Pearl GTL Project
LINDE ENGINEERING
Shell Project No: HP-3000-QAT Contractor Project No : 5887
Project Document Number: T- 4.234.543 Project Rev.: A Page 2 of 22
Purchase Order Number:
2MH127
Tag/Item Number(s): N/A
Unit(s): ASU
PCWBS: Z
QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION
E A 16.07.08 Ready for Construction SB EO AG RFC
D O 11.06.08 Issued for Company Comments FB EO AG ICC
C O 05.06.08 Issued for Company Comments FB EO AG ICC
B
Issued for Review FB EO AG IFR
A Issued for Internal Review FB EO AG IIR
GAMA Rev.
Project Rev
Date Description Prepared
By Checked
By
Approved By
Status
No. No. ORIGINATOR
LINDE ENGINEERING AG
Document Title:
QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Contractor
Gama Qatar Co. W. L. L.
Document No. LOC470
GAM PRO QAC GTL 025 E
Org.
Code
Doc.
Type
Disc. Code
Geogr. Area
Seq.
No
Rev. No
Vendor Code
Project Document Number: T-4.234.543
Rev No: A
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 4 of 22
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TABLE OF CONTENTS
1. SCOPE ________________________________________________________________________ 5
2. PURPOSE _____________________________________________________________________ 5
3. REFERENCES _________________________________________________________________ 5
4. DEFINITIONS _________________________________________________________________ 6
5. RESPONSIBILITIES ____________________________________________________________ 6
5.1. The Section or Site Engineer will be responsible for the following:__________________________ 6
5.2. The QCE will be responsible for the following: __________________________________________ 7
5.3. The QCI will be responsible for the following: __________________________________________ 7
5.4. The Lab Technician will be responsible for the Following: ________________________________ 7
6. PROCEDURE __________________________________________________________________ 8
6.1. Pre Activities _____________________________________________________________________ 8
6.2. Procedure For Testing ______________________________________________________________ 8
6.3. General Notes For cleaning & tightness (FSI) __________________________________________ 8
7. ATTACHMENTS ______________________________________________________________ 10
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 5 of 22
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1. SCOPE
This QC Procedure defines the type and extent of inspection and testing to be carried out to verify all activities related to the installation and testing of Manholes and Pits for Sewers and atmospheric Drainage.
2. PURPOSE
The purpose of this procedure is to detail all inspections and testing to be conducted in order to verify that Manholes, Joint Boxes, Catch Basins, Inspection Chambers, and Pits for Sewers and Drainage conform to specified requirements. Drainage confirm to specified project requirements and specification.
3. REFERENCES
DEP.34.14.20.31.GEN : Drainage Facilities and Primary Treatment T-4.234.074 : MTS for Back Filling Works T-4.234.144 : QA/QC for Site Preparation and Earthworks
T-4.234. 575 : ITP for Concrete Works T-4.234.144 : Procedure for Earth Works DEP.31.40.10.19 GEN : GRP Pipelines & piping systems.
T-4.234.087 : MTS for U/G GRP Piping T-4.259.776 / 778 : AOC-PITS & Manholes plan view & sections
T-4.234.573 : ITP for site Preparation and Earth Works T-4.231.172 : Engineering, Procurement, Prefabrication, Installation, Testing and cleaning of U/G piping (Flawless Start-up) T.13.377.360 : Flawless Start-up Initiative (FSI)
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 6 of 22
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4. DEFINITIONS
Company : QSGTL and/or its PMC Contractor : Linde Engineering AG Sub Contractor : Gama Qatar Co. W.L.L. Contract : QSGTL Pearl Plant C2 ASU Construction Works CS : Construction Supervisor ITP : Inspection and Test Plan QCR : Quality Control Record QCP : Quality Control Procedure QCE : Quality Control Engineer QCI : Quality Control Inspector Lab. Tech. : Lab Technician QA/QC : Quality Assurance / Quality Control TPI : Third Party Inspection ITL : Independent Testing Laboratory
5. RESPONSIBILITIES
5.1. THE SECTION OR SITE ENGINEER WILL BE RESPONSIBLE FOR THE FOLLOWING:
Ensure that the work is carried out to the required Project Specifications and drawings as well as in accordance with the approved ITPs, QCPs.
