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Page 2 of 2

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

Inspection and Test Procedure

No.

TitleR

evisionD

ate000 509 7320

Roofing Inspection

15 Apr 11

000 509 7400 Equipm

ent 15 A

pr 11000 509 7410

Field Fabricated Tanks 15 A

pr 11000 509 7430

Refractory C

oncrete 15 A

pr 11000 509 7500

Underground Piping

15 Apr 11

000 509 7510 Aboveground Piping

15 Apr 11

000 509 7520 Pressure Testing

15 Apr 11

000 509 7560 C

hemical C

leaning of Pipe 15 A

pr 11000 509 7600

Electrical Inspection 15 A

pr 11000 509 7610

Electrical Testing 15 A

pr 11000 509 7620

Electrical Equipment

15 Apr 11

000 509 7640 Electrical H

eat Tracing 15 A

pr 11000 509 7700

Control System

s Instrumentation

15 Apr 11

000 509 7710 C

ontrol System C

alibration 15 A

pr 11000 509 7800

Coatings and Linings

15 Apr 11

000 509 7810 Insulation

15 Apr 11

000 509 7820 Fireproofing Inspection

15 Apr 11

000 509 7830 C

athodic Protection 15 A

pr 11000 509 7850

Telecomm

unication Inspection 15 A

pr 11000 509 7910

Welding Inspection

15 Apr 11

000 509 7920 N

ondestructive Examination

15 Apr 11

000 509 7930 Positive M

aterial Identification 15 A

pr 11000 509 7950

Hardness Testing

15 Apr 11

000 509 F0000 Q

uality Control Form

s 15 A

pr 11

The Fluor Site Quality Program

for this Project is described and documented in this Site

Quality M

anual.

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Page 1 of 2

Fluor Corporation C

ompany C

onfidential Site Q

uality Manual

FOR

EWO

RD

The objective of the site quality program for this project is to ensure that construction is perform

ed in accordance w

ith the drawings, specifications, applicable local law

s, and standards. A further objective is to provide docum

ented evidence that confirms that the prim

ary objective has been m

et. The site quality control program as delineated in this m

anual is tailored to meet the quality

surveillance, inspection, testing, and documentation requirem

ents for construction/installation perform

ed by subcontractors of Fluor (Morning Star).

The site quality program is based upon the principals stated in the O

perating System

Requirem

ents (OSR

) and any applicable Operating System

Implem

entation Plan (OSIP). It is

designed to cover quality aspects related to construction, construction managem

ent and m

aintenance activities.

The Site Quality M

anager will coordinate the construction quality surveillance, inspection, testing,

and documentation activities. H

e will m

onitor construction and quality activities to the extent necessary to provide construction m

anagement w

ith adequate confidence that appropriate m

easures are being taken to control and achieve quality. The quality activity will em

phasize preventing nonconform

ance to drawings and specifications but detecting and correcting it if it

occurs.

If Fluor performs construction activities using our ow

n labor force, the quality control responsibility rem

ains with Fluor. The Fluor construction supervision and construction engineering staffs are

primarily responsible for the attainm

ent of the quality requirements established by the draw

ings, specifications and contract. The supervisory, construction engineering and quality staffs w

ill perform

quality control inspection, testing, surveillance and documentation activities as outlined in

this manual. The prim

ary responsibility for performing quality w

orkmanship rests w

ith those actually perform

ing the work under the supervision of the Fluor construction staff.

When construction is subcontracted, the quality control responsibilities governing the

subcontractor's work are usually delegated to the subcontractor. The overall responsibility for

verifying quality in construction remains w

ith Fluor. This is done by surveillance and audits when

the responsibility for quality activities has been delegated to the subcontractor. The subcontractors are to provide the m

easures required to achieve the contract quality requirements.

The subcontractor's quality control responsibility is established by procedure 000 509 0210 and is stated in their contract. Both Fluor inspection form

s and ExxonMobil M

echanicalCom

pletion R

ecords will be used to docum

ent required inspections and testing. Specific contractor inspection and testing form

s may also be used w

ith prior approval.

This site specific Quality M

anual is the governing document for the Fluor quality system

and will

be maintained current to achieve project quality objectives.

This Manual is not applicable to ASM

E Boiler and Pressure Vessel Code w

ork. The Fluor "Quality

Control System

Manual for Boiler and Pressure Vessel C

ode Work" w

ill be applied to ASME and

National Board Inspection C

ode Work certified by Fluor.

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Page 2 of 2

Fluor Corporation C

ompany C

onfidential Site Q

uality Manual

The Project Procedures Manual (PPM

), used in conjunction with the Site Q

uality Manual,

contains approved procedures used to identify, document, and verify the appropriate review

s and approvals of changes to design docum

ents that are requested by field organizations and provides requirem

ents for document control.

The Fluor Construction Technology staff w

ill conduct independent audits of project compliance to

this manual. The audits are conducted to provide the Project M

anager, Site Manager, and C

lient w

ith a project independent evaluation of the site quality program status and adequacy. The initial

audit will be conducted at approxim

ately 10% m

echanical completion and additional audits on a

periodic basis throughout construction.

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Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

MA

NU

AL PR

EPAR

ATIO

N A

ND

MA

INTEN

AN

CE

SCO

PE

This procedure provides guidance for converting the 509 series of Corporate Site Q

uality procedures from

Knowledge O

nLine to a Site Quality M

anual for a specific project. It is applicable to C

onstruction, Construction M

anagement, M

aintenance, or projects with any

of these combinations.

GEN

ERA

L

The initial draft of the project specific Site Quality M

anual is initiated by Construction Technology's

Corporate Q

uality Manager. It is to be based on reference procedures of the 509 series of Site

Quality procedures from

the Construction Know

ledge Com

munity that are listed in the Table of

Contents section 000 509 0000. These reference procedures have been prepared to m

eet the requirem

ents of International Standard ISO-9000. The bracket sym

bols ([::---::]) seen throughout these procedures identify changes or additions that are to be m

ade in converting them to project

specific procedures. Other changes are to be m

ade as needed to be compatible w

ith the project requirem

ents and scope. The set of procedures in the 509 series represents the accumulated

knowledge and experience gained from

many construction projects. U

se of these reference procedures as baseline docum

ents will result in im

proved consistency between projects and

entities, thus fulfilling the goal of consistency in execution. Proposed changes to these reference procedures should be com

municated to C

onstruction Technology's Corporate Q

uality Manager.

Upon assignm

ent of the Site Quality M

anager, he/she begins development of the draft Site Q

uality M

anual (SQM

) to assure conformance to the site-specific requirem

ents. The completed and

approved project specific SQM

should be in place for usage as soon after contract award as

possible. As a minim

um, parts of the m

anual should be developed for control of construction activities before the activities are perform

ed. These activities usually begin with qualifying and

issuing RFQ

's to bidders for work to be subcontracted (see 000 509 0200 and 0210). If these

activities begin prior to assignment of the Site Q

uality Manager, C

onstruction Technology's C

orporate of Quality M

anager will function as the Site Q

uality Manager until the assignm

ent is m

ade.

