Construction Quality Assurance Manual

PRODUCED BY: REVIEWED BY: APPROVED BY:
Eng.
Eng. Silvia Castaneda Ames Eng.
General manager
Head of Quality Management System Deputy manager
Signature: Signature: Signature:
Date: 02/14/2012 Date: 02/14/2012 Date: 02/14/2012
0 FOR APPLICATION 14/02/2012 S. Castaneda

REV. DESCRIPTION DATE ELABORATED REVISED I APPROVE
STORY OF CHANGE
XXXX SAC
EITHER MANUAL VALIDITY: 02/14/12 VERSION: 0
REPLACES: Page 1 of 34
CONSTRUCTION QUALITY CONTROL AND ASSURANCE

MANUAL
All information contained in this document is confidential and property of XXXXXXX S. A., its total or XXX-GO-CQA-MQ
partial reproduction being prohibited without prior authorization from the Company.
VALIDITY: 02/14/12 VERSION: 0 XXX-GO-CQA-MQ Page 2 of 34
Construction Quality Control and Assurance

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INDEX
1. Introduction 3
2. Goals 4
3. Purpose 4
4. Terminology 4
5. Obligations and Qualification of personnel 5
6. Quality Assurance of Civil Works 6
7. Quality Assurance of Mechanical Works 10
8. Pipe Quality Assurance 23
9. Quality Assurance – Electrical and Instrumentation and control 28
10. Work deficiencies 30
11. Documentation 31

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1. INTRODUCTION
This document summarizes the general guidelines to take into account during the development of all
processes in the projects developed by XXXX SAC.
This program presents the tasks that must be performed by the Engineer in charge of Construction Quality
Assurance (CQA) on site, for all XXXX SAC projects, emphasizing the monitoring and testing that must be
carried out carefully during construction. construction.
XXX-GO-CQA-MQ CQA Manual Page3 of 34


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2. OBJECTIVE
1.1 The main objective of this Section is:
1.1.1 Ensure appropriate construction techniques and procedures are used.
1.1.2 That the project is developed in accordance with the technical specifications and design
plans.
3. PURPOSE
3.1 The purpose of this CQA Manual is to identify and define problems that may occur during
construction and verify that these are corrected before completion, to deliver a service or product
of adequate quality to the client.
4. TERMINOLOGY
4.1 Quality Assurance (QA) : Verification of quality control functions with the purpose of
determining whether they have been carried out correctly and adequately. It is the total effort to
propose, organize, direct and control quality in a production system with the objective of giving the
customer quality products that meet their expectations.
4.2 Quality Control (QC): Tests, observations and related functions carried out during the
installation of the system, in order to determine that this work is conducted in accordance with the
approved Drawings and Specifications.
4.3 CQA Engineer: Primary managing engineer responsible for the supervision and/or
performance of Construction Quality Assurance tasks described in the specifications. The CQA
Engineer is further responsible for the supervision of CQA personnel and all tasks assigned to them.
The inspection, observation, approval or other actions of the CQA Engineer in no way limit the
obligations and responsibilities of the Site Resident, related to the requirements of these
specifications.
4.4 CQA Assistant : Person responsible for supervising and conducting CQA programs and field
trials.


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4.5 Project Construction Plans and Specifications : Includes all Plans and
Specifications related to the Project, also considering modifications to the design and approved
cabinet drawings.
4.6 As-Built Plans : Also referred to as “Record Plans”. These plans record dimensions, details
and coordinates of the facility after completion of construction.
4.7 WPS : Welding Procedura Specification
4.8 Flushing : Technique used for pre-operational cleaning of circuits that contain oils, whether
lubrication, cooling or heating.
5. OBLIGATIONS AND QUALIFICATION OF PERSONNEL

5.1 CQA Staff Obligations
5.1.1 The CQA Engineer has the obligation and responsibility of implementing the
elements for the development of the CQA Plan to ensure that the construction of the
facilities is carried out in accordance with the Construction Plans and Specifications.
5.1.2 The Engineer will make every effort necessary to achieve efficient communication and
Effectively with customer representatives on matters related to testing and observation
procedures and results of materials or on-site testing.
5.1.3 The function of the Engineer is not to direct construction activities, however
However, he may advise the Engineer. Resident in aspects that can improve the quality or
rapid progress of the work.
5.1.4 The QC Engineer and his assistants will make every effort to facilitate and
Promptly provide test results to the CQA Engineer.
5.1.5 The CQA engineer will inform the client of any non-conforming aspects that do not
can be resolved immediately


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5.1.6 The CQA Engineer must receive qualification from the Quality Control staff
proposed by management, for evaluation and approval before the start of the work. If the CQA
Engineer, based on the documentation received, determines that the proposed personnel
is not suitable for carrying out the QC program, he must inform in writing what the
reasons were for such determination, with sufficient time so that the Area can replace to
this staff.
5.2 CQA Staff Qualifications
5.2.1 Depending on the jobs to be inspected, CQA personnel will have a

Formal academic preparation in Industrial, civil, mechanical, electrical and/or
instrumentation engineering.
5.2.2 CQA Engineers will have experience in reinforced concrete works and assembly of
metallic structures, electromechanical manufacturing and assembly, electricity and/or
instrumentation.
5.2.3 CQA support staff will have technical, practical and administrative experience, which
which will allow adequate implementation of the CQA Plan.
5.2.4 All CQA staff must be able to communicate effectively with the
Client and subcontractors, so that there is a clear understanding regarding construction
activities and the CQA Plan.
5.2.5 Additionally, they will be required to have knowledge of specific field practices.
and construction techniques, as well as all codes and regulations related to material
handling, observation of test procedures, equipment and reporting procedures.