Ensure that the surveyor has completed the setting out and reference points complying with the RFC drawings.
Ensure that all parties who are required to make any kind of test or inspections are suitably informed as to the overall programme of the works and daily inspection and testing requirements.
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 7 of 22
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5.2. THE QCE WILL BE RESPONSIBLE FOR THE FOLLOWING:
Review all relevant documentation & test reports issued by parties involved (Surveyor and QC inspectors) and submit Records to the CONTRACTOR.
Ensure that all other discipline activities that require to be inspected have been inspected and approved.
Organize and allocate inspection works to the quality control inspectors.
Ensure signatures are obtained from CONTRACTOR/COMPANY on the various Forms as required.
Carry out statistical analysis of the test results to improve quality control operations on site and to advise construction of the results.
Issue NCR's (non confirmation report) when and where required and to check that construction provides the appropriate corrective action.
5.3. THE QCI WILL BE RESPONSIBLE FOR THE FOLLOWING:
To ensure that he is fully aware of the daily construction programme.
To ensure that he attends all inspection points in a timely manner and records the results of his inspections on the appropriate forms.
Completion and filing of all inspection records under his responsibility and reporting to QCE.
5.4. THE LAB TECHNICIAN WILL BE RESPONSIBLE FOR THE FOLLOWING:
To ensure that he is fully aware of the daily construction programme.
To ensure that he attends and performs the required test properly in a timely manner and records the results accordingly.
Reviewing and issuing all relevant lab test reports to the QCE in a timely manner.
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 8 of 22
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6. PROCEDURE
6.1. PRE ACTIVITIES
All materials to be used have been inspected and approved prior to their incorporation
into the works.
Before commencing any excavation, details and locations of existing underground pipes, drains, cables, etc. shall be obtained and utmost precaution must be taken to prevent damage.
The excavation has been carried, surveyed and compaction has been inspected and
released by the Contractor.
De-watering of all excavations, if necessary, is in place and operational. The de-watering shall be continued until the excavation has been backfilled.
All Manholes, Joint Boxes, Catch Basins, Inspection Chambers and Pits have been
constructed in accordance with the RFC drawings and have been released for the next stage of construction.
6.2. PROCEDURE FOR TESTING
Sewer pipelines will be water tested in sections based on DEP-34-14-20-31. GEN. The
HYDRO TEST will be perform as per Method Statement - T.4.234.553 (preparation under progress)
Pipe lasers shall be used to ensure correct alignment and straightness of pipes.
6.3. GENERAL NOTES FOR CLEANING & TIGHTNESS (FSI)
Tightness:
During bolt tightening to flanges, to avoiding leaking flanges arising from installation problems with the bolt, the wrong type of bolts and thread damaged bolts will be neglected. The Joint Control Procedure (T.13.377.453) will be followed and carry out detail line check prior to offer for acceptance as per FSI Class 1.1.1.
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 9 of 22
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Leaking valves will be observed and found if it is manufacturing defect, the valve must be replaced. Or otherwise if found any debris in valve seat as a result of transportation from production area; execute spot check to remove the debris before tightening the valve as per FSI- T.13.377.360 Clause 1.2.6.
If leaks in pipe walls will be observed in U/G piping system due to insufficient production, allowing heavy equipments to damage lines after installation, the minimum depth will be ensured and the access way shall be shifted as per FSI- Clause 1.3.1 & 1.3.2. Apply the T.13.377.455 Amendments to DEP 61.10.08.11-Gen & T.13.377.454, Amendments to DEP 70.10.70.11-Gen.
