025-pro for sewer & drainage.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No : 5887

Project Document Number: T- 4.234.543 Project Rev.: A Page 2 of 22

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

E A 16.07.08 Ready for Construction SB EO AG RFC

D O 11.06.08 Issued for Company Comments FB EO AG ICC

C O 05.06.08 Issued for Company Comments FB EO AG ICC

B

Issued for Review FB EO AG IFR

A Issued for Internal Review FB EO AG IIR

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470

GAM PRO QAC GTL 025 E

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T-4.234.543

Rev No: A

Doc. Title : QUALITY CONTROL PROCEDURE FOR SEWER & DRAINAGE

Doc No: : GAM-PRO-QAC-GTL-025 Rev. E Date: 16.07.08

T-4.234.543 Rev. A Page 4 of 22

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TABLE OF CONTENTS

1. SCOPE ________________________________________________________________________ 5

2. PURPOSE _____________________________________________________________________ 5

3. REFERENCES _________________________________________________________________ 5

4. DEFINITIONS _________________________________________________________________ 6

5. RESPONSIBILITIES ____________________________________________________________ 6

5.1. The Section or Site Engineer will be responsible for the following:__________________________ 6

5.2. The QCE will be responsible for the following: __________________________________________ 7

5.3. The QCI will be responsible for the following: __________________________________________ 7

5.4. The Lab Technician will be responsible for the Following: ________________________________ 7

6. PROCEDURE __________________________________________________________________ 8

6.1. Pre Activities _____________________________________________________________________ 8

6.2. Procedure For Testing ______________________________________________________________ 8

6.3. General Notes For cleaning & tightness (FSI) __________________________________________ 8

7. ATTACHMENTS ______________________________________________________________ 10



T-4.234.543 Rev. A Page 5 of 22

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1. SCOPE

This QC Procedure defines the type and extent of inspection and testing to be carried out to verify all activities related to the installation and testing of Manholes and Pits for Sewers and atmospheric Drainage.

2. PURPOSE

The purpose of this procedure is to detail all inspections and testing to be conducted in order to verify that Manholes, Joint Boxes, Catch Basins, Inspection Chambers, and Pits for Sewers and Drainage conform to specified requirements. Drainage confirm to specified project requirements and specification.

3. REFERENCES

DEP.34.14.20.31.GEN : Drainage Facilities and Primary Treatment T-4.234.074 : MTS for Back Filling Works T-4.234.144 : QA/QC for Site Preparation and Earthworks

T-4.234. 575 : ITP for Concrete Works T-4.234.144 : Procedure for Earth Works DEP.31.40.10.19 GEN : GRP Pipelines & piping systems.

T-4.234.087 : MTS for U/G GRP Piping T-4.259.776 / 778 : AOC-PITS & Manholes plan view & sections

T-4.234.573 : ITP for site Preparation and Earth Works T-4.231.172 : Engineering, Procurement, Prefabrication, Installation, Testing and cleaning of U/G piping (Flawless Start-up) T.13.377.360 : Flawless Start-up Initiative (FSI)



T-4.234.543 Rev. A Page 6 of 22

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4. DEFINITIONS

Company : QSGTL and/or its PMC Contractor : Linde Engineering AG Sub Contractor : Gama Qatar Co. W.L.L. Contract : QSGTL Pearl Plant C2 ASU Construction Works CS : Construction Supervisor ITP : Inspection and Test Plan QCR : Quality Control Record QCP : Quality Control Procedure QCE : Quality Control Engineer QCI : Quality Control Inspector Lab. Tech. : Lab Technician QA/QC : Quality Assurance / Quality Control TPI : Third Party Inspection ITL : Independent Testing Laboratory

5. RESPONSIBILITIES

5.1. THE SECTION OR SITE ENGINEER WILL BE RESPONSIBLE FOR THE FOLLOWING:

Ensure that the work is carried out to the required Project Specifications and drawings as well as in accordance with the approved ITPs, QCPs.

Ensure that the surveyor has completed the setting out and reference points complying with the RFC drawings.

Ensure that all parties who are required to make any kind of test or inspections are suitably informed as to the overall programme of the works and daily inspection and testing requirements.



T-4.234.543 Rev. A Page 7 of 22

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5.2. THE QCE WILL BE RESPONSIBLE FOR THE FOLLOWING:

Review all relevant documentation & test reports issued by parties involved (Surveyor and QC inspectors) and submit Records to the CONTRACTOR.

