QUALITY ASSURANCE/QUALITY CONTROL PROGRAM

quality assurance/quality Control Program

The purpose of this Plan is to address the procedures and monitoring requirements for construction of the project. This Plan is intended to:

  1. Define the responsibilities of parties involved with the construction.
  2. Provide guidance in the proper construction of the major components of the project.
  3. Establish testing protocols.
  4. Establish guidelines for construction documentation.
  5. Provide the means for assuring that the project is constructed in conformance to the Technical Specifications, permit conditions, applicable regulatory requirements, and Construction Drawings.

This procedure sets forth the construction quality program requirements that are to be applied to work performed by DAMASConstruction Institution (DCI). It is intended that thisQA program will meet the requirements of the DAMASConstruction Institution (DCI) Quality Policy as it relates to Construction Services. This QA/QC policy is also intended to ensure that all construction activities are performed in complete conformance with the approved construction drawings and all applicable standards, specifications and contract requirements.

The decision to implement this QA program for a particular construction job will be made at the sole discretion of the management of DAMASConstruction Institution (DCI).

The decision to implement this program (or any part of this program) for a particular job will be based on, but will not be limited to, the following criteria:

  1. Size and cost of the project
  2. Effect of the project on the overall goals of the Company
  3. Critical nature of the job (quality/safety)

Each construction site shall have at least one DAMASConstruction Institution (DCI) QC representative or individual identified as the QA/QC contact. Depending on the construction site, this QA/QC function may be expanded to include additional personnel as dictated by the size of the project and/or scope of work activities. The organizational structure for the project shall be aligned in such a manner as to allow the onsite QC representative the necessary autonomy to perform the QA/QC function in an unbiased manner.
In addition, the onsite DAMASConstruction Institution (DCI) QC representative will work with the Corporate QC Coordinator to conduct periodic assessments of the overall QA/QC implementation for the project.

This section describes the scope of project management responsibility, authority and interrelationships.

  1. Managing Director
  2. The Managing Director has ultimate responsibility for organizing to implement the quality system.
  3. Prepares and signs the quality policy statement for organizing to implement the quality system.
  4. Delegate day to day operation of the quality system to the quality assurance manager.
  5. Establishes an organizational structure that separate quality assurance activity from project management.
  6. Ensures that a management review of the quality system is performed at least annually to ensure its continuing suitability and effectiveness.
  7. Participates as a member of the contract committee.

 

  1. Project Technical Manager
  2. Directs over-all project management.
  3. Actively supports quality management for the project.
  4. Provides support to the quality assurance manager in the implementation of the project quality control plan.
  5. Determine work and construction methods to be implemented during the construction phase.

 

  • Quality Assurance and Control Manager
  1. He has the overall control and authority in the DAMASConstruction Institute (DCI) QA/QC organization.
  2. Has the responsibility and authority for the implementation of the project quality control plan.
  3. Assists other project stuff in training field staff and in the supervision of applying the QA/QC policy.
  4. Assists the procurement manager selection of suppliers and subcontractors.
  5. Reviews purchase orders and subcontract documentation to ensure that the quality requirements have been adequately conveyed to suppliers and subcontractors for all items of permanent project equipment.

 

  1. Quality Inspectors
  2. Carry out inspection of works by DAMASConstruction Institute (DCI) QA/QC Manager.
  3. Conducts field checks to confirm the work is performed in accordance with the current revisions of drawings and specifications.
  4. Reports any deviations from the required specifications and standards to DAMASConstruction Institute (DCI) QA/QC Manager.
  5. Provides support to DAMASConstruction Institute (DCI) field staff in arranging the testing of materials and workmanship based on required specifications and drawings.
  6. Coordinates with DAMASConstruction Institute (DCI) field staff in ensuring all required testing has been performed and that acceptable result has been achieved.
  7. Ensures that all materials and equipment procured by either client or DAMASConstruction Institute (DCI) are in compliance with contract requirements. They shall ensure that client approval and/or the required factory or supplier compliance certificate have been obtained upon delivery of available material at the project site.
  8. Responsible for preparing all documentation related to material acceptance and certification.

 

 

  1. QC Technicians
  2. The QC technicians will perform test as required by the Quality Inspectors on equipment and materials procured by either the client or DAMASConstruction Institution (DCI) to verify conformance of specifications.

