ATTACHMENT F ENGINEERING, PROCUREMENT AND …

City of Coffeyville

C8220 Foundations and Underground Utilities

ATTACHMENT F

ENGINEERING, PROCUREMENT AND CONSTRUCTION MANAGEMENT

QUALITY PLAN

Generation Facility No. 2

Engineering, Procurement,

Construction Management Quality

Plan

Rev No. Issue Date Description Prepared by: Approved by:

A 4/1/2015 Draft Steven E. McKenna Anthony Decker Chris Guggino

B

EPCM Quality Plan

COC EPCM Quality Plan i 4/1/2015

TABLE OF CONTENTS

1.0 INTRODUCTION ......................................................................................................... 1-1 1.1 Purpose & Scope .............................................................................................................. 1-1 1.2 Quality Policy .................................................................................................................. 1-1 1.3 Quality Objectives ........................................................................................................... 1-1

2.0 QUALITY PLAN FOR ENGINEERING ........................................................................ 2-1 2.1 Q1 Review ....................................................................................................................... 2-1 2.2 Q2 Review ....................................................................................................................... 2-1 2.3 Q3 Review ....................................................................................................................... 2-2 2.4 Q4 Review ....................................................................................................................... 2-2 2.5 Q5 Review ....................................................................................................................... 2-3 2.6 Q6 Review ....................................................................................................................... 2-4 2.7 Q Review Document Management System ..................................................................... 2-5

3.0 QUALITY PLAN FOR CONSTRUCTION .................................................................... 3-1 3.1 Organization ..................................................................................................................... 3-1 3.2 Document Control ............................................................................................................ 3-1 3.3 Material Management ...................................................................................................... 3-1 3.4 Measure and Testing Equipment ..................................................................................... 3-2 3.5 Construction Quality Verification and Acceptance ......................................................... 3-3 3.6 Turnover Packages ........................................................................................................... 3-7 3.7 Non-Conformance Control .............................................................................................. 3-7 3.8 Corrective and Preventative Action ................................................................................. 3-8

4.0 ENGINEERING QUALITY RECORDS ........................................................................ 4-1

5.0 QUALITY VERIFICATION PROCEDURES ................................................................. 5-1

6.0 QUALITY VERIFICATION CHECKLISTS ................................................................... 6-1

7.0 CONSTRUCTION FORMS .......................................................................................... 7-1

COC EPCM Quality Plan 1-1 4/1/2015

1.0 INTRODUCTION

1.1 Purpose & Scope This document describes the processes utilized by City of Coffeyville, KS (COC) to control and improve the

quality of services and deliverables for the Generation Facility No. 2 (GFNo2).

1.2 Quality Policy Contractors will strive to provide services which satisfy all contractual and regulatory requirements, with an

additional focus on internal and external customer expectations.

All contractors are expected to perform their responsibilities in accordance with the applicable quality

requirements, and to strive for customer satisfaction and continuous improvement. Maintaining high degrees of

quality, integrity, and responsiveness are core values at COC.

1.3 Quality Objectives All quality verifications, inspections, and reporting are intended to verify compliance with Quality standards. The

processes described in the GFNo2 Engineering, Procurement, and Construction Management Quality Plan will

also result in identifying where quality is not being achieved on isolated and repetitive tasks. Repetitive issues

require a heightened vigilance with training, greater management, improved execution, and verification of the

work specific to the recurring issue. Quality, integrity, and personal accountability are core values at COC.


2.0 QUALITY PLAN FOR ENGINEERING

The Burns & McDonnell Project Management Team will follow Burns & McDonnell’s standard quality control

procedures for the Project’s design-related activities. This process will take each project design through six steps

to ensure each stage is well documented and adequately reviewed.

Below are the six levels of the Engineering Quality Review Process:

2.1 Q1 Review The purpose of the Q1 conceptual design review is to determine that Project requirements will be met and those

project requirements are defined so that the project team clearly understands the scope and limitations of services.

The Q1 review is not intended to include detailed technical aspects of the project.

2.1.1 Scope The scope of the Q1 Review encompasses review completion of typical preliminary project activities (see Q1

Review Form), typically one review per project.

2.1.2 Independent Reviewers The Project Manager will assign team of independent reviewers.

2.1.3 Q1 Verification The Engineering Manager is responsible for verifying Q1 Reviews are completed and comments are resolved.

2.1.4 Q1 Monitoring The Chicago Regional Office Energy Quality Manager shall be responsible for monitoring implementation and

effectiveness of Q1 Reviews.

2.2 Q2 Review The purpose of the Q2 review is to determine that the various technical systems of all disciplines which have been

developed to implement requirements that are appropriate and compatible and that each individual system is

represented by sufficient technical concepts, layout, and criteria and detail so final contract documents may be

developed from the basic design with minimum supervision.

2.2.1 Scope This scope of the Q2 Review encompasses review completion of typical intermediate project activities (see Q2

Review Form), typically one review per Engineering discipline.

Quality Plan for Engineering


2.2.2 Independent Reviewers The Project Manager will assign independent reviewers.


2.2.4 Q2 Monitoring The Chicago Regional Office Energy Quality Manager is responsible for monitoring implementation and


2.3 Q3 Review The purpose of this review is to verify that the design has been correctly interpreted and transferred correctly to

specifications and drawings. An initial review is done by the engineer responsible for the design. Following this,

the applicable documents are routed for independent review.

2.3.1 Scope The scope of the Q3 Review encompasses checking/cross-checking of all design documents in design packages.

This review is performed for every Design Package prior to first formal use on the project. Each review is

repeated to check any design changes made after initial review.

2.3.2 Independent Reviewers The engineer responsible for the design shall make the initial review.

2.3.3 Q3 Verification The Engineer Manager is responsible for verifying Q3 Reviews are completed and comments are resolved.



2.4 Q4 Review The purpose of the Peer Review is to perform a detailed checking of the design packages.



2.4.1 Scope The scope of the Q4 Review encompasses a secondary independent peer review of each design packages. This

review is performed for every Design Package prior to first formal use on the Project. Key areas required to be

checked:

1. Perform a detailed check of the engineer’s calculations and related drawings to insure that they were

done in accordance with the project specifications, appropriate codes and standards and are

mathematically correct.

2. Perform a detailed check of the design drawings to insure that:

A. Drawings are consistent with the project scope and specifications.

B. Drawings are dimensionally correct.

C. Drawings are consistent with the, layouts and other basic definition documents

D. Drawings are consistent with submittal information.

E. Drawings are consistent with other discipline documents.

2.4.2 Independent Reviewers The Department Managers or Engineering Manager shall assign reviewers.




2.5 Q5 Review The purpose of the Q5 review is to assure commercial documents for purchasing and construction contracts are

complete with regard to legal requirements for the work intended.

2.5.1 Scope The scope of the Q5 Review encompasses a review of contractual/legal procurement front-ends to be used with

purchase orders and contract packages.



2.5.2 Responsibility Construction Design-Build will provide all flow-downs from the prime contract to be incorporated into the

standard Construction Agreement or Purchase Order. The EPC Project Manager shall review and approve all flow

downs.

2.5.3 Q5 Verification Whenever modifications to the contract or purchase order potentially compromise the standard agreements, the

EPC Project manager shall review and approve such changes. If required, the EPC Project Manager or designee

shall engage the Legal Department in Q5 Review monitoring.

2.5.4 Q5 Monitoring The CDB Quality Manager is responsible for monitoring implementation and effectiveness of Q5 Reviews.

2.6 Q6 Review This is a Review of Procurement, Contract, and Subcontract (P/C/SC) Packages for Equipment, Materials, and

Construction Services. The purpose of this review is to insure the following:

1. The construction package (which is usually a combination of several different disciplines) is a

consistent, understandable document.

2. The concept of construction, installation and installation details are consistent with good construction

practice.

2.6.2 Scope The scope of the Q6 Review encompasses a review of P/C/SC packages (Design Package + General

Requirements + Contractual/Legal Documents). This review will be performed for every P/C/SC package prior to

submitting to first formal use.

2.6.3 Reviewer Assignment The Construction Project Manager should assign reviewers.

2.6.4 Q6 Verification The Construction Project Manager is responsible for verifying Q6 Reviews are completed and comments are

resolved.



2.6.5 Q6 Monitoring The CDB Global Practice Quality Manager is responsible for monitoring implementation and effectiveness of

Q6 Reviews.

2.7 Q Review Document Management System The Burns & McDonnell Quality Tracker System (QTS) shall be employed for generating, recording, and storing

all Q review forms.


3.0 QUALITY PLAN FOR CONSTRUCTION

The responsibility for Quality Control shall be upon every member of the Project Site personnel. At no point shall

quality be compromised for the sake of production. This Quality Plan has been developed specifically for the City

of Coffeyville, KS recip project. This plan addresses construction, material fabrication, material receiving, and

material handling.

3.1 Organization All verification personnel will be fully qualified in the particular discipline for which they are responsible.

3.2 Document Control Quality documents are defined as documents that specify design, testing, and inspection information such as

technical specifications, design drawings, material test reports, testing and examination reports, Punch-out Phase

punch lists and Non-conformance Reports.

Resident Project Representatives will perform Document Control Audits on a random basis.

Contractor Quality records will be delivered to Resident Project Representative as project progresses and are

completed. Resident Project Representative will collect and store these Quality records at field office. The Quality

records will be placed into their defined System Turnover Package for traceability. COC will have access to these

Quality records for review at any time requested. The hard copies will be stored onsite until final completion of

the project.

3.3 Material Management

3.3.1 General 1. Materials management activities include the receipt, identification, storage, and maintenance of

materials at the jobsite.

2. Materials include equipment, parts, components, assemblies, and construction materials.

3. Materials management activities will be performed by Contractors.

3.3.2 Receiving 1. Materials will be checked upon receipt to verify the following:

A. Quantities are correct.

B. Labels or tags specify the correct information.

C. Items were not damaged during shipment.

Quality Plan for Construction


2. Additional inspections will be made at the time of receiving when required for a particular material.

3. Material receipts will be documented. Additionally, any items found to be unacceptable or incorrect

upon receipt will be identified and documented for disposition.

4. Documentation received with material deliveries (e.g. operating manuals, installation instructions,

material certifications, etc.) will be identified and stored in accordance with project procedures.

3.3.3 Storage 1. Materials will be stored in designated areas.

2. Materials will be stored in accordance with specification requirements and manufacturer’s

recommendations to prevent damage or degradation prior to use.

3.3.4 Maintenance 1. Materials will be maintained in accordance with specification requirements and manufacturer’s

recommendations.

2. A Material Maintenance Log will be prepared for each material or material group to specify the

required maintenance activities and the schedule for performing the activities.

3. Maintenance activities will be documented on the Maintenance Log and supplemental reports when

applicable.

3.4 Measure and Testing Equipment

3.4.1 Equipment Measuring and test equipment shall be of the proper type, range and accuracy, and shall be checked for accuracy

at established intervals.

3.4.2 Calibration Intervals The Contractor’s QA/QC Manuals shall establish the intervals or amount of use between calibration checks based

on instrument stability characteristics, intended use and, where applicable, Code requirements.

3.4.3 Calibration Identification Each controlled instrument shall be identified with a unique control number and a calibration label indicating the

calibration due date. Instruments requiring calibration checks shall not be used until calibrated. Doubtful or

damaged equipment shall be rechecked for accuracy prior to use.



3.4.4 Custodial Control and Care 1. Contractors shall be responsible for the receipt, storage and control of measuring and testing equipment

(M&TE) at Site locations.

2. M&TE logs, as well as a calibration records file, shall be maintained at each project by the Contractor’s

Quality Control Representative. The log shall indicate the M&TE requiring calibration, serial number

of the M&TE, initial calibration due date, frequency of recalibration, the date the M&TE is returned or

transfers to another location and the location of transfer.

3. Upon receipt of M&TE at any location (whether new or transferred), Contractors shall: assign a control

number (new M&TE only – if not assigned by the manufacture); verify the M&TE’s calibration status;

apply a calibration label (if applicable); enter the calibration record into the calibration records file,

and; add the equipment to the M&TE Log.

3.4.5 Calibration Checks and Records 1. Calibration checks shall be performed by an independent calibration agency using reference standards

or devices which have a known valid relationship to national standards, where such standards exist.

2. Calibration checks shall be documented on a certificate of calibration, or other suitable certification,

attesting to the use of a nationally recognized standard. A certification sticker or label, with the

calibration date and calibration due date, including the initials of the technician performing the test,

shall be attached to the test equipment permanently.

3. Resident Project Representative will verify that appropriate calibration records are being maintained by

all Contractors and that the records are available when requested.

3.5 Construction Quality Verification and Acceptance

3.5.1 General Each Contractor is responsible for developing and implementing an effective quality control system to ensure that

construction activities are performed in accordance with the applicable specification requirements. The

Contractors are responsible for performing quality control inspections of their work.

3.5.2 Contractor Quality Control System The Contractor shall submit their quality control manual with quality records to Resident Project Representative

for review and approval. If the Contractor’s quality control system does not meet the minimum requirements set

forth in this Quality Plan, then Contractor may adopt this manual as their Quality Plan or resubmit a revised

Quality Plan that is acceptable to COC.



The Contractor will establish witness and hold points for each inspection operation and activity. The Inspection &

Test Plans (ITP’s) will incorporate all COC’s requested inspection and hold points. The ITP’s will be reviewed

prior to starting work activities. If the Contractor does not have sufficient ITP’s then the Contractor shall adopt

COC’s CF-014 Inspection Matrix.

3.5.3 Quality Verifications, and Testing Site Personnel will perform all field quality-related verifications and testing as required by this Quality Plan, and

the Contract Specification requirements.

• Resident Project Representative will monitor the quality of the Contractor’s work in phases through

document review, preparatory meetings, and random inspections of the construction work. The

inspections may be performed by using third party inspectors and laboratories, superintendents, or quality

assurance personnel. General activities associated with each phase are specified in the following sections.

3.5.4 Document Review Resident Project Representative will review and/or approve the Contractor’s documents which are required to be

submitted per the Contract Documents. Resident Project Representative will verify all necessary documents are

approved prior to starting a particular work activity.

3.5.5 Preparatory Meetings Resident Project Representative will hold a preparatory meeting with each major Contractor. The preparatory

meeting will include the following items:

1. Review of the Contract scope of work.

2. Review of the Contract Specifications with regard to materials, welding, erection, installation, testing,

coatings, handling, documentation, etc.

3. Review of the requirements associated with the quality verification activities to be performed by the

Contractor during the course of construction.

4. Review of the requirements specified on the construction documents.

5. Verify the Contractor has a written quality control program fully addressing all of the above

requirements.

6. Review of all necessary Contractor submittals required prior to mobilization.



Resident Project Representative will document the items discussed during the meeting in a written report. Any

items that require further action will be identified along with the party responsible for resolving the issue and the

due date. Reports shall be distributed in accordance with project procedures.

3.5.6 Initial Inspection Resident Project Representative will perform an Initial Inspection early in the start of each major work activity to

verify that the Contractor is fulfilling their responsibilities with respect to the quality control requirements. The

Initial Inspection will include the following activities:

1. Verify any action items identified during the Preparatory Meeting were resolved.

2. Inspect the initial work performed by the Contractor to verify the Contractor’s work is in accordance

with the requirements specified in the Quality Assurance Manual and any pertinent Contract

Documents.

3. Verify the Contractor is implementing their quality control procedures at the jobsite.

4. Prepare a report documenting the specific activities performed during the Initial Inspection, and

identify any items of non-conformance or other items of concern for follow-up and resolution.

3.5.7 Follow-Up Inspections Resident Project Representative will perform Follow-up Inspections of the Contractor’s work on a random basis

after the Initial Inspection and through the completion of the work activity. The frequency and extent of Follow-

up Inspections will be based on the scope of work, and the Contractor performance. The Follow-up Inspections

will include the following activities:

1. Verify any non-conformances or action items identified during the Initial Inspection or a previous

Follow-up Inspection have been resolved. Work should not be proceeding where non-conformances

have been identified but have not been resolved, unless an approved work-around plan is in place.

2. Inspect a representative sample of work performed by the Contractor since the Initial Inspection or

previous Follow-up Inspection to verify conformance with the requirements specified in the contract

documents.

3. Verify that the Contractor is implementing their quality control procedures at the jobsite.

4. Prepare a report documenting the specific activities performed during each Follow-up Inspection, and

identify any items of non-conformance or other items of concern for follow-up and resolution



3.5.8 Final Inspection Resident Project Representative will perform final inspections on a random basis at or near the completion of

work activities or pre-defined increments of the work activities. These inspections will include the following

items:

1. Perform final inspections of any work performed by the Contractor found deficient during the Initial

and Follow-up Inspections. Verify all work is in compliance with the specifications and most current

drawing revision at the time of final inspection.

2. Prepare a report documenting the specific activities performed during each Final Inspection. From the

inspection, develop a punch list of all items found to be incomplete or not in compliance with the

Contract Documents, referenced specifications, and the latest drawing revision at the time of the

inspection. This would include any outstanding items of non-conformance or action items identified

during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular

work activity.

3. Perform follow-up activities to verify that each item on the punch list is completed and/or corrected and

is acceptable.

3.5.9 Acceptance Resident Project Representative will typically accept or release construction activities by phases, areas, or

segments. The project will define the method and the construction activities associated with each phase, area, or

segment.

Resident Project Representative will verify the following prior to issuing final acceptance for a particular phase,

area, or segment:

1. Construction is complete.

2. Resident Project Representative and Contractors have completed all inspection, testing, and quality

control activities.

3. Resident Project Representative has completed all quality verification activities.

4. All final inspection punch list items and non-conformance items are resolved and accepted.

5. All pertinent testing and commissioning reports have been provided and accepted by Resident Project

Representative.



3.6 Turnover Packages The Turnover Package is a collection of construction documentation associated with a particular phase, area, or

system. It typically includes all quality documentation such as material certifications, test reports, inspection

reports, non-conformance reports, and final inspection punch lists. It may also include selected drawings and/or

other documentation required per the Contract Documents.

1. The project will define the System Turnover Packages associated with the particular project.

2. Resident Project Representative will assemble, review, and approve the Turnover Packages associated

with each project. In some cases, documents provided by Contractors may be pre-assembled by the

Contractor.

3.7 Non-Conformance Control

3.7.1 Definition Non-conformances (NCRs) are defined as items or conditions that are not in compliance with designated

requirements, instructions, or specifications.

3.7.2 Identification Non-conformances may be identified by any party, including COC, Suppliers, and Contractors.

3.7.3 Documented All non-conformances are to be documented and tracked to verify they are resolved in an acceptable manner. The

method of documentation varies depending on the type of non-conformance, the point at which it was detected,

and the method that was used to detect it.

Items or conditions deemed to be serious, critical, and/or major non-conformances shall be documented via a

formal Non-conformance Report. Examples that fall into this category would include the following:

1. A failure to plan or fully implement the proper quality control activities for a particular item.

2. Identification of completed work that is not in accordance with specification requirements.

3. Multiple or chronic minor non-conformances of the same type that continue to occur over a period of

time. This represents a failure in the quality control system, or implementation of the system, to carry

out corrective action in a timely manner.

4. A Non-conformance that may adversely impact safety or operability unless repaired by a controlled

process that has not been previously approved.



3.7.4 Identification Materials and work products found to be out of compliance will be identified and may not be used for operation

or subsequent work activities until the Non-conformance has been resolved.

Processes or testing activities found to be out of compliance will be identified and will not be considered as

acceptable until the Non-conformance has been resolved.

3.7.5 Disposition Non-conformances will be evaluated by a responsible party to determine the most appropriate response or follow-

up. This would generally fall into one of the following categories:

1. Non-conformance can be accepted in the current condition.

2. Non-conformance will require some re-work or corrective action although the final product or process

will still not be fully compliant with the specification requirements.

3. Non-conformance will require some re-work or corrective action in order to bring the final product or

process into full compliance with the specification requirements.

4. Non-conformance can or will not be accepted and the product or process will need to be replaced.

The proposed disposition and associated corrective action, if required, should generally be suggested by the

supplier or Contractor responsible for the work.

A disposition to accept a Non-conformance in that it is not fully in accordance with the specification requirements

must be approved by an authorized representative of COC.

3.7.6 Acceptance A disposition to accept a Non-conformance that is not fully in accordance with the specification requirements

must be approved by an authorized representative of COC.

A disposition that requires re-work or corrective action will be verified by the appropriate inspection, testing, or

document review method prior to being accepted.

3.8 Corrective and Preventative Action Resident Project Representative will review and monitor NCR’s and quality reports on a regular basis to identify

trends that require corrective and/or preventative action. NCR’s are Key Performance Indicators on how well

Contractors are adhering to Quality Requirements within the Contract Specifications and this quality plan.



Repetitive issues require a heightened vigilance with training, management involvement, improved execution and

verification of the work specific to the reoccurring issues.

Engineering Quality records


4.0 ENGINEERING QUALITY RECORDS

Number Title Rev FORM No. ENGINEERING QUALITY RECORDS

TS-C-3 Q1 - Independent Review of Project Planning and Conceptual Design Activities 0

TS-C-4 Q2 - Independent Review of Preliminary Project Execution and Design Activities 0

TS-C-5 Q3 - Designer’s Review of Design Notes, Drawings, and Specifications 0

TS-C-6 Q4 - Independent Review of Design Documents 0

TS-C-11 Q5 - Review of Contractual-Legal Documents and Specifications 0

TS-C-7 Q6 - Review of Design and Construction Packages 0

Quality Verification Procedures


5.0 QUALITY VERIFICATION PROCEDURES

All Quality Verification Procedure are not required however employed on an as-needed basis.

Procedure No. Quality Verification Procedures Rev SECTION - 1 SITE WORK

QVP-1.01 Site Preparation & Excavation 0

QVP-1.02 Misc. Site Work 0

QVP-1.03 Piling 0

QVP-1.04 Drilled Piers 0

SECTION - 2 CONCRETE

QVP-2.01 Concreting 3

SECTION - 3 STRUCTURAL STEEL

QVP-3.01 Steel Fabrication and Erection 2

SECTION - 4 BUILDINGS

QVP-4.01 Building Erection 0

SECTION - 5 PIPING

QVP-5.00 General Verification Procedure for Piping 1

QVP-5.01 Verification Procedure for Pre-Hydro - Hydro - Post-Hydro 2

QVP-5.03 Verification Procedure for Pneumatic Testing 0

SECTION - 6 INSTRUMENTATION & ELECTRICAL

QVP-6.01 Instrumentation Installation RICE

QVP-6.02 Electrical Installation RICE

SECTION - 7 EQUIPMENT SETTING

QVP-7.01 Stationary Equipment 0

QVP-7.02 Rotating Equipment 0

SECTION - 8 COATINGS

QVP-8.01 Coatings 1

SECTION - 9 INSULATION, FIREPROOFING AND HEAT TRACE

QVP-9.01 Insulation 0

QVP-9.02 Fireproofing 0

QVP-9.04 Electric Tracing 0

SECTION - 10 SPECIAL PROCESSES

QVP-10.01 Welding 1

QVP-10.02 Nondestructive Testing 1

Quality Verification Checklists


6.0 QUALITY VERIFICATION CHECKLISTS

Procedure No. Quality Verification Checklists Rev SECTION - 1 SITE WORK

QVC-1.01 Checklist for Surveying 0

QVC-1.02 Checklist for Demolition 0

QVC-1.03 Checklist for Excavation and Backfill 0

QVC-1.05 Checklist for Plant Road and Vehicle Parking 0

QVC-1.08 Checklist for Piling 0

QVC-1.09 Checklist for Drilled Piers 1


QVC-2.01 Checklist for Concreting 1


QVC-3.01 Checklist for Structural Steel Erection 0


QVC-4.01 Checklist for Buildings 0

SECTION - 5 PIPING

QVC-5.01 Checklist for Underground Piping 0


QVC-7.01 Checklist for Stationary Equipment 0

QVC-7.02 Checklist for Rotating Equipment 0


QVC-8.01 Checklist for Coatings Application 0


COC only uses Construction Forms

All Quality Verification Checklists are not required, however employed on an as-needed basis.

Construction Forms


7.0 CONSTRUCTION FORMS

Form No. Construction Forms Rev SECTION - 0 GENERAL

CF-001 Notice of Acceptance 2

CF-002 Nonconformance Report 0

CF-003 Non-Conformance Report Log 1

CF-004 Material Receiving Report 0

CF-005 Material Receiving Log 1

CF-006 Signoff Contractor to Burns & McDonnell 3

CF-007 Receiving Overage, Shortage, and Damage Report 0

CF-008 Welding Conformance 0

CF-009 Master Punch list 0

CF-010 Equipment Maintenance Log 0

CF-011 Daily Field Report 2

CF-012 Drawing Control Audit 1

CF-013 Quality Performance Measurement System 2

CF-014 Burns & McDonnell Inspection Matrix 0

SECTION - 1 SITE WORK

CF-101 Pier/Pile Installation Log 0

CF-102 Soils Log 0

CF-103 Authorization to Backfill Record 1

CF-1130 Drilled Shaft Foundation Record 0


CF-200 Concrete Placement Log 1

CF-201 Concrete Placement Application, Authorization, and Record 2

CF-202 Grout Placement Application, Authorization, and Record 3


CF-301 Structural Steel Authorization and Acceptance Record 4


Use QVC-4.01 Checklist for Buildings

SECTION - 5 PIPING

CF-501 Piping Pressure Test Record 2

CF-503 Holiday Test Record Log 3

CF-504 Tie-In Application, Authorization, and Record 1

SECTION - 6 ELECTRICAL

Electrical Forms current QV6.02-1a thru QV6.02-18


CF-701 Equipment Installation Log 0

CF-702 Stationary Equipment Placement Application, Authorization, and Record 1

CF-703 Equipment Plumb Record 1

Construction Forms


CF-704 Final Closing Authorization Record 2

CF-705 Rotating Equipment Placement Application, Authorization, and Record 1

CF-706 Coupling Alignment Record 1


CF-801 Coating Record 1


CF-901 Insulation Placement Application, Authorization, and Record 1

CF-902 Fireproofing Placement Application, Authorization, and Record 1

CF-904 Electric Tracing Placement Application, Authorization, and Record 1

SECTION - 10 SPECIAL PROCESSES

CF-1001 Weld Log / Traveler 0

CF-1002 Welder Qualification and Maintenance Log 0

CF-1004 NDE Rejects 0

All Construction Forms are not required, however employed on an as-needed basis.

City of Coffeyville, KS Construction Quality Verification Procedure

QVP No. 1.01 – Site Preparation & Excavation Activities Rev 0

Uncontrolled Copy Page 1 of 6

1.0 Scope 1.1 This procedure defines the activities that City of Coffeyville, KS will perform in verifying the

quality of work performed by Contractors associated with Site Preparation & Excavation construction activities.

1.2 This procedure is to be used in conjunction with the general requirements specified in City of

Coffeyville, KS Construction Quality Verification Procedure No. 1.00 – Site Work – General. 1.3 Requirements that pertain to the contractor with regard to construction, testing, inspection,

documentation, etc., are specified in the contract package, referenced specifications, and construction drawings.

2.0 References 2.1 Forms

The following forms are used to document the quality verification activities specified in this procedure.

QVC-1.01 – Survey Inspection Checklist

QVC-1.02 – Demolition Inspection Checklist QVC-1.03 – Excavation & Backfill Inspection Checklist

CF-102 – Soils Log CF-103 – Authorization to Backfill Record

2.2 Standards

PIP CVS02005 – Topographic and Plant Surveys Specification PIP CVS02100 – Site Preparation, Excavation and Backfill Specification PIP CVS02700 – Excavation and Backfill for Underground Piping ASTM D1557 – Standard test methods for Laboratory Compaction Characteristics of Soil using modified effort ASTM D698 – Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort ASTM D6938 – Standard Test Method for In-Place Density and Water Content of Soil and Soil- Aggregate by Nuclear Methods (Shallow Test) ASTM D4429 – Standard Test Method for CBR (California Bearing Ratio) of Soils in Place PIP CVS02350 – Roadway and Area paving Construction Specification AREA – American Railroad Engineering Association Burns & McDonnell Engineering Specifications

3.0 Definitions

See associated PIP Specifications for the definition of terms. 4.0 Procedure 4.1 General

4.1.1 Surveying:




• The Engineering drawings and specifications shall describe the benchmarks, base

lines, and control points to be used for basic control. A system of permanent monuments shall be established onsite from this base line and elevation unless provided for by the owner.

4.1.2 The following work activities are generally associated with Surveying activities:

• Equipment Type

• Equipment Calibration • Layout and Checking • Earth Work • Foundation Locations • Underground Utilities • Traversing

4.1.3 Demolition

• All demolition of existing equipment, piping, instruments, and foundations shall be performed as indicated on the Contract Drawings, including Demolition Piping Plans and Elevation Drawings, Demolition P&ID’s, Foundation Demolition Drawings, and demolition details.

4.1.4 Site Preparation

• Clearing and Grubbing • Stripping • Rough Grading • Erosion Control

4.1.5 Excavation

• Structural Excavation • Earthen Excavation • Trenching for Pipe, Conduit, etc…(PIP CVS02700) • Rock Excavation

4.1.6 Stockpiling

• Stockpile material for proper drainage • Dispose of contaminated soils

4.1.7 Disposal of Excess and Waste Materials

• Designate a spoil area with Client and plan for removal

4.1.8 Backfill

• An independent soils consultant shall be used for compaction testing. The Soils Consulting Firm will perform the necessary laboratory tests for the soil material being compacted to determine the maximum density at optimum moisture content following the ASTM test method specified.

• The Soils Consulting Firm will perform in-place tests to determine the density of the compacted fill using the specified test method. The results of the tests shall be recorded and delivered to City of Coffeyville, KS.




• Cohesion-less soils shall be compacted to the relative density as specified in the contract documents. The Soils Consulting Firm shall perform the necessary laboratory tests to determine the in-place density required to meet the specified relative density. The Soils Consulting Firm shall perform in-place tests to determine the relative density of the compacted fill. The results of the tests shall be recorded and delivered to City of Coffeyville, KS.

• The contractor may use any type of compaction equipment deemed necessary to obtain the specified density. If the results of the compaction test show that the fill material must be dried, the fill shall be dried by scarifying, disk harrowing or rotary tilling of the loose lifts to reduce moisture by aeration. If the material is to be wetted, water shall be added either on the fill or at the borrow pit.

• Analyze the suitability of backfill: special backfill, compacted backfill, and structural quality backfill.

• Sieve Analysis (ASTM C136, ASTM D422 or ASTM D1140) • Liquid and Plastic limit determination (ASTM D4318) • Modified Proctor Test (ASTM D1557) or Standard Proctor Test (ASTM D698) • Granular Soils Tests (ASTM D4253) and (ASTM D4254) • Test the Density and Moisture content of compacted backfill material (ASTM D2922)

4.1.9 Base Course

• Cleared, grubbed and stripped • Modified Proctor test (ASTM D1557) or Standard Proctor Test (ASTM D698)

4.1.10 Dewatering

• Provide proper drainage of all excavations, fills, stockpiles, borrow pits throughout the project.