Cleanliness:
The pipe lines are plugged with construction debris during storage and at site execution; it will be prevented by spot check on applied preservation prior to storage at site and at site during execution; Ensure that removal of preservation materials to the internal surface prior to installation, using such as steam, compressor suction as per PS, Part IV, Ch.10, Flawless Start-up, Q2.
If the pipe line having ingress of debris due to insufficient capping of open pipe spools during prefabrication and/or transportation from lay down areas for piping erection, a) instill Built it clean policy at piping prefabrication shops, b) Ensure that pipe capping materials are available at fabrication shop c) Ensure that the pipe spool lay down area is properly drained and pipe supports off the ground in a position not collecting water or flanges toughing the soil.
To avoiding dirt in lines (inadequate control(post-picking) during installation), specify dedicated team responsible for the control and management of the pipe spools during installation as per Clause 1.3 & 1.6 of T.13.377.360
Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE
Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08
T-4.234.543 Rev. A Page 10 of 22
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7. ATTACHMENTS
GAM-QCR-QAC-GTL-001 : Check list Initial Earth Work Cleaning & Grading
GAM-QCR-QAC-GTL-006 : Inspection Check list - Survey Report
GAM-QCR-QAC-GTL-007 : Inspection Check list - Backfill utilities / Foundations
GAM-QCR-QAC-GTL-008 : Inspection Check list Excavation utilities / Foundations
GAM-QCR-QAC-GTL-012 : Inspection Check list Concrete Foundations/Structures
GAM-QCR-QAC-GTL-013 : Inspection Check list - Blinding Concrete.
GAM-QCR-QAC-GTL-014 : Inspection Check list & Pre pour Card
GAM-QCR-QAC-GTL-015 : Inspection Check list & Post pour Card
GAM-QCR-QAC-GTL-024 : Inspection Check list - U/G Civil Pipe Lines.
GAM-QCR-QAC-GTL-026 : Inspection Check list Manhole Leak Test
INSPECTION CHECKLIST
EARTHWORKS CLEARING AND GRADING
FORM NO: GAM-QCR-QAC-GTL-001 Rev.0
ITP: GAM-ITP-QAC-GTL- Date :
Location Bldg/Area :
Drawing Reference Nos :
SIGN OFF AS ACCEPTED
GAMA QATAR LINDE PEARL GTL
Name
Position
Signature
Date
0.
1 Check work site, stock pile haul roads, disposal areas and any existing utilities clearly identified N/A YES NO
2 Check that the Surveyor has established bench marks and confirmed elevations N/A YES NO
3 Check work site and any existing utilities staked out (confirmed by surveyor or attach surveyor's report)
N/A YES NO
4 Check provisions for de-watering (if appl.) N/A YES NO
5 Check provisions for demolition of existing structures. (if appl.) N/A YES NO
6 Check valid work permits obtained for all areas N/A YES NO
7 Check site cleared of all unsuitable soil & rubbish N/A YES NO
8 Check all unsuitable material hauled away to designated disposal area. N/A YES NO
9 Check any retained soils are properly stock piled N/A YES NO
10 Check retained soils appear acceptable and sampled as required N/A YES NO
11 Check site properly graded to designated levels (confirmed by surveyor or attach surveyor's report)
N/A YES NO
12 Check base soil appears acceptable & sampled as required N/A YES NO
13 Check base scarified (if required) N/A YES NO
Comments:
INSPECTION CHECKLIST
SURVEYORS REPORT.
FORM NO: GAM-QCR-QAC-GTL-006
Rev. 0
ITP REF. NO: GAM-ITP-QAC-GTL- REV. 0
DATE :
Location Bldg/Area:
No :
SIGN OFF WILL CONFIRM RELEASE TO EXCAVATE.
GAMA QATAR LINDE PEARL GTL
Name
Position
Signature
Date
0.
Briefly describe the intention of the Survey and purpose giving details of the utility/ excavation.