 

  1. Documentation Clerks
  2. Clerks will be specifically assigned for assisting quality inspectors in documentation and other clerical work. Their function will be to organize the documents in an easily retrievable manner and generate periodic reports that can interpret the results of inspections in a consolidated format for submittal to client and review.
  1. Activities
  2. Its function is to check, measure, test and inspect materials, equipment and work to confirm its compliance with contract requirements.
  3. The QC personnel shall track construction activities and with close coordination with field engineers determine when it is necessary to conduct inspections, exercising control and documentation of all inspections made.
  4. When necessary, a formal non-conformance procedure is to be initiated to advise the client of deficiencies identified during inspection and testing.
  5. Verification of activities may be carried out by QA/QC Manager, field staff, testing agencies/specialists and DAMASConstruction Institution (DCI) QA/QC staff.
  6. Procedures are established to plan and control activities that contribute to the quality at work. These procedures provide details of the activities that shall be used by the project staff to implement the quality systems.
  7. All verification activities undertaken by DAMASConstruction Institution (DCI) nominated personnel shall be documented to provide a record which together with quality control records from the basis of assurance.
  8. To provide independent acceptance, inspections at hold and final inspection points nominated as inspection and test requirements, the QA manager and project staff shall coordinate with the representatives of the client.
  9. The QA/QC activities related to procurement will, in general, be the following to ensure that the work and materials conform to contract requirements:
  10. Perform testing as required as under the technical provisions of the contract.
  11. Prepare and submit daily QC reports.
  12. Inspect materials as they are delivered on site to insure compliance with approved shop drawings and contract specifications through close coordination with engineering department.
  13. Conduct off-site inspection of supplies and materials to be incorporated into the work.
  14. Maintain test reports and/or records of all QC activities. These records shall be available for and/or submitted to the client.
  15. The inspection and testing procedures will be conducted in three Phases: Preparatory Inspection, Initial Inspection and Follow-up Inspection.
  16. A copy of all documentation in reference to standards, specifications, procedures and inspection of equipment and materials used in the fabrication and construction of the work shall be maintained in work site office.
  17. The fabrication and field construction activities shall conform, at a minimum to client standards, submitted drawings, project specifications, and other contract documents. DAMASConstruction Institution (DCI) shall adhere to its procedures as approved by the client.

Preparation of daily QA/QC documentation will consist of daily field reports prepared by the QA/QC Site Manager which may include QA/QC monitoring logs and testing data sheets. This information may be regularly submitted to and reviewed by the Construction Manager. Daily field reports will include documentation of the observed activities during each day of activity. The daily field reports may include monitoring logs and testing data sheets. At a minimum, these logs and data sheets will include the following information:

  • the date, project name, location, and other identification;
  • a summary of the weather conditions;
  • a summary of locations where construction is occurring;
  • equipment and personnel on the project;
  • a summary of meetings held and attendees;
  • a description of materials used and references of results of testing and documentation;
  • identification of deficient work and materials;
  • results of re-testing corrected “deficient work;”
  • an identifying sheet number for cross referencing and document control;
  • descriptions and locations of construction monitored;
  • type of construction and monitoring performed;
  • description of construction procedures and procedures used to evaluate construction;
  • a summary of test data and results;
  • calibrations or re-calibrations of test equipment and actions taken as a result of re-calibration;
  • decisions made regarding acceptance of units of work and/or corrective actions to be taken in instances of substandard testing results;
  • a discussion of agreements made between the interested parties which may affect the work; and
  • Signature of the respective QA/QC Site Manager.

Construction Problems and Resolution Data Sheets, to be submitted with the daily field reports prepared by the QA/QC Site Manager, describing special construction situations, will be cross-referenced with daily field reports, specific observation logs, and testing data sheets and will include the following information, where available:

  • an identifying sheet number for cross-referencing and document control;
  • a detailed description of the situation or deficiency;
  • the location and probable cause of the situation or deficiency;
  • how and when the situation or deficiency was found or located;
  • documentation of the response to the situation or deficiency;
  • final results of responses;
  • measures taken to prevent a similar situation from occurring in the future;
  • signature of the QA/QC Site Manager and a signature indicating concurrence by the Construction Manager.

 

The Construction Manager will be made aware of significant recurring non-conformance with the Drawings, Technical Specifications, or QA/QC Plan. The cause of the non-conformance will be determined and appropriate changes in procedures or specifications will be recommended. These changes will be submitted to the Construction Manager for approval. When this type of evaluation is made, the results will be documented and any revision to procedures or specifications will be approved by the Contractor and Engineer.

A summary of supporting data sheets, along with final testing results and the

QA/QC Site Manager’s approval of the work, will be required upon completion of construction.

