comprehensive welding qa/qc plan sample · 2018-03-09 · pat [pick the date] comprehensive welding...

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Comprehensive Welding QA/QC Plan Sample Selected pages (not a complete plan)

Part 1: Project-Specific Quality Plan

Part 2: Company Quality Manual

Part 3: Submittal Forms

Contact: Ed Caldeira 410-451-8006

PROJECT-SPECIFIC WELDING QUALITY PLAN TABLE OF CONTENTS Background Information .......................................................................................................................... 7

Customer .................................................................................................................................................... 7 Project Name .............................................................................................................................................. 7 Project Number .......................................................................................................................................... 7 Project Location .......................................................................................................................................... 7 Overall Project Description ......................................................................................................................... 7 [CompanyName] Scope of Work ................................................................................................................ 7

A. [CompanyName] Quality Policy ........................................................................................................... 8 B. Key Elements of the Weld Quality Plan ................................................................................................ 9

Project Quality Assurance/Quality Control Plan Overview ...................................................................... 12

C. Project Quality Coordination and Communication ............................................................................. 13 D. Project QC Personnel ......................................................................................................................... 17

Project QC Job Position Assignments ....................................................................................................... 17 Project QC Organization Chart ................................................................................................................. 18

E. Duties, Responsibilities, and Authority of QC Personnel .................................................................... 19 F. Personnel Qualifications and Technical Certifications ........................................................................ 25

Personnel Certification Requirements ..................................................................................................... 27

G. Qualification of Third Party Inspection/Testing Companies and Subcontractors and Suppliers ......... 33

Third Party Weld Inspection Qualification Requirements ........................................................................ 33 Qualification ............................................................................................................................................. 33 Purchase Order Approval ......................................................................................................................... 34

H. Quality Training ................................................................................................................................. 36 I. Weld Project Quality Specifications .................................................................................................... 39

Compliance with Industry Welding Standards ......................................................................................... 39 Project -Specific Welding Procedure Standards ....................................................................................... 39 Local fabrication and erection Codes ....................................................................................................... 40

J. Design Controls ................................................................................................................................... 44

Design Reviews ......................................................................................................................................... 44 Design Review Plan ................................................................................................................................... 45

K. Material Inspection Traceability and Quality Controls ....................................................................... 48

Identification of Lot Controlled Materials ................................................................................................ 48 Heat Traceability of Metals ...................................................................................................................... 48 Material Receiving and Inspection ........................................................................................................... 49

L. Weld Inspection and Test Plan ........................................................................................................... 53

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Questions? Call Ed Caldeira 410-451-8006

Welding Inspection and Testing Standards .............................................................................................. 54 Calibration of Inspection, Measuring, and Test Equipment ..................................................................... 55

M. Work Task Quality Inspections .......................................................................................................... 58

Identification of Quality Inspected Work Tasks ........................................................................................ 58 Required Inspections For Each Work Task ............................................................................................... 58 Daily Quality Control Report ..................................................................................................................... 59

N. Control of Corrections and Nonconformances ................................................................................... 66

Marking of Nonconformances and Observations ..................................................................................... 66 Control the Continuation of Work ............................................................................................................ 66 Recording of Nonconformances ............................................................................................................... 66 Quality Manager Disposition of Nonconformance Reports ..................................................................... 67 Corrective Actions .................................................................................................................................... 67 Nonconformance Preventive Actions ....................................................................................................... 68

O. Project Completion Inspections ......................................................................................................... 70

Punch-Out QC Inspection ......................................................................................................................... 70 Pre-Final Customer Inspection ................................................................................................................. 70 Final Acceptance Customer Inspection .................................................................................................... 71

P. Project Quality Records and Documents ............................................................................................ 74 Q. Quality Assurance Surveillance .......................................................................................................... 77

Project Quality Performance Surveillance ................................................................................................ 77 Project Quality Audits ............................................................................................................................... 77 Project Audit Plan ..................................................................................................................................... 78 Project Audit Requirements ..................................................................................................................... 78

R. Additional Quality Control Requirements .......................................................................................... 80

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I. WELD PROJECT QUALITY SPECIFICATIONS Fulfilling customer contract expectations is a primary objective of the [CompanyName] Quality System. To ensure that customer expectations will be fulfilled, [CompanyName] clearly defines the requirements for each contract before it is approved.

