Quality Assurance and Control

JOB INSTRUCTION 10 Volumen 4
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QUALITY ASSURANCE AND CONTROL
INDEX
1.0 QUALITY ASSURANCE AND CONTROL
2.0 DEGREES OF INSPECTION
30 INSPECTION AND TESTING
4.0 SHOP TESTS
5.0 SITE TESTS

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1.0 QUALITY ASSURANCE AND CONTROL
Contractor shall establish and maintain a documented quality system in accordance with ISO 9001 (2000).
The project quality plan shall incorporate the agreements resulting from any tender clarification and shall
include formal acknowledgement that any procedure identified as requiring preparation or amendment has
been completed.
1.0.1 This system shall include documented procedures and instructions and an
organization for the effective implementation of these procedures and instructions.
1.0.2 This system shall be approved by ECOPETROL.
1.1 Contractor shall identify the functions and responsibilities of key QA/QC personnel in his
home office, in vendor's and subcontractor's shops, and in the field.
1.2 Contractor shall insure that all applicable Colombian regulations, laws and codes are
incorporated into the Works together with ECOPETROL's minimum requirements as specified
in these bid documents.
1.3 Contractor's quality system for detail engineering shall incorporate:
a. Identification of specified design criteria.
b. Interdisciplinary reviews for translation of design criteria into engineering documents.
c. Identification of engineering documents requiring review and/or approval.
d. Use of specified quality standards in engineering documents, including acceptance

criteria, inspections and test.
e. Identification and control of deviations from specified quality standards and/or

engineering requirements.
f. Identification of criteria for selection and review of materials.
g. Identification of all codes, standards and regulations that affect the engineering and
fabrication activities, etc.
h. Identification of specified requirements and responsibilities of the engineering groups

associated with preparation, review, approval, control and distribution of documents to
interfacing engineering organizations.
i. Identification of documents requiring engineering interface and provision for resolution

of comments.
j. Coordination of internal and external engineering groups which provide design criteria
or technical input to a project.
k. Identification of engineering documents selected for use in the interface management.

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l. Control and documentation of specified verification or reverification, including

identification of the reviewer, methods used, results and scope.
m. Evaluation of effects of changes to previously verified documents, and reverification of

the documents as determined necessary by the evaluation.
n. Review and/or approval of engineering drawings, specifications, and documents, etc.
1.3.1 Verification or checking shall be performed prior to issue for construction of

engineering documents to verify completion and accuracy of design by means of
reviews, interdisciplinary reviews, or alternate calculations. Verification reviews
shall be performed by Contractor personnel other than those who did the design.
Errors and engineering deficiencies identified by engineering verification after the
document is released, shall be documented and processed in accordance with the
engineering change requirements of this section, etc.
1.4 Vendor quality control procedures shall be required for approval by ECOPETROL for
fabrication, inspection and testing of exchangers, vessels, tankage, valves, piping. Vendor
procedures for inspection and testing of electrical and DCS equipment shall also be approved
by ECOPETROL.
1.5 Contractor will monitor the effectiveness of vendors' quality assurance techniques and quality
standards. Contractor will conduct necessary destructive and non-destructive tests and
mechanical tests including those required by third party inspection agencies in addition to
carrying out dimensional checks and surface examinations. Contractor shall, as a minimum
provide inspection as indicated in Exhibits 10-1 and 10-2.
1.6 Exhibit 10-3 is a list of minimum acceptable field inspection activities. Contractor shall utilize
this information in his quality control manual to establish the scope of Contractor's inspections
and those by sub-contractors. Where direct hire rather than subcontract work is performed,
then Contractor shall perform all inspections and tests indicated "by subcontractor". Note shall
be made in Contractor's quality control manual of special items, witness and hold points, and
frequency of inspection and forms which apply.
1.7 The quality control procedures for field inspection shall be prepared by Contractor in a manual
in accordance with paragraph 1.0 above. Contractor's procedures for inspection and testing,
including forms and frequency of inspections shall be fully described. It is emphasized that
the quality control procedures implemented during construction shall be based upon
Contractor's procedures and not those of subcontractors and sub-subcontractors.
1.8 Contractor shall prepare a report of each inspection performed by Contractor in vendors'
shop, and transmit to ECOPETROL a copy.
1.9 Contractor shall prepare a listing of fabrication and construction non-conformances with the
specifications, update the listing monthly and submit a copy to ECOPETROL. A description of
repair will be provided to ECOPETROL.
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1.10 Shop Inspection shall consist of conducting, in sequence, one or more distinct acts or
examination and test of a material, item, or equipment in such a way as to determine if it
complies with the requirements of the purchase order and has the quality of workmanship to
satisfy the special service it is expected to withstand. The various examinations and tests
usually include:
a) Monitoring the effectiveness of a vendor's quality assurance techniques.
b) Evaluating a vendor's quality standards, which may lead to establishing stricter

acceptance norms if the existing ones are considered inadequate.
c) Destructive and nondestructive tests.
d) One or more forms of mechanical tests.
e) Dimensional checks.
f) Surface examinations.
g) Review of material and test certificates
h) Review of welder certificates
Quality control procedure for shop inspection shall include Contractor's "Control and test
specifications" or equivalent, for each type of equipment, clearly indicating hold and witness
points and degree of inspection at other fabrication points. Different types of equipment will
require various degrees of inspection. All tests and inspection procedures shall be approved
by ECOPETROL.
1.11 Contractors Quality Plan shall include documentation of his investigations and appraisals of
prospective vendors and subcontractors not included in ECOPETROL's approved list.
2.0 DEGREES OF INSPECTION
2.1 LEVEL 0 INSPECTION
Inspectors are not involved in the inspection. Materials or equipment to be inspected in this
Level are such as those procured by catalogue or from market without any design
requirements.
2.2 LEVEL I INSPECTION
The involvement of Quality Control Inspectors will consist primarily of the review of all
documentation required from the manufacturer (or vendor) and the determination of correct
quantities of materials or equipment as ordered. The inspector will perform a visual inspection
prior to preparation for shipment from the vendor's facilities. This will be performed to insure
acceptable quality and compliance with the requirements of the purchase order.
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The inspector will initiate contact with the manufacturer or vendor prior to his processing of
the order and establish an inspection schedule which will be non-disruptive to the
manufacturer's or vendor's normal procedures.
After the schedule has been set, it will be the responsibility of the manufacturer to provide
advance notification of the need for inspection.
It will be Contractor's Quality Control Department's responsibility to provide an inspector when

requested, in order to facilitate timely disposal of the order.
2.3 LEVEL II INSPECTION
Inspection by Contractor's Quality Control Department or other authorized inspection

company will be a part of the purchase order. Inspection will consist of the review of all
required documentation, the determination of correct quantities of materials or equipment as
ordered, dimensional checks of items, and final witness testing of the completed product. The
Inspector will visually inspect equipment prior to shipping from vendor's facilities.
The inspector will contact the manufacturer in order to establish an inspection schedule which
will be nondisruptive to the manufacturer's normal procedures.
Manufacturer will provide proper advance notification of need for inspection. It will be
contractor's responsibility to provide an inspector when requested in order to facilitate timely
disposal of the order.
2.4 LEVEL III INSPECTION
Inspection by Contractor's Quality Control Department or other authorized inspection company

will be a requirement of the Purchase Order. The involvement of the inspectors will be carried
out at numerous preselected inspection points. The inspector will arrange a meeting with the
manufacturer at his facilities prior to initiation of fabrication. At this meeting, both parties will
agree on testing procedures and determine appropriate inspection points in the fabrication
schedule.
It will be the responsibility of the manufacturer to provide advance notice of the need for
inspection. It will be the responsibility of the Contractor's Quality Control to provide an
inspector when required. This inspection will include:
a) Detailed monitoring of materials procured for use on this order.
b) Review and approval of all certified documentations, verification of compliance with

project specifications and vendor drawings.
c) Witness testing of components prior to assembly.
d) Approval of all NDE (Non-Destructive Examination) test reports.
e) Check heat treating facilities, if possible.

