meet the same requirements designed for those used on
mobile cranes.
Verify that line speeds are slow enough to permit complete control
at all times.
Guideline G-27
Rigging Components
A. General
Have a competent person inspect components each day before

use for damage or defects.
Do not use hardware in other than intended use.
Do not exceed rated capacities.
Check for load capacity identification markings on the component.
B. Wire Rope Clips
Ensure that the U-bolt is applied over the dead end of wire rope and
live end rests in saddle; never saddle a dead horse.
Ensure that clip nuts are tightened evenly.
With a single clip, apply one base width from dead end of rope.
When two clips are required, ensure that the second clip is applied
as near to the loop or thimble as possible.
When three or more clips are required, ensure that clips are spaced
evenly with no slack in the wire rope.
C. Hooks
Visually inspect hooks for cracks, nicks, wear, gouges, and deformation.
Periodically perform non-destructive examination of hooks used in
frequent load cycles.
Inspect hooks to ensure that throat opening has not opened, that
tip is not bent more than 10 degrees out of plane, or that hook is
not distorted in any way.
Remove hooks from service that have excessive wear.
Do not repair, alter, rework, or reshape hooks by welding, heating,
burning, or bending.
For threaded shanks, the minimum thread engagement should not
be less than one thread diameter.
D. Eye Bolts
Do not use an eye bolt if it shows signs of wear or damage or if it

is bent or elongated.
For regular nut and shoulder eye bolts, apply load in the plane of
the eyenot at an angle.
E. Swivel Hoist Rings
Do not use swivel hoist rings if ring shows sign of corrosion, wear,
or damage or if the bail is bent or elongated.
Check already installed rings with a torque wrench before use.
Remove any spacers or washers installed between bushing flange
and mounting surface and retorque before use.
Ensure bail freely pivots 180 and swivels 360.
G-26-2
G-27-1
Rigging Components
Guideline G-27
F. Block and Tackle
Do not use if block and tackle show signs of permanent deformation, significant wear, or damage.
Inspect swivel fittings for shoulder running clearance, lateral
movement, wear, and deformation.
Inspect and refurbish bearings on sheaves that are loose or
wobbly.
Make sure the sheave groove matches the wire rope diameter.
Check sheaves for signs of deep or unusual channeling, rutting, or
corrugating along the walls and at the bottom of its groove.
Periodically inspect sheaves for groove diameter, bent or cracked
flanges, worn hubs, cracked welds, or cracked spokes.
Avoid excessive fleet anglesthe angle between the wire rope and
the sheave as it enters or leaves the sheave.
Fleet angles in excess of 2 can cause excessive wear and
rope twisting.
G. Slings
Do not use if damaged or defective.

Do not shorten with knots, bolts, or other makeshift devices.
Do not kink sling legs.
Balance basket hitch sling loads to prevent slippage.
Pad or protect slings from damage from sharp edges on the load.
Do not apply shock loadings.
Do not pull slings from under a load when the load is resting on the
sling.
H. Shackles
Identify load rating on the shackle.

Apply angle loads in the plane of the bow.
Do not side load round pin shackles.
Do not exceed 120 including angle between slings connected to a
shackle.
Reduce shackle working load limit per manufacturer requirements
when pad eye is less than shackle opening.
G-27-2
Guideline G-28

A. General
Verify that suspended work platform use is the safest and most
practical way to accomplish the task.
Ensure that all crane inspections are current.
Check that all hooks have a current inspection and have positive
locking type hook latches.
Ensure that the load chart is in the crane and that the operator is
familiar with all special chart requirements.
Verify that crane operational aids and safety devices are functioning and that the operator knows how to use them.
Ensure that the crane is on firm footing and the crane outriggers are
extended, down, and locked as applicable.
Check that the crane is level within 1% and is on a firm surface.
Verify stability of the footing during the full cycle of operation
test.
Ensure that the operator is able to verify that the crane is level.
Ensure that a firm, level "runway" or travel path has been prepared
for the weight and configuration of the crane used.
Ensure that counterweights are per crane manufacturer requirements.
Ensure that load lines are properly reeved and laying on drums.
Ensure that all drum hoists have full control load lowering and that
free fall is not used.
Check that the boom angle and radius indicator operates properly.
Check that the boom length indicator on telescoping booms operates properly.
Ensure that the positive anti two block device operates properly.
B. Rigging Requirements
Ensure that each bridle leg is connected to the master link or

shackle and that the load is evenly shared by all bridle legs.
Ensure that all rigging, wire rope, shackles, rings, master links, and
other rigging hardware have a safety factor of 5.
When non-spin cable is used, a safety factor of 10 is required.
Check that all wire rope eye fittings have thimbles.
Ensure that all load hooks are closed with locking type latches.
Ensure that all suspended work platform rigging equipment is
exclusive for that use.
Inspect all rigging for kinks and damage.
Check that all shackle pins are nut with pin retainer type.
G-28-1
1997, 2001 Bechtel
Guideline G-28
C. Suspended Work Platform Requirements
Ensure that the platform is designed with a safety factor of 5.

Ensure that the maximum rated load and personnel capacity is
posted on the platform.
Ensure that the platform is provided with a perimeter grabrail,
guardrail, mid-rail, and toeboard.
Ensure that body harness anchorage points are provided.
Ensure that the access gate opens inward and is positively
prevented from swinging outward while the platform is in use.
Ensure that the access gate has positive locking to prevent
accidental opening during operation.
Ensure that employees can stand upright in the platform.
Ensure that overhead protection is provided on the platform when
there is a potential of falling objects.
D. Proof-Testing, Trial Lift, Inspection, and Pre-Lift Meeting
Ensure that a pre-lift meeting is held with the operator, signal person(s), employee(s) to be lifted, and the person responsible for the
work.
Ensure that employees will be protected from special hazards such
as electrical hazards and power lines and in operations where the
platform will be out of the operator's view.
Ensure that a suspended work platform use authorization has been
issued, dated, and approved for the work.
Verify that the platform and rigging are proof-tested to 125% of the
platform rated capacity.
Verify that an unoccupied trial lift is performed with the platform
loaded to the anticipated lift weight.
Perform a trial lift each time the crane is moved.
Perform a post-trial lift crane inspection and correct any deficiencies.
Ensure that actual loads are less than 50% of the crane rating.
Verify that all systems, controls, and safety devices are functioning
properly and that no interferences exist.
Before lifting personnel, hoist the platform slightly to verify it hangs
level.
Check that all hoist ropes are free of kinks.
Check that multi-part lines are not twisted around each other.
Check that the hook is centered over the load.
Recheck the crane bearing surface and relevel the crane as
required.
Reinspect crane safety components, dogs, pawls, and brakes after
the trial lift.
G-28-2
Guideline G-28
Ensure that the load and boom hoist drum brakes, swing brakes,
and locking devices are engaged when the occupied platform is in
a stationary working position.
Ensure that employees keep all body parts inside the platform during operations.
Ensure that the operator remains at the controls when the crane
engine is running and the platform is occupied.
Make sure that platform use is discontinued when there is an indication of dangerous weather conditions or other danger.
Make sure that the operator and signal person are in constant hand
signal or voice communications during operations.
Make sure that employees remain in sight or in direct communication with the operator or signal person.
Ensure that all employees on the platform wear a properly
anchored body belt or harness system.
Ensure that materials and tools are secured to prevent movement
during the lift.
Make sure that no other object is lifted using any of the crane load
lines while the platform is suspended.
Verify that a trial lift calculation sheet has been completed, signed,
and dated.
G-28-3
Guideline G-31
General Welding
General Welding
Verify that no rust, burning slag, grease, paint, moisture, or other

foreign matter is present on joint before welding.
Verify that proper pre-heat is applied before welding.
Check that each layer of the weld is free from flux, slag, and
surface defects.
Verify that welds are of the full shape and section required.
For full penetration welds, verify that proper back gouging or
grinding of root to sound metal before second side welding.
Check that an adequate shrinkage allowance is made so that
distortions will not result.
Verify that completed welds are inspected/examined as specified.
Temporary welds have the same requirements as final welds.
Note: Welding requirements are specified in the project-specific

Special Processes Manual (SPM), and all field inspections must
be based on these requirements. The following guidelines are
typical of the requirements included in the SPM.
A. Preplanning
Verify that welding procedures are approved for use and available
at the site.
Verify that welders are qualified for position and welding process.
Ensure that adequate facilities are available for welder testing on
site and that lighting and ventilation are adequate.
Check that welding machines, welding leads, flowmeters, regulators, and support tools for welding activities are in good working
condition.
B. Weld Rod Storage
Verify that new rods are stored in unopened, hermetically (airtight)

sealed containers.
Check that loose rods are stored in holding ovens until withdrawn
for use.
Verify that un-used weld rods that have been exposed to the atmosphere are returned to a holding oven for re-drying before re-issue
as required by the contract documents.
Make sure that a system is in place to ensure that weld rods are not
re-dried more than one time.
Verify that weld rods that have been wet are not used.
C. Field Welding Inspection
Verify that all work is performed per the applicable welding code or
standard as required by the contract documents.
Verify that welders assigned to the work are qualified for the
process and applicable code.
Make sure that a protective cover or shelter is provided to protect
the welder and welding process from wind and rain.
Check that welding screens and/or blankets are provided to protect
personnel, material, and equipment from weld flashes and weld
splatter, as necessary.
Check that edges or surfaces to be welded are correctly prepared,
shaped, and cleaned.
Verify that members are tacked together in the specified joint configuration before welding.
Verify the type and size of rod used.
Verify that root openings do not exceed specified tolerance.
1997, 2001 Bechtel

G-31-1
Guideline G-31
D. Visual Inspection of Completed Welds
Check fillet welds for leg and throat size.

Check butt/grove welds for excessive or insufficient reinforcement.
Check for defects such as undercut, overlap, slag inclusions, and
excessive porosity.
E. Weld Repairs
Report any weld defects to the Field Welding Engineer for

disposition.
Verify that removal of weld metal for the full length of any cracks as
specified by the contract documents before re-welding.
F. Do not allow the following:
Cut-off of anchor bolts or rebar without approval.

Use of grinding wheels, files, or tools on stainless, inconel, or
monel base metal alloys that were previously contaminated by use
on mild steel or iron.
Unapproved tack welds to rebar, anchor bolts, or structural steel.
Unapproved heating or cutting structural steel.
Welding on crane booms without prior authorization of the Field
Welding Engineer.
Unapproved use of heat to align piping and equipment.
Welding unprotected from wind, rain, snow, or blowing sand.
G-31-2
Guideline G-32
Nondestructive Examination
Code Welding
Note: Code welding requirements are specified in the projectspecific Special Processes Manual (SPM), and all field inspections
must be based on these requirements. The following guidelines
are typical of the requirements included in the SPM.
A. Code Requirements
As required by the contract, verify that welding and other related

criteria meet the requirements of the following or other codes
and/or standards specified:
ASME Boiler and Pressure Vessel Code, Sections I, V, VIII,
and X
ANSI B31.1, Power Piping; B31.3, Refinery Piping; and
B31.9, Building Piping
API 650, Welded Steel Tanks for Oil Storage; and API 620,
Recommended Rules for Design and Construction of Large
Welded Low Pressure Storage Tanks
AWWA, Water Storage Tanks
AWS 1.1, Structural Steel
Verify that the following have been submitted and approved, when
applicable:
Quality control program
Welding and brazing procedures
Welding procedure qualification test records
Postweld heat treatment procedure
Nondestructive examination and inspection procedures
Verify that the approved filler material control procedure is available
at the site and is being followed.
Magnetic particle
Monitor method, sequence of operations, examination medium, surface temperature, and lighting.
Check magnetizing current, prod spacing, and direction of
magnetization.
Check examination coverage.
Review indication evaluation.
Liquid penetrant
Verify penetrant material type/group.
Check lighting, surface cleaning, penetrant application, and
penetrant dwell time.
Check temperature, penetrant removal, and drying.
Check developer application and developer time.
Review indication evaluation.
C. Post-process
Verify that radiographic film is properly identified (both film and film
jacket).
Verify that NDE subcontractor evaluation for film quality (technique,
density, sensitivity) and report.
Verify that Bechtel Level II or III evaluation of weld quality and
report.
Verify that weld and base metal surface conditions and external
cleanliness are restored.
B. Work Operations
Check that the proper type and size of welding electrode is used.
Ensure that welders are qualified for the welds being made.
Check in-process welding techniques, including:
Base metal surface preparation (bevel preparation and metal
cleanliness)
Fit-up and preheat temperature
Correct filler material, interpass temperature, and interpass
cleaning
Machine setting and shielding gas
Verify weld quality. Review General Welding Guideline.
Verify that code nondestructive examination and postweld heat
treatment requirements are satisfied.
1997, 2001 Bechtel

G-32-1
Guideline G-33
G-33-2
Guideline P-1
Guideline G-34
General Piping
Heat Treatment
Note: Postweld heat treatment requirements are specified in
the project-specific Special Processes Manual (SPM),
and all field inspections must be based on these requirements. The following guidelines are typical of the
requirements included in the SPM.
A. Pre-Process
Determine the location, size, and quantities of welds to be treated.

Select the temperature monitoring equipment and the number and
location of thermocouples to be used.
Select the heating, controlling, and recording devices to be used.
Determine the required preparation of surfaces to be heat treated.
B. In-Process
Monitor the following during the heat treatment:

Heating and cooling rates
Holding temperatures
Time and temperature controlled, measured, and recorded
Record the type, number, and location of temperature measuring
and recording devices.
Verify that temperature of weldment and adjacent base material is
at proper level before protective insulation is stripped off.
C. Post-Process
Check that thermocouples and other temporary attachments are

removed and affected areas are visually examined.
Verify that weld and base metal external and internal surface cleanliness is restored.
A. Preplanning
Review applicable contract documents, codes, and standards

applicable to the piping system installation and identify specific
requirements.
B. Receiving Inspection
Check that material is properly packaged and free of damage.

Check material for proper identification.
Check that permanent tags are attached to valves as specified.
Verify that quantities, sizes, material, surface preparation, weight,
type of joint material and/or gaskets, bolt sizes and types, hanger
sizes and types, finish or cleanliness, and end closures of received
piping materials.
Verify that the required documents are received with shipment.
Segregate and document items not conforming to specified
requirements.
Verify that required code data reports and documentation are
received with code piping materials.
Verify that required heat stamping or code stamps are on code piping material.
C. Storage and Handling
Review need for any special processing.

Ensure that storage and handling are per procedures, specifications, and/or special instructions.
Provide for segregated storage of code piping materials.
Verify that cleanliness is maintained during storage.
D. Fabrication
Before fabrication, check installation area and resolve interferences

with structural steel, electrical raceway, HVAC ductwork, and other
commodities.
Verify that current revision of drawings are being used for fabrication.
Verify that proper material has been requisitioned from storage.
Inspect fabricated pipe spools to verify cleanliness, dimensions,
and configuration.
Verify that proper storage and identification of fabricated pipe
spools.
E. General Piping Installation
After cutting or beveling, ensure that piping is cleaned and reamed

to full size.
Ensure that proper depth shoes or spacers are provided on pipe
supports and racks to accommodate required insulation.
Verify that specified protective coatings have been applied.
G-34-1
P-1-1
General Piping
Guideline P-1
Check that non-ferrous to ferrous piping connections are made with

dielectric unions/couplings.
Verify correct installation by checking configuration, orientation,
location, and dimensions of the installed piping system.
Verify correct installation of low point drains, high point vent assemblies, expansion loops, and expansion joints.
Verify that pipe, openings, valves, and fixtures are protected from
dirt, foreign objects, and damage during construction.
Ensure that all open pipe and valve ends are capped to prevent entry of dust, dirt, and moisture.
Ensure that pipe connections do not transmit stress to equipment
flanges and nozzles.
F. Welded Piping Installation
Check that pipe ends are square before beveling.

Check fit-up and beveling before welding piping joints.
Verify that pipe completed welds are free of metal "icicles," loose
material, or other obstructions that could retard the flow of gases
and fluids through the piping system.
During construction, ensure that open ends of piping are protected
with temporary closure plugs.
G. Screwed Piping Installation
Check that cut pipe ends are reamed to full size.

Check that threads are clean cut and free of burrs.
Ensure that joints in screwed piping are made up with joint compound or teflon tape.
H. Flanged Piping Installation
Ensure that flanged joints are faced true and square.

Check that gasket material is suitable for the intended application,
including temperature, pressure, and working medium.
Check that bolting material is properly lubricated before torquing.
Verify that flange bolts are properly torqued.
I.
Guideline P-2
Large Pipe
A. Preplanning
Review design drawings for constructability, interferences,

problems for erection, and scheduling.
Preplan piping installation. Review General Piping Guideline.
Perform receiving inspection of piping materials.
Ensure that material is properly stored and maintained.
Perform periodic material inventories and reorder required materials as necessary.
Check building areas for possible interferences.
Check that required piping sleeves and openings are installed in
walls and floors before concrete placement.
B. Installation
Monitor required field changes in piping systems and obtain

required engineering approvals before performing the work.
Ensure that the work is performed per applicable project procedures.
Ensure that exception reports are properly prepared and
processed.
Ensure that changes that may result in interferences or that may
cause delays are coordinated with other disciplines.
Review other discipline design drawings for possible interferences
and schedule impacts.
C. Testing
Ensure that installed pipe has been released for testing.

