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W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc
W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc
Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0000 Revision 0, 10 June 2103
Administrative Procedure No. 000 509 0000 000 509 0010 000 509 0020 000 509 0040 000 509 0050 000 509 0090 000 509 0110 000 509 0130 000 509 0140 000 509 0150 000 509 0160 000 509 0170 000 509 0180 000 509 0200 000 509 0210 000 509 0220 000 509 0230 000 509 0240 000 509 0250 000 509 5100
Title Table of Contents / Date Revision Page Foreword Manual Preparation and Maintenance Organization and Responsibilities Document Control Process Control Inspection, Measuring and Test Equipment Control of Nonconformances Corrective Action Preventive Action Quality Records Quality Audits Personnel Training and Qualification Site Subcontractor Qualification Contractor Quality Requirements Surveillance of Construction Activities Field Receiving Inspection Turnover Material & Equipment Storage & Maintenance Activity Plan for Construction
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
Inspection and Test Procedure No. 000 509 7000 000 509 7010 000 509 7020 000 509 7030 000 509 7040 000 509 7050 000 509 7060 000 509 7070 000 509 7080 000 509 7090 000 509 7100 000 509 7200 000 509 7300 000 509 7310 000 509 7320 000 509 7400
Title Inspection and Testing Soils Bituminous Concrete Paving Pilling - Steel H - Piles Piling Pre-Cast Concrete Piles Piling - Timber Piles Piling - Closed End Concrete Filled Pipe Piles Piling - Concrete Filled Thin Shell Pipe Piles Drilled Caissons Augered Cast-In-Place Piles Concrete and Grout Structural Steel Buildings Heating Ventilating and Air Conditioning Roofing Inspection Equipment
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0000 Revision 0, 10 June 2103
Inspection and Test Procedure No. 000 509 7410 000 509 7420 000 509 7430 000 509 7440 000 509 7460 000 509 7470 000 509 7500 000 509 7510 000 509 7520 000 509 7550 000 509 7560 000 509 7570 000 509 7600 000 509 7610 000 509 7620 000 509 7640 000 509 7700 000 509 7710 000 509 7800 000 509 7810 000 509 7820 000 509 7830 000 509 7910 000 509 7920 000 509 7930 000 509 7950 000 509 F0000
Title Field Fabricated Tanks Cooling Tower Refractory Concrete Gas Turbine/Generator Steam Turbine/Generator Generator Testing Underground Piping Aboveground Piping Pressure Testing Hygienic Tubing Chemical Cleaning of Pipe Steam Tracing for Pipe and Equipment Electrical Inspection Electrical Testing Electrical Equipment Electrical Heat Tracing Control Systems Instrumentation Control System Calibration Coatings and Linings Insulation Fireproofing Inspection Cathodic Protection Welding Inspection Nondestructive Examination Positive Material Identification Hardness Testing Quality Control Forms
Revision Date 10 June 13 VOID VOID VOID VOID VOID 10 June 13 10 June 13 10 June 13 VOID 10 June 13 VOID 10 June 13 10 June 13 10 June 13 VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
The Fluor Site Quality Program for this Project is described and documented in this Site Quality Manual.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F00501 000.509.F00502 000.509.F01101 000.509.F01102 000.509.F01103 000.509.F01104 000.509.F01301 000.509.F01302 000.509.F01303 000.509.F01401 000.509.F01402 000.509.F01501 000.509.F01601 000.509.F01701 000.509.F01702 000.509.F01801 000.509.F02001 000.509.F02002 000.509.F02003 000.509.F02004 000.509.F02005 000.509.F02006 000.509.F02201 000.509.F02202 000.509.F02301 000.509.F02401 000.509.F02402 000.509.F02403 000.509.F02404 000.509.F02405
FORMS INDEX Form Title Request For Information Request For Information Log Calibration Assignment Log and Record I.M.T.E. Sign In/Out History of Use Log Calibrations Tickler File Calibration Data Sheet Nonconformance Report Nonconformance Report Log Hold Tag/Sticker Corrective Action Report Corrective Action Status Log Preventive Action Log Quality Records Control Audit Finding Audit Summary Project Specific Quality Training Site Subcontractor Qualification Soil Testing Laboratory Evaluation Record Asphalt Testing Laboratory Evaluation Record Concrete Batch Plant Evaluation Record Concrete Testing Laboratory Evaluation Record NDE Subcontractor Evaluation Record Surveillance Report Surveillance Report Log Receiving Inspection Checklist Transfer of Care, Custody and Control (Turnover Notice) System Walkdown Notice Mechanical Completion Civil Checklist Mechanical Completion Electrical/Instrumentation Checklist Mechanical Completion/Mechanical Checklist
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F02406 000.509.F02407 000.509.F02408 000.509.F02409 000.509.F02501 000.509.F02502 000.509.F70001 000.509.F70002 000.509.F70101 000.509.F70102 000.509.F70103 000.509.F70104 000.509.F70105 000.509.F70201 000.509.F70202 000.509.F70204 000.509.F70301 000.509.F70302 000.509.F70303 000.509.F70801 000.509.F70901 000.509.F71001 000.509.F71002 000.509.F71003 000.509.F71004 000.509.F71005 000.509.F71006 000.509.F71007 000.509.F71008 000.509.F71009 000.509.F71010
FORMS INDEX Form Title Mechanical Completion/Quality Control Checklist Master Punch List Record Interim Turnover Notice Mechanical Completion Certificate Storage Inspection Checklist Equipment Protection Preservation and Inspection Record Inspection and Test Plan Inspection and Test Plan Soil Inspection Checklist Field Compaction Test Record Density of Soil Place by the Sand-Cone Method ASTM D-1566 AASHTO-T-191 Nuclear Moisture-Density Test Report Soil Density Test Log Bituminous Concrete Paving Inspection Checklist Bulk Specific Gravity Nuclear Density Test Report Bituminous Concrete Pile Driving Inspection Record Pile Driving Record Record of Pile Driving Caisson Inspection Record Augered Cast-In-Place Pile Record Pre-Concrete Inspection Checklist Concrete Inspection Record Concrete Pour Card Cementitious Grout Inspection Record Cementitious Grout Testing Record Epoxy Resin Grout Inspection Record Concrete Compression Strength Test Record Concrete Placement Log Grout Placement Log Concrete Batch Plant Inspection Record
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID 10 June 13 10 June 13 VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F72002 000.509.F72003 000.509.F73001 000.509.F73002 000.509.F73003 000.509.F73004 000.509.F73005 000.509.F73006 000.509.F73007 000.509.F73008 000.509.F73009 000.509.F73010 000.509.F73011 000.509.F73012 000.509.F73013 000.509.F73014 000.509.F73015 000.509.F73016 000.509.F73101 000.509.F73102 000.509.F73201 000.509.F74001 000.509.F74002 000.509.F74003 000.509.F74004 000.509.F74005 000.509.F74006 000.509.F74007 000.509.F74008 000.509.F74009 000.509.F74010 000.509.F74011 000.509.F74012 000.509.F74013 000.509.F74014 000.509.F74015 000.509.F74016
FORMS INDEX Form Title Structural Steel Inspection Torque Wrench Calibration Log Building Inspection and Test Checklist Final Building Inspection Summary Carpentry Checklist Painting Checklist Plumbing Checklist Ceramic Tile Checklist Concrete Checklist Structural Steel Checklist Masonry (Brickwork) Checklist Plaster Checklist Doors, Windows, Hardware, Glazing Checklist Computer (Raised) Floors Checklist Prefab Wall Element Systems Checklist Building Metal Siding And Roofing Checklist Buildings Water Proofing And Damp Proofing Checklist Suspended Ceiling Checklist HVAC Inspection Record Buildings Air Conditioning Checklist Roofing Inspection Checklist Equipment Installation Checklist Heat Exchangers & Reboilers Installation Record Electrostatic Precipitator Checklist Inspection Record Static Equipment Tray Installation Inspection Record Air Cooled Heat Exchanger Inspection Checklist Air Cooler Run In Test Report Reciprocating Compressor Inspection Record Fan Installation Inspection Checklist Furnaces Inspection Record Fuel Gas Steam Generator Inspection Checklist Steam Turbine Inspection Checklist Agitators/Mixers Inspection Checklist Equipment/Piping Strain and Alignment Inspection Form Installation Checklist Travelling Cranes Package Equipment Installation Checklist
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID 10 June 13 10 June 13 VOID VOID 10 June 13 10 June 13 VOID VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F74017 000.509.F74018 000.509.F74019 000.509.F74020 000.509.F74021 000.509.F74022 000.509.F74024 000.509.F74025 000.509.F74026 000.509.F74027 000.509.F74028 000.509.F74029 000.509.F74030 000.509.F74031 000.509.F74032 000.509.F74033 000.509.F74101 000.509.F74102 000.509.F74103 000.509.F74104 000.509.F74105 000.509.F74106 000.509.F74201 000.509.F74301 000.509.F74401 000.509.F74402 000.509.F74405 000.509.F74406 000.509.F74407 000.509.F74408 000.509.F74601 000.509.F74602 000.509.F74603 000.509.F74604 000.509.F74605 000.509.F74606
FORMS INDEX Form Title Desuperheaters/Ejectors Inspection Checklist Filters/Strainers Installation Record Centrifugal Compressor Inspection Record Rotating Equipment Inspection Record Rotating Equipment Alignment Record Belt Driven Equipment Alignment Record Inspection Record For Draw Off Tray Leak Test Report Inspection Record For Air Coolers Final Closing Authorization Record API 686 Baseplate Installation Checklist (Prior to Grouting) API 686 Equipment Grouting Checklist API 686 Alignment Check Sheet Baseplate Leveling Record Reverse Dial Alignment Record Piping Alignment Data Sheet Rotating Equipment (Face-Rim) Alignment Record Tank Elevation Tolerances Record Inspection Record Field Erected Tank Tank Plate Dimensional Control Record Field Erected Tank Water Filling And Settlement Record Field Erected Tank Tank Leak Test Record Tank Test Certificate Inspection Record Cooling Tower Field Installed Refactory Record Gas Turbine/Generator Gear Inspection Checklist Gas Turbine Inspection Record Shop-Fabricated Field-Erected Stack Inspection Record Heat Recovery Steam Generator Inspection Record Breeching And Duct Work Inspection Record Equipment Protection Activities Record Gas Turbines Site Daily Activities Log Stg Foundation Settlement Record Stg Fixators Stg Sole Plates Stg Front Standard Base Plate Assembly Exhaust Hood Horizontal Joint Levelness