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f) Review heat treatment charts.
g) Visual inspection of final assembled equipment.
h) Witness of final hydrostatic tests or performance as per specification.
i) Witness of loop and system function tests.
j) The preparation of the order for shipment will be inspected and approved prior to
inspector's release for shipment. This could apply to subvendors as well if purchaser
requests.
2.5 LEVEL IV INSPECTION
Inspection by Contractor's Quality Control Department or other authorized inspection company

will be a requirement of the Purchase Order. The involvement of Quality Control will be on a
continuous in-house resident inspection basis with unlimited random access will apply to
subvendors as well.
Inspection will arrange a meeting with the manufacturer at the fabricating shop prior to
initiation of fabrication. At that time, all parties will discuss manufacturing and testing
procedures and determine all inspection requirements.
The inspection requirements will be defined in the pre-manufacture meeting and approved by
the appropriate contractor's project engineer. This inspection will include:
a) Detailed monitoring of all materials procured for use on this order, review and approval
of all certified documentation, verification of compliance with project specifications and
drawings.
b) Witness fabrication and testing of components prior to assembly.
c) Approval of all NDE (Non-Destructive Examination) test reports.
d) Inspection of all heat treatment work test or performance test as per specification.
e) The preparation of an order for shipment will be inspected and approved prior to the
inspector's release for shipment.
f) Inspection applies to subvendors as well, if required.
3.0 INSPECTION AND TESTING
3.1 The whole of the plant covered by this Contract is subject to inspection and test by ECOPETROL
should he so require, during manufacture and erection. The costs of all tests and inspections,
excluding the costs of ECOPETROL representative, shall be born by Contractor until acceptance of
the test or inspection by ECOPETROL.
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3.2 Where no test is specified then the various items of plant, materials and equipment shall be tested
in accordance with the relevant Standards acceptable to ECOPETROL. Where no appropriate
standard is available, tests shall be carried out in accordance with the maker's standard practice
which must meet with the approval of ECOPETROL.
3.3 Fourteen days written notice of the readiness of plant (or parts thereof) for test or inspection shall
be given and every facility shall be provided by the Contractor to enable ECOPETROL to carry out
the inspection and witness the test.
3.4 No equipment shall be packed, prepared for shipment, or dismantled for the purpose of packing for
shipment unless it has been inspected and approved (or inspection has been waived) and written
instructions have been received from ECOPETROL.
3.5 Contractor shall submit a copy of his program to control the quality of manufacture, material control
and documentation, and 3 unpriced copies of all purchase orders and sub-orders to ECOPETROL.
All orders and sub-orders placed by Contractor shall contain the following instruction:
"This material may be subject to inspection and test by ECOPETROL or his Representative, with
whom contact shall be made before commencing manufacture to agree on inspection procedures
and visits."
3.6 Contractor shall state in his purchase orders and guarantee the technical particulars listed in the
Contract Documents. These guarantees and particulars shall be binding and shall not be departed
from without the written permission of ECOPETROL.
3.7 Contractor shall guarantee that all equipment supplied complies with the Contract and shall as a
minimum, provide inspection as recommended in Exhibit 10-1.
If guarantees are not met and/or if any item fails to comply with the requirements of the Contract in
any respect whatsoever at any stage of manufacture, test or erection, ECOPETROL may reject the
item, or defective component thereof, whichever he considers necessary. After adjustment or
modification as directed by ECOPETROL, Contractor shall submit the item for further inspection
and/or test. In the event of a defect on any item being of such a nature that the requirements of the
Contract cannot be fulfilled by adjustment or modification, such item shall be replaced by
Contractor, at his own expense to the entire satisfaction of ECOPETROL.
3.8 Contractor shall be responsible for the proper execution of all tests or work or plant or materials
carried out or supplied by a sub-contractor, wherever such tests may be carried out, to the same
extent as if the work, plant or materials were carried out or supplied by Contractor himself.
Contractor can use his own specialists and/or employ an independent specialist agency, approved
by ECOPETROL, to perform off-site inspection services including but not limited to the following:
a) Perform the critical inspections specified in Exhibits 10-2 and 10-3 applying the latest standard
editions of codes and practices.
b) Approve all welding procedures for code pressure containing items, and shop fabricated piping.
c) Witness and approve weld procedure qualification tests.

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d) Approve or obtain proof of previous approval of welders.
e) Approve radiographic examination results for all alloy welds and for carbon steel welds in plates
as described in the specification.
f) Approve all ultrasonic examination results.
3.9 Contractor shall submit all welding procedures and fabrication drawings to ECOPETROL for
approval.
3.10 Welders employed by Contractor at Site shall be qualified by third parties supplied by Contractor,
with the approval of ECOPETROL.
3.11 Contractor shall give notice to ECOPETROL of upcoming inspections with adequate time for
ECOPETROL to provide an inspector, if ECOPETROL so chooses. For shop inspections of
equipment, ECOPETROL will notify Contractor of the specific hold points at which certain
equipment will be inspected by ECOPETROL or his designated representative. For Site
inspections, the extent of ECOPETROL inspection will be determined and communicated during the
Site coordination meetings. Contractor shall notify ECOPETROL of shop and Site inspections
required by ECOPETROL by means of a mutually agreeable procedure and form. Inspection by
ECOPETROL at Site shall be requested by Contractor only after Contractor has satisfied himself
that the equipment subject to inspection and/or test has been installed, inspected, and is ready for
test.
3.12 Duplicate sets of all principal test records, test certificates and performance curves shall be
supplied for all tests carried out in accordance with the provision of this Contract, within 30 days of
the completion of the Test.
These test records, certificates and performance curves shall be supplied for all tests, whether or
not they have been witnessed by the ECOPETROL. The information given on such test certificates
and curves shall be sufficient to identify the materials or equipment to which the certificate refers
and should also bear the Contract reference and heading.
Upon completion the Contractor shall produce three copies of bound and indexed volumes of test
certificates for all equipment supplied, in the English language.
3.13 Contractor shall determine the regulatory inspections required by authorities at the site. Contractor
shall engage a third party inspection Agency for mandatory inspection, as required, and shall notify
the authorities of tests, as required.
3.14 Contractor shall submit copies of his inspection reports to ECOPETROL and/or his inspection
agency.
4.0 SHOP TESTS
4.1 Functional, electrical, material, mechanical and hydraulic tests shall be carried out during and after
assembly in the shop. The extent and method of recording the results shall be agreed with
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ECOPETROL in ample time to enable the tests to be satisfactorily witnessed or to make any
changes to the proposed program of tests.
4.2 All instruments and apparatus used in the performance of the tests shall be provided by the
Contractor to the approval of ECOPETROL and, if required by ECOPETROL, shall be calibrated to
an agreed standard at a laboratory of national standing to be nominated by the Contractor and
approved by ECOPETROL.
4.3 The cost of carrying out such calibrations shall be born by Contractor in all cases.
4.4 At the time of ECOPETROL's Inspection, Contractor shall have available all tools and equipment
necessary to enable any tests, specified or implied, to be properly performed.
4.5 Copies of all previous relevant shop test results shall be provided for the use of ECOPETROL at the
time of any inspection or witnessing of tests.
4.6 After satisfactory completion of the witnessed tests, ECOPETROL shall witness and/or approve the
methods of dismantling and packing of each item.
4.7 Contractor shall provide test pieces free of charge as required by ECOPETROL to enable the
quality of the material to be determined at the Contractor's expense. ECOPETROL may, at his
discretion and by specific arrangement, accept certified particulars of tests carried out in his
absence.
4.8 Contractor may submit test certificates of tests which have been carried out on identical equipment.
Notwithstanding any provision in a standard ECOPETROL may have the right to accept such
certificates in lieu of the specified type tests or to reject them. Type tests are required on all
equipment whether specifically noted or not, to prove the general design of the equipment in
accordance with the relevant Contract standards. The type tests prescribed shall be carried out at
Contractor's cost in all cases where such certificates are not available or are rejected.
4.9 All non-destructive examinations shall be carried out by fully qualified operators using the
techniques acceptable to ECOPETROL.
4.10 Heat Exchangers
The following describes minimum specific requirements:
a) Any unusual or intricate tube expanding process shall be proven by means of a procedure test
carried out under correctly simulated conditions (that is - in the horizontal or vertical position in
line with production procedure). Procedure tests shall be carried out for all tube/tubesheet
connections. Test pieces shall be sectioned, etched, and in the case of expanded joints,
checked for hardness.
b) It is essential that where tube joints are to be expanded after seal welding, an air or gas leak
test be performed prior to expansion.
c) 'U' tubes shall be subjected to 100 percent hydrostatic test before assembly. Vendors must
understand that plugging of defective tubes will not be permitted. Inspectors must check that
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post-manipulation heat treatment is carried out and certified before Contractor's assembly of
tubes in bundles.
d) It is essential that the Contractor's inspector should check the following on all tube bundles
before assembly into the shell, or attachment of tubesheet(s) as appropriate:
1. Baffle pitch
2. Baffle cut
3. Baffle type
4. Tube diameter
5. Tube pitch
6. Tubepass arrangement.
e) Electro-slag welding must not be carried out without the prior sanction of ECOPETROL and
then only after full procedure tests have been established and approved.
f) Relief valves must be tested to demonstrate their ability to relieve at the set pressure and to
re-seat correctly with 4 percent blowdown. These tests must be performed at least three times
on each valve.
Tests shall be performed and certified by a third party shop at Contractor's expense prior to
delivery of the relief valves to the site. Retesting at site shall be performed by Contractor.
g) Functional testing shall be provided for engineered instrumentation systems including but not
limited to:
Panels with panel mounted instruments

