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Sociedad Minera Cerro Verde S.A.A. Document No. 240K-C2-OT-05-002
Cerro Verde Production Unit Expansion Revision C
Project No. A6CV
Administrative
Title Revision Date
Procedure No.
Inspection and
Test Procedure Title Revision Date
No.
000 509 7000 Inspection and Testing 28 Feb 12
000 509 7010 Soils 28 Feb 12
000 509 7020 Bituminous Concrete Paving 28 Feb 12
000 509 7030 Pilling - Steel H - Piles 28 Feb 12
000 509 7040 Piling – Pre-Cast Concrete Piles 28 Feb 12
000 509 7050 Piling - Timber Piles VOID
000 509 7060 Piling - Closed End Concrete Filled Pipe Piles VOID
000 509 7070 Piling - Concrete Filled Thin Shell Pipe Piles VOID
000 509 7080 Drilled Caissons VOID
000 509 7090 Augered Cast-In-Place Piles 28 Feb 12
000 509 7100 Concrete and Grout 28 Feb 12
000 509 7200 Structural Steel 28 Feb 12
000 509 7300 Buildings 28 Feb 12
000 509 7310 Heating Ventilating and Air Conditioning 28 Feb 12
000 509 7320 Roofing Inspection 28 Feb 12
000 509 7400 Equipment 28 Feb 12
Inspection and
Test Procedure Title Revision Date
No.
000 509 7410 Field Fabricated Tanks 28 Feb 12
000 509 7420 Cooling Tower VOID
000 509 7430 Refractory Concrete VOID
ITP 509 7440 Gas Turbine/Generator VOID
ITP 509 7460 Steam Turbine/Generator VOID
ITP 509 7470 Generator Testing VOID
000 509 7500 Underground Piping 28 Feb 12
000 509 7510 Aboveground Piping 28 Feb 12
000 509 7520 Pressure Testing 28 Feb 12
000 509 7550 Hygienic Tubing VOID
000 509 7560 Chemical Cleaning of Pipe 28 Feb 12
000 509 7570 Steam Tracing for Pipe and Equipment VOID
000 509 7600 Electrical Inspection 28 Feb 12
000 509 7610 Electrical Testing 28 Feb 12
000 509 7620 Electrical Equipment 28 Feb 12
000 509 7640 Electrical Heat Tracing VOID
000 509 7700 Control Systems Instrumentation 28 Feb 12
000 509 7710 Control System Calibration 28 Feb 12
000 509 7800 Coatings and Linings 28 Feb 12
000 509 7810 Insulation 28 Feb 12
000 509 7820 Fireproofing Inspection 28 Feb 12
000 509 7830 Cathodic Protection 28 Feb 12
000 509 7910 Welding Inspection 28 Feb 12
000 509 7920 Nondestructive Examination 28 Feb 12
000 509 7930 Positive Material Identification 28 Feb 12
000 509 7950 Hardness Testing 28 Feb 12
000 509 F0000 Quality Control Forms 28 Feb 12
The Fluor Site Quality Program for this Project is described and documented in this Site Quality Manual.
FOREWORD
The objective of the site quality program for this project is to ensure that construction is performed in
accordance with the drawings, specifications, applicable local, state and federal standards and Codes. A
further objective is to provide documented evidence that confirms that the primary objective has been
met. The site quality control program as delineated in this manual, is tailored to meet the quality
surveillance, inspection, testing, and documentation requirements for construction/installation performed
by subcontractors and Fluor self-perform construction.
The site quality program is based upon the principals stated in the Operating System Requirements
(OSR) and any applicable Operating System Implementation Plan (OSIP). It is designed to cover quality
aspects related to construction, construction management and maintenance activities.
The Site Quality Manager will coordinate the construction quality surveillance, inspection, testing, and
documentation activities. He will monitor construction and quality activities to the extent necessary to
provide construction management with adequate confidence that appropriate measures are being taken
to control and achieve quality. The quality activity will emphasize preventing nonconformance to
drawings and specifications but detecting and correcting it if it occurs.
When Fluor performs construction activities using our own labor force, the quality control responsibility
remains with Fluor. The Fluor construction supervision and construction engineering staffs are primarily
responsible for the attainment of the quality requirements established by the drawings, specifications and
contract. The supervisory, construction engineering and quality staffs will perform quality control
inspection, testing, surveillance and documentation activities as outlined in this manual. The primary
responsibility for performing quality workmanship rests with those actually performing the work under the
supervision of the Fluor construction staff.