Photographs will be taken and documented in order to serve as a pictorial record of work progress, problems, and mitigation activities. These records will be presented to the Construction Manager upon completion of the project. Photographic reporting data sheets, where used, will be cross-referenced with observation and testing data sheet(s), and/or construction problem and solution data sheet(s).

Design and/or specifications changes may be required during construction.

In such cases, the CQA Site Manager will notify the Engineer. Design and/or specification changes will be made with the written agreement of the Engineer and will take the form of an addendum to the Drawings and Technical Specifications.

An internal audit in the field shall be performed to verify quality control activities are in accordance with written procedures and general provisions. The audit shall include but not limited to: 

  • Personnel Certification.
  • Material Tracing.
  • Document Control Records
  • Test Equipment Calibration Records.
  • Daily Reports.

 

The quality inspector on site shall perform a continuous audit on a dat to day basis reporting any non-conformances in application of the QA/QC policy to the QA/QC manager. The quality inspector shall also investigate corrective procedures within his term of responsibility or inform the QA/QC manager accordingly for further action.

 

The QA/QC manager, project manager, and quality inspectors shall perform a minimum of three random audits at 10-20%, 50-60, and 80-90% completion of the work. The results of these audits are to be recorded for inspection by the client or his representative.Random audits shall be performed at any time especially when circumstances changes, such as major changes in the QA/QC policy, new personnel, and to verify corrective actions are properly performed and documented.

Audit shall be carried out according to checklists previously prepared to suit each particular case and activity or facility to be audited. A report shall be issued on completion of each audit giving a summary of the findings and recommendations for corrective action if necessary.

When corrective actions are recommended, the time limit for their implementation should be stated.  The activity concerned should be audited again at the expiration of the time limit to verify correction of the identified non-conformance.

  1. Purpose & Scope

DAMASConstruction Institute (DCI) shall implement and maintain a document control system to ensure:

  • Documents effecting quality are approved prior to issue for construction.
  • Latest issue of approved documentation is in use on the construction site.
  • Documents are complete and unambiguous.

 

  1. Responsibility

Overall responsibility for planning and control of the document control system for QA/QC matters shall be assigned to the QA/QC supervisor. He shall establish and maintain the following records and files. It shall be his responsibility to see these records are properly maintained and stored after project completion and that each of the subcontractors (if any) on this contract establish and maintain similar records.

 

  1. Tests & Records

A record of all tests field sequentially and by work categories. All tests including but not limited to the following shall be controlled and properly documented:

  • All testing shall be documented using QA/QC inspection forms.
  • A file for Daily QC Reports and Weekly Reports.
  • A record of all vendors’ and technical approvals filed consecutively by submittal number and index.
  • A file of current and governing contract plans and specifications, variation orders, shop drawings and technical standards issued by the client.
  • A file of operations and maintenance manuals for contractor-furnished equipment (if applicable).
  • Contract materials receiving report file.
  • A record/documentation file of properly logged non-conformance reports to be used for future reference and evaluation purposes.
  • The above QC documentations shall be in English language and of legible quality for easy processing/reproduction. Client’s projects inspection team shall have access to records and documentation filed and maintained, and shall also have copies of all test reports.

 

  1. Control Procedure

The following documents shall be controlled in accordance with this procedure:

  • Contract Specification.
  • Contract Drawings.
  • Approved Shop Drawings.
  • Request for information.

  1. The QA/QC inspector in conjunction with the site engineer shall check all purchasing documentation prior to dispatch to potential manufacturers, subcontractors and suppliers.

    The goods, materials, equipment or work to be performed shall be checked with the following guidelines:

    • Description of goods, materials, equipment or work to be performed.
    • Quantity
    • Required delivery date.
    • Sample/prototype requirements.
    • Formal QA/QC requirements.
    • Identification, packing, handling and delivery conditions.
    • Documentation of drawings, test certificates, operating manual, etc.
    • All documentation shall be in English and shall be legible.

  1. All material deliveries to the site shall be inspected and checked by QC inspector to ensure the materials are not damaged or defective and conforms to the material approvals, purchase orders, and packing lists.

    A materials receipt checklists shall be used as guidelines in checking delivered products.

The purpose of this procedure is to outline the general guidelines necessary to insure that the quality of items received on DAMAS CONSTRUCTION INSTITUTE (DCI) construction projects is in compliance with manufacture’s literature, applicable codes, standards and specifications and is maintained throughout the receipt, storage and handling process.