Developm

ent of the Site Quality M

anual

Each section/procedure identified by 000 509 0000 is reviewed for consistency and applicability

with project scope. C

hanges or additions will be required of the follow

ing sections as noted:

- Inspection and Test Procedures (7000 7999)

- Table of C

ontents / Date R

evision Page (0000)

Under "R

evision Date."

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Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

Revision dates for all pages of all procedures in the Site Q

uality Manual should

match the dates in this Table of C

ontents.

Revisions to the Site Q

uality Manual shall not w

aiver or negate OSR

requirements

or mandatory construction codes.

Revision of Site Specific M

anual

The Site Quality M

anager controls the site issue and revision of the Site Quality M

anual. The m

anual is to be revised by procedure. A vertical line in the margin shall identify the revised

portions. The revision status shall be shown on the Title page of the m

anual. The Table of C

ontents shall show the revision date of each revised procedure and shall be reissued for each

revision.

The Corporate Q

uality Control M

anager in each of the respective offices shall review and approve

the Issued for Construction Site Q

uality Manual prior to the approval signatures being obtained.

Each subsequent revision to the Site Quality M

anual shall also be approved by the Corporate

Quality C

ontrol Manager.

The Site Q

uality Manager, C

onstruction Engineering Manager, and Site M

anager should approve each revision by signing the Approval Page. The C

lient should also be given the opportunity for approval of the Site Q

uality Manual.

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Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

OR

GA

NIZA

TION

AN

D R

ESPON

SIBILITIES

This section describes the site quality organization for performing activities described by this

manual. It also provides a general description of responsibilities. Specific responsibilities are

described in the individual procedures of this manual.

The Site Manager is responsible for the execution of the project construction activities w

hich includes construction quality. The delegation of authority to the Site Q

uality Manager for the

direction and coordination of quality activities is made w

ith the objective of maintaining the

effectiveness of this quality program.

The Site Manager shall provide adequate resources and assign sufficient trained personnel to

manage the w

ork and effectively carry out these verification activities, including internal quality audits. The personnel assigned to these verification activities shall be independent of those having direct responsibility for the w

ork being performed.

OR

GA

NIZA

TION

The project organization for site quality personnel are shown on the Site O

rganizational Chart

maintained by the Site M

anager. Contractors m

ay also have their own Q

uality Organizations

which w

ill provide for their first line of inspection responsibilities.

RESPO

NSIB

ILITIES

Quality related activities are conducted by Site Q

uality and other groups. The activities and persons conducting them

will be under the functional control of the Site Q

uality Manager for the

execution of the activity. Attachment 1- Q

uality Responsibility M

atrix summ

arizes the activities and the persons responsible for execution. Prim

ary responsibility for execution and verification of quality-related activities w

ill be established on the Inspection/Test Plan or procedures.

Site Quality M

anager

The Site Quality M

anager has the responsibility, authority, and organizational freedom to audit,

inspect and witness construction activities and to verify com

pliance to contract quality requirem

ents. This responsibility includes actions such as assist the construction staff in prevention of quality problem

s, identification of quality-related problems should they occur,

initiation or recomm

endation of solutions and verification of corrective action. In addition, he/she is responsible for coordination of quality-related activities w

ithin the Construction staff and w

ith the site C

lient quality representatives. He/she m

aintains the construction quality control procedures and provides technical assistance and training to construction supervision. H

e/she will have an

active role in assisting with the prevention of quality problem

s.

The Site Quality M

anager reports directly to the Site Manager w

ith a technical supervision channel to C

onstruction Technology's Corporate Q

uality Manager.

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Page 2 of 2

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

The Construction staff includes a C

onstruction Engineering organization to ensure prompt

engineering interpretations and decisions, review of draw

ings, certificates and other data to be subm

itted to the Client, and to actively participate in the surveillance of field construction, and to

verify compliance to design/engineer requirem

ents. Construction Engineering w

ill provide assistance to the Site Q

uality Manager as necessary to assist in achieving quality objectives.

NO

TE: C

onstruction Engineers report to the Site Quality M

anager when they are

executing inspection/surveillance activities.

Subcontractors

The subcontractor quality organization will be in accordance w

ith the contract requirements and

described in their approved equivalent Site Quality M

anual.

ATTA

CH

MEN

TS

Attachments 1 -

Quality R

esponsibility Matrix

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Attachment 1 . . . Page 1 of 14

PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R

esponsibility S=Secondary R

esponsibility (1) M

ust obtain Engineering Approval

Quality R

esponsibility Matrix

Section 1 - CIVIL

1.1 Construction Surveying

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Review

the construction surveying methods used by the C

ontractor. X

Check established reference points .

XC

heck control points established for construction layout on a periodic basis. X

Check the construction layout of the contractor's w

ork. X

Review

and file completed survey notes prepared by the contractor.

X

P

erform periodic surveillance on survey activities and docum

entation.

X

1.2 Soils R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor in-process soils work, including cut and fill elevations, spoil and fill m

aterial, compaction

methods and equipm

ent. X

Perform

formal audit of S

oils Testing Laboratory X

Monitor C

ontractor's work to verify conform

ance to requirements.

X

S

Monitor S

oil Testing Laboratory activities for soils testing frequency, test identification and com

pleteness. X

Verify the docum

entation of deficiencies and test failure and follow up to assure corrective action

is taken and documented.

X

Audit the soils docum

entation to verify correctness, completeness of coverage, retrievability as

filed and inspection results. X

Perform

and document soils testing

TES

T LAB

S

Inspect excavations for unstable and unsuitable soils TE

ST LA

B

SV

erify the insitu soils are suitable to support foundation loads TE

ST LA

B

SV

erify backfill material is satisfactory

TEST LA

B

SV

erify placement of the fill com

plies with contract specifications

TES

T LAB

S

1.3 Contracted Piling

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Qualify Pile Supplier

XR

eview and approve concrete m

ix design and mix trials

X (1) Technically m

onitor the indicator pile testing program

XC

heck final pile locations. X

S

Monitor in-process pile driving.

XS

M

onitor and test pile concreting activities. X

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PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


1.4 Asphalt

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Review

asphalt mix designs

X (1)

Monitor in-process asphalt construction including preparation of subgrade or previous course,

asphaltic materials, spreading equipm

ent, compaction equipm

ent, materials and testing.

XS

Perform

formal audit using A

sphalt Test Laboratory Evaluation R

ecord X

Monitor C

ontractor's quality control activities to verify conformance to requirem

ents for asphalt testing frequency, test identification and traceability and the docum

entation of inspection and testing

X

Review

the documentation of the asphalt inspection and testing activities for accuracy and

completeness.

X

Verify the docum

entation of deficiencies and test failures and follow up to assure corrective

action is taken and documented.

X

Audit the asphalt docum

entation to verify correctness, completeness of coverage, review

ability as filed and inspection results.

X

Conduct asphalt testing and asphalt m

aterials testing TE

ST LA

B

S

1.5 Structural Concrete

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Review

and approve mix designs

X (1)

S

Perform

formal audit of C

oncrete Testing Laboratory. X

Audit batch plant facilities.

