Quality Management System

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 1 of 36

TF FPM QUALITY MANAGEMENT SYSTEM

ENGINEERING, SUPPLY CHAIN MANAGEMENT, CONSTRUCTION MANAGEMENT AND CONSTRUCTION EQUIPMENT MANAGEMENT

0

19 August 2005

Issued For Information & Planning

Charles J. Brazel

Dean Campbell

Revision

Date

Revision Description

Developed By

Approved By

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 2 of 36

DOCUMENT CONTROL SHEET

Controlled Copy No. Issued To (Name): Organization:

______________________________ ______________________________ ______________________________

This is a Controlled Document. It is subject to audit and recall and therefore shall be carefully maintained and readily available. The person/organization listed above is responsible for maintaining this document in an up-todate condition by incorporating subsequent revisions or new sections as they become available. This document must not be transferred nor reassigned except by TF-FPM Technical Document Management (TDM). This document is the property of Tripatra-Fluor. Upon request, reassignment that ends the need for this document, or upon termination of employment with your company or the TF-FPM Contract, it must be returned to Project Technical Document Management. Tripatra-Fluor Flexible Project Management Tripatra-Fluor Consortium Teladan Building Complex PT. CPI Duri 28884 Riau Province Sumatra, Indonesia

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 3 of 36

TABLE OF CONTENTS

12.0 QUALITY MANAGEMENT..................................................................................................................4 12.11.1 PROCEDURE...............................................................................................................................23

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

12.0

Quality Management System Revision 0 19 August 2005 Page 4 of 36

QUALITY MANAGEMENT Quality management on the project is the shared responsibility of all project team members. Everyone on the team – from engineers and designers, to suppliers and subcontractors, to construction field personnel – performs activities that are essential to the quality of the constructed facility. Fluor Operating System Fluor is committed to providing quality services by complying with the Fluor operating system. The principles of the operating system are defined and documented in our corporate quality manual, the Operating System Requirements (OSR). Work performed in compliance with the OSR in turn complies with the requirements of ISO 9001:2000. For the purposes of this section, the terms “operating system” and “quality system” may be used interchangeably.

12.1

ORGANIZATION AND RESPONSIBILITIES 12.1.1 Quality Groups, Procedures, and Documents The following groups are responsible for verifying that project activities related to quality are being properly performed by the project team: •

Quality Assurance – The Quality Assurance group supports and monitors the quality of the overall project, and as requested, supports Supply Chain Management and Construction Quality groups. Procedures for the Quality Assurance group activities are described in this section.

•

Supply Chain Management – Quality support within the Supply Chain Management group consists of three areas i.e. contract document review and input, procurement document review and input and supplier quality surveillance (SQS). These quality groups monitor the quality of material, equipment and services procured for the project.

•

Construction Quality – The Construction Supervision Management supports and monitors the quality of the field construction effort for the project, including both Subcontractors and self perform activities. This is accomplished through direct interface and direction of discipline Quality Control inspectors.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 5 of 36

12.1.2 Project QA/QC Manager The Project QA/QC Manager is responsible for overall management of the quality verification activities of the Project. The Project Quality Manager reports to the Program Manager for all project quality functions. The Project Quality Manager will be the main interface for internal and external organizations, including CPI, for all Project quality matters. The Project Quality Manager will have the specific responsibilities and the delegated authorities to accomplish the following: Provide overall management of the Project Quality (QA/QC) function, and assure that an effective quality program is in place, and implemented at all levels of the project Provide regular reviews of the Project Quality System, and develop, maintain, and ensure implementation of this Project QA Plan Provide reviews and approvals of vendor/subcontractor quality documents

project

quality

documents,

including,

Assist in review and selection of vendors/suppliers/subcontractors, as necessary Provide document control and quality records management assistance to Technical Document Management (TDM) Prepare input to the monthly status report covering audit activities deviations and nonconformances and the summary of corrective actions to Project Management, and others as required, identifying the quality problem areas and what will be done about them. 12.1.3 Lead Auditor/Auditor The lead auditor/auditor will prepare audit schedules, audit checklist, perform audits, issue audit reports, maintain audit logs and track audit noncomformities and corrective action, both internal and external over the entire project. 12.1.4 Senior QA/QC Engineer The Senior QA/QC Engineer performs review and input to Contract documents and Purchase Order documents to verify that the requirements of this Quality Plan, Contract, Codes, Standards, Drawings, Specification and client requirements are included as appropriate prior to issue of Contract or Procurement documents. The Senior QA/QC Engineer reports directly to the Supply Chain Manager and functionally to the Project QA/QC Manager.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 6 of 36

12.1.5 Senior QA/QC Inspector The Senior QA/QC Inspector directs the day to day activities of the discipline Quality Control inspectors. He communicates directly with construction management/supervision personnel to provide the required inspection personnel to support their specific Project needs. He reviews daily Quality Control inspection reports provided by the discipline Quality Control inspectors. He prepares a weekly summary report of inspections which will include any deviations, NCRs and concerns and submits to the Project QA/QC Manager. He communicates with other Senior QA/QC Inspectors to coordinate Quality Control inspection personnel with other Business Units. He performs inspection of inprocess or completed work to supplement the Quality Control inspectors. He reports directly to the construction management/supervision and functionally to the Project QA/QC Manager 12.1.6 Discipline QA/QC Inspector The Discipline QA/QC Inspector performs daily inspection of in-process work activities, signs inspection forms, reviews Subcontractor QC inspection activities, prepares daily inspection reports and verifies codes, standards, specifications and drawings are being applied as required to the work process. He reports directly to the Senior QA/QC Inspector. 12.1.7 Vendor/Supplier Inspector These inspectors are discipline specific and will perform Inspection/Surveillance of shop fabricated materials or components as required. Inspections are based on Purchase Order requirements. These inspectors may be either subcontracted or permanent FPM inspection personnel. 12.2

Design Change Control When field conditions dictate changes to the design specifications and/or drawings, a Field Change Request (FCR), Form 000 509 F0051, will be processed and approved to ensure proper control and documentation. The FCR applies only to work not started. FCRs will be initiated by the Construction Manager/Supervisor who will maintain a FCR Log, Form 000 509 F0052. FCRs will be forwarded to the TF-FPM Engineering Manager for approval and/or action. Subcontractor’s change requests will be sent to the TF-FPM Construction Manager for submittal to the TF-FPM Engineering Manager for evaluation and processing. The Construction Manager/Supervisor shall describe the design change requested in terms that can be easily understood by those who review it, including appropriate references, specific drawings and specifications to illustrate the recommended change. To minimize delay in construction, authority for deviation from specifications and drawings may be acquired by direct communication with the TF-FPM Engineering Manager pending processing of the FCR. A copy of the Record of Telephone

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 7 of 36

Conversation or email communication will accompany the FCR transmitted to the TFFPM Engineering Manager. The Design Engineer portion of the FCR establishes the approval or disapproval of the field recommended change or recommends alternatives. The signed original will be returned to the TF-FPM Construction Manager for disposition or authority to proceed. The TF-FPM Engineering Manager shall maintain a file that contains a full history of the action and data supporting the approval of each FCR.

