West Q
urna I 000 509 0000
Contract N
o: W3Q
R
21 Apr 11Project Location: Basra, Iraq
Page 1 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
TAB
LE OF C
ON
TENTS / D
ATE R
EVISION
PAG
E
Adm
inistrativeProcedure N
o.Title
RevisionD
ate
000 509 0000 Table of C
ontents / Date R
evision Page
15 Apr 11
000 509 0010 Forew
ord 15 A
pr 11000 509 0020
Manual P
reparation and Maintenance
15 Apr 11
000 509 0040 O
rganization and Responsibilities
15 Apr 11
000 509 0050 D
ocument C
ontrol 15 A
pr 11000 509 0090
Process C
ontrol 15 A
pr 11000 509 0110
Inspection, Measuring and Test Equipm
ent 15 A
pr 11000 509 0130
Control of N
onconformances
15 Apr 11
000 509 0140 C
orrective Action 15 A
pr 11000 509 0150
Preventive Action 15 A
pr 11000 509 0160
Quality R
ecords
15 Apr 11
000 509 0170 Q
uality Audits 15 A
pr 11000 509 0180
Personnel Training and Qualification
15 Apr 11
000 509 0220 Surveillance of C
onstruction Activities 21 A
pr 11000 509 0240
Turnover 15 A
pr 11000 509 0250
Material & Equipm
ent Storage & Maintenance
15 Apr 11
000 509 5100 Activity Plan for C
onstruction 15 A
pr 11
Refer to the Project Procedures M
anual for Site Construction Execution,
Contracts, M
aterial Managem
ent, and other Adm
inistrative Procedures not covered in this m
anual.
Inspection and Test Procedure
No.
TitleR
evisionD
ate000 509 7000
Inspection and Testing 15 A
pr 11000 509 7010
Soils 15 A
pr 11000 509 7020
Bituminous C
oncrete Paving 15 A
pr 11000 509 7030
Pilling - Steel H - Piles
15 Apr 11
000 509 7040 Piling Pre-C
ast Concrete Piles
15 Apr 11
000 509 7060 Piling - C
losed End Concrete Filled Pipe Piles
15 Apr 11
000 509 7070 Piling - C
oncrete Filled Thin Shell Pipe Piles 15 A
pr 11000 509 7080
Drilled C
aissons 15 A
pr 11000 509 7090
Augered Cast-In-Place Piles
15 Apr 11
000 509 7100 C
oncrete and Grout
15 Apr 11
000 509 7200 Structural Steel
15 Apr 11
000 509 7300 Buildings
15 Apr 11
000 509 7310 H
eating Ventilating and Air Conditioning
15 Apr 11
West Q
urna I 000 509 0000
Contract N
o: W3Q
R
21 Apr 11Project Location: Basra, Iraq
Page 2 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
Inspection and Test Procedure
No.
TitleR
evisionD
ate000 509 7320
Roofing Inspection
15 Apr 11
000 509 7400 Equipm
ent 15 A
pr 11000 509 7410
Field Fabricated Tanks 15 A
pr 11000 509 7430
Refractory C
oncrete 15 A
pr 11000 509 7500
Underground Piping
15 Apr 11
000 509 7510 Aboveground Piping
15 Apr 11
000 509 7520 Pressure Testing
15 Apr 11
000 509 7560 C
hemical C
leaning of Pipe 15 A
pr 11000 509 7600
Electrical Inspection 15 A
pr 11000 509 7610
Electrical Testing 15 A
pr 11000 509 7620
Electrical Equipment
15 Apr 11
000 509 7640 Electrical H
eat Tracing 15 A
pr 11000 509 7700
Control System
s Instrumentation
15 Apr 11
000 509 7710 C
ontrol System C
alibration 15 A
pr 11000 509 7800
Coatings and Linings
15 Apr 11
000 509 7810 Insulation
15 Apr 11
000 509 7820 Fireproofing Inspection
15 Apr 11
000 509 7830 C
athodic Protection 15 A
pr 11000 509 7850
Telecomm
unication Inspection 15 A
pr 11000 509 7910
Welding Inspection
15 Apr 11
000 509 7920 N
ondestructive Examination
15 Apr 11
000 509 7930 Positive M
aterial Identification 15 A
pr 11000 509 7950
Hardness Testing
15 Apr 11
000 509 F0000 Q
uality Control Form
s 15 A
pr 11
The Fluor Site Quality Program
for this Project is described and documented in this Site
Quality M
anual.
West Q
urna I 000 509 0010
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 1 of 2
Fluor Corporation C
ompany C
onfidential Site Q
uality Manual
FOR
EWO
RD
The objective of the site quality program for this project is to ensure that construction is perform
ed in accordance w
ith the drawings, specifications, applicable local law
s, and standards. A further objective is to provide docum
ented evidence that confirms that the prim
ary objective has been m
et. The site quality control program as delineated in this m
anual is tailored to meet the quality
surveillance, inspection, testing, and documentation requirem
ents for construction/installation perform
ed by subcontractors of Fluor (Morning Star).
The site quality program is based upon the principals stated in the O
perating System
Requirem
ents (OSR
) and any applicable Operating System
Implem
entation Plan (OSIP). It is
designed to cover quality aspects related to construction, construction managem
ent and m
aintenance activities.
The Site Quality M
anager will coordinate the construction quality surveillance, inspection, testing,
and documentation activities. H
e will m
onitor construction and quality activities to the extent necessary to provide construction m
anagement w
ith adequate confidence that appropriate m
easures are being taken to control and achieve quality. The quality activity will em
phasize preventing nonconform
ance to drawings and specifications but detecting and correcting it if it
occurs.
If Fluor performs construction activities using our ow
n labor force, the quality control responsibility rem
ains with Fluor. The Fluor construction supervision and construction engineering staffs are
primarily responsible for the attainm
ent of the quality requirements established by the draw
ings, specifications and contract. The supervisory, construction engineering and quality staffs w
ill perform
quality control inspection, testing, surveillance and documentation activities as outlined in
this manual. The prim
ary responsibility for performing quality w
orkmanship rests w
ith those actually perform
ing the work under the supervision of the Fluor construction staff.
When 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 w
ith 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 m
easures 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. Both Fluor inspection form
s and ExxonMobil M
echanicalCom
pletion R
ecords will be used to docum
ent required inspections and testing. Specific contractor inspection and testing form
s may also be used w
ith prior approval.
This site specific Quality M
anual 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 ASM
E Boiler and Pressure Vessel Code w
ork. The Fluor "Quality
Control System
Manual for Boiler and Pressure Vessel C
ode Work" w
ill be applied to ASME and
National Board Inspection C
ode Work certified by Fluor.
West Q
urna I 000 509 0010
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 2 of 2
Fluor Corporation C
ompany C
onfidential Site Q
uality Manual
The Project Procedures Manual (PPM
), used in conjunction with the Site Q
uality Manual,
contains approved procedures used to identify, document, and verify the appropriate review
s and approvals of changes to design docum
ents that are requested by field organizations and provides requirem
ents for document control.
The Fluor Construction Technology staff w
ill conduct independent audits of project compliance to
this manual. The audits are conducted to provide the Project M
anager, Site Manager, and C
lient w
ith a project independent evaluation of the site quality program status and adequacy. The initial
audit will be conducted at approxim
ately 10% m
echanical completion and additional audits on a
periodic basis throughout construction.