XInspect form

work, reinforcing steel and im

pediments prior to concrete placem

ent. X

S

Monitor in process concreting activities.

XS

Monitor C


ents for concrete testing frequency, test identification and traceability, and the docum

entation of inspection and testing.

X

Monitor post-concreting activities such as concrete curing, stripping, visual exam

ination for line, form

and surface defects and checks for anchor bolt locations. Verify that 28-day strength tests

are acceptable. X

S

Conduct concrete testing at the point of placem

ent TE

ST LA

B

S

1.6 Grouting of M

achinery and Structural Steel Base Plates

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Review

and approve mix design. C

heck materials prior to start of w

ork to verify that the m

aterials have not deteriorated or that shelf life has not been exceeded. X (1)

S

Monitor in-process grouting. The inspections shall include base preparation,m

aterials, forming,

placing, curing and hamm

er void test. X

S

Witness grout testing by C

ontractor. X

Monitor the C

ontractor's quality control activities to verify conformance to placem

ent procedures and docum

entation requirement.

X

Conduct grout testing at site

TEST LA

B

S

West Q

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Contract N

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PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M

ust obtain Engineering Approval Section 2 - STR

UC

TUR

AL STEEL

2.1 Structural Steel R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor in process steel erection to verify fabrication is correct and erection is in accordance w

ith drawings. D

ocument fabrication errors on a N

CR

. X

S

Witness bolting procedure including calibration of torque w

renches and load indicating washers.

XS

Maintain docum

entation X

Inspect the erected steel structure. X

Ensure that erected steel structures have coatings installed i.a.w

. drawings

X

S

Monitor the C

ontractor's quality activities to verify conformance to requirem

ents for bolt tensioning procedures.

X

Schedule final acceptance inspection activities betw

een Contractor and Field E

ngineering or construction.

XS

Audit the structural steel docum

entation to verify correctness of data.

X

Section 3 - BU

ILDIN

GS

3.1 Buildings

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Review

all Contractor proposed building m

aterials prior to use. X

(1)

Verify that the building location level and position are correct prior to construction.

XInspect the entire building upon com

pletion and document deficiencies.

X S

Docum

ent building acceptance X

Monitor the in process construction to verify that the w

ork is i.a.w. draw

ings. X

SS

chedule final acceptance activities X

SM

onitor the Contractor's quality control activities to verify test frequency, identification and

traceability X

Audit building docum

entation X

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PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


Section 4 - EQU

IPMEN

T 4.1 Equipm

ent R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CInspect installed equipm

ent for acceptance upon completion, including attachm

ents to the equipm

ent, e.g. foundations, sheds, buildings, auxiliaries, etc. which com

prise the entire assem

bled unit. X

Initiate action to acquire vendor representative as required. P

MC

oordinate with engineering for participation of m

echanical discipline engineers, if required. P

MM

onitor the in-process installation of each equipment unit.

XS

Coordinate w

ith vendor representative who technically supervises equipm

ent installation. X

Verify vendor representative's checklists and acceptance records are signed and attached to

appropriate construction documents.

XS

Verify the equipm

ent requirements are being satisfied by the C

ontractor. X

S

M

onitor equipment preservation i.a.w

. Site requirem

ents. X

Monitor the C

ontractor's quality control activities to verify conformance to inspection, testing and

documentation requirem

ents. X

4.2 Field Fabricated Tanks R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor the foundation construction including soils, asphalt and concrete work.

X

S

Check elevation dim

ensions of tank shells. X

Check the erected dim

ensions of tank shells. X

S

Inspect fabricated tank structure upon com

pletion. X

S

C

heck the settlement and rebound of the foundation during and after hydrotest.

XS

Verify w

elder performance qualifications.

SX

Verify welding procedure testing has been accom

plished and procedures are acceptable.

X M

onitor in-process welding

XS

Witness in-process exam

ination as performed by the N

DE

contractor, including reviewing

radiographs, witnessing P

T, MT, vacuum

box and leak testing X

Verify that equipm

ent and components associated w

ith tankage have been correctly installed, adjusted, tested, confirm

ed for proper function and inspected. X

S

Inspect the tested tank prior to closing, including final clean-up. X

SV

erify that the Contractor has affixed a nam

eplate listing the required data. X

S

V

erify that the Contractor has subm

itted the required certification. X

S

Monitor the C

ontractor's quality control activities to verify conformance inspection, testing and

documentation requirem

ents. X

Witness hydrostatic testing

SX

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PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


Section 5 - PIPING

5.1 U

nderground Piping R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor in-process excavation and backfill. X

SInspect installed underground pipelines for acceptance.

X S

Color code the lines, indicated as punched and accepted, on a copy of the underground piping

plan. X

Verify that the Testing Lab is perform

ing the required soils testing of backfill. X

S

M

onitor in-process coating and wrapping, including surface preparation, coating and w

rapping m

ethods and materials and arrangem

ent for intermediate storage and stockpiling of coasted

pipes.X

S

Inspect in-process pipe fabrication and installation i.a.w. draw

ings. X

SP

erform a final inspection of the line, w

hen the underground piping is complete, but prior to the

coating and wrapping of joints and fittings.

XS

Verify the C

ontractor has completed coating and w

rapping of joints and fittings on tested line. X

S

W

itness holiday testing of the coating and wrapping. C

ontractor shall document tests.

XS

Verify that required N

DE

is complete on the lines to be inspected.

XW

itness the pressure test. S

X Inspect the tested system

to ensure that all items have been properly com

pleted (restoration). X

S

M

onitor the Contractor's quality control activities to verify conform

ance to testing and docum

entation requirements.

X

5.2 Site Shop Fabrication R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CS

egregate and store pipe fittings, upon receipt, according to size and material. Identify storage

location with com

modity code num

ber. M

M

Pipe w

ill be marked full length w

ith comm

odity code number.

MM

Maintain docum

entation M

MIssue piping m

aterials to Contractors

MM

Inspect special flange faces for correct finish and face protection. X

SM

onitor in-process pipe fabrication activities. X

SV

erify latest edition of piping drawings is being used.

XS

Random

check on base material ID

on pipe, fittings and spools. Spools shall be clearly

identified in two locations.

XS

Monitor storage of com

pleted spools at pipe shop including preservations. X

S

M

onitor pipe identification, documentation and tim

ely performance of N

DE

. X

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Contract N

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PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


5.3 Aboveground Piping Erection R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CP

ipe will be m

arked full length with com

modity code num

ber. Alloy pipe and fittings shall be

additionally color coded. Alloy storage areas shall be clearly identified.

MM

Maintain piping spool identity m

arkings of piping spools fabricated off site. M

MV

erify MTR

's are received and that heat numbers correspond. M

aintain documentation

MM

Verify P

MI requirem

ents are satisfied prior to placement in stock.

MM

SV

erify correct pipe is issued to Contractor.

MM

Monitor in-process erection I.a.w

. drawings. C

lassify and record spool fit problems.