Drawing Numbers For Location give Marked up copy of Drawing:
1. Confirm that surveying equipment is calibrated
Calibration Cert No :
2. Check that the drawings noted above are approved for use. N/A YES NO
3. Check all existing utilities are clearly identified and staked out N/A YES NO
4. Confirm that the proposed excavation is clearly staked/ Marked out. N/A YES NO
5. Confirm depth of excavation. N/A YES NO
Surveyors Comments plus any additional survey information.
INSPECTION CHECKLIST
BACKFILL UTILITIES / FOUNDATIONS
FORM NO: GAM-QCR-QAC-GTL-007
Rev. 0
ITP REF. NO: GAM-ITP-QAC-GTL- REV. 0
DATE:
Location Bldg/Area:
Drawing Reference Nos
SIGN OFF AS ACCEPTED
GAMA QATAR LINDE PEARL GTL
Name
Position
Signature
Date
0.
ITEM DESCRIPTION
BACKFILL UTILITY
1 Confirm that Utility is completed tested and released for BACKFILL N/A YES NO
2 Confirm that sand fill is completed N/A YES NO
3 Confirm that fill is being laid in layers as required by the specification. N/A YES NO
4 Confirm that compaction test have been performed and results recorded. N/A YES NO
5 If the Utility requires tiles to be laid confirm that this has been done. N/A YES NO
6 If warning tape is required confirm that it has been laid N/A YES NO
BACKFILL FOUNDATIONS
7 Confirm that the foundation has been released for Coating and Backfill N/A YES NO
8 Confirm that the foundation has been coated with liquid membrane as require by specification N/A YES NO
9 Confirm that the foundation has been covered with hardboard and overlain with polyethylene. N/A YES NO
10 Confirm that fill is being laid in layers as required by the specification. N/A YES NO
11 Confirm that compaction test have been performed and results recorded. N/A YES NO
COMMENTS :
INSPECTION CHECKLIST
EXCAVATION FOR UTILITIES AND
FOUNDATIONS
FORM NO: GAM-QCR-QAC-GTL-008
Rev.0
ITP REF. NO: GAM-ITP-QAC-GTL- REV. 0
DATE:
Location Bldg/Area:
Drawing Reference Nos:
SIGN OFF AS ACCEPTED
GAMA QATAR LINDE PEARL GTL
Name
Position
Signature
Date
0.
ITEM DESCRIPTION
1 Check route/area is clearly staked / Marked out by Surveyor N/A YES NO
2 Check all existing utilities clearly identified and staked out N/A YES NO
3 If Utility trench check that it complies with depth & width shown on drawing. N/A YES NO
4 If foundation Base confirm size and depth are correct to approved drawings/ surveyors report.
N/A YES NO
5 Check bedding material for foundation or Utility trench is clean and free of stones and laid to proper depth
N/A YES NO
6 For drainage confirm levels falls etc mark on drawing (show levels Manhole to Manhole).
N/A YES NO
7 If Geotextile is to be used confirm that it is positioned to the correct requirements. N/A YES NO
8 Confirm base compaction test have to be performed prior to bedding. N/A YES NO
9 Check de-watering properly maintained (if required) N/A YES NO
10 Check trench is properly battered, framed or sheeted (if required) N/A YES NO
1. Stage completion release to lay UTILITY or 2. Blinding for Foundation Base.
COMMENTS :
QSGTL PEARL PROJECT
C2 ASU Construction Works
FORM NO: GAM-QCR-QAC-GTL-
012
INSPECTION FORM FOR CONCRETE FOUNDATIONS / STRUCTURES
ITP GAM-ITP-QAC-GTL- Date:
INSPECTION FORM FOR CONCRETE FOUNDATIONS / STRUCTURES
DRAWING & REVISION No.