The Project Manager ensures that the information in customer contracts clearly defines customer expectations and that the necessary details are provided to set requirements for fabrication and erection.

[CompanyName] personnel and subcontractors and suppliers are accountable for compliance to standards-based written specifications.

To achieve expectations reliably and consistently, specifications are clearly spelled out, not only for results but also for processes. Specifications apply to materials, work steps, qualified personnel and subcontractors and suppliers, safe work rules, and environmental work conditions.

Standards ensure that results are specified rather than left to discretionary practices.

All [CompanyName] fabrication and erection activities comply with generally accepted good workmanship practices and industry standards.

COMPLIANCE WITH INDUSTRY WELDING STANDARDS Codes that may apply to this project include those listed below.

REGULATORY CODES AND INDUSTRY STANDARDS

Description Reference Standard No. Reference Standard Title

Beveling, alignment, heat treatment, and inspection of weld

ASME B31.1 Power Piping

Requirements for piping of fluids ASME B31.3 Process Piping

Workmanship and techniques for welded construction

AWS D1.1/D1.1M Structural Welding Code – Steel

Welding standards AWS B2.1/B2.1M Specification for Welding Procedure and Performance Qualification

Framing and reinforcing openings through a steel deck

SDI DDP Deck Damage and Penetrations

Minimum spacings and edge distances for screws

AISI SG02-KIT North American Specification for the Design of Cold-Formed Steel Structural Members

Installation of chimneys, vents, and smokestacks

NFPA 211 Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances

Installation of bracing and permanent bracing and bridging

CFSEI Field Installation Guide for Cold-Formed Steel Roof Trusses

Install high-strength bolts RCSC's "Specification for Structural Joints Using ASTM A 325 or A 490 Bolts"

PROJECT -SPECIFIC WELDING PROCEDURE STANDARDS

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J. DESIGN CONTROLS Welding design controls are in place to assure the quality of welding designs for this project.

A design plan is used to document the design control process. The Design Plan is included as an exhibit in this subsection.

The first control point will be of the review of design inputs. The Design Manager will assure that all necessary information is available to perform the required design work. The Design Manager will also assure that expectations for design outputs are well defined.

Intermediate reviews will be carried out as indicated on the design control plan. The last review is the design output review.

A record of all reviews will be recorded on the Design Review form. A Design Review form exhibit is included in this subsection.

The President has appointed [DesignManagerName] as the Design Manager. [DesignManagerName] will control the design process with specific quality responsibilities, duties, and the authority to carry them out.

DESIGN REVIEWS DESIGN INPUT REQUIREMENTS REVIEW The Quality Manager ensures that the information in design inputs clearly defines customer expectations and that the necessary details are provided to set requirements for design.

The Quality Manager obtains design specifications from the customer and conducts a customer design input review to ensure that:

• Customer design input requirements and specifications are complete • Design process review milestones are specified when necessary • Customer design output requirements and specifications are complete for review milestones as

well as the completed design • Customer design requirements and specifications are compatible with the relevant regulations,

[CompanyName] quality standards, and Quality System requirements • [CompanyName] has the capability to deliver the completed design in the time allotted

The Quality Manager identifies supplemental design specifications that supplement customer specifications when they are needed to ensure a quality design.

Before design work begins, the Quality Manager makes sure that all design requirements are clearly understood, all discrepancies are resolved, and all requirements are agreed upon. Once these requirements are met, the Quality Manager approves the design input.

The Quality Manager ensures that design input documents are verified by qualified personnel. The person responsible must verify:

• Design input specification are approved by a customer authority • Design input specifications are complete • Design input requirements and specifications are compatible with the relevant regulations,

[CompanyName] quality standards, and Quality System requirements

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K. MATERIAL INSPECTION TRACEABILITY AND QUALITY CONTROLS Products and materials are controlled to assure the use of only correct and acceptable items. Controls include identification of the inspection status. Materials that require lot control traceability and the method of traceability are listed on the Controlled Materials form included as an exhibit in this subsection.

IDENTIFICATION OF LOT CONTROLLED MATERIALS The Quality Manager determines types of project materials that require quality controls.

For each type of quality-controlled material, the Quality Manager determines lot control traceability requirements, if any, and specifies the means of lot identification. Identification methods may include physical labels, tags, markings and/or attached certification documents.

When lot controlled materials are received, the Superintendent verifies that materials have the specified lot identifications.