4.1.11 City of Coffeyville, KS will perform quality verification activities to ensure that each work

activity is completed in accordance with the project specifications. These quality verification activities can be classified into one of the following categories:

• Preparatory meeting prior to starting construction. • Initial inspections of construction. • Inprocess inspections during construction – random to full-time. • Final inspection after completing construction – random to 100% • Review of records of construction

4.1.12 The type of quality verification activities to be performed for each work activity, and the

extent thereof, is described in this procedure. 4.1.13 All quality verification activities will be performed by personnel that have the necessary

skills, training, and certifications for the particular task.

4.2 Preparatory Meetings

4.2.1 Preparatory Meetings are held with contractors prior to the start of construction for each major work activity or group of activities. The purpose of the Preparatory Meeting is to verify the following:




• Verify that the contractor fully understands the job specification requirements.

• Review the contractor’s quality control program and how it will be implemented for the work activity.

• Verify that all required documentation has been reviewed or approved and that the

contractor has the most current versions.

• Review requirements for permits and/or authorizations that will be required during the course of construction.

• Review the quality verification activities that City of Coffeyville, KS plans to perform

and coordinate the necessary notifications from the contractor for any hold or witness points.

4.2.2 The following work activities require a Preparatory Meeting prior to starting construction.

• Surveying • Demolition • Excavation • Trenching • Stockpiling • Backfilling • Testing & Inspection Requirements

4.2.3 When multiple contractors are responsible for a given work activity, a separate

Preparatory Meeting will be held with each contractor. 4.2.4 When a given contractor is responsible for multiple work activities, the Preparatory

Meeting may include more than one work activity. 4.2.5 For work activities with multiple phases, a separate Preparatory Meeting is not

necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Excavating although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.

4.3 Initial Inspections

4.3.1 City of Coffeyville will perform a thorough inspection of the initial construction work performed by each contractor for each work activity. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:

• Verify any action items identified during the Preparatory Meeting were resolved.

• Fully inspect the initial work performed by contractor to verify that it is in accordance

with the requirements specified in the contract documents.




• Verify that the contractor is implementing their quality control procedures at the jobsite.

• Prepare a Master Punch-list documenting the specific activities performed during the

Initial Inspection and identify any items of nonconformance or other action items for follow-up and resolution.

4.4 Follow-up Inspections

4.4.1 City of Coffeyville, KS will perform Follow-up Inspections of the contractor’s work on a random but regular basis starting immediately after the Initial Inspection and through the completion of the work activity. The frequency and extent of Follow-up Inspections will be based on the scope of work, contractor performance, and associated risk to the project. The Follow-up Inspections will include the following activities:

Verify that any Nonconformancies or action items identified during the Initial

Inspection or a previous Follow-up Inspection have been resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place. Follow Construction Site Quality Manual 7.0. Use CF-002 forms.

Inspect a representative sample of work performed by the contractor since the Initial

Inspection or previous Follow-up Inspection to verify that it is in accordance with the requirements specified in the contract documents.

Verify that the contractor is implementing their quality control procedures at the

jobsite. Prepare a Master Punch-list documenting the specific activities performed during

each Follow-up Inspection and identify any items of nonconformance or other action items for follow-up and resolution.

4.5 Final Inspection

4.5.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the pre-placement activities. The Final Inspection will include the following items:

Perform a final inspection of any work performed by the contractor that was not

previously inspected during the Initial and Follow-up Inspections but would be prudent to assure the final quality of the work. Verify that all work is in compliance with the specifications and most current drawing revision at the time of final inspection.

Prepare a Master Punch-list documenting the specific activities performed during

each Final Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.




Specify the estimated date for which each item on the punch list should be completed or corrected to be in compliance.

Perform follow-up activities to verify that each item on the punch list is completed

and/or corrected and is acceptable.

4.6 Acceptance

4.6.1 City of Coffeyville, KS will typically accept or release each area prior to commencing Site Work activities.

4.6.2 Burns & McDonnell will verify the following prior to issuing final acceptance for a

particular area:

• Pre-placement activities are complete. • The contractor has completed all inspection, testing, and quality control activities.

• City of Coffeyville, KS has completed all quality verification activities.

• All final inspection punch list items are resolved and accepted.

5.0 Records 5.1 The Quality Verification Activities associated with this procedure are recorded on the following

forms:

• QVC-1.01 – Survey Inspection Checklist • QVC-1.02 – Demolition Inspection Checklist • QVC-1.03 – Excavation & Backfill Inspection Checklist • CF-102 – Soils Log • CF-103 – Authorization to Backfill Record


QVP No. 1.02 –Misc. Site Work Activities Rev 0



quality of work performed by contractors associated with Misc. Site Work construction activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of





QVC-1.05 – Inspection Checklist for Plant Road and Vehicle Parking

2.2 Standards

PIP CVS02350 – Roadway and Area paving Construction Specification PIP STS03001 – Plain and Reinforced Concrete Specifications AREA – American Railroad Engineering Association Burns & McDonnell Engineering Specifications

3.0 Definitions

See associated PIP Specifications for the definition of terms. 4.0 Procedure 4.1 General

4.1.1 Unpaved Surfaces

• Topsoil • Seed and sod • Placement of topsoil, seed, or sod • Weed Control

4.1.2 Plant Road and Vehicle Parking

• Gravel Pavement • Asphalt Pavement • Concrete Pavement

4.1.3 Fencing

• Post distances




• Concrete Foundation • Concrete Finish • Gates

4.1.4 Railroad

• Site Preparation • Tie Material and Spacing • Rail Weight • Tie Plate and Spiking • Tie Joints • Tie Welding • Ballast quality, size graduation, thickness, and compaction. • Switch Installation • Track Alignment

4.1.5 City of Coffeyville, KS will perform quality verification activities to ensure that each work activity is completed in accordance with the project specifications. These quality verification activities can be classified into one of the following categories:






4.2.1 Preparatory Meetings are held with contractors prior to the start of construction for each major work activity or group of activities. The purpose of the Preparatory Meeting is to verify the following: • Verify that the contractor fully understands the job specification requirements.

• Review the contractor’s quality control program and how it will be implemented for

the work activity.

• Verify that all required documentation has been reviewed or approved and that the contractor has the most current versions.

• Review requirements for permits and/or authorizations that will be required during

the course of construction.

• Review the quality verification activities that Burns & McDonnell plans to perform and coordinate the necessary notifications from the contractor for any hold or witness points.





• Seeding and Sodding • Plant Roads and Vehicle parking • Fencing • Railroads • Testing & Inspection Requirements




necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Asphalting although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.


4.3.1 City of Coffeyville, KS will perform a thorough inspection of the initial construction work performed by each contractor for each work activity. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:










Inspection or a previous Follow-up Inspection have been resolved. Work should not be proceeding where Nonconformancies have been identified but have not been




resolved, unless an approved work-around plan is in place. Follow Construction Site Quality Manual 7.0. Use CF-002 forms.












Specify the estimated date for which each item on the punch list should be

completed or corrected to be in compliance. Perform follow-up activities to verify that each item on the punch list is completed


4.6 Acceptance

4.6.1 City of Coffeyville, KS will typically accept or release each area prior to commencing Site Work activities.

4.6.2 City of Coffeyville, KS will verify the following prior to issuing final acceptance for a

particular area:

• Pre-placement activities are complete. • The contractor has completed all inspection, testing, and quality control activities.







forms:

• QVC-1.04 – Inspection Checklist for Unpaved Surfaces • QVC-1.05 – Inspection Checklist for Plant Road and Vehicle Parking • QVC-1.06 – Inspection Checklist for Site Fencing • QVC-1.07 – Inspection Checklist for Plant Railroad


QVP No. 1.03 – Piling Installation Activities Rev 0



quality of work performed by contractors associated with Piling Installation activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of





QVC-1.08 – Piling Inspection Checklist

CF-101 – Pier/Pile Installation Log

2.2 Standards

PIP STS02360 – Driven Pile Specification PIP STS0202465 – Augered Cast-in-Place Pile Installation Specification ACI 543R – Design, Manufacture, and Installation of Concrete Piles QVP 2.00 – Concreting

3.0 Definitions

See relevant PIP Specification for the definition of terms associated with Piling. 4.0 Procedure 4.1 General

4.1.1 Pile Types typically associated with construction:

• Auger Cast in Place Piles • Steel Pipe Piles • Concrete-filled thin shelled piles • Structural Steel “H” Piles • Step taper Piles • Pre-stressed concrete Piles • Timber Piles

4.1.2 The following work activities are associated with Piling pre-placement activities:

• Geotechnical Report Analysis




• Procedures for protection, handling and storage of Piles • Identification and description of equipment for handling and installing piles • Equipment, Procedures and Data sheets • Pile Installation Procedures, including pre-drilling and or jetting • Calibration Certificates of pressure gauges and Bounce chamber gauges • Automated Instrumentation and Monitoring Equipment • WPS with Supporting PQR • AWS Welder Certification • Pile and pile accessory material certifications • Plan of sequence of driving • Concreting procedures QVP-2.00 if applicable are met

4.1.3 The following work activities are generally associated with Piling Installation activities:

• Pre-Drilling • Jetting • Driving Caps or Helmets • Pile Heave • Pile Cut off

4.1.4 The following work activities are generally associated with Post-Piling Installation activities:

• Final Visual and Dimensional Inspection • Concrete Testing • Pile-Driving Analyzer and Pile Load Testing • Rejected Load Tests shall be determined by the Engineer of Record








4.2.1 Preparatory Meetings are held with contractors prior to the start of construction for each major work activity or group of activities. The purpose of the Preparatory Meeting is to verify the following:












• Installation Procedures • Placement of reinforcement and embedded Items • Inspection and Testing Requirements




necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Piling Installation although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.










• Prepare a Master Punch-list documenting the specific activities performed during the Initial Inspection and identify any items of nonconformance or other action items for follow-up and resolution.


4.4.1 City of Coffeyville, KS will continually monitor the post-installation activities through completion. The Follow-up Inspections will include the following activities:

Verify that post-placement activities are in accordance with the requirements

specified in the contract documents.

Verify that the contractor is implementing their quality control procedures during this activity.














4.6 Acceptance




4.6.1 City of Coffeyville, KS will typically accept or release each area prior to commencing Excavation activities.


particular area:

• Post-Placement activities are complete. • The contractor has completed all inspection, testing, and quality control activities.




forms:

• QVC-1.08 – Piling Inspection Checklist • CF-101 – Pier/Pile Installation Log


QVP No. 1.04 – Drilled Pier Activities Rev 0



quality of work performed by contractors associated with Drilled Pier activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of





QVC-1.09 – Drilled Pier Inspection Checklist

CF-101 – Pier/Pile Installation Log

2.2 Standards

PIP STS02380 – Specification for the Construction of Drilled Piers ACI 336.1-01 – Specification for the Construction of Drilled Piers Deep Foundations Institute: DFI-ADSC – Drilled Pier Inspector’s Manual QVP 2.00 – Concreting

3.0 Definitions

See PIP CVS02100 for the definition of terms associated with Excavation. 4.0 Procedure 4.1 General

4.1.1 The following work activities are associated with Drilled Piers pre-placement activities:

• Geotechnical Report Analysis • Equipment, Procedures and Data sheets • Drilling Procedures, including pre-drilling and or jetting • Calibration Certificates of gauges • Automated Instrumentation and Monitoring Equipment • WPS with Supporting PQR • AWS Welder Certification • Certified Mill Test Reports • Plan of sequence of Drilling • Bell Dimension Testing Plan • Concreting procedures QVP-2.00 are met




4.1.2 The following work activities are generally associated with Drilled Piers Installation

activities:

• Pre-Drilling • Jetting • Drilling • Controlled Slurry, Slurry testing and Slurry Disposal • Dewatering Prior to Installation of Concrete • Bell Dimension Test • Steel Casing and Liner • Reinforcing Steel • Concreting • Placement of Embedded Items • Casing Withdrawal

4.1.3 The following work activities are generally associated with Post-Installation activities:

• Grouting • Concrete Testing • Final Visual and Dimensional Inspection • Graphical Plot Report of Theoretical concrete volume and actual measured volume

versus depth or elevation for each Drilled Pier constructed by the slurry displacement method.

• Pier Probing Tests • Rejected Tests shall be determined by the Engineer of Record













the work activity.






• Installation Procedures • Placement of reinforcement and embedded Items • Inspection and Testing Requirements




necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Drilled Pier Installation although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.













4.4.1 City of Coffeyville, KS will continually monitor the post-installation activities through completion. The Follow-up Inspections will include the following activities:

Verify that post-placement activities are in accordance with the requirements
















4.6 Acceptance

4.6.1 City of Coffeyville, KS will typically accept or release each area prior to commencing Excavation activities.




4.6.2 City of Coffeyville, KS will verify the following prior to issuing final acceptance for a particular area:

• Post-Placement activities are complete. • The contractor has completed all inspection, testing, and quality control activities.




forms:

• QVC-1.09 – Drilled Pier Inspection Checklist • CF-101 – Pier/Pile Installation Log


QVP No. 2.01 – Concreting Rev 3


1.0 Scope

1.1 This procedure defines the activities that City of Coffeyville, KS will perform in verifying the quality of work performed by contractors associated with concreting construction activities.

1.2 Requirements that pertain to the contractor with regard to construction, testing, inspection, documentation, etc., are specified in the contract package, referenced specifications, and construction drawings.

2.0 References

2.1 Forms


QVC-2.01 – Inspection Checklist for Concreting

CF-200 – Concrete Log CF-201 – Concrete Placement Application, Authorization, and Record CF-202 – Grout Placement Application, Authorization, and Record

2.2 Standards

ACI 311.1R – Manual for Concrete Inspection ACI 311.4R – Guide for Concrete Inspection

3.0 Definitions

See ACI 116R for the definition of terms associated with concreting.

4.0 Procedure

4.1 General

4.1.1 The following work activities are associated with concrete pre-placement activities:

• Excavation • Dewatering • Bearing Capacity • Trenching • Formwork • Reinforcement • Embedded Items

4.1.2 The following work activities are associated with concrete placement activities:

• Mixing • Pour / Application • Slump Tests • Air Content Tests • Test Sample Preparation

4.1.3 The following work activities are associated with concrete placement activities:

• Curing • Form Removal • Concrete Testing • Final Visual and Dimensional Inspection






4.1.5 The type of quality verification activities to be performed for each work activity and the

extent thereof is described in this procedure. 4.1.6 All quality verification activities will be performed by personnel that have the necessary

skills, training and certifications for the particular task.




the work activity.




• Review the quality verification activities that City of Coffeyville, KS plans to perform and coordinate the necessary notifications from the contractor for any hold or witness points.




necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for formwork although their scope may include constructing the forms for many foundations over the course of the project. However a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.













4.4.1 City of Coffeyville, KS will perform Follow-up Inspections of the contractor’s work on a random but regular basis starting immediately after the Initial Inspection and through the completion of the work activity. The frequency and extent of Follow-up Inspections will be based on the scope of work, contractor performance and associated risk to the project. The Follow-up Inspections will include the following activities:


Inspection or a previous Follow-up Inspection have been resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place. Follow Construction Site Quality Manual 7.0 Non Conformance Control. Use CF-002 forms.







4.5.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the pre-placement, placement and post-placement activities. The Final Inspection will include the following items:


previously inspected during the Initial and Follow-up Inspections but would be




prudent to assure the final quality of the work. Verify that all work is in compliance with the specifications and most current drawing revision at the time of final inspection.


each Final Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections and Follow-up Inspections for the particular work activity.




4.6 Acceptance

4.6.1 City of Coffeyville, KS will typically accept or release each area prior to commencing concrete placement activities.


particular area:

• Pre-placement, Placement and Post-placement activities are complete. • The contractor has completed all inspection, testing, and quality control activities.



5.0 Records

5.1 The Quality Verification Activities associated with this procedure are recorded on the following forms:

• QVC-2.01 – Inspection Checklist for Concreting

• CF-200 – Concrete Placement Log

• CF-201 – Concrete Placement Application, Authorization, and Record

• CF-202 – Grout Placement Application, Authorization, and Record

City of Coffeyville, KS

Construction Quality Verification Procedure No. 3.01 – Steel Erection Rev 2


1.0 Scope 1.1 This procedure defines the general activities that City of Coffeyville, KS will perform in verifying

the quality of work performed by contractors performing steel erection. 1.2 Additional detailed requirements are specified in supplemental Construction Quality Verification

Procedures for specific operations associated with steel erection. 1.3 Requirements with regard to construction, testing, inspection, documentation, etc., are specified

in the contract package, referenced specifications, and on construction drawings. 2.0 References 2.1 Supplemental City of Coffeyville, KS Construction Quality Verification Procedures

The following procedures are to be used in conjunction with this procedure. QVP-10.01 – Welding

2.2 Standard Industry Specifications

The following is a list of standard specifications associated with concrete placement that may be referenced in this procedure, supplemental Construction Quality Verification Procedures, and/or contract specifications.

AISC Code of Standard Practice for Steel Buildings and Bridges AWS D1.1 – Structural Steel Code RCSC – Specification for Structural Joints using ASTM A325 or A490 Bolts

2.3 Forms

The following forms are used to document quality verification activities.

QVC-3.01 – Inspection Checklist for Structural Steel Erection QVC-10.01 – Inspection Checklist for Welding CF-301 – Structural Steel Authorization and Acceptance Record

3.0 Definitions

See AISC and AWS D1.1 for the definition of terms associated with steel erection. 4.0 Procedure 4.1 General

4.1.1 City of Coffeyville, KS will perform activities to verify the quality of the following work activities associated with steel erection.

4.1.1 Marking




4.1.1.1 Marking of Structural Steel piece marks shall be stipulated in the Contract Documents

4.1.1.2 Typical Types of Marking:

4.1.1.2.1 Paint or Marker 4.1.1.2.2 Tie Wired Metal Tags

4.1.1.2.3 Stamped plates welded on (Preferred method)

4.1.1.2.4 Bead Welds

4.1.2 Grouting

4.1.2.1 Type of Grout will be specified in the Contract Documents 4.1.2.2 Verify area to be grouted is clean and free of debris and water

4.1.3 Setting

4.1.3.1 Verify all Structural Steel Components are being erected per the Contract Documents and Drawings

4.1.3.2 Verify piece mark identifications tags are attached and located in the

appropriate coordinance during installation per the contract.

4.1.3.3 Verify Columns and Beams are plumb, level and square.

4.1.3.4 Verify drilled holes are in proper locations and deburred as necessary.

4.1.4 Welding

4.1.4.1 Welding should be in accordance with QVP-10.01 - Verification Procedure for Welding.

4.1.4.2 100% Visual Weld Inspection Required by Contractor. 4.1.4.3 Structural Steel Drawings shall be Weld Mapped and have Welder

Identification Symbols for Turn-Over Packages. 4.1.4.4 All Non Destructive Testing shall be determined by the Engineer of

Record

4.1.5 Bolting

4.1.5.1 Tension Calibrator: Skidmore test shall be performed, not less than three per size, grade and length for Snug-Tightened Joints, Pre-tensioned and Slip Critical Joint bolt-up connections.

4.1.5.1.1 Agreed upon percentage of Bolted Connections shall be

Visually Inspected.




4.1.5.1.2 Snug-Tightened: Visually ensure that the plies of the connected elements have been brought into firm contact.

4.1.5.1.3 Pre-tensioned and Slip Critical Joints: Turn of the Nut,

Calibrated Wrench, Twist off type, and Direct Tension Indicators can be used.

4.1.5.1.4 Direct Tension Indicators shall be inspected with Feeler

Gauges.

4.1.5.1.5 Minimum three sides down with Visual Paint indicated.

4.1.6 Application of Protective Coatings

4.1.7 The quality verification activities will be performed by City of Coffeyville, KS in the following stages:

• Preparatory meeting prior to starting construction. • Inprocess inspections during construction – random to full-time. • Final inspection after completing construction – random to 100% • Review of records of construction

4.1.8 The type of quality verification activities to be performed for each work activity, and the extent thereof, is described in this procedure.

4.1.9 All quality verification activities will be performed by personnel that have the necessary skills, training, and certifications for the particular task.


4.2.1 Preparatory Meetings are held with contractors prior to starting work. The purpose of the Preparatory Meeting is to verify the following:

• Verify that the contractor and/or testing agency fully understands the job specification requirements.





4.2.2 When multiple contractors are responsible for a given work activity, a separate Preparatory Meeting will generally be held with each contractor.

4.2.3 For work activities with multiple phases, a separate Preparatory Meeting is not necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for steel erection in several locations at various times. However a follow-up meeting may be warranted if there are extended




periods between phases or if problems are identified during inspections of the contractor’s work.


4.3.1 City of Coffeyville, KS will monitor the initial steel erection activities. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:


• Fully inspect the initial work performed by contractor to verify that it is in accordance with the requirements specified in the contract documents.




4.4.1 City of Coffeyville, KS will continually monitor the placement activities through completion. The Follow-up Inspections will include the following activities:

Verify that ongoing steel erection activities are in accordance with the requirements specified in the contract documents.


Verify that any Nonconformancies or action items identified during the Initial Inspection or a previous Follow-up Inspection have been resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place. Follow Construction Site Quality Manual 7.0 Non Conformance Control. Use CF-002 forms.

Prepare a Master Punch-list documenting the specific activities performed during each Follow-up Inspection and identify any items of nonconformance or other action items for follow-up and resolution.


4.5.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the steel erection activities. Final Inspections may be performed in phases or completion by area. The Final Inspection will include the following items:




each Final Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced




specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections and Follow-up Inspections for the particular work activity.




4.6 Acceptance


• Steel erection activities are complete. • The contractor has completed all inspection, testing, and quality control activities.



5 Records


• QVC-3.01 – Inspection Checklist for Structural Steel Erection

• QVC-10.01 – Inspection Checklist for Welding

• CF-301 – Structural Steel Authorization and Acceptance Record

CONSTRUCTION QUALITY MANUAL PROCEDURE

ISSUED DATE EFFECTIVE DATE

4/8/08 4/8/08

REV. NO:

0

PROCEDURE NO:

QVP-4.01

Page 1 of 5

TITLE:

BUILDINGS


The Building Quality Control Checklist QVC-4.01 is used to document job performance during preliminary, intermediate and final building stages and are maintained in Quality Control Records files. A Preliminary Stage – QC Checklist QVC-4.01 1. Material Receiving and Warehousing, Refer to Section 4.0 of the Site Quality Manual,

Material Management for specific requirements. CF-004, CF-005 and CF-007 Forms Shall be Used.

2. General

(a) Verify that permits and licenses are posted. (b) Verify building foundations are as specified. (c) Verify lines, grades, elevations, etc. are as specified. (d) Verify embedded items such as anchor bolts, sleeves, piping, conduit,

etc., are installed in accordance with Design Drawings. B Intermediate Stage – QC Checklist QVC-4.01 1. Masonry

Verify the following:

(a) Concrete masonry units are as specified. (b) Blocked walls are true and plumb, and vertical joints are staggered and

centered on the block above and below. Blocks are laid in full mortar beds with filled end joints.

(c) Corner and double corner blocks, half blocks, fillers, veneer blocks, etc., as may be defined to form corners, returns, openings, and offsets; are placed so as to maintain a proper bond throughout the length of the wall.

(d) Lintels over door and window openings are of reinforced concrete firmly bedded in mortar of the same quality as used in laying up the walls.

(e) Correct placement of lintel (top is top) and that they have an 8-inch (8”) bearing at each end.

(f) Horizontal reinforcement is installed in grout-filled cells as specified. (g) Vertical reinforcement is installed in grout-filled cells as specified. (h) Cement materials and aggregate are as specified. (i) Mortar joints are as specified and fully bedded, level, and not



4/8/08 4/8/08

REV. NO:

0

PROCEDURE NO:

QVP-4.01

Page 2 of 5

TITLE:

BUILDINGS


furrowed; and head joints are buttered to fill the joints, and shoved tight.

(j) Mortar joints are compressed and compacted to ensure a watertight job.

(k) There are no broken or chipped blocks where used on exposed masonry Work.

(l) Holes are filled; and masonry Work is clean of dirt, mortar, stains, or other defacements.

2. Metals


(a) Erection of metal buildings is as specified. (b) Building steel is as specified. (c) Insulation is installed as specified. (d) Ridge caps, rakes, jambs, sills, eaves, corner flashing, roof and wall

panels are installed as specified. (e) Closure strips, seal tape, and caulking is as specified. (f) Fasteners on interior and exterior panels are as specified. (g) Gutters and downspouts are installed, fastened, sealed, plumb, and

graded as specified. 3. Thermal and Moisture Protection


(a) Hollow cores of concrete blocks are filled with specified insulation. (b) Styrofoam board between interior wall paneling and concrete block

walls is installed as specified. (c) Blanket insulation is securely fastened to roof deck with wire mesh or

tapping specified. 4. Roofing


(a) Roof is constructed as specified. (b) Roof surfaces are free from dirt, rubbish, and other substances before

roofing operations. (c) Roof surfaces are free of depressions or projections. (d) Flashing is placed and jointed as specified.



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(e) Roof insulation and vapor barrier installed as specified. (f) Slope, seams, and fasteners on metal roofs are as specified. (g) Roof drains are installed as specified. (h) Asphalt roof materials are as specified. (i) Roof gravel is as specified. (j) Roof hatches, skylights, and vents are installed as specified.

5. Doors and Windows


(a) Doors, hinges, locks, threshold, closure weather-stripping, and necessary trim are installed as specified.

(b) Windows, window openings, and screening are as specified. (c) Paint colors on walls and panels are as specified.

6. Ventilators


(a) Ventilators are installed as specified. (b) Bird screens are installed as specified. (c) Fasteners and sealant are as specified. (d) Balanced backdraft dampers installed as specified. (e) Manual chain operators installed and function as specified. (f) Ventilator disconnect switch installed as specified.

7. Louvers


(a) Louvers for tightness and free movement. (b) Integral bird screens are installed. (c) Flashing and color-coated frames are installed as specified.

8. Rolling Steel Doors


(a) Paint color is as specified. (b) Doors fit and operate as specified.



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(c) Weather-stripping, windlocks, doorstops, and hardware installed as specified.

9. Plumbing


(a) Plumbing and drainage systems are installed as specified. (b) Fixtures are plumb and securely fastened in place. (c) Local authority or Owner’s Inspector notified for the rough-in or final

piping inspection, where required. Refer to Sections 5 & 10 for specific Piping inspections.

10. HVAC


(a) Ducts/piping are placed in straight lines, parallel or perpendicular to walls and partitions; and riser and stubs are vertical.

(b) Temporary openings in piping and ducts are protected to prevent any foreign material from entering systems.

(c) Ducts/piping and fittings are installed free from plaster, paint, grease, or other foreign material.

(d) Duct work and supports, duct insulation, diffusers, registers, dampers, and accessories are installed as specified.

(e) Ventilation and exhaust systems are installed as specified. (f) Relief and pressure regulating valves are set for the proper pressure

and tested. (g) Thermostats and control instruments are calibrated, adjusted, and set to

operate as specified. (h) Tests, starts, and balancing of air conditioning, heating, ventilating,

and exhaust systems has been performed as specified

11. Electrical


(a) Electrical Work and material is as specified. (b) Inspection and testing has been performed Refer to Section 6 for

Electrical Inspection requirements.



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C Final Stage – QC Checklist QVC-4.01


(1) Sealant and caulking for interior and exterior openings are completed. (2) Flashing on exterior face of structural members, pipe, conduit, tubing, and

other items extending through walls is completed and colors are as specified. (3) Final cleanup included inaccessible spaces such as ceiling space, crawl space,

computer floors, etc. (4) Ceilings and side walls under the roof are free of any indications of water

stains. (5) Drains and plumbing fixtures are installed and/or tested as specified. (6) Windows, doors, locks, and latches are installed as specified and operable. (7) Ceramic tile and grout installed as specified. (8) Walls, ceilings, and floors are installed as specified. (9) Light fixtures and grounding installed as specified. (10) Equipment is installed and tested as specified. (11) Fireproofing is installed as specified. (12) Fire Protection System is installed and tested as specified. (13) Paint is applied as specified. (14) Form No. CF-501, Request for Partial Building System Test Approval, is

utilized for the Building System Test. (15) Form No. CF-501, Building Test System Punch-out, is utilized for follow-up

of the punch-out list. (16) Form No. CF-009, Completion of Building Master Punch List for Project

Building Test System is utilized upon completion. (17) HVAC systems have been tested and balanced.

D Reference(s) None


Construction Quality Verification Procedure No. 5.00 – Piping – General Rev RICE


1.0 Scope 1.1 This procedure defines the general activities that City of Coffeyville, KS will perform in verifying

the quality of work performed by contractors associated with Piping Fabrication and Erection. 1.2 Additional detailed requirements are specified in supplemental Construction Quality Verification

Procedures for specific operations associated with Piping Fabrication and Erection. 1.3 Requirements that pertain to the contractor with regard to construction, testing, inspection,


2.0 References 2.1 Supplemental City of Coffeyville, KS Construction Quality Verification Procedures

The following procedures are to be used in conjunction with this procedure in verifying the work performed by contractors for specific operations associated with Piping Fabrication and Erection. QVP-5.01 – Pre-Hydro Inspection Activities QVP-5.01 – Hydro inspection activities QVP-5.01 – Post-Hydro Inspection Activities


The following is a list of standard specifications associated with Piping Fabrication and Erection that may be referenced in this procedure, supplemental Construction Quality Verification Procedures, and/or contract specifications.

ASME II – Materials ASME V – Nondestructive Examination ASME IX– Welding and Brazing Qualifications ASME B31.1 – Power Piping ASME B31.9 – Building services Piping ASNT– SNT-TC-1A – Nondestructive Examination Burns & McDonnell Engineering Specifications

2.3 Forms

The following forms are used to document quality verification activities.

CF-501 – Hydro Inspection CF-009 – Master Punch List Log CF-503 – Holiday Test Record Log

3.0 Definitions

See Governing Spec or Code 4.0 Procedure




4.1 Tie-In Approval

4.1.1 The following work activities are associated with Tie-In Processes:

4.1.1.1 Identify Quality Procedures for Tie-In work.

4.1.1.2 Verify proper Location of the Tie-in.

4.1.1.3 Verify Lock out Tag out Procedure is met.

4.1.1.4 Existing pipe thickness measurement via Ultrasonic Inspection verified before cutting into existing pipe.

4.1.1.5 Surface Preparation for welding per QVP-10.01, Section 4.10.

4.1.1.6 PT Inspection per QVP-10.2.

4.1.1.7 Repair of Base Metal Defects per QVP-10.01 Section 4.11.

4.1.1.8 Contractor shall verify proper Fit-up and Alignment per QVP-10.01 Section 4.12, Contractors WPS and Governing Codes.

4.1.1.9 Verify Welding per Contractor’s WPS.

4.1.1.10 Final NDE per QVP-10.02.

4.1.1.11 Hydro Testing shall either be completed with a Car-Ber testing method or NDE in Lieu of Hydro and a Service Test with prior approval.