Ensure that all other discipline activities that require to be inspected have been inspected and approved.

Organize and allocate inspection works to the quality control inspectors.

Ensure signatures are obtained from CONTRACTOR/COMPANY on the various Forms as required.

Carry out statistical analysis of the test results to improve quality control operations on site and to advise construction of the results.

Issue NCR's (non confirmation report) when and where required and to check that construction provides the appropriate corrective action.

5.3. THE QCI WILL BE RESPONSIBLE FOR THE FOLLOWING:

To ensure that he is fully aware of the daily construction programme.

To ensure that he attends all inspection points in a timely manner and records the results of his inspections on the appropriate forms.

Completion and filing of all inspection records under his responsibility and reporting to QCE.

5.4. THE LAB TECHNICIAN WILL BE RESPONSIBLE FOR THE FOLLOWING:

To ensure that he is fully aware of the daily construction programme.

To ensure that he attends and performs the required test properly in a timely manner and records the results accordingly.

Reviewing and issuing all relevant lab test reports to the QCE in a timely manner.



T-4.234.543 Rev. A Page 8 of 22

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6. PROCEDURE

6.1. PRE ACTIVITIES

All materials to be used have been inspected and approved prior to their incorporation

into the works.

Before commencing any excavation, details and locations of existing underground pipes, drains, cables, etc. shall be obtained and utmost precaution must be taken to prevent damage.

The excavation has been carried, surveyed and compaction has been inspected and

released by the Contractor.

De-watering of all excavations, if necessary, is in place and operational. The de-watering shall be continued until the excavation has been backfilled.

All Manholes, Joint Boxes, Catch Basins, Inspection Chambers and Pits have been

constructed in accordance with the RFC drawings and have been released for the next stage of construction.

6.2. PROCEDURE FOR TESTING

Sewer pipelines will be water tested in sections based on DEP-34-14-20-31. GEN. The

HYDRO TEST will be perform as per Method Statement - T.4.234.553 (preparation under progress)

Pipe lasers shall be used to ensure correct alignment and straightness of pipes.

6.3. GENERAL NOTES FOR CLEANING & TIGHTNESS (FSI)

Tightness:

During bolt tightening to flanges, to avoiding leaking flanges arising from installation problems with the bolt, the wrong type of bolts and thread damaged bolts will be neglected. The Joint Control Procedure (T.13.377.453) will be followed and carry out detail line check prior to offer for acceptance as per FSI Class 1.1.1.



T-4.234.543 Rev. A Page 9 of 22

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Leaking valves will be observed and found if it is manufacturing defect, the valve must be replaced. Or otherwise if found any debris in valve seat as a result of transportation from production area; execute spot check to remove the debris before tightening the valve as per FSI- T.13.377.360 Clause 1.2.6.

If leaks in pipe walls will be observed in U/G piping system due to insufficient production, allowing heavy equipments to damage lines after installation, the minimum depth will be ensured and the access way shall be shifted as per FSI- Clause 1.3.1 & 1.3.2. Apply the T.13.377.455 Amendments to DEP 61.10.08.11-Gen & T.13.377.454, Amendments to DEP 70.10.70.11-Gen.

Cleanliness:

The pipe lines are plugged with construction debris during storage and at site execution; it will be prevented by spot check on applied preservation prior to storage at site and at site during execution; Ensure that removal of preservation materials to the internal surface prior to installation, using such as steam, compressor suction as per PS, Part IV, Ch.10, Flawless Start-up, Q2.

If the pipe line having ingress of debris due to insufficient capping of open pipe spools during prefabrication and/or transportation from lay down areas for piping erection, a) instill Built it clean policy at piping prefabrication shops, b) Ensure that pipe capping materials are available at fabrication shop c) Ensure that the pipe spool lay down area is properly drained and pipe supports off the ground in a position not collecting water or flanges toughing the soil.

To avoiding dirt in lines (inadequate control(post-picking) during installation), specify dedicated team responsible for the control and management of the pipe spools during installation as per Clause 1.3 & 1.6 of T.13.377.360



T-4.234.543 Rev. A Page 10 of 22

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7. ATTACHMENTS

GAM-QCR-QAC-GTL-001 : Check list Initial Earth Work Cleaning & Grading

GAM-QCR-QAC-GTL-006 : Inspection Check list - Survey Report

GAM-QCR-QAC-GTL-007 : Inspection Check list - Backfill utilities / Foundations

GAM-QCR-QAC-GTL-008 : Inspection Check list Excavation utilities / Foundations

GAM-QCR-QAC-GTL-012 : Inspection Check list Concrete Foundations/Structures

GAM-QCR-QAC-GTL-013 : Inspection Check list - Blinding Concrete.