X

S

Ensure face flange protection is m

aintained. X

SM

onitor proper bolt tensioning. X

S

Monitor correct gasket installed.

XS

M

onitor erection to ensure that pipe installations are not subjected to undesirable stress. X

SC

heck pipe drawings to assure latest revision in the field.

XS

Assist C

ontractor to maintain current piping test status.

S

X

Monitor C

ontractor's activities to established quality control practices.

X

Monitor in process pipe erection and transfer of heat num

bers. Verify that N

DE

is performed in

a timely m

anner. Monitor pipe and w

elding traceability including PW

HT, P

MI and H

ardness Testing.

X

5.4 Piping Inspection - Punching R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CFlag deficiencies w

hen not visually obvious. X

E

nter punch lists into data base. X

Check w

ork, noted as complete, on punch lists to assure item

s were corrected.

XInitiate action w

ith Contractor on punching results. A

dd additional discrepancies to punch list. Initial and date punch list for each item

corrected. X

Monitor the C

ontractor's punching activities. X

Verify that punching deficiencies are identified, docum

ented and follow up to verify corrective

action is taken. X

Verify that m

easures are taken to assure ND

E, P

WH

T, PM

I and traceability is completed prior to

pressure testing. X

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PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


5.5 Pressure Testing of Piping R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor pressure testing performed by C

ontractor. X

SR

eview draw

ings and specifications to verify pressure test package limits, equipm

ent to be included or excluded, valves opened or closed and test blind locations.

XS

Verify that the m

aximum

allowable test pressure of the w

eakest component w

ithin the system is

not exceeded. X

S

Verify (through N

EW

S) that all N

DE

is complete prior to testing.

S

X V

erify that shop spool/cut sheets are included in test packages and all ND

E, P

WH

T and welder

info is recorded. S

X

Review

Contractor's pressure test package, including m

arked up isometric draw

ings indicating test blind locations, valve position (open/closed) and other inform

ation relating to test. X

S

Monitor preparation of test system

against test package. X

Monitor restoration of the tested system

. X

Monitor C

ontractor's pressure testing and documentation activities.

S

X

Review

test package for completion

SX

Inspect the system prior to testing notifying C

ontractor of deficiencies. Mark P

ressure Test R

ecord, "Ready to Test". N

otify client when acceptable for test. G

ive permission to proceed

with test.

XS

Inspect system under pressure. V

erify test pressure and duration of test. Procure test

acceptance signatures from C

ontractor and QIB

. S

X

When equipm

ent is included in the test, verify that pressure test does not exceed nameplate.

X

S

5.6 Piping Internal Cleaning

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Review

and approve the cleaning and preservation procedures and the limits agree w

ith draw

ings. X

Establish hold points for w

itnessing tests. X

Monitor preparatory and in-process cleaning activities for com

pliance with procedures and

specs.X

S

Coordinate the m

onitoring of Contractor inspection and testing activities.

XS

Verify the C

ontractor is preparing documentation as inspections and tests are being perform

ed. X

S

V

erify that internal cleaning has been accomplished.

XM

onitor the Contractor's quality control activities.

X

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


Section 6 - ELECTR

ICA

L 6.1 U

nderground Electrical R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

C

Monitor in-process installation of the grounding system

including, grounding rod installation, backfilling. C

olor coding of drawings to track progress.

XS

Witness resistance to earth tests.

X S

M

onitor in-process duct bank and electrical manhole installations.

X

Witness initial testing of shielded cable, i.e,. insulation resistance test of pow

er cable on reels, continuity test of reeled instrum

ent cable. X

S

Inspect cable trench prior to installation of cable. X

Monitor in-process installation of underground cable. Inspect in-process cable pulling.

X

S

Inspect in-process cable splicing. X

S

Witness random

testing of installed underground cable, i.e. insulation resistance test (megger)

cables and DC

hypot medium

and high voltage cables prior to termination.

XS

Inspect installation of cables upon completion of each layer to ensure spacing, labeling, etc. is

correct.X

S

Inspect sand backfill per lift for quality of materials, depth and com

paction. X

SV

erify the Contractor final as-built draw

ings are in conformance.

X

S

Verify that the C

ontractor is preparing documentation concurrent w

ith construction as inspection and testing are perform

ed. X

S

Monitor the C

ontractors' quality control activities.

X

6.2 Aboveground Electrical R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor in-process installation of electrical conduit and cable tray, including welding of supports.

X

Witness initial testing of shielded cable, i.e., insulation resistance test of pow

er cable on reels, continuity test of reeled instrum

ent cable and resistance and continuity on electrical heat tracing cables.

XS

Monitor in-process cable pulling and installation.

XW

itness random testing of installed cable, i.e., insulation resistance test on pow

er and instrum

entation cables, continuity and insulation resistance testing on heat tracing and hypot of m

edium and high voltage cables.

XS

Verify client is being notified in advance of tests that require w

itness. X

S

V

erify terminal to term

inal checks to ensure continuity and correctness of installation. X

S

Verify conduit seals have been poured.

XS

Inspect installation upon completion.

XS

Verify that the C



ed. X

S

Monitor the C

ontractor's quality control activities.

X

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


6.3 Electrical Equipment

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Monitor in-process installation of equipm

ent. X

S

M

onitor equipment preservation activities

XS

Witness testing of installed equipm

ent. X

SC

oordinate with vendor representative w

ho will technically supervise installation. E

nsure docum

entation is complete.

XS

Verify Q

IB is being notified in advance of tests requiring w

itnessing. X

SInspect electrical installation w

hen complete.

XS

Verify that the C



ed. X

S

Monitor the C

ontractor's quality control activities.

X

Section 7-CO

NTR

OL SYSTEM

S 7.1 C

ontrol Systems Site Shop O

perations R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CN

otify construction upon receipt of each instrument shipm

ent for inspection. M

M

For nonconform

ing items, issue a D

amage R

eport or NC

R.

MM

Issue instruments to C

ontractor. M

MInspect each instrum

ent shipment. D

eficiencies shall be reported to the Material M

anager. X

Inspect instrument m

aterials i.a.w.sec.10 &

project procedures X

Docum

ent the receiving inspection. X

7.2 Control System

s Field Operations

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Monitor the C

ontractor's in-process instrument installation including racks, panels, consoles,

locations,mounting,process pipe connections, Instrum

ent air tubing,pneumatic signal tubing,heat

tracing and instrument w

iring X

S

Witness pressure testing of the instrum

ent piping and tubing documentation.

X

S

Witness calibration of test guages.

XS

Monitor continuity tests of instrum

ent cables.Verify that cable term

inations are correct. X

SW

itness checks of control system loops. E

stablish notification system for IM

T. X

S

W

itness all loop checks X

S

Assure all instrum

ent installation inspections and meggar tests are com

plete X

S

Inspect instrum

ent installations upon completion.

XS

Monitor the C

ontractor's quality control activities. S

X

Verify docum

entation procedures are being followed.

XS

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


Section 8 - CO

ATIN

GS, LIN

ING

S, INSU

LATIO

N A

ND

CA

THO

DIC

PRO

TECTIO

N

8.1 Coatings

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Ensure that the paint system

is i.a.w. specifications.