4.1.1.11.1 NDE in Lieu of Hydro shall be kept to a minimum.

4.1.1.12 Verify Painting is complete

4.1.1.13 Verify Heat Tracing is complete

4.1.1.14 Verify Insulation is complete

4.1.1.15 Fill out and Complete CF-504 Tie-In Placement Application, Authorization, and Record.

4.2 Flange Inspections:

4.2.1 The following work activities are associated with Flange Inspection Procedures.

4.2.1.1 Identify whether City of Coffeyville, KS procedure meets the Client’s requirements or if City of Coffeyville, KS needs to overlay our procedure with the Client’s procedure.

4.2.2 All Other Bolted Piping and Equipment Flange Connections.

4.2.2.1 All flange connections shall use gasket materials specified in the Engineering Drawings.

4.2.2.2 Garlock gaskets may be used in lieu of permanent gaskets for Pressure Testing purposes.

4.2.2.2.1 Garlock gaskets shall only be used where Temporary Hydro blinds will be installed. Use one Garlock gasket per side of the blind.

4.2.2.2.2 Do not use Garlock gaskets beyond their pressure rating.

4.2.2.3 Upon completion of Pressure Testing, replace all temporary gaskets with their specified permanent gaskets and retighten the bolts.




4.2.2.3.1 The Inspector shall use a Hammer to perform the “Tap of the Nut” Inspection for loose bolts.

4.2.2.3.2 Thread protrusion shall protrude a minimum 2 threads beyond the nut and not to exceed 4 threads beyond the nut. This provides ease for maintenance.

4.2.2.3.3 Repeat the prior steps until the QC Inspector deems the flange connection acceptable.

4.2.2.4 All other gaskets within the Pressure Test Boundaries shall be deemed Acceptable upon Acceptance of the Pressure Test and Sign off of the Post Hydro Test Release located on CF-501.

4.3 City of Coffeyville, KS will perform activities to verify the quality of the following work activities associated with Above Ground Piping Fabrication and Erection.

4.3.1 Pre-Hydro Test Release: signatures required

• Tie-In Approval Procedure • Piping Conforms to Drawings and Specifications • NDE/PMI/PWHT/BHN Complete • In-Line Instruments removed • Valve orientation correct • Valves open as required • Blinds installed as applicable • Data logged into the System Line List Tracker • Data logged into Master Punch List • Red-Line and mark-up Hydro Boundaries on Master set of P&ID’s

4.3.2 Hydro Test: signatures required

• Gauge Number • Gauge Range encompasses middle third • Gauge Calibration • Test media • Test pressure • Temperature • Test length

4.3.3 Post-Hydro test release: signatures required

• Blinds pulled • Supports Installed • Spring Hanger stops removed • Plugs installed • High Point and Low Point plugs installed • In-line Instruments installed • Proper Bolts and Gaskets • Valve orientation correct • System blown free of test medium

4.3.4 Final Acceptance Signature:




• Painting Complete • Insulation Complete • Heat Tracing Complete and Tested • Holiday Testing Complete and Signed off • Master Punch List Log Complete and Signed off

4.4 City of Coffeyville, KS will perform activities to verify the quality of the following work activities associated with Underground Piping Fabrication and Erection in correlation of paragraph 4.2 of this procedure.

4.4.1 Preparation of bedding for underground pipe is very important. Proper preparation will help ensure an installation which will be trouble free.

• Pipe to be installed in clay, shale or rock may require a compacted loam or fine granular material base. See Burns & McDonnell supplied piping specifications.

• Pipe to be installed in compacted sand, sandy loam or granular soil may require no additional base work unless specified on contract drawings or in the Piping Specifications.

• Sand filled cloth bags may be used to aid in setting underground lines. These sand bags need not be removed upon completion of installation. This procedure requires the design engineer’s approval.

4.4.2 Applications of field coating and wrapping shall be in accordance with contract specifications. Check for the following:

• Welds are clear of splatter • Pipe is clear of loose mill scale, rust, oil, grease, dirt and other foreign matter. • Primer is being used which is compatible with the existing line coating system. • Proper overlap of tape according to specifications. • Coating of valves for complete coverage.

4.2.5 Test and inspect coated and wrapped pipe for voids and leaks by means of a holiday detector prior to installation in ditch and prior to backfilling. The test should be witnessed by City of Coffeyville, KS. Record results on the Holiday Test Record Log CF-503. Records will be maintained by Contractor. Move pipe with slings only.

4.2.6 Inspect initial backfill of coated and wrapped pipe to ensure that soil is free from debris that could damage coating. Initial backfill is to be same material as bedding. Pipe shall be covered with this material to a depth specified which will protect the pipe from damage, after which the excavation may be backfilled with any suitable material, or as specified in job specifications or job standards.

4.2.7 Prior to testing, inspect underground pressure system using underground piping

drawings to ensure that proper anchors, supports, and thrust blocks have been installed.

4.2.8 Lines which include service hydrants with self draining valves must be set in a well drained, granular base and thoroughly flushed to prevent debris from causing valve malfunction.

4.2.9 Use QVP-5.01 – Pre-Hydro – Hydro – Post Hydro Inspection Activities and QVC-5.01 Checklist for Underground Piping to supplement this procedure.

4.5 The quality verification activities performed by City of Coffeyville, KS for each work activity are categorized as follows:

• Preparatory meeting prior to starting construction. • In-process inspections during construction – random to full-time.




• Final inspection after completing construction – random to 100% • Review of records of construction

A detailed list of the type and extent of quality verification activities associated with each category is specified in the supplemental Construction Quality Verification Procedures applicable to the particular work activity.

4.6 All quality verification activities will be performed by personnel that have the necessary skills, training, and certifications to perform the particular task.


QVP No. 5.01 – Pre-Hydro – Hydro – Post Hydro Inspection Activities Rev RICE



quality of work performed by contractors associated with Piping Fabrication and Erection. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of

Coffeyville, KS Construction Quality Verification Procedure No. 5.00 – Piping Fabrication and Erection – General.

1.3 Requirements that pertain to the contractor with regard to construction, testing, inspection,



The following forms are used to document the quality verification activities specified in this procedure. QVC-5.01 - Checklist for Underground Piping

CF-501 – Hydro Inspection Workbook pages 1 thru 4 CF-502 – System Line List Tracker CF-009 – Master Punch List Log CF-503 – Holiday Test Record Log CF-504 – Tie-In Placement Application, Authorization, and Record

3.0 Definitions

See Governing Spec or Code table of contents for definitions 4.0 Procedure 4.1 General

4.1.1 The following work activities are associated with Pre-Hydro Release activities:

4.1.1.1 Test Packages shall be assembled and submitted for review by the contractor to City of Coffeyville, KS

4.1.1.2 Test packages shall include but not limited to:

4.1.1.2.1 Signed CF-501 pages one thru four.

4.1.1.2.2 Highlighted Line list.

4.1.1.2.3 Highlighted Isometric drawings Weld mapped per QVP-10.01 Paragraph 4.16.2.

4.1.1.2.4 Contractor Weld Log or Weld Traveler correlated to the Weld Maps.

4.1.1.2.5 Highlighted P&ID’s with Hydro boundaries Red-Lined.

4.1.1.2.6 Detailed Support drawings.

4.1.1.2.7 Calibration sheet for Hydro testing Gauges.




4.1.1.2.8 Material Certifications (As Needed by Client).

4.1.1.2.9 Any RFI’s or technical clarifications.

4.1.1.3 Test package shall be walked down for compliance.

4.1.1.3.1 Verify Piping, Piping Components and Supports conform to Applicable

Codes, Specifications and Drawings.

4.1.1.3.2 NDE/PMI/PWHT/BHN verified and accepted by Site QC manager.

4.1.1.3.3 In-Line Instruments removed.

4.1.1.3.4 Valve orientation correct.

4.1.1.3.5 Valves open as required.

4.1.1.3.6 Blinds installed where applicable and in accordance with Hydro workbook - Blind Flange Matrix worksheet CF-501.

4.1.1.3.7 Log applicable data into the System Line List Tracker CF-502.

4.1.1.3.8 Log Data and List Priority Codes into the Master Punch List CF-009.

4.1.1.3.8.1 Reminder: Priority Code 1 will prevent Hydro Testing.

4.1.1.3.9 Red-Line and mark-up Hydro Boundaries on Master set of P&ID’s.

4.1.1.3.10 Sign off all Pre-Hydro sections and release package for Testing.

4.1.2 The following work activities are associated with Hydro Testing Acceptance activities:

4.1.2.1 Follow Hydro procedures located in CF-501 Hydro Workbook – Hydro Procedure worksheet for Filling – Testing – Gauge Zeroing – Draining.

4.1.2.2 Sign off each of the following steps upon verification.

4.1.2.2.1 Verify the Gauge Number correlates with the Calibration sheets.

4.1.2.2.2 Verify Gauge range encompasses Middle Third Rule.

4.1.2.2.3 Verify Gauge Calibration dates are correct.

4.1.2.2.4 Verify test Media correct.

4.1.2.2.5 Verify required Test Pressure is correct and Actual Test Pressure meets this requirement.

4.1.2.2.5.1 Required test pressure shall correlate with the Line

list and Isometric Drawing requirements.

4.1.2.2.5.2 When multiple pressures are required use the upper test pressure.

4.1.2.2.5.3 Do not exceed Flange ratings.

4.1.2.2.5.4 Break up test package to meet Flange rating specifications as needed.

4.1.2.2.6 Verify Temperature. 4.1.2.2.7 Verify Test Length meets minimum code of construction holding time

before Hydro walk-down commences.




4.1.3 The following work activities are associated with Post-Hydro verification activities:

4.1.3.1 Sign each of the following steps upon verification.

4.1.3.1.1 Blinds pulled where required.

4.1.3.1.2 Supports are installed per drawings.

4.1.3.1.3 Spring hanger stops are removed.

4.1.3.1.4 All plugs are installed.

4.1.3.1.5 In-line Instruments are installed.

4.1.3.1.6 Proper Bolts and Gaskets are used.

4.1.3.1.7 Valve orientation is correct.

4.1.3.1.8 System is blown free of Test medium.

4.1.4 The following work activities are required before Final Acceptance:

4.1.4.1 Sign Final Acceptance upon completion of the following:

4.1.4.1.1 Painting Complete: See QVP – 8.01

4.1.4.1.2 Insulation Complete: See QVP – 9.01

4.1.4.1.3 Electric Tracing Complete and Tested See QVP – 9.04

4.1.4.1.4 Holiday testing: See CF-503

4.1.4.1.5 Master Punch List Log Complete and Signed off CF-009



4.1.6 The type of quality verification activities to be performed for each work activity and the extent thereof is described in this procedure.

4.1.7 All quality verification activities will be performed by personnel that have the necessary



4.2.1 Preparatory meetings are held with contractors prior to the start of construction for specified work activities in order to verify the following: • Verify that the contractor fully understands the job specification requirements. • Review the contractor’s quality control program and how it will be implemented for

the work activity.





contractor has the most current versions. • Review requirements for permits and/or authorizations that will be required during

the course of construction. • Review the quality verification activities that City of Coffeyville, KS plans to perform



• Inspection and testing Requirements • Hydro Inspection Test Plan and Procedures • Pre-Hydro – Hydro – Post-Hydro – Final Acceptance Walk-down procedure • Turn-Over Package Content and Formatting Requirements and procedures. See

Construction Site Quality Manual section 6.0.

4.2.3 When multiple contractors are responsible for a given work activity, a separate Preparatory Meeting will be held with each contractor.

4.2.4 When a given contractor is responsible for multiple work activities, the Preparatory

Meeting may include more than one work activity. 4.2.5 For work activities with multiple phases or occurrences, a separate Preparatory Meeting

is not necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Hydro-testing although their scope may include several Hydro-tests over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.













• Verify that piping is being placed in accordance with the requirements specified in

the contract documents.

• Verify that the contractor is implementing their quality control procedures during this activity.

• Verify that any Nonconformancies or action items identified during placement are

quickly resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place. Follow Construction Site Quality Manual 7.0. Use CF-002 forms.

• Prepare a Master Punch-list documenting the specific activities performed during



4.5.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the placement activities. The Final Inspection will include the following items:

• Perform a final inspection of any work performed by the contractor that was not


• Prepare a Master Punch-list documenting the specific activities performed during


• Specify the estimated date for which each item on the punch list should be

completed or corrected to be in compliance. CF-009

• Perform follow-up activities to verify that each item on the punch list is completed and/or corrected and is acceptable.

4.6 Acceptance





• Pipe fabrication, erection, welding and coating activities are complete. • The contractor has completed all inspection, testing, and quality control activities.




forms

• QVC-501 - Checklist for Underground Piping

• CF-501 – Hydro Inspection Workbook pages 1 thru 4

• CF-502 – System Line List Tracker

• CF-009 – Master Punch List Log

• CF-503 - Holiday Test Record Log

• CF-504 – Tie-In Placement Application, Authorization, and Record

City of Coffeyville, KS Engineering

Pneumatic Testing

Procedure

Rev No. Issue Date Description Prepared by: Approved by:

0 9/22/2014 Pneumatic Testing Steven E. McKenna Don Bogart

FLINT HILLS RESOURCES EPC Quality Manual Rev. DRAFT

Date: 06 Jun 2012

Page 2 of 8


QVP No. 5.03 - Pneumatic Testing Rev 0

i

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................ 1

2.0 REFERENCES ................................................................................................................ 1 2.1 Forms ...................................................................................................................................1 2.2 Standard Industry Specifications .........................................................................................1

3.0 DEFINITIONS .................................................................................................................. 2 See ASME PCC-2 ............................................................................................................................2

4.0 PROCEDURE .................................................................................................................. 2 4.1 Safety ...................................................................................................................................2

5.0 PRE- PNEUMATIC TESTING VERIFICATIONS ............................................................. 3

6.0 PNEUMATIC TESTING VERIFICATIONS ...................................................................... 4 6.1 Test Medium ........................................................................................................................4 6.2 Competent Person ................................................................................................................4 6.3 Regulation of Pressure .........................................................................................................4 6.4 Termination Valve ...............................................................................................................4 6.5 Overpressure relief protection..............................................................................................5 6.6 Gauge Location ....................................................................................................................5 6.7 Pressurization .......................................................................................................................5

7.0 POST-PNEUMATIC TESTING VERIFICATION ACTIVITIES ......................................... 6 7.1 QVP-5.01 .............................................................................................................................6

8.0 ATTACHMENT A ............................................................................................................ 7



Page 1 of 8

1.0 Scope

1.1 This document defines the City of Coffeyville, KS procedure used when performing Pneumatic

Testing.

1.2 Due to the potential for the release of significant amounts of stored energy, pneumatic testing is

neither the preferred nor recommended practice of City of Coffeyville, KS. In certain

circumstances projects may request to perform pneumatic testing in which case Burns &

McDonnell requires prior approval from the CDB Manager of Field Operations, Corporate

Director of Safety, CDB Manager of Quality, Piping Engineer of Record, and EPC Project

Manager. See attachment “A” below for approval process signatures. Attachment “A” shall be

developed by the City of Coffeyville, KS Project Management Team.

1.3 This procedure is to be used in conjunction with the requirements specified in City of Coffeyville,

KS Construction Quality Verification Procedure No. 5.01 – Pre-Hydro – Hydro – Post Hydro

Inspection Activities.

2.0 References

2.1 Forms

2.1.1 The following forms are used to document the quality verification activities specified in

this procedure.

CF-501 – Pressure Testing Inspection Workbook pages 1 thru 4


2.2.1 The following is a list of standard specifications associated with Pneumatic Testing

that may be referenced in this procedure, supplemental Construction Quality

Verification Procedures, and/or contract specifications.

ASME PCC-2 – Part 5 Examination and Testing Section ASME B31.1 – Power Piping ASME B31.3 – Process Piping ASME B31.4 – Pipeline Transportation Systems for Liquids and Slurries ASME B31.5 – Refrigeration Piping and Heat transfer Components ASME B31.8 – Gas Transmission and Distribution Piping systems ASME B31.9 – Building services Piping



Page 2 of 8

3.0 Definitions

See ASME PCC-2: Pneumatic test requirements section for definitions

4.0 Procedure

4.1 Safety

4.1.1 Due to the potential for the release of significant amounts of stored energy, Safety

shall be thoroughly planned.

4.1.2 A Safety Meeting shall be held with all personnel to discuss the planned pneumatic

testing activities.

4.1.3 Test boundaries shall be calculated using the City of Coffeyville, KS Pneumatic

Testing Calculator.

4.1.3.1 The City of Coffeyville, KS Pneumatic Testing Calculator is a MS Excel

Spreadsheet developed by using ASME PCC-2 Article 5.1, Mandatory

Appendix II Stored Energy Calculations for Pneumatic Pressure Tests

Formulas and ASME PCC-2 Article 5.1, Mandatory Appendix III Safe

Distance Calculations for Pneumatic Pressure Tests Formulas.

4.1.3.2 The MS Excel Spreadsheet was developed by Steven E. McKenna, Burns &

McDonnell Manager of Quality, CDB and has been verified and validated by

Anthony Jercha, P.E., City of Coffeyville, KS P&I Chief Piping Engineer.

4.1.3.3 All boundaries shall be marked with red “Danger Do Not Enter” flagging with

signs distributed around the calculated safety perimeter. The perimeter shall

be calculated using the City of Coffeyville, KS Pneumatic Testing Calculator.

The test boundary shall include all piping within the test. The radius is defined

by the distance from the pressurized pipe.

4.1.4 All nonessential personnel shall be evacuated from the designated test boundaries.

4.1.4.1 City of Coffeyville, KS prefers pneumatic testing be performed during off work

hours; such as evenings or weekends when all nonessential personnel are

not onsite.



Page 3 of 8

4.1.5 Only essential personnel (Inspectors, pressure regulator operators) are allowed inside

the test boundaries.

4.1.6 During increases of pressure on the system, all essential personnel shall identify the

safest location within boundaries as practical.

4.1.7 Perimeter watchers shall be located as such to prevent any personnel from entering

into the test boundaries.

5.0 Pre- Pneumatic Testing Verifications

5.1 Develop Site Specific Pneumatic Testing Procedures and submit to City of Coffeyville, KS

Construction Design-Build Manager of Field Operations, Corporate Director of Safety, Manager

of Quality - CDB, Piping Engineer of Record, and EPC Project Manager for approval. See

attachment “A” below. Attachment “A” shall be developed by the City of Coffeyville, KS Project

Management Team.

5.2 The Testing Procedure shall establish the following:

5.2.1 Define the Code of Construction; i.e. ASME B31.3, B31.1…

5.2.2 Define the piping system’s Design Pressure in psig from the Project Engineering Line

List.

5.2.2.1 Work with the Project Piping Engineer when reviewing the Line List and

determining Pneumatic Test Pressures

5.2.3 Calculate piping system Test Pressures using the rules from the code of construction

as limitations differ per each Code book

5.2.4 Measure the Center Line Linear Footage of the piping system to be tested. The piping

linear footage shall be measured using the Center Line to Center Line approach.

5.2.5 Define the pipe diameters of the system to be tested

5.2.6 Define the pipe wall thickness of the system to be tested

5.2.7 Perform the calculations using the City of Coffeyville, KS Pneumatic Testing

Calculator



Page 4 of 8

5.2.8 For each test calculate Stored Energy measured in ft-lbs

5.2.9 For each test calculate TNT Comparator measured in lbs

5.2.10 Any test exceeding .5 lbs in TNT Comparator is unacceptable

5.2.11 For each test calculate the required test boundaries

5.3 Submit the test procedure per section 5.0 for approval

5.4 Follow QVP-5.01 - Verification Procedure for Pre-Hydro - Hydro - Post-Hydro procedure for pre-

test walk downs and releases. City of Coffeyville, KS will verify installations and sign the release

to test section of CF-502 prior to testing all systems.

6.0 Pneumatic Testing Verifications

6.1 Test Medium

6.1.1 The test medium shall be either clean, dry, oil-free air, or a nonflammable, nontoxic

gas. The air should meet the requirements of Class 1, 2, or 3 air per ISO 8573-1:2001,

Compressed Air - Part 1: Contaminants and Purity Classes, should be used with a

dew point ranging from −4°F to −94°F. Inert gases such as Nitrogen is preferred

however not required.

6.2 Competent Person

6.2.1 Pressurization shall be under the control by one competent person at all times.

6.2.2 The Competency of this person shall be evaluated by the City of Coffeyville, KS Site

Manager. The City of Coffeyville, KS Site Manager shall evaluate and approve the

contractor’s elected competent person’s training and experience in Pneumatic

Testing.

6.3 Regulation of Pressure

6.3.1 Regulation of the pressure through a manual valve is not allowed. In all tests the

pressure shall be regulated through an automatic pressure regulator. The operability

of pressure regulator shall be verified by City of Coffeyville, KS and the contractor.



Page 5 of 8

6.4 Termination Valve

6.4.1 The temporary air supply piping from the compressor shall have a Ball Valve for quick

termination of supply air at the first sign of any discrepancies. The City of Coffeyville,

KS approved competent person shall be located at the termination valve throughout

the pressure test.

6.5 Overpressure relief protection

6.5.1 Overpressure relief protection shall be provided. The set pressure of a calibrated

pressure relief device shall be not more than the greater of the test pressure plus 5

psig, or 105% of the test pressure. Each over pressure relief device shall have

documentation of calibration traceable to the calibration sticker placed on the over

pressure relief device. Calibration of each pressure relief device shall be within 6

month intervals.

6.5.2 The overpressure relief device shall be placed downstream of the termination valve on

the temporary air supply piping. No obstructions shall be placed between the

termination valve and the overpressure relief valve.

6.6 Gauge Location

6.6.1 At least two calibrated pressure gauges shall be placed into the system test. One at

the source of pressure and the other at the furthest extent of the pressure test from

the source. Each pressure gauge shall have documentation of calibration traceable to

the calibration sticker placed on each gauge.

6.6.2 The pressure source shall be isolatable from the piping to be tested without isolating

the pressure gauges from the piping being tested.

6.7 Pressurization

6.7.1 The pressure shall be brought to the lesser of 25% test pressure or 20 psig slowly.

Once 20 psig has been obtained; block in the supply and hold for ten (10) minutes or

until the entire line has been inspected for leaks using a Liquid Leak Detector such as

“Snoop” or manufactured equivalent for leaks.



Page 6 of 8

6.7.2 At the first sign of any discrepancy the pressure shall be released slowly as per

section 6.7.7 and all repairs made at that time.

6.7.3 Once repairs have been completed and approved by the inspection personnel the test

may be resumed starting at step 6.7.1.

6.7.4 The pressure shall then be brought up in 25% of the required test pressure in

increments slowly and held for ten minutes or until the entire line has been inspected

for leaks using Liquid Leak Detector such as “Snoop” or manufactured equivalent for

leaks until fifty percent (50%) of the required test pressure has been achieved.

6.7.5 The pressure will then be brought up in twenty-five percent (25%) of the required test

pressure increments with hold points at each five percent (5%) increment until the

required test pressure has been achieved. Each hold point should be at three minutes

to allow piping strains to equalize.

6.7.6 The required test pressure will then be held for not less than ten (10) minutes or until

the entire line has been checked with each joint inspected with Liquid Leak Detector

such as “Snoop” or manufactured equivalent for leaks.

6.7.7 The pressure will then be released slowly at no more than five percent (5%) per

minute.

7.0 Post-Pneumatic Testing Verification Activities

7.1 QVP-5.01

7.1.1 Use QVP-5.01 verification procedure for pre-hydro testing, hydro testing, and post-

hydro testing for post-test walk downs and final acceptance. Burns & McDonnell will

verify reinstatement installations and sign the final acceptance section of CF-501.

Burns & McDonnell Construction Quality Verification Procedure


Page 7 of 8

8.0 ATTACHMENT A

This is for Pneumatic Pressure Testing Approval only

Line # Service Material Type

Actual Pipe

Diameter

Material Thickness (inches)

Design Pressure

Testing Pressure

(psig)

Center Line Pipe

linear footage

Stored Energy (ft-lbs)

TNT Comp. (lbs)

Minimum Boundary

Radius (ft)

Approvals Printed Name Signature Date

City of Coffeyville, KS Manager of Field Operations

City of Coffeyville, KS Director of Safety

City of Coffeyville, KS CDB Manager of Quality

Piping Engineer of Record

EPC Project Manager


QVP No. 6.01 – Instrumentation & Controls RICE


1.0 Scope 1.1 This procedure defines the activities that City of Coffeyville, KS shall perform in verifying the

quality of work performed by contractors associated with Instrumentation Installation activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of

Coffeyville, KS Construction Quality Verification Procedure No. 6.00 – Instrumentation & Electrical – General.





CF-501 – Pressure Testing Worksheets

3.0 Procedure 3.1 General

3.1.1 The following work activities are associated with Instrumentation & Controls Installation activities:

• Installation • Pretest Verifications and Inspection • Testing • Calibrations • Inspections

3.1.2 Installation:

3.1.2.1 All Instrumentation & Controls shall be installed in accordance with approved COC Instrument Installation Detail Drawings.

3.1.2.2 In order to maintain quality control during the installation of Instrumentation & Controls, the following shall apply:

3.1.2.2.1 Local temperature indicators (dial thermometers, etc.) should be

installed immediately prior to start up in order to avoid damage to the instruments during construction.

3.1.2.2.2 Orifice plates, turbine meters, all rotameter, floats, etc. shall not be in the line during testing, flushing, or pre-start up operations.

3.1.2.2.3 Orifice flanges shall be checked to ensure that taps are drilled through prior to installation of the block valves.

3.1.3 Pretest Verifications and Inspections:




3.1.3.1 P&ID Verifications:

3.1.3.1.1 The Contractor shall compare each instrument installation drawing against the Piping and Instrumentation Diagram (P&ID) and the project instrument specifications and standards. Any discrepancy between the installation drawing and the P&ID or specifications shall be brought to the attention of City of Coffeyville, KS for resolution and approval.

3.1.3.2 Field Inspection Verifications:

3.1.3.2.1 The Contractor shall physically check all instrument installations to ascertain that the installation agrees with instrument drawings.

3.1.3.2.2 The following Field Inspection Check Guide represents a list of basic items which should be checked by the Contractor as the instrument installation progresses and prior to testing of instrument systems:

♦ Verify instruments complete and undamaged as received from storage, including installation instructions and a checklist of parts.

♦ Verify instruments haven’t been damaged during or after installation. ♦ Verify all instruments tagged per the Engineering specification. ♦ Verify the tags fastened securely. ♦ Verify process piping valves and tubing conforms to the piping

specifications. ♦ Verify instruments are located and mounted where they are readily

accessible and visible from existing ladders, platforms, or grade. (Accessibility of instrument installation from ground or permanent platforms should be reviewed for operation needs, serviceability, and safety).

♦ Verify all items installed in accordance with the appropriate Engineering drawing, standards and specifications. Verify required minimum straight pipe lengths upstream and downstream from an instrument have been achieved.

♦ Verify instrument connections to process-line in correct location. (Wherever possible, instrument piping manifold block valves shall be located close to and within easy reach of the instrument).

♦ Verify high-pressure and low-pressure connections from pressure tap to instrument connections have proper continuity.

♦ Verify flow-meter installations are correct with regard to seal pot requirements and their method of support.

♦ Do instruments have off-spec plugs? (Replace where deemed necessary).

♦ Verify support of instruments and related piping are adequate to ensure minimum vibration.

♦ Verify painting complete on field instruments that require corrosion resistant surfaces to protect them from atmosphere.

♦ Verify instrument and control piping are installed in an orderly manner and are properly supported.

♦ Verify threaded thermometer and thermocouple wells are seal welded. ♦ Verify local-mounted instruments securely and neatly attached. ♦ Verify tubing is properly supported. ♦ Verify tubing unions are accessible for maintenance.




♦ Verify tubing is routed so as not to impede access to instruments or control valves.

♦ Verify Conduit Seals are installed where necessary.

3.1.4 Testing:

3.1.4.1 Prior to the final instrument inspection, a pressure test shall be made on all signal air lines to assure non-leak conditions. Use CF-501 to record all Pressure Tests.

3.1.4.1.1 Air supply tubing to the filter/regulator shall be tested at line pressure using leak detector solution (Snoop, Leak-Tec or equal).

3.1.4.1.2 The tubing downstream of the filter/regulator shall normally be brought up to operating pressure (e.g. 20 psig for 3-15 psig units and 35 psig for 6-30 psig units, etc.).

3.1.4.2 In the event instrument air is not available for testing, instrument quality air from a compressor, bottled dry air, or nitrogen can be used as the test medium.

3.1.4.3 All connections shall be bubble-tested using leak detector solution.

3.1.4.4 Tests shall be in accordance with QVP-5.01 paragraph 4.1.2 and approved by City of Coffeyville, KS personnel.

3.1.4.5 When required by project specifications, instrument process lead lines are pressure tested in the following manner at applicable pressures:

3.1.4.5.1 Leads are to be subjected to the specified pressure with nitrogen or other available inert gas; and all connections, joints, fittings, etc. are to be checked for leakage with Snoop, Leak-Tec (or equal) leak detector solution.

3.1.4.5.2 Instrument is to be protected from damage by over-pressure or over-differential.

3.1.4.5.3 Test pressure must not exceed the manufacturer's pressure rating.

3.1.4.6 Electronic signal wiring, electrical instrument wiring, and thermocouple lead wiring shall be checked for continuity, grounding and shielding in accordance with project electrical specifications. When conducting tests, instruments subject to damage must be disconnected or protected. Protection from welding damage shall also be provided.

3.1.5 Calibration:

3.1.5.1 When the job contract includes field calibration in the scope of work to be performed, the specific requirements and the method of calibration shall be in accordance with project instrument specifications.

3.1.5.1.1 Factory calibration shall be maintained whenever possible. Contractor shall perform calibration and testing when specified.

3.1.5.1.2 The Contractor shall maintain a file of instrument specifications on which calibration shall be verified.

3.1.5.1.3 City of Coffeyville, KS shall supply a table of all alarm and shutdown settings. Response of alarm and shutdown systems shall be checked and recorded.




3.1.5.1.4 Alarms, sequences and shutdown systems shall be tested by simulated conditions and responses recorded.

3.1.6 Flow Instruments:

3.1.6.1 Indicating flow instruments, rotameter, turbine meters, etc. shall be checked for proper operation and orientation.

3.1.6.2 Differential type flow instruments calibration is covered under section 4.1.9.1.

3.1.6.3 Flow instrument tags, model, type and material shall be verified as per engineering specifications.

3.1.7 Temperature Instruments:

3.1.7.1 Potentiometric type instruments shall be checked to their specific range at three points by imposing a millivolt signal.

3.1.7.2 Check thermocouples for proper installation, thermocouple type, lead wire type and polarity of connection. The application of a low heat source to the thermocouple tip is a recommended method if thermocouple can be easily removed. A high level millivolt signal shall be generated at the thermocouple head to check continuity as a secondary method. Action and matching readout shall be observed at the final readout device.

3.1.7.3 Temperature control instruments shall be checked in accordance with procedure for calibration of transmitters and receivers. Bi-metal dial thermometers and fully compensated filled systems for local indication shall not be calibrated in the field. Do not alter manufacturer's calibration.

3.1.7.4 Temperature instrument tags, model, type and material shall be verified as per engineering specifications.

3.1.8 Pressure Instruments:

3.1.8.1 Pressure transmitters and receivers are covered below.

3.1.8.2 Local pressure controllers shall be checked at 25%, and 100% of scale range. Output signal shall be observed and control action shall be set per instrument specification sheet.