West Q
urna I 000 509 0020
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 1 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
MA
NU
AL PR
EPAR
ATIO
N A
ND
MA
INTEN
AN
CE
SCO
PE
This procedure provides guidance for converting the 509 series of Corporate Site Q
uality procedures from
Knowledge O
nLine to a Site Quality M
anual for a specific project. It is applicable to C
onstruction, Construction M
anagement, M
aintenance, or projects with any
of these combinations.
GEN
ERA
L
The initial draft of the project specific Site Quality M
anual is initiated by Construction Technology's
Corporate Q
uality Manager. It is to be based on reference procedures of the 509 series of Site
Quality procedures from
the Construction Know
ledge Com
munity that are listed in the Table of
Contents section 000 509 0000. These reference procedures have been prepared to m
eet the requirem
ents of International Standard ISO-9000. The bracket sym
bols ([::---::]) seen throughout these procedures identify changes or additions that are to be m
ade in converting them to project
specific procedures. Other changes are to be m
ade as needed to be compatible w
ith the project requirem
ents and scope. The set of procedures in the 509 series represents the accumulated
knowledge and experience gained from
many construction projects. U
se of these reference procedures as baseline docum
ents will result in im
proved consistency between projects and
entities, thus fulfilling the goal of consistency in execution. Proposed changes to these reference procedures should be com
municated to C
onstruction Technology's Corporate Q
uality Manager.
Upon assignm
ent of the Site Quality M
anager, he/she begins development of the draft Site Q
uality M
anual (SQM
) to assure conformance to the site-specific requirem
ents. The completed and
approved project specific SQM
should be in place for usage as soon after contract award as
possible. As a minim
um, parts of the m
anual should be developed for control of construction activities before the activities are perform
ed. These activities usually begin with qualifying and
issuing RFQ
's to bidders for work to be subcontracted (see 000 509 0200 and 0210). If these
activities begin prior to assignment of the Site Q
uality Manager, C
onstruction Technology's C
orporate of Quality M
anager will function as the Site Q
uality Manager until the assignm
ent is m
ade.
Developm
ent of the Site Quality M
anual
Each section/procedure identified by 000 509 0000 is reviewed for consistency and applicability
with project scope. C
hanges or additions will be required of the follow
ing sections as noted:
- Inspection and Test Procedures (7000 7999)
- Table of C
ontents / Date R
evision Page (0000)
Under "R
evision Date."
West Q
urna I 000 509 0020
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 2 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
Revision dates for all pages of all procedures in the Site Q
uality Manual should
match the dates in this Table of C
ontents.
Revisions to the Site Q
uality Manual shall not w
aiver or negate OSR
requirements
or mandatory construction codes.
Revision of Site Specific M
anual
The Site Quality M
anager controls the site issue and revision of the Site Quality M
anual. The m
anual 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 m
anual. The Table of C
ontents shall show the revision date of each revised procedure and shall be reissued for each
revision.
The Corporate Q
uality Control M
anager in each of the respective offices shall review and approve
the Issued for Construction Site Q
uality Manual prior to the approval signatures being obtained.
Each subsequent revision to the Site Quality M
anual shall also be approved by the Corporate
Quality C
ontrol Manager.
The Site Q
uality Manager, C
onstruction Engineering Manager, and Site M
anager should approve each revision by signing the Approval Page. The C
lient should also be given the opportunity for approval of the Site Q
uality Manual.
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 1 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
OR
GA
NIZA
TION
AN
D R
ESPON
SIBILITIES
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 w
hich includes construction quality. The delegation of authority to the Site Q
uality Manager for the
direction and coordination of quality activities is made w
ith 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 w
ork 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 w
ork being performed.
OR
GA
NIZA
TION
The project organization for site quality personnel are shown on the Site O
rganizational Chart
maintained by the Site M
anager. Contractors m
ay also have their own Q
uality Organizations
which w
ill provide for their first line of inspection responsibilities.
RESPO
NSIB
ILITIES
Quality related activities are conducted by Site Q
uality and other groups. The activities and persons conducting them
will be under the functional control of the Site Q
uality Manager for the
execution of the activity. Attachment 1- Q
uality Responsibility M
atrix summ
arizes the activities and the persons responsible for execution. Prim
ary responsibility for execution and verification of quality-related activities w
ill be established on the Inspection/Test Plan or procedures.
Site Quality M
anager
The Site Quality M
anager has the responsibility, authority, and organizational freedom to audit,
inspect and witness construction activities and to verify com
pliance to contract quality requirem
ents. This responsibility includes actions such as assist the construction staff in prevention of quality problem
s, identification of quality-related problems should they occur,
initiation or recomm
endation of solutions and verification of corrective action. In addition, he/she is responsible for coordination of quality-related activities w
ithin the Construction staff and w
ith the site C
lient quality representatives. He/she m
aintains the construction quality control procedures and provides technical assistance and training to construction supervision. H
e/she will have an
active role in assisting with the prevention of quality problem
s.
The Site Quality M
anager reports directly to the Site Manager w
ith a technical supervision channel to C
onstruction Technology's Corporate Q
uality Manager.
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 2 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
The Construction staff includes a C
onstruction Engineering organization to ensure prompt
engineering interpretations and decisions, review of draw
ings, certificates and other data to be subm
itted to the Client, and to actively participate in the surveillance of field construction, and to
verify compliance to design/engineer requirem
ents. Construction Engineering w
ill provide assistance to the Site Q
uality Manager as necessary to assist in achieving quality objectives.
NO
TE: C
onstruction Engineers report to the Site Quality M
anager when they are
executing inspection/surveillance activities.
Subcontractors
The subcontractor quality organization will be in accordance w
ith the contract requirements and
described in their approved equivalent Site Quality M
anual.
ATTA
CH
MEN
TS
Attachments 1 -
Quality R
esponsibility Matrix
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 1 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
Quality R
esponsibility Matrix
Section 1 - CIVIL
1.1 Construction Surveying
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Review
the construction surveying methods used by the C
ontractor. X
Check established reference points .
XC
heck control points established for construction layout on a periodic basis. X
Check the construction layout of the contractor's w
ork. X
Review
and file completed survey notes prepared by the contractor.
X
P
erform periodic surveillance on survey activities and docum
entation.
X
1.2 Soils R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor in-process soils work, including cut and fill elevations, spoil and fill m
aterial, compaction
methods and equipm
ent. X
Perform
formal audit of S
oils Testing Laboratory X
Monitor C
ontractor's work to verify conform
ance to requirements.
X
S
Monitor S
oil Testing Laboratory activities for soils testing frequency, test identification and com
pleteness. X
Verify the docum
entation of deficiencies and test failure and follow up to assure corrective action
is taken and documented.
X
Audit the soils docum
entation to verify correctness, completeness of coverage, retrievability as
filed and inspection results. X
Perform
and document soils testing
TES
T LAB
S
Inspect excavations for unstable and unsuitable soils TE
ST LA
B
SV
erify the insitu soils are suitable to support foundation loads TE
ST LA
B
SV
erify backfill material is satisfactory
TEST LA
B
SV
erify placement of the fill com
plies with contract specifications
TES
T LAB
S
1.3 Contracted Piling
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Qualify Pile Supplier
XR
eview and approve concrete m
ix design and mix trials
X (1) Technically m
onitor the indicator pile testing program
XC
heck final pile locations. X
S
Monitor in-process pile driving.