Ensure that post-test punchlists are completed and that pipe is
released for painting and/or insulation, as specified.
Release the completed system to Startup.
Rack Piping Installation
Check that rack piping is neatly installed in common racks and runs
parallel in both vertical and horizontal planes.
Check that piping is pitched for venting or draining.
Check that adjacent lines are grouped in common vertical and
horizontal planes.
J. System Punchlist
Walkdown assigned system(s) using system and design drawings

to verify completion status.
Prepare a punchlist by listing:
Items that do not conform to contract requirements
Items that are not complete
Verify completion of punchlist items when reported complete.
Update and reissue as necessary.

P-1-2
1997, 2001 Bechtel

P-2-1
Guideline P-4
Guideline P-3
Small Pipe
Embedded Piping
A. Preplanning
A. Preplanning
Preplan the piping installation. Review General Piping Guideline.

Determine the small pipe to be field routed.
Determine the small pipe to be detailed on field-prepared
isometrics.
Prepare small pipe layout and isometric drawings.
Check building areas for interferences before preparation of
isometrics.
Perform required receiving inspection.
Ensure that pipe and pipe fittings are properly marked, identified,
and stored.
Check that required piping sleeves and openings are installed in
walls and floors before concrete placement.
Monitor drawing changes and ensure that they are incorporated in
the field drawings.
Check that required project procedures have been prepared.
B. Installation
Monitor required field changes in field-routed piping systems and

update field drawings accordingly.
Ensure that the work is performed per applicable project procedures.
Ensure that exception reports are properly prepared and
processed.
Verify that the embedded piping installation schedule is compatible

with the concrete placement schedule.
Verify that material receiving inspections have been performed.
Check that embedded pipe, fittings, and associated material are
properly marked, identified, and stored.
Make sure that material that does not conform to design requirements is segregated and documented.
Identify embedded piping that must be coated and wrapped.
Check for potential interferences with reinforcing bar, structural
steel, and formwork and ensure that adequate space is available
for embedded piping installation before starting the work.
B. Installation
Verify that piping is physically located per the design drawings.

Document any dimensional installation deviations on "as-built"
drawings.
Verify that piping is adequately supported and secured against
movement during concrete or backfill placement.
Verify that system or partial system pressure tests have been conducted and accepted before embedding any piping.
Ensure that adequate space is available to erect and pressure test
connection piping.
Make sure that all openings in the system, such as floor drains,
equipment drains, and connecting piping joints, have been sealed
and that any valves in the vicinity of the concrete placement or
backfill have been protected for cleanliness against damage.
C. Testing
Ensure that installed pipe has been released for testing.

Ensure that post-test punchlists are completed and that pipe is
released for painting and/or insulation, as specified.
Release the completed system to Startup.
P-3-1
1997, 2001 Bechtel
P-4-1
1997, 2001 Bechtel
Guideline P-5
Guideline P-6
Storm and Sanitary Sewer
HDPE Piping
A. Preplanning
Ensure that requisitions and quotation requests for reinforced concrete pipe (RCP) to be used in refinery or chemical plant applications specify the intended application.
Even though material specifications are the same, RCP manufacturers often provide a better quality, more leaktight product to refinery and chemical plant applications.
B. Installation
Verify that the piping installation is properly aligned and sloped.

Check that horizontal sanitary soil, storm, and drainage piping
is installed at a uniform grade as required by the contract documents or local code requirements.
Check that vent piping is graded to provide venting of plumbing fixtures and freedom from condensation.
Check locations of all existing crosslines.
Make sure that required shoring or excavation shields are used as
required and that ladders are properly located for emergency
egress.
Determine the correct testing equipment, procedures, and acceptance criteria to be used.
Monitor the excavation of trenches for correct alignment and
elevations. Review Excavation Guideline.
Check that pipe is properly bedded.
Check that soil and waste system connections are made correctly
and that each fixture or piece of equipment is equipped with a codeaccepted trap.
Check that cleanouts are located to provide easy rodding.
To ensure that cleanouts are accessible, verify that cleanouts
are extended to grade, floor, or wall.
Check that each plumbing vent penetrating the roof is provided with
flashing per contract document requirements.
Ensure that backfill placement and compaction procedures will protect piping from breakage or movement.
Verify that backfill meets compaction requirements.
P-5-1
1997, 2001 Bechtel
HDPE A category of high-density polyethylene piping products

used in water, waste, electrical conduit, slurry lines, and
gas pipe services. Pipe joining is performed by plastic
welding, socket connections, or butt heat fusion.
A. Material Handling
Make sure that the pipe is not handled with chains or drug over
sharp rocks or other abrasive materials.
Use canvas slings and pad forklifts where they directly contact
the pipe.
Check that material is stored to avoid crushing or piercing.
B. Trenching
Ensure that the pipe trench provides a continuous bedding of

undisturbed or well-compacted soil free of rocks and other debris.
Provide a 4-inch (10 cm) minimum bedding of sand or other finegrained fill material over rock, ledge, hardpan, or boulders.
To minimize the width of the trench required, join piping aboveground before lowering the pipe into the trench.
Verify that minimum burial depth is provided for the piping as
specified in the project specification or as required by local codes.
C. Pipe Placement
Make sure that the piping is handled with care to avoid buckling and
twisting.
Check that the piping is not bent to a radius smaller than that
permitted by the manufacturer.
Typically 20 times the outside diameter of the pipe for regular
bends and 125 times the outside diameter is a fitting is included in the bend.
Check that the pipe is slightly snaked in the trench to accommodate
for pipe expansion and contraction due to temperature changes.
In warm weather, make sure that the pipe is allowed to fully contract by allowing the pipe cool to ground temperature before trimming and joining adjacent sections.
Make sure that gas pipe is buried the required distance from steam
lines, hot water lines, power lines, and other sources of heat to
avoid temperatures in excess of 140F (60C) or as required by
local codes.
Check that protective sleeves are provided at all gas pipe service
branches and transition fittings to protect against bending and
shear forces.
If tracer wires or metallic tape are installed to assist in locating
buried gas lines, make sure that they are installed at least 4 inches
(10 cm) from the pipe.
1997, 2001 Bechtel

P-6-1
HDPE Piping
Guideline P-6
D. Pipe Fusion
Check that fusion equipment is in proper working order and perform

a trial fusion at the start of each day.
Check that fusion tools, pipe, and fittings are free of contaminants
before use.
Remove sections of pipe with cuts, gouges, and deep scratches
before fusing.
Square pipe ends to remove any damaged or necked down
surface.
Check that the pipe ends are wiped with a clean cotton rag to
remove any foreign substance and cuttings from the inside diameter.
Avoid synthetic fiber rags because they may melt and char
against the heater.
Ensure that joined surfaces are simultaneously heated by the
fusion tool for the specified time.
Check that the two heated surfaces are brought together to form a
smooth, continuous seal and are held in that position until solidified.
Clean heater surfaces after every joint with a wooden implement.
Do not use metal tools.
Check that transition fittings are used when HDPE pipe is joined to
other materials.
E. Backfilling and Compaction
Provide the greater of 4 inches (10 cm) or one pipe diameter of

compacted fill over the buried pipe.
Ensure that fill is free of large rocks, dirt clods, frozen earth, and
decomposable debris such as wood.
Verify that fill is compacted as specified density.
Check that voids beneath service connections and transitions are
filled and compacted by hand or with a tamper as appropriate.
Check that the fill is placed in successive layers and spread uniformly to fill the trench completely without voids.
When heavy equipment is used to consolidate the final backfill,
ensure that care is taken to avoid damage to the pipe and that
24 inches (60 cm) of previously compacted cover is in place.
Guideline P-7
Valves
A. Preplanning
Preplan the valve installation. Review General Piping Guideline.

Perform required receiving inspection.
Check that valves are properly handled, stored, and maintained.
Check building areas for interferences with valves installation and
operation.
Verify that valves are the correct size, type, and pressure rating and
are installed in their correct location and orientation.
Read the manufacturer tags and not the vendor tags to verify
valve information.
Perform required valve installation in-process inspections.
Complete valve installation progress reporting.
Perform periodic valve inventories and initiate field purchases of
valves if necessary.
Monitor P&ID deviations and obtain required design approvals for
changes.
Ensure that extra valve stem packing, bonnet gaskets, pressure
seals, plugs, and flange gaskets needed for repairs are available.
Review piping design drawings and vendor valve detail sheets for
compatibility, including material and end preps.
Ensure that required operating and setting instructions and procedures are available.
Check that operating and setting activities are performed per applicable instructions, procedures, and valve/operator manufacturer
instructions.
B. Installation
Ensure that required exception reports are prepared and

processed.
Verify that required valve operator supports are installed.
Make sure that measures are taken to protect valve bodies and
internals from heat effects of welding.
C. Testing
Check valve pressure capacity and ensure that it is greater than the
required piping pressure test. Review Leak Testing Guideline.
P-6-2
1997, 2001 Bechtel

P-7-1
Guideline P-8

A. Preplanning
Verify that the material receiving inspection has been performed

and that hangers and supports are acceptable for installation.
Determine which hangers will be field fabricated and which will be
vendor supplied.
Survey and locate hanger structural attachment locations.
Check installation areas for possible interference.
Make sure that hanger fabrication and installation are scheduled to
precede piping installation.
Ensure that spring hanger travel stops remain in place during
installation, testing, and system hanger checkout.
Make sure that shock suppresser internals and reservoir are protected when disassembling for repair or refilling.
Check that supports and hangers not designated as anchors do not
restrict the free expansion and contraction of piping due to temperature changes.
Check that pipe anchors and pipe guides are installed at locations noted in the contract documents.
C. Checkout
Verify that hanger and support checkout is performed per applicable contract documents.
D. Temporary Supports
Use the following table for temporary pipe support spacing:
B. Installation
Check that hangers and supports are installed per detail drawings
and within the tolerances allowed in contract documents.
Check that hanger and support spacing comply with contract document requirements. Unless otherwise specified:
Support intervals will prevent sagging of the line.
Spacing will prevent excessive loading on any one hanger.
Piping will not be supported from other piping.
Hangers will be installed at valve and equipment locations.
For fire protection piping, the following NFPA 13 requirements apply
unless otherwise specified in the contract documents, by the manufacturer, or in local codes:
Maximum hanger spacing not to exceed 10 feet (3 m).
Maximum hanger spacing may be increased to 15 feet (4.5
m) for steel pipe that does not use vertically installed concrete
expansion anchors as structural attachments.
Maximum unsupported end pipe section not to exceed 2 feet
(0.6 m).
Verify that perforated metal bands, wire, or punched hole strap
material is not used for piping supports.
Verify that the most current approved drawing revision is being
used for hanger fabrication, installation, and checkout.
Check that P&ID and piping drawing changes are incorporated on
applicable hanger support drawings.
Ensure that all required exception reports are properly prepared
and processed.
P-8-1
Guideline P-8
MAXIMUM SPACING
STEEL
GASES
COPPER
WATER
PIPE SIZE
WATER
1/2"
5'-0"
6'-0"
3/4"
5'-0"
6'-0"
1"
7'-0"
9'-0"
5'-0"
4'-0"
11/2"
9'-0"
11'-0"
7'-0"
2"
10'-0"
13'-0"
8'-0"
21/2"
11'-0"
14'-0"
8'-0"
3"
12'-0"
15'-0"
9'-0"
31/2"
13'-0"
16'-0"
4"
14'-0"
17'-0"
10'-0"
6"
17'-0"
21'-0"
8"
19'-0"
24'-0"
10"
22'-0"
28'-0"
17'-0"
P-8-2
Guideline P-12
Guideline P-11
Plastic-Lined Pipes
Lined Pipe Gaskets
A. Handling/Assembly
A. Materials
Ensure that protective end caps on the piping are left in place until
the piping is ready for installation.
Check that the piping is assembled with clean, new machine bolts.
Check that a bolt lubricant is applied to the full length of the bolt
threads.
Ensure that over-torquing which may cause damage to the plastic
sealing surface is avoided.
Verify that tightening of the flange bolts with a torque wrench, using
a crisscross pattern that alternately tightens the bolts located 180
apart.
Check that hanger supports are located near the flange connections, where flow changes direction, and in areas of high load concentrations such as clusters of valves or fittings.
B. Painting/Preparation
Ensure that sandblasting and painting is done with care to protect

the raised plastic face.
Make sure that protective end caps are in place at all times during
sandblasting operations, and that sandblast grit is directed away
from the flange face.
If the exterior of the pipe is to be treated with a heat-curable protective coating, ensure that caution is exercised during the heating
process.
Never apply heat in excess of the liner's rated maximum
temperature limit.
1997, 2001 Bechtel

P-11-1
Ensure that gasketed joints are fabricated only for pipe lined with
Saran or thermally stabilized polypropylene resins.
They cannot be used for pipe lined with Kynar PVDF or PTFE
resins.
Ensure that polypropylene-lined pipe utilized for gasketed joints is
thermally stabilized (light gray liner color; blue color-code band).
Do not use non-thermally stabilized polypropylene-lined pipe
for gasketed joints (off-white liner color; white color-code
band).
B. Fabrication
Check the cutting of the pipe to the desired length, using a parting
or square-end cutter.
Make sure that hacksaws or wheel-type cutters are not used.
Hacksaws tend to lead, which produces non-right-angle cuts.
Wheel-type cutters also produce a slightly beveled cut that
leaves burrs and causes severe stress risers in the plastic
liner.
Check that cut-off length of pipe and finished, face-to-face
length are the same.
Check pipe end preparation:
Cut the metal 3/16" from the end of the pipe using the same
parting or square-end cutter, cutting through until the surface
of the plastic liner is reached.
The 3/16" cutback dimension is the same for all sizes of pipe.
Tolerances for the cutback are +0" / -1/64". Because of the
importance of these tolerances, ensure that a steel scale is
used to layout the 3/16" dimension.
Carefully cut the plastic liner to achieve the proper outside
diameter dimension. Make sure that the stops on hand cutter
are accurately set to achieve this dimension.
Inspect the end and outside surface of the plastic liner stub.
Because the quality of the completed joint depends partly on
the surface condition of the plastic liner stub, imperfections
must be removed.
Ensure that cracks, nicks, and gouges are filed or lightly
sanded away.
Check that the feather at the beginning of the standard tapered
pipe thread on the steel pipe is removed to prevent interference
with proper joint makeup because it will tend to curl over the liner
stub.
Check that the flange or union fitting is screwed on the pipe until the
end of the 3/16" plastic liner projection is flush with the face of the
flange or union.
1997, 2001 Bechtel

P-12-1
Lined Pipe Gaskets
Guideline P-12
Determine the flush position by placing a straight-edge across

the face of the flange or union; the plastic liner must contact
the straight edge.
When flanges are used, they should be adjusted by a slight
amount of further tightening to align flange bolt holes at either
end of the pipe spool.
If the thread chasers are badly worn or if the die is set to cut an
oversize thread, it may be impossible to screw on a flange as far as
necessary. Should this occur, remove the flange, set the die to cut
a slightly deeper thread, rechase the thread, then screw on the
flange and adjust it as required.
Check that the proper gasket is inserted into the recess formed
between the projecting plastic liner and the chamfer at the face of
the flange or union fitting.
Whether a half or full gasket should be used is determined by
the type of connection being made.
The choice of gasket elastomer type is based on temperature
and chemical service.
Check that a color-coded plastic band is attached to the spool.
Use a blue band for gasketed polypropylene-lined pipe.
Use a green band for pipe lined with Saran.
Make sure a plywood cover is bolted to the spool to protect the
plastic projection.
P-12-2
Guideline P-13
Kynar-Lined Pipe
A. Forming Flared Faces
Check that cutting oil, shavings, and dirt are wiped from exposed
plastic stub, using a nonflammable cleaning solvent and clean rag.
Check setup:
Check alignment and centering by dry running proper sized
forming tool into flange bolt holes.
Check that guide pins fit freely in the bolt holes with the
clamping dogs behind the flange.
Loosen adjusting nuts, center tool, and retighten nuts if
adjustment is needed.
Remove tool, attach hydraulic hose, and set aside.
Check preheating:
Lightly grease aluminum flaring die with a high temperature
grease.
Preheat die to 280F - 300F (138C - 149C) with hot plate,
oven, or torch.
Use 300F (149C) temperature-sensing crayon or a pyrometer to monitor to monitor preheating.
Do not heat preformer cone die; it is used at room temperature.
Check heating:
Attach heat cup to hot air gun, set heater dials per manufacturer recommendation, and allow gun to preheat for 15 to 20
minutes.
Place the proper locking collar over the plastic stub and place
tight against the flange face, with curved crimped edge
inward, fitting into flange chamfer.
For forming faces of Kynar, be sure to only use locking collar
with 5/32" diameter holes; do not use collar with 1/16" or
3/32" diameter holes, which is designed for PTFE-lined pipe.
For 1" - 2" pipe, place heat gun and heat cup to flange and
heat plastic stub to 200F - 230F (93C - 110C). Use a
230F (110C) temperature-sensing crayon to monitor.
Rotate hot air gun frequently to ensure uniform heating.
For 3" - 8" pipe, place heat gun and heat cup to flange and
heat plastic stub to 240F - 250F (116C - 121C). Use a
250F (121C) temperature-sensing crayon to monitor.
Rotate hot air gun frequently to ensure uniform heating.
1997, 2001 Bechtel