12.3 Technical Document Management Design Engineering documents such as specifications and drawings that are issued to the site are controlled and issued on site in accordance with this practice. Construction Management maintains an up-to-date register of drawings and specifications. This practice is designed to ensure that the latest drawings issued to the site, including shop drawings, specifications and instructions, as well as authorized changes thereto, are delivered to the proper locations and personnel responsible for performance of the work. This practice also provides for the prompt removal of obsolete documents from all points of issue or use. The Construction Management/Supervision reviews engineering documents for adequacy and completeness to perform the work and coordinates site needs for clarification with the designer. Subcontractors obtain clarification through the TF-FPM Construction Manager. Construction Management maintains drawings and specification control records, processes all design document changes, ensures proper authority for the changes, and prompt removal of obsolete documents from the field. The TF-FPM Engineering Manager is responsible for control of shop drawing submittals and certifications to include assuring that submittals are received and/or distributed. The TF-FPM Engineering Manager will maintain as-built marked-up drawings. These drawings will be maintained in a current condition. Subcontractors will submit as-built information through the TF-FPM Construction Manager. 12.3.1 Subcontractors Subcontractors are responsible for procedures necessary to assure that all documents provided for construction are maintained to the most up-to-date revisions. Documents include procedures, letters, telexes, purchase requisitions, purchase orders, design drawings, specifications, reference drawings, vendor drawings, field sketches, test reports, etc. Documents affecting individual Subcontractors work are forwarded to the Subcontractor by the Supply Chain Manager. Subcontractor prepared field sketches and "as-built" drawings originating at the

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 8 of 36

construction site shall be documented and controlled in accordance with the "Field Change Request" (FCR) requirements described in this practice. 12.3.2 Submittals Submittals are reviewed under the direction of the Supply Chain Manager. Contractor technical submittals are forwarded to TF-FPM Engineering Manager. A submittal list shall be maintained reflecting the specification reference, description, date received, and the status of acceptance through Engineering approval. The TF-FPM Project Quality Manager shall review submittals related to Quality Control requirements. 12.3.3 Material/Equipment Documentation Documents related to materials, materials receiving and issue are controlled in accordance to procurement practices. 12.3.4 Quality Control Documentation Documents and data identified as quality records are processed retained and protected as described in section 12.13 "Quality Records". Primary responsibility for ensuring adequate control of quality related documents rest with the TF-FPM Project Quality Manager.

12.4 Process Control For most site production activities, the drawings and specifications provide adequate work instruction. These may be supplemented with additional instructions to control work sequencing, recording of installation data, material selection, etc. However, certain construction work processes require special instructions to establish the controls necessary to achieve acceptable quality, of the completed work, for the following reasons: • Quality results of the completed work cannot be fully verified by subsequent inspection and/or testing. • Quality deficiencies may only become apparent after the item has entered service or operation. 12.4.1 Special Processes "Special processes" are highly dependent on the control of process parameters or the skill of the operator or both and are characterized by the need for one or more of the following control measures. • • • 67743248.doc

Written Method Statement or Procedure Procedure Qualification Operator Qualification

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

•

Quality Management System Revision 0 19 August 2005 Page 9 of 36

In-Process Inspection

Special processes commonly encountered on sites include, but may not be limited to: • Welding and Post Weld Heat Treatment • Welder Qualification • Nondestructive Examination (including radiography, magnetic particle, liquid penetrant, ultrasonic, and positive material identification - RT, MT, PT, UT, and PMI) • Pressure Testing and Flushing of Piping Systems • Other processes needing procedural control. Special processes must be accomplished and documented under controlled conditions by appropriately qualified personnel using approved procedures and equipment in accordance with the governing specifications and the associated referenced codes and standards. 000 509 F78001 000 509 F79001 000 509 F79002 000 509 F79201 000 509 F79202 000 509 F79203 000 509 F79204

Coating Inspection Record Daily Welding Report Post Weld Heat Treatment Log Welder B31.3 Random Radiography Control Log Nondestructive Examination Request/Record Radiographic Rejectable Defects Statistics Welding/NDE Status Log

12.5 Inspection Measuring and Test Equipment This procedure describes the methods to be used for the control, calibration, maintenance and recall of inspection, measuring and test equipment (IMTE) used to demonstrate conformance of construction work activities to the specified requirements. It is not applicable to calibration of permanent plant devices. Inspection, measuring and test equipment (IMTE), including test software, shall be selected, calibrated and controlled in a manner which is consistent with the required inspection, testing and examination requirements. Environmental conditions shall be suitable for the calibrations, inspections, measurements and tests being carried out. All IMTE shall be uniquely identified. This unique identification may consist of a manufacturer's unique serial number along with model number and/or the assignment and application of a unique Inventory Control Number (ICN). The handling, preservation, and storage of inspection, measuring and test equipment shall be such that the accuracy and fitness for use is maintained.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 10 of 36

All calibrations shall be performed using certified equipment having a known valid relationship to nationally recognized standards; where no such standards exist, the basis used for calibration shall be documented. "Conformance check" means the operations required to ensure that an item of measuring equipment is in a state of compliance with requirements for its intended use. Non-adjustable measuring and test equipment is not considered as calibrated equipment. Equipment of this nature (e.g. cube and proctor molds, measuring tapes, rulers, chains) is subject to a "conformance check" to dimensional, volumetric or other requirements and does not require any further verification unless apparent damage or other factors require reverification. It is the responsibility of the end-user to comply with the requirements of this section. All IM & TE calibration requirements shall be identified on Attachment 1. This attachment is used to list the various types of IM & TE in use and their associated calibration frequencies, calibration procedures and tolerances. Calibration procedures, frequencies, and tolerances may be obtained in conjunction with obtaining the services of an outside calibration vendor or from manufacturers. A procedure number shall be assigned. If the manufacturer has an assigned number, this should be used. Calibration procedures are quality records and shall be maintained in site files. Procedures such as published standards, practices (e.g., ASTM) or written calibration instructions from the manufacturer may be used. In the absence of either a published standards practice or an adequate manufacturer's procedure, a written procedure for the calibration method shall be written and approved for use. In addition to the above, calibration procedures should include at least the following basic information:

67743248.doc

•

Identity of the item to be calibrated using the procedure.

•

Calibration comparison standards and calibration support equipment to be used.

•

Provisions to obtain and record "as-found" accuracy measurement prior to any adjustments.

•

Sequence of operations.

•

Checks, tests and measurements instructions.

•

Calibration acceptance tolerances.

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 11 of 36

•

Calibration adjustment instructions.

•

Safety considerations.

•

Special instructions (when applicable).

•

Documentation and labeling instructions related to the specific item to be calibrated.