XS
M
onitor and test pile concreting activities. X
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 2 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
1.4 Asphalt
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Review
asphalt mix designs
X (1)
Monitor in-process asphalt construction including preparation of subgrade or previous course,
asphaltic materials, spreading equipm
ent, compaction equipm
ent, materials and testing.
XS
Perform
formal audit using A
sphalt Test Laboratory Evaluation R
ecord X
Monitor C
ontractor's quality control activities to verify conformance to requirem
ents for asphalt testing frequency, test identification and traceability and the docum
entation of inspection and testing
X
Review
the documentation of the asphalt inspection and testing activities for accuracy and
completeness.
X
Verify the docum
entation of deficiencies and test failures and follow up to assure corrective
action is taken and documented.
X
Audit the asphalt docum
entation to verify correctness, completeness of coverage, review
ability as filed and inspection results.
X
Conduct asphalt testing and asphalt m
aterials testing TE
ST LA
B
S
1.5 Structural Concrete
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Review
and approve mix designs
X (1)
S
Perform
formal audit of C
oncrete Testing Laboratory. X
Audit batch plant facilities.
XInspect form
work, reinforcing steel and im
pediments prior to concrete placem
ent. X
S
Monitor in process concreting activities.
XS
Monitor C
ontractor's quality control activities to verify conformance to requirem
ents for concrete testing frequency, test identification and traceability, and the docum
entation of inspection and testing.
X
Monitor post-concreting activities such as concrete curing, stripping, visual exam
ination for line, form
and surface defects and checks for anchor bolt locations. Verify that 28-day strength tests
are acceptable. X
S
Conduct concrete testing at the point of placem
ent TE
ST LA
B
S
1.6 Grouting of M
achinery and Structural Steel Base Plates
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Review
and approve mix design. C
heck materials prior to start of w
ork to verify that the m
aterials have not deteriorated or that shelf life has not been exceeded. X (1)
S
Monitor in-process grouting. The inspections shall include base preparation,m
aterials, forming,
placing, curing and hamm
er void test. X
S
Witness grout testing by C
ontractor. X
Monitor the C
ontractor's quality control activities to verify conformance to placem
ent procedures and docum
entation requirement.
X
Conduct grout testing at site
TEST LA
B
S
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 3 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval Section 2 - STR
UC
TUR
AL STEEL
2.1 Structural Steel R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor in process steel erection to verify fabrication is correct and erection is in accordance w
ith drawings. D
ocument fabrication errors on a N
CR
. X
S
Witness bolting procedure including calibration of torque w
renches and load indicating washers.
XS
Maintain docum
entation X
Inspect the erected steel structure. X
Ensure that erected steel structures have coatings installed i.a.w
. drawings
X
S
Monitor the C
ontractor's quality activities to verify conformance to requirem
ents for bolt tensioning procedures.
X
Schedule final acceptance inspection activities betw
een Contractor and Field E
ngineering or construction.
XS
Audit the structural steel docum
entation to verify correctness of data.
X
Section 3 - BU
ILDIN
GS
3.1 Buildings
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Review
all Contractor proposed building m
aterials prior to use. X
(1)
Verify that the building location level and position are correct prior to construction.
XInspect the entire building upon com
pletion and document deficiencies.
X S
Docum
ent building acceptance X
Monitor the in process construction to verify that the w
ork is i.a.w. draw
ings. X
SS
chedule final acceptance activities X
SM
onitor the Contractor's quality control activities to verify test frequency, identification and
traceability X
Audit building docum
entation X
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 4 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
Section 4 - EQU
IPMEN
T 4.1 Equipm
ent R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CInspect installed equipm
ent for acceptance upon completion, including attachm
ents to the equipm
ent, e.g. foundations, sheds, buildings, auxiliaries, etc. which com
prise the entire assem
bled unit. X
Initiate action to acquire vendor representative as required. P
MC
oordinate with engineering for participation of m
echanical discipline engineers, if required. P
MM
onitor the in-process installation of each equipment unit.
XS
Coordinate w
ith vendor representative who technically supervises equipm
ent installation. X
Verify vendor representative's checklists and acceptance records are signed and attached to
appropriate construction documents.
XS
Verify the equipm
ent requirements are being satisfied by the C
ontractor. X
S
M
onitor equipment preservation i.a.w
. Site requirem
ents. X
Monitor the C
ontractor's quality control activities to verify conformance to inspection, testing and
documentation requirem
ents. X
4.2 Field Fabricated Tanks R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor the foundation construction including soils, asphalt and concrete work.
X
S
Check elevation dim
ensions of tank shells. X
Check the erected dim
ensions of tank shells. X
S
Inspect fabricated tank structure upon com
pletion. X
S
C
heck the settlement and rebound of the foundation during and after hydrotest.
XS
Verify w
elder performance qualifications.
SX
Verify welding procedure testing has been accom
plished and procedures are acceptable.
X M
onitor in-process welding
XS
Witness in-process exam
ination as performed by the N
DE
contractor, including reviewing
radiographs, witnessing P
T, MT, vacuum
box and leak testing X
Verify that equipm
ent and components associated w
ith tankage have been correctly installed, adjusted, tested, confirm
ed for proper function and inspected. X
S
Inspect the tested tank prior to closing, including final clean-up. X
SV
erify that the Contractor has affixed a nam
eplate listing the required data. X
S
V
erify that the Contractor has subm
itted the required certification. X
S
Monitor the C
ontractor's quality control activities to verify conformance inspection, testing and
documentation requirem
ents. X
Witness hydrostatic testing
SX
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 5 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
Section 5 - PIPING
5.1 U
nderground Piping R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor in-process excavation and backfill. X
SInspect installed underground pipelines for acceptance.
X S
Color code the lines, indicated as punched and accepted, on a copy of the underground piping
plan. X
Verify that the Testing Lab is perform
ing the required soils testing of backfill. X
S
M
onitor in-process coating and wrapping, including surface preparation, coating and w
rapping m
ethods and materials and arrangem
ent for intermediate storage and stockpiling of coasted
pipes.X
S
Inspect in-process pipe fabrication and installation i.a.w. draw
ings. X
SP
erform a final inspection of the line, w
hen the underground piping is complete, but prior to the
coating and wrapping of joints and fittings.
XS
Verify the C
ontractor has completed coating and w
rapping of joints and fittings on tested line. X
S
W
itness holiday testing of the coating and wrapping. C
ontractor shall document tests.
XS
Verify that required N
DE
is complete on the lines to be inspected.
XW
itness the pressure test. S
X Inspect the tested system
to ensure that all items have been properly com
pleted (restoration). X
S
M
onitor the Contractor's quality control activities to verify conform
ance to testing and docum
entation requirements.
X
5.2 Site Shop Fabrication R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CS
egregate and store pipe fittings, upon receipt, according to size and material. Identify storage
location with com
modity code num
ber. M
M
Pipe w
ill be marked full length w
ith comm
odity code number.
MM
Maintain docum
entation M
MIssue piping m
aterials to Contractors
MM
Inspect special flange faces for correct finish and face protection. X
SM
onitor in-process pipe fabrication activities. X
SV
erify latest edition of piping drawings is being used.
XS
Random
check on base material ID
on pipe, fittings and spools. Spools shall be clearly
identified in two locations.