X

S

Monitor perform

ance of materials preservation activities.

XS

Monitor surface preparation.V

erify inspection documentation.

XS

Monitor in-process coatings applications.

XS

Check dry film

thickness of applied coatings. X

SInspect the w

orkmanship of com

pleted finishes. X

SM


S

X

Verify the C

ontractor has prepared the QC

documentation.

S

X

Audit coating docum

entation. X

8.2 Insulation R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor performance of m

aterial preservation activities. X

Monitor in-process installation of the insulation m

aterials. X

SV

erify the Contractor has prepared the quality control docum

entation X

S

Inspect the com

pleted work.

XS

D

ocument acceptance.

SX

8.3 Linings R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor performance of m

aterial preservation activities. X

S

M

onitor surface preparation. X

S

Verify C

ontractor is performing tem

perature and humidity checks for tank linings.

X S

Monitor in-process lining application.

XS

Test applied linings to verify proper surface profile, thickness, and lining continuity. X

SM

onitor Contractor's tank lining holiday inspections.

XS

Observe tank lining curing activities.

X S

Inspect the w

orkmanship of the com

pleted lining. X

S

M


S

X

Audit coating docum

entation. X

Verify that lining m

aterials comply w

ith specs. Ensure that m

anufacture test certificates correspond w

ith filed batch number records.

XS

Monitor storage facilities.

XE

nsure refractory applicators are experienced and qualified. X

SM

onitor to ensure materials are properly m

ixed. X

SM

onitor surface preparation to ensure mounting studs and reinforcem

ents are correctly installed. X

S

E

nsure that test plates,cubes,etc,from refractory applications are taken at the required

frequencies X

S

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


8.4 Cathodic Protection - U

nderground Structures. R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CSubm

it data to Engineering for determination of anode spacing

X (1) E

stablish a procedure to assure work is not started prior to acceptance of previous w

ork. X

Monitor the survey after each cathodic protection system

is energized. X

SV

erify materials being installed.

XM

onitor installation activities. X

S

Monitor deep w

ell preparation activities including data logs. X

Monitor anode backfill operation.

XW

itness hamm

er testing of thermite w

elds X

SW

itness electrical test used to determine current flow

when the anode is backfilled w

ith coke breeze.

XS

Monitor testing and com

missioning activities.

XS

Inspect the completed w

ork. X

S

Audit cathodic protection docum

entation.

X

8.5 Cathodic Protection - Tanks and Vessels

RESPO

NSIB

ILITY A

CTIVITY

Construction

QA

/QC

Verify m

aterials are within specification and are properly protected from

damage.

X

V

erify the vessel cathodic protection materials w

ere installed. X

Monitor installation activities

XS

V

erify personnel use of protective clothing (when reg's)

XInspect the com

pleted workm

anship. X

SM

onitor testing and comm

issioning activities. X

SA

udit cathodic protection documentation.

X

Section 9 - WELD

ING

9.1 Pipe W

elding R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CV

erify the WP

S's have been approved by the W

elding Engineer.

X (1)

S

Monitor qualification tests of C

ontractor's welders.

X

E

nsure that welder ID

badges have been issued and displayed. X

SC

heck Contractors control of w

elder symbols.

XS

Check C

ontractor's control of welding consum

ables. X

SM

onitor in-process welding including consum

ables, joint preparation,fit-up preheat, interpass heat, W

PS

variables and final visual X

S

Verify C

ontractor is documenting w

elds on the Daily W

elding Report.

XS

Verify completed w

elds are being documented on piping draw

ings. X

SM

onitor in-process post weld heart treatm

ent. X

SA

udit welding docum

entation. X

Verify transfer of piping m

aterial heat numbers.

XS

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


9.2 Structural and Reinforcing Steel W

elding R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CV

erify the WP

S's have been approved by the W

elding Engineer.

X

(1) M

onitor qualification tests of welders.

X

Monitor in-process w

elding including consumables, joint preparation and final visual inspection.

XS

Audit w

elding documentation.

X

9.3 Piping Nondestructive Exam

ination (ND

E) R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CPre-qualify N

DE C

ontractor X

Verify that the N

DE

Contractor has established procedures that com

ply with project

specifications. X

Daily entry of w

eld data to NE

WS

program.

SX

Establish and maintain N

DE docum

entation files.

X R

eview C

ontractor ND

E personnel certifications.

X

V

erify approval of ND

E C

ontractor and procedures. X

Verify N

DE

Contractor's procedure to provide visual status of w

elds requiring ND

E.

X

S

elect welds for exam

ination S

X

Perform

Nondestructive exam

inations N

DE

CO

NTR

AC

TOR

S

Review

radiographic film, C

ontractor's interpretation and reports. X

Verify code com

pliance for rejected welds.

XM

aintain a tickler file of rejected welds.

XV

erify, through audit, welding and N

DE

records are traceable to the weld.

XV

erify through NE

WS

that ND

E is com

pleted prior to pressure testing.

X

Audit the N

DE

lab X

Monitor the N

DE

Contractor's production to verify that w

elds are examined w

ithin 48 hours of notification.

X

Verify all field welds are num

bered and identified on drawings.

XE

nsure that weld num

ber and welder's sym

bols are low stress stam

ped or otherwise m

arked on pipe.

XS

Ensure that an accurate D

aily Welding R

eport is maintained.

SX

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


9.4 Pipe hardness Testing R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CM

onitor the Contractor to verify w

eld identity system and com

pliance to specification.

X

Establish confidence that tests are being preform

ed i.a.w. test equipm

ent instructions.

X

Verify the C

ontractor's compliance w

ith hardness testing and documentation.

X

V

erify Contractor's procedure for visual identification of rejected w

elds.

X

Maintain a P

WH

T tickler file for rejected welds.

XV

erify hardness testing is complete prior to pressure testing.

XW

itness tests required by the specifications as performed by C

ontractor.

X

Schedule final acceptance inspection activities betw

een the Contractor and the Field E

ngineer.

X

Monitor the C


ents for test frequency, identification and traceability.

X

Section 10 - Field Receiving

10.1 Field Receiving (IM

T) R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CC

ontrol receiving operations including ID of item

to purchase order, verification of quantity and size exam

ination for shipping protection and damage, m

aintenance of inspection docum

entation. M

M

Issuance of periodic receiving reports to Construction S

uperintendents when technical

assistance is required. M

M

Inspect received material/equipm

ent, providing technical assistance, when requested.

S

X

10.2 Field Receiving -C

ontractor R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CR

eceive all contractor purchased equipment and m

aterials M

MR

eview m

aterial test reports against received materials and m

aintain on file M

M

S

Issue equipment and m

aterials to the Contractor

MM

Inspect received material/equipm

ent, providing technical assistance when requested

X

S

Assure that the contractor perform

s the equipment and m

aterial protection as required by m

anufacturers instruction or specification requirements

XS

West Q

urna I 000 509 0040

Contract N

o: W3Q

R



PM=Procurem

ent Manager

MM

=Material M

anager X

=Primary R


esponsibility (1) M


10.3 Positive Material Identification (PM

I) R

ESPON

SIBILITY

AC

TIVITY C

onstruction Q

A/Q

CN

otify QA

of receipt of material requiring P

MI.