Revision Date VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F74607 000.509.F74608 000.509.F74609 000.509.F74701 000.509.F74702 000.509.F75001 000.509.F75002 000.509.F75003 000.509.F75101 000.509.F75102 000.509.F75103 000.509.F75201 000.509.F75501 000.509.F75502 000.509.F75503 000.509.F75504 000.509.F75505 000.509.F75506 000.509.F75507 000.509.F75508 000.509.F75509 000.509.F75601 000.509.F75701 000.509.F76001 000.509.F76002 000.509.F76003 000.509.F76004 000.509.F76005 000.509.F76006 000.509.F76007 000.509.F76008
FORMS INDEX Form Title Stg Shell/Casing Load Test Stg Piping Attachment Stg Foundation Top of Concrete Elevations Generator Test Checklist Generator Cold Resistance Test Record Underground Pipe Inspection Record Insulation Resistance (Insulated Flanges-Underground Piping) Test Record Holiday (Spark) Test Record Aboveground Pipe Inspection Record Visual Inspection of Flanges, Gaskets and Bolting Weld Map Record Pressure Test Report Hygienic Drawing Revision Log Hygienic Material Receiving Log Hygienic Valve Receiving Inspection Report Hygienic Vessel Nozzle Receiving Inspection Report Hygienic Tube/Fitting Receiving Inspection Report Hygienic Pre-weld Inspection Checklist Hygienic Welder Qualification Report Hygienic Orbital Weld Log Hygienic Post Installation Checklist Pipe Cleaning and Verification Checklist Mechanical Heat Tracing Inspection Record Conduit And Cable Tray Checklist Electrical Manhole Inspection Checklist Medium & High Voltage Underground Cable Splice Inspection Record Medium and High Voltage Cable Termination Checklist Cable Pulling Inspection Checklist Fan/Speed Reducer/Motor Inspection Checklist Switch House Inspection Checklist Lighting Receptacle, Instrument Distribution Panels Inspection Checklist
Revision Date VOID VOID VOID VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID VOID VOID VOID VOID VOID VOID VOID 10 June 13 VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
FORMS INDEX Form Title Electrical Motor Inspection Checklist Aboveground Conduit Inspection Checklist Lighting Panelboard Inspection Record Underground Conduit (Duct Bank) Inspection Grounding/Earthing System (Grid or Loop) Inspection Record Cable Termination Checklist Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record Insulation Resistance (Power, Control Wire And Cable) Test Record Insulation Resistance (Instrument Wire And Cable) Test Record DC High Potential Test (Medium Voltage Cable) Record Current Transformer (And Ammeter) Test Record LV Over-current And Earth/Ground-Fault Protection Relay Test Over-current/Ground Fault Protection Relay (Induction Type) Test Over-current/Ground Fault Protection Relay (Thermal Type) Test Switching Units HV Switchgear Inspection And Test Record Ground Electrode Resistance Inspection Test Record Ground Fault Protection Relay Induction Inspection and Test Record Grounding Continuity Inspection and Test Record Grounding Rod Inspection and Test Record Bus Bar Assemblies LV Switchgear Test Record Neutral Grounding/Earthing Resistor Test Record Ground Continuity (Non Electrical) Equipment/Structures Test Record Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record Insulation Resistance (Equipment) Test Record Insulation Resistance (Transformer) Test Record Liquid Dielectric Strength Test Record DC Proof Test Record for Motors Feeder Breaker (480V MCC) Test Record Breaker/Contractor (480V MCC) Test Record 460V Motor Circuit (480V MCC) Test Record Medium Voltage Motor Circuit Test Record Equipment Absorption Ration and Polarization Index Test Record (Megger) Insulation Resistance (Medium Voltage Power Cables) Test Record Bus Throat Insulation and Ductor Reports Circuit Breaker Contract Timing Test Report
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
000.509.F76101 000.509.F76102 000.509.F76103 000.509.F76104 000.509.F76105 000.509.F76106 000.509.F76107 000.509.F76108 000.509.F76109 000.509.F76110 000.509.F76111 000.509.F76112 000.509.F76113 000.509.F76114 000.509.F76115 000.509.F76116 000.509.F76117 000.509.F76118 000.509.F76119 000.509.F76120 000.509.F76121 000.509.F76122 000.509.F76123 000.509.F76124 000.509.F76125 000.509.F76126 000.509.F76127 000.509.F76128 000.509.F76129
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F76130 000.509.F76131 000.509.F76132 000.509.F76133 000.509.F76134 000.509.F76135 000.509.F76201 000.509.F76202 000.509.F76203 000.509.F76204 000.509.F76205 000.509.F76206 000.509.F76207 000.509.F76208 000.509.F76209 000.509.F76210 000.509.F76211 000.509.F76212 000.509.F76213 000.509.F76214 000.509.F76215 000.509.F76216 000.509.F76217 000.509.F76218 000.509.F76219 000.509.F76220 000.509.F76221 000.509.F76222 000.509.F76223 000.509.F76224 000.509.F76225 000.509.F76226 000.509.F76227 000.509.F76228 000.509.F76229 000.509.F76230 000.509.F76231
FORMS INDEX Form Title Vacuum Circuit Breaker Ductor Insulation Report Drawout Vacuum Breaker Inspection Test Main Bus Insulation and Ductor Report Electric Motor Run-In Test Record Drawout Air Circuit Breaker Inspection Record Insulation Resistance (Rotating Equipment) Test Record Emergency Generators Inspection Checklist Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units) Inspection LV Switchgear (Including Incoming and Sectionalizer Units) Inspection of Outgoing LV Switchgear Inspection of Static Supply Unit (UPS) Motor Control Centers Inspection Checklist Motor Control Centers (Motors and Starters) Inspection Record High Voltage Motors and Starters Motors Checklist Control and Relay Panels Inspection Checklist Electronic Equipment Inspection Checklist Power Panel Inspection Checklist Switchgear Inspection Checklist Low Voltage Feeders Inspection Record High Voltage Cable Inspection and Test Record Electrical Equipment Inspection Record Control Scheme Inspection Checklist Power Transformer Inspection Checklist Switching Units HV Switchgear Inspection and Test Record Switching Units HV Switchgear Inspection Checklist Liquid Filled Transformer Inspection Record Busway Inspection Record Switchgear Inspection Record Motor Control Center Inspection Record Battery and Battery Charger Inspection Record Liquid Immersed Medium Voltage Disconnect Switch Inspection Record Electric Motor Electrical Activities Inspection Record Electric Motor Mechanical Activities Inspection Record Electric Motor for Compressor Installation Checklist Compressor Vibration Checklist Vibration Probe Record
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F76232 000.509.F76233 000.509.F76401 000.509.F76402 000.509.F77001 000.509.F77002 000.509.F77003 000.509.F77004 000.509.F77005 000.509.F77006 000.509.F77007 000.509.F77008 000.509.F77101 000.509.F77102 000.509.F77103 000.509.F77104 000.509.F77105 000.509.F77106 000.509.F77107 000.509.F78001 000.509.F78002 000.509.F78101 000.509.F78102 000.509.F78201 000.509.F78202 000.509.F78301 000.509.F79001 000.509.F79002 000.509.F79201 000.509.F79202 000.509.F79203
FORMS INDEX Form Title Dry Type Lighting, Receptacle & Instrument Transformers Checklist Instrument Wire and Cables Continuity Checks >50VDC Heat Trace Test Log Electrical Heat Trace Inspection Record Instrumentation Inspection Checklist Instrument Loop Checklist Inspection Impulse Line Pressure Test Sheet Instrument Grounding System Check Sheet Installation Check Sheet (Local Instruments) Orifice Plate Specification Check Report Control Systems Quality Loop Check Record Instrument Calibration Sheet Safety Valve Tracking Sheet Relief Valve Inspection and Final Acceptance Switch Calibration Data Record Valve Calibration Data Record Control System Test Equipment Calibration Log Loop Mechanical Completions & Acceptance Record Coating Inspection Record Lining Inspection Record Equipment Thermal Insulation Inspection Piping Thermal Insulation Record Release For Application/Inspection Of Fireproofing Checklist Fireproofing Inspection Preconstruction Checklist Cathodic Protection Inspection Report Daily Welding Report Post Weld Heat Treatment Log Welder B31.3 Random Radiography Control Log Nondestructive Examination Request/Record Radiographic Rejectable Defects Statistics
Revision Date 10 June 13 10 June 13 VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
Form Number 000.509.F79204 000.509.F79205 000.509.F79206 000.509.F79301 000.509.F79302 000.509.F79303 000.509.F79304 000.509.F79501 000.509.F79502 000.509.F79503
FORMS INDEX Form Title Welding/NDE Status Log Ferrite Test Report Welding/NDE Double Joints Status Log PMI Inspection Record Bulk Material Positive Material Identification Record Pipe Spool Positive Material Identification Record Point Sheet Weekly PMI Log Verification Of Training For Hardness Testing Report Of Vision Test Hardness Testing Report
Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0010 Revision 0, 10 June 2013