Perform and record (Form 000 509 F01104) the calibration in accordance with the above established calibration procedures and/or contract the services of an outside calibration services vendor. Upon completion of initial calibration, enter the equipment in the Calibration Assignment Log (Form 000 509 F01101) and record other data required by this log. 12.5.2 History of Use The end user shall maintain a history of use for IM & TE to enable an assessment of the validity of previous calibrations, inspections, measurements and test results when calibration as-found data reveals out-of-tolerance data points. The history shall be documented using IM & TE Sign In/Out-History of Use Log (Form 000 509 F01102) and keep current to record each usage of the IM & TE. If out of tolerance conditions are found, a Nonconformance Report shall be prepared in accordance with section 12.10 Control of Nonconformances. If out-of-tolerance conditions are found during recalibrations an evaluation shall be conducted to determine if inspection, measurement, test or calibration results obtained with the out-of-tolerance instrument are still valid. Evaluations shall be documented, and where required, repetitions of readings shall be compared to original results. It is the responsibility of the end user to use calibrated equipment within the environmental operating range(s) or restrictions/limitations specified by the instrument manufacturer. NOTE: Temperature or other compensating calculations shall be applied to any inspection, measurement, test or calibration results when such compensations are specified by the instrument manufacturer and/or when they can affect the basis of the results obtained. Upon satisfactory completion of calibrations, and after the recalibration due date has been determined (calculated), the end user shall make entries on the "Calibrations Tickler File"

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 12 of 36

(Form 000 509 F01103) to aid in the tracking and recall of items for scheduled recalibration. 12.6

Inspection and Testing

Each Subcontractor is responsible for providing services and performing work in accordance with the design and quality requirements as required by the TF-FPM contract. The TF-FPM approach to construction management requires each Subcontractor to staff and perform the inspection activities, with the TF-FPM construction management and quality teams performing surveillance of the contractor activities. Based on the capability of the Subcontractor, information obtained during prequalification of bidders, and project management preference, TF-FPM may elect to either provide the quality procedures to the Subcontractor or require the Subcontractor to provide the procedures. TF-FPM will inspect the Subcontractor’s work for the following work activities: •

To ensure that all work adheres strictly to all requirements of the TFFPM Contract and governing agencies where the work is being performed. •

To maintain quality system procedures to ensure that tasks performed will comply with the TF-FPM Contract. • To prevent deficiencies through pre-construction quality control coordination. •

To detect and correct deficiencies in a timely manner.

• To provide an auditable record of all tests, inspections, procedures, non-compliance and corrections, and any other pertinent data as required. •

Verify compliance with contractor’s quality procedures, including those quality procedures of subtier/suppliers.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 13 of 36

•

To provide a basis of measuring the Subcontractor’s performance for input to TF-FPM Contractor Resource Database. TF-FPM will monitor testing of the Subcontractor's work for the following activities: The Construction Subcontractor is responsible for quality and for implementing the measures necessary to achieve compliance to specified requirements. The Subcontractor will ensure that the TF-FPM representative is given sufficient time to witness tests and inspect work performed by the Subcontractor. The following items are considered minimum notification: Concrete placements Holiday testing Punching of lines prior to hydrotest Pressure testing Acceptance inspection of buildings Bolt tensioning DC (Direct Current) High Potential (over 2,000 volt cable) Motor run-ins Tests to electrical equipment Loop checks Acceptance inspection of vessels and equipment Other tests

1 Day 4 Hours 2 Days 4 Hours 2 Days 4 Hours 4 Hours 4 Hours 4 Hours 4 Hours 1 Day 2 Hours

When inspection reveals work not conforming to requirements, the Construction Subcontractor will be informed and will perform work necessary to achieve compliance. The Construction Subcontractor has primary responsibility for quality. The Subcontractor is to implement the measures necessary to build quality into the work in accordance with the contract, drawings, and specifications. Inspection of the Construction Subcontractor's work by TF-FPM does not relieve the Subcontractor of the obligation to comply with requirements of the contract documents. 12.7

Inspection and Test Plans Within two weeks of the award of the Contract, the Subcontractor shall submit to TF-FPM for approval Inspection and Test Plans (ITP) prepared either to TF-FPM format (see Attachment A) or to the Subcontractor's own format provided this contains equivalent data. The purpose of the ITP is for the Contractor to describe on one document the inspection and testing activities for each definable feature of work. As a minimum the plans shall address the quality control requirements of the contractual requirements, specifications, and drawings, as well as the standards and codes referenced therein. However, these requirements are not considered exclusive, the Subcontractor being responsible for

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 14 of 36

adding to these minimum requirements to the extent that the Subcontractor considers necessary to obtain appropriate quality levels. Definitions: Inspection- visual checks of a qualitative nature but also including dimensional measurements. Tests- measured verifications of one or more characteristics or of performance, both being carried out to ascertain whether or not the specified requirements have been met. The ITP shall include the following features: •

a list of the inspection and test points presented in sequence in the order in which they are to be performed

•

for each point, reference to a document stating the acceptance criteria for each point, the "verification document" i.e. the document to be checked or the one used to record the result of the inspection or test for each point for both Subcontractor and TF-FPM, where required, an indication of: "W" for "Witness Point" "R" for "Review" "H" for "Hold Point"

Once the ITP has been approved by TF-FPM the Subcontractor shall apply it. Any modification or deviation from the plan must have prior written approval of TF-FPM.

12.8

Receiving Inspection of Material/Components Warehouse personnel shall perform the initial visual inspection of the materials/components for obvious shipping damage. If there has been shipping damage, initiate an O, S, and D Report in accordance with Warehouse Procedures. The warehouse staff shall notify the Supply Chain Manager upon receipt of items listed on the Purchase Order or Inspection and Test Plan where receipt inspection by the Quality Inspector is required. Receiving inspection shall be handled in accordance with section 9.0 of the Project Procedures Manual (PPM).

12.9

Quality Audits

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 15 of 36

The Program Manager is responsible for ensuring that all project activities that affect quality are periodically subject to formal audit. To accomplish this audit function, the Project Quality Manager has been delegated the responsibility for scheduling and performing quality audits of various activities of TF-FPM and Subcontractors. He has designated Quality personnel to assist and perform these audits. All quality audits shall be performed by a Lead Auditor who shall be trained and qualified to perform these audits. The training and qualification of Lead Auditor are the responsibility of the Project Quality Manager. When appropriate for the project, the Lead Auditor may authorize additional Auditors to perform specific types of audits for which they are trained. For discipline audits, members of the discipline are assigned to perform the audit. These individuals are generally not qualified as Auditors, but are Discipline Audit Specialists who are technically qualified to evaluate the activities of their disciplines. The quality audits shall be performed in accordance with an audit schedule. The Project Quality Manager is responsible for developing and maintaining an overall project audit schedule. This audit schedule shall ensure that all major activities are periodically audited. 12.9.1 Schedule The Project Quality Manager shall establish and maintain an overall schedule of the proposed quality audits. This schedule shall identify the auditee, audited activity, and month of the proposed audit. This schedule shall be revised as required and shall be issued and maintained as a quality record on a yearly basis. 12.9.2

Scope

The following procedure shall be used by the Project Quality Manager to conduct periodic audits of TF-FPM and Subcontractor quality activities on the FPM Contract. This procedure may be used or modified to provide guidance for auditing the unique activities of various specialty vendors/suppliers. The purpose of these quality audits is to verify implementation of the approved quality management systems both internal and external to TF-FPM. In addition audits are performed to determine the quality health of the Project and compliance to client requirements. •

Quality Audits – Quality audits are performed by the Project Quality Manager and other assigned audit team members to ensure that activities are being performed according to issued project procedures, Fluor requirements such as the OSR and Contract terms. The most common quality audits are the startup or readiness audit, the OSR audit, and the close-out audit.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

•

Quality Management System Revision 0 19 August 2005 Page 16 of 36

Discipline Audits – Discipline audits are performed with the assistance of assigned individuals from the department being audited. These audits verify the technical adequacy and correctness of the work being performed, whether TF-FPM requirements are being met, and whether Contract terms are being satisfied. Discipline Audits are separately conducted on one specific project discipline at a time.