Multiplexing systems
Analyzers
DCS
4.11 Pressure Vessels
Pressure Vessels shall be inspected and tested in accordance with ASME Section VIII, Div. 1.
ASME stamp is required.
All cast forged or fabricated pressure vessels or enclosures, and all completed pipes, bends
and fittings which are to be subjected to an internal pressure or vacuum during operation shall
be subject to a pressure test in fabricator's works to ASME Boiler and Pressure Vessel Codes.
All pressure tests shall be carried out prior to surface coating and cast iron enclosures may be
subjected to hammering during tests.
Water containing chlorides shall not be used for austenitic steel to avoid cracking in stress
areas.
Unless otherwise specified hydrostatic tests shall be maintained for 30 minutes at 1.5 times
the design pressure except tanks at atmospheric pressure which shall be tested at static water
pressure for 24 hours.
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Pneumatic or nitrogen tests may be carried out by submersion in water or by the application of
soapy water to external surfaces to reveal leaks by air bubbles, as agreed with ECOPETROL.
Other gas leak detection tests such as helium or hexafluoride tests may be carried out to a
specification as agreed with ECOPETROL.
4.12 Component Equipment
Component tests shall be carried out to the following standards:
a) Heat exchangers shall be tested to ASME VIII pressure vessel code and the relevant
TEMA Code.
b) Pressure Gauges shall be tested to ANSI B401.
c) Any expansion bellows shall be tested with an adjacent section of pipe but bellows
must be protected during test.
d) Items which may suffer damage such as steam traps and instrument bellows or
similar, may be tested at design pressure only.
4.13 Pipework
The requirements of this paragraph apply to both shop and site fabricated piping. All steel piping
shall be inspected in accordance with ANSI B31.3.
For all steel pipework the circumferential butt weld shall be subject to at least 10% radiography for
low pressure systems as agreed with ECOPETROL. For each defective circumferential weld, two
additional circumferential welds must be radiographed. If the defective circumferential welds equals
or exceeds 40%, all welds must be removed and rewelded and the requirements of this Job
Instruction repeated.
All pipework after completion of any fabrication shall be hydraulically tested in accordance with the
relevant standards.
Pipework systems shall be identified in accordance with ECOPETROL's color identification system
described in Job Instruction 15.
4.14 Rotating Equipment
All rotating equipment shall be tested and witnessed in accordance with the requirements of the
Project Specifications.
The performance tests shall be conducted through the full operating range of the pump to closed
valve conditions and ECOPETROL will require to witness pump tests as specified.
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A minimum of five measurement points shall be obtained to produce curves indicating flow/head,
flow/power absorber, flow/efficiency with NSPH or suction head for each pump with calculations
converting shop test results to site conditions.
4.15 Electrical Equipment
Where a type test is specified, type test certificates may be submitted for tests which have been
carried out on identical equipment. Notwithstanding any provision in International Standards or
other specification, ECOPETROL shall have the right to accept such certificates in lieu of the
specified type tests or reject them. The type test specified shall be carried out in all cases where
such certificates are not available or are rejected.
4.16 Motors
Inspection and testing of electric motors shall be in accordance with ANSI/IEEE and NEMA Codes.
4.17 Batteries
Tests on batteries shall be carried out in accordance with a test schedule to be produced from the
manufacturers recommended procedures and approved by ECOPETROL.
The agreed tests shall cover as a minimum requirement the complete charge and discharge tests
on each set of batteries, carried out and recorded in such a manner as to permit verification of the
ampere-hour capacity of the battery. In conjunction with these tests ECOPETROL shall select at
random five reference cells and the voltage curves, and temperatures relevant to these cells shall
be checked during three hour and ten hour discharge cycles.
4.18 Chargers
All chargers shall be tested under working conditions such that the various voltage/current control
features can be adequately demonstrated to the satisfaction of ECOPETROL.
Routine tests shall be carried out and the input current balance demonstrated while the charger is
delivering its full rated output.
The Contractor shall demonstrate to the satisfaction of the Purchaser that the heat dissipation of the
charger when delivering its full rated output does not exceed the value quoted in his tender and
accepted by ECOPETROL.
4.19 Low Voltage Equipment
Unless specified elsewhere to the contrary, all power, control, alarm and indication circuits and all
components of all equipment with a rated operating voltage not exceeding 1000 V AC or 1200 V DC
shall be subjected to dielectric tests, applied between all circuits and between each circuit and
earth.
These dielectric tests shall comprise a 2 kV power frequency test for one minute, preceded and
followed by a 500 V insulation resistance test.
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Components containing semi-conductors connected within the equipment may be disconnected