 

Generally, items shall be received, stored and handled in accordance with the manufacturer’s recommendations. In addition, specific requirements listed in job site specifications shall be followed as they apply to items received on site. In lieu of recommendations and specifications, the guidelines listed in this procedure shall be followed.This procedure is an integral part of the DAMAS Construction Institute (DCI) Quality Assurance Program.

Responsibility

Generally, it will be the responsibility of DAMASConstruction Institute(DCI) to insure that items received on site are received, stored and handled in a manner that will maintain the quality of the items received. DAMASConstruction Institute(DCI) will perform whatever inspections are deemed necessary to insure the quality of items is being maintained.

Receiving Inspection Requirements

A preliminary visual inspection shall be performed prior to unloading to determine if any damage occurred during shipping and to insure compliance to the applicable purchase order. Observations shall be made for the following:

  • Tie Down Failure
  • Rough Handling
  • Fire
  • Excessive Exposure
  • Environmental Damage

Any indication of the above conditions shall be brought to the attention of the appropriate discipline leads, preferably before unloading. Receipt, storage and handling requirements for specific items may be found in the particular discipline inspection procedures: Civil Inspection, Electrical Inspection, Mechanical Inspection and Welding Inspection.

After unloading, the following areas should also be checked:

  • Identifications and Markings – verify that identifications and markings are in accordance with applicable codes, specifications, drawings, purchase orders, etc.
  • Manufacturing Documentation – assurance that the item received was fabricated, tested and inspected prior to shipment; if required, assure that mill test reports or other required documentation has been received and all items met or exceeded requirements.
  • Physical Damage – perform a closer inspection than what was done prior to unloading to check for broken, cracked, missing, deformed or misaligned parts.
  • Cleanliness – perform a more thorough visual inspection to assure that accessible internal and external areas and components are free of dirt, mill scale, weld spatter, oil, grease, etc. as required by specifications or manufacturer’s recommendations.
  • Results of the above inspection should be documented.

Storage Requirements

Items shall be stored in a manner that will maintain the quality of the item and minimize the possibility of damage due to corrosion, contamination, deterioration or physical damage.

First and foremost, items shall be stored in accordance with manufacturer’s recommendations and job site specifications.

The purpose of this procedure is to outline the general guidelines necessary to assure that the civil construction activities performed on DAMASConstruction Institute(DCI) construction projects are performed in accordance with applicable codes, standards, specifications and drawings.

 

Scope

This procedure will cover general inspection criteria in the areas of:  Soils Inspection, Reinforcing Steel Inspection, Concrete Inspection, Grouting Inspection, Structural Steel Inspection, Coatings Inspection, and Ductwork Inspection and Insulation.

 

Construction activities and subsequent inspection criteria shall be based on job site specifications, procedures and drawings. In lieu of jobsite specifications or where referenced by jobsite specifications, national codes and standards shall be used.

 

Responsibility

Generally, it will be the responsibility of DAMASConstruction Institute(DCI) to insure that construction activities are performed in accordance with applicable specifications, procedures, drawings, codes and standards. SCG DAMASConstruction Institute(DCI) shall perform whatever inspections and tests are deemed necessary to insure that construction activities are being performed in accordance with job requirements.

Earthwork construction activities shall be performed in accordance with job site specifications, procedures and drawings. Soils inspection shall be performed by qualified personnel who shall verify that requirements of the specifications, procedures and drawings are being met.

Reinforcing steel shall be received, stored and handled in accordance with procedure (Storage and Handling of Products). As part of the receipt inspection, mill test reports shall be checked and fabricated bars shall be randomly checked against the bar lists for compliance.

 

Key Inspection Attributes:

In addition to the receipt inspection items listed above, the following are minimum key inspection items that should be checked and or verified as a part of reinforcing steel inspection:

  • Reinforcing steel is stored off the ground in a well drainedgraveled lay down area in accordance with the storage requirements.
  • Reinforcing steel is installed per the drawings (note location, spacing, number, type and size of bars placed).
  • Reinforcing steel has at least the minimum amount of concrete cover on outside edges as specified on the drawings.
  • Cleanliness of the reinforcing steel. Verify that all mud, oil, excessive rust, etc. has been removed from the reinforcing steel.
  • Reinforcing steel lap splices are of the length specified on the drawings.
  • Mechanical splices (if required) are installed per manufacturer’s recommendations.
  • Reinforcing steel is tied securely and will not move or be dislodged during concrete placement.
  • The Pour Card has been signed indicating that the reinforcing steel is ready for concrete placement.
  1. Concrete construction activities shall be performed in accordance with job site specifications, procedures and drawings. Concrete inspection and testing shall be performed by qualified personnel who shall verify that requirements of the specifications, procedures and drawings are being met.

 

 

Key Inspection Attributes:

Following are key inspection items for each type of batch plant inspection:

Initial Inspection

  • verify that aggregates are loaded in correct bins
  • verify that aggregates are not contaminated
  • verify that scales and measuring devices have current calibration stickers and appear to be working properly
  • verify that concrete trucks are in good working condition
  • Verify that overall operation of the plant appears to be professional, orderly, reasonably clean, well maintained, etc.
  • Verify that batch tickets will supply necessary information (amount of hold back water list of ingredients, batch times, size of load, indication of mix ordered, etc.)

 

Concrete Pre placement

Concrete pre placement construction activities shall consist of foundation preparation, rebar and embed placement, form construction and all other activities necessary to prepare for concrete placement.

 

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified prior to concrete placement:

  • verify that the concrete foundation surface has been cleaned of any laitance
  • verify that the concrete foundation surface has been sufficiently roughened to provide adequate bonding to the new concrete
  • verify that all trash (mud, dirt, paper) has been removed from the placement area
  • verify that the placement area is damp but not wet
  • verify that all puddles of water have been removed
  • in the case of a soil foundation, verify that it has been properly compacted
  • verify that forms appear sufficiently sturdy to support the weight of the wet concrete
  • verify that the forms are clean and free of foreign materials
  • verify that form release agent has been applied to the forms
  • verify that large holes and cracks have been filled to prevent mortar loss
  • verify that the reinforcing steel has been properly installed (secure, properly spaced and placed, proper clearance between reinforcing steel and the form work and free of all foreign material)
  • verify that all embedded items have been properly installed (secure, properly spaced and placed, free of all foreign material)
  • verify that the placement area is clean and free of foreign material
  • verify that necessary precautions have been taken for hot or cold weather concreting
  • verify that arrangements have been made to allow for the proper placement of the concrete

Concrete placement activities shall consist of the actual placing of the concrete and all testing that is required on the fresh concrete prior to and during placement.

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified prior and during concrete placement:

  • Prior to depositing concrete in the placement, verify that the concrete has been tested for slump, air content, temperature, etc. and verify that it met all specification requirements
  • verify that the concrete is being placed to allow for proper consolidation and prevent segregation
  • verify that the concrete is being properly vibrated
  • verify that special care is being taken around sumps, tanks, etc. to provide for adequate consolidation and prevent the formation of air pockets.
  • verify that testing is being performed at the frequency and at the location required by the specifications
  • verify that the concrete is being finished per the requirements of the specifications or drawings

Concrete post placement activities shall consist of application and maintenance of curing compound or other methods of curing, form removal, concrete repair and storage of concrete cylinders.

 

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified as part of concrete post placement activities:

  • verify that the required method of curing has been initiated
  • verify that the placement is checked regularly to insure continuous curing (watch for dry spots)
  • Verify that curing is maintained as long as required.
  • verify that severe weather precautions have been taken as required (hot or cold weather)
  • verify that concrete forms have been left in place as long as required to insure that form removal will not damage the concrete or workers (be cautious of forms supporting the weight of the concrete to insure the concrete has gained sufficient strength to support its own weight)
  • If repair of concrete is required, verify that it is repaired in accordance with specifications (based on the severity of the repair, determine if a non-conformance report is required)

Non shrink structural grout shall be shipped to the job site in bags and shall be received, stored and handled in accordance with procedure (Storage and Handling of Products).

 

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified as part of grout placement activities.

  • verify that the grout meets the requirements of the job in regard to intended use, required compressive strength and workability
  • check the date on the grout bags to insure that the grout has not exceeded the indicated shelf life
  • Verify that the concrete foundation that will receive the grout has been cleaned, roughened and saturated with water for 24 hours prior to grout placement.
  • verify that the grout has been mixed per manufacturer’s literature. It is recommended that a test batch be mixed prior to the first production placement to verify that workability and compressive strength requirements are met.
  • Verify the temperature of the mixed grout to insure compliance to specifications and/or manufacturer’s literature. Ice water or hot water should be considered as means of regulating the mixed grout temperature.
  • Verify that grout forms have been constructed to facilitate rapid, continuous placement and complete filling of the space to be grouted.
  • Verify that, depending on the size of the grout placement, the form on the grout placing side has been constructed at a 45°angle.
  • Verify that for large grout placements, metal bands or straps have been placed under the base plates to facilitate moving grout into difficult areas. These should only be used if allowed by the grout manufacturer.
  • verify that grouting only proceeds from the grout placing side of the form to prevent the entrapment of air pockets
  • verify that all required testing is done in accordance with specifications
  • Verify that the grout is cured in accordance with manufacturer’s recommendations and/or specifications.