P-13-1
Kynar-Lined Pipe
Guideline P-13
When field forming, use adequate ventilation (indoors, use exhaust

fans). Avoid breathing vapors resulting from overheating and
possible degradation of plastic.
Check face forming:
Engage hydraulic forming tool to flange and lock into position.
Place preformer die on cylinder pin of tool and advance forward into plastic stub.
Hold in place for approximately 10 seconds at gauge pressure
of 1,000 psi (70 kg/cm2).
For 3" - 8" (8 cm - 20 cm) pipe, attach the preheated forming
die to the hydraulic cylinder on the forming tool.
With die centered in plastic stub, insert tool reaction arms
through flange holes and insert locking pins in arms, making
sure that the pins do not bear on the raised lettering of the
flange.
Apply hydraulic pressure to form face. Because the pressure
will drop as the plastic flows, repeatedly pump pressure back
up again until constant pressure is maintained for 2 minutes.
Avoid excessive force on the preformer cone, causing thinning of liner against end of steel shell.
Release pressure and retract cylinder.
Immediately replace preformer die with preheated aluminum
flaring die and again extend cylinder forward to complete
forming of face.
Maintain pressure on flaring die at 3,000 psi (210 kg/cm2) for
2 minutes.
Clamp flaring die to flange and retract and remove forming
tool assembly.
Leave die in place until plastic, steel pipe shell, and flange
have been properly cooled to room temperature by air cooling
or water bath.
For 3" - 8" (8 cm - 20 cm) pipe, attach bolts through free
flange holes and secure flaring die to flange. Retract the
hydraulic cylinder; remove locking pins and forming tool. Cool
the plastic to room temperature using cooling air or water.
Then remove die from flange.
To assure properly flared face, it is extremely important to
cool plastic and flange to room temperature.
To identify Kynar liner, check that a black color-coded plastic band
is attached to lined pipe spools.
Kynar-Lined Pipe
Guideline P-13
Make sure that a plywood cover is bolted to the flange to protect the
plastic face and to prevent the face from remembering its preformed shape and pulling away from flange.
B. TroubleshootingKynar Face Forming

If the plastic face is smashed flat, thin on one side, or distorted on
one side while the other side appears normal, one of the following
may have occurred:
The reaction frame may not be adjusted parallel to the flange
face causing the forming die to bear more heavily on one side
of the flare than on the other.
The plastic liner extension may not have been heated evenly.
One side of the liner may have been hot, the other cold.
Ensure that the hot air gun is rotated while heating the liner.
If the flare face raises up from the flange, one of the following may
have occurred:
The flaring die may have been removed before cooling was
complete.
The plastic was not heated sufficiently.
If the flare face is folded or wrinkled, one of the following may have
occurred:
The plastic may have been overheated.
The molding die may have been incorrectly applied. Make
sure that the liner end does not catch on face of flaring die,
causing buckling instead of smooth outward flaring
P-13-2
P-13-3
Guideline P-14
PTFE-Lined Pipe
PTFE-Lined Pipe
If a heat gun is used for heating:

Make sure that the proper size heat cup is used.
Check that heat gun is allowed to preheat for 15 to 20 minutes.
When gun is ready, check that the gun with heat cup is placed
against the flange and heated until the plastic stub becomes
translucent.
Check that the heat gun is frequently rotated to balance the
heat over the plastic surface.
When field forming by either method, use adequate ventilation
(indoors, use exhaust fans). Avoid breathing vapors resulting
from overheating and possible degradation of plastic.
A. Joining Preparation
Check that any notches on end of exposed plastic stub are filed or
sanded away.
Check that cutting oil, shavings, and dirt are wiped away from the
pipe stub, using a nonflammable cleaning solvent and clean rag.
B. Joining
Make sure that the proper size flaring die and forming tool are used.
Check that the clamping block assembly guide pin matches the
flange bolt holes.
With the molding die centered in the extended liner and the drive
screw retracted, check that the guide pins fit freely in the bolt holes
with the clamping dogs behind the flange.
Loosen the adjusting nuts, center the tool, and retighten the
nuts if adjustment is needed.
Check that the proper locking collar is placed over the plastic stub
and tightened against the flange face with the curved crimped edge
inward fitting into the flange chamfer.
For the PTFE face, check that the locking collar has 1/16" or 3/32"
diameter holes. Do not use collars with 5/32" diameter holes, which
are designed for Kynar-lined pipe.
C. Field Forming
If a torch is used for heating:

Make sure that a MAPP/air or LPG/air torch is used with an
aspirating nozzle (#3 tip) to provide flooding type heat.
Check that the torch is held at a 90 angle to the pipe so that
flame tip barely touches plastic.
Check that the torch is continuously moved around the plastic
until one-half of the stub thickness turns translucent.
Ensure that the inside of the stub is then heated with the torch
held at a 45 angle and the torch is moved continually around
the plastic.
Ensure that the process is repeated from outside to inside
until the entire stub has become translucent.
Verify that the torch flame is kept just inside the cut edge of
the plastic stub and is not allowed to directly contact this
edge.
P-14-1
1997, 2001 Bechtel
Guideline P-14
D. Preforming
Check the insertion of the cone-shaped preformer tool into translucent plastic stub and that a gradual rocking motion is used to
enlarge the opening in the plastic.
Verify that the preformer is then fully inserted into the flange face to
quench the inner side wall.
When in the translucent (gel) state, PTFE is very shock sensitive.
Make sure the force is applied gently with the preformer.
With the forming die centered in the plastic stub, check that the
forming tool guide pins are placed into the flange holes and that the
clamping dogs are locked in place.
Ensure that the forming die is cranked snug to the flange and that
cool air or water is used to speed cooling of the plastic to room temperature.
After cooling, make sure that the tool is removed.
To assure properly flared face, it is extremely important to cool the
plastic and flange to room temperature.
Verify that a color-coded plastic band is attached to the spool to
identify the PTFE liner.
plastic face and to prevent the face from remembering its preformed shape and pulling away from the flange.
E. Troubleshooting PTFE Face Forming
If small cracks or splits develop around the edge of the formed face,
one of the following may have occurred:
Torch flame was allowed to dwell on the edge of the PTFE
stub, causing overheating and degradation of the liner.
Liner ends were not smoothed properly after the cutoff
operation.
If the liner splits during the flaring operation:
P-14-2
PTFE-Lined Pipe
Guideline P-14
Excessive force may have been used during the preforming

step. While in the gel state, PTFE is extremely shock sensitive. Exercise care to avoid jarring the PTFE in this state.
Carefully insert the preformer fully to the flange face to
quench the inner side of the wall completely before continuing
with the preforming step.
If the flare face raises up from the flange, one of the following may
have occurred:
The flaring tool may have been removed before cooling was
complete.
The liner may not have been heated sufficiently.
P-14-3
Guideline P-15

A. Installation
Check that all cutting oil, shavings, and dirt are wiped from exposed
plastic stub of the clamped prepared pipe using a nonflammable
cleaning solvent and clean rag.
Check proper fit-up:
Spring compressed on forming tool while attaching molding
die.
Guide pin fit in clamping block assembly to match the flange
bolt holes.
With the molding die centered in the extended liner and the
drive screw retracted, check that guide pins fit freely in the
bolt holes with the clamping dogs behind the flange.
Loosen adjusting nuts, center tool, and retighten nuts if
adjustment is needed.
Remove forming tool.
Check that proper size heat cup attached to hot air gun
Use standard heat cup for 1" to 4" pipe.
Use special baffle heat cup for 6" or 8" pipe.
Ensure that the heat gun is preheated for 15-20 minutes using the
heat to warm the molding die.
Check that the heat gun and cup are placed against the flange and
that the cup position is rotated periodically to balance heat over
surface of plastic stub.
Heating time will vary with ambient conditions.
Heat until the plastic stub appears to be uniformly wet and
glossy, checking softness with clean glove.
If pipe is clamped in horizontal position and excessive plastic
droop occurs, rotate pipe to control.
When field forming, use adequate ventilation (indoors, use
exhaust fans). Avoid breathing vapors resulting from
overheating and possible degradation of the plastic.
Check flange to pipe adhesion process:
Plastic is ready for adhesion when saran feels like putty or
polypropylene feels like rubber and looks shiny.
Remove hot air gun, fold end of sagging plastic stub out
toward the outside diameter of the flange, and form plastic
back to face of flange with gloved hand.
Quickly align molding tool and forming die assembly to plastic
and crank the molding die tight to the flange.
Allow plastic to cool several minutes before removing forming
tool.
1997, 2001 Bechtel

P-15-1
Guideline P-15
The plastic face diameter on field-formed spools may be

somewhat smaller than that on factory-supplied spools. This
will not, however, affect pipe performance.
Verify that plastic-lined pipe is correctly identified:
Green plastic band for saran-lined pipe spools
White plastic band for polypropylene-lined pipe spools
plastic face.
B. Troubleshooting Saran and Polypropylene Face Forming
If plastic face appears distorted, one side normal and the other side
erratic and not fully formed, one of the following may have
occurred:
The hot air gun was not properly rotated to ensure uniform
heating.
The heat setting was too high for conditions, thereby not
allowing plastic resin to heat uniformly.
Not enough pressure on forming die to fill out molding cavity.
If the plastic face has rough laminar pattern molded in the surface,
one of the following may have occurred:
Soft plastic was not properly rolled back and preformed with
gloved hands before molding.
Too much time was taken to hand form soft plastic, thus allowing air-hardened skin to form before molding tool is applied.
If plastic face is well molded but has flow lines in surface, one of the
following may have occurred:
Molding die was not preheated before forming operation.
Too much time was taken to hand form soft plastic, thus
allowing air hardened skin to form before molding tool is
applied.
Excessive flash at outer diameter and center of plastic face
allowed to heat to excess, lower heat setting, and/or shorten
heating time
Too much force was applied to molding die, thus forcing hot
plastic into tooling allowances.
If excessive flash occurs on the inside diameter of the plastic after
the molding tool is removed, one of the following may have
occurred:
The heated plastic was not properly hand formed before
molding, allowing forming die mandrel to push soft plastic
inside pipe.
Excessive pressure was applied to die causing very soft
plastic to flow past die mandrel.
Molding tool was not properly centered causing die mandrel to
engage soft plastic and push it inside pipe.
P-15-2
Guideline P-15
Inside diameter was undersized due to over-compression of

pipe by flanging with too much force.
C. Final Joint Surfacing
Excessive flash may be cut from molded end with any properly
sharpened knife.
Surface of plastic face may be reshaped with flat file, preferably in
rotary motion on face (seal area).
Surface of plastic face may be reheated and remolded to improve
one of poor quality.
Do not use grease on aluminum molding dies where contact is
made with plastic molding surface; the plastic will tend to laminate
if mixed with grease.
P-15-3
Guideline P-21
D. Refrigeration Piping
A. Preplanning
Verify that procedures are developed and approved indicating

flushing and cleaning sequence and the steps to be performed.
Check that all welded connections are complete and that the piping
system is released for flushing and cleaning operations.
Make sure that flushing is not carried out through any machinery or
equipment that may be damaged by flushing.
Ensure that line debris is not flushed into dead ends or associated
vessels.
Make sure that heat exchangers are isolated wherever possible
until initial flushing is complete.
If a cleaning solvent is used, check that no materials in the system
will be damaged by its use.
Preplan the disposal of all flushing and passivating materials and
ensure that the disposal meets applicable regulation requirements.
Guideline P-21
Check that installation of cleaning of refrigeration piping and

accessories is per manufacturer requirements.
E. Domestic Water Piping
Check that all lines are flushed with fresh, clean, potable water
before disinfection.
Verify that piping is disinfected before final acceptance per AWWA
C601 unless other required in contract documents or local codes.
B. Work Operations
Check that orifice plates and flow nozzles are removed from the
line.
Check that temporary spacers or spool pieces are provided where
necessary to avoid straining the pipe where in-line components
have been removed.
Check that all high points are vented to ensure that the cleaning
solution will contact all inside surfaces of the pipe.
Check that sufficient bypasses are installed to ensure the flow of
the cleaning solution through all desired parts of the system.
Ensure that adequate venting is provided to prevent vacuums
forming in the system.
Maintain continuous surveillance of the flushing and cleaning
operations to ensure compliance with procedure requirements.
C. After Cleaning, Passivating, and Flushing is Complete

and the System has been Drained and Dried
Inspect all accessible points of the system to ensure that it is free

of scale, rust, loose paint, and film and is of correct surface appearance. This is usually done at the end of the flush and before fluid
re-entry into holding tanks.
Check that all removed items are correctly reinstalled.
If testing is not to be performed immediately, ensure that the piping
is sealed.
Make regular inspections after cleaning to ensure that the piping is
kept sealed.
Where specified for critical components or systems, verify that
nitrogen blanket is re-established per manufacturer instructions
and project procedures.
1997, 2001 Bechtel

P-21-1
P-21-2
Guideline P-22
Leak Testing
Leak Testing
A. Preplanning
Make sure that system identification and test boundaries are
defined early.
Perform a pre-test inspection by walking down the system and verifying accessibility for inspection, completeness per P&ID, tightness
of flanged joints, and chalking of joints, as applicable.
Establish the test medium, test pressures, and test boundaries for
each test, including blind flange thickness determinations.
Tag test boundaries per approved procedures and as required.
Sample and test hydrostatic test medium to determine if it is
acceptable or detrimental to the vessel internals and alloy piping.
Verify that test gauges have been calibrated per project procedures
and that the calibration due date is shown on the test gauge.
To validate that test gauges are still within the prescribed
calibration period, check the test gauges against a master
gauge before testing.
Ensure that the maximum test pressure is within 30% to 70% of
gauge range.
Identify components not capable of safely withstanding the required
system test pressure and ensure that those components are
removed or isolated from the system.
Identify systems that must be laid up after testing and that the
required layup medium is available for use before the start of the
test.
Determine if the system will or will not require draining after the
hydrostatic test.
Verify that all required test vents and drains are installed and that
fill points are established.
Make sure that required testing equipment, relief valves, pressure
regulators, valves, strainers, temporary piping, and temporary fittings are available before the start of hydrostatic testing.
Check that all system valves are positioned as required.
All system valves are typically placed in the open position.
Confirm that system relief valves have been blinded or removed, as
required.
Check that the system is adequately supported for expected
loading during hydrostatic testing.
Check that test equipment and temporary piping have been flushed
before connection to system.
Guideline P-22
Check that the system to be tested has been flushed before

testing, if required.
Verify that required test witnesses, such as the quality control
inspector, the authorized code inspector, or the client representative, have been notified in advance of scheduled test.
B. Pneumatic Testing
Ensure that a project procedure is prepared summarizing pneumatic pressure testing requirements.
Make sure that the immediate area surrounding the system test is
roped off and that personnel are kept out of the roped off area
during pneumatic test.
Verify that test pressure is maintained for the specified period.
If a pressure drop is observed, check for audible air leaks in
the system.
Verify that the system is gas tight by applying an approved soap
bubble solution to all joints (pneumatic test only).
C. Pressure Piping Testing
Verify that testing is limited to only those systems released for testing.
Confirm that testing is performed to approved procedures and
specifications.
Ensure that qualified personnel perform the testing.
Make sure that personnel safety is exercised throughout the testing
process.
Verify that the proper test medium is used.
Verify that the test medium is at proper temperature, as applicable.
Check that system pressurization stages are maintained, if
required.
Verify that the system is held for the specified time at the required
test pressure before inspecting for leaks.
Ensure that testing documentation is maintained, completed, and
accepted by the responsible field engineer and required witnesses.
Make sure that tested systems are properly vented and drained for
layup and/or properly restored for turnover.
D. Fire Protection Piping Testing
Determine local code requirements for leak testing including

minimum pressure, hold time, allowable pressure drop, and test
certification requirements.
1997, 2001 Bechtel

P-22-1
P-22-2
Guideline P-23
Guideline P-24
Pipe Insulation
A. Storage
Maintain surveillance of the storage conditions of the insulation

materials.
Check that material drawn from storage for application is dry and
undamaged.
B. Preplanning
Verify that all required hydrostatic and nondestructive testing has

been performed before application of insulation.
Ensure that any required surface coating has been applied.
Ensure that pipe surface is free of moisture before application of
insulation.
C. Installation
Check that correct type and thickness insulation is applied.

Check that the support fittings (banding straps, "S" and "J" clips,
etc.) are of the proper material.
Where a vapor barrier is required, check that it is correctly applied
to the proper thickness and that its integrity is maintained throughout.
Check that protective metal coverings are applied so that underlying insulation or vapor barrier is undamaged.
Ensure that piping or equipment supports do not damage the insulation.
To isolate the effects of a break-in insulation or vapor barrier, the
barrier should be sealed to the pipe at every fitting and at supports.
All removable vessel heads and manways should be fitted with
removable insulation.
When abrasive insulation material such as cellular glass is used on
lines or equipment subject to vibration, coat the inside surface to
prevent damage to the lines or equipment.
When more than one layer is to be applied, check that:
All joints of the previous layer are sealed before application of
the next layer.
All joints between one layer and another are "offset."
P-23-1
1997, 2001 Bechtel
A. Material
Review contract documents to determine installation and acceptance criteria.

Determine pipe isolator sizes, hardware, and installation locations.
For freestanding spring isolators, check the following materials on
receipt for shipping damage and completeness:
Sound-deadening pads
Leveling and connecting bolts for both the equipment and the
structural base
Adjustable stops, both up and down
Hot dip galvanized steel components
Cadium-plated and neoprene-coated springs
Lateral limit stops on springs where required
Type and model of isolator identified on component
Springs clamped to bases and not welded
For rubber shear isolators, check the following materials on receipt
for shipping damage and completeness:
Confirm if single and/or double isolator(s) provided.
Verify that the isolator is properly housed with bolt holes for
attaching equipment and structural base.
Hot dip galvanized steel components.
For suspended pipe and equipment isolators, check the following
materials on receipt for shipping damage and completeness:
Hot dip galvanized steel components.
Ensure that the isolator is adjustable to transfer the load to
the spring.
For suspended piping support, confirm that the isolator is a
combination rubber-in-shear and spring type.
Confirm that a rubber grommet is provided surrounding the
bottom suspension rod as required by the contract documents.
Check inertia block framing:
Check that reinforcing bar is included with the vendor-supplied isolator frame.
Check that the block is framed to provide support for base
pipe elbow supports.
Check the quality and completeness of frame welding and
bracing.
P-24-1
1997, 2001 Bechtel

B. Installation
Guideline P-24
Verify the installation of vibration isolation system on mechanical

equipment, piping, and ductwork per contract documents to prevent
the transmission of objectionable vibration and structure born noise
to the building and occupied spaces.
Check that suitable holddowns and limit stop devices have been
installed to maintain equipment isolators at correct static deflection
while connecting piping and ducts.
After installation and adjustment, check that the equipment is
allowed to float free and that limit stops are out of contact during startup and operation.
Check that the installed isolation system will not interfere with the
operation of the mechanical equipment.
Check that flexible isolator systems are adjusted to match equipment weight distribution to provide a stable mounting decoupled
system.
The isolation system frequency shall not differ by more than
10%.
The following units typically are installed with vibration isolators:
Floor-mounted air handlers
Ceiling-mounted air handlers and fans
Duct-mounted fans
Chilled water, hot water, and cooling water pumps
Pump to boiler nozzle connections
Air-cooled condensing packages
Check loaded and unloaded isolator heights to verify that the load
is correctly spread and that the difference in height is about equal
to the specified deflection.
Check that spring isolators have 50% capacity remaining after
loading.
Check that rubber shear isolators are not splitting or cracking or are
being cut by attached bases or adjacent equipment.
Verify that equipment is level and not transmitting substantial loading to adjacent piping or ducts through the equipment flanges. To
do this:
Observe pipe-to-equipment alignment before bolt-up
Randomly test by disconnecting flanged connections at
equipment and determining if alignment remains.
Verify that the isolators are attached to structurally sound locations
on the equipment frame.
Check that isolators are attached to equipment and structural
supports using hot-dipped or plated fasteners.
Verify that the isolators are plumb when loaded.
P-24-2

C. Ductwork Supports
Guideline P-24
Verify that vibration isolators are used:

With duct hangers where specified
To connect ductwork with equipment with flexible duct connectors
To segment ductwork using flexible duct connectors where
specified
Check that isolation pads are provided at the base support and on
lateral struts for duct riser supports.
P-24-3
Guideline M-1
Guideline M-2
General Equipment Setting
Rotating Equipment
A. Installation
Check that embedded anchor bolts are installed per design.

Verify that adequate anchor bolt projection has been provided.
Verify that baseplates are level.
If more than one baseplate, verify that the baseplates are all on the
same plane.
If shims are required, determine correct size, thickness, and shape
of shims required.
Make sure that no undue stresses are created when the equipment
is connected to piping, ductwork, or conduit.
Check rotation of motors before energizing.
Make sure that coupling is not energized when checking
motor rotation.
Verify manufacturer lubrication requirements before energizing.
Check that grouting or dry-packing of foundation plates are complete and cured before energizing.
A. Preplanning
Review the equipment specifications and the approved plans,

methods, procedures and sequence of operations. Major items to
be considered:
Equipment manufacturer installation instructions
Accuracy of anchor bolt layout
Grouting techniques
B. General
Ensure that rotating equipment is the correct size, type, and rating
as specified.
Verify that vendor has provided lifting lugs as required for component handling.
Ensure that proper handling and storage techniques are employed.
Verify that rotating elements turn freely before installation.
Verify that rotating elements are turned periodically during construction or layup. Make sure that manufacturer instructions are
followed.
C. Anchor Installation
Verify accuracy of embedments, anchor bolt layout, size, dimensions, and elevation, before and after placing concrete and foundation.
Protect anchor bolt threads from dirt, rust, and mechanical damage.
D. Equipment Installation
Verify that the equipment bed plate is installed per manufacturer

instructions and that vendor representative is present when setting
critical items such as sole plates where required.
Verify that grout and air release holes are provided in each
compartment of the equipment bed plate.
Ensure that foundation surface preparation is complete.
Check that all rigging and handling equipment is safe and will
properly handle component loads. Review Rigging Guideline.
Take care when transporting, handling, and setting rotating
equipment.
Check that equipment location coordinates and elevations are
correct.
Ensure proper equipment lubrication before installation including:
Shipping and/or field storage lubricants drained
Lubricant reservoirs flushed and cleaned
Reservoirs filled with correct quantities of approved lubricants
M-1-1
1997, 2001 Bechtel
M-2-1
1997, 2001 Bechtel
Rotating Equipment
Guideline M-2
E. Alignment, after equipment is set, shimmed, and bolted

down, before grout and before making piping connec
tions.
Do not allow holddown nuts to be pulled down so strongly that bed

plate is distorted.
Provide tapered spacers for anchor bolt nuts bearing against
tapered bed plate flanges.
Verify that grout is mixed and placed per manufacturer instructions.
Review Equipment Grouting Guideline.
Recheck alignment after grouting.
F. Piping Connections
Visually check the suction and discharge before pipe hook-up.

Verify that rotating elements turn freely.
Check that all welders engaged in the equipment installation are
qualified to AWS, ASME, AWA, and/or ANSI codes as applicable
unless otherwise required in the contract or local codes.
Make pipe connections after grout is cured.
Do not allow pipe connections to transmit stress to equipment
Re-check alignment. Relieve stresses, as required.
Check that gland leak-offs are properly piped to drains.
Verify that glands and seals have proper packing correctly tightened.
Check that lube oil and bearing cooling water piping is correctly
installed.
Verify that sleeves are installed for this piping where necessary.
Determine that supports for piping, tubing, and instruments do not
cause interference.
Check that the doweling is done after acceptable coupling alignment or after hot alignment, if applicable.
Check that thermocouple leads, capillary tubing and pressure tubing are neatly and conveniently run and that all instrument connections properly penetrate covers, lagging, and other sheet metal.
Make sure that all vents and drains are properly installed and are
clear.
Determine that proper provisions are made for installing protective
strainers during system flushing.
Re-check alignment as required to ensure that no additional stresses are imposed on the equipment.
Ensure that coupling alignment is performed per manufacturer
installation instructions and as specified. Review Coupling
Alignment Guidelines.
M-2-2
Guideline M-3
Coupling Alignment
A. Preplanning
Check equipment for proper location/orientation and elevation.

Before coupling work is started, ensure that lockout procedures are
followed and safety tags are posted as applicable on the following:
Breakers to electric motor drivers
Air or steam supply valves to mechanical drivers
Pump suction and discharge shutoff valves
Ensure that required electrical testing such as motor rotation or
bump test is completed before coupling the equipment.
B. Before Connecting Piping but after Shimming and

Anchor Bolt Tightening
With coupling bolts removed, check coupling halves of both driver

and driven machinery to ensure concentricity of coupling rim and
component axes. Use manufacturer alignment recommendations.
Check coupling halves for parallel alignment to ensure that equipment center lines are coaxial. Correct parallel displacement before
next step.
Check coupling halves for angular alignment to ensure that coupling faces are parallel. Correct angular displacement before final
alignment.
C. Alignment Work Operations
Monitor coupling alignment when piping connections to driven

machinery are made.
Repeat alignment check after piping connections are complete.
Rework piping or supports, as required.
Recheck alignment and record final readings on alignment data
sheet, when satisfactory.
Make up coupling after correct direction of rotation of driver has
been established.
Ensure that coupling bolts and set screws are tight and secured
against accidental loosening.
Recheck alignment during initial startup/operation, as required.
M-3-1
1997, 2001 Bechtel
Guideline M-4
A. Preplanning
Check vendor data, specifications, layout drawings for interface

with other disciplines.
Check equipment for proper location, orientation and elevation.
Before any sheave alignment work is started, ensure that lockout
procedure is followed and safety tags are posted as applicable on
the following:
Breakers on electric motor drivers
Pump/compressor suction and discharge shutoff valves
Ensure that the equipment baseplate grout is complete and accepted.
For fans, ensure that base vibration dampeners are properly
installed.
Check foundation bolts and nuts for proper size and tightness
(including vibration mounts, if applicable).
Before installing the belts, check the following:
Sheave of both driving and driven equipment to ensure concentricity of sheave rim and equipment
Damaged or dirty sheave(s)
V-groove alignment of sheaves on driving and driven equipment; V-belts must enter and leave sheaves without side binding.
Guideline M-4
Rework piping or supports if required.

Recheck alignment per the above step. Record final readings on
data alignment sheet, when satisfactory.
Recheck belt tension per belt manufacturer recommendations.
Check belt guards for proper clearance, alignment and security.
Recheck belt tension and alignment during initial startup/operation,
as required.
Determine that all data required by startup are properly coordinated.
Make sure that thermocouple leads, capillary tubing, and pressure
tubing are neatly and conveniently run and that all instrument connections properly penetrate covers, lagging, and other sheet metal.
Verify that rotating elements are turned periodically during construction or layup. Make sure that manufacturer instructions are
followed.
Make sure that all vents and drains are properly installed and are
clear.
Determine that proper provisions are made for installing the protective strainers during system flushing.
Check alignment as required to ensure that no additional stresses
are imposed on the equipment.
B. Belt Installation and Alignment
Verify that the outer edge of the sheave hub does not extend
beyond equipment shaft. Also, verify that the inner edge does not
touch the equipment. If sheaves are not same thickness, it will be
necessary to align center lines.
Verify that shafts of both driving and driven equipment are parallel.
Check for matched sets on multi-belt units.
Ensure that all belts are installed with the slack on the same side.
After installation of belts, ensure that sheaves on driving and driven equipment are secured to their respective shafts per manufacturer instructions. Check belt tension per manufacturer instructions.
Verify that the driven equipment has been securely bolted and doweled to the baseplate as specified.
Verify that the driver is securely bolted to the equipment baseplate
by holddown bolts and however, remains adjustable (i.e., no dowels) for belt tensioning adjustments during maintenance.
Monitor shaft alignment when piping connections to driven equipment are made (if any).
Repeat above step after piping connections are completed.
M-4-1
1997, 2001 Bechtel
M-4-2
Guideline M-5
E. Equipment Grouting
A. Preplanning
Review the equipment specifications and the approved plans,

methods, procedures, and sequence of operations. Major items to
be considered include:
Equipment manufacturer installation instructions
Accuracy of anchor bolt layout
Grouting techniques
Manufacturer storage and layup procedures
Inspection and maintenance for corrosion and cleanliness
control before, during, and after assembly
B. General
Check that equipment is correct size, type, and rating as specified.

Ensure that correct equipment manuals and drawings are available.
Verify that vendor has provided lifting lugs as required for component handling.
Check that all rigging and handling equipment for offloading and
moving meets requirements. Review Rigging Guideline.
Ensure that all rigging and handling equipment is engineered for
conditions of all specific moves to the final location of the equipment.
Check that miscellaneous steel and concrete block walls that may
obstruct setting of equipment are omitted until after setting.
Confirm any steel framing omission with design engineering.
Ensure that curbs, piping projecting above the floor, cable trays, or
other similar items will not interfere with rigging or skidding the
equipment into place.
Ensure that all accessories supplied by the equipment vendor, such
as piping, level indicators, temperature indicators, pressure
gauges, and switches, are installed.
C. Embedded Equipment
Ensure that all embedded equipment drains, conduit, grounding

cables, and other below floor level facilities are in place before placing concrete.
D. Anchor Installation
Check anchor bolt layout, elevation, projection, and thread length:

Determine if anchor bolt sleeves are required.
Ensure that bolt threads are protected.
M-5-1
1997, 2001 Bechtel
Guideline M-5
Verify that equipment bed plate is installed per manufacturer

instructions and that vendor representative is present when setting
critical components such as soleplates.
Check grouting preparation including removal of laitance, cleanup,
wet down, grout dams, and provisions for grout and air release
holes in bed and foundation plates.
Verify that sole plates meet manufacturer requirements and are
installed in correct location, elevation, and slope and have the
required anchor bolt clearance.
Verify that grout is mixed and placed per manufacturer requirements. Review Equipment Grouting Guideline.
F. Equipment Installation
Take care during transportation, handling, and setting equipment.

Review Rigging Guideline.
Check the centerline and elevation of each piece of equipment.
Verify that the accuracy and tolerance of all locating dimensions satisfy final requirements.
Allow for proper insulation clearance around equipment.
Check all insulation for proper thickness.
Check that all fixed points for thermal expansion are at designated
location and expansion is in the required direction.
Check that all bolts, studs, and nuts are the proper material.
Verify that flange bolt torquing is performed to manufacturer and
specification requirements.
Verify that required bolt tightening sequences are followed.
Ensure that all piping connections are properly aligned and are not
transmitting stress to the equipment.
Check manufacturer data before welding attachments to equipment.
Consult manufacturer before welding on vessels and piping that
have special coating, lining, or paint.
Check that all welders engaged in the equipment installation are
qualified to AWS, ASME, AWA, and/or ANSI codes as applicable
unless otherwise required in the contract or local codes.
Properly support all pipe, tubing, conduit, and ductwork and check
that connections to equipment are performed as specified.
Check all piping, particularly drains, to verify that design slope,
P-traps, or air breaks are maintained throughout runs.
Check that all required pressure taps, thermowells, thermocouples,
test connections, vents and drains are in proper locations.
M-5-2
Guideline M-5
Ensure that all valves, instruments, tubing, gauge lines, control air
components, and capillary tubing are effectively protected from all
construction activity.
Check that small pipe design does not encroach on clear space left
for tube bundle withdrawal.
Check that all system flush requirements are compatible with manufacturer procedures for equipment maintenance.
Guideline M-6
Pumps
A. Receipt Inspection
Ensure that pumps are inspected on board vehicle on arrival at the

site.
Inspect for visual evidence of shipping damage.
Carefully check any associate piping bundles for completeness or damage.
B. Installation
Check that equipment pads, platforms, or hangers required to support the equipment are complete before starting the installation.
Verify that the equipment is installed per contract documents.
Verify that vibration isolators and flexible connections are installed
as required.
Check that all piping, check valves, controls, and structural supports for the equipment are installed as required.
Verify that all required electrical connections are complete.
Verify that belt guards are arranged to permit oiling, testing, and
use of a tachometer with the guard in place.
Ensure that a belt guard access door is provided to measure
belt tension.
Verify that the pump has been aligned to operate without noticeable
vibration.
Ensure that the equipment is protected from dirt, foreign objects,
and damage during the installation period.
Witness all balancing and testing required by the contract documents.
Witness required equipment performance tests demonstrating that
the equipment functions as intended.
Verify that all debris is removed from the work site and that all
equipment including castings, sumps, and motors are cleaned
before final acceptance.
Check wet and dry sump elevations, access gratings, and safety
devices for proper installation.
Verify that in-flow drains are clear of any obstruction.
Check that inlet and discharge line flanges are correctly installed
and securely gasketed.
Ensure that equipment lubrication fittings can be accessed easily.
Verify that unit controls are installed per contract documents and
function properly.
C. Testing
Verify that fire pump test satisfies the requirements of NFPA 20 or

specified code.
M-5-3
M-6-1
1997, 2001 Bechtel
Guideline M-7
Guideline M-8
Elevated Steel Tanks
A. Preplanning
Verify that all required shop testing has been completed and data
sheets, test reports, and certifications are submitted.
Inspect for obvious damage to the tank.
Verify that there are no unrelieved welds on stress-relieved tanks,
e.g., ladder clips, pipe supports, etc.
Inspect internally for cleanliness and proper internal coating
system.
No one may enter a "confined space" until safety inspection
has been performed and determination made that their are no
harmful gases, vapors, fumes, or mists present in the tank
and proper ventilation is provided or proper respirator and
protective clothing is worn as required.
Ensure that concrete foundations have been sufficiently cured.
Check anchor bolts for correct location, elevation, and protection.
B. Tank Erection
Take care to prevent damage during movement, handling, and setting operations. Review Rigging Guideline.
Check for correct orientation of tank and nozzles.
Ensure that the following conform to specification and code requirements:
Erection
Welding
Nondestructive examination
Testing
Cathodic protection, as applicable
Outside painting
Disinfection
A. Preplanning
Verify that tank is manufactured in conformance with applicable

local codes.
U.S. Environmental Protection Agency requirements require
nonpermeable liners for hydrocarbon or hazardous material
underground storage tanks.
Verify that all required shop testing has been completed and data
sheets, test reports, and certifications are submitted.
Inspect for obvious damage to the tank.
Make sure that chocks are used to prevent the tank from rolling
while in temporary storage at the site.
Inspect internally for cleanliness and proper internal coating system.
Conduct holiday tests on any coating repair areas.
No one shall enter a "confined space" until safety inspection
has been performed and determinations made that there are
no harmful gases, vapors, fumes, or mists present in the tank
If double walled tank is provided with a vacuum in the interstice,
check vacuum level and compare with the level when the tank left
the factory.
Advise manufacturer of any difference.
Pressurize single wall steel tanks and fiberglass reinforced plastic
(FRP) tanks to 5 psi and soap bubble test for leaks:
Weld seams of steel tanks
The entire surface of FRP tanks
Check that bedding is of acceptable material, thickness, and compacted according to specification requirements. Review Cut and
Cover Excavation and Backfill Guideline.
B. Tank Setting
Check that care is taken to prevent damage during movement,

handling and setting operations. Review Rigging Guideline.
Only use designated lift lugs to move the tank.
Ensure that the installation is according to shop drawings, applicable code requirements, and manufacturer instructions. Check the
following as applicable:
Welding
Nondestructive examination
Testing
Cathodic protection
Painting
M-7-1
1997, 2001 Bechtel
M-8-1
1997, 2001 Bechtel
Guideline M-8
Check bedding and backfill for acceptable material, uniformity, and

compaction per specification and applicable codes.
Ensure that backfill and bedding are of the same material.
For steel tanks, check that:
Sand, crushed stone, or pea gravel is used for bedding and
backfill.
Bedding and backfill is free of large, sharp rocks that could
damage coatings.
For FRP tanks, check that:
Pea gravel is used for bedding and backfill material.
Crushed stone or sand is only used where specifically permitted.
Check for minimum bedding depth of 12 inches (30 cm) unless otherwise specified.
Check that required tank buoyancy anchors are installed.
Make sure that standard buried reference cells provided for cathodic protection are installed level with the bottom of the tank.
Check backfill compaction under the tank's lower quadrants to prevent settlement after burial.
C. Piping Connections
Make sure that sealants are compatible with both tank and piping
materials.
Check that piping is well inserted into the tank flange.
Test both tank and piping for integrity.
Conduct cathodic protection tests to make sure that the tank is
electrically isolated from other structures.
D. Tank Deflection
Check FRP tanks for deflections and verify that it is less than the
maximum diameter change allowed by the manufacturer.
E. Installation Documentation
Maintain checklists of all installation activities.