during the application of these dielectric tests, subject to the approval of ECOPETROL.
4.20 Fire Alarm and Control Equipment Paging and Announcer Systems
The complete system including central control equipment, peripherals, power supplies etc. shall be
set up and system performance tests carried out using a full simulation of all inputs.
A 48 hour simulation test shall be carried out successfully before shipment of the system or any part
of the system. Such testing shall include thermal cycling and adequate soak testing to ensure that
the initial burn in period to detect premature component failure, is exceeded.
The supplier shall submit his proposed schedules for test having adequate time for approval by
ECOPETROL. The test schedules shall be designed to demonstrate the complete capability of the
system including both hardware and software, to meet the requirements of this specification and the
application.
Particular attention shall be given to testing system loading and processing time to ensure
satisfactory performance when the full system is running under load. The supplier must clearly
state the method he proposes to use to demonstrate that the specified requirements are met.
Each module of the application software and all other major items of software, including the
operating system, utilities and all other pre-written modules shall be shown to be capable of
functioning correctly on the selected hardware configuration.
4.21 Electric Cable and Wiring
Inspection and testing of electric cable and wiring shall be in accordance with the relevant NEC,
NEMA and IEEE Codes, and include where appropriate, the following:
a) Appearance test
b) Construction test
c) Conductor resistance test
d) Withstand voltage test
e) Insulation resistance test
f) Impulse test
g) Insulation and sheath tension test
h) Heat test
i) Winding and heat test
j) Low temperature winding test
k) Cold resistance test
l) Heat deformation test
m) Heat shrinkage test
n) Oil resistance test
o) Flame resistance test
In addition to the above items, tensile strength, heat resistance and heat deformation tests at 75°C
shall be performed for the PVC material of 75°C thermal rating.
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5.0 SITE TESTS
During the course of erection, ECOPETROL shall have full access for inspecting the progress of the work,
checking its accuracy and witnessing such checks as may be required by him. During and on completion
of erection, tests and inspection on all plant shall be carried out by Contractor and witnessed by
ECOPETROL to demonstrate adequately that the equipment as erected on site, is entirely suitable for
commercial operation. Following performance of such tests and inspections, Contractor shall issue a
formal inspection report.
Prior to pre-commissioning tests being commenced, the Contractor shall supply for ECOPETROL's
approval, suitable check lists covering all items of plant and systems. These lists shall include, as a
minimum, the following:
a) Contract title
b) Plant item/system name
c) Schedule of checks to be carried out
d) Space for data obtained during checks to be entered and initialled
e) Space for date and names of persons carrying out and witnessing tests
f) Item/system data
g) Space for remarks
Contractor shall provide at Site the necessary certified instruments and gauges and any other equipment
necessary for checking the installation.
5.1 Site Tests for Mechanical Plant
a) Routine hydraulic tests, where required, and non-destructive testing of site assembled
components in accordance with the relevant ASME, ANSI or API requirements.
b) Flushing out all pipework
c) Operation of all protective and alarm devices
d) Rotation tests
e) Alignment and clearance
5.2 Site Tests for Electrical Plant
All site tests shall be carried out in accordance with the relevant IEEE/NEC Codes including high
voltage, insulation resistance, continuity of operation tests on all items of equipment as well as the
following specific tests.
a) Switchgear
After completion of erection and cabling all main and control circuits shall be subjected to the
high voltage tests specified in the applicable IEEE/NEC Codes.
The insulation resistance of all circuits shall be measured before and after the high voltage
tests.
All equipment shall be operated to prove that the tripping devices are satisfactory over the
auxiliary voltage limits.
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For adjacent equipment forming part of the complex switchboard, a 'Ducter' or similar
continuity test shall be carried out to prove the connections made on Site.
b) Contactors
Tests to prove contactor operation, together with high voltage tests as specified in the
applicable IEEE/NEC Codes.
c) Control, Relay and Metering Panels Instruments and Protective Devices
After complete erection and cabling, all circuits shall be subjected to the high voltage tests
specified in the relevant IEEE/NEC.
The insulation resistance of all circuits shall be measured before and after any high voltage
tests.
Primary and secondary injection tests shall be carried out to check the ratio and polarity of
the current transformers and the operation of the protective gear instruments. These tests
shall be repeated over an agreed range of relay settings. Approved operational tests shall
be carried out to prove that the interlocking features, remote control, sequential operation,
etc., are satisfactory.
d) Batteries and Chargers
Batteries and chargers will be required to undergo charge and discharge tests at site similar
to those specified for the tests at the manufacturer's shop.
e) Fire Alarm and Control Equipment, Paging and Announcer Systems
It will not be assumed that equipment leaving the manufacturer's works in good order has
arrived on site in equally good order. Therefore, each part of the system shall be inspected
on site and shall be demonstrated to be functional before the system is confirmed to be
ready for a full test. Particular attention shall be paid to any item showing signs of imperfect
packing, mishandling or other potential damage or faults.
Subsequent to the satisfactory completion of the above inspections and tests, each function
shall be connected up and the complete circuit tested end-to-end.
Where any tests involve access to or interference with equipment that has already been
commissioned, a Permit to work must be obtained and any instructions or limitation strictly
adhered to.
f) Cables
Tests shall be carried out by Contactor on the cables after installation in accordance with
relevant NEC/IEEE Codes.
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Where short lengths of power cables have been jointed and connected to switchgear or
transformers, and cannot be easily disconnected, the high voltage test on such cables may,
at the discretion of ECOPETROL, be reduced to those appropriate to the switchgear and
transformers.
Where disconnectable links are provided in the equipment to enable the cable to be isolated
for testing, Contractor shall disconnect and reconnect these links free of charge as directed
by ECOPETROL.
Where it is necessary for the metal sheath of single core power or other cables to be
insulated from earth, e.g. where insulated glands are used, Contractor shall demonstrate to
the satisfaction of ECOPETROL by suitable tests, that the required conditions have been
fulfilled.
g) Earthing
The resistance of each separate electrode shall be measured by an approved method. The
resistance of each complete system to the general body of the earth shall also be measured.
Measurements shall be made over such a period as ECOPETROL may require to
determine the limits within which the earth resistance values will vary according to climatic
conditions. In any event, the electrode system resistance is not to be more than 0.5 ohms.
5.3 Noise
Tests shall be carried out by Contractor, together with the supply of all necessary test
instruments, to prove that the various items of plant and equipment meet the specified noise
levels.
5.4 Cleaning and Painting
Piping and equipment cleaning shall be carried out by Contractor according to the Contract
Specifications. For piping and equipment which are to be painted Contractor shall follow the
recommendations of the paint manufacturer and Contractor shall provide the necessary
instrumentation to carry out the specified inspection and tests to the satisfaction of ECOPETROL.
5.5 Adjustment of Plant
When the plant is completely erected and before the reliability trial and official tests are made,
Contractor shall be entitled to carry out preliminary tests and to make any adjustments necessary.
All such adjustments and tests shall not alter the Contract completion date. The setting of
clearances and all other adjustments provided for the tests shall be normal working adjustments
and shall be retained without alteration for the full defects liability period.
5.6 Contractor will be responsible for testing and qualifying all welders in accordance with the
specified requirements to the satisfaction of ECOPETROL within 1 month before they are
permitted to work on the Works.
5.7 Contractor, at his cost, will provide erection specialists where necessary to obtain full guarantees
or otherwise ensure proper installation of specialized machinery or equipment. Equipment
Page 17 of 55
manufacturer's representative or erection specialist will be required for all heavy rotating
machinery and other special or critical equipment.
5.8 Materials of Colombian origin or manufacture where applicable and provided they comply with
the requirements of the Contract shall be used to the exclusion of imported materials. In no
circumstances will Contractor be permitted to substitute imported materials unless he proves to
the satisfaction of ECOPETROL that locally manufactured materials are not available or if
available are not of an accepted standard.
5.9 Contractor shall make provision for receiving, offloading, checking and storing all materials
delivered to site for use in construction. Checked and accepted materials must be logged and
segregated from unaccepted materials. Disposal of unacceptable material must be tracked and
reported to ECOPETROL.
5.10 Contractor will protect all stored equipment from the environment to keep it in a satisfactory
condition so as to maintain suppliers' guarantees. A preventative maintenance program shall be
established by Contractor, and approved by ECOPETROL.
5.11 Testing of materials and equipment will be carried out in accordance with the requirements of the
Contract. ECOPETROL may witness all tests.
5.12 Contractor will open up all vessels and columns described by the UOP Project Specifications so
that these can be examined by ECOPETROL, before they are closed for final testing. Such
opening will include opening of tray manways. The fitting of each tray or internals in vessels and
columns will be checked by ECOPETROL either before final closure of the vessel or before/during
fitting the next tray.
Contractor will close all internal and external manways of vessels and columns. Testing by
Contractor will be limited to those vessels and columns whose external shell or nozzles are
modified.
5.13 Contractor will not open/close heat exchangers, pumps and compressors for inspection.
Opening/closing of such equipment by Contractor will be limited to specific works described by the
UOP Project Specifications.
5.14 Exhibit 12-4 is a list of minimum acceptable quality requirements for instruments.
Page 18 of 55
EXHIBIT 10-1
EQUIPMENT LIST RECOMMENDED FOR INSPECTION
VESSELS LEVEL
FRACTIONATOR COLUMNS 3
(Absorbers, scrubbers, etc.)
RECEIVERS, SEPARATORS 3
MIXING AND RESIDENCE DRUMS 3

(Feed, settlers, vent, surge, etc.)
REACTORS 3
EXCHANGERS
(All) Reboilers, Air-coolers, Water-coolers, etc. 3
HEATERS
(All) Charge, reboilers, interheaters, reformer, etc. 3
PUMP/DRIVERS
(All) Charge, product, reflux, etc. 2
COMPRESSORS
Make-up and recycle, boosters 3
VESSEL TRAYS 2
INSTRUMENTS
STANDARD OFF THE SHELF ITEMS 1

(transmitters, thermocouples, gauges, etc.)
ENGINEERED EQUIPMENT (DCS, Control panel, etc.) 3
CONTROL VALVES/RELIEF VALVES 3

(high pressure/alloy)
ANALYZERS 2
SHOP FABRICATED PIPING
HIGH PRESSURE/ALLOY SERVICE 3
HIGH PRESSURE STEAM TURBINES 3
AGITATORS 2
LUBRICATION/CONTROL OIL SYSTEMS 2
OTHER 1
Page 19 of 55
ELECTRICAL EQUIPMENT LEVEL
Power transformers, switchgear, motor starters,

bus duct, high voltage cable, battery charger,
150KW and over motor, control panel, inverter 3
ELEMENTS OF STORAGE TANKS 3
STEEL STRUCTURE 3
Page 20 of 55
EXHIBIT 10-2
SHOP INSPECTION RESPONSIBILITIES
Abbreviations for the table are as follows:
C Contractor
V Vendor
S Subcontractor
P Inspection to be Performed
R Inspection Reports/Records to be Reviewed
W Full Witness Inspection
SW Spot Witness
FI Full Inspection
CHECK/INSPECTION ITEM C V REMARKS
PRESSURE VESSELS AND FIRED HEATERS
Qualification
Check of WPS R P
Welding Procedure Qualification Test R FI/P
Welder's Performance Qualification Test R FI/P
Material Inspection
Chemical Analysis R P
Mechanical Test R P Simulated

heat (Including
Impact Test, If
Specified) treatment
of test
coupon, if
applicable
Nondestructive Examination R P If specified

