Professional Documents
Culture Documents
1 Scope............................................................. 2
2 Applicable Documents................................... 2
3 Definitions...................................................... 5
4 Inspection Department (ID) Responsibilities.. 6
5 Inspection Assessment Group (IAG)
Responsibilities...................................... 8
6 Vendor Inspection Division (VID)
Responsibilities...................................... 9
7 Operations Inspection Division (OID)
Responsibilities.................................... 13
8 Projects Inspection Division (PID)
Responsibilities.................................... 15
9 Inspection Department Reporting
Responsibilities.................................... 23
10 Deviations to Company Requirements......... 28
1 Scope
This Saudi Aramco Engineering Procedure (SAEP) defines the responsibilities and
activities of the Inspection Department (ID) on all Saudi Aramco capital projects. This
procedure provides a summary of the major quality management activities of the ID
during all phases of new projects.
2 Applicable Documents
The requirements contained in the following documents apply to the extent specified in
this procedure.
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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 1 July 2008
Next Planned Update: 1 July 2013 Inspection Coverage on Projects
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Document Responsibility: Inspection Department SAEP-1150
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Drafting Manual
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Document Responsibility: Inspection Department SAEP-1150
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3 Definitions
For the purposes of this procedure, the following definitions apply. Further quality
definitions can be located in ISO 9000.
Proponent: The Saudi Aramco organization responsible for the final acceptance and
operation of the facilities being constructed.
Inspection & Test Plan (I&TP): An I&TP is a document based on the detailed
manufacturing, fabrication and construction program which identifies each process
description, sets out the related sequence of activities to be inspected, examined and
tested and lists the relevant approved procedures for a particular material, component,
assembly, or, in some cases, type of work. It shall include identification of
requirements for documents, acceptance criteria to be used, who is responsible for what,
the inspection surveillance to be performed and the type and level of inspection
including hold, witness and review points of Contractor/Sub-contractor and Saudi
Aramco.
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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 1 July 2008
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Quality Assessment: Generally replaces the term 'Quality Audit'. A systematic and
independent examination to determine whether quality activities and related results
comply with planned arrangements and whether these arrangements are implemented
effectively and are suitable to achieve objectives.
Quality Assurance (QA): All the planned and systematic activities implemented
within the quality system, and demonstrated as needed, to provide adequate confidence
that an entity will fulfill requirements for quality.
Quality Control (QC): The operational techniques and activities that are used to fulfill
requirements for quality.
Short Form Contracts (SFC): Generally, short form contracts are used where the total
estimated value of the work is less than SR 500,000 and the duration of the work is less
than 6 months.
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Document Responsibility: Inspection Department SAEP-1150
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4.1.4 Provide Quality Assurance services that ensure the safe operation of all
lifting equipment working on Company facilities.
ID's involvement on a capital project does not relieve SAPMT, the vendor,
manufacturer, or the contractor of the responsibility to comply with Scope of
Work requirements, all Saudi Aramco Standards and specifications, mandatory
Standard Drawings, Company adopted National or International Codes and
Standards and Project Specifications.
The ID shall monitor and assess the Quality Management system and
Products/Facilities being supplied by the Vendor/Contractor/Fabricator in
accordance with Saudi Aramco Standards, Purchase Orders, and/or Schedule Q.
Material inspection levels shall be defined in accordance with SAER-1972 and
Schedule Q.
Inspection Representation
Design &
Project Cons-
Bid Technical Procure- Procure- Cons- Pre-
Proposal Design truction
Explanation Bid ment ment truction Commission-
Develop- Phase Kick-off
Meeting Evaluation Kick-Off Phase Phase ing Phase
ment Meeting
Meeting
VID X(1) X(2) X(5) X X X
(5)
OID X X(4) X(4)
(1) (2) (5) (3)
PID X X X X X X X
(5)
IAG X X X X
(5)
PQM X X X X X X X X X
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Document Responsibility: Inspection Department SAEP-1150
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Notes:
1. Attachment VI of Schedule Q, Novaited POs, and Project Quality Plan.
2. Presentation of quality requirements (PID/VID as required).
3. PID reviews design packages.
4. OID reviews NDT procedures and technician certifications.
5. As requested by SAPMT
During project proposal, a detailed Project Quality Plan will be prepared jointly
by SAPMT and the PQM as defined by GI-0400.001 and SAEP-14 (refer to
PQP Template, available on the Inspection Department website). The PQP will,
among other things, outline the Saudi Aramco Inspection Team manning levels
and mobilization schedule, define the relationship between Inspection and
SAPMT, define project objectives and responsibilities, and outline authorities
and channels of communication.