XS
Monitor storage of com
pleted spools at pipe shop including preservations. X
S
M
onitor pipe identification, documentation and tim
ely performance of N
DE
. X
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 6 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
5.3 Aboveground Piping Erection R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CP
ipe will be m
arked full length with com
modity code num
ber. Alloy pipe and fittings shall be
additionally color coded. Alloy storage areas shall be clearly identified.
MM
Maintain piping spool identity m
arkings of piping spools fabricated off site. M
MV
erify MTR
's are received and that heat numbers correspond. M
aintain documentation
MM
Verify P
MI requirem
ents are satisfied prior to placement in stock.
MM
SV
erify correct pipe is issued to Contractor.
MM
Monitor in-process erection I.a.w
. drawings. C
lassify and record spool fit problems.
X
S
Ensure face flange protection is m
aintained. X
SM
onitor proper bolt tensioning. X
S
Monitor correct gasket installed.
XS
M
onitor erection to ensure that pipe installations are not subjected to undesirable stress. X
SC
heck pipe drawings to assure latest revision in the field.
XS
Assist C
ontractor to maintain current piping test status.
S
X
Monitor C
ontractor's activities to established quality control practices.
X
Monitor in process pipe erection and transfer of heat num
bers. Verify that N
DE
is performed in
a timely m
anner. Monitor pipe and w
elding traceability including PW
HT, P
MI and H
ardness Testing.
X
5.4 Piping Inspection - Punching R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CFlag deficiencies w
hen not visually obvious. X
E
nter punch lists into data base. X
Check w
ork, noted as complete, on punch lists to assure item
s were corrected.
XInitiate action w
ith Contractor on punching results. A
dd additional discrepancies to punch list. Initial and date punch list for each item
corrected. X
Monitor the C
ontractor's punching activities. X
Verify that punching deficiencies are identified, docum
ented and follow up to verify corrective
action is taken. X
Verify that m
easures are taken to assure ND
E, P
WH
T, PM
I and traceability is completed prior to
pressure testing. X
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 7 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
5.5 Pressure Testing of Piping R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor pressure testing performed by C
ontractor. X
SR
eview draw
ings and specifications to verify pressure test package limits, equipm
ent to be included or excluded, valves opened or closed and test blind locations.
XS
Verify that the m
aximum
allowable test pressure of the w
eakest component w
ithin the system is
not exceeded. X
S
Verify (through N
EW
S) that all N
DE
is complete prior to testing.
S
X V
erify that shop spool/cut sheets are included in test packages and all ND
E, P
WH
T and welder
info is recorded. S
X
Review
Contractor's pressure test package, including m
arked up isometric draw
ings indicating test blind locations, valve position (open/closed) and other inform
ation relating to test. X
S
Monitor preparation of test system
against test package. X
Monitor restoration of the tested system
. X
Monitor C
ontractor's pressure testing and documentation activities.
S
X
Review
test package for completion
SX
Inspect the system prior to testing notifying C
ontractor of deficiencies. Mark P
ressure Test R
ecord, "Ready to Test". N
otify client when acceptable for test. G
ive permission to proceed
with test.
XS
Inspect system under pressure. V
erify test pressure and duration of test. Procure test
acceptance signatures from C
ontractor and QIB
. S
X
When equipm
ent is included in the test, verify that pressure test does not exceed nameplate.
X
S
5.6 Piping Internal Cleaning
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Review
and approve the cleaning and preservation procedures and the limits agree w
ith draw
ings. X
Establish hold points for w
itnessing tests. X
Monitor preparatory and in-process cleaning activities for com
pliance with procedures and
specs.X
S
Coordinate the m
onitoring of Contractor inspection and testing activities.
XS
Verify the C
ontractor is preparing documentation as inspections and tests are being perform
ed. X
S
V
erify that internal cleaning has been accomplished.
XM
onitor the Contractor's quality control activities.
X
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 8 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
Section 6 - ELECTR
ICA
L 6.1 U
nderground Electrical R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
C
Monitor in-process installation of the grounding system
including, grounding rod installation, backfilling. C
olor coding of drawings to track progress.
XS
Witness resistance to earth tests.
X S
M
onitor in-process duct bank and electrical manhole installations.
X
Witness initial testing of shielded cable, i.e,. insulation resistance test of pow
er cable on reels, continuity test of reeled instrum
ent cable. X
S
Inspect cable trench prior to installation of cable. X
Monitor in-process installation of underground cable. Inspect in-process cable pulling.
X
S
Inspect in-process cable splicing. X
S
Witness random
testing of installed underground cable, i.e. insulation resistance test (megger)
cables and DC
hypot medium
and high voltage cables prior to termination.
XS
Inspect installation of cables upon completion of each layer to ensure spacing, labeling, etc. is
correct.X
S
Inspect sand backfill per lift for quality of materials, depth and com
paction. X
SV
erify the Contractor final as-built draw
ings are in conformance.
X
S
Verify that the C
ontractor is preparing documentation concurrent w
ith construction as inspection and testing are perform
ed. X
S
Monitor the C
ontractors' quality control activities.
X
6.2 Aboveground Electrical R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor in-process installation of electrical conduit and cable tray, including welding of supports.
X
Witness initial testing of shielded cable, i.e., insulation resistance test of pow
er cable on reels, continuity test of reeled instrum
ent cable and resistance and continuity on electrical heat tracing cables.
XS
Monitor in-process cable pulling and installation.
XW
itness random testing of installed cable, i.e., insulation resistance test on pow
er and instrum
entation cables, continuity and insulation resistance testing on heat tracing and hypot of m
edium and high voltage cables.
XS
Verify client is being notified in advance of tests that require w
itness. X
S
V
erify terminal to term
inal checks to ensure continuity and correctness of installation. X
S
Verify conduit seals have been poured.
XS
Inspect installation upon completion.
XS
Verify that the C
ontractor is preparing documentation concurrent w
ith construction as inspection and testing are perform
ed. X
S
Monitor the C
ontractor's quality control activities.
X
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 9 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
6.3 Electrical Equipment
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Monitor in-process installation of equipm
ent. X
S
M
onitor equipment preservation activities
XS
Witness testing of installed equipm
ent. X
SC
oordinate with vendor representative w
ho will technically supervise installation. E
nsure docum
entation is complete.
XS
Verify Q
IB is being notified in advance of tests requiring w
itnessing. X
SInspect electrical installation w
hen complete.
XS
Verify that the C
ontractor is preparing documentation concurrent w
ith construction as inspection and testing are perform
ed. X
S
Monitor the C
ontractor's quality control activities.
X
Section 7-CO
NTR
OL SYSTEM
S 7.1 C
ontrol Systems Site Shop O
perations R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CN
otify construction upon receipt of each instrument shipm
ent for inspection. M
M
For nonconform
ing items, issue a D
amage R
eport or NC
R.
MM
Issue instruments to C
ontractor. M
MInspect each instrum
ent shipment. D
eficiencies shall be reported to the Material M
anager. X
Inspect instrument m
aterials i.a.w.sec.10 &
project procedures X
Docum
ent the receiving inspection. X
7.2 Control System
s Field Operations
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Monitor the C
ontractor's in-process instrument installation including racks, panels, consoles,
locations,mounting,process pipe connections, Instrum
ent air tubing,pneumatic signal tubing,heat
tracing and instrument w
iring X
S
Witness pressure testing of the instrum
ent piping and tubing documentation.