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6. QUALITY ASSURANCE OF CIVIL WORKS
6.1 Concrete Quality Assurance
6.1.1 In this section, the QC/QA and testing requirements are established.
observation for concrete installation operations. This work includes, but is not limited to,
review of design mixes and QC information, as well as compliance testing for foundation
construction, slabs and other related aspects. QC staff will deliver submissions in
accordance with specifications. Additionally, you will develop and submit a schedule for
installation that includes complete testing of all materials, a submission of the installation
manual and pre-construction QC.
6.1.2 ASTM Standards
6.1.2.1 Specifications
The following ASTM (American Society for Testing and Materials) materials specifications will be used
as the basis for all materials testing:
• ASTM C33-93 Standard Specification for Concrete Aggregates.

• Standard Specification for Ready-Mixed Concrete ASTM C94-96.
• Standard Specification for Portland Cement ASTM C150-98.
• ASTM C260-95 Standard Specification for Air-Fixing Mixtures for Concrete.
• ASTM C494-92 Standard Specification for Chemical Mixtures for Concrete.
6.1.2.2 Test Methods
During all field and laboratory testing, the following ASTM test methods will be used and strictly
followed:
• Standard Test Method for Unit Weight and Voids in Aggregate. ASTM C29/29M-91A.
• Standard Practice for Making and Curing Test Samples in the Field. ASTM C31/C31M-96.


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• Standard Method for Testing Compressive Strength of Cylindrical Samples of
Concrete. ASTM C39-96.
• Standard Method of Testing Fine Materials Passing the 75-um Sieve (No. 200) in Mineral
Aggregates by Washing. ASTM C117-95.
• Standard Test Method for Specific Gravity and Absorption of Coarse Aggregate. ASTM C127-88
(1993).
• Standard Test Method for Specific Gravity and Absorption of Fine Aggregate. ASTM C128-93.
• Standard Test Method for Sieving Analysis of Fine and Coarse Aggregates. ASTM C136-96A.
• Standard Test Method for Air Content (Gravimetry), Unit Weight and Yield of Concrete. ASTM
C138-92.
• Standard Test Method for Hydraulic Cement Concrete Settlement. ASTM C143-90A.
• Standard Method of Testing Air Content of Freshly Mixed Concrete by the
Pressure Method. ASTM C231-97.
• Standard Temperature Test Method of Fresh Portland Cement Concrete

Mixed. ASTM C1064-86.
• Standard Test Method for Determining Soil Moisture Content by the Microwave Oven Method.
ASTM D4643-93.
6.1.2.3 Tests and Test Frequencies
The attached Table shows the CQA tests that the Engineer will perform and the frequencies of these
tests. Additionally, the QC Engineer will provide the client with the following information:
• A QC plan of the Project to be carried out.

• Plant equipment and mixer truck certifications.
• All certifications for each shipment of cement from the cement supplier.
• All Proof of Delivery.
• All QC information from XXXX SA


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6.1.2.4.1 The CQA person assigned to perform field testing will be a
qualified field with a minimum of 3 years of experience in concrete testing, who will work under
the direct supervision of the Quality Engineer and the Inspector on behalf of the Client.
6.1.2.4.2 The CQA person assigned to perform the laboratory tests will be a
Type of Material / Minimum Frequency

Test Description Coarse Aggregate
Fine Aggregate (Sand) Wet Concrete (Uncured) Dry Concrete (Cured)
(Gravel)
ASTM C136-96a Gradation 1/200 m3 1/200 m3 NA NA
200 Mesh Wash

1/200 m3 1/200 m3 NA NA
ASTM C117-95
ASTM C1064-86
NA NA 1/50 m3 NA
Temperature
Settlement Test
NA NA 1/50 m4 NA
ASTM C143-90a
ASTM C237-97 Air Content NA NA 1/50 m5 NA
ASTM C31/C31M-96 4 cylinders/100 m3 or 4

NA NA NA
Cylinder Testing cylinders every two days
Resistance of 1 at 7 days 2 at
NA NA NA
ASTM C39-96 Compression the 28 days
6.1.2.4
Personnel
qualified laboratory technician with a minimum of 5 years experience in laboratory testing, who
will work under the direct supervision of the Quality Engineer or Field Technician.
6.1.2.4.3 Steel Quality Assurance
6.2.1 All structural steel components (W beams, angles, struts, etc.) must be manufactured
using high quality steel materials, which must meet the requirements of ASTM A36.