Structural steel, including high strength bolts, washers and nuts shall be received, stored and handled in accordance with procedure: Storage and Handling of Products. As a part of receipt inspection, individual members shall be randomly checked against the fabrication drawings via the piece number for compliance.

 

Erection

Structural steel erection, high strength bolting and welding processes shall be in accordance with job site specifications, procedures, and drawings; Daily activities should be recorded.

 

Prior to erecting steel, the steel erector shall be provided with documentation that shows that the concrete in the footings, piers and walls and the mortar in masonry piers and walls has attained either 75 percent of the intended minimum compressive design strength or sufficient strength to support the loads imposed during steel erection. In addition, the steel erector shall receive written notification of any repairs, replacements and modifications to the anchor bolts.

 

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified as part of structural steel erection activities:

  • structural members are assembled per the drawings
  • Fit up bolts and drift pins shall not be used to bring out of tolerance fabricated members and parts into place.
  • drift pins shall not be driven with such force as to damage adjacent metal
  • burning of bolt holes shall not be allowed
  • no cutting of structural steel will be permitted without approval.
  • high strength nuts and bolts shall be discarded if the nut cannot be turned freely by hand the entire threaded length of the bolt
  • Visual welding inspection shall be performed.

Paints and coatings shall be received, stored and handled in accordance with procedure: Storage and Handling of Products. A Materials Safety Data Sheet shall be on site for each type of coatings received and should be reviewed by the appropriate personnel before the start of work.

 

Paint and/or coatings shall be applied in accordance with job site specifications, procedures, drawings and manufacturer’s recommendations. Daily activities should be recorded.

 

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified as part of paints and coatings application activities:

  • Ambient Conditions – check at the beginning of work and every 4 hours thereafter or more often if conditions change
  • air temperature
  • wet bulb temperature
  • relative humidity
  • dew point
  • wind velocity
  • surface temperature of material being coated
  • Surface Preparation
  • Surface has been cleaned per specification requirements.

Wet Film Thickness Readings

  • numerous wet film thickness readings should be taken to gauge technique and ultimate dry film thickness

 

 

Dry Film Thickness Readings

  • dry film thickness readings should be taken to verify compliance to specifications (take minimum of 5 measurements spaced evenly over every 100 square feet)
  • Holiday Detection
  • testing to detect holidays (pinholes), if required by specifications
  • repair of holidays if detected

Ductwork components shall be received, stored and handled in accordance with

Procedure: Storage and Handling of Products.

Ductwork components shall be assembled in accordance with job site specifications, procedures, drawings and manufacturer’s recommendations. Daily activities should be recorded.

 

 

Key Inspection Attributes

Following are minimum key inspection items that should be checked and/or verified as part of ductwork assembly activities:

  • Duct assembled in proper sequence per drawings and specifications
  • Duct erected plumb and square per specification requirements
  • All stitch welds completed per drawings and specifications and inspected
  • All seal welds completed per drawings and specifications and inspected
  • Expansion joints erected and installed per drawings and specifications
  • Duct assembly free of dirt and trash
  • Access doors installed per drawings and specifications and closed and tight
  • Ductwork sealed as required
  • Ductwork tested as required
  • Lagging and insulation installed per drawings and specifications
  • verify thickness and type of insulation required
  • name plates, code stamps, etc. are to be left exposed
  • stagger joints on double layer insulation
  • insulation must be kept dry until properly weatherproofed

Purpose

This procedure establishes guidelines for the construction and installation inspection of electrical components at DAMASConstruction Institute(DCI) construction projects.

 

Scope

Electrical components covered under this procedure shall include, but not limited to, grounding systems, embedded items, raceway and cable tray systems, cable installation and termination, and electrical equipment. In lieu of manufacturer’s recommendations and specifications, the guidelines in this procedure shall be followed.

 

Responsibility

It is the responsibility of DAMASConstruction Institute (DCI) to ensure that electrical equipment is received, stored, maintained, handled and installed in a manner that will ensure the quality of equipment. Whatever inspections shall be performed to ensure the quality of items being installed has been maintained.