(such as Ultrasonic Examination)
Visual & Dimensional Check R FI/P
Template and Anchor Bolt
Check of Template and Gauge Plate R FI/P
Check of Anchor Bolt R FI/P
Formed Head
Page 21 of 55
Non-destructive Examination R FI/P If Specified
Heat Treatment Data R P
Check of Edge and Fit-up
VT for Edge R FI/P Including back

gouged surface
MT or PT for Edge SW FI/P Including back

gouged surface
If specified
Fit-up Inspection SW FI
PT for Base Metal Surface to be Overlay

Welded R FI/P If specified
NDE Procedure R FI/P
Check of Weldment
Visual Inspection and Check of Leg length of

Fillet Weld SW FI
RT for Butt Weld SW FI/P Film review
MT or PT for all Weld and Temporary Welded

Area after Ground Off SW FI/P If specified
PT for Overlay Weld SW FI/P If specified
UT for Groove Weld SW FI/P If specified
Hardness Test of Weld SW FI/P If specified
Check of PWHT with Recording Chart R P If specified
Chemical Analysis of Overlay Weld R FI/P If specified
Overall Visual and Dimensional Check
Main Body SW FI/P
Outer Clip and Supporting Lug SW FI
Inner Structure SW FI If any
Tracing Materials
Check of the Identification Marking to the

Page 22 of 55
Records R FI/P
Production Control Test FW FI/P If specified
Pressure test
Air Test for Reinforcing Plate and/or Loose- SW FI/P

sleeve Type of Liners
Hydrostatic Test FW FI/P
Pre-shipping Inspection
Check of Cleanliness and Dryness SW FI
Check of Painting and/or Rust Preventing SW FI

Coating
Check of Gasket Contact Face SW FI
Check of Marking for Construction SW FI
Check of Name Plate SW FI
Check of Accessories SW FI
SHELL AND TUBE EXCHANGERS
Qualification
Check of WPS R P
Welding Procedure Qualification Test R FI/P Including tube to

tubesheet
Weld
Welder's Performance Qualification Test R P
Material Inspection
Mechanical Test (Including Impact Test, if

Applicable) R P Simulated
heat
treatment of test
coupon if
applicable
Non-destructive Examination R P If specified

Page 23 of 55
Visual & Dimensional check R FI/P
Stress Relief after Bending of Tube R P In case of U-tube
Check of Anchor Bolt R FI/P
Formed Head
Non-destructive Examination R FI/P If specified
Heat Treatment Data R P If specified
VT for Edge SW FI Including back

gouged surface
MT or PT for Edge SW FI/P Including

back
gouged surface
PT for Base Metal Surface to be Overlay R FI/P If specified

Welded
Check of Weldment
Visual Inspection and Check of Leg Length of

Fillet Weld SW FI
RT for Butt Weld W FI/P Film review
MT or PT for all Weld and Temporary Welded SW FI/P If specified

Area after Ground Off
PT for Tube to Tubesheet Weld SW FI/P If specified

(after PWHT)
Chemical Analysis of Overlay Weld R FI/P If specified

Page 24 of 55
Main Body SW FI/P
Tube Bundle SW FI/P Including

flatness of
gasket
contact face
Passing of Template into Shell SW FI In case of

removable bundle
Stacking Assembly SW FI If any
Tracing of Materials
Check of the Identification markings to the

Records R FI/P
Production Control Test SW FI/P If specified
Pressure Test
Air Test for Reinforcing Plate and/or Loose SW FI/P

Sleeve
Check of Painting and/or Rust Preventing

Coating SW FI
Check of Marking for Construction SW FI
AIR COOLED EXCHANGERS
Qualifications
Check of WPS R P
Welding Procedure Qualification Test R FI/P Including

tube to
tubesheet
weld
Page 25 of 55
Welder's Performance Qualification Test R FI/P Including tube to

tubesheet
weld
Material Inspection
Mechanical Test (Including Impact, Test, if

Applicable) R P Simulated
heat
treatment of test
coupon if applicable
Non-destructive Examination R P If specified

Check of Setting Bolt R FI/P
VT for Edge SW FI Including back

gouged surface,
if any
MT or PT for Edge SW FI/P Including back

gouged surface
if any
Check of Weldment
Visual Inspection and Check of Leg Length of

Fillet Weld SW FI
RT for Butt Weld SW FI/P Film review
MT or PT for all Weld and Temporary Welded

Areas after Gouged Off SW FI/P If specified
PT for Tube To Tubesheet Weld (after PWHT) SW FI/P If specified

Page 26 of 55
Structure and Assembly SW FI/P If specified
Tube Bundle SW FI/P
Identification mark - FI
Tracing of Material
Check of the Identification Markings to the

Records R FI/P
Production Control Test SW FI/P If specified
Pressure Test
Air Test for Reinforcing Plate and/or Loose-

sleeve Type of Liners SW FI/P
Hydrostatic Test for Main Body FW FI/P
Pneumatic Test for Tube Sheet and Bolted Plug FW FI/P
Motor Driven Unit
Induction Motor R FI/P
Speed Transfer Unit or Pulley R FI/P
Blade and Blade Balance R FI/P
Louver
Dimensional and Visual Check R FI/P
Performance Test R FI/P
Check of Painting and/or Rust Preventing

Coating SW FI
Check of Marking For Construction SW FI

Page 27 of 55
CENTRIFUGAL PUMPS
Material Check
Material Test R R For main

Parts
Check of Traceability R Fl/P For main

Parts
Nondestructive Test R Fl/P Include

Impact
test, if
specified
Hydrostatic Test SW FI/P if specified
Rotor Dynamic Balance Test R Fl/P
Running Test
Mechanical Running Test FW FI/P if specified
Vibration Measurement FW Fl/P if specified
Performance Measurement Test RN FI/P If specified
NPSH Test RN FI/P *Witness test
is not required,
if NPSHA-
NPSHR
over 0.6m
WITNESS OF FINAL l_ HYDROSTATIC TEST 0F PERFORMANCE AS

PER SPECIFICATION SW Fl
WITNESS OF LOOP AND SYSTEM FUNCTION TEST SW FI
L/O Unit Running Test R Fl/P If specified
SoundLevelTest SW Fl/P For
reference
Dismantling Check after Running Test SW FI/P
Clearance Measurement R Fl/P
Run-out Measurement R Fl/P
Dimensional and Visual Check SW Fl/P
Alignment Check R Fl/P
Check of Spare Parts R Fl/P
Check of Accessories R Fl/P
Inspection of Auxiliary Equipment R Fl/P
ELECTRICAL EQUIPMENT AND MATERIALS
Power Transformer (larger than 1,000 KVA)

Page 28 of 55
Visual inspection and dimensional check W FI/P
Measurement of Winding resistance W P
Measurement of insulation resistance W P
Polarity and phase relationship W P
Ratio test W P
Impedance test R P
No-load test W P
Temperature rise test R P
High potential test W P
Measurement of tangent R P
Inspection for components W FI/P
Test for protection devices W P
Switchgear
- Visual inspection and dimensional check W FI/P
- Mechanical operation test W P
- Electrical operation test and

control/metering wiring test W P
- Insulation Resistance W P
- High potential test W P
- Test Report and certificate
(a) Circuit breaker R P
(b) Protective relays R P
(c) Small electrical apparatus R P
- PT, CT circuit test R P
- Operation and calibration of

protective relay W P
Motor Combination Starter Same as switchgear
Motor Control Center Same as switchgear