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6.3 Reinforcement Rods
6.3.1 Reinforcing bars must be installed in an efficient manner and in accordance with current
industry standards. If necessary, CQA personnel must provide continuous or partial
observations of the installation of concrete structures using reinforcement to ensure that
construction is carried out in accordance with approved construction plans and
specifications. QA staff may require testing of construction materials if they believe there
are materials that do not meet quality standards for construction.
6.4. Structural steel
6.4.1 The CQA Engineer may require testing of construction materials if he believes that there are
materials that do not meet quality standards for construction.
7. QUALITY ASSURANCE OF MECHANICAL WORKS
7.1 Organization for the Project
7.1.1 For the development of the project, XXXX SAC will carry out the review of the design,
manufacturing and/or assembly of the corresponding equipment. For this purpose, a
precise and defined organization will be in place, which will be in charge of the different
functions and responsibilities inherent to quality, with the aim of achieving the level of
quality anticipated by the project.
7.1.2 The personnel assigned to the assembly will be made up of specialists in manufacturing,
assembly and qualified operators.
7.2 General features
7.2.1 XXXXX SAC will carry out, at a minimum, the following:
• Identification of the necessary processes.

• Determination of the sequence and interaction of these processes.


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• Determination of criteria and methods so that the operation and control of these
processes are effective.
• Ensure the availability of the resources necessary for the operation and
process monitoring.
• Monitor, measure and analyze these processes.

• Implement actions to achieve planned results and continuous improvement.
7.3 Resource management
7.3.1 Material resources
7.3.1.1 XXXX SAC will determine the resources necessary for the development of the mechanical
works of the project and will assign them as planned to ensure compliance with the
requirements.
7.3.2 Human Resources
7.3.2.1 All personnel designated by the Operations Management for the execution of the
processes that will affect the quality in this Project, including the Quality Control staff, will
be competent for the work to be performed.
7.3.2.2 In the case of the personnel who will carry out the welding processes, this must be
Previously qualified by a specialized and independent company through standardized
tests that ensure its efficient performance.
7.3.2.3 The Work Coordinator will maintain and make available to the QC Supervision the
qualification records of the welders that accredit that competence.
7.3.2.4 The QA/QC Engineer, in accordance with the project specifications, will determine the
Welding Procedures (WPS) that will be used in manufacturing and must be attached as
part of its Quality Plan.


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7.3.3 Infrastructure
7.3.3.1 The Operations Management will determine the necessary infrastructure for the development
of this Project, which includes work spaces, machinery and equipment for the processes,
means of communication, etc.
7.4 Process execution planning
7.4.1 The Work Coordinator must identify and plan the necessary processes for the
manufacturing and/or assembly of the project's mechanical equipment:
• The requirements that the teams must meet.

• The execution processes.
• The necessary material, human and documentation resources.
• The machinery and equipment for the execution of the processes.
• Quality Control activities and acceptance criteria.
• Records for the control of processes and products.
7.5 Shopping
7.5.1 According to what is indicated, the Logistics Department will make the purchases
of the Project materials to suppliers evaluated and approved by the Work Coordinator for
each specific material. The Logistics Department will guarantee and be responsible for
strict compliance with the Standards and Codes indicated in the technical specifications. In
the event that any of the materials acquired by the Logistics Department do not meet the
specifications, they will be replaced at the cost of the Logistics staff.
7.5.2 CQA staff will verify that the purchasing requirements for the materials or
services to be acquired, as well as their description, are clearly specified in the
corresponding purchasing documents, to ensure compliance with the required technical
specifications and requirements.


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7.6 Verification of Purchased Goods
7.6.1 The goods purchased by the Department. Logistics for this Project will be controlled at
arrive at the Customer's plant to verify compliance with the technical specifications
indicated in the purchasing documents. For materials or products that require it, CQA staff
must require the presentation of the corresponding Quality Certificates. These certificates
must be delivered by the suppliers along with the materials or products to be received
and must show, according to the material or product in question, the following:
• Identification of the material or product.

• Physical, chemical and mechanical properties, as applicable.
• Other applicable specifications.
7.6.2 It will be verified that the values are within the ranges established in the
Applicable standard or code and other requirements that said materials or products must
meet.
7.6.3 The same treatment will be applied in the case of receiving equipment purchased for the
client,
which must arrive accompanied by their Quality Guarantees and corresponding
complementary documentation, such as Installation Drawings, Operation Manuals,
Maintenance, etc. As the case may be, those that will be delivered to the Client as part of
the Quality Dossier.
7.6.4 Only the goods that will be received and may be used in the respective processes.
comply with the documentation and technical specifications of the Project.
7.6.5 CQA Staff will carry out the inspection at the reception for which they will have
respective formats and Inspection Point Plan.
7.7 Process Control
7.7.1 CQA staff will carry out inspection of all processes herein
Project under controlled conditions. These controlled conditions include:


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• The availability of input information and corresponding technical specifications at

the points where they are required by the Client or CQA Supervision.
• The use of the appropriate machinery and equipment for each of the processes,
including the corresponding hardware and software according to the process.
• The use of monitoring and measurement devices for the processes that
require.
• The execution of release and delivery activities.