FOREWORD The objective of the site quality program for this project is to ensure that construction is performed in accordance with the drawings, specifications, applicable local, state and federal standards and Codes. A further objective is to provide documented evidence that confirms that the primary objective has been met. The site quality control program as delineated in this manual is tailored to meet the quality surveillance, inspection, testing, and documentation requirements for construction/installation performed by subcontractors and Fluor self-perform construction. The site quality program is based upon the principals stated in the Operating System Requirements (OSR) and any applicable Operating System Implementation Plan (OSIP). It is designed to cover quality aspects related to construction, construction management and maintenance activities. The Site Quality Manager will coordinate the construction quality surveillance, inspection, testing, and documentation activities. He will monitor construction and quality activities to the extent necessary to provide construction management with adequate confidence that appropriate measures are being taken to control and achieve quality. The quality activity will emphasize preventing nonconformance to drawings and specifications but detecting and correcting it if it occurs. When Fluor performs construction activities using our own labor force, the quality control responsibility remains with Fluor. The Fluor construction supervision and construction engineering staffs are primarily responsible for the attainment of the quality requirements established by the drawings, specifications and contract. The supervisory, construction engineering and quality staffs will perform quality control inspection, testing, surveillance and documentation activities as outlined in this manual. The primary responsibility for performing quality workmanship rests with those actually performing the work under the supervision of the Fluor construction staff. When an element of 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 with 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 measures 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. This site specific Quality Manual 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 ASME Boiler and Pressure Vessel Code work. The Fluor "Quality Control System Manual for Boiler and Pressure Vessel Code Work" will be applied to ASME and National Board Inspection Code Work certified by Fluor.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0010 Revision 0, 10 June 2013
The Project Procedures Manual (PPM), used in conjunction with the Site Quality Manual, contain or identify approved procedures used to identify, document and verify the appropriate reviews and approvals of changes to design documents that are requested by field organizations and provide requirements for document control. The Fluor Construction Technology staff will conduct independent audits of project compliance to this manual. The audits are conducted to provide the Project Manager, Site Manager, and Client with a project independent evaluation of the site quality program status and adequacy. The initial audit will be conducted at approximately 10% mechanical completion and additional audits on a periodic basis throughout construction.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0020 Revision 0 , 10 June 2013
SCOPE This procedure provides guidance for converting the 509 series of Corporate Site Quality procedures from Knowledge OnLine to a Site Quality Manual for a specific project. It is applicable to Construction, Construction Management, Maintenance, or projects with any of these combinations. GENERAL The initial draft of the project specific Site Quality Manual is initiated by Construction Technology's Corporate Quality Manager. It is to be based on reference procedures of the 509 series of Site Quality procedures from the Construction Knowledge Community that are listed in the Table of Contents section 000.509.0000. These reference procedures have been prepared to meet the requirements of International Standard ISO-9000. The bracket symbols ([::---::]) seen throughout these procedures identify changes or additions that are to be made in converting them to project specific procedures. Other changes are to be made as needed to be compatible with the project requirements and scope. The set of procedures in the 509 series represents the accumulated knowledge and experience gained from many construction projects. Use of these reference procedures as baseline documents will result in improved consistency between projects and entities, thus fulfilling the goal of consistency in execution. Proposed changes to these reference procedures should be communicated to Construction Technology's Corporate Quality Manager. Upon assignment of the Site Quality Manager, he/she begins development of the draft Site Quality Manual (SQM) to assure conformance to the site-specific requirements. The completed and approved project specific SQM should be in place for usage as soon after contract award as possible. As a minimum, parts of the manual should be developed for control of construction activities before the activities are performed. These activities usually begin with qualifying and issuing RFQ's to bidders for work to be subcontracted (see 000.509.0200and 000.509.0210). If these activities begin prior to assignment of the Site Quality Manager, Construction Technology's Corporate of Quality Manager will function as the Site Quality Manager until the assignment is made Development of Site Specific Quality Manual Each section/procedure identified by 000.509.0000 is reviewed for consistency and applicability with project scope. Changes or additions will be required of the following sections as noted: Inspection and Test Procedures (7000 - 7999); Select the procedures that are applicable to the contracted work scope. Select the applicable forms from the procedures if all are not needed. Review the "Responsibilities" Section and modify, if needed, to suit the project organization. Also delete either the "Self-Perform" or "Subcontracted" Section, if not applicable. Table of Contents / Date Revision Page (0000); Under "Procedure Number" and "Title" change to include only those procedures used in the project manual.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0020 Revision 0 , 10 June 2013
Under "Revision Date." enter the date, month and year for all initially approved procedures. Enter appropriate dates for each project revision it undergoes after initial project approval. Revision dates for all pages of all procedures in the project specific manual should match the dates in this Table of Contents. Revisions to the Site Quality Manual shall not waiver or negate OSR requirements or mandatory construction codes. Revision of Site Specific Manual The Site Quality Manager controls the site issue and revision of the Site Specific Quality Manual. The manual 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 manual. The Table of Contents shall show the revision date of each revised procedure and shall be reissued for each revision. The Corporate Quality Control Manager in each of the respective offices shall review and approve the Issued for Construction Site Quality Manual prior to the approval signatures being obtained. Each subsequent revision to the Site Quality Manual shall also be approved by the Corporate Quality Control Manager. The Site Quality Manager, Construction Engineering Manager, and Site Manager should approve each revision by signing the Approval Page. The Client should also be given the opportunity for approval of the Site Quality Manual.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
ORGANIZATION AND RESPONSIBILITIES 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 which includes construction quality. The delegation of authority to the Site Quality Manager for the direction and coordination of quality activities is made with 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 work 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 work being performed. ORGANIZATION The project organization for site quality personnel are shown on the Site Organizational Chart maintained by the Site Manager. RESPONSIBILITIES Quality related activities are conducted by Site Quality and other groups. The activities and persons conducting them will be under the functional control of the Site Quality Manager for the execution of the activity. Attachment 1- Quality Responsibility Matrix summarizes the activities and the persons responsible for execution. Primary responsibility for execution and verification of quality-related activities will be established on the Inspection/Test Plan or procedures.
Site Quality Manager The Site Quality Manager has the responsibility, authority, and organizational freedom to audit, inspect and witness construction activities and to verify compliance to contract quality requirements. This responsibility includes actions such as assist the construction staff in prevention of quality problems, identification of quality-related problems should they occur, initiation or recommendation of solutions and verification of corrective action. In addition, he/she is responsible for coordination of quality-related activities within the Construction staff and with the site Client quality representatives. He/she maintains the construction quality control procedures and provides technical assistance and training to construction supervision. He/she will have an active role in assisting with the prevention of quality problems. The Site Quality Manager reports directly to the Site Manager with a technical supervision channel to Construction Technology's Corporate Quality Manager. The Construction staff includes a Construction Engineering organization to ensure prompt engineering interpretations and decisions, review of drawings, certificates and other data to be submitted to the Client, and to actively participate in the surveillance of field construction, and to verify compliance to
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
design/engineer requirements. Construction Engineering will provide assistance to the Site Quality Manager as necessary to assist in achieving quality objectives. NOTE: Construction Engineers report to the Site Quality Manager when they are executing inspection/surveillance activities.
Subcontractors The subcontractor quality organization will be in accordance with the contract requirements and described in their approved equivalent Site Quality Manual. ATTACHMENTS Attachments 1 Quality Responsibility Matrix
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
Quality Responsibility Matrix Section 1 - CIVIL 1.1 Construction Surveying ACTIVITY Review the construction surveying methods used by the Contractor. Check established reference points . Check control points established for construction layout on a periodic basis. Check the construction layout of the contractor's work. Review and file completed survey notes prepared by the contractor. Perform periodic surveillance on survey activities and documentation. 1.2 Soils ACTIVITY Monitor in-process soils work, including cut and fill elevations, spoil and fill material, compaction methods and equipment. Perform formal audit of Soils Testing Laboratory Monitor Contractor's work to verify conformance to requirements. Monitor Soil Testing Laboratory activities for soils testing frequency, test identification and completeness. Verify the documentation of deficiencies and test failure and follow up to assure corrective action is taken and documented. Audit the soils documentation to verify correctness, completeness of coverage, retrievability as filed and inspection results. Perform and document soils testing Inspect excavations for unstable and unsuitable soils Verify the insitu soils are suitable to support foundation loads Verify backfill material is satisfactory Verify placement of the fill complies with contract specifications 1.3 Contracted Piling ACTIVITY Qualify Pile Supplier Review and approve concrete mix design and mix trials Technically monitor the indicator pile testing program Check final pile locations. Monitor in-process pile driving. Monitor and test pile concreting activities.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
RESPONSIBILITY Construction QA/QC X X X X X X RESPONSIBILITY Construction QA/QC X X S X X X TEST LAB TEST LAB TEST LAB TEST LAB TEST LAB S S S S S
S S X
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
1.4 Asphalt ACTIVITY Review asphalt mix designs Monitor in-process asphalt construction including preparation of subgrade or previous course, asphaltic materials, spreading equipment, compaction equipment, materials and testing. Perform formal audit using Asphalt Test Laboratory Evaluation Record Monitor Contractor's quality control activities to verify conformance to requirements for asphalt testing frequency, test identification and traceability and the documentation of inspection and testing Review the documentation of the asphalt inspection and testing activities for accuracy and completeness. Verify the documentation of deficiencies and test failures and follow up to assure corrective action is taken and documented. Audit the asphalt documentation to verify correctness, completeness of coverage, review ability as filed and inspection results. Conduct asphalt testing and asphalt materials testing 1.5 Structural Concrete ACTIVITY Review and approve mix designs Perform formal audit of Concrete Testing Laboratory. Audit batch plant facilities. Inspect formwork, reinforcing steel and impediments prior to concrete placement. Monitor in process concreting activities. Monitor Contractor's quality control activities to verify conformance to requirements for concrete testing frequency, test identification and traceability, and the documentation of inspection and testing. Monitor post-concreting activities such as concrete curing, stripping, visual examination for line, form and surface defects and checks for anchor bolt locations. Verify that 28-day strength tests are acceptable. Conduct concrete testing at the point of placement 1.6 Grouting of Machinery and Structural Steel Base Plates ACTIVITY Review and approve mix design. Check materials prior to start of work to verify that the materials have not deteriorated or that shelf life has not been exceeded. Monitor in-process grouting. The inspections shall include base preparation,materials, forming, placing, curing and hammer void test. Witness grout testing by Contractor. Monitor the Contractor's quality control activities to verify conformance to placement procedures and documentation requirement. Conduct grout testing at site
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
X TEST LAB
S S
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
Section 2 - STRUCTURAL STEEL 2.1 Structural Steel ACTIVITY Monitor in process steel erection to verify fabrication is correct and erection is in accordance with drawings. Document fabrication errors on a NCR. Witness bolting procedure including calibration of torque wrenches and load indicating washers. Maintain documentation Inspect the erected steel structure. Ensure that erected steel structures have coatings installed i.a.w. drawings Monitor the Contractor's quality activities to verify conformance to requirements for bolt tensioning procedures. Schedule final acceptance inspection activities between Contractor and Field Engineering or construction. Audit the structural steel documentation to verify correctness of data. Section 3 - BUILDINGS 3.1 Buildings ACTIVITY Review all Contractor proposed building materials prior to use. Verify that the building location level and position are correct prior to construction. Inspect the entire building upon completion and document deficiencies. Document building acceptance Monitor the in process construction to verify that the work is i.a.w. drawings. Schedule final acceptance activities Monitor the Contractor's quality control activities to verify test frequency, identification and traceability Audit building documentation
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
Section 4 - EQUIPMENT 4.1 Equipment ACTIVITY Inspect installed equipment for acceptance upon completion, including attachments to the equipment, e.g. foundations, sheds, buildings, auxiliaries, etc. which comprise the entire assembled unit. Initiate action to acquire vendor representative as required. Coordinate with engineering for participation of mechanical discipline engineers, if required. Monitor the in-process installation of each equipment unit. Coordinate with vendor representative who technically supervises equipment installation. Verify vendor representative's checklists and acceptance records are signed and attached to appropriate construction documents. Verify the equipment requirements are being satisfied by the Contractor. Monitor equipment preservation i.a.w. Site requirements. Monitor the Contractor's quality control activities to verify conformance to inspection, testing and documentation requirements. 4.2 Field Fabricated Tanks ACTIVITY Monitor the foundation construction including soils, asphalt and concrete work. Check elevation dimensions of tank shells. Check the erected dimensions of tank shells. Inspect fabricated tank structure upon completion. Check the settlement and rebound of the foundation during and after hydrotest. Verify welder performance qualifications. Verify welding procedure testing has been accomplished and procedures are acceptable. Monitor in-process welding Witness in-process examination as performed by the NDE contractor, including reviewing radiographs, witnessing PT, MT, vacuum box and leak testing Verify that equipment and components associated with tankage have been correctly installed, adjusted, tested, confirmed for proper function and inspected. Inspect the tested tank prior to closing, including final clean-up. Verify that the Contractor has affixed a nameplate listing the required data. Verify that the Contractor has submitted the required certification. Monitor the Contractor's quality control activities to verify conformance inspection, testing and documentation requirements. Witness hydrostatic testing
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
Section 5 - PIPING 5.1 Underground Piping ACTIVITY Monitor in-process excavation and backfill. Inspect installed underground pipelines for acceptance. Color code the lines, indicated as punched and accepted, on a copy of the underground piping plan. Verify that the Testing Lab is performing the required soils testing of backfill. Monitor in-process coating and wrapping, including surface preparation, coating and wrapping methods and materials and arrangement for intermediate storage and stockpiling of coasted pipes. Inspect in-process pipe fabrication and installation i.a.w. drawings. Perform a final inspection of the line, when the underground piping is complete, but prior to the coating and wrapping of joints and fittings. Verify the Contractor has completed coating and wrapping of joints and fittings on tested line. Witness holiday testing of the coating and wrapping. Contractor shall document tests. Verify that required NDE is complete on the lines to be inspected. Witness the pressure test. Inspect the tested system to ensure that all items have been properly completed (restoration). Monitor the Contractor's quality control activities to verify conformance to testing and documentation requirements. 5.2 Site Shop Fabrication ACTIVITY Segregate and store pipe fittings, upon receipt, according to size and material. Identify storage location with commodity code number. Pipe will be marked full length with commodity code number. Maintain documentation Issue piping materials to Contractors Inspect special flange faces for correct finish and face protection. Monitor in-process pipe fabrication activities. Verify latest edition of piping drawings is being used. Random check on base material ID on pipe, fittings and spools. Spools shall be clearly identified in two locations. Monitor storage of completed spools at pipe shop including preservations. Monitor pipe identification, documentation and timely performance of NDE.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
S S S S S X
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
5.3 Aboveground Piping Erection ACTIVITY Pipe will be marked full length with commodity code number. Alloy pipe and fittings shall be additionally color coded. Alloy storage areas shall be clearly identified. Maintain piping spool identity markings of piping spools fabricated off site. Verify MTR's are received and that heat numbers correspond. Maintain documentation Verify PMI requirements are satisfied prior to placement in stock. Verify correct pipe is issued to Contractor. Monitor in-process erection I.a.w. drawings. Classify and record spool fit problems. Ensure face flange protection is maintained. Monitor proper bolt tensioning. Monitor correct gasket installed. Monitor erection to ensure that pipe installations are not subjected to undesirable stress. Check pipe drawings to assure latest revision in the field. Assist Contractor to maintain current piping test status. Monitor Contractor's activities to established quality control practices. Monitor in process pipe erection and transfer of heat numbers. Verify that NDE is performed in a timely manner. Monitor pipe and welding traceability including PWHT, PMI and Hardness Testing. 5.4 Piping Inspection - Punching ACTIVITY Flag deficiencies when not visually obvious. Enter punch lists into data base. Check work, noted as complete, on punch lists to assure items were corrected. Initiate action with Contractor on punching results. Add additional discrepancies to punch list. Initial and date punch list for each item corrected. Monitor the Contractor's punching activities. Verify that punching deficiencies are identified, documented and follow up to verify corrective action is taken. Verify that measures are taken to assure NDE, PWHT, PMI and traceability is completed prior to pressure testing.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
5.5 Pressure Testing of Piping ACTIVITY Monitor pressure testing performed by Contractor. Review drawings and specifications to verify pressure test package limits, equipment to be included or excluded, valves opened or closed and test blind locations. Verify that the maximum allowable test pressure of the weakest component within the system is not exceeded. Verify (through NEWS) that all NDE is complete prior to testing. Verify that shop spool/cut sheets are included in test packages and all NDE, PWHT and welder info is recorded. Review Contractor's pressure test package, including marked up isometric drawings indicating test blind locations, valve position (open/closed) and other information relating to test. Monitor preparation of test system against test package. Monitor restoration of the tested system. Monitor Contractor's pressure testing and documentation activities. Review test package for completion Inspect the system prior to testing notifying Contractor of deficiencies. Mark Pressure Test Record, "Ready to Test". Notify client when acceptable for test. Give permission to proceed with test. Inspect system under pressure. Verify test pressure and duration of test. Procure test acceptance signatures from Contractor and QIB. When equipment is included in the test, verify that pressure test does not exceed nameplate. 5.6 Piping Internal Cleaning ACTIVITY Review and approve the cleaning and preservation procedures and the limits agree with drawings. Establish hold points for witnessing tests. Monitor preparatory and in-process cleaning activities for compliance with procedures and specs. Coordinate the monitoring of Contractor inspection and testing activities. Verify the Contractor is preparing documentation as inspections and tests are being performed. Verify that internal cleaning has been accomplished. Monitor the Contractor's quality control activities.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
X X S
S X
X S
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
Section 6 - ELECTRICAL 6.1 Underground Electrical ACTIVITY Monitor in-process installation of the grounding system including, grounding rod installation, backfilling. Color coding of drawings to track progress. Witness resistance to earth tests. Monitor in-process duct bank and electrical manhole installations. Witness initial testing of shielded cable, i.e,. insulation resistance test of power cable on reels, continuity test of reeled instrument cable. Inspect cable trench prior to installation of cable. Monitor in-process installation of underground cable. Inspect in-process cable pulling. Inspect in-process cable splicing. 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. Inspect installation of cables upon completion of each layer to ensure spacing, labeling, etc. is correct. Inspect sand backfill per lift for quality of materials, depth and compaction. Verify the Contractor final as-built drawings are in conformance. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractors' quality control activities. 6.2 Aboveground Electrical ACTIVITY Monitor in-process installation of electrical conduit and cable tray, including welding of supports. Witness initial testing of shielded cable, i.e., insulation resistance test of power cable on reels, continuity test of reeled instrument cable and resistance and continuity on electrical heat tracing cables. Monitor in-process cable pulling and installation. Witness random testing of installed cable, i.e., insulation resistance test on power and instrumentation cables, continuity and insulation resistance testing on heat tracing and hypot of medium and high voltage cables. Verify client is being notified in advance of tests that require witness. Verify terminal to terminal checks to ensure continuity and correctness of installation. Verify conduit seals have been poured. Inspect installation upon completion. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractor's quality control activities.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
X X X X X X X X
S S S S S S X
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
6.3 Electrical Equipment ACTIVITY Monitor in-process installation of equipment. Monitor equipment preservation activities Witness testing of installed equipment. Coordinate with vendor representative who will technically supervise installation. Ensure documentation is complete. Verify QIB is being notified in advance of tests requiring witnessing. Inspect electrical installation when complete. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractor's quality control activities. Section 7-CONTROL SYSTEMS 7.1 Control Systems Site Shop Operations ACTIVITY Notify construction upon receipt of each instrument shipment for inspection. For nonconforming items, issue a Damage Report or NCR. Issue instruments to Contractor. Inspect each instrument shipment. Deficiencies shall be reported to the Material Manager. Inspect instrument materials i.a.w.sec.10 & project procedures Document the receiving inspection. 7.2 Control Systems Field Operations ACTIVITY Monitor the Contractor's in-process instrument installation including racks, panels, consoles, locations,mounting,process pipe connections, Instrument air tubing,pneumatic signal tubing,heat tracing and instrument wiring Witness pressure testing of the instrument piping and tubing documentation. Witness calibration of test guages. Monitor continuity tests of instrument cables.Verify that cable terminations are correct. Witness checks of control system loops. Establish notification system for IMT. Witness all loop checks Assure all instrument installation inspections and meggar tests are complete Inspect instrument installations upon completion. Monitor the Contractor's quality control activities. Verify documentation procedures are being followed.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
Section 8 - COATINGS, LININGS, INSULATION AND CATHODIC PROTECTION RESPONSIBILITY Construction QA/QC Ensure that the paint system is i.a.w. specifications. X S Monitor performance of materials preservation activities. X S Monitor surface preparation.Verify inspection documentation. X S Monitor in-process coatings applications. X S Check dry film thickness of applied coatings. X S Inspect the workmanship of completed finishes. X S Monitor the Contractor's quality control activities. S X Verify the Contractor has prepared the QC documentation. S X Audit coating documentation. X 8.1 Coatings ACTIVITY 8.2 Insulation ACTIVITY Monitor performance of material preservation activities. Monitor in-process installation of the insulation materials. Verify the Contractor has prepared the quality control documentation Inspect the completed work. Document acceptance. 8.3 Linings ACTIVITY Monitor performance of material preservation activities. Monitor surface preparation. Verify Contractor is performing temperature and humidity checks for tank linings. Monitor in-process lining application. Test applied linings to verify proper surface profile, thickness, and lining continuity. Monitor Contractor's tank lining holiday inspections. Observe tank lining curing activities. Inspect the workmanship of the completed lining. Monitor the Contractor's quality control activities. Audit coating documentation. Verify that lining materials comply with specs. Ensure that manufacture test certificates correspond with filed batch number records. Monitor storage facilities. Ensure refractory applicators are experienced and qualified. Monitor to ensure materials are properly mixed. Monitor surface preparation to ensure mounting studs and reinforcements are correctly installed. Ensure that test plates,cubes,etc,from refractory applications are taken at the required frequencies
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
X X X X X X
S S S S
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
8.4 Cathodic Protection - Underground Structures. ACTIVITY Submit data to Engineering for determination of anode spacing Establish a procedure to assure work is not started prior to acceptance of previous work. Monitor the survey after each cathodic protection system is energized. Verify materials being installed. Monitor installation activities. Monitor deep well preparation activities including data logs. Monitor anode backfill operation. Witness hammer testing of thermite welds Witness electrical test used to determine current flow when the anode is backfilled with coke breeze. Monitor testing and commissioning activities. Inspect the completed work. Audit cathodic protection documentation. 8.5 Cathodic Protection - Tanks and Vessels ACTIVITY Verify materials are within specification and are properly protected from damage. Verify the vessel cathodic protection materials were installed. Monitor installation activities Verify personnel use of protective clothing (when reg's) Inspect the completed workmanship. Monitor testing and commissioning activities. Audit cathodic protection documentation. Section 9 - WELDING 9.1 Pipe Welding ACTIVITY Verify the WPS's have been approved by the Welding Engineer. Monitor qualification tests of Contractor's welders. Ensure that welder ID badges have been issued and displayed. Check Contractors control of welder symbols. Check Contractor's control of welding consumables. Monitor in-process welding including consumables, joint preparation,fit-up preheat, interpass heat, WPS variables and final visual Verify Contractor is documenting welds on the Daily Welding Report. Verify completed welds are being documented on piping drawings. Monitor in-process post weld heart treatment. Audit welding documentation. Verify transfer of piping material heat numbers.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
S S S S X
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
9.2 Structural and Reinforcing Steel Welding ACTIVITY Verify the WPS's have been approved by the Welding Engineer. Monitor qualification tests of welders. Monitor in-process welding including consumables, joint preparation and final visual inspection. Audit welding documentation. 9.3 Piping Nondestructive Examination (NDE) ACTIVITY Pre-qualify NDE Contractor Verify that the NDE Contractor has established procedures that comply with project specifications. Daily entry of weld data to NEWS program. Establish and maintain NDE documentation files. Review Contractor NDE personnel certifications. Verify approval of NDE Contractor and procedures. Verify NDE Contractor's procedure to provide visual status of welds requiring NDE. Select welds for examination Perform Nondestructive examinations Review radiographic film, Contractor's interpretation and reports. Verify code compliance for rejected welds. Maintain a tickler file of rejected welds. Verify, through audit, welding and NDE records are traceable to the weld. Verify through NEWS that NDE is completed prior to pressure testing. Audit the NDE lab Monitor the NDE Contractor's production to verify that welds are examined within 48 hours of notification. Verify all field welds are numbered and identified on drawings. Ensure that weld number and welder's symbols are low stress stamped or otherwise marked on pipe. Ensure that an accurate Daily Welding Report is maintained.
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
X S X X X X X X X X
X S
S X
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
9.4 Pipe hardness Testing ACTIVITY Monitor the Contractor to verify weld identity system and compliance to specification. Establish confidence that tests are being preformed i.a.w. test equipment instructions. Verify the Contractor's compliance with hardness testing and documentation. Verify Contractor's procedure for visual identification of rejected welds. Maintain a PWHT tickler file for rejected welds. Verify hardness testing is complete prior to pressure testing. Witness tests required by the specifications as performed by Contractor. Schedule final acceptance inspection activities between the Contractor and the Field Engineer. Monitor the Contractor's quality control activities to verify conformance to requirements for test frequency, identification and traceability. Section 10 - FIELD RECEIVING 10.1 Field Receiving (IMT) ACTIVITY Control receiving operations including ID of item to purchase order, verification of quantity and size examination for shipping protection and damage, maintenance of inspection documentation. Issuance of periodic receiving reports to Construction Superintendents when technical assistance is required. Inspect received material/equipment, providing technical assistance, when requested. 10.2 Field Receiving -Contractor ACTIVITY Receive all contractor purchased equipment and materials Review material test reports against received materials and maintain on file Issue equipment and materials to the Contractor Inspect received material/equipment, providing technical assistance when requested Assure that the contractor performs the equipment and material protection as required by manufacturers instruction or specification requirements
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013
10.3 Positive Material Identification (PMI) ACTIVITY Notify QA of receipt of material requiring PMI. Maintain PMI test results with receiving documentation. Verify receipt of PMI reports from suppliers and fabricators, Verify Contractor has established a system to maintain material ID through receiving, storage, issue, fabrication and election. Implement procedures for PMI. Monitor contractor's maintenance of piping material identification. Perform PMI as required by specification. Verify ID marking are accomplished per specification. Verify controls have been established to prevent the in advertent use of materials failing examination. Verify the filing, maintenance and retention of documentation. Assure that PMI equipment is calibrated.