MM

Maintain P

MI test results w

ith receiving documentation.

MM

Verify receipt of P

MI reports from

suppliers and fabricators, M

MV

erify Contractor has established a system

to maintain m

aterial ID through receiving, storage,

issue, fabrication and election. X

Implem

ent procedures for PM

I. X

Monitor contractor's m

aintenance of piping material identification.

XS

Perform

PM

I as required by specification. X

Verify ID

marking are accom

plished per specification. X

SV

erify controls have been established to prevent the in advertent use of materials failing

examination.

SX

Verify the filing, m

aintenance and retention of documentation.

XA

ssure that PM

I equipment is calibrated.

X

Section 11 - EQU

IPMEN

T AN

D M

ATER

IAL PR

OTEC

TION

11.1 Equipm

ent and Material Protection

RESPO

NSIB

ILITY A

CTIVITY

Construction

QA

/QC

Monitor equipm

ent and material preservation in storage and docum

ent. M

M

S

11.2 Equipment and M

aterial Protection (Contractor)

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Monitor C

ontractors in-process equipment and m

aterial protection/preservation activities. X

SC

heck Contractors in-process equipm

ent and material

XS

Audit the C

ontractor Material and equipm

ent protection activities. X

Section 12 - Masterpiece Program

12.1 M

asterpiece Program

RESPO

NSIB

ILITYA

CTIVITY

Construction

QA

/QC

Develop M

asterpiece List X

S

Ensure C

ontractor is using correct materials, draw

ings and specifications X

S

A

dvise contractor when a M

asterpiece is required X

SInspect M

asterpiece prior to QA

notification X

SR

equest client's presence during inspection S

XD

ocument acceptance of the M

asterpiece S

X N

otify client of accepted Masterpiece

SX

Maintain the M

asterpiece log X

Maintain M

asterpiece model as reference standard

XS

Monitor the C

ontractor's quality control activities to verify conformance to draw

ings and specifications

X

West Q

urna I 000 509 0050

Contract N

o: W3Q

R

15 April 11Project Location: Basra, Iraq

Page 1 of 3

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

DO

CU

MEN

T CO

NTR

OL

SCO

PE

The Project Procedures Manual describes the D

ocument C

ontrol system to be used by site

construction personnel.

GEN

ERA

L

Engineering Docum

ents

- D

esign Engineering documents such as specifications and draw

ings that are issued to C

onstruction are controlled and issued on site in accordance with this procedure.

Construction Engineering m

aintains an up-to-date register of drawings and

specifications.

- Please see the Project Procedures M

anual, Sect. 15.4.4 Project Docum

ent and Data

Managem

ent (PDD

M) at the Site for specific details.

Request For Inform

ation

- D

esign documents, including draw

ings and specifications, sometim

es have discrepancies, conflicting inform

ation, or missing inform

ation. When field conditions

dictate changes to the design specifications and/or drawings, a R

equest For Inform

ation (RFI), Form

000 509 F00501, will be subm

itted for approval to ensure proper control and docum

entation. RFIs w

ill be initiated by the Construction

Engineering Manager w

ho will m

aintain a RFI Log, Form

000 509 F00502.


anual, Sect. 11.4.2 for specific detail for this procedure.

Specification Deviation

- If the R

FI is written to request a deviation from

a specification then a SpecificationD

eviation Request (SD

R) Form

shall be initiated by the Fluor Field Engineer. This requires D

esign Engineering and Client Approval before the deviation can be

approved. Reference the Fluor Engineering Procedure, Section 8 of the Project

Procedures Manual.

As-B

uilt Draw

ings

- Subcontractor prepared field sketches and "as-built" draw

ings originating at the construction site shall be docum

ented and controlled.


anual, Sect 11.5 for specific details.

West Q

urna I 000 509 0050

Contract N

o: W3Q

R


Page 2 of 3

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

Material/Equipm

ent Docum

ents

- D

ocuments related to m

aterials, materials receiving and issue are controlled in

accordance to procurement procedures.

Quality C

ontrol Docum

ents

-D

ocuments and data identified as quality records are processed, retained and protected

as described in 000 509 0160 "Quality R

ecords". Primary responsibility for ensuring

adequate control of quality related documents rests w

ith the Site Quality M

anager.

DO

CU

MEN

T AU

DITS

Construction Engineering M

anager

- D

etermine docum

ent audit plan and schedule audits. A minim

um of 5%

of documents

issued to the document holder w

ill be randomly selected for the audit sam

ple. The num

ber of document holders to be audited w

ill be determined by the C

onstruction Engineering M

anager.

Docum

ent Control

-U

sing a printout or list of documents and current revisions, com

pare documents and

revisions held by document holders and note any discrepancies. N

otify the C

onstruction Engineering Manager of m

ajor discrepancies.

Construction Engineering M

anager

- For m

ajor discrepancies identified by Docum

ent Control audits of docum

ents, investigate and provide recom

mended resolution.

Revision C

ontrol of the Site Quality M

anual

- Site Q

uality Manager

- R

evision dates for all pages of all procedures in the manual should m

atch the dates in the Table of C

ontents.

- The Site Q

uality Manager, C

onstruction Engineering Manager, Site M

anager and the C

lient (optional) will approve each revision by signing the "Approval Page".

- Forw

ard the approved revision and affected documents to D

ocument C

ontrol for m

aintenance and distribution to all manual holders.

West Q

urna I 000 509 0050

Contract N

o: W3Q

R


Page 3 of 3

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

REFER

ENC

ES

Project Procedures Manual - Sections 8,11, and 15 for PD

DM

Procedures

Quality C

ontrol Forms:

000 509 F00501 R

equest For Information

000 509 F00502 - Request For Inform

ation Log

ATTA

CH

MEN

TS

Attachment 1 R

equest For Information (R

FI) Form Instructions

West Q

urna I 000 509 0050

Contract N

o: W3Q

R



Request for Inform

ation (RFI) Form

Instructions

Project N

ame:

The P

roject Nam

e (i.e. West Q

urna I)

Project #:

The P

roject Num

ber (i.e. W3Q

R)

Date:

The date the R

equest is originated.

RFI #:

U

nique number given to each individual R

FI Form.

WB

S:

W

ork Breakdow

n Structure unique to the P

roject, if applicable

Work P

ackage No.:

C

onstruction Work P

ackage number, if applicable.

Turnover/Startup S

ystem N

o.: Turnover/S

tartup system num

ber, if applicable.

Discipline:

P

rimary discipline affected by the R

equest (Civil, S

tructural, Piping etc.)

Request To:

E

nter Nam

e of Individual submitted to (John D

oe)

Com

pany/Location

Enter N

ame of C

ompany and its location of the requested organization

(Fluor-Houston)

Phone N

umber/E

mail

E

nter phone number of the individual subm

itted to and/or email address

Subject

E

nter the subject of the request

Specifications/D

ocuments:

List all issued drawings, docum

ents, and specifications impacted by the

request.