Page 29 of 55
Bus Duct
- Measurement of insulation resistance W P
Cable (Each size and voltage level of H/V cables)
- Visual inspection and dimensional check SW FI/P
- Measurement of Conductor resistance W P
- Measurement of Insulation resistance W P
- Bending test R P
- Tensile strength test R P
- Flame resistance test (If applicable) R P
Lighting Fixture & Receptacle
- Visual inspection and dimensional check R FI/P
- Measurement of insulation resistance R P
Battery
- Visual inspection and dimensional check R FI/P
- Check of initial charge record R P
- Check of discharge record R P
Battery Charger
- Visual inspection and dimensional check W P
- Performance test W P
(a) Manual voltage adjustable

range check W P
(b) Automatic operation for floating

and equalizing W P
(c) Determination of efficiency and power factor W P

Page 30 of 55
(d) Voltage drop test W P
(e) Dropper test W P
- Temperature rise test R P
- Sequence and alarm test W P
Motor
- Below 150 KW
(a) Visual inspection and

dimensional check R FI/P
(b) Insulation resistance R P
(c) Measurement of no-load current R P
(d) Determination of locked

rotor current R P
(e) Measurement of winding resistance R P
(f) Measurement of vibration R P
- 150 KW and over (One set of each type)
(a) Visual inspection and

dimensional check W FI/P
(b) Measurement of Insulation resistance W P
(c) Measurement of no-load current W P
(d) Determination of locked

rotor current W P
(e) Measurement of winding resistance W P
(f) Measurement of vibration R P
(g) High potential test W P
(h) Bearing inspection SW P
(i) Measurement of air gap SW P
- 750 KW and over (in addition to 150 KW and over)
(a) Current-time characteristics R P
(b) Current-speed characteristics R P

Page 31 of 55
(c) Speed-time characteristics R P
(d) Speed-torque characteristics R P
Neutral Ground Resister
- Visual inspection and dimensional check R P
- Measurement of resistance R P
- High potential test R P
Control Panel
- Operation test W P
- Inspection for components W FI/P
Inverter
- Operation test W P
- Performance test of charger W P
- Performance test of inverter W P
Communication Equipment
- Visual inspection and dimensional

check R FI/P
- Measurement of insulation resistance R P
- High potential test R P
- Electrical performance test R P
- Operation test R P
Page 32 of 55
Cathodic Protection W FI/P
HVAC Systems W P
Page 33 of 55
EXHIBIT 10-3
FIELD QA/QC REQUIREMENTS
PS ECOPETROL
C Contractor
V Vendor
S Subcontractor
P Inspection to be Performed
R Inspection Reports/Records to be Reviewed
W Full Witness Inspection
SW Spot Witness
FI Full Inspection
S C PS
1.0 CIVIL
1.1 Soil Investigation P R R
1.2 Earth Work
- Fill P SW W
- Excavation P SW -
- Back Fill P W SW
1.3 Lean Concrete P SW SW
1.4 Concrete Work
- Concrete Strength Tests P SW SW
- Reinforcing Bar Work P SW W
- Formwork P SW W
- Anchor Bolt Setting P W/R W
- Concrete Mixing Work P SW SW
- Concrete Pouring P SW SW
1.5 Sewer Piping P SW SW
S C PS
1.6 Open Ditch P SW/R SW
1.7 Cable Trench P SW SW
1.8 Underground Piping & P SW SW

Manhole Septic Tank
Page 34 of 55
1.9 Concrete Pavement P SW SW
1.10 Foundation Piling S SW SW
1.11 Sewer and Drainage Systems P SW SW
1.12 Bitumen Surface Pavement P SW SW
1.13 Gravel Surfacing P SW SW
1.14 Precast Concrete P SW W
1.15 Tank Foundation P SW W
1.16 Fence and Gate P SW SW
2.0 STEEL STRUCTURAL WORK
2.1 Prefabrication
- Material R R R
- Cutting and Drilling P SW -
- Welding
Welders Qualification Test P R R

Certificate
Base Metal P R R
Assembly P SW R
Weld Profiles P SW R
S C PS
Final Inspection P SW W
Straightness, length, P SW W
shapes and others
2.2 Field Check
- Dimensional Check P W SW
- High Strength Bolting

Demonstration of tightening P SW W
method and procedure
Tightness of bolts P SW W
Welding procedure P R R
Page 35 of 55
specification
Welders qualification test R R R

certificate
Assembly R SW R
Weld profiles
- Visual Check for Ladder, P SW SW

Handrail and Steel Floor
3.0 FIRE PROOFING
3.1 Material P R SW
3.2 Demonstration of Application P W SW
3.3 Final Visual Check P W SW
3.4 Dimensional Check P W SW
S C PS
4. EQUIPMENT INSTALLATION
(COLUMN, VESSEL, HEAT EXCHANGER, FIRED HEATER)
4.1 Before Installation
- Installation Sequence P R R
- Transportation Route P R R
- Construction Equipment P R SW
- Weather Condition P R R
- Check of Harmful Damage and P SW SW

Distortion during Transportation
4.2 Foundation (Confirmation)
- Surface of Foundation P R SW
- Location of Anchor Bolt P SW/R SW

(Adjustment with template if any)
Page 36 of 55
- Projection of Anchor Bolt P SW/R SW
- Damage of Threads P SW/R SW
4.3 Installation
- Placing Condition of Shim and Wedge P SW SW
- Elevation P W SW
- Alignment
Plumbness and leveling P W W
Tightness of Lock Nuts P W SW
S C PS
4.4 Grouting
-Preparation for Grouting P SW SW
-Grouting Material P R SW
-Grouting Placement and Finish P SW SW
4.5 Loosening Slide End Anchor Bolt P W W
5.0 INSTALLATION OF TOWER INTERNALS
5.1 Material
-Materials, quantities and P R R

Dimensions of all parts
(tray deck, downcomer, bolts & nuts,
washer, gasket, etc.)
5.2 During and after Installation
Levelness of Support Ring P SW SW
- Visual Check P SW W
- Leakage Test of Draw-off Pans P SW W
5.3 Final Check and Cleaning

Page 37 of 55
- Visual Check P SW W
- Cleaning P SW W
- Installation on Manway Deck P SW W
- Closure of Vessel Manhole P W W
S C PS
6.0 INSTALLATION AND ALIGNMENT OF PUMPS
6.1 Foundation (Confirmation)
- Anchor Bolts or Anchor Holes
Location P SW SW
Projection P SW SW
Dimension P SW SW
- Surface of Foundation P SW SW
6.2 Installation
- Temporary Setting P SW/R SW

Position and elevation
- Measurement of Level P SW/R SW
- Tightness of Anchor Bolts P SW/R W

and Liner Plates
6.3 Grouting
- Preparation for grouting P SW SW
- Grouting Material
Kind and quantity P R SW
Mixing ratio P SW/R SW
- Curing of Grout P SW R
6.4 Initial Alignment
- Measure of Axial Alignment P SW W

Page 38 of 55
S C PS
- Measurement of Face P SW W
Alignment
6.5 Alignment of Connecting Pipes
- Parallelness P W W
- Clearance P W W
- Off Center P W W
6.6 Alignment after Connecting Pipes
- Measurement of Axial P W W
Alignment
- Measurement of Face P W W
Alignment
6.7 Final Check
- Rotation by Hand or Turning P W W

Device
- All Accessories and Supplement P W W
6.8 Hot Alignment
- Axial Alignment P W W
- Face Alignment P W W
7.0 INSTALLATION OF AIR-COOLED EXCHANGERS
S C PS
7.1 Material
- Materials and Dimensions of P SW/R SW
S C PS
Structures Tube Bundles,
Fans, Speed
Page 39 of 55
- Reducers and Drivers P SW/R SW
7.2 Layout of Anchor Bolts and

Setting Bolts (Confirmation)
- Center Distance P W SW
- Diagonal Distance P W SW
- Projection and Sizes P W SW
7.3 Installation of Plenum
- Roundness of Fan Rings P SW/R SW
- Tightness of Setting Bolts P SW/R SW
7.4 Machinery Mount
- Level of Machinery Mounts P SW SW
- Tightness of Setting Bolts P SW W
7.5 Tube Bundle
- Tightness of Setting Bolts P SW W
- Removal of Shipping Bolts P SW W

or Clips
7.6 Parts Alignment of Mechanical
- Plumbness of Fan Shaft P SW/R W
S C PS
- Plumbness of Motor Shaft for V-Bolt type P SW/R W
- Level (Sheave to sheave) P SW/R W
- Tip Clearance P SW/R SW
- Tension of V-Belts P SW/R SW
- Blade Pitch Angle P SW/R R
- Tightness of Setting Bolts P SW/R W
7.7 Vibration
Page 40 of 55
- Vibration Monitor Check P SW/R W
- Vibration Test P SW/R W
8.0 PIPING WORK (INCLUDING FIRED HEATER)
8.1 Material
- Material Identification P SW SW
- Material Quality, Surface, etc. P SW SW
8.2 Preparation
- Edge Preparation P SW SW
- Preheating P SW SW
- Preparation of Welding P SW SW
S C PS
8.3 Welding
- Welding Procedure P W R
Qualification Test
- Welder Qualification Test P R R
- Certificate
8.4 Visual Inspection of Welds P W SW
8.5 Nondestructive Examination
- Radiographic Examination P W/R R
- Liquid Penetrant P W/R R