3.1.8.3 Pressure instrument tags, model, type and material shall be verified as per engineering specifications.

3.1.9 Level Instruments:

3.1.9.1 For differential type level instruments

3.1.9.1.1 Verify Correct Seal Fluid is installed in each leg (As Applicable).

3.1.9.1.2 Verify the Transmitter is installed at the correct elevation.

3.1.9.1.3 Verify the high side of the Transmitter is connected to the bottom tap of the Vessel.

3.1.9.1.4 Verify the impulse lines are sloped correctly.

3.1.9.1.5 Any changes made during verification to the span or upper/lower range points shall be documented on the I/O list.




3.1.9.2 Float type level instruments shall be checked for mechanical operation.

3.1.9.3 Level controllers shall be installed per manufacturer’s OEM Manual.

3.1.9.4 Level instruments tags, models and components material shall be verified per engineering specifications.

3.1.10 Control Valves:

3.1.10.1 Verify orientation in pipe line with respect to flow pattern.

3.1.10.2 Control valve top works should be oriented to permit easy access to positioners, transducers, side mounted hand wheels and other accessories.

3.1.10.3 Verify air failure position, travel indicator adjustment, and open and close diaphragm pressures.

3.1.10.4 Set positioner, booster or relays for the correct action of input and output signal range. CAUTION: Bench settings shall not be changed without express permission of City of Coffeyville, KS.

3.1.10.5 Limit switches shall be adjusted and set.

3.1.11 Transmitters and Receivers:

3.1.11.1 Calibration of transmitters and receivers shall not be performed unless required by project specifications.

3.1.11.2 Transmitter and receiver tags, model, type and material shall be verified to engineer’s specifications.

3.1.12 On/Off Valve:

3.1.12.1 Verify Solenoid Valve and Limit Switches are installed correctly and meet specifications.

3.1.12.2 Verify Instrument Air Supply is connected correctly.

3.1.12.3 Verify Valve flow direction is correct.

3.1.13 Inspections:

3.1.13.1 A final completed field inspection of all Instrumentation & Controls shall be made by the Contractor to confirm that instrumentation has been installed according to applicable drawings and specifications.

3.1.14 City of Coffeyville, KS shall perform quality verification activities to ensure that each work activity is completed in accordance with the project specifications. These quality verification activities can be classified into one of the following categories:



extent thereof, is described in this procedure.




3.1.16 All quality verification activities shall be performed by personnel that have the necessary skills, training, and certifications for the particular task.



• Review the contractor’s quality control program and how it shall be implemented for

the work activity.


• Review requirements for permits and/or authorizations that shall be required during




• Installation • Testing • Calibrations • Inspections

3.2.3 When multiple contractors are responsible for a given work activity, a separate Preparatory Meeting shall be held with each contractor.



necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Loop Checks although their scope may include performing Loop Checks for many systems over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.


3.3.1 City of Coffeyville, KS shall perform a thorough inspection of the initial construction work performed by each contractor for each work activity. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection shall include the following:





• Fully inspect the initial work performed by contractor to verify that it is in accordance with the requirements specified in the contract documents.

• Verify that the contractor is implementing their quality control procedures at the

jobsite.



4.4.1 City of Coffeyville, KS shall perform Follow-up Inspections of the contractor’s work on a random but regular basis starting immediately after the Initial Inspection and through the completion of the work activity. The frequency and extent of Follow-up Inspections shall be based on the scope of work, contractor performance, and associated risk to the project. The Follow-up Inspections shall include the following activities:









4.5.1 City of Coffeyville, KS shall perform a Final Inspection at or near the completion of the pre-placement activities. The Final Inspection shall include the following items:




each Final Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This




would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.




4.6 Acceptance

4.6.1 City of Coffeyville, KS shall typically accept or release each area prior to commencing Instrumentation activities.

4.6.2 City of Coffeyville, KS shall verify the following prior to issuing final acceptance for a

particular area:

• City of Coffeyville, KS has reviewed and accepted all documentation • The contractor has completed all inspection, testing, and quality control activities.




forms:

• CF-501 – Pressure Testing Worksheets


QVP No. 6.01 – Electrical Rev. RICE


The Electrical Quality Control Checklists, Form Nos. QV6.02-1A through QV6.02-1D, are used to document job performance during preliminary, intermediate and final building stages and are maintained in Quality Control Records files.

A. Preliminary Stage: (1) Receiving of electrical equipment and warehousing procedures shall be verified

against the Bills of Material using Form No. CF-004, Materials Received Report, or Contractor Material Received Report.

(2) Verification shall be made reviewing the electrical equipment supplied by the vendors versus the Specifications shown in the Bills of Material.

(3) Material Receiving and Warehousing, Refer to Section 4.0 of the Site Quality Manual, Material Management for specific requirements. CF-004, CF-005 and CF-007 Forms Shall be Used.

(4) Verify to ensure that the equipment is protected against physical damage due to construction work, and protected against moisture and condensation accumulations during the time it is stored.

(5) Verification during installation, that the equipment is properly supported and securely anchored in place.

(6) Verification to ensure that access to the equipment is unobstructed for maintenance and operation.

(7) Form No. QV6.02-02, Equipment Checklist, shall be used to verify installation and for final sign-off.

(8) Verify conduit and wireway installations, separation of voltage levels is maintained, fittings installed as required, conduit and wireways are properly supported and anchored, conduit and fitting connections are properly and securely made, and the conduit and wireways are protected against moisture accumulation.

(9) Verify entire conduit system using Form No. QV6.2-03, Conduits Checklist. (10) Form No. QV6.02-04, Underground Electrical Conduit Inspection, shall be completed

before backfill. (11) Form No. QV6.02-05, Seals and Drains Checklist, shall be used for seal and drain

checkout. (12) Form No. QV6.02-06, Cable Tray Checklist, shall be used to checkout cable tray

installation. (13) Form No. QV6.02-07, Lighting Checklist, shall be used for lighting installation

verification checkout. (14) Form No. QV6.02-08, Pole Lines Checklist, shall be used for pole line verification. (15) Form No. QV6.02-09, Grounding Checklist; Form No. QV6.02-10, Grounding Test

Report and Form No. QV6.02-11, the Ground Rod Resistance Test Report shall be used for grounding installation and verification.

B. Intermediate Stage Verification

(1) Cable installation; checks have been made to verify that proper procedures are being used, and that wire and cables are installed without any apparent damage, using Form No. QV6.02-12, Cable and Wire Checklist.

(2) Verify terminations have been inspected to ensure that they are secure and correct,




color coding is correct, wires are properly and clearly tagged, wire ends are properly and clearly tagged, and that wire ends are properly prepared for connection to the terminals.

(3) Grounding has been inspected to ensure that connections are properly made. C. Final Stage 1. A review and verification of contract and field checkout and testing procedures will be

performed. Test records shall be verified to ensure that results are in compliance with the Specifications. Verifications shall be made periodically to insure that the test contractor is performing the tests, as required. The test reports to be verified shall include, but are not limited to:

(a) megger tests of equipment and cables, (b) sag and tension reports for pole lines, (c) phasing and rotation of motors, (d) operational tests of motor starters and motors, (e) relay coordination tests and simulated operation tests of motor, and (f) process and instrument control circuits.

Seals shall be checked to verify seals are properly made and poured and that poured seals are marked. Additionally, inspection and acceptance forms will be verified.

2. Records defining the electrical equipment, installations, connections, and testing required by

the Quality Control Program shall be maintained in the form of:

(a) Checklist covering standard items not specifically detailed on Design Drawings.

(b) Copies of Design Drawings marked to show what items were checked, and comments on those items.

(c) Written notes for items and observations of a general nature where neither the checklists nor drawings can be utilized.

3. Completion of the three stages should provide further assurance that the electrical

installations have been completed in accordance with customer Specifications, and are available for plant startup and operation.

D. Overall Guidelines for Verifications:

(1) The following minimum check tests and testing procedures shall be verified and/or performed, as required, to ensure compliance with the Specifications.

(2) Motor Starters


(a) Fuses and overload heaters are the proper size and rating.




(b) Circuit breakers are of the proper capacity on the instantaneous and time delay systems.

(c) Continuity of control systems. (d) Proper opening and closing from both remote and local stations. (e) Mechanical interlock, if provided.

(3) High Potential Testing of Cables

(a) Verify high potential testing has been performed on cables rated 5,000 volts or

higher. (b) All cable runs shall be installed, complete with splices and terminations.

Conductors have been removed from equipment not under test, and grounded. (c) Maximum test voltages for circuits are in accordance with the manufacturer’s

recommendations. (d) Form No. QV6.02-13, Insulation Resistance Test and DC High Voltage Test on

Electric Cables and Wires, shall be used.

(4) Motors

(a) Minimum Value of insulation resistance shall be as shown in the following table.

(b) 1,000 HP and below – Class A & B insulation

600V 4,160V 1.5 MΩ 5.0 MΩ

(c) Motors that fail the insulation resistance must be dried out. If drying is

required, it should be continued until four consistently high resistance values are obtained. Readings should be taken at four-hour intervals.

(5) Control and Instrument Circuits

(a) Control and instrument circuits have been inspected for continuity, grounds,

operation, and insulation resistance. (b) Verify wire and terminal connections have been inspected for proper

identifications, polarity, and tightness. There shall be no loose wires.

(6) Grounding

(a) Ground resistance at connection to equipment enclosures or neutrals has been tested with a suitable megger to ensure that it does not exceed 5 , or as specified.

(b) Verify each ground well for proper conductor size and connections. (c) Verify location of each ground well shown on the Drawings. (d) Form No. QV6.02-11, Ground Rod Resistance Test Report, and/or Form No.

QV6.02-10, Grounding Test Report shall be used to verify and record these




tests.

(7) Uninterruptible Power Systems.

(a) Verify all connections for tightness. (b) Verify all incoming and outgoing breakers for proper positions. (c) Verify input of the ac battery charger voltages. (d) Verify output of the ac and dc voltages. (e) The following tests have been performed in accordance with the

manufacturer’s recommendation before the units are put into service.

Synchronizing AC outputs; AC input and output No break; AC/DC Battery output voltage and charger operation, during AC input failure. Manufacturer’s recommendations for test verifications have been followed.

(8) Turbo-generators

(a) The emergency generator shall be verified for automatic starting, generation,

and power transfer during a simulated loss of normal power according to the manufacturer’s instructions.

(b) The turbo-generator for critical fan coolers shall be verified in accordance with the manufacturer’s recommendations and under their supervision.

(9) General – Installations and Equipment

(a) Verify for compliance of installations with Design Drawings, Standards,

Specifications, and Codes. (b) Verify for consistency and quality of workmanship. (c) Verify for compliance of rack and control panel settings and positioning. (d) Verify inspection and acceptance forms for accuracy and completeness.

F Reference(s)

None

G. Forms

Electrical (1) QV6.02-A through QV6.2-D, Electrical QC Checklists (2) QV6.02-02, Equipment Checklist (3) QV6.02-03, Conduits Checklist. (4) QV6.02-04, Underground Electrical Conduit Inspection




(5) QV6.02-05, Seals and Drains Checklist (6) QV6.02-06, Cable Tray Checklist (7) QV6.02-07, Lighting Checklist (8) QV6.02-08, Pole Lines Checklist (9) QV6.02-09, Grounding Checklist (10) QV6.02-10, Grounding Test Report (11) QV6.02-11, Ground Rod Resistance Test Report (12) QV6.02-12, Cable and Wire Checklist (13) QV6.02-13, Insulation Resistance Test and DC High Voltage Test on Electric Cables

and Wires (14) QV6.02-18, Battery and Charger Test and Inspection

Material Receiving and Warehousing

CF-004 CF-005 CF-007


QVP No. 7.01 – Stationary Equipment Placement Rev 0



quality of work performed by contractors associated with Stationary Equipment placement construction activities.


Coffeyville, KS Construction Quality Verification Procedure No. 7.00 – Equipment – General. 1.3 Requirements that pertain to the contractor with regard to construction, testing, inspection,




QVC-7.01 – Checklist for Stationary Equipment

CF-701 – Equipment Installation Log CF-702 – Stationary Equipment Installation Application, Authorization, and Record CF-703 – Equipment Plumb Record CF-704 – Final Closing Authorization Record

2.2 Standards

ASME I – Rules for Construction of Power Boilers ASME VIII – Rules for the Construction of Pressure Vessels API 510 – Pressure Vessel Inspection Code API RP 534 – Heat Recovery Steam Generators API 650 – Welded Steel Tanks for Oil Storage API 560 – Fired Heaters for General Refinery Services API 660 – Shell and Tube Heat Exchangers for General Refinery Services API 661 – Air-Cooled Heat Exchangers for General Refinery Services API 662 - Plate Heat Exchangers for General Refinery Services API RP686 – Recommended Practices for Machinery Installation and Installation Design AWWA D 100 – Welded Steel Tanks for Water Storage Burns & McDonnell Engineering Specifications PIP– Process Industry Practices Vendor Recommendations

3.0 Definitions

See Governing Spec or Code 4.0 Procedure 4.1 General




4.1.1 The following work activities are generally associated with Receiving Inspection activities: See Site Quality Manual Section 4.0 Materials Management.

4.1.1.1 Upon receipt of equipment verify the following

• Name Plate date • Nozzle/Flange size, location and orientation • Lifting Lug arrangements • Anchor Bolt hole size and location on equipment • Anchor Bolt Template • Coating on equipment • Incomplete work and items removed for shipping • Physical Damage from shipping • OEM Manual for Equipment Preservation

4.1.2 The following work activities are associated with Pre-installation activities:

4.1.2.1 Verify Anchor bolt locations are checked against equipment base plate (Hole location and size) for proper layout, plumbness, projection/thread length and acceptable physical condition. Anchor bolts and nuts are free of oxidation and dirt and are clean and lubricated as required.

4.1.2.2 Verify If the stationary equipment is being placed on a concrete foundation and requires grouting, the foundation shall be properly prepared and inspected in accordance with applicable design drawings, details and specifications prior to setting equipment on the foundation.

4.1.2.3 Verify the concrete foundation has been cured in accordance with project concrete specification. Unless otherwise approved by the responsible engineering organization, concrete foundations are required to attain at least 80% of the twenty-eight (28) day design compressive strength prior to supporting equipment loads.

4.1.2.4 Verify if the stationary equipment is being placed on structural steel, the steel shall be in compliance with QVP-3.00.

4.1.2.5 Verify that Shims are smooth with rounded corners, flat and free of dirt or foreign materials. Good practice is to use a combination of shims yielding a shim pack of no more than five (5) shims. Shims that will be grouted in place should be carbon steel. Exposed shims that will be left in place should be stainless steel. Shims should not be galvanized, laminated or painted.

4.1.2.6 Verify Bed plates (fixed and sliding ends) are painted and/or coated in accordance with project specifications. Inspection of slide plate lubrication, Teflon or similar surface shall be complete.

4.1.3 The following work activities are associated with Installation activities:

4.1.3.1 Locating, Setting and Plumbing Equipment

4.1.3.1.1 Prior to setting, make a final check of the elevation of any shims, anchor bolt locations, anchor bolt projections, slide/bed plate lubrication, and nozzle orientation. Ensure that all Inspections for plumbness or settlement are in place.

4.1.3.1.2 Position the equipment on the foundation or slide/bed plate in its final location. Nozzle elevations shall be set in accordance with the design documents.




4.1.3.1.3 Equipment levelness can be achieved by adjusting jacking screws, shimming below the equipment, adjusting fixators, leveling wedges, or by using dual wedges with adjusting screws and tightening the hold down bolt nut to hold the equipment in place. Elevation adjustment nuts should not be used as the only means of support under equipment that will be grouted in and become a permanent part of the foundation. The equipment will require shims to assist the adjustment nuts for support of the equipment.

4.1.3.1.4 If the equipment/unit is placed on structural steel, shims should be the same material as the structural support member. Shims should be welded to the support member.

4.1.3.1.5 Hold down bolts should not be bolt bound. The hold down bolts should be reasonably centered based on a visual examination. Undercutting of hold down bolts is not permitted. The equipment/unit vendor may permit slotting of the bolt holes to relieve the condition. When slotting or over sizing bolt holes, a larger washer may be required.

4.1.3.1.6 Prior to removal of lifting equipment, make a final check of plumbness, levelness and correct alignment.

4.1.3.1.7 CF-703 Equipment Plumb Record shall be used.

4.1.3.1.8 Ensure that sliding plates and slotted holes are properly aligned for thermal expansion. Assure that the proper gap (typically 1/16”) exists between the hold down bolt washers and equipment to allow for thermal expansion. Verify double nuts are tightened against each other or other means of securing the connection shall be used, where specified by the design documents.

4.1.3.1.9 Electrical grounding on high or elevated equipment should be completed as soon as practical after the equipment has been set to protect equipment in the event of lighting.

4.1.3.2 Grouting of Equipment

4.1.3.2.1 Grout type shall be as specified in the design documents.

4.1.3.2.2 After the grout has cured, loosen any leveling bolts/nuts and remove shims, if required. Dry pack any void areas created if the shims are removed.

4.1.3.3 Piping Alignment to Equipment

4.1.3.3.1 Piping systems shall be installed and positioned to bring the piping flanges or weld ends into satisfactory alignment with the equipment flanges or weld ends. Pipe ends welded or flanged, of connecting pipe shall not be “cold pulled” into position nor should any undue pipe stress be placed on the nozzles.

4.1.3.3.2 Flange bolts at equipment flanges shall be capable of removal by hand without binding, prying or stress when loosened.




4.1.3.3.3 Flange face separation should be within the gasket spacing plus 1/16 inch or in accordance with the vendor’s recommendations.

4.1.3.3.4 Piping should be supported by the permanent fixed and spring supports and hangers. As a minimum, the first three permanent load bearing supports on each side of the equipment should be sufficiently structurally completed to accept full design loading prior to connecting to equipment flanges or weld ends.

4.1.3.4.1 Temporary supports may be installed provided that excessive nozzle loads are not imparted to the equipment flanges or weld ends.

4.1.3.3.5 Installed hangers shall be set to design loads. Stops should remain installed for all spring hangers and spring supports until after Hydro testing and prior to the start of commissioning activities.

4.1.3.3.6 Adjusting the spring tension of spring hangers or springs supports as a method of achieving piping alignment to equipment is not acceptable.

4.1.3.3.7 Pressure testing of piping systems should be performed after piping alignment and fit up to the equipment. Pressure testing should be complete prior to final closure of the equipment and in accordance with QV-5.0.

4.1.3.4 Equipment Internals

4.1.3.4.1 Equipment internals shall be installed and inspected in accordance with design documents.

4.1.3.4.2 Field pressure testing of equipment is not normally required if the component has been tested in the shop, unless required by the client or design documents.

4.1.3.4.3 Equipment may be included within the boundaries of a piping test if the test medium is compatible with the equipment and the equipment maximum allowable pressure or differential pressure is not exceeded and adequate support is provided for hydrostatic loads.

4.1.3.4.4 Equipment normally in vapor or gas service shall have the foundation design load verified when the test medium is a liquid to ensure that the foundation is not overloaded.

4.1.3.4.5 Vessel or column trays or internals shall be tested where required by the design documents.

4.1.3.5 Cleanliness and Final Closure

4.1.3.5.1 Cleanliness inspections shall be performed prior to final closure of each component to assure that cleanliness is in accordance with project and equipment vendor requirements and any desiccant or like preservatives have been removed.




4.1.3.5.2 Cleanliness inspections should be performed for each chamber of the piece of equipment but not necessarily each opening.

4.1.3.5.3 Where man-ways for access are not provided, cleanliness inspections shall be performed prior to pipe bolt up or weld out.

4.1.3.5.4 CF-704 Final Closing Authorization Record shall be used.

4.1.4 The following work activities are generally associated with Post placement activities:

• Lubrication Inspections • Instrumentation and Controls Inspections • Grounding Inspections • Coating Inspections • Insulation and or Heat Tracing Inspections • Fireproofing Inspections



• Preparatory meeting prior to starting construction. • Initial inspections of construction. • In process inspections during construction – random to full-time. • Final inspection after completing construction – random to 100% • Review of records of construction





4.2.1 Preparatory Meetings are held with contractors prior to installing equipment. Additional meetings may be held for subsequent equipment installations if needed. The purpose of the Preparatory Meeting is to verify the following: • Verify that the contractor and/or testing agency fully understands the job specification

requirements.










Preparatory Meeting will be held with each contractor. 4.2.3 For work activities with multiple phases, a separate Preparatory Meeting is not

necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for installing Equipment in several locations at various times. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.


4.3.1 City of Coffeyville, KS will monitor the initial placement activities. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:





• Prepare a Master Punch-List (CF-009) documenting the specific activities performed

during the Initial Inspection and identify any items of nonconformance or other action items for follow-up and resolution.


4.4.1 City of Coffeyville, KS will continually monitor the equipment installation activities through completion. The Follow-up Inspections will include the following activities:

• Verify that equipment is being installed in accordance with the requirements



• Verify that any Nonconformancies or action items identified during placement are



during each Follow-up Inspection and identify any items of nonconformance or other action items for follow-up and resolution.





4.5.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the

equipment installation activities. The Final Inspection will include the following items:

• Perform a final inspection of any work performed by the contractor that was not previously inspected during the Initial and Follow-up Inspections but would be prudent to assure the final quality of the work. Verify that all work is in compliance with the specifications and most current drawing revision at the time of final inspection.


during each Final Inspection and develop a Punch-List (CF-009 )of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.

• Specify the estimated date for which each item on the Punch-List (CF-009) should be

completed or corrected to be in compliance. • Perform follow-up activities to verify that each item on the Punch-List (CF-009) is

completed and/or corrected and is acceptable.

4.6 Acceptance


• Equipment installation activities are complete. • The contractor has completed all inspection, testing, and quality control activities.


• All final inspection Punch-List (CF-009) items are resolved and accepted.

• Log completion into CF-701 – Equipment Installation Log


forms:

• QVC-7.01 – Checklist for Stationary Equipment

• CF-701 – Equipment Installation Log

• CF-702 – Equipment Installation Application, Authorization, and Record

• CF-703 – Equipment Plumb Record

• CF-704 – Final Closing Authorization Record


QVP No. 7.02 – Rotating Equipment Placement Rev 0



quality of work performed by contractors associated with Rotating Equipment placement construction activities.


Coffeyville, KS Construction Quality Verification Procedure No. 7.00 – Equipment – General. 1.3 Requirements that pertain to the contractor with regard to construction, testing, inspection,




QVC-7.02 - Checklist for Rotating Equipment

CF-701 – Equipment Installation Log CF-704 – Final Closing Authorization Record CF-705 – Rotating Equipment Installation Application, Authorization, and Record CF-706 – Coupling Alignment Record

2.2 Standards

API RP 686 – Recommended Practices for Machinery Installation and Installation Design

3.0 Definitions

See Governing Spec or Code 4.0 Procedure 4.1 General

4.1.1 The following work activities are generally associated with Receiving Inspection activities: See Site Quality Manual Section 4.0 Materials Management.

4.1.1.1 Upon receipt of equipment verify the following

• Name Plate date • Nozzle/Flange size, location and orientation • Lifting Lug arrangements • Anchor Bolt hole size and location on equipment • Anchor Bolt Template • Coating on equipment • Incomplete work and items removed for shipping




• Physical Damage from shipping • OEM Manual for Equipment Preservation

4.1.2 The following work activities are associated with Pre-installation activities:

4.1.2.1 Verify Anchor bolts locations are checked against equipment base plate (hole location and size) for proper layout, plumbness, projection/thread length and acceptable physical condition. Anchor bolts and nuts are free of oxidation and dirt, and are clean and lubricated as required.

4.1.2.2 Verify If the rotating equipment is being placed on a concrete foundation and requires grouting, the foundation shall be properly prepared and inspected in accordance with applicable design drawings, details and specifications prior to setting equipment on the foundation.

4.1.2.3 Verify the concrete foundation has been cured in accordance with project concrete specification. Unless otherwise approved by the responsible engineering organization, concrete foundations are required to attain at least 80% of the twenty-eight (28) day design compressive strength prior to supporting equipment loads.

4.1.2.4 Verify if the rotating equipment is being placed on structural steel, the steel shall be in compliance with QV-3.0.

4.1.2.5 Verify the Coating of the Structural steel and on the bottom of the equipment or equipment skid shall be checked for compliance with project requirements.

4.1.3 The following work activities are associated with Installation activities:

4.1.3.1 Soleplate Installation and Leveling:

4.1.3.1.1 Verify soleplate load bearing surfaces for flatness prior to being set.

4.1.3.1.2 Soleplate leveling can be achieved by adjusting jacking screws, shimming below the soleplates, adjusting fixators, leveling wedges or by using dual wedges with adjusting screws and tightening the anchor bolt nut to hold the soleplate in place. Elevation adjustment nuts should not be used as the only means of support under soleplates that will be grouted in and become a permanent part of the foundation. The soleplate will require shims to assist adjustment nuts for support of the equipment.

4.1.3.1.3 Levelness of the soleplates should be measured diagonally across corners to ensure that the soleplate does not rock across diagonal support points.

4.1.3.1.4 For equipment installations where the equipment is bolted to the soleplates prior to grouting, an alignment check should be performed to verify that coupling spacing and final alignment can be achieved without modification to the equipment feet or hold down bolts.

4.1.3.1.5 Grout soleplates in accordance with applicable design specifications or vendor recommendations.




4.1.3.1.6 After the grout has set and cured, remove or loosen jack screws or remove shims, if required. Dry pack any void areas. Retighten anchor bolt nuts and re-verify levelness of the soleplates prior to setting equipment.

4.1.3.2 Locating, Setting and Plumbing Equipment:

4.1.3.2.1 The first piece of equipment set shall be that piece to which all others will be aligned and is considered the fixed component.

4.1.3.2.2 Position the equipment on the soleplate or foundation level and in its final location. Base plate and/or nozzle elevations shall be set in accordance with the design documents. Elevation and level should be achieved using jacking bolts, leveling nuts, shims, or fixators. Verify elevation and levelness using a machinist level or equivalent.

4.1.3.3 Rough Alignment of the Equipment:

4.1.3.3.1 Prior to grouting equipment, a rough alignment check should be performed to verify that coupling spacing and final alignment can be achieved without modifying the hold down bolts or the machine feet.

4.1.3.3.2 Ensure components, such as shaft bearings and gearboxes, are adequately clean and lubricated prior to shaft rotation.

4.1.3.3.3 Reverse Dial, Rim and Face, or Laser Alignment shall be used to perform alignment operations.

4.1.3.3.4 Verify the shims are smooth with rounded corners, flat and free of dirt or foreign materials. Shims that will be grouted in place may be either carbon steel or stainless steel. Exposed shims that will be left in place shall be stainless steel. Shims shall not be galvanized, laminated or painted.

4.1.3.3.5 Adjust the piece of equipment to the required spacing between shafts in accordance with the manufacturer’s specification. For equipment with large thrust readings, the shaft should be in its operating position for this measurement unless directed otherwise by design documents and/or vendor recommendations.

4.1.3.4 Grouting of Equipment Base Plates

4.1.3.4.1 Verify the existence of pour and vent holes are adequate.

4.1.3.4.2 Verify Grout type meets Engineering Specifications.

4.1.3.4.3 After the grout has cured, loosen any leveling bolts/nuts and remove shims, if required. Dry-pack grout in any void areas created by shim removal.

4.1.3.4.4 Perform a ping test listening for hollow areas. Not all hollow pings mean significant voids. Non shrink grout can separate from the bottom of the Base Plates creating a hollow sound.

4.1.3.4.5 Verify all Anchor Bolts are tight.

4.1.3.5 Preliminary Alignment:




4.1.3.5.1 Review the Manufacturer’s Installation Manual to determine any special alignment procedure or sequence that may be required for a particular piece of equipment as well as the required axial shaft positioning during coupling gap measurements for equipment with large end floats.

4.1.3.5.2 The preliminary alignment process consists of three main parameters in the following sequence:

4.1.3.5.2.1 Equipment/base plate is level to within specified tolerances.

4.1.3.5.2.2 Shafts are precisely aligned and positioned axially (Coupling spacing is correct).

4.1.3.5.2.3 Soft foot or rocking is within allowable values.

4.1.3.5.2.4 These parameters are measured and corrected independently. However, correction of one may impact either or both of the other two. Therefore adjustment of one parameter should be followed by measurements of all parameters until through an iterative process; all parameters are within specified tolerances.

4.1.3.5.2.5 On indicator arm spans (or coupling gaps) over five inches, indicator sag may introduce error in the parallel alignment readings. Indicator sag is the deflection caused by the weight of the indicator(s) and the indicator support arm.

4.1.3.5.2.6 Always check and measure the sag as alignment readings must be adjusted to account for the sag.

4.1.3.5.2.7 One method of checking for indicator sag is to attach the indicator support arm and indicator(s) to a rigid shaft or pipe using the same spacing and post height as in the actual alignment configuration. “Zero” the indicator on the top of the pipe and rotate the pipe 180° (indicator at the bottom position).

4.1.3.5.2.8 The indicator support arm may sag away from the pipe; hence, any change in indicator reading will be attributable to indicator sag and the indicator reading will be twice the true indicator sag.

4.1.3.5.2.9 To correct readings for indicator sag, subtract twice the amount of true sag from the bottom reading and correct the side readings by subtracting the actual amount of the true sag.

4.1.3.5.2.10 Indicator sag becomes a factor in angular alignment only when the indicator sag is significant. Best practice would be to make the indicator support arm more rigid rather than account for indicator sag in angular alignment readings.




4.1.3.5.2.11 Vertical alignments, both parallel and angular, are not affected by indicator sag.

4.1.3.5.2.12 When shafts are rotated during alignment, always rotate shafts in the same direction and as indicated for the driven piece of equipment.

4.1.3.5.2.13 Verify level of the driven component first, and then proceed to adjusting the vertical angularity, followed by elevation/vertical parallelism. The horizontal adjustments can now be made without shim changes.

4.1.3.5.2.14 Perform rocking or soft-foot checks on each equipment foot and not at the coupling. In the absence of vendor or design criteria, good practice is to limit permissible movement to 0.002 inch at each foot. Note: If not corrected, a soft foot condition may result in the loosening of the equipment hold-down bolts, metal fatigue or cracking of the equipment foot. When equipment feet are tightened with an existing soft foot condition, the bedplate, casing or body of the equipment may twist creating internal misalignment resulting in uneven wear and potential premature failure of the component.

4.1.3.5.2.15 Hold down bolts should not be bolt bound. The hold down bolt hole should be reasonably centered based on a visual examination. Undercutting of hold down bolts is not acceptable. The equipment vendor may permit slotting or over sizing of the bolt hole(s) to relieve the condition. When slotting or over sizing bolt hole(s), a larger washer may be required.

4.1.3.5.2.16 After soft–foot has been eliminated, recheck all

alignment parameters and record the accepted Coupling Alignment Record CF-706

4.1.3.6 Piping Alignment:

4.1.3.6.1 Piping systems shall be installed and positioned to bring the piping flanges or weld ends into satisfactory alignment with the equipment flanges or weld ends. Pipe ends welded or flanged, of connecting pipe shall not be “cold pulled” into position nor should any undue pipe stress be placed on the nozzles.