GAM-QCR-QAC-GTL-014 : Inspection Check list & Pre pour Card

GAM-QCR-QAC-GTL-015 : Inspection Check list & Post pour Card

GAM-QCR-QAC-GTL-024 : Inspection Check list - U/G Civil Pipe Lines.

GAM-QCR-QAC-GTL-026 : Inspection Check list Manhole Leak Test

INSPECTION CHECKLIST

EARTHWORKS CLEARING AND GRADING

FORM NO: GAM-QCR-QAC-GTL-001 Rev.0

ITP: GAM-ITP-QAC-GTL- Date :

Location Bldg/Area :

Drawing Reference Nos :

SIGN OFF AS ACCEPTED

GAMA QATAR LINDE PEARL GTL

Name

Position

Signature

Date

0.

1 Check work site, stock pile haul roads, disposal areas and any existing utilities clearly identified N/A YES NO

2 Check that the Surveyor has established bench marks and confirmed elevations N/A YES NO

3 Check work site and any existing utilities staked out (confirmed by surveyor or attach surveyor's report)

N/A YES NO

4 Check provisions for de-watering (if appl.) N/A YES NO

5 Check provisions for demolition of existing structures. (if appl.) N/A YES NO

6 Check valid work permits obtained for all areas N/A YES NO

7 Check site cleared of all unsuitable soil & rubbish N/A YES NO

8 Check all unsuitable material hauled away to designated disposal area. N/A YES NO

9 Check any retained soils are properly stock piled N/A YES NO

10 Check retained soils appear acceptable and sampled as required N/A YES NO

11 Check site properly graded to designated levels (confirmed by surveyor or attach surveyor's report)

N/A YES NO

12 Check base soil appears acceptable & sampled as required N/A YES NO

13 Check base scarified (if required) N/A YES NO

Comments:


SURVEYORS REPORT.

FORM NO: GAM-QCR-QAC-GTL-006

Rev. 0

ITP REF. NO: GAM-ITP-QAC-GTL- REV. 0

DATE :

Location Bldg/Area:

No :

SIGN OFF WILL CONFIRM RELEASE TO EXCAVATE.


Name

Position

Signature

Date

0.

Briefly describe the intention of the Survey and purpose giving details of the utility/ excavation.

Drawing Numbers For Location give Marked up copy of Drawing:

1. Confirm that surveying equipment is calibrated

Calibration Cert No :

2. Check that the drawings noted above are approved for use. N/A YES NO

3. Check all existing utilities are clearly identified and staked out N/A YES NO

4. Confirm that the proposed excavation is clearly staked/ Marked out. N/A YES NO

5. Confirm depth of excavation. N/A YES NO

Surveyors Comments plus any additional survey information.


BACKFILL UTILITIES / FOUNDATIONS


Rev. 0


DATE:

Location Bldg/Area:

Drawing Reference Nos



Name

Position

Signature

Date

0.

ITEM DESCRIPTION

BACKFILL UTILITY

1 Confirm that Utility is completed tested and released for BACKFILL N/A YES NO

2 Confirm that sand fill is completed N/A YES NO

3 Confirm that fill is being laid in layers as required by the specification. N/A YES NO

4 Confirm that compaction test have been performed and results recorded. N/A YES NO

5 If the Utility requires tiles to be laid confirm that this has been done. N/A YES NO

6 If warning tape is required confirm that it has been laid N/A YES NO

BACKFILL FOUNDATIONS

7 Confirm that the foundation has been released for Coating and Backfill N/A YES NO

8 Confirm that the foundation has been coated with liquid membrane as require by specification N/A YES NO

9 Confirm that the foundation has been covered with hardboard and overlain with polyethylene. N/A YES NO

10 Confirm that fill is being laid in layers as required by the specification. N/A YES NO

11 Confirm that compaction test have been performed and results recorded. N/A YES NO

COMMENTS :


EXCAVATION FOR UTILITIES AND

FOUNDATIONS


Rev.0


DATE:

Location Bldg/Area:

Drawing Reference Nos:



Name

Position

Signature

Date

0.