Examination
- Magnetic Particle P W/R R

Examination
8.6 Post Heat Treatment
- Post Heat Treatment P W/R SW
- Hardness Test P SW/R W

Page 41 of 55
8.7 Pressure Test P W W
8.8 Tape Wrapping P SW W
8.9 Coating P SW W
8.10 Line Check
- Line Layout P W/R R
S C PS
- Size, Dimension, P W/R R

Rating, etc.
- Valve, Fitting, Component P W/R R

Arrangement
- Finishing (Line Flushing) P W/R W
9.0 ELECTRICAL WORK
9.1 Switchgear and Control Gear

(132KV, 6.6 KV, 500 V)
- Visual Inspection P SW W
- Check SWGR Condition and P SW SW

the Storage Condition
- Insulation Resistance P W SW
Measurement
- Power Frequency Test P SW W

(132 KV 11KV)
- Interlocks and Controls Test P W W
- Operation Test P W W
- Relay Test P W W
- Final Setting of Relays P W W
- Phase Rotating Test P W W
9.2 Power Transformer

Page 42 of 55
- Visual Inspection P W W
- Check Position of Tap Changer P W W
Insulation Resistance P W W
S C PS
Measurement
- Sudden Pressure Relay Test P W W

with Manual Accuation
- Polarity Test (Shop data review) P W W
- Ratio Test (Shop data review) P R W
9.3 Motor
- Visual Inspection P SW SW
- Insulation Resistance P W SW
Measurement
- Inspection of Direction of P W W
Rotation
- Half Hour No-Load running P W W

Test (During this test, check
vibration, noise and bearing
temperature)
9.5 Inverter (Emergency Power System)
- Insulation Resistance P W W
Measurement
- Sequence Test P W W
- Phase Rotation Check P W W
9.6 Cable
- Check Cable Trench P SW SW

(it shall be clean and free from any objects)
S C PS
- Check Situation of Installed Cables P SW SW

Page 43 of 55
- Insulation Resistance P W W
Measurement
- High Voltage Test D.C. P W W

(above 1,000 V cables)
- Electrical Continuity Test) P W W
9.7 Earthing System
- Earthing Resistance P W W
Measurement
9.8 Sequence Test Including All Control Cables P W W
9.9 Voltage and Phase Rotation Check of P W W

Electrical Distribution System
9.10 Lighting System
- Insulation Resistance Measurement P W W
- Lighting Circuit Test P W W
- Illumination Level Check P W W
9.11 HVAC Systems
9.12 Communications Systems
10.0 INSTRUMENTATION WORK
S C PS
10.1 Control Center
- Instrument Panel Board, Console, P W W

Rack, etc.
- Visual Inspection after Installation P W W
10.2 Instrument Impulse Lines
- Visual Inspection
Page 44 of 55
Tag No. P SW SW
High and low pressure of d/p P SW SW
Slope P SW SW
Support P SW SW
Material and rating P SW SW
Purging/steam trace P SW SW
- Pressure and Leakage Test P SW/R W
10.3 Analyzer Sampling Lines
- Visual Inspection
Tag No. P SW SW
Sample system P W SW
Take-off P W SW
Support P SW SW
Material and rating P SW SW
- Pressure and leakage test P SW/R W
10.4 Wiring
- Visual Inspection Cable P SW SW

ladder rack installation
Support P SW SW
Cable identification and Tag No. P SW SW
Cable gland, sealing fitting and compound P SW SW
Cable marker P SW SW
- Continuity P SW/R SW
S C PS
- Insulation Resistance Test
Line to line P SW/R SW

Line to ground P SW/R SW
10.5 Pneumatic signal lines
- Visual Inspection
Tag No. P SW SW
Support P SW SW
- Leak Test and Identification
Air blow and continuity P SW/R SW

Leak P SW/R SW
10.6 Instrument Air Supply

Page 45 of 55
- Visual Inspection
Tag No. P SW SW
Segregation P SW SW
Support P SW SW
Line size P SW SW
Material P SW SW
- Leak Test and Air Blow
Leak P SW/R SW
Air Blow P SW/R SW

Page 46 of 55
S C PS
10.7 Calibration and Loop Test
- Calibration
Zero and range test of all analogue instruments P SW/R W

Measuring range P SW/R W
Direct and reverse action of controllers P SW/R W
Stroke of control valves P SW/R W
Operation test of online analysis P SW/R W
with calibration gas
Alarm set point P SW/R W
- Loop Test
Input signal loop P W/R W

Output signal loop P W/R W
10.8 Minor Instruments

(Orifice, PG, TG, LG)
- Visual Inspection
Tag No. P W SW
Scale P W SW
Location (direction) P W SW
Accessibility P W SW
- Dimension per Drawing P W/R SW
10.9 DCS
- Visual Inspection after Installation P W W
- Stand Alone Test
DCS Diagnostics P W/R W
- System Functions for DCS
System Restart P W/R W

Power Final Restart P W/R W
System Page Function P W/R W
Page 47 of 55
S C PS
11.0 INSULATION
11.1 Before Application Work
- Check of Material Quality P SW SW

and Dimensions
- Check of Keeping Condition of P SW SW

Insulation Material from Moisture,
Water or Rain
- Confirmation of Insulation System P SW R
- Check of Equipment and Piping to be P SW R

Insulated
Surface P SW SW
Support P SW SW
Finishing hydrostatic test or P SW SW

pneumatic test
11.2 During Application Work
- Weather Condition P SW SW
- Insulation Thickness P SW SW
- Number of Layer P SW SW
- Bank or Wire Spacing P SW SW
- Lapped Length of Jacket P SW SW
- Filling P SW SW
11.3 Final Visual Check P SW SW
S C PS
12.0 PAINTING
12.1 Check of Material
- Brands P SW/R SW
Page 48 of 55
- Color Code P SW/R SW
- Caution P SW/R SW
- Term of Validity P SW/R SW
12.2 Visual Check of Surface Preparation P SW SW
12.3 Weather Condition (Wind, rain, P SW SW

temperature and humidity)
12.4 Check of Each Layer (Wet film P W SW

thickness, interval and no. of layer)
12.5 Check of Total Dry Film Thickness P W W
12.6 Final Visual Check P W W
13.0 ATMOSPHERIC STORAGE TANK
13.1 Confirmation of foundation
- Marking of center point and P W W

orientation marks of 0°, 90°,
190° and 270°
- Dimensional check P W W
13.2 Bottom
- Visual and dimensional check P SW/R W
S C PS
Vacuum test P W W
13.3 Annular plate

(including shell to bottom)
- Vacuum test P W W
- Mag. particle examination P W W
- Dry or liquid penetrant examination P W W
13.4 Shell plate
- Visual and dimensional check P SW/R SW

Page 49 of 55
- Radiographic examination P SW/R R
- Measurement of level, roundness P SW/R SW

and plumbness for first shell ring
13.5 Shell appurtenance
- Orientation and dimension P SW/R SW
- Air tightness test for P W SW

reinforcing plate
13.6 Pontoon
- Leakage test applying oil penetration P W W
13.7 Deck plate
- Oil penetration or vacuum test P W W
S C PS
13.8 Roof plate
- Visual and dimensional check P SW/R SW
- Pneumatic test P W W
13.9 Roof appurtenances
- Orientation, dimension P SW SW
13.10 Heating Unit
- Pressure test P W W
13.11 Welding
- Welding Procedure P W W
Qualification Test If performed
at site
- Welder's Performance P W R
Qualification Test Certificate
Page 50 of 55
13.12 After the erection works
- Water filling test P W W
14.0 INSTALLATION OF TOWER INTERNALS
14.1 Materials, quantities and dimensions P R W

of all parts (tray deck, downcomer,
bolts and nuts, washer, gasket, etc.)
S C PS
14.2 During and after installation
- Levelness of support ring P W W
- Visual check P W SW
- Leakage test of draw-off pans P W W
14.3 Final check and cleaning
- Visual check P SW SW
- Cleaning P SW SW
- Installation of manway deck P SW W