• Procedures and Instructions for operation and/or control activities, for cases where
necessary.
7.7.2 Within the framework of these conditions, some relevant points of the controls are
detailed.
to be implemented:
7.7.2.1 Design Control
7.7.2.1.1 When Engineering is included in the scope of the Construction Project, CQA staff will
clearly identify all input data necessary for the execution of the corresponding design.
7.7.2.1.2 The output information (drawings, technical specifications, etc.) will include the review
and verification of the data so that they satisfy the initial requirements and the
established acceptance criteria.
7.7.2.1.3 All plans and technical specifications to be used in the Project must be approved by the
Client and must be marked “Approved for Construction”.
7.7.2.1.4 CQA personnel must maintain written control and clearly note each of the revisions of the
plans that are generated by them.
7.7.2.1.5 If any subsequent modification arises in the Client's design, this will be identified,
recorded and must receive the Client's approval.


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7.7.2.2 Authorization to Start Manufacturing and Assembly
7.7.2.2.1 Authorization for the start of project activities must follow the following
stages:
• Manufacturing and/or assembly will begin when the plans reviewed and approved for
Construction by the Client are available and available, in addition to the general and
detailed manufacturing schedule evaluated by the Operations Area.
• The manufacturing and/or assembly process will begin when the project has all the
supporting documentation of the materials that will be incorporated in the
manufacturing and with the corresponding programming.
• This programming will be required according to the general schedule of the Project.
• The Quality Management Plan must be approved and the complete designation of the
people who will assume the detailed functions must be made according to the Project
Organization Chart proposed to the client.
• The assembly process will begin when the Client issues the corresponding authorization
that ensures that all civil works prior to the execution of said assembly have been
carried out, as well as that said works have been approved by the Client.
• To begin the manufacturing assembly process, the Client must review and approve the
Assembly Drawings, as well as the Executive Assembly Procedure, which must be
submitted in a timely manner.
• The activities prior to the start of assembly, defined in the respective Execution Plans
and Procedures, and which will include those corresponding to Safety, must be
completed, controlled and verified to begin the assembly processes themselves.
7.7.2.3 Control in the Execution of Processes
7.7.2.3.1 In the execution of the processes, the controls established in the approved Procedures,
Instructions, or Inspection Point Plans will be applied.


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7.7.2.3.2 These documents define the controls and tests that must be carried out through
all processes, with a record of the inspections carried out in the respective Quality
Records indicated in said documents.
7.7.2.4 Process Validation
7.7.2.4.1 CQA Personnel will validate or qualify welding processes since welding behavior cannot be
verified through subsequent monitoring or measurement activities and any deficiencies
would become evident only after the structures are being used.
7.7.2.4.2 Weld strength cannot be guaranteed by inspection results alone. To know the resistance
of the weld, it needs to be destroyed, so validation of the welding processes is required,
as well as the qualification of the welder who is going to execute said processes.
Validation or qualification will demonstrate the ability of the welding processes to achieve
the required strengths.
7.7.2.4.3 At the beginning of the manufacturing and assembly processes, CQA Personnel must
previously qualify the welding processes to be used in the Project, as well as the welders
who will execute said processes.
7.7.2.5 Identification and traceability
7.7.2.5.1 CQA Personnel will identify fabrications through their respective coding and/or
identification sticker, throughout all Construction processes. The Resident must identify
the structures that are inspected and that present any Non-Conformity, to avoid their
unintentional use.
7.7.2.5.2 To facilitate traceability, CQA personnel will monitor and record the Project's unique
component identification.
7.7.2.5.3 All manufacturing records, as well as Quality Control records, will refer to the
identification or coding of each component or equipment.


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7.7.2.6 Customer Property
7.7.2.6.1 All information, documentation and goods received by XXXX SAC for any Project, which are supplied by
the Client and/or representative, will be treated as property of the Client.
7.7.2.6.2 XXXX SAC will safeguard the confidentiality of the information and documentation and will
take care of the assets while they are under its control. XXXX SAC will identify, verify,
protect and safeguard the assets that require it. If any of these goods deteriorate or are in
any way deemed unsuitable for use, they must be recorded and communicated to the
Client.
7.7.2.7 Product Preservation
7.7.2.7.1 XXXX SAC will preserve the conformity of the products resulting from the processes of this
project during their development and until the final destination of said products. This
preservation will include the identification, handling, packaging, storage and/or protection
of these.
7.7.2.8 Control of Measuring Devices
7.7.2.8.1 XXXX SAC will determine the necessary devices to provide evidence of the conformity of
the Construction of all projects with the established requirements. These devices can be,
among others, according to the applicability in the Project: vernier calipers, micrometers,
paint thickness gauges, squares of different sizes, levels, gages, theodolite, topographic
level, torque meter, etc.
7.8 Monitoring and Measurement of Processes and Products
7.8.1 Process Quality Control
7.8.1.1 For the Project, CQA staff will establish appropriate methods for monitoring and
measuring, through Quality Control, the manufacturing processes.