12.9.3 Procedure The Project Quality Manager shall notify the auditee approximately fourteen days in advance of the audit. This notification shall include the time and place of the audit, the audited activities, audited documents (if applicable), Lead Auditor and audit team members. Discipline audits are managed by a qualified Lead Auditor but the actual investigation is done by a Discipline Audit Specialist assigned from the discipline being audited who need not be a qualified Lead Auditor. The Discipline Audit Specialist (sometimes called a Discipline Auditor) is usually a subject matter expert in the area being audited. The Lead Auditor’s role is to provide procedural, administrative, and general guidance and facilitate the entry and exit meetings. The Lead Auditor prepares a checklist for the audit from the referenced documents that covers the audited activities. A marked-up copy of the procedures or manual sections may also be used in lieu of a written checklist. For jobsite construction audits, the Subcontractor’s approved Construction Quality Control Plan, referenced procedures, inspection and test plans, contract documents, project plans and specifications will be the primary sources used to produce audit items. For supplier audits, a standard generic checklist may be used and modified during the audit to fit conditions. Discipline Audit Specialists may prepare audit checklists for their areas of expertise for the approval of the Lead Auditor. Audit team members should become familiar with the appropriate audit-related working documents as necessary to facilitate and substantiate the audit. These working documents should refer to the source of each requirement, and may be modified and expanded during the course of the audit. The Lead Auditor and the audit team conduct the entry meeting to inform project and department management of the audit scope and other specifics, such as: • • • •

67743248.doc

Special plans for the audit (focus on a certain area, omit certain topics, etc.) Intended timing of the audit, including date of the exit meeting Who will be audited Auditee concerns

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

• • • •

Quality Management System Revision 0 19 August 2005 Page 17 of 36

Constructive intent of the audit Pace of the audit Auditee and Auditor contact information Documentation of the entry meeting attendance

The Lead Auditor, Auditors and Discipline Audit Specialists complete the audit using the prepared audit checklists. Findings are identified and discussed with the auditee’s supervisor or manager, if possible during the audit. Copies of pertinent documentation may be assembled to support findings. Findings during an audit will result in the Lead Auditor issuing one of the following: • • •

Corrective Action (CA) for nonconformities Preventive Action (PA) for potential nonconformities Observation of opportunities for improvement

Any team member can identify the existence of a finding or nonconformity, but only a representative of the QA group is authorized to issue a formal request for Corrective or Preventive Action, or an Observation. Requests for Corrective or Preventive Action will be attached to the audit report and transmitted to the person responsible for addressing the nonconformity, such as the lead for the discipline in which the finding was discovered. Forms 000 509 F01401 Corrective Action Report, 000 509 F1402 Corrective Action Status Log, 000 509 F01501 Preventive Action Log Conditions that can be improved but do not constitute an actual nonconformity may be documented in the Audit Report as an Observation. Observations do not require followup from the audit team.

The Lead Auditor and the audit team then conduct the exit meeting with applicable Auditee management to inform them of the audit findings:

67743248.doc

•

Present the results of the audit to attendees. For discipline audits, the Discipline Audit Specialist presents the audit results to the Discipline Lead and other attendees.

•

As applicable, identify any nonconformities found, and strive for agreement with the Auditee regarding the preliminary wording of the requests for corrective or preventive action. This helps ensure the requests will be acted on in a timely manner.

•

When practical, send a preliminary copy of the findings to the Auditee.

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 18 of 36

•

Set a time frame when responses are due from the Auditee, for example, within a month.

•

Document exit meeting attendance.

The Lead Auditor will prepare and issue the Audit Report to the Program Manager within 10 working days after completion of the audit. The format of the Audit Report is optional but should contain the following sections: Scope, Executive Summary, Audit Report, and Conclusions (or Recommendations). The Project Quality Manager shall prescribe the format to be used for Audit Reports. Copies of findings, if any, should be attached as part of the Audit Report. The Auditee will then respond with a plan for correction or prevention of each audit finding, and estimated completion dates. A target date of 30 calendar days to complete the actions is common. After the Auditee responds to the CA or PA, the Lead Auditor will: • • •

Review the responses for adequacy Track CAs and PAs utilizing the status log Notify Project Management of open items on a regular basis

The Lead Auditor will document any actions taken regarding overdue responses. The Audit Status Log may be used for this purpose. Unsatisfactory situations should be brought to the attention of the Project Quality Manager and if need be the Program Manager for resolution.

The Lead Auditor will review the auditee’s responses to the audit findings. The Lead Auditor shall review (verify if necessary) the corrective action and, if acceptable, close the finding. Copies of the closed audit findings, signed by the Lead Auditor, shall be returned to the auditee. The audit will be closed when all findings are acceptable.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 19 of 36

12.9.5Follow-up and close-out audit findings. Before closing out each audit finding, the Lead Auditor must verify that corrective and preventive actions are satisfactorily completed and effective. After determining that all nonconformities are resolved, the Lead Auditor completes the close-out verification section of the corrective or preventive action and notifies the Auditee. 12.9.6 Ensure audit documentation is retained. Copies of the Audit Report will be retained in the project file as indicated in the Project File Index and Retention Schedule. Checklists used to conduct audits are an aid and do not require retention. The Project Quality Manager may retain backup, supporting, or audited documents during the life of the project for reference purposes, in either hardcopy or electronic form.

12.10 Control of Nonconformances

This procedure describes the methods and responsibilities for controlling nonconforming items to prevent their inadvertent use or installation when other control methods, inspection reports, surveillance reports (930 509 0220), etc. are considered inadequate. This procedure provides for the identification, documentation, evaluation, disposition, notification, segregation (prevention of inadvertent use/installation), and reinspection of these nonconforming items. 12.10.1

Nonconforming Conditions Nonconformance Reports are issued when there are: •

Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition.

•

Deficiencies of a serious or repetitive nonconforming nature as determined by the Project Quality Manager.

•

Construction damage has occurred to existing or turned over plant property. Nonconformances shall be documented using Form 000 509 F0131 Noncomformance Report (NCR), 000 509 F01302 Nonconformance Report Log

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

12.10.2

Quality Management System Revision 0 19 August 2005 Page 20 of 36

Responsibility for issuing NCRs

The Subcontractors have the first responsibility for the identification, control, and disposition of nonconforming items within their Scope of Work. TF-FPM will issue a Nonconformance Report when the Subcontractor has not issued one. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition. Inspection personnel usually initiate Nonconformance Reports; however, anyone may initiate an NCR. 12.10.3

Control of Nonconforming Items

The TF-FPM Supply Chain Manager, Construction Supervision Manager and the Subcontractor will take measures to provide holding areas or other methods for segregating nonconforming items to prevent unauthorized use, mixing with conforming items or incorporating into future construction. Where physical segregation is not practical, tagging, marking or other positive means of identification is acceptable. The TFFPM Project Quality Manager may elect to use "HOLD" tags/stickers (Form 000 509 F01303) for additional assurance.