X
S
Witness calibration of test guages.
XS
Monitor continuity tests of instrum
ent cables.Verify that cable term
inations are correct. X
SW
itness checks of control system loops. E
stablish notification system for IM
T. X
S
W
itness all loop checks X
S
Assure all instrum
ent installation inspections and meggar tests are com
plete X
S
Inspect instrum
ent installations upon completion.
XS
Monitor the C
ontractor's quality control activities. S
X
Verify docum
entation procedures are being followed.
XS
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 10 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
Section 8 - CO
ATIN
GS, LIN
ING
S, INSU
LATIO
N A
ND
CA
THO
DIC
PRO
TECTIO
N
8.1 Coatings
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Ensure that the paint system
is i.a.w. specifications.
X
S
Monitor perform
ance of materials preservation activities.
XS
Monitor surface preparation.V
erify inspection documentation.
XS
Monitor in-process coatings applications.
XS
Check dry film
thickness of applied coatings. X
SInspect the w
orkmanship of com
pleted finishes. X
SM
onitor the Contractor's quality control activities.
S
X
Verify the C
ontractor has prepared the QC
documentation.
S
X
Audit coating docum
entation. X
8.2 Insulation R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor performance of m
aterial preservation activities. X
Monitor in-process installation of the insulation m
aterials. X
SV
erify the Contractor has prepared the quality control docum
entation X
S
Inspect the com
pleted work.
XS
D
ocument acceptance.
SX
8.3 Linings R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor performance of m
aterial preservation activities. X
S
M
onitor surface preparation. X
S
Verify C
ontractor is performing tem
perature and humidity checks for tank linings.
X S
Monitor in-process lining application.
XS
Test applied linings to verify proper surface profile, thickness, and lining continuity. X
SM
onitor Contractor's tank lining holiday inspections.
XS
Observe tank lining curing activities.
X S
Inspect the w
orkmanship of the com
pleted lining. X
S
M
onitor the Contractor's quality control activities.
S
X
Audit coating docum
entation. X
Verify that lining m
aterials comply w
ith specs. Ensure that m
anufacture test certificates correspond w
ith filed batch number records.
XS
Monitor storage facilities.
XE
nsure refractory applicators are experienced and qualified. X
SM
onitor to ensure materials are properly m
ixed. X
SM
onitor surface preparation to ensure mounting studs and reinforcem
ents are correctly installed. X
S
E
nsure that test plates,cubes,etc,from refractory applications are taken at the required
frequencies X
S
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 11 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
8.4 Cathodic Protection - U
nderground Structures. R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CSubm
it data to Engineering for determination of anode spacing
X (1) E
stablish a procedure to assure work is not started prior to acceptance of previous w
ork. X
Monitor the survey after each cathodic protection system
is energized. X
SV
erify materials being installed.
XM
onitor installation activities. X
S
Monitor deep w
ell preparation activities including data logs. X
Monitor anode backfill operation.
XW
itness hamm
er testing of thermite w
elds X
SW
itness electrical test used to determine current flow
when the anode is backfilled w
ith coke breeze.
XS
Monitor testing and com
missioning activities.
XS
Inspect the completed w
ork. X
S
Audit cathodic protection docum
entation.
X
8.5 Cathodic Protection - Tanks and Vessels
RESPO
NSIB
ILITY A
CTIVITY
Construction
QA
/QC
Verify m
aterials are within specification and are properly protected from
damage.
X
V
erify the vessel cathodic protection materials w
ere installed. X
Monitor installation activities
XS
V
erify personnel use of protective clothing (when reg's)
XInspect the com
pleted workm
anship. X
SM
onitor testing and comm
issioning activities. X
SA
udit cathodic protection documentation.
X
Section 9 - WELD
ING
9.1 Pipe W
elding R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CV
erify the WP
S's have been approved by the W
elding Engineer.
X (1)
S
Monitor qualification tests of C
ontractor's welders.
X
E
nsure that welder ID
badges have been issued and displayed. X
SC
heck Contractors control of w
elder symbols.
XS
Check C
ontractor's control of welding consum
ables. X
SM
onitor in-process welding including consum
ables, joint preparation,fit-up preheat, interpass heat, W
PS
variables and final visual X
S
Verify C
ontractor is documenting w
elds on the Daily W
elding Report.
XS
Verify completed w
elds are being documented on piping draw
ings. X
SM
onitor in-process post weld heart treatm
ent. X
SA
udit welding docum
entation. X
Verify transfer of piping m
aterial heat numbers.
XS
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 12 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
9.2 Structural and Reinforcing Steel W
elding R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CV
erify the WP
S's have been approved by the W
elding Engineer.
X
(1) M
onitor qualification tests of welders.
X
Monitor in-process w
elding including consumables, joint preparation and final visual inspection.
XS
Audit w
elding documentation.
X
9.3 Piping Nondestructive Exam
ination (ND
E) R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CPre-qualify N
DE C
ontractor X
Verify that the N
DE
Contractor has established procedures that com
ply with project
specifications. X
Daily entry of w
eld data to NE
WS
program.
SX
Establish and maintain N
DE docum
entation files.
X R
eview C
ontractor ND
E personnel certifications.
X
V
erify approval of ND
E C
ontractor and procedures. X
Verify N
DE
Contractor's procedure to provide visual status of w
elds requiring ND
E.
X
S
elect welds for exam
ination S
X
Perform
Nondestructive exam
inations N
DE
CO
NTR
AC
TOR
S
Review
radiographic film, C
ontractor's interpretation and reports. X
Verify code com
pliance for rejected welds.
XM
aintain a tickler file of rejected welds.
XV
erify, through audit, welding and N
DE
records are traceable to the weld.
XV
erify through NE
WS
that ND
E is com
pleted prior to pressure testing.
X
Audit the N
DE
lab X
Monitor the N
DE
Contractor's production to verify that w
elds are examined w
ithin 48 hours of notification.
X
Verify all field welds are num
bered and identified on drawings.
XE
nsure that weld num
ber and welder's sym
bols are low stress stam
ped or otherwise m
arked on pipe.
XS
Ensure that an accurate D
aily Welding R
eport is maintained.
SX
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 13 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
9.4 Pipe hardness Testing R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CM
onitor the Contractor to verify w
eld identity system and com
pliance to specification.
X
Establish confidence that tests are being preform
ed i.a.w. test equipm
ent instructions.
X
Verify the C
ontractor's compliance w
ith hardness testing and documentation.
X
V
erify Contractor's procedure for visual identification of rejected w
elds.
X
Maintain a P
WH
T tickler file for rejected welds.
XV
erify hardness testing is complete prior to pressure testing.
XW
itness tests required by the specifications as performed by C
ontractor.
X
Schedule final acceptance inspection activities betw
een the Contractor and the Field E
ngineer.
X
Monitor the C
ontractor's quality control activities to verify conformance to requirem
ents for test frequency, identification and traceability.
X
Section 10 - Field Receiving
10.1 Field Receiving (IM
T) R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CC
ontrol receiving operations including ID of item
to purchase order, verification of quantity and size exam
ination for shipping protection and damage, m
aintenance of inspection docum
entation. M
M
Issuance of periodic receiving reports to Construction S
uperintendents when technical
assistance is required. M
M
Inspect received material/equipm
ent, providing technical assistance, when requested.