Maintain photographs of all installations for future reference.
M-8-2
Guideline M-11
Boilers
A. Preplanning
Check vendor data, installation procedures, specifications, and layout drawings for corrections and interface with other disciplines.
Ensure that all boiler erection and assembly drawings are approved
for installation.
Check that a detailed vendor shipping list is available before any
components are received at the site.
Determine the number, location, and schedule or erection "hold
points" and coordinate with the "Authorized Inspector."
Thoroughly check all shipping lists and bills of material against the
drawings.
Ensure that vendor has provided lifting lugs, lift beams, and alignment clips for component handling and assembly.
Ensure that vendor has specified preservative and paint requirements.
Check that all bolts, studs, and nuts are the proper material.
B. Anchor Installation
Check anchor bolts for correct location, free length, sleeve condition, thread projection and protection before foundation concrete is
placed.
C. Boiler Installation
Check that all rigging and handling equipment is safe and will properly handle component loads. Review Rigging Guideline.
Take care during transport, handling, and setting operations.
Ensure that vendor representative is available during installation
operations, as required.
Check for insulation clearance around pipe and equipment.
Check that all required pressure taps, thermowells, thermocouples,
rest connections, vents, and drains are provided in proper locations.
Verify that piping, instrumentation, and equipment are protected
from freeze-up.
Drill and fill all dowels, as required.
Check that all welders engaged in boiler erection are qualified to
applicable AWS, ASME, AWA, and/or ANSI codes or as required by
local codes.
Check that spare parts and installation/maintenance tools are available for turnover to owner.
Ensure that the boiler flushing and/or chemical cleaning requirements are satisfied.
M-11-1
1997, 2001 Bechtel
Guideline M-12
Guideline M-13
Condensers
Heat Exchangers
A. Submittals
Check vendor data, installation procedures, specifications, and layout drawings for interface with other disciplines.
Verify that vendor has provided lifting beams as required by the
specifications.
Verify that waterboxes are hydrostatically tested at the vendor shop
before delivery to site.
Verify that weld footage, weld configurations, and a weld distortion
control procedure is available from the vendor.
B. General
Verify that vendor has coated shop-prepared weld ends with deoxaluminite to preclude corrosion before field welding.
Verify that the vendor has provided lifting lugs and alignment clips
for component handling and assembly.
Ensure that all shortage items are promptly identified and replacement is expedited.
Check that torque values and tightening sequence for waterbox
bolts/nuts are available from the vendor.
If waterboxes are rubber lined, check that lining is not separating
due to shipping damage, storage, and handling.
Check that space gaskets and/or "O" rings are available.
Check that blank nozzles are capped off.
C. Installation
Verify that condenser concrete foundation pad (piers) and anchor

bolts are in proper location, orientation, and elevation.
Take care during transportation, handling, and setting condenser.
Review Rigging Guideline.
Ensure that vendor representative is available during installation
operations, as required.
Ensure that equipment grouting is performed per manufacturer
instructions. Review Equipment Grouting Guideline.
Check nozzle protrusions for clearances before skidding in preassembled condensers.
Verify that welding is performed by qualified welders.
Ensure that nondestructive examination is performed as specified.
M-12-1
1997, 2001 Bechtel
A. Preplanning
Check that nitrogen blanket pressure is within prescribed limits

when vessels arrive at site.
Follow manufacturer and code requirements before any repair work
on the vessel or its appurtenances.
Ensure that all steel, equipment, and piping that prevent rigging
and placement of the vessels are not erected until after setting.
Check all critical layout dimensions between vessels and main turbine, then between vessels and building steel.
Check that anchor bolts (pedestal-supported vessels) are accurately set to line and line grade and within tolerance.
Check that support hangers and support steel (hanger-supported
vessels) are accurately set to line and grade within tolerance.
Check that benchmarks are established to verify line and grade and
are provided so that accurate line of sight is preserved the completion of work.
Plan large cross-around piping placement at most advantageous
time.
Check that all equipment and structures in vicinity will permit
designed expansion of vessel and its piping.
Do not block vessel manway doors or other critical access items
with permanent components.
Ensure that no work is done inside the vessel until it is effectively
vented and purged. Review the manufacturer suggested procedure. Satisfy all state, federal, and jobsite safety requirements.
B. Installation
Follow the manufacturer requirements and specifications when

removing temporary covers and internal shipping braces.
Verify that at frequent intervals that all vessel internals are effectively protected from contamination when factory-supplied covers
are removed.
If welding is required, check that manufacturer-approved specifications, materials, and procedures are used.
Verify that welding is performed by qualified welders.
Ensure that nondestructive examination is performed as specified.
Check that all touchup painting of vessel interior uses only that
paint supplied and/or specified by the manufacturer.
M-13-1
1997, 2001 Bechtel
Guideline M-14
Columns and Vessels
Columns and Vessels

A. Preplanning
Inspect equipment at time of receipt for damage and/or shortages.

Document any shipping or erection damage by photograph.
Check that stress-relieved vessels are stenciled. DO NOT WELD.
On large diameter equipment, it is desirable to have anchor bolt
templates made by the fabricator and shipped early to site before
pouring foundation.
B. Field-Fabricated Columns and Vessels
Perform dimensional, orientation and plumbness checks as work

progresses.
Where mating flanges occur, check horizontal and vertical alignment and also alignment of bolt holes.
Check that all welding is performed per contract and code requirements.
Inspect internals and externals for correct configuration and
completeness.
C. Before Column or Vessel Erection
Prepare a heavy lift rigging plan per Bechtel rigging standards.

Check anchor bolt and skirt hole orientation and anchor bolt
projection.
Inspect anchor bolts for damage.
Establish elevations for setting leveling blocks.
Check large diameter columns for ovality before erection to identify
possible tray installation problems.
Ensure that the concrete foundation has been sufficiently cured.
Ensure that grading, timber mats, and track spurs are complete per
the heavy lift rigging plan.
Perform compaction tests on structural fill placed to accommodate
the heavy lift.
Verify that slide plates are installed and that lubrication, teflon, and
double nuts are used where required.
Verify that all welds on stress-relieved vessels have been stress
relieved.
Specifically check ladder, instrument, and pipe support attachment welds.
Verify that there is no obvious damage to the vessel and no obvious misalignment or bow in the shell.
Check that suitable drainage is available to protect the tank pad.
D. Column and Vessel Setting
Make a final check of the elevations of the leveling blocks and

anchor bolt locations and projections, before final setting.
M-14-1
1997, 2001 Bechtel
Guideline M-14
After checking, locally grout the shims to prevent removal.

Check that protective lattice, lubricants, and paint are removed and
surfaces cleaned where grouting is required.
Before removal of lifting equipment, make a final check of plumbness and correct alignment.
Maintain an equipment settlement survey record and review the
results of each elevation check.
E. Column and Vessel Testing
Inspect internally for cleanliness and any debris.

No one may enter a "confined space" until safety inspection
has been performed and determination made that their are no
harmful gases, vapors, fumes, or mists present in the tank
Verify that a written procedure has been prepared for testing large
columns and vessels.
Ensure that testing is performed per the correct procedure and
document the results.
Testing of columns and vessels that have been shop tested may
not be required.
For convenience in testing piping, however, most columns
and vessels are included in the piping tests.
Ensure that trays are tested as required by the contract and
document the results.
F. Final Inspection of Columns and Vessels
Before columns and vessels are headed up, ensure that they are
cleaned out and the internals are inspected.
G. Trays
Check trays for levelness.

If levelness tolerance is not specified, use the following:
All trays 12 ft (3.5 m) diameter and smaller should not be
more than 1/4" (6 mm) out of level.
All trays larger than 12 ft (3.5 m) in diameter should not be
more than 3/8" (9 mm) out of level.
Check orientation of trays with the vessel drawings.
Check that downcomers are sealed by weirs of the proper height.
Check downcomer and weir height dimensions against the vessel
drawings.
Check that trays are securely anchored to the vessel and that all
tray manways are properly installed following the inspection.
Check for proper gasket installation to ensure tightness.
M-14-2
Columns and Vessels
Guideline M-14
Ensure that bubble caps and tray valves are installed and that
valves are free on valve trays.
Check all trays for cleanliness.
Check weep hole requirements on seal pan trays.
H. Nozzles
Check the orientation of vessel nozzles.

Verify that process nozzles are located on the proper trays.
Check thermowell locations and projections into vessels.
I.
Distributors
Guideline M-15
Steam Turbines
A. Preplanning
Check the orientation and location of distributors.

Check that distributors are properly supported and anchored to the
vessel.
Check drilled holes and/or spray nozzle for size, number, and
orientation.
Make certain that none of the holes or nozzles are plugged.
Check orientation and location of mist eliminators.

Make certain that the pads are firmly supported and anchored.
Ensure that eliminators can maintain wash if located in an atmosphere where choking or plugging would be expected.
J. Mist Eliminators
K. Miscellaneous
Check that all internal bolts are stamped with the correct material
symbol.
Check weirs for proper orientation, height, and weep holes.
Check that davits are installed and working properly.
Inspect vortex breakers.
Check that leak testing nipples in nozzle-reinforcing pads extend
beyond insulation.
Check location of level control nozzles.
Ensure that name plates are readable and are securely fastened.
Check overall cleanliness.
Verify that all other internals are complete.
L. Catalyst Loading
Check all elevations marked in vessels for catalyst levels.

Request frequent client inspections and approvals.
Obtain client signed Inspection Reports for record and filing.
Review and retain copies of equipment settlement survey records.
M. Documentation
Verify that all reports and records are retained in the project files.
Verify that all code reports and inspection reports are retained in
the project files.

Remove shaft movement stops.
Inspect bearings.
Apply approved rust preservative to exposed machined surfaces
and machined surfaces inside bearing housings.
Apply an approved oil treatment to the journal bearings.
Rotate shaft weekly if shaft stops have been removed.
Verify that foundation anchor bolts match baseplate anchor bolt
locations.
Prepare foundation surfaces for grouting.
Prepare baseplate bottom surfaces with approved primer for epoxy
grouting.
B. Installation
Set baseplate on foundation.

Level baseplate.
Prepare grout forms.
Grout baseplate and cure grout.
Remove leveling screws and tighten anchor bolts to specified
torque.
Install coupling hub and verify pull-up.
Set equipment shafts level by adjusting shims at support feet.
Check distance between shaft ends with shafts in normal running
positions.
If necessary, move equipment positions.
C. Alignment
Align equipment shafts.

Make cold offset adjustment required by manufacturer to allow for
thermal growth of the equipment to a hot running condition with
shafts level.
Check cold alignment and adjust as necessary.
Temporary dowel equipment feet.
Set clearance on equipment holddown bolts and spacers
as required.
Set centerline alignment key clearances.

Set radial growth key clearances as required.
Install steam supply and exhaust piping.
Make last field weld well away from turbine.
Break main piping flanges one at a time and monitor shaft alignment for position changes indicating pipe strain.

M-14-3
M-15-1
1997, 2001 Bechtel
Steam Turbines
Guideline M-15
Do not use come-a-longs to pull piping into position for bolt up

or to hold piping while checking for pipe strain.
Make up lube oil interconnecting piping for oil console.
Clean interconnecting and other field-fabricated oil piping.
D. Lube Oil Flushing
Install flushing screens at each equipment oil connection.

Alternatively, jumper each oil connection to drain and cover to
protect from entrance of foreign material.
Flush oil system.
Fabricate auxiliary piping and ensure that piping has room for thermal expansion.
Connect all instruments and electrical signals.
E. Instrument Calibration and Checkout
Calibrate all instruments:

Vibration probes, proximeters, and panel readouts.
RTDs and T/Cs
Trip and throttle valve position micro switches
Pressure switches, differential pressure switches, and
temperature switches
Sealing and leak off steam pressure control loops and valves
Bearing and control oil pressure control loops and valves
Bearing oil temperature control loop and valve
Level switches
I/P transducer calibrations
Verify that all restricted orifices are installed.
Set tachometer and governor magnetic pickup clearances.
Set mechanical overspeed trip clearance.
Verify total shaft float.
Verify radial and thrust bearing clearance.
Check governor drive gear backlash, bearing clearance, and
coupling.
Check turning gear, adjust engagement, verify motor direction,
adjust disengagement mechanism, and adjust indicating micro
switch.
Check instrument and electrical loops between local panel and
control room.
Verify that governor remote speed set point signal loop.
M-15-2
Steam Turbines
Guideline M-15
F. System Restoration and Startup
Remove temporary jumpers and screens and reconnect oil piping

for normal service.
Drain reservoir and clean out all debris.
Replace filter cartridges and refill reservoir with clean oil.
Verify that lube system pump start/stop and test system pressure
controls during upset.
Verify lube system rundown tank functionality.
Static test governor and governor actuator.
Program governor as required.
Check governor valves, prepilot, pilot, and main servomotor linkage.
Ensure that total travel of valves agrees with prepilot travel.
Verify that governor actuator/prepilot action on trip and action of
emergency shutdown cylinder for valve closure.
Blowdown main steam supply, exhaust steam header, leakoff and
sealing steam headers, gland ejector steam supply, and air removal
system steam supply.
Test exhaust pressure relief valve and install in exhaust piping
between turbine and first downstream block valve.
Verify operation of main condenser condensate pumps and level
control loop.
Verify operation of air removal system ejectors, inter/after condenser, drain traps or drain piping loops, and vent system.
Check relief valve operation for each stage.
Verify that hogger is able to achieve vacuum in reasonable
time.
Connect all piping while monitoring for piping strains.
Verify that all alarms and trips are functional.
Test local panel and control room emergency stop button.
Verify trip and throttle valve operation during simulated trip.
Verify action of trip and throttle valve exercising system.
Verify operation of extraction/induction non-return valve shutdown
cylinder and valve disk closure system.
Check that disk counterweight is fixed and adjusted properly.
M-15-3
Guideline M-16
Guideline M-17
Combustion Gas Turbines
Diesel Engines
A. Preplanning
B. Installation
Check cold alignment as required.

Verify that baseplate is properly grouted.
Check that jacksrews are removed and foundation bolts are
tightened.
Recheck cold alignment.
Check installation of special spool pieces and verify that no piping
strain is applied to equipment.
Verify installation of fuel filters.
Check that pipe supports are properly installed.
Recheck cold alignment.
Flush lube and seal oil systems, refill reservoir with new oil, and
change oil filters.
Check reservoir oil heater.
Check instrumentation loops.
Verify that grounding strap is installed.
Check starter motor and direction of rotation.
Check that coupling and guard are installed.
Check inlet plenum and verify vacuum is cleaned.
Inspect clean air house.
Verify that all site-fabricated piping pressure was tested as
required.
Verify that all site-fabricated piping was chemically cleaned as
required.
Verify oil protection unit setup.
M-16-1
1997, 2001 Bechtel
A. Preplanning

Check that certification documentation has been received.
Check nameplate data.
B. Installation
Check installation location per design requirements.

Verify that resilient mounting is fitted.
Verify that coupling and coupling bolts are fitted.
Check cold alignment.
Ensure that dowels are properly installed and hold down bolts are
tightened as required.
Check that shims are installed correctly.
Check that coupling guard is properly installed.
Verify that air inlet filter is installed and is accessible for maintenance.
Check that exhaust silencer is installed including personnel
protection.
Check expansion joints for free movement.
C. Checkout
Check engine lubrication including oil type and level.