ITEM DESCRIPTION

1 Check route/area is clearly staked / Marked out by Surveyor N/A YES NO

2 Check all existing utilities clearly identified and staked out N/A YES NO

3 If Utility trench check that it complies with depth & width shown on drawing. N/A YES NO

4 If foundation Base confirm size and depth are correct to approved drawings/ surveyors report.

N/A YES NO

5 Check bedding material for foundation or Utility trench is clean and free of stones and laid to proper depth

N/A YES NO

6 For drainage confirm levels falls etc mark on drawing (show levels Manhole to Manhole).

N/A YES NO

7 If Geotextile is to be used confirm that it is positioned to the correct requirements. N/A YES NO

8 Confirm base compaction test have to be performed prior to bedding. N/A YES NO

9 Check de-watering properly maintained (if required) N/A YES NO

10 Check trench is properly battered, framed or sheeted (if required) N/A YES NO

1. Stage completion release to lay UTILITY or 2. Blinding for Foundation Base.

COMMENTS :

QSGTL PEARL PROJECT

C2 ASU Construction Works

FORM NO: GAM-QCR-QAC-GTL-

012

INSPECTION FORM FOR CONCRETE FOUNDATIONS / STRUCTURES

ITP GAM-ITP-QAC-GTL- Date:


DRAWING & REVISION No.

TYPE OF STRUCTURE :

LOCATION :

No :

TYPE OF ACTIVITY

GAMA - QC LINDE COMPANY REMARKS

SIGN DATE SIGN DATE SIGN DATE

1.0 Surveying, Setting Out & Excavation

2 Existing Ground / Formation Level

2.1 Bottom Level Correct

2.2 Dimension checked

2.3 Strata acceptable

2.4 Excavation is completed and approved for next activity

3 Blinding

4 Footing

4.1 Formworks / Rebars / Dimensions / Cleanliness / Oil / Support

4.2 Inserts

5 Pedestal

5.1 Formworks & Rebars

5.2 Anchor Bolts & Inserts

6 Concrete Pouring (1)

7 Concrete Pouring (2)

8 Concrete Surface Inspection

9 Concrete Protection

9.1 Epoxy Coating

9.2 Polyethylene Sheet

9.3 Hardboard

10 Backfilling

QSGTL PEARL PROJECT

C2 ASU Construction Works

FORM NO: GAM-QCR-QAC-GTL-

012


ITP GAM-ITP-QAC-GTL- Date:

10.1 Area free of deleterious

material prior to backfilling



TYPE OF STRUCTURE :

LOCATION :

No :

TYPE OF ACTIVITY

GAMA - QC LINDE COMPANY REMARKS

SIGN DATE SIGN DATE SIGN DATE

10.2 Layers for fill material marked on the sides of the excavation or with pins.

10.3 Adjacent to below ground structures correctly coated and protected in accordance with project specification

10.4 Compaction test done

11.0 Final Survey Concrete As built


LEAN / BLINDING CONCRETE


ITP REF. NO: GAM-ITP-QAC-GTL- Date :

Location Bldg/Area: Drawing Reference Nos

No :


GAMA QATAR LINDE QSGTL

Name

Position

Signature

Date

DESCRIPTION

1 Verify surveying setting out of Base location and blinding concrete level is as per drawings N/A YES NO

2 Verify Base Compaction results are conforming to Specifications. N/A YES NO

3 Confirm thickness is to be 50mm Minimum N/A YES NO

4 Confirm forms are in place N/A YES NO

5 Blinding Concrete receival & placement inspection. N/A YES NO

6 Verify Concrete Curing N/A YES NO

7 Check application of membrane / Polyethylene is in accordance with manufacturers instructions and specification.

N/A YES NO

8 Compressive strength to be recorded by Laboratory N/A YES NO

COMMENTS :


CONCRETE PRE POUR INSPECTION


ITP REF. NO: GAM-ITP-QAC-GTL- Date:

Location Bldg/Area:

No:

Drawing Reference Nos :