X X S
Section 11 - EQUIPMENT AND MATERIAL PROTECTION 11.1 Equipment and Material Protection RESPONSIBILITY ACTIVITY Construction QA/QC Monitor equipment and material preservation in storage and document. 11.2 Equipment and Material Protection (Contractor) ACTIVITY Monitor Contractors in-process equipment and material protection/preservation activities. Check Contractors in-process equipment and material Audit the Contractor Material and equipment protection activities. Section 12 - MASTERPIECE PROGRAM 12.1 Masterpiece Program ACTIVITY Develop Masterpiece List Ensure Contractor is using correct materials, drawings and specifications Advise contractor when a Masterpiece is required Inspect Masterpiece prior to QA notification Request client's presence during inspection Document acceptance of the Masterpiece Notify client of accepted Masterpiece Maintain the Masterpiece log Maintain Masterpiece model as reference standard Monitor the Contractor's quality control activities to verify conformance to drawings and specifications
PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval
MM
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013
DOCUMENT CONTROL SCOPE This procedure describes the Document Control system to be used by site construction personnel. GENERAL Engineering Documents Design Engineering documents such as specifications and drawings that are issued to Construction are controlled and issued on site in accordance with this procedure. Construction Engineering maintains an up-to-date register of drawings and specifications. This procedure is designed to ensure that the latest drawings issued to construction, including shop drawings, specifications and instructions, as well as authorized changes thereto, are delivered to the proper locations and personnel responsible for performance of the work. This procedure also provides for the prompt removal of obsolete documents from all points of issue or use. The Construction Engineering staff reviews engineering documents for adequacy and completeness to perform the work and coordinates site needs for clarification with the designer. Subcontractors obtain clarification through the Fluor Construction Engineering Manager. Construction Engineering maintains drawings and specification control records, processes all design document changes, ensures proper authority for the changes, and prompt removal of obsolete documents from the field. The Construction Engineering Manager is responsible for control of shop drawing submittals and certifications to include assuring that submittals are received and/or distributed. The Construction Engineering Manager will maintain as-built marked-up drawings. These drawings will be maintained in a current condition. The as-built data will be submitted to Design Engineering in accordance with this procedure. Subcontractors will submit as-built information through the Fluor Construction Engineering Manager.
Request For Information When field conditions dictate changes to the design specifications and/or drawings, a Request For Information (RFI), Form 000.509.F00501, will be submitted for approval to ensure proper control and documentation. RFIs will be initiated by the Construction Engineering Manager who will maintain a RFI Log, Form 000.509.F00502. RFIs will be forwarded to the Design Engineer for approval and/or action. Subcontractor submittals will be sent to the Fluor Contracts Manager for submittal to the Fluor Construction Engineering Manager for evaluation and processing.
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The Construction Engineer shall describe the condition or design change requested in terms that can be easily understood by those who review it, including appropriate references, specific drawings and specifications to illustrate the recommended change. To minimize delay in construction, authority for deviation from specifications and drawings may be acquired by direct communication with the Design Engineer and the Client pending processing of the RFI. A copy of the Record of Telephone Conversation will accompany the RFI transmitted to the Design Engineer and the Client. Approval of the Clients construction site representative should be acquired, if possible. The Design Engineer and the Client portion of the RFI indicate approval or disapproval of the field recommended change or recommends alternatives. The signed original will be returned to the Site Manager for disposition or authority to proceed. The Construction Engineering Manager shall maintain a file that contains a full history of the action and data supporting the approval of each Request For Information.
Subcontractor Documents The subcontractors are responsible for procedures necessary to assure that all documents provided for construction are maintained to the most up-to-date revisions. Documents include procedures, letters, telexes, purchase requisitions, purchase orders, design drawings, specifications, reference drawings, vendor drawings, field sketches, test reports, etc. Documents affecting individual subcontractor's work are forwarded to the subcontractor by the Contracts Manager. Subcontractor prepared field sketches and "as-built" drawings originating at the construction site shall be documented and controlled in accordance with the Request For Information (RFI) requirements described in this procedure.
Submittals - Field Contracts Submittals are reviewed under the direction of the Construction Engineering Manager. Subcontractor technical submittals are forwarded to Construction Engineering Manager. A submittals list shall be maintained reflecting the specification reference, description, date received, and the status of acceptance through Construction Engineering approval. The Site Quality Manager shall review submittals related to quality control requirements.
Material/Equipment Documents Documents related to materials, materials receiving and issue are controlled in accordance to procurement procedures.
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Quality Control Documents Documents and data identified as quality records are processed, retained and protected as described in 000.509.0160 "Quality Records". Primary responsibility for ensuring adequate control of quality related documents rests with the Site Quality Manager.
Procedure - Procedures issued by site personnel are controlled as described by this procedure. Vendor Documents - Vendor document supplied by Fluor Engineering Document Control to the Fluor Site Document Control for filing and distribution will be in accordance with the Project File Index and the Distribution Matrix System. PROCEDURE - The Construction Engineering Manager shall establish a standard distribution for design documents drawings and specifications with the Client. - Document Control shall provide document inventory control and receipt, and distribution accountability. This is accomplished making distribution in accordance with the Distribution Matrix System. Distribution is by individual document holder. These documents will be stamped in red with the Site Document Control stamp indicating date received. The Site Document Control stamp will be used to identify drawings, ISO, Instrumentation Specification Data Sheets, specifications, etc. Distribution of manuals will be by name and numbered copy. - A document transmittal record will be utilized for the distribution and issue of all controlled documents. The document recipient must sign the transmittal record and return it to Document Control within 10 days of issue. - Document recipients shall be responsible for control of documents upon receipt. Document Control will periodically (minimum quarterly) audit document recipients to ensure proper documents are available for use and that superseded documents have been removed from the field. Should a superseded document be required to be retained for inspection or historical data, the document will be identified as "VOID" or "SUPERSEDED" to prevent inadvertent use of the document for fabrication/installation activities.
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RECEIPT AND DISTRIBUTION OF DOCUMENTS Construction Engineering Manager - Establish document control log system for receipt of documents and provided standard distribution as indicated on the Distribution Matrix System. Document Control - Drawings (design, vendor and field sketch), specifications - Review receipt transmittal and enter date received in the Electronic Tracking System. - Review distribution list and reproduce copies as required. - Prepare distribution transmittals and distribute documents accordingly. Document Control - Manuals - Based on input from Site Manager, determine distribution for each type manual. Maintain a "Master" manual in Document Control and reproduce copies as required. - Assign individuals numbered manuals, prepare distribution transmittals and distribute accordingly. Document Recipient - Sign transmittal acknowledging receipt of documents and return signed transmittal Document Control within 10 days. - Replace superseded documents as required with the new documents. Destroy or return the superseded documents (except for inspection or historical record) to Document Control. The document recipient is responsible for maintaining documents current. Document Control - Destroy returned superseded documents.
REPRODUCTION AND ISSUE OF REQUESTED DOCUMENTS Requester - Fill out document request form and present to Document Control.
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Document Control - Reproduce documents requested and obtain receipt acknowledgement from requester upon issue.
DOCUMENT AUDITS Construction Engineering Manager - Determine document audit plan and schedule audits. A minimum of 5% of documents issued to the document holder will be randomly selected for the audit sample. The number of document holders to be audited will be determined by the Construction Engineering Manager. Document Control - Using a printout or list of documents and current revisions, compare documents and revisions held by document holders and note any discrepancies. Notify the Construction Engineering Manager of major discrepancies. Construction Engineering Manager For major discrepancies identified by Document Control audits of documents, investigate and provide recommended resolution.
Revision Control of the Site Quality Manual Site Quality Manager Revision dates for all pages of all procedures in the manual should match the dates in the Table of Contents. The Site Quality Manager, Construction Engineering Manager, Site Manager and the Client (optional) will approve each revision by signing the "Approval Page". Forward the approved revision and affected documents to Document Control for maintenance and distribution to all manual holders.
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Questions/Description/Conflict: Detail the missing information, discrepancies, questions or conflicts that must be resolved prior to construction activities continuing in the affected areas. Attach additional sheets, drawings, or sketches, if further explanation is required. Recommended Solution: Indicate the action that the requestor believes is required to provide an acceptable solution to resolve the discrepancies and conflicts indicated on the request. Additional sheets, sketches, digital photos or drawings may be attached to provide a clear explanation of the intended resolution. The person originating the request and provided recommended action. List the current position of the originator on the project. The date the request is submitted for approval. List Company name of the originator List name of Fluor person approving the request for submission to the Engineer of Record (Generally, the Fluor Site Engineering Manager will receive the request and approve its submission to the Design Engineer.) List the current position of the approver. The date the request is approved for submission Enter the date in which the resolution of the request must be made in order not to delay the activities in question
Originated By: Title: Date: Originators Company Name Approval For Originator By
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Response
The respondents resolution (generally the Design Engineer, Project Engineering Manager, CM, or Fluors Construction Engineering Manager) to the question, information, discrepancy, or conflict. The signature of the person making the response. (Lead Construction Discipline Engineer, Construction Engineering Manager or Design Lead Discipline Engineer, etc.) List the current position of the Approver on the project. The date the request is approved for transmittal to the Design Engineer. The signature of the person reviewing and approving the request prior to implementation. (This action might require Client approval. If the response changes the design (AFC Drawings or Specifications) the Engineer of Record must approve the resolution.) List the current position of the Approver on the project. The date the request is approved for implementation by the Client or Project Engineering Manager or designee. Indicate using the checkbox if the RFI response is acceptable for closure of the RFI. Generally, the Construction Engineering Manage must respond to this question. Indicate using the checkbox if the RFI response has a cost impact that will require an estimate or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor. Indicate using the checkbox if the RFI response has a schedule impact that will require an adjustment in the contract schedule or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor Inter the name and date the RFI was closed and verified. List all parties requiring a copy of the completed request once the response has been received.