4.1.3.6.2 Flange bolts at equipment flanges shall be capable of removal by hand without binding, prying or stress when loosened.

4.1.3.6.3 Flange face separation should be within the gasket spacing plus 1/16 inch or in accordance with the vendor’s recommendations.

4.1.3.6.4 Piping should be supported by the permanent fixed and spring supports and hangers. As a minimum, the first three permanent load bearing supports on each side of the equipment should be sufficiently structurally completed to accept full design loading prior to connecting to equipment flanges or weld ends.




4.1.3.6.5 Temporary supports may be installed provided that excessive nozzle loads are not imparted to the equipment flanges or weld ends.

4.1.3.6.6 Installed hangers shall be set to design loads. Stops should remain installed for all spring hangers and spring supports until after Hydro testing and prior to the start of commissioning activities.

4.1.3.6.7 Adjusting the spring tension of spring hangers or springs supports as a method of achieving piping alignment to equipment is not acceptable.

4.1.3.7 Pressure Testing of Rotating Equipment

4.1.3.7.1 Field pressure testing of equipment is not normally required if the component has been tested in the shop, unless required by the client or design documents.

4.1.3.7.2 Equipment may be included within the boundaries of a piping test if the test medium is compatible with the equipment and the equipment maximum allowable pressure or differential pressure is not exceeded and adequate support is provided for hydrostatic loads.

4.1.3.7.3 Equipment normally in vapor or gas service shall have the foundation design load verified when the test medium is a liquid to ensure that the foundation is not overloaded.

4.1.3.7.4 Pressure testing of piping shall be performed after preliminary

piping alignment and fit up to the equipment. Pressure testing shall be complete prior to final alignment.

4.1.3.8 Cleanliness and Final Closure

4.1.3.8.1 Cleanliness inspections shall be performed prior to final closure of each component to assure that cleanliness is in accordance with project and equipment vendor requirements and any desiccant or like preservatives have been removed.

4.1.3.8.2 Cleanliness inspections should be performed for each chamber of the piece of equipment but not necessarily each opening.

4.1.3.8.3 Where man-ways for access are not provided, cleanliness inspections shall be performed prior to pipe bolt up or weld out.

4.1.3.8.4 Final Closing Authorization Record CF-704 shall be used.

4.1.3.9 Equipment Assembly:

4.1.3.9.1 Complete specific rotating equipment assembly in accordance with the design documents.

4.1.3.10 Final Alignment

4.1.3.10.1 Piping alignment shall be completed prior to starting final alignment activities.




4.1.3.10.2 On equipment with flanged piping connections, final alignment should be performed on the equipment with the attaching piping in the unbolted and bolted condition to verify the absence of unacceptable connective pipe strain. In both cases, the alignment must remain within the specified tolerances.

4.1.3.10.3 For pieces of equipment with common suction and/or discharge piping (such as pairs of pumps) all shaft alignments should be monitored during the piping-up operations.

4.1.3.10.4 On equipment with welded piping connections, final alignment should be performed on the equipment first with the hold-down bolts loose and then with the hold down bolts tight, unless directed otherwise by design documents, to verify the absence of unacceptable connective pipe strain. In both cases the alignment shall remain within the specified tolerances. Controlled welding of these types of joints is recommended.

4.1.3.10.5 Equipment shall not be moved to achieve alignment with equipment that has been moved due to pipe strain. The cause of the pipe strain shall be corrected by rework of the pipe and/or hangers and supports or by addition of hangers and/or supports via approved design document.

4.1.3.10.6 If equipment adjustment or re-shimming is required during the final alignment, all affected alignment parameters, including soft-foot, shall be re-verified.

4.1.3.10.7 Record acceptable final alignment readings in both the free state and connected state on the Coupling Alignment Record CF-706

4.1.3.11 Coupling Assemble and Bolt-Up

4.1.3.11.2 Assure that all uncoupled testing is complete prior to final coupling assembly and bolt up.

4.1.3.11.3 Re-verify coupling spacing, install coupling spacer and align match marks if provided. Follow coupling vendor instructions for assembly of coupling hardware, lubrication and bolting requirements.

4.1.3.11.4 Install coupling guard.

4.1.3.12 Chain or Belt Driven Equipment

4.1.3.12.2 For chain or belt driven equipment, only a final alignment operation is required.

4.1.3.12.3 Alignment may be checked using a straightedge, level or string line across the sheave or sprocket faces.

4.1.3.12.4 Belt alignment is to assure that the centerline of the drive and driven pulley grooves are aligned to the design documents and equipment vendor requirements. Allowance must be made at the face(s) of the pulley(s) with a straight edge to account for uneven pulley thickness.




4.1.3.12.5 The installation of the belts at operating tension shall not be performed prior to turnover unless specified in the design documents or directed by the Client or Startup. Chains should be installed unless directed otherwise by the Client or Startup.

4.1.3.12.6 Applications where multiple belt sheaves are used may require matched belt sets. Ensure that matched belt sets are used, where required. Do not mix sets as damaged or missing belts may require replacing the entire set.

4.1.4 The following work activities are generally associated with Post placement activities:

• Lubrication Inspections • Instrumentation and Controls Inspections • Grounding Inspections • Painting or Coating Inspections • Insulation and or Heat Tracing Inspections • Fireproofing Inspections








4.2.1 Preparatory Meetings are held with contractors prior to making the equipment installation. Additional meetings may be held for subsequent equipment installations if needed. The purpose of the Preparatory Meeting is to verify the following: • Verify that the contractor and/or testing agency fully understands the job specification

requirements.











Preparatory Meeting will be held with each contractor. 4.2.3 For work activities with multiple phases, a separate Preparatory Meeting is not

necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for installing equipment in several locations at various times. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.


4.3.1 City of Coffeyville, KS will monitor the initial placement activities. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:









Verify that equipment is being placed in accordance with the requirements specified

in the contract documents.


Verify that any Nonconformancies or action items identified during placement are


Prepare a Master Punch-List (CF-009) documenting the specific activities performed









Prepare a Master Punch-List (CF-009) documenting the specific activities performed

during each Final Inspection and develop a Punch-List of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.

Specify the estimated date for which each item on the Punch-List should be

completed or corrected to be in compliance. Perform follow-up activities to verify that each item on the Punch-List is completed


4.6 Acceptance


• Equipment Placement activities are complete.

• The contractor has completed all inspection, testing, and quality control activities.


• All final inspection Punch-List items are resolved and accepted.

• Log completion into CF-701 – Equipment Installation Log

5.0 Records


• QVC-7.02 – Checklist for Rotating Equipment

• CF-701 – Equipment Installation Log

• CF-704 – Final Closing Authorization Record

• CF-705 – Rotating Equipment Installation Application, Authorization, and Record

• CF-706 – Coupling Alignment Record


QVP No. 8.01 – Coatings Application Rev 1



quality of work performed by contractors associated with application of coatings. 1.2 Requirements for the contractor with regard to construction, testing, inspection, documentation,

etc., are specified in the contract package, referenced specifications, and construction drawings. The contractor shall perform all inspections and tests necessary to ensure that surface preparation and coating application comply with these requirements.



• QVC-8.01 – Coating Application Inspection Checklist • CF-801 – Coatings Record

2.2 Standards

SSPC-PA 1 Paint Application Specification No. 1 for Steel Note: SSPC-PA 1 provides general guidance regarding painting steel. It should be used as a reference in addition to the project specification.

3.0 Definitions

NA 4.0 Procedure 4.1 General

4.1.1 The following work activities are generally associated with coating application activities:

• Surface Preparation • Mixing • Application • Thickness Measurement


activity is completed in accordance with the project specifications. These quality verification activities generally take place in the following stages:

• Preparatory meeting prior to starting application. • Initial inspections at start of application process. • Inprocess inspections during the application process – random to full-time. • Final inspection after completing the application process – random to 100%




• Review application records.

4.1.3 The type of quality verification activities to be performed for each work activity, and the extent thereof, are described in this procedure and the referenced Inspection Checklist(s).

4.1.4 All quality verification activities will be performed by personnel that have the necessary



4.2.1 Preparatory Meetings are held with contractors prior to starting the application process. The purpose of the Preparatory Meeting is to verify the following: • Verify that the contractor and/or testing agency fully understands the job specification

requirements.







4.2.2 When multiple contractors are responsible for a given work activity, a Preparatory

Meeting will be held with each contractor. 4.2.3 For work activities with multiple phases, a separate Preparatory Meeting is not

necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for applying coatings in several locations at various times. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.


City of Coffeyville, KS will monitor the initial coating application activities. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:

• Verify any action items identified during the Preparatory Meeting were resolved. • Inspect the surface preparation prior to the first coating application (see checklist). • Inspect initial coating application activities (see checklist).




• Initial thickness measurement activities (see checklist). • Prepare a Master Punch-list documenting the specific activities performed during the Initial

Inspection and identify any items of nonconformance or other action items for follow-up and resolution.


City of Coffeyville, KS will continually monitor the coating application activities through completion. The Follow-up Inspections will include the following activities:

Verify that coatings are being applied in accordance with the requirements specified in the

contract documents. Verify that the contractor is implementing their quality control procedures during this activity. Verify that any Nonconformancies or action items identified during the application process

are quickly resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place.

Prepare a Master Punch-list documenting the specific activities performed during each

Follow-up Inspection and identify any items of nonconformance or other action items for follow-up and resolution.


City of Coffeyville, KS will perform a Final Inspection at or near the completion of the coating application activities. The Final Inspection will include the following items:

Perform a final inspection of any work performed by the contractor that was not previously

inspected during the Initial and Follow-up Inspections but would be prudent to assure the final quality of the work. Verify that all work is in compliance with the specifications, data sheets, and most current drawing revision at the time of final inspection.

Prepare a Master Punch-list documenting the specific activities performed during each Final

Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.

Specify the estimated date for which each item on the punch list should be completed or

corrected to be in compliance. Perform follow-up activities to verify that each item on the punch list is completed and/or

corrected and is acceptable.

4.6 Acceptance

City of Coffeyville, KS will verify the following prior to issuing final acceptance for a particular area:




• All coating application activities are complete. • The contractor has completed all inspection, testing, and quality control activities. • City of Coffeyville, KS has completed all quality verification activities. • All final inspection punch list items are resolved and accepted.

4.7 Handling and Storage

• Coated items should not be handled or moved until all coatings have been properly dried or cured.

• Coated items should be handled with equipment such as wide belt slings, web belts, and

wide padded skids in order to prevent damage to the coating. Handling equipment that is likely to cause damage and should not be used includes chains, cables, hooks, tongs, etc.

• Coated items should be stacked off of the ground during storage and separated so that they

do not bear against each other. 5.0 Records 5.1 The Quality Verification Activities associated with this procedure are recorded on the following

forms:

• QVC-8.01 – Coating Application Inspection Checklist • CF-801 – Coatings Report


QVP No. 9.01 – Insulation Inspection Activities Rev 0



quality of work performed by contractors associated with Insulation activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of

Coffeyville, KS Construction Quality Verification Procedure No. 9.00 – Insulation and Heat Tracing – General.




The following forms are used to document the quality verification activities specified in this procedure. CF-501 – Hydro Inspection Workbook pages 1 thru 4 CF-502 – System Line List Tracker CF-009 – Master Punch List Log CF-901 – Insulation Placement Application, Authorization and Record

3.0 Definitions

See Governing Spec or Code for definitions 4.0 Procedure 4.1 General

4.1.1 The following work activities are associated with Pre-Insulation Release activities:

4.1.1.1 Verify Hydro Test is Complete and Accepted

4.1.1.2 Verify Post-Hydro Test is Complete and Accepted

4.1.1.3 Verify Heat Tracing is Complete and Accepted

4.1.1.4 Verify the Insulation type and thickness correlates with each Line Number and/or Equipment number to the Line List, Isometric Drawings and P&ID’s.

4.1.1.5 Verify Curing times if using Refractory.

4.1.1.6 Complete CF-901 REV 0 -Insulation Placement Application, Authorization and Record to release the Contractor to Insulate.

4.1.2 The following work activities are associated with Insulation Acceptance activities:

4.1.2.1 Verify Insulation is installed per specifications.

4.1.2.2 Verify Condition of insulation material as installed.




4.1.2.3 Verify lagging material is in accordance with specifications.

4.1.2.4 Verify Thickness of insulation.

4.1.2.5 Verify Location of insulation and lagging in accordance with plans and specifications.

4.1.2.6 Verify Method of attaching insulation.

4.1.2.7 Verify Method of securing lagging.

4.1.2.8 Verify Insulation support rings installed.

4.1.2.9 Verify Joints staggered if double layer of insulation applied.

4.1.2.10 Verify Openings through jacketing sealed or caulked.

4.1.2.11 Verify Insulation beveled at flanged connections to remove bolts without damaging insulation.

4.1.2.12 Fill out Complete CF-901 REV 0 -Insulation Placement Application,

Authorization and Record.

4.1.2.13 Sign off CF-501 REV 0 - Hydro Worksheets at Final Acceptance per QVP-5.01.

4.1.2.14 Sign off CF-502 REV 0 - System Line Lists Tracker 4.1.3 City of Coffeyville, KS will perform quality verification activities to ensure that each work


Preparatory meeting prior to starting construction. Initial inspections of construction. In process inspections during construction – random to full-time. Final inspection after completing construction – random to 100% Review of records of construction




4.2.1 Preparatory meetings are held with contractors prior to the start of construction for specified work activities in order to verify the following: Verify that the contractor fully understands the job specification requirements. Review the contractor’s quality control program and how it will be implemented for

the work activity. Verify that all required documentation has been reviewed or approved and that the





Review requirements for permits and/or authorizations that will be required during the course of construction.

Review the quality verification activities that City of Coffeyville, KS plans to perform



Inspection and testing Requirements Insulation Inspection Insulation Walk-down procedure Turn-Over Package Content requirements and procedures. See Construction Site

Quality Manual section 6.0.




is not necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Installing Insulation although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.



Verify any action items identified during the Preparatory Meeting were

resolved. Fully inspect the initial work performed by contractor to verify that it is in

accordance with the requirements specified in the contract documents. Verify that the contractor is implementing their quality control procedures at

the jobsite. Prepare a master punch-list documenting the specific activities performed







Verify that Insulation is being placed in accordance with the requirements

specified in the contract documents. Verify that the contractor is implementing their quality control procedures

during this activity. Verify that any Nonconformancies or action items identified during placement

are quickly resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place. Follow Construction Site Quality Manual 7.0. Use CF-002 forms.

Prepare a Master Punch-list documenting the specific activities performed




Perform a final inspection of any work performed by the contractor that was

not previously inspected during the Initial and Follow-up Inspections but would be prudent to assure the final quality of the work. Verify that all work is in compliance with the specifications and most current drawing revision at the time of final inspection.

Prepare a master punch-list documenting the specific activities performed

during each Final Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.



Perform follow-up activities to verify that each item on the punch list is completed and/or corrected and is acceptable.

4.6 Acceptance


Insulation activities are complete.




The contractor has completed all inspection, testing, and quality control activities.

City of Coffeyville, KS has completed all quality verification activities.

All final inspection punch list items are resolved and accepted.


forms

CF-901 – Insulation Placement Application, Authorization and Record CF-501 – Hydro Inspection Workbook pages 1 thru 4

CF-502 – System Line List Tracker

CF-009 – Master Punch List Log


QVP No. 9.02 – Fireproofing Inspection Activities Rev 0



quality of work performed by contractors associated with Insulation activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of





The following forms are used to document the quality verification activities specified in this procedure. CF-501 – Hydro Inspection Workbook pages 1 thru 4 CF-502 – System Line List Tracker CF-009 – Master Punch List Log CF-902 – Fireproofing Placement Application, Authorization and Record

3.0 Definitions


4.1.1 The following work activities are associated with Pre-Fireproofing Release activities:

4.1.1.1 Verify Painting is Complete and Accepted.

4.1.1.2 Verify Structural Steel and Equipment is installed and inspected.

4.1.1.3 Verify Anchor Bolts are Knocked Down

4.1.1.4 Verify Wire Mesh Type and Installation is per Specifications

4.1.1.5 Fill out CF-902 REV 0 - Fireproofing Placement Application, Authorization and Record to release the Contractor to Fireproof.

4.1.2 The following work activities are associated with Insulation Acceptance activities:

4.1.2.1 Verify Condition of Fireproofing material as installed.

4.1.2.2 Verify Type of Fireproofing correlates with Referenced Drawing Number and/or Equipment number.

4.1.2.3 Verify Thickness of Fireproofing with a Depth gauge.




4.1.2.4 Verify joints are sealed or caulked.

4.1.2.5 Complete Sign offs CF-902 REV 0 -Fireproofing Placement Application, Authorization and Record.

4.1.2.6 Sign off CF-502 REV 0 - System Line Lists Tracker 4.1.3 City of Coffeyville, KS will perform quality verification activities to ensure that each work







the work activity. • Verify that all required documentation has been reviewed or approved and that the


the course of construction. • Review the quality verification activities that City of Coffeyville, KS plans to perform



• Inspection and testing Requirements • Fireproofing Inspection • Fireproofing Walk-down procedure




• Turn-Over Package Content requirements and procedures. See Construction Site Quality Manual section 6.0.




is not necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Installing Fireproofing although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.



• Verify any action items identified during the Preparatory Meeting were

resolved. • Fully inspect the initial work performed by contractor to verify that it is in

accordance with the requirements specified in the contract documents. • Verify that the contractor is implementing their quality control procedures at

the jobsite. • Prepare a Master Punch-list documenting the specific activities performed




• Verify that Fireproofing is being placed in accordance with the requirements

specified in the contract documents. • Verify that the contractor is implementing their quality control procedures

during this activity. • Verify that any Nonconformancies or action items identified during placement





• Prepare a Master Punch-list documenting the specific activities performed




• Perform a final inspection of any work performed by the contractor that was







4.6 Acceptance


• Fireproofing activities are complete.

• The contractor has completed all inspection, testing, and quality control

activities.


• All final inspection punch list items are resolved and accepted. 5.0 Records 5.1 The Quality Verification Activities associated with this procedure are recorded on the following

forms

• CF-902 – Fireproofing Placement Application, Authorization and Record • CF-501 – Hydro Inspection Workbook pages 1 thru 4





• CF-009 – Master Punch List Log


QVP No. 9.04 – Electric Tracing Inspection Activities Rev 0



quality of work performed by contractors associated with Electric Tracing activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of





The following forms are used to document the quality verification activities specified in this procedure. QVC-9.04 - Checklist for Electric tracing Placement CF-501 – Hydro Inspection Workbook pages 1 thru 4 CF-502 – System Line List Tracker CF-009 – Master Punch List Log CF-904 – Electric Tracing Placement Application, Authorization and Record

3.0 Definitions


4.1.1 The following work activities are associated with Pre-Electric Tracing Release activities:

• Verify Hydro Test is Complete and Accepted

• Verify Post-Hydro Test is Complete and Accepted

• Verify Coatings is Complete and Accepted

• Verify the Electric Tracing type correlates with each Line Number and/or Equipment number to the Line List, Isometric Drawings and P&ID’s.

• Megger Test Cable on the spool

• CF-904 REV 0 – Initial Release section of the Electric Tracing Placement Application, Authorization and Record to release the Contractor to Electric Trace.

4.1.2 The following work activities are associated with Electric Tracing Installation activities:

• Lock Out Tag Out if applicable • OEM Procedures available




• Wire Termination • Splice connections • Controller Installations • GFCI Breaker Installation if Applicable • Megger tests • Tracing Circuits identified

4.1.3 The following work activities are associated with Post-Electric Tracing Installation

activities:

• Tracing Circuits Identified • Placement of Electric Trace Stickers • Final Megger test • Completion of the Electric Tracing Placement Application, Authorization and Record

to release the Contractor to Electric Trace. • Inspection Checklists Completion







the work activity. • Verify that all required documentation has been reviewed or approved and that the








• Inspection and testing Requirements • Electric Tracing Inspection and Test Plan and Procedures • Electric Tracing Walk-down procedure • Turn-Over Package Content requirements and procedures. See Construction Site

Quality Manual section 6.0.




is not necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Installing Electric Tracing although their scope may include several areas over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.




resolved. • Fully inspect the initial work performed by contractor to verify that it is in

accordance with the requirements specified in the contract documents. • Verify that the contractor is implementing their quality control procedures at

the jobsite. • Prepare a Master Punch-list documenting the specific activities performed







• Verify that Electric Tracing is being placed in accordance with the

requirements specified in the contract documents. • Verify that the contractor is implementing their quality control procedures

during this activity. • Verify that any Nonconformancies or action items identified during placement






• Perform a final inspection of any work performed by the contractor that was







4.6 Acceptance


• Electric Tracing activities are complete.

• The contractor has completed all inspection, testing, and quality control

activities.





• All final inspection punch list items are resolved and accepted. 5.0 Records 5.1 The Quality Verification Activities associated with this procedure are recorded on the following

forms

• CF-904 – Electric Tracing Placement Application, Authorization and Record • CF-501 – Hydro Inspection Workbook pages 1 thru 4


• CF-009 – Master Punch List Log if applicable


Construction Quality Verification Procedure No. 10.01 – General Welding Standards Rev 2

Page 1 of 16

1.0 SCOPE

1.1 This standard applies to the fabrication, installation, repair and alteration of welded piping systems. This is a general welding standard to aid in determining Contractor adherence to Governing Codes and Design Specifications.

1.2 This procedure defines the activities that City of Coffeyville, KS will perform in

verifying the quality of work performed by contractors associated with Welding.

1.3 This procedure is to be used in conjunction with the general requirements specified in City of Coffeyville, KS Construction Quality Verification Procedure No. 10.00 – Special Processes – General.

1.4 Requirements that pertain to the contractor with regard to construction, testing,

inspection, documentation, etc., are specified in the contract package, referenced specifications, and construction drawings.

2.0 References

2.1 Standard Industry Specifications: See QV-10.0 - General Verification Procedure for Special Processes Paragraph 2.2

2.2 Forms

The following forms are used to document the quality verification activities specified in this procedure. QVC-10.01 - Checklist for Welding CF-1001 – Weld Log / Traveler CF-1002 – Welder’s Continuity Log CF-1003 – Hot Tap Application, Authorization, and Record

3.0 Definitions

See Governing Spec or Code table of contents for definitions

4.0 Procedure

4.1 The following will aid in determining Applicable Governing Codes. See References below, Project Specifications and ASME Code Book Introduction Sections for further details.

4.1.1 B31.1 Power Piping generally refers to: Steam Piping systems having an

operating pressure in excess of 15 psig; high temperature water piping systems subject to temperatures in excess of 250°F and/or pressures in excess of 160 psig; any piping system using an organic or combustible thermal fluid or gas as a heat transfer media and subject to temperatures in excess of 250°F and; fuel gas or fuel piping systems downstream of the plant’s meter set assembly within the plant’s property lines.



Page 2 of 16

4.1.2 Boiler External Piping (BEP) systems in which Section I of the ASME Boiler and Pressure Vessel Code has administrative control. BEP is considered as that piping which begins at power boiler terminal points and extends up to and includes the valve or valves required by ASME Section I. The boiler terminal points are: the first circumferential joint for welding end connections; the face of the first flange in bolted flanged connections, or; the first threaded joint in that type of connection. All other piping within the scope of this standard is defined as non-boiler external piping.

4.1.3 Process Piping refers to a variety of piping systems found in petroleum

refineries, chemical, pharmaceutical, textile, paper, semiconductor, and cryogenic plants, and related processing plants and terminals. There are four (4) classifications of process piping; high pressure piping; category M fluid service; category D fluid service, and; normal fluid service.

4.1.3.1 A piping system is classified as a High Pressure Piping

System when design or operating pressures exceed the pressure limits of a class 2,500 ANSI flange at the intended operating temperature.

4.1.3.2 A piping system is classified as a Category M Process Piping

System when the medium is toxic or hazardous, and when the potential for personal exposure is judged to be significant and exposure to a small amount of media caused by leakage can produce serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken.

4.1.3.3 A piping system is classified as a Category D Process Piping

System when all of the following apply:

4.1.3.3.1 The fluid handled by the system is nontoxic and not damaging to human tissue;

4.1.3.3.2 The design gage pressure between 15 and 150 psi,

and;

4.1.3.3.3 The design operating temperature range of the piping system is between –20°F and 366°F.

4.1.3.4 Process piping systems not subject to the rules of .1, .2 and .3

above are classified as Normal Fluid Service Process Piping Systems (e.g., the base code piping systems).

4.1.3.5 An additional term that may apply to process piping systems is

Severe Cycle Conditions. The owner is responsible for identifying severe cyclic conditions, where it applies and the specific manufacturing, installation, inspection and testing requirements.



Page 3 of 16

4.2 This standard supplements the Sub-contractors Welding Procedure Specifications (WPS) and Quality Manual by providing the general fabrication, quality control and welding requirements necessary to comply with the referenced construction codes and project specifications. The Contractor shall be responsible for implementation of Quality Functions before and during fabrication, erection and testing

4.3 Welding Procedure Specifications

4.3.1 All WPS shall be Verified and Accepted by City of Coffeyville, KS before welding commences.

4.3.2 The Contractor shall supply all WPS’s with supporting PQR’s to City of

Coffeyville, KS for Record retention.

4.4 Base Metals

4.4.1 Materials and piping components for BEP shall be controlled in accordance with requirements established in City of Coffeyville, KS Site Quality Manual Section 4.0. When the scope of the project involves both BEP and Non-Boiler External piping, BEP materials shall be segregated from non-boiler external piping materials unless all materials are purchased and received using BEP procedures and material certification. Site specific material control procedures may be established where needed.

4.4.2 The physical identification of materials and piping components shall be

maintained throughout construction up to and including the point of installation.

4.4.3 The Sub-Contractor shall be responsible for transferring identification

markings to all pieces prior to subdividing materials.

4.4.4 Should it become impossible to maintain full physical identification, a coded identification system may be used. The coded identification system used for BEP shall be acceptable to the Authorized Inspector.

4.4.5 Contractor shall verify that the mill test reports are forwarded to job file. If

MTRs are not accompanying material at time of receiving, the Contractor shall request MTR be supplied by Material Vendor.

4.4.6 All materials shall be checked by the contractor for any obvious signs of

imperfections (e.g., gouges, laminations, laps, dog marks, etc) See paragraphs 4.10 and 4.11 of this procedure.

4.4.6.1 NCR’s shall be written for materials that do not meet required

specifications following the Construction Site Quality Manual Paragraph 7.0

4.5 Welding Filler Metals and Storage



Page 4 of 16

4.5.1 The specification and AWS-SFA classification of welding filler metals shall conform to the applicable WPS.

4.5.2 Welding material shall be stored in a dry indoor controlled storage area

and dispersed as needed.

4.5.2.1 Manufacturer's identification (e.g., labels or packaging identifying the specification and classification of the material) shall be maintained.

4.5.2.2 Use of the proper filler metals shall be verified during fit-up, in-

process and final weld inspections by the Sub-Contractor

4.5.2.3 Unused portions of filler metals shall be returned to the point of issuance for disposition, re-storage or disposal. Damaged, unidentifiable, or improperly stored electrodes shall be destroyed.

4.5.3 When project conditions warrant (e.g., BEP erection projects or projects

involving various types of alloys) a Filler Metal Withdrawing Slip system should be implemented to provide positive tracking of filler metals to each production joint.

4.5.3.1 Welders should be issued one classification of filler metals at a

time (e.g., ER80S-B3 & E9018-B3 is acceptable; E7018 & E9018-B3 is not acceptable; ER80S-B2 & E9018-B3 is not acceptable; etc.).

4.5.3.2 Welders should be issued stub buckets for the collection of rod

stubs and any covered electrodes with damage flux covering. Unused portions of weld material shall be returned (in stub buckets) to the point of issuance for disposition, re-storage or disposal.

4.5.4 Bare Rods and Consumable Inserts

4.5.4.1 Bare filler rods shall be flag tagged on each end or double

embossed with the specific AWS classification to assure positive identification. Consumable inserts shall be tagged.

4.5.4.2 Bare GTAW filler rods may be returned to storage provided

each piece possesses at least one of its original flag tags or end stamps. If the rod cannot be identified it shall be destroyed.

4.5.5 GMAW / FCAW Filler Wire

4.5.5.1 Spool wire issued for semi-automatic welding processes shall be removed from the machine and returned to the point of



Page 5 of 16

issuance at the end of each shift. Alternately, pre-loaded feeders may be issued and returned.

4.5.5.2 The manufacturer's label identifying the AWS classification

and SFA specification of the wire shall be maintained on the spool at all times.

4.5.6 SMAW Electrodes

4.5.6.1 When containers of low hydrogen electrodes are opened, they shall be immediately placed into bulk (300 lb.) holding ovens and stored at the temperatures prescribed in Table 10.1.

4.5.6.2 Electrodes shall not be issued in quantities greater than that

required for the maximum out-of-oven time period prescribed in Table 10.1 unless issued in portable holding ovens.

4.5.6.3 Portable ovens shall be factory preset at an average

temperature of 300° F. They should be energized and preheat prior to dispatch. Once the welder reaches his designated work area, the portable rod ovens shall be promptly energized before he or she starts work.

Table 10.1 - Coated Electrode Storage

AWS CLASSIFICATION BULK OVEN TEMP. MAX. OUT-OF-OVEN TIME

E6010, E6011 Ambient Not Applicable E6012, E6013, E6019, E6020, E6022, E6027, E7014, E7024, E7027

150 to 200 degrees F

8 hours

Low Hydrogen: E70XX 250 to 325°F 4 hours E80XX 250 to 325°F 2 hours E90XX 250 to 325°F 1 hours

E100XX-110XX 250 to 325°F 1/2 hour Stainless Steel:

E-XXX-15, E-XXX-16 250 to 325°F 8 hours

Manufacturer recommended storage temperatures shall be used for electrode classifications not shown above.

4.6 Shielding Gases

4.6.1 Shielding gases shall be of an AGA Welding Grade quality and shall

conform to the composition specified on the WPS.

4.7 Stainless Steels and Nickel Alloy Materials



Page 6 of 16

4.7.1 Contaminants detrimental to stainless steel and nickel alloys include: carbon, iron, scale, rust, carbonaceous halogenated and sulfur bearing chemicals and other residual chemical films. One of the most troublesome types of contaminants is surface contamination by copper, bronze, lead or zinc from hammers, clamps, tools and galvanized or coated work surfaces. Small amounts of these materials on the surface of stainless steel can lead to cracking in the high-temperature heat affected zone of a weld.

4.7.2 To prevent carbon and iron impregnation, stainless and nickel alloy

materials should be handled with nylon web slings instead of metal chains or forks. They should be stored indoors whenever practical. Stainless steels subject to extended outdoor storage should be covered for protection against winter road salts. Coverings, when used, should be polyethylene, nylon or TFE-fluorocarbon plastics. Canvas and polyvinylchloride plastics shall not be used as they form detrimental corrosive substances upon decomposition.

4.7.3 Stainless steel materials should not be allowed to come in contact with

carbon or other low alloy materials. Metal pipe racks and storage shelves should be covered with a stainless cladding, clean wood cribbing, paperboard or other suitable material.