5.2 Perform internal assessments on the activities of Inspection teams and Saudi
Aramco Inspection representatives assigned to LSTK and LSPB capital projects.
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Document Responsibility: Inspection Department SAEP-1150
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5.4 Compile and report the monthly Project Quality Indices for all applicable
projects (PQI).
VID provides quality monitoring and inspection support for projects during the proposal
and design & procurement phases to ensure compliance with schedule Q requirements,
Saudi Aramco Standards and Specifications. VID shall conduct quality monitoring and
participate in surveys & assessments of vendors with the contractors as needed to assist
SAPMT during design and procurement activities.
The SAIR will work independent of schedule and cost decisions. He reports to
PQM and/or SAPMT depending on his location and size of the project as
detailed in GI-0400.001. He is primarily responsible for SAPMT interface,
problem solving, interpretation of Company standards, promoting and building
awareness of project quality requirements among the project team and
Contractors, communication of previous lessons learned, development of
effective preventive actions system with Contractors and Vendors, and
providing assistance in resolving issues relating to project quality. All formal
communications with the Contractor shall be through the Company
Representative.
The SAIR may be assigned to the site office during the construction phase to
follow-up on remaining procurement and material receiving activities.
VID may be involved, but shall not be limited to, participation in the
defining of material inspection levels, development of PQP, review of
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Document Responsibility: Inspection Department SAEP-1150
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In coordination with the PQM, VID shall attend project bid explanation
meetings. They shall focus the Contractor's attention on the
requirements of Schedule Q for design and procurement. If required,
they will also present all items of concern from OID and PID. A list of
items or a presentation of project quality requirements should be
developed and reviewed with SAPMT prior to the meeting.
For all projects exceeding $50 MM, the PQM will coordinate with the
Inspection Assessment Group (IAG) in developing a schedule of
assessments to be performed on Contractor Quality Systems during the
design& procurement phase of the project. A VID representative
should participate in these assessments and attend the opening and
closing meetings as an observer and provide assistance as required.
VID should follow-up on Corrective Action Request (CARs) generated
by these assessments.
In coordination with the PQM, VID shall ensure that Contractor's and
major sub-Contractor's procurement Quality plans and inspection
procedures are prepared in accordance with Schedule Q. Comments
shall be forwarded to SAPMT for resolution with the Contractor. If
SAIR is located at OOK contractor office, then he shall assist to ensure
that Construction related Quality plans, inspection procedures, and
inspection checklists are forwarded to PQM for review and comment.
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For projects that contractor office is located OOK, VID shall represent
the ID during the scheduled Design Review meetings at the
Contractor's design office.
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Document Responsibility: Inspection Department SAEP-1150
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OID's quality activities on new construction projects are generally limited to NDT
procedures, NDT assessments, NDT technician certifications, radiation safety, lifting
devices (Cranes, slings, etc.), and pressure relief valves used on all Company property.
In addition, OID is responsible for inspection coverage of repair and new construction
that is Proponent managed in the Dhahran area.
For effective planning and timely support, OID/NDT Unit will maintain close
contact with PID to obtain the name and the date of mobilization for NDT sub-
contractors. See paragraph 8.12.
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Document Responsibility: Inspection Department SAEP-1150
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OID shall follow their internal procedures for the inspection of all cranes,
elevators, below-the-hook lifting equipment owned and operated by Saudi
Aramco or by Contractors and used on Saudi Aramco projects, for compliance
with Saudi Aramco Safety Standards and relevant GIs. Cranes and elevators
that conform to these standards will have an inspection sticker affixed. Below-
the-hook lifting equipment will be marked with the safe working load and ID
number, unique to that particular piece of equipment, either by tagging or
stamping prior to acceptance by OID.
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Document Responsibility: Inspection Department SAEP-1150
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B of this procedure for BI-1900 projects, but guidelines will vary and
will be limited for smaller short-term Work Order projects of lesser
scope and complexity. Details are included in DFIG internal
procedures.
PID is responsible for quality monitoring for all stages of construction and pre-
commissioning up to final acceptance, to ensure compliance with applicable standards
and project specifications
PID's monitoring activities and coverage will vary from project to project based
on the type of contract, project scope and complexity, geographical locations,
Contractor experience, PID's level of involvement may also vary based on the
effectiveness of the Contractor's Quality System.