Respondent:
Cost Impact?
Schedule Impact?
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REQUEST TO (RESPONDENT):
RESPONDENTS COMPANY/LOCATION
PHONE/EMAIL
QUESTIONS/DESCRIPTION OF CONFLICT:
ORIGINATOR (Sign)
TITLE
DATE
APPROVED (Sign)
TITLE
DATE
RESPONDENT (Sign)
TITLE
DATE
APPROVED (Sign)
TITLE
DATE
ARE THE QUESTION AND RESPONSE ADEQUATE FOR CLOSURE OF THIS RFI? YES NO YES NO IS THERE A SCHEDULE IMPACT DUE TO THIS RFI? IF YES, SITE INSTRUCTION TO BE ISSUED DISTRIBUTION:
IS THERE A COST IMPACT DUE TO THIS RFI? IF YES, SITE INSTRUCTION TO BE ISSUED
YES
NO
THE WORK WAS COMPLETED AS NOTED ON THIS CLOSED RFI AND VERIFIED BY DATE:
The response to this RFI is NOT an authorization to perform a change to the contract. Work may proceed in accord with the response only if such work involves NO change in cost or schedule. If the response involves change in cost or schedule, a Site Instruction or similar document must be received before the response can be executed. Where no Site Instruction is indicated, action must be taken in accordance with Article 15.0 of Part III, Section 15.2 and subject work must not proceed in accordance with Section 15.3 or 15.4 of Part III, General Terms of the Fluor Standard Contract.
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ID A00502A
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PROCESS CONTROL
SCOPE This procedure identifies construction work processes that require process control. GENERAL For most site production activities, the drawings and specifications provide adequate work instruction. These may be supplemented with additional instructions to control work sequencing, recording of installation data, material selection, etc. However, certain construction work processes require special instructions to establish the controls necessary to achieve acceptable quality, of the completed work, for the following reasons: Quality results of the completed work cannot be fully verified by subsequent inspection and/or testing. Quality deficiencies may only become apparent after the item has entered service or operation.
Special Processes "Special processes" are highly dependent on the control of process parameters or the skill of the operator or both and are characterized by the need for one or more of the following control measures. Written Method Statement or Procedure Procedure Qualification Operator Qualification In-Process Inspection
Special processes encountered on sites include, but may not be limited to: Welding and Post Weld Heat Treatment Welder Qualification Nondestructive Examination (including radiography, magnetic particle, liquid penetrant, ultrasonic, and positive material identification VT, RT, MT, PT, UT, and PMI) Other processes needing procedural control as determined by Project Management.
Special processes identified must be accomplished and documented under controlled conditions by appropriately qualified personnel using approved procedures and equipment in accordance with the governing specifications and the associated referenced codes and standards.
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PROCEDURE Site Quality Manager The Site Quality Manager shall coordinate with the Construction 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 mechanisms, i.e. procedures, qualifications, etc. are specified in the RFP and implemented before the start of work. Process control measures and responsibilities shall be identified on the applicable procedures or ITPs.
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SCOPE This procedure describes the methods to be used for the control, calibration, maintenance and recall of inspection, measuring and test equipment (IMTE) used to demonstrate conformance of construction work activities to the specified requirements. It is not applicable to calibration of permanent plant devices. GENERAL Inspection, measuring and test equipment (IMTE), including test software, shall be selected, calibrated and controlled in a manner which is consistent with the required inspection, testing and examination requirements. Environmental conditions shall be suitable for the calibrations, inspections, measurements and tests being carried out. All IMTE shall be uniquely identified. This unique identification may consist of a manufacturer's unique serial number along with model number and/or the assignment and application of a unique Inventory Control Number (ICN). The handling, preservation, and storage of inspection, measuring and test equipment shall be such that the accuracy and fitness for use is maintained. All calibrations shall be performed using certified equipment having a known valid relationship to nationally recognized standards; where no such standards exist, the basis used for calibration shall be documented. "Conformance check" means the operations required to ensure that an item of measuring equipment is in a state of compliance with requirements for its intended use. Non-adjustable measuring and test equipment is not considered as calibrated equipment. Equipment of this nature (e.g. cube and proctor molds, measuring tapes, rulers, chains) is subject to a "conformance check" to dimensional, volumetric or other requirements and does not require any further verification unless apparent damage or other factors require re-verification. It is the responsibility of the end-user to comply with the requirements of this section. IMTE shall be selected utilizing Attachment I "Criteria for the Selection of Inspection, Measuring and Testing Equipment" and Attachment II shall be used for guidance in procurement of calibration equipment and/or services. All IMTE calibration requirements shall be identified, on Attachment 3 - IM & TE Calibration Requirements List. This attachment is used to list the various types of IMTE in use and their associated calibration frequencies, calibration procedures and tolerances. Calibration procedures, frequencies, and tolerances may be obtained in conjunction with obtaining the services of an outside calibration vendor or from
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manufacturers. A procedure number shall be assigned. If the manufacturer has an assigned number, this should be used. Calibration procedures are quality records and shall be maintained in site files. Procedures such as published standards, practices (e.g., ASTM) or written calibration instructions from the manufacturer may be used. In the absence of either a published standards practice or an adequate manufacturer's procedure, a written procedure for the calibration method shall be written and approved for use. In addition to the above, calibration procedures should include at least the following basic information: Identity of the item to be calibrated using the procedure. Calibration comparison standards and calibration support equipment to be used. Provisions to obtain and record "as-found" accuracy measurement prior to any adjustments. Sequence of operations. Checks, tests and measurements instructions. Calibration acceptance tolerances. Calibration adjustment instructions. Safety considerations. Special instructions (when applicable). Documentation and labeling instructions related to the specific item to be calibrated.
Perform and record (Form 000.509.F01104) the calibration in accordance with the above established calibration procedures and/or contract the services of an outside calibration services vendor. Upon completion of initial calibration, enter the equipment in the Calibration Assignment Log (Form 000.509.F01101) and record other data required by this log.
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History of Use The end user shall maintain a history of use for IMTE to enable an assessment of the validity of previous calibrations, inspections, measurements and test results when calibration as-found data reveals out-oftolerance data points. The history shall be documented using IMTE Sign In/Out-History of Use Log (Form 000.509.F01102) and keep current to record each usage of the IMTE. If out of tolerance conditions are found, a Nonconformance 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 determine if inspection, measurement, test or calibration results obtained with the out-of-tolerance instrument are still valid. Evaluations shall be documented, and where required, repetitions of readings shall be compared to original results. It is the responsibility of the end user to use calibrated equipment within the environmental operating range(s) or restrictions/limitations specified by the instrument manufacturer. NOTE: Temperature or other compensating calculations shall be applied to any inspection, measurement, test or calibration results when such compensations are specified by the instrument manufacturer and/or when they can affect the basis of the results obtained. Upon satisfactory completion of calibrations, and after the recalibration due date has been determined (calculated), the end user shall make entries on the "Calibrations Tickler File" (Form 000.509.F01103) to aid in the tracking and recall of items for scheduled recalibration. DOCUMENTATION Electronic recording of the information that is required by the documentation in this procedure is permissible. All documents (except labels) generated in accordance with this procedure should be maintained in appropriate protected files throughout the construction phase of the project, and for the period of time there after specified (if any) or turned over to the Client if required.
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FORMS Quality Support Forms: 000.509.F01101 000.509.F01102 000.509.F01103 000.509.F01104 Calibration Assignment Log and Record IMTE Sign In/Out-History of Use Log Calibration Tickler File Calibration Data Sheet
ATTACHMENTS Attachment 1 Attachment 2 Attachment 3 Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE) Criteria for Procuring Calibration Services IM & TE Calibration Requirements List
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Attachment 1 Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE) 1. IMTE includes inspection, measurement and/or testing equipment used to determine final acceptance. IMTE shall have a manufacturer's stated accuracy (and precision, where applicable) that exceeds the construction installation inspection, measurement and/or testing tolerance(s). IMTE shall have the durability, stability and appropriate measurement ranges consistent with the intended use(s). Calibration standards that will be required for the initial and subsequent recalibrations shall be identified when selecting IMTE. Such calibration standards shall be requisitioned or the services of a calibration facility with the calibration standards shall be contracted. NOTE: Obtaining calibration standards or services can usually require more time to procure than the time required to select and procure the needed IMTE. 5. Purchase requisitions for IMTE, calibration standards, and calibration facility services should clearly state the requirements for accuracy, precision (where applicable), range, durability and/or stability, environmental, handling, other applicable technical requirements.
2.
3.
4.
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Attachment 2 -
The following are recommended guidelines for preparing a purchase order for obtaining the services of a calibration supplier to calibrate Inspection, Measuring and Test Equipment (IM&TE). 1. The following information should be provided to the supplier: a) b) c) d) description and unique identification of each piece of IM&TE; assigned calibration interval; calibration accuracy required; any relevant environmental requirements of use or calibration.