4.7.4 Hammers, chippers, pliers, files, grips, clamps and other tools intended

to be used on stainless steel should be manufactured of hardened tool steel or chrome plated steel. Any of these tools previously used on carbon and low alloy steels shall be thoroughly cleaned before using on stainless steel. Work benches and fixtures fabricated from mild steels should be stainless clad or provided with another suitable contamination barrier.

4.7.5 Wire brushes shall be stainless steel and shall not have been used on

other materials.

4.7.6 Grinding and flapper wheels should be of an aluminum oxide type and shall not have been used.

4.7.7 Other materials: Consumables, such as markers, adhesive tapes,

cleaning solvents, testing chemicals and cutting lubricants shall be those specifically marketed and sold for use on stainless and nickel alloy materials. Restrictions on sulfur and halogen content shall conform to the project specifications.

4.8 Welder Qualification

4.8.1 Welders and welding operators shall be given assignments within the

ranges of their ASME Section IX or AWS D1.1 qualifications. All Welders Continuity Log and Welder Performance Qualification Records (WPQs) shall be kept and maintained throughout project. The contractor shall submit updates to City of Coffeyville, KS throughout the duration of the project.



Page 7 of 16

4.8.2 Contractor shall assign each qualified welder a stencil to be used for

work identification. Stencils shall be issued by the Contractor.

4.8.2.1 Every weld must be stamped at least once. Continuous welds are to be stamped a minimum of once every three (3) linear feet. A paint marker may be substituted with prior approval by City of Coffeyville, KS.

4.8.3 City of Coffeyville, KS, with justification, shall have the right to require

requalification of a welder or welding operator.

4.8.4 The Contractor shall be responsible for assigning and supervising Code welders.

4.9 Welding machines

4.9.1 City of Coffeyville, KS shall be supplied Welding Machine Certifications prior to welding by the contractor.

4.9.2 All welding machines shall have a calibration sticker placed in common

view for inspections

4.9.3 City of Coffeyville, KS QC Inspector shall verify Welding Machine calibrations and sticker placement per QVC-10.01

4.10 Surface Preparation for Welding

4.10.1 Weld joint design shall be as specified on the applicable WPS. The butt

welding end preparations given in ANSI B16.25 are also acceptable.

4.10.2 Base materials may be prepared by thermal cutting, machining, chipping, grinding, or combinations of these, provided the required alignment can be achieved. When thermal methods are used, excess material (dross) shall be removed from the surface by mechanical means to assure all oxidized metal is removed from the surface to be welded.

4.10.3 Thermal cutting of stainless steel shall be limited to the plasma (PAC)

cutting processes.

4.10.4 Surfaces for welding shall be clean and shall be free from paint, oil, rust, scale, and other contaminants detrimental to welding. Oil or grease should be removed by wiping with a clean lint free material moistened with isopropyl alcohol or other approved solvents.

4.10.5 Weld preps shall be checked for any obvious signs of imperfections (e.g.,

laminations, laps, dog marks, etc.). If detected, minor exploratory grinding may commence to remove the defect as long as the weld prep tolerances of the WPS can be maintained.



Page 8 of 16

4.10.5.1 Weld metal build-up to correct fabricator errors, gaps and alignment criteria shall only be accomplished after generating an NCR and a repair plan is made. See paragraphs 3.8 and 3.14.

4.11 Repair of Base Metal Defects

4.11.1 Unacceptable defects identified in base materials shall be removed by

grinding or machining, and need not be repaired by welding, provided the remaining section thickness is not reduced below the required minimum thickness and the area is blended into the surrounding surface (maintaining the required 3 to 1 taper). If welded repairs are necessary: Verify the defect has been removed by either MT or PT Inspection before welding commences. See QVP-10.02.

4.12 Fitting And Alignment

4.12.1 The inside diameters of piping components to be butt welded shall be

aligned as accurately as is practicable within existing Code tolerances on diameters, wall thicknesses, and out-of roundness. Alignment shall be preserved during welding using bars, jacks, clamps, tack welds, or other appropriate means.

4.12.2 The internal misalignment of the ends to be joined shall not exceed 1/16

in. unless the piping design or governing code specifically state otherwise.

4.12.3 When the internal misalignment exceeds the allowable, the component with the wall extending internally shall be internally transitioned. Transitioning shall result in a piping component thickness not less than the minimum design thickness and the change in contour shall not exceed 30° degrees. Spacing of the root shall conform to the WPS.

4.12.4 When components with different outside diameters or wall thicknesses

are welded together the weld shall form a gradual transition not exceeding a slope of 30 degrees from the smaller to the larger diameter component. This condition may be met by adding weld metal, if necessary, beyond what would otherwise be the toe of the weld.

4.12.5 Backing Rings may only be used when permitted by Project

Specifications. Backing Rings shall be made of weldable quality and compatible with the base metals.

4.12.6 Tack welds used to secure alignment shall either be removed completely

when they have served their purpose, or their starting and stopping ends shall be feathered by suitable means so that they may be satisfactorily incorporated into the final weld.

4.13 Socket Welded Assembly



Page 9 of 16

4.13.1 (1/16”) gap shall be maintained and verified according to Governing Code and Specifications

4.13.1.1 The fit between the socket or sleeve and the pipe or tube shall

conform to applicable standards for socket weld fittings and in no case shall the inside diameter of the socket or sleeve exceed the outside diameter of the pipe or tube by more than 0.080 inch.

4.14 Attachments

4.14.1 All attachments whether permanent or temporary shall be made by

qualified welders using a qualified WPS. Preheat, PWHT and NDE shall apply when applicable by governing code and specifications requires it.

4.15 Production Welding 4.15.1 Shielding Gas and Inert Gas Purging

4.15.1.1 Shielded gas and inert gas purging shall conform to the WPS.

Flow rates are established on the WPS although increased flow rates may be necessary in some instances to adjust for prevailing conditions

4.15.2 Pre-Heat

4.15.2.1 Preheat shall be in accordance with the specified WPS and governing code. The base metal temperature prior to welding shall be at or above the specified minimum temperature in all directions from the point of welding for a distance of 3” or 1.5 times the base metal thickness, whichever is greater. The base metal temperature for tack welds shall be at or above the specified minimum temperature for a distance not less than 1” in all directions from the point of welding.

4.15.2.2 Induction, resistance, infrared or flame heating methods may

be used, depending upon which is most practical.

4.15.2.3 Preheat temperature shall be checked by use of temperature indicating crayons, thermocouple pyrometers, or other suitable means to ensure that the temperature specified in the WPS is obtained prior to and maintained during welding.

4.15.3 Interruption of Welding

4.15.3.1 Verify the Minimum requirements are met using the Interruption of Welding section of the governing code.



Page 10 of 16

4.15.3.2 Verify Pre-Heat specified in the WPS is applied before welding resumes.

4.15.4 Weld progression

4.15.4.1 Vertical welding progression shall govern unless prior approval from Site Quality Control Manager. Horizontal position welding requires that the succeeding beads be deposited on the lower face of the groove and placed one above the other. This sequence may be modified to allow placement of one stringer bead at the top of the groove with the remainder of the passes layered from bottom to top.

4.15.5 Intermediate Passes

4.15.5.1 Each bead of a weld shall be cleaned of slag, flux and other foreign material prior to depositing subsequent beads. Starts and stops shall be staggered, cleaned carefully and ground if necessary to provide sound weld material prior to depositing additional weld metal.

4.16 Finished Welds

4.16.1 All welds shall be Visually Inspected by the Sub-contractors certified QC

Inspector 4.16.2 All welds shall be Weld Mapped, As-Built and Weld Logged.

4.16.2.1 Isometric Drawings in correlation with As-Builts shall have all

field welds identified by a pre-approved method.

4.16.2.1.1 Isometric drawings have associated line numbers designated.

4.16.2.1.2 Start numbering welds per Isometric drawing. If an Isometric drawing has multiple pages with a single designated line number continue numbering from previous weld mapped Isometric drawing.

4.16.2.1.3 If an Isometric drawing has multiple line numbers, weld map per Isometric drawing.

4.16.2.1.4 Contractors weld log shall distinguish each weld associated with Isometric drawing and line number. Use CF-1001 Weld Log.

4.16.3 Each welder shall mark his assigned identifying symbol adjacent to the

welds which he makes using an approved method of marking.

4.16.4 All finished welds shall be visually free of cracks, porosity, slag, under-fill, under-cut, surface lack of fusion, arc strikes and any other linear indications.



Page 11 of 16

4.16.5 Surface of welds shall be sufficiently free from coarse ripples, grooves,

overlaps and abrupt ridges and valleys to permit proper interpretation of required Nondestructive examinations.

4.17 Fillet and Socket Welds

4.17.1 In making fillet welds, the weld metal shall be deposited in such a way as

to secure adequate penetration into the base metal at the root of the weld.

4.17.2 Sharp transition angles and re-entrant corners shall be avoided.

4.17.3 A minimum of two weld passes shall be deposited on each weld joint

with staggered starts and stops. Welding shall not be performed without the addition of filler metal.

4.17.4 When preheat is required, it shall be applied evenly around the weld area

and shall include a minimum of four inches on all sides of the weld toes, or as the component configuration permits.

4.18 Seal Welds

4.18.1 Seal welds on threaded joints shall cover all exposed threads and shall

be performed by qualified welders using the appropriate Welding Procedure Specification. When threaded joints are to be seal welded, joint compounds shall not be used.

4.19 Branch Connections

4.19.1 Three main types: See Governing Codes and Design Specification for details

4.19.1.1 Partial Penetration Branch Connections

4.19.1.2 Full Penetration Threaded and Socket Welded Branch

Connections

4.19.1.3 Welded Pipe to Pipe Branch Connections

4.20 Hot Tapping

4.20.1 See API RP 2201 – Safe Hot Tapping Practices for Guidelines. 4.20.2 These procedures for making hot taps on equipment and pipelines

containing flammable, toxic or other materials represent a composite of petroleum industry safe practices for this type of work as compiled by the American Petroleum Institute Committee on Safety and Fire Protection. They are to be used as minimum standards; however, they cannot be expected to cover all contingencies which may be encountered. If a



Page 12 of 16

special need or problem exists, additional restrictions or precautions will be imposed by the Contractor and approved by Burns & McDonnell, keeping in mind that safety of the operation is the first consideration. In this procedure, the term equipment is to include vessels, columns, tanks, exchangers, piping and any other equipment under internal or external pressure.

4.20.3 Hot tapping involves welding and subsequent drilling on equipment that

is in service. Drilling or plugging associated with leak repairs does not fall within the scope of this procedure. The possibility of burning through the wall of the equipment during welding can be minimized by equipment prior to welding. Every case is different, and equipment or piping containing most materials may be hot tapped, provided the temperature-pressure limitations stamped on the hot tap machine nameplate are not exceeded, and all preliminary preparations have been followed.

4.20.4 Welding or hot tapping equipment in service shall not be performed if the

following mechanical or material limitations are exceeded, unless the Plant Engineer or Plant Manager has evaluated the circumstances and approved welding and/or hot tapping.

4.20.4.1 Metal temperature less than 50°F. 4.20.4.2 Metal temperature greater than 700°F unless supplemental

cooling of the hot tapping machine is provided.

4.20.4.3 Pressure less than atmospheric.

4.20.4.4 Materials requiring post weld heat treatment.

4.20.4.5 Equipment that is clad or lined (loose strip or refractory).

4.20.5 Welding of clips or other attachments to pressure equipment that is in service requires the same approval procedure followed for hot tap approval.

4.20.6 Pressure equipment requiring welding of attachments or hot tapping

must have an established flow or, in the case of storage tanks or vessels, the hot work must be a minimum of two (2) feet below the surface of the liquid contained.

4.20.7 Multiple hot taps may not be approved on a single form. Each hot tap

requires individual evaluation and approval process.

4.21 Repair of Weld Metal Defects 4.21.1 Weld metal surface defects shall be removed to sound metal by an

approved procedure and repaired using the applicable WPS.



Page 13 of 16

4.21.2 After repairs are made, the repaired area shall be re-inspected and/or re-examined using the same inspection and examination methods used on the original weld.

4.22 City of Coffeyville, KS will perform quality verification activities to ensure that

each work activity is completed in accordance with the project specifications. These quality verification activities can be classified into one of the following categories:

• Preparatory meeting prior to starting construction. • Initial inspections of construction. • In-process inspections during construction – random to full-time. • Final inspection after completing construction – random to 100% • Review of records of construction

4.23 The type of quality verification activities to be performed for each work activity and the extent thereof is described in this procedure.

4.24 All quality verification activities will be performed by personnel that have the necessary skills, training, and certifications for the particular task.


4.25.1 Preparatory meetings are held with contractors prior to the start of

construction for specified work activities in order to verify the following:






4.25.2 The following work activities require a Preparatory Meeting prior to

starting construction.

• Inspection and testing Requirements • Hydro Inspection Test Plan and Procedures • Pre-Hydro – Hydro – Post-Hydro – Final Acceptance Walk-down

procedure • Turn-Over Package Content and Formatting Requirements and

procedures. See Construction Site Quality Manual section 6.0.




Page 14 of 16

4.25.4 When a given contractor is responsible for multiple work activities, the

Preparatory Meeting may include more than one work activity.

4.25.5 For work activities with multiple phases or occurrences, a separate Preparatory Meeting is not necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for welding although their scope may include different welding processes over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.


4.26.1 City of Coffeyville, KS will perform a thorough inspection of the initial

construction work performed by each contractor for each work activity. The purpose of this inspection is to verify that the contractor is capable of performing the work in accordance with the project specifications. The initial inspection will include the following:


resolved. • Fully inspect the initial work performed by contractor to verify that it is

in accordance with the requirements specified in the contract documents.




4.27.1 City of Coffeyville, KS will continually monitor the installation activities through completion. The Follow-up Inspections will include the following activities:

• Verify that welding is being performed in accordance with the

requirements specified in the contract documents.


• Verify that any Nonconformancies or action items identified during

placement are quickly resolved. Work should not be proceeding where Nonconformancies have been identified but have not been resolved, unless an approved work-around plan is in place.



Page 15 of 16

• Prepare a Master Punch-list documenting the specific activities performed during each Follow-up Inspection and identify any items of nonconformance or other action items for follow-up and resolution.


4.28.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the system installation activities. The Final Inspection will include the following items:

• Perform a final inspection of any work performed by the contractor

that was not previously inspected during the Initial and Follow-up Inspections but would be prudent to assure the final quality of the work. Verify that all work is in compliance with the specifications and most current drawing revision at the time of final inspection.

• Prepare a Master Punch-list documenting the specific activities

performed during each Final Inspection and develop a punch list of all items that were found to be incomplete or not in compliance with the contract documents, referenced specifications, and the latest drawing revision at the time of the inspection. This would include any outstanding items of nonconformance or action items identified during previous Preparatory Meetings, Initial Inspections, and Follow-up Inspections for the particular work activity.

• Specify the estimated date for which each item on the punch list

should be completed or corrected to be in compliance.


4.29 Acceptance


• Welding activities are complete.

• The contractor has completed all inspection, testing, and quality

control activities.



4.29.2 Welder Conformance Sheet

• Shall be filled out and signed and incorporated in each system turnover package in section 6 following the Turnover Master procedure.



Page 16 of 16

5.0 Records

5.1 The Quality Verification Activities associated with this procedure are recorded on the following forms

• QVC-10.01 - Checklist for Welding

• CF-1001 – Weld Log / Traveler • CF-1002 – Welder’s Continuity Log • CF-1003 – Hot Tap Application, Authorization, and Record


QVP No. 10.02 – Nondestructive Evaluation Rev 2



quality of work performed by contractors associated with Nondestructive Evaluation activities. 1.2 This procedure is to be used in conjunction with the general requirements specified in City of

Coffeyville, KS Construction Quality Verification Procedure No. 10.00 – Special Processes – General.





QVC-10.02 – Inspection Checklist for NDE-PWHT-HT-PMI

CF-1001 – Weld Log CF-1004 – NDE Rejects

2.2 Standards

ASME V – Nondestructive Examination Procedures ASNT - SNT-TC-1A - Personnel Qualification and Certification in Nondestructive Testing ASNT - CP-189 Standard for Qualification and Certification of Nondestructive Testing personnel. ASNT – ACCP: Central Certification Program may be used to fulfill the examination and demonstration requirements of the contractor’s written practice. ASTM E543 - will reference all ASTM Standards for Nondestructive Testing AWS-Q1 – Certified Welding Inspector Certifications API 510 – In-service pressure vessel inspection certification API-570 – In-service piping inspection certification API-653 – In-service Tank inspection certification

3.0 Definitions

See ASNT-SNT-TC-1A for the definition of terms associated with Nondestructive Evaluation 4.0 Procedure 4.1 General

4.1.1 The following work activities are associated with Nondestructive Evaluation activities:

• Visual Examinations (VT) • Magnetic Particle Examinations (MT) • Liquid Penetrant Examinations (PT)




• Radiographic Examinations (RT) • Ultrasonic Examinations (UT)

4.1.2 Contractors QC Inspectors shall be certified and meet following criteria:

4.1.2.1 QC Inspectors shall have an eye examination at least once per year to assure optical capability. VT personnel shall be capable of distinguishing the No. 2 characters on a standard Jaeger test chart (or equal) as well as far vision acuity equivalent to 20/30 Snellen Fraction. Visual capability may be corrected or uncorrected. Visual acuity shall be documented and submitted to City of Coffeyville, KS for review and acceptance.

4.1.2.2 QC Inspectors shall be certified as a VT-Level II or III and have sufficient

knowledge of the specific qualitative and quantitative acceptance criterion contained in Governing Codes. That knowledge shall be demonstrated by passing a written specific examination. The minimum passing grade shall be 70% which shall be documented and submitted to City of Coffeyville, KS for review and acceptance.

4.1.2.3 Alternatives to a written contractors written examination:

4.1.2.3.1 Current Certified Welding Inspector per AWS-Q1.

4.1.2.3.2 Current Visual Inspection certification Level II or III per ASNT-SNT-TC-1A.

4.1.2.3.3 Either shall be submitted to City of Coffeyville, KS for review and acceptance

4.1.3 The contractor shall visually inspect 100% of all field welds. All welds shall be visually free of the following:

4.1.3.1 Cracks, porosity, slag, under-fill, under-cut, surface lack of fusion, arc strikes and any other linear indications.

4.1.4 All welds shall be Weld Mapped, As-Built and Weld Logged per City of Coffeyville, KS QVP-10.01 Paragraph 4.16.2.

4.1.5 All welds shall be documented on CF-1001: Weld Log

4.1.6 All NDE shall be performed by certified inspection personnel in accordance with ASNT-SNT-TC-1A. A Minimum of Level II or III certification is required for interpretation and shall be interpreted per Governing Code specified by City of Coffeyville, KS.

4.1.6.1 Certified personnel shall submit evidence of current Level II or III

certification (by the contractor or NDE employer experienced in construction) who established competency by specific examinations in accordance with ASNT-SNT-TC-1A. All documents shall be given to City of Coffeyville, KS for review and approval. Methods shall be limited to visible processes; AC yoke for MT and solvent removable for PT. Contractors NDE Procedures shall be submitted and approved by City of Coffeyville, KS prior to commencing work.

4.1.6.2 All NDE Rejects shall be repaired in accordance with QVP-10.01 Paragraph 4.21 and documented on CF-1004.




4.1.6.2.1 Weld repairs shall be examined using the same technique, procedures and acceptance criteria used to examine the original welds.

4.1.6.3 All NDE contractors shall submit their Quality manual containing NDE procedures, personnel certification documents, calibration of measurement and test equipment, radiation safety procedures and a site emergency action plan to recover their radiation source in a time efficient and safe manner.

4.1.6.4 The Site emergency action plan shall be reviewed and accepted by City of Coffeyville, KS and the client site management prior to commencing work.

4.1.7 MT/PT Inspections:

4.1.7.1 During the Preparatory meeting, all MT/PT Inspections shall be specified and approved in order to determine best application for sensitivity for each scenario. For example PT Inspection would be best suited for Surface preparation inspections for Tie-In procedures. MT Inspections would be best suited for final inspection on Slip-On flange welds. MT/PT Inspection requirements shall conform to Engineering specifications, Client specifications and Governing Codes.

4.1.7.2 All MT/PT Inspections shall conform to Pre-Approved NDE Contractors procedures, ASME Section V procedures and ASTM E543 referenced procedures.

4.1.7.3 Interpretations and results shall be delivered to City of Coffeyville, KS in a Pre-Approved documented report. Each Report shall be given a Control Number starting with MT/PT-001 and continues until the end of project. Control numbers shall be logged for each weld inspected on CF-1001 form. Traceability shall be maintained throughout the project.

4.1.7.3.1 Each report shall contain the following but not limited to: Date, Project Number, Line Number, Field Weld Number, Material Type, Size, Thickness, Weld Joint Configuration, Welder Stencil and Governing Code.

4.1.7.4 All equipment shall be inspected for current and documented calibration stickers and has traceability to documents provided in the Quality manual submitted.

4.1.8 RT/UT Inspections:

4.1.8.1 During the Preparatory meeting, all RT/UT Inspections shall be specified and approved in order to determine best application for sensitivity for each scenario. For example RT Inspection would be best suited for all butt welded joints. UT Shear-wave inspections shall have prior-approval from Burns & McDonnell and the Client. RT/UT Inspection requirements shall conform to Engineering specifications, Client specifications and Governing Codes.

4.1.8.2 All RT/UT Inspections shall conform to Pre-Approved NDE Contractors procedures, ASME Section V procedures and ASTM E543 referenced procedures.




4.1.8.3 Radiography and or Ultrasonic Inspections shall be performed in accordance governing Codes, Standards and Engineering specifications. When the Weld is required to be Post Weld Heat Treated all Radiography and Ultrasonic Inspections shall be performed After Post Weld Heat Treatment.

4.1.8.4 Interpretations and results shall be delivered to City of Coffeyville, KS in a Pre-Approved documented report. Each Report shall be given a Control Number starting with RT/UT-001 and continues until the end of project. Control numbers shall be logged for each weld inspected on CF-1001 form. The Control number shall be labeled on the Film Envelope, RT/UT report and weld log. Traceability shall be maintained throughout the project.

4.1.8.5 All Line numbers and Field weld numbers and subsequent views shall be recorded and interpreted on approved RT report. Densities shall be recorded for each radiograph. All relevant information shall be recorded on the RT report and submitted for review and acceptance by City of Coffeyville, KS.

4.1.8.5.1 Each report shall contain the following but not limited to: Date, Project Number, Line Number, Field Weld Number, Material Type, Size, Thickness, Weld Joint Configuration, Welder Stencil and Governing Code.

4.1.8.6 All Radiographs shall be Reviewed and Accepted by City of Coffeyville, KS. City of Coffeyville, KS reserves the right to reject film due to poor Quality and film handling techniques at contractor’s expense. City of Coffeyville, KS reserves the right to reject or accept weld quality issues in accordance with governing codes.

4.1.8.7 All equipment shall be inspected for current and documented calibration stickers and has traceability to documents provided in the Quality manual submitted.

4.1.8.8 All RT personnel shall have Calibrated radiation survey meters on their person during device exposure, Calibrated Radiation Safety Alarms and Calibrated Pocket Dosimeters. All Barricades shall be in place with signs in accordance with Radiation safety procedures.



4.1.10 The type of quality verification activities to be performed for each work activity, and the extent thereof, is described in this procedure.






4.2.1 Preparatory Meetings are held with contractors prior to the start of construction for each

major work activity or group of activities The purpose of the Preparatory Meeting is to verify the following: • Verify that the contractor fully understands the job specification requirements.


the work activity.






• Contractors QC Inspectors Activities • VT, MT, PT, RT and UT Requirements per Governing Code • Tie-In NDE Procedure • NDE in Lieu of Hydro Allowances




necessarily required for each phase. For example, only one Preparatory Meeting would typically be held with a contractor responsible for Tie-Ins although their scope may include performing Tie-Ins for many systems over the course of the project. However, a follow-up meeting may be warranted if there are extended periods between phases or if problems are identified during inspections of the contractor’s work.









• Verify that the contractor is implementing their quality control procedures at the

jobsite.












4.5.1 City of Coffeyville, KS will perform a Final Inspection at or near the completion of the inspection activities. The Final Inspection will include the following items:








Specify the estimated date for which each item on the punch list should be completed or corrected to be in compliance.

Perform follow-up activities to verify that each item on the punch list is completed


4.6 Acceptance

4.6.1 City of Coffeyville, KS will typically accept or release each area prior to commencing NDE activities.


particular area:

• City of Coffeyville, KS has reviewed and accepted all documentation • The contractor has completed all inspection, testing, and quality control activities.




forms:

• QVC-10.02 – Inspection Checklist for NDE-PWHT-HT-PMI • CF-1001 – Weld Log • CF-1004 – NDE Rejects

City of Coffeyville, KS Surveying Inspection Checklist

Subcontract No. Inspector:

Subcontractor: Signature:

Item or Area I.D.: Date:

THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF SURVEYING.

No. Description Accept Reject Comments

QVC-1.01 – Inspection Checklist for Surveying

1 Verify Equipment used is in accordance with the Contract Documents

2 Verify Equipment is Calibrated in accordance with Manufacturers Specifications

3 Verify Survey Markers are easily identified and placed securely

4 Verify all Earth work baselines are set outside of the excavated areas to avoid destruction

5 Verify Foundation Orientations and Locations are in accordance with Engineering Specifications and Drawings.

6 Verify Anchor Bolt Locations before and after Concrete Pour

7 Verify a Centerline has been established for ditches and trenches needing dug

8 Verify surveyor is using a closed, loop or connecting traverse to control the parcel/project boundary area.

9 Verify traverses originate and tie into an existing control point of similar accuracy.

City of Coffeyville, KS Demolition Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF DEMOLITION.


QVC-1.02 – Inspection Checklist for Demolition

1 Verify Start and Stop Points are clearing identified.

2 Verify Hazardous Materials i.e. Lead, asbestos, contaminated pipe…

3 Verify LOTO guidelines are being met.

4 Verify Demo materials are properly stored in marked containers.

5 Verify adjacent foundations, utilities, etc. are adequately shored or otherwise protected.

6 Verify utility lines are capped, plugged or protected by appropriate means.

7 Verify areas are clean and in workable state for future use.

City of Coffeyville, KS Excavation & Backfill Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF EXCAVATION & BACKFILL.


QVC-1.03 – Inspection Checklist for Excavation & Backfill

1 Excavation:

2 Underground installations located prior to excavating

3 Excavation and construction area does not impede natural drainage

4 Excavation and construction area does not back water onto adjoining property

5 Existing bench marks and base line not tampered with

6 Excavation performed to required width and excavation limits established

7 Excavation width allows for form placement and access for inspection

8 Excavation completed to required grade and final grade limits established

9 Unsuitable materials removed as required (organic, peat, over-saturated material)

10 Final excavation grade smooth, compacted, and free of loose material

11 Slopes (if required) excavated to correct degree of slope

12 Over-excavation (if present) correct within required approved procedures

13 Berms, dikes and ditches constructed to keep surface water out of excavation

14 Excavation free of excessive moisture and Dewatering maintained

15 Excavated materials placed in correct stockpile or waste area

16 Excavation material stockpiles properly constructed and not contaminated

17 Seal slab placed (if required)

18 Protective Poly-sheeting (Visqueen) placed (if required)

19 Backfill:

20 Material source location as specified and approved

21 Material source soil classification as required

22 "California Bearing Ratio" performed (if required)

23 Material source not contaminated

24 Backfill material placed to required zone width

25 Backfill material placed in correct fill zone

26 Backfill material placed to required loose lift thickness as specified

27 Backfill material free of large rocks, roots, lumps, etc…

28 Backfill material compacted with correct compaction equipment

29 Classification tests in fill materials performed to required test frequency

30 Field compaction tests performed to required test frequency

31 Moisture content test performed to required test frequency

32 Moisture density test (proctor) obtained for each type soil type

33 Backfill material is evenly distributed around pipes, duct banks, etc

34 All required ground wire connections have been installed prior to backfilling

City of Coffeyville, KS Plant Road and Vehicle Parking Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF INITIAL, FOLLOW-UP, AND FINAL INSPECTIONS


QVC-1.05 – Inspection Checklist for Plant Road and Vehicle Parking Page 1 of 2

1 Sub-grade Scarifying:

2 • Removal of rock, etc., depth

3 • Moisture content

4 • Sub-grade elevations

5 Sub-grade Preparation:

6 • Materials to specifications

7 • Proper equipment

8 • Ditches

9 • Elevations, density after rolling

10 • Shaping, compacting

11 Laboratory tests

12 • Gradation of materials

13 • Curves and densities

14 • Field density tests (Forms completed and signed)

15 Asphalt concrete pavement

16 • Asphalt cement as specified

17 • Coarse aggregate as specified

18 • Fine aggregate as specified

19 • Cement mixed as specified

20 Asphalt tack coat

21 • Material as specified

22 • Surface clean and dry

23 • Uniform spray

24 Prime tack coat

25 • Material as specified

26 • Base course clean and dry

27 • Base coat uniform spray

28 Transporting

29 • Truck beds free of holes an depressions

30 • Truck equipped with proper tarps

31 • Truck beds coated

32 • Truck bed insulated (as applicable)

33 Spreading

34 • Availability of personnel and equipment

35 • Uniform mix

36 • Mix temperature

City of Coffeyville, KS Plant Road and Vehicle Parking Inspection Checklist






QVC-1.05 – Inspection Checklist for Plant Road and Vehicle Parking Page 2 of 2

37 • Surface tolerances

38 • Spread depth

39 • Number of Samples

40 Rolling

41 • Procedure as specified

42 • Proper rolling of joints and edges, etc.