For detailed guidelines on how PID perform their disciplined inspections, refer
to Appendix A, Appendix B, and for detailed PID checklists, see the ID intranet
web page under PID division.
If the contractor does not adhere to the quality requirements, PID may be
required to provide additional inspection support as outlined in Schedule Q.
8.4 Planning
PID coverage begins with the engineering reviews of the project proposal and
detailed design per SAEP-14 and SAEP-303.
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8.6.6 The contractor's plan for third party civil testing laboratories, Weld test
Centers, RV Calibrators, NDT testing agencies, and ready mix
concrete/asphalt suppliers.
8.6.8 The need for conducting surveys of concrete/asphalt suppliers that are
not included in the Saudi Aramco approved list. Note: Survey forms
are available from ID - Batch Plant Inspection Group.
PID shall receive RFIs for all Hold and Witness Points as identified in the
Contractor's approved ITPs. Immediately upon receipt, the PID representative
shall sign and date the RFI and return the signed copies to the Contractor and
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SAPMT. For specific projects situations, PID, SAPMT, and the Contractor
should agree on a suitable method of handling RFIs, i.e.: When faxed.
The RFI form is used to notify PID that an inspection point is ready for
PID inspection by the Contractor's QC personnel and normally verified
by SAPMT prior to PID inspection. The form is not to be used as an
inspection point approval or disapproval. Any comments regarding
acceptance or rejection of work, shall be reported as described in
Section 9, "Inspection Department Reporting Responsibilities".
PID has the authority to monitor on going construction activities even if an RFI
was not received. The level of inspection coverage shall be in direct relation to
the effectiveness of the Contractor's quality system and his ability to provide
acceptable quality.
PID will assist SAPMT in enforcing and interpreting Company standards and
specifications. PID should recommend solutions to construction problems/
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violations and if possible consult with the assigned Specialist in the Engineering
Services Organization.
At the beginning of each new project where NDT is required, PID will provide
OID with the name and the date of mobilization for the NDT Sub-Contractor(s).
See paragraph 7.1. Additionally, PID in support of SAPMT, will liaise with the
NDT Unit to ensure that all sub-contracted NDT personnel and their procedures
have received approval before starting any work on the project.
PID shall ensure that all lifting equipment installed is inspected by the crane
inspection group of OID prior to signing MCC.
8.14.2.1 Schedule
8.14.2.2 Checklists
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The PQM will coordinate with the Inspection Assessment Group (IAG)
in developing a schedule of assessments to be performed on Contractor
Quality Systems during the project. A PID representative should
participate in assessments for the construction and pre-commissioning
phases, and attend the opening and closing meetings as an observer and
provide assistance as required. PID should follow-up on Corrective
Action Requests (CARs) generated by these assessments.
PID should monitor the Contractor training program to ensure that all
Contractor and Sub-Contractor personnel are familiar with the project
quality requirements for their area of responsibility. Prior to the start
of each new construction activity, PID should verify that the contractor
is providing ongoing training in the applicable QCPs, ITPs, and
applicable standards and specifications to the assigned QC inspectors.
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PID representatives will ensure that all Contractors working under a short form
contract, develop and comply with a quality control/quality assurance program.
At his discretion, the PQM/Sr. Supervisor may approve QCPs/ITPs for the work
activity to be performed in lieu of a quality plan. Contractor QC personnel shall
be sufficiently experienced and qualified to perform inspection of the work
performed.
8.16 Materials/Equipment
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8.17.1 The Batch Plant and Civil Testing Group (BP&CTG) of PID is
responsible for the evaluation, approval, and monitoring of
concrete/asphalt batch plants, pre-cast concrete plants, and civil
materials testing laboratories in accordance with SAEP-1152. Each
PID inspection office is responsible to perform the day-to-day
monitoring of batching and pre-cast plants in their area, and to submit a
monthly monitoring report for each batch plant to BP&CTG. If
concerns are detected affecting a specific project, the responsible
SAPMT shall be informed.
Commentary Note:
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Document Responsibility: Inspection Department SAEP-1150
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8.19 Records
PID shall ensure production of the construction quality records of the project are
maintained and are available at the work site. SAPMT is responsible for:
a) Preparing the original and revised Project Records in accordance with the
Drafting Manual and SAEP-122.
b) Furnishing to the Proponent copies of essential information, quality-related
documents, vessel inspections, and pertinent project information that will
assist operations in the future.
8.20.1 General
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For smaller less complex projects, it is still required that both Logbooks
be used however, PID has the option to combine the Violation and
Action Item Logbook and the RFI and Surveillance Activities Logbook
into a single logbook entitled "Inspection Logbook", and shall then
locate it in the SAPMT field office at the job-site. The single logbook
may also include entries for all inspection disciplines.
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9.4.1 General
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If a valid NCR has been rejected by SAPMT, the PQM / PID Sr.
Supervisor should contact the SAPMT Project Manager to discuss the
concern and to evaluate the need for worksheet issuance in accordance
with GI-0400.001. The worksheet however, could be issued without
further discussion if the situation warrants it.
EDRs should be issued where investigation of the Vendor's quality system and/or
the performance of the Saudi Aramco assigned Inspection Agency is required.
Issuance should not be undertaken for minor instances of material or equipment
deficiencies.
9.6 Worksheet
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Document Responsibility: Inspection Department SAEP-1150
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The PQM or his representative(s) shall calculate a monthly PQI jointly with
SAPMT and Contractor representatives. The PQI is a measure of contractor
compliance to project quality requirements and the approved quality plan per the
forms shown in Appendix D.
Each project contract shall denote applicable document precedence and Standard
cut-off date to be used to determine inspection criteria. Generally Saudi Aramco
Standards, mandatory Standard Drawings, and Company adopted National or
International Codes and Standards, take precedence over the construction
drawings, project specifications, and the scope of work. A waiver is required to
deviate from Saudi Aramco Standards even when the proponent agrees with the
deviation. Refer to SAEP-302 for details.
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Document Responsibility: Inspection Department SAEP-1150
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Revision Summary
1 July 2008 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with no other changes.
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Document Responsibility: Inspection Department SAEP-1150
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PID coverage begins with the engineering review of the project proposal and
detailed design per SAEP-303. This provides Inspection with the opportunity to
provide timely input to the project.
At least thirty days prior to the start of the applicable work, the
concrete mix design shall be submitted for review and approval in
accordance with the requirements of Schedule Q. PID shall review and
approve the mix design as per the requirements of SAEP-1152.
Site work and ancillary site material installation will be monitored by Inspection.
PID may review material laboratory reports, inspect the laying down of fill, and
monitor compaction tests. Utility piping and sewer systems will be inspected to
ensure installation and testing are performed according to specifications.
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Document Responsibility: Inspection Department SAEP-1150
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PID will review the pile-driving procedure including the equipment to be used to
drive piles. Pile-driving activities will be monitored and all splice-welds will be
inspected as required by the specification.
For onshore applications, the inspector will check the protective coating on the
pile as specified in the project specifications. PID will review SAPMT's pile-
diving records (including the geotechnical report, results of test pile, required
blow count, and tip elevations).
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PID will monitor internal and external craftwork for correct use of materials and
installations according to project requirements, and relevant Saudi Aramco
Standards and Specifications. Framing will be monitored to ensure that
materials are the size, shape, quality, and type specified. All cabinets, internal
walls, doors, jambs, floor tiles, windows, and all finishes will be monitored for
acceptable quality. PID will verify and witness tests as required on all
concealed installations prior to covering.
PID will verify that structural steel works comply with project requirements for
strength, dimensional tolerance, and methods of fabrication/installation.
Tightening of bolts will randomly be inspected for compliance with the bolting
specifications. Welding, NDT, and coating will be monitored for conformance
to project documents, Company standards and procedures, and applicable codes.
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Document Responsibility: Inspection Department SAEP-1150
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A.10 Welding
PID will issue JCC's prior to the start of work to all certified
and registered welders, welding operators, and/or brazers.
The JCC shall be kept in their possession at all times.
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SAES-W series standards require that the Contractor review and track
project and Welder repair rates daily. PID will monitor and evaluate
production weld repair rates and welder performance weekly. The
target for maximum project repair rate (calculated on a joint basis)
should normally not exceed 5%. The repair rate for welders
(calculated on a linear basis) must not exceed 5% weekly.
PID will monitor the postweld heat treatment of critical piping and
vessels on Saudi Aramco construction projects to ensure compliance
with project specifications and applicable industry codes/standards.
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A.14 Gaskets
PID shall randomly monitor all flange bolt torquing to ensure that the
Contractor is using properly calibrating equipment, correct tightening
sequence, and required torque values as described in his approved
QCP/ITP.