2. The calibration supplier must provide the following information 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 must be furnished, if a recognizable standard i.e. ASTM, ANSI/ASME, 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 number; 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) limits of permissible error; f) calibration standard used (including serial numbers and certificates) and traceability; g) details of any maintenance, servicing, adjustment, 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, tamper-resistant system, all adjustment access points after calibration, where practical. The system used shall provide visual evidence of tampering. 5. The calibration supplier shall immediately notify the purchaser of any IM&TE discovered to be out of calibration by more than the stated accuracy tolerance or any piece of IM&TE that shows indication of tampering. The purchaser shall determine if the calibration process should continue. 6. The calibration supplier shall package and ship each piece of IM&TE in such a manner to preclude damage and to preserve the calibrated condition.
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Attachment 3 END USER Surveyor Surveyor Surveyor Surveyor Surveyor Mechanical Mechanical Electrical Electrical Electrical Millwrights Millwrights Millwrights Welding
IM & TE Calibration Requirements List DESCRIPTION Chain Level Transit Tape Distamat Pressure Gauges Torque Wrenches Meggars Simpson Mulit-Meter Digital Mulit-Meter Calipers Dial Indicators Micrometers Rod Oven Thermostat FREQUENCY Initial Conformance 6 Months 6 Months Initial Conformance 6 Months 6 Months 6 Months 6 Months 6 Months 6 Months 3 Months 3 Months 3 Months 6 Months PROCEDURE Visual* TOLERANCES 1/8 (0.32cm) (2) Per Procedure Per Procedure 1/8 (0.32cm) (2) Per Procedure 5% (2) 5% (2) 3% (2) 3% (2) 3% (2) .02MM (2) .02MM (2) .02MM (2) 5F (15C) (2)
Visual*
Notes: 1) ALL WORN AND/OR DEFECTIVE MEASURING EQUIPMENT IS REMOVED FROM THE SYSTEM AND DISPOSED OF. RECORDS INDICATING REMOVAL/DISPOSAL DATE ARE MAINTAINED. THESE TOLERANCES ARE LISTED FOR SITUATIONS WHERE NO OTHER RECOMMENDED TOLERANCES ARE PROVIDED.
2)
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ID A01101
Date Calibrated Calibration Due Date
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ID A01102
Area/System/PKG No.
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CALIBRATIONS TICKLER FILE Month Sunday Monday Tuesday Wednesday Year Thursday Friday
ID A01103
Saturday
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
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ID A01104
Job No.
Fail Position
As Found
Calibration
Output
Output
Mounted Accessories
Remarks
Calibrated By
Date
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CONTROL OF NONCONFORMANCES
SCOPE This procedure describes the methods and responsibilities for controlling nonconforming items to prevent their inadvertent use or installation when other control methods, inspection reports, surveillance reports (000.509.0220), etc. are considered inadequate. This procedure provides for the identification, documentation, evaluation, disposition, notification, segregation (prevention of inadvertent use/installation), and reinspection of these nonconforming items (excluding ASME Code items). GENERAL Types of NCRs Nonconformances are classified as: Use as Is- Permission to use an item that does not conform to specified requirements. Rework- Action taken on a nonconforming item to make it conform to specified requirements. Repair- Action taken on a nonconforming item to make it acceptable for use. Items Requiring an NCR Nonconformance Reports are issued when there are: Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition. Deficiencies of a serious or repetitive nonconforming nature as determined by the Site Quality Manager Construction damage has occurred to existing or turned over plant property.
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Responsibility for Identifying Nonconformances Fluor will issue Nonconformance Reports on self-perform work, when applicable. The Construction Subcontractors have the first responsibility for the identification, control, and disposition of nonconforming items within their Scope of Work. Fluor will issue a Nonconformance Report when the Construction Subcontractor has not issued one. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition. Inspection personnel usually initiate Nonconformance Reports; however, anyone may initiate an NCR.
Control of Nonconforming Items The Construction Manager will take measures to provide holding areas or other methods for segregating nonconforming items to prevent unauthorized use, mixing with conforming items or incorporating into future construction. Where physical segregation is not practical, tagging, marking or other positive means of identification is acceptable. The Site Quality Manager may elect to use "HOLD" tags/stickers (Form 000.509.F01303) for additional assurance.
PROCEDURE Documentation of Nonconformance For materials and equipment identified as nonconforming (per the descriptions in the "General" section of this procedure), generate a Nonconformance Report (Form 000.509.F01301) to document the nonconforming item(s). The report is to be processed as follows: Initiator Enter the date the nonconformance is documented. Enter either Fluor, the name of the Subcontractor or Vendor to identify organization responsible for the nonconforming work. Use the entries in the header of the form to provide unique traceability and identification to the nonconforming item.
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240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013
Enter a complete description of the nonconforming condition. The initiator may propose a disposition, but it is not required. Enter the root cause of the nonconforming condition. The initiator provides the NCR completed as noted above to the Site Quality Manager.
Site Quality Manager NOTE: Evaluate the report to determine that the described condition is a valid nonconformance. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition. If a Construction Subcontractor has issued the NCR, it should not be duplicated by Fluor. Assign a unique number to the report and enter the number on the report and on the "Nonconformance Report Log" (Form 000.509.F01302). If a hold tag is needed, enter the hold tag number and have the hold tag installed on the item. The hold tag number should be the same as the NCR number. If a hold tag is not to be used, enter NA. The Site Quality Manager provides the NCR completed as noted above to the Construction Engineering Manager. Also send a copy to the Fluor Shop Inspection Coordinator for nonconformances attributed to a vendor.
Construction Engineering Manager Evaluate the proposed disposition, modify if necessary, or enter the disposition. If the nonconforming condition will not be corrected in full conformance with the applicable specification, the Project Design Engineer shall accept the disposition. In this case, check "yes" and obtain the Project Design Engineer approval. Any documentation provided by the Design Engineer that supports the disposition should be attached to the NCR original. For subcontractor NCR's, this approval is obtained through the Fluor Construction Engineering Manager.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013
If the disposition corrects the nonconformance to full compliance with the applicable specification, check "no". After completing the disposition instructions and obtaining the required approvals, sign and date. Send the original NCR to the Site Quality Manager and copy to the Site Manager. Site Manager Upon receipt of the approved NCR disposition, perform the applicable construction actions specified in the NCR disposition. (Request removal of QC hold tag prior to performing work, if one has been applied.) Site Quality Manager (or Inspector) NOTE: The Site Quality Manager or Fluor Subcontractors or subtier subcontractor initiating NCR's that require Project Design Engineer approval should send a copy of the approved NCR to the Fluor Site Quality Manager (prior to performing the actions specified in the NCR disposition, if possible). DOCUMENTATION The Site Quality Manager shall retain all NCRs and the NCR log in the Quality Files. FORMS Quality Forms: 000.509.F01301 - Nonconformance Report 000.509.F01302 - Nonconformance Report Log 000.509.F01303 - Hold Tag/Sticker Attachment Attachment 1 Attachment 2 - Instruction for completion of Non-Conformance Report - Nonconformance Routing Chart Upon verification of satisfactory completion of the disposition, sign and date. Obtain other required approvals as required.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013
Attachment 1 - Instruction for completion of Non-Conformance Report (NCR) 1 Description of Non-conformance: The initiator shall describe the requirements that were not met and a detailed description of the Non-conformance. Root Cause: The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s) including and explanation will be stated. Cause Code C01 C02 C03 C04 C05 C06 C07 C08 C08a C08b C08c C08d C08e C08f C09 C10 C11 C99 Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Procedure (except procedure not followed) Procedure/Work Process not followed - select from below Not Aware of Procedure (includes not trained) Ignored Procedure (includes no time / low priority / not important) Misapplied Procedure (includes not understood / thought not to apply) Not Effective (needs update / improvement / is inappropriate) / incorrect Incorrect Reference to Procedure (includes incorrectly specified) Procedure Not in Native Language People Driven Systems Driven Work Environment Other
NOTE: If codes 7 or 8 are used, list the procedure(s) identified as the root cause. Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code. 3 Disposition Use-as-is Re-work Repair
Requires design Engineer and Client approval. Restore to original Specification, does not require Design Engineer or Client approved. Does not meet original specification, correct (repair) for fit-for-use condition. Requires approval from design engineer and may require approval of client. Provide instructions for implementation or justification of the selected disposition. IMPLEMENTATION Once implementation is satisfactorily implemented, sign the Disposition Completed block. 4 Action verified and Non-Conformance Closed The Fluor inspector shall indicate the method used for verification of corrective action. Sign the signature block indicating acceptance of corrective action. 5 The Fluor Site Quality Manager shall review the NCR for completeness and acceptance of the corrective action.
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013
NCR Initiated
Corrective Action: 1) Remove/Replace Rework to Full Design Intent Corrective Action Approved
Corrective Action
NOTE 1
3) Use As Is
Reject
Accepts
Note 1: If corrective action is 2 or 3, distribution to be same as that shown when NCR closed. If corrective action is 1, exclude area EPCM from distribution until NCR is closed. Note 2: For NCRs on Activities within Regulating Authority Scope, they need to Review/Accept
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Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
240K-C2-05-002 Site Quality Manual 000 509 F01301 Revision 0, 10 June 2013
NONCONFORMANCE REPORT
Tag Description: P. O. No.: Subcontractor: Initiated by: Area/Location DWG. No./Rev. Inspection Classification Subcontractor Fluor Date: Unit/Equip No. Spec./Rev. Tag No.: Turnover System: Client Other Hold Tag Yes
ID A01301A