When an element of construction is subcontracted, the quality control responsibilities governing the
subcontractor's work are usually delegated to the subcontractor. The overall responsibility for verifying
quality in construction remains with Fluor. This is done by surveillance and audits when the responsibility
for quality activities has been delegated to the subcontractor. The subcontractors are to provide the
measures required to achieve the contract quality requirements. The subcontractor's quality control
responsibility is established by procedure 000.509.0210 and is stated in their contract.
This site specific Quality Manual is the governing document for the Fluor quality system and will be
maintained current to achieve project quality objectives.
This Manual is not applicable to ASME Boiler and Pressure Vessel Code work. The Fluor "Quality
Control System Manual for Boiler and Pressure Vessel Code Work" will be applied to ASME and National
Board Inspection Code Work certified by Fluor.
The Project Procedures Manual (PPM), used in conjunction with the Site Quality Manual, contain or
identify approved procedures used to identify, document and verify the appropriate reviews and approvals
of changes to design documents that are requested by field organizations and provide requirements for
document control.
The Fluor Construction Technology staff will conduct independent audits of project compliance to this
manual. The audits are conducted to provide the Project Manager, Site Manager, and Client with a
project independent evaluation of the site quality program status and adequacy. The initial audit will be
conducted at approximately 10% mechanical completion and additional audits on a periodic basis
throughout construction.
SCOPE
This procedure provides guidance for converting the 509 series of Corporate Site Quality procedures from
Knowledge OnLine to a Site Quality Manual for a specific project. It is applicable to Construction,
Construction Management, Maintenance, or projects with any of these combinations.
GENERAL
The initial draft of the project specific Site Quality Manual is initiated by Construction Technology's
Corporate Quality Manager. It is to be based on reference procedures of the 509 series of Site Quality
procedures from the Construction Knowledge Community that are listed in the Table of Contents section
000.509.0000. These reference procedures have been prepared to meet the requirements of
International Standard ISO-9000. The bracket symbols ([::---::]) seen throughout these procedures
identify changes or additions that are to be made in converting them to project specific procedures. Other
changes are to be made as needed to be compatible with the project requirements and scope. The set of
procedures in the 509 series represents the accumulated knowledge and experience gained from many
construction projects. Use of these reference procedures as baseline documents will result in improved
consistency between projects and entities, thus fulfilling the goal of consistency in execution. Proposed
changes to these reference procedures should be communicated to Construction Technology's Corporate
Quality Manager.
Upon assignment of the Site Quality Manager, he/she begins development of the draft Site Quality
Manual (SQM) to assure conformance to the site-specific requirements. The completed and approved
project specific SQM should be in place for usage as soon after contract award as possible. As a
minimum, parts of the manual should be developed for control of construction activities before the
activities are performed. These activities usually begin with qualifying and issuing RFQ's to bidders for
work to be subcontracted (see 000.509.0200and 000.509.0210). If these activities begin prior to
assignment of the Site Quality Manager, Construction Technology's Corporate of Quality Manager will
function as the Site Quality Manager until the assignment is made
Each section/procedure identified by 000.509.0000 is reviewed for consistency and applicability with
project scope. Changes or additions will be required of the following sections as noted:
- Inspection and Test Procedures (7000 - 7999); Select the procedures that are
applicable to the contracted work scope. Select the applicable forms from the
procedures if all are not needed. Review the "Responsibilities" Section and modify,
if needed, to suit the project organization. Also delete either the "Self-Perform" or
"Subcontracted" Section, if not applicable.
- Table of Contents / Date Revision Page (0000); Under "Procedure Number" and "Title"
change to include only those procedures used in the project manual.
Under "Revision Date." enter the date, month and year for all initially approved
procedures. Enter appropriate dates for each project revision it undergoes after
initial project approval.
Revision dates for all pages of all procedures in the project specific manual should match
the dates in this Table of Contents.
Revisions to the Site Quality Manual shall not waiver or negate OSR requirements or
mandatory construction codes.
The Site Quality Manager controls the site issue and revision of the Site Specific Quality Manual. The
manual is to be revised by procedure. A vertical line in the margin shall identify the revised portions. The
revision status shall be shown on the Title page of the manual. The Table of Contents shall show the
revision date of each revised procedure and shall be reissued for each revision.
The Corporate Quality Control Manager in each of the respective offices shall review and approve the
“Issued for Construction” Site Quality Manual prior to the approval signatures being obtained.
Each subsequent revision to the Site Quality Manual shall also be approved by the Corporate Quality
Control Manager.
The Site Quality Manager, Construction Engineering Manager, and Site Manager should approve each
revision by signing the Approval Page. The Client should also be given the opportunity for approval of the
Site Quality Manual.