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mechanics defined for these, so as to verify that the requirements and technical
specifications established for the Project are met.
7.8.1.2 This Quality Control will be carried out at the appropriate stages of each process, defined
by their impact on compliance with the Project requirements.
7.8.1.3 Quality Control in the processes for every project will consist, at a minimum, of the
controls and inspections indicated below and which will be carried out from the reception
of the materials to be used until the final delivery of the product.
7.8.2 Controls and Inspections
7.8.2.1 Controls and inspections will be carried out during the following processes:
• In the reception of materials and supplies that will enter the processes in Plant and
Work.
• In the stages prior to manufacturing.
• In the manufacturing processes themselves.
• In the Release of fabrications for dispatch to Work.
• In the assembly processes.
• Final control for delivery.
7.8.2.2 The controls and inspections will be carried out by CQA personnel in accordance with the
Procedures, Instructions, Inspection Point Plans or Complementary Technical Instructions
that have been prepared for this purpose. All the results of these controls and inspections
will be recorded in the Formats designed for each of them and indicated in each of the
aforementioned documents.
7.8.2.3 As part of the QA, and during each of the processes, the Resident and the CQA staff, as
required, will provide the facilities for the Supervision or a representative of the client to
inspect on-site the documentation associated with the Quality Control and the execution
of the manufacturing processes themselves.


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7.8.3 Controls and Inspections in the Reception of Materials and Supplies
7.8.3.1 The controls will be carried out in the plant or work, as the case may be, upon the arrival of the
materials and supplies for the construction of the project, to verify compliance with
technical specifications.
7.8.3.2 The presentation of the Quality Certificates corresponding to the materials and supplies
that require it will be of special importance. These Certificates will be delivered by
suppliers, but issued by manufacturers. The Certificates must show, according to the
material or product:
• Identification of the material or supply.

• Physical, chemical and mechanical properties, as applicable.
• Compliance with any other specifications established by the Project.
7.8.4 Controls and Inspections in the Preliminary Stages of Metal Constructions
7.8.4.1 Qualifications applicable to metal-mechanical construction processes will be carried out.
7.8.4.2 The welding processes that will be used in the manufacture of the equipment, as well as
the qualification of the personnel who will carry out said processes, will be carried out in
accordance with the Inspection Point protocols and/or Complementary Technical
Instructions prepared for this purpose.
7.8.4.3 The documents for the execution of these Qualifications will be:
• Mechanical Work Inspection Point Protocols.

• Welding Procedures Specification (WPS.)
• Welding Procedures Record (PQR)
• Welders Qualification.
7.8.4.4 The controls and inspections defined in the Point of Check Protocols will be carried out.
Inspection and/or Complementary Technical Instructions corresponding to each
manufacturing process of the Structures for all Projects.
7.8.4.5 The Penetrating Dye test will be applied as a non-destructive test to the cords.
welding.


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7.8.4.6 The controls to be carried out in the manufacturing processes and their documentation
corresponding will be, at least:
• Inspection of the Authorized.

• Dimensional Control Format.
• Visual Weld Inspection.
• Procedures for Welding WPS Elements.
• Inspection Point Plan.
• Inspection for Penetrating Liquids.
• Inspection format for penetrating liquids.
• Structure Inspection.
• Sandblasting inspection.
• Arenado Reports.
• Paint Inspection.
• Painting Reports.
• Paint Inspection
7.8.5 Controls and Inspections during On-Site Processes
7.8.5.1 Quality Control in the processes corresponding to the work must be carried out by
specialized personnel and must have specific documentation of the processes that will be
carried out at the work site. Quality Control in the work, according to the scope of the
project, will be carried out in accordance with what is established in the quality
management plan and its related control documents.
7.8.5.2 In the case of specialized tests such as Non-Destructive Welding Tests that are required on
Site, these will be carried out by field personnel and will be inspected by CQA Supervision
personnel.
7.8.6 During the Assembly Processes
7.8.6.1 At least the following inspections will be carried out and recorded according to their
applicability:
• Preliminary Topographical Layout.

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7.8.9 Final Control for Deliveryand Inspection.
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7.8.9.1 Before the delivery of each manufacturing to the Client, CQA staff will carry out a final
• Vibration Level.
physical and documentary control to verify compliance with all requirements.
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THIS DOCUMENT IS DISTRIBUTED AS AN UNCONTROLLED COPY AND HAS A VALIDITY OF 3 YEARS FROM THE DATE OF ITS APPROVAL. THE QUALITY MANAGEMENT
requirements established in the project plans and specifications.

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• Handling, storage, transportation and care.

• Inspection, test and operation status.
• Non-conformity of material, parts or components.
• Corrective action.


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• Quality assurance records.
• Audits.
7.8.10 Quality Control Records
7.8.10.1 All Procedures, Inspection Point Plans or Technical Instructions

Complementary measures must refer to the records in which evidence of the controls
carried out and compliance with the requirements established for the Project will be left.
7.8.10.2 These records indicate the person(s) who authorizes the release of the
manufacturing in its different processes and in the final control.
8.0 QUALITY ASSURANCE OF PIPING WORKS
8.1 Design Control
8.1.1 When Engineering is included in the scope of the Construction Project, the
CQA staff will clearly identify all input data necessary for the execution of the
corresponding design.
8.1.2 The output information (drawings, technical specifications, etc.) will include the review
and
verification of data so that it meets the initial requirements and established acceptance
criteria.
8.1.3 All plans and technical specifications to be used in the Project must be
approved by the Client and must be marked “Approved for Construction”.
8.1.4 CQA staff must maintain written control and clearly note each of the
revisions of the plans that are generated by him.
8.1.5 If any subsequent modification arises in the Client's design, this will be
identified, registered and must receive the approval of the Client.