The Superintendent maintains lot identification at all production phases from receipt, through production, installation, or assembly, to final completion. Acceptable methods for preserving lot identification include physically preserving observable lot identifications, recording the lot identification on a work task quality inspection form or other work record, or collecting the physical lot identifier as a record along with supplemented with location.

If lot controlled materials are without lot identification, the Superintendent deems the materials as nonconforming and segregates them and/or clearly marks them to prevent inadvertent use. The Superintendent treats the material according to the company policy for nonconformances. Only the Quality Manager can re-identify or re-certify the materials.

HEAT TRACEABILITY OF METALS Heat numbers are traced for metals including:

• Carbon steel • Galvanized steel • Aluminum • Stainless steel

Heat identification of metals includes:

• Material supplier heat number is either marked by the material supplier or reproduced by the Superintendent or other competent person. As an alternative an adhesive label or tag on the bundle is an acceptable method.

• When metal is cut into pieces, the heat number is marked on each piece (except scrap) • Color code is painted on all four corners of each piece of plate material. • Color code is painted on both ends of strip material. • Bundles of material may be marked on one piece. If a piece is removed from the bundle, heat

trace information must be transferred so that both the piece and the bundle are identified. When the bundle is separated, each individual piece is marked.

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[CompanyName] Metals Material Receiving Inspection Report

Version 20130819 Project ID Project Name P.O.# Supplier Receipt Date

[ProjectNumber] [ProjectName]

Type of Material (i.e., steel plate)

Material Description (nominal dimensions)

Heat Number/ Serial Number/Markings

Condition / Damage Color Code Marking

Receiving Inspector Approval Signature / Date Government Representative Name/Approval Date

Material Receiving Inspection Passed

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QUALITY MANUAL TABLE OF CONTENTS

1. Quality System Management and Responsibilities ............................................................................... 8

1.1. Overview .............................................................................................................................................. 8 1.2. [CompanyName] Quality Policy ........................................................................................................... 8 1.3. Quality Duties, Responsibilities, and Authority ................................................................................... 8 1.4. Quality System Performance Measures ............................................................................................ 10 1.5. Customer Satisfaction Performance Measures ................................................................................. 11 1.6. Exceptions .......................................................................................................................................... 11

2. Project Quality Assurance/Quality Control Plan ................................................................................. 12

2.1. Overview ............................................................................................................................................ 12 2.2. [CompanyName] Project License and Qualification Requirements .................................................. 12 2.3. Project Personnel and Qualifications ................................................................................................ 13 2.4. Project Quality Assurance/Quality Control Plan ................................................................................ 13 2.5. Identification of Quality Controlled Work Tasks................................................................................ 14 2.6. Project Quality Inspection and Test Plan ........................................................................................... 14 2.7. Project Quality Communications Plan ............................................................................................... 14 2.8. Project Quality Training Plan ............................................................................................................. 14 2.9. Customer Training On Operation and Maintenance ......................................................................... 14 2.10. Project Records and Documentation Plan ....................................................................................... 15 2.11. Project Audit Plan ............................................................................................................................ 15

3. Contract Specifications ....................................................................................................................... 16

3.1. Overview ............................................................................................................................................ 16 3.2. Contract Technical Specifications ...................................................................................................... 16 3.3. Contract Drawings ............................................................................................................................. 16 3.4. Contract Submittals ........................................................................................................................... 16 3.5. Customer Submittal Approval ........................................................................................................... 18 3.6. Contract Warranty ............................................................................................................................. 18 3.7. Contract Review and Approval .......................................................................................................... 19

4. Design Review and Control ................................................................................................................ 20

4.1. Overview ............................................................................................................................................ 20 4.2. Design Input Review .......................................................................................................................... 20 4.3. Project Design Quality Assurance/Quality Control Plan .................................................................... 20 4.4. Design Progress Reviews ................................................................................................................... 21 4.5. Design Output Verification and Approval .......................................................................................... 21

5. Project-Specific Quality Standards ..................................................................................................... 22

5.1. Overview ............................................................................................................................................ 22 5.2. Regulatory Codes ............................................................................................................................... 22

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5.3. Industry Quality Standards ................................................................................................................ 22 5.4. Material and Equipment Specifications ............................................................................................. 22 5.5. Work Process Specifications .............................................................................................................. 23 5.6. Controlled Material Identification and Traceability .......................................................................... 23 5.7. Measuring Device Control and Calibration ........................................................................................ 23 5.8. [CompanyName] Quality Standards .................................................................................................. 24 5.9. Application of Multiple Sources of Specifications ............................................................................. 24