Questions/D

escription/Conflict:

Detail the m

issing information, discrepancies, questions or conflicts that

must be resolved prior to construction activities continuing in the affected

areas. Attach additional sheets, draw

ings, or sketches, if further explanation is required.

Recom

mended S

olution: Indicate the action that the requestor believes is required to provide an acceptable solution to resolve the discrepancies and conflicts indicated on the request. A

dditional sheets, sketches, digital photos or drawings

may be attached to provide a clear explanation of the intended

resolution.

Originated B

y: The person originating the request and provided recom

mended action.

Title: List the current position of the originator on the project.

Date:

The date the request is submitted for approval.

Originators C

ompany N

ame

List Com

pany name of the originator

Approval For O

riginator By

List name of Fluor person approving the request for subm

ission to the E

ngineer of Record (G

enerally, the Fluor Site E

ngineering Manager w

ill receive the request and approve its subm

ission to the Design E

ngineer.)

Title: List the current position of the approver.

Date:

The date the request is approved for submission

West Q

urna I 000 509 0050

Contract N

o: W3Q

R



Date R

eply Required:

Enter the date in w

hich the resolution of the request must be m

ade in order not to delay the activities in question

Response

The respondents resolution (generally the Design Engineer, P

roject E

ngineering Manager, C

M, or Fluors C

onstruction Engineering

Manager) to the question, inform

ation, discrepancy, or conflict.

Respondent:

The signature of the person making the response. (Lead C

onstruction D

iscipline Engineer, C


anager or Design Lead

Discipline E

ngineer, etc.)

Title: List the current position of the A

pprover on the project.

Date:

The date the request is approved for transmittal to the D

esign Engineer.

Approval for R

espondent: The signature of the person review

ing and approving the request prior to im

plementation. (This action m

ight require Client approval. If the

response changes the design (IFC D

rawings or S

pecifications) the E

ngineer of Record m

ust approve the resolution.)

Title: List the current position of the A

pprover on the project.

Date:

The date the request is approved for implem

entation by the Client or

Project E

ngineering Manager or designee.

Adequate C

losure? Indicate using the checkbox if the R

FI response is acceptable for closure of the R

FI. Generally, the C


anage must

respond to this question.

Cost Im

pact? Indicate using the checkbox if the R

FI response has a cost impact that

will require an estim

ate or a request for contractor pricing. If the answer

is yes, indicate the requirement for a S

I to be issued to the Contractor.

Schedule Im

pact? Indicate using the checkbox if the R

FI response has a schedule impact

that will require an adjustm

ent in the contract schedule or a request for contractor pricing. If the answ

er is yes, indicate the requirement for a S

I to be issued to the C

ontractor

Closed R

FI and Date V

erified: Inter the nam

e and date the RFI w

as closed and verified.

Distribution:

List all parties requiring a copy of the completed request once the

response has been received.

West Q

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Contract N

o: W3Q

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15 Aug 10Project Location: Basra, Iraq

Page 1 of 2

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

PRO

CESS C

ON

TRO

L

SCO

PE

This procedure identifies construction work processes that require process control.

GEN

ERA

L

For most site production activities, the draw

ings and specifications provide adequate work

instruction. These may be supplem

ented with additional instructions to control w

ork sequencing, recording of installation data, m

aterial selection, etc. How

ever, certain construction work

processes require special instructions to establish the controls necessary to achieve acceptable quality, of the com

pleted work, for the follow

ing reasons:

Q

uality results of the completed w

ork cannot be fully verified by subsequent inspection and/or testing.

Q

uality deficiencies may only becom

e apparent after the item has entered service or

operation.

Special Processes

"Special processes" are highly dependent on the control of process parameters or the skill of the

operator or both and are characterized by the need for one or more of the follow

ing control m

easures.

x W

ritten Method Statem

ent or Procedure x

Procedure Qualification

x O

perator Qualification

x In-Process Inspection

Special processes encountered on sites include, but m

ay not be limited to:

x W

elding and Post Weld H

eat Treatment

x W

elder Qualification

x N

ondestructive Examination (including radiography, m

agnetic particle, liquid penetrant, ultrasonic, and positive m

aterial identification VT, RT, M

T, PT, UT, and PM

I)

Special processes identified m

ust be accomplished and docum

ented under controlled conditions by appropriately qualified personnel using approved procedures and equipm

ent in accordance w

ith the governing specifications and the associated referenced codes and standards.

West Q

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Contract N

o: W3Q

R

15 Aug 10Project Location: Basra, Iraq

Page 2 of 2

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

PRO

CED

UR

E

Site Quality M

anager

The Site Quality M

anager shall coordinate with the C

onstruction Engineering Manager, to

research the project contract work scope and specifications in order to identify the special

processes that will be utilized. If the processes are to be contracted, ensure that the

required control mechanism

s, i.e. procedures, qualifications, etc. are specified in the RFP

and implem

ented before the start of work. Process control m

easures and responsibilities shall be identified on the applicable procedures or ITPs.

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o: W3Q

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Page 1 of 4

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

INSPEC

TION

, MEA

SUR

ING

AN

D TESTIN

G EQ

UIPM

ENT

SCO

PE

This procedure describes the methods to be used for the control, calibration, m

aintenance and recall of inspection, m

easuring and test equipment (IM

TE) used to demonstrate conform

ance of construction w

ork activities to the specified requirements. It is not applicable to calibration of

permanent plant devices.

GEN

ERA

L

Inspection, measuring and test equipm

ent (IMTE), including test softw

are, shall be selected, calibrated and controlled in a m

anner which is consistent w

ith the required inspection, testing and exam

ination requirements.

Environmental conditions shall be suitable for the calibrations, inspections, m

easurements and

tests being carried out.

All IMTE shall be uniquely identified. This unique identification m

ay consist of a manufacturer's

unique serial number along w

ith model num

ber and/or the assignment and application of a unique

Inventory Control N

umber (IC

N).

The handling, preservation, and storage of inspection, measuring and test equipm

ent shall be such that the accuracy and fitness for use is m

aintained.

All calibrations shall be performed using certified equipm

ent having a known valid relationship to

nationally recognized standards; where no such standards exist, the basis used for calibration

shall be documented.

"Conform

ance check" means the operations required to ensure that an item

of measuring

equipment is in a state of com

pliance with requirem

ents for its intended use.

Non-adjustable m

easuring and test equipment is not considered as calibrated equipm

ent. Equipm

ent of this nature (e.g. cube and proctor molds, m

easuring tapes, rulers, chains) is subject to a "conform

ance check" to dimensional, volum

etric or other requirements and does not require

any further verification unless apparent damage or other factors require re-verification.

It is the responsibility of the end-user to comply w

ith the requirements of this section.

IMTE shall be selected utilizing Attachm

ent I "Criteria for the Selection of Inspection, M

easuring and Testing Equipm

ent" and Attachment II shall be used for guidance in procurem

ent of calibration equipm

ent and/or services.