S
X
10.2 Field Receiving -C
ontractor R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CR
eceive all contractor purchased equipment and m
aterials M
MR
eview m
aterial test reports against received materials and m
aintain on file M
M
S
Issue equipment and m
aterials to the Contractor
MM
Inspect received material/equipm
ent, providing technical assistance when requested
X
S
Assure that the contractor perform
s the equipment and m
aterial protection as required by m
anufacturers instruction or specification requirements
XS
West Q
urna I 000 509 0040
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1 . . . Page 14 of 14
PM=Procurem
ent Manager
MM
=Material M
anager X
=Primary R
esponsibility S=Secondary R
esponsibility (1) M
ust obtain Engineering Approval
10.3 Positive Material Identification (PM
I) R
ESPON
SIBILITY
AC
TIVITY C
onstruction Q
A/Q
CN
otify QA
of receipt of material requiring P
MI.
MM
Maintain P
MI test results w
ith receiving documentation.
MM
Verify receipt of P
MI reports from
suppliers and fabricators, M
MV
erify Contractor has established a system
to maintain m
aterial ID through receiving, storage,
issue, fabrication and election. X
Implem
ent procedures for PM
I. X
Monitor contractor's m
aintenance of piping material identification.
XS
Perform
PM
I as required by specification. X
Verify ID
marking are accom
plished per specification. X
SV
erify controls have been established to prevent the in advertent use of materials failing
examination.
SX
Verify the filing, m
aintenance and retention of documentation.
XA
ssure that PM
I equipment is calibrated.
X
Section 11 - EQU
IPMEN
T AN
D M
ATER
IAL PR
OTEC
TION
11.1 Equipm
ent and Material Protection
RESPO
NSIB
ILITY A
CTIVITY
Construction
QA
/QC
Monitor equipm
ent and material preservation in storage and docum
ent. M
M
S
11.2 Equipment and M
aterial Protection (Contractor)
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Monitor C
ontractors in-process equipment and m
aterial protection/preservation activities. X
SC
heck Contractors in-process equipm
ent and material
XS
Audit the C
ontractor Material and equipm
ent protection activities. X
Section 12 - Masterpiece Program
12.1 M
asterpiece Program
RESPO
NSIB
ILITYA
CTIVITY
Construction
QA
/QC
Develop M
asterpiece List X
S
Ensure C
ontractor is using correct materials, draw
ings and specifications X
S
A
dvise contractor when a M
asterpiece is required X
SInspect M
asterpiece prior to QA
notification X
SR
equest client's presence during inspection S
XD
ocument acceptance of the M
asterpiece S
X N
otify client of accepted Masterpiece
SX
Maintain the M
asterpiece log X
Maintain M
asterpiece model as reference standard
XS
Monitor the C
ontractor's quality control activities to verify conformance to draw
ings and specifications
X
West Q
urna I 000 509 0050
Contract N
o: W3Q
R
15 April 11Project Location: Basra, Iraq
Page 1 of 3
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
DO
CU
MEN
T CO
NTR
OL
SCO
PE
The Project Procedures Manual describes the D
ocument C
ontrol system to be used by site
construction personnel.
GEN
ERA
L
Engineering Docum
ents
- D
esign Engineering documents such as specifications and draw
ings that are issued to C
onstruction are controlled and issued on site in accordance with this procedure.
Construction Engineering m
aintains an up-to-date register of drawings and
specifications.
- Please see the Project Procedures M
anual, Sect. 15.4.4 Project Docum
ent and Data
Managem
ent (PDD
M) at the Site for specific details.
Request For Inform
ation
- D
esign documents, including draw
ings and specifications, sometim
es have discrepancies, conflicting inform
ation, or missing inform
ation. When field conditions
dictate changes to the design specifications and/or drawings, a R
equest For Inform
ation (RFI), Form
000 509 F00501, will be subm
itted for approval to ensure proper control and docum
entation. RFIs w
ill be initiated by the Construction
Engineering Manager w
ho will m
aintain a RFI Log, Form
000 509 F00502.
- Please see the Project Procedures M
anual, Sect. 11.4.2 for specific detail for this procedure.
Specification Deviation
- If the R
FI is written to request a deviation from
a specification then a SpecificationD
eviation Request (SD
R) Form
shall be initiated by the Fluor Field Engineer. This requires D
esign Engineering and Client Approval before the deviation can be
approved. Reference the Fluor Engineering Procedure, Section 8 of the Project
Procedures Manual.
As-B
uilt Draw
ings
- Subcontractor prepared field sketches and "as-built" draw
ings originating at the construction site shall be docum
ented and controlled.
- Please see the Project Procedures M
anual, Sect 11.5 for specific details.
West Q
urna I 000 509 0050
Contract N
o: W3Q
R
15 April 11Project Location: Basra, Iraq
Page 2 of 3
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
Material/Equipm
ent Docum
ents
- D
ocuments related to m
aterials, materials receiving and issue are controlled in
accordance to procurement procedures.
Quality C
ontrol Docum
ents
-D
ocuments and data identified as quality records are processed, retained and protected
as described in 000 509 0160 "Quality R
ecords". Primary responsibility for ensuring
adequate control of quality related documents rests w
ith the Site Quality M
anager.
DO
CU
MEN
T AU
DITS
Construction Engineering M
anager
- D
etermine docum
ent audit plan and schedule audits. A minim
um of 5%
of documents
issued to the document holder w
ill be randomly selected for the audit sam
ple. The num
ber of document holders to be audited w
ill be determined by the C
onstruction Engineering M
anager.
Docum
ent Control
-U
sing a printout or list of documents and current revisions, com
pare documents and
revisions held by document holders and note any discrepancies. N
otify the C
onstruction Engineering Manager of m
ajor discrepancies.
Construction Engineering M
anager
- For m
ajor discrepancies identified by Docum
ent Control audits of docum
ents, investigate and provide recom
mended resolution.
Revision C
ontrol of the Site Quality M
anual
- Site Q
uality Manager
- R
evision dates for all pages of all procedures in the manual should m
atch the dates in the Table of C
ontents.
- The Site Q
uality Manager, C
onstruction Engineering Manager, Site M
anager and the C
lient (optional) will approve each revision by signing the "Approval Page".
- Forw
ard the approved revision and affected documents to D
ocument C
ontrol for m
aintenance and distribution to all manual holders.
West Q
urna I 000 509 0050
Contract N
o: W3Q
R
15 April 11Project Location: Basra, Iraq
Page 3 of 3
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
REFER
ENC
ES
Project Procedures Manual - Sections 8,11, and 15 for PD
DM
Procedures
Quality C
ontrol Forms:
000 509 F00501 R
equest For Information
000 509 F00502 - Request For Inform
ation Log
ATTA
CH
MEN
TS
Attachment 1 R
equest For Information (R
FI) Form Instructions
West Q
urna I 000 509 0050
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Attachment 1 . . . Page 1 of 2
Request for Inform
ation (RFI) Form
Instructions
Project N
ame:
The P
roject Nam
e (i.e. West Q
urna I)
Project #:
The P
roject Num
ber (i.e. W3Q
R)
Date:
The date the R
equest is originated.
RFI #:
U
nique number given to each individual R
FI Form.
WB
S:
W
ork Breakdow
n Structure unique to the P
roject, if applicable
Work P
ackage No.:
C
onstruction Work P
ackage number, if applicable.