6. Project Purchasing ............................................................................................................................. 25

6.1. Overview ............................................................................................................................................ 25 6.2. Qualification of Outside Organizations and Company Departments ................................................ 25 6.3. Quality Responsibilities of Key Subcontractor and Supplier Personnel............................................. 26 6.4. Requirements for Subcontractor QC Plan ......................................................................................... 27 6.5. Subcontractor and Supplier Quality Policy ........................................................................................ 27 6.6. Project Subcontractor and Supplier List ............................................................................................ 28 6.7. Purchase Order Requirements .......................................................................................................... 28 6.8. Project Purchase Order Approvals..................................................................................................... 28

7. Process Controls ................................................................................................................................. 29

7.1. Overview ............................................................................................................................................ 29 7.2. Project Startup and Quality Control Coordination Meeting .............................................................. 29 7.3. Preparatory Project Quality Assurance/Quality Control Plan Planning ............................................. 29 7.4. Weekly Quality Planning and Coordination Meetings ....................................................................... 30 7.5. Process Control Standards ................................................................................................................. 30 7.6. Daily Quality Control Report .............................................................................................................. 32 7.7. Monthly Quality Control Report ........................................................................................................ 32

8. Inspections and Tests ......................................................................................................................... 33

8.1. Overview ............................................................................................................................................ 33 8.2. Required Work Task Quality Inspections and Tests........................................................................... 33 8.3. Material Inspections and Tests .......................................................................................................... 33 8.4. Work in Process Inspections .............................................................................................................. 34 8.5. Work Task Completion Inspections ................................................................................................... 34 8.6. Inspection of Special Processes ......................................................................................................... 35 8.7. Independent Measurement and Tests .............................................................................................. 35 8.8. Commissioning Functional Acceptance Tests .................................................................................... 35 8.9. Hold Points for Customer Inspection ................................................................................................. 35 8.10. Quality Inspection and Test Specifications ...................................................................................... 35 8.11. Inspection and Test Acceptance Criteria ......................................................................................... 35 8.12. Inspection and Test Status ............................................................................................................... 36 8.13. Independent Quality Assurance Inspections ................................................................................... 36 8.14. Inspection and Test Records ............................................................................................................ 36 8.15. Project Completion and Closeout Inspection .................................................................................. 37

9. Nonconformances and Corrective Actions ......................................................................................... 39

9.1. Overview ............................................................................................................................................ 39

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9.2. Nonconformances ............................................................................................................................. 39 9.3. Corrective Actions ............................................................................................................................. 40

10. Preventive Actions ........................................................................................................................... 42

10.1. Overview .......................................................................................................................................... 42 10.2. Identify Preventive Actions for Improvement ................................................................................. 42 10.3. Train Preventive Actions for Improvement ..................................................................................... 42

11. Quality System Audits ...................................................................................................................... 44

11.1. Overview .......................................................................................................................................... 44 11.2. Project Quality System Audit ........................................................................................................... 44 11.3. Company-wide Quality System Audit .............................................................................................. 44

12. Record and Document Controls ........................................................................................................ 45

12.1. Overview .......................................................................................................................................... 45 12.2. Quality System Documents ............................................................................................................. 45 12.3. Document Controls .......................................................................................................................... 45 12.4. Record Controls ............................................................................................................................... 46

13. Appendix .......................................................................................................................................... 48

13.1. Definitions of Terms ........................................................................................................................ 48

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CROSS REFERENCES The [CompanyName] Quality System complies with ANSI/ISO/ASQ Q9001-2008: Quality management systems - Requirements

ISO 9001:2008 Requirement [CompanyName] Quality Manual Section

4 Quality management system

4.1 General requirements Key Elements of the Quality System

4.2 Documentation requirements 12 Record and Document Controls

5 Management responsibility

5.1 Management commitment [CompanyName] Quality Policy 1.3 Quality Duties, Responsibilities, and Authority 11.3Company-wide Quality System Audit

5.2 Customer focus [CompanyName] Quality Policy

5.3 Quality policy [CompanyName] Quality Policy

5.4 Planning 1.4 Quality System Performance Measures 11 Quality System Audits

5.5 Responsibility, authority and communication 1.3Quality Duties, Responsibilities, and Authority 2.3.2 Appointment of Key Project Personnel