12.10.4

Documentation of Nonconformance

For materials and equipment identified as nonconforming generate a Nonconformance Report (Form 000 509 F01301) to document the nonconforming item(s). The report is to be processed as follows: Initiator •

Enter the date the nonconformance is documented.

• Enter either the name of the Subcontractor or Vendor to identify organization responsible for the nonconforming work. • Use the entries in the header of the form to provide unique traceability and identification to the nonconforming item. •

Enter a complete description of the nonconforming condition.

•

The initiator may propose a disposition, but it is not required.

•

Enter the root cause of the nonconforming condition.

The initiator provides the NCR completed as noted above to the Project Quality Manager. 67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 21 of 36

Project Quality Manager • Evaluate the report to determine that the described condition is a valid nonconformance. It is not necessary to have more than on Nonconformance Report active on the identical nonconforming condition. If a Construction Contractor has issued the NCR, it should not be duplicated by the TF-FPM Project Quality Manager. • Assign a unique number to the report and enter the number here and on the "Nonconformance Report Log" (Form 000 509 F01302). • If a hold tag is needed, enter the hold tag number and have the hold tag installed on the item. The hold tag number should be the same as the NCR number. If a hold tag is not to be used, enter NA. The TF-FPM Project Quality Manager provides the NCR completed as noted above to the Subcontractor, the applicable TF-FPM Manager and to CPI. Applicable TF-FPM Manager • Evaluate the proposed disposition, modify if necessary, or enter the disposition. • If the nonconforming condition will not be corrected in full conformance with the applicable specification, the TF-FPM Engineering Managers, as applicable, shall accept the disposition. In this case, check "yes" and the TFFPM Engineering Manager shall provide supporting information/documentation to accept the disposition as is. The TF-FPM Engineering Manager shall obtain CPI approval in such cases. Any documentation that supports the disposition shall be attached to the NCR. For Subcontractor NCR's, this approval is obtained through the TF-FPM Engineering Manager and the TF-FPM Construction Supervision Manager. • If the disposition corrects the nonconformance to full compliance with the applicable specification, check "no". • After completing the disposition instructions and obtaining the required approvals sign and date. Send the original NCR to the TF-FPM Quality Manager and copy to the TF-FPM Construction Supervision Manager. TF-FPM Construction Supervision Manager

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 22 of 36

Upon receipt of the approved NCR disposition, perform the applicable construction actions specified in the NCR disposition. (Remove the QC hold tag prior to performing work, if one has been applied.) TF-FPM Project Quality Manager (or Inspector) • The Subcontractor initiating NCR's that require TF-FPM Engineering approval should notify the TF-FPM Project Quality Manager or Inspector (prior to performing the actions specified in the NCR disposition, if possible) and as applicable.. • Upon verification of satisfactory completion of the disposition, sign and date. •

Obtain other required approvals as required.

12.11 CORRECTIVE ACTION AND PREVENTIVE ACTION This procedure establishes the method of obtaining and documenting corrective actions for significant conditions which are adverse to quality, such as failure to properly implement procedures, programmatic failure due to inadequate procedures or failure to correct repetitive problems. The corrective action process involves: • • • • • •

Reviewing nonconformities Determining their cause Evaluating the action necessary to ensure that nonconformities do not recur Determining and implementing the action needed Recording the results of actions taken Reviewing corrective action taken

Definitions Nonconformity – The non-fulfillment of specified requirements. Also referred to as a nonconformance. Correction – The correction (fixing) of a nonconforming item to make it acceptable. When correcting an item, consideration should be given to whether other work is also affected. Corrective Action – The action taken to eliminate the cause(s) of nonconformities. Corrective Action should be appropriate to the magnitude of the problem and commensurate with the risks encountered.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 23 of 36

Root Cause – Underlying reason(s) for occurrence of a nonconformity. A root cause is determined by through analysis, (e.g. asking the question “why?” until the underlying reason has been revealed). Responsible Person – The individual responsible for the group of system where a nonconformity is identified. They would be responsible for ensuring its timely correction. Significant Condition – operating system and/or procedural deficiencies evaluated by management (as to the magnitude of the problem and commensurate to the risks encountered) and judged to warrant a Corrective Action Report (CAR). The need for a Corrective Action Report is usually identified by the Project Quality Manager or inspection personnel; however, any one may identify the need for a CAR.

12.11.1

PROCEDURE

A nonconformity may be identified through activities such as internal audit, surveillance, management review, or external audit finding. A nonconformity is evaluated (based on severity) to determine the appropriate level of corrective action needed to prevent recurrence. Consideration is given to the impact of the nonconformity on project cost, schedule or quality issues. Not all nonconformities require root cause analysis and/or corrective action. It is acceptable for management to determine that only correction is necessary. Root cause analysis and corrective action are applied where the reward is greater than the effort. Corrective action is documented on the CAR (Corrective Action Report) form: 000 509 F01401 Coordination of CARs is the responsibility of the Project Quality Manager. The Project Quality Manager reviews identified nonconformities to determine if a CAR is appropriate. If so, Sections 1 and 2 of the CAR form are completed and the CAR is recorded on a status log (000 509 F01402). Equivalent forms and logs are permitted providing the essential elements of the example form and log are addressed. The CAR is transmitted to the Responsible Person for further action. The Responsible Person completes Section 3 and 4 of the CAR form (refer to Attachment 01 – Corrective Action Response Instructions) and returns it to the Project Quality Manager.

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 24 of 36

Should it become necessary to void or cancel a CAR during the initiation cycle (upon discovery that no nonconformity actually exists, or a CAR covering this condition already exists), and explanation will be written on the original report. The report will be signed and dated by the responsible person and copies provided to appropriate distribution including the person who identified the deficiency/condition. The Project Quality Manager is responsible for ensuring that the nonconfromity has been corrected and that the corrective action taken to eliminate the cause of nonconformity is effective. The Project Quality Manger will also ensure completion of Section 5 of the CAR form and update the Status Log. A completed copy of the CAR form will be retained. In cases where an activity (that is the subject of CAR) occurs infrequently, or where root cause analysis is determined to be not necessary, the CAR may be closed following correction of the nonconformity without verifying effectiveness of the corrective action.