TYPE OF STRUCTURE :
LOCATION :
No :
TYPE OF ACTIVITY
GAMA - QC LINDE COMPANY REMARKS
SIGN DATE SIGN DATE SIGN DATE
1.0 Surveying, Setting Out & Excavation
2 Existing Ground / Formation Level
2.1 Bottom Level Correct
2.2 Dimension checked
2.3 Strata acceptable
2.4 Excavation is completed and approved for next activity
3 Blinding
4 Footing
4.1 Formworks / Rebars / Dimensions / Cleanliness / Oil / Support
4.2 Inserts
5 Pedestal
5.1 Formworks & Rebars
5.2 Anchor Bolts & Inserts
6 Concrete Pouring (1)
7 Concrete Pouring (2)
8 Concrete Surface Inspection
9 Concrete Protection
9.1 Epoxy Coating
9.2 Polyethylene Sheet
9.3 Hardboard
10 Backfilling
QSGTL PEARL PROJECT
C2 ASU Construction Works
FORM NO: GAM-QCR-QAC-GTL-
012
INSPECTION FORM FOR CONCRETE FOUNDATIONS / STRUCTURES
ITP GAM-ITP-QAC-GTL- Date:
10.1 Area free of deleterious
material prior to backfilling
INSPECTION FORM FOR CONCRETE FOUNDATIONS / STRUCTURES
DRAWING & REVISION No.
TYPE OF STRUCTURE :
LOCATION :
No :
TYPE OF ACTIVITY
GAMA - QC LINDE COMPANY REMARKS
SIGN DATE SIGN DATE SIGN DATE
10.2 Layers for fill material marked on the sides of the excavation or with pins.
10.3 Adjacent to below ground structures correctly coated and protected in accordance with project specification
10.4 Compaction test done
11.0 Final Survey Concrete As built
INSPECTION CHECKLIST
LEAN / BLINDING CONCRETE
FORM NO: GAM-QCR-QAC-GTL-013
ITP REF. NO: GAM-ITP-QAC-GTL- Date :
Location Bldg/Area: Drawing Reference Nos
No :
SIGN OFF AS ACCEPTED
GAMA QATAR LINDE QSGTL
Name
Position
Signature
Date
DESCRIPTION
1 Verify surveying setting out of Base location and blinding concrete level is as per drawings N/A YES NO
2 Verify Base Compaction results are conforming to Specifications. N/A YES NO
3 Confirm thickness is to be 50mm Minimum N/A YES NO
4 Confirm forms are in place N/A YES NO
5 Blinding Concrete receival & placement inspection. N/A YES NO
6 Verify Concrete Curing N/A YES NO
7 Check application of membrane / Polyethylene is in accordance with manufacturers instructions and specification.
N/A YES NO
8 Compressive strength to be recorded by Laboratory N/A YES NO
COMMENTS :
INSPECTION CHECKLIST
CONCRETE PRE POUR INSPECTION
FORM NO: GAM-QCR-QAC-GTL-014
ITP REF. NO: GAM-ITP-QAC-GTL- Date:
Location Bldg/Area:
No:
Drawing Reference Nos :
SIGN OFF AS ACCEPTED
GAMA QATAR LINDE QSGTL
Name
Position
Signature
Date
ITEM DESCRIPTION
1
Check that existing concrete surface properly chipped & concrete pouring place is clean
and construction joints, if any, are adequately prepared
N/A YES NO
2 Check that form work installation is proper and release agent applied properly N/A YES NO
3 Check that rebar free from rust, damage and installed as per drawings IF REQUIRED check embedded items are compliant
N/A YES NO
4 Check that reinforcement Bars are the correct size as drawing N/A YES NO
5 Check that reinforcement are spaced correctly N/A YES NO
6 Check adequacy of spacers and specified concrete cover N/A YES NO
7 Check that Embedded items are placed as per the construction Drawings N/A YES NO