This section describes the site quality organization for performing activities described by this manual. It
also provides a general description of responsibilities. Specific responsibilities are described in the
individual procedures of this manual.
The Site Manager is responsible for the execution of the project construction activities which includes
construction quality. The delegation of authority to the Site Quality Manager for the direction and
coordination of quality activities is made with the objective of maintaining the effectiveness of this quality
program.
The Site Manager shall provide adequate resources and assign sufficient trained personnel to manage
the work and effectively carry out these verification activities, including internal quality audits. The
personnel assigned to these verification activities shall be independent of those having direct
responsibility for the work being performed.
ORGANIZATION
The project organization for site quality personnel are shown on the Site Organizational Chart
maintained by the Site Manager.
RESPONSIBILITIES
Quality related activities are conducted by Site Quality and other groups. The activities and persons
conducting them will be under the functional control of the Site Quality Manager for the execution of the
activity. Attachment 1- Quality Responsibility Matrix summarizes the activities and the persons
responsible for execution. Primary responsibility for execution and verification of quality-related activities
will be established on the Inspection/Test Plan or procedures.
The Site Quality Manager has the responsibility, authority, and organizational freedom to audit, inspect
and witness construction activities and to verify compliance to contract quality requirements. This
responsibility includes actions such as assist the construction staff in prevention of quality problems,
identification of quality-related problems should they occur, initiation or recommendation of solutions and
verification of corrective action. In addition, he/she is responsible for coordination of quality-related
activities within the Construction staff and with the site Client quality representatives. He/she maintains
the construction quality control procedures and provides technical assistance and training to construction
supervision. He/she will have an active role in assisting with the prevention of quality problems.
The Site Quality Manager reports directly to the Site Manager with a technical supervision channel to
Construction Technology's Corporate Quality Manager.
The Construction staff includes a Construction Engineering organization to ensure prompt engineering
interpretations and decisions, review of drawings, certificates and other data to be submitted to the Client,
and to actively participate in the surveillance of field construction, and to verify compliance to
design/engineer requirements. Construction Engineering will provide assistance to the Site Quality
Manager as necessary to assist in achieving quality objectives.
NOTE: Construction Engineers report to the Site Quality Manager when they are
executing inspection/surveillance activities.
Subcontractors
The subcontractor quality organization will be in accordance with the contract requirements and described
in their approved equivalent Site Quality Manual.
ATTACHMENTS
Section 3 - BUILDINGS
3.1 Buildings RESPONSIBILITY
ACTIVITY Construction QA/QC
Review all Contractor proposed building materials prior to use. X (1)
Verify that the building location level and position are correct prior to construction. X
Inspect the entire building upon completion and document deficiencies. X S
Document building acceptance X
Monitor the in process construction to verify that the work is i.a.w. drawings. X S
Schedule final acceptance activities X S
Monitor the Contractor's quality control activities to verify test frequency, identification and
X
traceability
Audit building documentation X
Section 4 - EQUIPMENT
4.1 Equipment RESPONSIBILITY
ACTIVITY Construction QA/QC
Inspect installed equipment for acceptance upon completion, including attachments to
the equipment, e.g. foundations, sheds, buildings, auxiliaries, etc. which comprise the X
entire assembled unit.
Initiate action to acquire vendor representative as required. PM
Coordinate with engineering for participation of mechanical discipline engineers, if
PM
required.
Monitor the in-process installation of each equipment unit. X S
Coordinate with vendor representative who technically supervises equipment
X
installation.
Verify vendor representative's checklists and acceptance records are signed and
X S
attached to appropriate construction documents.
Verify the equipment requirements are being satisfied by the Contractor. X S
Monitor equipment preservation i.a.w. Site requirements. X
Monitor the Contractor's quality control activities to verify conformance to inspection,
X
testing and documentation requirements.
Section 5 - PIPING
5.1 Underground Piping RESPONSIBILITY
ACTIVITY Construction QA/QC
Monitor in-process excavation and backfill. X S
Inspect installed underground pipelines for acceptance. X S
Color code the lines, indicated as punched and accepted, on a copy of the
X
underground piping plan.
Verify that the Testing Lab is performing the required soils testing of backfill. X S
Monitor in-process coating and wrapping, including surface preparation, coating and
wrapping methods and materials and arrangement for intermediate storage and X S
stockpiling of coasted pipes.
Inspect in-process pipe fabrication and installation i.a.w. drawings. X S
Perform a final inspection of the line, when the underground piping is complete, but
X S
prior to the coating and wrapping of joints and fittings.