12.12 Surveillance/Inspection of Construction Activities This procedure describes the responsibilities and activities for quality surveillance and inspection of Subcontractors. This procedure is applicable to the CPI work awarded by or assigned to TF-FPM for construction management. It is to be used to oversee the inspection testing and work activities of Subcontractors. This procedure is also used to verify adequacy of self performed work. The TF-FPM Project Quality Manager is responsible for the quality program for the FPM project and is responsible for implementing and managing a program of quality surveillance and inspection. Surveillance and inspection is the monitoring by witnessing and observation of the Subcontractor’s Quality Control Program implementation during construction/installation work activities. Surveillance and inspection is performed to the extent necessary to provide adequate confidence that appropriate measures are taken to control and achieve quality. The TF-FPM Engineering Manager shall be contacted for final resolution/interpretation of design specifications or drawing requirements, when a conflict develops between the Subcontractor's interpretation and that of the TF-FPM Quality Inspection personnel. 12.12.1

Procedure

Quality Assurance Manager

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 25 of 36

The TF-FPM Project Quality Manager or Senior QA/QC Inspector will assign surveillance and inspection responsibilities to TF-FPM inspection personnel and in conjunction with Construction Supervision personnel NOTE: Scope, duration, and intensity of surveillance, inspection and/or verification activities shall be determined by the TF-FPM Project Quality Manager/Senior QA/QC Inspector through an evaluation of the scope of the activities being performed and the quality history of the workers.

Inspector Perform periodic surveillance, inspection and/or verification activities. NOTE: The inspector should refer to the applicable inspection/test plans or procedures and use them for determining surveillance activities. When surveillance is performed on activities not addressed by inspection/test procedures; the work process instructions (usually drawings and specifications) should be used to guide the inspector. Indicate the results of the surveillance and inspection verification activity in the following manner: •

Record on the Surveillance and Inspection Report those areas or items monitored or reviewed. If no deficiencies are found during this surveillance and inspection, so state (satisfactory), sign, and date report. Form 000 509 F02201 Surveillance Report, Form 000 509 F01303 Hold Tag/Sticker

•

When a deficiency is found and will need a follow-up inspection to verify conformity, identify it on the Surveillance and Inspection Report. Notify the contractor of the deficiency and record the corrective action being taken by the contractor to resolve it.

•

Follow-up and record the completion of the corrective action, sign and date.

•

If corrective action is not initiated to resolve the deficiency within fourteen (14) days, notify the TF-FPM Project Quality Manager. The TF-FPM Project Quality Manager may initiate and process a nonconformance report if needed.

Nonconformance Reports are issued when there are: •

67743248.doc

Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition.

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 26 of 36

•

Deficiencies of a serious or repetitive nonconforming nature as determined by the Quality Assurance Manager

•

Construction damage has occurred to existing or turned over plant property.

Nonconformances shall be documented using Form 000 509 F01301. The TF-FPM Project Quality Manager/Senior QA/QC Inspector shall review the results of the surveillance and/or verification activities recorded on the Surveillance and Inspection Report and signify review and concurrence by signing and dating. The TF-FPM Project Quality Manager/ Senior QA/QC shall advise the Construction Supervision Manager of serious quality problems. All Surveillance and Inspection Reports shall be retained in the Quality files by Subcontractor/Project/Job number. 12.13 Quality Records

This procedure describes maintenance of Quality Records generated for and/or by construction. Quality Records are documented evidence that construction conformed to requirements of the Design Specifications. Quality Records include: • • • • •

Test and inspection reports Radiographs Material and equipment certificates required by specification Equipment maintenance/preservation records As-built drawings

Subcontractors are responsible for the preparation of Quality Records and are responsible for maintenance and retrievability of the records. Subcontractors shall maintain and turnover records as stated in their approved Quality Plan upon completion/system turnover. 12.13.1

Procedure

In coordination with the Construction Supervision Manager and any other group manager who receives or generates quality records, identify the quality records that will be retained during construction and identify the record custodian by job title. Record this information on Form 000 509 F0161 (Quality Records Control).

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 27 of 36

Reference the Project File Index and Record Retention Schedule Practice 000 037 1104. In coordination with CPI and other record custodians, define the Quality Records that are to be submitted to CPI upon completion of work and identify this on the Quality Records Control form. The TF-FPM Project Quality Manager in coordination with the Construction Supervision Manager and the Engineering Manager will identify all Quality Records (or copies of records) that will be retained by Technical Document Control for each subcontract/project. These records shall be identified on the Quality Records Control form. NOTE: Reference Attachment 1 for a sample of a completed Quality Records Control form. Maintain the Quality Records Control form current and, if possible, before records are received on site or generated. 12.13.2

Technical Document Controller

The Technical Document Controller use file records based on the Project Directory for inspection, testing, and other Quality Control records. The system shall ensure that records are readily retrievable and protected. The system shall allow the records required for turnover to be easily separated by turnover packages. The system is to be identified on the Quality Records Control Form. Prior to filing the record the custodian shall review the documents to verify the following: • Documents are appropriate • Documents are complete • Entries are correct • Documents are legible • Documents signed/initialed by authorized person Review vendor generated documents to verify the records are complete and legible. The custodian shall resolve any discrepancies noted during the document review with the originator or originator's supervisor. Resolve any discrepancies with vendor documents through Supply Chain Management.

12.14

Forms

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 28 of 36

000 509 F0051

Field Change Request

000 509 F0052

Field Change Request Log

000 509 F0111C

Calibration Assignment Log and Record

000 509 F0112C

I M T E Sign In/Out History of Use Log

000 509 F0113C

Calibrations Tickler File

000 509 F01104C

Calibration Data Sheet

000 509 F01301

Nonconformance Report

000 509 F01302

Nonconformance Report Log

000 509 F01303

Hold Tag/Sticker

000 509 F01401

Corrective Action Report

000 509 F01402

Corrective Action Status Log

000 509 F01403

Punch List QA/QC

000 509 F01501

Preventive Action Log

000 509 F01601

Quality Records Control

000 509 F02201

Surveillance Report

000 509 F02202

Surveillance Report Log

000 509 F02301

Material Transfer Inspection Checklist

000 509 F78001(1)

Coating Inspection Record

000 509 F78001(2)

Coating and Lining Holiday Test Record

000 509 F79001

Daily Welding Report

000 509 F79002

Post Weld Heat Treatment Log

000 509 F79201(1)

Welder B31.3 Random Radiography Control Log

000 509 F79201(2)

Instruction Pre ASME B31.3 Random Radiography for Welder

000 509 F79204(1)

Welding / NDE Status Log

000 509 F79204(2)

Welding / NDE Status Log (Double Joints)

000 509 F0171

Audit Finding

000 509 F0172

Audit Summary

000 509 F02401

Pre-mobilization Checklist

000 509F02402

RFI (Request for Information)

000 509 F70101

Soil Inspection Checklist

000 509 F70102

Field Compaction Test Record

000 509 F70103

Density of Soil Place by the Sand-Cone Method ASTM D-1566 AASHTO-T-191

000 509 F70104

Nuclear Moisture-Density Test Report

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 29 of 36

000 509 F70105

Soil Density Test Log

000 509 F70106

California Bearing Ratio (CBR)

000 509 F70201

Bituminous Concrete Paving Inspection Check List

000 509 F70202

Bulk Specific Gravity

000 509 F70203

Bituminous Concrete Compaction (AASHTO T 230)