Verify that new lube filter installed.
Check that cooling radiator is accessible for fill and drain.
Verify that crankcase and oil relief vents are installed.
Check that all instruments are installed.
Check that theoretical rotation is the same as the driven equipment.
Verify that starting system is properly installed and ready for start.
Verify that cooling system is charged with the correct coolant
mixture.
Check gauge board against P&IDs.
Verify that the emergency shutdown and/or fuel shutoff valves at
the unit are operational.
M-17-1
1997, 2001 Bechtel
Guideline M-18
D. Burners
A. General
Check that nameplate is correctly installed and that nameplate

information is correct and legible.
Check erection for compliance with specification requirements and
verify that any deviations are documented.
Verify that welding procedures are approved for use.
Verify that field welding, heat treatment, and stress relieving are
performed per approved procedures and are properly documented.
Verify that nondestructive examination has been performed and
documented on field welds as required.
Check that hydrostatic testing is performed per contract and
applicable code requirements.
Ensure that exposed surfaces, easily accessible by operators,
with surface temperatures over 150F (65C) are insulated for
personnel protection.
Ensure that safe access is provided to all valves and instruments.
Check that all spare parts have been provided and are available.
B. Heater Casing
Check sources of air infiltration:

Sealing devices provided at entry and exit points for all tubes
Packing provided around convection section tubes at the end
of tube sheets
Convection section header boxes gasketed as required
Check that large panels are adequately supported.
Additional stiffening may be required to prevent bowing.
Check that rainwater cannot accumulate in arches, angles, or
channels.
C. Access and Observation Doors
Check that adequate radiant section observation doors have been

provided for the tubes, supports, walls, arch, and burner flames.
Make sure that convection section observation doors have been
installed to view representative tubes, extended surface, and tube
sheets.
Make sure that doors fit properly to minimize air infiltration.
Make sure that any explosion on pressure release doors will not
discharge flue gas in a direction where personnel exposure could
occur.
M-18-1
1997, 2001 Bechtel
Guideline M-18
Check that installed burners are protected from mechanical damage and that all refractory material is kept dry.
Make sure that there is no serious refractory damage and that
burner internals are clear of debris.
Check for adequate clearance between burner tiles and floor
refractory.
Check gun size, position, and alignment.
Ensure that suitable ignition equipment has been provided.
Check that spares have been provided.
Make sure that both ignitor guns and the burner assembly can be
removed while the heater is in operation.
Check that the burner support is adequate to ensure that burner
alignment does not change while in service.
Ensure that suitable flame scanners are provided and that spares
are available.
E. Dampers
Check operability of all dampers.

Check critical dampers such as flue gas/combustion air
bypass dampers both internally and externally.
Verify that tight closure and ease of operation for all dampers.
Check for the potential of thermal growth problems.
Check that stack damper indicator corresponds with damper position and that stops have been provided.
Make sure that forced draft heaters cannot be over pressured by
improper damper operation.
Check that hot service mechanical bearings are properly installed
and are adequate for expected operating conditions.
Outboard installation is preferred to reduce operating temperature.
Check for shaft leakage in forced or induced draft systems.
Check that individual burner dampers are capable of locking in the
fully open or fully closed position.
F. Burner Piping
Inspect burner fuel valving system to ensure that burner startup,

operating, and shutdown requirements are met.
Inspect ignitor fuel valving system to ensure that ignitor startup,
operating, and shutdown requirements are met.
Check that required insulation and steam tracing is properly
installed.
Check that piping flexibility and support are adequate for gun height
repositioning.
M-18-2
Guideline M-18
Make sure that only minor thermal growth forces will be

imposed at the burner gun to piping junctions.
Check that fuel piping has been properly seal welded.
G. Radiant and Convection Section Coils
Review support and guide system for freedom of movement.

Make sure that inlet and outlet piping does not impose
excessive force on the coil assemblies.
Check for adequate thermal movement clearances inside heater, at
tube entry and exit points, and at crossover piping.
Inspect the operability of piping spring and counterweight supports.
H. Soot Blowers
Check that steam piping is properly sloped and trapped.

Ensure that blowers are properly serviced for startup per manufacturer recommendations.
Conduct blower run-in test per manufacturer recommendations.
Ensure that limit switches are positioned correctly.
Ensure that the lance has adequate clearances when in the
soot blower cavity.
Adjust poppet valves to provide required lance steam
pressure.
I.
Guideline M-18
K. Refractory Placement and Insulation
Verify that the installation, curing, and drying of refractory are

performed per manufacturer requirements.
Inspect completed refractory and insulation installation and
document any deviations.
Check that all expansion joint packing is installed and that no
thermal expansion problems are evident.
Make sure that convection section setting will not impose forces on
the arch noise area.
Ensure that all required field testing is complete including production, cold crushing, and density tests.
L. Dryout
Make sure that hydrostatic test water is removed from coils to the
maximum extent possible.
Ensure that fuel lines are steam blown dry but not through the
burner guns.
Check the performance of all burners during the dryout operation.
Monitor the thermal movement of tubes, tube support systems, and
refractory during dryout for evidence of problems.
Air Preheaters
Check installation per manufacturer instructions.

Check instrumentation to ensure that thermal performance of
the air preheater is controlled and enables safe operation.
Make sure that cleaning facilities are adequate to maintain
thermal performance.
Make sure that air/flue gas dampers will provide for satisfactory operation of the fired heater with the air preheat system
bypassed.
J. Fans
Check instrumentation installation per design requirements.

Check bearing lubrication and cooling systems.
Check operability of forced draft fan inlet guide vane assembly.
Make sure that ductwork does not impose loads on fans.
Check operability of automatic backflow check for forced draft fans
operating in parallel.
M-18-3
M-18-4
Guideline M-19
Water Treatment Equipment

A. Receipt Inspection
Check that tanks and vessels are inspected onboard vehicle at

arrival.
Inspect top of load for damage; determine degree of preassembly.
Carefully check bundled piping for completeness.
Check the lining and interior of all vessels or tanks on arrival.
B. Installation Preplanning
Ensure that overhead and side clearances are adequate for tanks
and vehicle, both inside and outside building.
Ensure that construction activities do not block access for charging
tanks with resin or filter bed material.
C. Installation
Do not allow welding or burning on lined tanks, vessels, or piping

unless vendor instructions are followed exactly.
Check that system flushes do not disrupt filter beds or resin beds.
Check that drains and flush down effluent from acid and alkali storage tanks go only to drain lines provided for that service.
Guideline M-21
HVAC Installation
A. Preplanning
All ductwork, frames, connections, stiffeners, and access doors are

hot dipped galvanized steel unless otherwise specified.
Check that temporary test facilities are provided for leak testing of
ductwork, where specified.
B. Installation
Check all rooftop fan decks to ensure that all flashing and sealing
are completely effective.
Ensure that damper and filter mounting frames are not distorted
during assembly.
Verify that sheet metal plenums, casings, and blank-offs are
smooth and even inside, airtight, and reinforced to eliminate vibration or pulsation during operation.
Check that access doors in insulated casings and housings have
frames of heavy galvanized structural steel members and inspection windows constructed of two sheets of plexiglass with air space
between.
Check that access doors open to the outside of the housing on the
fan suction side and to the inside of the housing on the fan discharge side.
Check all turning vanes for proper materials and installation.
Check that all joints are sealed and leak tested, as required, before
insulating or covering.
Check all ductwork, duct hangers, duct joint details, and equipment
supports for compliance with the project drawings and specifications.
C. Testing
Witness all balancing and testing required by the contract documents.
M-19-1
1997, 2001 Bechtel
M-21-1
1997, 2001 Bechtel
Guideline M-22
Ductwork
Ductwork
A. Installation
Inspect ductwork for correct gauge material, overall size, cross sectional area, reinforcement, use of correct flexible connections,
alignment without undue deformation of flexible connections, and
use of specified hangers.
Check that pilot tube access holes with threaded plugs have been
provided in the ducts and plenums for taking air flow measurements used in system balancing.
Ensure that chambers or casings attached to masonry at louvers or
registers are secured with expansion bolts with mastic grout
between angles and construction.
Make sure that duct openings are capped during construction to
prevent entry of dust and debris.
Check that riser supports allow free vertical movement of the duct.
Supports shall only be attached to structural framing members
and structure concrete.
Do not anchor supports to metal decking unless specifically
detailed.
Do not use friction beam clamps.
Check that duct joints are made with gasketed flanges or welded
flanges as specified and are properly reinforced at the joints and
between the joints.
Ensure that sealants conform to specified fire hazard classification.
Check that negative pressure safety relief valves are provided
as specified.
Check that spiral lock seam duct and flat oval duct are locked with
a minimum of three equally spaced drive screws and sealed with
duct tape unless otherwise specified.
Verify that there are no dents in the male portion of the slip
fitting collar.
Check that fibrous glass duct installation is per manufacturer
requirements.
Check that supports are provided as specified.
Check that leakage rates do not exceed maximum allowed.
Ensure that sealants are per manufacturer requirements.
Check that acoustical duct linings are installed with fire-resistant
adhesive and are secured with welded pins or welding cup head
pins as specified.
Verify installation and operation of control, fire, and smoke
dampers.
M-22-1
1997, 2001 Bechtel
Guideline M-22
Check the operation of each damper

All damper motors are protected before and after mounting.
Dampers are easy working and provided with steel shafts and
end bearings.
Key-operated regulators are provided where damper fixing or
locking devices are not exposed or accessible.
Mounting brackets for damper motors or other duct supported
equipment have not been broken, removed, or damaged.
Damper motors are adequate for service intended.
Nylon or teflon bushing and seals on damper units are not
damaged by heating, metal chips, or misalignment.
Ensure that volume dampers and splitters are installed where
shown and in the following locations:
Provide a splitter for each safety branch
Provide a volume damper for each horizontal supply and
exhaust branch from vertical risers serving two or more floors.
Provide instrument test holes where required for balancing
system
Ensure that manual dampers, splitters, and deflectors are installed
where required for proper air flow and balancing of the air handling
systems.
Verify that the space between the duct or duct insulation and the
sleeved or framed opening in fire-rated wall and floor penetrations
is sealed as specified.
Check that removable handholes are installed:
Where necessary to reset fire or smoke dampers
Where required to adjust extractors
Where other devices inside ducts require service
Verify that handholes at fire or smoke dampers are of heat-retardant wire glass and located so that the damper position is visible.
Check that access doors or panels are provided adjacent to automatic dampers, at fire dampers, and where required for proper
maintenance and servicing.
Verify that fire damper fusible links are not defaced, missing, mixed,
or placed in the wrong fire damper.
Check that the entire fire damper is outside the air stream while in
the open position.
Verify that ductwork turning vanes are correctly installed.
B. Testing
Check plenum drains before system testing to ensure that they are
not plugged and that traps are water sealed.
Check for any undue vibration or movement in the ductwork during
pre-operational testing.
M-22-2
Ductwork
Guideline M-22
Verify that the system is substantially airtight with no audible

leaks.
Verify that the maximum leakage rate is no more than 5% of
system operating air flow at system static pressure before
covering the ductwork with insulation or concealing it behind
masonry or drywall.
Leak test duct risers and branch ducts for high pressure ductwork
including all flexible metal hose runouts to the joints where the duct
risers tie into the main.
Verify that the maximum leakage rate is no more than 1% of
system operating air flow at 1.25 times system operating pressure before covering the ductwork with insulation or concealing it behind masonry or drywall.
Identify each orifice tube used in the leak test with a unique
identification number that can be correlated to the calibration
curve.
Leak test the mains after the vertical duct risers or branch
ducts have been tested and accepted and after the central
station air handling apparatus has been installed.
Check that all flexible connections in the system are jumpered with
copper cable bolted to each side of connectors to the ductwork or
frame of major equipment.
Verify that a continuous ground is provided for all ductwork
through installed jumpers via grounded equipment.
C. Cleaning
Verify that the interior of all ducts, plenums, and casing is cleaned
of all debris and is blown free of all small particles of rubbish and
dust.
Before installing outlet faces, verify that interior of the system
is provided with a final vacuum cleaning.
Check that all equipment is wiped clean to remove oil, dust, dirt,
and paint spots.
Make sure that temporary filters are provided for all fans that are
operated during construction.
Verify that new filters are installed after all construction debris has
been removed from the structure and all duct systems have been
vacuum cleaned.
Make sure that the completed system is maintained in a clean condition until final acceptance.
M-22-3
Guideline M-23
HVAC Fans
A. Preplanning
Inspect equipment on receipt at the site for completeness and

visible damage.
B. Installation
Inspect equipment when installed for damage including bent members, dents in panels, broken or deformed motor mounts, damaged
roll filter and controls, and deformed vibration isolator assemblies.
Check equipment installation for location, level, plumbness, and
anchorage per manufacturer requirements.
Check all rooftop fan decks to ensure that all flashing and sealing
are completely effective.
Check that vibration isolators are installed per manufacturer
requirements.
Verify that the spring in the isolator is not fully compressed.
Check access doors and hatches:
Verify that they have been provided with tightly fitted seals.
Check for interference with other equipment or structures
when the doors or hatches are opened.
Verify that the access doors and panels are large enough for the
inspection and maintenance.
Check that access is adequate to permit personnel access
and for removal of internal equipment.
Verify that access doors open to the outside of the housing on
the fan suction side and to the inside of the housing on the
fan discharge side.
Check that required acoustical lining is installed where required
and that the material satisfies fire rating requirements.
Verify that the equipment lines up with duct installation without
excessive deformation of flexible connections.
Check that piping, controls, and structural supports for the equipment are installed as required.
Check all motors for mounting, line-up, ease of turning, sufficient
and suitable belts in drive (if applicable), belt guard mounting, and
lubrication fitting installation.
Lubrication fittings should be installed in easily accessible
locations.
Check power wiring, control wiring, and control piping for proper
installation.
Check all control panels for location, mounting, and completeness.
M-23-1
1997, 2001 Bechtel
HVAC Fans
Guideline M-23
Check that the equipment is identified with a fixed label per contract
requirements.
Check filters for type, cleanliness, and operation.
Check that electrical equipment and metal portions of installation
are bonded and securely connected to the station grounding system.
Verify that an access door has been provided in the belt
guard to measure belt tension.
Verify that the fan has been adjusted to operate without noticeable
vibration.
Make sure that the equipment is protected from dirt, foreign
objects, and damage during the installation period.
Check that all debris is removed from the work site and that all
equipment, including fan scrolls, housings, blades, and motors, is
cleaned before final acceptance.
C. Testing
Verify that system balancing and testing are completed as required

and that the equipment performs as intended.
Guideline M-24

A. Installation
Check that equipment pads, platforms, or hangers required to support the equipment are complete before starting the installation.
Verify that cooling and heating coils are properly located away from
permanent equipment for ease of access and removal.
Verify that tube fins on heat exchanger coils are not flattened or
defaced or plugged with dirt.
Check for visible damage to the HVAC system including bent members, dents in panels, and broken glass.
Check for completeness of the system installation using the latest
revision of the contract documents.
Verify that all panels are identified with a fixed label per contract
document requirements.
Check for equipment line-up for level and plumbness using shims
as required.
Check that the line-up is securely fastened after leveling and alignment.
Check for interferences with other plant equipment or structures:
Doors can be opened fully
Easy access to interior of line-up
Cable connections accessible
Conduit entry accessible
Check that breakers, transformers, and other electrical devices can
be easily be removed from the line-up for maintenance, repair, or
replacement.
Verify that the ground bus is complete for the entire length of the
line-up and is connected at both ends to the station ground bus.
Verify that all conduits entering the equipment room are sealed to
prevent the entry of water into the room.
Check that all wall and floor penetrations are fire sealed as
required.
Check that room doors and door frames have a Class B fire rating
label.
Check that the roof, cable trench penetrations, and other areas
subject to water leaking are waterproofed and that all leaks have
been stopped.
Check all electrical cables for damage, during and after installation.
Verify that the ground bus is connected to the station ground system.
Verify that bus bar connecting bolts are properly tightened.