Manual
8.2 Prefabrication
8.2.1 Prefabrication of carbon steel pipe is included in the scope. The

Pipe prefabrication will be carried out in a workshop for pipes larger than 2''. The rest of
the pipe will be prefabricated on site and the corresponding isometrics will be created.
8.2.2 The pipe and pipe accessories must be received and stored, differentiating
materials and avoiding contact between those that are not compatible.
8.2.3 Cuts and preparation of the components necessary to make the joints.
8.2.4 Transfer of brands. Making joints and indelible marking as appropriate.

themselves, so that the traceability of materials and welders is ensured.
8.2.5 Supply and assembly of the necessary protections for the correct conservation of the
set.
8.3 Mounting
8.3.1 Mechanical assembly of pipes in which the assembly of pipes will be included (with
welded joints, flanged joints, threaded joints, etc.), of any type of material, carbon and/or
alloy steel, HDPE, etc. transportation, storage, unloading and lifting, cutting and edge
preparation, non-destructive testing, applicable heat treatments, definitive and
provisional pipe supports (including supply and manufacturing in the latter case),
scaffolding assembly.
8.3.2 Also included is the assembly of flanges for connections of any type up to
valve, assembly of accessories and corresponding valves, vent lines, purge lines and anti-
corrosion protection, as well as pre-cleaning of the pipes before assembly, flushing of the
assembled systems and hydraulic testing at 1.50 times the design pressure and system
emptying.
8.4 Systems Flushing
8.4.1 Supply, manufacturing and assembly of all the elements necessary for the
performing hydraulic tests, replacing venturis, blind flanges,


Manual
pressure gauges, recorders, etc., to be used and in general all the logistics
necessary to
the realization of them.
8.4.2 Supply, manufacturing and assembly of all the elements necessary for assembly
of auxiliary elements.
8.4.3 Supply of auxiliary supports necessary to carry out assembly and testing
hydrostatic. These supports should not be fixed to the pipe.
8.4.4 Assembly of tanks, hoppers, etc. Which are indicated in the description of the different
systems where a series of general activities must be observed:
8.4.4.1 Introduction of equipment and components in their location
8.4.4.2 Pre-align benches in their coordinates including pre-leveling. Keep record.
8.4.4.3 Receive anchor bolts for final leveling.
8.4.4.4 Supervise the placement of mortar without shrinkage as indicated in the

specification. Once the setting time has passed, tighten the anchor bolts, checking
the leveling. Keep record.
8.4.4.5 Present, assemble and couple pipes. When coupling pipes, control means such as
dial gauges, etc. will be used. And the corresponding report will be made. If there
is any type of tension, the appropriate corrections will be made to eliminate it.
8.4.6 Motors, pumps, valves, actuators, etc. They must be protected during the assembly
phase.
8.4.7 Alignment and leveling must be carried out and documented in the motor pump
assemblies, whether they come assembled or were assembled on site.
8.4.8 Safety valves for final tests to be carried out by a Collaborating Entity of the
Administration for commissioning of said valve, along with all documentation.


Manual
8.4.9 For the assembly of the feed water pumps, a series must be observed
of general activities:
8.4.9.1 Introduction of racks and/or pumps in their location.
8.4.9.2 Pre-align benches in their coordinates including pre-leveling. Keep record. Receive
anchor bolts for final leveling.
8.4.9.3 Supervise the placement of the mortar without shrinkage as indicated in the
specification. Once the setting time has passed, tighten the anchor bolts, checking
the leveling. Keep record.
8.4.9.4 Assemble electric motor and all its components that indicate their weights on the
motor.
8.4.9.5 When coupling pipes, control means such as dial gauges, etc. will be used. And the
corresponding report will be made. If there is any type of tension, the appropriate
corrections will be made to mitigate it.
8.4.9.6 Align motor with pump. The alignment will be carried out according to the
manufacturer's specifications and instructions. Keep record. The motor will not be
coupled until the direction of rotation has been tested.
8.4.9.7 Assemble couplings with all their screws. Mount protections.
8.5.1 The marking of the set of pipes included in the scope of the project will be carried out.
8.5 Marking
To do this, the following considerations will be taken into account:
8.5.1.1 All documentation concerning the design and supply that is necessary for the processing
of the marking will be required.
8.5.1.2 All documentation relating to prefabrication and assembly will be collected, among
others:


Manual
• Materials
- Quality certificate of pipes and accessories supplied
- Quality certificate for input materials.
- Casting traceability control.
- Welding
- Homologation of welding procedures.
- Welding approval certificates.
- Procedure specifications.
- Control and monitoring of welds, non-destructive testing and heat treatments.
- Homologation of welders.
- Evidence
- Inspection points program.
- Non-destructive testing and heat treatment reports.
- Personnel qualification certificates.
8.6
- Dimensional control report.
Requirements
- Hydrostatic test.
8.6.1 All documents will be taken into account when carrying out the work.
existing contractual agreements: plans, specifications and standards.
8.6.2 The lack of detected documents, indefinitions, design errors, etc. they must
be documented and must be submitted for correction. For this, a registry will be used. For

the modifications that are made, the same will be used.