Verify the Contractor has completed coating and wrapping of joints and fittings on
X S
tested line.
Witness holiday testing of the coating and wrapping. Contractor shall document tests. X S
Verify that required NDE is complete on the lines to be inspected. X
Witness the pressure test. S X
Inspect the tested system to ensure that all items have been properly completed
X S
(restoration).
Monitor the Contractor's quality control activities to verify conformance to testing and
X
documentation requirements.
Section 6 - ELECTRICAL
6.1 Underground Electrical RESPONSIBILITY
ACTIVITY Construction QA/QC
Monitor in-process installation of the grounding system including, grounding rod
X S
installation, backfilling. Color coding of drawings to track progress.
Witness resistance to earth tests. X S
Monitor in-process duct bank and electrical manhole installations. X
Witness initial testing of shielded cable, i.e,. insulation resistance test of power cable
X S
on reels, continuity test of reeled instrument cable.
Inspect cable trench prior to installation of cable. X
Monitor in-process installation of underground cable. Inspect in-process cable pulling. X S
Inspect in-process cable splicing. X S
Witness random testing of installed underground cable, i.e. insulation resistance test
X S
(megger) cables and DC hypot medium and high voltage cables prior to termination.
Inspect installation of cables upon completion of each layer to ensure spacing,
X S
labeling, etc. is correct.
Inspect sand backfill per lift for quality of materials, depth and compaction. X S
Verify the Contractor final as-built drawings are in conformance. X S
Verify that the Contractor is preparing documentation concurrent with construction as
X S
inspection and testing are performed.
Monitor the Contractors' quality control activities. X
Section 9 - WELDING
9.1 Pipe Welding RESPONSIBILITY
ACTIVITY Construction QA/QC
Verify the WPS's have been approved by the Welding Engineer. X (1) S
Monitor qualification tests of Contractor's welders. X
Ensure that welder ID badges have been issued and displayed. X S
Check Contractors control of welder symbols. X S
Check Contractor's control of welding consumables. X S
Monitor in-process welding including consumables, joint preparation,fit-up preheat,
X S
interpass heat, WPS variables and final visual
Verify Contractor is documenting welds on the Daily Welding Report. X S
Verify completed welds are being documented on piping drawings. X S
Monitor in-process post weld heart treatment. X S
Audit welding documentation. X
Verify transfer of piping material heat numbers. X S
DOCUMENT CONTROL
SCOPE
This procedure describes the Document Control system to be used by site construction personnel.
GENERAL
Engineering Documents
- Design Engineering documents such as specifications and drawings that are issued to
Construction are controlled and issued on site in accordance with this procedure. Construction
Engineering maintains an up-to-date register of drawings and specifications. This procedure is
designed to ensure that the latest drawings issued to construction, including shop drawings,
specifications and instructions, as well as authorized changes thereto, are delivered to the
proper locations and personnel responsible for performance of the work.
- This procedure also provides for the prompt removal of obsolete documents from all points of
issue or use.
- The Construction Engineering staff reviews engineering documents for adequacy and
completeness to perform the work and coordinates site needs for clarification with the designer.
Subcontractors obtain clarification through the Fluor Construction Engineering Manager.
Construction Engineering maintains drawings and specification control records, processes all
design document changes, ensures proper authority for the changes, and prompt removal of
obsolete documents from the field.
- The Construction Engineering Manager is responsible for control of shop drawing submittals
and certifications to include assuring that submittals are received and/or distributed.
- The Construction Engineering Manager will maintain as-built marked-up drawings. These
drawings will be maintained in a current condition. The as-built data will be submitted to Design
Engineering in accordance with this procedure. Subcontractors will submit as-built information
through the Fluor Construction Engineering Manager.
- When field conditions dictate changes to the design specifications and/or drawings, a Request
For Information (RFI), Form 000.509.F00501, will be submitted for approval to ensure proper
control and documentation. RFIs will be initiated by the Construction Engineering Manager
who will maintain a RFI Log, Form 000.509.F00502. RFIs will be forwarded to the Design
Engineer for approval and/or action. Subcontractor submittals will be sent to the Fluor
Contracts Manager for submittal to the Fluor Construction Engineering Manager for evaluation
and processing.
- The Construction Engineer shall describe the condition or design change requested in terms
that can be easily understood by those who review it, including appropriate references, specific
drawings and specifications to illustrate the recommended change.
- To minimize delay in construction, authority for deviation from specifications and drawings may
be acquired by direct communication with the Design Engineer and the Client pending
processing of the RFI. A copy of the Record of Telephone Conversation will accompany the
RFI transmitted to the Design Engineer and the Client. Approval of the Client’s construction
site representative should be acquired, if possible.