Name

Position

Signature

Date

ITEM DESCRIPTION

1

Check that existing concrete surface properly chipped & concrete pouring place is clean

and construction joints, if any, are adequately prepared

N/A YES NO

2 Check that form work installation is proper and release agent applied properly N/A YES NO

3 Check that rebar free from rust, damage and installed as per drawings IF REQUIRED check embedded items are compliant

N/A YES NO

4 Check that reinforcement Bars are the correct size as drawing N/A YES NO

5 Check that reinforcement are spaced correctly N/A YES NO

6 Check adequacy of spacers and specified concrete cover N/A YES NO

7 Check that Embedded items are placed as per the construction Drawings N/A YES NO

8 Check that Anchor Bolts are placed as per the construction Drawings. N/A YES NO

9 Check that Waterstop is fixed correctly if required N/A YES NO

10 Check that all civil piping is fixed and ready for casting N/A YES NO

11 Check that all electrical items are fixed and ready for casting N/A YES NO

12 Check that all mechanical items are fixed and ready for casting N/A YES NO

13 Check that all Anchor bolts and embedded items are installed as required, if applicable. N/A YES NO

Comments:


CONCRETE POST POUR INSPECTION

FORM NO: GAM-QCR-QAC-GTL-015 ITP REF. NO: GAM-ITP-QAC-GTL- Date :

Location Bldg/Area: No :

Drawing Reference:

SIGN OFF AS ACCEPTED ONLY AFTER COMPLETION OF ALL WORKS & CURING


Name

Signature

Date

POST POUR INSPECTION

CAST DATE CAST TIME Approximately STRIPPING DATE / TIME

1 Confirm Dimensional Check taken: Attach sketch or marked up drawing of dimension taken

NA YES NO

2 Confirm surveyor has reported . NA YES NO

3 Confirm Embedded items have been check and accept by Mech. NA YES NO

EXAMINATION OF POUR AFTER STRIPPING

Describe any surface defects and their probable cause, and what remedial measures are necessary :

REPAIRS

If major repairs are to be carried out give repair sheet No

CURING RECORD

4. DAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CHECKED

NOTE: Water Curing Check the curing daily tick the box. If Curing Compound is used write below Curing Compound type

GENERAL COMMENTS


CONCRETE POST POUR INSPECTION

FORM NO: GAM-QCR-QAC-GTL-015 ITP REF. NO: GAM-ITP-QAC-GTL- Date :

Location Bldg/Area: No :

Drawing Reference:

SIGN OFF AS ACCEPTED ONLY AFTER COMPLETION OF ALL WORKS & CURING


Name

Signature

Date

THIS RECORD SHEET TO BE USED ONLY IF REQUIRED

CONCRETE REPAIR RECORD SHEET Supervisor / Inspectors name Date RFI No.

Provide Sketch or photo and give brief description of repair and repair material.

Is the defect

1. HONEYCOMBING

2. SEPARATION

3. OTHER

1. Check bonding agent applied (if required) NA YES NO

2. Check only designated repair materials are utilised NA YES NO

3. Check repair materials properly applied NA YES NO

4. Check curing application (if required) NA YES NO

INSPECTION FORM FOR U/G LINES (CIVIL)

REPORT NO.:

SYSTEM NO.:

Serial TYPE OF ACTIVITY GAMA - CONSTRUCTION GAMA - Q.C. CTJV REMARKS

No. SIGNATURE DATE SIGNATURE DATE SIGNATURE DATE

1 Surveying, Setting Out and Excavation

2 Sand Bedding / Sand Bags Setting

3 Laying of Pipe / Alignment

4 Line Test

5 Wrapping&coating

6 holiday Test

7 Backfilling Sand

8 Backfilling above Sand

Form No.: GAM-QCR-QAC-GTL-024 REV.0

TYPE OF LINE

LOCATION

PEARL GTL PROJECT

C2- ASU


MANHOLE, CATCH BASINS & PITS LEAK TEST REPORT

LEGEND: MANHOLE CATCH BASIN PIT OTHERS

DWG. Number Item No. Date Time Remarks

TEST COMPLETED SUCCESFULLY WITHOUT ANY VISUAL LEAK.

NOTE : LEAK TEST WILL START AFTER ABSORBING WATER BY STRUCTURE IS STABILIZE.

FORM. NO.: GAM-QCR-QAC-GTL-026 REV.0

C2-ASU

PEARL GTL PROJECT

REPORT NO :

DATE

NO :

AREA :

COMPLY

NOT COMPLY

GAMA--CONSTRUCTION GAMA--QC LINDE COMPANY NAME SIGNATURE DATE

025-pro for sewer & drainage.pdf

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