5.6 Management review 11 Quality System Audits

6 Resource management

6.1 Provision of resources 2 Project Quality Assurance/Quality Control Plan 6 Project Purchasing

6.2 Human resources 2.8 Project Quality Training Plan

6.3 Infrastructure 2.4 Project Quality Assurance/Quality Control Plan

6.4 Work environment 7 Process Controls

7 Product realization

7.1 Planning of product realization 3 Contract Specifications 2 Project Quality Assurance/Quality Control Plan

7.2 Customer-related processes 3 Contract Specifications 5 Project-Specific Quality Standards 2.7 Project Quality Communications Plan

7.3 Design and development 4 Design Review and Control

7.4 Purchasing 6 Project Purchasing

7.5 Production and service provision 5 Project-Specific Quality Standards 7 Process Controls

7.6 Control of monitoring and measuring equipment 5.7 Measuring Device Control and Calibration

8 Measurement, analysis and improvement

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8.1 General 8 Inspections and Tests 10 Preventive Actions

8.2 Monitoring and measurement 1.4 Quality System Performance Measures 8.14 Inspection and Test Records 11 Quality System Audits

8.3 Control of nonconforming product 9 Nonconformances and Corrective Actions

8.4 Analysis of data 10 Preventive Actions 11 Quality System Audits

8.5 Improvement 10 Preventive Actions

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7. PROCESS CONTROLS HOW WORK IS CARRIED OUT

7.1. OVERVIEW The construction process plan defines how project work is to be done and approved for the overall project. The construction process plan is communicated to all key personnel, subcontractors and suppliers in a startup meeting. As the project proceeds, work task plans provide additional details of how each individual work task is carried out. Work tasks planning meetings are used to communicate expectations of the work task plan to key personnel responsible for carrying out the work task.

7.2. PROJECT STARTUP AND QUALITY CONTROL COORDINATION MEETING Prior to the commencement of work, the Project Manager holds a meeting to discuss and coordinate how project work will be performed and controlled. Key personnel from [CompanyName], subcontractors and suppliers meet to review expectations for project quality results as well as quality assurance and quality control policies and procedures including:

• Key requirements of the project • The Project Quality Assurance/Quality Control Plan • Required quality inspections and tests • The project submittal schedule • Quality policies and heightened awareness of critical quality requirements • Project organization chart and job responsibilities • Methods of communication and contact information • Location of project documents and records

7.3. PREPARATORY PROJECT QUALITY ASSURANCE/QUALITY CONTROL PLAN PLANNING

7.3.1. WORK TASK REQUIREMENTS REVIEW

In preparation for the start of an upcoming work task, the Superintendent reviews an integrated and coordinated set of documents that collectively define quality requirements for the work task including:

• Objectives and acceptance criteria of the work task • Quality standards that apply to the work task • Work instructions, process steps, and product installation instructions that apply to the work task • Shop drawings • Submittals • Tools and equipment necessary to perform the work • License, certification, or other qualification requirements of personnel assigned to work • Required records of the process and resulting product • The subcontractor contracted to perform the work, if applicable • Customer contract requirements • Required quality inspections and tests • Method for clearly marking nonconformances to prevent inadvertent use • Location of quality system records and documents • Personnel training

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7.3.2. PREPARATORY SITE INSPECTION

The Superintendent also performs a quality inspection of the work area and:

• Assesses completion of required prior work • Verifies field measurements • Assures availability and receiving quality inspection status of required materials • Identifies any nonconformances to the requirements for the work task to begin • Identifies potential problems

7.3.3. WORK TASK PREPARATORY QUALITY PLANNING MEETINGS

Prior to the start of a work task, the Superintendent conducts a meeting with key company, subcontractor personnel responsible for carrying out, supervising, or inspecting the work, and interested customer representatives.

During the meeting, the Superintendent communicates the work task quality requirements and reinforces heightened awareness for critical requirements. Topics for a work task quality plan meeting include:

• Conflicts that need resolution • Required quality documents and a verification of availability to personnel carrying out,

supervising, or inspecting the work task • Record keeping requirements and the availability of necessary forms • Review methods and sequences of installation • Special details and conditions • Standards of workmanship • Heightened awareness of critical quality requirements • Quality risks • Work tasks quality inspection form

7.4. WEEKLY QUALITY PLANNING AND COORDINATION MEETINGS The Superintendent conducts a meeting with key company, subcontractor and supplier personnel responsible for carrying out, supervising, or inspecting the work, and interested customer representatives.