- The Design Engineer and the Client portion of the RFI indicate approval or disapproval of the
field recommended change or recommends alternatives. The signed original will be returned to
the Site Manager for disposition or authority to proceed.
- The Construction Engineering Manager shall maintain a file that contains a full history of the
action and data supporting the approval of each Request For Information.
Subcontractor Documents
- The subcontractors are responsible for procedures necessary to assure that all documents
provided for construction are maintained to the most up-to-date revisions. Documents include
procedures, letters, telexes, purchase requisitions, purchase orders, design drawings,
specifications, reference drawings, vendor drawings, field sketches, test reports, etc.
Documents affecting individual subcontractor's work are forwarded to the subcontractor by the
Contracts Manager.
- Subcontractor prepared field sketches and "as-built" drawings originating at the construction
site shall be documented and controlled in accordance with the Request For Information (RFI)
requirements described in this procedure.
- Submittals are reviewed under the direction of the Construction Engineering Manager.
Subcontractor technical submittals are forwarded to Construction Engineering Manager. A
submittals list shall be maintained reflecting the specification reference, description, date
received, and the status of acceptance through Construction Engineering approval. The Site
Quality Manager shall review submittals related to quality control requirements.
Material/Equipment Documents
- Documents related to materials, materials receiving and issue are controlled in accordance to
procurement procedures.
- Documents and data identified as quality records are processed, retained and protected as
described in 000.509.0160 "Quality Records". Primary responsibility for ensuring adequate
control of quality related documents rests with the Site Quality Manager.
Procedure
Vendor Documents
- Vendor document supplied by Fluor Engineering Document Control to the Fluor Site Document
Control for filing and distribution will be in accordance with the Project File Index and the
Distribution Matrix System.
PROCEDURE
- The Construction Engineering Manager shall establish a standard distribution for design
documents drawings and specifications with the Client.
- Document Control shall provide document inventory control and receipt, and distribution
accountability. This is accomplished making distribution in accordance with the Distribution
Matrix System. Distribution is by individual document holder. These documents will be
stamped in red with the Site Document Control stamp indicating date received. The Site
Document Control stamp will be used to identify drawings, ISO, Instrumentation Specification
Data Sheets, specifications, etc.
- A document transmittal record will be utilized for the distribution and issue of all controlled
documents. The document recipient must sign the transmittal record and return it to Document
Control within 10 days of issue.
- Document recipients shall be responsible for control of documents upon receipt. Document
Control will periodically (minimum quarterly) audit document recipients to ensure proper
documents are available for use and that superseded documents have been removed from the
field. Should a superseded document be required to be retained for inspection or historical
data, the document will be identified as "VOID" or "SUPERSEDED" to prevent inadvertent use
of the document for fabrication/installation activities.
- Establish document control log system for receipt of documents and provided standard
distribution as indicated on the Distribution Matrix System.
- Review receipt transmittal and enter date received in the Electronic Tracking System.
- Based on input from Site Manager, determine distribution for each type manual. Maintain a
"Master" manual in Document Control and reproduce copies as required.
Document Recipient
- Sign transmittal acknowledging receipt of documents and return signed transmittal Document
Control within 10 days.
- Replace superseded documents as required with the new documents. Destroy or return the
superseded documents (except for inspection or historical record) to Document Control. The
document recipient is responsible for maintaining documents current.
Document Control
Requester
Document Control
- Reproduce documents requested and obtain receipt acknowledgement from requester upon
issue.
DOCUMENT AUDITS
- Determine document audit plan and schedule audits. A minimum of 5% of documents issued
to the document holder will be randomly selected for the audit sample. The number of
document holders to be audited will be determined by the Construction Engineering Manager.
Document Control
- Using a printout or list of documents and current revisions, compare documents and revisions
held by document holders and note any discrepancies. Notify the Construction Engineering
Manager of major discrepancies.
- For major discrepancies identified by Document Control audits of documents, investigate and
provide recommended resolution.
- Revision dates for all pages of all procedures in the manual should match the dates in the
Table of Contents.
- The Site Quality Manager, Construction Engineering Manager, Site Manager and the Client
(optional) will approve each revision by signing the "Approval Page".
- Forward the approved revision and affected documents to Document Control for maintenance
and distribution to all manual holders.
REFERENCES
ATTACHMENTS
Response The respondent’s resolution (generally the Design Engineer, Project Engineering
Manager, CM, or Fluor’s Construction Engineering Manager) to the question,
information, discrepancy, or conflict.