M-23-2
M-24-1
1997, 2001 Bechtel
Guideline M-24
Guideline M-25
Verify that vibration isolators and flexible connections have been

installed as required.
Verify that an access door has been provided in the belt
guard to measure belt tension.
Check that multiple type fan belts are machine-matched sets.
Verify that pressure gauges have been provided across filter banks
to indicate pressure drop.
Check that coils on rails are adequately supported and can be easily removed.
Make sure that the coils are not used to support piping.
Ensure that all coil vents and drains are properly terminated.
Check that piping connections to coil header to obtain counter
flow of air and water are complete.
Check that condensate drain pipe is routed from each unit
drain pan to nearest floor drain.
Make sure that equipment is protected from dirt, foreign objects,
and damage during the installation period.
Check that all debris is removed from the work site and that all
equipment including housing, coils, supports, fan and damper
blades, belts, guards, and motors are cleaned before final acceptance.
Forced Draft Cooling Fans
Witness required equipment performance tests demonstrating that

the equipment functions as intended.
Make sure new air filters are installed after the completion of
the performance test.
C. Pre-Operational Checkout
B. Testing
M-24-2
A. Preplanning

Check that fan and motor bearings are lubricated while equipment
is in pre-installation storage per manufacturer recommendations.
Ensure that shaft is rotated weekly.
B. Fan Installation
Check fan shaft at two locations 90 apart to verify that the shaft is
vertical and plumb.
Verify that fan shaft to hub bolting is torqued correctly.
Check fan blade to shroud clearance and concentricity.
Verify that all blade pitch angles are set.
Check that the maximum blade tip deviation relative to one another does not exceed the maximum allowed by the manufacturer.
Check the fan blade holding screw/bolt torque.
Verify that the blade control is installed and functional.
Verify that the pitch angle is set (fixed or auto).
Check that the lube lines are installed.
Verify that the fan guard is installed.
Check that the motor and sheaves are installed.
Verify that the sheaves are aligned.
Verify that the fan belts are installed and tensioned.
Verify that the belt guard is installed.
Check that the vibration switch is set.
Verify that the grounding strap is installed.
Check the operation of the start-stop switch at the motor, grade,
and control room.
Check the direction of fan rotation.
Verify that indicating lights are functional.
Ensure that the 4-hour motor run test is completed.
Check vibration level at vibration switch.
Re-check shaft and sheave alignment after run test.
Check motor amperage during operation at minimum, maximum,
and normal fan pitch.
Verify that exchanger bundle tie rods are loose.
M-25-1
1997, 2001 Bechtel
Guideline M-31
Guideline M-32
Crane and Hoist Installation
A. Runway
A. Preplanning
Ensure that runway beam(s) and (girders) are straight and level
and within specification tolerances.
Ensure that runway rails are straight, level, and parallel within
specification tolerances.
Ensure that runway end stops and trolley bumpers are installed.
B. Installation
Verify that nondestructive examination (NDE) has been performed

and accepted on the crane hook.
Verify that cables and sheaves are free of excessive wear and
abrasions.
Verify that slings and chains, hooks, and eyes have no evidence of
defects, excessive wear, or damage.
Ensure that crane and hoist installation is performed per manufacturer instructions and as specified. Check that vendor representative is present during erection operations, as required.
Ensure that wire rope is of correct material, diameter, lay, and pitch.
Check that hoist controls are supplied per specifications.
Adjust all hoist holding, hoist control, bridge, and trolley brakes as
required.
Satisfy lubrication requirements before operating the crane or hoist.
Check that test weights (based on heaviest weight to be lifted) are
available for field testing, as required.
Ensure that vendor representative is present during operational
testing and/or certification and final acceptance.
B. Test ProcedureCranes
M-31-1
1997, 2001 Bechtel
Monitor the actual test and indicate acceptance of each operation

before proceeding to the next operation.
Assemble proper test weights as specified on the crane test data
sheet, and use proper rigging for the test tag lines.
Position crane to make an over-the-rear lift, on level ground, with
extended outriggers, if so equipped.
Adjust boom to proper initial radius per crane test data.
Attach rigging devices so that the head of the boom and the center
of the test load are near plumb.
Tension load, and hold before initial lift off; confirm that all riggings
devices are in their proper positions.
Lift load approximately 12 to 18 inches (30 to 46 cm) from grade
and hold for short period to observe stability.
Stability will be determined by observation of the bearing of
the crane outriggers or tracks that maintain the load from 11/2
to 2 minutes.
Lower load back to, but not in contact with, the grade; this lowering
must be performed and controlled at a slow rate.
Lift load approximately 5 ft (1.5 m) above grade.
Observe stability.
Lower load by repeating initial load lowering.
Observe stability.
Lift load to approximately 10 ft (3 m) above grade.
Lower load by repeating load lowering operation.
Lift load to slightly less than "two block" position, and hold approximately 10 to 15 seconds.
Observe stability.
Lower load at a reasonable rate of speed with control of the planetary lowering system of the crane and brake load to a complete stop
approximately 4 to 8 inches (10 to 20 cm) from grade.
M-32-1
1997, 2001 Bechtel
Guideline M-32
Observe stability.
Lower boom to final radius, with load no higher than approximately
12 inches (30 cm) from grade.
Observe stability.
Rotate crane 90 degrees at a slow rate of speed.
Observe stability.
Rotate crane 180 degrees via the rear of the crane. Note: avoid
rotation of load beyond either of the forward outriggers.
Observe stability.
Return crane to initial lift radius and set down load.
Complete test report and all supporting documentation and forward
to records.
M-32-2
Guideline E-1

A. Rigid Steel Conduit
Verify that conduits and fittings to be embedded are of the size indicated on the drawings, are galvanized rigid steel, and are per specification requirements.
Verify that conduit and stub up locations are per drawing requirements.
Check that there are no running threads on conduit (not allowed per
the National Electric Code).
Check that approved expansion couplings are installed at all
expansion joints and in conduit runs greater than 300 ft (90 m)
and/or as required by the contract documents.
Ensure that installed couplings are listed as "concrete tight."
Check that threads are coated with conductive sealing material to
seal and ensure electrical continuity of conduit installation.
Check that conduit runs crossing contraction or expansion joints
are at 90 degrees to the joint.
Check that conduits are rigid and will adequately maintain correct
location and spacing during concrete placement.
Check that conduit is supported clear of reinforcing bar.
Ensure that conduit is coated or wrapped with a bituminous
compound or tape in areas of possible contact with reinforcing
bar.
Where practicable, avoid contact between dissimilar metals to eliminate the possibility of galvanic action.
Ensure that open conduit ends are capped and pull boxes sealed
to prevent the entry of foreign materials.
Ensure that all conduit is swabbed, rodded, or balled after installation to remove any foreign material and is then capped.
Verify that the number of bends in a run of conduit between pull
points does not exceed a total of four 90 degree bends or 360
degrees total unless cable pulling calculations indicate the conduit
installation is acceptable.
Check that threads are coated with an approved corrosion-resistant
material where conduit galvanizing has been removed for field
threading.
Verify that conduit bends meet the minimum bend radius requirements listed in the table unless otherwise specified in the contract
documents.
Ensure that installed conduit is checked for obstructions (mandrel
pulled through embedded conduit to remove foreign material)
before installing cable.
E-1-1
1997, 2001 Bechtel
Guideline E-1
Check that conduits terminating in cable trays are securely

connected to the tray to provide a good electrical bond.
Document conduit installation deviations on as-built drawings.
B. Rigid Nonmetallic Conduit
Ensure that conduits and fittings are of the size and type as
indicated in the drawings and manufactured per specification
requirements. Check that all field bends are free of cuts, dents, or flats.
Ensure that each length of nonmetallic conduit is clearly marked
with material identity (type) at least every 10 ft (3 m).
Ensure that nonmetallic conduit is not used in hazardous (classified) locations.
Check that cut ends of conduit are reamed to remove rough edges.
Ensure that location of conduits and stub outs are as shown on the
drawings.
Check that all joints between lengths of conduits and between
conduit couplings, fittings, and boxes are made by approved methods.
Check that conduit bends meet the minimum bend radius requirements as shown in the table included in the guideline or as
otherwise approved by the engineer.
Ensure that the number of bends in a run of conduit between pull
points does not exceed the equivalent of four quarter bends
(360 degrees total) including bends located immediately at the
outlet or fitting unless cable pulling calculations indicate the conduit
installation is acceptable.
Check that "as built" conduit locations are noted on drawings.
Ensure that conduit bends meet the minimum bend radius as
follows or as otherwise specified.
MINIMUM CONDUIT BEND RADIUS

CONDUIT SIZE (IN.)
MINIMUM RADIUS (IN.)
1/2
4
3/4
5
1
6
11/4
8
11/2
10
2
12
21/2
15
3
18
3 1/2
21
4
24
5
30
6
36
E-1-2
Guideline E-2
Raceway
A. Receiving and Storage
Check that material received is of the type and quantity specified

and bears a UL label where applicable.
Check that raceway is stored where it will be kept clean and protected against damage.
B. Installation
Verify that installations are per project plans, raceway schedules,

specifications, notes, and details.
Check embedded conduit for correct installation before concrete is
placed.
Verify that raceway installation meets the requirements for cable
installation, such as:
Conduit radius and number of bends between pull points
Location of pull points
Access for pulling equipment and cable reels as adequate at
pull points
Check that protective end caps or plugs are installed in the ends of
embedded conduits and ducts to keep foreign material from entering the raceway.
Verify that raceway is properly:
Grounded
Supported
Identified
C. Documentation
Check that raceway card system, if used, or other system is functioning correctly.
E-2-1
1997, 2001 Bechtel
Guideline E-3
Witness insulation resistance test at 1,000 volts dc on all control

wiring. Minimum insulation resistance shall be 1,000,000 ohms.
Verify that the proper type, range, and connections of all instrument
transformers.
Confirm correct polarity of all current transformers electronically.
Verify that short-circuiting links have been removed from current
transformers after checking that secondary circuits are complete.
Verify that all meter connections are complete and that the meters
have been properly calibrated.
Verify that all protective relays, auxiliary relays, trip coils, trip circuit
seal-in and target coils, and fuses are the correct type and range.
Verify that all wedges, ties, and blocks installed by the manufacturer to prevent damage during shipment have been removed.
Check all relays per manufacturer instructions.
Set all relays per provided settings.
Check time-current characteristics with a test kit approved by
the relay manufacturer.
Measure battery system charging voltage and each individual cell
voltage, verifying that measured values are within manufacturer tolerances.
Ensure that all changes of connection, insertion, and removal of
meters, relays, and other devices are made so that the secondary
circuits of energized current transformers are not opened even
momentarily.
A. Preplanning
Check that switchgear tools such as levers and earth sticks are
received with the equipment and are either properly secured to the
equipment or have a separate tool box that can be installed near
the switchgear.
Check that the size and spacing of terminal blocks conform to the
type of cables, lugs, and voltage level specified.
Check that the switchgear name plate is received along with the
equipment and includes all required information.
B. Inspection
Verify that mounting channels and brackets are located as specified.

Check that embedded floor mounting channels are level and on the
same plane.
Make sure that there are no high spots between mounting channels
to cause warping of switchgear panels.
Verify that the panels have not been racked or warped during transit.
Make sure that all jacks are raised evenly when jacking switchgear
to remove shipping skids.
Ensure that embedded conduit and ground cables are not damaged when setting switchgear.
Make sure that panels and switchgear are adequately protected
from dust, dirt, moisture, water, and mechanical damage during
construction.
Ensure that switchgear and instrument shipping blocks are kept in
place until heavy cables are installed.
Check that wall-mounted panels are level and set off the wall
enough to ensure that unevenness of wall will not warp panels.
Check that embedded wall panels are adequately braced before
concreting to prevent warping.
C. Final Acceptance
Compare actual wiring connections with wiring diagrams.

Inspect all devices and equipment for shipping or handling damage.
Verify that bolted bus joints are torqued per manufacturer instructions using a calibrated torque wrench.
Verify that the performance of all mechanical operators by conducting contact alignment tests on breakers and operating mechanisms per manufacturer instructions.
Witness minimum pickup voltage tests on all trip and closing coils.
Review electrical continuity checks of all current, potential, and
control circuits.
E-3-1
1997, 2001 Bechtel
E-3-2
Guideline E-3
Guideline E-4
A. Preplanning
Verify that temporary storage is provided for protection against

moisture, blowing dust, temperature extremes, and other environmental elements per manufacturer instructions.
Make sure that manufacturer representative is available during
installation as required by the contract.
Make sure that foundation grades and bolt locations are correct
before installing equipment.
Check that the size and spacing of terminal blocks conform to the
type of cables, lugs, and voltage level specified.
Check that the equipment name plate is received along with the
equipment and includes all required information.
B. Installation
Check that equipment is installed per manufacturer instructions.

Verify that electrical service conforms to the requirements of the
applicable electrical code or standard such as NEC, NFPA, or
ANSI.
Check leveling and alignment of equipment to specified tolerances.
Check torquing of mounting bolts.
Verify that baseplates or equipment is shimmed, leveled, and
aligned before grouting.
Verify that grout mixing and placement are performed per manufacturer requirements. Review Equipment Grouting Guideline.
Verify that welding conforms to specified structural welding codes.
Verify that the equipment is correctly and permanently identified as
required by contract documents.
Verify that power, instrumentation, and control cables are identified
at each end.
Guideline E-4
Witness insulation resistance test at 1,000 volts dc on all control

wiring. Minimum insulation resistance shall be 1,000,000 ohms.
Verify that the proper type, range, and connections of all instrument
transformers.
Confirm correct polarity of all current transformers electronically.
Verify that short-circuiting links have been removed from current
transformers after checking that secondary circuits are complete.
Verify that all meter connections are complete and that the meters
have been properly calibrated.
Verify that all wedges, ties, and blocks installed by the manufacturer to prevent damage during shipment have been removed.
Verify functional testing of equipment to demonstrate performance
per the manufacturer specifications.
Retain copies of test results for project records.
Ensure that changes of connection, insertion, and removal of
meters, relays, and other devices are made so that the secondary
circuits of energized current transformers are not opened even
momentarily.
C. Testing
Check that all test equipment used for testing is calibrated and
operating properly.
Compare actual connections with wiring diagrams.
Inspect all devices and equipment for shipping or installation damage.
Verify that bolted bus joints are torqued per manufacturer instructions using a calibrated torque wrench.
Witness electrical continuity checks of all current, potential, and
control circuits using wiring diagrams as a reference.
E-4-1
1997, 2001 Bechtel
E-4-2
Guideline E-5
Wire and Cable
Wire and Cable

A. General
Verify that cable voltage rating, insulation type, conductor size,

number of conductors, shielding, cable and conductor identification, and reel markings are correct.
Verify that cable and reels are free of damage.
Verify that cable ends are properly sealed to preclude water and
moisture damage.
Ensure that proper equipment and unloading methods are used to
prevent damage to cable during handling operations.
Verify that cable reels are tagged or color coded, as required.
Guideline E-5
Verify that cable is temporarily coiled after installation and properly

supported to preclude cable damage.
Verify that cable routing is correct.
Check that the length of the cable route conforms to the specified
cut length plus a reasonable allowance
E. Documentation
Retain cable pulling records in SETROUTE.
B. Storage
Check that the cable storage area is properly fenced, well lighted,
and level, with adequate drainage.
Check that reels are on chocks or timbers and properly spaced.
Verify that a running inventory of reel numbers by location and color
code is maintained.
C. Before Installing Cable
Verify that duct lengths are in field before cutting cable.

Check that material and cable pulling equipment is available and
adequate.
Ensure that there is a method of communication when pulling
cable.
Review manufacturer recommendations for cable installation.
Verify that pulling compound is compatible with the cable being
installed.
Check if the cable will be pulled from the correct drum number per
the SETROUTE schedule
D. Installing Wire and Cable in Raceways
Check ambient temperature and weather conditions before pulling

cable outdoors and ensure that temperature is not below recommended minimum.
Verify that raceway, conduit, and ductbank are complete and clean
and that cable can be installed.
Ensure that craft have required SETROUTE pull cards and tags.
Verify that cable pulling calculations have been performed as
required.
Check pulling tensions and direction of pull.
Check dynamometer reading when necessary.
Check pulling set ups and equipment for compliance with safety
requirements.
Ensure that cables rated at more than 15 kV are pulled down grade.
Verify that temporary cable identification tags are installed.
E-5-1
1997, 2001 Bechtel
E-5-2
Guideline E-6
Terminations
Terminations
A. Low Voltage
Ensure that connection diagrams used are the latest revision.

Ensure that cable jacket strippers do not cut the insulated conductors.
Ensure that cable jackets are stripped reasonably close to the point
of termination.
Ensure that insulated conductors are stripped to the required length.
Ensure that strippers do not cut or nick the conductor strands.
Ensure that terminal lugs are the proper conductor range and stud
size.
Ensure that correct crimping tool is used.
Ensure that the ratchet on the crimping tool is in good working order.
Check that no more than two connectors are terminated under each
terminal screw.
Check that no two conductors are crimped in the same compression
connector unless shown on a drawing or allowed by specification.
Check that thermocouple terminations have the proper lugs and
tools.
Ensure that cables are properly supported.
Ensure that cables are correctly and permanently identified after termination.
Where specified, ensure that sleeve, block-outs, or slots are properly sealed.
Guideline E-6
Ensure that minimum installed radius is not violated.