All IMTE calibration requirem

ents shall be identified, on Attachment 3 IM

& TE Calibration

Requirem

ents List. This attachment is used to list the various types of IM

TE in use and their

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Contract N

o: W3Q

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Page 2 of 4

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

associated calibration frequencies, calibration procedures and tolerances. Calibration procedures,

frequencies, and tolerances may be obtained in conjunction w

ith obtaining the services of an outside calibration vendor or from

manufacturers. A procedure num

ber shall be assigned. If the m

anufacturer has an assigned number, this should be used. C

alibration procedures are quality records and shall be m

aintained in site files.

Procedures such as published standards, practices (e.g., ASTM) or w

ritten calibration instructions from

the manufacturer m

ay be used. In the absence of either a published standards practice or an adequate m

anufacturer's procedure, a written procedure for the calibration m

ethod shall be w

ritten and approved for use.

In addition to the above, calibration procedures should include at least the following basic

information:

x Identity of the item

to be calibrated using the procedure.

x C

alibration comparison standards and calibration support equipm

ent to be used.

x Provisions to obtain and record "as-found" accuracy m

easurement prior to any

adjustments.

x Sequence of operations.

x C

hecks, tests and measurem

ents instructions.

x C

alibration acceptance tolerances.

x C

alibration adjustment instructions.

x Safety considerations.

x Special instructions (w

hen applicable).

x D

ocumentation and labeling instructions related to the specific item

to be calibrated.

Perform and record (Form

000 509 F01104) the calibration in accordance with the above

established calibration procedures and/or contract the services of an outside calibration services vendor.

Upon com

pletion of initial calibration, enter the equipment in the C

alibration Assignment Log

(Form 000 509 F01101) and record other data required by this log.

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o: W3Q

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Page 3 of 4

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

History of U

se

The end user shall maintain a history of use for IM

TE to enable an assessment of the validity of

previous calibrations, inspections, measurem

ents and test results when calibration as-found data

reveals out-of-tolerance data points.

The history shall be documented using IM

TE Sign In/Out-H

istory of Use Log (Form

000 509 F01102) and keep current to record each usage of the IM

TE.

If out of tolerance conditions are found, a Nonconform

ance Report shall be prepared in

accordance with 000 509 0130.

If out-of-tolerance conditions are found during recalibrations an evaluation shall be conducted to determ

ine if inspection, measurem

ent, test or calibration results obtained with the out-of-tolerance

instrument are still valid.

Evaluations shall be documented, and w

here required, repetitions of readings shall be compared

to original results.

It is the responsibility of the end user to use calibrated equipment w

ithin the environmental

operating range(s) or restrictions/limitations specified by the instrum

ent manufacturer.

NO

TE: Temperature or other com

pensating calculations shall be applied to any inspection, m

easurement, test or calibration results w

hen such compensations are specified by the

instrument m

anufacturer and/or when they can affect the basis of the results obtained.

Upon satisfactory com

pletion of calibrations, and after the recalibration due date has been determ

ined (calculated), the end user shall make entries on the "C

alibrations Tickler File" (Form

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

DO

CU

MEN

TATIO

N

Electronic recording of the information that is required by the docum

entation in this procedure is perm

issible. All documents (except labels) generated in accordance w

ith this procedure should be m

aintained in appropriate protected files throughout the construction phase of the project, and for the period of tim

e there after specified (if any) or turned over to the Client if required.

West Q

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Contract N

o: W3Q

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Page 4 of 4

Fluor Corporation C

ompany C

onfidentialSite Q

uality Manual

FOR

MS

Quality Support Form

s:

000 509 F01101 -

Calibration Assignm

ent Log and Record

000 509 F01102 -

IMTE Sign In/O

ut-History of U

se Log

000 509 F01103 - C

alibration Tickler File

000 509 F01104 - C

alibration Data Sheet

Note: O

r Com

pany Approved Equivalent forms m

ay be used to control IMTE.

ATTA

CH

MEN

TS

Attachment 1

- C

riteria for the Selection of Inspection, Measuring and Test Equipm

ent (IMTE)

Attachment 2

- C

riteria for Procuring Calibration Services

Attachment 3

- IM

& TE Calibration R

equirements List

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Contract N

o: W3Q

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Attachment 1. . . Page 1 of 1

CR

ITERIA

FOR

THE SELEC

TION

OF IN

SPECTIO

N,

MEA

SUR

ING

AN

D TESTIN

G EQ

UIPM

ENT (IM

TE)

1. IM

TE includes inspection, measurem

ent and/or testing equipment used to determ

ine final acceptance.

2. IM

TE shall have a manufacturer's stated accuracy (and precision, w

here applicable)

that exceeds the construction installation inspection, measurem

ent and/or testing tolerance(s).

3. IM

TE shall have the durability, stability and appropriate measurem

ent ranges

consistent with the intended use(s).

4. C

alibration standards that will be required for the initial and subsequent recalibrations

shall be identified w

hen selecting IMTE. Such calibration standards shall be

requisitioned or the services of a calibration facility w

ith the calibration standards shall be contracted.

NO

TE: Obtaining calibration standards or services can usually require m

ore time to

procure than the time required to select and procure the needed IM

TE.

5. Purchase requisitions for IM

TE, calibration standards, and calibration facility services

should clearly state the requirements for accuracy, precision (w

here applicable), range, durability and/or stability, environm

ental, handling, other applicable technical requirem

ents.

West Q

urna I 000 509 0110

Contract N

o: W3Q

R



CR

ITERIA

FOR

PRO

CU

RIN

G C

ALIB

RA

TION

SERVIC

ES

The following are recom

mended guidelines for preparing a purchase order for obtaining the

services of a calibration supplier to calibrate Inspection, Measuring and Test Equipm

ent (IM&TE).

1. The follow

ing information should be provided to the supplier:

a)

description and unique identification of each piece of IM&TE;

b)

assigned calibration interval;

c) calibration accuracy required;

d)

any relevant environmental requirem

ents of use or calibration.

2. The calibration supplier m

ust provide the following inform

ation as part of their calibration records:

a)

source of calibration equipment used and current certificate(s) of traceability to a

recognized national standard;

b) identification of the calibration procedure(s) used (if the procedure is produced by the calibration supplier, a copy m

ust be furnished, if a recognizable standard i.e. ASTM,

ANSI/ASM

E, is used no copy is needed).

3. The calibration records supplied by the calibration supplier for each item

of IM&TE calibrated

must include:

a)

item identification num

ber;

b) date of calibration;

c)

the records of the "before", "as received" or "as found" condition including actual values and the "as calibrated" or "as left" values;

d)

identification of the calibration procedure used;

e) lim

its of permissible error;

f)

calibration standard used (including serial numbers and certificates) and traceability;

g)

details of any maintenance, servicing, adjustm

ent, repairs or modifications carried out;

h)

identification of person performing the calibration;

i)

identification of person responsible for the correctness of the information provided.

4. The calibration supplier shall seal, using a unique, tam

per-resistant system, all adjustm

ent access points after calibration, w

here practical. The system

site quality manaul - rev 1

Documents