Respondent: The signature of the person making the response. (Lead Construction Discipline
Engineer, Construction Engineering Manager or Design Lead Discipline
Engineer, etc.)
Title: List the current position of the Approver on the project.
Date: The date the request is approved for transmittal to the Design Engineer.
Approval for Respondent: The signature of the person reviewing and approving the request prior to
implementation. (This action might require Client approval. If the response
changes the design (AFC Drawings or Specifications) the Engineer of Record
must approve the resolution.)
Title: List the current position of the Approver on the project.
Date: The date the request is approved for implementation by the Client or Project
Engineering Manager or designee.
Adequate Closure? Indicate using the checkbox if the RFI response is acceptable for closure of the
RFI. Generally, the Construction Engineering Manage must respond to this
question.
Cost Impact? Indicate using the checkbox if the RFI response has a cost impact that will
require an estimate or a request for contractor pricing. If the answer is yes,
indicate the requirement for a SI to be issued to the Contractor.
Schedule Impact? Indicate using the checkbox if the RFI response has a schedule impact that will
require an adjustment in the contract schedule or a request for contractor pricing.
If the answer is yes, indicate the requirement for a SI to be issued to the
Contractor
Closed RFI and Date Verified: Inter the name and date the RFI was closed and verified.
Distribution: List all parties requiring a copy of the completed request once the response has
been received.
PROCESS CONTROL
SCOPE
This procedure identifies construction work processes that require process control.
GENERAL
For most site production activities, the drawings and specifications provide adequate work instruction.
These may be supplemented with additional instructions to control work sequencing, recording of
installation data, material selection, etc. However, certain construction work processes require special
instructions to establish the controls necessary to achieve acceptable quality, of the completed work, for
the following reasons:
• Quality results of the completed work cannot be fully verified by subsequent inspection and/or
testing.
• Quality deficiencies may only become apparent after the item has entered service or operation.
Special Processes
"Special processes" are highly dependent on the control of process parameters or the skill of the operator
or both and are characterized by the need for one or more of the following control measures.
Special processes encountered on sites include, but may not be limited to:
Special processes identified must be accomplished and documented under controlled conditions
by appropriately qualified personnel using approved procedures and equipment in accordance
with the governing specifications and the associated referenced codes and standards.
PROCEDURE
The Site Quality Manager shall coordinate with the Construction Engineering Manager, to
research the project contract work scope and specifications in order to identify the special
processes that will be utilized. If the processes are to be contracted, ensure that the required
control mechanisms, i.e. procedures, qualifications, etc. are specified in the RFP and
implemented before the start of work. Process control measures and responsibilities shall be
identified on the applicable procedures or ITPs.
SCOPE
This procedure describes the methods to be used for the control, calibration, maintenance and recall of
inspection, measuring and test equipment (IMTE) used to demonstrate conformance of construction work
activities to the specified requirements. It is not applicable to calibration of permanent plant devices.
GENERAL
Inspection, measuring and test equipment (IMTE), including test software, shall be selected, calibrated
and controlled in a manner which is consistent with the required inspection, testing and examination
requirements.
Environmental conditions shall be suitable for the calibrations, inspections, measurements and tests
being carried out.
All IMTE shall be uniquely identified. This unique identification may consist of a manufacturer's unique
serial number along with model number and/or the assignment and application of a unique Inventory
Control Number (ICN).
The handling, preservation, and storage of inspection, measuring and test equipment shall be such that
the accuracy and fitness for use is maintained.
All calibrations shall be performed using certified equipment having a known valid relationship to
nationally recognized standards; where no such standards exist, the basis used for calibration shall be
documented.
"Conformance check" means the operations required to ensure that an item of measuring equipment is in
a state of compliance with requirements for its intended use.
Non-adjustable measuring and test equipment is not considered as calibrated equipment. Equipment of
this nature (e.g. cube and proctor molds, measuring tapes, rulers, chains) is subject to a "conformance
check" to dimensional, volumetric or other requirements and does not require any further verification
unless apparent damage or other factors require reverification.
It is the responsibility of the end-user to comply with the requirements of this section.
IMTE shall be selected utilizing Attachment I "Criteria for the Selection of Inspection, Measuring and
Testing Equipment" and Attachment II shall be used for guidance in procurement of calibration equipment
and/or services.
All IMTE calibration requirements shall be identified, on Attachment 3 - IM & TE Calibration Requirements
List. This attachment is used to list the various types of IMTE in use and their associated calibration
frequencies, calibration procedures and tolerances. Calibration procedures, frequencies, and tolerances
may be obtained in conjunction with obtaining the services of an outside calibration vendor or from
manufacturers. A procedure number shall be assigned. If the manufacturer has an assigned number, this
should be used. Calibration procedures are quality records and shall be maintained in site files.