Procedures for testing and installation of relief valves are described in SAEP-
318, 319, 1131 and SAES-J-600. Prior to obtaining the relief valve computer
number, PID or the Proponent's Inspection Supervisor will review and sign for
the validity of data entered on the Relief Valve Authorization form (3099-A-
ENG) against the P&ID and calculation sheets. PID will inspect the installation
of the relief valve, and sign the verification portion of Form (3099-A-ENG).
Assignment of identifying numbers and entry of the approved Form (3099-A-
ENG) will be arranged through the Relief Valve Administrator of OID.
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PID will verify that all contractor personnel associated with the
preparation, application, or direct supervision of protective coatings are
qualified and certified per SAEP-316 by a Saudi Aramco certified
Level II Coating Inspector. PID will also verify that all contractor
personnel associated with the inspection of protective coatings are
qualified and certified in accordance with Schedule Q.
PID will monitor the installation of cathodic protection for tanks, pipelines,
offshore structures, and plant applications. This will include the witness of drill
stem resistance measurement tests, holiday testing of Anode cables, a check for
proper anodes/anode beds, correct number of test and bonding stations,
insulation flanges and spools, and associated equipment or materials. PID will
also check for correct system polarity, continuity of test station conductors, and
the timely application of temporary CP on newly constructed facilities. PID will
verify that construction drawings have been reviewed and approved by the
SAES-X series of standards.
A.18 Electrical
For electrical conductors and equipment, PID will monitor tests for ground-
resistance measurements, cable insulation, and equipment testing. All
installations that are intended to be concealed will be monitored prior to back-
fill or covering. Construction and installation methods will be monitored to
ensure that no damage is done to materials or equipment. PID will check that all
medium and high voltage cable splicers hold valid splicer certification cards,
and will issue JCC's prior to the commencement of splicing. Prior to
energization of power distribution systems, PID will verify installation is sound
and safe to energize. All pre-commissioning activities performed prior to
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Document Responsibility: Inspection Department SAEP-1150
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A.19 Communications
A.19.1 Quality Monitoring Responsibility
The PID Communications Group is responsible for quality monitoring
of Outside Plant (OSP) projects and Premise Distribution Systems
(PDS).
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Document Responsibility: Inspection Department SAEP-1150
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B.2 Welding
B.2.1 Welding procedure and Welder qualifications
B.2.2 Non-destructive testing Procedures, Personnel, and activity start-up
B.2.3 Start of fabrication and welding activities
B.2.4 Selection of points for NDT
B.2.5 Radiographic film interpretation by Company certified Interpreters
B.2.6 Repair of cracked welds
B.2.7 Stress relieving
B.2.8 Tie-in welds
B.2.9 Socket weld gap and thread engagement
B.3 Brazing
B.3.1 Brazing procedure
B.3.2 Brazer qualifications
B.3.3 Certification of brazed joint at job site
B.5 Piping/Pipelines
B.5.1 Pipe bending
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Document Responsibility: Inspection Department SAEP-1150
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B.7 Vessels
B.7.1 Lay-up of vessels
B.7.2 Vessels closure
B.10 Plumbing
B.10.1 Sand bedding and cover
B.10.2 Head test, sanitary lines
B.10.3 Pressure test, water lines
B.10.4 Test sanitary manholes
B.10.5 Closing of walls and ceilings
B.11 HVAC
B.11.1 Prior to installation of duct insulation
B.11.2 Installation of HVAC units
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B.12 Civil
B.12.1 Prior to closure of formwork
B.12.2 Prior to concrete placement, grouting, and asphalting
B.12.3 Prior to bituminous coating of buried concrete structures
B.12.4 Prior to asphalt roofing placement
B.12.5 Prior to commencement of the initial bending of epoxy coated
reinforcing bar
B.12.6 Verify that a geo-technical survey has been carried out
B.12.7 Prior to closure of walls and ceilings
B.12.8 Bottom of excavations
B.12.9 After preparation of the bottom of foundations
B.12.10 Before backfilling around structures
B.12.11 After preparing the existing sub-grade, and after each layer for road
construction
B.12.12 Sand cover of piping
B.12.13 Concrete prior to any repair
B.13 Electrical
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B.14 Communications
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B.14.3 Manholes
B.14.3.1 Excavation for bracing/shoring when depth reaches 5' and
until completion
B.14.3.2 Internal form work before pouring concrete for duct
terminators, inserts, etc.
B.14.3.3 Grounding connections when rods are outside of manhole
B.14.3.4 Ring and cover frame installation
B.15 Cranes
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INSPECTION
INSPECTION DEPARTMENT SAPMT
DEPT.
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