Manual
8.7 Quality Assurance in Construction
8.7.1 Throughout the development of the work, it will be ensured that Quality in Construction
is adequate, complying with everything described in the respective Quality Plan, tests and
work procedures specified for each work.
8.7.2 The procedures are the documents that describe how each should be carried out.
one of the tasks of the different activities, when it has to be carried out, where it has to be
applied, and who or those have to carry it out, being structured as follows:
• Object.
• Scope.
• Responsibilities.
• Operational Method.
• Materials and Media to be used.
• Standards and Documentation.
• Previous requirements.
• Quality control etc.
8.7.3 The records of the tasks carried out in the procedures must be reflected in the Inspection
Point Protocols.
8.7.4 Monitoring compliance with the Testing protocols will be carried out by the person
responsible for quality in the work, ensuring that the tests are carried out in the periods
and quantities specified therein.
8.7.5 The Supervision will carry out internal audits on the work to ensure the proper course of
Quality, correcting any deviation that may arise.
8.8 Quality Assurance in Trials and Tests
8.8.1 All measurement and testing equipment, own or external, will be calibrated.
must be accredited by means of a certificate.


Manual
9.0 QUALITY ASSURANCE – ELECTRICAL AND INSTRUMENTATION AND CONTROL
9.0.1 Each supplier or contractor will provide adequate information for the
quality assurance, in order to provide reasonable assurance that instruments, equipment,
cables and other materials used in construction have been manufactured in accordance
with the indicated specifications and other standards applicable in the industry or implied
by such standards and specifications.
9.0.2 For each project, CQA staff will establish and maintain a system
effective quality assurance system, with relevant documentation to demonstrate
compliance with all requirements for services, equipment used and fabrications, in
accordance with the relevant section of the project specification.
9.0.3 The personnel in charge of Instrumentation and control must demonstrate their ability
to define and ensure the effective implementation of quality assurance requirements for
Instrumentation and control activities.
9.0.4 The Means to be used for quality assurance will be:
• Inspections.
• Test control.
• Calibration and control of testing and measurement equipment.
• Handling, storage, transportation and care.
• Inspection, test and operation status.
• Non-conformity of material, parts or components.
• Corrective action.
• Quality assurance records.
• Audits.
9.1 Calibration Equipment
9.1.1 The following is a list of the minimum equipment that the security personnel must have.
instrumentation and control, which must be available to perform calibrations

Control and Assurance Manual

Construction Quality
satisfactory. The list may be revised and expanded, according to the specific needs of the
project.
■ Pneumatic calibration equipment, 3 to 15 psi.

■ Current loop calibrator equipment 4 to 20 mA, as source and as reading. With
accuracy equal to or better than 0.05%, it must have a current certificate of having
been calibrated, no older than one year.
■ Megameter, 5000 Volts.
9.1.2 Original tools must be used, fake tools will not be accepted.
9.2 Procedure
9.2.1 The person responsible for quality will, in a timely manner, deliver the formats of the
protocols to be used for the various assembly activities: cable routing, insulation
measurement and continuity tests, panel inspection, instrument calibration, etc.
9.2.2 The procedure will be as follows:
9.2.2.1 The equipment will be inspected upon arrival at the warehouse. With equipment
specifications, verify the integrity of parts and whether they meet the
specification. If any anomaly is found, a report will be issued to the Construction
supervision. In order to take the precautions that the case requires.
9.2.2.2 Before being assembled, the instruments, if possible, must be tested in the XXXX
SAC field workshop, and a bench calibration must be performed in order to detect
any anomalies in their operation.
9.2.2.3 The finally assembled instrument will be checked and calibrated again in situ, if
possible with the process variables.
9.2.2.4 The person responsible for quality will receive the protocols issued by the
supervisor of the electrical and control part, corresponding to the inspection and
calibration of the installed instruments and equipment, the subject of the project.
Of being


Manual
necessary, you can ask the instrument technician to verify the
calibration
of an instrument or adjustment of equipment.
10 .0 WORK DEFICIENCIES
10.1 Upon discovering the existence of any deficiency in the work, the Engineer
CQA will immediately determine the nature and magnitude of the problem, inform the
Resident, Company Quality Manager and Operations Management about the issue and
provide the necessary documentation . If such deficiencies cause significant delays in
construction or major new work is needed, the Engineer must inform the Manager about
the issue in question.
10.2 The Resident must correct the deficiency and thereby satisfy the Engineer
of Quality with said work. However, in the event that the Resident cannot correct the
problem, he or she must recommend a possible solution and inform the Quality Engineer
for approval.
10.3 A new test must be performed on the corrected deficiency before the
Resident carry out additional work. The Quality Engineer must document all new tests and
the steps taken to correct the problem in a field construction inspection report and on
results recording forms related to the construction problem and its solution.
11 .0 DOCUMENTATION
11.1 Daily Reports
11.1.1 At a minimum, daily reports should include field notes, a summary

of daily construction activities, activities associated with testing and records of results and
observations. All project records will be kept on file in a well-organized project file at the
workplace, which will be available to Management and the Quality Manager for review at
all times. In addition, the Engineer must prepare a summary report, based on the daily
records and the results and observation records. daily reports


Manual
of the Quality Engineer must be available for the Resident to review, the
which must include the following information:
• Date, project name and location.