43 • Surfaces true to established grade

44 Final

45 • Surface areas as specified

46 • Traffic protection

47 • Site cleanup

48 • Quality records

City of Coffeyville, KS Piling Inspection Checklist






QVC-1.08 – Inspection Checklist for Piling

1 Verify Geo-Tech Report is available on-site

2 Verify Piling Installation Procedures and Execution Plan meet Site Requirements

3 Verify Pile Type, Size and Length meet the required Engineering Specifications

4 Verify Pile Driving Equipment meet the required Engineering Specifications:

5 • Ram

6 • Anvil

7 • Striker Plate

8 • Hammer Cushion

9 • Drive Head

10 • Pile Cushion

11 Verify Calibration Certificates of Pressure gauges are current

12 Verify Operating Rate and Pressure of Pile Driving equipment are within Engineering Specifications and procedures

13 Verify Blow Counts are recorded and in compliance with Engineering Specifications

14 Verify Grouting Procedures are in compliance for Auger Cast in Place Piles

15 Verify Design Mix and Compliance Verifications are met for Auger Cast in Place Piles

16 Verify Grout Flow Tests meet the required Engineering Specifications for Auger Cast in Place Piles

17 Verify Volume of Grout used for Auger Cast in Place Piles

18 Verify Reinforcement Bar MTR’s are in compliance

19 Verify Reinforcement Bar Cages meet Engineering Design and Specifications

20 Verify Pile Splices are within Engineering Specifications

21 Verify Welding QVP-10.01 Procedures have been met if applicable

22 Verify Pile Cut-Off and Tip elevations

23 Verify Pile Heave is within Engineering Specifications

24 Verify Degree of Axial Alignment is within Engineering Specifications

25 Verify Pile is not damaged during installation

26 Verify Pile Load tests are performed per Contract Documents and meet Engineering Specifications

27 Verify Pile Spacing is in compliance with Engineering Specifications

28 Verify All field revisions recorded on "AS-BUILT" drawings.

City of Coffeyville, KS Drilled Pier Inspection Checklist






QVC-1.09 – Inspection Checklist for Drilled Piers

1 Verify Geo-Tech Report is available on-site

2 Verify Drilled Pier Installation Procedures and Execution Plan meet Site Requirements

3 Verify Depth of excavations are in compliance with Engineering Specifications

4 Verify Bell Dimensions are in compliance with Engineering Specifications

5 Verify size, length, material type and wall thickness of the steel casing meet the required Engineering Specifications:

6 Verify size, length, material type and strength of liner meet the required Engineering Specifications:

7 Verify Splice Details are in accordance with Engineering Specifications

8 Verify Pier Diameters are in accordance with Engineering Specifications

9 Verify In-Hole Slurry Tests meets Engineering Specifications

10 Verify Concreting QV-2.0 Procedures are in compliance

11 Verify Reinforcement Bar MTR’s are in compliance

12 Verify Reinforcement Bar Cages meet Engineering Design and Specifications

13 Verify Design Mix and Compliance Verifications are met

14 Verify Test Specimens meet the required Engineering Specifications

15 Verify Batch Plant Pour Cards are received and in accordance with Engineering Specifications

16 Verify Sand Cement Grout mixture is in accordance with Engineering Specifications

17 Verify Welding QVP-10.01 Procedures have been met

18 Verify Pier Cut-Off and Tip elevations

19 Verify Degree of Axial Alignment is within Engineering Specifications

20 Verify NDE report: Sonic Echo, Impulse Test or Cross-hole sonic logging (if applicable)

21 Verify Drilled Pier Spacing is in compliance with Engineering Specifications

22 Verify All field revisions recorded on "AS-BUILT" drawings.

23 Verify anchorage embedment’s are installed in compliance with Engineering Design and Specifications

City of Coffeyville, KS Concrete Inspection Checklist

Contract No. Inspector:

Contractor: Signature:


THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS PRIOR TO BEGINNING THE CONCRETE PLACEMENT.


QVC-2.01 – Inspection Checklist for Concreting Page 1 of 2

Concrete Pre Placement:

1 Condition of sub-grade and base.

2 All required soils testing complete and acceptable.

3 Form location, alignment, elevation, orientation, plumb, and grade.

4 Form construction (bracing, ties, joints, etc.)

5 Form surfaces are clean and coated with parting agents as required.

6 Chamfer strip installation.

7 Water stop installation.

8 Reinforcing steel size and material certifications.

9 Reinforcing steel location, spacing, and orientation.

10 Reinforcing steel construction (bracing, spices, ties, etc.)

11 Reinforcing steel is clean and free of rust and scale.

12 Reinforcing steel dowels are plumb.

13 Anchor bolt size and material certifications.

14 Anchor bolt location, orientation, projection, and plumb.

15 Anchor bolt thread protection.

16 Layout of pipes and conduits.

17 Layout of drains and sleeves.

18 Layout of electrical grounding wire / grid.

19 Layout of other inserts and embeddments.

Concrete Placement:

20 Concrete type, mixture, and uniformity.

21 Placement equipment is in good working order.

22 Starting time for placement and establish required completion time.

23 Temperature of concrete and ambient temperature at start of placement.

24 Placement rate.

25 Test specimens are taken and identified.

26 Cold joints do not form and concrete does not segregate during placement.

27 Vibrator size and frequency.

28 Roughing of intermediate surface layers.

29 Placement is completed within the allotted time.

30 Temperature of concrete upon completing placement.

31 Vapor barrier is intact after placement.

32 Location, orientation, projection of anchor bolts and other embeddments.

33 Leveling and screeding.

34 Application of surface treatments (if required).

City of Coffeyville, KS Concrete Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS PRIOR TO BEGINNING THE CONCRETE PLACEMENT.


QVC-2.01 – Inspection Checklist for Concreting Page 2 of 2

35 Surface finish.

36 Anchor bolt threads and other embeddments are clean from concrete.

Concrete Post Placement:

37 Surface protection and/or insulation is in place.

38 Storage and identification of test specimens.

39 Field testing of test specimens (when required).

40 Monitor concrete temperature during curing.

41 Post-tensioning.

42 Condition of concrete after form removal.

43 Subsequent surface treatments and/or repairs.

City of Coffeyville, KS Structural Steel Erection Inspection Checklist




VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS:


QVC-3.01 – Inspection Checklist for Structural Steel Erection – Rev. 0

1 Foundations and piers are in correct location.

2 Anchor bolts and embedded items are of correct size and location.

3 Bearing devices (wedges, shims, leveling screws, etc.) are correct.

4 Welding verified in accordance with QVC-10.01.

5 Structural Steel Drawing Weld Mapped with Welder ID’S

6 Working points and working lines are identified and maintained during erection.

7 Position and alignment is within acceptable tolerances.

8 Overall dimensions are correct.

9 Bolting was purchased from on acceptable manufacture (when required)

10 Bolting matches the provided Certified Mill Test Reports (CMTR’s).

11 Bolting dimensions are acceptable.

12 Bolt holes in structural steel are clean and correctly sized and located.

13 Skidmore Test performed

14 Bolting is installed and verified per applicable method of installation as specified in the RCSC specification.

15 NDE is performed and documented as required.

16 Fire Proofing Complete as required

17 Protective Coatings as required

18 Grouting Complete as required

City of Coffeyville, KS Building Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF INITIAL, IN-PROCESS AND FINAL INSPECTIONS.


QVC-4.01 – Inspection Checklist for Buildings Page 1 of 5

1 Foundations inspections and test complete:

2 • Latest Engineering documentation and Proper Records

3 • Piles

4 • Soils

5 • Concrete

6 • Foundation checked for location, elevation, and orientation prior to starting

construction.

7 • Building inspection completed and documented per COC Procedures

8 Building tests completed and accepted. Building tests performed for this building

9 • Electrical

10 • Heating

11 • Plumbing

12 • Air Conditioning

13 • Ventilation

14 • Fire Protection

15 • Punch list items cleared and Final inspection completed

16 MASONARY:

17 • Approved panels and/or material samples.

18 • Material certifications if required

19 • Masonry units, color, texture, grade size, defect tolerance

20 • Masonry mortar, cement, aggregate, lime and water

21 • Mortar cube test, if required.

22 • Anchors, ties, flashing – type, size, shape and material.

23 MASONRY CONSTRUCTION

24 • Ambient temperature above minimum

25 • Masonry layout firs structural framing

26 • Embedded items

27 • Control joint type and location

28 • Caulked joints

29 • Openings framed, anchored, filled with mortar

30 • Weep holes

31 • Anchors, ties, joint reinforcing

32 • Flashing installation

33 • Foundation waterproofing or damp proofing

34 WORKMANSHIP

35 • Bond pattern, visual appearance








36 • Mortar joints, visual appearance

37 • Brick work plumb and true, all in one plane

38 • Plaster finishing

39 ABOVE CEILING INSPECTION

40 • Roof Framing

41 • Joist Bridging

42 • No tears in liner

43 • GWB Walls taped

44 • Top of walls sealed

45 • Sleeves

46 • Fire-stopping/Seals

47 • Roof boots

48 PLUMBING:

49 • DWV Pipe

50 • Plumbing Pipe Tested

51 • Pipe Insulated AND labeled

52 ELECTRICAL:

53 • Speakers

54 • Fire Alarm/ Mass Notification

55 • Power to fans

56 • Power to lights

57 • Fixtures supported to structure

58 • Power to other equipment

59 • Firestopping

60 • Ceiling Grid

61 • Splay Bracing

62 OTHER:

63 • ATFP Bracing

64 • Seismic Bracing

65 DRYWALL CONSTRUCTION

66 • Verify use of materials: Gypsum board, Joint Cement and Tape and Nails

67 INSTALLATION OF DRYWALL

68 • Gypsum board is stored in a dry, ventilated enclosed building.

69 • Surfaces to receive drywall conform to line and grade.

70 • Gypsum board held tight against support with nailing starting at center

progressing toward perimeter.








71 • Paper surfaces torn around nail head has additional nail driven two inches

away. Cut and fit gypsum board is not forced into place.

72 • Thin coats of cement applied immediately after taping.

73 • Coats of cement on joint and nail depressions have 24 hours between

applications.

74 • Final cement coat feathered 12” to 16” each side of joint and is sanded

smooth.

75 WORKMANSHIP

76 • Installed gypsum board free from damage

77 • All cemented joint and nail depressions will present smooth and uniform

appearance when wall is painted.

78 RESILIENT FLOOR COVERING INCLUDING ASPHALT, VINYL-ASBESTOS, VINYL AND RUBBER TITLE AND FLOOR COVERING (As Applicable)

79 • Verify use of materials: Tile color, type, size, thickness, Molding color, type,

size, primer, adhesive or cement

80 LAYING OF TILE

81 • Subfloor preparation, Felt lining or underlayment, Layout pattern of cut tiles

at wall line and wall openings. Application of adhesive.

82 WORKMANSHIP

83

• Tiles lid point to point, Tile joint tight, Tile pattern as specified, Tile cuts at wall base or wall opening correct, Tiles cleaned and waxed after completion, Tiles protected after waxing with construction paper.

84 METAL DOORS AND WINDOWS

85 • Verify use of materials: Approved materials and samples, Guarantees, for

electric power operators, Doors, Primer and Hardware

86 INSTALLATION OF DOORS AND WINDOWS

87

• Frames anchored, plumb, square level, All clearances adequate, Caulking provided where required, Weather stripping installed where required, Hardware properly adjusted, Glazing installation adequate as required and Lubricants provided where needed

88 WORKMANSHIP

89 • Each unit operates smoothly and easily, Doors flush and snug with jams,

Window frames and flush and snug with sashes.

90 • Units with tension adjustment mechanisms are in proper adjustment and

Painted surfaces cosmetically pleasing and Clean up is satisfactory

91 ROOFING

92 • Verify use of correct materials

93 INSTALLATION: Install insulation per specifications and manufactures recommendations.

94 WORKMANSHIP

95

• Install insulation not exposed to weather, Applied insulation and completed roofing protected at all times against damage, Insulation and membrane laps are uniform, Flashing details acceptable and Clean up satisfactory.

96 CERAMIC TILE








97 • Verify use of correct materials: Approved materials and samples, type, size

and color pattern. Mortar type and color

98 APPLICATION OF TILE

99 • Wall tile, location and anchorage of studs or furring

100 • Wall tile lath, placement, lap and support

101 • Wall tile scratch coat and float coat applied and cured properly.

102 • Wall tile soaked and free water removed prior to application

103 • Wall tile accessories are required

104 • Wall tile firmly set

105 • Wall tile wetted before grouting

106 • Wall tile grout, placing, tooling, curing and cleaning

107 • Floor tile installed after wall tile

108 • Floor tile setting bed preparation as specified

109 • Floor tile setting bed mix satisfactory

110 • Floor tile solidly bedded

111 • Floor tile layout acceptable

112 • Floor tile waterproofing and reinforcement when required

113 • Floor tile cuts wall base openings acceptable

114 WORKMANSHIP

115

• Tiles free of chips or cracks, Grout joints uniformly tooled, Grout tiles all in one plane, Tile pattern uniform and consistent and Tile cuts as baseline, corners or openings are satisfactory.

116 FIRE PROTECTION SYSTEM

117 • Verify use of correct materials: Approved materials, Piping and fittings,

Sprinkler systems, Equipment and Electrical

118 FIRE PROTECTION CONSTRUCTION PER SPECIFICATION AND DRAWINGS

119 • Installation of sprinkler system

120 • Piping installation

121 • Cement lined piping

122 • System flushing

123 • Hydrostatic testing

124 • Acceptance testing

125 • Fire detectors

126 • Fire proofing

127 • Instrument cable trays

128 • Hydrant spacing and type

129 • Sprinklers, Equipment and Devices








130 • Functional Testing

131 o Fixed water spray

132 o Fixed foam

133 o Fixed alarm

134 o Fire detection

135 o Gas detection

136 o Gas suppression

137 WORKMANSHIP: Visual Appearance, Labels and Clean up

138 HVAC SYSTEM

139 • Verify use of correct materials: Approved materials, equipment and control

system

140 INSTALLATION OF HVAC SYSTEM PER SPECIFICATION AND DRAWINGS

141 • HVAC System installation

142 • Control System

143 • Handling units

144 • Condensing units

145 • Exhaust fans

146 • Filters

147 • Vibration isolators

148 • Piping and valves

149 • Drain piping

150 • Duct work

151 • Insulation

152 • Louvers

153 • Automatic control system

154 WORKMANSHIP: Visual Appearance, Labels and Clean up

155 Testing, Balance and Start-up of HVAC System per Drawing and Specifications

City of Coffeyville, KS Underground Piping Inspection Checklist






QVC-5.01 – Inspection Checklist for Underground Piping Page 1 of 2

1 Underground firewater, open/closed process drains and cooling water lines:


3 • Proper Materials, Fit-up, WPS’s, PQR’s and WPQ’s

4 • Coating material meet specifications

5 • Proper Handling being used: slings and padded cribbing

6 • Installation per Engineering Drawings and Specifications

7 • Welded joints wrapped

8 • Holiday free per specifications

9 • Holiday repairs per specifications

10 • Pressure Tested per QVP-5.00 and QVP-5.01

11 • Proper ditch, bedding, backfill, compaction and slope on drain lines

12 • Required Inspections complete

13 • Thrust blocks per specifications

14 • Elevation and Installation of buffalo boxes

15 • Valve extensions installed

16 Concrete Lined Pipe:




20 • Damage to Lining

21 • Proper Joint “Buttering”

22 • Required Inspections and Testing complete

23 • Proper ditch, bedding, backfill, compaction and slope

24 Reinforced Concrete Pipe:




28 • Proper Joint Seals



31 Furan, PVC and Epoxy Pipe:



34 • Proper Joint Make-up


City of Coffeyville, KS Underground Piping Inspection Checklist






QVC-5.01 – Inspection Checklist for Underground Piping Page 2 of 2


37 Vitrified Clay and Cast Iron Pipe



40 • Proper Joint Make-up


City of Coffeyville, KS Stationary Equipment Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF INITIAL, IN-PROCESS AND FINAL INSPECTIONS FOR TOWERS & COLUMNS.


QVC-7.01 – Inspection Checklist for Stationary Equipment

1 Name Plate data is correct

2 Storage and Maintenance Procedures (OEM Recommendations) Implemented

3 Foundation and Anchor Bolts Verified and Acceptable

4 Anchor bolt sleeves sealed with minimal expanding foam or equivalent

5 Structural Steel Complete and Acceptable

6 Slide/Bed Plates Installed and Level

7 Equipment is shimmed and set

8 Centerline Location correct and verified

9 Equipment Orientation, Elevations and Nozzle Size and Rating verified

10 Exchanger: Floating End has adequate clearance

11 Plumbness verified

12 Grounding complete and verified

13 Grouting complete and verified

14 Anchor Bolt Torques verified

15 Piping Alignment verified

16 Pipe Supports Installed per Isometric Drawing

17 Tray Installation:

18 • Installation, Orientation and Levelness verified

19 • Down-comers sealed by weirs of proper height

20 • Bubble Caps and Tray valves are installed

21 • Process Nozzles are located on the proper trays

22 • Field Testing trays are complete

23 Distributer Installation:

24 • Orientation and Location verified

25 • Drilled Holes for spray nozzles are the correct size, number and

orientation. Holes are clear of obstruction

26 Mist Eliminator orientation and locations verified

27 Catalyst or packing loading is complete

28 All internals complete and verified

29 Davits Installed and work properly

30 Ladders and Platforms complete and verified

31 Testing and Inspections complete and verified

32 Flushing and Cleaning complete and verified

33 Internal cleanliness Inspections complete and verified

34 Man-ways, Closures and Gaskets Installed and verified

35 Instrumentation and Controls complete and verified

36 Painting and Coatings complete and verified

City of Coffeyville, KS Stationary Equipment Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF INITIAL, IN-PROCESS AND FINAL INSPECTIONS FOR TOWERS & COLUMNS.


QVC-7.01 – Inspection Checklist for Stationary Equipment

37 Heat Tracing complete and verified

38 Insulation complete and verified

39 Fireproofing complete and verified

40 CF-704 Final Closing Authorization Record complete

41 CF-702 – Stationary Equipment Installation Application, Authorization, and Record Complete

42 Enter Sign-Off in CF-701 Equipment Installation Log

City of Coffeyville, KS Rotating Equipment Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF INITIAL, IN-PROCESS AND FINAL INSPECTIONS FOR ROTATING EQUIPMENT.


QVC-7.02 – Inspection Checklist for Rotating Equipment

1 Name Plate data is correct

2 Storage and Maintenance Procedures (OEM Recommendations) Implemented

3 Preservatives and Desiccant removed and clean

4 Foundation and Anchor Bolts (Locations & Projections) complete and verified

5 Anchor Bolt Sleeves sealed with minimal expanding foam or equivalent

6 Load Bearing/Leveling Surfaces of plates, blocks, rails and sole plates flat and level within tolerances

7 Equipment set on foundation

8 Centerline location and elevation verified

9 Anchor Bolt Torques verified

10 Verify surface is ready for Grout

11 Preliminary alignment and soft foot verification complete

12 Grouting complete and verified

13 Grounding Complete

14 Preservatives and desiccant cleaned and removed

15 Auxiliary systems cleaned, flushed and connected (Lube oil, purge, cooling…)

16 Mechanical seals, packing, wipers…cleaned, installed and verified

17 Impellers (blades, ribbons, helices…) installed properly with correct rotation

18 Internal clearance verifications complete (Impellers)

19 Final (Cold) alignment complete (Pipe Stress Check)

20 System charged with correct lubricant

21 Bearings, Housing and Gear Cases marked for the proper oil level

22 Rotation of driven and driving equipment verified

23 Run-in for a period as recommended by the manufacturer, uncouple and check bearings for over heating and check Vibrations.

24 Coupling Assembled

25 Sheaves and Belts aligned and tensioned

26 Temporary Strainers in suction piping installed and verified

27 Motor Heater installed (As Required)

28 Check and Run-In Pumps; maintain them after Turn-Over; and do any required doweling of the pumps and drivers (As Required)

29 Hot Alignment Check (As Required)

30 Paint Complete

31 Heat Tracing Complete

32 Insulation Installed

33 Instrumentation and Controls Complete and verified

34 CF-705 – Rotating Equipment Installation Application, Authorization, and Record Complete

35 Enter Sign-Off in CF-701 Equipment Installation Log

City of Coffeyville, KS Coatings Application Inspection Checklist




THE INSPECTOR SHALL VERIFY THAT THE FOLLOWING ITEMS ARE IN ACCORDANCE WITH THE SPECIFICATION AND DRAWING REQUIREMENTS AT THE TIME OF THE INSPECTION.


QVC-8.01 – Inspection Checklist for Coating Application

1 Pre-Coating Inspection

1.1 Verify that coating, thinning, and blasting materials are as specified.

1.2 Verify that storage conditions for all materials are adequate and properly maintained.

1.3 Verify that surfaces not to be coated are masked off or otherwise protected prior to surface preparation and coating application to adjacent surfaces.

2 Pre-Surface Preparation

2.1 Verify that oil and grease are removed prior to surface preparation.

2.2 Verify that welds and sharp edges have been suitable prepared.

3 Surface Preparation

3.1 Verify that the air supply is clean and free of oil and moisture.

3.2 Verify the cleanliness and dryness of abrasives.

3.3 Verify the adequacy of cleaning and blasting equipment, hoses, etc.

3.4 Verify the ambient, substrate, and dew point temperatures are appropriate.

3.5 Verify that visible burrs, slivers, slag, scale, and weld spatter are removed.

3.6 Verify anchor profile.

4 Coating Application:

4.1 Verify the materials are as specified, properly labeled, and shelf life is not expired.

4.2 Verify the mixing, thinning, and induction times are per the specifications.

4.3 Verify that the proper application equipment is being used.

4.4 Verify that the air supply is clean and free from oil and moisture.

4.5 Verify that the ambient, substrate, and dew point temperatures are appropriate.

4.6 Verify that the wet film thickness is being checked during application.

4.7 Verify that recoat times are in accordance with the specifications.

4.8 Visually inspect coatings for defects and uniform appearance.

4.9 Verify dry film thickness of individual passes.

4.10 Verify daily coating records are being maintained.

5 Final Acceptance

5.1 Visually inspect the final surface for color, defects, and uniform appearance.

5.2 Verify dry film thickness.

5.3 Verify that any identified repairs were made and are acceptable.

5.4 Verify the coating system has cured prior to handling.

5.5 Verify all daily coating records are complete.


Form No. CF-001, Rev. 2

NOTICE OF ACCEPTANCE Project: Location: Contract: Contractor: System No.: System Description: Notice of Acceptance Number: Date: NOTICE is hereby given to the above named Contractor that the Work performed by Contractor Pursuant to the above Contract for said project is accepted as of the below stated date for and only for: (check applicable)

Purpose of final acceptance of said Work under said Contract. Acceptance of this Work is contingent upon Contractor completing the following in-completed Work by: If such Work is not completed by this date, this acceptance shall be void and as if never given.

See attached pages for the System Master Punch-list See attached pages for the Management of Change Log

This notice shall not relieve Contractor of any responsibilities under the guarantee provisions of the Contract. Dated: (City of Coffeyville, KS) Signed:

Dated: (Client) Signed:

City of Coffeyville, KS Non-Conformance Report

Project No. Report No.

Contract, Subcontract, or Purchase Order No. Page No.

Contractor, Subcontractor, or Supplier: Date:


SECTION 1 – IDENTIFICATION

Item No.: Supplier or Sub:

Item Description: Location:

Contact:

Phone:

Description of Non-Conformance and Original Requirement::

Non-Conformance Identified By (Name): Signature: Date:

SECTION 2 – DISPOSITION AND CORRECTIVE ACTION

Disposition: Accept As-Is Accept Pending Further Corrective Action Reject / Scrap

Description of Proposed Corrective Action:

Disposition / Corrective Action Proposed By (Name): Signature: Date:

Approved By COC (Name): Signature: Date:

SECTION 3 – VERIFICATION OF CORRECTIVE ACTION (IF REQUIRED)

Corrective Action Completed On (Date):

Corrective Action Verified By (Name): Signature: Date:

Approved By COC (Name): Signature: Date:

Form No. CF-003, Rev. 1 1 of 1

City of Coffeyville, KS Project Number:Project: Non-Conformance Log

Non-Conformance

Report No.

Contractor / Supplier

Unit or Area

Date Opened Description

Date Disposition Approved

Date Closed Remarks

Location:

City of Coffeyville, KS Material Receiving Report


Project No.: MRR No.:

Supplier: Date Received:

PO/Contract #: Carrier:

Comments:

RECEIVING INSTRUCTIONS

1. Perform receiving inspection, complete checklist, and initial all items.

2. If material is damaged or quantities do not match the Bill of Lading, complete separate form CF-007, Overage, Shortage, and Damage Report and obtain carrier’s signature prior to leaving the jobsite. Record OS&D report number.

3. Document all items included in shipment and/or attach shipping papers that specify the number of pieces, boxes, or barrels making up the total shipment.

RECEIVING CHECKLIST

No. Activity Acceptable Unacceptable OS&D Rpt. No. Initial

1 Verify quantities received are in accordance with the quantities specified in the Shipping Papers.

2 Inspect materials for signs of damage including missing tags, coating damage, etc.

3 Mark boxes and crates to be put into storage are marked with the purchase order number and tag number(s).

RECORD OF ITEMS RECEIVED

Item No. on P.O.

Quantity Ordered Unit

Quantity Receive

d Description Tag No. Storage

Area

CHECK BOX IF ADDITIONAL ITEMS ARE LISTED ON SUPPLEMENTAL SHEET

DELIVERY / RECEIPT APPROVED BY

Organization Name (Print) Signature Date

Carrier

Subcontractor

Contractor

Owner

City of Coffeyville, KS Material Receiving Report


MRR No.: Supplementary Sheet No.:

SUPPLEMENTAL RECORD OF ITEMS RECEIVED

Item No. on P.O.

Quantity Ordered Unit Quantity

Received Description Tag No. Account Codes


City of Coffeyville, KS Project Number:Project: Material Receiving Log

Contract No. Load No. Item on P.O. MRR No. OS&D

No. P.O. No. Supplier Item Description Part No. Date Received

Laydown Yard Location Quantity Unit Notes

Location:


SUBCONTRACTOR SYSTEMS TURNOVER ACCEPTANCE


This system has been installed and tested in accordance with the Project

Specifications, Standards, Drawings, Applicable Codes and Standards.

This system is complete and ready for acceptance. Items on the attached

Exceptions List will be submitted to you for your acceptance upon completion.

The attached system turnover documentation is being transferred to you for your

care, custody and control. This Document does not relieve either party from any

agreements or responsibilities outlined in the Subcontract or Contract

Documents.

The System as defined on the attached P&ID’s and/or drawings will be deemed

acceptable by the Client for care, custody and control when the Client Project

Representative signs this package.

FINAL ACCEPTANCE

Accepted by Contractor Rep: Date:

Accepted by COC Rep: Date:

Accepted by Owner Rep: Date:

City of Coffeyville, KS Overage, Shortage, and Damage Report

Form No. CF-007 Rev. 0

Project No.: OS&D No.:

Supplier/Contractor: MRR No.:

PPO/Contract #: Date Received:

Carrier:

Comments:

Item No. on P.O.

Over Short Damaged Quantity Ordered

Quantity Received Description of Damage Tag No’s.

OVERAGE, SHORTAGE, OR DAMAGE AKNOWLEDGED BY

Organization Name (Print) Signature Date

Carrier

Subcontractor

Contractor

Owner



Welding Conformance Report

SYSTEM The following items are verified for completion:

1. System installed per applicable Codes, Specifications, and Drawings

2. Correct Base Metals, Filler Metals verified and used

3. Qualified Welders, WPS’s, and PQR’s used

4. Weld Maps attached

5. Required Visual and Non-Destructive Examinations Performed per all applicable

Codes & Standards

6. Test reports and results documented and attached Contractor (QA/QC Manager)_________________________________Date_______ Contractor (Project Manager)_________________________________Date_______ COC. Representatiive_________________________________________Date_______ Client Representatiive_________________________________________Date_______


Project

Client (1) Must be completed before hydro

Contract # (2) Must be completed before startup

Contractor Complete (3) Can be completed after startupContractor Total

Item Description Location Hydro /Line # Priority Date

ReportedResponsible

PartyPromise

Date% Complete

& Date Contractor City of Coffeyville, KS Owner

MASTER PUNCHLIST

Priority Codes

SIGN-OFFS

Form No. CF-010 REV 0 1 of 1

City of Coffeyville, KS Project Number:

TAG NO. DATE Description of Work Performed Lube Rotate Megger HeaterNitrogen Blanket Person

Project: Location:

Form No. CF-011, Rev 2 1 of 2

DAILY FIELD REPORT Site Weather Temp

Visitors Vendor Material Or Equip Deliv. Inspection & Testing Performed

COC or Subcontractor Quantity Craft Brief Description & Location of Work Performed

Yes No

Date:

Significant Activity Brief Description

Signature:

Delays:FWA Authorization:Project Photos Taken:

E-Mail:Phone Conversation:

See Page 2 of this report for details

Client:

For The Record - PROBLEMS / COMMENTS / DELAYS

8 am Noon 4 pm

Clear Cloudy Rain

Dry Muddy

Job Name: Job Number: Location:COC Rep:


DAILY FIELD REPORT Site Weather Temp

Date:Client:

8 am Noon 4 pm

Clear Cloudy Rain

Dry Muddy

Job Name: Job Number: Location:COC Rep:

PHOTOS

Photo # 1 Photo # 2

Photo # 3 Photo # 4

Photo Description: Photo Description:

Photo Description: Photo Description:

City of Coffeyville, KS Drawing Control Audit

Form No. CF-012, Rev 1

PROJECT INFORMATION

Client: Contract No.:

Project No.: Contractor:

DRAWINGS FROM CITY OF COFFEYVILLE, KS SITE OFFICE TO SUBCONTRACTOR’S SITE OFFICE

Drawing No. Revision No. Type of Drawing Date Received

Acceptable (Y/N) Comments

1

2

3

4

5

SAME DRAWINGS FROM SUBCONTRACTOR’S SITE OFFICE TO SUBCONTRACTOR’S FIELD FOREMEN’S OFFICE



1

2

3

4

5

NEW DRAWINGS FROM SUBCONTRACTOR’S FIELD FOREMEN’S OFFICE TO SUBCONTRACTOR’S SITE OFFICE



1

2

3

4

5

SAME DRAWINGS FROM SUBCONTRACTOR’S SITE OFFICE TO CITY OF COFFEYVILLE, KS SITE OFFICE



1

2

3

4

5

Approved by COC Site QC Manager: Date:

Approved by COC Site Manager: Date:

1 of 1

Total OpenTotal Open

Total NDE AcceptedTotal NDE Rejected

NDE Rejection Rate20% BW's 100% BW's

NonconformanceClosedProcurement Driven

5% BW's

Contractor Driven Closed

Quality Key Performance Indicators

Report as of

Reject Rate

Total NDE Complete2% SW's 10% BW's

4/13/2015Project Name: Project No:

P66 TOP Flex ProjectResponsibility Matrix for Inspections and Signoffs

Form No. CF-014, Rev 1 1 of 3 Printed 4/13/2015; 3:21 PM

Form No. Description Contractor City of Coffeyville, KS Client Client Representative Comments

CF-001 System Notice of AcceptanceCF-002 Non-Conformance Report N/ACF-004 Material Receiving Record N/ACF-006 Subcontractor Signoff to COC N/ACF-007 Receiving Overage, Shortage and Damage Report N/ACF-008 Welding Conformance N/ACF-009 Master PunchlistCF-012 Drawing Control Audit N/ACF-103 Authorization to Backfill

1) Authorization to Backfill2) Final Testing3) Final Acceptance

CF-201 Concrete Placement Application, Authorization and Record reference to mechanical completion matrix item H-41) Authorization to Place Concrete2) Concrete Placement Record/ Inspection3) Record of Post Placement / Form Removal4) Final Acceptance

CF-202 Grout Placement Application, Authorization and Record1) Authorization to Place Grout2) Grout Placement Record/ Inspection3) Record of Post Placement / Form Removal4) Final Acceptance

CF-301 Structural Steel Authorization and Acceptance Record reference to mechanical completion matrix item I-41) Authorization to Place Structural Steel2) Structural Steel Placement Record/ Inspections3) Record of Post Placement 4) Final Acceptance

QVC-4.01 Checklist for BuildingsCF-501 Hydrotesting Inspections reference to mechanical completion matrix item C-2,6,8

1) Pre-Hydro Test Release Participate in Pre-hydro walk down2) Hydro Test3) Post-Hydro/ System Restoration4) Final Acceptance Participate in Post-hydro walk down

CF-503 Holiday Test Record LogCF-504 Tie-in Placement Application, Authorization and Record

1) Authorization to Perform Tie-In2) Record of Tie-In3) Record of Post-Tie-In Activities4) Final Acceptance

CF-601 Loop Acceptance Record reference to mechanical completion matrix item B-191) Instrument Calibration Acceptance2) Instrument Installation Acceptance3) Loop Functional Acceptance Scheduled loop tests

CF-702 Stationary Equipment Placement Application, Authorization and Record reference to mechanical completion matrix item D-4 & 5, F-31) Authorization to Place Stationary Equipment2) Record of Stationary Equipment Placement3) Record of Post Placement Activities




4) Final AcceptanceCF-703 Equipment Plumb RecordCF-704 Equipment Final Closing Authorization Record

1) Authorizatation to Close2) Final Acceptance of Closure

CF-705 Rotating Equipment Placement Application, Authorization and Record1) Authorization to Place Rotating Equipment2) Record of Rotating Equipment Placement3) Record of Post Placement Activities4) Final Acceptance

CF-706 Coupling Alignment Record1) Final Acceptance of Alignment

CF-801 Coating Record reference to mechanical completion matrix item K-3CF-901 Insulation Placement Application, Authorization and Record reference to mechanical completion matrix item L-3

1) Authorization to Place Insulation2) Final Acceptance of Insulation System

CF-902 Fireproofing Placement Application, Authorization and Record reference to mechanical completion matrix item J-31) Authorization to Place Fireproofing2) Final Inspection

CF-903 Steam Tracing Placement Application, Authorization and Record1) Authorization to Place Steam Tracing2) Final Inspection

CF-904 Electric Tracing Placement Application, Authorization and Record1) Authorization of Electric Tracing Installation2) Record of Post-Placement Activities3) Megger Testing (4X)4) Final Acceptance

QV6.02-03 Conduit Checklist - Routing PlanQV6.02-04 Underground Electrical Conduit InspectionQV6.02-05 Conduit Seals and Drains ChecklistQV6.02-06 Cable Tray ChecklistQV6.02-07 Lighting ChecklistQV6.02-08 Pole Lines ChecklistQV6.02-09 Grounding ChecklistQV6.02-10 Grounding Test ReportQV6.02-11 Ground Rod Resistance Test ReportQV6.02-12 Cable and Wire ChecklistQV6.02-13 Insulation Resistance Test and DC High Voltage Test on Cables and WiresQV6.02-14 Switchgear Test RecordQV6.02-15 Switchgear Circuit Breakers Test RecordQV6.02-16 AC Medium Voltage Motors Test RecordQV6.02-17 600 Volt Motors Test Record

SignatureCOC Acceptance

DateTitle




SignatureClient Acceptance

Title Date



Pier/Pile Installation Log

Number Testing Agency Area Description Date Results Action Required

Project: Location:



Number Testing Agency Location Description Date Results Action Required

Project: Location:

City of Coffeyville, KS Authorization to Backfill Record

Form No. CF-103, Rev1

EXCAVATION INFORMATION

Project No.: Date of Backfill:

Contract No.: Civil Work Completed and Acceptable (Y/N):

Contractor: Piping Work Completed and Acceptable (Y/N):

Unit / Area: Electrical Work Completed and Acceptable (Y/N):

Drawing No.: Fill Material Inspected and Acceptable (Y/N):

Recorded By (Name): Date:

RECORD OF COMPLIANCE

THE ABOVE EXCAVATED AREA HAS BEEN TESTED AND INSPECTED IN ACCORDNCE WITH THE APPLICABLE CONSTRUCTION DRAWINGS, CODES AND ENGINEERING SPECIFICATIONS. ALL WORK IS CERTIFIED TO BE ACCEPTABLE. FILL MATERIAL HAS BEEN INSPECTED FOR SUITABILITY AND IS FREE OF ALL CONTAMINATED DEBRIS.