Procedures such as published standards, practices (e.g., ASTM) or written calibration instructions from
the manufacturer may be used. In the absence of either a published standards practice or an adequate
manufacturer's procedure, a written procedure for the calibration method shall be written and approved
for use.
In addition to the above, calibration procedures should include at least the following basic information:
Provisions to obtain and record "as-found" accuracy measurement prior to any adjustments.
Sequence of operations.
Safety considerations.
Perform and record (Form 000.509.F01104) the calibration in accordance with the above established
calibration procedures and/or contract the services of an outside calibration services vendor.
Upon completion of initial calibration, enter the equipment in the Calibration Assignment Log
(Form 000.509.F01101) and record other data required by this log.
History of Use
The end user shall maintain a history of use for IMTE to enable an assessment of the validity of previous
calibrations, inspections, measurements and test results when calibration as-found data reveals out-of-
tolerance data points.
The history shall be documented using IMTE Sign In/Out-History of Use Log (Form 000.509.F01102) and
keep current to record each usage of the IMTE.
If out of tolerance conditions are found, a Nonconformance Report shall be prepared in accordance with
000.509.0130.
Evaluations shall be documented, and where required, repetitions of readings shall be compared to
original results.
It is the responsibility of the end user to use calibrated equipment within the environmental operating
range(s) or restrictions/limitations specified by the instrument manufacturer.
Upon satisfactory completion of calibrations, and after the recalibration due date has been determined
(calculated), the end user shall make entries on the "Calibrations Tickler File" (Form 000.509.F01103) to
aid in the tracking and recall of items for scheduled recalibration.
DOCUMENTATION
Electronic recording of the information that is required by the documentation in this procedure is
permissible. All documents (except labels) generated in accordance with this procedure should be
maintained in appropriate protected files throughout the construction phase of the project, and for the
period of time there after specified (if any) or turned over to the Client if required.
FORMS
ATTACHMENTS
Attachment 1 - Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE)
Attachment 1
Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE)
1. IMTE includes inspection, measurement and/or testing equipment used to determine final
acceptance.
2. IMTE shall have a manufacturer's stated accuracy (and precision, where applicable)
that exceeds the construction installation inspection, measurement and/or testing tolerance(s).
3. IMTE shall have the durability, stability and appropriate measurement ranges
consistent with the intended use(s).
4. Calibration standards that will be required for the initial and subsequent recalibrations
shall be identified when selecting IMTE. Such calibration standards shall be
requisitioned or the services of a calibration facility with the calibration standards shall be
contracted.
NOTE: Obtaining calibration standards or services can usually require more time to procure
than the time required to select and procure the needed IMTE.
5. Purchase requisitions for IMTE, calibration standards, and calibration facility services
should clearly state the requirements for accuracy, precision (where applicable), range, durability
and/or stability, environmental, handling, other applicable technical requirements.
The following are recommended guidelines for preparing a purchase order for obtaining the services of
a calibration supplier to calibrate Inspection, Measuring and Test Equipment (IM&TE).
2. The calibration supplier must provide the following information as part of their calibration
records:
3. The calibration records supplied by the calibration supplier for each item of IM&TE calibrated must
include:
4. The calibration supplier shall seal, using a unique, tamper-resistant system, all adjustment access
points after calibration, where practical. The system used shall provide visual evidence of
tampering.
5. The calibration supplier shall immediately notify the purchaser of any IM&TE discovered to be out of
calibration by more than the stated accuracy tolerance or any piece of IM&TE that shows indication
of tampering. The purchaser shall determine if the calibration process should continue.
6. The calibration supplier shall package and ship each piece of IM&TE in such a manner to preclude
damage and to preserve the calibrated condition.
Notes:
I M T E Description: I M T E No.:
Month Year
Calibration Range
Calibration Procedure
As Found Calibration
0% 0%
25% 25%
75% 75%
100% 100%
Mounted Accessories
Remarks
Calibrated By Date
CONTROL OF NONCONFORMANCES
SCOPE
This procedure describes the methods and responsibilities for controlling nonconforming items to prevent
their inadvertent use or installation when other control methods, inspection reports, surveillance reports
(000.509.0220), etc. are considered inadequate. This procedure provides for the identification,
documentation, evaluation, disposition, notification, segregation (prevention of inadvertent
use/installation), and reinspection of these nonconforming items (excluding ASME Code items).
GENERAL
Types of NCRs
Use as Is- Permission to use an item that does not conform to specified requirements.