DAMASConstruction Institute(DCI) is responsible for coordinating work activities with other disciplines involved in electrical discipline installations. And will ensure all deficiencies have been resolved.

 

Construction Systems

Storage and Handling of Electrical Equipment

When electrical equipment has been received and placed in its designated area, all documentation and storage requirements will be performed as recommended by the manufacturer. Some key inspection attributes include but are not limited to the following:

 

  • Visual inspection of equipment received
  • Damage
  • Correct size, layout, type, labels, etc.
  • Loose wiring or components
  • Complete shipment
  • Physical integrity check of equipment upon receipt and storage
  • Electrical and mechanical integrity checks of rotating and non rotating equipment
  • Maintenance requirements of equipment while in temporary or final storage location; including the use of temporary heaters and protection from the weather
  • Documentation of all equipment received, stored or handled

 

Cable Installation

Power, control and telecommunication conductors are essential for any plant.

Proper installation techniques will limit stress damage to conductors and reduce operational testing requirements of the conductor over its service life. Some key inspection attributes include but are not limited to the following:

  • Cable manufacturer specifications for:
  • Cable reel storage and field handling practices
  • Cable reel set up requirements
  • Cable pulling tension(s)
  • Bending radius and training radius
  • Approved cable pulling equipment / material (lubricants)
  • Special cable installation
  • Cable separation and support requirements
  • Spare cable installation checks
  • Spliced or coiled cable checks
  • Cable installation techniques
  • Cable testing after installation
  • Cable installation documentation

Equipment Installation

Equipment installation includes but is not limited to rotating equipment, enclosures, transformers and other associated equipment. Proper installation techniques are mandatory to ensure equipment functions as intended. Equipment checks will verify equipment location, orientation, configuration, supports and anchoring systems are in accordance with site specifications.

Equipment and system testing will ensure equipment will function during start up and operational phases. As a minimum, a check will be made to verify all electrical equipment has been installed in accordance with site drawings, specifications and manufacturer recommendations. Some key inspection attributes include but are not limited to the following:

  • Equipment manufacturer specifications for:
  • General equipment installation
  • Special equipment installation
  • Rigging, lifting and handling practices
  • Equipment stored in permanently installed location
  • Electrical and mechanical integrity checks for rotating and non rotating equipment
  • Equipment Installation documentation

Purpose

The purpose of this procedure is to outline the general guidelines necessary for the inspections of mechanical equipment, piping systems, piping support structures, instrumentation, valves, insulation and lagging, and hydrostatic testing at DAMASConstruction Institute(DCI) construction projects.

 

Scope

Mechanical equipment covered under this procedure shall include, but not be limited to, motorized and non-motorized valves, pumps, compressors, tanks, heat exchangers, fired and unfired vessels, filter vessels, in line components (expansion joints, etc.) and other equipment that is within the mechanical inspection scope of work.

Generally, mechanical equipment, piping, piping support structures, in line components, instrumentation, valves, and insulation and lagging should be received, stored, maintained and installed in accordance with manufacturer’s recommendations and mechanical engineering practices. In addition, specific requirements listed in project specifications and drawings shall be followed. In lieu of manufacturer’s recommendations and specifications, the guidelines in this procedure should be followed.

 

Responsibility

Generally, it will be the responsibility DAMASConstruction Institute(DCI) to ensure that mechanical equipment, piping, piping supports, in line components, instrumentation, valves, insulation and lagging are received, stored, maintained, handled, and installed in a manner that will ensure the

quality of equipment received. Inspections and tests shall be performed as deemed necessary to ensure that the quality of items is maintained.

 

 

 

Mechanical Equipment Maintenance Requirements

When mechanical equipment has been received and all preliminary inspections have been performed, couplings for driven equipment that are not installed, (loosely attached to the equipment), should be removed, packaged, tagged and placed in storage until equipment installation prior to equipment turnover. Inspection personnel should complete a maintenance checklist (refer to sample forms for an example) and update same as needed until equipment has been released to plant operations personnel.