8 Check that Anchor Bolts are placed as per the construction Drawings. N/A YES NO
9 Check that Waterstop is fixed correctly if required N/A YES NO
10 Check that all civil piping is fixed and ready for casting N/A YES NO
11 Check that all electrical items are fixed and ready for casting N/A YES NO
12 Check that all mechanical items are fixed and ready for casting N/A YES NO
13 Check that all Anchor bolts and embedded items are installed as required, if applicable. N/A YES NO
Comments:
INSPECTION CHECKLIST
CONCRETE POST POUR INSPECTION
FORM NO: GAM-QCR-QAC-GTL-015 ITP REF. NO: GAM-ITP-QAC-GTL- Date :
Location Bldg/Area: No :
Drawing Reference:
SIGN OFF AS ACCEPTED ONLY AFTER COMPLETION OF ALL WORKS & CURING
GAMA QATAR LINDE QSGTL
Name
Signature
Date
POST POUR INSPECTION
CAST DATE CAST TIME Approximately STRIPPING DATE / TIME
1 Confirm Dimensional Check taken: Attach sketch or marked up drawing of dimension taken
NA YES NO
2 Confirm surveyor has reported . NA YES NO
3 Confirm Embedded items have been check and accept by Mech. NA YES NO
EXAMINATION OF POUR AFTER STRIPPING
Describe any surface defects and their probable cause, and what remedial measures are necessary :
REPAIRS
If major repairs are to be carried out give repair sheet No
CURING RECORD
4. DAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CHECKED
NOTE: Water Curing Check the curing daily tick the box. If Curing Compound is used write below Curing Compound type
GENERAL COMMENTS
INSPECTION CHECKLIST
CONCRETE POST POUR INSPECTION
FORM NO: GAM-QCR-QAC-GTL-015 ITP REF. NO: GAM-ITP-QAC-GTL- Date :
Location Bldg/Area: No :
Drawing Reference:
SIGN OFF AS ACCEPTED ONLY AFTER COMPLETION OF ALL WORKS & CURING
GAMA QATAR LINDE QSGTL
Name
Signature
Date
THIS RECORD SHEET TO BE USED ONLY IF REQUIRED
CONCRETE REPAIR RECORD SHEET Supervisor / Inspectors name Date RFI No.
Provide Sketch or photo and give brief description of repair and repair material.
Is the defect
1. HONEYCOMBING
2. SEPARATION
3. OTHER
1. Check bonding agent applied (if required) NA YES NO
2. Check only designated repair materials are utilised NA YES NO
3. Check repair materials properly applied NA YES NO
4. Check curing application (if required) NA YES NO
INSPECTION FORM FOR U/G LINES (CIVIL)
REPORT NO.:
SYSTEM NO.:
Serial TYPE OF ACTIVITY GAMA - CONSTRUCTION GAMA - Q.C. CTJV REMARKS
No. SIGNATURE DATE SIGNATURE DATE SIGNATURE DATE
1 Surveying, Setting Out and Excavation
2 Sand Bedding / Sand Bags Setting
3 Laying of Pipe / Alignment
4 Line Test
5 Wrapping&coating
6 holiday Test
7 Backfilling Sand
8 Backfilling above Sand
Form No.: GAM-QCR-QAC-GTL-024 REV.0
TYPE OF LINE
LOCATION
PEARL GTL PROJECT
C2- ASU
DRAWING & REVISION No.
MANHOLE, CATCH BASINS & PITS LEAK TEST REPORT
LEGEND: MANHOLE CATCH BASIN PIT OTHERS
DWG. Number Item No. Date Time Remarks
TEST COMPLETED SUCCESFULLY WITHOUT ANY VISUAL LEAK.
NOTE : LEAK TEST WILL START AFTER ABSORBING WATER BY STRUCTURE IS STABILIZE.
FORM. NO.: GAM-QCR-QAC-GTL-026 REV.0
C2-ASU
PEARL GTL PROJECT
REPORT NO :
DATE
NO :
AREA :
COMPLY
NOT COMPLY
GAMA--CONSTRUCTION GAMA--QC LINDE COMPANY NAME SIGNATURE DATE