Accepted by COC Site Superintendent: Date:

AUTHORIZATION TO BACKFILL

AUTHORIZATION IS HEREBY GRANTED FOR BACKFILLING THE SPECIED AREA ABOVE.

Accepted by COC Site Quality Manager: Date:

FINAL TESTING

FINAL TESTING HAS BEEN COMPLETED BY A THIRD PARTY INSPECTION COMPANY AND DEEMED ACCEPTABLE. ALL RECORDS HAVE BEEN OBTAINED AND FILED ACCORDINGLY.

Accepted by COC Site Quality Manager: Date:

FINAL ACCEPTANCE


Accepted by COC Rep : Date:


City of Coffeyville, KS Drilled Shaft Foundation Record


DRILLED SHAFT

Project No.: Shaft Location / Number:

Project Name: Estimated Quantity of Concrete Pour (Cu. Yards):

Client: Target Slump (in):

Contract No.: Required Design Strength (psi):

Ref. Drawing No.: Required Elevation (ft):


RECORD OF DRILLED SHAFT FOUNDATION PLACEMENT

AS DESIGNED (Per Drawing)

Shaft Log (Unusual Drilling Conditions, Location of Obstructions, and all other pertinent information) T.O.C. Elevation Elevation

Diameter of Shaft (ft)

Length of Shaft (ft)

Embedment Length (ft)

Rock Embedment (ft)

Length of Rebar (ft)

AS BUILT

Date/Time Started

Date/Time Completed

Diameter of Shaft (in)

Length of Shaft (ft)

Embedment Length (ft)

Rock Embedment (ft)

REBAR

Length of Rebar (ft)

Rebar Size “W”

Rebar Size “X”

Rebar Size “Y”

EXCAVATION

Excavated Soil (Cy)

Excavated Rock (Cy)

CONCRETE POUR: Date/Time Start & Stop UNCASED SHAFT CASED SHAFT

Neat Volume Qty (Cy) Cylinder Test 7 Day psi Dry Slurry Tremie

Air Content (%) Cylinder Test 14 Day psi

Slump (in) Cylinder Test 28 Day psi

Temperature (ºF) Cylinder Test 56 Day psi

FINAL ACCEPTANCE

Approved by Contractor Rep: Date:

Approved by COC Rep: Date:

Approved by Client Rep: Date:



Batch Ticket Pour Date QVC-2.01 CF-201 CF-202 Test Number Test Date Area Area Description Contractor Testing Agency 7 Day

Break14 Day Break

28 Day Break

56 Day Break Acceptance

Project: Location: Concrete Installation Log

City of Coffeyville, KS Concrete Placement Application, Authorization, and Record


APPLICATION TO PLACE CONCRETE

Project No.: Estimated Quantity of Concrete Pour (Cu. Yards):

Contract No.: Target Slump:

Contractor: Required Design Strength:

Pour No. / I.D.: Required Elevation:

Unit / Area: Required Finish:

Ref. Drawing No.: Required Curing Time:

Scheduled Date / Time of Pre-Placement Inspection: Compaction Report Required (Y/N):

Scheduled Date / Time of Concrete Placement: Compressive Break Strength Testing Required (Y/N):

Application Made By (Name): Date:

RECORD OF PRE-PLACEMENT ACTIVITIES

Soils Compaction Testing Completed and Accepted (Y/N): Completed Pre-Placement Inspection Checklist (Y/N):


AUTHORIZATION TO PLACE CONCRETE

Contractors Contractor Owner (if required)

Civil Mechanical Electrical Other

Company Name: City of

Coffeyville, KS

Authorized By:

Date:

RECORD OF CONCRETE PLACEMENT

Date / Time of Starting Placement: Description of Weather During Placement:

Date / Time of Completing Placement: Temperature During Placement (High and Low):

Actual Quantity of Concrete Pour (Cu. Yards): Number of Test Specimens Taken:

Observed Slump: Completed Placement Inspection Checklist (Y/N):


RECORD OF POST-PLACEMENT ACTIVITIES

Date / Time of Form Removal: Completed Post-Placement Inspection Checklist (Y/N):


FINAL ACCEPTANCE

Approved by Contractor Rep: Date:

Approved by COC Rep: Date:

Approved by Client Rep: Date: Note: Attach applicable Concrete Testing Reports.

City of Coffeyville, KS Grout Placement Application, Authorization, and Record


APPLICATION TO PLACE GROUT

Project No.: Scheduled Date / Time of Pre-Placement Inspection:

Contract No.: Scheduled Date / Time of Grout Placement:

Contractor: Required Finish:

Unit / Area: Required Curing Time:

Ref. Drawing No.: Compressive Break Strength Testing Required (Y/N):

Vessel Pump Exchanger Structural Steel Other

Equipment ID: Structural Steel ID:

Grout Type: Product Name:

Application Made By (Name): Date:


Surface Preparation (Concrete/Metal) per Specifications (Y/N): Grout Mixing per Specs and Manufacturer’s Recommendations (Y/N):

Grout Type per Specifications (Y/N): All Foreign Materials Removed (Y/N):

Formwork straight, level, plumb and sealed per specifications (Y/N): Foundation Wetted per Manufacturer’s Recommendations (Y/N):


AUTHORIZATION TO PLACE GROUT

Signature: Date: Contractor Owner (if required)

Requested By:

Authorized By: City of Coffeyville,

KS

RECORD OF GROUT PLACEMENT

Date / Time of Starting Placement: Grout Placement per Manufacturer’s Recommendations (Y/N):

Date / Time of Completing Placement: Base-plate Support Frames fully in Grout (Y/N):

Description of Weather During Placement: Finishing and Curing per Specifications (Y/N):

Temperature During Placement (High and Low): Number of Test Specimens Required:



Visual Inspection Acceptable (Y/N): Ping Tests (As required) Performed and Acceptable (Y/N):


FINAL ACCEPTANCE



Accepted by Owner Rep: Date: Note: Attach applicable Grout Testing Reports.

City of Coffeyville, KS Structural Steel Authorization and Acceptance Record


STRUCTURAL STEEL IDENTIFICATION

Project No.: Structural Steel ID:

Contract No.: Unit / Area:

Contractor: Reference Drawing:

Joint Design: Snug Tightened Pre-Tensioned Slip-Critical Skidmore I.D.: Skidmore Calibration:

RECORD OF PRE-PLACEMENT OF STRUCTURAL STEEL ACTIVITIES

Compressive Strength Break Testing Completed and Accepted (Y/N): Anchor Bolts and Embedded Items of the correct size and Location (Y/N):


AUTHORIZATION TO PLACE STRUCTURAL STEEL


Requested By:


KS

RECORD OF STRUCTURAL STEEL PLACEMENT

Piece Mark Identification Type and Location Correct (Y/N): Drilled Holes in Proper Locations (Y/N):

Overall Dimensions & Alignment Correct (Y/N): Welders Certified to AWS D1.1 (Y/N):

Bearing devices (wedges, shims, leveling screws, etc.) are correct. Structural Steel Drawings Weld Mapped (Y/N):

Faying Surfaces Inspected and Acceptable (Y/N): Protective Coatings Complete (Y/N):

Skidmore Test Performed and Acceptable (Y/N): Authorization to Grout (CF-202) Complete (Y/N):

Bolting Verified and Acceptable (Y/N): Required NDE Performed & Accepted (Y/N):



Completed Post-Placement Walk-down (Y/N): Authorization to Fireproof (CF-902) Complete (Y/N):


SUMMARY OF STRUCTURAL STEEL INSPECTIONS


FINAL ACCEPTANCE



Accepted by Owner’s Rep: Date:

Rev Date: 2/27/20081 of 2

Scope

Piping and miscellaneous fabricated components produced by ContractorsThe requirement for hydrostatic test pressure and duration will be defined by theapplicable Hydro Inspection Test Plan.

Purpose

To provide the technical requirements for equipment set-up, apparatus, and applicationof pressure when performing hydrostatic pressure tests in accordance with published standards.

Setup

The test item shall be positioned in such a manner that all bolted or welded jointsare fully exposed for examination during the test. The piping or componets shall be

components prior to the pre hydro walk-down.

The test item shall be adequately supported throughout its entire length. The support system must be capable of supporting the total weight of the test itemwhen full of test medium.

All openings shall be securely closed using gaskets, test covers, bolting, and plugs of correct size, type, and rating.

All test blinds shall be given a unique identification number by the Quality Department and logged on the Test Blind Index.

Test blind flanges shall be equal to the strength of the flange to be blinded in accordance with the Flange Blind Matrix. All test blinds shall be fully fastened with fasteners of equal strength to that of the service bolting. Bolting torque values shall be adequate to prevent leakage at the joint.

Test plugs shall be solid bar hex or round bull plugs. Visually inspect the threads for wear and damage before use. Ensure the plug achieves full thread engagement when installing in the test item.

Vents & Drains shall be provided at all high & low points as required to purge possible air pockets during filling and drain the system upon completion.

Pressure gages used in pressure testing shall be indicating pressure gaugesand shall be connected directly to the test item. If the indicating pressuregauge is not readily visible to the operator controlling the pressure applied,an additional gauge shall be provided where it will be visible to the operator throughout the duration of the test. For systems with a large volumetric content, it is recommended that a recording gauge be used in addition to the indicating gauge.

Indicating pressure gauges used in testing shall have a range not less than one and one half (1 1/2) of the intended maximum test pressure.The test pressure shall be located within the middle third of the gauge.

0 Steven E. McKenna

1.0

2.0

3.0

3.1

clearly marked with identifying marks, these markings shall be on the pipe or

Hydrostatic Pressure Testing ProcessDate 2/27/2008 Approved By:Revision

3.8

3.2

3.3

3.4

3.5

3.6

3.7

3.9

Rev Date: 2/27/20082 of 2

0 Steven E. McKenna

Hydrostatic Pressure Testing ProcessDate 2/27/2008 Approved By:Revision

Setup Continued…

All gauges shall be checked prior to each test or series of tests to ensure that calibration has been performed within one year of the test date.

The test medium temperature shall be 30 degrees F above the minimum design temperature whenever possible, but under no circumstances shall the temperature be less than 60 degrees F or greater than 120 degrees F.

Filling and Pressurizing

Fill the test item completely with the test medium while the high-point ventis open allowing the air to escape. The hydrostatic test technician mustensure that the test item is completely purged of air.

Disconnect or isolate all low pressure filling lines and other apparatus notrated for the test pressure.

Gradually apply the test pressure as defined on the Hydro Inspection TestPlan, making sure that the test pressure does not exceed the limits of the test.

Once the desired test pressure is achieved, close the quick close valve, then the gate valve, and disconnect the pressure pump from the test item.

Examination

Maintain the required test pressure for a minimum of ten (10) minutes and then proceed with the examination of the test item.

Examinations for leakage shall be made of all joints and connections and shall show no visual evidence of weeping or leakage.

Upon satisfactory completion of the test, gradually release the pressure and witness gauge zero. Begin disassembly of the test apparatus. Drain system accordingly.

Documentation

Ensure that all applicable signatures are noted on the Hydro Inspection Test Plan prior to releasing the test pressure from the test item and the test status shall be documented on the Hydro Inspection Test Plan.

4.1

4.2

4.3

4.4

3.10

3.11

4.0

3.0

6.0

6.1

5.0

5.1

5.2

5.3

City of Coffeyville, KS Holiday Test Record Log


PROJECT INFORMATION

Project No.: Unit / Area:

Contract No.: System:

Contractor: Holiday Equipment Name:

HOLIDAY INSPECTION SPECIFICATIONS

TEST VOLTAGE = 250 x √microns or TEST VOLTAGE = 1250 x √ mils

FUSION BOND EPOXY = 1600 – 3000 V

TAPES = 6000 – 12000 V

HEAT SHRINK = 8000 – 15000 V

COALTAR = 12500 – 35000V

RECORD OF HOLIDAY INSPECTIONS

Line No.: Sht. No.: Test Origin: Test Termination: Release Date:

HOLIDAY INSPECTION PROCEDURE

1) Calculate Test Voltage as described in formulae above or use Project Specifications

2) Fix a Lead from pipe substrate to ground

3) Connect Leads to Holiday Detector in accordance with operation instructions

4) Adjust to required test voltage

5) Test Holiday detector by touching electrode to exposed subtrate

6) Pass electrode over coated surface at maximum rate of 20 feet per minute

7) Mark Holiday areas

8) Repair area as needed

9) Follow Safety precautions per Owner’s Manual

FINAL ACCEPTANCE




City of Coffeyville, KS Tie-In Application, Authorization, and Record


APPLICATION TO PERFORM TIE-IN

Project No.: System:

Contract No.: Isometric Drawing:

Contractor: P&ID:

Unit / Area: Tie-in No’s.:


Clients Tie-In Specifications Reviewed (Y/N) Ultrasonic Thickness Test Performed and Acceptable (Y/N):

Tie-in Location Verified and Acceptable (Y/N): Bake out Procedure Performed (As Required) and Acceptable (Y/N):

Pre Task Analysis Performed and Signed (Y/N): WPS w/ Supporting PQR Reviewed and Acceptable (Y/N):

LOTO Performed and Verified (Y/N): Welder Performance Qualification (WPQ) Acceptable (Y/N):

Materials of Construction (MTR’s) Obtained and Acceptable (Y/N): PWHT Procedures (As required) Reviewed and Acceptable (Y/N):

PMI (As Required) Performed and Acceptable (Y/N): NDE Procedures Reviewed and Acceptable (Y/N):


AUTHORIZATION TO PERFORM TIE-IN


Requested By:


KS

Authorized By:

RECORD OF TIE-IN

Surface Preparation within Specifications (Y/N): In-Process NDE Performed (As Required) and Acceptable (Y/N):

Surface Prep. NDE Inspection Performed and Acceptable (Y/N): Piping Installed per Drawings and Specifications (Y/N):

Fit-up and Alignment with Specifications (Y/N): 5% NDE Requirements Met and Acceptable: (Y/N):

Welding in Accordance with WPS (Y/N): NDE in Lieu of Hydro (As Required) Complete and Acceptable (Y/N):

Hardness Testing Complete and Acceptable (Y/N): Car Ber Hydro Test (As required) Performed and Acceptable (Y/N):


RECORD OF POST-TIE-IN ACTIVITIES

Area Clean and Acceptable to Client (Y/N): Insulation (As Required) Performed and Acceptable (Y/N):

Painting Performed and Acceptable (Y/N): Flange Connections (Bolting and Gaskets) Acceptable (Y/N):

Heat Tracing (As Required) Performed and Acceptable (Y/N): Service Test (As required) Performed and Acceptable (Y/N):


SUMMARY OF TIE-IN INSPECTIONS


FINAL ACCEPTANCE





Project Number:

Equipment Name Tag No. System Drawing No. Mech. Contractor

Receiving Inspection

Pre-Installation

Installation Complete

Internals Complete Paint ST/ET Insulation Fire -

proofingFinal

Closure

City of Coffeyville, KSProject: Location:

City of Coffeyville, KS Stationary Equipment Placement Application, Authorization, and Record


APPLICATION TO PLACE STATIONARY EQUIPMENT


Contract No.: Equipment ID:

Contractor: Drawing No.:

Unit / Area: Scheduled Date / Time of Equipment Placement:


Receipt Inspection Performed and Accepted (Y/N): Rigging and Lift Plan Reviewed and Approved (Y/N):

Name Plate Data Inspected and Approved (Y/N): Shims Inspected and Approved (Y/N):

Concrete Preparation Completed and Accepted (Y/N): Torque Method and Sequence Reviewed and Approved (Y/N):

Compressive Strength Records Obtained and Approved (Y/N): Bed Plates (Fixed and Sliding Ends) Inspected and Approved(Y/N):

Anchor Bolts Inspected and Approved (Y/N): Structural Steel Inspected and Approved (Y/N):


AUTHORIZATION TO PLACE STATIONARY EQUIPMENT


Requested By:


KS

RECORD OF STATIONARY EQUIPMENT PLACEMENT

Initial Plumb and Level Check Performed (Y/N): Shims welded to Support Member of Steel if required (Y/N):

Nozzle Orientation Inspected and Acceptable (Y/N): Hold Down Bolts Inspected and Acceptable (Y/N):

Sliding Plates and Slotted Holes are Aligned and Acceptable (Y/N): Final Plumb, Level and Alignment Acceptable (Y/N):



Grouting Inspected and Acceptable (Y/N): Cleanliness Inspection Performed and Acceptable (Y/N):

Piping Alignment Performed and Acceptable (Y/N): Final Closure (CF-704) Acceptable (Y/N):

Equipment Internals Inspected and Acceptable (Y/N): Electrical Grounding Complete and Acceptable (Y/N):


SUMMARY OF STATIONARY EQUIPMENT INSPECTIONS


FINAL ACCEPTANCE




City of Coffeyville, KS Equipment Plumb Record


EQUIPMENT INFORMATION




Unit / Area: Date of Equipment Placement:

RECORD OF MEASUREMENTS

LOOKING NORTH

INSTRUMENT USED:

READINGS

TOP BOTTOM

COORDINATES:

COMMENTS:

LOOKING EAST

INSTRUMENT USED:

READINGS

TOP BOTTOM

COORDINATES:

COMMENTS:

FINAL ACCEPTANCE




City of Coffeyville, KS Equipment Closing Authorization Record






Unit / Area: Date of Equipment Closure:

RECORD OF COMPLIANCE

THE ABOVE EQUIPMENT / PIPING HAVE BEEN SUPPLIED AND FITTED IN ACCORDNCE WITH THE APPLICABLE DRAWINGS, SPECIFICATIONS, AND MANUFACTURER’S STANDARDS. IT IS CERTIFIED TO BE MECHANICALLY ACCEPTABLE. EQUIPMENT HAS BEEN INSPECTED FOR CLEANLINESS AND IS FREE OF ALL DEBRIS.

Accepted by COC: Date:

AUTHORIZATION TO CLOSE

AUTHORIZATION IS HEREBY GRANTED FOR FINAL CLOSING OR SEALING OF THIS EQUIPMENT/PIPING.

Accepted by COC: Date:

FINAL CLOSURE

THE ABOVE EQUIPMENT / PIPING FLANGES HAVE BEEN SUPPLIED AND FITTED FOR PROPER NUTS, BOLTS, GASKETS AND TORQUING VALUES AND TECHNIQUE. FINAL CLOSING HAS BEEN COMPLETED.

COC Representative: Date:

FINAL ACCEPTANCE




City of Coffeyville, KS Rotating Equipment Placement Application, Authorization, and Record


APPLICATION TO PLACE ROTATING EQUIPMENT




Unit / Area: Scheduled Date / Time of Equipment Placement:


Receipt Inspection Performed and Accepted (Y/N): Rigging and Lift Plan Reviewed and Approved (Y/N):

Name Plate Data Inspected and Approved (Y/N): Shims Inspected and Approved (Y/N):

Concrete Preparation Completed and Accepted (Y/N): Sole Plates Inspected and Approved (Y/N):

Compressive Strength Records Obtained and Approved (Y/N): Grouting of Soleplates Inspected and Approved (Y/N):

Anchor Bolts Inspected and Approved (Y/N): Initial Alignment Check Acceptable (Y/N):


AUTHORIZATION TO ROTATING EQUIPMENT


Requested By:


KS

RECORD OF ROTATING EQUIPMENT PLACEMENT

Base Plate and/or Nozzle Elevations Inspected and Acceptable (Y/N): Ping Test Performed and Acceptable of Base Plate (Y/N):

Rough Alignment Performed and Acceptable (Y/N): Preliminary Alignment Performed and Acceptable (Y/N):

Components (Shaft Bearings & Gearboxes) Cleaned and Lubricated (Y/N): Soft Foot Check Performed and Acceptable (Y/N):



Piping Alignment Performed and Acceptable (Y/N): Final Alignment Performed and Acceptable (Y/N):

Cleanliness Inspection Performed and Acceptable (Y/N) Uncoupled Testing Performed and Acceptable (Y/N):

Final Closure (CF-704) Acceptable (Y/N): Final Coupling Assembly and Bolt Up Performed and Acceptable (Y/N):


SUMMARY OF ROTATING EQUIPMENT INSPECTIONS


FINAL ACCEPTANCE




City of Coffeyville, KS Coupling Alignment Record


RIM RUNOUT FACE RUNOUT


Project No.: Equipment ID:

Subcontract No.: Manufacturer & S/N:

Subcontractor: Coupling Type:

Unit / Area: Coupling S/N & Model:

System: Manufacturer Recommended Gap:

Drawing No.: RPM at Coupling:

Type of Bearing on Equipment: Driver End: Driven End:

Shaft End Play (Thrust) on Equipment: Driver End: Driven End:

RECORD OF MEASUREMENTS

Alignment By: Dial Indicator Reverse Dial Indicator Laser

Alignment: Hot Cold Indicator On: Driver Driven

0°

270° 90°

180°

SINGLE ROTATION DOUBLE ROTATION

0° 0° 0° 0° 0° 0°

90° 90° 90° 90° 90° 90°

180° 180° 180° 180° 180° 180°

270° 270° 270° 270° 270° 270°

RIM RUNOUT A FACE RUNOUT A RIM RUNOUT B FACE RUNOUT B ANGULAR ALIGNMENT

PARALLEL ALIGNMENT

COUPLING GAP:____________

FINAL ACCEPTANCE

Accepted by Subcontractor Rep: Date:



POST PLACEMENT INSPECTION

Grout Inspected and Acceptable (Y/N): Pipe Strain Checked and Acceptable (Y/N):

Coupling Guard Installed and Acceptable (Y/N): Lubrication Complete and Acceptable (Y/N):

DRIVE DRIVEN

City of Coffeyville, KS Coatings Record


AUTHORIZATION TO PAINT

Project No.: Coating System:

Contract No.: Drawing No’s.:

Contractor: Equipment ID:

Material Coated: Unit / Area:


CONDITIONS

Condition Start of Blasting Start of Coating Mid-Point of Coating End of Coating

Time:

Ambient Temperature (F):

Relative Humidity (%):

Dew Point Temperature (F):

Substrate Temperature (F):

Description of Weather Conditions:

SURFACE PREPARATION

Condition of Surface Prior to Blasting: Required Anchor Profile:

Method of Removing Contamination Prior to Blasting: Anchor Profile Measured:

Method of Blasting:

Abrasive Type / Grade:

Degree of Cleanliness Obtained:

APPLICATION

Method of Application: DFT Gage Type / Model:

Date Calibrated:

Coating Pass Coating Type Batch No. Coating Color Thinner Type DFT Specified DFT Measured Time Between Coatings

Primer

Intermediate

Finish

FINAL ACCEPTANCE




City of Coffeyville, KS Insulation Placement Application, Authorization, and Record


APPLICATION TO PLACE INSULATION

Project No.: Equipment ID:

Contract No.: Insulation Type:

Contractor: Insulation Thickness:

Unit / Area: Inspection Ports Required (Y/N):

System: Insulation Jackets Required (Y/N):

Hydro test No. Refractory Insulation Required (Y/N):

P&ID’s: Required Curing Time:

Line No’s: Heat Tracing Inspections Complete and Accepted (Y/N):

Painting Complete and Accepted (Y/N):


Post-Hydro Testing Walk-Down Completed and Accepted (Y/N): Equipment Inspections Completed and Accepted (Y/N):

Recorded By (Name): Date: Recorded By (Name): Date:

AUTHORIZATION TO PLACE INSULATION


Requested By:


KS

RECORD OF INSULATION PLACEMENT

Insulation Installed per Specs (Y/N): Refractory Installed per Specs (Y/N):

Barrier Installed per Specs (Y/N): Curing Time per Specs (Y/N):

Jacket Installed per Specs (Y/N): Support Rings Installed per Specs (Y/N):

Caulking Complete (Y/N): Flanged Connection Assessable (Y/N):



Date / Time Inspection: Completed Post-Placement Walk-down (Y/N):


SUMMARY OF INSULATION INSPECTIONS


FINAL ACCEPTANCE




City of Coffeyville, KS Fireproofing Placement Application, Authorization, and Record


APPLICATION TO PLACE FIREPROOFING

Project No.: Reference Drawing:

Contract No.: Fireproofing Type: Insulation Concrete Other

Contractor: Fireproofing Thickness:

Unit / Area: Sealing Compound Type:

System:

Structural Steel ID:

Equipment ID:


Inspection Walk-Downs Completed and Accepted (Y/N): Equipment Inspections Completed and Accepted (Y/N):

Recorded By (Name): Date: Recorded By (Name): Date:

AUTHORIZATION TO PLACE FIREPROOFING


Requested By:


KS

RECORD OF FIREPROOFING PLACEMENT

Painting Complete (Y/N): Wire Mesh Type per Specs (Y/N):

Plumb (Y/N): Fireproofing Installed per Specs (Y/N):

Anchor Bolts Knocked Down (Y/N): Correct Centerline (Y/N):

Wire Mesh Installed per Specs (Y/N): Correct Elevation (Y/N):



Date / Time Inspection: Completed Post-Placement Walk-down (Y/N):


SUMMARY OF FIREPROOFING INSPECTIONS


FINAL ACCEPTANCE




City of Coffeyville, KS Electric Tracing Placement Application, Authorization, and Record


APPLICATION TO PLACE ELECTRIC TRACING

Project No.: OEM Installation Procedure Available (Y/N):

Contract No.: Estimated Quantity of Cable:

Contractor: Junction Box ID:

Unit / Area: Required Design Voltage:

Circuit ID: Required Heating Cable Type:

Hydro Test No. Controller Type Required:

P&ID’s: Cable Attachment Bands Required: Tape or Stainless Steel Bands

Painting Complete and Accepted (Y/N): LOTO Required (Y/N):


Megger on Reel Testing Completed and Accepted (Y/N): Preparatory Meeting Held (Y/N):


AUTHORIZATION TO ELECTRIC TRACE


Requested By::


KS

RECORD OF ELECTRIC TRACING PLACEMENT

Circuit ID: GFCI Breaker if Applicable:

Junction Box used: Voltage Range:

Megger Test Complete (Y/N): Completed Placement Inspection Checklist (Y/N):



Date / Time of Inspection Walk-down: Completed Placement Inspection Checklist (Y/N):


SUMMARY OF TESTING

Megger Accept Reject Repaired Date / Time: Megger Accept Reject

On Reel On Reel

Post Cable Installation Post Cable Installation

Post Insulation Installation Post Insulation Installation

Prior Connecting Power Prior Connecting Power


FINAL ACCEPTANCE





Project Number:

Weld Log/Traveler

Work in Progress Repair Average Diameter Average ThicknessWork Completed Tie-In Welds #DIV/0! #DIV/0!

Contractor System P&ID ServiceIsometric Drawing Diameter: inches Wall Thickness: inches Material: P-No. Joint Design

Weld Number Welder I.D. WPS Filler Material Preheat: oF PWHT Date Completed VT Date Completed NDE

Date NDE Completed 1st Reject NDE Date 2nd Reject 3rd Reject Hardness Brinnell Date Completed

Location of ISO


Form No. CF1002, Rev 0 1 of 1

WELDER QUALIFICATION LOGWELDER NAME STENCIL Test Date End Date Plate Th. Pipe Dia./Th. Progression Joint Process Position Comments


Project Number:

Welds RejectedCount Line No. Weld No. Welder ID Rej view Reason R1 Acc/Rej R2 Acc/Rej Tracer 1 Acc/Rej Tracer 2 Acc/Rej

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