 

Piping Systems Inspection

When inspecting piping systems the following items should be checked:

  • Check piping per installation drawings noting material, size, pipe schedule and location where piping is to be installed; be aware of how the various components will be connected such as welded, bell-and-spigot, soldered, brazed, screwed or flanged connections.
  • Check drawings and specifications for any non-destructive testing that may be required and ensure that all NDE is performed.
  • Note location of components that are a part of the system such as valves, pumps, orifice plates, flanges, instrumentation connections etc. and ensure that components are installed as required.
  • Inspect piping during fit-up for cleanliness making sure that all dirt, oil, grime, or other foreign matter is removed prior to final fit-up.
  • Inspect gaskets to ensure that gaskets are in good condition noting condition of bolt holes, any evidence of wear, and cleanliness of gasket.
  • Ensure that all flanged joints are fit up so that the gasket contact faces bear uniformly on the gasket, and then are assembled with relatively uniform bolt stress using the prescribed torque sequence. All bolts should be engaged so that there is visible evidence of complete threading through the nut or threaded attachment. Any compound or lubricant used in threaded joints shall be suitable for the service conditions, and shall not react unfavorably with either the service fluid or the piping materials.
  • For field routed piping systems, check that piping has been routed in such a manner as to avoid other systems and equipment allowing for insulation and movement that occurs during operation.
  • Check drawings and specifications for other tests which must be performed on various piping systems such as air pressure tests and hydro testing. Ensure that these tests are performed as needed and document the results of these tests.

Purpose

The purpose of this procedure is to outline the general guidelines for the visual inspection of welding performed at DAMASConstruction Institute(DCI) construction projects.

 

Scope

This procedure is an integral part of the DAMASConstruction Institute(DCI) QualityAssurance Program and is intended for use on DAMASConstruction Institute(DCI) construction projects.

 

 

 

Responsibility

Generally, it will be the responsibility of DAMASConstruction Institute(DCI) to ensure that welding is performed according to the applicable section of the governing codes, approved welding procedure specifications, and project specifications and drawings.

 

Inspections shall be performed ranging from random observations to total weld inspection as deemed necessary to ensure weld quality.The degree of weld inspection will be based on the structural significance, prior experience, and past observations.

 

Visual Welding Inspection

DAMASConstruction Institute(DCI) shall insure that welders and welding operators are qualified in the process being performed. If applicable, inspection personnel will be aware of any welder retest dates and welder’s symbols. Inspection personnel shall be responsible for preparing and maintaining a Visual Weld Inspection Report as needed for inspected welds at project locations.

 As required, inspection personnel shall monitor the welding process during the following stages for compliance to codes and specifications.

  • Check that work areas are being kept clean and safe; that electrode stubs and damaged electrodes are being discarded in the designated electrode disposal containers, and that electrodes are stored properly.
  • Inspect post-weld clean up – weld area should be brushed or cleaned by acceptable methods and surface slag, dirt, mill scale, etc. should be removed.
  • Inspect completed weld – inspect the completed weld and heat-affected zones for surface discontinuities and examine for proper weld profile and proper blending of adjoining surfaces.
  • Verify post weld heat treatment
  • Determine if weld is acceptable or unacceptable per applicable standards; if unacceptable, ensure immediate repair or place weld on hold pending corrective action.
  • Document the inspection on the Visual Weld Inspection Report.

 

Acceptance Criteria

The acceptance criteria for all welding performed on DAMASConstruction Institute(DCI) construction projects will be controlled by the applicable section of the governing code, and project specifications and drawings. In general, inspection personnel should also verify that:

  • Welds are correct size, length and placement per drawings.
  • No specific weld has been omitted.
  • No unspecified weld has been added without approval.
  • All NDE processes are performed in accordance with applicable codes and standards.

 

Welding Machines

All machines being used for welding shall be in satisfactory working condition and set at

WPS nominal amperages required to maintain a stable arc for the type and size of electrode, welding position, and particular weld joint configuration. Any unsafe conditions such as worn leads, tripping hazards, electrical shock, or fire hazards shall be noted and reported to the appropriate personnel.

Base Material Composition

Welding procedure specifications (WPS) shall be referenced to verify the required base material composition for weld elements. Base material composition may be assessed by checking manufacturer mill test reports or purchase orders. Any base metal imperfections or deviations should be noted and/or rectified prior to welding.

 

Weld Repair/Rework

It is important that construction not progress to the point that welds cannot be inspected.

Inspection personnel shall be notified in a timely manner in order to inspect completed welds while the welds are still accessible. For welds that have unacceptable discrepancies and repair/rework is required, work shall be performed to the same specifications as the original weld (unless there is special engineering documentation to change processes). The completed weld shall meet the same acceptance standards as the original weld. Welds found unacceptable shall be noted on the Visual Inspection Report stating the reason(s) for rejection. When the repaired/reworked weld has been found acceptable, the Visual Inspection Report shall be updated to verify acceptance.

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