Turnover/Startup S
ystem N
o.: Turnover/S
tartup system num
ber, if applicable.
Discipline:
P
rimary discipline affected by the R
equest (Civil, S
tructural, Piping etc.)
Request To:
E
nter Nam
e of Individual submitted to (John D
oe)
Com
pany/Location
Enter N
ame of C
ompany and its location of the requested organization
(Fluor-Houston)
Phone N
umber/E
E
nter phone number of the individual subm
itted to and/or email address
Subject
E
nter the subject of the request
Specifications/D
ocuments:
List all issued drawings, docum
ents, and specifications impacted by the
request.
Questions/D
escription/Conflict:
Detail the m
issing information, discrepancies, questions or conflicts that
must be resolved prior to construction activities continuing in the affected
areas. Attach additional sheets, draw
ings, or sketches, if further explanation is required.
Recom
mended S
olution: Indicate the action that the requestor believes is required to provide an acceptable solution to resolve the discrepancies and conflicts indicated on the request. A
dditional sheets, sketches, digital photos or drawings
may be attached to provide a clear explanation of the intended
resolution.
Originated B
y: The person originating the request and provided recom
mended action.
Title: List the current position of the originator on the project.
Date:
The date the request is submitted for approval.
Originators C
ompany N
ame
List Com
pany name of the originator
Approval For O
riginator By
List name of Fluor person approving the request for subm
ission to the E
ngineer of Record (G
enerally, the Fluor Site E
ngineering Manager w
ill receive the request and approve its subm
ission to the Design E
ngineer.)
Title: List the current position of the approver.
Date:
The date the request is approved for submission
West Q
urna I 000 509 0050
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Attachment 1 . . . Page 2 of 2
Date R
eply Required:
Enter the date in w
hich the resolution of the request must be m
ade in order not to delay the activities in question
Response
The respondents resolution (generally the Design Engineer, P
roject E
ngineering Manager, C
M, or Fluors C
onstruction Engineering
Manager) to the question, inform
ation, discrepancy, or conflict.
Respondent:
The signature of the person making the response. (Lead C
onstruction D
iscipline Engineer, C
onstruction Engineering M
anager or Design Lead
Discipline E
ngineer, etc.)
Title: List the current position of the A
pprover on the project.
Date:
The date the request is approved for transmittal to the D
esign Engineer.
Approval for R
espondent: The signature of the person review
ing and approving the request prior to im
plementation. (This action m
ight require Client approval. If the
response changes the design (IFC D
rawings or S
pecifications) the E
ngineer of Record m
ust approve the resolution.)
Title: List the current position of the A
pprover on the project.
Date:
The date the request is approved for implem
entation by the Client or
Project E
ngineering Manager or designee.
Adequate C
losure? Indicate using the checkbox if the R
FI response is acceptable for closure of the R
FI. Generally, the C
onstruction Engineering M
anage must
respond to this question.
Cost Im
pact? Indicate using the checkbox if the R
FI response has a cost impact that
will require an estim
ate or a request for contractor pricing. If the answer
is yes, indicate the requirement for a S
I to be issued to the Contractor.
Schedule Im
pact? Indicate using the checkbox if the R
FI response has a schedule impact
that will require an adjustm
ent in the contract schedule or a request for contractor pricing. If the answ
er is yes, indicate the requirement for a S
I to be issued to the C
ontractor
Closed R
FI and Date V
erified: Inter the nam
e and date the RFI w
as closed and verified.
Distribution:
List all parties requiring a copy of the completed request once the
response has been received.
West Q
urna I 000 509 0090
Contract N
o: W3Q
R
15 Aug 10Project Location: Basra, Iraq
Page 1 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
PRO
CESS C
ON
TRO
L
SCO
PE
This procedure identifies construction work processes that require process control.
GEN
ERA
L
For most site production activities, the draw
ings and specifications provide adequate work
instruction. These may be supplem
ented with additional instructions to control w
ork sequencing, recording of installation data, m
aterial selection, etc. How
ever, certain construction work
processes require special instructions to establish the controls necessary to achieve acceptable quality, of the com
pleted work, for the follow
ing reasons:
Q
uality results of the completed w
ork cannot be fully verified by subsequent inspection and/or testing.
Q
uality deficiencies may only becom
e 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 follow
ing control m
easures.
x W
ritten Method Statem
ent or Procedure x
Procedure Qualification
x O
perator Qualification
x In-Process Inspection
Special processes encountered on sites include, but m
ay not be limited to:
x W
elding and Post Weld H
eat Treatment
x W
elder Qualification
x N
ondestructive Examination (including radiography, m
agnetic particle, liquid penetrant, ultrasonic, and positive m
aterial identification VT, RT, M
T, PT, UT, and PM
I)
Special processes identified m
ust be accomplished and docum
ented under controlled conditions by appropriately qualified personnel using approved procedures and equipm
ent in accordance w
ith the governing specifications and the associated referenced codes and standards.
West Q
urna I 000 509 0090
Contract N
o: W3Q
R
15 Aug 10Project Location: Basra, Iraq
Page 2 of 2
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
PRO
CED
UR
E
Site Quality M
anager
The Site Quality M
anager shall coordinate with the C
onstruction 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 mechanism
s, i.e. procedures, qualifications, etc. are specified in the RFP
and implem
ented before the start of work. Process control m
easures and responsibilities shall be identified on the applicable procedures or ITPs.
West Q
urna I 000 509 0110
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 1 of 4
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
INSPEC
TION
, MEA
SUR
ING
AN
D TESTIN
G EQ
UIPM
ENT
SCO
PE
This procedure describes the methods to be used for the control, calibration, m
aintenance and recall of inspection, m
easuring and test equipment (IM
TE) used to demonstrate conform
ance of construction w
ork activities to the specified requirements. It is not applicable to calibration of
permanent plant devices.
GEN
ERA
L
Inspection, measuring and test equipm
ent (IMTE), including test softw
are, shall be selected, calibrated and controlled in a m
anner which is consistent w
ith the required inspection, testing and exam
ination requirements.
Environmental conditions shall be suitable for the calibrations, inspections, m
easurements and
tests being carried out.
All IMTE shall be uniquely identified. This unique identification m
ay consist of a manufacturer's
unique serial number along w
ith model num
ber and/or the assignment and application of a unique
Inventory Control N
umber (IC
N).
The handling, preservation, and storage of inspection, measuring and test equipm
ent shall be such that the accuracy and fitness for use is m
aintained.
All calibrations shall be performed using certified equipm
ent having a known valid relationship to
nationally recognized standards; where no such standards exist, the basis used for calibration
shall be documented.
"Conform
ance check" means the operations required to ensure that an item
of measuring
equipment is in a state of com
pliance with requirem
ents for its intended use.
Non-adjustable m
easuring and test equipment is not considered as calibrated equipm
ent. Equipm
ent of this nature (e.g. cube and proctor molds, m
easuring tapes, rulers, chains) is subject to a "conform
ance check" to dimensional, volum
etric or other requirements and does not require
any further verification unless apparent damage or other factors require re-verification.
It is the responsibility of the end-user to comply w
ith the requirements of this section.
IMTE shall be selected utilizing Attachm
ent I "Criteria for the Selection of Inspection, M
easuring and Testing Equipm
ent" and Attachment II shall be used for guidance in procurem
ent of calibration equipm
ent and/or services.