Check that cables meet megger or hypot testing, if required.
Ensure that connections to bus bars or motor leads are correctly
torqued.
Check that connections are properly insulated.
Ensure that ground leads are connected to ground bus and properly routed.
Check that cables are properly supported.
Ensure that sleeves, conduits, and cutouts are sealed after cables
are terminated and tested, where specified.
C. Installing Cable
check if the length of the route conforms to the cut length plus a
reasonable allowance.
B. Medium Voltage
Ensure that the correct termination kits are used and installed per
manufacturer instructions.
Check that cable jackets are cut squarely without jagged edges.
Ensure that metallic shielding tape is not cut when the jacket is
removed.
Check that metallic shielding tape is cut without jagged edges.
Ensure that semi-conducting shield is cut squarely without cutting
the insulation.
Check that there are not cuts or gouges in the insulation.
Ensure that dimensions of the jacket, shielding tape, and semiconductor are compatible with the termination kit.
Check that semiconductor paints, tapes, or extruded layers are completely removed from the insulation.
Ensure that insulation is thoroughly cleaned using an approved solvent.
Check that conductor strands are not nicked or cut when the insulation is removed.
Ensure that correct size and type of lug are used.
Check that correct crimping tool and die are used.
Ensure that shield cable termination is correctly grounded.
Check that stress relieving material is heated completely to shrink
tubing.
Ensure that cables are correctly and permanently identified.
E-6-1
1997, 2001 Bechtel
E-6-2
Guideline E-7
Lighting Systems
Lighting Systems
A. General
Verify that installed lighting systems, including panels, transformers, raceway, lights, wiring, and receptacles, conform to drawing,
specification, and applicable electrical code requirements.
B. Fixtures and Switches
Verify that installed fixture and switch locations, mounting methods,

and mounting heights are per lighting layout drawings.
Check that conduit and boxes are properly installed and supported.
Ensure that local lighting switches (single pole or 3-way) are
installed per layout drawings.
Verify that switch mounting heights conform with the specification
requirements.
Verify that installed fixtures and switches are the type, voltage, and
wattage specified.
Verify that fixtures and switches are connected to the correct electrical panel circuit.
Check that the lighted area illumination level is acceptable by visual inspection or by the use of a light meter to verify specified foot
candle level.
Verify that lighting fixtures are properly grounded.
Verify that fixtures and switches are tagged per contract requirements.
C. Convenience Outlets
Verify that installed receptacles are the type and rating specified.
Verify that receptacles are installed in the required locations and at
the correct height.
Verify that receptacles are correctly phased and grounded.
Verify that receptacles are properly terminated and connected to
the correct branch circuit.
Verify that receptacles are tagged per contract requirements.
D. Wiring
Verify that type, size, and color code of lighting wires are per contract requirements.
Check that fixture terminations are properly installed.
E. Lighting Panel
Verify that lighting panel and circuit breaker type, size, and rating
are per lighting panel schedule.
Check panel mounting height per design requirements.
Verify that lighting panels name plates show lighting panel number
and location per contract requirements.
Ensure that a typed circuit directory is provided in a protected holder with clear window on the inside of the panel door.
E-7-1
1997, 2001 Bechtel
Guideline E-7
Verify that branch circuit breaker ratings comply with lighting panel
schedule and are installed in the correct location shown on the
schedule.
Verify that the lighting panel enclosure is properly grounded.
Verify that tags and name plates provided are per purchase order
and contract requirements.
F. Lighting Transformers
Verify that the type, size, and rating of transformers are per single
line diagrams, drawings, and/or specifications.
Check that transformer "equipment" and "neutral grounds" are
properly installed.
G. Pole-Mounted Fixtures
Verify that concrete base complies with design drawing requirements.

Double nut pole to mounting bracket or base and verify that the
pole is plumb.
Grout void between concrete base and panel, if required.
Verify that luminaries and photoelectric controls are installed per
manufacturer requirements.
Verify that lighting standards are properly grounded.
H. Tunnel Lighting
Verify that required fixture supports are installed and that fixtures
and supports are not mounted on or in contact with ducts or pipes.
Verify that the lighting fixtures are installed at the required locations
and in the proper alignment specified.
Ensure that fixture vent holes are not blocked and permit free air
flow to the fixture.
Verify that fixtures are properly aligned by aiming adjustable fixtures to provide the required illumination.
Do this just before final acceptance.
Verify final cleaning of the lighting system:
Clean lighting fixture bottoms, trim, reflecting surfaces, lenses,
baffles, louvers, and reflector cones during installation.
Mask lighting fixture trims and bottoms to protect them during
installation.
Verify that the correct lamp is installed in each fixture.
Ensure that temporary lighting fixtures, lamps, and associated
wiring, conduit, and boxes are removed after the permanent system is operational.
Verify that the exit fixtures are installed over doorways as specified.
E-7-2
Guideline E-8
Grounding
Grounding
D. Ground Fault Return Path
A. Preplanning
Review job drawings and specifications for grounding requirements.
B. Equipment Review
Check that all normally non-current-carrying metal parts of electrical equipment, enclosures, building steel, and other specified structures are grounded as follows:
Steel columns are grounded to the grounding grid as specified.
Motors are grounded to the ground grid or to a grounded
structural member as specified.
Metallic raceway (tray, conduit, and junction boxes) is grounded as specified.
Electrical equipment such as transformers, switchgear, motor
control centers, and control panels are grounded as specified.
C. Grounding Grid
Check that ground cable, stub-ups, and ground pads are properly
located.
Check that the grounding grid is installed not less than 30" (76 cm)
below finished grade unless otherwise specified.
Ensure 24" (60 cm) minimum separation between grounding rods
and/or bare grounding conductors, concrete structures, or piles
unless otherwise specified.
Check that ground rods are driven into the ground until the top of
the rod is 6" (15 cm) above the elevation of the grounding conductor unless otherwise specified.
Verify that buried ground cables crossing buried metallic structures
are either installed a minimum of 36" (90 cm) apart or are insulated as specified.
Check that buried ground cables installed parallel to electrically isolated underground metallic piping are separated by at least 10 ft (3
m).
Check that ground cable is #4/0 AWG stranded bare copper cable
unless otherwise noted.
Check that earth connections are protected with an approved
greasing compound
Check that thermal weld ground branch joints are properly completed and that earthing tape is applied per specifications
E-8-1
1997, 2001 Bechtel
Guideline E-8
Check that all electrical equipment energized from a low-resistance

or solidly grounded system operating at greater than 120 volts has
a continuous ground fault return patch using the following methods:
Trays carrying power cables require a bare conductor
along the outside of the tray.
Rigid steel conduits are considered an effective ground
fault return path and require no conductor with the conduits. However, the tray ends of rigid steel conduits
should be jumpered to the tray's ground fault conductor.
Metallic tubing carrying power cables have a ground fault
conductor in the conduit.
Flexible conduits 1-1/2 inch (38 mm) and larger carrying
power cables have a ground fault conductor (jumper).
Embedded nonmetallic conduits carrying power cables
have a ground fault conductor.
Duct banks have a ground fault conductor embedded in
the top center surface of the duct bank concrete or on top
of the duct bank. Power conduits branching off also
require the ground fault conductor to follow. The ground
fault conductor must be continuous inside manholes.
Ground fault conductors should be installed to both ends
of the ground bus for MCCs, switchgear, or load centers.
E-8-2
Guideline E-9
Guideline E-10
Batteries
Cathodic Protection
A. Installation
Check that batteries, racks, and accessories are the type, size, and
rating required by specifications and drawings.
Verify that battery chargers are of specified type and constructed
per NEMA or per applicable code.
Verify that enclosures are NEMA Type 1 (or as required by applicable code) with instruments, indicating lights, and control devices
mounted on front door.
Check installation and wiring for compliance with specifications,
drawings, and manufacturer instructions.
Verify that batteries and battery chargers have been shop tested
and data sheets submitted, as required.
Verify that field testing has demonstrated that the equipment functions over the entire range of operation.
Verify that battery rooms have adequate forced ventilation to preclude the build-up of an explosive mixture of hydrogen gas gassed
from the batteries during charging.
Verify that battery rooms not having forced ventilation have explosion-proof electrical installations for raceway, light fixtures, light
switches, receptacles, telephones, and equipment.
Check that completed battery Installation allows enough space for
maintenance
Check that batteries, MCCBs, and cables are correctly identified
B. Testing
Witness the following field testing:

Insulation resistance tests
Performance test of each battery per IEEE 450 or as specified
E-9-1
1997, 2001 Bechtel
A. Installation
Check that the type, size, and rating of transformers and rectifiers
are as required by specifications and drawings.
Verify that enclosures are sheet metal per NEMA IS1.1 with welded seams and hinged doors.
Check mounting of circuit breakers, ammeters, and voltmeters on
inside panel of enclosures.
Check that rectifier semiconductors are high-current silicon diodes
with input and output sides protected by zeener type selenium
surge plates and lightening arresters.
Check impressed current anodes and sacrificial anodes, if any, for
correct type and configuration.
Verify that cable terminations are made with acceptable type terminal and crimping tools.
Check anodes and cathodic protection cables for correct type and
size.
Check the installation of rectifiers panels.
Check installation of test stations for location, terminations, and
that they are correctly identified.
Check buried rectifiers cables for correct depth, bedding, and backfill, as specified.
Check anode installations.
Verify that the cathodic protection systems are electrically isolated
from the grounding system and reinforced concrete foundations.
Check bonding of waterline joints to ensure electrical continuity.
Verify continuity of conductors after backfill.
Verify that all test results are included in the final survey report.
Check that rectifier cables and anode cables are properly identified
and numbered on both sides
Verify that the as-built location of anodes and the ring are identified
on the design drawings
E-10-1
1997, 2001 Bechtel
Guideline J-1

A. Submittals
Ensure that vendor packages are complete and conform to purchase order, requisitions, drawings, P&IDs and specifications.
Check that vendor and/or subcontract drawings and specifications
are accurate, complete, and conform to codes.
Ensure that instrument primary taps are correctly oriented and

sized and provide sufficient elevation for correct sensing line slope.
Ensure that flareless type fittings are installed only where specified.
Ensure that dissimilar metals are not joined directly in socket welding but by other approved methods.
B. Installation Review
Ensure that racks, panels, instruments, and sensing lines are free
of interferences.
Ensure that instrument locations are accessible for mounting, operation and maintenance.
Check that instruments are located as close as practical to the primary tap.
Locate locally mounted instruments near the most convenient
point of use consistent with good measuring practice.
Sensing lines should be as short as practical.
Check that all instruments and connecting lines have allowance
made for movement of equipment by seismic loading, vibrations, or
expansion or contraction caused by temperature changes.
Ensure that lines or connections open to atmosphere are protected
against ingress of foreign matter.
Unprotected openings should have a gooseneck, or equivalent, attached to protect against falling particles.
Check that process connections and root valves are located so that
they are accessible. Ensure that root valve stem and handle are
installed clear of mainline insulation.
Ensure that manufacturer installation requirements, including those
relating to unsupported span and minimum bend-radius of capillary
tubing, are followed.
Check that sensing lines have a continuous slope to promote their
being kept either full or free of liquid, as appropriate.
Ensure that flareless type fittings are harder than tubing they grip.
Check that flareless versus socket welding fittings are installed in
systems and areas per instrument piping specifications.
Ensure that instruments are properly oriented and mounted per
instrument manufacturer instructions and as specified.
Check that instruments are not subject to excessive vibration or
shock to impair proper operation.
Ensure that instrument primary taps are located per instrument
connection details.
J-1-1
1997, 2001 Bechtel
Guideline J-1
J-1-2
Guideline J-2
Instrument Piping and Tubing

A. Installation
Ensure that instrument system is fabricated and installed per drawings and specifications.
Verify that brazing and soldering are per specifications and procedures.
Ensure that Instrument system contains isolation and blowdown
valves at each elevation as required.
Verify that instrument lines are sized per instrument and piping
specifications.
Ensure that required tubing slopes are provided.
Verify that instrument tubing bends are free of wrinkles and flat
spots.
Ensure that instrument tubing is properly supported and protected
from potential damage.
J-2-1
1997, 2001 Bechtel
Guideline J-3
Instrument Mounting Supports

A. Fabrication
Check that instrument mounting supports are fabricated from

approved materials.
Ensure that instrument mounting supports are fabricated and
installed per instrument mounting details.
B. Installation
Check that supports are located and oriented per instrument location drawings and sensing line isometrics.
Ensure that concrete fasteners are the correct size (length and
diameter) and type as specified. Review Concrete Expansion
Anchor Guideline.
Check that concrete fasteners are properly located and installed
per manufacturer instructions.
Ensure that instrument mounting supports requiring welding, are
welded per approved procedures and examined as specified.
Review Welding Guideline.
Check that weld materials and welder identification numbers are
stamped or etched on instrument mounting supports, where specified.
Ensure that instrument mounting supports requiring documentation
are stamped or etched with identification number.
Check that instrument valves and bypass manifold valves are rigidly mounted to mounting structure.
Ensure that open-end pipe supports are properly sealed.
Check that mounting baseplates are grouted per drawings, specifications, and grout manufacturer's instructions. Review Equipment
Grouting Guideline.
Ensure that mounting supports are painted, as specified. Review
Painting Guideline.
J-3-1
1997, 2001 Bechtel
Guideline J-4
Instrumentation Cleanliness
A. Work Operations
Ensure that installed instruments, racks, and panels are protected

with temporary covers, enclosures, or barriers.
Verify that instrument port openings are sealed from dirt, moisture,
and other contaminates.
Ensure that tools, such as files, grinders, and brushes, used in fabrication and installation of stainless steel materials have not been
used previously on other materials.
During pipe fabrication, ensure that openings are plugged before
leaving area unattended.
Ensure that material storage areas are inspected periodically for
good housekeeping practices.
Visually check material for unsealed openings subject to dirt and
moisture during receiving, storage, fabrication, and installation;
seal as required.
Ensure that all material remains clean during handling, receiving,
storage, fabrication and installation including after installation per
instrument manufactures procedures and as specified.
J-4-1
1997, 2001 Bechtel
Guideline J-5
Instrumentation Testing
A. Preplanning
Perform a pre-test inspection by walking down the line and verifying inspection accessibility, completeness, flanged joints tightness,
and joint chalking.
Ensure that test boundaries are properly tagged site procedures.
Verify that test gauges are calibrated per project procedures and
that the calibration due date is shown on the test gauge.
To validate that test gauges are still within the prescribed calibration period, check the test gauges against a master gauge
before testing.
Ensure that the maximum test pressure is within 30% to 70% of
gauge range.
Check that test gauges are calibrated by a qualified instrument laboratory.
Make sure that items not capable of safely sustaining test pressures are removed or isolated from the system.
B. Testing
Verify that only systems released for testing are tested.

Verify that testing is performed per approved procedures and specifications.
Ensure that testing is performed by qualified personnel.
Check that the proper test medium is used.
Check that the test medium is at proper temperature.
Verify that the system is tested between the minimum and maximum test procedures specified.
Verify that the test pressures are held for specified time limit.
Typically a 10 minute minimum holding time is required.
Ensure that testing progress charts are maintained when required.
Verify that documentation forms are accurately completed per project procedures.
Ensure that documented tests are witnessed when required and
that documentation forms are signed by the authorized witness.
Verify that the system is gastight by applying an approved soap
bubble solution to all joints (pneumatic test only).
J-5-1
1997, 2001 Bechtel
Guideline J-6
Instrumentation System Release

A. Preplanning
Visually check instrument installation by walking down system and

verifying conformance to latest revision of sensing line isometric or
instrument installation detail.
Visually check that instrument installation conforms to P&ID design.
Visually check that sensing line and instrument supports conform to
drawings.
Visually check that instrument root valves are installed with stems
in the proper position.
Visually check instrument sensing lines for correct vents and
drains.
Check sensing lines for correct slope.
Visually check instrument installations for damage and missing
parts.
Visually check pipe and tubing for smooth wrinkle-free bends and
that bend radii are per drawings and specifications.
Visually check that instrument racks and panels are properly grouted.
Visually check instruments for protective coverings.
Visually check that hanger rack and tray mounting bolts and nuts
are tight.
J-6-1
1997, 2001 Bechtel

Mechanical and Electrical Field Inspection Guideline

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Mechanical and Electrical Field Inspection Guideline

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2002 Bechtel Corporation

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1997, 2001 Bechtel.qxd-6263-03/03 (old 5709-11/01)

Heavy Lift Rigging

Rigging Method Selection

Field Inspection Guidelines

1997, 2001 Bechtel

Flushing, Testing, and Insulating

Flushing and Cleaning

General Mechanical Inspections

General Equipment Setting

Underground Storage Tanks

Heating, Ventilating, and Air

Crane and Hoist Installation

Instrument Installation Review

Embedded Rigid Conduit

C. After Performing Inspections

A. Before Performing any Inspections

Review the contract, specifications, drawings, industry standards,

Check that only approved materials have been used.

Field Inspection Guidelines

1997, 2001 Bechtel

Check that materials being used and structures, coatings, or

A. Personal Safety and General Crew Safety

Check that energy potentials such as excavations, confined

Field Inspection Guidelines

1997, 2001 Bechtel

Check that employees are not exposed to amounts in excess of

F. Flammable and Combustible Liquids

Check that only approved and properly labeled containers, portable

G. Fire Prevention Measures

H. Welding and Cutting Operations

Check that hot work permits are being used.

Check that cylinders are segregated in well-ventilated areas.

Check that only qualified, trained personnel operate laser equipment.

Check that illumination is provided and is adequate for the task

M. Worker Activity Checklist

Is the employee watching what he/she is doing?

N. Head, Eye, and Face Protection

Ensure that appropriate head protection is provided and used by all

Check that respirators are an approved type (e.g., U.S. Bureau of

P. Safety Harnesses/Lifelines/Retractable Reels

Check that safety equipment is used for employee safety only.

Q. Occupational Noise Exposure

Ensure that employees are provided with hearing protection when

R. Scaffolds and Ladders

Check that portable ladders are tied, blocked, or otherwise secured

S. Excavation, Shoring, and Trenching

Check for underground structures such as gas, water, electric, and

T. Hoists, Cranes, and Derricks

Check cables and sheaves for excessive wear and abrasion.

Make sure that general site housekeeping is up to standards.

W. Miscellaneous Safety and Health Issues

Check that covers are on hazardous or flammable waste containers.

Check that containers for drinking water are so labeled.

Ensure that an authorized/affected worker completes a tag/lockout

B. Working in a Tag/Lockout Condition

Ensure that an authorized/affected worker verifies that isolation or

C. Temporary Removal of Tag/Lockout Devices for Testing

Field Inspection Guidelines

1997, 2001 Bechtel

Establish a method to monitor and verify equipment isolation if

D. Release of a Tag/Lockout Condition

Receiving and Storage