000 509 F70204

Nuclear Density Test Report – Bituminous Concrete

000 509 F70301

Pile Driving Inspection Record

000 509 F70302

Pile Driving Record

000 509 F70303

Record of Pile Driving

000 509 F70401

Foundation Survey

000 509 F70402

Anchor Bolt with Template Setting

000 509 F70403

Anchor Bolt with Gauge Setting

000 509 F70801

Caisson Inspection Record

000 509 F70901

Augered Cast-In Place Pile Record

000 509 F71001

Pre-Concrete Inspection Checklist

000 509 F71002

Concrete Inspection Record

000 509 F71003

Concrete Pour Card

000 509 F71004

Cementitious Grout Inspection Checklist

000 509 F71005

Cementitious Grout Testing Record

000 509 F71006

Epoxy Resin Grout Inspection Record

000 509 F71007

Concrete Compressive Strength Test Record

000 509 F71008

Concrete Placement Log

000 509 F71009

Grout Placement Log

000 509 F71010

Concrete Batch Plant Inspection Record

000 509 F72001

Leveling Inspection

000 509 F72002

Structural Steel Inspection Checklist

000 509 F72003

Torque Wrench Calibration Log

000 509 F72004

Steel Structure Material Receiving Report

000 509 F72005

Steel Structure Dimension Control

000 509 F72006

Steel Structure Damage Record

000 509 F72007

Fit-Up Visual Welding Inspection

000 509 F72008

Plumbness Inspection

000 509 F72009

Coordinate Inspection

000 509 F72010

Straightness Inspection

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 30 of 36

000 509 F72011

Painting Inspection

000 509 F73001

Building Inspection and Test Checklist

000 509 F73002

Final Building Inspection Summary

000 509 F73003

Carpentry Checklist

000 509 F73004

Painting Checklist

000 509 F73005

Plumbing Checklist

000 509 F73006

Ceramic Tile Checklist

000 509 F73007

Concrete Checklist

000 509 F73008

Structural Steel Checklist

000 509 F73009

Masonry (Brick Work) Checklist

000 509 F73010

Plaster Checklist

000 509 F73011

Doors, Windows, Hardware, Glazing Checklist

000 509 F73012

Computer (Raised) Floor Checklist

000 509 F73013

Prefab Wall Element System Checklist

000 509 F73014

Building Metal Siding and Proofing Checklist

000 509 F73015

Buildings Water Proofing & Damp Proofing Checklist

000 509 F73016

Suspended Ceiling Checklist

000 509 F73101

HVAC Inspection Record

000 509 F73102

Buildings Air Conditioning Checklist

000 509 F73201

Roofing Inspection Checklist

000 509 F74001

Equipment Installation Checklist

000 509 F74002

Heat Exchangers and Reboilers Installation Checklist

000 509 F74003

Electrostatic Precipitator Checklist

000 509 F74004

Inspection Record Static Equipment

000 509 F74005

Tray Installation Inspection Record

000 509 F74006

Air Cooled Heat Exchanger Inspection Checklist

000 509 F74007

Air Cooler Run In Test Report

000 509 F74008

Reciprocating Compressor Inspection Record

000 509 F74009

Fan Installation Inspection Checklist

000 509 F74010

Furnaces Inspection Checklist

000 509 F74011

Fuel Gas Steam Generator Inspection Checklist

000 509 F74012

Steam Turbine Inspection Checklist

000 509 F74013

Agitators/Mixers Inspection Checklist

000 509 F74014

Equipment/Piping Strain and Alignment Inspection Record

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 31 of 36

000 509 F74015

Installation Checklist Traveling Cranes

000 509 F74016

Package Equipment Installation Checklist

000 509 F74017

Desuperheaters/Ejectors Inspection Checklist

000 509 F74018

Filters/Strainers Inspection Checklist

000 509 F74019

Centrifugal Compressor Inspection Checklist

000 509 F74020

Rotating Equipment Inspection Checklist

000 509 F74021

Alignment Certificate

000 509 F74022

Belt Driven Equipment Alignment Record

000 509 F74024

Inspection Record for Draw Off Tray Leak Test Report

000 509 F74025

Inspection Record for Air Coolers

000 509 F74026

Final Closing Authorization Record

000 509 F74027

API 686 Baseplate Installation Checklist (Prior to Grouting)

000 509 F74028

API 686 Grouting Checklist

000 509 F74029

API 686 Alignment Check Sheet

000 509 F74030

Baseplate Leveling Record

000 509 F74031

Reverse Dial Alignment Record

000 509 F74032

Piping Alignment Data Sheet

000 509 F74101

Tank Elevation Tolerances Record

000 509 F74102

Inspection Record Field Erection Tank

000 509 F74103

Tank Plate Dimensional Control Record Field Erection Tank

000 509 F74104

Water Filling and Settlement Record Field Erected Tank

000 509 F74105

Tank Leak Test Record

000 509 F74106

Tank Test Certificate

000 509 F74201

Cooling Tower Inspection Checklist

000 509 F74301

Field Installed Refractory Record

000 509 F74401

Gas Turbine/Generators Gear Inspection Checklist

000 509 F74402

Gas Turbine/Generators Gear Inspection Checklist

000 509 F74405

Shop-Fabricate Field-Erected Stack Inspection Checklist

000 509 F74406

Heat Recovery System Generator Inspection Record

000 509 F74407

Breeching and Duct Work Inspection Record

000 509 F74408

Equipment Protection Activities Record

000 509 F74601

Site Daily Activities Log

000 509 F74602

Construction Checks and Quality Inspection Record STG Foundation Settlement Record

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 32 of 36

000 509 F74603

Construction Checks and Quality Inspection Record STG Fixators

000 509 F74604

Construction Checks and Quality Inspection Record STG Sole Plate

000 509 F74605

Construction Checks and Quality Inspection Record STG Front Standard Baseplate Assembly

000 509 F74606

Construction Checks and Quality Inspection Record Exhaust Hood Horizontal Joint Levelness

000 509 F74607

Construction Checks and Quality Inspection Record STG Sheell / Casing Load Test

000 509 F74608

Construction Checks and Quality Inspection Record STG Piping Attachment

000 509 F74609

Construction Checks and Quality Inspection Record STG Foundation Top of Concrete Elevations

000 509 F74701

Generator Test Checklist

000 509 F74702

Generator Cold Resistance Test Record

000 509 F75001

Underground Pipe Inspection Checklist

000 509 F75002

Insulation Resistance (Insulated Flanges-Underground Piping) Test Record

000 509 F75003

Holiday (Spark) Test Record

000 509 F75101

Above Ground Pipe Inspection Checklist

000 509 F75102

Visual Inspection of Flanges, Gaskets and Bolting

000 509 F75202

Pressure Test Report

000 509 F75501

Hygienic Drawing Revision Log

000 509 F75502

Hygienic Material Revision Log

000 509 F75503

Hygienic Valve Receiving Inspection Report

000 509 F75504

Hygienic Vessel Nozzle Inspection Report

000 509 F75505

Hygienic Tube/Fitting Receiving Inspection Report

000 509 F75506

Hygienic Preweld Inspection Checklist

000 509 F75507

Hygienic Welder Qualification Report

000 509 F75508

Hygienic Orbital Weld Log

000 509 F75509

Hygienic Post Installation Checklist

000 509 F75601

Pipe Cleaning and Verification Checklist

000 509 F75602

Hydrostest Checklist

000 509 F75603

Hydrotest Package Contents

000 509 F75604

Line Number Checklist

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 33 of 36

000 509 F75605

Hydrostatic Test Flow Chart

000 509 F76001

Conduit & Cable Tray Checklist

000 509 F76002

Electrical Manhole Inspection Checklist

000 509 F76003

Medium and High Voltage Underground Cable Splice Inspection Record

000 509 F76004

Medium and High Voltage Cable Termination Checklist

000 509 F76005

Cable Pulling Inspection Check List

000 509 F76006

Fan/Speed Reducer/Motor Inspection Check List

000 509 F76007

Switch House Inspection Checklist

000 509 F76008

Lighting, Receptacle, Instrument Distribution Panels Inspection Checklist

000 509 F76009

Electrical Motor Inspection Checklist

000 509 F76010

Aboveground Conduit Inspection Checklist

000 509 F76011

Lighting Panel board Inspection Record

000 509 F76012

Underground Conduit (Duct Bank) Inspection

000 509 F76013

Grounding/Earthing System (Grid or Loop) Inspection Record

000 509 F76014

Grounding/Earthing System (Grid or Loop) Inspection Record

000 509 F76101

Grounding/Earthing Resistance Readings (Resistance-to-Earth and Loop Continuity) Test Record

000 509 F76103

Insulation Resistance (Instrument Wire and Cable) Test Record

000 509 F76104

DC High Potential Test (Medium Voltage Cable) Record

000 509 F76105

Current Transformer (and Ammeter) Test Record

000 509 F76106

LV Over-current and Earth/Ground-Fault Protection Relay Test

000 509 F76107

Over-current/Ground Fault Protection Relay (Induction Type) Test

000 509 F76108

Over-current/Ground Fault Protection Relay (Thermal Type)

000 509 F76109

Switching Units HV Switchgear Inspection and Test Record

000 509 F76111

Ground Fault Protection Relay Induction Inspection and Test Record

000 509 F76112

Grounding Continuity Inspection and Test Record

000 509 F76113

Grounding Rod Inspection and Test Record

000 509 F76114

Bus Bar Assemblies LV Switchgear Test Record

000 509 F76115

Neutral Grounding/Earthing Resistor Test Record

000 509 F76116

Ground Continuity (Non Electrical) Equipment/Structures Test Record

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 34 of 36

000 509 F76117

Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record

000 509 F76118

Insulation Resistance (Equipment) Test Record

000 509 F76120

Liquid Dielectric Strength Test Record

000 509 F76121

DC Proof Test Record for Motors

000 509 F76122

Feeder Breaker (480V MCC) Test Record

000 509 F76123

Breaker/Contractor (480V MCC) Test Record

000 509 F76124

460V Motor Circuit (480V MCC) Test Record

000 509 F76125

Medium Voltage Motor Circuit Test Record

000 509 F76126

Equipment Absorption Ration and Polarization Ration Test Record (Meger)

000 509 F76127

Insulation Resistance (Medium Voltage Power Cables) Test Record

000 509 F76128

Bus Throat Insulation and Ductor Report

000 509 F76129

Circuit Breaker Contact Timing Test Report

000 509 F76130

Vacuum Circuit Breaker Ductor Insulation Report

000 509 F76131

Drawout Vacuum Breaker Inspection Record

000 509 F76132

Main Bus Insulation and Ductor Report

000 509 F76133

Electric Motor Run-In Test Record

000 509 F76134

Drawout Air Circuit Breaker Inspection Record

000 509 F76135

Insulation Resistance (Rotating Equipment) Test Record

000 509 F76201

Emergency Generators Inspection Checklist

000 509 F76202

Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units)

000 509 F76203

Inspection LV Switchgear (Including Incoming and Sectionalizer Units)

000 509 F76204

Inspection of Outgoing Unit – LV Switchgear

000 509 F76205

Inspection of Static supply Unit (UPS)

000 509 F76206

Motor Control Centers Inspection Checklist

000 509 F76207

Motor Control Centers Inspection Record

000 509 F76210

Control and Relay Panels Inspection Checklist

000 509 F76211

Electronic Equipment Inspection Checklist

000 509 F76212

Power Panel Inspection Checklist

000 509 F76213

Switchgear Inspection Checklist

000 509 F76214

Low Voltage Feeders Inspection Record

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 35 of 36

000 509 F76215

High Voltage Cable Inspection and Test Record

000 509 F76216

Electrical Equipment Inspection Record

000 509 F76217

Motors Checklist

000 509 F76218

Power Transformer Inspection Checklist

000 509 F76219

Switching Units – HV Switchgear Inspection and Test Record

000 509 F76221

Liquid – Filled Transformer Inspection Record

000 509 F76222

Busway Inspection Record

000 509 F76223

Switchgear Inspection Record

000 509 F76224

Motor Control Center Inspection Record

000 509 F76225

Battery and Battery Charger Inspection Record

000 509 F76226

Liquid Immersed Medium Voltage Disconnect Switch Inspection Record

000 509 F76227

Electric Motor – Electrical Activities Inspection Record

000 509 F76228

Electric Motor – Mechanical Activities Inspection Record

000 509 F76229

Electric Motor for Compressor Installation Checklist

000 509 F76230

Compressor Vibration Checklist

000 509 F76231

Vibration Probe Record

000 509 F77001

Instrumentation Inspection Checklist

000 509 F77002

Instrument Loop Inspection Checklist

000 509 F77003

Impulse Line Pressure Test Sheet

000 509 F77004

Instrument Grounding System Check Sheet

000 509 F77005

Installation Check Sheet (Local Instruments)

000 509 F77006

Orifice Plates Inspection Checklist

000 509 F77007

Instrument Loop Check Sheet

000 509 F77008

Safety Valve Tracking Sheet

000 509 F77009

Relief Valve Inspection and Final Acceptance

000 509 F77110

Electrical Instrument Material Verification

000 509 F78001(1)

Coating Inspection Record

000 509 F78002

Linings Inspection Record

000 509 F78101

Equipment Thermal Insulation Inspection Checklist

000 509 F78102

Piping Thermal Insulation Inspection Checklist

000 509 F78201

Fireproofing Inspection Release for Applications of Fire Proofing and Inspection Checklist

000 509 F78202

Fireproofing Inspection Preconstruction Checklist

67743248.doc

Tripatra Fluor Consortium Flexible Program Management Project Contract 1523-OM

Quality Management System Revision 0 19 August 2005 Page 36 of 36

000 509 F79001

Daily Welding Report

000 509 F79002

Post Weld Heat Treatment Log

000 509 F79201(1)

Welder B31.3 Random Radiography Control Log

000 509 F79201(2)

Instruction Pre ASME B31.3 Random Radiography for Welder

000 509 F79202

Nondestructive Examination Record

000 509 F79203

Radiographic Rejectable Defects Statistics

000 509 F79204(1)

Welding / NDE Status Log

000 509 F79204(2)

Welding / NDE Status Log (Double Joints)

000 509 F79205

Visual Check and NDE Request

000 509 F79501

Verification of Training for Hardness Testing

000 509 F79502

Report of Vision Test

000 509 F79503

Hardness Testing Report

67743248.doc