All IMTE calibration requirem
ents shall be identified, on Attachment 3 IM
& TE Calibration
Requirem
ents List. This attachment is used to list the various types of IM
TE in use and their
West Q
urna I 000 509 0110
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 2 of 4
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
associated calibration frequencies, calibration procedures and tolerances. Calibration procedures,
frequencies, and tolerances may be obtained in conjunction w
ith obtaining the services of an outside calibration vendor or from
manufacturers. A procedure num
ber shall be assigned. If the m
anufacturer has an assigned number, this should be used. C
alibration procedures are quality records and shall be m
aintained in site files.
Procedures such as published standards, practices (e.g., ASTM) or w
ritten calibration instructions from
the manufacturer m
ay be used. In the absence of either a published standards practice or an adequate m
anufacturer's procedure, a written procedure for the calibration m
ethod shall be w
ritten and approved for use.
In addition to the above, calibration procedures should include at least the following basic
information:
x Identity of the item
to be calibrated using the procedure.
x C
alibration comparison standards and calibration support equipm
ent to be used.
x Provisions to obtain and record "as-found" accuracy m
easurement prior to any
adjustments.
x Sequence of operations.
x C
hecks, tests and measurem
ents instructions.
x C
alibration acceptance tolerances.
x C
alibration adjustment instructions.
x Safety considerations.
x Special instructions (w
hen applicable).
x D
ocumentation and labeling instructions related to the specific item
to be calibrated.
Perform and record (Form
000 509 F01104) the calibration in accordance with the above
established calibration procedures and/or contract the services of an outside calibration services vendor.
Upon com
pletion of initial calibration, enter the equipment in the C
alibration Assignment Log
(Form 000 509 F01101) and record other data required by this log.
West Q
urna I 000 509 0110
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 3 of 4
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
History of U
se
The end user shall maintain a history of use for IM
TE to enable an assessment of the validity of
previous calibrations, inspections, measurem
ents and test results when calibration as-found data
reveals out-of-tolerance data points.
The history shall be documented using IM
TE Sign In/Out-H
istory of Use Log (Form
000 509 F01102) and keep current to record each usage of the IM
TE.
If out of tolerance conditions are found, a Nonconform
ance Report shall be prepared in
accordance with 000 509 0130.
If out-of-tolerance conditions are found during recalibrations an evaluation shall be conducted to determ
ine if inspection, measurem
ent, test or calibration results obtained with the out-of-tolerance
instrument are still valid.
Evaluations shall be documented, and w
here required, repetitions of readings shall be compared
to original results.
It is the responsibility of the end user to use calibrated equipment w
ithin the environmental
operating range(s) or restrictions/limitations specified by the instrum
ent manufacturer.
NO
TE: Temperature or other com
pensating calculations shall be applied to any inspection, m
easurement, test or calibration results w
hen such compensations are specified by the
instrument m
anufacturer and/or when they can affect the basis of the results obtained.
Upon satisfactory com
pletion of calibrations, and after the recalibration due date has been determ
ined (calculated), the end user shall make entries on the "C
alibrations Tickler File" (Form
000 509 F01103) to aid in the tracking and recall of items for scheduled recalibration.
DO
CU
MEN
TATIO
N
Electronic recording of the information that is required by the docum
entation in this procedure is perm
issible. All documents (except labels) generated in accordance w
ith this procedure should be m
aintained in appropriate protected files throughout the construction phase of the project, and for the period of tim
e there after specified (if any) or turned over to the Client if required.
West Q
urna I 000 509 0110
Contract N
o: W3Q
R
15 Apr 11Project Location: Basra, Iraq
Page 4 of 4
Fluor Corporation C
ompany C
onfidentialSite Q
uality Manual
FOR
MS
Quality Support Form
s:
000 509 F01101 -
Calibration Assignm
ent Log and Record
000 509 F01102 -
IMTE Sign In/O
ut-History of U
se Log
000 509 F01103 - C
alibration Tickler File
000 509 F01104 - C
alibration Data Sheet
Note: O
r Com
pany Approved Equivalent forms m
ay be used to control IMTE.
ATTA
CH
MEN
TS
Attachment 1
- C
riteria for the Selection of Inspection, Measuring and Test Equipm
ent (IMTE)
Attachment 2
- C
riteria for Procuring Calibration Services
Attachment 3
- IM
& TE Calibration R
equirements List
West Q
urna I 000 509 0110
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 1. . . Page 1 of 1
CR
ITERIA
FOR
THE SELEC
TION
OF IN
SPECTIO
N,
MEA
SUR
ING
AN
D TESTIN
G EQ
UIPM
ENT (IM
TE)
1. IM
TE includes inspection, measurem
ent and/or testing equipment used to determ
ine final acceptance.
2. IM
TE shall have a manufacturer's stated accuracy (and precision, w
here applicable)
that exceeds the construction installation inspection, measurem
ent and/or testing tolerance(s).
3. IM
TE shall have the durability, stability and appropriate measurem
ent ranges
consistent with the intended use(s).
4. C
alibration standards that will be required for the initial and subsequent recalibrations
shall be identified w
hen selecting IMTE. Such calibration standards shall be
requisitioned or the services of a calibration facility w
ith the calibration standards shall be contracted.
NO
TE: Obtaining calibration standards or services can usually require m
ore time to
procure than the time required to select and procure the needed IM
TE.
5. Purchase requisitions for IM
TE, calibration standards, and calibration facility services
should clearly state the requirements for accuracy, precision (w
here applicable), range, durability and/or stability, environm
ental, handling, other applicable technical requirem
ents.
West Q
urna I 000 509 0110
Contract N
o: W3Q
R
15 Apr 2011Project Location: Basra, Iraq
Attachment 2 . . . Page 1 of 1
CR
ITERIA
FOR
PRO
CU
RIN
G C
ALIB
RA
TION
SERVIC
ES
The following are recom
mended guidelines for preparing a purchase order for obtaining the
services of a calibration supplier to calibrate Inspection, Measuring and Test Equipm
ent (IM&TE).
1. The follow
ing information should be provided to the supplier:
a)
description and unique identification of each piece of IM&TE;
b)
assigned calibration interval;
c) calibration accuracy required;
d)
any relevant environmental requirem
ents of use or calibration.
2. The calibration supplier m
ust provide the following inform
ation as part of their calibration records:
a)
source of calibration equipment used and current certificate(s) of traceability to a
recognized national standard;
b) identification of the calibration procedure(s) used (if the procedure is produced by the calibration supplier, a copy m
ust be furnished, if a recognizable standard i.e. ASTM,
ANSI/ASM
E, is used no copy is needed).
3. The calibration records supplied by the calibration supplier for each item
of IM&TE calibrated
must include:
a)
item identification num
ber;
b) date of calibration;
c)
the records of the "before", "as received" or "as found" condition including actual values and the "as calibrated" or "as left" values;
d)
identification of the calibration procedure used;
e) lim
its of permissible error;
f)
calibration standard used (including serial numbers and certificates) and traceability;
g)
details of any maintenance, servicing, adjustm
ent, repairs or modifications carried out;
h)
identification of person performing the calibration;
i)
identification of person responsible for the correctness of the information provided.
4. The calibration supplier shall seal, using a unique, tam
per-resistant system, all adjustm
ent access points after calibration, w
here practical. The system