• Weather report.
• Description of the construction progress.
• Summary of test results, identified as passed, failed, or in the case of failure, retested.
• Reception of external materials, in addition to external certificates or tests for the

materials.
• Summary of decisions made that consider the acceptance of the work and/or the
taking of corrective actions.
• Signature of the Engineer.
11.2 Weekly Progress Reports
11.2.1 The field representative of the Quality Engineer must prepare a report
weekly progress report summarizing both QC and CQA construction activities for the
applicable period, for which the Engineer shall review daily reports, observation
summaries and data records, in addition to the Weekly progress reports provided during
your field visit.
11.2.2 It will also analyze the progress obtained, the results of all QC tests and
CQA observations and documentation with the payroll of QC/CQA personnel in order to
ensure that construction is of excellent quality.
11.3 Design Change Reports
11.3.1 Design changes may need to be made during construction.

and to the specifications, so in these cases, the Resident will notify the representative in
the field. Such changes will only be carried out by agreement


Manual
written (with respective signatures) between the Resident and the Client. All Design
Changes must be recorded and filed on site; Likewise, it is the responsibility of the
Resident and the Quality Engineer to include these changes in the Construction Plans (As-
built), and to make them known in writing to the field personnel, so that there is due
evidence of this communication.
11.4 Construction Difficulty Reports
11.4.1 In the event that the Resident encounters difficulties in the execution of any
specific activity required, a special report must be prepared to provide details about the
problem(s) that have arisen. The Resident, the Quality Engineer and the field
representative must meet to analyze and find a solution to any problem. If changes to the
construction specifications become necessary, the Quality Engineer and the Client must
be notified, who must approve them in writing.
11.5 Final report
11.5.1 After completing the project, the Engineer must prepare a final report of
appropriate construction inspection to be presented to Management and the Quality
Manager; You must also keep the originals of all the documents used in your office. The
objective of said report will be to verify that the work was carried out in accordance with
the construction plans and these specifications; and at a minimum it must contain:
• A summary of all construction activities.

• A description of the important problems that arose during construction and the
solution taken around them.
• A list of changes (if any) made from the construction plans and specifications, as well
as the justification for their execution.
• Photographs, each one with a description of the corresponding activity.


Manual
11.6 Registration Drawings (As-Built)
11.6.1 It will be the responsibility of the Technical Construction Office to prepare a set of as-built
plans or to register them, which must be carried out during the course of construction.
These must precisely locate all the construction items. The Quality Engineer will provide
all the base maps needed to develop the registration plans, the latter being sent in the
first instance to his representative in the field for review and approval within two weeks
after completing each construction phase and then sent in final (revised) form to the
Quality Engineer after receiving and incorporating the comments of the field
representative.
In turn, the Quality Engineer can carry out topographic surveys and prepare as-built
11.6.2 documentation during the completion of the work. However, this does not relieve the
Technical office of its obligations to prepare as-built records for the project, as required in
these specifications. It is of utmost importance that all Design Changes made during
construction are included in the As-Built, being the strict responsibility of the Technical
office.

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PRODUCED BY: REVIEWED BY: APPROVED BY:

Signature: Signature: Signature:

Date: 02/14/2012 Date: 02/14/2012 Date: 02/14/2012

0 FOR APPLICATION 14/02/2012 S. Castaneda

CONSTRUCTION QUALITY CONTROL AND ASSURANCE

Construction Quality Control and Assurance

5. Obligations and Qualification of personnel 5

6. Quality Assurance of Civil Works 6

7. Quality Assurance of Mechanical Works 10

8. Pipe Quality Assurance 23

9. Quality Assurance – Electrical and Instrumentation and control 28

10. Work deficiencies 30

Construction Quality Control and Assurance

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Construction Quality Control and Assurance

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Construction Quality Control and Assurance

4.7 WPS : Welding Procedura Specification

5. OBLIGATIONS AND QUALIFICATION OF PERSONNEL

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Construction Quality Control and Assurance

5.2 CQA Staff Qualifications

5.2.1 Depending on the jobs to be inspected, CQA personnel will have a

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6.1 Concrete Quality Assurance

6.1.2 ASTM Standards

• ASTM C33-93 Standard Specification for Concrete Aggregates.

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• Standard Temperature Test Method of Fresh Portland Cement Concrete

6.1.2.3 Tests and Test Frequencies

• A QC plan of the Project to be carried out.

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Construction Quality Control and Assurance

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Type of Material / Minimum Frequency

ASTM C136-96a Gradation 1/200 m3 1/200 m3 NA NA

200 Mesh Wash

ASTM C237-97 Air Content NA NA 1/50 m5 NA

ASTM C31/C31M-96 4 cylinders/100 m3 or 4

6.1.2.4.3 Steel Quality Assurance

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Construction Quality Control and Assurance

6.4. Structural steel

7. QUALITY ASSURANCE OF MECHANICAL WORKS

7.1 Organization for the Project

7.2 General features

7.2.1 XXXXX SAC will carry out, at a minimum, the following:

• Identification of the necessary processes.

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Construction Quality Control and Assurance

• Monitor, measure and analyze these processes.

7.3 Resource management

7.3.1 Material resources

7.3.2 Human Resources

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7.4 Process execution planning

• The requirements that the teams must meet.

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Construction Quality Control and Assurance

7.6 Verification of Purchased Goods