The meeting is held on a nominal weekly schedule. During the meeting, the Superintendent facilitates coordination among the participants, communication among the participants, and reinforces heightened awareness for critical requirements.

The Superintendent maintains a record of the meeting event on the Daily Quality Control Report.

7.5. PROCESS CONTROL STANDARDS

7.5.1. JOB-READY START WORK STANDARDS

Work on a work task starts only when conditions do not adversely impact quality, comply with government regulations, contract technical specifications, industry standards, or product installation instructions.

The Quality Manager identifies supplemental start-work requirements that apply to a specific project when they are necessary to assure quality results.

7.5.2. WORK IN PROCESS STANDARDS

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List of Included Forms

Welding Forms:

• Form QW-484A Welding Operator Qualification • Form QW-484B Welding Operator Qualification • Form QW-483 Welding Procedure Qualification Record • Form P-4A Welded Piping Inspection • Form P-4B Assembled Piping Inspection • Metals Material Receiving Inspection Report • Material Inspection and Receiving Report • Project Personnel Qualification Form • Weld Personnel Certifications and Licenses • Qualified Weld Inspector List

Standard Forms:

• Project Organization Chart Form • Quality Manager Appointment Form • Project Manager Appointment Form • Project Superintendent Appointment Form • Project Design Manager Appointment Form • Quality Controlled Task List Form • Quality Inspection and Test Plan Form • Project Quality Communications Plan Form • Point Of Contact List Form • Project Quality Training Plan Form • Task Training Plan and Log Form • Project Quality Records Plan Form • Project Submittal Form • Change Order Form • Project Design Process Plan Form • Design Review Meeting Participant Form • Design Review Form • Project Regulatory Building Codes Form • Test Equipment Calibration Form • Lot Controlled Materials Form • Project Subcontractor or Supplier Qualification Form • Subcontractor and Supplier Certifications and Licenses Form • Source of Supply Form

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• Preconstruction Meeting Form • Task Project Quality Control Plan Form • Task Project Quality Control Planning Meeting Form • Daily Quality Control Report Form • Monthly Quality Control Report Form • Task Inspection Form • Project Completion Inspection Form • Inspection and Test Report Form • Nonconformance Report Form • Nonconformance Report Control Log Form • Training Record Form • Project Quality System Audit Form • Quality System Audit Form • Project Document Control Form

Military Forms:

• Preparatory Phase Checklist • Initial Phase Checklist Form • Contractor Production Report • Contractor Quality Control Report • Testing Plan and Log

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Form QW-484A Welding Operator Qualification

http://files.asme.org/asmeorg/Codes/Publications/BPVC/16605.pdf

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[CompanyName] Project Personnel Qualification Form

Version 20130819

Name: Job Position:

Project ID Project Name Approval Approved By [ProjectNumber] [ProjectName] Yes

No

Review Topics

Project-Related Job Credentials

Certification required:

Certifications and expiration dates:

Training required:

Training completed and expiration date:

Licenses required:

License and expiration dates:

Type and length of experience required:

Certifications and expiration dates:

Qualifications

Knowledge of Company quality standards Knowledge of Company job responsibilities and authority Demonstrated skills and knowledge Demonstrated ability Demonstrated results

Qualification Notes:

Provisional Approval: Action plan for improvement

Follow-up results and date

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Metals-Structural Steel Framing 05.12.00 Feb2012

Project: Phase: Contract#: Vendor:

9101Field Operations

Crew:

Compliance Verification o Compliance with initial job-ready

requirements o Compliance with material inspection and tests o Compliance with work in process first article

inspection requirements o Compliance with work in process inspection

requirements o Compliance with Task completion inspection

requirements o Compliance with inspection and test plan o Compliance with safety policies and procedures

Reported Nonconformances and incomplete items:

FTQ 2TQ Heightened Awareness Checkpoints

o o Shop applied primer and galvanizing intact and without blemishes 2580

o o Drainage holes installed to prevent water traps with unobstructed openings 2581

o o Bearing base plates fully and evenly supported 2582

o o Connecting bolts, washers, and nuts tight and clean of dirt/rust 2583

o o Welded connections continuous, even, clean, and free of blow holes or other irregularities 2584

o o Connecting hardware and welds primed with paint of the same quality as the shop coat 2585

o o Openings in structural members approved by ENGINEER 2586

o o Spray-on fireproofing evenly applied and without gaps 2587

o o Framing members free of twist, bow, buckle, or other directional irregularity 2588

o o Framing members installed plumb, level, and true to line 2589

FTQ Scores and Completion Sign-off

Field Mgmt.-Superintendent Inspection 91.45.01

Quality 5 4 3 2 1 Notes:

On-Time 5 4 3 2 1 Notes:

Safety 5 4 3 2 1 Notes:

Sign and date*: Cell # / ID #:: _________________________________ Signed: _________________________________ Date: _________________Task has been has been verified complete and in compliance with contract drawings and specifications except for non-conformances and incomplete items reported above.

Field Mgmt.-QA Inspection 91.45.02



Quality ScoreOn-Time ScoreSafety Score

5 = 100% NO problems5 = On Time5 = 100% NO problems

4 = 1 minor problems 4 = Late 4 = 1 minor problem

3 = Hotspot or 2-3 minor3 = Late by 1 day 3 = Hotspot or 2-3 minor

2 = 6+ or major problems 2 = Late by 2 days 2= 4+ or major problem

1 = Excessive problems1 = Late more than 2 days1= Injury

Copyright 2011 First Time Quality

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Plumbing-Facility Water Distribution 22.11.00 Feb2012



Crew:








o o Piping and appurtenances are UL or NSF certified 1334

o o Fittings / Connections tight and leak free 1335

o o Piping not placed above electrical panels or switchgear 1336

o o Firestops installed at penetrations through fire partitions// fire walls// smoke partitions// or floors 1337

o o Penetrations through floor// exterior wall and roof sealed and made watertight 1338

o o Piping secured to prevent movement and chafe 1339

o o Pumps securely mounted and properly aligned with intake and discharge piping 1340

o o Flow/Pressure sensor cabling led separately or shielded from power cabling 1341

o o Service Manuals supplied to Owner 1342

o o Owner instructed in use and maintenance of Water Distribution system 1343

















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Heating// Ventilating// and Air Conditioning (HVAC)-Facility Fuel-Oil Piping 23.11.13

Feb2012



Crew:








o o Piping material/coatings/gaskets/connectors compatible with Fuel Oil 1452

o o Piping adequately supported to prevent sagging and stress 1453

o o Piping protected from chafe at all supports// clamps// and contact points 1454

o o Installed Piping system pressure tested in accordance with local regulations 1455

o o Valve operational positions (open vs. closed) clearly indicated 1456

o o Coatings and coverings intact and without scratches// pin holes// or gaps 1457

o o Piping and appurtenances are free of leaks 1458

o o Pumps// control valves// pressure relief assemblies// and vents are operational 1459

o o Vents discharge to approved areas and are free of blockages 1460

o o Readouts and indicators clearly visible 1461

















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LIST OF INCLUDED INSPECTION FORMS FOR WELDING

METALS

• Metal Decking • Metal Railings • Metal Stairs • Structural Steel Framing

PLUMBING

• Electric Domestic Water Heaters

• Facility Potable‐Water Storage Tanks

• Facility Sanitary Sewerage • Facility Storm Drainage • Facility Water Distribution • Fuel‐Fired Domestic Water

Heaters • Plumbing Fixtures • Plumbing Insulation

HVAC

• Air Outlets and Inlets • Air Terminal Units • Breechings//Chimneys// and

Stacks • Central Cooling Equipment • Commissioning of HVAC • Cooling Towers • Facility Fuel‐Oil Piping • Facility Fuel‐Storage Tanks • Facility Natural‐Gas Piping • Furnaces • Heating Boilers • HVAC Air Cleaning Devices • HVAC Ducts and Casings • HVAC Fans • HVAC Insulation • HVAC Piping and Pumps • HVAC Water Treatment • Indoor Central‐Station Air‐

Handling Units • Instrumentation and Control for

HVAC • Refrigerant Piping • Testing// Adjusting// and

Balancing for HVAC


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For More Information, contact: Ed Caldeira • Caldeira Quality, LLC • First Time Quality℠

410‐451‐8006 • www.firsttimequality.com • [email protected]

For More Information:

Contact: Ed Caldeira

410‐451‐8006

www.firsttimequality.com

[email protected]