- The Construction Subcontractors have the first responsibility for the identification, control,
and disposition of nonconforming items within their Scope of Work. Fluor will issue a
Nonconformance Report when the Construction Subcontractor has not issued one. It is
not necessary to have more than one Nonconformance Report active on the identical
nonconforming condition.
- The Construction Manager will take measures to provide holding areas or other methods
for segregating nonconforming items to prevent unauthorized use, mixing with conforming
items or incorporating into future construction. Where physical segregation is not
practical, tagging, marking, or other positive means of identification is acceptable. The
Site Quality Manager may elect to use "HOLD" tags/stickers (Form 000.509.F01303) for
additional assurance.
PROCEDURE
Documentation of Nonconformance
- For materials and equipment identified as nonconforming (per the descriptions in the
"General" section of this procedure), generate a Nonconformance Report (Form
000.509.F01301) to document the nonconforming item(s). The report is to be processed
as follows:
Initiator
• Enter either Fluor, the name of the Subcontractor or Vendor to identify organization
responsible for the nonconforming work.
• Use the entries in the header of the form to provide unique traceability and
identification to the nonconforming item.
The initiator provides the NCR completed as noted above to the Site Quality
Manager.
NOTE: Evaluate the report to determine that the described condition is a valid
nonconformance. It is not necessary to have more than one Nonconformance
Report active on the identical nonconforming condition. If a Construction
Subcontractor has issued the NCR, it should not be duplicated by Fluor.
• Assign a unique number to the report and enter the number on the report and on
the "Nonconformance Report Log" (Form 000.509.F01302).
• If a hold tag is needed, enter the hold tag number and have the hold tag installed
on the item. The hold tag number should be the same as the NCR number. If a
hold tag is not to be used, enter NA.
The Site Quality Manager provides the NCR completed as noted above to the
Construction Engineering Manager. Also send a copy to the Fluor Shop Inspection
Coordinator for nonconformances attributed to a vendor.
• If the nonconforming condition will not be corrected in full conformance with the
applicable specification, the Project Design Engineer shall accept the disposition.
In this case, check "yes" and obtain the Project Design Engineer approval. Any
documentation provided by the Design Engineer that supports the disposition
should be attached to the NCR original. For subcontractor NCR's, this approval is
obtained through the Fluor Construction Engineering Manager.
• After completing the disposition instructions and obtaining the required approvals,
sign and date.
Send the original NCR to the Site Quality Manager and copy to the Site Manager.
Site Manager
Upon receipt of the approved NCR disposition, perform the applicable construction
actions specified in the NCR disposition. (Request removal of QC hold tag prior to
performing work, if one has been applied.)
DOCUMENTATION
The Site Quality Manager shall retain all NCR’s and the NCR log in the Quality Files.
FORMS
Quality Forms:
Attachment
1 Description of Non-conformance:
The initiator shall describe the requirements that were not met and a detailed description of the Non-conformance.
2 Root Cause:
The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s)
including and explanation will be stated.
NOTE: If codes 7 or 8 are used, list the procedure(s) identified as the root cause.
Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code.
3 Disposition
Use-as-is Requires design Engineer and Client approval.
Re-work Restore to original Specification, does not require Design Engineer or Client approved.
Repair Does not meet original specification, correct (repair) for “fit-for-use” condition.
Requires approval from design engineer and may require approval of client.
Provide instructions for implementation or justification of the selected disposition.
IMPLEMENTATION
Once implementation is satisfactorily implemented, sign the “Disposition Completed” block.
The Fluor inspector shall indicate the method used for verification of corrective action. Sign the signature block
indicating acceptance of corrective action.
5 The Fluor Site Quality Manager shall review the NCR for completeness and acceptance of the corrective action.
Site Quality
Lead Field Engineer
Nonconform ance NCR Manager
Recomm ended Disposition/
Discovered Initiated Review/Confirm s/
Signature
Signs
Site Quality
Manager Site Quality
Assigns Num ber Manager
for Routing
Corrective Action:
1) Remove/Replace Corrective
Rework to Action
Full Design Intent Approved
Reject
Accepts Quality
Quality
Execution of Manager
Manager
Corrective Action Closes
Verifies
NCR
Distribution:
Quality Manager
Distributes
Closed NCR
Note 1: If corrective action is 2 or 3, distribution to be same as that shown when NCR closed. If corrective action
is 1, exclude area EPCM from distribution until NCR is closed.
Note 2: For NCR’s on Activities within Regulating Authority Scope, they need to Review/Accept
DESCRIPTION OF NONCONFORMANCE