Final inspection
- Closure of vessel manhole P W W
15.0 REFRACTORY
15.1 Surface preparation P SW SW
15.2 Anchor installation
- Check material quality P SW SW
- Check fit up P W SW
- Check weldment P SW SW
15.3 Procedure
- Review P W SW
- Demonstration test P W W
Page 51 of 55
S C PS
15.4 Application
- Temperature P SW SW
- Weather conditions P SW SW
- Equipment P SW SW
- Visual check P SW SW
15.5 Final check
- Visual P W W
- Test P W SW
Page 52 of 55
EXHIB1T 10 - 4
PROJECT QUALITY PLAN FOR INSTRUMENTS
1. WARRANTY
1.1 The vendor shall guarantee the system, all hardware. firmware and software to be free from all defects in
design, workmanship and/or materials and shall replace or correct at his own expense, including any and all
transportation and labour cost to plant site within warranty.
1.2 Contractor shall define with DCS and other equipment vendors a testing procedure to ensure that the DCS
system fulfill all the requirements of 'this specification and the material requisition made by the contractor.
1.3 Vendor quality control procedure shall be required for approval by ECOPETROL for fabrication, inspection
and testing of valves, DCS and other electronics equipments.
1.4 Contractor shall monitor the effectiveness of vendors quality assurance techniques and quality standards.
1.4.1 Contractor shall as a minimum provide inspection as indicated in exhibits 10-1 and 10-2 of these Job
instruction.
1.4.2 Quality control procedure for shop inspection shall include contractor's "Control and test specifications" or
equivalent,for each type of equipment
2. SERVICES SPECIFICATIONS
2.1 Fabrication and services
• The following services will be part of the DCS supply:

• Project management for the engineering, fabrication and final assembly of DCS.
• Assistance to the suppliers of packaged equipment whose control equipment will be interfaced to the
DCS communication network (if any).
• Engineering and system testing assistance during installation and commissioning. CONTRACTOR and
DCS supplier shall ensure that spare parts are available for the system throughout its estimated lifetime
of 15 years from start-up.
• The supplier shall provide support with parts and engineering expertise to the ECOPETROL for any
future system modifications and extensions
• DCS vendor shall accredit a representative office in Colombia that guarantee the site services mentioned
before and a spare supply capacity of at least 15 years.
• The representatives office shall offer a support organizations that assure and adecuate service quality
3. DOCUMENTATION
Contractor shall define with vendors the supply of the following minimum documentation:
3.1 Technical documentation of each component of the system. This documentation shall include:
Operating manual for all equipment. Maintenance manual for all equipment.
Page 53 of 55
3.2 Architectural scheme for overall system.
3.3 Interconnection diagrams.
3.4 Dimensional drawing of each equipment.
3.5 Card files layout and I/O layout with indication of electronic cards location and cards description.
3.6- Power Supplies one line diagram for all devices of the system with indication of current rating.
3.7 Detailed grounding scheme of the different parts of the system to the control grounding point and
indication of resistance grounding leg.
3.8 input/output signal list with service and main configuration information (location, type of signal, alarm,
range).
3.9 Terminal strips drawing for electronic cabinets and auxiliar bays showing all references for
interconnections.
3.10 Configuration manual with examples of build control loops.
3.11 Contractor shall supply the following minimum documentation:
3.11.1 Shall include all documents produced such as specifications, data sheets, diagrams:
• Instrument design/purchasing specifications.

• Process control diagrams.
• Instrument index.
• Instrument specification/data sheets.
• Functional process control specification
• Control room layouts.
• Instrument logic diagramsD
• CS Configuration Code
• Instrument inquiry/purchase requisitions.
• Instrument location plans
• Instrument loop diagrams.
• Instrument tray/conduit/cable/piping layout. Instrument installation details.
• Instrument winterization schedule.
• Instrument wiring/termination lists.
Page 54 of 55
3.12 As built documents.
After installation work completion the following documents shall be issued "as built" including all the
modifications performed during erection:
• Instrument list - Cable list

• Control room panels and racks arrangement drawing control room system.
• Instrument power supply distribution drawings. - Interlock and sequence drawings.
• Junction boxes arrangements drawings. - Loop drawings.
4. SOFTWARE
The DCS will be supplied completed with system software and applications software to achieve the effective
plant monitoring control and management as listed:
4.1 System Software
• System building
• System diagnostic
• Programming
4.2 Application Software
• Controls units configuration

• Operator station configuration
• Graphic configuration
• Trend recording configuration
• I/O configuration
All the software and hardware configuration tools necessary to build and to modify the configuration of
DCS must be provided.
5. TRAINING
Training courses shall be provided for ECOPETROL personnel or his representatives
These courses must not be standard but specific to the applications (control and maintenance).
As a minimum, the following courses must be provided:
Page 55 of 55
• DCS architecture
• DCS interface cards (control and maintenance):
Hardware description
Configuration
Maintenance
• Communication equipment
• Operator console:
Hardware description
Configuration
Maintenance
The necessary manual-, text books and work books which are required for training must be provided.
5.1 Training duration at vendor shop. Training service for ECOPETROL or his representatives shall have
the following duration: Training for ECOPETROL/representative: 4 weeks for 4 people
5.2 Training duration on site. Training site during precommissioning and commissioning period by mean of
"training on the job activity" for two groups of twelve (12) persons.
5.3 Operators training. The operator will be trained on site during job activity.

Quality Assurance and Control

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JOB INSTRUCTION 10 Volumen 4

QUALITY ASSURANCE AND CONTROL

1.0 QUALITY ASSURANCE AND CONTROL

2.0 DEGREES OF INSPECTION

30 INSPECTION AND TESTING

4.0 SHOP TESTS

5.0 SITE TESTS

1.0 QUALITY ASSURANCE AND CONTROL

1.0.2 This system shall be approved by ECOPETROL.

1.3 Contractor's quality system for detail engineering shall incorporate:

a. Identification of specified design criteria.

b. Interdisciplinary reviews for translation of design criteria into engineering documents.

c. Identification of engineering documents requiring review and/or approval.

d. Use of specified quality standards in engineering documents, including acceptance

e. Identification and control of deviations from specified quality standards and/or

f. Identification of criteria for selection and review of materials.

h. Identification of specified requirements and responsibilities of the engineering groups

i. Identification of documents requiring engineering interface and provision for resolution

k. Identification of engineering documents selected for use in the interface management.

l. Control and documentation of specified verification or reverification, including

m. Evaluation of effects of changes to previously verified documents, and reverification of

n. Review and/or approval of engineering drawings, specifications, and documents, etc.

1.3.1 Verification or checking shall be performed prior to issue for construction of

a) Monitoring the effectiveness of a vendor's quality assurance techniques.

b) Evaluating a vendor's quality standards, which may lead to establishing stricter

c) Destructive and nondestructive tests.

d) One or more forms of mechanical tests.

g) Review of material and test certificates

h) Review of welder certificates

2.0 DEGREES OF INSPECTION

2.1 LEVEL 0 INSPECTION

2.2 LEVEL I INSPECTION

It will be Contractor's Quality Control Department's responsibility to provide an inspector when

2.3 LEVEL II INSPECTION

Inspection by Contractor's Quality Control Department or other authorized inspection

2.4 LEVEL III INSPECTION

Inspection by Contractor's Quality Control Department or other authorized inspection company

a) Detailed monitoring of materials procured for use on this order.

b) Review and approval of all certified documentations, verification of compliance with

c) Witness testing of components prior to assembly.

d) Approval of all NDE (Non-Destructive Examination) test reports.

e) Check heat treating facilities, if possible.

f) Review heat treatment charts.

g) Visual inspection of final assembled equipment.

h) Witness of final hydrostatic tests or performance as per specification.

i) Witness of loop and system function tests.

2.5 LEVEL IV INSPECTION

Inspection by Contractor's Quality Control Department or other authorized inspection company

b) Witness fabrication and testing of components prior to assembly.

c) Approval of all NDE (Non-Destructive Examination) test reports.

f) Inspection applies to subvendors as well, if required.

3.0 INSPECTION AND TESTING

c) Witness and approve weld procedure qualification tests.

d) Approve or obtain proof of previous approval of welders.

f) Approve all ultrasonic examination results.

4.0 SHOP TESTS

4.10 Heat Exchangers

The following describes minimum specific requirements:

Panels with panel mounted instruments

4.11 Pressure Vessels

4.12 Component Equipment

Component tests shall be carried out to the following standards: