SOCIEDAD MINERA CERRO VERDE S.A.A.CERRO VERDE PRODUCTION UNIT EXPANSION PROJECT NO. A6CV SITE QUALITY MANUAL DOCUMENT NO. 240K-C2-OT-05-002 REV. 0 19 JUNE 2013 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV Document No. 240K-C2-OT-05-002 Revision 0 SITE QUALITY MANUAL This page is intentionally blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\240K-C2-OT-05-002-0_Cover.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0000 Revision 0, 10 June 2103 TABLE OF CONTENTS / DATE REVISION PAGE Administrative Procedure No. 000 509 0000 000 509 0010 000 509 0020 000 509 0040 000 509 0050 000 509 0090 000 509 0110 000 509 0130 000 509 0140 000 509 0150 000 509 0160 000 509 0170 000 509 0180 000 509 0200 000 509 0210 000 509 0220 000 509 0230 000 509 0240 000 509 0250 000 509 5100 Title Table of Contents / Date Revision Page Foreword Manual Preparation and Maintenance Organization and Responsibilities Document Control Process Control Inspection, Measuring and Test Equipment Control of Nonconformances Corrective Action Preventive Action Quality Records Quality Audits Personnel Training and Qualification Site Subcontractor Qualification Contractor Quality Requirements Surveillance of Construction Activities Field Receiving Inspection Turnover Material & Equipment Storage & Maintenance Activity Plan for Construction Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 Inspection and Test Procedure No. 000 509 7000 000 509 7010 000 509 7020 000 509 7030 000 509 7040 000 509 7050 000 509 7060 000 509 7070 000 509 7080 000 509 7090 000 509 7100 000 509 7200 000 509 7300 000 509 7310 000 509 7320 000 509 7400 Title Inspection and Testing Soils Bituminous Concrete Paving Pilling - Steel H - Piles Piling – Pre-Cast Concrete Piles Piling - Timber Piles Piling - Closed End Concrete Filled Pipe Piles Piling - Concrete Filled Thin Shell Pipe Piles Drilled Caissons Augered Cast-In-Place Piles Concrete and Grout Structural Steel Buildings Heating Ventilating and Air Conditioning Roofing Inspection Equipment Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0000 Rev 0 Table of Contents.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0000 Revision 0, 10 June 2103 Inspection and Test Procedure No. 000 509 7410 000 509 7420 000 509 7430 000 509 7440 000 509 7460 000 509 7470 000 509 7500 000 509 7510 000 509 7520 000 509 7550 000 509 7560 000 509 7570 000 509 7600 000 509 7610 000 509 7620 000 509 7640 000 509 7700 000 509 7710 000 509 7800 000 509 7810 000 509 7820 000 509 7830 000 509 7910 000 509 7920 000 509 7930 000 509 7950 000 509 F0000 Title Field Fabricated Tanks Cooling Tower Refractory Concrete Gas Turbine/Generator Steam Turbine/Generator Generator Testing Underground Piping Aboveground Piping Pressure Testing Hygienic Tubing Chemical Cleaning of Pipe Steam Tracing for Pipe and Equipment Electrical Inspection Electrical Testing Electrical Equipment Electrical Heat Tracing Control Systems Instrumentation Control System Calibration Coatings and Linings Insulation Fireproofing Inspection Cathodic Protection Welding Inspection Nondestructive Examination Positive Material Identification Hardness Testing Quality Control Forms Revision Date 10 June 13 VOID VOID VOID VOID VOID 10 June 13 10 June 13 10 June 13 VOID 10 June 13 VOID 10 June 13 10 June 13 10 June 13 VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 The Fluor Site Quality Program for this Project is described and documented in this Site Quality Manual. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0000 Rev 0 Table of Contents.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F00501 000.509.F00502 000.509.F01101 000.509.F01102 000.509.F01103 000.509.F01104 000.509.F01301 000.509.F01302 000.509.F01303 000.509.F01401 000.509.F01402 000.509.F01501 000.509.F01601 000.509.F01701 000.509.F01702 000.509.F01801 000.509.F02001 000.509.F02002 000.509.F02003 000.509.F02004 000.509.F02005 000.509.F02006 000.509.F02201 000.509.F02202 000.509.F02301 000.509.F02401 000.509.F02402 000.509.F02403 000.509.F02404 000.509.F02405 FORMS INDEX Form Title Request For Information Request For Information Log Calibration Assignment Log and Record I.M.T.E. Sign In/Out History of Use Log Calibrations Tickler File Calibration Data Sheet Nonconformance Report Nonconformance Report Log Hold Tag/Sticker Corrective Action Report Corrective Action Status Log Preventive Action Log Quality Records Control Audit Finding Audit Summary Project Specific Quality Training Site Subcontractor Qualification Soil Testing Laboratory Evaluation Record Asphalt Testing Laboratory Evaluation Record Concrete Batch Plant Evaluation Record Concrete Testing Laboratory Evaluation Record NDE Subcontractor Evaluation Record Surveillance Report Surveillance Report Log Receiving Inspection Checklist Transfer of Care, Custody and Control (Turnover Notice) System Walkdown Notice Mechanical Completion Civil Checklist Mechanical Completion Electrical/Instrumentation Checklist Mechanical Completion/Mechanical Checklist Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 1 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F02406 000.509.F02407 000.509.F02408 000.509.F02409 000.509.F02501 000.509.F02502 000.509.F70001 000.509.F70002 000.509.F70101 000.509.F70102 000.509.F70103 000.509.F70104 000.509.F70105 000.509.F70201 000.509.F70202 000.509.F70204 000.509.F70301 000.509.F70302 000.509.F70303 000.509.F70801 000.509.F70901 000.509.F71001 000.509.F71002 000.509.F71003 000.509.F71004 000.509.F71005 000.509.F71006 000.509.F71007 000.509.F71008 000.509.F71009 000.509.F71010 FORMS INDEX Form Title Mechanical Completion/Quality Control Checklist Master Punch List Record Interim Turnover Notice Mechanical Completion Certificate Storage Inspection Checklist Equipment Protection Preservation and Inspection Record Inspection and Test Plan Inspection and Test Plan Soil Inspection Checklist Field Compaction Test Record Density of Soil Place by the Sand-Cone Method ASTM D-1566 AASHTO-T-191 Nuclear Moisture-Density Test Report Soil Density Test Log Bituminous Concrete Paving Inspection Checklist Bulk Specific Gravity Nuclear Density Test Report – Bituminous Concrete Pile Driving Inspection Record Pile Driving Record Record of Pile Driving Caisson Inspection Record Augered Cast-In-Place Pile Record Pre-Concrete Inspection Checklist Concrete Inspection Record Concrete Pour Card Cementitious Grout Inspection Record Cementitious Grout Testing Record Epoxy Resin Grout Inspection Record Concrete Compression Strength Test Record Concrete Placement Log Grout Placement Log Concrete Batch Plant Inspection Record Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID 10 June 13 10 June 13 VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 2 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F72002 000.509.F72003 000.509.F73001 000.509.F73002 000.509.F73003 000.509.F73004 000.509.F73005 000.509.F73006 000.509.F73007 000.509.F73008 000.509.F73009 000.509.F73010 000.509.F73011 000.509.F73012 000.509.F73013 000.509.F73014 000.509.F73015 000.509.F73016 000.509.F73101 000.509.F73102 000.509.F73201 000.509.F74001 000.509.F74002 000.509.F74003 000.509.F74004 000.509.F74005 000.509.F74006 000.509.F74007 000.509.F74008 000.509.F74009 000.509.F74010 000.509.F74011 000.509.F74012 000.509.F74013 000.509.F74014 000.509.F74015 000.509.F74016 FORMS INDEX Form Title Structural Steel Inspection Torque Wrench Calibration Log Building Inspection and Test Checklist Final Building Inspection Summary Carpentry Checklist Painting Checklist Plumbing Checklist Ceramic Tile Checklist Concrete Checklist Structural Steel Checklist Masonry (Brickwork) Checklist Plaster Checklist Doors, Windows, Hardware, Glazing Checklist Computer (Raised) Floors Checklist Prefab Wall Element Systems Checklist Building Metal Siding And Roofing Checklist Buildings Water Proofing And Damp Proofing Checklist Suspended Ceiling Checklist HVAC Inspection Record Buildings Air Conditioning Checklist Roofing Inspection Checklist Equipment Installation Checklist Heat Exchangers & Reboilers Installation Record Electrostatic Precipitator Checklist Inspection Record Static Equipment Tray Installation Inspection Record Air Cooled Heat Exchanger Inspection Checklist Air Cooler Run In Test Report Reciprocating Compressor Inspection Record Fan Installation Inspection Checklist Furnaces Inspection Record Fuel Gas Steam Generator Inspection Checklist Steam Turbine Inspection Checklist Agitators/Mixers Inspection Checklist Equipment/Piping Strain and Alignment Inspection Form Installation Checklist Travelling Cranes Package Equipment Installation Checklist Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID 10 June 13 10 June 13 VOID VOID 10 June 13 10 June 13 VOID VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 3 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F74017 000.509.F74018 000.509.F74019 000.509.F74020 000.509.F74021 000.509.F74022 000.509.F74024 000.509.F74025 000.509.F74026 000.509.F74027 000.509.F74028 000.509.F74029 000.509.F74030 000.509.F74031 000.509.F74032 000.509.F74033 000.509.F74101 000.509.F74102 000.509.F74103 000.509.F74104 000.509.F74105 000.509.F74106 000.509.F74201 000.509.F74301 000.509.F74401 000.509.F74402 000.509.F74405 000.509.F74406 000.509.F74407 000.509.F74408 000.509.F74601 000.509.F74602 000.509.F74603 000.509.F74604 000.509.F74605 000.509.F74606 FORMS INDEX Form Title Desuperheaters/Ejectors Inspection Checklist Filters/Strainers Installation Record Centrifugal Compressor Inspection Record Rotating Equipment Inspection Record Rotating Equipment Alignment Record Belt Driven Equipment Alignment Record Inspection Record For Draw Off Tray Leak Test Report Inspection Record For Air Coolers Final Closing Authorization Record API 686 Baseplate Installation Checklist (Prior to Grouting) API 686 Equipment Grouting Checklist API 686 Alignment Check Sheet Baseplate Leveling Record Reverse Dial Alignment Record Piping Alignment Data Sheet Rotating Equipment (Face-Rim) Alignment Record Tank Elevation Tolerances Record Inspection Record Field Erected Tank Tank Plate Dimensional Control Record Field Erected Tank Water Filling And Settlement Record Field Erected Tank Tank Leak Test Record Tank Test Certificate Inspection Record Cooling Tower Field Installed Refactory Record Gas Turbine/Generator Gear Inspection Checklist Gas Turbine Inspection Record Shop-Fabricated Field-Erected Stack Inspection Record Heat Recovery Steam Generator Inspection Record Breeching And Duct Work Inspection Record Equipment Protection Activities Record – Gas Turbines Site Daily Activities Log Stg Foundation Settlement Record Stg Fixators Stg Sole Plates Stg Front Standard Base Plate Assembly Exhaust Hood Horizontal Joint Levelness Revision Date VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID VOID W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 4 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F74607 000.509.F74608 000.509.F74609 000.509.F74701 000.509.F74702 000.509.F75001 000.509.F75002 000.509.F75003 000.509.F75101 000.509.F75102 000.509.F75103 000.509.F75201 000.509.F75501 000.509.F75502 000.509.F75503 000.509.F75504 000.509.F75505 000.509.F75506 000.509.F75507 000.509.F75508 000.509.F75509 000.509.F75601 000.509.F75701 000.509.F76001 000.509.F76002 000.509.F76003 000.509.F76004 000.509.F76005 000.509.F76006 000.509.F76007 000.509.F76008 FORMS INDEX Form Title Stg Shell/Casing Load Test Stg Piping Attachment Stg Foundation Top of Concrete Elevations Generator Test Checklist Generator Cold Resistance Test Record Underground Pipe Inspection Record Insulation Resistance (Insulated Flanges-Underground Piping) Test Record Holiday (Spark) Test Record Aboveground Pipe Inspection Record Visual Inspection of Flanges, Gaskets and Bolting Weld Map Record Pressure Test Report Hygienic Drawing Revision Log Hygienic Material Receiving Log Hygienic Valve Receiving Inspection Report Hygienic Vessel Nozzle Receiving Inspection Report Hygienic Tube/Fitting Receiving Inspection Report Hygienic Pre-weld Inspection Checklist Hygienic Welder Qualification Report Hygienic Orbital Weld Log Hygienic Post Installation Checklist Pipe Cleaning and Verification Checklist Mechanical Heat Tracing Inspection Record Conduit And Cable Tray Checklist Electrical Manhole Inspection Checklist Medium & High Voltage Underground Cable Splice Inspection Record Medium and High Voltage Cable Termination Checklist Cable Pulling Inspection Checklist Fan/Speed Reducer/Motor Inspection Checklist Switch House Inspection Checklist Lighting Receptacle, Instrument Distribution Panels Inspection Checklist Revision Date VOID VOID VOID VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 VOID VOID VOID VOID VOID VOID VOID VOID VOID 10 June 13 VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 5 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F76009 000.509.F76010 000.509.F76011 000.509.F76012 000.509.F76013 000.509.F76014 FORMS INDEX Form Title Electrical Motor Inspection Checklist Aboveground Conduit Inspection Checklist Lighting Panelboard Inspection Record Underground Conduit (Duct Bank) Inspection Grounding/Earthing System (Grid or Loop) Inspection Record Cable Termination Checklist Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record Insulation Resistance (Power, Control Wire And Cable) Test Record Insulation Resistance (Instrument Wire And Cable) Test Record DC High Potential Test (Medium Voltage Cable) Record Current Transformer (And Ammeter) Test Record LV Over-current And Earth/Ground-Fault Protection Relay Test Over-current/Ground Fault Protection Relay (Induction Type) Test Over-current/Ground Fault Protection Relay (Thermal Type) Test Switching Units HV Switchgear Inspection And Test Record Ground Electrode Resistance Inspection Test Record Ground Fault Protection Relay Induction Inspection and Test Record Grounding Continuity Inspection and Test Record Grounding Rod Inspection and Test Record Bus Bar Assemblies LV Switchgear Test Record Neutral Grounding/Earthing Resistor Test Record Ground Continuity (Non Electrical) Equipment/Structures Test Record Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record Insulation Resistance (Equipment) Test Record Insulation Resistance (Transformer) Test Record Liquid Dielectric Strength Test Record DC Proof Test Record for Motors Feeder Breaker (480V MCC) Test Record Breaker/Contractor (480V MCC) Test Record 460V Motor Circuit (480V MCC) Test Record Medium Voltage Motor Circuit Test Record Equipment Absorption Ration and Polarization Index Test Record (Megger) Insulation Resistance (Medium Voltage Power Cables) Test Record Bus Throat Insulation and Ductor Reports Circuit Breaker Contract Timing Test Report Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 000.509.F76101 000.509.F76102 000.509.F76103 000.509.F76104 000.509.F76105 000.509.F76106 000.509.F76107 000.509.F76108 000.509.F76109 000.509.F76110 000.509.F76111 000.509.F76112 000.509.F76113 000.509.F76114 000.509.F76115 000.509.F76116 000.509.F76117 000.509.F76118 000.509.F76119 000.509.F76120 000.509.F76121 000.509.F76122 000.509.F76123 000.509.F76124 000.509.F76125 000.509.F76126 000.509.F76127 000.509.F76128 000.509.F76129 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 6 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F76130 000.509.F76131 000.509.F76132 000.509.F76133 000.509.F76134 000.509.F76135 000.509.F76201 000.509.F76202 000.509.F76203 000.509.F76204 000.509.F76205 000.509.F76206 000.509.F76207 000.509.F76208 000.509.F76209 000.509.F76210 000.509.F76211 000.509.F76212 000.509.F76213 000.509.F76214 000.509.F76215 000.509.F76216 000.509.F76217 000.509.F76218 000.509.F76219 000.509.F76220 000.509.F76221 000.509.F76222 000.509.F76223 000.509.F76224 000.509.F76225 000.509.F76226 000.509.F76227 000.509.F76228 000.509.F76229 000.509.F76230 000.509.F76231 FORMS INDEX Form Title Vacuum Circuit Breaker Ductor Insulation Report Drawout Vacuum Breaker Inspection Test Main Bus Insulation and Ductor Report Electric Motor Run-In Test Record Drawout Air Circuit Breaker Inspection Record Insulation Resistance (Rotating Equipment) Test Record Emergency Generators Inspection Checklist Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units) Inspection LV Switchgear (Including Incoming and Sectionalizer Units) Inspection of Outgoing – LV Switchgear Inspection of Static Supply Unit (UPS) Motor Control Centers Inspection Checklist Motor Control Centers (Motors and Starters) Inspection Record High Voltage Motors and Starters Motors Checklist Control and Relay Panels Inspection Checklist Electronic Equipment Inspection Checklist Power Panel Inspection Checklist Switchgear Inspection Checklist Low Voltage Feeders Inspection Record High Voltage Cable Inspection and Test Record Electrical Equipment Inspection Record Control Scheme Inspection Checklist Power Transformer Inspection Checklist Switching Units – HV Switchgear Inspection and Test Record Switching Units – HV Switchgear Inspection Checklist Liquid – Filled Transformer Inspection Record Busway Inspection Record Switchgear Inspection Record Motor Control Center Inspection Record Battery and Battery Charger Inspection Record Liquid Immersed Medium Voltage Disconnect Switch Inspection Record Electric Motor – Electrical Activities Inspection Record Electric Motor – Mechanical Activities Inspection Record Electric Motor for Compressor Installation Checklist Compressor Vibration Checklist Vibration Probe Record Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 7 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F76232 000.509.F76233 000.509.F76401 000.509.F76402 000.509.F77001 000.509.F77002 000.509.F77003 000.509.F77004 000.509.F77005 000.509.F77006 000.509.F77007 000.509.F77008 000.509.F77101 000.509.F77102 000.509.F77103 000.509.F77104 000.509.F77105 000.509.F77106 000.509.F77107 000.509.F78001 000.509.F78002 000.509.F78101 000.509.F78102 000.509.F78201 000.509.F78202 000.509.F78301 000.509.F79001 000.509.F79002 000.509.F79201 000.509.F79202 000.509.F79203 FORMS INDEX Form Title Dry Type Lighting, Receptacle & Instrument Transformers Checklist Instrument Wire and Cables Continuity Checks >50VDC Heat Trace Test Log Electrical Heat Trace Inspection Record Instrumentation Inspection Checklist Instrument Loop Checklist Inspection Impulse Line Pressure Test Sheet Instrument Grounding System Check Sheet Installation Check Sheet (Local Instruments) Orifice Plate Specification Check Report Control Systems Quality Loop Check Record Instrument Calibration Sheet Safety Valve Tracking Sheet Relief Valve Inspection and Final Acceptance Switch Calibration Data Record Valve Calibration Data Record Control System Test Equipment Calibration Log Loop Mechanical Completions & Acceptance Record Coating Inspection Record Lining Inspection Record Equipment Thermal Insulation Inspection Piping Thermal Insulation Record Release For Application/Inspection Of Fireproofing Checklist Fireproofing Inspection Preconstruction Checklist Cathodic Protection Inspection Report Daily Welding Report Post Weld Heat Treatment Log Welder B31.3 Random Radiography Control Log Nondestructive Examination Request/Record Radiographic Rejectable Defects Statistics Revision Date 10 June 13 10 June 13 VOID VOID 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 8 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 Form Number 000.509.F79204 000.509.F79205 000.509.F79206 000.509.F79301 000.509.F79302 000.509.F79303 000.509.F79304 000.509.F79501 000.509.F79502 000.509.F79503 FORMS INDEX Form Title Welding/NDE Status Log Ferrite Test Report Welding/NDE Double Joints Status Log PMI Inspection Record Bulk Material Positive Material Identification Record Pipe Spool Positive Material Identification Record “Point” Sheet Weekly PMI Log Verification Of Training For Hardness Testing Report Of Vision Test Hardness Testing Report Revision Date 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 10 June 13 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 9 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F0000 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F0000 Rev 0 Forms Index.doc Page 10 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0010 Revision 0, 10 June 2013 FOREWORD The objective of the site quality program for this project is to ensure that construction is performed in accordance with the drawings, specifications, applicable local, state and federal standards and Codes. A further objective is to provide documented evidence that confirms that the primary objective has been met. The site quality control program as delineated in this manual is tailored to meet the quality surveillance, inspection, testing, and documentation requirements for construction/installation performed by subcontractors and Fluor self-perform construction. The site quality program is based upon the principals stated in the Operating System Requirements (OSR) and any applicable Operating System Implementation Plan (OSIP). It is designed to cover quality aspects related to construction, construction management and maintenance activities. The Site Quality Manager will coordinate the construction quality surveillance, inspection, testing, and documentation activities. He will monitor construction and quality activities to the extent necessary to provide construction management with adequate confidence that appropriate measures are being taken to control and achieve quality. The quality activity will emphasize preventing nonconformance to drawings and specifications but detecting and correcting it if it occurs. When Fluor performs construction activities using our own labor force, the quality control responsibility remains with Fluor. The Fluor construction supervision and construction engineering staffs are primarily responsible for the attainment of the quality requirements established by the drawings, specifications and contract. The supervisory, construction engineering and quality staffs will perform quality control inspection, testing, surveillance and documentation activities as outlined in this manual. The primary responsibility for performing quality workmanship rests with those actually performing the work under the supervision of the Fluor construction staff. When an element of construction is subcontracted, the quality control responsibilities governing the subcontractor's work are usually delegated to the subcontractor. The overall responsibility for verifying quality in construction remains with Fluor. This is done by surveillance and audits when the responsibility for quality activities has been delegated to the subcontractor. The subcontractors are to provide the measures required to achieve the contract quality requirements. The subcontractor's quality control responsibility is established by procedure 000.509.0210 and is stated in their contract. This site specific Quality Manual is the governing document for the Fluor quality system and will be maintained current to achieve project quality objectives. This Manual is not applicable to ASME Boiler and Pressure Vessel Code work. The Fluor "Quality Control System Manual for Boiler and Pressure Vessel Code Work" will be applied to ASME and National Board Inspection Code Work certified by Fluor. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0010 Rev 0 Foreword.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0010 Revision 0, 10 June 2013 The Project Procedures Manual (PPM), used in conjunction with the Site Quality Manual, contain or identify approved procedures used to identify, document and verify the appropriate reviews and approvals of changes to design documents that are requested by field organizations and provide requirements for document control. The Fluor Construction Technology staff will conduct independent audits of project compliance to this manual. The audits are conducted to provide the Project Manager, Site Manager, and Client with a project independent evaluation of the site quality program status and adequacy. The initial audit will be conducted at approximately 10% mechanical completion and additional audits on a periodic basis throughout construction. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0010 Rev 0 Foreword.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0020 Revision 0 , 10 June 2013 MANUAL PREPARATION AND MAINTENANCE SCOPE This procedure provides guidance for converting the 509 series of Corporate Site Quality procedures from Knowledge OnLine to a Site Quality Manual for a specific project. It is applicable to Construction, Construction Management, Maintenance, or projects with any of these combinations. GENERAL The initial draft of the project specific Site Quality Manual is initiated by Construction Technology's Corporate Quality Manager. It is to be based on reference procedures of the 509 series of Site Quality procedures from the Construction Knowledge Community that are listed in the Table of Contents section 000.509.0000. These reference procedures have been prepared to meet the requirements of International Standard ISO-9000. The bracket symbols ([::---::]) seen throughout these procedures identify changes or additions that are to be made in converting them to project specific procedures. Other changes are to be made as needed to be compatible with the project requirements and scope. The set of procedures in the 509 series represents the accumulated knowledge and experience gained from many construction projects. Use of these reference procedures as baseline documents will result in improved consistency between projects and entities, thus fulfilling the goal of consistency in execution. Proposed changes to these reference procedures should be communicated to Construction Technology's Corporate Quality Manager. Upon assignment of the Site Quality Manager, he/she begins development of the draft Site Quality Manual (SQM) to assure conformance to the site-specific requirements. The completed and approved project specific SQM should be in place for usage as soon after contract award as possible. As a minimum, parts of the manual should be developed for control of construction activities before the activities are performed. These activities usually begin with qualifying and issuing RFQ's to bidders for work to be subcontracted (see 000.509.0200and 000.509.0210). If these activities begin prior to assignment of the Site Quality Manager, Construction Technology's Corporate of Quality Manager will function as the Site Quality Manager until the assignment is made Development of Site Specific Quality Manual Each section/procedure identified by 000.509.0000 is reviewed for consistency and applicability with project scope. Changes or additions will be required of the following sections as noted: Inspection and Test Procedures (7000 - 7999); Select the procedures that are applicable to the contracted work scope. Select the applicable forms from the procedures if all are not needed. Review the "Responsibilities" Section and modify, if needed, to suit the project organization. Also delete either the "Self-Perform" or "Subcontracted" Section, if not applicable. Table of Contents / Date Revision Page (0000); Under "Procedure Number" and "Title" change to include only those procedures used in the project manual. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0020 Rev 0 Manual Preparation and Maintenance.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0020 Revision 0 , 10 June 2013 Under "Revision Date." enter the date, month and year for all initially approved procedures. Enter appropriate dates for each project revision it undergoes after initial project approval. Revision dates for all pages of all procedures in the project specific manual should match the dates in this Table of Contents. Revisions to the Site Quality Manual shall not waiver or negate OSR requirements or mandatory construction codes. Revision of Site Specific Manual The Site Quality Manager controls the site issue and revision of the Site Specific Quality Manual. The manual is to be revised by procedure. A vertical line in the margin shall identify the revised portions. The revision status shall be shown on the Title page of the manual. The Table of Contents shall show the revision date of each revised procedure and shall be reissued for each revision. The Corporate Quality Control Manager in each of the respective offices shall review and approve the “Issued for Construction” Site Quality Manual prior to the approval signatures being obtained. Each subsequent revision to the Site Quality Manual shall also be approved by the Corporate Quality Control Manager. The Site Quality Manager, Construction Engineering Manager, and Site Manager should approve each revision by signing the Approval Page. The Client should also be given the opportunity for approval of the Site Quality Manual. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0020 Rev 0 Manual Preparation and Maintenance.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 ORGANIZATION AND RESPONSIBILITIES This section describes the site quality organization for performing activities described by this manual. It also provides a general description of responsibilities. Specific responsibilities are described in the individual procedures of this manual. The Site Manager is responsible for the execution of the project construction activities which includes construction quality. The delegation of authority to the Site Quality Manager for the direction and coordination of quality activities is made with the objective of maintaining the effectiveness of this quality program. The Site Manager shall provide adequate resources and assign sufficient trained personnel to manage the work and effectively carry out these verification activities, including internal quality audits. The personnel assigned to these verification activities shall be independent of those having direct responsibility for the work being performed. ORGANIZATION The project organization for site quality personnel are shown on the Site Organizational Chart maintained by the Site Manager. RESPONSIBILITIES Quality related activities are conducted by Site Quality and other groups. The activities and persons conducting them will be under the functional control of the Site Quality Manager for the execution of the activity. Attachment 1- Quality Responsibility Matrix summarizes the activities and the persons responsible for execution. Primary responsibility for execution and verification of quality-related activities will be established on the Inspection/Test Plan or procedures. Site Quality Manager The Site Quality Manager has the responsibility, authority, and organizational freedom to audit, inspect and witness construction activities and to verify compliance to contract quality requirements. This responsibility includes actions such as assist the construction staff in prevention of quality problems, identification of quality-related problems should they occur, initiation or recommendation of solutions and verification of corrective action. In addition, he/she is responsible for coordination of quality-related activities within the Construction staff and with the site Client quality representatives. He/she maintains the construction quality control procedures and provides technical assistance and training to construction supervision. He/she will have an active role in assisting with the prevention of quality problems. The Site Quality Manager reports directly to the Site Manager with a technical supervision channel to Construction Technology's Corporate Quality Manager. The Construction staff includes a Construction Engineering organization to ensure prompt engineering interpretations and decisions, review of drawings, certificates and other data to be submitted to the Client, and to actively participate in the surveillance of field construction, and to verify compliance to W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 1 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 design/engineer requirements. Construction Engineering will provide assistance to the Site Quality Manager as necessary to assist in achieving quality objectives. NOTE: Construction Engineers report to the Site Quality Manager when they are executing inspection/surveillance activities. Subcontractors The subcontractor quality organization will be in accordance with the contract requirements and described in their approved equivalent Site Quality Manual. ATTACHMENTS Attachments 1 Quality Responsibility Matrix W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 2 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 Quality Responsibility Matrix Section 1 - CIVIL 1.1 Construction Surveying ACTIVITY Review the construction surveying methods used by the Contractor. Check established reference points . Check control points established for construction layout on a periodic basis. Check the construction layout of the contractor's work. Review and file completed survey notes prepared by the contractor. Perform periodic surveillance on survey activities and documentation. 1.2 Soils ACTIVITY Monitor in-process soils work, including cut and fill elevations, spoil and fill material, compaction methods and equipment. Perform formal audit of Soils Testing Laboratory Monitor Contractor's work to verify conformance to requirements. Monitor Soil Testing Laboratory activities for soils testing frequency, test identification and completeness. Verify the documentation of deficiencies and test failure and follow up to assure corrective action is taken and documented. Audit the soils documentation to verify correctness, completeness of coverage, retrievability as filed and inspection results. Perform and document soils testing Inspect excavations for unstable and unsuitable soils Verify the insitu soils are suitable to support foundation loads Verify backfill material is satisfactory Verify placement of the fill complies with contract specifications 1.3 Contracted Piling ACTIVITY Qualify Pile Supplier Review and approve concrete mix design and mix trials Technically monitor the indicator pile testing program Check final pile locations. Monitor in-process pile driving. Monitor and test pile concreting activities. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X X X X X RESPONSIBILITY Construction QA/QC X X S X X X TEST LAB TEST LAB TEST LAB TEST LAB TEST LAB S S S S S X RESPONSIBILITY Construction QA/QC X X (1) X X X S S X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 3 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 1.4 Asphalt ACTIVITY Review asphalt mix designs Monitor in-process asphalt construction including preparation of subgrade or previous course, asphaltic materials, spreading equipment, compaction equipment, materials and testing. Perform formal audit using Asphalt Test Laboratory Evaluation Record Monitor Contractor's quality control activities to verify conformance to requirements for asphalt testing frequency, test identification and traceability and the documentation of inspection and testing Review the documentation of the asphalt inspection and testing activities for accuracy and completeness. Verify the documentation of deficiencies and test failures and follow up to assure corrective action is taken and documented. Audit the asphalt documentation to verify correctness, completeness of coverage, review ability as filed and inspection results. Conduct asphalt testing and asphalt materials testing 1.5 Structural Concrete ACTIVITY Review and approve mix designs Perform formal audit of Concrete Testing Laboratory. Audit batch plant facilities. Inspect formwork, reinforcing steel and impediments prior to concrete placement. Monitor in process concreting activities. Monitor Contractor's quality control activities to verify conformance to requirements for concrete testing frequency, test identification and traceability, and the documentation of inspection and testing. Monitor post-concreting activities such as concrete curing, stripping, visual examination for line, form and surface defects and checks for anchor bolt locations. Verify that 28-day strength tests are acceptable. Conduct concrete testing at the point of placement 1.6 Grouting of Machinery and Structural Steel Base Plates ACTIVITY Review and approve mix design. Check materials prior to start of work to verify that the materials have not deteriorated or that shelf life has not been exceeded. Monitor in-process grouting. The inspections shall include base preparation,materials, forming, placing, curing and hammer void test. Witness grout testing by Contractor. Monitor the Contractor's quality control activities to verify conformance to placement procedures and documentation requirement. Conduct grout testing at site PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X (1) S X X X X X TEST LAB S RESPONSIBILITY Construction QA/QC X (1) S X X X X S S X X TEST LAB S S RESPONSIBILITY Construction QA/QC X X (1) S S X X TEST LAB S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 4 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 Section 2 - STRUCTURAL STEEL 2.1 Structural Steel ACTIVITY Monitor in process steel erection to verify fabrication is correct and erection is in accordance with drawings. Document fabrication errors on a NCR. Witness bolting procedure including calibration of torque wrenches and load indicating washers. Maintain documentation Inspect the erected steel structure. Ensure that erected steel structures have coatings installed i.a.w. drawings Monitor the Contractor's quality activities to verify conformance to requirements for bolt tensioning procedures. Schedule final acceptance inspection activities between Contractor and Field Engineering or construction. Audit the structural steel documentation to verify correctness of data. Section 3 - BUILDINGS 3.1 Buildings ACTIVITY Review all Contractor proposed building materials prior to use. Verify that the building location level and position are correct prior to construction. Inspect the entire building upon completion and document deficiencies. Document building acceptance Monitor the in process construction to verify that the work is i.a.w. drawings. Schedule final acceptance activities Monitor the Contractor's quality control activities to verify test frequency, identification and traceability Audit building documentation PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X X X X S X X S X S S RESPONSIBILITY Construction QA/QC X (1) X X X X X S S X X S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 5 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 Section 4 - EQUIPMENT 4.1 Equipment ACTIVITY Inspect installed equipment for acceptance upon completion, including attachments to the equipment, e.g. foundations, sheds, buildings, auxiliaries, etc. which comprise the entire assembled unit. Initiate action to acquire vendor representative as required. Coordinate with engineering for participation of mechanical discipline engineers, if required. Monitor the in-process installation of each equipment unit. Coordinate with vendor representative who technically supervises equipment installation. Verify vendor representative's checklists and acceptance records are signed and attached to appropriate construction documents. Verify the equipment requirements are being satisfied by the Contractor. Monitor equipment preservation i.a.w. Site requirements. Monitor the Contractor's quality control activities to verify conformance to inspection, testing and documentation requirements. 4.2 Field Fabricated Tanks ACTIVITY Monitor the foundation construction including soils, asphalt and concrete work. Check elevation dimensions of tank shells. Check the erected dimensions of tank shells. Inspect fabricated tank structure upon completion. Check the settlement and rebound of the foundation during and after hydrotest. Verify welder performance qualifications. Verify welding procedure testing has been accomplished and procedures are acceptable. Monitor in-process welding Witness in-process examination as performed by the NDE contractor, including reviewing radiographs, witnessing PT, MT, vacuum box and leak testing Verify that equipment and components associated with tankage have been correctly installed, adjusted, tested, confirmed for proper function and inspected. Inspect the tested tank prior to closing, including final clean-up. Verify that the Contractor has affixed a nameplate listing the required data. Verify that the Contractor has submitted the required certification. Monitor the Contractor's quality control activities to verify conformance inspection, testing and documentation requirements. Witness hydrostatic testing PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X PM PM X X X X S S X X S RESPONSIBILITY Construction QA/QC X X X X X S S S S S X X X S X X X X X S S S S X S X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 6 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 Section 5 - PIPING 5.1 Underground Piping ACTIVITY Monitor in-process excavation and backfill. Inspect installed underground pipelines for acceptance. Color code the lines, indicated as punched and accepted, on a copy of the underground piping plan. Verify that the Testing Lab is performing the required soils testing of backfill. Monitor in-process coating and wrapping, including surface preparation, coating and wrapping methods and materials and arrangement for intermediate storage and stockpiling of coasted pipes. Inspect in-process pipe fabrication and installation i.a.w. drawings. Perform a final inspection of the line, when the underground piping is complete, but prior to the coating and wrapping of joints and fittings. Verify the Contractor has completed coating and wrapping of joints and fittings on tested line. Witness holiday testing of the coating and wrapping. Contractor shall document tests. Verify that required NDE is complete on the lines to be inspected. Witness the pressure test. Inspect the tested system to ensure that all items have been properly completed (restoration). Monitor the Contractor's quality control activities to verify conformance to testing and documentation requirements. 5.2 Site Shop Fabrication ACTIVITY Segregate and store pipe fittings, upon receipt, according to size and material. Identify storage location with commodity code number. Pipe will be marked full length with commodity code number. Maintain documentation Issue piping materials to Contractors Inspect special flange faces for correct finish and face protection. Monitor in-process pipe fabrication activities. Verify latest edition of piping drawings is being used. Random check on base material ID on pipe, fittings and spools. Spools shall be clearly identified in two locations. Monitor storage of completed spools at pipe shop including preservations. Monitor pipe identification, documentation and timely performance of NDE. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X X X X X X X X S X S S S S S S X X S X S S RESPONSIBILITY Construction QA/QC MM MM MM MM X X X X X S S S S S X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 7 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 5.3 Aboveground Piping Erection ACTIVITY Pipe will be marked full length with commodity code number. Alloy pipe and fittings shall be additionally color coded. Alloy storage areas shall be clearly identified. Maintain piping spool identity markings of piping spools fabricated off site. Verify MTR's are received and that heat numbers correspond. Maintain documentation Verify PMI requirements are satisfied prior to placement in stock. Verify correct pipe is issued to Contractor. Monitor in-process erection I.a.w. drawings. Classify and record spool fit problems. Ensure face flange protection is maintained. Monitor proper bolt tensioning. Monitor correct gasket installed. Monitor erection to ensure that pipe installations are not subjected to undesirable stress. Check pipe drawings to assure latest revision in the field. Assist Contractor to maintain current piping test status. Monitor Contractor's activities to established quality control practices. Monitor in process pipe erection and transfer of heat numbers. Verify that NDE is performed in a timely manner. Monitor pipe and welding traceability including PWHT, PMI and Hardness Testing. 5.4 Piping Inspection - Punching ACTIVITY Flag deficiencies when not visually obvious. Enter punch lists into data base. Check work, noted as complete, on punch lists to assure items were corrected. Initiate action with Contractor on punching results. Add additional discrepancies to punch list. Initial and date punch list for each item corrected. Monitor the Contractor's punching activities. Verify that punching deficiencies are identified, documented and follow up to verify corrective action is taken. Verify that measures are taken to assure NDE, PWHT, PMI and traceability is completed prior to pressure testing. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC MM MM MM MM MM X X X X X X S S S S S S S X X X S RESPONSIBILITY Construction QA/QC X X X X X X X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 8 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 5.5 Pressure Testing of Piping ACTIVITY Monitor pressure testing performed by Contractor. Review drawings and specifications to verify pressure test package limits, equipment to be included or excluded, valves opened or closed and test blind locations. Verify that the maximum allowable test pressure of the weakest component within the system is not exceeded. Verify (through NEWS) that all NDE is complete prior to testing. Verify that shop spool/cut sheets are included in test packages and all NDE, PWHT and welder info is recorded. Review Contractor's pressure test package, including marked up isometric drawings indicating test blind locations, valve position (open/closed) and other information relating to test. Monitor preparation of test system against test package. Monitor restoration of the tested system. Monitor Contractor's pressure testing and documentation activities. Review test package for completion Inspect the system prior to testing notifying Contractor of deficiencies. Mark Pressure Test Record, "Ready to Test". Notify client when acceptable for test. Give permission to proceed with test. Inspect system under pressure. Verify test pressure and duration of test. Procure test acceptance signatures from Contractor and QIB. When equipment is included in the test, verify that pressure test does not exceed nameplate. 5.6 Piping Internal Cleaning ACTIVITY Review and approve the cleaning and preservation procedures and the limits agree with drawings. Establish hold points for witnessing tests. Monitor preparatory and in-process cleaning activities for compliance with procedures and specs. Coordinate the monitoring of Contractor inspection and testing activities. Verify the Contractor is preparing documentation as inspections and tests are being performed. Verify that internal cleaning has been accomplished. Monitor the Contractor's quality control activities. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X S X X S S X X X S S X S S X X S X X S S X X S RESPONSIBILITY Construction QA/QC X X X X X X X S S S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 9 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 Section 6 - ELECTRICAL 6.1 Underground Electrical ACTIVITY Monitor in-process installation of the grounding system including, grounding rod installation, backfilling. Color coding of drawings to track progress. Witness resistance to earth tests. Monitor in-process duct bank and electrical manhole installations. Witness initial testing of shielded cable, i.e,. insulation resistance test of power cable on reels, continuity test of reeled instrument cable. Inspect cable trench prior to installation of cable. Monitor in-process installation of underground cable. Inspect in-process cable pulling. Inspect in-process cable splicing. Witness random testing of installed underground cable, i.e. insulation resistance test (megger) cables and DC hypot medium and high voltage cables prior to termination. Inspect installation of cables upon completion of each layer to ensure spacing, labeling, etc. is correct. Inspect sand backfill per lift for quality of materials, depth and compaction. Verify the Contractor final as-built drawings are in conformance. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractors' quality control activities. 6.2 Aboveground Electrical ACTIVITY Monitor in-process installation of electrical conduit and cable tray, including welding of supports. Witness initial testing of shielded cable, i.e., insulation resistance test of power cable on reels, continuity test of reeled instrument cable and resistance and continuity on electrical heat tracing cables. Monitor in-process cable pulling and installation. Witness random testing of installed cable, i.e., insulation resistance test on power and instrumentation cables, continuity and insulation resistance testing on heat tracing and hypot of medium and high voltage cables. Verify client is being notified in advance of tests that require witness. Verify terminal to terminal checks to ensure continuity and correctness of installation. Verify conduit seals have been poured. Inspect installation upon completion. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractor's quality control activities. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X X X X X X X X X X X S S S S S S S X RESPONSIBILITY Construction QA/QC X S S S X X X X X X X X S S S S S S S X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 10 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 6.3 Electrical Equipment ACTIVITY Monitor in-process installation of equipment. Monitor equipment preservation activities Witness testing of installed equipment. Coordinate with vendor representative who will technically supervise installation. Ensure documentation is complete. Verify QIB is being notified in advance of tests requiring witnessing. Inspect electrical installation when complete. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractor's quality control activities. Section 7-CONTROL SYSTEMS 7.1 Control Systems Site Shop Operations ACTIVITY Notify construction upon receipt of each instrument shipment for inspection. For nonconforming items, issue a Damage Report or NCR. Issue instruments to Contractor. Inspect each instrument shipment. Deficiencies shall be reported to the Material Manager. Inspect instrument materials i.a.w.sec.10 & project procedures Document the receiving inspection. 7.2 Control Systems Field Operations ACTIVITY Monitor the Contractor's in-process instrument installation including racks, panels, consoles, locations,mounting,process pipe connections, Instrument air tubing,pneumatic signal tubing,heat tracing and instrument wiring Witness pressure testing of the instrument piping and tubing documentation. Witness calibration of test guages. Monitor continuity tests of instrument cables.Verify that cable terminations are correct. Witness checks of control system loops. Establish notification system for IMT. Witness all loop checks Assure all instrument installation inspections and meggar tests are complete Inspect instrument installations upon completion. Monitor the Contractor's quality control activities. Verify documentation procedures are being followed. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X S X S X S X X X X S S S S X RESPONSIBILITY Construction QA/QC MM MM MM X X X RESPONSIBILITY Construction QA/QC X X X X X X X X S X S S S S S S S S X S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 11 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 Section 8 - COATINGS, LININGS, INSULATION AND CATHODIC PROTECTION RESPONSIBILITY Construction QA/QC Ensure that the paint system is i.a.w. specifications. X S Monitor performance of materials preservation activities. X S Monitor surface preparation.Verify inspection documentation. X S Monitor in-process coatings applications. X S Check dry film thickness of applied coatings. X S Inspect the workmanship of completed finishes. X S Monitor the Contractor's quality control activities. S X Verify the Contractor has prepared the QC documentation. S X Audit coating documentation. X 8.1 Coatings ACTIVITY 8.2 Insulation ACTIVITY Monitor performance of material preservation activities. Monitor in-process installation of the insulation materials. Verify the Contractor has prepared the quality control documentation Inspect the completed work. Document acceptance. 8.3 Linings ACTIVITY Monitor performance of material preservation activities. Monitor surface preparation. Verify Contractor is performing temperature and humidity checks for tank linings. Monitor in-process lining application. Test applied linings to verify proper surface profile, thickness, and lining continuity. Monitor Contractor's tank lining holiday inspections. Observe tank lining curing activities. Inspect the workmanship of the completed lining. Monitor the Contractor's quality control activities. Audit coating documentation. Verify that lining materials comply with specs. Ensure that manufacture test certificates correspond with filed batch number records. Monitor storage facilities. Ensure refractory applicators are experienced and qualified. Monitor to ensure materials are properly mixed. Monitor surface preparation to ensure mounting studs and reinforcements are correctly installed. Ensure that test plates,cubes,etc,from refractory applications are taken at the required frequencies PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X S X S X S S X RESPONSIBILITY Construction QA/QC X X X X X X X X S S S S S S S S S X X S X X X X X X S S S S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 12 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 8.4 Cathodic Protection - Underground Structures. ACTIVITY Submit data to Engineering for determination of anode spacing Establish a procedure to assure work is not started prior to acceptance of previous work. Monitor the survey after each cathodic protection system is energized. Verify materials being installed. Monitor installation activities. Monitor deep well preparation activities including data logs. Monitor anode backfill operation. Witness hammer testing of thermite welds Witness electrical test used to determine current flow when the anode is backfilled with coke breeze. Monitor testing and commissioning activities. Inspect the completed work. Audit cathodic protection documentation. 8.5 Cathodic Protection - Tanks and Vessels ACTIVITY Verify materials are within specification and are properly protected from damage. Verify the vessel cathodic protection materials were installed. Monitor installation activities Verify personnel use of protective clothing (when reg's) Inspect the completed workmanship. Monitor testing and commissioning activities. Audit cathodic protection documentation. Section 9 - WELDING 9.1 Pipe Welding ACTIVITY Verify the WPS's have been approved by the Welding Engineer. Monitor qualification tests of Contractor's welders. Ensure that welder ID badges have been issued and displayed. Check Contractors control of welder symbols. Check Contractor's control of welding consumables. Monitor in-process welding including consumables, joint preparation,fit-up preheat, interpass heat, WPS variables and final visual Verify Contractor is documenting welds on the Daily Welding Report. Verify completed welds are being documented on piping drawings. Monitor in-process post weld heart treatment. Audit welding documentation. Verify transfer of piping material heat numbers. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X (1) X X X X X X X X X X S S S S S S X RESPONSIBILITY Construction QA/QC X X X X X X S S S X RESPONSIBILITY Construction QA/QC X (1) S X X S X S X X X X X X S S S S S X S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 13 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 9.2 Structural and Reinforcing Steel Welding ACTIVITY Verify the WPS's have been approved by the Welding Engineer. Monitor qualification tests of welders. Monitor in-process welding including consumables, joint preparation and final visual inspection. Audit welding documentation. 9.3 Piping Nondestructive Examination (NDE) ACTIVITY Pre-qualify NDE Contractor Verify that the NDE Contractor has established procedures that comply with project specifications. Daily entry of weld data to NEWS program. Establish and maintain NDE documentation files. Review Contractor NDE personnel certifications. Verify approval of NDE Contractor and procedures. Verify NDE Contractor's procedure to provide visual status of welds requiring NDE. Select welds for examination Perform Nondestructive examinations Review radiographic film, Contractor's interpretation and reports. Verify code compliance for rejected welds. Maintain a tickler file of rejected welds. Verify, through audit, welding and NDE records are traceable to the weld. Verify through NEWS that NDE is completed prior to pressure testing. Audit the NDE lab Monitor the NDE Contractor's production to verify that welds are examined within 48 hours of notification. Verify all field welds are numbered and identified on drawings. Ensure that weld number and welder's symbols are low stress stamped or otherwise marked on pipe. Ensure that an accurate Daily Welding Report is maintained. PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X (1) X X S X RESPONSIBILITY Construction QA/QC X X S X X X X X S NDE CONTRACTOR X S X X X X X X X X X S S X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 14 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 9.4 Pipe hardness Testing ACTIVITY Monitor the Contractor to verify weld identity system and compliance to specification. Establish confidence that tests are being preformed i.a.w. test equipment instructions. Verify the Contractor's compliance with hardness testing and documentation. Verify Contractor's procedure for visual identification of rejected welds. Maintain a PWHT tickler file for rejected welds. Verify hardness testing is complete prior to pressure testing. Witness tests required by the specifications as performed by Contractor. Schedule final acceptance inspection activities between the Contractor and the Field Engineer. Monitor the Contractor's quality control activities to verify conformance to requirements for test frequency, identification and traceability. Section 10 - FIELD RECEIVING 10.1 Field Receiving (IMT) ACTIVITY Control receiving operations including ID of item to purchase order, verification of quantity and size examination for shipping protection and damage, maintenance of inspection documentation. Issuance of periodic receiving reports to Construction Superintendents when technical assistance is required. Inspect received material/equipment, providing technical assistance, when requested. 10.2 Field Receiving -Contractor ACTIVITY Receive all contractor purchased equipment and materials Review material test reports against received materials and maintain on file Issue equipment and materials to the Contractor Inspect received material/equipment, providing technical assistance when requested Assure that the contractor performs the equipment and material protection as required by manufacturers instruction or specification requirements PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval RESPONSIBILITY Construction QA/QC X X X X X X X X X RESPONSIBILITY Construction QA/QC MM MM S X RESPONSIBILITY Construction QA/QC MM MM MM X X S S S W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 15 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0040 Revision 0, 10 June 2013 10.3 Positive Material Identification (PMI) ACTIVITY Notify QA of receipt of material requiring PMI. Maintain PMI test results with receiving documentation. Verify receipt of PMI reports from suppliers and fabricators, Verify Contractor has established a system to maintain material ID through receiving, storage, issue, fabrication and election. Implement procedures for PMI. Monitor contractor's maintenance of piping material identification. Perform PMI as required by specification. Verify ID marking are accomplished per specification. Verify controls have been established to prevent the in advertent use of materials failing examination. Verify the filing, maintenance and retention of documentation. Assure that PMI equipment is calibrated. RESPONSIBILITY Construction QA/QC MM MM MM X X S X S X X X X X S Section 11 - EQUIPMENT AND MATERIAL PROTECTION 11.1 Equipment and Material Protection RESPONSIBILITY ACTIVITY Construction QA/QC Monitor equipment and material preservation in storage and document. 11.2 Equipment and Material Protection (Contractor) ACTIVITY Monitor Contractors in-process equipment and material protection/preservation activities. Check Contractors in-process equipment and material Audit the Contractor Material and equipment protection activities. Section 12 - MASTERPIECE PROGRAM 12.1 Masterpiece Program ACTIVITY Develop Masterpiece List Ensure Contractor is using correct materials, drawings and specifications Advise contractor when a Masterpiece is required Inspect Masterpiece prior to QA notification Request client's presence during inspection Document acceptance of the Masterpiece Notify client of accepted Masterpiece Maintain the Masterpiece log Maintain Masterpiece model as reference standard Monitor the Contractor's quality control activities to verify conformance to drawings and specifications PM=Procurement Manager MM=Material Manager X=Primary Responsibility S=Secondary Responsibility (1) Must obtain Engineering Approval MM S RESPONSIBILITY Construction QA/QC X X S S X RESPONSIBILITY Construction QA/QC X S X X X S S S X S S S X X X X S X W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0040 Rev 0 Organization and Responsibilities.doc Page 16 of 16 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 DOCUMENT CONTROL SCOPE This procedure describes the Document Control system to be used by site construction personnel. GENERAL Engineering Documents Design Engineering documents such as specifications and drawings that are issued to Construction are controlled and issued on site in accordance with this procedure. Construction Engineering maintains an up-to-date register of drawings and specifications. This procedure is designed to ensure that the latest drawings issued to construction, including shop drawings, specifications and instructions, as well as authorized changes thereto, are delivered to the proper locations and personnel responsible for performance of the work. This procedure also provides for the prompt removal of obsolete documents from all points of issue or use. The Construction Engineering staff reviews engineering documents for adequacy and completeness to perform the work and coordinates site needs for clarification with the designer. Subcontractors obtain clarification through the Fluor Construction Engineering Manager. Construction Engineering maintains drawings and specification control records, processes all design document changes, ensures proper authority for the changes, and prompt removal of obsolete documents from the field. The Construction Engineering Manager is responsible for control of shop drawing submittals and certifications to include assuring that submittals are received and/or distributed. The Construction Engineering Manager will maintain as-built marked-up drawings. These drawings will be maintained in a current condition. The as-built data will be submitted to Design Engineering in accordance with this procedure. Subcontractors will submit as-built information through the Fluor Construction Engineering Manager. - - - - Request For Information When field conditions dictate changes to the design specifications and/or drawings, a Request For Information (RFI), Form 000.509.F00501, will be submitted for approval to ensure proper control and documentation. RFIs will be initiated by the Construction Engineering Manager who will maintain a RFI Log, Form 000.509.F00502. RFIs will be forwarded to the Design Engineer for approval and/or action. Subcontractor submittals will be sent to the Fluor Contracts Manager for submittal to the Fluor Construction Engineering Manager for evaluation and processing. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 1 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 - The Construction Engineer shall describe the condition or design change requested in terms that can be easily understood by those who review it, including appropriate references, specific drawings and specifications to illustrate the recommended change. To minimize delay in construction, authority for deviation from specifications and drawings may be acquired by direct communication with the Design Engineer and the Client pending processing of the RFI. A copy of the Record of Telephone Conversation will accompany the RFI transmitted to the Design Engineer and the Client. Approval of the Client’s construction site representative should be acquired, if possible. The Design Engineer and the Client portion of the RFI indicate approval or disapproval of the field recommended change or recommends alternatives. The signed original will be returned to the Site Manager for disposition or authority to proceed. The Construction Engineering Manager shall maintain a file that contains a full history of the action and data supporting the approval of each Request For Information. - - - Subcontractor Documents The subcontractors are responsible for procedures necessary to assure that all documents provided for construction are maintained to the most up-to-date revisions. Documents include procedures, letters, telexes, purchase requisitions, purchase orders, design drawings, specifications, reference drawings, vendor drawings, field sketches, test reports, etc. Documents affecting individual subcontractor's work are forwarded to the subcontractor by the Contracts Manager. Subcontractor prepared field sketches and "as-built" drawings originating at the construction site shall be documented and controlled in accordance with the Request For Information (RFI) requirements described in this procedure. - Submittals - Field Contracts Submittals are reviewed under the direction of the Construction Engineering Manager. Subcontractor technical submittals are forwarded to Construction Engineering Manager. A submittals list shall be maintained reflecting the specification reference, description, date received, and the status of acceptance through Construction Engineering approval. The Site Quality Manager shall review submittals related to quality control requirements. Material/Equipment Documents Documents related to materials, materials receiving and issue are controlled in accordance to procurement procedures. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 2 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 Quality Control Documents Documents and data identified as quality records are processed, retained and protected as described in 000.509.0160 "Quality Records". Primary responsibility for ensuring adequate control of quality related documents rests with the Site Quality Manager. Procedure - Procedures issued by site personnel are controlled as described by this procedure. Vendor Documents - Vendor document supplied by Fluor Engineering Document Control to the Fluor Site Document Control for filing and distribution will be in accordance with the Project File Index and the Distribution Matrix System. PROCEDURE - The Construction Engineering Manager shall establish a standard distribution for design documents drawings and specifications with the Client. - Document Control shall provide document inventory control and receipt, and distribution accountability. This is accomplished making distribution in accordance with the Distribution Matrix System. Distribution is by individual document holder. These documents will be stamped in red with the Site Document Control stamp indicating date received. The Site Document Control stamp will be used to identify drawings, ISO, Instrumentation Specification Data Sheets, specifications, etc. Distribution of manuals will be by name and numbered copy. - A document transmittal record will be utilized for the distribution and issue of all controlled documents. The document recipient must sign the transmittal record and return it to Document Control within 10 days of issue. - Document recipients shall be responsible for control of documents upon receipt. Document Control will periodically (minimum quarterly) audit document recipients to ensure proper documents are available for use and that superseded documents have been removed from the field. Should a superseded document be required to be retained for inspection or historical data, the document will be identified as "VOID" or "SUPERSEDED" to prevent inadvertent use of the document for fabrication/installation activities. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 3 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 RECEIPT AND DISTRIBUTION OF DOCUMENTS Construction Engineering Manager - Establish document control log system for receipt of documents and provided standard distribution as indicated on the Distribution Matrix System. Document Control - Drawings (design, vendor and field sketch), specifications - Review receipt transmittal and enter date received in the Electronic Tracking System. - Review distribution list and reproduce copies as required. - Prepare distribution transmittals and distribute documents accordingly. Document Control - Manuals - Based on input from Site Manager, determine distribution for each type manual. Maintain a "Master" manual in Document Control and reproduce copies as required. - Assign individuals numbered manuals, prepare distribution transmittals and distribute accordingly. Document Recipient - Sign transmittal acknowledging receipt of documents and return signed transmittal Document Control within 10 days. - Replace superseded documents as required with the new documents. Destroy or return the superseded documents (except for inspection or historical record) to Document Control. The document recipient is responsible for maintaining documents current. Document Control - Destroy returned superseded documents. REPRODUCTION AND ISSUE OF REQUESTED DOCUMENTS Requester - Fill out document request form and present to Document Control. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 4 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 Document Control - Reproduce documents requested and obtain receipt acknowledgement from requester upon issue. DOCUMENT AUDITS Construction Engineering Manager - Determine document audit plan and schedule audits. A minimum of 5% of documents issued to the document holder will be randomly selected for the audit sample. The number of document holders to be audited will be determined by the Construction Engineering Manager. Document Control - Using a printout or list of documents and current revisions, compare documents and revisions held by document holders and note any discrepancies. Notify the Construction Engineering Manager of major discrepancies. Construction Engineering Manager For major discrepancies identified by Document Control audits of documents, investigate and provide recommended resolution. Revision Control of the Site Quality Manual Site Quality Manager Revision dates for all pages of all procedures in the manual should match the dates in the Table of Contents. The Site Quality Manager, Construction Engineering Manager, Site Manager and the Client (optional) will approve each revision by signing the "Approval Page". Forward the approved revision and affected documents to Document Control for maintenance and distribution to all manual holders. - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 5 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 REFERENCES Quality Control Forms: 000.509.F00501 - Request For Information 000.509.F00502 - Request For Information Log ATTACHMENTS Attachment 1 – Request For Information (RFI) Form Instructions W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 6 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 Attachment 1 – Request For Information (RFI) Form Instructions Project Name: Project #: Date: RFI #: WBS: Work Package No.: Turnover/Startup System No.: Discipline: Request To: Company/Location Phone Number/Email Subject Specifications/Documents: The Project Name (i.e. Butanol) The Project Number (i.e. 00662255) The date the Request is originated. Unique number given to each individual RFI Form. Work Breakdown Structure unique to the Project, if applicable Construction Work Package number, if applicable. Turnover/Startup system number, if applicable. Primary discipline affected by the Request (Civil, Structural, Piping etc.) Enter Name of Individual submitted to (John Doe) Enter Name of Company and its location of the requested organization (FluorGreenville) Enter phone number of the individual submitted to and/or email address Enter the subject of the request List all issued drawings, documents, and specifications impacted by the request. Questions/Description/Conflict: Detail the missing information, discrepancies, questions or conflicts that must be resolved prior to construction activities continuing in the affected areas. Attach additional sheets, drawings, or sketches, if further explanation is required. Recommended Solution: Indicate the action that the requestor believes is required to provide an acceptable solution to resolve the discrepancies and conflicts indicated on the request. Additional sheets, sketches, digital photos or drawings may be attached to provide a clear explanation of the intended resolution. The person originating the request and provided recommended action. List the current position of the originator on the project. The date the request is submitted for approval. List Company name of the originator List name of Fluor person approving the request for submission to the Engineer of Record (Generally, the Fluor Site Engineering Manager will receive the request and approve it’s submission to the Design Engineer.) List the current position of the approver. The date the request is approved for submission Enter the date in which the resolution of the request must be made in order not to delay the activities in question Originated By: Title: Date: Originator’s Company Name Approval For Originator By Title: Date: Date Reply Required: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 7 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0050 Revision 0, 10 June 2013 Response The respondent’s resolution (generally the Design Engineer, Project Engineering Manager, CM, or Fluor’s Construction Engineering Manager) to the question, information, discrepancy, or conflict. The signature of the person making the response. (Lead Construction Discipline Engineer, Construction Engineering Manager or Design Lead Discipline Engineer, etc.) List the current position of the Approver on the project. The date the request is approved for transmittal to the Design Engineer. The signature of the person reviewing and approving the request prior to implementation. (This action might require Client approval. If the response changes the design (AFC Drawings or Specifications) the Engineer of Record must approve the resolution.) List the current position of the Approver on the project. The date the request is approved for implementation by the Client or Project Engineering Manager or designee. Indicate using the checkbox if the RFI response is acceptable for closure of the RFI. Generally, the Construction Engineering Manage must respond to this question. Indicate using the checkbox if the RFI response has a cost impact that will require an estimate or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor. Indicate using the checkbox if the RFI response has a schedule impact that will require an adjustment in the contract schedule or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor Inter the name and date the RFI was closed and verified. List all parties requiring a copy of the completed request once the response has been received. Respondent: Title: Date: Approval for Respondent: Title: Date: Adequate Closure? Cost Impact? Schedule Impact? Closed RFI and Date Verified: Distribution: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0050 Rev 0 Document Control.doc Page 8 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F00501 Revision 0, 10 June 2013 REQUEST FOR INFORMATION (RFI) PROJECT NAME WBS (Work Breakdown Structure) WORK PACKAGE PROJECT # TURNOVER/STARTUP SYSTEM DATE RFI # DISCIPLINE REQUEST TO (RESPONDENT): RESPONDENT’S COMPANY/LOCATION PHONE/EMAIL SUBJECT: SPECIFICATIONS/DOCUMENTS/DWGS REFERENCED OR IMPACTED: QUESTIONS/DESCRIPTION OF CONFLICT: ORIGINATOR’S RECOMMENDED SOLUTION: ORIGINATOR (Sign) TITLE DATE APPROVED (Sign) TITLE DATE ORIGINATOR’S (SUB) CONTRACTOR COMPANY NAME: REPLY REQUIRED BY: RESPONSE: ORIGINATOR’S (SUB) CONTRACT #: RESPONDENT (Sign) TITLE DATE APPROVED (Sign) TITLE DATE ARE THE QUESTION AND RESPONSE ADEQUATE FOR CLOSURE OF THIS RFI? YES NO YES NO IS THERE A SCHEDULE IMPACT DUE TO THIS RFI? IF YES, SITE INSTRUCTION TO BE ISSUED DISTRIBUTION: IS THERE A COST IMPACT DUE TO THIS RFI? IF YES, SITE INSTRUCTION TO BE ISSUED YES NO THE WORK WAS COMPLETED AS NOTED ON THIS CLOSED RFI AND VERIFIED BY DATE: The response to this RFI is NOT an authorization to perform a change to the contract. Work may proceed in accord with the response only if such work involves NO change in cost or schedule. If the response involves change in cost or schedule, a Site Instruction or similar document must be received before the response can be executed. Where no Site Instruction is indicated, action must be taken in accordance with Article 15.0 of Part III, Section 15.2 and subject work must not proceed in accordance with Section 15.3 or 15.4 of Part III, General Terms of the Fluor Standard Contract. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F00501 Rev 0 Request for Information.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F00501 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F00501 Rev 0 Request for Information.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F00502 Revision 0, 10 June 2013 REQUEST FOR INFORMATION LOG RFI No. Date Opened Originator Discipline Date Closed Description Of Request ID A00502A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F00502 Rev 0 Request for Information Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F00502 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F00502 Rev 0 Request for Information Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0090 Revision 0, 10 June 2013 PROCESS CONTROL SCOPE This procedure identifies construction work processes that require process control. GENERAL For most site production activities, the drawings and specifications provide adequate work instruction. These may be supplemented with additional instructions to control work sequencing, recording of installation data, material selection, etc. However, certain construction work processes require special instructions to establish the controls necessary to achieve acceptable quality, of the completed work, for the following reasons: • Quality results of the completed work cannot be fully verified by subsequent inspection and/or testing. Quality deficiencies may only become apparent after the item has entered service or operation. • Special Processes "Special processes" are highly dependent on the control of process parameters or the skill of the operator or both and are characterized by the need for one or more of the following control measures. Written Method Statement or Procedure Procedure Qualification Operator Qualification In-Process Inspection Special processes encountered on sites include, but may not be limited to: Welding and Post Weld Heat Treatment Welder Qualification Nondestructive Examination (including radiography, magnetic particle, liquid penetrant, ultrasonic, and positive material identification – VT, RT, MT, PT, UT, and PMI) Other processes needing procedural control as determined by Project Management. Special processes identified must be accomplished and documented under controlled conditions by appropriately qualified personnel using approved procedures and equipment in accordance with the governing specifications and the associated referenced codes and standards. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0090 Rev 0 Process Control.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0090 Revision 0, 10 June 2013 PROCEDURE Site Quality Manager The Site Quality Manager shall coordinate with the Construction Engineering Manager, to research the project contract work scope and specifications in order to identify the special processes that will be utilized. If the processes are to be contracted, ensure that the required control mechanisms, i.e. procedures, qualifications, etc. are specified in the RFP and implemented before the start of work. Process control measures and responsibilities shall be identified on the applicable procedures or ITPs. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0090 Rev 0 Process Control.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 INSPECTION, MEASURING AND TESTING EQUIPMENT SCOPE This procedure describes the methods to be used for the control, calibration, maintenance and recall of inspection, measuring and test equipment (IMTE) used to demonstrate conformance of construction work activities to the specified requirements. It is not applicable to calibration of permanent plant devices. GENERAL Inspection, measuring and test equipment (IMTE), including test software, shall be selected, calibrated and controlled in a manner which is consistent with the required inspection, testing and examination requirements. Environmental conditions shall be suitable for the calibrations, inspections, measurements and tests being carried out. All IMTE shall be uniquely identified. This unique identification may consist of a manufacturer's unique serial number along with model number and/or the assignment and application of a unique Inventory Control Number (ICN). The handling, preservation, and storage of inspection, measuring and test equipment shall be such that the accuracy and fitness for use is maintained. All calibrations shall be performed using certified equipment having a known valid relationship to nationally recognized standards; where no such standards exist, the basis used for calibration shall be documented. "Conformance check" means the operations required to ensure that an item of measuring equipment is in a state of compliance with requirements for its intended use. Non-adjustable measuring and test equipment is not considered as calibrated equipment. Equipment of this nature (e.g. cube and proctor molds, measuring tapes, rulers, chains) is subject to a "conformance check" to dimensional, volumetric or other requirements and does not require any further verification unless apparent damage or other factors require re-verification. It is the responsibility of the end-user to comply with the requirements of this section. IMTE shall be selected utilizing Attachment I "Criteria for the Selection of Inspection, Measuring and Testing Equipment" and Attachment II shall be used for guidance in procurement of calibration equipment and/or services. All IMTE calibration requirements shall be identified, on Attachment 3 - IM & TE Calibration Requirements List. This attachment is used to list the various types of IMTE in use and their associated calibration frequencies, calibration procedures and tolerances. Calibration procedures, frequencies, and tolerances may be obtained in conjunction with obtaining the services of an outside calibration vendor or from W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 1 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 manufacturers. A procedure number shall be assigned. If the manufacturer has an assigned number, this should be used. Calibration procedures are quality records and shall be maintained in site files. Procedures such as published standards, practices (e.g., ASTM) or written calibration instructions from the manufacturer may be used. In the absence of either a published standards practice or an adequate manufacturer's procedure, a written procedure for the calibration method shall be written and approved for use. In addition to the above, calibration procedures should include at least the following basic information: Identity of the item to be calibrated using the procedure. Calibration comparison standards and calibration support equipment to be used. Provisions to obtain and record "as-found" accuracy measurement prior to any adjustments. Sequence of operations. Checks, tests and measurements instructions. Calibration acceptance tolerances. Calibration adjustment instructions. Safety considerations. Special instructions (when applicable). Documentation and labeling instructions related to the specific item to be calibrated. Perform and record (Form 000.509.F01104) the calibration in accordance with the above established calibration procedures and/or contract the services of an outside calibration services vendor. Upon completion of initial calibration, enter the equipment in the Calibration Assignment Log (Form 000.509.F01101) and record other data required by this log. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 2 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 History of Use The end user shall maintain a history of use for IMTE to enable an assessment of the validity of previous calibrations, inspections, measurements and test results when calibration as-found data reveals out-oftolerance data points. The history shall be documented using IMTE Sign In/Out-History of Use Log (Form 000.509.F01102) and keep current to record each usage of the IMTE. If out of tolerance conditions are found, a Nonconformance Report shall be prepared in accordance with 000.509.0130. If out-of-tolerance conditions are found during recalibrations an evaluation shall be conducted to determine if inspection, measurement, test or calibration results obtained with the out-of-tolerance instrument are still valid. Evaluations shall be documented, and where required, repetitions of readings shall be compared to original results. It is the responsibility of the end user to use calibrated equipment within the environmental operating range(s) or restrictions/limitations specified by the instrument manufacturer. NOTE: Temperature or other compensating calculations shall be applied to any inspection, measurement, test or calibration results when such compensations are specified by the instrument manufacturer and/or when they can affect the basis of the results obtained. Upon satisfactory completion of calibrations, and after the recalibration due date has been determined (calculated), the end user shall make entries on the "Calibrations Tickler File" (Form 000.509.F01103) to aid in the tracking and recall of items for scheduled recalibration. DOCUMENTATION Electronic recording of the information that is required by the documentation in this procedure is permissible. All documents (except labels) generated in accordance with this procedure should be maintained in appropriate protected files throughout the construction phase of the project, and for the period of time there after specified (if any) or turned over to the Client if required. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 3 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 FORMS Quality Support Forms: 000.509.F01101 000.509.F01102 000.509.F01103 000.509.F01104 Calibration Assignment Log and Record IMTE Sign In/Out-History of Use Log Calibration Tickler File Calibration Data Sheet ATTACHMENTS Attachment 1 Attachment 2 Attachment 3 Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE) Criteria for Procuring Calibration Services IM & TE Calibration Requirements List W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 4 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 Attachment 1 Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE) 1. IMTE includes inspection, measurement and/or testing equipment used to determine final acceptance. IMTE shall have a manufacturer's stated accuracy (and precision, where applicable) that exceeds the construction installation inspection, measurement and/or testing tolerance(s). IMTE shall have the durability, stability and appropriate measurement ranges consistent with the intended use(s). Calibration standards that will be required for the initial and subsequent recalibrations shall be identified when selecting IMTE. Such calibration standards shall be requisitioned or the services of a calibration facility with the calibration standards shall be contracted. NOTE: Obtaining calibration standards or services can usually require more time to procure than the time required to select and procure the needed IMTE. 5. Purchase requisitions for IMTE, calibration standards, and calibration facility services should clearly state the requirements for accuracy, precision (where applicable), range, durability and/or stability, environmental, handling, other applicable technical requirements. 2. 3. 4. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 5 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 Attachment 2 - Criteria for Procuring Calibration Services The following are recommended guidelines for preparing a purchase order for obtaining the services of a calibration supplier to calibrate Inspection, Measuring and Test Equipment (IM&TE). 1. The following information should be provided to the supplier: a) b) c) d) description and unique identification of each piece of IM&TE; assigned calibration interval; calibration accuracy required; any relevant environmental requirements of use or calibration. 2. The calibration supplier must provide the following information as part of their calibration records: a) source of calibration equipment used and current certificate(s) of traceability to a recognized national standard; b) identification of the calibration procedure(s) used (if the procedure is produced by the calibration supplier, a copy must be furnished, if a recognizable standard i.e. ASTM, ANSI/ASME, is used no copy is needed). 3. The calibration records supplied by the calibration supplier for each item of IM&TE calibrated must include: a) item identification number; b) date of calibration; c) the records of the "before", "as received" or "as found" condition including actual values and the "as calibrated" or "as left" values; d) identification of the calibration procedure used; e) limits of permissible error; f) calibration standard used (including serial numbers and certificates) and traceability; g) details of any maintenance, servicing, adjustment, repairs or modifications carried out; h) identification of person performing the calibration; i) identification of person responsible for the correctness of the information provided. 4. The calibration supplier shall seal, using a unique, tamper-resistant system, all adjustment access points after calibration, where practical. The system used shall provide visual evidence of tampering. 5. The calibration supplier shall immediately notify the purchaser of any IM&TE discovered to be out of calibration by more than the stated accuracy tolerance or any piece of IM&TE that shows indication of tampering. The purchaser shall determine if the calibration process should continue. 6. The calibration supplier shall package and ship each piece of IM&TE in such a manner to preclude damage and to preserve the calibrated condition. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 6 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 Attachment 3 END USER Surveyor Surveyor Surveyor Surveyor Surveyor Mechanical Mechanical Electrical Electrical Electrical Millwrights Millwrights Millwrights Welding IM & TE Calibration Requirements List DESCRIPTION Chain Level Transit Tape Distamat Pressure Gauges Torque Wrenches Meggars Simpson Mulit-Meter Digital Mulit-Meter Calipers Dial Indicators Micrometers Rod Oven Thermostat FREQUENCY Initial Conformance 6 Months 6 Months Initial Conformance 6 Months 6 Months 6 Months 6 Months 6 Months 6 Months 3 Months 3 Months 3 Months 6 Months PROCEDURE Visual* TOLERANCES ±1/8” (0.32cm) (2) Per Procedure Per Procedure ±1/8” (0.32cm) (2) Per Procedure ±5% (2) ±5% (2) ±3% (2) ±3% (2) ±3% (2) ±.02MM (2) ±.02MM (2) ±.02MM (2) ±5°F (15°C) (2) Visual* Notes: 1) ALL WORN AND/OR DEFECTIVE MEASURING EQUIPMENT IS REMOVED FROM THE SYSTEM AND DISPOSED OF. RECORDS INDICATING REMOVAL/DISPOSAL DATE ARE MAINTAINED. THESE TOLERANCES ARE LISTED FOR SITUATIONS WHERE NO OTHER RECOMMENDED TOLERANCES ARE PROVIDED. 2) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 7 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0110 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0110 Rev 0 Inspection, Measuring and Testing.doc Page 8 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01101 Revision 0, 10 June 2013 CALIBRATION ASSIGNMENT LOG AND RECORD Equipment/Instrument Identification No. Item Description Size-Range Manufacturer Model No. Manufacturer Serial No Calibration Frequency Calibration Tolerance ID A01101 Date Calibrated Calibration Due Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01101 Rev 0 Calibration Assignment Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01101 Rev 0 Calibration Assignment Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01102 Revision 0, 10 June 2013 I M T E SIGN IN/OUT HISTORY OF USE LOG I M T E Description: Name Badge No. Date Out I M T E No.: Date In ID A01102 Area/System/PKG No. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01102 Rev 0 IMTE sign in out history Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01102 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01102 Rev 0 IMTE sign in out history Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01103 Revision 0, 10 June 2013 CALIBRATIONS TICKLER FILE Month Sunday Monday Tuesday Wednesday Year Thursday Friday ID A01103 Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01103 Rev 0 Calibrations Tickler File.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01103 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01103 Rev 0 Calibrations Tickler File.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01104 Revision 0, 10 June 2013 CALIBRATION DATA SHEET Area/Location Tag No. Model No. Direct Calibration Range Calibration Procedure Manufacturer Serial No. Reserve Unit No. Project Description Type Size Action ID A01104 Job No. Fail Position As Found Calibration Input 0% 25% 75% 100% Output Input 0% 25% 75% 100% Output Mounted Accessories Remarks Calibrated By Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01104 Rev 0 Calibration Data Sheet.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01104 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01104 Rev 0 Calibration Data Sheet.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013 CONTROL OF NONCONFORMANCES SCOPE This procedure describes the methods and responsibilities for controlling nonconforming items to prevent their inadvertent use or installation when other control methods, inspection reports, surveillance reports (000.509.0220), etc. are considered inadequate. This procedure provides for the identification, documentation, evaluation, disposition, notification, segregation (prevention of inadvertent use/installation), and reinspection of these nonconforming items (excluding ASME Code items). GENERAL Types of NCRs Nonconformances are classified as: Use as Is- Permission to use an item that does not conform to specified requirements. Rework- Action taken on a nonconforming item to make it conform to specified requirements. Repair- Action taken on a nonconforming item to make it acceptable for use. Items Requiring an NCR Nonconformance Reports are issued when there are: Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition. Deficiencies of a serious or repetitive nonconforming nature as determined by the Site Quality Manager Construction damage has occurred to existing or turned over plant property. Nonconformances shall be documented using Form 000.509.F01301 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0130 Rev 0 Control of Nonconformances.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013 Responsibility for Identifying Nonconformances Fluor will issue Nonconformance Reports on self-perform work, when applicable. The Construction Subcontractors have the first responsibility for the identification, control, and disposition of nonconforming items within their Scope of Work. Fluor will issue a Nonconformance Report when the Construction Subcontractor has not issued one. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition. Inspection personnel usually initiate Nonconformance Reports; however, anyone may initiate an NCR. - Control of Nonconforming Items The Construction Manager will take measures to provide holding areas or other methods for segregating nonconforming items to prevent unauthorized use, mixing with conforming items or incorporating into future construction. Where physical segregation is not practical, tagging, marking or other positive means of identification is acceptable. The Site Quality Manager may elect to use "HOLD" tags/stickers (Form 000.509.F01303) for additional assurance. PROCEDURE Documentation of Nonconformance For materials and equipment identified as nonconforming (per the descriptions in the "General" section of this procedure), generate a Nonconformance Report (Form 000.509.F01301) to document the nonconforming item(s). The report is to be processed as follows: Initiator • • Enter the date the nonconformance is documented. Enter either Fluor, the name of the Subcontractor or Vendor to identify organization responsible for the nonconforming work. Use the entries in the header of the form to provide unique traceability and identification to the nonconforming item. • W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0130 Rev 0 Control of Nonconformances.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013 • • Enter a complete description of the nonconforming condition. The initiator may propose a disposition, but it is not required. Enter the root cause of the nonconforming condition. The initiator provides the NCR completed as noted above to the Site Quality Manager. Site Quality Manager NOTE: Evaluate the report to determine that the described condition is a valid nonconformance. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition. If a Construction Subcontractor has issued the NCR, it should not be duplicated by Fluor. • Assign a unique number to the report and enter the number on the report and on the "Nonconformance Report Log" (Form 000.509.F01302). If a hold tag is needed, enter the hold tag number and have the hold tag installed on the item. The hold tag number should be the same as the NCR number. If a hold tag is not to be used, enter NA. The Site Quality Manager provides the NCR completed as noted above to the Construction Engineering Manager. Also send a copy to the Fluor Shop Inspection Coordinator for nonconformances attributed to a vendor. • Construction Engineering Manager • • Evaluate the proposed disposition, modify if necessary, or enter the disposition. If the nonconforming condition will not be corrected in full conformance with the applicable specification, the Project Design Engineer shall accept the disposition. In this case, check "yes" and obtain the Project Design Engineer approval. Any documentation provided by the Design Engineer that supports the disposition should be attached to the NCR original. For subcontractor NCR's, this approval is obtained through the Fluor Construction Engineering Manager. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0130 Rev 0 Control of Nonconformances.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013 If the disposition corrects the nonconformance to full compliance with the applicable specification, check "no". • After completing the disposition instructions and obtaining the required approvals, sign and date. Send the original NCR to the Site Quality Manager and copy to the Site Manager. Site Manager Upon receipt of the approved NCR disposition, perform the applicable construction actions specified in the NCR disposition. (Request removal of QC hold tag prior to performing work, if one has been applied.) Site Quality Manager (or Inspector) NOTE: The Site Quality Manager or Fluor Subcontractors or subtier subcontractor initiating NCR's that require Project Design Engineer approval should send a copy of the approved NCR to the Fluor Site Quality Manager (prior to performing the actions specified in the NCR disposition, if possible). • • DOCUMENTATION The Site Quality Manager shall retain all NCR’s and the NCR log in the Quality Files. FORMS Quality Forms: 000.509.F01301 - Nonconformance Report 000.509.F01302 - Nonconformance Report Log 000.509.F01303 - Hold Tag/Sticker Attachment Attachment 1 Attachment 2 - Instruction for completion of Non-Conformance Report - Nonconformance Routing Chart Upon verification of satisfactory completion of the disposition, sign and date. Obtain other required approvals as required. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0130 Rev 0 Control of Nonconformances.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013 Attachment 1 - Instruction for completion of Non-Conformance Report (NCR) 1 Description of Non-conformance: The initiator shall describe the requirements that were not met and a detailed description of the Non-conformance. Root Cause: The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s) including and explanation will be stated. Cause Code C01 C02 C03 C04 C05 C06 C07 C08 C08a C08b C08c C08d C08e C08f C09 C10 C11 C99 Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Procedure (except procedure not followed) Procedure/Work Process not followed - select from below Not Aware of Procedure (includes not trained) Ignored Procedure (includes no time / low priority / not important) Misapplied Procedure (includes not understood / thought not to apply) Not Effective (needs update / improvement / is inappropriate) / incorrect Incorrect Reference to Procedure (includes incorrectly specified) Procedure Not in Native Language People Driven Systems Driven Work Environment Other 2 NOTE: If codes 7 or 8 are used, list the procedure(s) identified as the root cause. Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code. 3 Disposition Use-as-is Re-work Repair Requires design Engineer and Client approval. Restore to original Specification, does not require Design Engineer or Client approved. Does not meet original specification, correct (repair) for “fit-for-use” condition. Requires approval from design engineer and may require approval of client. Provide instructions for implementation or justification of the selected disposition. IMPLEMENTATION Once implementation is satisfactorily implemented, sign the “Disposition Completed” block. 4 Action verified and Non-Conformance Closed The Fluor inspector shall indicate the method used for verification of corrective action. Sign the signature block indicating acceptance of corrective action. 5 The Fluor Site Quality Manager shall review the NCR for completeness and acceptance of the corrective action. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0130 Rev 0 Control of Nonconformances.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0130 Revision 0, 10 June 2013 Attachment 2 - Nonconformance Routing Chart Site Quality Manager Review/Confirm s/ Signs Lead Field Engineer Recomm ended Disposition/ Signature Nonconform ance Discovered NCR Initiated Site Quality Manager Assigns Num ber Site Quality Manager for Routing Corrective Action: 1) Remove/Replace Rework to Full Design Intent Corrective Action Approved Corrective Action NOTE 1 2) Repair Applicable Design Authority Review Disposition Approve or Disapprove NOTE 2 3) Use As Is Reject Execution of Corrective Action Quality Manager Verifies Accepts Quality Manager Closes NCR Distribution: Quality Manager Distributes Closed NCR Note 1: If corrective action is 2 or 3, distribution to be same as that shown when NCR closed. If corrective action is 1, exclude area EPCM from distribution until NCR is closed. Note 2: For NCR’s on Activities within Regulating Authority Scope, they need to Review/Accept W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0130 Rev 0 Control of Nonconformances.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01301 Revision 0, 10 June 2013 NONCONFORMANCE REPORT Tag Description: P. O. No.: Subcontractor: Initiated by: Area/Location DWG. No./Rev. Inspection Classification Subcontractor Fluor Date: Unit/Equip No. Spec./Rev. Tag No.: Turnover System: Client Other Hold Tag Yes ID A01301A Sub – System: Location: NCR No. No Discipline/Responsibility: Audit No. (If Applicable) DESCRIPTION OF NONCONFORMANCE ROOT CAUSE CAUSE CODE(S) DISPOSITION Use as is Rework Repair Other DISPOSITION BY Design Eng. Approval Req. Construction Engineer Date Yes No DISPOSITION COMPLETED BY Contractor Date Design Engineer Date ACTION VERIFIED AND NON-CONFORMANCE CLOSED VERIFICATION METHOD DOC REVIEW FLUOR INSPECTOR INSPECTION OTHER DATE FLUOR-VERIFIED DISPOSITION AND RECOMMENDED CLOSURE OF NCR FLUOR SITE QUALITY MANAGER DATE W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01301 Rev 0 Non Conformance Repor.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01301 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01301 Rev 0 Non Conformance Repor.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01302 Revision 0, 10 June 2013 NONCONFORMANCE REPORT LOG Page _______of _______ NCR No. Discipline Hold Tag Date Opened Date Closed ID A01302 Description of Nonconformance W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01302 Rev 0 Non Conformance Report Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01302 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01302 Rev 0 Non Conformance Report Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01303 Revision 0, 10 June 2013 HOLD TAG/STICKER ID A01303 HOLD Hold Tag No._____________________ DO NOT USE NCR Number_____________________ (DO NOT REMOVE THIS TAG) (Recommended Color: Red with Green Letters) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01303 Rev 0 Hold Tag-Sticker.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01303 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01303 Rev 0 Hold Tag-Sticker.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0140 Revision 0, 10 June 2013 CORRECTIVE ACTION SCOPE This procedure establishes the method of obtaining and documenting corrective actions for significant conditions which are adverse to quality, such as failure to properly implement procedures, programmatic failure due to inadequate procedures or failure to correct repetitive problems. The corrective action process involves: Reviewing nonconformities Determining their cause Evaluating the action necessary to ensure that nonconformities do not recur Determining and implementing the action needed Recording the results of actions taken Reviewing corrective action taken GENERAL Definitions Nonconformity – The non-fulfillment of specified requirements. Also referred to as a nonconformance. Correction – The correction (fixing) of a nonconforming item to make it acceptable. When correcting an item, consideration should be given to whether other work is also affected. Corrective Action – The action taken to eliminate the cause(s) of nonconformities. Corrective Action should be appropriate to the magnitude of the problem and commensurate with the risks encountered. Root Cause – Underlying reason(s) for occurrence of a nonconformitynonconformity. A root cause is determined by through analysis, (e.g. asking the question “why?” until the underlying reason has been revealed). Responsible Person – The individual responsible for the group of system where a nonconformitynonconformity is identified. They would be responsible for ensuring its timely correction. Significant Condition – operating system and/or procedural deficiencies evaluated by management (as to the magnitude of the problem and commensurate to the risks encountered) and judged to warrant a Corrective Action Report (CAR). This may also include where a trend is noted (ie the same nonconforming condition occurs three or more times). The need for a Corrective Action Report is usually identified by the Site Quality Manager or inspection personnel; however, any one may identify the need for a CAR. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0140 Rev 0 Corrective Action.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0140 Revision 0, 10 June 2013 PROCEDURE A nonconformity may be identified through activities such as internal audit, surveillance, management review, or external audit finding. A nonconformity is evaluated (based on severity) to determine the appropriate level of corrective action needed to prevent recurrence. Consideration is given to the impact of the nonconformity on project cost, schedule or quality issues. Not all nonconformities require root cause analysis and/or corrective action. It is acceptable for management to determine that only correction is necessary. Root cause analysis and corrective action are applied where the reward is greater than the effort. Corrective action is documented on the CAR (Corrective Action Report) form: 000.509.F01401 Coordination of CARs is the responsibility of the Site Quality Manager. The Site Quality Manager reviews identified nonconformities to determine if a CAR is appropriate. If so, Sections 1 and 2 of the CAR form are completed and the CAR is recorded on a status log (000.509.F01402). Equivalent forms and logs are permitted providing the essential elements of the example form and log are addressed. The CAR is transmitted to the Responsible Person for further action. The Responsible Person completes Section 3 and 4 of the CAR form (refer to Attachment 01 – Corrective Action Response Instructions) and returns it to the Site Quality Manager. Should it become necessary to void or cancel a CAR during the initiation cycle (upon discovery that no nonconformity actually exists, or a CAR covering this condition already exists), and explanation will be written on the original report. The report will be signed and dated by the responsible person and copies provided to appropriate distribution including the person who identified the deficiency/condition. The Site Quality Manager is responsible for ensuring that the nonconformity has been corrected and that the corrective action taken to eliminate the cause of nonconformity is effective. The Site Quality Manger will also ensure completion of Section 5 of the CAR form and update the Status Log. A completed copy of the CAR form will be retained. In cases where an activity (that is the subject of CAR) occurs infrequently, or where root cause analysis is determined to be not necessary, the CAR may be closed following correction of the nonconformity without verifying effectiveness of the corrective action. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0140 Rev 0 Corrective Action.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0140 Revision 0, 10 June 2013 DOCUMENTATION The Corrective Action Report and associated attachments shall be retained in the Quality Control Files by the Site Quality Manager. The status of open CAR’s will be reviewed with Site Management on a periodic basis to ensure timely close out of the CAR’s. REFERENCES Quality Control Forms: 000.509.F01401 000.509.F01402 Corrective Action Report Corrective Action Report Log ATTACHMENTS Attachment 1 - Corrective Action Response Instructions W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0140 Rev 0 Corrective Action.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0140 Revision 0, 10 June 2013 Attachment 1 - Corrective Action Response Instructions Corrective Action Report (CAR) The Responsible Person is required to respond to each CAR within a target of 30 days after the issue of the CAR. Responses may be provided on the CAR form, or by other written means. Responses are required to address the following points: CAR Section 3 – Correction of Nonconformity Provide a detailed explanation of the action that will be taken to resolve the specific problem identified on the CAR and state when the action has been or will be completed. Identify other work affected and if additional actions or controls are needed. CAR Section 4 – Corrective Action Section In addition to correcting the nonconformity, the Responsible Person needs to assess it’s severity/impact to see if further analysis is warranted (i.e. determine the root cause and develop a plan to prevent recurrence). When evaluating the severity of the nonconformity consideration should be given to its impact on project cost, schedule or quality issues (e.g. resulting in excessive rework). This decision is indicated by marking yes or no in Section 4 or the CAR. Root Cause: The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s) including an explanation will be stated. Cause Code C01 C02 C03 C04 C05 C06 C07 C08 C08a C08b C08c C08d C08e Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Procedure (except procedure not followed) Procedure/Work Process not followed - select from below Not Aware of Procedure (includes not trained) Ignored Procedure (includes no time / low priority / not important) Misapplied Procedure (includes not understood / thought not to apply) Not Effective (needs update / improvement / is inappropriate) / incorrect Incorrect Reference to Procedure (includes incorrectly specified) Description W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0140 Rev 0 Corrective Action.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0140 Revision 0, 10 June 2013 Cause Code C08f C09 C10 C11 C99 Description Procedure Not in Native Language People Driven Systems Driven Work Environment Other Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code Plan To Prevent Recurrence: Provide details of corrective actions that have been taken or will be taken to prevent recurrence of the condition (root cause) that led to the reported Nonconformity and state when the corrective actions to prevent recurrence have been or will be completed. Upon completion, sign and date. If issued electronically, name and date may be typed. Response Coordination and Processing Upon completion of sections 3 & 4 of the above reports, route to the Site Quality Manager. The Site Quality Manager, upon receipt of all responses, provides for follow-up and close-out where applicable. Closed out CAR’s (Section 5 Completed) are to be copied to the Construction Technology Quality Manager. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0140 Rev 0 Corrective Action.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0140 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0140 Rev 0 Corrective Action.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01401 Revision 0, 10 June 2013 CORRECTIVE ACTION REPORT 1 - Identification Supplier Name: CAR Number: Personnel contracted: 2 - Nonconformity Contract/P.O. No.: Originator: Discipline: Date: ID A01401A Reference: Requirement: Description: Contributing Cause(s): [List code number(s) see Att. 1 of 000 509 0140] 3 – Correction of Nonconformity (By Responsible Person) Plan to address the Nonconformity (e.g. correct/repair/waiver) Estimated Completion Date: 4 – Corrective Action Section (By Responsible Person) In the judgement of the Responsible Person, is an analysis of the root cause(s) of this nonconformity required (including determining a plan to prevent recurrence) in light of the magnitude of the problem and the risk involved? (If Yes, continue: if no, mark N/A below). Yes / No Root Cause(s): List code number(s) see 000.509.0140.att. 1, and explain underlying reason why nonconformity occurred Plan to Prevent Recurrence: Responsible Person: 5 – Closeout Verification Correction of Nonconformity: Verifier: Date: Estimated Completion Date: Date: Corrective Action Implemented and Effective: (only completed when a root cause was determined see 4 above) Evaluator: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01401 Rev 0 Corrective Action Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01401 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01401 Rev 0 Corrective Action Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01402 Revision 0, 10 June 2013 CORRECTIVE ACTION STATUS LOG CAR No. Date Initiated Description of CAR Contractor/Supplier Contract/P.O. No. Responsible Person ID A01402A Response Received Date Date Closed W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01402 Rev 0 Corrective Action Status Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01402 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01402 Rev 0 Corrective Action Status Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0150 Revision 0, 10 June 2013 PREVENTIVE ACTION SCOPE This procedure provides guidance on methods to identify conditions (or circumstances) which have the potential to cause nonconformities GENERAL Definitions Preventive Action: The action taken to eliminate the cause of potential nonconformities. Preventive action will be appropriate to the magnitude of the potential nonconformity and commensurate with the potential risks that may be encountered. Nonconformities: The non-fulfillment of specified requirements. Preventive action involves the detection and elimination or modification of work performance conditions (or circumstances) which have a potential to cause nonconformities. Each employee should continually evaluate his/her work process to identify potential nonconformities. PROCEDURE Project Personnel Review appropriate sources of information that may be used to identify potential nonconformities such as: Surveillance Reports Internal Quality Audits Client Feedback Lessons Learned Analysis and improvement of work process and operations Value Awareness Suggestion Monthly Project Reviews Employee Suggestions Registrar Feedback The Site Quality Manager is aware of the various sources of potential nonconformities listed above and, as appropriate, will determine if an identified item should be considered for preventive action. Consideration should be based on the item’s potential impact on project cost, schedule or quality. NOTE: Note all potential nonconformities require preventive action. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0150 Rev 0 Preventive Action.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0150 Revision 0, 10 June 2013 Potential nonconformities that could adversely affect the Project will have the following steps performed: Determine cause of the potential nonconformity and record it on the log. Refer to cause codes listed below. Determine what action is required to prevent occurrence of nonconformity (i.e. issue surveillance or audit observations, revision of a work process or procedure) and add the appropriate Elimination Code number to the log (See Attachment 1). Confirm that action was taken to prevent the potential nonconformity from occurring and record this information in the preventive action log. Preventive Actions that eliminate potential nonconformities will be submitted for management review. A log is to be maintained that records a description of the potential nonconformity, the contributing cause (see Cause Code table below), the action determine necessary to eliminate the cause (see Elimination Code table below). NOTE: Any log is permitted provided it contains the same basic information as Attachment 1. CAUSE CODES Code Description C01 Client Driven C02 Communication Driven C03 Equipment or Material C04 External Phenomenon C05 Location Driven C06 Management Driven C07 Procedure (except procedure not followed) C08 Procedure/Work Process not followed - select from below C08a Not Aware of Procedure (includes not trained) C08b Ignored Procedure (includes no time / low priority / not important) C08c Misapplied Procedure (includes not understood / thought not to apply) C08d Not Effective (needs update / improvement / is inappropriate) / incorrect C08e Incorrect Reference to Procedure (includes incorrectly specified) C08f Procedure Not in Native Language C09 People Driven C10 Systems Driven C11 Work Environment C99 Other Refer to 000.042.1000 Att. 2 in KOL for a definition of each cause code W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0150 Rev 0 Preventive Action.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0150 Revision 0, 10 June 2013 Code E01 E02 E03 E04 E05 E99 ELIMINATION CODES Description Revision/modification of work process/document Issuance of QA/QC report to affected personnel Issuance of document/procedure Training/orientation of affected personnel Verbally advising affected personnel Other FORMS Quality Control Forms: 000.509.F02201 - Surveillance Report 000.509.F01501 - Preventive Action log 000.509.F01701 - Audit Finding 000.509.F01702 - Audit Summary W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0150 Rev 0 Preventive Action.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0150 Revision 0, 10 June 2013 This page intentionally left blank. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0150 Revision 0, 10 June 2013 PREVENTIVE ACTION LOG Project Number: PA No. Issue Date Source Description Project Name: Cause Code Elimination Code Confirmation of Action Verified by Date Closed Cause Code C01 C02 C03 C04 C05 C06 Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Cause Code C07 C08 C09 C10 C11 C99 Description Procedure (except procedure not followed) Procedure/Work Process not followed People Driven Systems Driven Work Environment Other Elimination Code E01 E02 E03 E04 E05 E99 Description Revision/modification of work process/document Issuance of QA/QC report to affected personnel Issuance of document/procedure Training/orientation of affected personnel Verbally advising affected personnel Other W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0150 Rev 0 Preventive Action.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01501 Revision 0, 10 June 2013 PREVENTIVE ACTION LOG Project Name : PA No. Issue Date Source Description Project Number: Cause Code Elimination Code Confirmation of Action ID A01501A Verified by Date Closed Cause Code C01 C02 C03 C04 C05 C06 Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Cause Code C07 C08 C09 C10 C11 C99 Description Procedure (except procedure not followed) Procedure/Work Process not followed People Driven Systems Driven Work Environment Other Elimination Code E01 E02 E03 E04 E05 E99 Description Revision/modification of work process/document Issuance of QA/QC report to affected personnel Issuance of document/procedure Training/orientation of affected personnel Verbally advising affected personnel Other W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01501 Rev 0 Preventive Action Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01501 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01501 Rev 0 Preventive Action Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01701 Revision 0, 10 June 2013 AUDIT FINDING 1) ID A01701 Finding Number: Audit Date: Project/Contract Number: Project Name: Auditor(s): Auditee Personnel Contacted: 2) A. Reference: B. Requirement: Continued on back 3) Deficiency: Continued on back 4) Proposed Disposition: Expected Completion Date: 5) Corrective Action Evaluation, and Response: Disposition (Action taken to correct deficiency) Completion Date: 6) Auditee Signature: Auditor Concurrence with disposition: Date: Date: 7) Continued on back 8) Auditor Follow-up and Close-out Verification: Auditor Signature: Date Deficiency closed: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01701 Rev 0 Audit Finding.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01701 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01701 Rev 0 Audit Finding.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01702 Revision 0, 10 June 2013 AUDIT SUMMARY Project: Client: Project Number: Audit Location: Audit Scope: Construction Audit Number: Audit Dates: Report Date: ID A01702 Summary of Audit Results: Entry Meeting Date: The entry & exit meeting were conducted with: A summary of the audit results is as follows: Exit Meeting Date: Quality Manual Principles assessed. Deficiencies reported. Quality Manual Principles found to be satisfactory. Observations for improvement. Previous Findings and Action Follow-up: Finding Number Status – (Open or Closed) Date Closed Lead Auditor Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01702 Rev 0 Audit Summary.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01702 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01702 Rev 0 Audit Summary.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 QUALITY RECORDS SCOPE This procedure describes maintenance of Quality Records generated for and/or by construction. GENERAL Quality Records are documented evidence that construction conformed to requirements of the Design Specifications. Quality Records include: • • • • • Test and inspection reports Radiographs Material and equipment certificates required by specification Equipment maintenance/preservation records As-built drawings Designated construction staff arestaff is responsible for the preparation of Quality Records and are usually responsible for maintenance and retrievability of the records. Records that are identified as “Confidential” in any confidentiality agreement shall be controlled in accordance with specific procedures established by that agreement. PROCEDURE • Site Quality Manager In coordination with the Construction Engineering Manager and any other group manager who receives or generates quality records, identify the quality records that will be retained during construction and identify the record custodian by job title. Record this information on Form 000.509.F01601 (Quality Records Control). Reference the Project File Index and Record Retention Schedule Practice 000.037.1182. In coordination with the client and other record custodians, define the Quality Records that are to be submitted to the client upon completion of work and identify this on the Quality Records Control form. The Fluor Site Quality Manager in coordination with the Site Manager will identify all Quality Records (or copies of records) that will be retained in the Records Retention Center. Identify this on the Quality Records Control form. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 1 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 NOTE: Reference Attachment 1 for a sample of Site Specific Quality Records Control form. [:: Attachment 1 should be made site specific ::] Maintain the Quality Records Control form current and, if possible, before records are received on site or generated. • Custodian Establish and maintain a filing system for inspection, testing, and other Quality Control records. The system shall ensure that records are readily retrievable and protected. The system shall allow the records required for turnover to be easily separated by turnover packages. The system is to be identified on the Quality Records Control Form. Prior to filing the record the custodian shall review the documents to verify the following: Documents are appropriate Documents are complete Entries are correct Documents are legible Documents signed/initialed by authorized person Review vendor generated documents to verify the records are complete and legible. The custodian shall resolve any discrepancies noted during the document review with the originator or originator's supervisor. Resolve any discrepancies with vendor documents through the Fluor purchasing department. Corrections to records are accomplished by authorized personnel (i.e. record originator or originator's supervisor) by striking a single line through the erroneous entry, entering the correct information and initialing and dating the change. Turnover Maintain the records until they are requested by project turnover and/or assigned to the Records Retention Center. NOTE: Subcontractors will retain their records until they are requested by Fluor. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 2 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 The Site Quality Manager will generate a checklist and verify that all required quality records have been completed and those designated for turnover are included in the Turnover Package. All supporting documentation relating to mechanical completion/system turnover will be retained by Fluor until system acceptance by Client. After system acceptance by Client, this documentation will be transferred to Client under separate correspondence. FORMS Quality Control Form: 000.509.F01601- Quality Records Control ATTACHMENT Attachment 1 - Sample of Site Specific Quality Records Control Form Note: List all forms and designate if they are to be turned over. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 3 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Attachment 1 - Sample of Site Specific Quality Records Control Form Record Identification Form # 000 509 F00501 000 509 F00502 000 509 F01101 000 509 F01102 000 509 F01103 000 509 F01104 000 509 F01301 000 509 F01302 000 509 F01303 000 509 F01401 000 509 F01402 000 509 F01501 000 509 F01601 000 509 F01701 000 509 F01702 000 509 F01801 000 509 F02001 000 509 F02002 000 509 F02003 000 509 F02004 000 509 F02005 000 509 F02006 000 509 F02201 000 509 F02202 000 509 F02301 000 509 F02401 000 509 F02402 000 509 F02403 000 509 F02404 000 509 F02405 000 509 F02406 000 509 F02407 Title Request For Information Request For Information Log Calibration Assignment Log and Record I.M.T.E. Sign In/Out History of Use Log Calibrations Tickler File Calibration Data Sheet Nonconformance Report Nonconformance Report Log Hold Tag/Sticker Corrective Action Report Corrective Action Status Log Preventive Action Log Quality Records Control Audit Finding Audit Summary Project Specific Quality Training Site Subcontractor Qualification Soil Testing Laboratory Evaluation Record Asphalt Testing Laboratory Evaluation Record Concrete Batch Plant Evaluation Record Concrete Testing Laboratory Evaluation Record NDE Subcontractor Evaluation Record Surveillance Report Surveillance Report Log Receiving Inspection Checklist Transfer of Care, Custody and Control (Turnover Notice) System Walkdown Notice Mechanical Completion Civil Checklist Mechanical Completion Electrical/Instrumentation Checklist Mechanical Completion/Mechanical Checklist Mechanical Completion/Quality Control Checklist Master Punch List Record Custodian Job Title or Sub Name CEM CEM CEM CEM CEM CEM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM COMM CEM CEM CEM CEM CEM CEM System Turnover Package Y = Yes N = No N N N N N N N N N N N N N N N N N N N N N N N N N Y Y Y Y Y Y Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 4 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F02408 000 509 F02409 000 509 F02501 000 509 F02502 000 509 F70001 000 509 F70002 000 509 F70101 000 509 F70102 000 509 F70103 000 509 F70104 000 509 F70105 000 509 F70201 000 509 F70202 000 509 F70204000 509 F70203 000 509 F70301000 509 F70204 000 509 F70302000 509 F70301 000 509 F70303000 509 F70302 000 509 F70801000 509 F70303 000 509 F70901000 509 F70801 000 509 F71001000 509 F70901 000 509 F71002000 509 F71001 000 509 F71003000 509 F71002 000 509 F71004000 509 F71003 000 509 F71005000 509 F71004 Title Interim Turnover Notice Mechanical Completion Certificate Storage Inspection Checklist Equipment Protection Preservation and Inspection Record Inspection and Test Plan Inspection and Test Plan Soil Inspection Checklist Field Compaction Test Record Density of Soil Place by the Sand-Cone Method ASTM D-1566 AASHTO-T-191 Nuclear Moisture-Density Test Report Soil Density Test Log Bituminous Concrete Paving Inspection Checklist Bulk Specific Gravity Nuclear Density Test Report – Bituminous ConcreteBituminous Concrete Compaction Pile Driving Inspection RecordNuclear Density Test Report – Bituminous Concrete Pile Driving RecordPile Driving Inspection Record Custodian Job Title or Sub Name CEM CEM MM MM SQM SQM CEM CEM CEM CEM CEM CEM CEM CEM System Turnover Package Y = Yes N = No Y Y Y Y N N Y Y Y Y Y Y Y Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y Record of Pile DrivingPile Driving Record CEM Y Caisson Inspection RecordRecord of Pile Driving Augered Cast-In-Place Pile RecordCaisson Inspection Record Pre-Concrete Inspection ChecklistAugered Cast-InPlace Pile Record Concrete Inspection RecordPre-Concrete Inspection Checklist Y Concrete Pour CardConcrete Inspection Record Cementitious Grout Inspection RecordConcrete Pour Card Cementitious Grout Testing RecordCementitious Grout Inspection Record CEM Y CEM Y CEM CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 5 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F71006000 509 F71005 000 509 F71007000 509 F71006 000 509 F71008000 509 F71007 000 509 F71009000 509 F71008 000 509 F71010000 509 F71009 000 509 F72002000 509 F71010 000 509 F72003000 509 F72002 000 509 F73001000 509 F72003 000 509 F73002000 509 F73001 000 509 F73003000 509 F73002 000 509 F73004000 509 F73003 000 509 F73005000 509 F73004 000 509 F73006000 509 F73005 000 509 F73007000 509 F73006 000 509 F73008000 509 F73007 000 509 F73009000 509 F73008 000 509 F73010000 509 F73009 Title Epoxy Resin Grout Inspection RecordCementitious Grout Testing Record Concrete Compression Strength Test RecordEpoxy Resin Grout Inspection Record Concrete Placement LogConcrete Compression Strength Test Record Grout Placement LogConcrete Placement Log Concrete Batch Plant Inspection RecordGrout Placement Log Structural Steel InspectionConcrete Batch Plant Inspection Record Torque Wrench Calibration LogStructural Steel Inspection Building Inspection and Test ChecklistTorque Wrench Calibration Log Final Building Inspection SummaryBuilding Inspection and Test Checklist Carpentry ChecklistFinal Building Inspection Summary Painting ChecklistCarpentry Checklist Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code Y CEM Y CEM Y CEM SQM N CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y Plumbing ChecklistPainting Checklist CEM Y Ceramic Tile ChecklistPlumbing Checklist CEM Y Concrete ChecklistCeramic Tile Checklist CEM Y Structural Steel ChecklistConcrete Checklist Masonry (Brickwork) ChecklistStructural Steel Checklist Plaster ChecklistMasonry (Brickwork) Checklist CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 6 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F73011000 509 F73010 000 509 F73012000 509 F73011 000 509 F73013000 509 F73012 000 509 F73014000 509 F73013 000 509 F73015000 509 F73014 000 509 F73016000 509 F73015 000 509 F73101000 509 F73016 000 509 F73102000 509 F73101 000 509 F73201000 509 F73102 000 509 F74001000 509 F73201 000 509 F74002000 509 F74001 000 509 F74003000 509 F74002 000 509 F74004000 509 F74003 000 509 F74005000 509 F74004 000 509 F74006000 509 F74005 000 509 F74007000 509 F74006 000 509 F74008000 509 F74007 Title Doors, Windows, Hardware, Glazing ChecklistPlaster Checklist Computer (Raised) Floors ChecklistDoors, Windows, Hardware, Glazing Checklist Prefab Wall Element Systems ChecklistComputer (Raised) Floors Checklist Building Metal Siding And Roofing ChecklistPrefab Wall Element Systems Checklist Buildings Water Proofing And Damp Proofing ChecklistBuilding Metal Siding And Roofing Checklist Suspended Ceiling ChecklistBuildings Water Proofing And Damp Proofing Checklist HVAC Inspection RecordSuspended Ceiling Checklist Buildings Air Conditioning ChecklistHVAC Inspection Record Roofing Inspection ChecklistBuildings Air Conditioning Checklist Equipment Installation ChecklistRoofing Inspection Checklist Heat Exchangers & Reboilers Installation RecordEquipment Installation Checklist Electrostatic Precipitator ChecklistHeat Exchangers & Reboilers Installation Record Inspection Record Static EquipmentElectrostatic Precipitator Checklist Tray Installation Inspection RecordInspection Record Static Equipment Air Cooled Heat Exchanger Inspection ChecklistTray Installation Inspection Record Air Cooler Run In Test ReportAir Cooled Heat Exchanger Inspection Checklist Reciprocating Compressor Inspection RecordAir Cooler Run In Test Report Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 7 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F74009000 509 F74008 000 509 F74010000 509 F74009 000 509 F74011000 509 F74010 000 509 F74012000 509 F74011 000 509 F74013000 509 F74012 000 509 F74014000 509 F74013 000 509 F74015000 509 F74014 000 509 F74016000 509 F74015 000 509 F74017000 509 F74016 000 509 F74018000 509 F74017 000 509 F74019000 509 F74018 000 509 F74020000 509 F74019 000 509 F74021000 509 F74020 000 509 F74022000 509 F74021 000 509 F74024000 509 F74022 000 509 F74025000 509 F74024 000 509 F74026000 509 F74025 Title Fan Installation Inspection ChecklistReciprocating Compressor Inspection Record Furnaces Inspection RecordFan Installation Inspection Checklist Fuel Gas Steam Generator Inspection ChecklistFurnaces Inspection Record Steam Turbine Inspection ChecklistFuel Gas Steam Generator Inspection Checklist Agitators/Mixers Inspection ChecklistSteam Turbine Inspection Checklist Equipment/Piping Strain and Alignment Inspection FormAgitators/Mixers Inspection Checklist Installation Checklist Travelling CranesEquipment/Piping Strain and Alignment Inspection Form Package Equipment Installation ChecklistInstallation Checklist Travelling Cranes Desuperheaters/Ejectors Inspection ChecklistPackage Equipment Installation Checklist Filters/Strainers Installation RecordDesuperheaters/Ejectors Inspection Checklist Centrifugal Compressor Inspection RecordFilters/Strainers Installation Record Rotating Equipment Inspection RecordCentrifugal Compressor Inspection Record Rotating Equipment Alignment RecordRotating Equipment Inspection Record Belt Driven Equipment Alignment RecordRotating Equipment Alignment Record Inspection Record For Draw Off Tray Leak Test ReportBelt Driven Equipment Alignment Record Inspection Record For Air CoolersInspection Record For Draw Off Tray Leak Test Report Final Closing Authorization RecordInspection Record For Air Coolers Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 8 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F74027000 509 F74026 000 509 F74028000 509 F74027 000 509 F74029000 509 F74028 000 509 F74030000 509 F74029 000 509 F74031000 509 F74030 000 509 F74032000 509 F74031 000 509 F74033000 509 F74032 000 509 F74101000 509 F74033 000 509 F74102000 509 F74101 000 509 F74103000 509 F74102 000 509 F74104000 509 F74103 000 509 F74105000 509 F74104 000 509 F74106000 509 F74105 000 509 F74201000 509 F74106 000 509 F74301000 509 F74201 000 509 F74401000 509 F74301 000 509 F74402000 509 F74401 Title API 686 Baseplate Installation Checklist (Prior to Grouting)Final Closing Authorization Record API 686 Equipment Grouting ChecklistAPI 686 Baseplate Installation Checklist (Prior to Grouting) API 686 Alignment Check SheetAPI 686 Equipment Grouting Checklist Baseplate Leveling RecordAPI 686 Alignment Check Sheet Reverse Dial Alignment RecordBaseplate Leveling Record Piping Alignment Data SheetReverse Dial Alignment Record Rotating Equipment (Face-Rim) Alignment RecordPiping Alignment Data Sheet Tank Elevation Tolerances RecordRotating Equipment (Face-Rim) Alignment Record Inspection Record Field Erected TankTank Elevation Tolerances Record Tank Plate Dimensional Control Record Field Erected TankInspection Record Field Erected Tank Water Filling And Settlement Record Field Erected TankTank Plate Dimensional Control Record Field Erected Tank Tank Leak Test RecordWater Filling And Settlement Record Field Erected Tank Tank Test CertificateTank Leak Test Record Inspection Record Cooling TowerTank Test Certificate Field Installed Refactory RecordInspection Record Cooling Tower Gas Turbine/Generator Gear Inspection ChecklistField Installed Refactory Record Gas Turbine Inspection RecordGas Turbine/Generator Gear Inspection Checklist Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 9 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F74405000 509 F74402 000 509 F74406000 509 F74405 000 509 F74407000 509 F74406 000 509F74408000 509 F74407 000 509 F74601000 509F74408 000 509 F74602000 509 F74601 000 509 F74603000 509 F74602 000 509 F74604000 509 F74603 000 509 F74605000 509 F74604 000 509 F74606000 509 F74605 000 509 F74607000 509 F74606 000 509 F74608000 509 F74607 000 509 F74609000 509 F74608 000 509 F74701000 509 F74609 000 509 F74702000 509 F74701 000 509 F75001000 509 F74702 000 509 F75002000 509 F75001 Title Shop-Fabricated Field-Erected Stack Inspection RecordGas Turbine Inspection Record Heat Recovery Steam Generator Inspection RecordShop-Fabricated Field-Erected Stack Inspection Record Breeching And Duct Work Inspection RecordHeat Recovery Steam Generator Inspection Record Equipment Protection Activities Record – Gas TurbinesBreeching And Duct Work Inspection Record Site Daily Activities LogEquipment Protection Activities Record – Gas Turbines Stg Foundation Settlement RecordSite Daily Activities Log Stg FixatorsStg Foundation Settlement Record Custodian Job Title or Sub Name System Turnover Package Y = Yes N = No Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code Stg Sole PlatesStg Fixators Stg Front Standard Base Plate AssemblyStg Sole Plates Exhaust Hood Horizontal Joint LevelnessStg Front Standard Base Plate Assembly Stg Shell/Casing Load TestExhaust Hood Horizontal Joint Levelness Stg Piping AttachmentStg Shell/Casing Load Test Stg Foundation Top of Concrete ElevationsStg Piping Attachment Generator Test ChecklistStg Foundation Top of Concrete Elevations Generator Cold Resistance Test RecordGenerator Test Checklist Underground Pipe Inspection RecordGenerator Cold Resistance Test Record Insulation Resistance (Insulated FlangesUnderground Piping) Test RecordUnderground Pipe Inspection Record CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 10 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F75003000 509 F75002 000 509 F75101000 509 F75003 000 509 F75102000 509 F75101 000 509 F75103000 509 F75102 000 509 F75201000 509 F75103 000 509 F75501000 509 F75201 000 509 F75502000 509 F75501 000 509 F75503000 509 F75502 000 509 F75504000 509 F75503 000 509 F75505000 509 F75504 000 509 F75506000 509 F75505 000 509 F75507000 509 F75506 000 509 F75508000 509 F75507 000 509 F75509000 509 F75508 000 509 F75601000 509 F75509 000 509 F75701000 509 F75601 000 509 F76001000 509 F75701 Title Holiday (Spark) Test RecordInsulation Resistance (Insulated Flanges-Underground Piping) Test Record Aboveground Pipe Inspection RecordHoliday (Spark) Test Record Visual Inspection of Flanges, Gaskets and BoltingAboveground Pipe Inspection Record Weld Map RecordVisual Inspection of Flanges, Gaskets and Bolting Pressure Test ReportWeld Map Record Hygienic Drawing Revision LogPressure Test Report Hygienic Material Receiving LogHygienic Drawing Revision Log Hygienic Valve Receiving Inspection ReportHygienic Material Receiving Log Hygienic Vessel Nozzle Receiving Inspection ReportHygienic Valve Receiving Inspection Report Hygienic Tube/Fitting Receiving Inspection ReportHygienic Vessel Nozzle Receiving Inspection Report Hygienic Pre-weld Inspection ChecklistHygienic Tube/Fitting Receiving Inspection Report Hygienic Welder Qualification ReportHygienic Pre-weld Inspection Checklist Hygienic Orbital Weld LogHygienic Welder Qualification Report Hygienic Post Installation ChecklistHygienic Orbital Weld Log Pipe Cleaning and Verification ChecklistHygienic Post Installation Checklist Mechanical Heat Tracing Inspection RecordPipe Cleaning and Verification Checklist Conduit And Cable Tray ChecklistMechanical Heat Tracing Inspection Record Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 11 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F76002000 509 F76001 000 509 F76003000 509 F76002 000 509 F76004000 509 F76003 000 509 F76005000 509 F76004 000 509 F76006000 509 F76005 000 509 F76007000 509 F76006 000 509 F76008000 509 F76007 000 509 F76009000 509 F76008 000 509 F76010000 509 F76009 000 509 F76011000 509 F76010 000 509 F76012000 509 F76011 000 509 F76013000 509 F76012 000 509 F76014000 509 F76013 000 509 F76101000 509 F76014 000 509 F76102000 509 F76101 000 509 F76103000 509 F76102 000 509 F76104000 509 F76103 Title Electrical Manhole Inspection ChecklistConduit And Cable Tray Checklist Medium & High Voltage Underground Cable Splice Inspection RecordElectrical Manhole Inspection Checklist Medium and High Voltage Cable Termination ChecklistMedium & High Voltage Underground Cable Splice Inspection Record Cable Pulling Inspection ChecklistMedium and High Voltage Cable Termination Checklist Fan/Speed Reducer/Motor Inspection ChecklistCable Pulling Inspection Checklist Switch House Inspection ChecklistFan/Speed Reducer/Motor Inspection Checklist Lighting Receptacle, Instrument Distribution Panels Inspection ChecklistSwitch House Inspection Checklist Electrical Motor Inspection ChecklistLighting Receptacle, Instrument Distribution Panels Inspection Checklist Aboveground Conduit Inspection ChecklistElectrical Motor Inspection Checklist Lighting Panelboard Inspection RecordAboveground Conduit Inspection Checklist Underground Conduit (Duct Bank) InspectionLighting Panelboard Inspection Record Grounding/Earthing System (Grid or Loop) Inspection RecordUnderground Conduit (Duct Bank) Inspection Cable Termination ChecklistGrounding/Earthing System (Grid or Loop) Inspection Record Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test RecordCable Termination Checklist Insulation Resistance (Power, Control Wire And Cable) Test RecordGrounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record Insulation Resistance (Instrument Wire And Cable) Test RecordInsulation Resistance (Power, Control Wire And Cable) Test Record DC High Potential Test (Medium Voltage Cable) RecordInsulation Resistance (Instrument Wire And Cable) Test Record Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 12 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F76105000 509 F76104 000 509 F76106000 509 F76105 000 509 F76107000 509 F76106 000 509 F76108000 509 F76107 000 509 F76109000 509 F76108 000 509 F76109 000 509 F76110 000 509 F76111000 509 F76110 000 509 F76112000 509 F76111 000 509 F76113000 509 F76112 000 509 F76114000 509 F76113 000 509 F76115000 509 F76114 000 509 F76116000 509 F76115 000 509 F76117000 509 F76116 000 509 F76118000 509 F76117 000 509 F76119000 509 F76118 000 509 F76120000 509 F76119 000 509 F76121000 509 F76120 Title Current Transformer (And Ammeter) Test RecordDC High Potential Test (Medium Voltage Cable) Record LV Over-current And Earth/Ground-Fault Protection Relay TestCurrent Transformer (And Ammeter) Test Record Over-current/Ground Fault Protection Relay (Induction Type) TestLV Over-current And Earth/Ground-Fault Protection Relay Test Over-current/Ground Fault Protection Relay (Thermal Type) TestOver-current/Ground Fault Protection Relay (Induction Type) Test Switching Units HV Switchgear Inspection And Test RecordOver-current/Ground Fault Protection Relay (Thermal Type) Test Switching Units HV Switchgear Inspection And Test Record Ground Electrode Resistance Inspection Test Record Ground Fault Protection Relay Induction Inspection and Test RecordGround Electrode Resistance Inspection Test Record Grounding Continuity Inspection and Test RecordGround Fault Protection Relay Induction Inspection and Test Record Grounding Rod Inspection and Test RecordGrounding Continuity Inspection and Test Record Bus Bar Assemblies LV Switchgear Test RecordGrounding Rod Inspection and Test Record Neutral Grounding/Earthing Resistor Test RecordBus Bar Assemblies LV Switchgear Test Record Ground Continuity (Non Electrical) Equipment/Structures Test RecordNeutral Grounding/Earthing Resistor Test Record Ground Continuity (Electrical Equipment and Ground Test Bars) Test RecordGround Continuity (Non Electrical) Equipment/Structures Test Record Insulation Resistance (Equipment) Test RecordGround Continuity (Electrical Equipment and Ground Test Bars) Test Record Insulation Resistance (Transformer) Test RecordInsulation Resistance (Equipment) Test Record Liquid Dielectric Strength Test RecordInsulation Resistance (Transformer) Test Record DC Proof Test Record for MotorsLiquid Dielectric Strength Test Record Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM CEM Y Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 13 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F76122000 509 F76121 000 509 F76123000 509 F76122 000 509 F76124000 509 F76123 000 509 F76125000 509 F76124 000 509 F76126000 509 F76125 000 509 F76127000 509 F76126 000 509 F76128000 509 F76127 000 509 F76129000 509 F76128 000 509 F76130000 509 F76129 000 509 F76131000 509 F76130 000 509 F76132000 509 F76131 000 509 F76133000 509 F76132 000 509 F76134000 509 F76133 000 509 F76135000 509 F76134 000 509 F76201000 509 F76135 000 509 F76202000 509 F76201 000 509 F76203000 509 F76202 Title Feeder Breaker (480V MCC) Test RecordDC Proof Test Record for Motors Breaker/Contractor (480V MCC) Test RecordFeeder Breaker (480V MCC) Test Record 460V Motor Circuit (480V MCC) Test RecordBreaker/Contractor (480V MCC) Test Record Medium Voltage Motor Circuit Test Record460V Motor Circuit (480V MCC) Test Record Equipment Absorption Ration and Polarization Index Test Record (Megger)Medium Voltage Motor Circuit Test Record Insulation Resistance (Medium Voltage Power Cables) Test RecordEquipment Absorption Ration and Polarization Index Test Record (Megger) Bus Throat Insulation and Ductor ReportsInsulation Resistance (Medium Voltage Power Cables) Test Record Circuit Breaker Contract Timing Test ReportBus Throat Insulation and Ductor Reports Vacuum Circuit Breaker Ductor Insulation ReportCircuit Breaker Contract Timing Test Report Drawout Vacuum Breaker Inspection TestVacuum Circuit Breaker Ductor Insulation Report Main Bus Insulation and Ductor ReportDrawout Vacuum Breaker Inspection Test Electric Motor Run-In Test RecordMain Bus Insulation and Ductor Report Drawout Air Circuit Breaker Inspection RecordElectric Motor Run-In Test Record Insulation Resistance (Rotating Equipment) Test RecordDrawout Air Circuit Breaker Inspection Record Emergency Generators Inspection ChecklistInsulation Resistance (Rotating Equipment) Test Record Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units)Emergency Generators Inspection Checklist Inspection LV Switchgear (Including Incoming and Sectionalizer Units)Inspection of Switchgear BusBar Continuity (Including Incoming and Sectionalizer Units) Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 14 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F76204000 509 F76203 000 509 F76205000 509 F76204 000 509 F76206000 509 F76205 000 509 F76207000 509 F76206 000 509 F76208000 509 F76207 000 509 F76209000 509 F76208 000 509 F76210000 509 F76209 000 509 F76211000 509 F76210 000 509 F76212000 509 F76211 000 509 F76213000 509 F76212 000 509 F76214000 509 F76213 000 509 F76215000 509 F76214 000 509 F76216000 509 F76215 000 509 F76217000 509 F76216 000 509 F76218000 509 F76217 000 509 F76219000 509 F76218 000 509 F76220000 509 F76219 Title Inspection of Outgoing – LV SwitchgearInspection LV Switchgear (Including Incoming and Sectionalizer Units) Inspection of Static Supply Unit (UPS)Inspection of Outgoing – LV Switchgear Motor Control Centers Inspection ChecklistInspection of Static Supply Unit (UPS) Motor Control Centers (Motors and Starters) Inspection RecordMotor Control Centers Inspection Checklist High Voltage Motors and StartersMotor Control Centers (Motors and Starters) Inspection Record Motors ChecklistHigh Voltage Motors and Starters Control and Relay Panels Inspection ChecklistMotors Checklist Electronic Equipment Inspection ChecklistControl and Relay Panels Inspection Checklist Power Panel Inspection ChecklistElectronic Equipment Inspection Checklist Switchgear Inspection ChecklistPower Panel Inspection Checklist Low Voltage Feeders Inspection RecordSwitchgear Inspection Checklist High Voltage Cable Inspection and Test RecordLow Voltage Feeders Inspection Record Electrical Equipment Inspection RecordHigh Voltage Cable Inspection and Test Record Control Scheme Inspection ChecklistElectrical Equipment Inspection Record Power Transformer Inspection ChecklistControl Scheme Inspection Checklist Switching Units – HV Switchgear Inspection and Test RecordPower Transformer Inspection Checklist Switching Units – HV Switchgear Inspection ChecklistSwitching Units – HV Switchgear Inspection and Test Record Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 15 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F76221000 509 F76220 000 509 F76222000 509 F76221 000 509 F76223000 509 F76222 000 509 F76224000 509 F76223 000 509 F76225000 509 F76224 000 509 F76226000 509 F76225 000 509 F76227000 509 F76226 000 509 F76228000 509 F76227 000 509 F76229000 509 F76228 000 509 F76230000 509 F76229 000 509 F76231000 509 F76230 000 509 F76232000 509 F76231 000 509 F76233000 509 F76232 000 509 F76401000 509 F76233 000 509 F76402000 509 F76401 000 509 F77001000 509 F76402 000 509 F77002000 509 F77001 Title Liquid – Filled Transformer Inspection RecordSwitching Units – HV Switchgear Inspection Checklist Busway Inspection RecordLiquid – Filled Transformer Inspection Record Switchgear Inspection RecordBusway Inspection Record Motor Control Center Inspection RecordSwitchgear Inspection Record Battery and Battery Charger Inspection RecordMotor Control Center Inspection Record Liquid Immersed Medium Voltage Disconnect Switch Inspection RecordBattery and Battery Charger Inspection Record Electric Motor – Electrical Activities Inspection RecordLiquid Immersed Medium Voltage Disconnect Switch Inspection Record Electric Motor – Mechanical Activities Inspection RecordElectric Motor – Electrical Activities Inspection Record Electric Motor for Compressor Installation ChecklistElectric Motor – Mechanical Activities Inspection Record Compressor Vibration ChecklistElectric Motor for Compressor Installation Checklist Vibration Probe RecordCompressor Vibration Checklist Dry Type Lighting, Receptacle & Instrument Transformers ChecklistVibration Probe Record Instrument Wire and Cables Continuity Checks >50VDCDry Type Lighting, Receptacle & Instrument Transformers Checklist Heat Trace Test LogInstrument Wire and Cables Continuity Checks >50VDC Electrical Heat Trace Inspection RecordHeat Trace Test Log Instrumentation Inspection ChecklistElectrical Heat Trace Inspection Record Instrument Loop Checklist InspectionInstrumentation Inspection Checklist Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 16 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F77003000 509 F77002 000 509 F77004000 509 F77003 000 509 F77005000 509 F77004 000 509 F77006000 509 F77005 000 509 F77007000 509 F77006 000 509 F77008000 509 F77007 000 509 F77101000 509 F77008 000 509 F77102000 509 F77101 000 509 F77103000 509 F77102 000 509 F77104000 509 F77103 000 509 F77105000 509 F77104 000 509 F77106000 509 F77105 000 509 F77107000 509 F77106 000 509 F78001000 509 F77107 000 509 F78002000 509 F78001 000 509 F78101000 509 F78002 000 509 F78102000 509 F78101 Title Impulse Line Pressure Test SheetInstrument Loop Checklist Inspection Instrument Grounding System Check SheetImpulse Line Pressure Test Sheet Installation Check Sheet (Local Instruments)Instrument Grounding System Check Sheet Orifice Plate Specification Check ReportInstallation Check Sheet (Local Instruments) Control Systems Quality Control indexOrifice Plate Specification Check Report Loop Check RecordControl Systems Quality Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y Instrument Calibration SheetLoop Check Record Safety Valve Tracking SheetInstrument Calibration Sheet Relief Valve Inspection and Final AcceptanceSafety Valve Tracking Sheet Switch Calibration Data RecordRelief Valve Inspection and Final Acceptance Valve Calibration Data RecordSwitch Calibration Data Record Control System Test Equipment Calibration LogValve Calibration Data Record Loop Mechanical Completions and Acceptance RecordControl System Test Equipment Calibration Log Coating Inspection RecordLoop Mechanical Completions and Acceptance Record Lining Inspection RecordCoating Inspection Record Equipment Thermal Insulation InspectionLining Inspection Record Piping Thermal Insulation RecordEquipment Thermal Insulation Inspection CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 17 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # 000 509 F78201000 509 F78102 000 509 F78202000 509 F78201 000 509 F78301000 509 F78202 000 509 F79001000 509 F78301 000 509 F79002000 509 F79001 000 509 F79201000 509 F79002 000 509 F79202000 509 F79201 000 509 F79203000 509 F79202 000 509 F79204000 509 F79203 000 509 F79205000 509 F79204 000 509 F79206000 509 F79205 000 509 F79301000 509 F79206 000 509 F79302000 509 F79301 000 509 F79303000 509 F79302 000 509 F79304000 509 F79303 000 509 F79501000 509 F79304 000 509 F79502000 509 F79501 Title Release For Application/Inspection Of Fireproofing ChecklistPiping Thermal Insulation Record Fireproofing Inspection Preconstruction ChecklistRelease For Application/Inspection Of Fireproofing Checklist Cathodic Protection Inspection ReportFireproofing Inspection Preconstruction Checklist Daily Welding ReportCathodic Protection Inspection Report Post Weld Heat Treatment LogDaily Welding Report Welder B31.3 Random Radiography Control LogPost Weld Heat Treatment Log Nondestructive Examination Request/RecordWelder B31.3 Random Radiography Control Log Radiographic Rejectable Defects StatisticsNondestructive Examination Request/Record Welding/NDE Status LogRadiographic Rejectable Defects Statistics Ferrite Test ReportWelding/NDE Status Log Welding/NDE Double Joints Status LogFerrite Test Report PMI Inspection RecordWelding/NDE Double Joints Status Log Bulk Material Positive Material Identification RecordPMI Inspection Record Pipe Spool Positive Material Identification Record “Point” SheetBulk Material Positive Material Identification Record Weekly PMI LogPipe Spool Positive Material Identification Record “Point” Sheet Verification Of Training For Hardness TestingWeekly PMI Log Report Of Vision TestVerification Of Training For Hardness Testing Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y CEM Y SQM N SQM N SQM N W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 18 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 Record Identification Form # Title Custodian Job Title or Sub Name CEM System Turnover Package Y = Yes N = No Y Records Retention Center Y = Yes N = No Records Retention Center Retention (Years) File Locator Code 000 509 F79503000 509 Hardness Testing ReportReport Of Vision Test F79502 000 509 F79503 Hardness Testing Report GENERAL NOTES: Note #1 Note #2 Note #3 If NDE Reports contain data on more than one line, copies of the report shall be placed in each line file to which applies If radiographs are turned over to the Client, maintain the transmittal letter. A copy of the radiographic rejectable defects statistics are to be sent to the applicable Construction Technology Regional Welding Engineer as they are generated. Note #4 Reference the Project File Index for Fluor file numbers and retention periods.GENERAL NOTES: Note #1 Note #2 Note #3 If the NDE Reports contain data on more than one line, copies of the report shall be placed in each line file to which it applies. If radiographs are turned over to the Client, maintain the transmittal letter. A copy of the radiographic rejectable defects statistics are to be sent to the applicable Construction Technology Regional Welding Engineer as they are generated. Note #4 Reference the Project File Index for Fluor file numbers and retention periods. FILE LOCATOR CODES FILE LOCATOR CODES: R1 System No. R2 Form No. (by date of completion or alphabetical) R3R1 R5R3 R7R5 R7 ACRONYMS: ACRONYMS: CEM CACEM NDECCA NDEC Construction Engineering Manager Contracts AdministratorConstruction Engineering Manager NDE CoordinatorContracts Administrator NDE Coordinator SQM DESQ M RRCD E RRC Site Quality Control Manager Discipline EngineerSite Quality Control Manager Record Retention CenterDiscipline Engineer Record Retention Center Equipment No.System No. By FCR No.Equipment No. Line and SheetBy FCR No. Line and Sheet R4R2 R6R4 R6 Pour No.Form No. (by date of completion or alphabetical) Drawing No.Pour No. Drawing No. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 19 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0160 Revision 0, 10 June 2013 This page is intentionally blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0160 Rev 0 Quality Records.doc Page 20 of 20 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01601 Revision 0, 10 June 2013 QUALITY RECORDS CONTROL Record Identification Form # Title Custodian Job Title or Sub Name Turnover Y = Yes N = No ID A01601 Records Retention Center Retention Period File Locator Code GENERAL NOTES: Note #1 Note #2 Note #3 Note #4 Note #5 If the NDE Reports contain data on more than one line, copies of the report shall be placed in each line file to which it applies. If radiographs are turned over to the client, maintain the transmittal letter. Copies of these records are to be sent to the applicable Construction Technology Welding Engineer as they are generated. Reference the Project File Index for Fluor Daniel files numbers. Maintain by Equip. Tag. Number. FILE LOCATOR CODES: R1 R3 R5 R7 = = = = System No. Equipment No. By FDCR No. Line and Sheet R2 R4 R6 = Form No. (by date of completion or alphabetical) = Pour No. = Drawing No. ACRONYMS: CEM CA NDEC = Construction Engineering Manager = Contracts Administrator = NDE Coordinator CQM DE RRC = Site Quality Control Manager = Discipline Engineer = Records Retention Center W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01601 Rev 0 Quality Records Control.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01601 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01601 Rev 0 Quality Records Control.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0170 Revision 0, 10 June 2013 QUALITY AUDITS SCOPE This procedure describes the responsibilities and activities for performing quality audits of construction quality-related activities. Audits are performed to determine the effectiveness of the Fluor Site Quality Manual implementation as well as verifying compliance with established requirements. GENERAL Audits described by this procedure are directed at Fluor self-perform and subcontractor quality impacting activities that are not under the direct control of the Site Quality Manager. This procedure requires that audits be documented and tracked using the Quality Management System (QMS) tool. This is an established program used by Fluor across the company for management of quality audits. The program is Lotus Notes based. It can be found by going in to FDNet and typing http://www.fdglobal.com/fdglobal/workgrps/qa/qms.nsf in the URL bar at the top of the screen. Projects that do not have access to FDNet or projects that are experiencing connectivity issues with the Fluor network may be allowed to use the alternative forms noted in this procedure. The Site Quality Manager is responsible for performing these audits. He may self-perform or designate others to perform or assist him. The procedure section below is based on the audit being performed by an auditor designated by the Site Quality Manager. An audit is a planned and documented activity performed to determine, by evaluation of objective evidence, compliance with established requirements. These requirements can include the Site Quality Manual, drawings, specifications, codes, standards, plans and procedures PROCEDURE Site Quality Manager Ensure, if using QMS, that at least one person has been qualified as a lead auditor. This person will be responsible for all audits entered in to the QMS program. Qualification as a lead auditor will be in accordance with Section 2 of the QA Procedures Manual 000.042.1000 which is available in Knowledge On Line. Establish a schedule for conducting Quality Audits. Refer to Attachments I for schedule examples. It is preferred that the schedule in QMS be used, however other formats may be used. The schedule should show the audit dates for all subcontractors or internal activities to be assessed. Performance on previous audits should influence re-audit schedule. Request a copy of the QA Project Audit schedule to see when site audits are planned from the engineering office. - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0170 Rev 0 Quality Audits.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0170 Revision 0, 10 June 2013 - Ensure that personnel performing audits using QMS have obtained access rights and have taken the necessary training to be able to work in QMS. Access rights can be obtained from Barry Rittberg. His e-mail address is
[email protected]. His phone number is 949-349-2356. QMS and auditor training material are available and can be found in the Quality knowledge community in Knowledge On Line (KOL). The courses required to be taken for auditing are: QA020 – Training For Discipline Auditors (this is available in Fluor University) QA025 – How To Use Discipline Audit Checklists (this is available in Fluor University) Personnel who wish to become certified as lead auditors will be required to take the above training, perform three audits (as required by the QA Procedures Manual), and take a test. The test is to be coordinated with Barry Rittberg once the person has obtain certificates from Fluor University attesting that the above training courses have been successfully completed. The following training material is recommended if the above does not provide enough information to perform audits. - QA004 – Using QMS (this is considered required reading) QA021 – Internal Auditing Basics (this is a video to be watched) Develop an audit plan by reviewing the Quality Program (contractor's and/or Fluor’s) and identifying the items to be verified. This may be done by marking up an uncontrolled copy of the procedures, development of a checklist or other methods. This audit does not need to include activities that are subjected to surveillance (reference 000 509 0220). Previous audit results should be considered. It is recommended that personnel review the on-line training class QA-031 How To Create A Project Audit Plan if they are looking for guidance on how to develop an audit plan. This class is available in the quality community in Knowledge On Line. Review and concur with the plan, checklist, marked up procedures or other acceptable method of identifying items to be verified. Provide a copy of the audit log to the regional quality manager on a monthly basis if the project is not using QMS. - Auditor Ensure that the required QMS and auditor training, as detailed above, have been taken prior to starting an audit. Execute the audit in accordance with the established checklist. There is a detailed procedure 000.042.1000 in the quality knowledge community that describes the Fluor audit process. Personnel conducting construction audits are advised to review this document. Audit findings are to be created, issued and tracked in the QMS program. For projects that are not able to use QMS then a nonconformance or corrective action report (see procedures 000.509.0130 & 000.509.0140) is to be issued when an activity or action is found to - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0170 Rev 0 Quality Audits.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0170 Revision 0, 10 June 2013 not comply with a written requirement. Recommendations are to be treated as observations and will be noted in the narrative audit report. An audit summary report from QMS will summarize the audit results and can be used to manage the audit work process on the project. The audit report, and any associated findings, is to be issued to the Site Quality Manager (SQM) for processing (unless this task has been delegated by the SQM to another person) Projects that are not able to use QMS are to ensure that audits, nonconformances and corrective actions are logged. Sample log formats for nonconformances and corrective actions are referenced in procedures 000.509.0130 & 000.509.0140. Root Cause Analysis - Identify significant findings and conduct and document a root cause analysis of each. The root cause analysis method that may be used that includes the following steps: 1. Identify the problem 2. Determine the significance of the problem 3. Identify the causes (conditions or actions) immediately preceding and surrounding the problem. 4. Identify the reasons why the causes in the preceding step existed, working back to the root cause (the fundamental reason which, if corrected, will prevent recurrence of these and similar occurrences throughout the facility). The primary objective is to determine the direct, contributing and root causes so that effective corrective actions can be taken that will prevent recurrence. Site Quality Manager Review and, upon concurrence, sign the audit summary report (and any associated audit findings) and issue to the Site Manager. Review results of the audit with the Site Manager. A copy of the report is to be sent to the Construction Technology's Regional Quality Manager. Additional distribution should be as requested by the Site Manager. Maintain files of all audits. These files should include: - Audit Summary with attached Audit Finding Reports and checklist/marked up procedure. Copies of objective evidence obtained during the Audit. Copies of Audit Finding Reports closed upon completion of disposition and verification and acceptance by an auditor. - Keep track of outstanding audit findings and report this to the Site Manager on a regular basis. Frequency of reports is to be agreed between the Site Manager and the Site Quality Manager. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0170 Rev 0 Quality Audits.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0170 Revision 0, 10 June 2013 Site Quality Manager / Auditee Assign responsibility for disposition of deficiency and record in QMS. Findings raised in QMS are then e-mailed to the person responsible for correcting the finding. For projects that are not using QMS the person responsible for disposition is to be given a copy of the nonconformance report, along with follow-up reminders, via e-mail until the deficiency has been properly dispositioned. - Auditor Assist the Site Quality Manager with identifying any required root causes and following up on close out of findings. DOCUMENTATION QMS Audit summary with attached Audit Findings. Note, for projects not using QMS the audit report and summary are to be maintained by audit number in a file system Copy of closed audit findings Root Cause Analysis if required · - FORMS Quality Control Forms: 000 509 F01702 - Audit Summary (if not using QMS) ATTACHMENTS Attachment 1 - Audit Schedule (Fluor) – if not using schedule in QMS Attachment 2 -Audit Schedule (Subcontractor(s)) – if not using schedule in QMS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0170 Rev 0 Quality Audits.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0170 Revision 0, 10 June 2013 AUDIT SCHEDULE (Fluor Activities) Jan. Fluor Activities (1) (3) (2) Feb. Mar. April May June July Aug. Sept. Oct. Nov. Dec. INSTRUCTIONS FOR AUDIT SCHEDULE (SUBCONTRACTOR ) 1. Enter the name of all site subcontractors. 2. Draw a bar between the dates the subcontractor is expected to be on site. 3. Draw a box at the date an audit is anticipated and write the scheduled audit date in the box. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0170 Rev 0 Quality Audits.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0170 Revision 0, 10 June 2013 AUDIT SCHEDULE (Subcontractors) Subcontractors Jan. | Feb. | March | April | May | June | July | Aug. | Sept. | Oct. | Nov. | Dec. | (1) (3) (2) INSTRUCTIONS FOR AUDIT SCHEDULE (SUBCONTRACTOR) 1. Enter the name of all site subcontractors. 2. Draw a bar between the dates the subcontractor is expected to be on site. 3. Draw a box at the date an audit is anticipated and write the scheduled audit date in the box. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0170 Rev 0 Quality Audits.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01702 Revision 0, 10 June 2013 AUDIT SUMMARY Project: Client: Project Number: Audit Location: Audit Scope: Construction Audit Number: Audit Dates: Report Date: ID A01702 Summary of Audit Results: Entry Meeting Date: The entry & exit meeting were conducted with: A summary of the audit results is as follows: Exit Meeting Date: Quality Manual Principles assessed. Deficiencies reported. Quality Manual Principles found to be satisfactory. Observations for improvement. Previous Findings and Action Follow-up: Finding Number Status – (Open or Closed) Date Closed Lead Auditor Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01702 Rev 0 Audit Summary.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01702 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01702 Rev 0 Audit Summary.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0180 Revision 0, 10 June 2013 PERSONNEL TRAINING AND QUALIFICATION SCOPE This procedure identifies training in the field quality system requirements for personnel performing construction activities affecting quality. It covers the methods used for the analysis of supplemental training needs. The procedure also makes provisions for subsequent qualifications and certification (when required). GENERAL Training and orientation are important due to the need for clear definition, communication and understanding of work requirements that are essential to all construction work processes. This training is in addition to the routine orientation of quality requirements provided through daily contact and periodic meetings such as construction planning/review meetings. PROCEDURE Project Training Plans: • Site Quality Manager Coordinate training targeted at site management personnel for orientation to this site quality program. This target group should include the Site Manager, the Construction Manager, the Construction Engineering Manager, Site Discipline Engineers, Area Managers, Superintendents and others as determined by the Site Manager. The Site Manager may elect to invite Client representatives, especially those having a direct interface with the site quality program. Training for the site management group should provide an overview of Inspection and Testing Procedures for all disciplines and in depth training in all other sections of this Site Quality Manual. Coordinate training by discipline, targeted at craft personnel for orientation to this site quality program. Notes: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0180 Rev 0 Personnel Training and Qualification.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0180 Revision 0, 10 June 2013 Notes: The target group should include the craftsmen, Foremen, General Foremen, and Superintendents. Training for the group should provide in depth training in the Inspection and Testing procedures. It should provide an overview of the other sections of this Site Quality Manual. Determine the training needed for site personnel requiring certifications. Note: Construction Technology provides training and certification of NDE personnel and inspection personnel needing certification to ASME B31.1 and ASME B31.3. • Site Quality Manager/Technical Supervisor Coordinate training, when needed, for special processes identified in Procedure 000.509.0090. Note: The target group should include the individuals responsible for performing the special processes and their foremen. • Site Quality Manager/Construction Engineering Manager Coordinate training when training needs are identified by procedure 000.509.0140 "Corrective Action”, and 000.509.0150 “Preventive Action". PROJECT TRAINING SCHEDULES: • Site Quality Manager Coordinate site training schedule Ensure Site Manager’s approval of training schedule. Reschedule training session, as needed, as additional personnel are assigned to the project. Provide for instructor, facilities and equipment support. - Note: Instructors will usually be the Site Quality Manager, the Construction Engineering Manager and/or discipline engineers. Training needed for certification will usually be provided by Construction Technology. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0180 Rev 0 Personnel Training and Qualification.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0180 Revision 0, 10 June 2013 • Instructor Document the personnel receiving training on Form 000 509 F01801, or other suitable method. FORM Quality Control Form: 000.509.F01801 - Project Specific Quality Training W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0180 Rev 0 Personnel Training and Qualification.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0180 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0180 Rev 0 Personnel Training and Qualification.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01801 Revision 0, 10 June 2013 PROJECT SPECIFIC QUALITY TRAINING Training Subject: Instructor(s): Duration: Date: Attendees Member Number ID A01801 Job Title Note: Attach Training Outline Instructor Signature: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01801 Rev 0 Project Quality Training.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01801 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01801 Rev 0 Project Quality Training.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0200 Revision 0, 10 June 2013 SITE SUBCONTRACTOR QUALIFICATION SCOPE This procedure describes the initial qualification of site subcontractors. This procedure does not apply to subcontractors that have been previously approved by Fluor or the Owner. GENERAL When qualifications of site subcontractors include an evaluation of the Quality capabilities of the subcontractor, the evaluation shall be done in accordance with this procedure. PROCEDURE • • Qualification of Subcontractors Contracts Administrator Upon selection of a proposed subcontractor, the Contracts Administrator shall notify the Site Quality Manager and request a subcontractor qualification be performed. When construction has designated someone to technically supervise the proposed subcontractor, he shall also be notified. NOTE: The Contracts Administrator shall contact the subcontractor relative to the obtaining of documents, arranging of communication or establishment of meetings and/or visits. • Site Quality Manager/Technical Supervisor Upon notification (including receipt of subcontractor quality programs), review the qualifications of the proposed subcontractor based upon the quality requirements to be included in the Fluor subcontract. This review may include meetings and/or visits with the subcontractor candidate. The Site Quality Manager may use the "Site Subcontractor Qualification" guidelines (Form 000.509.F02001); however, this guide does not necessarily represent the quality requirements to the subcontractor and therefore should be used only as an aid to the evaluation. The Technical Supervisor should use the applicable "Evaluation Record" (Forms 000.509.F02002 and 000.509.F02006). Upon completion of the subcontractor qualification review, notify the Contracts Administrator of the results of the review and perform the actions stated below (as appropriate): If the subcontractor is not qualified, write a memo to the Contracts Administrator fully explaining the exact deficiencies that are required to be corrected along with the specific recommendations. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0200 Rev 0 Site Subcontractor Qualification.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0200 Revision 0, 10 June 2013 If the subcontractor is qualified, complete the "Site Subcontractor Qualification" form and evaluation record and forward to the Contracts Administrator. If the subcontractor is "conditionally" qualified, complete and forward the "Site Subcontractor Qualification" form as above, however include the specific limitations and/or actions that will be required. • Site Quality Manager/Technical Supervisor Process contractor qualification documents in accordance with the Document Control Section in the SPM and procedure 000.509.0160 (Quality Records). FORMS Quality Control Forms: 000.509.F02001 000.509.F02002 000.509.F02003 000.509.F02004 000.509.F02005 000.509.F02006 Site Subcontractor Qualification Soil Testing Laboratory Evaluation Record Asphalt Testing Laboratory Evaluation Record Concrete Batch Plant Evaluation Record Concrete Testing Laboratory Evaluation Record NDE Subcontractor Evaluation Record W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0200 Rev 0 Site Subcontractor Qualification.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 SITE SUBCONTRACTOR QUALIFICATION Project Name Subcontractor Address City, State, Zip PO Number Project Number RFP Number ID A02001 Scope of subcontracted work Subcontractor Quality Representative (1st in charge) Subcontractor Quality Representative (2nd in charge) Quality Management Reports To Title Phone Email Title Phone Email Title Qualification Approval Approved Required additional actions “Conditionally” Approved Not Approved Explain “Conditional Approval” here. Consider especially the additional cost if the subcontractor will need assistance in operation of the quality program. Site Quality Manager Date Site Contracts Administrator Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 1 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 1.0 Organization 1.1 1.2 1.3 1.4 1.5 Does the subcontractor have a quality control organization: Is an organization chart available: Does inspection have sufficient authority within the overall organization? Is inspection adequately organized and staffed to exercise its responsibilities: Are inspection reporting channels adequate: Does the subcontractor have a quality manual? Is the quality manual approved and signed by management? Does the subcontractor’s management periodically review their Quality program for effectiveness? Are the written procedures or instructions other than the Quality Manual? Does the subcontractor have an established and adequate training program for their personnel? Is the program compliant with international quality standards? Does the subcontractor have a design plan or procedure that: 1. 2. 3. 3.2 Provides for consideration of the design criteria and requirements? Lists all design document required, e.g., drawings and specifications? Identifies design responsibilities? 2.0 Quality Program 2.1 2.2 2.3 2.4 2.5 2.6 3.0 Design Control 3.1 4. Provides for the inclusion of acceptance criteria? Does the subcontractor have a procedure for the review and control of design documents that: 1. 2. 3. Designates responsibility for design review? Provides a method of design change control? Provides for the review of design changes and field changes by responsible personnel? 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 Is design reviewed for suitability of material and processes? Are the current revisions of the design documents known and available to engineering? Is the results of the design verification resolved according to a controlled and operative plan? Do design changes and corresponding document changes receive an adequate design verification. Is there a mechanism to incorporate field operations and requirement changes into the design documents? Is the design document release to purchasing and/or construction/manufacturing, controlled and adequate? Are required subcontractor documents clearly identified? Is the review of required subcontractor documents formalized as a procedure? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 2 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 4.0 Procurement Document Control 4.1 Does the subcontractor have an adequate procedure in use for Procurement Document Control? 4.2 Is each procurement document reviewed for the following: 1. 2. 3. 4. 5. 6. 7. 8. Subcontractor’s Quality requirements to their vendors? Customer’s Quality requirements to contractor’s vendors? A check for latest revision of drawings, specification, codes, etc.? Special packaging and preservation requirements? Special tests or certifications? Provisions for audits by subcontractor and/or customer? A check for the inclusion of design criteria of basis? Source Inspection requirements? 5.0 Instructions, Procedures and Drawings 5.1 5.2 5.3 Does subcontractor have a documented system of instructions, procedures and drawings? Do instructions, procedures and drawings identify all documents necessary to perform the work, i.e., codes, standards, etc.? What is the approval plan for deviations? Describe 5.4 5.5 6.0 6.1 6.2 Do instructions and procedures provide hold points where the documentation of conformance is provided? Do instructions, procedures and drawings exist at work locations? Does subcontractor have a procedure for approval and issue? Does document control include: 1. 2. 3. 4. Drawings? Specifications? Instructions? Procedures? Document Control 6.3 6.4 6.5 7.0 7.1 7.2 7.3 Is distribution of documents controlled by procedures? Are revisions to documents controlled by procedures? Are mark-up documents used? Does subcontractor evaluate sub-tier suppliers? 1. Are there adequate procedures in use to define sub-tier supplier requirements? Is a survey performed before qualifying a new supplier? Does the system provide for audits of supplier’s inspection program? Control or Purchased Material, Equipment and Services W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 3 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 7.4 7.5 7.6 8.0 Is there an approved supplier’s list? Does subcontractor require his sub-tier suppliers to furnish material certification and/or inspection reports? Does subcontractor perform receiving inspection activity? Identification and Control of Materials, Parts and Components 8.1 Does the subcontractor have procedures for identification of materials, parts and components? 8.2 8.3 8.4 8.5 Does the program provide controls to prevent mix of materials? Are materials in process traceable to manufacturer’s heat treatment number, lot number or other material where required? Does the program provide for specific traceability to piece, part or component? Is the inspection status of material, part of component easily identified? 9.0 Control or Special Processes 9.1 Does subcontractor have an adequate procedure in use to control qualification of special processes? 9.2 Are procedures available and adequate for the qualification of special process personnel? 9.3 Do procedures identify methods by which measurements will be made, e.g., current, temperature, etc.? 9.4 9.5 Do procedures provide for documentation of parameters? Are the procedures available at work locations for special processes? Does subcontractor have general procedures written for: 1. 2. 3. 10.2 1. 2. 3. 4. 5. 10.3 10.4 10.5 10.6 10.7 Receiving Inspection? In-Process Inspection? Final Inspection? Measuring equipment required? Parameters to be inspected? Criteria for determining quality conformance or rejection? Specification of the environment for the inspections (E.g., temperature controlled, etc.)? Identification of inspection holds points? 10.0 Inspection 10.1 Do written inspection instructions provide inspection personnel with: Are purchase orders, drawings, specifications, etc. available to inspection personnel? Is inspection documented by work order, shop traveler, history record, etc.? Is nonconforming material properly identified and segregated to prevent unauthorized use? Are provisions adequate to permit the customer to designate hold points for inspections? Do source and receiving inspection procedures provide for the proper handling, storage and preservation of materials and equipment? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 4 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 10.8 10.9 10.10 11.0 Is adequate inspection and test equipment available? Are inspection procedures and/or instructions reviewed and approved by higher authority than initiator prior to release? Are personnel performing inspections different than those that performed the activity being inspected? Does subcontractor have written test procedures in existence and used? Are accept-reject criteria specified in the test procedure? Does procedure provide a list of test instruments to be used? Are test results documented and maintained? Does inspection perform testing? Are there provisions in procedures to permit customer to witness test? Does the subcontractor have a program for calibration of inspection and test instruments? Does subcontractor have a calibration laboratory or approved source for calibration of inspection and test instruments? Are all inspection and test instruments uniquely identified? Are calibration dates and re-calibration due dates marked on tools and instruments? Are tool and instrument record cards maintained? Are calibration standards traceable to the N.I.S.T.? Does the program assure removal from service of equipment that has exceeded calibration period? Are inspection equipment and calibration standards properly handled and protected? Does subcontractor have written procedures that describe proper handling of material? Are their written procedures that describe proper storage of materials? 1. Do the procedures specify preservation and environmental conditions to be maintained during storage? 2. 3. 4. 5. 6. Are materials stored in such a manner as to prevent damage? Are storage facilities adequate for the type of materials stored? Is material, having service life, properly dated, stored and rotated in stock for control of shelf life? Are obsolete items purged from the stock area periodically? Are corrosive, toxic or flammable materials properly stored and segregated? Test Control 11.1 11.2 11.3 11.4 11.5 11.6 12.0 Control of Measuring and Test Equipment 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 Handling Storage and Shipping 13.1 13.2 13.3 14.0 14.1 14.2 14.3 14.4 14.5 Is their adequate procedure in use, which controls shipping activity? Does subcontractor have controls that permit determination of inspection and test status? Are shop travelers or tags used to show status of inspection or tests? Do shop travelers or tags have sign offs at each inspection station? Are inspection stamps used? Does inspection and test status information become part of final quality documentation? Inspection and Test Status W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 5 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 15.0 Nonconforming Materials, Parts or Components 15.1 Does subcontractor have written procedure(s) available for the identification and control of nonconforming items? 15.2 15.3 15.4 Does procedure(s) specify the identification to be used on item? Are nonconforming items segregated and adequately controlled to prevent their use? Is there a procedure for advising customer of all nonconformances that are applicable to the customer’s orders? 16.0 Corrective Action 16.1 Does subcontractor have an adequate procedure in use for control of the corrective action program? 16.2 16.3 16.4 16.5 16.6 16.7 Are causes of deficiencies identified? Is there approved documentation for the disposition of the item, scrap, repair acceptance, etc.? Is there a follow-up system to assure expedient response to corrective action requests? Are corrective action summaries reported to management? Are records of nonconformity and approved disposition traceable to the item? Are provisions made for the prompt action on customer’s comments resulting from inspections and audits? 17.0 Quality Records 17.1 Does subcontractor have a procedure/system identifying what records are to be maintained? 17.2 Are records maintained covering: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 17.3 17.4 Supplier Surveys? Inspection (Receiving, In-Process, Final)? Material (plus certification)? Audits? Inspection Reports? Inspection Instructions? Test Records? Test Logs? Failure Reports? Special Process Certification? Procedure Qualifications? Personnel Qualification (NDE, etc.)? Personnel Qualification – Welding? 14. Other Does the system provide for review of final data packages prior to shipment of equipment? Are record locations defined? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 6 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 17.5 17.6 17.7 17.8 18.0 Audits 18.1 18.2 18.3 18.4 18.5 18.6 Are retention periods defined? Is disposition of records defined? Does the system provide for storage of radiograph film to prevent deterioration and loss? Is customer release obtained before Quality records are destroyed? Does subcontractor have an adequate procedure/system defining the audit program? Is there a planned schedule? Is there a checklist provided for each audit? Is there a detailed report required for each audit? Is follow-up action prescribed (i.e., re-audit or deficient areas)? Are there internal quality system audits of: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Receiving Inspection? In-Process Inspections? Final Inspections? Quality Control Records? Nonconforming Material Control? Corrective Action Systems? Calibration of Inspection Tools and Instruments? Materials Control? Drawing and Procedure Control? Design Control? Special Processes? Packaging and Shipping Inspections? Other 18.7 Does management review audit reports? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 7 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02001 Rev 0 Site Subcontractor Qualification.doc Page 8 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02002 Revision 0, 10 June 2013 SOIL TESTING LABORATORY EVALUATION RECORD ID A02002 INDEX 1.0 INSTRUCTIONS 2.0 EQUIPMENT FOR SOILS INSPECTION AND TESTING 2.1 LABORATORY TESTING EQUIPMENT 2.2 FIELD TESTING EQUIPMENT 3.0 MANAGEMENT SUPERVISION 4.0 CONCLUSION AND REMARKS 5.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02002 Rev 0 Soil Testing Laboratory Evaluation Record.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02002 Revision 0, 10 June 2013 1.0 INSTRUCTIONS 1.1 This evaluation can only be made by the assigned Construction Engineer or others qualified to review soil testing laboratories. 1.2 The space to the right of each statement in this document should be completed with one, two, or three word answers, such as: Yes, No, Satisfactory, Unsatisfactory or, Does Not Apply, etc. 1.3 If any part of the testing laboratory has not been inspected, indicate to the right of the appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual statement. 1.5 The conclusions drawn by the Inspector should be based only upon observations and documentation noted in the body of the report. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02002 Revision 0, 10 June 2013 2.0 EQUIPMENT FOR SOILS INSPECTION AND TESTING 2.1 Laboratory Testing Equipment 2.1.1 Is equipment available to satisfy ASTM D 1140-54 "Amount of Material In Soils Finer Than The No. 200 Sieve?" 2.1.2 Is equipment available to satisfy ASTM D 1883-73 "Bearing Ratio of Laboratory-Compacted Soils?" 2.1.3 Is equipment available to satisfy ASTM D 423-66 "Liquid Limit of Soils?" 2.1.4 Is equipment available to satisfy ASTM D 3017-78 "Moisture Content of Soils, and Soil Aggregate in Place By Nuclear Methods (Shallow Depth)?" 2.1.5 Is equipment available to satisfy ASTM D 2216-80 "Moisture Content of Soil, Laboratory?" 2.1.6 Is equipment available to satisfy ASTM D 698-78 "Moisture-Density Relations of Soils, Using 5.5 LB. (2.5kg) Rammer, and 12-inch (304.8 mm) Drop?" 2.1.7 Is equipment available to satisfy ASTM D 1557-78 "MoistureDensity Relations of Soils Using 10-LB (4.5kg) Rammer, and 18inch (457.8 mm) Drop?" 2.1.8 Is equipment available to satisfy ASTM D 424-59 "Plastic Limit and Plasticity Index of Soils?" 2.1.9 Is equipment available to satisfy ASTM D 2049-69 "Relative Density of Cohesion-less Soils?" 2.1.10 Is equipment available to satisfy ASTM D 2166-66 "Unconfined Compressive Strength of Cohesive Soils?" 2.1.11 Is there and additional equipment required for this contract? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02002 Rev 0 Soil Testing Laboratory Evaluation Record.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02002 Revision 0, 10 June 2013 2.0 EQUIPMENT FOR SOILS INSPECTION AND TESTING (Cont’d) 2.2 Field Testing Equipment 2.2.1 Is equipment available to satisfy ASTM D 2922-78 "Density of Soil and Soil Aggregates in Place of Nuclear Methods (Shallow Depth)?" 2.2.2 Is equipment available to satisfy ASTM D 2937-71 "Density of soil in Place By The Drive-Cylinder Method?" 2.2.3 Is equipment available to satisfy ASTM D 2167-66 "Density of Soil in Place By The Rubber Balloon Method?" 2.2.4 Is equipment available to satisfy ASTM D 1556-64 "Density of Soil in Place By The Sand-Cone Method?" 2.2.5 Is equipment available to satisfy ASTM D 1194-72 "Bearing Capacity of soils for Static Load on Spread Footings?" 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02002 Revision 0, 10 June 2013 3.0 MANAGEMENT SUPERVISION 3.1 Is the Agency under the direction of a person charged with engineering managerial responsibility? 3.2 Does that peson have a Masters Degree in Soils from an accredited College or University, and is he/she a full time employee of the Agency? 3.3 Does he/she have at least five years of engineering experience in inspection and testing of soils? 3.4 Does the Supervising Laboratory Technician have at least five years experience performing tests on soils? 3.5 Does he/she demonstrate an ability to perform the tests normally required in the manner stipulated under ASTM or other governing procedures? 3.6 Does the Supervising Field Technician have at least five years experience in the kind of work involved on construction projects? 3.7 Does that person demonstrate either by oral or written examination, or both, the ability to perform correctly the duties required? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02002 Rev 0 Soil Testing Laboratory Evaluation Record.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02002 Revision 0, 10 June 2013 4.0 CONCLUSIONS AND REMARKS The Agency does have adequate facilities and qualified personnel to perform the work required by Fluor in accordance with contract specifications: 5.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02002 Rev 0 Soil Testing Laboratory Evaluation Record.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02003 Revision 0, 10 June 2013 ASPHALT TESTING LABORATORY EVALUATION RECORD ID A02003 INDEX 1.0 INSTRUCTIONS 2.0 EQUIPMENT FOR ASPHALT INSPECTION AND TESTING 3.0 MANAGEMENT SUPERVISION 4.0 CONCLUSION AND REMARKS 5.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02003 Rev 0 Asphalt Testing Laboratory Evaluation Record.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02003 Revision 0, 10 June 2013 1.0 INSTRUCTIONS 1.1 This evaluation can only be made by the assigned Construction Engineer or others qualified to inspect Asphalt Testing Laboratories. 1.2 The space to the right of each statement in this document should be completed with one, two, or three word answers, such as: Yes, No, Satisfactory, Unsatisfactory or, Does Not Apply, etc. 1.3 If any part of the testing laboratory has not been inspected, indicate to the right of the appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual statement. 1.5 The conclusions drawn by the Inspector should be based only upon observations and documentation noted in the body of the report. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02003 Rev 0 Asphalt Testing Laboratory Evaluation Record.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02003 Revision 0, 10 June 2013 2.0 EQUIPMENT FOR ASPHALT INSPECTION AND TESTING 2.1 Is equipment available to satisfy ASTM D-5 test for penetration of bituminous materials? 2.2 Is equipment available to satisfy ASTM D-92 test for flash and fire points by Cleveland open cup? 2.3 Is equipment available to satisfy ASTM D-113 test for ductility of bituminous materials? 2.4 Is equipment available to satisfy ASTM D-1754 test for effect of heat and air on asphalt materials (thin film oven test)? 2.5 Is equipment available to satisfy ASTM D 2042 test for solubility of asphalt materials in trichlorethylene? 2.6 Is equipment available to satisfy ASTM C-127 test for specific gravity and absorption of coarse aggregate? 2.7 Is equipment available to satisfy ASTM C-128 test for specific gravity and absorption of fine aggregate? 2.8 Is equipment available to satisfy ASTM C-136 test for sieve or screen analysis of fine and coarse aggregates? 2.9 Is equipment available to satisfy ASTM D 2172 test for quantitative extraction of bitumen form bituminous paving mixtures? 2.10 Is equipment available to satisfy ASTM D 1559 test for resistance to plastic flow of bituminous mixture using Marshall apparatus? 2.11 Is there any additional equipment required for this contract? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02003 Rev 0 Asphalt Testing Laboratory Evaluation Record.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02003 Revision 0, 10 June 2013 3.0 MANAGEMENT SUPERVISION 3.1 Is the Agency under the direction of a person charged with engineering managerial responsibility? 3.2 Does that person a Bachelors Degree of Science or Engineering from an accredited College or University, and is he/she a full time employee of the Agency? 3.3 Does he/she have at least five years of engineering experience in inspection and testing of asphalt? 3.4 Does the Supervising Laboratory Technician have at least five years experience performing tests on asphalt? 3.5 Does he/she demonstrate an ability to perform the tests normally required in the manner stipulated under ASTM or other governing procedures? 3.6 Does the Supervising Field Technician have at least five years experience in the kind of work involved on construction projects? 3.7 Does he/she demonstrate either by oral or written examination, or both, the ability to perform correctly the duties required? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02003 Rev 0 Asphalt Testing Laboratory Evaluation Record.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02003 Revision 0, 10 June 2013 4.0 CONCLUSIONS AND REMARKS The Agency does have adequate facilities and qualified personnel to perform the work required by Fluor in accordance with contract specifications: 5.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02003 Rev 0 Asphalt Testing Laboratory Evaluation Record.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02003 Rev 0 Asphalt Testing Laboratory Evaluation Record.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 INDEX 1.0 INSTRUCTIONS 2.0 MATERIALS AND STORAGE HANDLING 3.0 BATCHING EQUIPMENT 4.0 CENTRAL MIXER 5.0 TICKETING SYSTEM 6.0 DELIVERY FLEET 7.0 QUALITY CONTROL 8.0 CONCLUSIONS AND REMARKS 9.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 1 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 1.0 INSTRUCTIONS 1.1 This evaluation can only be made by the assigned Construction Engineer or others qualified to inspect Batch Plants. 1.2 The space to the right of each statement in this document should be completed with one, two, or three word answers, such as: Yes, No, Satisfactory, Unsatisfactory or, Does Not Apply, etc. 1.3 If any part of the testing laboratory has not been inspected, indicate to the right of the appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual statement. 1.5 If additional test equipment is required for a specific contract, other than that listed in this form, add to the list. 1.6 The conclusions drawn by the Inspector should be based only upon observations and documentation noted in the body of the report. NOTE: Is this plant certified to ASTM specification C94-80 (or equivalent international standard)? Is the plant National Ready Mix Certified? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 2 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD 2.0 MATERIALS AND STORAGE HANDLING 2.1 Cement 2.1.1 Suitability of silos: water tight and constructed to allow free movement to discharge openings. ID A02004 2.1.2 Are facilities adequate to provide for separation of different cement and cementious materials required for the project. 2.2 Aggregates 2.2.1 Is the unloading of transports and the building of stockpiles adequate to prevent segregation. 2.2.2 Will stockpile areas prevent contamination and allow for free draining? 2.3 Water 2.3.1 Is an adequate clean supply of water available? 2.3.2 Are cold weather and hot weather facilities adequate? 2.4 Admixtures 2.4.1 Are storage and handling systems for admixtures sufficient to prevent freezing? 2.4.2 Are the automatic measurement devices in working order? 2.4.3 Are measuring devices in plain view of the operator? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 3 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD 3.0 BATCHING EQUIPMENT 3.1 Scales 3.1.1 Is there a sticker on face of scales indicating date of the latest calibration? ID A02004 3.1.2 Are test weights available for checking scale accuracy? 3.2 Weight Batchers 3.2.1 Are the batchers for weighing materials freely suspended from a scale, and equipped with necessary charging and discharging mechanisms? 3.2.2 Is the cement weighed on scales or in weigh hoppers not used for weighing other concrete materials? 3.2.3 Are batchers large enough to receive the rated load with our making contact with the charging mechanism? 3.2.4 Are provisions made for removal of overload from batchers? 3.2.5 Are cement batchers provided with dust seals between charging mechanism hopper? 3.2.6 Is the weigh hopper vented to permit escape of air? 3.2.7 Is the hopper self-cleaning and fitted with means to assure complete discharge? 3.2.8 Are vibrators or other appurtenances installed in such a way as not to affect accuracy of weighing? 3.2.9 Is wind protection sufficient to prevent interference with weighing accuracy? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 4 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 3.0 BATCHING EQUIPMENT (Cont’d) 3.3 Water Meters 3.3.1 Are the meters equipped with a cut off device capable of stopping the flow within specified tolerance? 3.3.2 Does the operator have a visual indication of the volume of water used, at any time during the batching operation? 3.4 Dispensers for Liquid Admixture 3.4.1 Is there a separate dispenser for each liquid admixture in regular use? 3.4.2 Is the piping free of leaks and properly valved to prevent backflow or siphoning to insure that the measured amount is discharged? 3.4.3 Is each volumetric dispenser provided with an accurately calibrated container in which the admixture may be collected when it is desired to check the accuracy of measurement? 3.4.4 Do the volumetric admixture dispensers provide visual indication, or interlock cut off, when liquid admixture supply is not available to the dispenser? (This is to prevent the dispensing of air instead of admixture.) 3.5 Accuracy of Plant Batching 3.5.1 Have the cement and aggregate scale been calibrated, and is the calibration documentation on file? 3.5.2 Have the water meters been calibrated, and is the calibration documentation on file? 3.5.3 Have the admixture dispensers been calibrated, and is the calibration documentation on file? 3.5.4 Does the producer have compensation control for the free moisture on aggregate? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 5 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 3.0 BATCHING EQUIPMENT (Cont’d) 3.6 Batching Systems 3.6.1 Weight Batcher Controls 3.6.1.1 Manual Control: Are the batching devices actuated by hand, hydraulic, pneumatic, or electrical power assists? (circle one) 3.6.1.2 Semiautomatic Control:: Doe the semiautomatic weigh batcher control start the weighing operation of the material, and stop the flow automatically when the designated weight has been reached? 3.6.1.3 Does the semiautomatic interlocked weigh batcher control start the weighing operation of the material, and stop the flow automatically when the designated mass has been reached? 3.6.1.4 Is the system interlocked to assure that the discharge mechanism cannot be opened until the mass is within the allowable tolerance? 3.6.1.5 Automatic Control: Does the automatic weigh batcher control start the weighing operation of cement, aggregate, water or admixture, then stop the flow automatically when the designated mass has been reached? 3.6.1.6 Is the system interlocked to assure that: (a) The charging gate or valve cannot be opened until the scale has returned to zero balance; (b) The charging gate or valve cannot be opened if the discharge mechanism is open; (c) The discharge mechanism cannot be actuated until the mass of materials is within the allowable tolerance. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 6 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 3.0 BATCHING EQUIPMENT (Cont’d) 3.6 Batching Systems (Cont’d) 3.6.2 Volumetric Batching Device Controls 3.6.2.1 Manual Control: Manual volumetric control for or admixture exists when the volumetric measuring device is actuated manually with the accuracy of the measuring operation being dependent on the operator's visual observation of a volumetric indicator (such as, a digital meter display or a sight gage and his manual cut off of the flow at the desired volume.) Is the flow of water or admixture controlled by hand, pneumatic, hydraulic, or electrical power assists? (circle one) 3.6.2.2 Automatic Control: When actuated by a single starting signal, does an automatic volumetric control start the measuring operation and stop the flow automatically when the designated volume has been reached? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 7 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD 3.7 Recorders 3.7.1 Are permanent records of the quantity of cement, aggregate and water measured into a particular batch of concrete provided? 3.7.2 Are the recorders properly protected and capable of being locked? 3.7.3 Are provisions made for identifying the particular batch with the corresponding delivery ticket? 3.7.4 Do the recorders register empty balance? 3.7.5 Are the batched quantities of ingredients recorded? ID A02004 3.7.6 Do the recorders register the scale readings within the limits specified by ASTM-C 94-80? 3.7.7 Are the recorders used for all ingredients? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 8 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 4.0 CENTRAL MIXER 4.1 Is the plant capable of producing uniform concrete in the mixing time designated in ASTM specification C-94-80 for ready mixed concrete? 4.2 Is the plant equipped with timing devices that will not permit batches to be discharged before the predetermined mixing time has elapsed? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 9 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 5.0 TICKETING SYSTEM 5.1 Does the delivery ticket provide the following information? (Attach a sample of the ticket to this report.) 5.1.1 Name of Ready Mixed Concrete Company. 5.1.2 Ready mixed plant designation if more than one plant is used. 5.1.3 Serial number of ticket. 5.1.4 Truck number of designation. 5.1.5 Name of purchaser. 5.1.6 Name and Location of job. 5.1.7 Specific class or designation of concrete in conformance with job specifications. 5.1.8 Volume of concrete. 5.1.9 Date. 5.1.10 Time when batch was loaded. 5.1.11 Extra water added at the request of the receiver of the concrete, and his signature or initials. 5.1.12 Type and name of admixture and amount batched. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 10 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD 6.0 DELIVERY FLEET 6.1 Truck Mixers 6.1.1 Is the interior condition satisfactory with no appreciable accumulation of hardened concrete, or blades with excessive wear? ID A02004 (Blade wear shall be checked at the point of maximum drum diameter nearest to the drum head. When the height of the blade at this point, measured from the drum shell, is less than 90 percent of the original radial height, the blade is considered excessively worn. The manufacturer of the mixer will furnish original blade dimensions on request.) 6.1.2 Are the charging, discharge openings and chute is good condition; free from appreciable accumulations of cement or concrete; with surface clean and smooth? 6.1.3 Is the drum or container of such size, that the rating as a mixer (in volume of mixed concrete) does not exceed 63 percent of the gross volume of the mixer, disregarding blades? (This requirement is met by all mixers carrying a rating plate of the Truck Mixer Manufacturers Bureau.) 6.1.4 Is the mixer provided with a plate showing the manufacturers recommended operating speed for mixing? (The range must not be less than four or more than 18 r/min. to operate satisfactorily at recommended speed.) 6.1.5 Is the mixer provided with a counter to indicate the number of revolutions of the drum or blades? 6.1.6 On units equipped to batch the mixing water, is the equipment in proper working condition with gage glasses or water meters clean and legibly graduated; water pump or injection system in good working order with nozzles unobstructed, and without leakage into mixer? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 11 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 6.0 DELIVERY FLEET (Cont’d) 6.2 Summary of Fleet Conditions Total number of units available for use: Number of units checked and found acceptable: Number of units checked and found unacceptable: TRUCK NO. OR DESIGNATION OF INDIVIDUAL UNIT EXAMINED: ACCEPTABLE TRUCK MIXERS UNITS UNACCEPTABLE GIVE REASON AGITATOR UNITS NON-AGITATING UNITS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 12 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 7.0 QUALITY CONTROL 7.1 Are the Quality Control personnel independent of plant line personnel, and do they report directly to top management? 7.2 Do the Quality Control personnel have adequate experience and training to supervise concrete production of plant being inspected? 7.3 Are the test facilities adequate to perform physical tests of cement? 7.4 Are the test facilities adequate to perform physical test of aggregates? 7.5 Has the plant and/or trucks been approved for use by any inspecting bodies of governmental agencies or private institutions? 7.6 Are these inspection records on record? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 13 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02004 Revision 0, 10 June 2013 CONCRETE BATCH PLANT EVALUATION RECORD ID A02004 8.0 CONCLUSIONS AND REMARKS The Agency does have adequate facilities and qualified personnel to perform the work required by Fluor in accordance with contract specifications: 9.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02004 Rev 0 Concrete Batch Plant Evaluation Record.doc Page 14 of 14 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD ID A02005 INDEX 1.0 INSTRUCTIONS 2.0 EQUIPMENT FOR CONCRETE INSPECTION AND TESTING 2.1 LABORATORY EQUIPMENT 2.2 FIELD INSPECTION EQUIPMENT 3.0 DOCUMENTATION OF QUALIFICATIONS 4.0 MANAGEMENT SUPERVISION 5.0 CONCLUSION AND REMARKS 6.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 1 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD ID A02005 1.0 INSTRUCTIONS 1.1 This evaluation can only be made by the assigned Construction Engineer or others qualified to inspect Concrete Testing Laboratories. 1.2 The space to the right of each statement in this document should be completed with one, two, or three word answers, such as: Yes, No, Satisfactory, Unsatisfactory or, Does Not Apply, etc. 1.3 If any part of the testing laboratory has not been inspected, indicate to the right of the appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual statement. 1.5 The conclusions drawn by the Inspector should be based only upon observations and documentation noted in the body of the report. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 2 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD 2.0 EQUIPMENT FOR CONCRETE INSPECTION AND TESTING 2.1 Laboratory Equipment 2.1.1 Does the compression testing machine perform to ASTM E4-79 "Verification of Testing Machines", and ASTM C39-80 "Test for Compressive Strength of Cylindrical concrete Specimens?" ID A02005 2.1.2 Has the testing machine been calibrated and is the calibration documentation on file? 2.1.3 Are the facilities for preparing concrete test specimens in accordance with ASTM C192-81 "Making and Curing Concrete Test Specimens in the Laboratory?" 2.1.4 Are the facilities for curing concrete specimens in accordance with ASTM C511-76. 2.1.5 Are the facilities for capping concrete specimens in accordance with ASTM C617-76. 2.1.6 Does the equipment for testing concreting materials conforming to the following ASTM methods? 2.1.6.1 C136-81 Test for sieve or screen analysis of fine and coarse aggregate. 2.1.6.2 C127-80 Test for specific gravity absorption of fire aggregate. 2.1.6.3 C128-79 Test for specific gravity and absorption of fine aggregate. 2.1.6.4 C566-78 Test for total moisture content aggregate by drying. 2.1.6.5 C29-78 Test for unit weight of aggregate. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 3 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD ID A02005 2.0 EQUIPMENT FOR CONCRETE INSPECTION AND TESTING (Cont’d) 2.1 Laboratory Equipment (Cont’d) 2.1.7 Are the facilities for physical and chemical analysis of cement in accordance with ASTM C150-81? 2.1.8 Are the facilities for testing admixtures and related materials in accordance with ASTM? 2.1.9 Is there any additional equipment required for this contract? 2.2 Field Inspection Equipment 2.2.1 Are pocket thermometers available? 2.2.2 Is the equipment required by C231-81 "Test for Air Content of freshly Mixed Concrete by the Pressure Method," available? 2.2.3 Is the equipment required by C31-69, "Making and Curing concrete Compressive and Flexural Strength Test Specimens, in the field"? 2.2.4 Is the equipment required by ASTM C143-78 "Sampling Fresh Concrete," available? 2.2.5 Is the equipment required by ASTM C143-78, "Test for Slump of Portland Cement Concrete," available? 2.2.6 Is the equipment required by ASTM C138-77 "Test for Unit Weight, Yield and Air Content of Concrete," available? 2.2.7 Is there any additional equipment required for this contract? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 4 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD ID A02005 3.0 DOCUMENT OF QUALIFICATIONS 3.1 Has the Agency had its laboratory equipment and procedures inspected at intervals of not more than three years by a qualified national authority, as evidence of its competence to perform the required tests? 3.2 Has the Agency had its laboratory equipment and procedures inspected at intervals of not more than three years by a local jurisdictional body as evidence of its competence to perform the required test? 3.3 Are the Field Technicians certified to ACI 301 or other acceptable international recognized standard. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 5 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD 4.0 MANAGEMENT SUPERVISION 4.1 Is the Agency under the direction of a person charged with engineering managerial responsibility? ID A02005 4.2 Is that person a registered professional engineer and a full time employee of that Agency? 4.3 Does he/she have at least five years of engineering experience in inspection and testing of construction materials? 4.4 Does the Supervising Laboratory Technician have at least five years experience performing tests on construction materials? (He/she shall be able to perform the tests normally required in the manner stipulated under ASTM or other governing procedures.) 4.5 Does the supervising Field Technician have at least five years inspection experience in the kind of work involved on construction projects? (He/she shall be able to demonstrate either by written or oral examination, or both, the ability to perform correctly the duties required.) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 6 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 CONCRETE TESTING LABORATORY EVALUATION RECORD ID A02005 5.0 CONCLUSIONS AND REMARKS The Agency does have adequate facilities and qualified personnel to perform the work required by Fluor in accordance with contract specifications: 6.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 7 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02005 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02005 Rev 0 Concrete Testing Laboratory Evaluation Record.doc Page 8 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD ID A02006 INDEX 1.0 INSTRUCTIONS 2.0 GENERAL 2.1 NDE METHODS 2.2 PERSONNEL TRAINING AND CERTIFICATION 2.3 QUALITY ASSURANCE PROGRAM 2.4 MANAGEMENT 2.5 NDE PROCEDURES 2.6 RADIOACTIVE MATERIALS LICENSE 2.7 EXPERIENCE HISTORY 3.0 SPECIFIC 3.1 NDE METHOD ____________________________________ 4.0 CONCLUSION AND REMARKS 5.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 1 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD 1.0 INSTRUCTIONS ID A02006 1.1 This evaluation may only be made by the site nondestructure examination coordinator, or others qualified to review nondestructive examination contractors. 1.2 The space to the right of each statement in this document should be completed with one, two, or three word answers, such as: Yes, No, Satisfactory, Unsatisfactory or, Does Not Apply, etc. 1.3 If any function of the NDE contractor has not been inspected, indicate to the right of the appropriate statement by N.R. (Not Reviewed). 1.4 If additional comments are necessary, use the space available under each individual statement. 1.5 The conclusions drawn by the examiner should be based only upon observations and documentation noted in the body of the report. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 2 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD ID A02006 2.0 GENERAL 2.1 NDE Method Capabilities Radiography Ultrasonics Liquid Penetrant Magnetic Particle Visual (CW) Eddy Current PMI Time of Flight UT Other 2.2 Personnel Training and Certification 2.2.1 Does subcontractor have a written practice for the qualification and certification of NDE personnel? 2.2.2 Does written practice utilize SNT-TC-1A as the basis for the program? 2.2.3 Does written practice properly address examinations required for each level of certification? 2.2.4 Does initial experience fulfill the requirements of SNT-TC-1A? 2.2.5 Does initial training fulfill the requirements of SNT-TC-1A? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 3 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD 2.0 GENERAL (Cont’d) 2.3 Management 2.3.1 List key management/supervisory personnel and areas of responsibility. ID A02006 2.3.2 List NDE Level III personnel certified by examination. Add ASNT certificate number if applicable. 2.3.3 Does subcontractor have records of specific examinations administered to level III personnel certified on the basis of ASNT examinations? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 4 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD 2.0 GENERAL (Cont’d) 2.4 NDE Procedures ID A02006 2.4.1 Does subcontractor have written procedures for all NDE methods which he performs? 2.4.2 How does subcontractor ensure that procedures are updated to reflect the latest code requirements? 2.4.3 Do procedures allow interpretation for acceptance by Level I personnel? 2.4.4 List codes/standards that subcontractor's procedures reference. 2.4.5 Will subcontractor agree to submit all applicable NDE procedures and report forms to Fluor for review and authorization? W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 5 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD 2.0 GENERAL (Cont’d) 2.5 Experience History 2.5.1 List all past and present work in NDE (include summary of methods performed). ID A02006 2.5.1a Nuclear: 2.5.1b Non-Nuclear: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 6 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD 3.0 SPECIFIC 3.1 Indicate NDE Method: ______________________________________________ 3.1.1 Indicate number of Certified Level II Personnel:_____________________ 3.1.2 Indicate number of Certified Level I Personnel:_____________________ 3.1.3 List all applicable equipment (Type, MFG and QTY) used to perform examinations, obtain results and verify adequacy of test methods. ID A02006 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 7 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD 3.0 SPECIFIC (Cont’d) 3.1 NDE Method: ____________________________________________ (Cont’d) 3.1.4 Describe general condition of test equipment. ID A02006 3.1.5 Additional Comments: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 8 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 NDE SUBCONTRACTOR EVALUATION RECORD ID A02006 4.0 CONCLUSIONS AND REMARKS The Agency does have adequate facilities and qualified personnel to perform the work required by Fluor in accordance with contract specifications: 5.0 RECOMMENDATIONS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 9 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02006 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02006 Rev 0 NDE Subcontractor Evaluation Record.doc Page 10 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0210 Revision 0, 10 June 2013 CONTRACTOR QUALITY REQUIREMENTS SCOPE This procedure establishes the quality requirements for Site Contractors and is to be used for all site contracts that involve engineering, procurement and/or construction activities. APPLICATION This procedure is to be applied in preparation of the RFP (Request for Proposal) when documented test results and/or in-process inspection results of Contractor's Work are required, as determined by the Site Manager or representative. It utilizes the standard Attachment E (form 000.430.F0176) which is available in the Contract Management knowledge community in Knowledge On Line (KOL). GENERAL Contractor is responsible for providing services and performing work in accordance with the design and quality requirements as required by their contract. Company’s approach to construction management contracting normally requires each Contractor to staff and perform the inspection activities, with Company performing surveillance over the Contractor activities. Based on the capability of Contractor, information obtained during pre-qualifications of Bidders, and project management preference, Company may elect to either provide the QC procedures to the Contractor or require the Contractor to provide the procedures for Company approval. However, since Fluor utilizes a turnover software program, it is ideal if the Contractors use Fluor’s forms. This allows for consistency between Contractors in how they document their inspection and testing activities and it makes it easier to manage the turnover completion process. In some rare instances, the Company may also elect to perform the inspection – but this is not the preferred method when dealing with a construction contractor. The Contracts Management group has a Standard Contract Attachment E - Quality Management Requirements form 000 430 F0176 that is available in Knowledge On Line. This Attachment E is to be developed so that it is scope-specific for the contract RFP package it is to be included in. It needs to be scope specific so that it excludes requirements and references to forms that are not applicable to the contractors’ scope of work. The Site Quality Manager is to contact the Project Contracts Manager to request input to the contract RFP packages. This duty can be performed by the Regional Construction Quality Manager (RCQM) if a Site Quality Manager is not yet assigned to the project. The Construction Technical Services group can advise who the RCQM is for a particular area. Contractor quality requirements are to be monitored by either performing quality audits (refer to 000 509 0170) or by performing quality surveillances (refer to 000 509 0220. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0210 Rev 0 Contractor Quality Requirements.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0210 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0210 Rev 0 Contractor Quality Requirements.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0220 Revision 0, 10 June 2013 SURVEILLANCE OF CONSTRUCTION ACTIVITIES SCOPE This procedure describes the responsibilities and activities for quality surveillance of construction activities. GENERAL The Site Quality Manager is responsible for the quality program at the construction/installation site is responsible for implementing and managing a program of quality surveillance. This procedure requires that surveillances be documented and tracked using the Quality Management System (QMS) tool. This is an established program used by Fluor across the company for management of quality audits and surveillances. The program is Lotus Notes based. Go in to FDNet and type http://www.fdglobal.com/fdglobal/workgrps/qa/qms.nsf in the URL bar at the top of the screen to access the QMS program. Projects that do not have access to FDNet or are experiencing connectivity issues with the Fluor network may be allowed to use the alternative forms noted in this procedure. Surveillance is the monitoring by witnessing and observation of the Quality Program implementation during construction/installation work activities. This can involve verifying that a work process or procedure is being performed in accordance with a written requirement. Surveillance is performed to the extent necessary to provide adequate confidence that appropriate measures are taken to control and achieve quality. The responsible Construction Engineering Manager shall be contacted for final resolution/interpretation of design specifications or drawing requirements, when a conflict develops between interpretation of requirements and that of Quality Surveillance personnel. PROCEDURE Site Quality Manager Will assign surveillance responsibilities to inspection personnel. Ensure that personnel performing surveillances using QMS have obtained access rights and have taken the necessary training to be able to work in QMS. Access rights can be obtained from Barry Rittberg. His e-mail address is
[email protected]. His phone number is 949-349-2356. QMS for Contractor Surveillance training is available in the Quality knowledge community in Knowledge On Line (KOL). The course required to be taken for performing surveillances is: QA012 – QMS For Contractor Surveillance Reading material on using QMS is available (course QA-004) in the Quality community for those who want more information on using the QMS program. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0220 Rev 0 Surveillance of Construction Activities.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0220 Revision 0, 10 June 2013 NOTE: Scope, duration, and intensity of surveillance activities shall be determined by the Site Quality Manager through an evaluation of the scope of the activities being performed and the quality history of the workers or contractors. Surveillance Personnel Ensure that the required QMS training has been taken as described above. Perform periodic surveillance of work activities. NOTE: Surveillance personnel should refer to the applicable inspection/test plans (ITP’s) or procedures and use them for determining surveillance activities. When surveillance is performed on self-performed or subcontracted activities not addressed by inspection/test procedures; the work process instructions (usually drawings and specifications) should be used to guide the inspector. Indicate the results of the surveillance verification activity in the QMS program. Projects that are not able to use QMS can use Form 000 509 F02201. Record on the Surveillance Report those areas or items monitored or reviewed. If no deficiencies are found during this surveillance, so state (satisfactory) and forward to the Site Quality Manager for his review. NOTE: The “Inspector” may recommend a nonconformance or corrective action to be taken to correct the condition or deficiency. Refer to procedures 000.509.0130 and 000.509.0140. When a deficiency is found and will need a follow-up inspection to verify conformity, identify it in the QMS program. For projects that are not able to use QMS the deficiency will be noted on the Surveillance Report in the “Observation / Deficiency” section. Notify the responsible person of the deficiency and record the action being taken. For projects that are not able to use QMS the surveillance report is to be signed and forward to the Site Quality Manager for his review. The “Inspector” shall follow-up the deficiency to ensure the corrective action is completed. Corrective action should then be recorded in QMS for close out. For projects that are not able to use QMS the corrective action space in the surveillance report is to have the corrective action recorded and the “Inspector” shall then sign and date to indicate acceptance / completion and the report is considered closed. QMS will automatically log all surveillance reports raised within the QMS program. For projects that are not able to use QMS the Surveillance Report information is to be recorded on the log provided. The log will serve as a record of site surveillance reports as well as to status the reports as “Open” or “Closed”. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0220 Rev 0 Surveillance of Construction Activities.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0220 Revision 0, 10 June 2013 If corrective action is not initiated to resolve the deficiency within fourteen (14) calendar days, notify the Site Quality Manager. The Site Quality Manager may initiate and process a nonconformance or corrective action report if needed. Nonconformance Reports are issued when there are: Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition. Deficiencies of a serious or repetitive nonconforming nature as determined by the Site Quality Manager Construction damage has occurred to existing or turned over plant property. Nonconformances shall be documented by recording them within the QMS program. For projects that are not able to use QMS nonconformances are to be documented using Form 000 509 F01301. Site Quality Manager Review the results of the surveillance and/or verification activities recorded in QMS or on the Surveillance Report (if project is unable to use QMS). Signify review and concurrence by signing and dating the surveillance report (only if project is unable to use QMS). Advise the Site Manager of serious quality problems. - DOCUMENTATION All Surveillance Reports shall be retained in the QMS program. Projects that are not able to use QMS are to retain copies in the Quality Control files. FORMS Quality Control Form: 000 509 F02201 – Surveillance Report (only used if project is unable to use QMS) 000 509 F02202 – Surveillance Report Log (only used if project is unable to use QMS) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0220 Rev 0 Surveillance of Construction Activities.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0220 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0220 Rev 0 Surveillance of Construction Activities.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02202 Revision 0, 10 June 2013 SURVEILLANCE REPORT LOG REPORT NO. INITIATOR CONTRACTOR SUBJECT ID A02202A OPEN CLOSED BY / DATE W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02202 Rev 0 Surveillance Report Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02202 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02202 Rev 0 Surveillance Report Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0230 Revision 0, 10 June 2013 FIELD RECEIVING AND INSPECTION SCOPE This procedure describes the practice and methods to perform receiving inspection of permanent plant material and equipment. RESPONSIBILITIES - Self-Perform FREQUENCY OF ACTIVITY Per shipment received As project progresses As required by project ACTIVITY Warehouse receipt of material/items Determine inspection and storage level requirements Perform quality receipt inspection RESPONSIBILITY Warehouse Personnel Construction Engineer Site Quality Manager DOCUMENTATION O, S, and D (000 509 0230) Attachment 1 000.509.F02301 Responsibilities - Subcontracted Work FREQUENCY OF ACTIVITY Per shipment received As project progresses As required by project Per Procedure 000.509.0220 ACTIVITY Warehouse receipt of material/items Determine inspection and storage level requirements Perform quality receipt inspection Surveillance PROCEDURE • RESPONSIBILITY Subcontractor Subcontractor Subcontractor Site Quality Manager DOCUMENTATION O, S, and D (000 509 0230) Attachment 1 000.509.F02301 Form 000.509.F02201 Receipt of Material/Items: Warehouse personnel shall perform the initial visual inspection of the materials/items for obvious shipping damage. If there has been shipping damage, initiate an O, S, and D Report in accordance with Warehouse Procedures. Forward a copy of the O, S, and D Report to the Site Quality Manager for information. The warehouse staff shall notify the Quality Manager upon receipt of items listed on the Permanent Plant Material and Equipment Inspection List or items where receipt inspection by the Quality Inspector is indicated on the ITP. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0230 Rev 0 Field Receiving and Inspection.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0230 Revision 0, 10 June 2013 • Determine Inspection and Storage Requirements: Early in the project and continuing throughout the life of the project, the Construction Engineering Manager shall determine which items of permanent plant material and equipment that will require quality receiving inspection. The list shall be provided to the Site Quality Manager with a list of items to be inspected, along with any specific inspection and storage requirements. A typical list is provided as Attachment 2. Permanent Plant Material and Equipment Inspection List. • Quality Receipt Inspection: Prior to receipt of materials/equipment, the quality inspector shall research the purchase order, change orders, and specifications to determine the inspections and/or verifications to be performed. Prepare a Receiving Inspection Checklist, (000.509.F02301) for each item with the attributes to be inspected or verified, Reference Attachment 1 for attributes of inspection. Upon receipt of material/equipment, perform receipt inspection prior to unloading of the material/equipment, if possible. If material cannot be inspected prior to unloading, material should be unloaded and segregated from other material until receiving inspection can be performed. Inspect the material/equipment and associated vendor documentation for compliance with the requirements and document the results on the receiving inspection checklist (000.509.F02301). If the material/equipment is found to be nonconforming, attach a Hold Tag (000.509.F01303) and initiate a Non-conformance Report (000.509.F01301). - - - FORMS Quality Control Forms: 000.509.F01301 - Nonconformance Report 000.509.F01303 - Hold Tag 000.509.F02301 - Receiving Inspection Checklist ATTACHMENTS Attachment 1 Attachment 2 Attributes for Receiving Inspection Typical Permanent Plant Material and Equipment Inspection List W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0230 Rev 0 Field Receiving and Inspection.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0230 Revision 0, 10 June 2013 Attachment 1 Attributes for Receiving Inspection INSTRUCTIONS: Field Receiving Inspection Reference This inspection is to be performed after Receiving Operations performed by the Material Manager which have already confirmed identification of item per Purchase Order, identification of parts shipped separately, quantity and size of item, condition of shipping protection and damage. ANCHOR BOLTS Damage Corrosion Fit of Nut & Bolt Size Check REINFORCING STEEL Damage Corrosion Deformations Mill Markings Mill Certifications STRUCTURAL STEEL Damage Corrosion Welding Piece Marking Connectors Dimensional Checks FIELD FABRICATED TANKS Damage Corrosion Edges Prepared for Welding Mill Certifications Dimensional Checks SHOP FABRICATED TANKS & VESSELS Damage Corrosion Accessories Flange & Opening Protection Temporary Supports Dessicants Shop Coatings Dimensional Checks Name Plate Data MACHINERY Damage Corrosion Accessories Shipping Protection Temporary Supports Vendor Instructions Flange & Opening Protection Name Plate Data Shaft Rotation Welding EXCHANGERS/PRESSURE VESSELS Damage Cleanliness Corrosion Flange & Opening Protection Shipping Protection Temporary Supports Fan Blades Motors Gears Dessicants Vendor Instructions Name Plate Data Shaft Rotation FIRED HEATERS & BOILERS Damage Corrosion Flange & Opening Protection Edges Prepared for Welding Mill Certifications Dimensional Checks Name Plate Data Welding Accessories Refractory SPECIALITY EQUIPMENT Damage Corrosion Flange & Opening Protection Edges Prepared for Welding Dimensional Checks Name Plate Data Welding Accessories PIPE Cleanliness Shipping Prep Damage Corrosion Shop Coatings Pipe Markings Color Coding and/or PMI if applicable VALVES Identification Tags appropriately affixed and marked Damage Corrosion Flange & Opening Protections Moving Parts Valve Markings Positive Material Identification, if required FITTINGS, Alloy Damage Corrosion Piece Markings Positive Material Identification ELECTRICAL EQUIPMENT Damage Corrosion Name Plate Data Accessories Dimensional Checks Shipping Protection Temporary Supports ELECTRICAL MATERIAL Damage Corrosion Item Markings INSTRUMENTS Damage Corrosion Shipping Protection Item Markings Accessories COATINGS Damage Deterioration Cap Markings WELD FILLER MATERIAL Damage Properly Identified Mill Certifications W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0230 Rev 0 Field Receiving and Inspection.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0230 Revision 0, 10 June 2013 Attachment 2 I. CIVIL Typical Permanent Plant Material and Equipment Inspection List Civil materials such as: Structural steel components Load indicating bolts/washers II. MECHANICAL/PIPING MATERIALS All mechanical equipment that has an equipment tag number, such as: Pumps Heat Exchangers Vessels (Including Filters & Scrubbers) Trays Piping materials such as: Alloy Pipe Specialty piping components Weld Rod III. ELECTRICAL All electrical equipment that has an equipment tag number, such as: Motors Control Centers Switchgear Circuit Breakers Wire & Cable rated 5kV and higher (Hi-pot test prior to storage) IV. HYGIENIC TUBING SYSTEMS All Hygienic equipment and materials such as: Tubing Valves Nozzles V. APPROVALS Construction Engineering Manager__________________________________ Date: Quality Manager__________________________________ Date: Vessels Fittings Weld Rod Cyclones Flares Boilers API Tanks Protective coatings Specialty grouts W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0230 Rev 0 Field Receiving and Inspection.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01301 Revision 0, 10 June 2013 NONCONFORMANCE REPORT Tag Description: P. O. No.: Subcontractor: Initiated by: Area/Location DWG. No./Rev. Inspection Classification Subcontractor Fluor Date: Unit/Equip No. Spec./Rev. Tag No.: Turnover System: Client Other Hold Tag Yes ID A01301A Sub – System: Location: NCR No. No Discipline/Responsibility: Audit No. (If Applicable) DESCRIPTION OF NONCONFORMANCE ROOT CAUSE CAUSE CODE(S) DISPOSITION Use as is Rework Repair Other DISPOSITION BY Design Eng. Approval Req. Construction Engineer Date Yes No DISPOSITION COMPLETED BY Contractor Date Design Engineer Date ACTION VERIFIED AND NON-CONFORMANCE CLOSED VERIFICATION METHOD DOC REVIEW FLUOR INSPECTOR INSPECTION OTHER DATE FLUOR-VERIFIED DISPOSITION AND RECOMMENDED CLOSURE OF NCR FLUOR SITE QUALITY MANAGER DATE W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01301 Rev 0 Non Conformance Repor.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01301 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01301 Rev 0 Non Conformance Repor.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01303 Revision 0, 10 June 2013 HOLD TAG/STICKER ID A01303 HOLD Hold Tag No._____________________ DO NOT USE NCR Number_____________________ (DO NOT REMOVE THIS TAG) (Recommended Color: Red with Green Letters) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01303 Rev 0 Hold Tag-Sticker.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F01303 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F01303 Rev 0 Hold Tag-Sticker.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02301 Revision 0, 10 June 2103 RECEIVING INSPECTION CHECKLIST P.O. Number Supplier Mark No. Heat No. Date Received ID A02301 Project Number Receiving Hold Tag Attached Yes No Description Of Material/Equipment Material Test Reports Required Yes No Item #'S _______ Item No. Inspection Attributes* Quantity Accept Reject Hold Tag No. Nonconformance Report Number(s) Storage Requirements Remarks * Inspection Attributes are identified in Attachment 1 for certain items Prepared By/Date Inspector/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02301 Rev 0 Receiving Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02301 Revision 0, 10 June 2103 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02301 Rev 0 Receiving Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0240 Revision 0, 10 June 2013 TURNOVER SCOPE This procedure establishes the sequence of events leading up to the transfer of care, custody and control of completed systems or areas from Fluor to The Client. Fluor will request The Client's acceptance of buildings, systems or areas for care, custody, and control. RESPONSIBILITIES - Self-Performed ACTIVITY Determine scope of system Establish alphanumeric number and brief scope Establish mechanical completion dates Issue walk-down notice Generate master punchlist Generate exceptions list Generate discipline checklist Generate care, custody, and control package RESPONSIBILITY Turnover Engineer Turnover Engineer Commissioning/Start-up, engineering, construction management, and The Client Turnover Coordinator / Complete It Administrator Turnover Coordinator / Complete It Administrator Turnover Coordinator / Complete It Administrator Turnover Coordinator/ Complete It Administrator Turnover Coordinator / Complete It Administrator DOCUMENTATION Scoped drawings and Form 000 509 FXXXX Turnover master listing Form 000.509.F02401 FREQUENCY OF ACTIVITY Prior to start of work Prior to start of work Three weeks before mechanical completion date Two weeks before mechanical completion date Prior to mechanical completion date Form 000.509.F02402 Form 000.509.F02407 Exceptions list format site specific Form 000.509.F02403 Form 000.509.F02404 Form 000.509.F02405 Form 000.509.F02406 Transfer of care custody and control letter Form 000.509.F02401 Form 000.509.F02402 Form 000.509.F02403 Form 000.509.F02404 Form 000.509.F02405 Form 000.509.F02406 System scoping drawings, elementary or one line diagram. Hydro test report. Equipment list. Instrument list. Exceptions list. Loop list. Form 000.509.F02201 Prior to mechanical completion Prior to turnover of system or area Surveillance QC Inspector Per Procedure 000.509.0220 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0240 Rev 0 Turnover.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0240 Revision 0, 10 June 2013 Responsibilities - Subcontracted Work ACTIVITY RESPONSIBILITY DOCUMENTATION FREQUENCY OF ACTIVITY Determine scope of system Establish alphanumeric number and brief scope Establish mechanical completion dates Turnover Engineer / Subcontractor Turnover Engineer / Subcontractor Commissioning/Startup/ Engineering / Construction Management / and The Client Turnover Coordinator/ Complete It Administrator / Subcontractor Subcontractor/ Turnover Coordinator / Complete It Administrator Subcontractor/ Turnover Coordinator / Complete It Administrator Scoped drawings Turnover master listing Prior to start of work Prior to start of work Three weeks before mechanical completion date Two weeks before mechanical date Prior to mechanical completion date Prior to mechanical completion Form 000.509.F02401 Issue walk-down notice Form 000.509.F02402 Generate master punchlist Generate discipline checklist Form 000.509.F02407 Form 000.509.F02403 Form 000.509.F02404 Form 000.509.F02405 Form 000.509.F02406 Transfer of care, custody, and control letter Form 000.509.F02401 Form 000.509.F02402 Form 000.509.F02403 Form 000.509.F02404 Form 000.509.F02405 Form 000.509.F02406 System scoping drawings, elementary or one line diagrams Hydrotest Report Equipment List Instrument List Exceptions List Loop List Form 000.509.F02201 Generate care, custody, and control package Subcontractor/ Turnover Coordinator / Complete It Administrator Surveillance QC Inspector Per Procedure 000.509.0220 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0240 Rev 0 Turnover.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0240 Revision 0, 10 June 2013 PROCEDURE • Determine Scope of System: - Determine the areas and process units that make up a system scope boundary. - Once system scoping has been determined, each system will be assigned a name and an alphanumeric number. A brief description of scope boundary will be generated. This information will be compiled into a master list and distribution made. Scoped drawing will be prepared to indicate system boundaries. Identify content of turnover package and initiate package index. • Establish Mechanical Completion dates: - Mechanical completion dates for systems will be established with input from The Client Management and Fluor Commissioning / Startup, Construction, and Engineering. These dates will be used for tracking and scheduling. • Issue Walkdown Notice: - Approximately three (3) weeks before the established mechanical completion date for a system, a walkdown notice for Fluor will be issued (Form 000.509.F02402) • Generate Discipline Checklist: - Each discipline Manager will generate a checklist to verify all work has been completed as required by drawings and specifications. The Commissioning / Startup Administrator will generate a checklist to verify that all required quality records have been completed and those designated for turnover are included in the Turnover Package. • Generate Master Punchlist: - When the Fluor walkdown has been completed, a master punchlist will be compiled (Form 000.509.F02407). Complete It will be used to track and status the master punchlist. - The master punchlist will identify any incomplete items of work and/or errors in design or installation. The master punchlist will be issued to construction and engineering for corrective action. - Approximately two (2) weeks before the established mechanical completion date, the turnover coordinator will notify The Client that the system is ready for their walkdown. A copy of the open items from the master punchlist will be attached to the walkdown notice. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0240 Rev 0 Turnover.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0240 Revision 0, 10 June 2013 • Generate the Exception List: - After The Client walkdown has been completed, the CompleteIt Administrator will schedule a joint meeting between The Client and Fluor. The purpose of this meeting will be to reconcile the punch list. Any items that will impede pre-commissioning/commissioning or cannot be completed after commissioning/start-up shall be completed prior to the mechanical completion date. These items will be coded Category 1. Any remaining incomplete items will become items on the exceptions list and be included as part of the transfer of care, custody, and control package. - The items on the exceptions list will be categorized as 2, 3, 4 or 5. Category 2 items may be completed anytime with the approval of The Client. Category 3 items are generated by the client/operations. Category 4 items are added scope. Category 5 items are other issues. • Generate Care, Custody, and Control Package: - The turnover coordinator will assemble the transfer of care, custody, and control package. The package will contain, as applicable, the following documents: a) b) c) d) e) f) g) h) i) Transfer of Care, Custody, and Control Letter Discipline Managers Checklist System Scoping Drawings Elementary or One-Line Diagrams Hydrostatic Test Report Equipment List Instrument List Exceptions List Loop List - The Client management has ten (10) calendar days to respond to the transfer of care, custody, and control letter. At time of acceptance, The Client should tag equipment to indicate their control of that system. - The Client shall install lockout-type devices on all isolation equipment such as breakers, valves, etc. Fluor may also install lockout devices on system boundary isolation equipment. This action will be necessary to make safe any equipment or system that has not been completed and custody transferred to The Client. - All supporting documentation relating to mechanical completion/system turnover will be retained by Fluor until system acceptance by The Client. After system acceptance by The Client, this documentation will be transferred to The Client under separate correspondence. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0240 Rev 0 Turnover.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0240 Revision 0, 10 June 2013 FORMS Quality Control Forms: 000.509.F02401 000.509.F02402 000.509.F02403 000.509.F02404 000.509.F02405 000.509.F02406 000.509.F02407 000.509.F02408 000.509.F02409 Transfer of Care, Custody and Control (Turnover Notice) System Walkdown Notice Mechanical Completion Civil Checklist Mechanical Completion Electrical/Instrumentation Checklist Mechanical Completion/Mechanical Checklist Mechanical Completion/Quality Control Checklist Master Punch List Record Interim Turnover Notice Mechanical Completion Certificate W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0240 Rev 0 Turnover.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0240 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0240 Rev 0 Turnover.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02401 Revision 0, 10 June 2013 TURNOVER NOTICE This letter is to advise you that except as set forth below all work is essentially complete as of _____________and is ready for commissioning and start-up operations on this system. The respective equipment has been tested and operation will be under supervision of your representative upon your acceptance. Upon the date of your acceptance hereof, it is provided that mechanical completion and care, custody and control of the facilities described, hereby excepting those items on the attached Exception List, will be passed to The Client. Responsibility for loss or damage, excepting those items on the attached Exceptions List, is assumed by The Client and subrogation waived against Fluor under which The Client may hereafter carry in force on the facilities herewith transferred. Nothing herein contained shall be construed as relieving Fluor of any of its guarantees under the contract covering the facilities hereby transferred, except that the guarantee period with respect to the workmanship of Fluor subject to this Transfer shall commence to run upon your signed acceptance. Kindly acknowledge your acceptance and approval of the foregoing by signing and returning two of the enclosed copies of this letter, or advise in what respect the above described facilities are not ready for commissioning and initial start-up operations. Sincerely, Fluor Site Manager Accepted by: ____________________________________ CLIENT CONSTRUCTION MANAGER Date: ______________________ Accepted by: __________________________________ _ CLIENT START-UP LEADER Date: _____________________ W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02401 Rev 0 Transfer of Care Custody and Control.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02401 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02401 Rev 0 Transfer of Care Custody and Control.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02402 Revision 0, 10 June 2013 SYSTEM WALKDOWN NOTICE The Client: SYSTEM NUMBER: SYSTEM DESCRIPTION: Fluor ID A02402A The Client * Participation in this system walkdown is required by these persons or their designee. The others are notified for information only. The system is scheduled for a joint Fluor/The Client walkdown on ______________. The walkdown and punchlist must be complete within two (2) days. Punchlist items will be entered into MCPlus by designated punch entrants to produce the “Master System Punchlist” (MSP) to assist Fluor and The Client in establishing Category 2, 3, 4 & 5 items and tracing their acceptance and closure. Please notify me if your discipline can not perform the walkdown as scheduled. Systems Coordinator ____________________________________ Ext. ___________ W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02402 Rev 0 System Walkdown Notice.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02402 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02402 Rev 0 System Walkdown Notice.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02403 Revision 0, 10 June 2013 MECHANICAL COMPLETION CIVIL CHECKLIST The Client: SYSTEM NUMBER: SYSTEM DESCRIPTION: 1. 2. 3. 4. 5. 6. All paving is installed and properly sealed in accordance with the drawings and specifications. All structural steel, stairs, and grating is installed in accordance with the drawings and specifications. All structural steel base plates are grouted in accordance with the drawings and specifications. ID A02403A All structural steel requiring concrete fire proofing is installed in accordance with drawings and specifications. All approved gates and other safety devices are installed in accordance with drawings and specifications. All bollard posts are installed in appropriate locations in accordance with drawings and specifications. All construction debris are removed and the area is in a broom clean condition. All architectural work, which includes but is not limited to roofing, windows, and doors, etc., is in accordance with drawings and specifications. All structural steel, pipes, equipment, and other structures are painted in accordance with drawings and specifications. 7. 8. 9. 10. All civil related NCR’s that affect this system have been closed. Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Commissioning Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02403 Rev 0 Mechanical Completion Civil Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02403 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02403 Rev 0 Mechanical Completion Civil Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02404 Revision 0, 10 June 2013 MECHANICAL COMPLETION ELECTRICAL / INSTRUMENTATION CHECKLIST The Client: SYSTEM NUMBER: SYSTEM DESCRIPTION: Contract No.: ID A02404A 1. All electrical/instrumentation installations have been installed in accordance with design and vendor documents. All electrical cables have been meggered (and DC hi-pot tested if over 1000v rating) All associated switchgear, breakers, transformers, relays, busway, and distribution equipment has been inspected and/or tested in accordance with project specifications. All motors and air cooler fans have been meggered and bumped to check direction of rotation. All associated instruments have been calibrated, function tested and/or loop tested as required by project specifications . Instruments are calibrated and installed in accordance with design documents. Instruments and instrumentation tubing are tested as required by code and specifications. All electrical/instrumentation related NCR’s that affect his system have been closed. 2. 3. 4. 5. 6. 7. 8. Subcontractor Name: Signature: Date: Name: Fluor Commissioning Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02404 Rev 0 Mechanical Completion Electrical Instrumentation Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02404 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02404 Rev 0 Mechanical Completion Electrical Instrumentation Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02405 Revision 0, 10 June 2013 MECHANICAL COMPLETION / MECHANICAL CHECKLIST The Client: SYSTEM NUMBER: SYSTEM DESCRIPTION: ID A02405A 1. Piping is installed in accordance with design documents. Hydrotests have been completed. Pipe supports; hangers, guides, anchors, spring cans, etc., have been installed in accordance with design documents. Travel stops on spring hangers for water filled piping are to be removed after the applicable piping system has been filled with water. At this time "cold load setting" shall be verified. Travel stops on spring hangers for steam or gas filled piping have been removed by construction and cold load settings have been verified. Rotating equipment is installed in compliance with vendor and specification requirements. Cold alignment has been performed and base plates are grouted. Maintenance on applicable equipment has been performed. Temporary lubricants and rust inhibitors have been removed and initial lubrication is complete . All vessel internals, packing and desiccants are installed and Fluor's final closures are completed. Mechanical related NCRs that affect this system have been closed. Coatings; paint and insulation complete. 2. 3. 4. 5. 6. 7. 8. Subcontractor Name: Signature: Date: Name: Fluor Commissioning Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02405 Rev 0 Mechanical Completion Mechanical Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02405 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02405 Rev 0 Mechanical Completion Mechanical Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02406 Revision 0, 10 June 2013 MECHANICAL COMPLETION / QUALITY CONTROL CHECKLIST The Client: SYSTEM NUMBER: SYSTEM DESCRIPTION: ID A02406A 1. 2. Turnover notice and the supporting documentation has been received. Hydrostatic test packages for this system are complete, accepted, and are included in this system package. Quality control records for this system are complete and are included in this system package as required. All NCR’s, that affect this system, are closed and are on file. 3. 4. Subcontractor Name: Signature: Date: Name: Fluor Commissioning Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02406 Rev 0 Mechanical Completion Quality Control Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02406 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02406 Rev 0 Mechanical Completion Quality Control Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02407 Revision 0, 10 June 2013 Page: of Punch List TO System Description: Priority ‘1’ Items to be completed before handover of the Package to the next phase Priority ‘2’ Items may be completed anytime at the approval of Client Priority ‘3’ Items generated by the client/operations Priority ‘4’ Added scope PL No. Tag/Line/Cable Raised By/On Pri Status PL Item Description & Comments Priority ‘5’ Other Issues TO System: Print Date: Groups: VE – Vendor CC – Construction CM – Commissioning SU – Start Up Cleared Mat Eng Req’d by Date By Date By Date Verified Group Resp. (Disc) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02407 Rev 0 Master Punch List Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Component, System or Subsystem Number Description Exceptions to the above scope See Attached Punchlist Process Consistency Check By The Client SIGNATURES Date Accepted by The Client Mechanical Coordinator Released By Fluor Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02409 Rev 0 Mechanical Completion Certificate.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02409 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02409 Rev 0 Mechanical Completion Certificate.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02408 Revision 0, 10 June 2013 INTERIM TURNOVER NOTICE ___________________ As The Client's Project Manager and duly authorized representative, I hereby issue in accordance with Article 19 - Completion and Acceptance - of the Principal Document, this INTERIM TURNOVER NOTICE for: _________________. Interim Turnover Package _________________ Under the terms and conditions of: Contract Number ___________ Dated _________ Between The Client and Fluor, Inc. and certify that Mechanical Completion of the above portion of Work was achieved on __________________. A Master Punchlist is attached indicating items which are still incomplete or known to be deficient and the dates such items are to be finished or corrected. It shall remain as Fluor's responsibility to finish and correct this work by the dates so indicated, as well as correcting any deficiencies which are uncovered during the startup operations. The issuance of this TURNOVER NOTICE does not in any way denote The Client's concurrence that the Facility, or any part thereof, fully conforms to Job Specification nor relieve Fluor from its obligations under Article 20 - Warranties and Guarantees. It does constitute The Client's assumption of care, custody, control and responsibility for the above mentioned portion of the work. Notwithstanding, all conditions and terms of Contract No. _________ (Amended) are still valid. The Client/Date Fluor/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02408 Rev 0 Interim Turnover Notice.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02408 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02408 Rev 0 Interim Turnover Notice.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0250 Revision 0, 10 June 2013 MATERIAL AND EQUIPMENT STORAGE AND MAINTENANCE SCOPE This procedure defines the requirements for periodic inspection of the storage and maintenance of designated materials and equipment. RESPONSIBILITIES - Self-Perform / Subcontracted ACTIVITY Develop a material/equipment storage requirement list Generate the storage inspection checklist Inspect storage & maintenance Perform Preservation Activities Resolve discrepancies as appropriate Surveillance *Note 1: RESPONSIBILITY Subcontractor/ Construction Engineer or Project Engineer Subcontractor/Site Quality Manager Subcontractor/Site Quality Manager Subcontractor/Site Quality Manager Subcontractor/Site Quality Manager Site Quality Manager (*Note 1) DOCUMENTATION See Attachment 1 for "Sample" list Form: 000.509.F02501 Form: 000.509.F02501 Form: 000.509.F02502 Form: 000.509.F02501 Form: 000.509.F02501 FREQUENCY OF ACTIVITY Prior to receipt of material & equipment Prior to receipt of material & equipment Monthly during the life of the activity Each Item As required to resolve discrepancies Per procedure 000.509.0220 Surveillance is not required if the Fluor Quality Representative is performing the inspections. PROCEDURE • Storage Requirement List Develop a material/equipment storage requirement list (see Attachment 1 for a sample list) consisting of protective measures to prevent damage, deterioration, or contamination of material and equipment. • Storage Inspection Checklist Using the material/equipment storage requirement list as a guide, generate a storage inspection checklist (refer to Form 000.509.F02501for a sample of the storage inspection checklist). W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0250 Rev 0 Material and Equipment Storage and Maintenance.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0250 Revision 0, 10 June 2013 • Inspection of Storage and Maintenance Perform inspections of storage areas, including items stored "In-Place", on a monthly basis. Document any discrepancies noted during inspections. • Discrepancy Resolution Resolve any noted discrepancies with the appropriate parties. Perform re-inspection(s) to verify that the noted discrepancies have been corrected. FORMS Quality Control Form: 000.509.F02501 - Storage Inspection Checklist 000.509.F02502 - Equipment Protection Preservation and Inspection Record ATTACHMENTS Attachment 1 - Material/Equipment Storage Requirement List (Sample) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0250 Rev 0 Material and Equipment Storage and Maintenance.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0250 Revision 0, 10 June 2013 Attachment 1 - Material/Equipment Storage Requirement List The requirements for storage are divided into four levels with respect to protective measures to prevent damage, deterioration or contamination of items and materials based upon important physical characteristics, the ambient conditions during construction installation and operation of the item or material. Level A - Items classified to Level A are those that are exceptionally sensitive to environmental conditions and require special measures for protection from one or more of the following effects: temperatures outside required limits; sudden temperature changes; humidity and vapors; gravitational (g) forces; physical damage and air-borne contamination (e.g., rain, snow, dust, slat spray, fumes). The following shall be used as a guide for classifying items intended for Level A classification: a. b. c. Special electronic equipment and instrumentation. Special materials, such as chemicals that are sensitive to environment. Computers Level B - Items classified to Level B are those that are sensitive to environmental conditions and require measures for protection from the damaging effects of one or more of the following: temperature extremes, humidity and vapors, gravitational forces, physical damage and airborne contamination but do not require the special protection required for Level A items. The following shall be used as a guide for classifying items intended for Level B classification: a. b. c. d. e. f. g. h. i. Instrumentation Electrical penetrations Batteries Welding electrode and wire Motor control centers, switchgear, and control panels Motors and generators Precision-machined parts Erection spares, such as gaskets, "O" rings Air-handling filters Level C - Items classified to Level C are those that require protection from exposure to the environment, air-borne contaminants, gravitational forces, and physical damage. Protection from water vapor and condensation is not so important as that for Level B items. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0250 Rev 0 Material and Equipment Storage and Maintenance.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0250 Revision 0, 10 June 2013 The following shall be used as a guide for classifying items intended for Level C classification: a. b. c. d. e. f. g. h. Pumps Valves Fluid Filters Compressors Turbines Instrument cable Thermal insulation Fans and blowers Level D - Items classified to Level D are those that are less sensitive to the environment than Level C. These items require protection against the elements, air-borne contamination, and physical damage. The following shall be used as a guide for classifying items intended for Level D classification: a. b. c. d. e. f. g. h. i. Tanks Heat exchangers and parts Accumulators Demineralizers Evaporators Piping Electrical cable Structural items Reinforcing steel W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0250 Rev 0 Material and Equipment Storage and Maintenance.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0250 Revision 0, 10 June 2013 STORAGE REQUIREMENTS Items assigned a level of storage shall be maintained at this level of storage until they are removed from storage. Items removed from storage and installed, but not operating, shall have the assigned level of storage maintained. Levels of Storage Environmental conditions for items classified as levels A, B, C, and D described in this procedure shall meet the following requirements: Level A - Items shall be stored under those conditions described for Level B items but with any additional requirements detailed by the manufacturer and/or engineering representative. Level B - Items shall be stored within a fire-resistant, tear-resistant, weathertight, and well-ventilated building or equivalent enclosure. Precautions shall be taken against vandalism. This area shall be situated and constructed so that it will not be subjected to flooding; the floor shall be paved, or equal, and well-drained. Items shall be placed on pallets or shoring to permit air circulation. The area shall be provided with uniform heating and temperature control, or its equivalent, to prevent condensation and corrosion. Minimum temperature shall be 40°F (4C) and maximum shall be 140F (60C) or less if so stipulated by the manufacturer. Level C - Items shall be stored indoors, or equivalent, with all provisions and requirements as set forth in Level B items except that heat and temperature control is not required. Level D - Items may be stored outdoors in well-drained areas marked and designated for storage, preferable gravel-covered or paved, and reasonable removed from the actual construction and traffic so that possibility of damage from construction equipment is minimized. Items shall be stored in 4-inch (100mm) cribbing or equivalent to allow for air circulation and to avoid trapping water. Care of Stored Items Care of items in storage shall be exercised in accordance with the following: a. Items in storage shall have all covers, caps, plugs, or other closures intact. When it is necessary to remove a cover for access purposes, it shall be immediately replaced and properly resealed thereafter. Temporary preservatives shall be left intact during storage. Should reapplication of preservatives be required at the site, only those previously approved shall be used. Desiccant humidity indicators shall also be monitored, and desiccants shall be changed or reprocessed when specified. Instrumentation racks shall be energized as specified by the manufacturer. Space heaters enclosed in electrical items shall be energized. b. c. d. e. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0250 Rev 0 Material and Equipment Storage and Maintenance.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 0250 Revision 0, 10 June 2013 f. g. Rotating electrical equipment shall be given insulation resistance tests on a scheduled basis. The shafts of rotating equipment shall be rotated on a periodic basis. The degree of turn shall be 1 1/4 turn so that the parts receive a coating of lubrication where applicable, and so that the shaft does not come to rest in a previous position. Implement special instructions issued by the vendor or manufacturer for a particular piece of equipment. h. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-0250 Rev 0 Material and Equipment Storage and Maintenance.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02501 Revision 0, 10 June 2013 STORAGE INSPECTION CHECKLIST Storage Area/Item Storage Level YES 1. 2. 3. 4. 5. 6. 7. 8. 9. Are identifications and markings intact? Are covers, plugs, and caps intact? Are temporary preservatives and coatings intact? Is desiccant saturated? Any evidence of physical damage? Is proper cleanliness being maintained? Are instrument racks energized as specified? Are space heaters energized as specified? Has rotating equipment been rotated as specified? Date ID A02501 NO N/A 10. Has rotating equipment been tested as specified? 11. Evidence of damage to items hit by a forklift or truck? 12. Any water damage? 13. Is dust and dirt excessive? 14. Are items and materials on cribbing as specified? 15. Any container items broken or leaking? 16. Has storage level been maintained? Is Reinspection Required? Discrepancies: Yes No Remarks: Inspector/ Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02501 Rev 0 Storage Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02501 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02501 Rev 0 Storage Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02502 Revision 0, 10 June 2013 EQUIPMENT PROTECTION PRESERVATION AND INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Client Other Tag No.: Turnover System: Sub – System: Location: ID A02502 Initial Preservation Upon Receipt: Store on free draining ground or foundations. Inspect equipment protection by vendor. Tag and store accessory items. Reference Section For Additional Details Manufacturer: Corrosion Inhibitors/Lubricants (Note Type And Where Used): Date Performed Initials Frequency Indicate One: Days Weeks Months STD. Preservation Operations: Rotate Shaft 2-1/4 turns. Reference Section For Additional Details Date Performed Initials Date Performed Initials Frequency Date Performed Initials Date Performed Initials Frequency Describe: STD. Preservation Operations: Storage Conditions Damage Corrosion Flange Protection Accessory Conditions Reference Section For Additional Details Indicate One: Days Weeks Months Indicate: Days Weeks Months Special Instruction: (Project/Spec/Vendor) Date Performed Initials Date Performed Initial Remarks: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02502 Rev 0 Equipment Protection Preservation Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02502 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02502 Rev 0 Equipment Protection Preservation Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 ACTIVITY PLAN FOR CONSTRUCTION SCOPE This practice establishes instructions for the preparation of a project specific Activity Plan for Construction (inclusive of Construction Management and Maintenance). REFERENCES GENERAL • The Activity Plan is intended to: List the main activities to be performed in order to meet quality system requirements. Identify the work instructions for performing these activities. Assign responsibility for verification, and authorization of listed activities. Identify deviations from established minimum requirement work instructions provided by the Construction Operating Company. Provide for Operating Company acceptance of those deviations. N/A - • The Activity Plan - Construction - Reference Guide (Appendix I), is intended to provide guidance for development of a project specific Activity Plan - Construction. The following guidance is provided by the Reference Guide: Activity Description - This is a listing of primary activities performed on a construction project, except those activities for which Construction is not responsible (i.e., Project Management, Project Controls, Procurement, etc.). Work Instruction - This identifies the work instruction, procedure, practice, specification, or other guidance provided or referred to by Construction for performing the work activity. Basis of Check - This identifies either the checklist(s) or procedure used as a guide for checking the work. Inter-discipline Review - The individual(s) normally responsible for ensuring no conflicts between disciplines/departments exist. Independent Verification - This block is reserved for the entry of third party verification, (i.e., Testing Laboratory, Client, etc.), when applicable. Performed By - The title of the individual who is normally responsible for performing the work activity. - - - - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 1 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 - Checked By - The title of the individual responsible for checking and documenting activity compliance to work instructions, utilizing appropriate basis of check as required. This is normally someone other than the individual performing or directing the work. Approved by Construction - The title of the individual responsible for approving from a construction standpoint, that the work is accomplished and acceptable. Approved by Project - Usually reserved for project manager review and approval that the work performance and verification meets project and contract requirements. Approved by Client - to be used when the work performed requires the Client’s approval (usually specified by contract). NOTE: For subcontracted work, refer to the “Subcontractor Control” Section 1 of Appendix I for typical "Go-By". - - - PROCEDURE AND RESPONSIBILITIES • Site Manager or Designee Refer to Appendix I and revise as follows to develop the project specific AP - Construction. NOTE: The project specific "AP - Construction" may be developed by marking up the "AP - Construction - Reference Guide" (Appendix I) to indicate changes. Activity Description - Delete and add primary project specific activities as required. This should include activities Fluor is responsible for even though they may be performed by a Sub-contractor. Activities for which Fluor has no responsibility should not be listed on AP. Work instruction - Identify the work instruction, procedure, practice or specification for performing the Work Activity. If the work instruction is to be used without deviation from the Fluor Corporate Standard, the Fluor Corporate Descriptor as listed in the Reference Guide will be used. If a deviation to the Corporate Standard is made by project personnel, indicate the deviation by dropping the first three zero's of the Corporate Descriptor (e.g. 509 7031). If the work instruction is from a source outside Fluor (e.g., Client procedure or specifications), list the source document description. NOTE: Title descriptors noted in blocks of the Activity Plan - Construction may differ from those used in locations other than United States. Where this situation exists, use the Descriptors common to the location. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 2 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 Basis of check - Enter the checklist number or designation used as a guide for checking the work. Interdisciplinary Review - Specify the person responsible for reviewing and ensuring, thru crossdiscipline review, that no discipline or department conflicts exist. Independent Verification - enter a designator for any third party verification authority. This can apply to a Quality Control sub-contractor, testing subcontractor, Client, etc. Performed by - Enter the title of the person responsible for performing the activity. Checked By - Enter the title of the person responsible for checking and documenting activity compliance to work instruction utilizing appropriate basis of check as required. NOTE: "Checked By" in certain locations other than the United States will be performed by others disciplines that perform the Quality Control function and shall be so indicated as applicable. Approved by Construction - Enter the responsible individual (e.g., "CM" for Construction Manager) signifying that the work, has been accomplished and accepted per the listed instructions. Approved by Project - Enter the responsible individual (e.g., "PM" - for Project Manager or "OM" for Operations Manager) that has project function responsibility for approving the work. Usually involves contractual, administrative, engineering, and construction activities overview and responsibility. Intended to be the highest level of project activity approval. Approved by Client - Enter the Client representative (e.g., "Client PM"), when required by project contract or Project Procedures Manual that the work be approved. • Site Manager Sign and print name to indicate approval. • Operating Company Representative Sign and print name to indicate approval. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 3 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 • Site Manager After approval by the Operating Company Representative, if there are changes to the Work Instruction that result in deviations or if activities are added, notify the Operating Company Representative of these changes in writing. DOCUMENTATION Approved "Activity Plan - Construction" shall be maintained by the Site Manager until project completion. ATTACHMENTS Appendix I - Activity Plan - Construction (Reference Guide) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 4 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 Appendix I - Activity Plan – Construction Client Name Project Name Project Number PREPARATION ACTIVITY DESCRIPTION WORK INSTRUCTION BASIS OF CHECK INTER DISCIPLIN E REVIEW VERIFICATION INDEPENDENT VERIFICATION PERFORMED BY CHECKED BY AUTHORIZATION APPROVED BY CONSTR. APPROVED BY PROJECT APPROVED BY CLIENT Project Const. Plan Const. Org. Constructability 000.506.1300 000.506.1201 000.506.1100 000.506.1200 000.506.1300 000.506.1400 000.506.1500 000.506.1600 000.505.1601 000.505.2701 000.505.3201 Project Safety Plan in Compliance with FD-APS 000.505.2801 N/A N/A N/A N/A SM SM N/A N/A N/A N/A PM PM N/A PM PM N/A N/A PM Construction Engineering Human Resource Staffing Construction Turnover Project Safety Program Industrial Relations Program Construction Quality Control Plan Administrative Services ASME Code Work Document Control Personnel Training and Qualification Field Design Change Control Construction Process Control Site Preparation Geotechnical Investigation Excavation and Backfill Shotcrete Fireproofing Pile Installation Concrete Installation Grout Installation Structural Steel Installation Coatings and Wrapping of Steel Pipe Hot Insulation N/A N/A 000 509 0240 CEM N/A SM DCE FHRM CM N/A N/A SQM SM SM N/A N/A N/A PM N/A N/A S RSM N/A PM N/A Corporate QC Manual 000 509 xxxx N/A FD-B-PV Code Manual 000 510 xxxx 000.509.0050 000.509.0160 N/A 000.509.0150 000.509.0090 000.509.7010 000.509.7010 000.509.7820 000.509.7080 000.509.7100 000.509.7100 000.509.7200 000.509.7800 000.509.7810 Contract N/A SM IRRM N/A PM 000.505.1701 000.505.2401 Fluor-B-PV Code Manual 000 510 xxxx 000.509.0050 000.505.1601 000.509.0180 000.505.1400 000.509.0090 000.210.02010 000.210.02222 000.210.02224 000.215.03360 000.215.02370 000.215.02380 000.215.03300 000.215.03600A 000.215.03600B 000.215.05120 000.215.05130 000.285.86410 000.285.86210 000.285.86110 SQM CEM DQW CEM CEM CEM CEM DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE SVM CEM SM CM DCE DCE CM CM CM CM CM CM CM CM CM CEM N/A SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM SQM CM N/A N/A N/A N/A N/A CM SM CM CM CM CM CM CM CM CM N/A PM PM PM PM PM N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 5 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 PREPARATION ACTIVITY DESCRIPTION WORK INSTRUCTION BASIS OF CHECK INTER DISCIPLINE REVIEW VERIFICATION INDEPENDENT VERIFICATION PERFORMED BY CHECKED BY AUTHORIZATION APPROVED BY CONSTR. APPROVED BY PROJECT APPROVED BY CLIENT Internal Linings Raceway and Supports Installation Cable Installation 000.285.86310 000.265.65051 000.265.65052 000.265.65123 000.265.65126 000.265.65003 000.265.65301 000.265.65303 000.265.65313 000.265.65320 000.265.65382 000.265.65400 000.265.65480 000.265.65610 000.265.65630 000.265.65053 000.265.65053 000.265.65640 000.265.16111 000.265.65053 000.270.01851 000.270.70952 000.270.70001 000.270.70002 000.270.70003 000.270.70007 000.270.15121 000.265.65053 000.250.31003 000.250.31004 000.250.50026 000.250.50200 000.255.03161 000.250.03713 000.250.03711 000.250.03717 000.250.05360 000.250.17131 000.255.03161 000.250.50008 000.256.56001 000.256.56002 000.256.56003 000.256.56004 000.258.58001 000.258.58004 000.258.58010 000.258.58040 000.258.58050 000.259.59073 000.258.58061 000.258.58140 000.257.07041 000.257.18032 000.257.19033 000.257.57011 000.257.57020 000.257.57035 000.257.57103 000.270.70002 000.270.70950 000.270.70951 000.509.7800 Contract 000.509.7600 000.509.7600 000.509.7610 DCE DCE DCE CM CM CM SQM SQM SQM CM CM CM N/A N/A Equipment Installation 000.509.7400 000.509.7620 DCE CM SQM CM N/A Meggering and HiPot Testing Grounding Meggering and Maintenance of Electric Motors Electrical Heat Trace Receiving and warehousing of Instruments Electrical Instrument Installation Construction Testing Piping, Cement Lined Plastic and Plastic Lined Pipe 000.509.7600 000.509.7610 000.509.7620 000.509.7600 000.509.7610 000.509.7620 000.509.7600 000.509.7610 000.509.7620 000.509.7610 000.509.0230 000.509.0250 000.509.7600 000.509.7610 000.509.7620 * 000.509.7510 000.509.7500 111.509.7510 DCE CM SQM CM N/A DCE CM SQM CM N/A DCE DCE DCE CM CM WM SQM SQM SQM CM CM SM N/A N/A DCE CM SQM CM N/A DCE DCE DCE CM CM CM SQM SQM SQM CM CM CM N/A Mechanical Piping Installation 000.509.7500 000.509.7510 DCE CM SQM CM N/A Flanged Joints, Gaskets and Bolting Pipe Winterization Installation of Rotating Equipment 000.509.7500 000.509.7510 000.509.7500 000.509.7510 000.509.7400 DCE DCE CM CM SQM SQM CM CM N/A N/A DCE CM SQM CM N/A Installation of Tanks, Vessels - Heat Exchangers, Flares 000.509.7610 000.509.7500 000.509.7510 DCE CM SQM CM N/A Mechanical Instrument Installation 000.509.7700 000.509.7710 DCE CM SQM CM N/A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 6 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 PREPARATION ACTIVITY DESCRIPTION WORK INSTRUCTION BASIS OF CHECK INTER DISCIPLINE REVIEW VERIFICATION INDEPENDENT VERIFICATION PERFORMED BY CHECKED BY AUTHORIZATION APPROVED BY CONSTR. APPROVED BY PROJECT APPROVED BY CLIENT Pipe Cleaning Piping Heat Tracing Firewater Systems Fireproofing Sewer Systems Maintaining Quality Records Material Equipment Identification, Traceability and Inspection Test Status Nonconformance Reporting Corrective Action Site Supplier Quality Control System, Requirement Qualification and Surveillance Material and Equipment Receipt Inspection Material and Equipment Storage Handling Maintenance Inspection Measuring Test Equipment Surveillance of Construction Activities 000.250.18801 000.250.50300 000.245.00323 000.245.01431 000.250.50007 000.509.0160 000.509.7560 * 000.509.7610 000.509.7500 000.509.7510 000.509.7820 000.509.0220 000.509.0160 FD Inspection & Test Procedures 000 509 7xxx 000.509.0130 000.509.0140 000.509.0200 000.509.0210 000.509.0220 DCE DCE DCE DCE DCE SQM CM CM CM CM CM CM SQM SQM SQM SQM SQM SQM CM CM CM CM CM CM N/A N/A N/A N/A N/A N/A 000.509.7000 000.509.0230 SQM WM CM SQM CM N/A 000.509.0130 000.509.0140 000.509.0210 000.509.0200 000.509.0220 SQM SQM SQM CEM SQM CM SM SM N/A N/A SQM CEM SQM SM N/A 000.509.0230 000.509.0230 SQM WM CEM WM CEM SQM CM N/A 000.509.0250 000.509.0250 SQM SQM CM N/A 000.509.0110 000.509.0110 SQM CEM SQM CM N/A 000.509.0220 000.285.18034 000.285.18041 000.285.18101 000.285.19021 000.285.85001 000.285.85002 000.285.85010 000.285.85050 Subcontractor’s NDE Procedures 000.245.01431 000.215.02380 000.215.02370 000.285.86210 000.285.86310 000.285.86110 000.258.58001 000.258.58004 000.258.58010 000.258.58040 000.258.58050 000.258.58061 000.258.58140 000.257.07041 000.257.18032 000.257.19033 000.257.57103 API 650 Appendix H 000.257.57011 000.250.50027 000.509.0220 000.509.7910 000.509.7920 000.509.7930 000.509.7950 Fluor Welding Manual 000.512.xxxx SQM SQM SQM CM N/A Welding Metallurgy CEM CM SQM CM N/A SUBCONTRACTOR CONTROL Nondestructive Testing Fireproofing Drilled Piers, Caissons Auger Cast Piles Painting & Linings Hot Insulation 000.509.0220 000.509.7920 000.509.7820 Contract 000.509.7080 Contract 000.509.7080 Contract 000.509.7800 Contract 000.509.7810 Contract MNDT CEM CEM CEM CEM CEM SQM SUB SUB SUB SUB SUB SUB SQM DCE DCE DCE DCE DCE SM CM CM CM CM CM N/A N/A N/A N/A N/A N/A ASME Section VIII Vessel Work Contract CEM SUB SQM CM N/A Fired Heaters Field Fabricated Tank Retrofit (TK – 806) Cool Tower Installation Piping Tie-ins 000.509.7400 Contract 000.509.7400 Contract 000.509 Contract CEM SUB SQM DCE SQM DCE DCE DCE CM N/A CEM CEM CEM Client SUB SUB SUB CM CM CM N/A N/A N/A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 7 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 PREPARATION ACTIVITY DESCRIPTION WORK INSTRUCTION BASIS OF CHECK INTER DISCIPLINE REVIEW VERIFICATION INDEPENDENT VERIFICATION PERFORMED BY CHECKED BY AUTHORIZATION APPROVED BY CONSTR. APPROVED BY PROJECT APPROVED BY CLIENT Fire Protection/Sprinkler Systems Substation Equipment Modification Electrical Equipment Testing Hi-Pot and Acceptance Testing Electrical Heat Tracing Reactor Flex-R Instrumentation Installation Field Machining Geotechnical Investigation Mechanical/ Chemical Cleaning Post-Weld Heat Treatment (PWHT) Soil & Concrete Testing Underground Piping 000.245.00323 000.245.65301 000.265.65303 000.265.65320 000.265.65053 000.265.50300 000.270.01851 000.270.01511 Contract 000.210.02010 000.250.18801 000.250.50026 000.285.18041 Fluor Welding Manual 000.210.02222 000.210.02224 000.215.03300 000.245.00323 Contract CEM SUB DCE CM N/A Contract 000.509.7600 000.509.7610 000.509.7620 Contract Contract Contract Contract Contract 000.509.7560 000.509.0220 000.509.7920 000.509.7010 000.509.7100 000.509.7500 CEM SUB DCE CM N/A CEM SUB DCE CM N/A CEM CEM CEM CEM CEM CEM SQM SUB SUB SUB SUB SUB SUB DCE DCE SQC DCE DCE/SQM SQM DCE SQM SQM DCE CM CM CM CM CM CM N/A N/A N/A N/A N/A N/A CEM CEM SQM SUB SUB CM CM N/A N/A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 8 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 PQ CS CEM FL CM DCE DQW FHRM NDE IRRM LDE MWT N/A PD PM RSM SC SUB SVM SQM SM S WM CTM AEASSIGNED PROJECT QA ENGINEER CODE SPECIALIST/GREENVILLE CONSTRUCTION ENGINEERING MANAGER CONSTRUCTION FUNCTIONAL LEADER CONSTRUCTION MANAGER DISCIPLINE CONSTRUCTION ENGINEER DIRECTOR QUALITY CONTROL AND WELDING TECHNOLOGY FIELD HUMAN RESOURCE MANAGER FLUOR DANIEL NDE LEVEL III INDUSTRIAL RELATIONS REGIONAL MANAGER LEAD DISCIPLINE ENGINEER MANAGER WELDING TECHNOLOGY/GREENVILLE NOT APPLICABLE PROJECT DIRECTOR/PROJECT MANAGER PROJECT MANAGER REGIONAL SAFETY MANAGER SELF CHECK ONLY SUBCONTRACTOR SERVICE MANAGER SITE QC MANAGER SITE MANAGER SITE SAFETY MANAGER WAREHOUSE MANAGER CONTRACTS MANAGER _________________________________________ Print Signature ______________________________________ Print Signature _________________________________________ Signature ______________________________________ Signature FLUOR SITE MANAGER FLUOR OPERATING COMPANY REPRESENTATIVE * These checklists are provided in the "Discipline QC Functions" section (000.509.7xxx). W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 9 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 5100 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-5100 Rev 0 Activity Plan for Construction.doc Page 10 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7000 Revision 0, 10 June 2013 INSPECTION AND TESTING Definitions Inspection and tests are defined as follows: "Inspection" being visual checks of a qualitative nature but also including dimensional measurements. "Tests" being measured verifications of one or more characteristics or of performance, both being carried out to ascertain whether or not the specified requirements have been met. Inspection and Testing Procedures Inspection and test measures to be applied are presented in this section (7XXX). These procedures provide for the inspections and tests necessary to determine that the product is acceptable and for the documentation to record compliance with the established acceptance criteria. The inspection scope and frequency will be determined on a case-by-case basis with guidance provided in the "Responsibilities" section of each procedure. If specifications, vendor manuals, test procedures, codes/standards, or other such documents required by specifications to be used as acceptance criteria are not readily available to inspection personnel, the Site Quality Manager may include this information as attachments to these procedures. Attachments may also be used to list the source documents providing acceptance criteria for tests and inspections within the scope of each procedure. Inspection and Test Plans An Inspection and Test Plan (ITP) is a document used to list the quality related activities that pertain to a distinct scope of work or process. The ITP shall consist of the following features: a list of the inspection and test points presented in sequence in the order in which they are to be performed for each activity, reference to a document stating the acceptance criteria; for each activity, the "verification document" i.e. the document to be checked or the one used to record the result of the inspection or test; for each activity for both Contractor and FLUOR, where required, an indication of the scope of inspection as follows: I - Inspect T - Test W - Witness Point This indicates an Inspection/Text Activity on the ITP that requires a request for the presence of the Fluor Representative. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7000 Rev 0 Inspection and Testing.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7000 Revision 0, 10 June 2013 R - Review H - Hold Point This indicates an inspection or test which is considered vital to the quality, integrity and safe functioning of the material or services and which can only be achieved at this point. It is an Inspection/Test Activity on the ITP that requires the presence of the Fluor Representative. The Production/Erection Process cannot proceed beyond this point until it has been cleared by the Inspection Fluor Representative. ITPs may be used to record completion of activities, indicated by sign-off (acceptance). This is normally applicable to scopes of work encompassing a relatively self-contained unit such as a steam turbine or cooling tower. When this is the case ITP form 000.509.F70002shall be used. Otherwise for processes such as concrete placement or piping installation, Inspection and Test Plans shall be documented on form 000.509.F70001. ITPs may be used in lieu of or in conjunction with Inspection and Test Procedures. Inspection Cycles Adequate inspection will be performed to cover required construction operations. The inspection cycle normally includes preparatory, initial, follow-up and final inspection. This cycle is described below: Preparatory - Performed prior to beginning work to ensure the prerequisites are satisfied and requirements understood by those who perform the work. It includes a review of requirements; a check to assure that all materials and/or equipment are on hand and are approved and that all preliminary work has been completed. Initial - Performed at the outset of segments of work to get the work off to a proper start in full compliance with contract requirements. Follow-up - Performed daily or as frequently as necessary to assure continuing compliance with contract requirements. Final - Inspections that verify the acceptance of completed items. This occurs throughout fabrication and installation. Acceptance is indicated by use of the inspection checklist referenced by procedures of this section. - - - The inspection status of constructed or installed items is normally determined by reference to the inspection or test reports/checklists included as referenced forms to these procedures. These forms are completed concurrently with the construction /installation activities. Deficiencies that are found during inspection, and cannot be corrected at that time, are to be documented on Surveillance Reports (000.509.F02201), so that they can be tracked to closure. In special cases that are described by 000.509.0130where a NCR is needed, that documentation does not need to be duplicated by a Surveillance Report. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7000 Rev 0 Inspection and Testing.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7000 Revision 0, 10 June 2013 FORMS Quality Control Form: 000.509.F70001 - Inspection and Test Plan Form 000.509.F70002 - Inspection and Test Plan/Activity Completion From ATTACHMENTS Attachment 1 - Instructions for completion of the ITP form W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7000 Rev 0 Inspection and Testing.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7000 Revision 0, 10 June 2013 Attachment 1 Field Name Activity Description - Instructions for completion of the ITP form Description Identify the general activity or scope of work for the ITP Identify the specific activity that applies to the ITP Enter project name and number Enter Client name Enter contractor name (if subcontracted) Enter contract or subcontract number as applicable Uniquely Identify the ITP, ITP 509 7XXXX Project Name/Number Client Contractor Contract Number ITP Number Issue Date/Revision Number Enter the current issue date and revision Item Number Quality-Related Activity Requirement and Acceptance Criteria Used to identify the sequence of the quality-related activity Enter a description of the quality-related activity Enter the acceptance criteria or reference to the specification or other standard where the acceptance criteria may be found. Enter the Fluor position primarily responsible for executing Fluor’s participation in the activity. Use the code legend on the bottom of the ITP form to represent the entities. Use these fields to specify the level of participation required by the various entities. If an inspection record is to be used to document the inspection results, enter the form or record number. If the activity is recorded in CompleteIt indicate with a “Yes” Indicate if Fluor and/or Client signatures are required. Responsibility Scope of Inspection Inspection Record CompleteIt Input Completion Sign-off W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7000 Rev 0 Inspection and Testing.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70001 Revision 0, 10 June 2013 Inspection and Test Plan Description Client Project Name Contractor Project Location Contract Number Activity Project Number Item Inspection/Test Stage Requirement and Acceptance Criteria Document Number Issue Date ITP 509 7XXXX Revision X Scope of Inspection Inspection Responsibility Record Sub Fluor Client CompleteIT Input Inspection Legend: P = Perform I = Inspection T = Test R = Review and Approve W = Witness (Notification of authorized inspection personnel required) H = Hold (Mandatory, do not proceed without presence of authorized inspection personnel or signed waiver) Responsibility Legend: CS = Fluor Construction Supervision CEM = Fluor Construction Engineering Manager QI = Fluor Quality Inspector CWI = Fluor Certified Welding Inspector RI = Fluor Receiving Inspector NDE = Certified NDE Examiner W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70001 Rev 0 Inspection and Test Plan 1.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70002 Revision 0, 10 June 2013 Inspection and Test Plan Description Client Project Name Contractor Project Location Contract Number Document Number ITP 509 FXXXX Revision 0 Activity Project Number Issue Date Item Inspection/Test Stage Requirement and Acceptance Criteria Scope of Inspection Responsibility Sub Fluor Client Inspection/Test Record Completion Sign-Off Fluor Client Inspection Legend: P = Perform I = Inspection T = Test R = Review and Approve W = Witness (Notification of authorized inspection personnel required) H = Hold (Mandatory, do not proceed without presence of authorized inspection personnel or signed waiver) Responsibility Legend: CS = Fluor Construction Supervision CEM = Fluor Construction Engineering Manager QI = Fluor Quality Inspector CWI = Fluor Certified Welding Inspector RI = Fluor Receiving Inspector NDE = Certified NDE Examiner W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70002 Rev 0 Inspection and Test Plan 2.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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RESPONSIBILITIES - Self-Perform ACTIVITY Perform soils work Inspect in-process soils work RESPONSIBILITY Self-Perform QC Inspector 000.509.F70101 000.509.F70102 000.509.F70103 000.509.F70104 (Note 1) 000.509.F70105 Daily during life of activity DOCUMENTATION FREQUENCY OF ACTIVITY Test Soils Work Test Lab contracted to Fluor Civil Construction Engineer QC Inspection (Note 2) As Directed Technically Supervise Test Agency Surveillance NOTE 1: Daily during life of activity 000.509.F02201 Per Procedure 000.509.0220 Approved test agency reports on their letterhead is preferred over the use of forms for documenting soils tests, but it must contain at least the information provided by Forms 000.509.F70102, 000.509.F70103, 000.509.F70104. Fluor QC Surveillance is required for construction activities not being documented on other Inspection forms by Fluor Quality. NOTE 2: RESPONSIBILITIES - Subcontracted Work ACTIVITY Perform soils work Inspect in-process soils work RESPONSIBILITY Subcontractor Subcontractor 000.509.F70101 000.509.F70102 000.509.F70103 000.509.F70104 (Note 1) 000.509.F70105 Daily during life of activity DOCUMENTATION FREQUENCY OF ACTIVITY Test Soils Work Test Lab contracted to subcontractor As directed Technically Supervise Test Agency Surveillance NOTE 1: Subcontractor QC Inspector Form 000.509.F02201 Daily during life of activity Per Procedure 000.509.0220 Approved test agency reports on their letterhead is preferred over the use of forms for documenting soils tests, but it must contain at least the information provided by Forms 000.509.F70102, 000.509.F70103, 000.509.F70104. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7010 Rev 0 Soils.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7010 Revision 0, 10 June 2013 NOTE 2: GENERAL • Fluor QC Surveillance is required for construction activities not being documented on other Inspection forms by the Fluor Quality. Inspection Inspection will include the items on the Soil Inspection Checklist Inspection Reference (Form 000.509.F70101). As a minimum, there will be a Soils Inspection Checklist for each location represented by the Field Compaction Test Record (Form 000.509.F70102). Monitor on-site testing for compliance to approved test procedures and schedule. The soil density test shall be given unique numbers starting with number 1 and running consecutively until the last test. - - • Technical supervision of the test agency will include: Establishing that the test agency is qualified to perform the testing required. Schedule soils testing with the testing laboratory as required by the specifications. Review of personnel qualifications, procedures, test equipment, and job performance. Keeping the Contracts Manager informed on the laboratory's performance. Verify that results and test frequency conform to specification requirements and are traceable to work. Failing tests are to be backed up by acceptable tests or a NCR. Maintaining soils test and/or inspection records received from the test agency. This includes retention of failed tests. Retests shall be the same test number as the failed test using suffix R1, R2, etc. - • Refer to Attachment I for test and inspection acceptance criteria. FORMS Quality Control Forms: 000.509.F70101000.509.F70102000.509.F70103000.509.F70104000.509.F70105Soil Inspection Checklist Field Compaction Test Record Density of Soil in Place by the Sand-Cone Method Nuclear Moisture - Density Test Report Soil Density Test Log ATTACHMENTS Attachment 01 - Acceptance Criteria [::This appendix is optional. It may list test procedures and specifications for soils work. It may also contain the detailed criteria from these documents that will be needed by the inspector for determining acceptability.::]N/A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7010 Rev 0 Soils.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70101 Revision 0, 10 June 2013 SOIL INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70101A Client Other Sub – System: Location: Drawing No.: Specification No.: Inspection Reference 1. Excavation cleared of foreign and loose material. 2. Slopes shored or correctly stepped. 3. Fill Material cleans and conforms to requirements. 4. Lift thickness and compaction procedures in accordance with specifications. 5. Final elevation in accordance to drawings. 6. Moisture control acceptable. 7. Compaction Method and Equipment. 8. Soil Density Test Reports filed. Remarks: Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70101 Rev 0 Soil Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70101 Rev 0 Soil Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70102 Revision 0, 10 June 2013 FIELD COMPACTION TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70102A Client Other Sub – System: Location: Drawing No. Type of Subgrade Type Fill Laboratory Standard: Type Field Test Equip: Type Location Sketch S/N Date Specification No. Type Compactor Lift Thickness Test Date Min. Compaction Required: % Max. Density Optimum Moisture Correction Factor Test No. Elevation/ Depth Moisture % Dry Density Compaction % Acc/ Rej Comments: Tested By Approved By W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70102 Rev 0 Field Compaction Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70103 Revision 0, 10 June 2013 DENSITY OF SOIL IN PLACE BY THE SAND-CONE METHOD ASTM D-1566 - AASHTO-T-191 Date: Standard Sand Density ___________ kg/m³ Minimum Compaction Required (Standard Proctor) _____________% Fill Material Identification Location of Sample Maximum Dry Density kg/m³ Optimum Moisture __________ % Method of Test Original Weight Sand + Container Final Weight Sand + Container Total Weight Sand Used Sand Contained in Cone Total Sand in Volume of Hole Weight Wet Soil + Tare Weight Dry Soil + Tare Weight Water Weight Tare Weight Dry Soil Moisture Content % Weight Wet Soil + Tare Weight Tare Weight Wet Soil Weight Dry Soil Dry Density kg/m³ Percent Compaction ID C70103A Inspector: Reviewed by: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70103 Rev 0 Sand Cone Soil Density.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70104 Revision 0, 10 June 2013 NUCLEAR MOISTURE - DENSITY TEST REPORT Test Number Location Average Elevation: From To Mode & Depth Proctor Number Maximum Dry Density Optimum Moisture Density Count Density Count Ratio Wet Density PCF Moisture Count Moisture Count Ratio Moisture PCF Dry Density % Moisture % Compaction Required Minimum Compaction Standard Count Machine Number Density Moisture ID C70104A Remarks : Inspector: Reviewed by: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70104 Rev 0 Nuclear Soil Density.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70104 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70104 Rev 0 Nuclear Soil Density.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70105 Revision 0, 10 June 2013 SOIL DENSITY TEST LOG DENSITY TEST NO. DATE Comp % W % PLACEMENT REPRESENTED ACC REJ Comp % ID C70105A RE TEST RESULTS W ACC REJ ACC % REC W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70105 Rev 0 Soil Density Test Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70105 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70105 Rev 0 Soil Density Test Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7020 Revision 0, 10 June 2013 BITUMINOUS CONCRETE PAVING SCOPE The purpose of this procedure is to establish and define the inspection and testing necessary to verify conformance to design requirements for bituminous concrete paving. RESPONSIBILITIES - Self-Perform ACTIVITY Verify Subgrade acceptable Accept base and paving material qualification Inspect in-process base preparation and paving activities Perform test for base RESPONSIBILITY QC Inspector DOCUMENTATION 000 509 F70201 and 000 509 F70103 or 000 509 F70104 _____ FREQUENCY OF ACTIVITY Prior to installing base Prior to start of base and paving work Daily during activity Construction Engineer QC Inspector 000 509 F70201 000 509 F70201 and 000 509 F70103 or 000 509 F70104 (Note 1) 000 509 F70202 and 000 509 F70204 (Note 1) _____ Form 000 509 F02201 Testing Agency As required by project specifications As required by project specifications Daily during activity Per Procedure 000 509 0220 Perform test for paving Technically supervise Test Agency Surveillance Testing Agency Construction Engineer QC Inspection (Note 2) NOTE (1): An approved test agency reports on their letterhead is preferred for documenting tests but they must contain at least the information provided by these forms. NOTE (2): Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7020 Rev 0 Bituminous Concrete Paving.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7020 Revision 0, 10 June 2013 RESPONSIBILITIES - Subcontracted Work ACTIVITY Install base and paving Verify Subgrade acceptable Accept base and paving material qualifications Inspect in-process base preparation and paving activities Perform testing for base RESPONSIBILITY Subcontractor DOCUMENTATION _____ Form 000 509 F70201 and 000 509 F70103 or 000 509 F70104 _____ Form 000 509 F70201 Form 000 509 F70201 and 000 509 F70103 or 000 509 F70104 (Note 1) Form 000 509 F70202 and 000 509 F70204 (Note 1) _____ 000 509 F02201 FREQUENCY OF ACTIVITY _____ Prior to installing base Prior to start of base and paving work Daily during activity Subcontractor Subcontractor/ Construction Engineer Subcontractor Subcontractor As required by project specifications Perform testing for paving Technically supervise test agency Surveillance Subcontractor Subcontractor QC Inspector As required by project specifications Daily during activity Per Procedure 000 509 0220 NOTE (1): Fluor approved test agency reports on their letterhead is preferred for documenting tests but they must contain at least the information provided by these forms. PROCEDURE • Accept Base and Paving Materials Qualification: Prior to placing any bituminous paving, perform necessary tests to assure material compliance to project requirements. a) b) Verify that material qualification tests for the subgrade have been performed. Verify that material qualification test for the bituminous concrete paving have been performed and approved. Verify that proposed mix formulas have been tested and approved for use. c) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7020 Rev 0 Bituminous Concrete Paving.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7020 Revision 0, 10 June 2013 • Verify Subgrade Is Acceptable: a) That soft unstable or unsuitable material is removed and replaced with suitable material. b) That the subgrade conforms to the lines, grades and cross sections shown on the drawings. c) That the specified compaction has been obtained. Document these inspections on the "Bituminous Concrete Paving Inspection Checklist" 000 509 F70201 on a daily basis. • Inspect In-process Base Preparation and Paving Activities: Prior to and during base preparation and paving operations, perform the following verifications and inspections. Document findings on 000 509 F70201. a) Verify that paving and compaction equipment is in good working condition and is of the type and size specified by design. Verify that layer thickness and total thickness of base and paving is as specified. Verify that smoothness of base and paving is as specified. Verify that the prime coat is spread at the specified rate on the compacted base and allowed to cure and dry. Verify that no bituminous paving is placed during periods of unsuitable weather conditions. Verify the temperature of the bituminous concrete mix at time of spreading to assure conformance to specification requirements. Verify that the mix is placed to specified thickness for the surface course. Verify that paving mix is placed to specified width, overlapping strips at edges. Verify that pavement is periodically checked for proper line and grade and conforms to specified tolerances. Verify that construction joints between old and new pavements or between successive day's work have a continuous bond between adjoining work with same texture, density, and smoothness as other sections of bituminous paving. Verify that rolling is accomplished in accordance with requirements and continued until required density is obtained and no roller marks remain. b) c) d) e) f) g) h) i) j) k) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7020 Rev 0 Bituminous Concrete Paving.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7020 Revision 0, 10 June 2013 l) Verify that defective areas in new pavement are removed and replaced with fresh mix material and compacted to required density and smoothness. m) Verify that base course has been cleared of loose material and dust, and that a tack coat has been applied at the specified rate. Prior to paving over existing bituminous surfaces, perform the following inspections and document the results on 000 509 F70201. a) Verify that the surface to receive paving is patched, broomed, and free from dust and foreign material. Verify that the tack coat is applied to contact surfaces of previously constructed bituminous paving or surfaces abutting or projecting into pavement area at the specified rate of application. b) • Perform Test: Perform applicable test at frequency required in specifications, and record results on applicable forms. Appropriate testing standards are: a) Density of soil-in-place by the Sand Cone Method - ASTM-D-1556, AASHTO-T-191. (F70103) Density of soil and soil-aggregate in place by Nuclear Method - ASTM-D-2922. (F70104) Bulk specific gravity of Compacted Bituminous Mixtures - AASHTO-T166. (F70202) Bulk specific gravity of Compacted Bituminous Mixtures using Paraffin - Coated Specimens - ASTM-D-1188. Bulk specific gravity of Compacted Bituminous Mixtures using Saturated Surface Dry Specimens - ASTM-D-2726. Degree of pavement compaction of Bituminous Aggregate Mixtures - AASHTO-T230. Density of bituminous concrete in place by Nuclear Method - ASTM-D-2950. ::] [:: b) c) d) e) f) g) - Report failing or unsatisfactory test results to the paving contractor immediately for rework or corrective action. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7020 Rev 0 Bituminous Concrete Paving.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7020 Revision 0, 10 June 2013 FORMS Quality Control Forms: 000 509 F70103 - Density Of Soil In Place By The Sand Cone Method ASTM D-1556ASHTO-T-191 000 509 F70104 - Nuclear Moisture - Density Test Report 000 509 F70201 - Bituminous Concrete Paving Inspection Checklist 000 509 F70202 - Bulk Specific Gravity 000 509 F70204 - Nuclear Density - Bituminous Concrete ATTACHMENTS Attachment 1 - Acceptance Criteria [::This appendix is optional. It may list test procedures and specifications for soils work. It may also contain the detailed criteria from these documents that will be needed by the inspector for determining acceptability.::]N/A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7020 Rev 0 Bituminous Concrete Paving.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70103 Revision 0, 10 June 2013 DENSITY OF SOIL IN PLACE BY THE SAND-CONE METHOD ASTM D-1566 - AASHTO-T-191 Date: Standard Sand Density ___________ kg/m³ Minimum Compaction Required (Standard Proctor) _____________% Fill Material Identification Location of Sample Maximum Dry Density kg/m³ Optimum Moisture __________ % Method of Test Original Weight Sand + Container Final Weight Sand + Container Total Weight Sand Used Sand Contained in Cone Total Sand in Volume of Hole Weight Wet Soil + Tare Weight Dry Soil + Tare Weight Water Weight Tare Weight Dry Soil Moisture Content % Weight Wet Soil + Tare Weight Tare Weight Wet Soil Weight Dry Soil Dry Density kg/m³ Percent Compaction ID C70103A Inspector: Reviewed by: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70103 Rev 0 Sand Cone Soil Density.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70104 Revision 0, 10 June 2013 NUCLEAR MOISTURE - DENSITY TEST REPORT Test Number Location Average Elevation: From To Mode & Depth Proctor Number Maximum Dry Density Optimum Moisture Density Count Density Count Ratio Wet Density PCF Moisture Count Moisture Count Ratio Moisture PCF Dry Density % Moisture % Compaction Required Minimum Compaction Standard Count Machine Number Density Moisture ID C70104A Remarks : Inspector: Reviewed by: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70104 Rev 0 Nuclear Soil Density.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70104 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70104 Rev 0 Nuclear Soil Density.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70201 Revision 0, 10 June 2013 BITUMINOUS CONCRETE PAVING INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70201A Client Other Sub – System: Location: Subcontractor Location – Sta. 1. Subgrade acceptable Compaction Preparation Line/grade per drawing Base Preparation acceptable Equipment Layer thickness/total thickness Compaction Smoothness Material Paving acceptable Weather conditions Mix temperature Layer thickness/total thickness Overlaps/joints Rolling Tack coat Prime coat Repairs Finish surface smoothness Line/grade 4. Testing complete and acceptable Date To QC Inspector/Eng. 2. QC Inspector/Eng. 3. QC Inspector/Eng. Const. Eng. Remarks: Inspector/Eng.: Reviewed by: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70201 Rev 0 Bituminous Concrete Paving Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70201 Rev 0 Bituminous Concrete Paving Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70202 Revision 0, 10 June 2013 BULK SPECIFIC GRAVITY Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70202A Client Other Sub – System: Location: Date Location of Sample Subcontractor Type Mixture Sample # PARAFFIN COATED SPECIMENS Bulk SP gr. = A D-E - (D-A) F = = SP gr. A = Mass of dry specimen in air, g, D = Mass of dry specimen plus paraffin coating in air, g, E = Mass of dry specimen plus paraffin coating in water, g, F = Specific gravity of the paraffin at 25oC (77oF) + 2oF Method Used: AASHTO T 166 ASTM D 1188 UNCOATED SPECIMENS A B-C = = SP gr. Bulk SP gr. = A = Mass in grams of sample in air. B = Mass in grams of surface dry specimen in air. C = Mass in grams of sample in water. Method Used: Inspector: Reviewed by: AASHTO T 166 ASTM D 2726 Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70202 Rev 0 Bulk Specific Gravity.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70204A Client Other Sub – System: Location: Test Number Location Drawing Number Mode & Depth Marshell Test Number Maximum Density Density Count Density Count Ratio Wet Density % Compaction Specified Minimum Compaction Standard Count Machine Number Density Remarks: Draw Sketch Inspector: Reviewed by: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70204 Rev 0 Nuclear Bituminous Concrete Density .doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70204 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70204 Rev 0 Nuclear Bituminous Concrete Density .doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7030 Revision 0, 10 June 2013 STEEL H PILES SCOPE This procedure prescribes the installation, inspection, and testing of Steel H Piles. RESPONSIBILITIES - Self-Perform ACTIVITY Monitor pile load test Inspect in-process pile driving Check final pile locations/installation Surveillance RESPONSIBILITY Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer QC Inspection (Note 2) DOCUMENTATION _____ 000.509.F70301 000.509.F70302 000.509.F70303 Survey field books 000.509.F02201 FREQUENCY OF ACTIVITY As required Daily during life of activity As required As required RESPONSIBILITIES - Subcontracted Work ACTIVITY Perform pile load test (See Note 1) Monitor pile load test Inspect in-process pile driving (See Note 1) Check final pile installation NOTE 1: RESPONSIBILITY Subcontractor Civil Construction Engineer Subcontractor Subcontractor/ Civil Construction Engineer DOCUMENTATION _____ _____ 000.509.F70301 000.509.F70302 000.509.F70303 Survey Field Books FREQUENCY OF ACTIVITY As required by project specification As required Daily during life of activity As required Approved testing agency reports on their letterhead is acceptable for documenting pile information, but it must contain at least the information provided by Form(s) 000.509.F70301, 000.509.F70302, and 000.509.F70303 Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. NOTE 2: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7030 Rev 0 Steel H Piles.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7030 Revision 0, 10 June 2013 PROCEDURE • Monitor Pile Load Tests: Conduct tests under the direct supervision of the Civil Construction Engineer or their representative. The engineer or their representative is responsible for the following: a) b) c) d) e) Approve the general plan and equipment to be used for the test. Observe the driving of test and reaction piles. Observe the application of loading apparatus. Record test data. Prepare reports in accordance with ASTM D 1143, D 3689, or D 3966 as applicable. - Drive test piles in accordance with design specifications, using the same equipment to be used for production piles. Locate cribbing or reaction piles in accordance with ASTM D 1143, D 3698, or D 3966 as applicable. Install reaction and test piles at least seven (7) days prior to commencing load tests. Provide test piles from the same manufacturer as production piles. Axial Compression Conduct test in accordance with ASTM D 1143. Apply loads by employing both calibrated hydraulic jacks and load cells. Do not leave loaded jacks unattended. Use two (2) dial gages mounted independently on supported reference beams as primary system for measuring movement. Do not cross-connect reference beams. Use surveyor's level as a secondary measurement system. Use cyclic loading procedure in accordance with ASTM D 1143, Section 5.2. Take and record readings of time, load, and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100, and 120 minutes. During periods, when the load is held constant for more than 120 minutes, take and record reading at 60 minute intervals after the first 120 minutes. During unloading, take and record readings at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2, and 12 hours after all load has been removed. - - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7030 Rev 0 Steel H Piles.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7030 Revision 0, 10 June 2013 Axial Tension Load Test Conduct test in accordance with ASTM D 3689 except as modified below. Apply loads by employing both calibrated hydraulic jack and load cell. Do not leave loaded jack unattended. Use two (2) dial gages mounted on independently supported reference beams as primary system for measuring movement. Do not cross connect reference beams. Use surveyor's level as secondary system. Use cyclic loading procedure in accordance with ASTM D 3689, Section 7.3. Take and record reading of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100, and 120 minutes. During periods when the load is held constant for more than 120 minutes, take and record readings at 60 minute intervals after the first 120 minutes. During unloading, take and record readings at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2, and 12 hours after all load has been removed. - - - Lateral Load Tests Conduct test in accordance with ASTM D 3966 except as modified below. Apply loads employing both calibrated hydraulic jack and load cell. Do not leave loaded jacks unattended. Use a dial gage mounted on independently supported reference beams as primary system for measuring movement. Use surveyor's transit and scale as secondary system. Use cyclic loading procedure in accordance with ASTM D 3966 standard measuring procedures. - - • Inspect in-process pile driving: Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined refusal as ____ blows per foot. Contact the engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7030 Rev 0 Steel H Piles.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7030 Revision 0, 10 June 2013 - Use one specific model of pile driving hammer for driving all Steel H Piles. Operate pile driving hammer at the speed and conditions recommended by the manufacturer. Protect piles during driving with cushioned caps that do not absorb hammer energy. Use leads to secure the piles against lateral movement during driving. Drive piles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and tip elevation. The center of the pile at the cutoff elevation shall not deviate more than ___ inches from the location on the design drawings. Plumb pile alignment shall not deviate more than ___ inches per foot of pile length from the batter line on design drawings. Splice piles as detailed on design drawings. Cut tops of piles off and level within inches of the elevation shown on drawings. - - - • Provide uplift connection at locations and as described on design drawings. Prebored pilot holes are prohibited. Check Final Pile Location/Installation: Reject piles that do not meet all the requirements of design specifications including those that are damaged, cracked, misplaced, or driven out of alignment tolerances. FORMS Quality Control Forms: 000.509.F70301 - Pile Driving Inspection Record 000.509.F70302 - Pile Driving Record 000.509.F70303 - Record of Pile Driving W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7030 Rev 0 Steel H Piles.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70301 Revision 0, 10 June 2013 PILE DRIVING INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Driving Formula Weight Of Hammer Foundation Number Depth in m Blows Per m Depth in m Blows Per m Depth in m Blows Per m ID C70301A Tag No.: Turnover System: Client Other Sub – System: Location: Date Drop Type Of Hammer Pile Data Pile Number Dia: Tip Head Length of 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 Cut Off Bottom of Pile Overburden Design Length Kind of Pile Starting Time Stopping Time Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70301 Rev 0 Pile Drivig Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70302A Client Other Sub – System: Location: Project: Location: Pile Capacity: Pile Size: Weather Condition: Pile Number Length Date Driven Driver Type: Ramweight: Freefall Height: Pile Type: Pile Manufacturer: Horizontal 7,5 cm Maximum Point Elevation Cut-Off Elevation Blowcount Last m/cm Redriven Record: General Remarks: Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70302 Rev 0 Pile Driving Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70302 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70302 Rev 0 Pile Driving Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70303 Revision 0, 10 June 2013 RECORD OF PILE DRIVING Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70303A Client Other Sub – System: Location: General Information Job Number: Pile Type: Specified Capacity: Required Blows: Pile Size: Pile Number Orig. Length Date Driven Pile Data Jetting Depth Surface Elev. Driving Time Cut-Off Elev. Tip Elevation Cut-Off Length Blows Per cm. Blows Per cm. Blows Per cm. Blows Per cm. Blows Per cm. Blows Per cm. Hammer Data Make: Model: Stroke: Ram Weight: Rated Energy: Type: Action: Remarks: Depth Depth Depth Depth Depth Depth Subcontractor Name Signature Date Name Penetration Resistance Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70303 Rev 0 Record of Pile Driving.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70303 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70303 Rev 0 Record of Pile Driving.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7040 Revision 0, 10 June 2013 PRECAST CONCRETE PILES SCOPE This procedure prescribes the installation, inspection and testing of precast prestressed concrete piles. RESPONSIBILITIES - Self-Perform ACTIVITY Monitor pile load test Inspect in-process piling installation Check final pile location/installation Surveillance RESPONSIBILITY Civil Construction Engineer Civil Construction Engineer Senior Field Engineer QC Inspection (Note 2) DOCUMENTATION _____ 000.509.F70301 000.509.F70302 000.509.F70303 Survey Field Books 000.509.F02201 FREQUENCY OF ACTIVITY As required Daily during life of activity As required Per Procedure 000 509 0220 RESPONSIBILITIES - Subcontracted Work ACTIVITY Perform pile load test (See Note 1) Monitor pile load test Inspect in-process pile driving (See Note 1) Check final pile installation NOTE 1: RESPONSIBILITY Subcontractor Civil Construction Engineer DOCUMENTATION _____ _____ 000.509.F70301 000.509.F70302 000.509.F70303 Survey Field Books FREQUENCY OF ACTIVITY As required by project specification As required Subcontractor Subcontractor/ Civil Construction Engineer Daily during life of activity As required Approved testing agency reports on their letterhead is acceptable for documenting pile information, but it must contain at least the information provided by Form(s) 000.509.F70301, 000.509.F70302, and 000.509.F70303 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7040 Rev 0 Precast Concrete Piles.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7040 Revision 0, 10 June 2013 NOTE 2: Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. PROCEDURE • Monitor Pile Load Tests: Conduct tests under the direct supervision of the Senior Field Engineer or their representative. The Engineer or their representative is responsible for the following: a) b) c) d) e) Approve the general plan and equipment to be used for the test. Observe the driving of test and reaction piles. Observe the application of loading apparatus. Record test data Prepare reports in accordance with ASTM D1143, D3689 or D3966 as applicable. Drive test piles in accordance with design specifications, using the same equipment to be used for production piles. Locate cribbing on reaction piles in accordance with ASTM D1143, D3698 or D 3966 as applicable. Install reaction and test piles at least (7) days prior to commencing load tests. Provide test piles from the same manufacturer as production piles. Axial Compression - Conduct test in accordance with ASTM D1143. Apply loads by employing both calibrated hydraulic jacks and load cells. Do not leave loaded jacks unattended. Use two dial gages mounted independently on supported reference beams as primary system for measuring movement. Do not cross connect reference beams. Use surveyor's level as a secondary measurement system. Use cyclic loading procedure in accordance with ASTM D1143, Section 5.2. Take and record readings of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100 and 120 minutes. During periods when the load is held constant for more than 120 minutes, take and record readings at 60 minute intervals after the first 120 minutes. During unloading, take and record reading at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2 and 12 hours after all load has been removed. Axial Tension Load Test - Conduct test in accordance with ASTM D3689 except as modified below. - - - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7040 Rev 0 Precast Concrete Piles.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7040 Revision 0, 10 June 2013 - Apply loads by employing both calibrated hydraulic jack and load cell. Do not leave loaded jack unattended. Use 2 dial gages mounted on independently supported reference beams as primary system for measuring movement. Do not cross connect reference beams. Use surveyor's level as secondary system. Use cyclic loading procedure in accordance with ASTM D3689, Section 7.3. - - - Take and record reading of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100 and 120 minutes. During periods when the load is held constant for more than 120 minutes, take and record readings at 60 minute intervals after the first 120 minutes. During unloading, take and record readings at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2, and 12 hours after all load has been removed. Lateral Load Tests - Conduct test in accordance with ASTM D3966 except as modified below. Apply loads employing both calibrated hydraulic jack and load cell. Do not leave loaded jacks unattended. Use a dial gage mounted on independently supported reference beam as primary system for measuring movement. Use surveyor's transit and scale as secondary system. Use cyclic loading procedure in accordance with ASTM D3966, Section 6.3. Take and record readings to time, load, and pile movement in accordance with ASTM D3966 Standard Measuring Procedures. - - - - - • Inspect In-process Pile Driving: Prebored pilot holes are prohibited unless specified on the design drawings or approved by the Engineer. Do no drive piles prior to attainment of the minimum 28 day strength. Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined refusal as _____ blows per foot. Contact the Engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration. Use one specific model of pile driving hammer for driving all precast concrete piles. - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7040 Rev 0 Precast Concrete Piles.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7040 Revision 0, 10 June 2013 - Operate pile driving hammer at the speed and conditions recommended by the manufacturer. Protect piles during driving with cushioned caps that does not absorb hammer energy. Use loads to secure the piles against lateral movement during driving. Drive piles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and tip elevation. The center of the pile at the cutoff elevation shall not deviate more than _____ inches from the location on the design drawings. Plumb pile alignment shall not deviate more than _____ inch per foot of pile length from the batter line on design drawings. Drive top of piles to within _____ inch of the elevation on drawings. Provide uplift connection at locations and as described on design drawings. - - • Check Final Pile Location/Installation: Retest piles that do not meet all the requirements of design specifications including those that are damaged, cracked, misplaced, or driven out of alignment tolerances. FORMS Quality Control Forms: 000.509.F70301 - Pile Driving Inspection Record 000.509.F70302 - Pile Driving Record 000.509.F70303 - Record of Pile Driving W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7040 Rev 0 Precast Concrete Piles.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70301 Revision 0, 10 June 2013 PILE DRIVING INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Driving Formula Weight Of Hammer Foundation Number Depth in m Blows Per m Depth in m Blows Per m Depth in m Blows Per m ID C70301A Tag No.: Turnover System: Client Other Sub – System: Location: Date Drop Type Of Hammer Pile Data Pile Number Dia: Tip Head Length of 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 Cut Off Bottom of Pile Overburden Design Length Kind of Pile Starting Time Stopping Time Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70301 Rev 0 Pile Drivig Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70302A Client Other Sub – System: Location: Project: Location: Pile Capacity: Pile Size: Weather Condition: Pile Number Length Date Driven Driver Type: Ramweight: Freefall Height: Pile Type: Pile Manufacturer: Horizontal 7,5 cm Maximum Point Elevation Cut-Off Elevation Blowcount Last m/cm Redriven Record: General Remarks: Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70302 Rev 0 Pile Driving Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70302 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70302 Rev 0 Pile Driving Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70303 Revision 0, 10 June 2013 RECORD OF PILE DRIVING Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70303A Client Other Sub – System: Location: General Information Job Number: Pile Type: Specified Capacity: Required Blows: Pile Size: Pile Number Orig. Length Date Driven Pile Data Jetting Depth Surface Elev. Driving Time Cut-Off Elev. Tip Elevation Cut-Off Length Blows Per cm. Blows Per cm. Blows Per cm. Blows Per cm. Blows Per cm. Blows Per cm. Hammer Data Make: Model: Stroke: Ram Weight: Rated Energy: Type: Action: Remarks: Depth Depth Depth Depth Depth Depth Subcontractor Name Signature Date Name Penetration Resistance Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70303 Rev 0 Record of Pile Driving.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70303 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70303 Rev 0 Record of Pile Driving.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7090 Revision 0, 10 June 2013 AUGERED CAST-IN-PLACE PILES SCOPE This procedure prescribes the inspection and testing of Augered Cast-In-Place Piles. RESPONSIBILITIES – Subcontractor Work ACTIVITY Install Pile Grouting Install Reinforcing Steel Sonic Logging PVC Spoils Removal Inspect Pile Installation PROCEDURE Subcontractor shall use instrumentation to monitor pile installation, and shall make an electronic recording of acquired data. Data shall include grout pressure and grout volume vs. both depth and time, and angle of pile installation. A readout device shall be supplied so data may be monitored by Subcontractor and Fluor during installation of each pile. Data shall also be stored in an electronic format and both a printed and electronic copy shall be provided to Fluor for documentation of each pile’s installation record. RESPONSIBILITY Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor Quality Control Inspector DOCUMENTATION 000.509.F70901 000.509.F70901 000.509.F70901 000.509.F70901 FREQUENCY OF ACTIVITY Each Pile Each Pile Each Pile Each Pile or as required in Project Specification Each Pile Per 000.509.0220 General All Subcontractor supplied materials and proprietary items shall be subject to Fluor’s approval and shall be installed in accordance with the Contract Documents. All chemical admixtures which contain chloride are prohibited for use on this project. Materials Portland Cement Portland cement shall conform to ASTM C 150, type of cement as specified in the Contract Documents. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7090 Rev 0 Augered Cast in Place Piles.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7090 Revision 0, 10 June 2013 Mineral Admixture Mineral admixtures, if used, shall conform to ASTM C618 Class C or Class F, as specified in the Contract Documents. Fluidifier Fluidifier shall conform to ASTM C937 Water Water shall meet requirements of ASTM C94. Fine Aggregates Fine aggregate shall conform to ASTM C33. Reinforcing Bars Reinforcing bars shall conform to ASTME A615. High strength reinforcing bars shall conform to requirements of ASTM A722 Grade 150. Methods acceptable to Fluor shall be provided to facilitate proper centering of any steel cores or tension reinforcing installed in the piles. Grout Mixes The grout shall be a mixture of Portland cement, fine aggregate, pozzolanic material (when used), Fluidifier, and water, proportioned and mixed to produce a grout capable of being pumped. The grout shall be capable of maintaining the solids in suspension. The grout shall have a minimum 28-day compressive strength of 4000 psi unless noted other wise in the Contract Documents. Grout materials shall be accurately measured to meet design proportions. Grout shall be accurately measured to meet design proportions. Grout shall be mixed at the site for a minimum of 2 minutes. Maximum holding time in the mixer shall be as follows: Temperature of Grout oF Less than 70 (21oC) From 70 to 90 (70-90oC) Greater than 90 (90oC) Maximum Holding Time Hours 2.5 2.0 Shall not be used Grout shall be protected from low temperatures in accordance with ACI 306R and from high temperatures in accordance with ACI 305R. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7090 Rev 0 Augered Cast in Place Piles.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7090 Revision 0, 10 June 2013 Grout test cubes shall be made, cured and tested in accordance with ASTM C942. At least six 2-inch cubes shall be made for each 4 hours (or portion thereof) during which piles are placed, for each pile rig. Test each set of 6 cubes as follows: 2 cubes at 7 days, 2 cubes at 28 days and 2 cubes held in reserve. Test the flow of grout each time cubes are made and any time inconsistencies are observed per ASTM C939, except that the cone shall be modified to provide a ¾ - inch (19 mm) opening. Flow rates shall be between 10 and 25 seconds. The flow cone shall be provided by the Subcontractor. Construction Tolerances Pile centers shall be located within a tolerance of +/- 3 inches (75 mm) of the locations shown in the Contract Documents, unless directed otherwise by the Fluor or otherwise specified. Vertical piles shall be plumb within 2%. Adjacent Piles No piles shall be placed within 5 pile diameters, center to center, of adjacent piles containing grout that has set for less then 12 hours. Installation Procedures The length, drilling criteria, and installation procedures of production piles may be modified by Fluor from information obtained during the installation of the probe piles, reaction piles, test piles and the pile load test. Production piles shall be installed with the same equipment and identical procedures used for installation of probe piles and test piles, unless modified by Fluor. Drill at a continuous rate appropriate for the soil conditions until the required depth or refusal is reached. If refusal is reach prior to the required depth, notify Fluor immediately. Auger refusal is defined as a rate of auger penetration of less than 1 foot (30 cm) per minute of drilling with maximum torque and weight applied to the auger. Provide a plug in the bottom of the auger during drilling to prevent entry of soil or water into the hollow stem of the auger. When the auger reaches its specified depth, raise the auger 6 to 12 inches (15 to 30 cm) and begin grout pumping. Re-drill the auger to the previously established tip elevation before commencing auger withdrawal, after the grout pressure builds up. Continuously maintain a grout head of a least 5 feet (1.5 m) above the injection point during raising of the auger. If the auger jumps upward during withdrawal, if there is a decreased grout pressure, or if grouting is interrupted for any reason, reinsert the auger to 5 (1.5 m) feet below the tip of the auger when the interruption occurred or to the bottom of the pile, whichever is less and decrease the rate of withdrawal to prevent further jumping or pressure decreases. Rotate W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7090 Rev 0 Augered Cast in Place Piles.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7090 Revision 0, 10 June 2013 the auger slowly during withdrawal. Counter clockwise rotation shall not be allowed at any time. After grout is flowing at the ground surface from the auger flighting, the rate of grout injection and auger withdrawal shall be coordinated so that there is a constant grout flow at the surface. Place at least 115% of the theoretical grout volume in each 5-foot (1.5 m) increment of pile. If any 5-foot (1.5 m) increment is deficient, reinstall the pile by advancing the auger 10 feet (3 m) below the deficient grout interval or to the bottom of the pile, whichever is less and re-grout pile with a reduced rate of auger withdrawal. No pile shall be left partially completed overnight. All piles must be completely grouted and protected at the termination of each day’s operation. Reinforcing steel shall conform to the Contract Documents, shall be placed while the grout is still fluid and shall have centering fins, spacers or other devices to assure minimum grout cover as shown on the drawings or if not shown, at least 3 inches (7.5 cm) of cover. If the reinforcing steel cannot be placed to design elevation, the reinforcing steel shall be removed and the pile reinstalled. The cost for reinstalling the pile shall be borne by the subcontractor. Promptly clear the spoil that accumulates around the auger during augering and injection of the grout. Dispose of spoils as directed by Fluor. Obstructions If obstructions causing auger refusal are encountered above the desired tip elevation, complete the pile to the refusal depth in accordance with the specifications, unless directed otherwise by Fluor. Install additional adjacent piles as required by Fluor. Cutting Off Piles shall be cut off by removing fresh grout from the top of the pile or by cutting off hardened grout down to the final cut-off point. Adding grout after the pile has reached its initial set in order to raise the pile cut-off elevation shall not be permitted. Sleeves or casings shall be placed around the pile top when the pile cut-off elevations are above the surrounding ground surface elevation. FORMS Quality Control Forms: 000.509.F70901 000.509.F71005 Augered Cast-In-Place Pile Record Cementitious Grout Testing Record W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7090 Rev 0 Augered Cast in Place Piles.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70901 Revision 0, 10 June 2013 AUGERED CAST-IN-PLACE PILE RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C70901A Client Other Sub – System: Location: Contract No. Project: Owner: Engineer: Contractor: Grout Truck No Arrival Time Load (m) Pile No. Meets Specs. Observed By: Date Installed: Weather: Water Added On Site (1) Grout Sampling/Testing Time Sampled Time Initial Set Flowcone Grout Cube Data Time Made Set No. Ticket No. Batch Time DWG No. Pile No Ground Elev. (cm) Alignment Auger Dia. (mm) Start: Augering Finish: Depth (cm) Pile Tip Elev. (cm) Theor. Grout Vol. (cm) Start: Grouting Finish: Avg. Pump Pres. (kg/cm²) Grout Return (cm) Total Pump Strokes Before: After: Initial Installation ReGrout Depth Grouting Summary Pump Strokes Grout Factor Pump Pres. Re-Grouting Summary Depth (cm) Pump Strokes Grout factor W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70901 Rev 0 Augered Cast In Place Pile Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F70901 Revision 0, 10 June 2013 AUGERED CAST-IN-PLACE PILE RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor DWG No. Initial Installation ID C70901A Tag No.: Turnover System: Client Other Sub – System: Location: Re-Grouting Summary Grouting Summary ReGrout Depth Pump Strokes Grout Factor Pump Pres. Depth (cm) Pile No Pump Strokes Grout factor Total Grout Vol. (cm) Overall Grout Factor Tension Steel Placed Lap Splice Centralizers Sonic Logging PVC Cage Steel Piaced Lap Splice Centralizers: Grout Loss Drilling Adjacent Pile Remarks W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F70901 Rev 0 Augered Cast In Place Pile Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71005 Revision 0, 10 June 2013 CEMENTITIOUS GROUT TESTING RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C71005A Client Other Sub – System: Location: Subcontractor 1. Grout consistency as measured by Corps of Engineers flow cone (CRD-79) was Grout consistency is: Fluid Flowable Plastic Stiff Fluor FE/QA 2. Temperature was measured and is in accordance with manufacturer’s recommendation for materials, mixing, placing and curing. Outside Ambient Inside Ambient Equipment Plates Mixed Grout °C °C °C °C Mixing Water Grout Bags Foundations In-Place (1 Hr.) °C °C °C 3. Test cubes were sampled for this placement location. Test cubes sampled: Number Tag No. to Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71005 Rev 0 Cementitious Grout Testing Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71005 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71005 Rev 0 Cementitious Grout Testing Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7100 Revision 0, 10 June 2013 CONCRETE AND GROUT SCOPE This procedure applies to inspection and testing of structural concrete and grouting. RESPONSIBILITIES - Self-Perform ACTIVITY Supply Concrete Perform Concrete Placement Batch Plant Technical Supervision RESPONSIBILITY Supplier Civil Superintendent Civil Construction Engineer DOCUMENTATION Batch Ticket 000.509.F71003 000.509.F02004 (Concrete Batch Plant Evaluation Record) and 000.509.F71010 000.509.F71001 & 000.509.F71002 for Structural Concrete 000.509.F71004 for Cementitious Grout 000.509.F71006 for Epoxy Resin Grout 000.509.F71007, 000.509.F71008 000.509.F71010 for Batch Plant 000.509.F71003 (Concrete Pour Card) F71007 (Note 1) (plus 000.509.F71005 for cementitiousCementitious grout) 000.509.F02201 FREQUENCY OF ACTIVITY As required As required Initially then random For individual placements as required by specification. Each placement Each set of cylinders/cubes as required by specification. Per Procedure 000.509.0220 Concrete Inspection Civil Construction Engineer Coordination of Placement Test Concrete Surveillance NOTE 1: Civil Construction Engineer Test Agency (Note 1) QC Inspection (Note 2) Approved Test Agency Reports on their letterhead is preferred over the use of Form 000.509.F71007 and 000.509.F71005 for documenting concrete tests, but it must contain at least the information provided by these forms. Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. NOTE 2: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7100 Rev 0 Concrete and Grout.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7100 Revision 0, 10 June 2013 RESPONSIBILITIES - Subcontracted Work ACTIVITY Supply Concrete Perform Concrete Placement Batch Plant Technical Supervision RESPONSIBILITY Supplier Subcontractor Civil Construction Engineer DOCUMENTATION Batch Ticket 000.509.F71003 000.509.F02004 000.509.F71010 000.509.F71001 000.509.F71002 000.509.F71004 000.509.F71006 000.509.F71007 000.509.F71008 000.509.F71003 Approved test agency form in compliance with 000.509.F71007 and 000.509.F71005 000.509.F02005 000.509.F02201 FREQUENCY OF ACTIVITY As required As required Initially then random Concrete Inspection Subcontractor Each placement Coordination of Placement Test Concrete Technically Supervise Test Lab Surveillance NOTE 1: Civil Construction Engineer/ Subcontractor Test Lab Site Quality Manager QC Inspection (Note 2) As required As required by specification Initially then random Per Procedure 000.509.0220 Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. GENERAL • Concrete Inspection: Inspection will include the items on the applicable checklist (Forms 000.509.F71001 and 000.509.F71002, 000.509.F71004 or 000.509.F71006) depending on the type of concrete. Form 000.509.F71001 is completed before ordering concrete. Inspection is performed continuously during placement. Batch plant inspection is performed for individual placements in excess of 200 cubic yards and periodically. These inspections are recorded on Form 000.509.F71010. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7100 Rev 0 Concrete and Grout.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7100 Revision 0, 10 June 2013 - Monitoring of water addition to assure maximum allowable is not exceeded and verify that an additional minimum of 30 revolutions at mixing speed has been applied to the load. Monitoring on site inspection/testing for compliance to approved test procedures and schedule. - • Batch Plant Technical Supervision Establishing that the concrete supplier is capable of performing the contracted scope. Review and acceptance of the concrete suppliers mix design and retain copy on site. Schedule the concrete testing, with the Testing Agency, as required by specifications. Keeping the Contracts Manager informed of the batch plants performance. • Coordination of the placement will include: Obtaining agreement among the disciplines and/or subcontractors that concrete placement is ready to be performed. This agreement is documented on Form 000.509.F71003. Concrete placement shall not commence until all "sign offs" have been made. • Technical supervision of the Test Agency will include: Establishing that the Testing Agency is qualified to perform the work required. Schedule testing as required by specification. Schedule the Testing Agency to periodically sample the concrete materials at the batch plant and verify compliance with specification. Review of personnel qualifications, procedures, test equipment and job performance. Keeping the Contracts Manager informed of the Test Agency's performance. Verify that results and test frequency conform to specification requirements and are traceable to work. Failing tests are to be backed up by acceptable tests or an NCR. Maintain compression test summary on the "Concrete Placement Log" Form 000.509.F71008. Maintain test and/or inspection records received from the Test Agency. - - • Refer to Attachment I for test and inspection acceptance criteria. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7100 Rev 0 Concrete and Grout.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7100 Revision 0, 10 June 2013 FORMS Quality Support Forms: 000.509.F71010 - Batch Plant Inspection 000.509.F71001 - Pre-Concrete Inspection 000.509.F71003 - Concrete Pour Card 000.509.F71004 - Cementitious Grout Inspection Record 000.509.F71005 - Cementitious Grout Testing Record 000.509.F71006 - Epoxy Resin Grout Inspection Record 000.509.F71007 - Concrete Compression Strength Test Record 000.509.F71008 - Concrete Placement Log 000.509.F71009 - Grout Placement Log ATTACHMENTS Attachment I - Acceptance Criteria N/A [::This appendix is optional. It may list the test procedures and specifications for concrete work including grouting of structural steel and equipment base plates. It may also contain the detailed criteria from these documents that will be needed by the inspector for determining acceptability. For grout, when the specifications invoke the grout material manufacturer's instructions, and/or the supplier equipment installation instructions and specifications, the requirements from these documents will be stated in this appendix.::] W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7100 Rev 0 Concrete and Grout.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71010 Revision 0, 10 June 2013 CONCRETE BATCH PLANT INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Concrete Supplier To: QC Department Tag No.: Turnover System: ID C71010 Client Other Sub – System: Location: Class Of Concrete Batch Plant Operator Contract No.: From: Report Date: CC: Construction Contractor(s) Construction Manager(s) QC Supervisor(s) Civil Supervisor(s) Description 1. Cement silos are watertight and adequate to provide separate types of cement. 2. Aggregate stockpiles are free draining and adequate to provide separate types of aggregates. 3. Water supply is clean and adequate for all weather conditions. 4. Admixtures storage is prevented from freezing and suitable for separate types of admixtures. 5. On batching equipment the latest calibration is indicated and calibration documents are available. 6. Batching system: 7. Recording system: 8. Quality control: 9. Approved Material Used 10. Approved Mix Design Used Conclusion /Recommendations: Location: Remarks Contracts: Report No. Manual Control Visual Control Manual Manual Semi-Automatic Control Automatic Control Computer Print-Out Computer Print-Out Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71010 Rev 0 Concrete Batch Plant Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71010 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71010 Rev 0 Concrete Batch Plant Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71001 Revision 0, 10 June 2013 PRE-CONCRETE INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Concrete Structure/Location: Referenced Drawings: Concrete Rebar & Embed. Drawings No. 1. Forms Survey Checked Orientation Location (Coord) Size Elevation Clean And Oiled Chamfer Straight, Level, Plumb Adequate Bracing 2. Re-Bar Grade Size Splices Spacing Clearance Cleanliness 3. Sub-Foundation Piles Compaction Cleanliness Moisture Blinding Layer Elevation U/G Mech. & Elect 4. Embedments Anchor Bolts (Diameter, Length, Type) Anchor Bolts (Location, Projection) Per Survey Book Anchor Bolt Sleeves Anchor Bolt Grounding Thread Projection Weld Pads Angle Iron Inserts ID C71001A Tag No.: Turnover System: Client Other Sub – System: Location: Equipment/Structural Steel Drawing No. U/G Electrical Drawing No. U/G Mechanical Drawing No. Conduits Ground Wire/Earthing Water Stop 5. Misc. Keyways Blockouts Surface Roughened Bonding Agent Type Of Finish Sets/Test Specimen Hot/Cold Weather Protection Joints Special Placing Equip. Required (Tremies, Pumps, Form Vibrators Screeds) Leakage System In Place Finished Slope Adequate Support Pipes 6. Order Concrete To The Following Specifications: Mix Design Max. Aggregate Size Slump Admixtures Remarks Quantity Delivery Per Hour No. Of Test Cylinders/Set No. Sets Required SUBCONTRACTOR Fluor Concrete Pour Release Civil Superintendant Date Electrical FE Date Mechanical FE Date Civil FE Date Fluor QA Date Fluor QA Name: Name: Signature: Signature: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71001 Rev 0 Pre Concrete Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71001 Rev 0 Pre Concrete Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71003 Revision 0, 10 June 2013 CONCRETE POUR CARD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C71003A Client Other Sub – System: Location: Planning Information Originator Pour Number Location Design Mix Required Finish/Curing Special Instructions Pre Pour Release Civil Mechanical Electrical Survey Quality Control Pour Weather Placement Started Placement Completed Cu. Yards Placed Remarks Date Date Time Time Date Date Date Date Date Date Quantity Elevation Placing Temperature Air Content Slump m³ W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71003 Rev 0 Concrete Pour Card.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71003 Rev 0 Concrete Pour Card.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71004 Revision 0, 10 June 2013 CEMENTITIOUS GROUT INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: ID C71004A Tag No.: Turnover System: Inspection Classification Subcontractor Fluor Client Other Sub – System: Location: Subcontractor Fluor FE/QA GROUTING (Indicate Type): TYPE A - Cement Based Non-shrink 1.0 PRE-GROUTING INSPECTION 1.1 Shimplates installed according to specification, not protruding baseplate. 1.2 Base concrete was cleaned, roughened and pre-saturated for __________ hours. 1.3 Baseplate Size:_____________ Horizontal Clear:___________ 1.4 Vent holes in baseplates checked and are sufficient or additional holes were drilled. 1.5 Hold point for rotating equipment. Name:__________________________________ Date:________________ Vertical Clear: ____________ Signature:____________________________________________ 2.0 GROUTING INSPECTION 2.1 Specified materials did not exceed shelf life recommended by vendor. Grout Brand:______________________________________ 2.2 The mix procedure used was in accordance with the manufacturer’s recommendations. Mixer Type:___________________________ Capacity:________________ Mix Time/Batch:_______________________ Parts of Water/Bag:_____________________ Bags/Batch:_____________ 2.3 Curing according to manufacturer’s recommended _____________ hours. 2.4 Temperature measured, see manufacturer’s recommendations. Outside ambient: ____________ °C Mixing water: ____________ °C Inside ambient:____________ °C Mixed grout: ____________ °C 3.0 POST-GROUTING INSPECTION 3.1 Grout formwork removed. 3.2 Grout fixed to concrete base. 3.3 Grout finishing according to specification. 3.4 Grout coating applied. REMARKS: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71004 Rev 0 Cementitious Grout inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71004 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71004 Rev 0 Cementitious Grout inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71005 Revision 0, 10 June 2013 CEMENTITIOUS GROUT TESTING RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C71005A Client Other Sub – System: Location: Subcontractor 1. Grout consistency as measured by Corps of Engineers flow cone (CRD-79) was Grout consistency is: Fluid Flowable Plastic Stiff Fluor FE/QA 2. Temperature was measured and is in accordance with manufacturer’s recommendation for materials, mixing, placing and curing. Outside Ambient Inside Ambient Equipment Plates Mixed Grout °C °C °C °C Mixing Water Grout Bags Foundations In-Place (1 Hr.) °C °C °C 3. Test cubes were sampled for this placement location. Test cubes sampled: Number Tag No. to Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71005 Rev 0 Cementitious Grout Testing Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71005 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71005 Rev 0 Cementitious Grout Testing Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71006 Revision 0, 10 June 2013 EPOXY RESIN GROUT INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID C71006A Client Other Sub – System: Location: Subcontractor 1. Specified materials did not exceed shelf life recommended by vendor. 2. The materials were temperature stabilized 24 hours prior to mixing, and the aggregate was dry prior to mixing. (Indicate: ) Resin brand_________________ Catalyst brand_________________ 3. The mix procedure is in accordance with the manufacturer's recommendations. 4. The concrete is at least 14 days old prior to grouting. 5. The concrete bond surface is clean, roughened and dry. 6. Metal surfaces to be embedded in grout are clean. 7. Metal surfaces to be kept free of grout are caulked or covered with plastic tape. 8. Formwork sealed, watertight and coated to prevent bonding. 9. Anchor bolt holes sealed (if not to be grouted) or dried. 10. Foundation adequately protected against sunlight, rain or sudden temperature changes during grout placement. 11. Final cleaning of metal surfaces completed just prior to grouting. 12. Formwork checked for leaks during placement. 13. Placement complete within manufacturer's recommended time. 14. Foundation adequately protected against sunlight, rain or sudden temperature changes during grout curing. 15. Curing of grout was in accordance with manufacturer's recommendations. 16. The temperature was measured and is in accordance with manufacturer's recommendations for mixing, placing and curing. Outside Ambient: Aggregate: Inside Ambient: Resin: Catalyst: Remarks: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor FE/QA Mixed Grout: Equipment Plates: Foundation: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71006 Rev 0 Epoxy Resin Grout Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71006 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71006 Rev 0 Epoxy Resin Grout Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71007 Revision 0, 10 June 2013 CONCRETE COMPRESSION STRENGTH TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Mix Design No.: Contractor: Mix Proportions Cement, brand and type Fine agg., source Course agg., source Water, source Admixture, brand Admixture, brand Admixture, brand Identity Batch Wt. Contract No.: Date: Weather: Required Strength Unit Weight Slump Range Air Content Range Tag No.: Turnover System: ID C71007A Client Other Sub – System: Location: Concrete Supplier: Air Temp.: kg/m³ Test Data Specimen Identity Location and Volume Presented Truck No. Slump (cm) WT. (kg) Air % Temp. (°C) Test Days Test Strength (kg/cm²) Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71007 Rev 0 Concrete Compression Strength Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71007 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71007 Rev 0 Concrete Compression Strength Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F1008 Revision 0, 10 June 2013 CONCRETE PLACEMENT LOG Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID C71008 Other Results Sub – System: Location: Date Placed Location of Pour Represented Pour Number 7 Day Results 28 Day Results ACC. REJ. en m³ Placed en m³ Placed To Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71008 Rev 0 Concrete Placement Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F1008 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71008 Rev 0 Concrete Placement Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71009 Revision 0, 10 June 2013 GROUT PLACEMENT LOG Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID C71009 7 Day Results Sub – System: Location: Date Placed Placement Represented Placement Number 28 Day Results Other Results ACC. REJ. En m³ Placed En m³ Placed To Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71009 Rev 0 Grout Placement Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F71009 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F71009 Rev 0 Grout Placement Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7200 Revision 0, 10 June 2013 STRUCTURAL STEEL SCOPE This procedure describes the functions to be performed in the inspection of the erection of structural steel. RESPONSIBILITIES - Self-Perform ACTIVITY Verify acceptability of Interface Structures Erect Structural Steel Inspect In-process Structural Steel Erection Perform Final Inspection RESPONSIBILITY Civil Construction Engineer Civil Superintendent Civil Construction Engineer Civil Construction Engineer DOCUMENTATION 000.509.F72002 _____ 000.509.F72002 000.509.F72002 FREQUENCY OF ACTIVITY Once for each structure _____ Daily during life of activity Once per structure RESPONSIBILITIES - Subcontracted Work ACTIVITY Verify acceptability of Interface Structures Erect Structural Steel Inspect In-process Structural Steel Erection Perform Final Inspection Surveillance RESPONSIBILITY Civil Construction Engineer Subcontractor Subcontractor Subcontractor / Civil Construction Engineer Site Quality Manager DOCUMENTATION 000.509.F72002 _____ 000.509.F72002 FREQUENCY OF ACTIVITY Once for each structure _____ Daily during life of activity Once per structure Per Procedure 000.509.0220 000.509.F72002 000.509.F02201 PROCEDURE • Verify Interface Structures: Prior to structural steel being erected, verify that all interface work such as foundation elevations, and size and location of anchor bolts conform to the applicable drawings. Verify that concrete has attained adequate compressive strength before loading. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7200 Rev 0 Structural Steel.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7200 Revision 0, 10 June 2013 • Erection of Structural Steel: Structural steel shall be erected in accordance with the applicable project specifications. Assure structures are not loaded prior to sufficient progression of erection and completed boltup has been accepted. Welding shall be performed by AWS (or other approved recognized standards) qualified welders in accordance with weld procedure specifications approved by Fluor Manager Welding Technology or his representative. Modifications to steel member shall only take place upon issuance of direction from Construction Engineering. - - • In-Process Inspection of Structural Steel Erection: Inspect the in-process steel erection to verify that fabrication is correct and erection is in accordance with the drawings. Inspection shall include checking for plumbness, rectangularity, field welds, bolt tensioning and touch-up painting. Visual weld examination shall be performed in accordance with 000.509.7910, Welding Inspection. Document inspections on Form 000.509.F72002, Structural Steel Inspection Checklist. Highlighted steel erection drawings may be used in conjunction with checklist to provide a clear picture of sequence of events with dates of when areas, floors, and buildings have been accepted for workmanship. When a calibrated impact wrench is used for erection, the calibration shall be verify by the Civil Construction Engineer or QC Inspector and documented on Form 000.509.F72003, Torque Wrench Calibration Log. When bolting inspection by impact is required, it shall be performed with a separate calibrated inspection wrench. When “twist-off” type tension control structural bolt/nut/washer assemblies are specified they shall conform to ASTM F1852-98 and shall be, installed in accordance with the manufacturer'’ published specifications. When load indicating washers (LIW) are specified, installation inspection will be performed in accordance with the sample rate specified. Inspect bolts installed by turn-of-nut method in accordance with AISC Section 6, Specification or other approved recognized standard for Structural Joints using ASTM A325 or A490 bolts. - - - - - - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7200 Rev 0 Structural Steel.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7200 Revision 0, 10 June 2013 - The number of checklist completed should be a sufficient number to clearly indicate full coverage of all portions of the work on the project as work progresses. Each checklist generated should represent a well defined piece of work, i.e., building line, floor, run of pipe rack, etc. - • Perform Final Inspection: Perform final inspection, in part, or on the total structure. Document on Form 000.509.F72002, Structural Steel Inspection. Document deficiencies, for tracking purposes, on Form 000.509.F02201, Surveillance Report. - FORMS Quality Control Forms: 000.509.F72002 - Structural Steel Inspection Checklist 000.509.F72003 - Torque Wrench Calibration Log W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7200 Rev 0 Structural Steel.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7200 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7200 Rev 0 Structural Steel.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F72002 Revision 0, 10 June 2013 STRUCTURAL STEEL INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor ID S72002A Tag No.: Area/Unit: Client Other Turnover System: Sub – System: Drawing No.: Item 01 02 Specification No.: Subcontractor Fluor FE/QA Description of Check Foundation inspections and tests complete. Piles Soils Concrete Leveling plate or billet plate grouting complete and checked. FOUNDATIONS ANCHOR BOLTS 03 04 05 06 07 FIT-UP 08 09 10 11 12 BOLTS 13 14 15 16 17 18 Correct grade Correct length Correct size All bolts visually inspected to verify evidence of tightening Connections marked indicating statues Bolt tightening method used: Calibrated Wrench Load Indicating Washers Turn-of-Nut Snap-Off Fasteners Correct numbers location, and size Survey Group checks alignment, plumbness, spacing, and elevation for conformance to erection tolerances Match of member Members free of distortion Mating surfaces free of paint Grade and elevation Anchor bolts condition Base plate condition Bearings surface cleaned and protected Shimming of base plates WELDING 19 20 21 22 Welds approved by welding inspector Field coatings checked Fireproofing inspections and tests complete Final inspection complete Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F72002 Rev 0 Structural Steel Inspection.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F72002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F72002 Rev 0 Structural Steel Inspection.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F72003 Revision 0, 10 June 2013 TORQUE WRENCH CALIBRATION LOG Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID S72003Ar Client Other Turnover System: Sub – System: Minimum Fastener Tension (Kips) for: Dia. inches A325 Bolts 1/2 12.6 Kips 5/8 20.0 Kips 3/4 29.4 Kips 7/8 41.0 Kips 1 53.6 Kips 1 1/8 58.8 Kips 1 1/4 74.6 Kips 1 3/8 89.3 Kips 1 1/2 108.2 Kips Date Bolt Size Tension Reading* Before Adjustment A490 Bolts 15.8 Kips 26.2 Kips 36.8 Kips 51.5 Kips 67.2 Kips 84.0 Kips 107.1 Kips 127.1 Kips 165.4 Kips Tension Reading* After Adjustment Bolt Tightening Equipment Used: Calibrated Equipment Used: Signature * Each tension reading shall be the average of three bolts. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F72003 Rev 0 Torque Wrench Calibration Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F72003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F72003 Rev 0 Torque Wrench Calibration Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 BUILDINGS SCOPE This procedure describes the inspection and testing activities to be performed for buildings that are constructed by Fluor. RESPONSIBILITIES - Self-Perform ACTIVITY Verify foundations complete Review structural steel documents Monitor in-process building construction Inspect completed work Verify building complete Surveillance NOTE 1: RESPONSIBILITY Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer QC Inspection (Note 1) DOCUMENTATION 000.509.F73001 _____ 000.509.F02201 000.509.F73003 000.509.F73016 Procedure 000.509.7300 000.509.F02201 FREQUENCY OF ACTIVITY Daily during life of activity Prior to steel erection Daily during life of activity Each Item Once per building Per Procedure 000.509.0220 Surveillance is not required if the Fluor Quality representative is performing inspections. RESPONSIBILITIES - Subcontracted Work ACTIVITY Inspect in-process foundations Inspect in-process building superstructure Witness HVAC Test Inspect completed building Coordinate resolution of deficiencies Surveillance RESPONSIBILITY Subcontractor Subcontractor Civil Construction Engineer/ Site Quality Manager Subcontractor Discipline Engineer Site Quality Manager Subcontractor/ Civil Construction Engineer/ Site Quality Manager QC Inspection DOCUMENTATION 000.509.F73001 000.509.F02201 000.509.F73101 FREQUENCY OF ACTIVITY Daily during life of activity Daily during life of activity Each test 000.509.F73002 Once per building 000.509.F73002 As required to close open items Per Procedure 000.509.0220 000.509.F02201 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 1 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 PROCEDURE Attachments 1 through 9 are provided as inspection references to aid the inspector. • Verify Foundations are Complete: Check the elevations and locations of foundations, floor slabs, inserts and interior partitions. Document these checks on Form 000.509.F73001, Building Inspection Record. When tests and inspection activities are complete, document using Form 000.509.F73001, Building Inspection Record. - • Review of Structural Steel Documents: Verify structural steel certified mill test reports and certificates of compliance have been received have been reviewed. If applicable, verify the subcontractors have submitted required shop drawings, diagrams, schedules, etc., and are marked as authorized to proceed. - • Monitor In-Process Building Construction: The attachments contained in this procedure are intended to be used as guidelines for implementing this procedure. Using the applicable design drawings, inspect the in-process building superstructure construction activities to verify acceptability of work. Inspect membrane roofing system construction for strict compliance with drawings and specifications to include materials, substrate preparation, membrane installation and splicing, perimeter nailing, flashing and roof walkways. Verify completion of applicable tests, performance tests and test data records as required by specifications: electrical, plumbing system, fire protection system. Monitor subcontractor's HVAC duct, duct insulation, and equipment installation for compliance with drawings and specifications. - - - - • Witness HVAC Tests: Witness HVAC testing is performed in accordance with the requirements of Form 000.509.F73101. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 2 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 • Verify Building Complete: Verify the proper operations of the specific keying systems is demonstrated satisfactorily. Inspect the building when construction is complete. Deficiencies shall be documented on Form 000.509.F02407, Master Punch List. FORMS Quality Control Form: 000.509.F73001 - Building Inspection and Test Checklist 000.509.F73002 - Final Building Inspection Summary 000.509.F73003 - Carpentry Checklist 000.509.F73004 - Painting Checklist 000.509.F73005 - Plumbing Checklist 000.509.F73006 - Ceramic Tile Checklist 000.509.F73007 - Concrete Checklist 000.509.F73008 - Structural Steel Checklist 000.509.F73009 - Masonry (Brickwork) Checklist 000.509.F73010 - Plaster Checklist 000.509.F73011 - Doors, Windows, Hardware, Glazing Checklist 000.509.F73012 - Computer (Raised) Floors, Checklist 000.509.F73013 - Prefab Wall Element Systems Checklist 000.509.F73014 - Building Metal Siding and Roofing Checklist 000.509.F73015 - Buildings Water Proofing and Damp Proofing Checklist 000.509.F73016 - Suspended Ceiling Checklist ATTACHMENTS Attachment 1 - Buildings Masonry Inspection Reference Attachment 2 - Buildings Waterproofing and Dampproofing Inspection Reference Attachment 3 - Buildings Plaster Inspection Reference Attachment 4 - Buildings, Metal Doors and Windows Inspection Reference Attachment 5 - Buildings Drywall Construction Inspection Reference Attachment 6 - Buildings Resilient Floor Covering Inspection Reference Attachment 7 - Buildings Carpentry Inspection Reference Attachment 8 - Buildings Built-up Roofing Inspection Reference Attachment 9 - Buildings Ceramic Tile Inspection Reference W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 3 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 1 BUILDINGS MASONRY INSPECTION REFERENCE VERIFY USE CORRECT MATERIALS 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4. 5. Approved panels and/or material samples Materials certifications Masonry units, color, texture, grade, size, defect tolerance Masonry mortar, cement, aggregate, lime, water Mortar cube tests, if required Anchors, ties, flashing - type, size, shape and material Ambient temperature above minimum Masonry layout fits structural framing Embedded items Control joint type and location Caulked joints Openings framed, anchored, filled with mortar Weep holes Anchors, ties, joint reinforcing Flashing installation Foundation waterproofing or damp proofing Bond pattern, visual appearance Mortar joints, visual appearance Brick work plumb and true, all in one plane Pointing Cleaning INSPECT MASONRY CONSTRUCTION ASCERTAIN WORKMANSHIP W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 4 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 2 BUILDINGS WATERPROOFING AND DAMPPROOFING INSPECTION REFERENCE VERIFY USE CORRECT MATERIALS 1. 2. 3. 4. 5. 6. 7. Bitumen roofing felt Tar or asphalt damp proofing Mastic asphalt Hot application asphalt Bituminous adhesives Bituminous roofing Polyethylene sheet INSPECT APPLICATION OF DAMPPROOFING/WATERPROOFING 1. 2. 3. 4. 5. 6. 7. 8. 9. Surface preparation for cleanliness, smoothness, dryness Ambient temperature above 40F (4C) Material temperatures Prime coat Coats, laps, and thicknesses Waterproofing details at flashing or wall penetrations Waterproofing membrane type, application, reinforcing strips Waterproofing membrane protection against backfill Waterproofing reinforcing plies where required ASCERTAIN WORKMANSHIP 1. 2. Damp proof coating free of breaks, surface air voids in monolithic concrete Waterproof coating free of wrinkles and buckles W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 5 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 3 BUILDINGS PLASTER INSPECTION REFERENCE VERIFY USE OF CORRECT MATERIALS 1. 2. 3. 4. Approved material samples Metal stud partitions Metal lath Plaster materials INSPECT PLASTER WALL CONSTRUCTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Stud spacing and anchorage Studs properly anchored to adjoining walls Studs galvanized or protectively coated Studs attachment at openings as detailed on drawings Lath type, lapping, joints Lath screeds and grounds have a true, level and plane surface. Lath corner beads provided for external corners Lath installed at internal corners, where required Lath properly secured to studs Plaster area ambient temperature maintained above 55F (13oC) Plaster mix proportions, set characteristics as specified Plaster base surfaces properly prepared Plaster coats checked for thickness, density, uniformity Plaster base coat moistened before applying finish coats Plaster curing adequate ASCERTAIN WORKMANSHIP 1. 2. Each plaster coat, smooth, plumb, true, all in one plane White plaster coat free from cracks, crazing, blisters, pits, checks, discoloration W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 6 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 4 BUILDINGS, METAL DOORS AND WINDOWS INSPECTION REFERENCE VERIFY THE USE OF CORRECT MATERIALS 1. 2. 3. 4. 5. 6. 7. 8. 9. Approved material samples Guarantees, for electric power operators Doors, door bucks Window sashes and liners Hardware Window glass and glazing Caulking materials Electrical components for power operated doors Guides and panel sections for telescoping doors INSPECT INSTALLATION OF DOORS AND WINDOWS 1. 2. 3. 4. 5. 6. 7. Frames anchored, plumb, square and level All clearances adequate Caulking provided where required Weather stripping installed where required Hardware properly adjusted Glazing installation adequate Lubricants provided where needed ASCERTAIN WORKMANSHIP 1. 2. 3. 4. 5. 6. Each unit operates smoothly and easily Doors, flush and snug with jams Window frames, flush and snug with sashes Units with tension adjustment mechanisms are in proper adjustment Painted surfaces cosmetically pleasing Clean up is satisfactory W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 7 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 5 BUILDINGS DRYWALL CONSTRUCTION INSPECTION REFERENCE VERIFY USE OF CORRECT MATERIALS 1. Gypsum board 2. Joint cement 3. Joint tape 4. Nails INSPECT INSTALLATION OF DRYWALL 1. Gypsum board is stored in a dry, ventilated, enclosed building. 2. Ambient temperature is above freezing at time of joint cement application. 3. Surfaces to receive drywall conform to line and grade. 4. Gypsum board held tight against supports with nailing starting at center and progressing toward perimeter. 5. Paper surface torn around nail head has additional nail driven two inches away. 6. Cut and fit gypsum board is not forced into place. 7. Thin coats of cement applied immediately after taping. 8. Coats of cement on joint and nail depressions have 24 hours between applications. 9. Final cement coat feathered 12" to 16" (30-40 cm) each side of joint and is sanded smooth. ASCERTAIN WORKMANSHIP 1. Installed gypsum board free from damage. 2. All cemented joints and nail depressions will present smooth and uniform appearance when wall is painted. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 8 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 6 BUILDINGS RESILIENT FLOOR COVERING INSPECTION REFERENCE VERIFY CORRECT MATERIALS 1. 2. 3. 4. 5. Approved material samples Tile color, type, size, thickness Molding color, type, size Primer Adhesive or cement INSPECT LAYING OF TILE 1. 2. 3. 4. 5. Sub-floor preparation Felt lining or under-layment Temperature of stored material and laying area Layout pattern of cut tiles at wall line and wall openings Application of adhesives ASCERTAIN WORKMANSHIP 1. 2. 3. 4. 5. 6. Tiles laid point to point Tile joints tight Tile pattern as specified Tile cuts at wall base or wall opening correct Tiles cleaned and waxed after completion Tiles protected after waxing with construction paper *Includes asphalt, vinyl-asbestos, vinyl and rubber tile and floor covering. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 9 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 7 BUILDINGS CARPENTRY INSPECTION REFERENCE VERIFY USE OF CORRECT MATERIALS 1. 2. Specifies, grade, grade stamp Defect tolerance for checks, splits, shakes, pockets, decay, grain structure, knots, % heart wood or sapwood, bark, warp Moisture content checks Storage conditions Preservative treatment 3. 4. 5. INSPECT CARPENTRY CONSTRUCTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Stud spacing Double of top plates, when required Horizontal blocking Continuous blocking between joints and studs, for fastening wall materials Stud to plate nailing adequate Diagonal wind bracing, when required Solid blocking for fixtures and attachments Doubling of studs at openings Headers as detailed on drawings Soundproof partitions as required Vertical alignment of studs to form one plane for wall surface Framing fabrication line, level and fit Anchorage to concrete and masonry W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 10 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 8 BUILDINGS BUILT-UP ROOFING INSPECTION REFERENCE VERIFY THE USE OF CORRECT MATERIALS 1. 2. 3. 4. 5. 6. 7. 8. 9. Asphalt Nails and fasteners Insulation Vapor barrier Roofing felt Flashing Aggregate Installed roof samples, if required Roof guarantees, if specified INSPECT BUILT-UP ROOFING INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Surface to be roofed is dry, smooth, firm and dirt free Vapor barrier installation, provides complete seal of deck If insulation required, place by specified method immediately preceding placing of roofing felt - avoid wetting Maintain roofing felts above 50F (10C) for 24 hours prior to use Ambient temperature is 40F (4C) and rising for hot mopping of felt Felt is laid immediately behind mopping Temperature of bitumen is as required Extra plies installed where required, such as at eaves, rakes and flashing Roofing aggregates are as specified ASCERTAIN WORKMANSHIP 1. 2. 3. 4. Roofing felt plies free of air pockets, wrinkles and buckles Roofing felt laps are uniform and even Aggregate distribution is uniform Flashing detailing acceptable W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 11 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7300 Revision 0, 10 June 2013 Attachment 9 BUILDINGS CERAMIC TILE INSPECTION REFERENCE VERIFY THE USE OF CORRECT MATERIALS 1. 2. 3. Approved material samples Tile type, size and color pattern Mortar type and color INSPECT APPLICATION OF TILE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Wall tile, location and anchorage of studs or furring Wall tile lath, placement, lap and support Wall tile scratch coat and float coat applied and cured properly Wall tile soaked and free water removed prior to application Wall tile accessories are as required Wall tile firmly set Wall tile wetted before grouting Wall tile grout, placing, tooling, curing and cleaning Floor tile installed after wall tile Floor tile setting bed preparation as specified Floor tile setting bed mix satisfactory Floor tile solidly bedded Floor tile layout acceptable Floor tile waterproofing and reinforcement when required Floor tile cuts as wall base and openings acceptable ASCERTAIN WORKMANSHIP 1. 2. 3. 4. 5. Tiles free of chips or cracks Grout joints uniformly tooled Grout tiles all in one plane Tile pattern uniform and consistent Tile cuts at baseline, corners or openings are satisfactory W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7300 Rev 0 Buildings.doc Page 12 of 12 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73001 Revision 0, 10 June 2013 BUILDING INSPECTION AND TEST CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID B73001A Client Other Sub – System: Location: Building Description __________________________________ Bldg. No._________ Initials/Date 1. Receiving operations/inspections performed on the following building materials and/or equipment. 2. Equipment and material protection program performed on the following materials or equipment. 3. Foundation inspections and tests complete. Piles Soils Concrete 4. Foundation checked for location, elevation and orientation prior to starting superstructure. 5. Superstructure inspections complete. 6. Building tests complete. Building tests performed for this building: Electrical Air Conditioning 7. Final inspection complete. Remarks Heating Ventilation Plumbing Other Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73001 Rev 0 Building Inspection and Test Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73001 Rev 0 Building Inspection and Test Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73002 Revision 0, 10 June 2013 FINAL BUILDING INSPECTION SUMMARY Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID B73002B Client Other Sub – System: Location: Receiving: Inspection Performed (See Attached List) 1. Separate completion packages: Structural Steel Piling Civil / Concrete HVAC 2. Masonry Checklist 3. 4. 5. 6. 7. 8. 9. Roof Metal Sliding and Roofing Checklist Plaster Checklist Doors/Windows/Hardware/Glazing/Keyplan Checklist Insulation Checklist Ceiling Checklist Plumbing Checklist Ceramic Tiles Checklist Subcontractor Electrical Fluor FE/QA 10. Computer (Raised) Floors Checklist 11. Fire-Fighting System Checklist 12. Automatic Operated Components Checklist 13. Furniture / Kitchen Checklist 14. Surface Preparation / Finish Concrete Checklist 15. Sheeting / Cladding Checklist 16. Structural Steel Checklist 17. Carpentry Checklist 18. Painting Checklist 19. Pre Fab Wall Element Systems Checklist 20. Building Inspection and Test Checklist 21. Building water proofing and damp proofing Checklist Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73002 Rev 0 Final Building Inspection Summary.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73002 Rev 0 Final Building Inspection Summary.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73003 Revision 0, 10 June 2013 CARPENTRY CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73003A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 Description of Check Verify correct grade of materials used for all timber. Verify correct species of timber used. Verify use of correct preservative treatment. Verify compliance with priming requirements. Inspect timber construction dimensions. Inspect fabrication quality. Inspect joints. Inspect blocking. Studs aligned. Door lintels and frames per design requirements. Subcontractor Fluor FE/QA Notes: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73003 Rev 0 Carpentry Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73003 Rev 0 Carpentry Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73004 Revision 0, 10 June 2013 PAINTING CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID X73004A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify use of correct painting materials: 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Notes: Trade name and manufacturer Grade Manufacturer's data sheets Protection for applied paint Guarantees Pot or shelf life Correct colors Surface preparation Method of application Number of coats Thickness of dry film Evenness of applied coat Brush marks, sags, runs, etc. Cleanliness of area upon completion Inspect painting application: Ascertain workmanship: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73004 Rev 0 Painting Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID C73005A Client Other Turnover System: Sub – System: Item Description of check Subcontractor Fluor FE/QA Verify the use of correct plumbing materials 01 02 03 04 05 06 07 08 09 10 11 12 Notes: Sanitary waste and vent system Acid waste and vent system Potable water system Instrument air system Plumbing fixtures and equipment Hangers and supports Piping Joints Valves Fixtures Hydrotesting Correctness to codes, regulations Verify plumbing installation per design documents Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73005 Rev 0 Plumbing Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73006A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 Notes: Description of Check Type and color of tile per design documents Type and color of mortar per design documents Inspection of substrate Proportioning of mortar mixtures per design Application procedures acceptable per specifications Subsurface preparation per design Grout procedure, pointing acceptable per specifications Tile face plumb and in place, dividing over floor and wall surface Inspect for cracks, misalignment Grout joints uniform Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73006 Rev 0 Ceramic Tile Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID C73007A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA General: 01 02 03 04 05 06 07 08 09 10 11 Notes: Concrete test specimen reports filed Concrete mix designs approved Patching and repairs complete Embedments in place and correct location Floated Trowelled Floor slab hardener Material sources Material proportions Application method Workmanship Verify correct floor finishes: Verify correct use of granolithic concrete topping: Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73007 Rev 0 Concrete Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73007 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73007 Rev 0 Concrete Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73008 Revision 0, 10 June 2013 STRUCTURAL STEEL CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID S73008A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 Notes: Description of Check Structural elements (main structure, bulkheads, decks, platforms/ walkways, grating, roof)- installed and checked against drawings Structural elements - plumb, level, aligned All structural supports installed per design and all temporary aids/ brackets removed All temporary aids/ brackets/ steel removed Anchor bolt nuts tight Column base grouted Bolted connections checked Welded connections checked Stairs, handrails, ladders, floor plates in place and per design All penetrations installed, with sleeves/ kick plates of specified size complete with drain holes as required All welding and NDT work completed and cleared Coatings applied, touch-up complete Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73008 Rev 0 Structural Steel Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73008 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73008 Rev 0 Structural Steel Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73009 Revision 0, 10 June 2013 MASONRY (BRICKWORK) CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID C73009A Client Other Turnover System: Sub – System: Item Verify use of correct materials: 01 02 03 Description of Check Subcontractor Fluor FE/QA Engineering brick, face brick, common brick Cement, fine aggregate, water Wall ties, reinforcing, flashing Inspect construction of brickwork: 04 05 06 07 Coursing and wythes Application of mortar Inserts Tie-ins and anchoring Ascertain workmanship: 08 09 10 11 12 13 Notes: Alignment of bond Brickwork is plumb and true Mortar joints uniformly struck or tooled Cleanliness upon completion Pointing to masonry work Expansion joints in masonry work Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73009 Rev 0 Masonry Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73009 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73009 Rev 0 Masonry Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73010 Revision 0, 10 June 2013 PLASTER CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73010A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify the correct use of plaster materials: 01 02 03 04 Cement Lime Sand Water Inspect application of plaster: 05 06 07 08 09 Proportioning of plaster mixtures per design Application technique per design Subsurface preparation per design Thickness of application per design Installations of accessories like corner beads, etc. per design Ascertain workmanship: 10 11 12 13 Notes: Plaster face plumb and in one plane Plaster flush with inserts Troweled surface uniform No defects, such as cracks and blisters Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73010 Rev 0 Plaster Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73010 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73010 Rev 0 Plaster Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73011 Revision 0, 10 June 2013 DOORS, WINDOWS, HARDWARE, GLAZING CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73011A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Notes: Description of Check Correct materials used for doors, door bucks Correct materials used for window sash and liners Correct materials used for hardware Correct materials used for window glass and putty Correct materials used for electrical components for power operated doors Correct materials used for guides and panel sections for telescoping doors Verify the general operation of the doors Frames anchored plumb and level Doors and sashes not inhibited or bound from normal movement Hardware in good mechanical operation Glass well bedded and putty neatly trimmed Operation of overhead or telescoping doors (controls, smoothness and speed) Telescoping door guides installed, secured and aligned Installation hardware is correct Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73011 Rev 0 Doors Windows Hardware Glazing Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73011 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73011 Rev 0 Doors Windows Hardware Glazing Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73012 Revision 0, 10 June 2013 COMPUTER (RAISED) FLOORS CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73012A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 Notes: Description of Check Correct materials used for floor panels/elements. Correct materials used for floor supports. Correct materials used for floor finishing. Verify completion of installation per design. Verify system level and square. Floor system clean and free of damage. Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73012 Rev 0 Raised Floors Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73012 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73012 Rev 0 Raised Floors Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73013 Revision 0, 10 June 2013 PREFAB WALL ELEMENT SYSTEMS CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73013A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify the use of correct materials: 01 02 03 04 Frames Panels Glass Doors Inspect per design: 05 06 07 08 09 General operation Hardware Installation of panels and glass Wall finishing/paint system Wall panels anchored in accordance with design documents Ascertain workmanship: 10 Notes: Systems free of damage Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73013 Rev 0 Prefab Wall Element Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73013 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73013 Rev 0 Prefab Wall Element Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73014 Revision 0, 10 June 2013 BUILDING METAL SIDING AND ROOFING CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73014A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify the use of correct materials: 01 02 03 04 Correct siding profile Correct roofing profile Fasteners, flashing, closer strips and caulking Wall insulation Inspect installation of siding and roof panels per design: 05 06 07 08 09 Correct spacing of fasteners Insulation Supports for roof insulation Placement of closer strips Flashing Ascertain workmanship: 10 11 12 13 14 15 Notes: Alignment of seams and fasteners Tightness of joints Repair of damage to panels or finish Cleanliness upon completion Manufacturer’s warranty intact Systems free of damage Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73014 Rev 0 Building Metal Roofing and Siding Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73014 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73014 Rev 0 Building Metal Roofing and Siding Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73015 Revision 0, 10 June 2013 BUILDINGS WATER PROOFING AND DAMP PROOFING CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73015A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify use of correct asphalt material: 01 02 03 04 05 06 07 08 09 Bitumen roofing felt Horizontal damp proofing Mastic asphalt Hot application asphalt Bituminous adhesives Bituminous roofing Polyethylene sheet Insulation material Roof slope falls to roof drains Inspect application of asphaltic materials per design: 10 11 12 13 14 Notes: Surface preparation Coats, laps and thickness Methods of application Temperature of material and surface Manufacturer’s warranty intact Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73015 Rev 0 Buildings Waterproofing and Dampproofing Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73015 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73015 Rev 0 Buildings Waterproofing and Dampproofing Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73016 Revision 0, 10 June 2013 SUSPENDED CEILING CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID A73016A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify correct materials per design: 01 02 03 04 Ceiling board Joint cover strips Suspension system / exposed metal "T" system Timber brandering Inspect suspended ceiling construction: 05 06 07 08 Completion of all work above the ceiling, prior to start of work Suspension system (e.g., set level and square, prior to installation of ceiling board) Ceiling board fixed correctly to timber brandering Adoption for recessed lighting fixtures Ascertain workmanship: 09 10 11 Notes: Tightness of joints Cut boards at ceiling line Boards free of discoloration or damage Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73016 Rev 0 Suspended Ceiling Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73016 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73016 Rev 0 Suspended Ceiling Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7310 Revision 0, 10 June 2013 HEATING, VENTILATING AND AIR CONDITIONING DUCTWORK (HVAC) SCOPE This procedure establishes the method for inspection and verification that construction work on HVAC ductwork systems and sub-systems are acceptable. RESPONSIBILITIES - Self-Perform ACTIVITY Verify ductwork configuration Verify ductwork integrity Verify leak testing performed Verify connections to equipment Surveillance NOTE 1: RESPONSIBILITY Construction Engineer Construction Engineer Construction Engineer Electrical/Mechanical Engineer QC Inspector (Note 1) DOCUMENTATION 000.509.F73001 000.509.F73002 000.509.F73001 000.509.F73002 000.509.F73001 000.509.F73002 000.509.F73001 000.509.F73002 000.509.F02201 FREQUENCY OF ACTIVITY Upon completion of work Prior to turnover of system Prior to turnover of system Prior to turnover of system Per Procedure 000.509.0220 Surveillance is not required if the Fluor quality representative is performing inspections. RESPONSIBILITIES - Subcontracted Work ACTIVITY Verify ductwork configuration Verify ductwork integrity Perform leak test Connect duct to equipment Surveillance RESPONSIBILITY Subcontractor Subcontractor Subcontractor Subcontractor QC Inspector DOCUMENTATION 000.509.F73101 000.509.F73102 000.509.F73101 000.509.F73102 000.509.F73101 000.509.F73102 000.509.F73101 000.509.F73102 000.509.F02201 FREQUENCY OF ACTIVITY Upon completion of work Prior to turnover of system Prior to turnover of system Prior to turnover of system Per Procedure 000.509.0220 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7310 Rev 0 Heating, Ventilating and Air Conditioning Ductwork.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7310 Revision 0, 10 June 2013 PROCEDURE • Verify Ductwork Configuration: Identify the specific limits of the system/sub-system to be inspected. Obtain the latest approved revision of the drawings of the system/sub-system for verification of the work to be inspected. Verify that the installed configuration of the ductwork and hangers conforms to the drawings. Hangers and supports should be observed to assure the presence of all members. Ductwork should be observed to assure installation is within allowable tolerances for line and elevation. If there are any field "trim joints" that have not been previously inspected for acceptable completion and welding, they should be checked at this time. - • Verify Ductwork Integrity: Ductwork should be checked internally by means of the access doors to assure that it is free of obstructions such as construction debris, scrap, etc. which is to include the checking of fire dampers for obstruction. When this has been determined, the door shall be closed and sealed with an acceptance tag, in a manner that will require the tag to be broken to gain access. Use of the tag seal is intended to provide protection against unauthorized access to the ducts. Verify that any internal field-installed accessories, such as dampers, are in place. Inspections prior to release for testing shall verify that openings in the ductwork are closed or fitted with temporary blank-offs as required to establish the pressure boundaries for leak testing. - • Verify Leak Testing Performed: Verify that leak testing has been performed and that leakage rates are within allowable limits. The integrity of duct joints shall be confirmed via leak testing. After leak testing, verify that all temporary blank-offs are removed. • Verify Connections to Equipment: Verify that all external field-installed accessories, such as registers, grills and diffusers are in place. Verify that any required connections to equipment are complete and in accordance with the drawings. FORMS Quality Control Forms 000.509.F73101 - HVAC Inspection Checklist 000.509.F73102 - Buildings Air Conditioning Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7310 Rev 0 Heating, Ventilating and Air Conditioning Ductwork.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73101 Revision 0, 10 June 2013 HVAC INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID B73101B Client Other Sub – System: Location: Drawing No.: Subcontractor Inspection/Verification Checkpoints: 1. Materials are in accordance with Design Documents. 2. Air conditioning checklist complete. 3. Internal accessories complete. 4. Leak testing complete. 5. Temporary blank-offs removed. 6. Connections between duct and equipment complete/acceptable. 7. All Non-conformance Reports are closed. 8. Walkdown is complete. 9. Test/Performance runs according to specification: Type of Run Date Fluor FE/ QA 10. Other Inspection/Verification Activities performed as follows: Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73101 Rev 0 HVAC Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73101 Rev 0 HVAC Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73102 Revision 0, 10 June 2013 BUILDINGS AIR CONDITIONING CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor 1.0 Equipment 1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.1 3.2 3.3 4.1 4.2 4.3 4.4 4.5 4.6 Remarks: Subcontractor Name: Signature: Date: Name: Signature: Date: ID B73102A Tag No.: Turnover System: Client Other Sub – System: Location: Subcontractor Fluor FE/QA Specified equipment installed in accordance with manufacturer’s drawings and specifications. Coolers. Blowers/Ventilators. Filters. Heaters. Dryers. Duct supports installed per specifications. Joints airtight. Insulation installed per drawings. Volume extractors or balancing dampers installed. Sheet metal closing angles installed. Dampers installed. Ceiling diffusers checked. Ductwork interior clean of debris. Check for rattles and excessive noise. Punched and tested. Insulation installed as per drawings and specifications. Valve director furnished. Systems checked for completeness. Clean filters installed. Fan rotation checked. Balancing completed and controls systems adjusted. Balance position of balancing dampers marked. Test data recorded and verified. 2.0 Ductwork 3.0 Piping 4.0 Control Systems Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73102 Rev 0 Buildings Air Conditioning Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73101 Rev 0 HVAC Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7320 Revision 0, 10 June 2013 ROOFING INSPECTION SCOPE This procedure prescribes the roofing system inspection activities to be performed. RESPONSIBILITIES - Subcontracted ACTIVITY Install Roofing Roofing Installation General Requirements Inspect Roofing Installation of Adhered Membrane GENERAL • Inspect Roofing installation Develop plan for frequency of roofing installation inspections to be performed. Document results using Quality Control Form 000.509.F73201. Inform contractor daily of problems encountered to avoid rework or cover-up. Coordinate manufacturer representative inspections and respond to his findings. Notify appropriate craft supervision when his work, overhead or adjacent to roofing contractors work, impacts the quality aspect of the roofing system. RESPONSIBILITY Subcontractor Civil Construction Engineer Civil Construction Engineer 000.509.F73201 Daily during activity DOCUMENTATION FREQUENCY OF ACTIVITY 000.509.F73201 Daily during activity FORMS Quality Control Form: 000.509.F73201 - Roofing Daily Inspection Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7320 Rev 0 Roofing Inspection.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7320 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7320 Rev 0 Roofing Inspection.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73201 Revision 0, 10 June 2013 ROOFING INSPECTION CHECKLIST AREA: DATE: WEATHER: TEMPERATURE: Inspection Attribute General Requirements 1. Decking in the field of the roof, secured through ribs to supports at 30,5 cm on center. 2. Decking at corners (0,92 m²) and perimeters (1,8 width, or two deck panels, what ever is less) secured through ribs to supports at 15,24 cm on center. 3. Decking side laps attached to supports, and secured between supports at 91,4 cm on center maximum. 4. All penetrating elements, nailers, parapets and curbs installed. 5. All receiving surfaces free of splinters and protruberant fasteners. 6. Deck is free of moisture and debris. Inspector Date ID C73201A BUILDING: TIME: Sunny C Cloudy DEWPOINT: Rainy C Acceptable Remarks Foggy Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date 7. Verify drains are unblocked. Inspector Date Adhered Membrane 8. Insulation boards are not crushed. 9. Install tapered edge strips to form crickets. 10. Insulation boards to be half width or greater. 11. Insulation boards with 1,9 cm minimum edge bearing along upper flanges of the metal deck. 12. Insulation boards butted together. Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date 13. Fill insulation joints greater than 0.6 cm. Inspector Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73201 Rev 0 Roofing Inspection Checklist.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73201 Revision 0, 10 June 2013 ROOFING INSPECTION CHECKLIST 14. Isocyanurate boards are glass faced. 15. Insulation boards are FM approved with membrane. 16. Insulation fasteners installed every 0,18 m². 17. Insulation fasteners through metal deck upper flanges. 18. Sumps formed about drain. Inspector Date ID C73201A Inspector Date Inspector Date Inspector Date Inspector Date 19. Insulation fasteners driven flush to the top of the insulation without crushing or breaking the insulation surface. 20. Along perimeters and corners, insulation fasteners increased by 50 percent. 21. Loose lay sheet without stretching. Inspector Date Inspector Date Inspector Date 22. Sheets allowed to relax 30 minutes minimum. 23. Sheet seams 10,15 cm minimum. Inspector Date Inspector Date 24. Temperature of liquid adhesives and sealants 15,5°C minimum. 25. Fold EPDM sheet back 3 m without wrinkles or buckles. 26. Bonding adhesive stirred 5 minutes minimum (scrapping sides and bottom). 27. Surfaces to be bonded are clean and dry. 28. Bonding adhesives applied evenly without globs or puddles with mechanical roller dispenser. Bonding adhesive applied to both insulation and sheet at 11,15 m² to each surface. (Do not apply to seam surfaces). 29. Operation discontinued if condensation forms on adhesives. 30. Roll coated sheet on to coated substrate without wrinkles. Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73201 Rev 0 Roofing Inspection Checklist.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73201 Revision 0, 10 June 2013 ROOFING INSPECTION CHECKLIST 31. Bonded half of sheet brushed with a soft bristle broom. 32. Fold back unbonded half of sheet and repeat bonding process. 33. Install adjoining sheets in the same manner, edges overlapped 10/15 cm minimum, and formed with the flow of water. 34. Seams formed outside of sump. Inspector Date ID C73201A Inspector Date Inspector Date Inspector Date 35. Splice area cleaned by scrubbing with Sure-Seal HP splice wipe or clean natural rags saturated with Sure-Seal splice cleaner. Extra cleaning required at factory seams. 36. Cleaned material solid black in color with no streaking. 37. Top sheet held back during cleaning process. 38. Splicing cement stirred for 5 minutes minimum, scrapping sides and bottom. 39. Splicing cement applied to both mating surfaces with 11,5 cm medium nap roller. Adhesive applied smoothly, continuously, and uniformly to achieve a heavy coat. Adhesive not allowed to glob or puddle. 40. At corners and angles, splicing cement applied with 1,25 cm thick paint brush to achieve a smooth surface without brush marks. 41. Splicing cement applied at the rate of 9,29 m²/ per gallon. 42. Splicing cement allowed to dry until it is tacky, but will not stick or string to a dry finger touch and will not be moved when pushed with a dry finger. 43. If splicing cement over dried, fresh coat of splicing cement applied at half the rate. 44. Just before closing splice, bead of In-Seam Sealant between 0,3 and 0,6 cm applied a minimum of 1,2 cm from the inside edge of bottom sheet and a minimum of 5 cm from the lead edge of the top sheet. Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Page 3 of 6 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73201 Rev 0 Roofing Inspection Checklist.doc Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73201 Revision 0, 10 June 2013 ROOFING INSPECTION CHECKLIST 45. Sure-Seal HP splice wipes or Natural cloths contaminated by InSeam Sealant not reused for application of splice cleaner. 46. Top sheet rolled onto mating surfaces without stretching or buckling. 47. Seam wiped with hand toward edge. 48. Splice immediately rolled with a 5 cm wide steel roller with positive pressure toward outer edge. Roller not run parallel to seam. In-Seam Sealant remains evident and sensitive to the touch. 49. Wait two hours minimum, but before end of work day, probe seam. 50. Sure-Seal HP splice wipe or clean cloth dampened with splice cleaner used to clean the dry splice edge at least 0,02 cm beyond both sides of seam edge. 51. 0,7 cm bead of lap sealant applied to completely cover splice edge. 52. Lap sealant feathered with Carlisle tool. 53. RUSS (EPDM 0,11 cm minimum wide reinforced 15,24 cm EPDM) installed along perimeter, sections, expansion joints, curbs, and rising walls with gaps between strips not exceeding 2,5 cm. 54. RUSS fastened with Carlisle fasteners - through seam fastening plates to metal deck at 30 cm on center maximum, and pre-drilled holes in 15,2 to 22,8 cm from corners. 55. RUSS cleaned in accordance with membrane splices. 56. Membrane spliced to RUSS in accordance to membrane splices. 57. Vertical field seams at curbs and walls overlaid with 15,2 cm wide uncured Elastoform flashing. Inspector Date ID C73201A Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date Inspector Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73201 Rev 0 Roofing Inspection Checklist.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73201 Revision 0, 10 June 2013 ROOFING INSPECTION CHECKLIST ID C73201A Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73201 Rev 0 Roofing Inspection Checklist.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F73201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F73201 Rev 0 Roofing Inspection Checklist.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 EQUIPMENT SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for equipment erection and installation. RESPONSIBILITIES - Self-Perform ACTIVITY Implement storage, handling and maintenance requirement Check anchor bolt surveying Check level, alignment and plumbness Install/Erect equipment Monitor In-process Installation Activities Witness final alignment of rotating equipment Coordinate vendor activities Review guarantee requirements Perform final inspection of installed equipment Resolve any discrepancies identified NOTE 1: RESPONSIBILITY Construction Engineer/ Craft Supervision Construction Engineer Construction Engineer Mechanical Superintendent Site Quality Manager Millwright Superintendent Construction Engineer Construction Engineer Site Quality Manager Construction Engineer/ Site Quality Manager DOCUMENTATION _____ Survey Field Books Survey Field Books 000 509 F740XX 000 509 F740XX 000.509.F02201 000 509 F740XX Vendor Reports _____ 000 509 F740XX 000 509 F740XX FREQUENCY OF ACTIVITY As required by the controlling documents Prior to setting equipment Prior to setting equipment Once for each piece of equipment Daily during the life of the activity Once during final alignment As required by purchase order As required by purchase order Once after installation completed As required to resolve discrepancies Surveillance is not required is not required if the Fluor Quality representative is performing inspections. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 1 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 RESPONSIBILITIES - Subcontracted Work ACTIVITY Implement storage, handling and maintenance requirement Check anchor bolt surveying Check level, alignment and plumbness Install/Erect equipment Monitor In-process Installation Activities Witness final alignment of rotating equipment Coordinate vendor activities Review guarantee requirements Coordinate discipline inspections Perform final inspection of installed equipment Resolve any discrepancies identified Surveillance RESPONSIBILITY Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor/ Site Quality Manager Subcontractor/ Site Quality Manager Discipline Engineer Subcontractor/ Discipline Engineer Subcontractor Subcontractor/ Site Quality Manager Subcontractor Discipline Engineer Site Quality Manager Site Quality Manager DOCUMENTATION _____ Survey Field Books Survey Field Books 000 509 F740XX 000 509 F740XX 000 509 F740XX Vendor Reports _____ _____ 000 509 F740XX 000 509 F740XX 000.509.F02201 FREQUENCY OF ACTIVITY As required by the controlling documents Prior to setting equipment Prior to setting equipment Once for each piece of equipment Daily during the life of the activity Once during final alignment As required by purchase order As required by purchase order As required by specifications/ procedures Once after installation completed As required to resolve discrepancies Per Procedure 000.509.0220 PROCEDURE Client involvement in the witnessing of key aspects of erection, installation and checkout shall be carefully adhered to and documented by Client signature and date. Client notification of upcoming witness points will be given in writing a minimum of twenty-four (24) hours prior to the event. If required, notify the Client's Representative that final alignment is scheduled. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 2 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 • Implementation of Storage, Handling and Maintenance Requirements: The Construction Engineering Manager shall define the storage, handling and maintenance requirements for each type of equipment for implementation by site personnel. These requirements apply from receipt until turnover whether in lay down storage or set in place. Inspect/monitor prescribed equipment preservation activities. Document on Form 000.509.F02502. Verify that storage, handling and maintenance requirements are defined and implemented for each piece of equipment. Monitor these activities on a periodic basis or as required by specifications. - - • Verification of Anchor Bolts, Level, Alignment and Plumbness: Verify/check the anchor bolt locations and elevation, prior to setting the equipment on the foundation. • Installation/Erection of Equipment: The Mechanical Superintendent shall install/erect the equipment in accordance with the applicable drawings and specifications. Verify/check the plumb, alignment and orientation of equipment as well as the openings for elevation and location, immediately after installation. - • Monitor In-process Equipment Installation Activities: Initiate on Equipment Installation Checklist, Form 000 509 F740XX for each piece of equipment. Document the applicable in-process inspections as they are acceptably completed. Monitor/inspect the in-process installation of each equipment unit. Document inspection as it is completed on the applicable Equipment Inspection Record. Inspect for grouting of equipment as required by specification and drawings. - • Final Alignment of Rotating Equipment Witness the final alignment process and complete Form 000 509 F740XX to document this activity. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 3 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 • Coordination of Vendor Activities: The Construction Engineering Manager shall coordinate activities involving site vendors. Vendor schedules and purpose for site visits should be shared with site personnel for planning. Quality control will interface with the Vendor's Representative on matters of inspection and testing. Vendor checklists and acceptance records should be obtained for inclusion in turnover packages as project quality records. - • Review Guarantee Requirements: Inspect the equipment for guarantee requirements, when requirements are a part of the purchase order. • Final Inspection of Installed Equipment: Perform final equipment inspection at the completion of installation activities. • Resolve Discrepancies: Resolve exceptions and correct, deficiencies, with Client in-put as required. Perform/coordinate reinspections. FORMS Quality Control Forms: 000.509.F74001 000.509.F74002 000.509.F74003 000.509.F74004 000.509.F74005 000.509.F74006 000.509.F74007 000.509.F74008 000.509.F74009 000.509.F74010 000.509.F74011 000.509.F74012 000.509.F74013 000.509.F74014 000.509.F74015 000.509.F74016 Equipment Installation Checklist Heat Exchangers & Reboilers Installation Record Electrostatic Precipitator Checklist Inspection Record Static Equipment Tray Installation Inspection Record Air Cooled Heat Exchanger Inspection Checklist Air Cooler Run In Test Report Reciprocating Compressor Inspection Record Fan Installation Inspection Checklist Furnaces Inspection Record Fuel Gas Steam Generator Inspection Checklist Steam Turbine Inspection Checklist Agitators/Mixers Inspection Checklist Equipment/Piping Strain and Alignment Inspection Form Installation Checklist Travelling Cranes Package Equipment Installation Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 4 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 000.509.F74017 000.509.F74018 000.509.F74019 000.509.F74020 000.509.F74021 000.509.F74022 000.509.F74024 000.509.F74025 000.509.F74026 000.509.F74027 000.509.F74028 000.509.F74029 000.509.F74030 000.509.F74031 000.509.F74032 000.509.F74033 Desuperheaters/Ejectors Inspection Checklist Filters/Strainers Installation Record Centrifugal Compressor Inspection Record Rotating Equipment Inspection Record Rotating Equipment Alignment Record Belt Driven Equipment Alignment Record Inspection Record For Draw Off Tray Leak Test Report Inspection Record For Air Coolers Final Closing Authorization Record API 686 Baseplate Installation Checklist (Prior to Grouting) API 686 Equipment Grouting Checklist API 686 Alignment Check Sheet Baseplate Leveling Record Reverse Dial Alignment Record Piping Alignment Data Sheet Rotating Equipment (Face-Rim) Alignment Record ATTACHMENTS Attachment 1 - Equipment Inspection Reference W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 5 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 Attachment 1 EQUIPMENT INSPECTION REFERENCE General Requirements – Name plate data correct. – Equipment protection program in place and documented. – Anchor bolts checked for location, elevation and orientation. – Jackscrews removed and anchor bolt nuts tightened. – Pressure test documented. – Baseplate grouting complete and documented. – Field coatings checked. – Correct gaskets installed. – Correct stud bolts installed. – Final inspection performed and punch list items cleared. – Final closing authorization complete. Steam Turbines – Alignment checked and documented. – Freedom of movement and direction of rotation checked. – Bearing housing flushed and relubricated. – Carbon seals checked. – Governor mechanism free, set and operable. – Overspeed mechanism checked and tripout verified. Fired Heaters – Welding to tubes is complete and accepted. – Burner, snuffing steam and soot blower piping installed and accepted. – Convection sections team coil installed. – – – – Ductwork installed. Stack erected. Refractory installed and documented. Vendor representative provided service, and reports are on file. Shell & Tube Heat Exchangers – Slide plates installed and lubricated. – Nipples in re-pads of insulated exchangers. – Ladders and platforms installed. Air-cooled heat exchangers – Fan shaft centered and plumbed. – Fan blades installed, set to proper angle, and clearance checked. – Fan & driver checked for freedom of movement. – Belts installed or coupling lubricated. – Vibration switches checked. – Final alignment checked. – Belt or coupling guard in place. – Electrical driver checks complete. Compressors – – – – – – – – Lube and seal oil system flushed. Suction piping cleaned as per spec. Alignment checked and documented. Temporary suction screen installed. Coupling lubricated and closed. Pulsation dampening system checked. Driver activities complete. Vendor representative provided service, and reports are on file. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 6 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 EQUIPMENT INSPECTION REFERENCE Pumps – – – – – – Bearing housing flushed and lubricated. Temporary suction screen installed. Driver activities complete. Coupling lubricated and closed. Packing installed. Vendor representative provided service, and reports are on file. – Alignment checked and documented. Vessels: – – – – – – – – – – Slideplates installed and lubricated. Ladders and platforms erected. Internal shipping braces removed. Tray installation and orientation checked. Downcomers installation checked. Demisters checked. Packing and filter medium checked. Tray leak and level test complete. Refractory checked. Catalyst installed. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 7 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7400 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7400 Rev 0 Equipment.doc Page 8 of 8 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74001 Revision 0, 10 June 2013 EQUIPMENT INSTALLATION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74001A Other Turnover System: Sub – System: Equipment Description: Drawing No. Specification No. Vendor Drawing No. Subcontractor Assembly Orientation Elevation Shimming and Grouting Final Alignment and Rotation Bolting and Anchoring Instrumentation Vessel Closure Permit (Attach Closure Permit) Insulation Rigging and Handling (Attach Rigging Plan) Protection Cleaning, Lubrication, Adjustment, Packings Horizontal & Plumb Vessel Internals Check All Parts Cleanliness Operable Fluor FE/QA Item No. Tightness Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74001 Rev 0 Equipment Insptallation Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74001 Rev 0 Equipment Insptallation Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74004 Revision 0, 10 June 2013 INSPECTION RECORD STATIC EQUIPMENT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74004A Other Sub – System: Location: Subject 1. Verify nameplate data meets description. 2. Verify preservation integrity (if applicable). 3. Verify foundation and foundation bolts meet specified requirements. 4. Verify installation tolerances have been met. 5. Verify grouting meet specifications. 6. Verify all internals are correctly installed. 7. Verify all shipping devices have been removed. 8. Verify all vents, drains, and instruments con. etc. are installed in ACC. with equipment trim isometrics. 9. Verify alignments of piping connections are correct. 10. Verify coating system meets specified requirements. 11. Verify insulation meets specified equipment. 12. Verify prior to final closing for internal cleanliness. 13. Verify all ladders, platforms, stairways and walkways on correctly installed. 14. Orientation correct 15. Correct shimming installed 16. Tightness of anchor bolts nuts 17. Grouting completed 18. Sliding plate free (for horizontal vessels only ) & lubricated 19. Trays/down comers/support rings 20. Davits installed (Where applicable ) 21. Ready for closure 22. Closure certificate signed Subcontractor Name Signature Date Name Signature Date Subcontractor Fluor FE/QA Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74004 Rev 0 Inspection Record Static Equipment.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74004 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74004 Rev 0 Inspection Record Static Equipment.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74005 Revision 0, 10 June 2013 TRAY INSTALLATION INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: Client Other ID M74005AR Turnover System: Sub – System: TRAY No. 1 1 A B A B C 2 2 C 3 4 3 A 4 B F E D A B C F E D TRAY No. C Tray No. Design Dim’s Below Overflow A B Actual Dimensions C D E F Horizontally Working Value Contractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74005 Rev 0 Tray Installation Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74005 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74005 Rev 0 Tray Installation Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74008 Revision 0, 10 June 2013 RECIPROCATING COMPRESSOR INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74008A Client Other Sub – System: Location: Subcontractor 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Receive operations/inspection complete Equipment protection program instituted and documented Anchor bolts checked for location, elevation and orientation, prior to setting equipment. Equipment set: checked for location, elevation and orientation Nameplate data verified Preliminary alignment completed and documented. (Belt sheave alignment requires no documentation). Jackscrews removed and anchor bolt nuts tightened. Base grouting completed and documented Lube oil system flushed. Lubricant: Suction piping cleaned in accordance with specifications and documented. Final cold alignment set to manufacturer’s tolerances and documented (belt sheave alignment requires no documentation). Temporary suction screen installed Compressor and driver checked for freedom of measurement Driver activities completed and documented. Pulsation dampening system checked Belts installed, or coupling lubricated and closed. Lubricant: Belt or coupling guard in place and secured. Compressor and driver dowelled (when specified). Field coatings/insulation checked. Vendor representative provided service/supervision for the equipment. Vendor reports attached to this inspection record. Equipment protection program completed and documented. Final inspection complete. Punch items cleared. Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor FE/QA Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74008 Rev 0 Reciprocating Compresor Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74008 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74008 Rev 0 Reciprocating Compresor Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74009 Revision 0, 10 June 2013 FAN INSTALLATION INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: M74009A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 Description of Check Verify baseplate level and correctly grouted. Verify jackscrews removed and anchor bolts tightened. Verify temporary shipping preservatives/oils removed. Verify lubrication applied (where required). Verify excess piping strain alleviated. Verify final alignment as per specification. Verify blower driver checked for rotation. Verify gear unit checked (where applicable). Verify bearing lube system cleaned, flushed and operable. Verify belts installed or coupling connected. Verify packing installed. Verify blower and driver dowelled (where applicable). Verify casing drained. Verify inlet vanes set correctly and operable. Verify air filtration system correct. Verify all controls, protection devices and auxiliary systems correct. Verify all pipe supports correctly supported. Subcontractor Fluor FE/QA Notes: Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74009 Rev 0 Fan Installation Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74009 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74009 Rev 0 Fan Installation Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74013 Revision 0, 10 June 2013 AGITATORS/MIXERS INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74013A Client Other Turnover System: Sub – System: Item Description of Check 01 02 03 04 05 06 Verify mounting flange level (or plumb). Verify driver direction of rotation. Verify shaft plumb (or level). Verify shaft straightness. Verify alignment of drive shafts end clearance. inch Verify concentric parallel 1/4 Turn 1/2 Turn 3/4 Turn Full Turn Verify mechanical seal or packing in coupling cleaned, closed and lubed. Verify shaft turns freely by hand. Verify bearing house flushed and relubed. Verify seal fluid system operable. Verify lubricator operable. Verify driver doweled in place. Verify coupling guard in place. Verify grounding strap installed. Subcontractor Fluor FE/QA Remarks 07 08 09 10 11 12 13 14 Important: Do not start with dry mechanical seal. Notes: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74013 Rev 0 Agitators-Mixers Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74013 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74013 Rev 0 Agitators-Mixers Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74014 Revision 0, 10 June 2013 EQUIPMENT/PIPING FLANGE ALIGNMENT INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74014AR Client Other Turnover System: Sub – System: Report No.: Flange Misalignments: Vertical bolt hole offset Horizontal bolt hole offset Rotational offset Flange face parallelism Flange face separation Flange Misalignments: Vertical bolt hole offset Horizontal bolt hole offset Rotational offset Flange face parallelism Flange face separation Flange Misalignments: Vertical bolt hole offset Horizontal bolt hole offset Rotational offset Flange face parallelism Flange face separation Nozzle No.: cm cm cm cm cm Nozzle No.: cm cm cm cm cm Nozzle No.: cm cm cm cm cm cm cm cm cm cm cm cm cm cm cm Subcontractor Fluor FE/QA cm cm cm cm cm Subcontractor FluorFE/QA Subcontractor Fluor FE/QA IM & TE ID: Calibration Due Date: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74014 Rev 0 Equipment-Pipe Strain and Alignment Inspection Form.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74014 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74014 Rev 0 Equipment-Pipe Strain and Alignment Inspection Form.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74015 Revision 0, 10 June 2013 INSTALLATION CHECKLIST TRAVELLING CRANES Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74015A Client Other Turnover System: Sub – System: Item Note: Description of Check * Indicate Correct One Subcontractor Fluor FE/QA Definition 01 02 03 Verify configuration: fixed monorail/underhung bridge/overhead bridge/other .................................. (*) Verify marking safe working load: Beam Verify marking safe working load: Crane Verify type of drive 04 05 06 Hoist: Longitudinal: Transversal Type of lift: Verify fixed parts 07 i.e. runway beams, rails: Verify dimensions, positions, levels, fixing to structures, parallelism of rails / runway beams (if applicable), end stops, interlocks manual/electric/pneumatic (*) manual/electric/pneumatic (*) manual/electric/pneumatic (*) cable/chain (*) Verify moving parts 08 09 Notes: i.e., bridge, end carriages, drives, hoists, etc., for conformity and correct mechanical assembly Verify certification is complete, if required Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74015 Rev 0 Installation Checklist Travelling Cranes.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74015 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74015 Rev 0 Installation Checklist Travelling Cranes.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74016 Revision 0, 10 June 2013 PACKAGED EQUIPMENT INSTALLATION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74016A Client Other Turnover System: Sub – System: Item 01 02 Description of Check All shipping stops, bracing and packaging removed. Unit installed according to vendor instructions, undamaged, with skid location and orientation correct, holding down arrangement complete and secure. Check vibration mountings are secure and set correctly. Check equipment is level and shim material is to the correct specification. Nameplate details correct and in accordance with the datasheet. Nameplate securely attached, readable not obscured. Purchased equipment release note available. All shipped loose knocked down items re-installed in accordance with vendor’s installation instructions. Where preservation materials are installed, equipment is suitably marked “PRESERVATION INSIDE”. Unit clean and free from external damage and all paint work in good condition. Subcontractor Fluor FE/QA 03 04 05 06 07 08 09 Notes: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74016 Rev 0 Package Equipment Intallation Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74016 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74016 Rev 0 Package Equipment Intallation Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74018 Revision 0, 10 June 2013 FILTERS/STRAINERS INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74018A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 Notes: Description of Check Nameplate details are in accordance with data sheet. Check location is correct. Check filter is level and supports are correct. Check holding down bolts are fitted and torque settings are correct. Check external condition of filter. Check external fittings are correctly installed on filter. Check earthing is correctly fitted and to specification. Check vent / drain valves are fitted correctly. Check crossover valve is fitted correctly. Check balance line is fitted correctly. Check filter is internally clean. Check all filter elements are fitted correctly. Check all filter elements condition. Check all filter element types are correct. Check filter access lid is fitted correctly. Check access lid securing bolts are fitted and torque settings are correct. Check inlet and outlet pipework supports are secured / adequate. Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74018 Rev 0 Filters Strainers Installation Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74018 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74018 Rev 0 Filters Strainers Installation Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74019 Revision 0, 10 June 2013 CENTRIFUGAL COMPRESSOR INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74019A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 Description of Check Verify receipt operations/inspection complete. Verify equipment protection program instituted and documented. Verify anchor bolts checked for location, elevation and orientation, prior to setting equipment. Verify equipment set; checked for location, elevation and orientation. Verify nameplate data. Verify preliminary alignment completed and documented. Verify jackscrews removed and anchor bolt nuts tightened. Verify base plate grouting completed and documented when manufactured grouts are required. Verify lube and seal oil systems flushed. Lubricant: Verify suction piping cleaned in accordance with specifications and documented. Verify final cold alignment set to manufacturer's tolerances and documented. Verify temporary suction screen installed. Verify compressor and driver checked for freedom of measurement. Verify driver activities completed and documented. Verify coupling lubricated and closed. Lubricant: Verify coupling guard in place and secured. Verify compressor and driver doweled. Verify field coatings/insulation checked. Verify vendor representative provided service/supervision for this equipment. Vendor reports attached to this inspection record. Verify equipment protection program completed and documented. Verify final inspection complete. Subcontractor Fluor Field Engineering Name: Signature: Date: Name: Subcontractor Fluor FE/QA Fluor QA Name: Signature: Date: Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74019 Rev 0 Centrifugal Compressor Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74019 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74019 Rev 0 Centrifugal Compressor Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74020 Revision 0, 10 June 2013 ROTATING EQUIPMENT INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74020A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Notes: Description of Check Verify nameplate data. Verify preservation integrity. Verify foundation and foundation bolts meet specified requirements. Verify installation tolerance have been met. Verify grouting meet specifications. Verify all internals are correctly installed. Verify all shipping devices have been removed. Verify all vents, drains, instrument connections, etc., are installed in accordance with equipment trim isometrics. Verify alignments of piping connections are correct. Verify coating system meets specified requirements. Verify insulation meets specified equipment. Verify prior to final closing for internal cleanliness. Verify all ladders, platforms, stairways, and walkways are correctly installed. Verify all shafts for freedom of movement. Verify coupling alignment and installation. Verify direction of rotation. Verify electric motor. Verify installed coupling guard gives adequate protection. Verify correct quality and quantities of lubricants have been installed. Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74020 Rev 0 Rotating Equipment Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74020 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74020 Rev 0 Rotating Equipment Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74021 Revision 0, 10 June 2013 ROTATING EQUIPMENT ALIGNMENT CERTIFICATE Tag Description: P. O. No.: Subcontractor: Work Package: Subcontractor Fluor ID M74021AR Tag No.: Inspection Classification Area/Unit: Client Other Turnover System: Sub – System: Manual No. : Platform : Phase : Create Date : INFORMATION AND INSPECTION Manufacturer Test Equipment Used Type Type Serial No. Serial No Calibration Expiry Date Note : Indicate contents of completed report by the deletion of either “ Y “ of “ n/a “ as applicable. Page No. 2 of 6 3 of 6 4 of 6 5 of 6 6 of 6 Remarks: Flange Alignment Data Sheet Alignment Data Sheet - Uncoupled Alignment Data Sheet - Pipework Loose Alignment Data Sheet - Pipework Tight Uncoupled / Coupled Motor Run Data Sheet Record Sheet Description Y Y Y Y Y n/a n/a n/a n/a n/a W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74021 Rev 0 Rotating Equipment Alignment Record.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74021 Revision 0, 10 June 2013 ROTATING EQUIPMENT ALIGNMENT CERTIFICATE Manual No. : Phase : FLANGE ALIGNMENT Nozzle Alignment No. Description Line No. A B C Gasket Type 1 ID M74021Ar Inner Ring Yes No Remarks: (1) Spiral Wound / CAF / RTJ / Graylock W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74021 Rev 0 Rotating Equipment Alignment Record.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74021 Revision 0, 10 June 2013 ROTATING EQUIPMENT ALIGNMENT CERTIFICATE Manual No. : Phase : COUPLING ALIGNMENT - UNCOUPLED ID M74021Ar C DRIVER DRIVEN RIGID MOUNT Fig 1 A DRIVER B DRIVEN 0 A B B 90 180 B A 270 A A Fig 2 B C DRIVER DRIVEN D Fig 3 For face and periphery use clock C only. For reverse alignment use clock C and D. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74021 Rev 0 Rotating Equipment Alignment Record.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74021 Revision 0, 10 June 2013 RORATING EQUIPMENT ALIGNMENT CERTIFICATE Manual No. : Phase : COUPLING ALIGNMENT - COUPLED : PIPEWORK LOOSE N.B. For instructions of method of alignment including completion of alignment data sheet. See section 2.9 of Code of Practice “ Mechanical Commissioning “ METHOD OF ALIGNMENT EMPLOYED ........................................... LOOKING IN DIRECTION OF ............................................................ PIPEWORK FREE .............................................................................. LENGH OF COUPLER SPACER ....................................................... 5 DRIVER 4 ID M74021Ar 1 6 3 DRIVEN D.B.F.F. 7 2 1 RADIAL CONCENTRICITY OF EACH HALF COUPLING TO IT’S OWN SHAFT (Use for face/periphery and reverse alignment.) mm DRIVER GAUGE No. 1 mm DRIVEN GAUGE No. 2 mm mm mm mm mm mm 2 COUPLING GAP. FACE TO FACE. (AXIAL) (Use only for face/periphery method.) mm CLOCK GAUGES 3 & 4 mm mm mm 3 RADIAL CONCENTRICITY COUPLING FLANGES TO EACH OTHER (Use only for face/periphery and reverse alignment.) DRIVER GAUGE No. 5 mm DRIVEN GAUGE No. 6 mm mm mm mm mm mm mm W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74021 Rev 0 Rotating Equipment Alignment Record.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74021 Revision 0, 10 June 2013 ROTATING EQUIPMENT ALIGNMENT CERTIFICATE Manual No. : Phase : COUPLING ALIGNMENT - COUPLED : PIPEWORK TIGHT N.B. For instructions of method of alignment including completion of alignment data sheet. See section 2.9 of Code of Practice “ Mechanical Commissioning “ METHOD OF ALIGNMENT EMPLOYED ........................................... LOOKING IN DIRECTION OF ............................................................ PIPEWORK FREE .............................................................................. LENGH OF COUPLER SPACER ....................................................... 5 DRIVER 4 ID M74021Ar 1 6 3 DRIVEN D.B.F.F. 7 2 .1 RADIAL CONCENTRICITY OF EACH HALF COUPLING TO IT’S OWN SHAFT (Use for face/periphery and reverse alignment.) mm DRIVER GAUGE No. 1 mm DRIVEN GAUGE No. 2 mm mm mm mm mm mm 2 COUPLING GAP. FACE TO FACE. (AXIAL) (Use only for face/periphery method.) mm CLOCK GAUGES 3 & 4 mm mm mm 3 RADIAL CONCENTRICITY COUPLING FLANGES TO EACH OTHER. (Use only for face/periphery and reverse alignment.) DRIVER GAUGE No. 5 mm mm mm DRIVEN GAUGE No. 6 mm mm mm mm mm W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74021 Rev 0 Rotating Equipment Alignment Record.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74021 Revision 0, 10 June 2013 ROTATING EQUIPMENT ALIGNMENT CERTIFICATE Manual No. : Phase : UNCOUPLED / COUPLED MOTOR RUN DATA SHEET 1. Uncoupled Motor Run Time (mins) ID M74021Ar LV HV 2 0 4 30 6 60 8 90 10 120 15 150 20 180 25 210 30 240 Amb Temp Fan Casing temp Bearing temp DE Bearing temp NDE Vibration monitoring °C °C °C °C mm/s Remarks : 2. Coupled Motor Run Time (mins) LV HV 2 0 4 30 6 60 8 90 10 120 15 150 20 180 25 210 30 240 Amb Temp Fan Casing temp Bearing temp DE Bearing temp NDE Vibration monitoring °C °C °C °C mm/s Remarks : Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74021 Rev 0 Rotating Equipment Alignment Record.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74022 Revision 0, 10 June 2013 BELT DRIVEN EQUIPMENT ALIGNMENT RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74022AR Client Other Turnover System: Sub – System: Description of Check Pulley alignment Feeler gauge/straight edge on pulley faces. Subcontractor Fluor FE/QA A1 A2 A3 A4 View from top A1..............................................… A2..............................................… A3..............................................… A4..............................................… Belt tension C .000 cm .000 cm .000 cm .000 cm Adjust C to vendor’s recommendation. C………………………………..cm Notes: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74022 Rev 0 Belt Driven Equipment Alignment Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74022 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74022 Rev 0 Belt Driven Equipment Alignment Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74024 Revision 0, 10 June 2013 INSPECTION RECORD FOR DRAW OFF TRAY LEAK TEST REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74024A Client Other Sub – System: Location: Subject 1.0 Number of trays to be tested 2.0 Gaskets installed 3.0 Volume of water in trays before test Depth cm Subcontractor Fluor FE/QA 4.0 Volume of water in trays after 30 minutes. Depth 5.0 Test acceptable General Notes: cm Reason for failure: Corrective action required: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74024 Rev 0 Inspection Record for Draw Off Tray Leak Test.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74024 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74024 Rev 0 Inspection Record for Draw Off Tray Leak Test.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74025 Revision 0, 10 June 2013 INSPECTION RECORD FOR AIR COOLERS Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74025A Client Other Sub – System: Location: Subject 1.0 2.0 3.0 Verify motor rotation Install V-belts and adjust Auto – variable pitch fan. Operation check: 3.1 3.2 3.3 3.4 4.0 Apply _______ psi air to diaphram & adjust blade for maximum blade angle of ________. Adjust for minimum blade pitch angle of Verify fan rotation Motor amps, fan pitch under load conditions Amps 4.1 5.0 Verify vibration Subcontractor Fluor FE/QA Start fan & record motor ammeter reading: 4 hour test run: 5.1 5.2 5.3 Verify bearings Retighten belts Adjust blade pitch 6.0 Restart motor : 6.1 Verify motor amps if blade pitch changed Amps 7.0 Vibration switch test: 7.1 Trip simulation acceptable Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74025 Rev 0 Inspection Record For Air Coolers.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74025 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74025 Rev 0 Inspection Record For Air Coolers.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74026 Revision 0, 10 June 2013 FINAL CLOSING AUTHORIZATION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74026Ar Client Other Turnover System: Sub – System: 1. The above equipment has been supplied, erected and internally fitted in accordance with the applicable drawings, specifications and manufacturer's standard and is certified to be mechanically acceptable. Equipment has been inspected for cleanliness and is free of all debris. Fluor/Date 2. Authorization is hereby granted to effect final closing or sealing of this equipment. Client/Date 3. Final closing has been effected. Fluor/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74026 Rev 0 Final Closing Authorization Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74026 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74026 Rev 0 Final Closing Authorization Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74027 Revision 0, 10 June 2013 API 686 BASEPLATE INSTALLATION CHECKLIST (PRIOR TO GROUTING) Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID M74027A Sub – System: Location: Reference 3.5.2 3.5.3 Anchor bolts checked for: Clean and dry sleeves filled with a nonbonding moldable material such as spray foam Undamaged threads wrapped with duct tape for protection during chipping and grouting operation Foundation checked for: Breaks in aggregate to show that top of foundation has been chipped off to remove low-strength, high porosity concrete (laitance) Concrete grout areas clean and free of oil, dust and moisture Baseplate (or soleplate) checked for: (5 cm) minimum radiused corners Sufficient grout and air vent holes in each compartment Continuous welds that are free or cracks Stencil stating underside pre-coated with an epoxy primer Coupling guard bolts greased and installed to full depth. Elevation adjustment checked for: Subcont Fluor FE/QA 3.6.2 3.6.4 3.8.2 3.8.6 3.8.9 3.8.7 3.9.1.2 3.8.8 3.9.4.5 3.9.4.1 3.9.4.4 Adjustment nuts not used on anchor bolts Jackscrews liberally coated with paste wax or grease Jackscrews provided with stainless steel leveling pads Anchor bolts snug tight to hold baseplate in place Baseplate (or soleplate) raised to proper height per construction drawings Each machined mounting pads level to within 0,002 cm and centers are within 0,005 cm separation of each other (i.e., two pads three feet apart shall be a maximum of 0,015 cm from the correct elevation). Data Sheet for level record completed API 686 Chapter 5 paragraph number is referenced preceding each item. Proceed to ‘Baseplate Grouting Checklist’ (000 509 F74028) when all of the above items have been accepted. Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74027 Rev 0 API 686 Pre- Grout Baseplate Installation Checklist .doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74027 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74027 Rev 0 API 686 Pre- Grout Baseplate Installation Checklist .doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74028 Revision 0, 10 June 2013 API 686 EQUIPMENT GROUTING CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74028A Client Other Sub – System: Location: 4.1 MACHINERY INSTALLATION PREGROUT SETUP CHECKLIST Anchor Bolt Preparation Anchor bolt sleeves are clean and dry and filled with a nonbonding moldable material Anchor bolts are not tilted or bolt-bond and are perpendicular with respect to the bottom of the baseplate/soleplate Foundation anchor bolt threads are undamaged. Foundation anchor bolt threads have been wrapped with duct tape for protection. All anchor bolt locations and projections have been verified. Foundation preparation Subcont Fluor FE/QA Referenc e 3.5.2 3.5.2 3.5.3 3.5.3 3.5.4 3.6.1 3.6.2 3.6.2 3.6.2 3.6.3 3.6.4 An adequate weather-protective cover has been constructed over the areas to be grouted. Concrete foundation is roughened up and all laitance removed for a good grout bond. The minimum grout thickness under any portion of the baseplate/soleplate will be 2,5-5 cm. Foundation is free of structural cracks. All grout forms have been provided with 2,5 cm 45-degree chamfer strips at vertical corners and horizontal edges. Concrete grout areas are clean and free of oil, dust, and moisture. Grout Forms 3.7.1 3.7.3 3.7.4 3.7.5 Grout forms are of adequate strength to support the grout. Inside surfaces of grout have three coats of paste wax applied. Grout forms have been sealed to the foundation to prevent leaks. Grout forms have 2,5 cm, 45-degree chamfer strips at all vertical corners and at the horizontal surface of the grout. Mounting Plate Design Verification 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 3.8.7 Baseplate/soleplate has 5 cm minimum radiused corners. Anchor bolts have 0,3 cm annular clearance in baseplate or soleplate holes. All pump and other small baseplates have been provided with vertical leveling screws. Baseplates have been provided with one 5 cm minimum grout filling hole in the center of each bulkhead section and one 1,25 cm vent hole. Baseplates have sufficient grout and air vent holes in each compartment to allow for proper grouting. Elevation adjustment nuts will not be permanently grouted. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74028 Rev 0 API 686 Equipment Grouting Checklist.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74028 Revision 0, 10 June 2013 API 686 EQUIPMENT GROUTING CHECKLIST 3.8.8 3.8.9 3.8.10 Baseplate leveling jackscrews have been provided with stainless steel leveling pads. Baseplate welds are continuous and free of cracks. All grout pour and vent holes are accessible. Mounting Plate Preparation 3.9.1.1 3.9.1.2 3.9.1.3 3.9.1.4 Baseplate/soleplate has been blasted and all grouting surfaces prepared in accordance with the grout manufacturer’s recommendations. Three coats of paste wax have been applied to all surfaces where grout bond is not desired. These surfaces include jackscrews, grout forms and coupling guard bolts. All miscellaneous mounting plate holes are plugged to prevent the entrance of grout. Equipment to be grouted is isolated and in a strain-free condition with all piping, conduit and so forth, disconnected. Expansion Joints 3.9.2.1 3.9.2.2 Expansion joints placed on 1,2 to 1,8 meter intervals. Expansion joints fixed into position such that they will not move when grout is poured. Soleplate Installation and Leveling 3.9.3.1 3.9.3.7 3.9.3.9 3.9.4.1 3.9.4.2 1.9.4.5 The elevation to the top of equipment baseplate or soleplate referenced to the civil benchmark is in agreement with the construction grout drawing. All shims used in sub soleplates are AISI Standard type 300 stainless steel. All machined baseplate or soleplate surfaces are level in accordance with the specification and signed-off Data Sheets for level record have been completed. All baseplate elevations set in accordance with the construction drawings. A preliminary equipment alignment check has been made. All baseplate surfaces are level in accordance with the specification and signedoff Data Sheets for level record have been completed. Pregrout Setup 3.12.1 3.12.2 3.12.3 3.12.3 3.12.4 3.12.8 3.12.9 3.12.10 3.12.11 3.12.12 All surfaces in contact with grout are clean, dry and oil free. Anchor bolt nuts have been “snugged” into position to prevent baseplate/soleplate floating. Anchor bolt sleeves have been filled with flexible mastic material. Top of anchor bolt sleeve has been packed with a soft moldable material. Grout form elevation agrees with the construction drawings. Grouting material is in clean, dry, unopened containers and has been stored at a temperature of approximately 23,8˚C for 48 hours prior to grouting. All foundation and metal surfaces are within the temperature range of 18,3-32,2˚C Sufficient quantity of grouting materials are on hand at the jobsite to complete the job (15-25 percent extra). Clean tools, mixing equipment and safety supplies are on hand at the jobsite. Material Safety Data Sheets and personnel protection requirements have been reviewed with all grouting personnel. ID M74028A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74028 Rev 0 API 686 Equipment Grouting Checklist.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74028 Revision 0, 10 June 2013 API 686 EQUIPMENT GROUTING CHECKLIST 4.2 MACHINERY INSTALLATION GROUT PLACEMENT CHECKLIST Ambient temperature at beginning of grout pour _______˚C . Pre-grout meeting has been completed and all personnel understand the grout plan and individual responsibilities. Grout Mixing 3.13.2 3.13.3 3.13.3 3.13.4 Resin and hardener are mixed at 200-250 rpm for the specified time and no air entrainment is indicated. Full bags of aggregate are slowly added to blended resin/hardener liquid and mixed to completely wet-out the aggregate. No partial units of epoxy, resins, hardener or aggregate used. Grout mixed in a clean, slow-speed (15-20 r.p.m) portable mortar mixer (or in a wheelbarrow for small pours). Mounting Plate Grouting Grout is placed within its pot life. Time at beginning of pour: Time at end of pour: 3.14.2 3.14.2 3.14.3 3.14.4 3.14.5 3.14.7 3.14.9 No vibrator is used to facilitate grout placement. Grout pour rate is slow enough to permit air to escape. The grout volume used agrees with the estimated cavity volume. No grout leaks are observed. For special purpose equipment, a grout sample is obtained for each batch mixture (polystyrene cup full) for compressive strength testing. All samples are to be labeled and their batch placement location noted. All grout surface air bubbles are removed. Grout holes and vent holes filled with grout. Ambient temperature at end of grout pour _______ ˚C 4.3 3.15.1 3.15.1 3.15.3 3.15.4 3.15.5 3.15.6 MACHINERY INSTALLATION POST-GROUTING CHECKLIST Grout is of sufficient hardness to remove forms. Grout forms remained in place after grouting for 48-36 hours. Mounting plate jackscrew holes are filled with a flexible material such as RTV silicone rubber. Grout is checked for “softness” with a dial indicator. Baseplate/soleplate checked for soft foot at each anchor bolt location with a magnetic base dial indicator as anchor bolts are torqued. Base movement does not exceed 0,025 mm. Expansion joints sealed with elastic epoxy seam sealant. Top of machinery foundation painted with a grout-compatible nonskid protective coating. (AM) (PM) (AM) (PM) ID M74028A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74028 Rev 0 API 686 Equipment Grouting Checklist.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74028 Revision 0, 10 June 2013 API 686 EQUIPMENT GROUTING CHECKLIST Lubricate all anchor bolt threads liberally and torque anchor bolts in accordance with the manufacturer’s recommendations. 3.15.7 Anchor bolt size: Torque specification: Installed torque: 3.15.8 Ensure that all anchor bolts have full penetration of the anchor bolt nut and a minimum of 2 ½ threads protrude above the anchor bolt nut. Filling Grout Voids 3.16.1 Baseplate “sounded” for voids and all voids repaired. Indicate number of voids found, their size and their location: ID M74028A 3.16.2 3.16.3 3.16.3 3.16.4 3.16.5 Void areas have NPT 0,3 cm holes installed in opposite corners of void with grease fitting installed in one of the holes. Grout void fill and vent holes are in “communication”. Dial indicator used on mounting plate to monitor plate movement while filling grout void. All spilled grout is cleaned up with manufacturer’s approved solvent. Recheck baseplate to ensure that all voids are filled with grout. Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74028 Rev 0 API 686 Equipment Grouting Checklist.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74029 Revision 0, 10 June 2013 API 686 ALIGNMENT CHECK SHEET Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Client Other Tag No.: Turnover System: Sub – System: Location: ID M74029A Reference 5.1.1 Prealignment meeting held Roles & Responsibilities Contract and Back up Phone Numbers Alignment Table complete and available Taper Gauges available for checking piping flange alignment Shims SSTL or better material, not laminated and flat to 1/1000. At least 0,3cm thick but not more than 1,2 cm under movable machine foot. No more than one 0,3 cm thick shim under any foot. Sag of alignment fixture recorded (<0.8 mm/m) Alignment Checklist 5.1.3 5.1.12 Equipment installed and fixed machine centered on holes Fixed and movable machines shafts free to turn Pump seal locking devices disengaged Packing or blocking material removed Lubrication provided for bearings Coupling hubs runout rim and face readings is ≤0,005cm” or the manufacturer’s requirement, whichever is less. Check for Bolt-Bound condition All piping is disconnected Movable and fixed machine rotors DBSE or coupling spacer gap length acceptable when set to running position Minimize number of shims (Max 5 shims under any support) Shims are full bearing where practical (use largest pre-cut shim) Confirm Pump & Motor soft foot is not more than 0,005 cm” Sag of alignment fixture recorded (<0.8 mm/m) Alignment within tolerance before pipes and conduit attached Pipe strain confirmed to be within 0.005 cm shaft end deflection Alignment within tolerance after pipes and conduit attached Subcont Fluor FE/QA 5.1.4 5.1.5 5.1.11 5.4.1 5.4.2.1 5.4.2.1 5.4.4 5.5.1.1 5.4.5 5.4.5. 5.4.5 Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74029 Rev 0 API 686 Equipment Alignment Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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No.: Subcontractor: Inspection Classification Subcontractor Fluor Client Other Tag No.: Turnover System: Sub – System: Location: ID M74030A Z=____ Z=____ Z=____ Z=____ Z=____ Z=____ Limits: + ▻ Z Each pad level to within 0,002 cm/m (record reading and note direction with arrow) Slope between pads less than 0,005 cm/m (record reading and note direction with arrow) Soft foot less than 0,005 cm (record reading after grouting baseplate with equipment set) Before/After Grout (circle one) Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74030 Rev 0 Baseplate Leveling Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74030 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74030 Rev 0 Baseplate Leveling Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74031 Revision 0, 10 June 2013 REVERSE DIAL ALIGNMENT RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID M74031A Sub – System: Location: A Fixed Machine (Driven) (0) B (90) (0) Looking (270) (90) DBSE = _ _ _ _ (270) (180) Movable Machine (Driver) (180) A Fixed Machine (Driven) ______ Movable Machine (Driver) ______ B Before/After Piping (circle one) Thermal Growth (Motor) ______ Thermal Growth (Pump) ______ Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74031 Rev 0 Reverse Dial Alignment Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74031 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74031 Rev 0 Reverse Dial Alignment Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74032 Revision 0, 10 June 2013 PIPING ALIGNMENT DATA SHEET Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID M74032A Sub – System: Location: Machinery Installer: Machinery Identification: Feeler Gauge Readings Between Gasket Faces Flange Size: ______________________ 1. _______ _______ 8. Top or North Flange Size: ______________________ 1. _______ _______ 8. Top or North 2. _______ 2. _______ _______ 7. INLET 3. _______ _______ 7. OUTLET 3. _______ _______ 6. _______ 5. 4. _______ _______ 6. _______ 5. 4. _______ Pipe Strain Measurement Equipment nozzle and mating flange alignment tolerances shall be within the following maximum permissible limits: a. For steam turbines and compressors other than reciprocating types, 0,4mm (1/64 in. in.) for all alignment categories listed in Subpar. b. below. [For nozzles greater than NPS 24 (600 mm) (24 in.), the machinery vendor shall supply matting flanges.] b. For centrifugal pumps and other rotating machinery: Maximum Permissible Misalignment of Flanged Joints. In. Alignment Detail NPS 12 NPS 22 NPS 24 1. Vertical bolt hole offset 1/8 1/16 1/64 2. Horizontal bolt hole offset 1/8 1/16 1/64 3. Rotational offset 1/8 1/16 1/64 4. Flange face parallelism (across diameter) 1/64 1/64 1/64 5. Flange face separation, plus space required for gasket 1/8 1/16 1/64 Pipe Strain Readings Note: For horizontal machinery – Dial indicator readings on coupling hub flange. For vertical machinery – Dial indicator readings on driver-mount flange. Net Indicator Readings Inlet Flange Bolt-Up Outlet Flange Bolt-Up Horizontal Orientation (1) = or μm. or cm. = or μm. or cm. Vertical Orientation (2) = or μm. or cm. = or μm. or cm. (1) For vertical machinery, the horizontal orientation is perpendicular to pipe centerline when viewed from top. (2) For vertical machinery, the vertical orientation is parallel to pipe centerline when viewed from top. (3) Maximum shaft movement in either direction is 50 micrometers (0,005 cm). Subcontractor Fluor Field Engineering Fluor QA Name Signature Date Name Signature Date Name Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74032 Rev 0 Piping Alignment Datasheet.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74032 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74032 Rev 0 Piping Alignment Datasheet.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74033 Revision 0, 10 June 2013 ROTATING EQUIPMENT (FACE-RIM) ALIGNMENT RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74033A Client Other Turnover System: Sub – System: Equipment Tag No.: ______________ P P M M Piping Disconnected Notes: For Face-Rim Alignment Method: Record Readings on either driver or driven hub. Use the inner lines for face readings for that hub. For Reverse Alignment Method: Record the rim readings on both driver and driven hubs. Piping Connected Nominal Coupling Gap: ________________ Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74033 Rev 0 Rotating Equipment Face-rim Alignment Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74033 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74033 Rev 0 Rotating Equipment Face-rim Alignment Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7410 Revision 0, 10 June 2013 FIELD FABRICATED TANKS SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for field fabricated tanks. RESPONSIBILITIES - Self-Perform ACTIVITY Verify foundation surveying Inspect foundation construction Review and approve welding procedures Review and approve NDE procedures Monitor in-process welding and NDE activities Check dimensions of tank shell Inspect completed tank Witness testing Inspect tested tank prior to closing RESPONSIBILITY Construction Engineer DOCUMENTATION Survey Field Books FREQUENCY OF ACTIVITY Prior to start of erection Site Quality Manager Per 000.509.7100 Approval from Corporate Welding Engineering Approval from Corporate Level III Per 000.509.7910 Prior to start of erection Prior to start of welding activities Prior to start of NDE activities Daily during life of activity Periodically during life of activity Each tank Each tank Welding Engineering Corporate NDE Level III Site Quality Manager Site Quality Manager Site Quality Manager Site Quality Manager Site Quality Manager 000.509.F74103 000.509.F74102 000.509.F74026 Each tank W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7410 Rev 0 Field Fabricated Tanks.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7410 Revision 0, 10 June 2013 RESPONSIBILITIES - Subcontracted ACTIVITY Verify foundation surveying Inspect foundation construction Review and approve contractor's welding procedures Review and approve contractor's NDE procedures Check dimensions of tank shell Surveillance of weld and NDE activities. Inspect completed tank Witness testing Inspect tested tank prior to closing PROCEDURE • Foundation Surveying: • Verify that the foundation surveying is complete. RESPONSIBILITY Construction Engineer Subcontractor Welding Engineering DOCUMENTATION Survey Field Books 000.509.F02201 Approval from Corporate Welding Engineering Approval from Corporate Level III 000.509.F74103 000.509.F02201 000.509.F02201 000.509.F74102 000.509.F74104 000.509.F74105 000.509.F74106 000.509.F74026 FREQUENCY OF ACTIVITY Prior to start of erection Prior to start of erection Prior to start of welding activities Prior to start of NDE activities Periodically during life of activity Daily during life of activity Each tank Each tank Each tank Corporate NDE Level III Subcontractor Site Quality Manager/ Subcontractor Site Quality Manager/ Subcontractor Site Quality Manager/ Subcontractor Site Quality Manager/ Subcontractor Foundation Construction: Verify the foundation construction is complete and released for the tank erection. For subcontracted work ensure the erector has accepted the foundation prior to start of tank erection activities. • Review and Approval of Welding Procedure: Verify the welding procedures have been reviewed and approved by the Corporate Welding Manager or his representative. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7410 Rev 0 Field Fabricated Tanks.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7410 Revision 0, 10 June 2013 • Review and Approval of NDE Procedures: Verify the NDE Procedures have been reviewed and approved by the Corporate NDE Level III. • Dimension Checks of Tank: Monitor the in-process fabrication activities. Utilize From 000.509.F74102 to document the dimension checks. Verify the first course shell plates have been surveyed for levelness, circularity, and plumbness prior to setting the second course. Contractor must submit the results immediately after each survey has been completed. - • Completed tank Inspection: Verify that a final survey has been performed of the erected dimensions of the tank after all roof framing has been installed. Verify the tolerances for plumbness of roof columns and stilling wells, tank nozzles and modules are within those established by the specification. - • Witness Testing of Tank: Witness the hydrostatic test on the completed tank in accordance with the project specifications and applicable code requirements. Check the settlement and rebound of the foundation during and after the hydrotest. Excessive settlement data shall be referred immediately to the Site Engineering Manager. Obtain a copy of the tank test for inclusion in the permanent file. - • Inspection of Tested Tank Prior to Closing: Inspect the tested tank prior to closing, including final cleanup. Document the approval to close the tank using From 000.509.F74026. Verify that a nameplate according to code and the Manufacturer's Certification Letter and the as-built data has been provided as required by the specifications. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7410 Rev 0 Field Fabricated Tanks.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7410 Revision 0, 10 June 2013 FORMS Quality Control Forms: 000.509.F74101 000.509.F74102 000.509.F74103 000.509.F74104 000.509.F74105 000.509.F74106 000.509.F74026 000.509.F02201 Tank Elevation Tolerances Record Inspection Record Field Erected Tank Tank Plate Dimensional Control Record Field Erected Tank Water Filling And Settlement Record Field Erected Tank Tank Leak Test Record Tank Test Certificate Final Closing Authorization Record Surveillance Report W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7410 Rev 0 Field Fabricated Tanks.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74101 Revision 0, 10 June 2013 TANK ELEVATION TOLERANCES RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: Client Other ID M74101AR Turnover System: Sub – System: + 0 - 0 + 00 1 + 00 2 + 00 3 + 00 STATIONS 4 + 00 5 + 00 6 + 00 7+00 8+ 00 Note: Show vertical scale and units. TANK FOUNDATION DESIGN ELEV.____________________________ FOUNDATION DESIGN CROWN ELEV._________________________________________________ INSTRUCTIONS TANK FOUNDATION TOLERANCE Establish tank foundation tolerances and obtain tank fabricator acceptance before the start of tank erection. Starting at North Centerline with Station 0+00, and moving clockwise, establish stations at approximately half-sheet intervals around the tank. Do this by establishing the tank shell outline on the foundation and marking off the half-sheet intervals. Take level readings at each station and record on this form. Unless otherwise specified by the contract, the initial tolerance of foundations shall be in accordance with API-650. This exhibit may also be used to record shell and roof elevation tolerances, as well as settlement data, during and after signature of the Fabricator's Representative. Area Superintendent Date Foundation elevation tolerances in accordance with applicable specifications and drawings. Senior Field Engineer Foundation elevation tolerances checked and accepted. Date Fabricator's Representative Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74101 Rev 0 Tank Elevations Tolerance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74101 Rev 0 Tank Elevations Tolerance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74102 Revision 0, 10 June 2013 INSPECTION RECORD FIELD ERECTED TANK Subject 1.0 2.0 Inspection-Bottom 1.1 2.1 2.2 2.3 2.4 2.5 3.0 3.1 3.2 3.3 3.4 3.5 3.6 4.0 Testing 4.1 4.2 4.3 4.4 4.5 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Hydrotest water quality and temperature checked. Operation of vents and liquid gauges checked. Tank cleaned. Corner weld tested. Bottom seams vacuum tested. Foundation correct Dimension in accordance with design data Peaking/banding/Verticality & Roundness Nozzle Sizing, orientation & standouts Bottom drain location correct Arrangement traceability weld maps accepted Temporary attachments removed Bottom annulare plates level. Shell diameter checked at bottom, mid-height, top. Shell height checked. Shell banding checked. /Shell peaking checked. Wind girder erection checked. Location nozzle’s, manhole and stairway checked. Support columns for roof in place and plumb. Roof fittings locations checked. Roof seals installed and checked. Stairway and ladder locations checked. Fire extinguishing systems installed and checked. Internal spray and distributor piping and fittings checked. Inspection-Shell ID M74102A Subcontractor Fluor FE/QA Inspection-Roof Arrangement W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74102 Rev 0 Inspection Record Field Erected Tanks.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74102 Revision 0, 10 June 2013 INSPECTION RECORD FIELD ERECTED TANK Subject 6.0 Testing 6.1 6.2 6.3 6.4 6.5 6.6 7.0 7.1 7.2 7.3 7.4 7.5 7.6 8.0 8.1 8.2 9.0 9.1 9.2 9.3 9.4 9.5 Remarks All NDE completed and verified Floor Vacuum Test Nozzle reinforcing pad air test Fixed roof tightness test Hydrostatic Test Settlement under hydrotest recorded Ladders & platforms installed correctly Foam piping installed (where applicable) Sprinkler system installed (where applicable) Breather valves/Air vents installed Level gauges/ stilling wells installed Earthing Internal coatings External coatings Tank calibration carried out Nameplate data correct Tank cleaned out & ready for closure QC documentation reviewed & accepted Closure certificate signed ID M74102A Subcontractor Fluor FE/QA Attachments Surface Protection Final Acceptance Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74102 Rev 0 Inspection Record Field Erected Tanks.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74103 Revision 0, 10 June 2013 TANK PLATE DIMENSIONAL CONTROL RECORD FIELD ERECTED TANK Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74103AR cm. Client Other Turnover System: Sub – System: Type of Tank: Dimension check for: No. 1 2 3 4 5 6 7 8 9 10 Notes: Weld/Plate No. Diameter ( ) Roundness (HP) Height: ( cm. Volume: ) Verticality(HP) m3 ) Peaking/Banding(HP) ( No. 11 12 13 14 15 16 17 18 19 20 Tolerance Difference Acceptable Weld/Plate Tolerance Difference Acceptable No. Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74103 Rev 0 Tank Plate Dimensional Control Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74103 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74103 Rev 0 Tank Plate Dimensional Control Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74104 Revision 0, 10 June 2013 WATER FILLING AND SETTLEMENT RECORD FIELD ERECTED TANK Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74104A Client Other Sub – System: Location: Type of Tank: Diameter: cm Height: cm Volume: cm3 Water Filling No. 1 2 3 4 Full Increment Time From To Height cm cm cm cm Rate cm cm cm cm Holding Time .hrs .hrs .hrs .hrs Remarks Tank Settlement Record Section to be checked (degrees ) No. 1 2 3 4 5 Full Empty HP HP Stage Before Fill 0 - 45 45 - 90 90 - 135 135 - 180 180 - 225 225 - 270 270 - 315 215 - 360 Remarks HP Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74104 Rev 0 Water Filling and Settlement Record Field Erected Tanks.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74104 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74104 Rev 0 Water Filling and Settlement Record Field Erected Tanks.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74105 Revision 0, 10 June 2013 TANK LEAK TEST RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Type of Tank: Leak Test for: No. Test Area / Portion Test Date ID M74105AR Tag No.: Area/Unit: Inspection Classification Subcontractor Fluor Diameter: ( ) Vacuum Box (HP) Result Client Other cm Turnover System: Sub – System: cm Volume: ( Test date ) Air (HP) Result cm 3 Height:: ( No. ) Oil (HP) Test Area / Portion Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Name: Signature: Date: Client W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74105 Rev 0 Tank Leak Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74105 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74105 Rev 0 Tank Leak Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74106 Revision 0, 10 June 2013 TANK TEST CERTIFICATE Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID M74106 Client Other Sub – System: Location: Subject Bottom - Vacuum Test Numbers Subcontractor Fluor FE/QA Fittings - Air Test Numbers Roof - Vacuum Test Numbers Shell - Hydrostatic Test Numbers Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74106 Rev 0 Tank Test Certificate.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74106 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74106 Rev 0 Tank Test Certificate.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74026 Revision 0, 10 June 2013 FINAL CLOSING AUTHORIZATION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID M74026Ar Client Other Turnover System: Sub – System: 1. The above equipment has been supplied, erected and internally fitted in accordance with the applicable drawings, specifications and manufacturer's standard and is certified to be mechanically acceptable. Equipment has been inspected for cleanliness and is free of all debris. Fluor/Date 2. Authorization is hereby granted to effect final closing or sealing of this equipment. Client/Date 3. Final closing has been effected. Fluor/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74026 Rev 0 Final Closing Authorization Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F74026 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F74026 Rev 0 Final Closing Authorization Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7500 Revision 0, 10 June 2013 UNDERGROUND PIPING SCOPE This procedure applies to the activities associated with inspection and testing of underground piping. RESPONSIBILITY - Self-Perform Pipe Installation ACTIVITY Request Excavation Coordinate Excavation Release Inspect Excavation Welding Inspection and Testing Inspect on-site pipe fabrication & installation Cleaning of Pipe Pressure Test Coordinate Backfill Request/Release Backfill Inspection Surveillance RESPONSIBILITY Mechanical Supt. Const. Engineer/ Mechanical Site Quality Manager Per 000.509.7910 Site Quality Manager Per 000.509.7560 Per 000.509.7520 Construction Engr./ Mechanical Site Quality Manager Site Quality Manager DOCUMENTATION 000.509.F75001 000.509.F75001 000.509.F75001 Per 000.509.7910 000.509.F75001 Per 000.509.F75601 Per 000.509.F75201 000.509.F75001 000.509.F75001 000.509.F02201 FREQUENCY OF ACTIVITY Each excavation Each excavation Daily during life of activity and prior to laying pipe. Per 000.509.7910 Each installation Per 000.509.7560 Per 000.509.7520 Each backfill. Each backfill During life of activity RESPONSIBILITY - Subcontracted Pipe Installation ACTIVITY Request Excavation Coordinate Excavation Release Inspect Excavation Welding Inspection and Testing Inspect/Test On-Site Fabrication and Installation Cleaning of Pipe Pressure Test Inspect Coating, Wrapping, Cathodic Protection, Holiday Test, Insulation Resistance Backfill Request/Release Backfill Inspection Surveillance RESPONSIBILITY Subcontractor Const. Engineer/ Mechanical Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor Mechanical Supt. Site Quality Manager DOCUMENTATION 000.509.F75001 000.509.F75001 000.509.F75001 Per 000.509.7910 000.509.F75001 Per 000.509.F75601 Per 000.509.F75201 000.509.F75001 000.509.F75002 000.509.F75001 000.509.F75001 Not Required Form 000.509.F02201 FREQUENCY OF ACTIVITY Each excavation Each excavation Daily during life of activity and prior to laying pipe. Per 000.509.7910 During life of activity Per 000.509.7560 Per 000.509.7520 Daily during life of activity. Each backfill. Each installation. Daily during life of activity. Daily during life of activity. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7500 Rev 0 Underground Piping.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7500 Revision 0, 10 June 2013 PROCEDURE • Excavation Excavation Release will be signed off prior to the excavation. At this time the location that has been laid out for excavation will be accepted by the Construction Engineer and the Superintendents. The Form 000.509.F75001 shall represent only the piping that the excavation release is approved for (or piping within a single pressure test boundary), whichever is more restrictive. Additional forms are used as needed so that all underground piping is documented. Use Attachment 1 as a guide in performing inspections for inspection attributes. - • Welding Inspection and Testing Reference procedure 000.509.7910 for the welding inspection and testing requirements. • Pipe Fabrication and Installation Verify that pipe fabrication and installation activities are performed in accordance with the requirements documented in the applicable drawings and specifications. Use Attachment 1 (Underground Pipe Inspection Reference) as a guide in performing inspections. Use Form 000.509.F75001 to document inspection results. - • Cleaning of Pipe Reference Procedure 000.509.7560 for the cleaning of pipe inspection and testing requirements. • Pressure Testing of Piping Systems Verify that required pressure testing has been performed and documented in accordance with Procedure 000.509.7520. • Insulated Flanges - Insulation Resistance Test Insulation resistance testing of insulated flanges, should be performed in accordance with manufacturer instructions and the specifications and this test is documented on form (000.509.F75002). W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7500 Rev 0 Underground Piping.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7500 Revision 0, 10 June 2013 • Coating and Wrapping of Pipe Contact Quality Representative when coating and wrapping activities are to be performed so those activities can be monitored and required inspections and testing can be accomplished. Verify that piping fabrication meets all applicable requirements and that all installed pipe is ready for coating and wrapping. Coating and wrapping shall proceed only after completion of all NDE, successful pressure test, cathodic protection, and testing, including insulation resistance (insulated flanges) testing, Form 000.509.F75002. Monitor the coat and wrap work performance for compliance to specification. Identify, by marking on the surface of the wrapping, any areas found to be defective. Notify the pipe superintendent of any repair areas needing rework. Use Form 000.509.F75001 to document verification activities. - - • Holiday Testing Holiday testing should be performed in accordance with the equipment manufacturer instructions and the specifications, which may include: Testing of coated and wrapped pipe will be performed with an electric holiday detector, set at a maximum of 2400 volts D.C. for each 1/32" (0.8 cm) of coating thickness. Calibration and usage of the holiday detector instrument shall be in accordance with manufacturer's directions. Rework any areas identified as defective and reschedule inspection and test of repaired areas. Document holiday test results in the appropriate section of the Underground Pipe Inspection Record (000.509.F75001). Notify Piping Superintendent of the sections of accepted coated and wrapped piping which are ready for backfill. - - - - • Backfill Request/Release Backfill Release Form 000.509.F75001, will be signed off prior to backfilling. At this time, all work will be verified as complete, including punchlist items and holiday tests before filling over piping. Before filling over welded joints the pressure test must be complete. If the Backfill Release is for only a part of the piping represented by the Excavation Release, additional "Underground Pipe Inspection Records" should be prepared with the boundaries being released identified on the form. Inspection/Test acceptance and Backfill Release should be approved on the additional forms. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7500 Rev 0 Underground Piping.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7500 Revision 0, 10 June 2013 FORMS Quality Control Forms: 000.509.F75001 - Underground Pipe Inspection Checklist 000.509.F75002 - Insulation Resistance (Insulated Flanges - Underground Piping) Test Record 000.509.F75003 - Holiday (Spark) Test Record 000.509.F75201 - Pressure Test Report ATTACHMENTS Attachment 1 - Underground Pipe Inspection Reference W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7500 Rev 0 Underground Piping.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7500 Revision 0, 10 June 2013 Attachment 1 UNDERGROUND PIPE INSPECTION REFERENCE Pipe Fabrication and Installation • General • Line size correct Material correct Line slopes per drawing Branches located correctly High point vents installed Reducers located correctly Reducer type correct Gouges, nicks, surface damage • Excavation Slope per drawing Dimensions per drawing Compaction test before laying pipe Bedding • Coating and Wrapping Surface preparation Application per specification Materials per specification Repairs per specification Holiday Testing Valves Flow direction correct Item code number correct Bolts or studs correct Bypass installed (if required) Extensions installed • Cathodic Protection Electrical connections Flange insulating kit Insulated Flanges-Insulation Resistance Test Sacrificial material buried Rectification equipment installed • Flanged Connections Flange type, material, rating Flange face preparation and condition Gasket type and condition Bolting type, size, length Torque sequence and values • Pipe Supports Thrust blocks Sufficient supports Anchors installed W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7500 Rev 0 Underground Piping.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7500 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7500 Rev 0 Underground Piping.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75001 Revision 0, 10 June 2013 UNDERGROUND PIPE INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID P75001A Client Other Turnover System: Sub – System: Drawing Number Sheet Drawing Number Sheet Item 01 Description of Check Excavation releases: Construction Engineer – Mech. Mechanical Supt. Electrical Supt. Civil Supt. Subcontractor Fluor FE/QA 02 03 04 05 06 07 08 09 10 Location and excavation inspection completed Pipe fabrication and installation inspection completed Cleaning of pipe completed Pressure test satisfactory Insulation resistance (insulated flanges-underground piping) test satisfactory Coating and wrapping checked Holiday test satisfactory Cathodic protection completed Backfill request/release(s) obtained Construction Engineer – Mech. Site Quality Manager Client 11 Notes: Backfill inspection completed Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75001 Rev 0 Underground Pipe Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75001 Rev 0 Underground Pipe Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75002 Revision 0, 10 June 2013 INSULATION RESISTANCE (INSULATED FLANGES – UNDERGROUND PIPING) TEST RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID P75002AR Client Other Turnover System: Sub – System: Reference Drawing Test equipment No. Notes: 1. Use multi-volt-ohm meter tester or a gas electronics insulation checker model 601. 2. Minimum acceptable value is 10,000 ohms or a suitable reading using the gas electronics insulation checker model 601. Flange location Resistance (ohms) Date Subcontractor Fluor FE/QA Line number Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75002 Rev 0 Piping Flanges Insulation Resistance Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75002 Rev 0 Piping Flanges Insulation Resistance Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75003 Revision 0, 10 June 2013 HOLIDAY (SPARK) TEST RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID P75003AR Client Other Turnover System: Sub – System: ISO-Sheet Number Spool Number Subcontractor Fluor FE/QA Voltage setting: Subcontractor Name: Signature: Date: kV Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75003 Rev 0 Holiday Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75003 Rev 0 Holiday Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75201 Revision 0, 10 June 2013 PRESSURE TEST REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID P75201A Client Other Sub – System: Location: Test Package No.: ___________________ Description: _____________________________________________________ P. &I.D. No.(s) R P. &I.D. No.(s) Test Boundaries R P. &I.D. No.(s) R P. &I.D. No.(s) R ISO No.(s) Sht R ISO No.(s) Sht R ISO No.(s) Sht R Vessels or Equipment in test boundary: Test Conditions Test Medium _______________________________ Test Media/Metal Temp Min._____________ Ambient Temp. Min.____________________ Test Pressure Min.________________ Holding Time: Min. ______________ Test Gage Number: M.T.E.________ M.T.E.________ Date Last Calibrated: Max.______________ Chlorine Content __________________ Max.__________________ Actual_________________ Actual_____________ Actual_____________ ______________ ______________ Test Gage Range: Low_______ Low_______ High_______ High_______ Relief Valve Setting_______________ Actual______________ Pre-Test Inspections/Release Pre-Test Walkdown Complete: NDE, PWHT, PMI (if required) Complete/Accepted: Pipe Field Eng QA Inspector Date Date Verification of Satisfactory Test Results QC Inspector QA Inspector Verification of Line Restoration Date Date Pipe Field Engineer QA Inspector Remarks: Date Date For coordinate boundaried system such as oil water sewer, test beginning and ending coordinates shall be indicated on the attached drawings. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75201 Rev 0 Pressure Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75201 Rev 0 Pressure Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7510 Revision 0, 10 June 2013 ABOVEGROUND PIPING SCOPE This procedure applies to the activities associated with inspection and testing of aboveground piping. RESPONSIBILITIES - Self-Perform Pipe Installation ACTIVITY Welding Inspection and Testing Inspect on-site pipe fabrication and installation Cleaning of Pipe Inspect Insulation Pressure Test RESPONSIBILITY Per 000.509.7910 DOCUMENTATION Per 000.509.7910 000.509.F75101 000.509.F75102 000.509.F75103 000.509.F79001 Per 000.509.F75601 Per 000.509.F78102 Per 000.509.F75201 FREQUENCY OF ACTIVITY Per 000.509.7910 Site Quality Manager Per 000.509.7560 Per 000.509.7810 Per 000.509.7520 Each installation Per 000.509.7560 Per 000.509.7810 Per 000.509.7520 Responsibilities - Subcontracted Pipe Installation FREQUENCY OF ACTIVITY Per 000.509.7910 Each installation Per 000.509.7560 Per 000.509.7810 Per 000.509.7520 During life of activity ACTIVITY Welding Inspection & Testing Inspect on-site pipe fabrication and installation Cleaning of Pipe Inspect Insulation Pressure Test Surveillances PROCEDURE • RESPONSIBILITY Subcontractor Subcontractor Subcontractor Subcontractor Subcontractor Site Quality Manager DOCUMENTATION Per 000.509.7910 000.509.F75101 000.509.F75102 000.509.F75103 000.509.F79001 Per 000.509.F75601 Per 000.509.F78102 Per 000.509.F75201 Form 000.509.F02201 Welding Inspection and Testing Reference Procedure 000.509.7910 for the welding inspection and testing requirements. The Fluor Quality Control System Manual, Boiler and Pressure Vessel Code Work shall be invoked for self-perform work that will require ASME or National Board Code stamping. If the work is subcontracted and will require code stamping by the subcontractor, the subcontractor's Code program shall be invoked. Prior to the start of any work that will require Code Stamping, contact Scott Fincher, Corporate Code Specialist at 864 -2816796. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7510 Rev 0 Above Ground Piping.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7510 Revision 0, 10 June 2013 • Pipe Fabrication and Installation Verify that pipe fabrication and installation activities are performed in accordance with the requirements documented in the applicable drawings and specifications. Use Attachment 1 (Aboveground Pipe Inspection Reference) as a guide in performing inspections. Use Form(s) 000.509.F75101, 000.509.F75102, 000.509.F75103 and 000.509.F79001 to document inspection and examination results. - - • Cleaning of Pipe Reference Procedure 000.509.7560 for the cleaning of pipe inspection and testing requirements. • Insulation Inspection Reference Procedure 000.509.7810 for the insulation inspection requirements. • Pressure Testing of Piping Systems Verify that required pressure testing has been performed and documented in accordance with Procedure 000.509.7520. FORMS Quality Control Form: 000.509.F75101 - Aboveground Pipe Inspection Checklist 000.509.F75102 - Visual Inspection of Flanges, Gaskets and Bolting 000.509.F75103 - Weld Map Record 000.509.F75201 - Pressure Test Report 000.509.F75601 - Pipe Cleaning and Verification Checklist 000.509.F79001 - Daily Welding Report ATTACHMENTS Attachment 1 - Aboveground Pipe Inspection References W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7510 Rev 0 Above Ground Piping.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7510 Revision 0, 10 June 2013 Attachment 1 ABOVEGROUND PIPE INSPECTION REFERENCE GENERAL Line size correct. Material correct. Gouges, nicks, surface damage Installation straight and plumb. Line slopes per drawing. Branches located correctly. Branches reinforced. Weepholes in reinforcing pad. High point vents installed. Low point drains installed. Reducers located correctly. Reducer type correct Cold spring or prespring per drawing. Clearance for expansion. Exposure to contaminants. VALVES Flow direction correct. Item code number correct. Bolts or stud correct. Bypass installed (if required). Chain wheel installed. Extension installed. Stem oriented properly. Drain, flush, connections installed. FLANGED CONNECTIONS Flange material, type, and rating. Flange face preparation, condition, cleaning. Gasket type, thickness, condition, rating. Bolt type, size, length, lubrication. Torque sequence, values. PIPE SUPPORTS Field supports installed. Sufficient supports. Anchors installed. Guides installed. Proper shoes installed and welded. Spring hangers properly installed. INSTRUMENTS PSV's tested (correct item number). Correct control valves installed. Meter runs properly installed (jacking screws included). Valves at meter runs installed. Pressure gage valves installed. Pressure gages properly oriented. Temperature connections properly oriented. Sample connections installed. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7510 Rev 0 Above Ground Piping.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7510 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7510 Rev 0 Above Ground Piping.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75101 Revision 0, 10 June 2013 ABOVE GROUND PIPE INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID P75101A Client Other Turnover System: Sub – System: Item General 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 Notes: Description of Check System complies with P and ID's and isometric drawings. Piping fabrication ITR complete and accepted. All field weld inspection and NDE, traceability and history records complete and accepted. All NDT/stress relieving requirements performed in accordance with requirements and documented. Correct bolts and gaskets are installed at all mechanical joints. (Optional: Use form P75102A) All vents and drains are installed, including vents and drains for testing and are of correct pressure rating. Piping of correct material, schedule and type. Rating of all forged steel fittings is correct. Check valve materials - (use spec ref. in piping material specification, tags and nameplates. Branch reinforcements are correct. Compound on screwed connections in accordance with specifications. All pressure connections as per specification. Correct direction of flow through filters and strainers traps, check valves, globe valves and control valves. All instrument connections installed and any delicate instruments are isolated/ removed from test. All relief valves, bursting disks, and specified control valves have been removed. Check orifice valve tap orientation correct, taps and plugs have been seal welded and unused. Tapped holes are plugged and welded. Check orifice flanges have required upstream and downstream clearances, that bores have been ground and orifice plates have been removed. All thermowells are installed. All pipe supports installed according to drawings and specifications. Gags on spring supports and expansion joints are in position. Check that system is adequately supported such that no spring in pipework causes stress on pumps or vessel nozzles. All chainwheels and extended spindles installed. Subcontractor Fluor Field Engineering Name: Signature: Date: Subcontractor Fluor FE/QA Fluor QA Name: Signature: Date: Name: Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75101 Rev 0 Aboveground Pipe Inpsection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75101 Rev 0 Aboveground Pipe Inpsection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75102 Revision 0, 10 June 2013 VISUAL INSPECTION OF FLANGES, GASKETS, AND BOLTING Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID P75102A Client Other Turnover System: Sub – System: Line/Drawing No. Item 01 02 03 04 05 06 07 08 09 10 11 12 Notes: Description of Check Flange type and rating Flange preparation and cleaning Flange condition Gasket type Gasket condition and rating Bolting type Bolting size Lubrication Torque sequence correct Torque values verified Identification of torqued connection Rejected items flagged Line Class Sheet No. Subcontractor Rev. No. Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75102 Rev 0 Visual Inspections of Flanges Gaskets and Bolting.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75102 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75102 Rev 0 Visual Inspections of Flanges Gaskets and Bolting.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75103 Revision 0, 10 June 2013 WELD MAP RECORD Iso No.: Weld No. Date Made Welder Stencil RT ACC REJ RT Report No. PMI PWHT Weld No. Date Made Welder Stencil RT ACC REJ ID W75103 RT Report No. PMI PWHT W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75103 Rev 0 Weld Map Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75103 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75103 Rev 0 Weld Map Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75201 Revision 0, 10 June 2013 PRESSURE TEST REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID P75201A Client Other Sub – System: Location: Test Package No.: ___________________ Description: _____________________________________________________ P. &I.D. No.(s) R P. &I.D. No.(s) Test Boundaries R P. &I.D. No.(s) R P. &I.D. No.(s) R ISO No.(s) Sht R ISO No.(s) Sht R ISO No.(s) Sht R Vessels or Equipment in test boundary: Test Conditions Test Medium _______________________________ Test Media/Metal Temp Min._____________ Ambient Temp. Min.____________________ Test Pressure Min.________________ Holding Time: Min. ______________ Test Gage Number: M.T.E.________ M.T.E.________ Date Last Calibrated: Max.______________ Chlorine Content __________________ Max.__________________ Actual_________________ Actual_____________ Actual_____________ ______________ ______________ Test Gage Range: Low_______ Low_______ High_______ High_______ Relief Valve Setting_______________ Actual______________ Pre-Test Inspections/Release Pre-Test Walkdown Complete: NDE, PWHT, PMI (if required) Complete/Accepted: Pipe Field Eng QA Inspector Date Date Verification of Satisfactory Test Results QC Inspector QA Inspector Verification of Line Restoration Date Date Pipe Field Engineer QA Inspector Remarks: Date Date For coordinate boundaried system such as oil water sewer, test beginning and ending coordinates shall be indicated on the attached drawings. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75201 Rev 0 Pressure Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75201 Rev 0 Pressure Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75601 Revision 0, 10 June 2013 PIPE CLEANING AND VERIFICATION CHECKLIST Tag Description: P.O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID P75601A Sub – System: Location: Piping Services Group Identification No. Code Class Matl. System Cleanliness Level Q.C. Remarks Verified By Date Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75601 Rev 0 Pipe Cleaning and Verification Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75601 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75601 Rev 0 Pipe Cleaning and Verification Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79001 Revision 0, 10 June 2013 DAILY WELDING REPORT Subcontractor Unit Line No. Line Class Sheet No. Weld No. Type Weld Area Size Wall Thick. Welder Symbol Process Root Bal Fit-Up Visual Inspected ID W79001 Remarks Foreman Welding Inspector Date Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79001 Rev 0 Daily Welding Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79001 Rev 0 Daily Welding Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7520 Revision 0, 10 June 2013 PRESSURE TESTING SCOPE This procedure applies to pressure testing of installed piping systems. RESPONSIBILITIES - Self-Perform ACTIVITY Install Piping Define Test Boundaries Provide Preparation / Test Instructions Prepare the System for Testing Perform Pre-Test Inspections/Release Perform Test Verification of Satisfactory Test Results Provide Restoration Instructions Verify Completion of Restoration Surveillance of Testing and Restoration RESPONSIBILITY Self Perform Pipe Const. Engr. and Mech. Supt. Pipe Const. Engr. Mechanical Superintendent Pipe Const. Engr. Site Quality Manager Mechanical Superintendent Pipe Const. Engr. Site Quality Manager Pipe Const. Engr. Pipe Const. Engr. Site Quality Manager Site Quality Manager DOCUMENTATION _____ 000.509.F75201 000 509 F75201 _____ 000 509 F75201 000 509 F75201 _____ 000 509 F75201 000 509 F75201 _____ 000 509 F75201 000 509 F75201 000.509.F02201 FREQUENCY OF ACTIVITY _____ Each Test Package Each Test Package _____ Prior to Test Prior to Test _____ Test Completion Test Completion _____ Each Test Each Test Daily W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7520 Rev 0 Pressure Testing.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7520 Revision 0, 10 June 2013 RESPONSIBILITIES - Subcontracted ACTIVITY Install Piping Define Test Boundaries Provide Preparation / Test Instructions Prepare the System for Testing Perform Pre-Test Inspections/Release Perform Test Verification of Satisfactory Test Results Provide Restoration Instructions Verify Completion of Restoration PROCEDURE • Define Test Boundaries and Provide Preparation/Test Instructions: Boundaries and instructions in accordance with 000 250 3707 should be prepared and provided or made available to those responsible for Preparing the System for Testing, Performing Pre-test Inspection Release, Performing Test, and Verifying Satisfactory Test Results - Information should be included in pressure test packages. These packages are, as much as possible, to be assembled so that they comprise a portion or all of a piping system. This is required to facilitate system turnover at the end of the job. Each pressure test package shall contain the following: • Marked up P&IDs indicating extent of test; location and type of blinds; and equipment or instrumentation to be included or excluded from test. Piping isometrics for lines included in the test. Isometrics are to indicate location of blinds, valves open or closed, fill point, vent locations, equipment or instrumentation excluded from test and locations of required temporary supports. RESPONSIBILITY Subcontractor Subcontractor Pipe Const. Engr. Subcontractor Subcontractor Site Quality Manager Subcontractor Subcontractor Site Quality Manager Pipe Const. Engr. Subcontractor Site Quality Manager DOCUMENTATION _____ 000.509.F75201 000 509 F75201 _____ 000 509 F75201 000 509 F75201 _____ 000 509 F75201 000 509 F75201 _____ 000 509 F75201 000 509 F75201 FREQUENCY OF ACTIVITY _____ Each Test Package Each Test Package _____ Prior to Test Prior to Test _____ Test Completion Test Completion _____ Each Test Each Test • - Instruction items are on Form 000.509.F75201. Initiate this form and complete the instructions through "Test Conditions". W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7520 Rev 0 Pressure Testing.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7520 Revision 0, 10 June 2013 - Notes for special test situations. Instructions for marking temporary test materials for verifying line restoration. Special instructions and safety precautions when the test medium is a gas or vapor. Instructions for preventing air entrapment. Venting instructions. Test gage location. Identify all required "witnesses" of test. Require all joints including welds to be uninsulated and exposed for examination during the pressure test. Provide retest instructions after repair of leaks detected by the pressure test. - • Prepare the System for Testing: Make preparation for testing as required by test instructions, 000 250 3707 and 000 250 50050: • Perform Pre-test Inspections/Release: Verify completion (by walkdown) and acceptance of any required inspection, post-weld heat treatment, NDE, hardness testing, PMI, and any other required test/inspections. Verify piping system has been completely checked (punched out) and preparations for testing as required by test instructions are complete. - • Perform Test: Perform the test in accordance with test instructions. • Verification of Satisfactory Test Results: Upon the attainment of the required hydrostatic test pressure, for at least the minimum specified time, an inspection shall be made of all joints and connections. The inspection shall be made while the system is at the required test pressure. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7520 Rev 0 Pressure Testing.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7520 Revision 0, 10 June 2013 - Following the application of the pneumatic test pressure and reduction to the design pressure the entire line should be walked to determine if there is any audible evidence of leakage. Any leaks found at the time shall be marked and repaired after first depressuring the line. After this walkdown, all joints and welds shall be covered with a soap solution in order to detect any leakage. Soap shall be commercial preparation specifically for leak detection. - If leaks are found by pressure testing, mark their locations. Complete the Pressure Test Report actual test conditions for Test Media/Metal temperature, Test Pressure Test Gage Number and Calibration information. • Provide Restoration Instructions: Instructions to comply with restoration requirements of 000 250 50050 should be provided or made available to those responsible for restoring the system after pressure testing and for verifying completion of restoration. Information should include: Instructions for removal of temporary test material (blanks, blinds). Positioning of operating blinds. Draining instructions. Installation of equipment excluded from field test (valves, orifice plates, expansion joints, short pieces of pipe, new gaskets, bolts, vessel internals, etc.). Instructions for removal of temporary supports. Resetting spring hangers. Drying of instruments. Treatment of vent and drain connections. Cleaning of strainers. Painting and insulation. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7520 Rev 0 Pressure Testing.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7520 Revision 0, 10 June 2013 • Verification of Line Restoration: Verify that all restoration activities have been completed and the system(s) or partial system represented by this pressure test report is complete. FORMS Quality Control Form: 000.509.F75201 – Pressure Test Record W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7520 Rev 0 Pressure Testing.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7520 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7520 Rev 0 Pressure Testing.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75201 Revision 0, 10 June 2013 PRESSURE TEST REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID P75201A Client Other Sub – System: Location: Test Package No.: ___________________ Description: _____________________________________________________ P. &I.D. No.(s) R P. &I.D. No.(s) Test Boundaries R P. &I.D. No.(s) R P. &I.D. No.(s) R ISO No.(s) Sht R ISO No.(s) Sht R ISO No.(s) Sht R Vessels or Equipment in test boundary: Test Conditions Test Medium _______________________________ Test Media/Metal Temp Min._____________ Ambient Temp. Min.____________________ Test Pressure Min.________________ Holding Time: Min. ______________ Test Gage Number: M.T.E.________ M.T.E.________ Date Last Calibrated: Max.______________ Chlorine Content __________________ Max.__________________ Actual_________________ Actual_____________ Actual_____________ ______________ ______________ Test Gage Range: Low_______ Low_______ High_______ High_______ Relief Valve Setting_______________ Actual______________ Pre-Test Inspections/Release Pre-Test Walkdown Complete: NDE, PWHT, PMI (if required) Complete/Accepted: Pipe Field Eng QA Inspector Date Date Verification of Satisfactory Test Results QC Inspector QA Inspector Verification of Line Restoration Date Date Pipe Field Engineer QA Inspector Remarks: Date Date For coordinate boundaried system such as oil water sewer, test beginning and ending coordinates shall be indicated on the attached drawings. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75201 Rev 0 Pressure Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75201 Rev 0 Pressure Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7560 Revision 0, 10 June 2013 CHEMICAL CLEANING OF PIPE SCOPE The purpose of this procedure is to establish the inspection activities necessary to verify the process of cleaning the interior surface of piping is performed in accordance with approved requirements. RESPONSIBILITIES - Self-Perform/Subcontracted ACTIVITY Verify that all pressure testing & NDE are complete Commence cleaning operation Monitor chemical cleaning process GENERAL • Inspection Pre-Requisites • Verify that pressure testing and NDE are complete prior to release for cleaning. RESPONSIBILITY QC Inspector Construction Supt./ Subcontractor QC Inspector 000.509.F75601 000.509.F75601 DOCUMENTATION FREQUENCY OF ACTIVITY Prior to release for cleaning As required by project specs Daily during activity Inspection Monitor chemical cleaning process verifying that it is performed in accordance with approved project specifications and document on the pipe cleaning and verification checklist (000.509.F75601). Retain water test report and certificate of conformance and attach to the pipe cleaning and verification checklist (000.509.F75601). - FORMS Quality Control Form: 000.509.F75601- Pipe Cleaning and Verification Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7560 Rev 0 Cleaning of Pipe.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7560 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7560 Rev 0 Cleaning of Pipe.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75601 Revision 0, 10 June 2013 PIPE CLEANING AND VERIFICATION CHECKLIST Tag Description: P.O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID P75601A Sub – System: Location: Piping Services Group Identification No. Code Class Matl. System Cleanliness Level Q.C. Remarks Verified By Date Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75601 Rev 0 Pipe Cleaning and Verification Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F75601 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F75601 Rev 0 Pipe Cleaning and Verification Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7600 Revision 0, 10 June 2013 ELECTRICAL INSPECTION SCOPE This procedure applies to inspection of electrical installations. Refer to procedure 000.509.7010 and 000.509.7100 for work involving excavation, backfill, and concrete. RESPONSIBILITIES - Self-Perform ACTIVITY RESPONSIBILITY DOCUMENTATION OR INSPECTION REFERENCE _____ FREQUENCY OF ACTIVITY Each electrical item Daily during life of activity Each installation at completion Daily during life of activity and at completion Install electrical items Inspect in-process electrical installation Check final electrical installation Surveillance Electrical Superintendent Site Quality Manager/ Construction Engineer Site Quality Manager/ Construction Engineer Site Quality Manager (Note 1) 000 509 F760XX 000 509 F760XX 000 509 F02201 RESPONSIBILITIES - Subcontracted Work ACTIVITY Install electrical items Inspect in-process electrical installation Check final electrical installation Surveillance RESPONSIBILITY Subcontractor Subcontractor/ Site Quality Manager Subcontractor/ Site Quality Manager Site Quality Manager (Note 1) DOCUMENTATION _____ FREQUENCY OF ACTIVITY Each electrical item Daily during life of activity Each installation at completion Daily during life of activity and at completion 000 509 F760XX 000 509 F760XX 000.509.F02201 NOTE 1: Surveillance is not required if the Fluor Quality representative is performing inspections. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7600 Rev 0 Electrical Inspection.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7600 Revision 0, 10 June 2013 PROCEDURE • Inspect in-process electrical installation activities in accordance with the applicable specifications and drawings. The appropriate checklist should be initiated and completed to document inspection activities. Perform final installation checks in accordance with the applicable specifications and drawings. The final inspections should be completed on the applicable checklist. Perform surveillances daily during the life of electrical activities. Document results on Form 000.509.F02201. • • FORMS Quality Control Forms: 000.509.F76001 000.509.F76002 000.509.F76003 000.509.F76004 000.509.F76005 000.509.F76006 000.509.F76007 000.509.F76008 000.509.F76009 000.509.F76010 000.509.F76011 000.509.F76012 000.509.F76013 000.509.F76014 Conduit And Cable Tray Checklist Electrical Manhole Inspection Checklist Medium & High Voltage Underground Cable Splice Inspection Record Medium and High Voltage Cable Termination Checklist Cable Pulling Inspection Checklist Fan/Speed Reducer/Motor Inspection Checklist Switch House Inspection Checklist Lighting Receptacle, Instrument Distribution Panels Inspection Checklist Electrical Motor Inspection Checklist Aboveground Conduit Inspection Checklist Lighting Panelboard Inspection Record Underground Conduit (Duct Bank) Inspection Grounding/Earthing System (Grid or Loop) Inspection Record Cable Termination Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7600 Rev 0 Electrical Inspection.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76001 Revision 0, 10 June 2013 CONDUIT AND CABLE TRAY CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76001A Client Other Turnover System: Sub – System: Drawing: Item Description of Check Subcontractor Fluor FE/QA Cable Tray Verify the following are in accordance with design documents 01 02 03 04 05 06 07 08 Conduits Verify the following are in accordance with design documents 09 10 11 12 13 14 15 16 Notes: Subcontractor Name: Signature: Date: Supports Grounding Cable spacing Cable tie down Barriers Splice Plates Wall penetrations High voltage labels Workmanship Supports Pull joints Expansion joints Bonding jumpers Seals and drains High voltage labels Fittings Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76001 Rev 0 Conduit and Cable Tray Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76001 Rev 0 Conduit and Cable Tray Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76002 Revision 0, 10 June 2013 ELECTRICAL MANHOLE INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID C76002A Client Other Turnover System: Sub – System: Location Drawing Number Inspection Prior to Concrete Pour or Dry Packing Item Description of Check Subcontractor Fluor FE/QA 01 Verify opening size and location for compliance with drawings and specifications. Grounding/earthing in place and secure. 02 03 04 Pulling eyes and ladder rungs in place. Verify conduit size, orientation, type, location, adequate support and plugs/caps for compliance with drawings and specifications. Sump or drain provided in accordance with drawings. 05 Notes: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76002 Rev 0 Electrical Manhole Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76002 Rev 0 Electrical Manhole Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76003 Revision 0, 10 June 2013 MEDIUM AND HIGH VOLTAGE UNDERGROUND CABLE SPLICE INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Note: Inspection Classification Subcontractor Fluor Client Other Tag No.: Area/Unit: Turnover System: Sub – System: ID E76003AR This Inspection Record is for cables rated greater than 2000 volts. When this work is contracted, inspection may be documented on Contractor's detailed Inspection Record. Splice No.: Subcontractor Fluor FE/QA Reference Dwg.: Splice Kit Manufacturer: Kit No.: Circuit No.: From: Cable Rated Voltage: Cable Type: 01 To: Coordinates (Surveyor Complete And Initial/Date At Right) Trench Number: A West/East: B West/East: C West/East: Manhole Number: South/North South/North South/North Pull Box Number 02 Splice Make-up: A Acceptable B Acceptable C Acceptable Neutral Acceptable 03 04 05 06 Document DC High Potential (hypot) Test on 000 509 F76008, or obtain appropriate documentation from testing contractor. Sheath grounded/earthed, as required. Field changes recorded on "as-built" drawings. Splice markers installed, when required. Subcontractor Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA Name: Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76003 Rev 0 Medium and High Voltage Underground Cable Splice Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76003 Rev 0 Medium and High Voltage Underground Cable Splice Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76004 Revision 0, 10 June 2013 MEDIUM AND HIGH VOLTAGE CABLE TERMINATION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76004A Client Other Sub – System: Location: NOTE: This Inspection checklist is for terminations rated greater than 2000 Volts Circuit Number Drawing Number KIT Number KIT Manufacturer Subcontractor Fluor FE/QA Verify the following are acceptable in accordance with design documents: 1. 2. 3. 4. 5. 6. 7. 8. Cable size type, location, installation and routing Cable bend radius IAW specifications and cable jacket free of kinks Cable termination supports and support spacing IAW drawings and Specifications Cable installation neat and evenly spaced Cable free of surface damage Termination Kit/Materials installed IAW Manufacturer’s instructions Document DC High Potential Test (hypot) on 000 509 F76104 Cable Terminated IAW equipment manufacturer’s instructions, including torquing of bolted connections. Torque Wrench Number: Cal Date: Torqued at: 9. inch/foot lbs Left to Right Top to Bottom Front to Rear Check phase location and marking: IAW Specification requirements ΦA ΦB ΦC Acceptable Acceptable Acceptable 10. Metallic Sheaths/Shields/Armor grounded/earthed IAW termination detail drawings Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76004 Rev 0 Medium and High Voltage Cable Termination checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76004 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76004 Rev 0 Medium and High Voltage Cable Termination checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76005 Revision 0, 10 June 2013 CABLE PULLING INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Drawing Number: Item Description of Check Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76005A Client Other Turnover System: Sub – System: Subcontractor Fluor FE/QA Verify the applicable attributes listed below: 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 Notes: Subcontractor Name: Signature: Date: Name: Signature: Date: Underground conduit has been swabbed-out Cable tray is free of sharp edges Verify number of bends between pulling points does not exceed specification requirements Verify cable reel assignment and cutting schedule Verify cable voltage rating, minimum pulling temperature and type of pulling compound Verify arrows on high voltage cable reels for direction of pulling off reel Megger metal clad cables before pulling Verify instrument cable for continuity and isolation from drain wire before pulling Verify maximum permitted pulling tension not exceeded Megger power and control cable after installation (Record test results on E76006A) Megger instrument wire and cable after installation (Record test results on E76007A) Hypot medium and high voltage cable (Record test results on E76008A) Continuity check instrument wire after installation Bend radius of trained cable in accordance with specifications Cable is free of kinks, neat and cablelay is in accordance with drawings Spacing between instrument cable and power cable in accordance with design Cables identified per specification and drawings Cable ends sealed after cutting Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76005 Rev 0 Cable Pulling Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76005 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76005 Rev 0 Cable Pulling Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76006 Revision 0, 10 June 2013 FAN/SPEED REDUCER/MOTOR INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76006A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Check name plates Make Model Serial No 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 Notes: Fan Speed Reducer Gearbox Shafts Coupling Motor Equipment installation report completed Shaft / coupling torqued to requirements Coupling alignment report completed Fan blades ‘U’-bolts torqued to requirements Initial blade angle set correctly Check linkages and freedom of rotation Correct oil grade and level in speed reducer Fan housing fixed Installation acceptable Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76006 Rev 0 Fan Motor Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76006 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76006 Rev 0 Fan Motor Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76007 Revision 0, 10 June 2013 SWITCH HOUSES INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76007A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Tidiness and general condition of station and yard in satisfactory condition. Verify the following items: 01 Station exterior: Has the station been numbered and fire fighting instructions and danger signs been provided? Is the station equipment complete with: First aid/electrical shock treatment directions Verify instructions required by local authority. Key diagram of main power system Single line diagrams of switchgear Schematic/wiring diagrams of switchgear Blackboard and/or log book Sufficient caution and danger notices and spare fuses If a telephone is provided: Fire extinguisher State type: CO2/BCF 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 Special operating tools/grounding equipment Proper operation of: Safety locks Doors, door locks and panic bars Lighting, socket outlets, emergency lighting H. V. A. C. Verify appropriate and in operating condition. Notes: Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76007 Rev 0 Switch House Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76007 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76007 Rev 0 Switch House Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76008 Revision 0, 10 June 2013 LIGHTING, RECEPTACLE, INSTRUMENT DISTRIBUTION PANELS INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76008A Client Other Turnover System: Sub – System: Item Description of Check Verify the following are acceptable: 01 02 03 04 05 06 07 08 09 10 Ground bus in panel Panel equipment ground bond Wire markers (feeder) Directory complete Equipment number on nameplate Phase meter test ABC Touch-up painting complete Receptacle Panel Volt test all receptacles for standard HNG Orientation. All receptacles identified by circuit number on nameplate Lighting Panel With all lights on, compare branch circuit. “Hot” amps to branch neutral amps. Covers complete Provide the data and complete the following: 12.1 12.2 12.3 12.4 12.5 12.6 Notes: Subcontractor Name: Signature: Date: Name: Signature: Date: Subcontractor Fluor FE/QA 11 12 Main breaker amps Feeder Size Neutral underground at panel Ground wire size Megger at 1000V 0-0 Megger at 1000V 0-Gnd Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76008 Rev 0 Lighting Receptacle, Iinstrument Distribution Panel Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76008 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76008 Rev 0 Lighting Receptacle, Iinstrument Distribution Panel Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76009 Revision 0, 10 June 2013 ELECTRICAL MOTOR INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76009A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 Description of Check Verify motors nameplate data ratings and verify against motor list. Verify damage and missing parts. Verify foundation and foundation bolts meet specified requirements. Verify installation tolerance has been met. Verify all internals are correctly installed. Verify all shipping devices have been removed and check for cleanliness. Verify all vents, drains, instruments connection etc., are installed in accordance with equipment trim isometrics. Verify screens, guards and other personnel protective design features are correctly installed where applicable. Mounting Baseplate Level Grouting Junction box location Verify mounting bolts for tightness. Wired for proper rotation and rotation checked. Couplings/pulleys installed. Frame and casing sound and free of debris. Paint finish checked. Verify lubrication. Verify vibration. Subcontractor Fluor FE/QA Verify if the location and orientation is correct. 09 10 11 12 13 14 15 16 17 18 19 20 Notes: Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76009 Rev 0 Electrical Motor Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76009 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76009 Rev 0 Electrical Motor Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76010 Revision 0, 10 June 2013 ABOVEGROUND CONDUIT INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76010A Client Other Sub – System: Location: Drawing(s): Subcontractor 1. Supports and spacing in accordance with specification and drawings 2. Supports adjacent to terminal fittings 3. Conduits clean, stub-ups protected, open ends plugged, damage during construction repaired 4. Field bend radius correct in accordance with specifications and codes. Bends free of deformities 5. Expansion joints as shown on drawings 6. Installation neat and evenly spaced 7. Spacing between instrument and power conduit in accordance with project specifications 8. Spacing from hot pipes and hot surfaces maintained in accordance with project specifications 9. Conduit permanently and effectively grounded, unless specifications permit otherwise. Bonding jumpers installed around expansion joints 10. Proper fittings installed with threads fully engaged, no wrench cuts, conduit ends have bushings and covers installed 11. Seals and drains installed in accordance with drawings 12. Flexible conduit installed with proper bending radius and with standard fittings 13. Junction boxes leveled and supported with proper hubs, locknuts and bushings installed, in accordance with drawings. Junction boxes properly identified. 14. Adequate number of pulling points Conduits seals, as shown on the following drawings, poured and marked by Construction. (List drawing number or attached drawings): Fluor FE/QA Additional conduit seals, recorded on as-build drawings, poured and marked by Construction for the following: equipment, analyzer housing, local control panels, etc. (List Tag Numbers): Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76010 Rev 0 Aboveground Conduit Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76010 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76010 Rev 0 Aboveground Conduit Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76011 Revision 0, 10 June 2013 LIGHTING PANELBOARD INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76011A Client Other Sub – System: Location: Building: Area/Unit Panelboard Tag: Subcontractor Fluor FE/QA 1. Receiving Operations/Inspection complete 2. Equipment Protection Program instituted and documented 3. Check assembly for any missing parts 4. Enclosure approved for area classification 5. Panelboard circuit schedule filled out 6. Correct circuit breaker, fuse size and location 7. Neutral wire correctly color coded 8. Grounding/earthing installed and connected. Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars), completed 9. Seals installed (if required) 10. Check for breather and drain 11. Check panel load balance 12. Check color coding of branch circuit conductors 13. Clean out 14. Check mounting and supports 15. Fixtures and receptacles are correct type and installed as per drawings 16. Fixtures and receptacles on correct circuit 17. Nameplate, number of circuits and panelboard location per drawing 18. Correct glands installed (i.e., flameproof glands on explosionproof enclosures) 19. Megger buses including neutral. Record results on Form: 000 509 F76035: Insulation Resistance (Equipment) Test Record. Main disconnect and outgoing circuits should be open 20. Equipment protection program completed and documented 21. Final inspection complete. Punch List Record, cleared. Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76011 Rev 0 Lighting Panelboard Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76011 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76011 Rev 0 Lighting Panelboard Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76012 Revision 0, 10 June 2013 UNDERGROUND CONDUIT (DUCT BANK) INSPECTION Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor ID E76012A Tag No.: Turnover System: Client Other Sub – System: Location: Location Drawing No. Subcontractor Fluor FE/QA 1. Trenching checked for location, elevation and forming. Check for conflicts with other under ground construction 2. Conduit size, type and location checked for conformance to specifications and drawings, conduit sloped to drain into manholes. 3. Rigid steel elbows used for all stub-ups, including PVC runs. 4. Conduit seals installed in accordance with drawings. 5. Minimum concrete coverage will be in accordance with specifications on all sides on conduits 6. Conduit Spacing, Supports and Tie-downs correct. 7. Field bend radius correct per drawings/specifications. Bends free of deformities. 8. Pipe caps on all ends. 9. All conduit connection tightly made. 10. Reinforcing bars installed when specified. 11. All field changes recorded on as-built drawings 12. Trench/forms free of debris 13. Concrete coverage adequate; spaces not left exposed. 14. Concrete color in accordance with specifications 15. Stub-up concrete encasement correct 16. Stub-up dimensions and location checked. 17. Backfill and compaction correct 18. Conduits free of such things as stop pages and grout leakage 19. PVC conduit just above grade, plus elbow 20. Conduit blown and pull strings installed. Remarks: Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76012 Rev 0 Underground Conduit - Duct Bank Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76012 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76012 Rev 0 Underground Conduit - Duct Bank Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76013 Revision 0, 10 June 2013 GROUNDING/EARTHING SYSTEM (GRID OR LOOP) INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76013A Client Other Sub – System: Location: Note!!! This Inspection Record is for the (Check One): 1. Main Grounding/Earthing System: 2. Dedicated Instrument System: Reference Drawing: Subcontractor Fluor FE/QA 3. Primary conductor is correct size and type in accordance with drawings 4. Ground/earthing conductor burial depth and routing per drawings and specifications 5. Thermal/compression connections checks (no cold joints or burnouts) 6. Thermal/compression connection insulation checked 7. Ground/earthing anode locations and installation per drawings 8. Ground/earthing anode connections checked 9. Location, type, size and insulation color of equipment taps per drawings and protected during construction 10. System ground/earthing anode resistance-to-earth checked and recorded on Form: 000 509 F76101. Ground/Earthing Resistance Reading (Resistance to Earth and Loop Continuity) Test Record. 11. All field Revisions recorded on as-build drawings 12. Maximum allowable system ground resistance not to exceed 1 ohm. For dedicated instrument systems (i.e. – TDC 3000), the maximum allowable ground resistance is 1 ohm Remarks: Cal Date: Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76013 Rev 0 Grounding Earthing System Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76013 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76013 Rev 0 Grounding Earthing System Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76014 Revision 0, 10 June 2013 CABLE TERMINATION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76014A Client Other Sub – System: Location: Cable I. D. Number Drawing Number Verify the following are acceptable inaccordance with design documents: 1. Cable length adequate 2. Cable preparation proper 3. Termination lug correct Size/type 4. Crimping tool correct 5. Permanent cable I.D. correct 6. Terminals torqued per specification 7. Wire size, type, and color correct 8. Crimping tool correct Remarks Subcontractor Fluor FE/QA Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76014 Rev 0 Cable Termination Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76014 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76014 Rev 0 Cable Termination Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7610 Revision 0, 10 June 2013 ELECTRICAL TESTING SCOPE This procedure applies to testing of electrical installation. RESPONSIBILITIES - Self-Perform ACTIVITY Define Test Boundaries Provide Preparation Test Instructions Perform Electrical Test Verify Test Results Provide Restoration Instructions Verify Completion of Restoration RESPONSIBILITY Electrical Construction Engineer Electrical Construction Engineer Electrical Superintendent Site Quality Manager/ Electrical Construction Engineer Electrical Construction Engineer Site Quality Manager Electrical Supervisor DOCUMENTATION _____ _____ _____ 000 509 F761XX Applicable Form _____ 000 509 F761XX Applicable Form FREQUENCY OF ACTIVITY Each Test Package Each Test Package Each Test Package Test Completion Each Test Package Each Test RESPONSIBILITIES - Subcontracted Work ACTIVITY Define Test Boundaries Provide Preparation Test Instructions Perform Electrical Test Verify Test Results Provide Restoration Instructions Verify Completion of Restoration Surveillance RESPONSIBILITY Subcontractor Subcontractor Subcontractor Subcontractor/ Site Quality Manager Discipline Engineer Subcontractor/ Site Quality Manager Site Quality Manager (*Note 1) DOCUMENTATION _____ _____ _____ Applicable Form _____ _____ 000.509.F02201 FREQUENCY OF ACTIVITY Each Test Package Each Test Package Each Test Package Test Completion Each Test Package Each Test Each Test NOTE 1 - Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7610 Rev 0 Electrical Testing.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7610 Revision 0, 10 June 2013 PROCEDURE • Define Test Boundaries and Provide Preparation Test Instruction: Boundaries and test instructions provided by construction Electrical Construction Engineer shall be reviewed by inspection personnel prior to any testing activities. Notify the Fluor/Client of testing/inspections for their involvement which they have requested/required to witness. - • Test Field Installed Equipment: Perform test in accordance with the test instruction provided by Electrical Construction Engineering. • Verification of Test Results: Utilizing the test instructions and/or drawing(s) required, verify the acceptance of the test. Document the satisfactory results using the applicable forms referenced in this procedure. • Provide Restoration Instructions: Instructions to comply with restoration requirement of the applicable specification and/or drawing should be provided by Electrical Construction Engineering. • Verification of System Restoration: Verify that all restoration activities have been completed and the system(s) or partial system represented by this test package is complete. FORMS Quality Control Forms: 000.509.F76101 000.509.F76102 000.509.F76103 000.509.F76104 000.509.F76105 000.509.F76106 000.509.F76107 000.509.F76108 000.509.F76109 Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record Insulation Resistance (Power, Control Wire And Cable) Test Record Insulation Resistance (Instrument Wire And Cable) Test Record DC High Potential Test (Medium Voltage Cable) Record Current Transformer (And Ammeter) Test Record LV Over-current And Earth/Ground-Fault Protection Relay Test Over-current/Ground Fault Protection Relay (Induction Type) Test Over-current/Ground Fault Protection Relay (Thermal Type) Test Switching Units HV Switchgear Inspection And Test Record W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7610 Rev 0 Electrical Testing.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7610 Revision 0, 10 June 2013 000.509.F76110 000.509.F76111 000.509.F76112 000.509.F76113 000.509.F76114 000.509.F76115 000.509.F76116 000.509.F76117 000.509.F76118 000.509.F76119 000.509.F76120 000.509.F76121 000.509.F76122 000.509.F76123 000.509.F76124 000.509.F76125 000.509.F76126 000.509.F76127 000.509.F76128 000.509.F76129 000.509.F76130 000.509.F76131 000.509.F76132 000.509.F76133 000.509.F76134 000.509.F76135 Ground Electrode Resistance Inspection Test Record Ground Fault Protection Relay Induction Inspection and Test Record Grounding Continuity Inspection and Test Record Grounding Rod Inspection and Test Record Bus Bar Assemblies LV Switchgear Test Record Neutral Grounding/Earthing Resistor Test Record Ground Continuity (Non Electrical) Equipment/Structures Test Record Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record Insulation Resistance (Equipment) Test Record Insulation Resistance (Transformer) Test Record Liquid Dielectric Strength Test Record DC Proof Test Record for Motors Feeder Breaker (480V MCC) Test Record Breaker/Contractor (480V MCC) Test Record 460V Motor Circuit (480V MCC) Test Record Medium Voltage Motor Circuit Test Record Equipment Absorption Ration and Polarization Index Test Record (Megger) Insulation Resistance (Medium Voltage Power Cables) Test Record Bus Throat Insulation and Ductor Reports Circuit Breaker Contract Timing Test Report Vacuum Circuit Breaker Ductor Insulation Report Drawout Vacuum Breaker Inspection Test Main Bus Insulation and Ductor Report Electric Motor Run-In Test Record Drawout Air Circuit Breaker Inspection Record Insulation Resistance (Rotating Equipment) Test Record W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7610 Rev 0 Electrical Testing.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7610 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7610 Rev 0 Electrical Testing.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76101 Revision 0, 10 June 2013 GROUNDING/EARTHING RESISTANCE READINGS (RESISTANCE TO EARTH AND LOOP CONTINUITY) TEST RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Test Equipment: (Note 1) Reference Drawing: Notes: (Note 2) Inspection Classification Subcontractor Fluor Client Other Tag No.: Area/Unit: Turnover System: Sub – System: ID E76101AR 1. Record resistance-to-earth for each rod (or group of rods) with all other conductors disconnected. When a foundation is ohms for any used for grounding/earthing, measure resistance from anchor bolt to earth. Resistance not to exceed: single rod, designated group of rods or foundation, when tested in accordance with test method designated in specifications. 2. Check continuity from each equipment ground/earthing tap to ground/earthing loop bus or rod. If all taps between any two rods (indicate rod numbers below) or all taps connected to bus measure less than ohms, indicate check mark in "tap" column. Rod Number Or Foundation Resistance To Earth (Ohms) Ambient Temp. (C-F) Weather Taps ( ) Initials/Date Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76101 Rev 0 Grounding earthing Resistance Reading Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76101 Rev 0 Grounding earthing Resistance Reading Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76102 Revision 0, 10 June 2013 INSULATION RESISTANCE (POWER CONTROL WIRE & CABLE) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Test Equipment: Test Equipment: Ambient Temperature: Notes: 1. C F Tag No.: Turnover System: ID E76102A Client Other Test Voltage: Test Voltage: Date Sub – System: Location: Perform Insulation Resistance Test (megger) between each conductor and all other conductors and metallic sheath for cables with nonshielded conductors. Test between each conductor and shield for multiconductor cables with shielded conductors. Record lowest reading for each cable. Use 500V test set for cables rated 300 to 600 volts and 2500V test set for cable rated over 600 volts. Readings will vary inversely with temperature, and cable length. When Project specifies use of temperature correction factors, attach 2nd sheet with computed values. Indicate on each sheet "Measured" or "Temperature corrected". Wire Tagging Cable Rated Voltage Wire Or Cable Quantity Size From To Insulation Resistance (Megohms)* Initials 2. 3. Panel No. Circuit No. Feeder No. *Minimum acceptable Project values Cable Rated Voltage Test Duration Resistance For Cable Only (Megohms) Cable/Wire Size Or Amperage Resistance When Cable Connected to Equip (Ohms) Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76102 Rev 0 Insulation Resistance Power Control Wire Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76102 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76102 Rev 0 Insulation Resistance Power Control Wire Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76103 Revision 0, 10 June 2013 INSULATION RESISTANCE (INSTRUMENT WIRE AND CABLE) TEST RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76103AR Client Other Turnover System: Sub – System: Test Equipment: Ambient Temperature: Test Voltage: Notes: 1. 2. 3. 4. 5. Cable number or instrument number Record only the lowest value. MP - multi-pair cable, SP - single pair cable. Megger with instruments disconnected. Use 250 volt (or lower voltage, when specified) range on DC test set. Readings will vary with temperature and cable length.* Overall Shield to lead and armor (multipair cables only) (megohms) Conductor to conduit (single pair non-shielded cables) (megohms) Indicate MP or SP type (2) Shield to Conduit (single pair cables only) (megohms) Shield to Shield (multipair cables only) (megohms) (1) Conductor to Conductor (megohms) (1) Conductor to Shield (megohms) (1) *Minimum Acceptable Project Values Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76103 Rev 0 Insulation Resistance Instrument Wire Test Record.doc Page 1 of 2 Initials Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76103 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76103 Rev 0 Insulation Resistance Instrument Wire Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76104 Revision 0, 10 June 2013 DC HIGH POTENTIAL TEST (MEDIUM VOLTAGE CABLE) RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Circuit Number: Cable Size: Number Of Conductors: Cable Length: Insulation Type: Jacket Material: Weather: Test Equipment Used: Note: 1. 2. Temp.: C F Humidity: Date: (SQ.MM.) (MCM) Client Other Ref. Dwg.: From: No. Of Splices: Manufacturer: Thickness: To: Tag No.: Turnover System: Sub – System: Location: ID E76104A 3. 4. 5. 6. The test voltage shown below shall be reached in 10 equal voltage increments. After each voltage increase, the leakage current shall be allowed to stabilize during a 1-minute interval. If 1-minute intervals are insufficient to stabilize the current, the cable shall be discharged, and the test repeated with new time intervals of greater, but still equal, duration. Record the stabilized leakage current, in microamps, at the end of each time interval. Allow the voltage to remain constant at the full test voltage and record the leakage current for 5 minutes for unshielded cables and 15 minutes for shielded cables.* Read test equipment instruction manual prior to testing cable. When Project specifies the plotting of test results, attach 2ND sheet with separate plot for each phase. Note leakage current, in microamps, on "y" axis. Note step-voltage increase on "x" axis, followed by time, in minutes, for the dielectric absorption portion of the test. Voltage Hold Time At Each Step: Sec. Phase A3 Phase B3 Phase C4 kV kV kV kV kV kV kV kV kV kV (Record Leakage Current In Microampers) Time At Sec Min Min Min Min Min Min Min Min Min Min Min kV 30 1 2 3 4 5 6 7 8 9 10 11 Phase A3 Phase B3 Phase C4 *Maximum acceptable Project Values: (leakage current at end of 5 or 15 minutes). Maximum Acceptable Test Voltage Leakage Current Cable Rated Voltage (Kilovolts) (Kilovolts) (Microampers) 1 All Other Phases and Shields to be grounded Subcontractor Name Signature Date Name Signature Date Min 12 Min 13 Min 14 Min 15 Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76104 Rev 0 DC High Potential Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76104 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76104 Rev 0 DC High Potential Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76105 Revision 0, 10 June 2013 CURRENT TRANSFORMER (AND AMMETER) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76105A Client Other Sub – System: Location: Subcontractor Fluor FE/QA Location: Current transformer: Class: Ratio: 1.0 Switchgear No: Function: Type: VA rating: Panel No.: Serial No.: bar/wound Verify the following items: 1.1 Mechanical Damage 1.2 Tight Connections 1.3 Star-Point Connection and Ground Link Insulation resistance test, secondary winding at 500 V: phase to ground L2-G L3-G MΩ 2.0 L1-G 3.0 L1 4.0 L1 5.0 Resistance test secondary circuit (C) (including transformer winding and all secondary loads) L2 L3 Test CT polarity by battery flick test (C) L2 L3 Ω Ratio test (C) (to be combined with relay testing, if required) Phase L1 L2 A A A L3 5.1 5.3 Primary current Ammeter reading 5.2 Secondary current Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76105 Rev 0 Current Transformer Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76105 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76105 Rev 0 Current Transformer Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76106 Revision 0, 10 June 2013 LV OVERCURRENT AND EARTH/GROUND-FAULT PROTECTION RELAY TEST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76106A Client Other Sub – System: Location: Subcontractor Location: Relay: Manufacturer: Switchgear No.: Motor protection relay Type: Contractor rating: ______ A Motor FLC:_____A Panel No.: Fluor FE/QA Trip setting range: ______A 1.0 Primary injection test at selected trip setting ______ A all three phases connected in series 300 Cold 2.0 Test current in % setting Current, A 3.0 Relay Condition Relay Time, Seconds 4.0 Curve Time, Seconds (Supplied By Manufacturer) 5.0 Ground-fault relay Setting ______ A 300 Warm 120 Warm 105 Warm No Trip After ______ Min Measured pick-up current ______ A 6.0 Relay setting after test: 6.1 Thermal relay ______ A 6.2 Earth-fault relay ______ A 6.3 Setting sealed ______ Remarks Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76106 Rev 0 LV Over Current and Earth Fault Protection Relay Test.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76106 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76106 Rev 0 LV Over Current and Earth Fault Protection Relay Test.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76107 Revision 0, 10 June 2013 OVERCURRENT/GROUND-FAULT PROTECTION RELAY (INDUCTION TYPE) TEST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76107A Client Other Sub – System: Location: Subcontractor Fluor FE/QA Switchgear No.: Relay: Manufacturer: Current Setting Range: Time Setting Range: Test Setting Current A Time % S S S S 100 100 100 100 1) 1.3x 2x 4x Is Selected Setting: Injection Current Panel No. Overcurrent Inverse Time. Type: CT Ratio: Selected Setting: % Trip Time Seconds Curve 2) NA Actual NA Phase Measure and inject Minimum relay Operating current at 1) NOTE: The trip time curve will be supplied by the manufacturer 2) For pre-commissioning Inspection only Remarks A Primary A Secondary A Secondary Injection NA NA NA NA Primary Injection S S S S 1.3x 2x Check correct reset action Check correct trip action Check correct flag operation NOTES: S = preferably at selected setting NA = not applicable Values to be filled in for each overcurrent and earth-fault element Relay setting after test: Instantaneous element ______________A Current setting _______________A Time setting _______________% Adhesive label provided____________ Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76107 Rev 0 Over Current & Earth FP -Indn Type- Relay Test.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76107 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76107 Rev 0 Over Current & Earth FP -Indn Type- Relay Test.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76108 Revision 0, 10 June 2013 OVERCURRENT/GROUND-FAULT PROTECTION RELAY (THERMAL TYPE) TEST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76108A Client Other Sub – System: Location: Subcontractor Switchgear No.: Relay: Manufacturer: Trip setting range: Tap setting: Motor FLC: 1.0 2.0 Panel No: Overcurrent inverse time Type: Relay: Fluor FE/QA Rated current: Selected setting: Selected setting: A CT ratio: % % Secondary injection test Nominal injection current Is = tap setting x rated current = Injection current x ls A 4x 2x 4x 1x Operating Temperature cold warm warm warm Curve A Actual All three phases connected in series load to trip setting 105% Trip time running load indication % 3.0 Primary injection test (for pre-commissioning inspection only) Injection current = 100% FLC = A Running load indication = % 4.0 Relay setting after the test: Tap setting % Adhesive label provided Load to trip % Inst. setting x In NOTE: Trip time curve will be supplied by the manufacturer Remarks Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76108 Rev 0 Over Current GFP -Thermal Type- Relay Test.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76108 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76108 Rev 0 Over Current GFP -Thermal Type- Relay Test.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76109 Revision 0, 10 June 2013 SWITCHING UNITS HV SWITCHGEAR INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76109A Client Other Sub – System: Location: Rating: Manufacturer: Function: Switchgear No.: Subject 1.0 Record the reading of the operations counter 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 2.0 Check the following items and report any deviations/defects under remarks: Circuit labelling correct Operation of safety shutters Padlocking facilities Interlocking facilities, mechanical/electrical Mechanical position indicators, indicating lights Insulating bushings and barriers Cable box and terminations Alignment of main and auxiliary contacts Mechanical closing and tripping Electrical closing local/remote Electrical tripping local/remote Alarm indications local/remote Anti-condensation heater Test insulation resistance at 500 V ..............................megaohms Switching device: Type Panel No.: Reference Document: Subcontractor Fluor FE/QA Secondary and auxiliary wiring 2.1 Test insulation resistance at 500 V ..............................megaohms W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76109 Rev 0 Switching Units HV Switchgear Inspect & Test Records.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76109 Revision 0, 10 June 2013 SWITCHING UNITS HV SWITCHGEAR INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76109A Client Other Sub – System: Location: Subject 3.0 Earthing: 3.1 3.2 3.3 3.4 Verify the conditions of earthing bar and connections Test the earthing bar continuity ...............................microohms Record fuse type/rating .................... HV pressure test - circuit breaker (for pre-commissioning inspection only) C C Subcontractor Fluor FE/QA Test voltage DC Leakage Current - MA kV A B kV Tester used: 4.0 Phase Tester used: 5.0 Phase Conductivity test - circuit braker: R S T Insulation resistance - circuit braker: V DC A B C A B Test voltage Megaohms Ohm Ducter used: Current transformer test completed Sheet no.: Protection relay test completed Sheet no.: Remedial action required: Remarks Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76109 Rev 0 Switching Units HV Switchgear Inspect & Test Records.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76110 Revision 0, 10 June 2013 GROUND ELECTRODE RESISTANCE INSPECTION TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76110A Client Other Sub – System: Location: Additional Information: Reference Document: Tests of individual electrodes No. Length cm Vendor: Test Method Section cm2 Resistance Ohms Remarks Test grid system Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76110 Rev 0 Ground Electrode Resistance Inspection Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76110 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76110 Rev 0 Ground Electrode Resistance Inspection Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76111 Revision 0, 10 June 2013 GROUND FAULT PROTECTION RELAY INDUCTION INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76111A Client Other Sub – System: Location: Additional Information: Manufacturer: Time setting range: Selected setting:: Switchgear No.: Check correct trip action Current setting range: Selected setting: Relay: %: Panel No.: Type: CT ratio: A Reference Document: Check correct flag operation Notes: S = preferably at selected setting NA = Not Applicable Values to be filled in for each overcurrent and ground/fault element Relay setting after test: Instantaneous element Current setting Time setting Adhesive label provided Remarks: A A % Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76111 Rev 0 GFP Induction Relay Inspection and Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76111 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76111 Rev 0 GFP Induction Relay Inspection and Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76112 Revision 0, 10 June 2013 GROUNDING CONTINUITY INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76112A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 Description of Check Check earth bosses installed are welded correctly. Check conductor tape is jointed correctly. Check and confirm all cables are correctly sized. Check that the equipment is bonded to the main earth. Check all cables lugs are fitted correctly. Confirm maximum two cables are terminated to each earth boss. Confirm all contact points are clean and greased with the approved compound. Check all washers are of vibration proof type. Confirm cable protective measures (kick plates) are installed. For IS equipment ensure that a separate insulated earth bar has been installed and is earthed in accordance with project specifications. Test earth continuity resistance from main earthing point to the final earth point of the sub-system. Maximum 1.0 ohms. Ductor test across all tape joints. Maximum 1.0 ohms. Subcontractor Fluor FE/QA 08 09 10 11 12 Notes: This procedure should be used for major items of equipment (i.e., vendor’s skids, switchboards, etc.). Small power and equipment earthing will be confirmed correct on the respective check sheets. Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76112 Rev 0 Grounding Continuity Inspection and Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76112 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76112 Rev 0 Grounding Continuity Inspection and Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76113 Revision 0, 10 June 2013 GROUNDING ROD INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Subcontractor Fluor ID E76113A Tag No.: Inspection Classification Turnover System: Client Other Sub – System: Location: Drawing No.: Earth Test Rating: 1.0 Ground Temperature: Manufacturer: Ground Resistance In Ohms Test each ground rod with the earth tester and record reading in the following table. Ground Ground Ground Rod Ground Rod Ground Rod Resistance In Resistance In No. No. No. Ohms Ohms 2.0 Area Grounding Resistance (with all rods installed and connected) _____________ OHMS Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76113 Rev 0 Grounding Rod Inspection and Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76113 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76113 Rev 0 Grounding Rod Inspection and Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76114 Revision 0, 10 June 2013 BUS BAR ASSEMBLIES LV SWITCHGEAR TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76114A Rating: Client Other Sub – System: Location: Manufacturer: Reference Document: System voltage: Subject 1.0 Phase 2.0 2.1 Section: Switchgear No.: Subcontractor Fluor FE/QA Megaohms Cal Date: Insulation resistance test - bus-bar system at 500 V CC A Tester used: Conductivity test - bus-bar system (C) Megaohms Incomer 1 2-3 4-5 6-7 Incomer 7 B C Spout to spout Unit # A B C 3.0 3.1 3.2 3.3 3.4 3.5 3.6 Ducter used: Grounding system Check the continuity of the grounding bar and connections ....................... ohms Measure continuity of switchboard to main ground ......................... ohms Current transformer test (include. ammeter) completed Sheet no. ........... After energizing Check voltmeter reading: ............ Check phase rotation (C) ............. Remedial action completed: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76114 Rev 0 Busbar Assembly LV Swithcgear Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76114 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76114 Rev 0 Busbar Assembly LV Swithcgear Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76115 Revision 0, 10 June 2013 NEUTRAL GROUNDING/EARTHING REISTOR TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76115A Client Other Sub – System: Location: Test Equipment Test Equipment Test Voltage: Test Voltage: Cal. Date: Cal. Date: Notes!!! 1. Use 500 volt test set for 600 volt equipment and below, 2500 volt tests set for equipment rated over 600 volts. 2. Resistor must be disconnected from ground/earth and neutral during Insulation Resistance (megger) and DC Overpotential Tests. 3. Resistor must be disconnected from neutral during Cold Resistance Test. 4. Apply DC Overpotential Test between terminals and ground for the complete device. (The voltage applied between the terminals of each assembly and its grounded enclosure shall be twice the rated AC voltage plus 1000 V when rated 600 V or less, or 2.25 times the rated AC voltage plus 2000 V when rated over 600 V for 1 Minute.) This test is a Pass/Fail test based purely on withstand alone. 5. Inspect assembly for damage and missing parts. 6. Check to assure that the center tap ratio is correct, when CT is supplied with resistor. 7. Verify resistor reterminated. Tag Number Cold Resistance (ohms) Insulation Resistance (megaohms)* Overpotential () CT Ratio Pri-Sec Reterm () Subcontractor Fluor FE/QA *Minimum acceptable Project Values: Voltage Class Insulation Resistance (megaohms) Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76115 Rev 0 Neutral Grounding Resistor Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76115 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76115 Rev 0 Neutral Grounding Resistor Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76116 Revision 0, 10 June 2013 GROUND CONTINUITY (NONELECTRICAL) EQUIPMENT/STRUCTURES TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76116A Client Other Sub – System: Location: Test Equipment Used: Cal. Date: Weather Notes!!! 1. Vessels, tanks and structural steel bonded to the main grounding/earthing system, dedicated ground/earthing rod or foundation, as indicated on drawings listed below. 2. Measure resistance from ground/earthing wire tap (or anchor bolt) to tagged equipment frame or structural steel. Resistance not to exceed ohms. Drawings Measured Resistance (ohms) Subcontractor Fluor FE/QA Equipment Tag No. or Structure Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76116 Rev 0 Ground Continuity Equipment-Structure Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76116 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76116 Rev 0 Ground Continuity Equipment-Structure Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76117 Revision 0, 10 June 2013 GROUND CONTINUITY (ELECTRICAL EQUIPMENT AND GROUND TEST BARS) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76117A Client Other Sub – System: Location: Test Equipment Used: Cal. Date: Notes!!! 1. Weather Electrical equipment bonded to the main grounding/earthing system or dedicated ground/earthing rod, as indicated on drawings listed below. Measure resistance from ground/earthing wire tap to tagged equipment bus bars, tagged equipment enclosures, and any other points indicated on the drawings. Resistance not to exceed _______ ohms. Drawing Measured Resistance (ohms) Subcontractor Fluor FE/QA 2. Electrical Equipment Tag No. Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76117 Rev 0 Ground Continuity Equipment-Grnd Test Bars Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76117 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76117 Rev 0 Ground Continuity Equipment-Grnd Test Bars Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76118 Revision 0, 10 June 2013 INSULATION RESISTANCE (EQUIPMENT) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor ID E76118A Tag No.: Turnover System: o Client Other Sub – System: Location: Test Equipment: Ambient Temperature: Reference Drawing: o Substation: C F Ref. Spec.: Cal. Date: Notes!!! 1. Use 500 Volt test set for 600 Volt equipment and below, 2500/5000 Volt test set for equipment rated over 600 volts. 2. Switchgear MCC (other) For equipment with solid state control circuits, consult manufacturer’s literature for maximum test voltages. Insulation Resistance (megaohms)* ФA to G ФB to G Rated Test Voltage (kV) Voltage (kV) Subcontractor Fluor FE/QA ФC to G ФA to ФB ФB to ФC ФC to ФA *Minimum acceptable Project values: Equipment Voltage Class Resistance (megaohms) Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76118 Rev 0 Equipment Insulation Resistance Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76118 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76118 Rev 0 Equipment Insulation Resistance Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76119 Revision 0, 10 June 2013 INSULATION RESISTANCE (TRANSFORMER)TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76119A Client Other Sub – System: Location: Substation No. Test Equipment: Cal Date: Notes!! 1. Use 500 volt test set for 600 volt equipment and below, 2500 volt test set for equipment rated 601-5000 volts and 5000 volt test set for equipment rated over 5000 volts 2. 3. 4. 5. Test voltage to be applied for 1 minute duration and reading taken Neutral must be disconnected from ground during test Record temperature of insulating liquid for liquid-immersed transformers and surrounding air temperature for dry type transformers. Readings will vary inversely with temperature. When Project specifies use of temperature correction factors, attach 2nd sheet with computed values. Indicate on each sheet “measured” or “temperature corrected.” Equipment Tag No. Insulation Resistance (megaohms)* Primary ФA to G ФB to G ФC to G ФA to G Secondary ФB to G ФC to G Rated Pri To Sec Voltage Rating (kV) Pri-Sec Or Air Liquid Temp. (0C/0F) *Minimum acceptable Project values: Voltage Class Resistance (megaohms) Tester’s Name/Date Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76119 Rev 0 Transformer Insulation Resistance Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76119 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76119 Rev 0 Transformer Insulation Resistance Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76120 Revision 0, 10 June 2013 LIQUID DIELECTRIC STRENGTH TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76120A Client Other Sub – System: Location: Notes!! 1. Minimum acceptable breakdown voltage determined in accordance with the following: ANSI standard Other: 2. Test performed: At laboratory and test results attached. In the field to test procedure: Test equipment: Liquid Type and Spec. Minimum (kilovolts) Cal Date: Actual Breakdown Voltage Reading (kilovolts) Equipment Tag No. Subcontractor Fluor FE/QA Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76120 Rev 0 Liquid Dielectric Strength Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76120 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76120 Rev 0 Liquid Dielectric Strength Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76121 Revision 0, 10 June 2013 DC PROOF TEST RECORD FOR MOTORS Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76121A Client Other Sub – System: Location: Test Equipment: Cal Date: 0 0 Ambient Temperature: C F Notes!! 1. Equipment must meet minimum PI (Polarization Index) values prior to conducting this test. Complete Form: 000 509 F76053 Equipment Absorption Ration and Polarization Index Test Record. 2. Isolate each phase winding, whenever practical. If not practical, test of entire winding is acceptable. 3. Increase voltage at rate indicated below, until full test voltage is reached. This test is a Pass/Fail test based purely on withstand alone. 4. Test duration at full test voltage shall be: * minutes. 5. Read instruction manual prior to using test equipment 6. All other phases to be grounded/earthed Tag No. PI Rated AC Voltage (kV) Equipment Test Voltage (kV) () OK ФA ФB ФC Subcontractor Fluor FE/ QA *Project requirements as follows: Equipment Rated Voltage (kilovolts) Minimum PI Prior To Test DC Test Voltage Time to Reach Test Voltage (seonds) Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76121 Rev 0 DC Proof Test Record for Motors.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76121 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76121 Rev 0 DC Proof Test Record for Motors.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76122 Revision 0, 10 June 2013 FEEDER BREAKER (480V MCC) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76122A Client Other Sub – System: Location: Equipment Designation: Load Designation: Load (kW/kVA): Circuit Breaker MFR: Conductor Size: Voltage: Rating: Power: F.L.A: Setting: Ground: Subcontractor 1. 2. 3. 4. 5. 6. 7. 8. 9. Check nameplate data of breaker against approved supplier drawings Check breaker components for cleanliness Check mechanical function of breaker Check wiring for proper identification Check conduits/cables for tagging Check components for identification Check equipment for conformance to area classification Check installation for seals, breathers and drains Verify power conductor continuity Fluor FE/QA 10. Check that power cable Insulation Resistance Test (megger) is completed and that Form: 000 509 F76102: Insulation Resistance Test Record (Power, Control Wire and Cable), is on file Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76122 Rev 0 Feeder Breaker 480 V Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76122 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76122 Rev 0 Feeder Breaker 480 V Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76123 Revision 0, 10 June 2013 BREAKER/CONTACTOR (480V MCC) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76123A Client Other Sub – System: Location: Equipment Designation: Load Designation: Load (kW/kVA): Circuit Breaker Mfr.: Contactor Mfr.: Conductor Size: 1. 2. 3. 4. 5. 6. 7. 8. 9. Power: Voltage: F.L.A.: Rating: Size: Control: Ground: Subcontractor Check nameplate data of breaker, contactor fuses and relays against approved supplier drawings Check main and auxiliary contacts Check contactor/breaker components for cleanliness Check control fuses, CPT rating and coil voltage Check mechanical function of contactor and breaker Check wiring for proper identification Check conduits/cables for tagging Check components for identification Check equipment for conformance to area classification Fluor FE/QA Setting 10. Check installation for seals, breathers and drains 11. Verify continuity of all power and control leads 12. Check that power cable Insulation Resistance Test (megger) is completed and that Form: 000 509 F76102 13. Complete functional operation check of the control circuit using contract drawings and approved supplier drawings. Close and open the contactor using all control devices. Remarks: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76123 Rev 0 Breaker Contactor 480 V Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76123 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76123 Rev 0 Breaker Contactor 480 V Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76124 Revision 0, 10 June 2013 460 V MOTOR CIRCUIT (480V MCC) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76124A F.L.A.: S.F.: Rating: Size: Sub – System: Location: Equipment Designation: Motor Tag No.: kW/HP: Circuit Breaker Mfr.: Starter Mfr.: Conductor Size: 1. 2. 3. 4. 5. 6. 7. 8. 9. Power: Voltage: RPM: Setting: O/L HTR. Size: Ground: Subcontractor Fluor FE/QA Control: Check motor starter for cleanliness Check nameplate data and tagging of motor starter components for conformance to approved supplier drawings Check conduits and/or cables for correct tagging Check equipment and installation for conformance to area classification Check installation for seals, breathers and drains Check main and auxiliary contacts of breaker and contactors Manual check mechanical operation of breaker, contactor, O/L relay and O/L reset device Check continuity of power and control cables Complete functional operations check of the motor control circuit using the contract drawings and approved supplier drawings. Close and open the starter using all control devices 10. Verify completion of activities on Form: 000 509 F76227: Electric Motor-Electrical Activities Inspection Record, and Form: 000 509 F76228: Electric Motor Mechanical Activities Inspection Record, prior to motor bump and run-in, in accordance with Form: 000 509 F76133: Electric Motor Run-in Test Record Remarks Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76124 Rev 0 460V Motor Circuit Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76124 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76124 Rev 0 460V Motor Circuit Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76125 Revision 0, 10 June 2013 MEDIUM VOLTAGE MOTOR CIRCUIT TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76125A Client Other Sub – System: Location: Equipment Designation: Motor Tag No.: Manufacturer: KW/HP: Started Description: Manufacturer: Contactor Rating: Rated Current: Conductor Size: 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuse Size: Power: CT Ratio: Type: Rated Voltage: O/L Relay Setting: Control: Ground: Subcontractor Fluor FE/QA Check motor starter for cleanliness Check nameplates data and tagging of motor starter components for conformance to approved Supplier drawings Check conduits and/or cables for correct tagging Check equipment and installation for conformance to area classification Check installation for seals, breathers and drains Check main and auxiliary contacts of breaker and contactors Check mechanical operation of breakers, contactors and relay and O/L reset devices Check continuity of power and control cables Verify calibration and setting of protective relays F.L.A.: Serial No.: Service Factor: Rated Voltage: 10. Check wiring to surge arrestors, capacitors, stator RTDs and current transformers 11. Complete functional operations check of the motor control circuit using the contract drawings and approved Supplier drawings. Check to see that motor space heaters are fuctional. Close and open the starter using all control devices. 12. Verify completion of activities on Form: 000 509 F76227: Electric Motor-Electrical Activities Inspection Record and Form: 000 509 F76228: Electric Motor Mechanical Activities Inspection Record, prior to motor bump and run-in, in accordance with Form: 000 509 F76133: Electric Motor Run-in Test Record Comments: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76125 Rev 0 Medium Voltage Motor Circuit Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76125 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76125 Rev 0 Medium Voltage Motor Circuit Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76126 Revision 0, 10 June 2013 EQUIPMENT ABSORPTION RATIO AND POLARIZATION RATIO TEST RECORD (MEGGER) Tag Description: P. O. No.: Subcontractor: Equipment Tag No.: Test Voltage: Rel. Humidity: Notes!!! 1. Perform test as indicated on Test Records for each individual equipment type. Reference the following forms: Transformers: 000 509 F76119 Insulation Resistance (Transformer) Test Record Equipment: 000 509 F76118 Insulation Resistance (Equipment) Test Record Motors and Generators 000 509 F76135 Insulation Resistance (Rotating Equipment) Test Record 2. 3. Absorption Raito Polarization Index = = 1 Min. Resistance Value 30 Sec. Resistance Value 10 Min. Resistance Value 1 Min. Resistance Value Ohms to Ground 1 Min. Reading ΦA to Ground Ohms to Ground 10 Min. Reading ΦA to Ground Dielectric Absorption Ration Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76126A Client Other Sub – System: Location: o Test Equipment: Ambient Temperature: Equipment Temperature: C o F Ohms to Ground 30 Sec. Reading ΦA to Ground Polarization Index Ohms to Ground 30 sec. Reading ΦB to Ground Ohms to Ground 1 Min. Reading ΦB to Ground Ohms to Ground 10 Min. Reading ΦB to Ground Dielectric Absorption Ratio Polarization Index Ohms to Ground 30 Sec. Reading ΦC to Ground Ohms to Ground 1 Min. Reading ΦC to Ground Ohms to Ground 10 Min. Reading ΦC to Ground Dielectric Absorption Ratio Polarization Index Tester’s Name/Date Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76126 Rev 0 Equipment Absortion and Polarization Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76126 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76126 Rev 0 Equipment Absortion and Polarization Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76127 Revision 0, 10 June 2013 INSULATION RESISTANCE (MEDIUM VOLTAGE POWER CABLES) TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Test Equipment: Test Equipment: Ambient Temperature: Notes: 1. o o ID E76127A Tag No.: Turnover System: Client Other Sub – System: Location: Test Voltage: Test Voltage: C F Date Perform Insulation Resistance Test (megger) between each conductor and all other conductors and metallic sheath for cables with nonshielded conductors. Test between each conductor and shield for multiconductor cables with shielded conductors. Record lowest reading for each cable. Use 2500V test set for cable rated over 600 volts. Reading will vary inversely with temperature and cable length. When Project specifies use of temperature correction factors, attach 2nd sheet with computed values. Indicate on each sheet “Measured” or “Temperature corrected”. For Medium Voltage cables, perform megger test after final Hi-Pot Test. Wire Tagging Cable Rated Voltage Wire Or Cable Quantity Size From To Insulation Resistance (Megaohms)* A to Gnd B to Gnd C to Gnd Initials 2. 3. 4. Panel No. Circuit No. Feeder No. *Minimum acceptable Project values: Cable Rated Voltage Test Duration Resistance For Cable Only (Megaohms) Cable/Wire Size Or Amperage Resistance When Cable Connected to Equip (Ohms) Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76127 Rev 0 Insulation Resistance -Med V Power Cables- Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76127 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76127 Rev 0 Insulation Resistance -Med V Power Cables- Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76128 Revision 0, 10 June 2013 BUS THROAT INSULATION AND DUCTOR REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76128A Sub – System: Location: Date: By: Station & Transformer No.: Test Set /Manuf/Model: Calibration Date: Temperature: Humidity: Paint in Good Condition Inspect & Clean Bus Inspect & Clean Bus Throat Inspect Insulation Barriers N-S-E-W Same as Main Bus Inspect & Clean Insulators Heaters working Bus: A or B WIN# Insulation Resistance P-G in Megaohms A B C Insulation Resistance P-P in Megaohms A-B A-C B-C Ductor in Micro-ohms = < 50 minimum A B C Remarks (Condition of Equipment) Notify immediate supervisor if any readings are not within acceptable limits. Comments: Subcontractor Name Signature Date Name Signature Date Infrared bolts connection points: Results: Yes No Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76128 Rev 0 Bus Throat Insulation and Ductor Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76128 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76128 Rev 0 Bus Throat Insulation and Ductor Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76129 Revision 0, 10 June 2013 CIRCUIT BREAKER CONTACT TIMING TEST REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76129A Sub – System: Location: Date: By: Breaker WIN No. Cubicle No.: Closing Time Accept. Max/ms Contact 1 Contact 2 Contact 3 Time/ms as found/as left / / / Delta Closing Time* Station: Manufacturer: Test set mfg., model & S.N.: Cal. Date: Opening Time Pass/Fail Accept. Max/ms Time/ms as found/as left / / / Delta Closing Time * Pass/Fail Note: Maximum acceptable time can be found in the Manufacturers instruction manual. If test fails; notify your Supervisor *This is the biggest difference between contacts Comments: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76129 Rev 0 Circuit Breaker Contact timing Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76129 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76129 Rev 0 Circuit Breaker Contact timing Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76130 Revision 0, 10 June 2013 VACUUM CIRCUIT BREAKER DUCTOR INSULATION REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76130A Sub – System: Location: Date: By: Station: Test Set (Model & Mtg.): Cal Contact Resistance In Micro-ohms (50 maximum) * WIN # Counter Reading A Before B C A After B C Temperature: Humidity: Date: Tulips Lubricated Insulation of Breaker In Megohms Phase-Ground A B C Phase-Phase A-B A-C B-C Vacuum Bottle Integrity Test Good/Bad A B C Mechanism Inspected Operated at least 5 times Tripod with each relay Condition of Equipment (parts replaced etc.) S.N. of Breaker/ Feeder# Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76130 Rev 0 Vacuum Circuit Breaker Ductor Insulation Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76130 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76130 Rev 0 Vacuum Circuit Breaker Ductor Insulation Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76131 Revision 0, 10 June 2013 DRAWOUT VACUUM BREAKER INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76131A Client Other Sub – System: Location: Switchgear Tag No.: Serial No.: Subcontractor Fluor FE/QA One at a time, insert breakers into their respective cubicles and check the following: 1. Roll breaker into TEST position. (The spring charging mechanism should operate and charge spring) 2. Withdraw breaker to DISCONNECTED position 3. Roll breaker into the TEST position. Close breaker using door switch and check indication light for operation. Close breaker from remote control station where applicable 4. Trip breaker and check indication light. Trip from door switch and remote control station 5. Trip each breaker from each protection device and check relay targets for operation. Test proper operation of lockout device in closing circuit 6. Trip each breaker with its mechanical trip device 7. Measure insulation resistance between phases and between phase-to-ground with breaker withdrawn and closed. Record below 8. Perform contract resistance test and record below 9. Perform circuit breaker contract Timing test. Record on Test Record Form: 000 509 F76129 10. Perform Ductor Tests. Record on Test Record Form: 000 509 F76130 11. Perform DC Proof Test on vacuum bottles and record below 12. Roll breaker into CONNECTED position and test operation of latch check switch, if provided 13. Verify nameplate data (such as continuous amperes, interrupting amperes, etc.) is in accordance with supplier drawings Comments: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76131 Rev 0 Drawout Vacuum Breaker Inspection Test.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76131 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76131 Rev 0 Drawout Vacuum Breaker Inspection Test.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76132 Revision 0, 10 June 2013 MAIN BUS INSULATION AND DUCTOR REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76132A Sub – System: Location: Date: By: Insulation Resistance P-G in Megaohms A B C Station: Test Set /Manuf/Model: Calibration Date: Auto Xter made with Sudden Pressure Relay Manual Transfer Made (Both Ways) Temperature: Humidity: Paint in Good Condition WIN# PT Leads Inspect/Fuse Clips Clean Inspect & Clean Bush Throat Inspect & Clean Bus Inspect Insulation Barriers Inspect & Clean Insulators Bus: A or B N-S-E-W Insulation Resistance P-P in Megaohms A-B A-C B-C Auto Xter made with Source Breaker Ductor in Micro-ohms = < 50 minimum A B C Remarks (Condition of Equipment) Notify immediate supervisor if any readings are not within acceptable limits. Comments: Subcontractor Name Signature Date Name Signature Date Infrared bolts connection points: Results: Yes No Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76132 Rev 0 Main Bus Insulation and Ductor Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76132 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76132 Rev 0 Main Bus Insulation and Ductor Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76133 Revision 0, 10 June 2013 ELECTRIC MOTOR RUN-IN TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76133A Client Other Sub – System: Location: Reference Drawing: NOTES 1. Duration of tests to comply with project specifications. Test Equipment: Calibration Date: _______________________________ 2. Complete Form 000 509 F76227; Electric Motor – Electrical Activities Inspection Record. Test Voltage Actual voltage measured at motor control center ______Volts Rotation Check Bump motor to verify rotation motor must be uncoupled. No Load Current At beginning of test: _______ AMPS. At end of test: ________ AMPS. Temperature of Bearing Check bearing for high temperature: Before Start 15 Minutes after start 30 Minutes after start 1 Hour after start 2 Hours after start 3 Hours after start Vibration Make visual inspection during run; test and record any unusual vibration in remarks column. Noise Record any unusual noise in remarks column. Subcontractor Fluor Field Engineering Name Signature Date Name Signature Date Name Signature Date Remarks Subcontractor Fluor FE/QA Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76133 Rev 0 Electric Motor Run-in Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76133 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76133 Rev 0 Electric Motor Run-in Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76134 Revision 0, 10 June 2013 DRAWOUT AIR CIRCUIT BREAKER INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76134A Client Other Sub – System: Location: Switchgear Tag No.: Serial No.: Subcontractor Fluor FE/QA One at a time, insert breakers into their respective cubicles and check the following: 1. Roll breaker into TEST position. (The spring charging mechanism should operate and charge spring) 2. Withdraw breaker to DISCONNECTED position 3. Roll breaker into the TEST position. Close breaker using door switch and check indication light for operation. Close breaker from remote control station where applicable 4. Trip breaker and check indication light. Trip from door switch and remote control station 5. Trip each breaker from each protection device and check relay targets for operation. Test proper operation of lockout device in closing circuit 6. Trip each breaker with its mechanical trip device 7. 8. 9. Check contact alignment and wipe (air break only) Perform Insulation Resistance Test (megger) between each phase and to ground with breaker withdrawn and closed. Record on 000 509 F76127 Perform Contract Resistance Test and record below 10. Perform circuit breaker contact timing tests. Record on Test Record Form: 000 509 F76129 11. Perform Ductor Tests. Record on Test Record Form: 000 509 F76130 12. Roll breaker into CONNECTED position and test operation of latch check switch, if provided 13. Verify nameplate data (such as continuous amperes, interrupting amperes, etc.) is in accordance with supplier drawings Remarks: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76134 Rev 0 Drawout Air Circuit Breaker Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76134 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76134 Rev 0 Drawout Air Circuit Breaker Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76135 Revision 0, 10 June 2013 INSULATION RESISTANCE (ROTATING EQUIPMENT) TEST RECORD Tag Description: P. O. No.: Subcontractor: Motor Tag No.: Test Equipment: Ambient Temperature: How Known: Notes!!! 1. 2. 3. 4. 5. o ID E76135A Tag No.: Inspection Classification Subcontractor Fluor Test Voltage: C o Turnover System: Client Other Sub – System: Location: Cal Date: F Equip. Temp., If Know: Cal. Date o C o F Use 500 Volt test set for 600 Volt equipment and below, 2500/5000 Volt test set for equipment rated over 600 Volts. Test duration shall be 1 minute; note if otherwise: Disconnect each phase winding from neutral, wherever practical. If not practical, test may be made on entire winding. Document testing of low voltage and medium voltage equipment on separate sheets. Reading will vary inversely with temperature. When Project specifies use of temperature correction factors, attach 2nd sheet with computed values. Indicate on each sheet “Measured” or “Temperature Corrected”. Insulation Resistance (megohms)* ФA to G ФB to G ФC to G ФA to ФB ФB to ФC ФC to ФA Equipment Rated Voltage Equipment Tag No. Subcontractor Fluor FE/QA *Minimum acceptable Project values: Voltage Class Resistance (megohms) Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76135 Rev 0 Insulation Resistance Rotating Equipment Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76135 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76135 Rev 0 Insulation Resistance Rotating Equipment Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7620 Revision 0, 10 June 2013 ELECTRICAL EQUIPMENT SCOPE This procedure applies to inspection and testing of electrical equipment. RESPONSIBILITIES - Self-Perform ACTIVITY Install Equipment Inspect in-process Equipment Installation Inspect/Perform Equipment Protection RESPONSIBILITY Self Perform Site Quality Manager/ Construction Engineer Site Quality Manager/ Construction Engineer Electrical Supervisor Construction Engineer Construction Engineer Electrical Superintendent Site Quality Manager/ Construction Engineer Construction Engineer Site Quality Manager/ Construction Engineer Site Quality Manager (Note 1) DOCUMENTATION _____ 000 509 F762XX 000 509 F02201 000 509 F02201 _____ _____ _____ 000 509 F762XX _____ _____ 000.509.F02201 FREQUENCY OF ACTIVITY _____ Daily during life of activity Periodically Periodically Each Test Package Each Test Package Each Test Package Test Completion Each Test Package Each Test Each Test Define Test Boundaries Provide Preparation Test Instructions Test Field Installed Equipment Verify Test Results Provide Restoration Instructions Verify Completion of Restoration Surveillance NOTE 1: Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7620 Rev 0 Electrical Equipment.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7620 Revision 0, 10 June 2013 RESPONSIBILITIES - Subcontracted Work ACTIVITY Install Equipment Inspect in-process Equipment Installation Inspect/Perform Equipment Protection Define Test Boundaries Provide Preparation Test Instructions Test Field Installed Equipment Verify Test Results Provide Restoration Instructions Verify Completion of Restoration Surveillance RESPONSIBILITY Subcontractor Subcontractor/ Site Quality Manager Subcontractor/ Site Quality Manager Construction Engineer Construction Engineer Subcontractor Subcontractor/ Site Quality Manager Construction Engineer Subcontractor/ Construction Engineer Site Quality Manager Site Quality Manager (Note 1) DOCUMENTATION _____ 000 509 F762XX 000 509 F02201 _____ _____ _____ 000 509 F762XX _____ _____ 000.509.F02201 FREQUENCY OF ACTIVITY _____ Daily during life of activity Periodically Each Test Package Each Test Package Each Test Package Test Completion Each Test Package Each Test Each Test NOTE 1: Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. PROCEDURE • Inspect In-process Equipment Installation: Perform inspection of equipment installations in accordance with the applicable specifications and drawings. The appropriate check-list should be initiated and completed to document inspection and testing activities. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7620 Rev 0 Electrical Equipment.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7620 Revision 0, 10 June 2013 • Inspect/Perform Equipment Protection: Verify the equipment preservation and protection is adequately implemented in accordance with the requirements established by Construction Electrical Engineering. Document the verification process using 000.509.F02201. • Define Test Boundaries and Provide Preparation Test Instruction: Boundaries and test instructions provided by Construction Engineering shall be reviewed by inspection personnel prior to any testing activities. Notify the Client of testing/inspections for their involvement which they have requested/required to witness. • Test Field Installed Equipment: Perform test in accordance with the test instruction provided by Construction Engineering. • Verification of Test Results: Utilizing the test instructions and/or drawing(s) required, verify the acceptance of the test. Document the satisfactory results using the applicable forms contained in this manual. • Provide Restoration Instructions: Instructions to comply with restoration requirement of the applicable specification and/or drawing should be provided by Construction Engineering. • Verification of System Restoration: Verify that all restoration activities have been completed and the system(s) or partial system represented by this test package is complete. FORMS Quality Control Forms: 000.509.F02201 000.509.F76201 000.509.F76202 000.509.F76203 000.509.F76204 000.509.F76205 000.509.F76206 000.509.F76207 000.509.F76208 000.509.F76209 Surveillance Report Emergency Generators Inspection Checklist Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units) Inspection LV Switchgear (Including Incoming and Sectionalizer Units) Inspection of Outgoing – LV Switchgear Inspection of Static Supply Unit (UPS) Motor Control Centers Inspection Checklist Motor Control Centers (Motors and Starters) Inspection Record High Voltage Motors and Starters Motors Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7620 Rev 0 Electrical Equipment.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7620 Revision 0, 10 June 2013 000.509.F76210 000.509.F76211 000.509.F76212 000.509.F76213 000.509.F76214 000.509.F76215 000.509.F76216 000.509.F76217 000.509.F76218 000.509.F76219 000.509.F76220 000.509.F76221 000.509.F76222 000.509.F76223 000.509.F76224 000.509.F76225 000.509.F76226 000.509.F76227 000.509.F76228 000.509.F76229 000.509.F76230 000.509.F76231 000.509.F76232 000.509.F76233 Control and Relay Panels Inspection Checklist Electronic Equipment Inspection Checklist Power Panel Inspection Checklist Switchgear Inspection Checklist Low Voltage Feeders Inspection Record High Voltage Cable Inspection and Test Record Electrical Equipment Inspection Record Control Scheme Inspection Checklist Power Transformer Inspection Checklist Switching Units – HV Switchgear Inspection and Test Record Switching Units – HV Switchgear Inspection Checklist Liquid – Filled Transformer Inspection Record Busway Inspection Record Switchgear Inspection Record Motor Control Center Inspection Record Battery and Battery Charger Inspection Record Liquid Immersed Medium Voltage Disconnect Switch Inspection Record Electric Motor – Electrical Activities Inspection Record Electric Motor – Mechanical Activities Inspection Record Electric Motor for Compressor Installation Checklist Compressor Vibration Checklist Vibration Probe Record Dry Type Lighting, Receptacle & Instrument Transformers Checklist Instrument Wire and Cables Continuity Checks >50VDC W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7620 Rev 0 Electrical Equipment.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76201 Revision 0, 10 June 2013 EMERGENCY GENERATORS INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76201A Client Other Turnover System: Sub – System: Vendor: Reference Document: Item 01 02 03 04 05 06 07 08 09 10 11 12 Description of Check Verify nameplate date in accordance with drawings, specifications and requisitions Location and orientation Access and fixing correct Verify diesel, generator panels and enclosure for any visible signs of damage Measure insulation resistance prior to starting and record Verify electrical panel labelling Verify pilot lamp test Verify connections are tight Grounding connected and tight Verify make and type of battery Verify load circuit Make visual inspection during test run and record any unusual vibration and unusual noise in “Notes” space Subcontractor Fluor FE/QA Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76201 Rev 0 Emergency Generators Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76201 Rev 0 Emergency Generators Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76202 Revision 0, 10 June 2013 INSPECTION OF SWITCHGEAR BUS-BAR CONTINUITY (INCLUDING INCOMING AND SECTIONALIZER UNITS) Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76202A Client Other Sub – System: Location: Circuit Designation From To Busbar Conductivity, MΩ L1 L2 L3 N G Ducter # Subcontractor Fluor FE/QA NOTES: Conductivity measurements shall be carried out between adjacent outgoers or adjacent outgoer and incomers in order to verify the entire bus-bar path including 'droppers/risers'. For identical connections the measured values shall not differ by more than 20% from each other. Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76202 Rev 0 Inspection of Switchgear Bus-bar Continuity.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76202 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76202 Rev 0 Inspection of Switchgear Bus-bar Continuity.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76203 Revision 0, 10 June 2013 INSPECTION LV SWITCHGEAR (INCLUDING INCOMING AND SECTIONALIZER UNITS) Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76203A Client Other Sub – System: Location: Subcontractor Switchgear No.: Manufacturer: System voltage: 1.0 Rating: Section: Fluor FE/QA Insulation resistance test - bus-bar system at 500-VTester used: Phase L1-G............. L2-G MΩ L3-G MΩ Anti-condensation heaters working Test insulation resistance at 500 V 2.0 Grounding system Check the condition of the grounding bar and connections Measure continuity of switchboard to main earth MΩ Sheet No. 3.0 4.0 Current transformer test (incl. ammeter) Completed Yes No (Sheet F76012) After energizing Check voltmeter reading: Check phase rotation (C): Relay setting after the test: Tap setting ________% Adhesive label provided Load to trip ________% 5.0 Inst. Setting ________x In NOTE: Trip time curve will be supplied by the manufacturer Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76203 Rev 0 Inspection LV Switchgear.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76203 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76203 Rev 0 Inspection LV Switchgear.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76204 Revision 0, 10 June 2013 INSPECTION OF OUTGOING UNIT – LV SWITCHGEAR Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76204A Client Other Sub – System: Location: Subcontractor Location: Manufacturer: Panel No.: Switchgear No: Switching device type: Rating: Function: Fluor FE/QA 1.0 Check the following items and note any deviations/defects under remarks: 1.1 Circuit labeling 1.2 Mechanical damage 1.3 Door interlock 1.4 Mechanical position indication 1.5 Electrical closing local/remote 1.6 Electrical tripping local/remote 1.7 Alarm indication local/remote 1.8 Wiring connection and marking 1.9 test insulation resistance wiring at 500 V MΩ 2.0 3.0 4.0 5.0 6.0 Grounding; Verify the condition of the grounding bus and connections Insulation resistance test - switching device at 500 V Phase L1-E L2-E L3-E Protection relay test Restart relay tested Verify and record the fuse: Class Rating (E76106) result: MΩ Sheet No. s Condition Remarks Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76204 Rev 0 Inspection of Outgoi ng LV Switchgear.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76204 Revision 0, 10 June 2013 INSPECTION OF OUTGOING UNIT – LV SWITCHGEAR Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76204A Client Other Sub – System: Location: 7.0 LIGHTING CIRCUITS INSULATION RESISTANCE TEST * (fittings disconnected). Value MΩ Date Circuit Number Value MΩ Date Circuit Number CONVENIENCE OUTLETS * Circuit Number IR MΩ Residual Current Device Gnd Loop Impedance Polarity Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76204 Rev 0 Inspection of Outgoi ng LV Switchgear.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76205 Revision 0, 10 June 2013 INSPECTION OF STATIC SUPPLY UNIT (UPS) ID E76205A Subcontractor Fluor FE/QA Unit No.: Rectifier/Inverter: Battery Type: 1.0 AC/DC distribution board 1.1 Check: Manufacturer Serial No.: No. Of Cells/Volts: Good condition – no mechanical damage Correct labeling Correct grounding Insulation resistance at 500-V 1.2 Test: Bar 1 – Ground MΩ Bar 1 - Bar 2 MΩ Bar 2 – Earth Test ground-fault indication and detection 1.3 Record: Fuse size: 2.0 Verify the following items: Correct grounding Operating temperature No abnormal noise All parallel capacitors at same temperature 3.0 Verify correct operation of: Forced cooling fan Indicating lights/meters Interlock system Common alarm Cable connections Cleanliness No leaking capacitors Type: Actual load: MΩ W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76205 Rev 0 Inspection of Static Supply Units.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76205 Revision 0, 10 June 2013 INSPECTION OF STATIC SUPPLY UNIT (UPS) ID E76205A Subcontractor Fluor FE/QA 4.0 Check operating set points 4.1 Rectifier: V Boost charge voltage V Float charge voltage (Indicate if trip or alarm function) AC failure Rectifier failure High DC voltage V V S Low DC voltage Earth fault V Rectifier output oscilloscope check at normal load 4.2 Inverter: V Hz Inverter output voltage & frequency Inverter in synchronism Auto change-over: A. B. C. From inverter to by-pass From by-pass to inverter Inverter output oscilloscope check at normal load (Indicate if trip or alarm function) Low DC input Low AC output Inverter fail Fuse failure 5.0 Batteries 5.1 Check that all connections are tight and that anti-corrosive coating is provided 5.2 5.3 Check the liquid level of each cell Check the cells for leakage - Cell voltage and specific gravity tests - Battery discharge capacity test V V High DC input High AC output Load on bypass V V W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76205 Rev 0 Inspection of Static Supply Units.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76205 Revision 0, 10 June 2013 INSPECTION OF STATIC SUPPLY UNIT (UPS) 5.4 Unit No.: Normal load: Time DC Volts ID E76205A Subcontractor Fluor FE/QA Battery discharge capacity test Test Date: A DC Amps AC Volts AC Amps Hz 0 min 5 min Test guidelines: 1. Discharge load current to be equal to normal load current +/- 10%. 2. Simulate a rectifier power failure and discharge to the point of inverter trip or the specified minimum voltage. 3. Cell voltages may be measured during battery discharge, to detect defects. 4. Upon completion of the test carry out boost charging. 5.5 Unit No.: Temperature: Cell No. Volts S.G. Battery cell tests Test Date: °F Cell No. Volts S.G Cell No. Volts S.G. Record in coupled condition: Remarks: Subcontractor Name: Signature: Date: starting time (if over 1 s) s (A) Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76205 Rev 0 Inspection of Static Supply Units.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76205 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76205 Rev 0 Inspection of Static Supply Units.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76206 Revision 0, 10 June 2013 MOTOR CONTROL CENTERS INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76206A Client Other Turnover System: Sub – System: Item Description of Check – Record Data on E76207Ar Subcontractor Fluor FE/QA Verify the following are acceptable per design drawings: 01 02 03 04 05 06 07 08 09 10 11 12 Remote trip installed Ventilation filters Control PNL directory complete All nameplates complete Ground bus continuous Ground bus tied to plant GND Bus joints torqued All mechanical interlocks operational Unused knockouts plugged Floor anchors installed Grouting complete Touch up painting completed Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76206 Rev 0 Motor Control Center Inspection Checlist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76206 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76206 Rev 0 Motor Control Center Inspection Checlist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76207 Revision 0, 10 June 2013 MOTOR CONTROL CENTERS (MOTORS AND STARTERS) INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76207Ar Client Other Turnover System: Sub – System: Reference E76206A Incoming Feeder Size In. Fdr-Conduit or Cable Bus or Bus Duct Main Disconnect Rating Control Transformer Kva Cont Pnl Main Bkr or Fuse Size Horizontal Bus Rating Horizontal Bus Type Vertical Bus Rating Vertical Bus Type Megger at 1000v Megger at 1000v Ground Ground Bus Type Ground Bus Rating Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76207 Rev 0 Motor Control Center Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76207 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76207 Rev 0 Motor Control Center Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76208 Revision 0, 10 June 2013 HIGH VOLTAGE MOTORS AND STARTERS Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76208A Client Other Turnover System: Sub – System: Motors Complete the Motor Checklist, Form F76209, except for electrical test data. Starters Item Description of Check Subcontractor Fluor FE/QA Verify the following are acceptable in accordance with design documents: 01 02 03 04 05 06 07 08 09 All nameplates complete Ground bus tied to plant ground Unused knockouts plugged Floor anchors installed Grouting complete Touch-up painting complete Maintenance tools available Conduits labeled 4160 volts Control scheme check Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76208 Rev 0 High Voltage Motors and Starters.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76208 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76208 Rev 0 High Voltage Motors and Starters.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76209 Revision 0, 10 June 2013 MOTORS CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76209A Client Other Sub – System: Location: Control Scheme: 1.0 Mechanical As Installed Acceptable 1.01 Motor Equip. No. Nameplate 1.02 Belt Drive 1.03 Dowel Pins 1.04 Drain Plug 1.05 Gasket-Cond. Box 1.06 Weephole-Cond. Box 1.07 Bearing Temp. 2.0 Electrical As Installed 2.01 MCC Disc. Switch Size 2.02 Breaker Size 2.03 Fuse Size 2.04 Starter Size 2.05 OL Heater Size 2.06 OL CT’s Ratio 3.0 Actual Nameplate Data 3.01 MFG 3.02 H.P. 3.03 F.L.A. 3.04 S.F. 3.05 RPM 4.0 Electrical Test Data 4.01 Megger At 1000 V __________ Meg 4.02 Rotation CW __________ CCW __________ Remarks: Acceptable 1.08 Ericson Cplg. 1.09 Meyers Hub 1.10 Conduit Brace 1.11 Flex Conduit 1.12 Mtr Rotates Freely 1.13 Vibration 1.14 Noise 2.07 Meter CT’s Ratio 2.08 Feeder Cable Size 2.09 Control XFMR Size 2.10 Grounding 2.11 Local Disc. Switch 2.12 Motor Space Heater 3.06 Volts 3.07 ENCL. 3.08 INS. CL. 3.09 Temp. 3.10 Serial No. C 4.03 No Load Amps 4.04 Two (2) Hour Run YES NO Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76209 Rev 0 Motors Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76209 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76209 Rev 0 Motors Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76210 Revision 0, 10 June 2013 CONTROL AND RELAY PANELS INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76210A Client Other Turnover System: Sub – System: *NOTE: Control and alarm device testing to be done during control scheme and logic checks. Item Description of Check Subcontractor Fluor FE/QA Verify the following are acceptable in accordance with design documentation 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Panel ground wire installed Internal cooling fan Forced ventilation Nameplates complete Internal device labels complete Terminal strips labeled NEMA construction (I, 3R, etc.) of enclosure Field wire markers complete Unused knockouts plugged Convenience outlet phased Internal lighting complete Floor entrances sealed Touch up painting completed Annunciator wiring bundled and formed to allow removal of a single print wiring without shutdown. Future points are not blocked. Remarks: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76210 Rev 0 Control and Relay Panels Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76210 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76210 Rev 0 Control and Relay Panels Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76211 Revision 0, 10 June 2013 ELECTRONIC EQUIPMENT INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76211A Client Other Turnover System: Sub – System: Manufacturer: Serial No.: Item 01 02 03 04 05 06 Description of Check Type: Model No.: Rating: Style No.: Subcontractor Fluor FE/QA Inspect for damaged and missing parts Inspect for loose nuts and bolts Inspect for loose wiring connections Inspect for dirt and foreign materials Test per manufacturer’s instructions Record item number of UPS system of which above equipment is a part.* (* N/A for all components. Complete this item on from covering inverter portion of UPS as a record of the Complete System Test.) 07 Other: Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76211 Rev 0 Electronic Equipment Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76211 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76211 Rev 0 Electronic Equipment Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76112 Revision 0, 10 June 2013 POWER PANEL INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76212A Client Other Turnover System: Sub – System: Item Description of Check Subcontractor Fluor FE/QA Verify the following: 01 02 03 04 05 06 07 08 09 10 11 Remote trip installed Panel directory complete All nameplates complete Ground bus installed Ground bus tied to plant ground grid All mechanical interlocks operational Unused knockouts plugged Floor anchors installed Grouting complete Touch up painting complete Provide the data and complete the following: 11.1 Incoming Feeder Size 11.2 Main Disc. or Fuse Rating 11.3 Vertical Bus Rating 11.4 Vertical Bus Type 11.5 Megger at 1000V 11.6 Megger at 1000v Ground 11.7 Feeder Fuse Type Remarks: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76212 Rev 0 Power Panel Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76112 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76212 Rev 0 Power Panel Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76113 Revision 0, 10 June 2013 SWITCHGEAR INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76213A Client Other Turnover System: Sub – System: Item 1. 2. 3. 4. 5. 6. 7. 8. 9. Description of Check Subcontractor Fluor FE/QA Confirm that checks according to the certified equipment procedure have been performed for certified switchboards. Verify name plate details against data sheet. Visually inspect equipment for external damage. Inspect the switchboard for alignment and secure fixings. Confirm equipment is correctly located as per Switchroom layout drawings. Check all cable entries are correct to design requirements. Check earthing conforms to project specification. Inspect switchboard earth bar and ensure all earth terminations are correct and secure. Check inside of the switchboard is clean, dry and silica gel, etc., has been removed. Check all cubicle doors can be opened and are not obstructed. 10. Visually inspect the switchboard cubicles for damage. 11. Ensure that torque settings of Busbar shipping joints are in accordance with supplier requirements / specifications. 12. Check all equipment carries the correct circuit identification. 13. Ensure all Busbars are encapsulated as per specification. 14. Ensure that ducter tests are performed across all bolted shipping joints and readings are acceptable and recorded, a copy of which to be maintained within the construction dossiers. 15. On completion of all cable glanding confirm spare entries are correctly plugged. 16. Check gaskets and seals are not damaged. 17. Check all bolts are correct and none missing. Remarks: Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76213 Rev 0 Swithcgear Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76113 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76213 Rev 0 Swithcgear Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76214 Revision 0, 10 June 2013 LOW VOLTAGE FEEDERS INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76214A Client Other Turnover System: Sub – System: 1.0 Low Voltage Switchgear to MCC 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Type Installation Feeder Size Mechanical Installation Ground Conductor NEMA Standard Phasing Megger @ 1000V 0-0 Megger @ 1000V 0-Gnd 2.0 MCC to Disconnect, Power Panel, or Packaged Equipment 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 MCC Disc Switch Size Fuse Size Fuse Type Feeder Cable Size Wire Markers - Both Ends Ground Conductor NEMA Standard Phasing Megger @ 1000V 0-0 Megger @ 1000V 0-Gnd Remarks: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76214 Rev 0 Low Voltage Feeders Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76214 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76214 Rev 0 Low Voltage Feeders Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76215 Revision 0, 10 June 2013 HIGH VOLTAGE CABLE INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Tag No.: Area/Unit: ID E76215A Client Turnover System: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 Description of Check Cable is the correct type and size, see cable schedule. Cable glands are the correct type, and correctly fitted. Ensure IP sealing washers are fitted to gland, where required. Check earth bonding is correct to design drawings. On single core cables, ensure that cables are earthed as shown on the contract electrical drawings. Confirm cable route and segregation are correct. Check cable supports, cleating and banding are to specification. Check bending radius is within manufacturer’s recommendations. Check cable markers are correct through transits and each end. Confirm protective measures (kick plates) are fitted correctly. Test and confirm conductor continuity. Test and confirm earth wire continuity. Test and confirm drain wire continuity. Measure resistance of gland body to earth. Maximum 0,1 ohms. Test insulation resistance using a 5KV megger for 15 minutes. Minimum reading Megaohms. Ɯ Ɯ Ɯ Ɯ Ɯ Discharge all cores to earth for a minimum period of 15 minutes. Perform a pressure test and record current leakage. Stress cones fitted to manufacturer’s instructions. Minimum reading Megaohms. Ɯ Ɯ Discharge all cores to earth for a minimum period of 15 minutes. Subcontractor Fluor FE/QA Test and record insulation resistance using a 5KV megger for 15 minutes. 21 22 23 24 Notes: Discharge all cores to earth for a minimum period of 15 minutes. Reconnect all cores. Confirm all cable cores are laid correctly. Confirm correct terminations and fit terminal box cover. A Ɯ Test 11 to 13 inclusive. Test results are subject to manufacturer’s permissibles and length of cable. Both must be checked to confirm acceptable reading. Witness points. Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76215 Rev 0 High Voltage Cable Inspection and Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76215 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76215 Rev 0 High Voltage Cable Inspection and Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76216 Revision 0, 10 June 2013 ELECTRICAL EQUIPMENT INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76216A Client Other Sub – System: Location: Type Of Equipment: System Voltage: Size / Rating: Establish And Record The Length Of Cable: 1.0 2.0 Unit No.: Registration No: Subcontractor Fluor FE/QA Compare nameplate information with equipment record. Note any deviations under remarks. Establish and Record the following: 2.1 2.2 2.3 2.4 2.5 2.6 Equipment/circuit identification. Area classification. Type of Ex-protection/gas group/temperature class. Degree of enclosure protection. Electrical protection setting/rating. Actual maximum load/amp meter reading. Labeling correct. No unauthorized modifications. Enclosures and glasses satisfactory. Seals and gaskets satisfactory. Bolts and glands complete and tight. No undue accumulation of dust and dirt. No leakage of oil/compound. No damage to aboveground part of connected cables. Adequate protection of equipment and cables against corrosion, the weather, vibration and other adverse factors. Motor fans and couplings not rubbing on cowls/guards. Grounding in good condition. Oil levels in sight glasses correct. Padlock facilities correct. Silica gel in breathers satisfactory. Pressurization systems correct & tested. YES NO Fluor QA Name: Signature: Date: 3.0 Check the following items and report any deviations/defects under remarks: 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 4.0 Suitable for use in areas as classified: Subcontractor Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76216 Rev 0 Electrical Equipment Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76216 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76216 Rev 0 Electrical Equipment Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76217 Revision 0, 10 June 2013 CONTROL SCHEME INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76217A Client Other Turnover System: Sub – System: Control Scheme Mtr. Equipment No. Drawing No./Rev. Item Description of Check Subcontractor Fluor FE/QA Verify the following: 01 02 03 04 05 06 Remarks: Motor uncoupled Motor leads dropped (low voltage) Contractor in test position (high voltage) Solenoids disconnected Neutral grounded Wire markers complete Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76217 Rev 0 Control Scheme Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76217 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76217 Rev 0 Control Scheme Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76218 Revision 0, 10 June 2013 POWER TRANSFORMER INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76218A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 08 09 10 11 12 Description of Check Check all equipment is suitable for hazardous area. Verify equipment is suitable for IP rating. Verify name plate details against data sheet. Visually inspect equipment for external damage and leaks. Check equipment fixings and mountings are secure. Check air / water cooling ventilation air inlet / outlets are clear. If transformer is oil filled check level indicator shows correct level. Check terminal box interior for damage, cleanliness and remove packing. Ensure gland plates for outgoing single core feeders are non-magnetic. Check cable boxes for compound leaks. Check gaskets and seals are not damaged. Check all bolts are correct and none are missing. Subcontractor Fluor FE/QA Remarks: Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76218 Rev 0 Power Transformer Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76218 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76218 Rev 0 Power Transformer Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76219 Revision 0, 10 June 2013 SWITCHING UNITS HV SWITCHGEAR INSPECTION AND TEST RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76219A Client Other Sub – System: Location: Rating: Manufacturer: Function: Switchgear No.: Subject: 1.0 Record the reading of the operations counter 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 2.0 Check the following items and report any deviations/defects under remarks: Circuit labelling correct Operation of safety shutters Padlocking facilities Interlocking facilities, mechanical/electrical Mechanical position indicators, indicating lights Insulating bushings and barriers Cable box and terminations Alignment of main and auxiliary contacts Mechanical closing and tripping Electrical closing local/remote Electrical tripping local/remote Alarm indications local/remote Anti-condensation heater Test insulation resistance at 500 V ..............................Megaohms Switching device: Type Panel No.: Reference Document: Subcontractor Fluor FE/QA Secondary and auxiliary wiring 2.1 Test insulation resistance at 500 V ..............................Megaohms W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76219 Rev 0 Switching Units HV Switchgear Insp & Test Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76219 Revision 0, 10 June 2013 Subject 3.0 Earthing: 3.1 3.2 3.3 3.4 Verify the conditions of earthing bar and connections Test the earthing bar continuity ............................... Micro Ohm Record fuse type/rating .................... Subcontractor Fluor FE/QA HV pressure test - circuit breaker (for pre-commissioning inspection only) Test voltage DC Leakage Current - MA kV A B C kV Tester used: 4.0 Phase Tester used: 5.0 Phase Conductivity test - circuit braker: R S T Ohm Insulation resistance - circuit braker: V DC A B C Megaohms A B C Test voltage Ducter used: Current transformer test completed Sheet no.: Protection relay test completed Sheet no.: Remedial action required: Remarks Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76219 Rev 0 Switching Units HV Switchgear Insp & Test Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76220 Revision 0, 10 June 2013 SWITCHING UNITS – HV SWITCHGEAR INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Item 01 02 03 04 05 06 07 08 09 10 11 12 13 Description of Check Confirm certified equipment check sheets are complete. Check all cable check sheets are complete. Verify name plate details against datasheet. Confirm switchboard has been correctly sited. Visually inspect equipment for external damage. Check equipment fixings and mountings are secure. Ensure that torque settings of Busbar shipping joints are in accordance with supplier requirements / specifications. Check earthing conforms to project specification. Inspect switchboard earth bar and ensure all earth terminations are correct and secure. Ensure gland plates for outgoing single core feeders are non-magnetic. Check gaskets and seals are not damaged. Check all bolts are correct and none missing. Ensure that ducter tests are performed across all bolted shipping joints and readings are acceptable and recorded, a copy of which to be maintained within the construction dossiers. Ensure all Busbars are encapsulated as per specification. Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID E76220A Client Other Turnover System: Sub – System: Subcontractor Fluor FE/QA 14 Remarks Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76220 Rev 0 Switching Units HV Switchgear Insp Chklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76220 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76220 Rev 0 Switching Units HV Switchgear Insp Chklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76221 Revision 0, 10 June 2013 LIQUID-FILLED TRANSFORMER INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76221A Client Other Sub – System: Location: Substation: 1. 2. 3. 4. 5. 6. 7. 8. 9. Building: Transformer Tag No.: Subcontractor Fluor FE/QA Receiving Operations/Inspection complete Equipment Protection Program instituted and documented Tag number, voltage and kVA rating per plan drawings and one-line Check transformer nameplate against purchase specification Location, mounting and orientation per drawings Visually inspect for cleanliness and no chips, cracks or other apparent damage to bushings, radiators and tanks Check lubrication and freedom of rotation of cooling fans Check lubrication and freedom of motion of tap changers and other operating accessories Inspect fuses, disconnect switches and surge arrestors 10. Inspect for liquid leakage around tank, radiators and accessories 11. Collect samples of insulating liquid per manufacturer’s instructions and determine dielectric strength of insulating liquid. Record on Form: 000 509 F76120: Liquid Dielectric Strength Test Record 12. Check for continuity in all windings 13. Measure cold resistance of neutral grounding/earthing resistor and perform Insulation Resistance Test (megger) and DC Overpotential Test. Record readings on Form: 000 509 F76115: Neutral Grounding/Earthing Resistor Test Record 14. Neutral wire size, insulation and color per drawings/schedule 15. Case ground/earth and grounding/earthing resistor correctly installed. Measure bonding resistance of connections and record on Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars) 16. Check that incoming feeders have had Insulation Resistance Test (megger) performed and that Form: 000 509 F76102. Insulation Resistance Test Record (Power Control Wire and Cable), is on file 17. Check that incoming feeders have had DC High Potential Test (hypot) when required by specification and that Form: 000 509 F76104: DC High Potential Test Record (Medium Voltage Cable), is on file 18. Check inert gas pressure gage (pressure should be in accordance with manufacturer’s instructions) 19. Check temperature gage for proper operations 20. Check liquid level gage for proper operation and proper level of liquid in various compartments 21. Check sudden pressure relay and relief device 22. Alarm and control circuits connected and complete W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76221 Rev 0 Liquid Filled Transformer Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76221 Revision 0, 10 June 2013 LIQUID-FILLED TRANSFORMER INSPECTION RECORD Substation: 23. Building: ID E76221A 24. 25. 26. 27. 28. 29. 30. 31. 32. Transformer Tag No.: Subcontractor Primary/secondary cables/bus duct properly supported, insulated and protected against mechanical damage. Belted connections torqued in accordance with manufacturer’s recommendations. Torgue Wrench No. __________________ Cal. Date:_________________________ Check conductor size, insulation class and type Check conductor phasing and identification Check conduit connections Perform Insulation Resistance Test (megger) of transformer primary and secondary windings and record readings on Test Form: 000 509 F76119: Insulation Resistance (Transformer) Test Record Perform DC High Potential Test (hypot) when required by specification and record readings on Form: 000 509 F76104: DC High Potential Test Record Perform Insulation Power Factor (Doble) tests, when required by specifications and document on Project furnished Exhibit Measure primary and secondary voltages with tap changer in each position and verify that voltages ratios are per transformer nameplate. Apply construction power to primary transformer connection and measure secondary voltages. Primary voltage rating shall not be exceeded Record transformer tap setting below (Set at mid-tap unless otherwise indicated in Engineering Documents.) Check correct operation of control system for fans Fluor FE/QA 33. Check correct rotation of cooling fans 34. Check to assure connections are tight and secure 35. Alarm trip and fans start contact operational. High winding and/or liquid temperature alarm set at 900 C, or in accordance with manufacturer’s instructions 36. Mechanical relief device is reset 37. Spare control/alarm conductors taped or capped 38. Spare hubs or knockouts plugged 39. Paint scratches refinished 40. Handhold covers tightly secured 41. Supplier Representative provided service/supervision for the equipment Supplier test reports attached to this inspection Record 42. Confirm NDE tests are done after lifting lugs are installed for any defects in laminations. 43. Equipment Protection Program completed and documented 44. Final inspection complete. Punch List Record Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76221 Rev 0 Liquid Filled Transformer Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76222 Revision 0, 10 June 2013 BUSWAY INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76222A Sub – System: Location: Busway Tag No.: 1. 2. 3. 4. 5. 6. 7. 8. 9. Receiving Operations/Inspection Complete Equipment Protection Program instituted and documented Using supplier drawings, check entire assembly, including auxiliary equipment, for any missing parts Torque the connections according to manufacturer’s recommendations. Torque Wrench Number __________________ Cal Date ______________________ Inspect bus insulators for damage and cleanliness Drain holes unplugged Vertical and horizontal support spacing in accordance with manufacturer’s instructions Check for proper clearance, where visible, between busbars and between busbars and enclosure Gaskets installed (if required) Subcontractor Fluor FE/QA 10. Perform Insulation Resistance Test (megger) on bus and record on Test Record, Form: 000 509 F76118: Insulation Resistance (Equipment) Test Record 11. Busway housing grounded. Record bonding resistance on Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars) 12. Check for proper phasing after installation 13. Perform Ductor Tests. Record on Test Record Form: 000 509 F76128 14. Connect space heaters and check operability (when applicable) 15. Equipment Protection Program completed and documented 16. Final inspection complete. Punch items on Punch List Record Remarks: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76222 Rev 0 Busway Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76222 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76222 Rev 0 Busway Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76223 Revision 0, 10 June 2013 SWITCHGEAR INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76223A Client Other Sub – System: Location: Substation: Note!! #1 Building: Switchgear Tag No.: Subcontractor Fluor FE/QA 1. 2. 3. 4. 5. Test with circuit breakers withdrawn and with circuit breakers in operating position and open. All circuit transformer secondaries must be shorted before testing begins and instrument potential transformers must be racked in, but with fuses removed. Receiving Operations/Inspection complete Equipment Protection Program instituted and documented Check phasing of buses Remove shipping supports Check and inspect for completeness of all components. Torque bolted joints according to manufacturer’s recommendations. Torque Wrench Number _________________________ Cal Date_____________________________ 6. All devices installed such as: ground fault relays, volt meters, ammeters, breakers, fuses, etc. Location and type according to supplier drawings 7. Check control wiring (especially Field connections at shipping splits) 8. Perform Insulation Resistance Test (megger) buses and record on Test Record, Form: 000 509 F76118: DC High Potential Test (Hypot) Buses, when required by specification. Record on Form: 000 509 F76104, DC High Potential Test Record 9. Perform Insulation Resistance Test (megger) control and potential transformer primary windings and record on Test Record, Form: 000 509 F76119: Insulation Resistance (Transformer) Test Record 10. Perform Ductor Test. Record on Test Record Form: 000 509 F76130 11. Check control transformer fuses, type and size 12. Check potential transformer fuses, type and size 13. Check primary and secondary ratings of all transformers including control transformers 14. Check for proper grounding/earthing connections at both ends of assembly. Record bonding resistance on Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars) 15. Check ground/earth bus bar continuity to ensure connection has been made at shipping split points 16. Tagging correct 17. Cubicles clean, dry and dust free 18. Instruments zeroed 19. Space heaters are connected and operable 20. Insert and remove breaker of same rating in various units to ensure interchangeability 21. Check continuity of all fuses. Check size and type 22. Perform circuit breaker test W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76223 Rev 0 Switchgear Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76223 Revision 0, 10 June 2013 SWITCHGEAR INSPECTION RECORD 23. Terminals and connections tight and secure. Torque bolted connections Torque Wrench Number: Calibration Date:: 24. Mainbus and tapes (size according to supplier drawing) 25. Insulation Resistance Test (megger) the DC and AC control circuits, main and outgoing control disconnect devices open. Record results on Test Record, Form: 000 509 F76102 26. Check incoming power cables Insulation Resistance Tested (meggered) prior to connection to switchgear and that results recorded on Form: 000 509 F76102 27. Check DC High Potential Testing (hypot) of incoming power cables completed, when required by specification and recorded on Form: 000 509 F76104: DC High Potential Test Record (Medium Voltage Cable) 28. Incoming feeder terminations properly made up 29. Supplier Representative provided service/supervision for this equipment. Supplier test reports attached to this Inspection Record. 30. Equipment Protection Program completed and documented 31. Final inspection complete. Punch items on Punch List Record Remarks ID E76223A Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76223 Rev 0 Switchgear Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76224 Revision 0, 10 June 2013 MOTOR CONTROL CENTER INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Substation: 1. 2. 3. 4. 5. 6. 7. 8. 9. Receiving Operations/Inspection complete Equipment Protection Program instituted and documented Check for missing parts using supplier drawings. Inspect each unit or cubicle for proper nameplate in accordance with approved drawings Inspect main bus and bus taps to switches and potential transformers. Torque bolted joints in accordance with manufacturer’s recommendations Determine that all terminal block connections are secure and properly identified (especially Field connections at shipping splits) Manually operate switches and contactors. Check for freedom of all moving parts Check nameplate data for switches, contactors, fuses and relays against approved supplier drawings. Verify contactor auxiliary contacts, normally open/closed according to drawing Check for correct sizing of overload relay heaters in accordance with approved drawings Protective grounding/earthing is correctly installed and connected to main ground/earth. Verify Test Record, Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars), completed. Check main ground/earth bus for continuity between shipping sections Record Insulation Resistance (megger) readings on Test Record, Form: 000 509 F76118: Insulation Resistance (Equipment) Test Record. Test with disconnect switches connected and open. Test with disconnect switches connected and closed. For the second test, ensure that neutral is disconnected at starters. Reconnect neutral after second test Check that power and control cables for each cubicle Insulation Resistance Tested (megger) and that Form: 000 509 F76102: Insulation Resistance Test Record (Power Control Wire and Cable) Test Record, is on file Perform DC High Potential Test (hypot) when required by specification and record on Form: 000 509 F76104: DC High Potential Test Record (Medium Voltage Cable). Spot check overload relays for trip action by injecting current from relay testing equipment in accordance with relay sheets Check to see that enclosure space heaters are connected and operable (when applicable), and that MOTOR space heater circuits are functional Overload reset button free and functional Perform functional check of contactor. Use supplier or Fluor elementary drawing. Observe all Project safety precautions Check timing relays for correct type, size and time setting in accordance with drawings Building: Tag No.: Turnover System: Client Other ID E76224A Sub – System: Location: MCC Tag No.: Subcontractor Fluor FE/QA 10. 11. 12. 13. 14. 15. 16. 17. 18. Check control power transformers for correct size and voltage in accordance with drawings 19. Check main contact pressure, alignment and for full contact area (high voltage contactors, only) 20. Supplier Representative provided service/supervision for this equipment. Supplier test reports attached to this Inspection Record 21. Equipment Protection Program completed and documented 22. Final inspection complete. Punch items on Punch List Record. Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76224 Rev 0 Motor Control Center Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76224 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76224 Rev 0 Motor Control Center Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76225 Revision 0, 10 June 2013 BATTERY AND BATTERY CHARGER INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID E76225A Sub – System: Location: Substation: Building: Equipment Tag No.: Note!! When batteries are placed in service while work is still being performed around them, protection should be provided. Metal objects laid or dropped on them could cause a short or an explosion. Tarpaulin, plastic or similar material, should not be used because batteries in service require ventilation. 1. Receiving Operations/Inspection complete 2. 3. Equipment Protection Program instituted and documented Batteries and racks installed and checked for proper mechanical installation, including connections and number of cells 4. Batteries filled with electrolyte to proper level and charged in accordance with manufacturer’s recommendations 5. Lead acid batteries checked with hydrometer for correct specific gravity, in accordance with manufacturer’s specifications 6. Grounding/earthing connection checked. Record readings on Test Record Form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars) 7. Battery charger checked for proper installation, wiring complete and properly connected 8. Charger operates in accordance with manufacturer’s recommendations. Current output, voltage and operation of control components checked. 9. Check charger nameplate against approved supplier drawings 10. Accessory equipment such as hydrometer, thermometer, special wrenches and spare electrolyte accounted for 11. Batteries, battery racks and charger cleaned. Terminals and interconnectors covered with protective base 12. Test Charger for maximum rated output and correct operation, as required by Project specifications 13. Booster charge in accordance with manufacturer’s instructions 14. Set charger for float operation with adjustment of proper float voltage 15. Charger marked with float and boost charge voltage limits 16. Verify proper operations of low DC voltage relay and alarm contacts. Indicate limits 17. Verify proper operation of AC failure relays and alarm contacts 18. Verify ground detection relay or lights operate properly. Verify alarm output relays operate 19. Voltmeters checked, zeroed 20. Ammeters checked, zeroed 21. Fuses and circuit breakers in accordance with supplier drawings 22. Verify operation of charger output failure relay and alarm contacts 23. Supplier Representative provided service/supervision for this equipment. Supplier test reports attached to this inspection record 24. Equipment Protection Program completed and documented 25. Final inspection complete. Punch items on Punch List Record Subcontractor Fluor FE/QA Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76225 Rev 0 Battery and Battery Charger Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76225 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76225 Rev 0 Battery and Battery Charger Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76226 Revision 0, 10 June 2013 LIQUID IMMERSED MEDIUM VOLTAGE DISCONNECT SWITCH INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76226A Client Other Sub – System: Location: Subcontractor Fluor FE/QA 1. Receiving Operations/Inspection Complete 2. Tag Number, Voltage Rating per one line 3. Visually inspect for cleanliness and no chips or cracks or other apparent damage to bushings 4. Inspect for liquid leakage 5. Collect samples of insulating liquid and determine dielectric strength of insulation liquid. Record on Form: 000 509 F76120: Liquid Dielectric Strength Test Record. 6. Check connections and the jumpers at the terminals 7. Final inspection complete. Punch items on punch list record. Remarks Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76226 Rev 0 Liq Immersed Med V Disconn Switch Inspn Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76226 Revision 0, 10 June 2013 This page is intentionally blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76226 Rev 0 Liq Immersed Med V Disconn Switch Inspn Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76227 Revision 0, 10 June 2013 ELECTRIC MOTOR-ELECTRICAL ACTIVITIES INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Motor Tag No.: Tag No.: Turnover System: ID E76227A Client Other Sub – System: Location: Fluor FE/QA Subcontractor Note!!! Inspection of the Mechanical items related to this motor is documented on the appropriate Mechanical Exhibit for the driven equipment with similar Tag Number. 1. Equipment Protection Program instituted and documented 2. 3. 4. 5. Nameplate data agrees with motor list, plan drawings and one-line Motor type is suitable for use in area classification Check the power and control cables Insulation Resistance Tested (megger) prior to connection to motor For induction motors, perform the following motor test, as required by the specifications and document on the appropriate forms. For synchronous motors, test in accordance with manufacturer’s instructions a. Form: 000 509 F76135 Insulation resistance (Rotating Equipment) Test Record (megger) b. c. d. 6. Form: 000 509 F76121 DC Proof Test Record Form: 000 509 F76104 DC High Potential Test Record Insulation Resistance Test of Pedestal (when applicable): ____________ ohms 7. 8. 9. e. Form 000 509 F76126 Equipment Absorption Ratio and Polarization Index Test Record Grounding/Earthing conductors installed, connected and bonded resistance checked from motor frame to ground/earth system tap. Record resistance on form: 000 509 F76117: Ground Continuity Test Record (Electrical Equipment and Ground Test Bars). Motor splices and terminations complete. Spare wires (pigtails) on multiple voltage motors properly insulated Motor electrical accessories are properly connected and functioning such as space heater, thermocouples and vibrations switches Cable gland properly made up 10. Bonding jumper installed, when required, across flexible conduit 11. Control station nameplate installed 12. Covers are installed, bolts and nuts are tightened 13. Final inspection complete. Items Punch List Record Remarks Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76227 Rev 0 Electric Motor - Elect Activities Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76227 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76227 Rev 0 Electric Motor - Elect Activities Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76228 Revision 0, 10 June 2013 ELECTRIC MOTOR-MECHANICAL ACTIVITIES INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Motor Tag No.: Tag No.: Turnover System: ID E76228A Client Other Sub – System: Location: Subcontractor 1. 2. 3. 4. 5. 6. 7. 8. 9. Receiving Operations/Inspection complete Equipment Protection Program instituted and documented Anchor bolts checked for location, elevation and orientations prior to setting equipment Equipment set and checked for location, elevation and orientation Preliminary alignment completed and documented Jackscrews removed and anchor bolt nuts tightened Baseplate grouting complete and documented when manufactured grouts are required Fluor FE/QA Final cold alignment set to manufacturer’s tolerance and documented Motor electrical activities complete and documented on Form: 000 509 F76227: Electric MotorElectrical Activities Inspection Record 10. Grease or oil checked to assure proper filling 11. Field coating checked 12. Verify completion of activities on Form: 000 509 F76124 460 V Motor Circuit (480 V MCC) Test Record, Form: 000 509 F76125: Medium Voltage Motor Circuit Test Record, prior to motor bump and run-in, in accordance with Form: 000 509 F76133: Electric Motor Run-in Test record 13. Equipment Protection Program completed and documented 14. Final inspection complete. Mechanical punch items on Punch List Remarks Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76228 Rev 0 Electric Motor - Mechl Activities- Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76228 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76228 Rev 0 Electric Motor - Mechl Activities- Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76229 Revision 0, 10 June 2013 ELECTRIC MOTOR FOR COMPRESSOR INSTALLATION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76229A Client Other Sub – System: Location: MOTOR: DRIVEN EQUIP WIN: WIN: TAG: TAG: Initials/Date 1. 2. 3. 4. 5. 6. 7. 8. 9. Baseplate pads free of dirt and scale, and filed to remove high spots. Motor feet free of dirt and scale, and filed to remove high spots. Drilled and tapped holes in baseplate pads clean and threads undamaged. Motor weight verified, proper rigging and crane for lifting. Motor set on base, bolts snugged and motor checked for soft foot. Align the motor to the driven equipment with the proper offset to allow for thermal growth. Verify the coupling spacing will allow the motor to run on magnetic center when coupled. Connect the inlet and outlet oil lines to the motor bearing housings. Check to see if the lines have to be insulated from the housings. Commission the lube system and check for any oil leaks. 10. Install the vibration monitoring probes and calibrate to the monitor. 11. Electricians to connect the motor leads, connect the motor heaters and the winding RTD. 12. Electricians to perform the following checks: Set and test the protective relays and control devices Test wire insulation resistance of power and control circuits Test the motor winding insulation resistance Test the motor ground connections 13. Secure the motor coupling for a solo run of the motor 14. Run the motor solo for at least in hour or longer until the motor bearing temperatures, motor winding temperatures, and vibration levels stabalize. Verify the proper rotation of the motor 15. Stop the motor using the emergency shutdown. Time the coast down. 16. Couple the motor to the driven equipment and torque the coupling bolts to the prescribed value. Install the coupling guard. Subcontractor Fluor Field Engineering Fluor QA Name Signature Date Name Signature Date Name Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76229 Rev 0 Electric Motor for Compressor Installation Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76229 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76229 Rev 0 Electric Motor for Compressor Installation Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76230 Revision 0, 10 June 2013 COMPRESSOR VIBRATION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor ID E76230B Tag No.: Turnover System: Client Other Sub – System: Location: VIBRATION OB Vert Motor OB Horz IB Vert IB Horz Active Inactive Gear OB Vert OB Horz IB Vert IB Horz OB Vert Pinion OB Horz IB Vert IB Horz Active Inactive Comp OB Vert OB Horz IB Vert IB Horz Time W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76230 Rev 0 Compressor Vibration Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76230 Revision C, 28 February 2012 COMPRESSOR VIBRATION CHECKLIST Time ID E76230B TEMPERTURES Motor OB IB Active Gear Inactive OB IB Pinion OB IB Active Comp Inactive OB IB Seals OB IB Temp to Brgs Temp to Seals Press to Brgs DP to Seals Suction Press Discharge Press Suction Temp Discharge Temp Motor Amps Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76230 Rev 0 Compressor Vibration Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76231 Revision 0, 10 June 2013 VIBRATION PROBE RECORD Tag Description: P. O. No.: Subcontractor: Bently Nevada Probe: Inspection Classification Subcontractor Fluor ID E76231B Tag No.: Turnover System: Client Other Sub – System: Location: Compressor Number: 1 COMPRESSOR 2 3 4 GEAR 5 6 7 MOTOR 8 Bearing Probe Position Horiz. Type Probe Extension Cable Proximeter Radial Probe Gap Voltage Axial Probe Gap Voltage Against Against Mid Normal Counter Position Shoes Shoes Monitor Point Number No. 1 Compressor Outboard No. 2 Compressor Inboard No. 3 Gear H.S. No. 4 Gear H.S. Vert. Axial Key ø Horiz. Vert. Horiz. Vert. Horiz. Vert. Axial Horiz. No. 5 Gear L.S. No. 6 Gear L.S. No. 7 Motor Inboard No. 8 Motor Outboard Vert. Axial Horiz. Vert. Horiz. Vert. Horiz. Vert. Axial Key ø Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76231 Rev 0 Vibration Probe Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76231 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76231 Rev 0 Vibration Probe Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76232 Revision 0, 10 June 2013 DRY TYPE LIGHTING, RECEPTACLE & INSTRUMENT TRANSFORMERS CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Client Other Tag No.: Turnover System: Sub – System: Location: ID E76232B Equipment No.: Location Drawing: For: Lighting Receptacle or Instrument Nameplate Ship. Braces Removed Wire Markers Compl. Neutral Bond Size Ground Conductor Size Equipment Ground Phase Meter Test (ABC) Yes Yes No No System: Manufacturer: No-Load Volts Phase to Phase Rating Volts Tap Setting Insul. Class Temp. Rise Windings MCC Disc SW Size Fuse Size Fuse Type Fuse Type Feeder Size Touch-up Paint Cu C A1 V Test Equip. Cal. Date Tester AMB. Temp. Notes: 1) Use 500-volt test set for 600-volt equipment and below, 2500-volt test set for equipment rated over 601-5000 volts and 5000-volt test set for equipment rated over 5000 volts. 2) Test voltage to be applied for one-minute duration and reading taken. 3) Neutral must be disconnected from ground during test. 4) Record surrounding air temperature of transformers. 5) Readings will vary inversely with temperature. When project specifies use of temperature correction factors. Attach second sheet with computed values. Indicate on each sheet “Measured” or “Temperature Corrected”. Resistance (MEGOHMS)* Primary Secondary C to G A to G B to G C to G Pri to Sec Pri-Sec Voltage Rating (kV) Liquid or Air Temp (oC – oF) A to G B to G Comments: Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76232 Rev 0 Dry Type Lighting Trnasformer Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76232 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76232 Rev 0 Dry Type Lighting Trnasformer Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76233 Revision 0, 10 June 2013 INSTRUMENT WIRE & CABLES CONTINUITY CHECKS >50VDC Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID E76233 Client Other Sub – System: Location: Location: Reel #: Cable # Tester Size Size: Meter ID # RESULTS Conductor # Continuity Type Type: Calibration Date: Length Conductor # Continuity Conductor # Continuity Subcontractor Name Signature Date Name Signature Date Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76233 Rev 0 Instrmt Wire & Cable Continuity Check -50VDC.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F76233 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F76233 Rev 0 Instrmt Wire & Cable Continuity Check -50VDC.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7700 Revision 0, 10 June 2013 CONTROL SYSTEM INSTRUMENTATION SCOPE This procedure applies to the inspection of installations and loop check of instrumentation. RESPONSIBILITIES - Self-Perform ACTIVITY Inspect received instruments Inspect in-process instrument installation Inspect completed instrument installation Perform Pressure Testing of Tubing Verify Pressure Testing of Tubing Test Instrument Cables Verify Instrument Cable Testing Perform/ Verify Loop Check RESPONSIBILITY E & I Construction Engineer Instrument Superintendent Site Quality Manager/ E & I Construction Engineer Site Quality Manager/ E & I Construction Engineer Instrumentation Superintendent Site Quality Manager/ E & I Construction Engineer Electrical Superintendent Site Quality Manager Instrumentation Superintendent/ Site Quality Manager DOCUMENTATION _____ 000 509 F770XX 000 509 F770XX _____ 000 509 F770XX _____ 000 509 F770XX 000 509 F770XX FREQUENCY OF ACTIVITY Each Instrument Daily during life of activity Each Instrument Each Pressure Test Package Each Pressure Test Package Each cable Each cable Each loop RESPONSIBILITIES - Subcontracted Work ACTIVITY Inspect received instruments Inspect in-process instrument installation Inspect completed instrument installation Perform Pressure Testing on Tubing Verify Pressure Testing of Tubing Test Instrument Cables Verify Instrument Cable Testing Perform/ Verify Loop Check RESPONSIBILITY Subcontractor Subcontractor Subcontractor/ Site Quality Manager Subcontractor Subcontractor/ Site Quality Manager Subcontractor Subcontractor/ Site Quality Manager Subcontractor/ E & I Construction Engineer Site Quality Manager DOCUMENTATION _____ 000 509 F770XX 000 509 F770XX _____ 000 509 F770XX _____ 000 509 F770XX 000 509 F770XX FREQUENCY OF ACTIVITY Each Instrument Daily during life of activity Each Instrument Each Pressure Test Package Each Pressure Test Package Each cable Each cable Each loop W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7700 Rev 0 Control Systems Instrumentation.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7700 Revision 0, 10 June 2013 PROCEDURE • Receipt Inspection of Instruments: The E & I Construction Engineer and the Instrument Superintendent shall coordinate the receipt inspection of instruments to support the construction schedule. • In-Process and Completed Instrument Installation Inspections: Assure the instrument, if required by specification, is calibrated prior to installation. Inspect the in-process installations. Using a Mechanical Flow Diagram and Instrument Specification Data Sheet, perform a completed inspection prior to pressure testing. Document on Form 000.509.F77001. • Test Equipment Tubing: Verify the instrument tubing is properly installed, is not supported from uninsulated hot or cold pipes and adequately supported. Pressure test shall be conducted in accordance with specifications and the Instrument Specification Data Sheet. • Test Instrument Cables: Verify the instrument electrical installation inspections and megger tests are complete and acceptable. • Loop-Check Verification: Verify all installation inspections, pressure testing and continuity checks have been completed and documented. Notify the Client Representative, if requested to do so, prior to the loop check. Verify the loop check, which generally consist of operating all instruments in the loop. Document the final loop check on Form 000.509.F77002. (Quality Control Forms): Instrumentation Inspection Checklist 000.509.F77001 Instrument Loop Checklist Inspection 000.509.F77002 Impulse Line Pressure Test Sheet 000.509.F77003 Instrument Grounding System Check Sheet 000.509.F77004 Installation Check Sheet (Local Instruments) 000.509.F77005 Orifice Plate Specification Check Report 000.509.F77006 Control Systems Quality 000.509.F77007 Loop Check Record 000.509.F77008 Loop Mechanical Completion and Acceptance Record 000.509.F77107 - FORMS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7700 Rev 0 Control Systems Instrumentation.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77001 Revision 0, 10 June 2013 INSTRUMENTATION INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77001A Client Other Turnover System: Sub – System: Loop No.: Drawing(s) Item Description of Check Subcontractor Fluor FE/QA Verify the following attributes: 01 Instruments mounted at proper height. 02 Instrument stands secure and vibration free. 03 Correct piping/tubing materials used. 04 All tubing trays and supports per details. 05 All air supply and process tubing connected to proper parts per details. 06 All tubing fitting nuts torqued per specifications. 07 Good workmanship used in tubing installation and neat in appearance. 08 Signal/power leads have proper separation and angle of intersection. 09 Tubing/piping pressure tested prior to heat tracing or insulating. 10 Loop checked per specification. ANY DISCREPANCIES NOTED ABOVE AS FOLLOWS: Punch List Items from Above List Date Cleared Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77001 Rev 0 Instrumentation Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77001 Rev 0 Instrumentation Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77002 Revision 0, 10 June 2013 INSTRUMENT LOOP INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Cable No.: Cable Type: Item Description of Check 01 Measuring Element 02 Impulse Lines 03 Field Instrument 04 Panel Instrument 05 Control Valve 06 Solenoid Valve 07 Air Supplies 08 Transmission 09 Temperature 10 General Notes: Inspection Classification Subcontractor Fluor ID I77002A Tag No.: Area/Unit: Client Other Turnover System: Sub – System: Junction Box No.: Color/Loop No.: Subcontractor Fluor FE/QA Installation Correct Tappings Position Correct Location Correct Materials Correct According to Hook-Up Traced Pressure Tested Materials Correct Local Indicator Working Power Supply Correct Air Supply Correct Correct Installation Weather Protected Correct Installation Air Supply Correct Power Supply Correct Correct Installation Limit SW Tested Positioner Checked Size & Type Correct Stroke Tested I/P Transducer Checked Correct Installation Size & Type Correct Other (indicate) :________________ Correct Installation Blown Clear & Leak Tested Other (indicate) :________________ Pneumatic Lines Tested Insulation Checked (C-C, C-G) Continuity Checked T/C or RTD Checked Continuity Checked Correct Cable Loop Impedance Checked Support Correct Earthing Correct Tagging/Marking Correct Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77002 Rev 0 Instrument Loop Checklist Inspection.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77002 Rev 0 Instrument Loop Checklist Inspection.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77003 Revision 0, 10 June 2013 IMPULSE LINE PRESSURE INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77003A Client Other Turnover System: Sub – System: Instrument Tag No. Instrument Tag No. Fluor FE/QA Item Description of Check Instrument Tag No. Instrument Tag No. Subcontractor 01 02 03 04 05 Ferrules correctly installed and crimped Slope and supports correct Tubing blow clear Valve block seals correct Test pressure bar Notes: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77003 Rev 0 Impulse Line Pressure Test Sheet.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77003 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77003 Rev 0 Impulse Line Pressure Test Sheet.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77004 Revision 0, 10 June 2013 INSTRUMENT GROUNDING SYSTEM CHECK SHEET Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID I77004A Sub – System: Location: Description of accepted items: Grounding system Manufacturer: Drawings: Items to check: 1 2 3 4 5 6 7 8 9 10 11 Remarks All metal enclosures correctly grounded Cable shields/screens correctly grounded Safety barriers, convertors, etc. Correctly grounded Dedicated ICS ground correct ICS minus and ground correctly connected Isolation of the three ground systems from another correct Grounding cable to central point correct After testing: Three grounding systems connected together correctly Metal tray (trunking, conduits) correctly grounded Computer floor correctly grounded Frames (supports for consoles, cabinets) correctly grounded Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77004 Rev 0 Instrument Grounding System Checksheet.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77004 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77004 Rev 0 Instrument Grounding System Checksheet.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77005 Revision 0, 10 June 2013 INSTALLATION CHECK SHEET (LOCAL INSTRUMENTS) Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID I77005A Client Other Sub – System: Location: Instrument Tag No.: Range Witness Date Instrument Tag No.: Range Witness Date Subcontractor Fluor FE/QA 1. 2. 3. 4. 5. Verify correct instrument is installed at correct P.I.D. location, including correct tag number and model number Verify integrity of process installation (no open plugs etc.) Verify all instruments have been calibrated (certificates available, stickers on instruments) Verify accessibility Verify correct gasket materials installed Subcontractor Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA Name: Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77005 Rev 0 Installation Checksheet Local Instruments.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77005 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77005 Rev 0 Installation Checksheet Local Instruments.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77006 Revision 0, 10 June 2013 ORIFICE PLATES INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77006A Client Other Turnover System: Sub – System: Item 01 02 03 04 05 06 07 Notes: Description of Check Install orifice with sharp edge upstream Bevel edge, if any, must face downstream Make sure gaskets on each side of orifice do not obstruct orifice bore Identification tab on square edge plates must face upstream Verify correct labelling Verify orientation of pressure taps per specification of process Visually inspect for damage Subcontractor Fluor FE/QA Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77006 Rev 0 Orifice Plate Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77006 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77006 Rev 0 Orifice Plate Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77007 Revision 0, 10 June 2013 CONTROL SYSTEMS QUALITY CONTROL INDEX Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Location Function Type Spec Sheet Tag No.: Area/Unit: ID 77007 Client Other Turnover System: Sub – System: Pressure Test Sign-Off Calibration Sign-Off Loop Check Sign-Off Tag Number Flow Diagram Loop Diagram Number Installation Sign-Off Test Pressure Remarks Type Codes: E = Electrical P = Piped C = Combination (E &P) D = Direct or Mechanical Location Codes: P = Pipe F = Front of Main Control Panel B = Back of Main Control Panel R = Equipment Rack L = Local Panel H = Control House Sheet of Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77007 Rev 0 Controls System Quality.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77007 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77007 Rev 0 Controls System Quality.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77008 Revision 0, 10 June 2013 LOOP CHECK RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77008A Client Other Turnover System: Sub – System: Job No./Unit No.: Loop No.: Record Loop Component Tag No. Comments: System Installation Complete and Required Documents on File Control/Systems: Date: Electrical: Date: Loop Function Test Tested By: Start-Up Accepted By: Date: Accepted By: Date: Fluor Accepted By: Date: Date: Subcontractor Name: Signature: Date: Name: Signature: Date: Fluor Commissioning Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77008 Rev 0 Loop Check Record.doc.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77008 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77008 Rev 0 Loop Check Record.doc.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77107 Revision 0, 10 June 2013 LOOP MECHANICAL COMPLETION AND ACCEPTANCE RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: ID F77107 Turnover System: Client Other Sub – System: Location: Area: Instrument Loop Tag No.: Loop Schematic Drawing No.: Flow Diagram Drawing No.: This Loop _________________________________________is mechanically complete in accordance with Drawings and Specifications. Fluor/Date This Loop _________________________________________has been checked within the parameters listed on the instrument loop drawing, and/or mechanical flow diagram, and is acceptable. Fluor/Date Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77107 Rev 0 Loop Mechanical Completion and Acceptance Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77107 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77107 Rev 0 Loop Mechanical Completion and Acceptance Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7710 Revision 0, 10 June 2013 CONTROL SYSTEM CALIBRATION SCOPE This procedure applies to calibration of instruments for control systems. RESPONSIBILITIES - Self-Perform ACTIVITY Inspect Instrument RESPONSIBILITY Calibration Technician/ Site Quality Manager DOCUMENTATION 000.509.F77001 000.509.F77101 000.509.F77102 000.509.F77103 000.509.F77104 000.509.F77105 000.509.F77106 FREQUENCY OF ACTIVITY Each Instrument Test and Calibrate Instruments Calibration Technician/ Site Quality Manager Each Instrument Surveillance Test Equipment Site Quality Manager 000.509.F02201 Periodically throughout life of project RESPONSIBILITIES - Subcontracted Work ACTIVITY Inspect Instrument RESPONSIBILITY Subcontractor DOCUMENTATION 000.509.F77001 000.509.F77101 000.509.F77102 000.509.F77103 000.509.F77104 000.509.F77105 000.509.F77106 FREQUENCY OF ACTIVITY Each Instrument Test and Calibrate Instruments Subcontractor Each Instrument Surveillance Test Equipment Site Quality Manager 000.509.F02201 Periodically throughout life of project W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7710 Rev 0 Control System Calibration.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7710 Revision 0, 10 June 2013 PROCEDURE • Inspect Instrument: Inspect each instrument for apparent damage. Verify the tag number, nameplate data, material, scale, range, etc., against the information contained on the appropriate Instrument Specification Data Sheet, and enter data on Form 000.509.F77101. Damaged or nonconforming instruments shall be segregated and/or tagged to prevent inadvertent use or installation until acceptable disposition is obtained. - • Instrument Test and Calibration: Based on the requirements in the applicable Design Specifications, applicable manufacturer's recommendations and client requirements, calibrate the instruments and document on Form 000.509.F77101. • Test Equipment Surveillance: Perform surveillance of calibration activities on a periodic basis throughout the life of the project. Verify the Master Equipment used for calibration has calibration stickers on the instruments that indicate date of last check and date of next check with traceability to the National Institute of Standards and Technology. FORMS Quality Control Form: 000.509.F77001 – Instrumentation Inspection Checklist 000.509.F77101 - Instrument Calibration Sheet 000.509.F77102 - Safety Valve Tracking Sheet 000.509.F77103 - Relief Valve Inspection and Final Acceptance 000.509.F77104 – Switch Calibration Data Record 000.509.F77105 - Valve Calibration Data Record 000.509.F77106 – Control System Test Equipment Calibration Log W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7710 Rev 0 Control System Calibration.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77001 Revision 0, 10 June 2013 INSTRUMENTATION INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77001A Client Other Turnover System: Sub – System: Loop No.: Drawing(s) Item Description of Check Subcontractor Fluor FE/QA Verify the following attributes: 01 Instruments mounted at proper height. 02 Instrument stands secure and vibration free. 03 Correct piping/tubing materials used. 04 All tubing trays and supports per details. 05 All air supply and process tubing connected to proper parts per details. 06 All tubing fitting nuts torqued per specifications. 07 Good workmanship used in tubing installation and neat in appearance. 08 Signal/power leads have proper separation and angle of intersection. 09 Tubing/piping pressure tested prior to heat tracing or insulating. 10 Loop checked per specification. ANY DISCREPANCIES NOTED ABOVE AS FOLLOWS: Punch List Items from Above List Date Cleared Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77001 Rev 0 Instrumentation Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77001 Rev 0 Instrumentation Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77101 Revision 0, 10 June 2013 INSTRUMENT CALIBRATION SHEET Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID I77101A Sub – System: Location: Instrument Calibration Sheet Date: Tag Number: Manufacturer: Process Range and Units: Technician: Loop Service: Model: Area: Serial No.: (scfm, gpm, psig, oC , etc.) (in H20, psig, etc.) Transmitter Input Range and Units: Transmitter Output Signal For Flow Instruments: Orifice Plate Bore: Integrator Factor: For Differential Pressure Instruments: Suppression: Elevation: Test Equipment Used Serial No. Manufacturer Chart Factor: Chart Scale: (circle one) Linear – Square Root - Combination Fill Fluid: Fluid Type: Specific Gravity: Model No. Description For I/P Transducer Input Output Calibrated Due Date Input Standard Percent Input Value Output As Found As Left % Error Notes 0 25 50 75 100 Percent Error Calculation: Remarks: Subcontractor Acceptance: Fluor FE/QA Acceptance: Percent Error = “As Found” Output – “Correct” Output x 100 Span Output Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77101 Rev 0 Instrument Calibration Sheet.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77101 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77101 Rev 0 Instrument Calibration Sheet.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 FF77102 Revision 0, 10 June 2013 SAFETY VALVE TRACKING SHEET Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77102A Client Other Turnover System: Sub – System: Manufacturer Model No. Serial No. Calibration Tag Verification Pressure Setting Calibration Date System Status Pre-Hydrotest Post-Hydrotest Date Checked: Reinstatement Complete Calibration Tag Verification Pressure Setting Calibration Date System Status Pre-Hydrotest Post-Hydrotest Reinstatement Complete Calibration Tag Verification Pressure Setting Calibration Date System Status Pre-Hydrotest Post-Hydrotest Reinstatement Complete * Calibration date at turnover must be within 60 days of System turnover date. Subcontractor Name: Signature: Date: Name: Signature: Date: Date Checked: * Date Checked: * Fluor Field Engineering Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77102 Rev 0 Safety Valve Tracking Sheet.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 FF77102 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77102 Rev 0 Safety Valve Tracking Sheet.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77103 Revision 0, 10 June 2013 RELIEF VALVE INSPECTION AND FINAL ACCEPTANCE Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID I77103A Client Other Turnover System: Sub – System: Tag Number Orifice Size Inlet Rating Outlet Rating Set Pressure Manufacturer Model Number Serial Number Type Yes Marking in accordance with API 526 and specification. Connection size and rating in accordance with specification. Material of construction in accordance with specification. Center – To – Face Dimension in accordance with API 526. Set pressure in accordance with specification. Relief valve complies with ASME code requirements. Letter Designation of orifice is in accordance with specification. Relief valve tagged in accordance with Client Practices. No N/A Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77103 Rev 0 Relief Valve Inspection and Final Acceptance.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77103 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77103 Rev 0 Relief Valve Inspection and Final Acceptance.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77104 Revision 0, 10 June 2013 SWITCH CALIBRATION DATA RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: ID F77104 Turnover System: Client Other Sub – System: Location: Specification Sheet No.: Purchase Order No.: Serial No.: Test Equipment Model S/N Item No.: Function Set No. 1 Reset No. 1 Set No. 2 Reset No. 2 Set No. 3 Reset No. 3 Set No. 4 Reset No. 4 If Additional Setpoints, use second Sheet. Remarks: Specified Actual Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77104 Rev 0 Switch Calibration Data Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77104 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77104 Rev 0 Switch Calibration Data Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77105 Revision 0, 10 June 2013 VALVE CALIBRATION DATA RECORD Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Specification Sheet No.: Purchase Order No.: Serial No.: Fail Position: Test Equipment Bench Set: Model Item No.: Tag No.: ID F77105 Turnover System: Client Other Sub – System: Location: Length of travel: S/N Positioner: Manufacturer: Actuator* Input Output (Stem Travel) Positioner Input Output Stem Travel *Not Applicable for Double Acting Cylinders. Limit Switch Tag No.: Remarks: 0% Yes Type: No 50% 100% Open Closed Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77105 Rev 0 Valve Calibration Data Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77105 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77105 Rev 0 Valve Calibration Data Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77106 Revision 0, 10 June 2013 CONTROL SYSTEMS TEST EQUIPMENT CALIBRATION LOG Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Equipment: Model No.: Calibration Frequency: Tag No.: Turnover System: ID F77106 Client Other Sub – System: Location: Last Calibration Date Signature Last Calibration Date Signature Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77106 Rev 0 Control System Test Equipment Calibration Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F77106 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F77106 Rev 0 Control System Test Equipment Calibration Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7800 Revision 0, 10 June 2013 COATINGS AND LININGS SCOPE This procedure describes the inspection, testing, and documentation required to be performed for coatings. RESPONSIBILITIES - Self-Perform ACTIVITY Inspect surface preparation Verify color/type coatings approved Inspect in-process coating/lining Check Thickness Inspect completed coatings Follow-up any deficiencies identities RESPONSIBILITY Supervisor/Construction Engineer/Site Quality Manager Supervisor/Construction Engineer/ Site Quality Manager Supervisor/Construction Engineer/Site Quality Manager Supervisor/Construction Engineer/Site Quality Manager Supervisor/Construction Engineer/Site Quality Manager Supervisor/Construction Engineer/Site Quality Manager DOCUMENTATION 000.509.F78001 000 509 F78001 000 509 F78001 000.509.F78002 000 509 F78001 000 509 F78001 _____ FREQUENCY OF ACTIVITY Daily during life of activity As required by applications Daily during life of activity As required to verify thickness requirements _____ As required to close-out deficiencies RESPONSIBILITIES - Subcontracted Work ACTIVITY Inspect surface preparation Verify color/type coatings approved Inspect in-process coating/lining Check Thickness Inspect completed coatings Follow-up any deficiencies identities RESPONSIBILITY Subcontractor/Construction Engineer/Site Quality Manager Subcontractor/Construction Engineer/Site Quality Manager Subcontractor/Construction Engineer/Site Quality Manager Subcontractor/Construction Engineer/Site Quality Manager Subcontractor/Construction Engineer/Site Quality Manager Subcontractor/Construction Engineer/Site Quality Manager DOCUMENTATION 000.509.F78001 000 509 F78001 000 509 F78001 000.509.F78002 000 509 F78001 000 509 F78001 _____ FREQUENCY OF ACTIVITY Daily during life of activity As required by applications Daily during life of activity As required to verify thickness requirements _____ As required to close-out deficiencies W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7800 Rev 0 Coatings and Linings.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7800 Revision 0, 10 June 2013 PROCEDURE • Surface Preparation Inspections: • Verify the surface preparation is in accordance with the applicable specification. Protect adjacent areas to coating operations from sandblasting and paint overspray. Coating Approval: Verify that color/type of coatings has been approved and documented. Assure pot life of coating products are not exceeded prior to application. • In-process Coating/Lining Inspections: Coatings application shall not be performed during unacceptable weather conditions that violate the specification requirements for application. Inspect the in-process coating's applications, to verify that the work meets the requirements in accordance with the specifications. - • Thickness Verification/Final Inspection: Check dry film thickness of applied coatings in sufficient locations to verify the required thickness has been applied. Document the inspections on Form 000.509.F78001, Coatings Inspection. Perform final coating inspection after acceptable dry film thickness is achieved. Test applied linings in sufficient locations to verify proper surface profile, thickness or lining continuity, using test equipment designated in the specifications. Document the inspections on Form 000.509.F78002. When specifications establish application restrictions for temperature and humidity, perform checks with certified hygrometer and temperature indicator prior to starting each day's work. - - • Follow-up of Deficiencies: Inform craft supervision of any discrepancies on a daily basis. Immediate corrective action should be taken. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7800 Rev 0 Coatings and Linings.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7800 Revision 0, 10 June 2013 FORMS Quality Support Forms: 000.509.F78001 - Coating Inspection Record 000.509.F78002 - Lining Inspection Record ATTACHMENTS Attachment 1 Example – Acceptance Criteria W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7800 Rev 0 Coatings and Linings.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7800 Revision 0, 10 June 2013 Attachment 1 - EXAMPLE - ACCEPTANCE CRITERIA Coatings Inspection Guidelines Minimum Weekly Inspection Areas Storage: Environmental conditions per label Containers undamaged Shelf life not exceeded Pre-Cleaning of Metal Surfaces: Dry and oil free Sufficient lighting Blast material dry and oil free Air Supply clean and dry Post-Cleaning of Metal Surfaces: Surface profile adequate No flash rusting prior to primer Environmental conditions acceptable Coating In-Process: Application equipment acceptable Pot life limits not exceeded WFT/DFT measurements acceptable Repairs made with correct materials W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7800 Rev 0 Coatings and Linings.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78001 Revision 0, 10 June 2013 COATINGS INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: Client Other ID X78001AR Turnover System: Sub – System: Type Object: Piping Item Description of Check 01 02 03 04 Coating by approved manufacturer Surface preparation SSPC-SP value Surface dry-free from condensation Paint mixed, thinned and applied in accordance with manufacturer’s specification Brush Spray Roller Primer in accordance with specification Finish coat is acceptable Workmanship acceptable Tues PM AM PM Wed AM PM Thurs AM PM Subcontractor Fluor FE/QA Structural Steel Equipment Tank Exterior Tank Interior Object Location: Outdoors 05 06 07 Mon AM Indoors Conditions: Relative humidity % Substrate Temperature Ambient Temperature Dew Point Fri AM PM AM Sat PM Brandname Paint Batch No A Base B Hardener Coat No FT Application Method DFT Average Notes: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78001 Rev 0 Coating Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78001 Rev 0 Coating Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78002 Revision 0, 10 June 2013 LININGS INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID X78002AR Client Other Turnover System: Sub – System: Item Description of Check 01 02 Pressure tests have been satisfactorily completed on equipment to be lined. Internal surfaces to be lined have been visually inspected to verify that fabricated weldments are acceptable for lining application in accordance with NAC RP-01-78 or specified standard _______________________. Surface preparation is complete and has been checked with the surface profile comparator in accordance with SSPC-SP5 or specified method _____________ and visually examined in accordance with SSPC VIS-1 or specified standard ____________________. Temperature and humidity of lining area was checked daily with a sling hygromometer and was found to be in temperature and humidity ranges recommended by the manufacturer for application of lining. Mon Tues Wed Thurs Conditions AM PM AM PM AM PM AM PM Subcontractor Fluor FE/QA 03 04 Fri AM PM Sat AM PM Relative humidity % Substrate Temperature Ambient Temperature Dew Point 05 06 07 08 09 Notes: Liquid lining application has been visually inspected and accepted. Sheet or rubber lining installation has been checked with an approved holiday detector and has been accepted or identified; defects have been repaired. Lining thickness has been checked with a nordsen dry film thickness gage or ________________. Average lining thickness: ________________. Vulcanization has been performed satisfactorily. The lining surface has been checked for blisters, open seams, lifted edges, surface defects, pinholes and hardness. Completed linings have been marked in accordance with the specifications. Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78002 Rev 0 Lining Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78002 Rev 0 Lining Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7810 Revision 0, 10 June 2013 INSULATION SCOPE This procedure describes the inspection activities for insulation installation. RESPONSIBILITIES - Self-Perform ACTIVITY Coordination of Release for Insulation Install insulation Inspect in-process installation Inspect completed installation Surveillance NOTE 1: RESPONSIBILITY Discipline Construction Engineer Civil Superintendent Site Quality Manager Site Quality Manager QC Inspection (Note 1) DOCUMENTATION Form 000.509.F78101 _____ Form 000.509.F78101 Form 000.509.F78101 From 000.509.F02201 FREQUENCY OF ACTIVITY Each piece of equipment line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Per Procedure 000.509.0220 Surveillance is not required if the Fluor Quality representative is performing inspections. RESPONSIBILITIES - Subcontracted Work ACTIVITY Coordination of Release for Insulation Install insulation Inspect in-process installation Inspect completed installation Surveillance RESPONSIBILITY Piping Construction Engineer Subcontractor Subcontractor Subcontractor QC Inspection DOCUMENTATION Form 000.509.F78101 _____ Form 000.509.F78101 Form 000.509.F78101 Form 000.509.F02201 FREQUENCY OF ACTIVITY Each piece of equipment, line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Per Procedure 000.509.0220 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7810 Rev 0 Insulation.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7810 Revision 0, 10 June 2013 PROCEDURE • Release for Insulation: The construction engineer will issue the "Release for Insulation" (Form 000.509.F78101) to the insulator and QC, for sign-off prior to insulation. At this time all work will be verified as complete including; hydrostatic tests, and punch list items requiring completion, prior to insulation. • Install Insulation: Insulation shall be installed in accordance with the applicable drawings and specifications. • In-process Inspection for Insulation Activities: No insulation shall begin on a vessel, equipment, or piping until released by the appropriate field supervisor. Obtain a copy of the written release, (Form 000.509.F78101), for the insulation to be installed. Verify the insulation materials are free from damage and shelf life has not expired. Monitor the in-process installation activities to verify that insulation materials are installed in accordance with drawings, specifications, and manufacturer's recommendations. - - • Completed Installation Inspection: Inspect the competed insulation for workmanship and damage. Verify the installation conforms to applicable drawings and specifications, and document on Form 000.509.F78101. FORMS Quality Control Forms: 000.509.F78101 000.509.F78102 Equipment Thermal Insulation Inspection Checklist Piping Thermal Insulation Inspection Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7810 Rev 0 Insulation.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7810 Revision 0, 10 June 2013 INSPECTION REFERENCE INSULATION AND TRACING Verify insulation materials are free from damage Verify insulation materials shelf-life has not expired Insulation support clips installed. Clearances adequate for insulation. Electrical tracing installed. Steam tracing installed. Correct number of tracers. Tracer size correct. Tracer length correct. Trap detail correct. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7810 Rev 0 Insulation.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7810 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7810 Rev 0 Insulation.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78101 Revision 0, 10 June 2013 EQUIPMENT THERMAL INSULATION INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID IC78101A Client Other Turnover System: Sub – System: Release for Insulation Engineer: Inspector: Item Description of Check Date Date Subcontractor Fluor FE/QA Insulation Materials 01 02 03 Proper materials Verify insulation materials are free from damage Verify insulation materials shelf-life has not expired Hot Vessels and Equipment 04 05 06 07 08 Proper material thickness used Proper application at stiffener rings Nameplates left exposed Proper banding and breather springs used Proper use of filler and/or mastic materials Cold Vessels and Equipment 09 10 11 12 13 14 Proper material thickness used Proper insulation of attachments Proper contraction joint at support rings Nameplates left exposed Proper banding used Proper use of filler, joints seals and vapor seal Tank insulation – Hot 15 16 17 18 19 Proper spacing of welded pins for support Proper banding used (insulation/jacketing) Proper expansion system Proper lapping vertically and horizontally Proper use of “S” clips W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78101 Rev 0 Equipment Thermal Insulation Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78101 Revision 0, 10 June 2013 EQUIPMENT THERMAL INSULATION INSPECTION CHECKLIST Item 20 21 22 Description of Check Vertical support bars used on 50’ diameter and larger Proper flashing used per specification details Proper roof (build up) application over insulation ID IC78101A Fluor FE/QA Subcontractor Weatherproofing Hot Equipment 23 24 25 26 27 28 Proper use of weather proofing mastic at fittings Proper banding of metal jacket Proper use of “S” clips on vertical runs Corrugated jacketing on vessel Proper lap and metal screw spacing Proper main shield on vertical vessels Weatherproofing Cold Equipment 29 30 Proper use of vapor barrier mastic paint jacketing No use of screws on cold work except on standing seam systems Acoustical Lagging 31 32 33 34 35 Proper material thickness used Proper application at stiffener Nameplates left exposed Proper banding and breather springs used Proper use of filler and/or mastic materials Removable Covers 36 Notes: Proper stenciling or tagging for identification Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78101 Rev 0 Equipment Thermal Insulation Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78102 Revision 0, 10 June 2013 PIPING THERMAL INSULATION INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID IC78102A Client Other Turnover System: Sub – System: Release for Insulation Engineer: Inspector: **fill out applicable sections as determined by type of insulation** Item Description of Check Subcontractor Fluor FE/QA Date: Date: Insulation Materials 01 02 03 Proper Materials Verify insulation materials are free from damage Verify insulation materials shelf-life has not expired Insulating Hot Piping 04 05 06 07 08 09 10 11 12 13 Proper material thickness used Flanges, flanged valve bodies, bonnets and flanged fittings insulated Minimum clearances between insulation and adjacent surfaces 45 degrees to vertical runs properly supported Service over 454 °C shall be in two layers Joints staggered and proper wire ties Expansion joints spacing horizontal runs correct Proper clearance at flange breaks Tubing properly insulated Proper use of filler and/or mastic materials Insulation Cold Piping 14 15 16 17 18 19 20 21 Proper material thickness used Proper insulation of attachments Contraction joints at specified intervals Proper cradle diameter at supports 45 degrees to vertical runs properly supported Proper use of joints sealer for single and multiple layer applications Proper taping or banding used Proper use of filler materials, sealer and/or vapor barriers Page 1 of 2 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78102 Rev 0 Piping Thermal Insulation Inspection Checklist.doc Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78102 Revision 0, 10 June 2013 PIPING THERMAL INSULATION INSPECTION CHECKLIST Item Description of Check ID IC78102A Subcontractor Fluor FE/QA Weatherproofing Hot Piping 22 23 24 25 26 Proper use of weather proofing mastic at fittings Proper banding of metal jacket Proper use of “S” clips on vertical runs Proper lap and metal screw spacing Proper main shield on vertical vessels Weatherproofing Cold Piping 27 28 Proper use of vapor barrier mastic paint jacketing No use of screws on cold work except on standing seam systems Removable Covers 29 Remarks: Proper stenciling or tagging for identification Subcontractor Name: Signature: Date: Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78102 Rev 0 Piping Thermal Insulation Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7820 Revision 0, 10 June 2013 FIREPROOFING INSPECTIONS SCOPE This procedure prescribes the quality control methods used to verify conformance to design requirements during application of fireproofing. This procedure covers the following classifications of materials: a) b) c) d) e) Shotcrete (gunite) Sprayed Fibrous Sprayed Cementitious Magnesium Oxychloride (sprayed or troweled) Intumescent or Subliming Mastic RESPONSIBILITIES - Subcontracted Work ACTIVITY RESPONSIBILITY DOCUMENTATION 000.509.F78201 000.509.F78202 ----000.509.F78201 000.509.F78201 000.509.F02201 FREQUENCY OF ACTIVITY Daily ----Each installation Each installation Per procedure 000.509.0220 Coordinate release for Construction Engineer fireproofing Install fireproofing Inspect in-process installation Inspect completed installation Surveillance Subcontractor Subcontractor Subcontractor Site Quality Manager NOTE: Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7820 Rev 0 Fireproofing Inspections.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7820 Revision 0, 10 June 2013 PROCEDURE The following steps shall be performed as required by conditions, before preparation, and application of fireproofing. • Surfaces to be Fireproofed are released as follows: The Construction Engineer will initiate a Release for Application of Fireproofing (Form 000.509.F78201) for surfaces to be fireproofed. The Construction Engineer shall be responsible for technical oversight, mix design approval, and qualification of application equipment and crew performance. - • Install Fireproofing: Assure that the mix design, equipment type, and crew qualifications have been approved. Review the Release for Application of Fireproofing for authorization to start work. Fireproofing Subcontractor shall observe recognized safety rules during the work and shall use safe practices including materials, equipment/tools, and rigging/scaffolding. Inspections are to be performed and documented on the Fireproofing Inspection Checklist (Form 000.509.F78201). • Inspect In-Process Installation: Inspect surfaces to be fireproofed for cleanliness. Oil, grease, loose rust, scale, dirt, and other foreign matter shall be removed to assure adequate bonding. Inspect areas not to be fireproofed to assure that they are adequately protected. Monitor application of fireproofing materials to assure the following: a) b) Areas not to receive fireproofing are protected from contamination. Fireproofing materials are applied evenly, without mounds, bald spots, sags, or runs. - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7820 Rev 0 Fireproofing Inspections.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7820 Revision 0, 10 June 2013 • Inspect completed installation: Inspections shall be performed in a timely manner and coordinated with construction and subcontractor schedules and activities. a) b) Cured surfaces contain no cracks, blisters, or delamination. At least once for every 100 square feet (30 m) assure that the dried thickness is as required for the fire-rated protection as shown on the project drawings. - Construction supervision shall be kept informed of the inspection/test activity status including any nonconforming materials or work. Nonconformances shall be reported and dispositioned in accordance with 000.509.0130. • Surveillance of contractor activities: Verify that materials delivered/brought to the site meet the requirements of the Project specifications. Verify that materials are stored in accordance with the manufacturers recommendations. Verify that equipment to be used is in accordance with the material manufacturers recommendations. Verify that any required samples of each type of fireproofing are applied to representative surfaces to establish workmanship standards (Form 000.509.F78202). - - FORMS: Quality Control Forms: 000.509.F02201 - Surveillance Report 000.509.F78201 - Release for Application/Inspection of Fireproofing Checklist 000.509.F78202 - Fireproofing Inspection Preconstruction Checklist W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7820 Rev 0 Fireproofing Inspections.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7820 Revision 0, 10 June 2013 This page intentionally left blank. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78201 Revision 0, 10 June 2013 RELEASE FOR APPLICATIONS OF FIREPROOFING AND INSPECTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Work Package: Inspection Classification Subcontractor Fluor Tag No.: Area/Unit: ID F78201A Client Other Release Turnover System: Sub – System: Area Designation: From Elevation: Requested By: Exclusions/Remarks: Discipline Engineering Release Inspection Drawings: Work Inspected: To Elevation Date Date Item Description of Check 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 Name: Signature: Date: Subcontractor Fluor FE/QA Protection of areas not to be fireproofed Area(s) of surface(s) to be fireproofed Surface preparation Type of fireproofing Brand name (if applicable): Concrete grade: Application method: (not for brickwork) Skirt fireproofing required: Anchorage/reinforcement Slump test performed Compressive strength cylinders prepared Finished/cured surface Material thickness required Material thickness attained Sealing of joints/seams Cleanliness Gunned Formed Inside Outside Trowelled Normal Concrete Insulating Concrete Brickwork Proprietary Subcontractor Fluor Field Engineering Name: Signature: Date: Name: Signature: Date: Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78201 Rev 0 Release for Aplication of Fireproofing Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78201 Rev 0 Release for Aplication of Fireproofing Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78202 Revision 0, 10 June 2013 FIREPROOFING INSPECTION PRECONSTRUCTION CHECKLIST Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID F78202A Client Other Sub – System: Location: This checklist is to be filled out to document shotcrete panels made for mix design approval and subsequent panels made to qualify each application crew (i.e. nozzleman, delivery equipment operator and hoseman). Fireproofing Material and Mix Proportions Used: Panel Size and Description of Reinforcement: Positions of Panel as Shot: A- Horizontal B – Vertical C - Overhead Note: Clearly identify each panel with A, B or C, date completed, material used, nozzleman. Panel No. Position Nozzleman Delivery Equipment Operator Material Used Date Completed Subcontractor Name Signature Date Name Fluor Field Engineering Name Signature Date Fluor QA Signature Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78202 Rev 0 Fireproofing Pre-Construction Inspection Checklist.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78202 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78202 Rev 0 Fireproofing Pre-Construction Inspection Checklist.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7830 Revision 0, 10 June 2013 CATHODIC PROTECTION SCOPE This procedure outlines the inspection activities for subcontracted installation of cathodic protection. Cathodic protection is installed for tank internals, vessel internals, underground structures and piping systems. RESPONSIBILITIES - Subcontracted Work ACTIVITY Verify correct materials are used Verify vessel cathodic protection installed by shop fabricator Install Cathodic Protection Inspect in-process installation Witness hammer test of Thermite welds Witness anode backfill electrical test Inspect completed installation Monitor testing and commissioning Audit documentation Surveillance RESPONSIBILITY Construction Engineer Materials Manager / Site Quality Manager Subcontractor Subcontractor / Site Quality Manager Site Quality Manager Site Quality Manager Subcontractor / Site Quality Manager Field Engineering Site Quality Manager Site Quality Manager 000.509.F02201 DOCUMENTATION ----FREQUENCY OF ACTIVITY Prior to installation Upon receipt of materials ----Daily during life of activity As required As required Once after each installation completed Prior to start-up At completion of each installation Per procedure 000.509.0220 ------ ----000.509.F78301 NOTE 1: NOTE 2: Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. Surveillance is not required if the Fluor Site Quality Manager is performing inspections. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7830 Rev 0 Cathodic Protection.doc Page 1 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7830 Revision 0, 10 June 2013 The Construction Subcontractor is responsible for the quality of the cathodic protection installation and shall perform his own in-process installation inspection and testing procedures and document the results as defined in his contract and Quality Control Program. PROCEDURE General Requirements The following requirements are applicable to underground structures, vessels and tanks. Verify materials being installed conform to the specification requirements and are properly protected from damage. Monitor installation activities for compliance with specification. Inspect the workmanship of the completed cathodic protection for final acceptance. Monitor testing and commissioning activities for compliance with the requirements for inspection and testing established in specifications. Audit cathodic protection documentation to verify completeness, retrievability, timeliness of scheduled inspections and tests, and actions on results. Additional Requirements for Underground Structures Acquire Subcontractor's deep well electrical log data and strata data and submit to the Fluor Project Engineer for determination of anode spacing. Establish in coordination with the Construction Subcontractor and the Fluor Construction Supervisor, a procedure to assure work is not started prior to acceptance of previous work. Monitor the survey made after each cathodic protection system is energized to determine whether it satisfies the criteria for protection listed in the specifications. Monitor deep well preparation activities and verify preparation of the electrical log data and log of strata data obtained during drilling. Monitor anode backfill operation for compliance with specifications. Witness hammer testing of all Thermite weld connections to the structure. Witness electrical test used to determine when the anode is backfilled with coke breeze. Electrical test readings shall be recorded by the subcontractor and copy furnished to Fluor. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7830 Rev 0 Cathodic Protection.doc Page 2 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7830 Revision 0, 10 June 2013 Additional Requirements for Tanks and Vessels Verify that vessel cathodic protection materials were installed by the shop fabricator. Verify the Subcontractor personnel are wearing protective clothing if required for physical protection of the linings in tanks and vessels. When Cathodic Protection is applied to Equipment, record inspection on 000.509.F78301. REFERENCE 000.509.F02201 - Surveillance Report FORMS: Quality Control Forms: 000.509.F78301 - Cathodic Protection Inspection Report W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7830 Rev 0 Cathodic Protection.doc Page 3 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7830 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7830 Rev 0 Cathodic Protection.doc Page 4 of 4 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78301 Revision 0, 10 June 2013 CATHODIC PROTECTION INSPECTION REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: ID F78301 Turnover System: Client Other Sub – System: Location: Drawing No.:/P&ID No. Tag/Line No. Tank Pipe Test Station Origin of Inspection: Termination of Inspection Point: Number of Anode Ends Welded: Test Station No.: Operation Temperature: Anode Type: No. Of Anodes: Weld Area Cleaned: Welds Acceptable: Other : Rev. Sheet No. Is the Anode Ribbon secured to the pipe on 10 – 12 feet centers Notes: - Zinc Ribbon Anodes shall be used for Piping systems operating at or below 140f – Low Temperature System - Magnesium Ribbon Anodes shall be used on Pipes which operate from 141f to 250f - If more than one Anode is specified, each Anode end shall be welded to the Piping. - Reference – 414000-0-SP-4-CP-1 Comments: Date of Inspection: Witnessed by: Subcontractor Name: Signature: Date: Name: Fluor Field Engineering Name: Signature: Date: Fluor QA Signature: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78301 Rev 0 Cathodic Protection Inspection Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F78301 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F78301 Rev 0 Cathodic Protection Inspection Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 WELDING INSPECTION SCOPE This procedure applies to inspection of welds from joint preparation through final acceptance for welding performed to the following codes/standards: • • ASME Section I, "Power Boilers" (FD "QC System Manual for B&PV Code Work" also applies). ASME Section VIII, Division 1, Pressure Vessels (FD "QC System Manual for B&PV Code Work" also applies). ASME B31.1, "Power Piping" ASME B31.2, "Fuel Gas Piping" ASME B31.3, "Chemical Plant and Petroleum Refinery Piping" ASME B31.4, "Liquid Petroleum Transportation Piping Systems" ASME/ANSI B31.5, "Refrigeration Piping" ASME B31.8, "Gas Transmission and Distribution Piping Systems" ANSI/ASME B31.9, "Building Services Piping" ASME B31.11, "Slurry Transportation Piping Systems" ASME B96.1, "Welded Aluminum-Alloy Storage Tanks" API 620, "Recommended Rules for Design and Construction of Large Welded Low Pressure Storage Tanks" API 650, "Welded Steel Tanks for Oil Storage" AWWA D100 (identical to AWS D5.2) "Welded Steel Elevated Tanks, Standpipes, and Reservoirs for Water Storage" ANSI/AWS D1.1, "Structural Welding Code, Steel" ANSI/AWS D1.6 “Structural Welding Code, Stainless Steel” ANSI Z117.1, “Safety Requirements for Working in Tanks and other Confined Spaces” Fluor Practice 000 511 0101, “Certification of Nondestructive Personnel” • • • • • • • • • • • • • • • • W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 1 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 • • Fluor Welding Manual (Self perform work only) Applicable Project Specifications RESPONSIBILITIES - Self-Perform ACTIVITY Assign numbers to field pipe welds RESPONSIBILITY Construction Engineer Welder Foreman Weld Checking and Inspections (Non ASME Code) DOCUMENTATION Each piping isometric drawing Form 000.509.F79001 Daily Welding Report Form 000.509.F79002 Weld Heat Treatment Log Form 000.509.F79001 Daily Welding Report Form 000.509.F79002 Weld Heat Treatment Log Per Fluor "Quality Control System Manual for Boiler & Pressure Vessel Code Work" 000 510 XXXX None Form 000.509.F02201 Form 000.509.F79002 FREQUENCY OF ACTIVITY Each isometric requiring field welds Daily Certified Welding Inspector Welder Foreman Certified Welding Inspector Welder Foreman Daily Weld Checking and Inspections (ASME Code Stamped) Daily Daily Daily See general section Surveillance Certified Welding Inspector W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 2 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Responsibilities - Subcontracted Work ACTIVITY Assign numbers to field pipe welds RESPONSIBILITY Subcontractor Subcontractor Welding Foreman Subcontractor Certified Welding Inspector Subcontractor Welder Foreman Subcontracor Certified Welding Inspector Subcontractor Welder Foreman Subcontractor Certified Welding Inspector Site QC Manager DOCUMENTATION Each piping isometric drawing Form 000.509.F79001 Daily Welding Report Form 000.509.F79002 Weld Heat Treatment Log Form 000.509.F79001 Daily Welding Report Form 000.509.F79002 Weld Heat Treatment Log Per the subcontractor approved Quality Control System Manual for Boiler & Pressure Vessel Code Work FREQUENCY OF ACTIVITY Each isometric requiring field welds Daily Weld Checking and Inspections (Non ASME Code) Daily Weld Checking and Inspections (ASME Code Stamped) Daily Daily None Form 000.509.F02201 Form 000.509.F79002 Form 000.509.F02201 Daily Daily Surveillance Daily PROCEDURE • Assign Numbers to Field Pipe Welds Develop a weld map by assigning identity numbers to all pipe field welds on the isometric drawings, including site pipe shop fabrication welds, prior to the start of work. Number the welds consecutively in the direction of flow, starting with the first weld on each isometric sheet as No. 1, continuing through the last weld on that sheet. If the drawings break at a weld, and the weld appears on both drawings, assign the number on the upstream drawing. If additional welds must be added later to facilitate actual fabrication, the weld locations shall be identified with the next available consecutive number until all additional welds between design welds are identified. A log may be used to identify the weld numbers already assigned to insure that no duplication of weld numbers occur. The inside weld of a slip on flange will carry the suffix "S". Attachment welds, such as shoes or other supports shall be numbered with the next available number using the prefix "X". In the case of a reinforcing pad, all welds will refer to the field weld number joining the branch to header pipe. Use the prefix "PB" and "PH" for pad to branch and pad to header respectively. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 3 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 When straight run pipe is being double jointed on the ground, and it is not certain to which line it belongs, then use the prefix "DJ' before these field welds. Maintain a separate log of "DJ" welds and assign unique numbers starting with DJ-1. "DJ" welds are marked at 180 intervals. Weld maps shall accurately show the final location of all "DJ" welds. Note: Welder, NDE, PMI, PWHT information/results need not appear on the weld map but must be readily traceable to the weld map and placed with the weld map at system completion. Certain things need to be emphasized: Remember that it is of primary importance to assign a unique weld number to all field welding. Once this number is assigned, do not change it for any reason. Do not renumber isometrics to keep the weld numbers consecutive in the direction of flow. Use the next available number for any alterations or additional welds. If a portion of piping containing assigned welds is cut out of a system and discarded do not reuse these weld numbers but note on the isometric that these welds are void and show the new welds on the current isometric revision. Cut shop welds will be assigned field weld numbers. • Visual Check and Acceptance (By Foreman) In-process checking and surveillance of fabrication/erection welding is considered part of the foreman's normal supervisory duties, and includes: welder qualification verification, materials verification, control of welding consumables, joint preparation, fit-up, preheat, interpass heat, weld procedure variables, weld condition between passes, and the appearance of all finished welds. Acceptance criteria is provided by the applicable attachment to this procedure. For all welds in piping systems and for all other welds requiring post weld heat treatment or NDE, the foreman will prepare a "Daily Welding Report" (000.509.F79001) for completed welds to indicate his daily production and to document his visual check and acceptance of each weld. The foreman's signature on this form indicates his acceptance. The foreman provides these reports daily to the Certified Welding Inspector. If a weld is repaired because of rejected radiography, the identity of the repaired weld will maintain the identification number previously assigned except the designation "R1" shall be added after the joint number. A suffix shall designate subsequent repairs of the same welds, such as R2 and R3, until the weld is determined to be acceptable by radiographic examination. If welds are completely cut out the suffix shall be C1, C2, etc. The foreman should identify the first two welds made by a new welder, welding on a system requiring random RT, by noting in the "Remarks" section "1st weld" or "2nd weld" so that these welds can be examined by radiography to confirm welding proficiency in production. • Inspection by the Welding Inspector - (Certification Required) Except as noted below, a minimum of 5% of groove welds shall have fit-up inspection by the inspector. Each welder's work is to be represented. This percentage is to be increased, if necessary, to satisfy the inspector that acceptable workmanship is being achieved. The inspector W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 4 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 should normally be able to achieve adequate fit-up inspections without establishing hold points, but he may request hold points for fit-up inspection of specific joints. The "visually inspected" block on the form is initialed by the inspector to indicate joints on which he performed fit-up/final inspection. The inspector's signature on the Daily Welding Report indicates his acceptance of the completed weld(s). Acceptance criteria are specified by the applicable attachment to this procedure. The inspector should also verify that the Daily Welding Report has been accurately completed and the listed weld joints have been identified with the welder's stamp. The inspector provides these reports daily to the NDE Coordinator for scheduling of NDE. If the inspector considers any of the reported welds to be unacceptable, he will inform the foreman. If it is not repaired prior to turning in the Daily Welding Report, the unacceptable welds are lined out and recorded on a Surveillance Report (000.509.F02201) for tracking to closure. Exceptions to the level of inspection described by this paragraph are provided below: Inspection (By Certified Welding Inspector) is not required for welds in B31.3 Category D piping systems if welds in the system will not be subjected to radiography. Surveillance by procedure 000.509.0220 is adequate for these welds. For ASME B31.3 Category "M", "Severe Cyclic Conditions", longitudinal butt welds and "High Pressure Piping". In addition to the above, all material shall be verified and all fit-ups shall be inspected by the Certified Welding Inspector. - • Surveillance Surveillance as described by procedure 000.509.0220 is to be performed for all welding activities including postweld heat treatment using the applicable attachments to this procedure and the approved PWHT procedure. Surveillance Reports (000.509.F02201) will be prepared for all deficiencies found during surveillance or inspection. Surveillance reports will also be prepared for welds that were not subjected to the inspection described above by the Certified Welding Inspector (i.e., category D piping). W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 5 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 GENERAL Completion of Post Weld Heat Treatment will be documented on "Post- weld Heat Treatment Log" (000.509.F79002). The log is to be provided to the NDE Coordinator for scheduling hardness test if required. Temporary attachments shall be properly removed and areas visually examined. Welds requiring Code Stamping shall be examined and documented in accordance with "Fluor Quality Control System Manual, Boiler and Pressure Vessel Code Work," or the applicable Subcontractors quality program for boiler and pressure vessel code work. Certification of Welding Inspectors shall be performed in accordance with Fluor Procedure 000.511.0101 "Certification of Nondestructive Examination Personnel.", found in the Nondestructive Examination (NDE) Manual – Fluor Enterprises, Inc., 000.511.0000 For welded branch connections, perform final Weld Examination of the branch connection pressure weld prior to the addition of any reinforcing pad or saddle. For welds that will be inaccessible for inspection due to the fabrication process (eg; jacketed pipe, etc.) perform a visual inspection before fabrication renders these welds inaccessible. FORMS Quality Control Forms: 000.509.F02201 - Surveillance Report 000.509.F79001 - Daily Welding Report 000.509.F79002 - Postweld Heat Treatment Log ATTACHMENTS Attachment 1 Attachment 2 Attachment 3 Attachment 4 Attachment 5 Attachment 6 Attachment 7 Attachment 8 Attachment 9 Attachment 10 Attachment 11 Attachment 12 Attachment 13 Attachment 14 Attachment 15 Attachment 16 Attachment 17 Frequency of Visual Examinations Weldolet and Sockolet Fittings Attachment ANSI B16.11 Forged Steel Fittings ASME Section I Acceptance Criteria ASME Section VIII, Division I Acceptance Criteria ASME B31.1 Acceptance Criteria ASME B31.2 Acceptance Criteria ASME B31.3 Acceptance Criteria ASME B31.4 - ASME B31.8 - ASME B31.11 Acceptance Criteria ASME/ANSI B31.5 Acceptance Criteria ANSI/ASME B31.9 Acceptance Criteria ASME B96.1 Acceptance Criteria API 620 Acceptance Criteria API 650 Acceptance Criteria AWWA D100 (Identical to AWS D5.2) Acceptance Criteria ANSI/AWS D1.1 / D1.6 Acceptance Criteria Numbering of Pipe Weld Joints W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 6 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 1 - FREQUENCY OF VISUAL EXAMINATIONS 1.0 ASME SECTION 1 AND VIII, DIVISION 1 1.1 Visual examination frequency shall be in accordance with the Fluor Daniel Quality Control System Manual, Boiler and Pressure Vessel Code Work. 2.0 ASME B31.1 A. Boiler External Piping Visual examination frequency shall be in accordance with Fluor Daniel Quality Control System Manual, Boiler and Pressure Vessel Code Work. B. Non Boiler External Piping All completed welds shall have a visual examination. 3.0 ASME B31.2 3.1 All completed welds shall have a visual examination 4.0 ASME B31.3(B31.3 (1) A. Category "D" Fluid Service Visual examination shall be performed to the extent necessary to satisfy the examiner that components, materials, workmanship and welds conform to the requirements. B. "Normal Service Conditions" 1. Sufficient welds, materials and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. At least 5% of completed welds shall be examined. Each welder's work shall be included. Examine 100% of completed longitudinal welds, except those in components made from a listed specification (i.e., A53B welded pipe, A234 welded fillings). Random examination of the assembly of threaded, bolted, and other joints for conformance to engineering requirements. Random examination of alignment, guides, supports, and cold spring. Examination of erected piping for defects or deviations from engineering design. 2. 3. 4. 5. 6. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 7 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 7. When pneumatic testing is performed, all threaded, bolted, and other mechanical joints shall be examined. C. "Severe Cyclic Conditions" Same as #B above except all fabrication shall be examined. "Category "M" Fluid Service Same as #B above except all fabrication shall be examined. High Pressure Piping Same as #B above except all fabrication shall be examined. In-process weld examination frequency shall be to an extent such that the examiner is satisfied requirements are being met, except where in process inspection takes the place of random radiography required by B31.3 for Normal Fluid Service or Category "M" Fluid Service. The in-process examination in lieu of random radiography must be approved by the Engineer or Owner and shall include a final visual examination. D. E. NOTE(1): 5.0 ASME B31.4 5.1 5.2 5.3 All piping components shall be examined for damage prior to fabrication. All weld joints shall have a fit up, root pass, and final visual examination. All completed welds shall be cleaned and examined prior to coating operations. Irregularities that could damage the pipe coating shall be removed. 6.0 ASME/ANSI B31.5 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. 7.0 ASME B31.8 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 8 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 8.0 ANSI/ASME B31.9 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. 9.0 ASME B31.11 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. 10.0 ASME B96.1 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. 11.0 API 620 All completed welds shall have a visual examination. 12.0 API 650 All completed welds shall have a visual examination. 13.0 AWWA D100 (Identical to AWS D5.2) Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage. 14.0 ANSI/AWS D1.1 All completed welds shall have a visual examination. 15.0 ANSI/AWS D1.6 All completed welds shall have a visual examination. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 9 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 2 Weldolet and Sockolet Fittings Attachment W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 10 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 3 - ANSI B16.11 Forged Steel Fittings W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 11 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 4 - ASME Section I Acceptance Criteria 1.0 ASME SECTION I 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516G70, etc.) and per the Quality Control System Manual, B & PV Code Work (i.e; heat number). Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualification, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. Welding end transitions shall provide for a maximum 30 degree angle across the weld, with respect to the base metal (diameters, or plate thickness) on each side of the weld. Additionally where two thick sections taper down to the weld joint, the minimum angle formed by the O.D. of the base materials shall be 150 degrees. Fit-up and alignment of butt welds shall be in accordance with the WPS and the following where "t" is the nominal thickness of the thinner section at the joint (dimensions in inches). B. C. D. E. F. G. H. I. J. K. L. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 12 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 ALIGNMENT TOLERANCE OF JOINT TO BE BUTT WELDED (Note 1) Direction of Joints in Cylindrical Shells (Inches) Section Thickness (in) Up to 1/2, incl. Over 1/2 to 3/4, incl. Over 3/4 to 1 1/2, incl. Over 1 1/2 to 2, incl. Over 2 Longitudinal 1/4t 1/8 in. 1/8 in. 1/8 in. Lesser of 1/16 t or 3/8 in. (Millimeters) Circumferential 1/4t 1/4t 3/16 in. 1/8t Lesser of 1/8t or 3/4 in. Section Thickness (mm) Up to 12, incl. Over 12 to 19, incl. Over 19 to 38, incl. Over 38 to 50, incl. Over 50 Longitudinal 1/4t 3 3 3 Lesser of 1/16 t or 9.5 Circumferential 1/4t 1/4t 5 1/8t Lesser of 1/8t or 9.5 Note 1: Joints in spherical vessels and within heads and joints between cylindrical shells and hemispherical heads shall meet the requirements above for longitudinal joints in cylindrical shells. M. The depth of insertion of a pipe or tube into a socket or sleeve shall be at least 1/4" (6.3 cm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe or tube and of the socket; and in the case of a sleeve, there shall be at least 1/16" (1.5 mm) clearance between the butting ends of the pipe or tube. The fit between the socket or sleeve and the pipe or tube shall conform to applicable standards for socket weld fittings, and in no case shall the inside diameter of the socket or sleeve exceed the outside diameter of the pipe or tube by more than 0.080" (2 mm). 1.2 Final visual weld examination shall be in accordance with the following: A. B. No porosity allowed. No linear indications such as cracks, lack of fusion, cold laps or incomplete penetration are allowed. No slag or weld spatter allowed (including base material). No unfilled craters allowed (with or without associated shrinkage defects). No underfilled finished weld areas (outside surface of piping and tubing welds). Root concavity is permitted if the depression does not exceed the lesser of 3/32" (2.4 mm) or 20% of the thinner of the sections being joined. The contour of the C. D. E. F. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 13 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 concavity shall be smooth and the resulting thickness of the weld, including any outside reinforcement, shall be at least equal to the required thickness of the thinner section. G. Any allowable off-set on a finished weld shall be faired at a 3:1 taper over the width of the finished section. Additional weld metal may be added beyond edge of weld. Undercut shall not exceed 1/32" (0.8 mm) or 10% of the wall thickness whichever is less, and shall not encroach upon the required section thickness. As-welded surfaces are permitted, the surface of the welds shall be sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and valleys to allow for proper interpretations of NDE and to avoid stress raisers. Fillet weld size shall be a specified on the engineering drawing. Each weld joint shall be identified by one of the following methods: 1. The welder may stamp his identification mark adjacent to all welded joints or he/she may stamp adjacent to a continuous weld or a series of similar joints at intervals of not greater than three (3) feet (1 m). A record of welded joints, including the identification of the welder making the joint, may be used in lieu of stamping. H. I. J. K. 2. L. For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld. Butt weld reinforcement (internal or external) on each weld face shall meet the following: (Inches) M. Nominal Thickness (in) Up to 1/8 Over 1/8 to 3/16, incl. Over 3/16 to 1/2, incl. Over 1/2 to 1, incl. Over 1 to 2, incl. Over 2 to 3, incl. Over 3 to 4, incl. Over 4 to 5, incl. Over 5 Circumferential Joints in Pipe and Tubing (in) 3/32 1/8 5/32 3/16 1/4 Note 1 Note 1 Note 1 Note 1 Maximum Reinforcement (in) Other Welds 3/32 3/32 3/32 3/32 1/8 5/32 7/32 1/4 5/16 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 14 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 (Millimeters) Nominal Thickness (in) Up to 3 Over 3 to 5, incl. Over 5 to 12, incl. Over 12 to 25, incl. Over 25 to 50, incl. Over 50 to 76, incl. Over 76 to 101, incl. Over 101 to 127, incl. Over 127 Note 1: Circumferential Joints in Pipe and Tubing (in) 2.4 3 4 5 6.3 Note 1 Note 1 Note 1 Note 1 Maximum Reinforcement (in) Other Welds 2.4 2.4 2.4 2.4 3 4 5.5 6.3 8 The greater of 1/4 in. (6.3 mm) or 1/8 times the width of the weld in inches. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 15 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 5 - ASME Section VIII, Division I Acceptance Criteria 1.0 ASME Section VIII Division 1 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.) and per the Quality Control System Manual, B & PV code work (i.e.; heat number). Non-pressure parts shall be identified as to type and grade. Review drawing to determine if Charpy Vee Notch testing of base materials and/or weld materials, and production test plates, is required. CMTR’s required for plate material and all material requiring CVN testing. Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualification, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. For ASME Code Stamped items, filler material shall be traceable to the weld joint by AWS Classifications as a minimum. Traceability by heat and lot number to the weld joint is required for CVN vessels and may be required by a site specific specification for other vessels. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. When pressure parts, such as nozzle reinforcing pads, extend over pressure retaining welds, such welds shall be ground flush for the portion of the weld to be covered. Root concavity on the backside of the portion that is ground flush is not permitted. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. In addition, the edges of butt welds shall be held during welding so that the following tolerances (internal and external) are not exceeded. When fitted B. C. D. E. F. G. H. I. J. K. L. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 16 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 girth joints have deviations exceeding the permitted tolerances the joint shall be re-fit until the errors are within the limits specified. For Shells, the maximum out of roundness at any cross section shall not exceed 1% of the nominal diameter. ALIGNMENT TOLERANCES (Inches) Nominal Thickness (t), inch A* Up thru 1/2 1/4t Over 1/2 thru 3/4 1/8 in. Over 3/4 thru 1 1/2 1/8 in. Over 1 1/2 thru 2 1/8 in. Over 2 Lesser of 1/16t or 3/8 in. (Millimeter) Nominal Thickness (t), mm Up thru 12 Over 12 thru 19 Over 19 thru 38 Over 38 thru 50 Over 50 * A* 1/4t 3 3 3 Lesser of 1/16t or 9.5 Joint Categories B,C,D* 1/4t 1/4t 5 1/8t Lesser of 1/8t or 9.5 Joint Categories B,C,D* 1/4t 1/4t 3/16 in. 1/8t Lesser of 1/8t or 3/8 in. Category A joints include all longitudinal joints in shells, heads, transitions, spheres, and circumferential joints connecting hemispherical heads to shells. Category B, C and D include all other joints. M. Any offset within the allowable tolerances shall be faired to a 3 to 1 taper over the width of the finished weld (internally and externally). Additional weld metal may be added. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Where fillet welds are used, the lapped plates shall fit closely and be kept in contact during welding. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm). clearance between the end of the pipe and the internal shoulder of the socketweld fitting. N. 1.2 Final visual weld examination shall be in accordance with the following: A. Both sides (ID and O.D.) of butt welds and other full penetration groove welds shall be inspected. RT examination in lieu of VT of inaccessible I.D. is acceptable. No porosity allowed. B. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 17 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 C. No linear indications such as cracks, lack of fusion, cold laps or incomplete penetration are allowed. No slag or weld spatter allowed (including base material). No unfilled craters allowed (with or without associated shrinkage defects). No underfilled finished weld areas (outside surface of piping and tubing welds). Root concavity shall not reduce the weld below the base material thickness. Any allowable off-set on a finished weld shall be faired at a 3:1 taper over the width of the finished section. Additional weld metal may be added beyond edge of weld. Undercut shall not exceed 1/32 inch (0.8 mm), or 10% of the nominal thickness of the adjoining surface, whichever is less. As-welded surfaces are permitted, the surface of the welds shall be sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and valleys to allow for proper interpretations of NDE and to avoid stress raisers. Fillet weld size shall be a specified on the engineering drawing. Each weld joint shall be identified by one of the following methods: 1. The welder may stamp his identification mark adjacent to all welded joints or he/she may stamp adjacent to a continuous weld or a series of similar joints at intervals of not greater than three (3) feet (1 m). A record of welded joints, including the identification of the welder making the joint, may be used in lieu of stamping. D. E. F. G. H. I. J. K. L. 2. M. For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 18 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 N. Butt weld reinforcement (internal or external) shall meet the following: Maximum Reinforcement (in) Material Nominal Thickness, inch Less than 3/32 (2.4 mm) 3/32" (2.4 mm) thru 3/16 5 mm) Over 3/16 (5 mm) thru ½ (12 mm) Over ½ (12 mm) thru 1 (25 mm) Over 1 thru 2 (25-50 mm) Over 2 thru 3 (50-76 mm) Over 3 thru 4 (76-101 mm) Over 4 thru 5 (101-127 mm) Over 5 (127 mm) Circumferential Joints in Pipe/Tube 3/32 (2.4 mm) 1/8 (3 mm) 5/32 (4 mm) 3/16 (5 mm) ¼ (6.3 mm) ¼ (6.3 mm) ¼ (6.3 mm) ¼ (6.3 mm) 5/16 (8 mm) Other Welds 1/32 (0.8 mm) 1/16 (1.5 mm) 3/32 (2.4 mm) 3/32 (2.4 mm) 1/8 (3 mm) 5/32 (4 mm) 7/32 (5.5 mm) ¼ (6.3 mm) 5/16 (8 mm) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 19 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 6 - ASME B31.1 Acceptance Criteria 1.0 ASME B31.1 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e.; A106B, SA516 G70, etc.) and for Boiler External Piping per the Quality Control System Manual, B & PV code work (i.e.; heat number). Non-pressure parts shall be identified as to type and grade. Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualification, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. For ASME Code Stamped items, filler materials shall be traceable to the weld joint by AWS classification as a minimum. Tracing by heat and lot number to the weld joint may be required by site specific specification. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Note: For piping of over 3% nominal Chromium content fabricated to B31.1, visual for cracks after preheat is interrupted and restarted as permitted by the WPS. F. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Internal misalignment shall not exceed 1/16 (1.5 mm) inch unless the piping design specifically states a different allowable misalignment, in which case, the misalignment over 1/16 inch (1.5 mm) shall be tapered to a 1:3 maximum slope. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. B. C. D. E. G. H. I. J. K. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 20 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 L. Welding end transitions shall provide for a maximum 30 degree angle across the weld, with respect to the base metal on each side of the weld. Additionally, where two thick sections taper down to the weld joint, the minimum angle formed by the O.D. of the base materials shall be 150 degrees. Note: Longitudinal butt welded joints shall be aligned within 1/16 inch (1.5 mm) and inside surface shall not be tapered). The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. M. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting. Gap between O.D. of pipe and socket shall not exceed .040. 1.2 A final visual weld examination shall be in accordance with the following: A. B. C. D. E. F. G. No porosity allowed. No linear indications such as cracks, lack of fusion, cold laps or lack of penetration. No slag or weld spatter (including base material). No unfilled craters allowed (with or without associated shrinkage defects). No under filled (weld cap) areas. Root concavity shall not reduce the weld below the base material thickness. As-welded surfaces are permitted, the surface of the welds shall be sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and valleys to allow for proper interpretations of NDE and to avoid stress raisers. Undercut shall not exceed 1/32 inch (0.8 mm) and shall not reduce the wall thickness below minimum wall requirements (i.e., .875 X nominal wall for schedule pipe, the minimum ordered wall thickness of minimum wall pipe, and nominal wall minimum, minus .01 inch for nominal wall ordered pipe that is made from rolled and longitudinally welded plate). Any offset of outside butt welding surfaces shall be faired to a 30 degrees maximum taper over the width of the weld (excluding reinforcement). Welding end transitions shall be as follows: 1. The wall thickness in the transition region is not less than the minimum wall thickness of the adjoining pipe. Sharp reentrant angles and abrupt changes in slop in the transition region are avoided. H. I. J. 2. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 21 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 3. There is a gradual transition between the two items. The slope of the transition to the weld does not exceed 30 degrees. Weld metal may be added to meet this requirement. K. Butt weld reinforcement thickness shall meet the following: MAXIMUM REINFORCEMENT (in) Thickness of Base Metal Inches Up thru 1/8 (3 mm) Over 1/8 thru 3/16 (3-5 mm) Over 3/16 thru ½ (5-12 mm) Over 1/2 thru 1 (25-19 mm) Over 1 thru 2 (25-50 mm) Over 2 (50 mm) Notes: 1. >750F 1/16 (1.5 mm) 1/16 (1.5 mm) 1/16 (1.5 mm) 3/32 (2.4 mm) 1/8 (3 mm) 5/32 (4 mm) 350-750F 3/32 (2.4 mm) 1/8 (3 mm) 5/32 (4 mm) 3/16 (5 mm) ¼ (6.3 mm) See Note 5 <350F 3/16 (5 mm) 3/16 (5 mm) 3/16 (5 mm) 3/16 (5 mm) ¼ (6.3 mm) See Note 5 For double welded butt joints, the limitation on reinforcement given above shall apply separately to both inside and outside surfaces of the joint. For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the joint only. Internal reinforcement shall not exceed 1/16 inch (1.5 mm) for the GTAW process nor 3/32 inch (2.4 mm) for the SMAW process. The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being joined. The weld reinforcement thicknesses shall be determined from the higher of the abutting surfaces involved. The greater of 1/4 inch (6.3 mm) or 1/8 times the width of the weld in inches. 2. 3. 4. 5. L. Fillet weld sizes shall meet drawing requirements. Weld leg length for socket, slipon flanges and socket fittings shall be 1.09 time the pipe wall thickness for the hub thickness, whichever is less. Weld sizes for branch connections may be found in Figure A. For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld. Each weld shall be identified with the welders symbol or traceable by documentation. N. O. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 22 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 7 - ASME B31.2 Acceptance Criteria 1.0 ASME B31.2, FUEL GAS PIPING 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.). Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualification, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Tack welds shall be made by qualified welders. Tack welds that are to incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. For branch on pipe connections, the opening through the pipe shall align with the bore of the branch within 1/8 inch (3 mm) or one-half the branch wall thickness, whichever is less. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" 1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting. B. C. D. E. F. G. H. I. J. K. L. M. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 23 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 1.2 Final visual weld examination shall be in accordance with the following: A. B. No porosity. No linear indications such as cracks or cold laps or other indications that would compromise weld quality. When accessible for visual inspection, the depth of incomplete root penetration or lack of fusion at the root shall not exceed 1/32 inch or half the thickness of the weld reinforcement (located above the indication) whichever is smaller. The total length of such incomplete root penetration or lack of fusion at the root shall not exceed 1 1/2 inches (38 mm) in any 6 inches (15 cm) of weld length. Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip on flanges and socket fittings shall be 1.4 times the pipe wall thickness or the hub thickness whichever is less but no smaller than 1/8 inch (3 mm). Branch connection weld sizes are shown in Figure A. Undercut shall not exceed 1/32 inch (0.8 mm). *Weld reinforcement shall not exceed the following: COMPONENT REINFORCEMENT Thickness (in.) 1/2" (12 mm) and under Over 1/2" thru 1" (12-25 mm) Over 1" (25 mm) Thickness, Max (in.) 1/8" (3 mm) 5/32" (4 mm) 3/16" (5 mm) C. D. E. F. G. * For double welded joints this limitation or reinforcement shall apply to each surface of the weld separately. H. No under filled (weld cap) areas. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 24 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE A ASME B31.2 WELDED BRANCH DETAILS NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" (6.3 mm) or .7 x Tb Tr = nominal thickness of reinforcement, in. tmin = the smaller of Tb or Tr Tb = nominal thickness of branch wall Th = nominal thickness of header wall Detail (1) w = Tb + tc Detail (2) w = Th + tc Detail (3) w = Tr + tc or Tb + tc Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc w = Governing thickness for determining Postweld Heat Treat. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 25 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 8 - ASME B31.3 Acceptance Criteria 1.0 ASME B31.3, PROCESS PIPING 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e., A106B, SA516 G70, etc.) and heat number (if CVN testing required). Review drawing to determine if Charpy Vee Notch testing of base materials and/or weld materials is required. CMTR’s are required for all material requiring CVN testing. CMTR’s may be required for other piping as designated in a site specification. Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Tracing by AWS Classification, heat and lot number to the weld joint is required for CVN piping and may be required by a site specific specification for other piping. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. For branch on pipe connections, the opening through the pipe shall align with the bore of the branch within 1/8 inch (3 mm) or one-half the branch wall thickness, whichever is less. B. C. D. E. F. G. H. I. J. K. L. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 26 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 M. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting. When accessible for visual inspection, the internal condition of the root pass shall meet Figure A, B, or C as applicable. N. 1.2 Final Visual Weld Examination shall be in accordance with the following: A. Final Visual Weld Examination shall be in accordance with Figure A and B for "Nominal Service Conditions", "Severe Cyclic Conditions" and Category "D" Fluid Service. Category "M" fluid service shall be inspected to "Normal Service Conditions" of Figure A and Figure B. "High Pressure Piping shall be examined in accordance with Figure C. Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip-on flanges shall be a minimum of 1.4 times the pipe wall thickness or the hub thickness whichever is less. For socket welding fittings, other than flanges, the minimum weld leg lengths shall be 1.25 times the pipe wall thickness or 1/8 inch, whichever is greater. Weld sizes for branch connections may be found in Figure D. For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld. Perform Visual Weld Examination prior to other nondestructive examinations and post weld heat treatment. In addition, piping constructed of P3, P4, or P5 material, perform a final visual weld examination after postweld heat treatment. B. C. D. E. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 27 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE A ASME B31.3 WELD ACCEPTANCE CRITERIA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 28 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE B ASME B31.3 WELD ACCEPTANCE CRITERIA NOTES W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 29 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE C ASME B31.3 WELD CRITERIA NOTES AND WELD CRITERIA FOR TABLE K341.3.2A W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 30 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE D ASME B31.3 WELDED BRANCH DETAILS NOTES: here. These sketches show minimum acceptable welds. Welds may be larger than those shown tc = the smaller of 1/4" (6.3 mm) or .7 x Tb Tr = nominal thickness of reinforcement, in. tmin = the smaller of Tb or Tr Tb = nominal thickness of branch wall Th = nominal thickness of header wall Detail (1) w = Tb + tc Detail (2) w = Th + tc Detail (3) w = Tr + tc or Tb + tc Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc w = Governing thickness for determining Postweld Heat Treat. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 31 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 9 - ASME B31.4 - ASME B31.8 - ASME B31.11 Acceptance Criteria 1.0 ASME B31.4, "LIQUID PETROLEUM TRANSPORTATION PIPING SYSTEMS" ASME B31.8, "GAS TRANSMISSION AND DISTRIBUTION PIPING SYSTEMS" ASME B31.11, "SLURRY TRANSPORTATION PIPING SYSTEMS" 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e., A106B, SA516 G70, etc.) Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Details for unequal wall thickness are shown in Figure A. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. For branch on pipe connections, the opening through the pipe shall align with the bore of the branch within 1/8 inch (3 mm) or one-half the branch wall thickness, whichever is less. B. C. D. E. F. G. H. I. J. K. L. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 32 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 M. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting. Shallow crater cracks located at the stopping point of weld beads, and that are 5/32 inch (4 mm) or less in length are acceptable. * 1.2 Final Visual Weld Examination shall be in accordance with the following: A. Porosity is unacceptable when: 1. 2. The size of an individual pore exceeds 1/8 inch (3 mm). The size of an individual pore exceeds 25 percent of the thickness of the thinner member joined. For cluster porosity that occurs in the weld cap, if the diameter exceed 1/2 inch (12 mm) or, the group length in any continuous 12 inch (30 cm) length of weld exceeds 1/2 inch (12 mm) or, an individual pore within a cluster exceeds 1/16 inch (1.5 mm). 3. B. Incomplete penetration and incomplete fusion is unacceptable when: 1. 2. The length of an individual indication exceeds 1 inch (25 mm). The group of indications in any continuous 12 inch (30 cm) length of weld exceeds 1 inch (25 mm). The group of indications exceeds 8 percent of the weld length in any weld less than 12 inches (30 cm) in length. 3. C. Incomplete penetration due to high-low fit-up shall be unacceptable when: 1. 2. The length of an individual indication exceeds 2 inches (50 mm). The group of indications in any continuous 12 inch (30 cm) length of weld exceeds 3 inches (76 mm). D. Burn through (a portion of the root bead where excessive penetration has caused the weld puddle to be blown into the pipe) is unacceptable when: 1. The maximum dimension exceeds 1/4 inch (6.3 mm) and the internal root concavity is less than the thinnest adjacent base metal. The maximum dimension exceeds the thinner of the nominal wall thickness joined and the internal root concavity is less than the thinnest adjacent base metal. 2. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 33 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 3. If more than one burn-through is present, the sum of the maximum dimensions of separate burn-through exceeds 1/2 inch (12 mm) in any continuous 12 inch (30 cm) length of weld or the total weld length, whichever is less and the internal root concavity is less than the thinnest adjacent base metal. For pipe with an outside diameter less than 2 3/8 inch (6 cm), if more than one burn-through is present and the internal root concavity of more than one of the burn-through exceed that of the thinnest adjacent base metal. E. Undercut adjacent to the weld cap (external) or root pass (internal) is unacceptable when: 1. The group length of external and internal in combination in any continuous 12 inch (30 cm) length of weld exceeds 2 in. (50 mm). The group length of external and internal in combination exceeds one sixth of the total weld length. 2. F. Maximum dimensions of undercutting 1. Undercut depth shall not exceed 1/32 inch (0.8 mm) or 12 1/2% of the pipe wall thickness whichever is smaller. Undercut depth shall not exceed 1/64 inch (0.4 mm) or 6% to 12.5% of pipe wall thickness whichever is smaller for a maximum length of 2 inches (50 mm) in a continuous 12 inch (30 cm) weld length or 17% of the weld length, whichever is smaller. 2. G. Accumulation of Discontinuities excluding incomplete penetration due to high-low and undercutting, are unacceptable when: 1. The group length of indications in any continuous 12 inch (30 cm) length of weld exceeds 2 inches (50 mm). The group length of indications exceeds 8 percent of the weld length. 2. H. I. The weld cap (weld reinforcement) shall not exceed 1/16 inch 1.5 mm). Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip on flanges and socket fittings shall be 1.4 times the pipe wall thickness or the hub thickness whichever is less but no smaller than 1/8 inch (3 mm). Branch connection details and weld sizes are shown in Figures B, C, D, E, and F. For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld. Perform visual weld examination prior to other nondestructive examinations and postweld heat treatment. J. K. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 34 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE A ASME B31.4 - B31.8 - B31.11 WELD DETAILS FOR UNEQUAL WALL THICKNESS W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 35 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE B ASME B31.4 - B31.8 - B31.11 BRANCH CONNECTION DETAILS WITHOUT REINFORCEMENT W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 36 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE C ASME B31.4 - B31.8 - B31.11 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 37 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 10 - ASME/ANSI B31.5 Acceptance Criteria 1.0 ASME B31.5, REFRIGERATION PIPING 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.). Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be back-gouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. For branch on pipe connections, the opening through the pipe shall align with the bore of the branch within 1/8 inch (3 mm) or one-half the branch wall thickness, whichever is less. B. C. D. E. F. G. H. I. J. K. L. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 38 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 M. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting. When accessible for visual inspection, the internal condition of the root pass shall meet Figure A and B "Normal Service Conditions". N. 1.2 Final Visual Weld Examination shall be in accordance with the following: A. Final Visual Weld Examination shall be in accordance with Figure A and B for "Nominal Service Conditions". Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip-on flanges shall be a minimum of 1.4 times the pipe wall thickness or the hub thickness whichever is less. For socket welding fittings, other than flanges, the minimum weld leg lengths shall be 1.25 times the pipe wall thickness or 1/8 inch (3 mm), whichever is greater. Weld sizes for branch connections may be found in Figure C. For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld. Perform Visual Weld Examination prior to other nondestructive examinations and postweld heat treatment. B. C. D. E. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 39 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE A ASME B31.5 WELD ACCEPTANCE CRITERIA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 40 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE B ASME B31.5 WELD ACCEPTANCE CRITERIA NOTES W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 41 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE C ASME B31.5 WELDED BRANCH DETAILS NOTES: here. These sketches show minimum acceptable welds. Welds may be larger than those shown tc = the smaller of 1/4" (6.3 mm) or .7 x Tb Detail (1) w = Tb + tc Detail (2) w = Th + tc Detail (3) w = Tr + tc or Tb + tc Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc w = Governing thickness for determining Postweld Heat Treat. Tr = nominal thickness of reinforcement, in. tmin = the smaller of Tb or Tr Tb = nominal thickness of branch wall Th = nominal thickness of header wall W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 42 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 11 - ANSI/ASME B31.9 Acceptance Criteria 1.0 ASME B31.9, BUILDING SERVICES PIPING 1.1 In process examination shall meet the following: A. B. C. D. E. All base materials shall be identified as to type and grade (i.e; A53B, A570, etc.). Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be back-gouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lag, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. For branch on pipe connections, the opening through the pipe shall align with the bore of the branch within 1/8 inch (3 mm) or one-half the branch wall thickness, whichever is less. The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4" (6.3 mm). Before welding, there shall be at least 1/16" (1.5 mm) clearance between the end of the pipe and the internal shoulder of the socketweld fitting. F. G. H. I. J. K. L. M. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 43 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 1.2 Final Visual Examination shall be in accordance with the following: A. B. No porosity. No linear indications such as cracks or cold lap or other indications that would compromise weld quality. Lack of fusion. The length of un-fused areas shall not be more than 20% of the total length of the weld and no more than 1 1/2 inches (38 mm) in any 6 inch (15 cm) weld length. Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip on flanges and socket fittings shall be 1.1 times the wall thickness or the hub thickness whichever is less, but not less than 1/8 inch (3 mm). Branch connection weld sizes are shown in Figure A. Undercut shall not exceed 1/32 inch (0.8mm) or 12 1/2% of the wall thickness whichever is less. Weld reinforcement shall not exceed 3/16 inch (5 mm). When accessible for inspection, inside root penetration shall not exceed 1/8 inch (3 mm). C. D. E. F. G. H. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 44 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 FIGURE A ASME B31.9 WELDED BRANCH DETAILS NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" (6.3 mm) or .7 x Tb Tr = nominal thickness of reinforcement, in. tmin = the smaller of Tb or Tr Tb = nominal thickness of branch wall Th = nominal thickness of header wall Detail (1) w = Tb + tc Detail (2) w = Th + tc Detail (3) w = Tr + tc or Tb + tc Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc w = Governing thickness for determining Postweld Heat Treat. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 45 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 12 - ASME B96.1 Acceptance Criteria 1.0 ASME B96.1, "Welded Aluminum-Alloy Storage Tanks" 1.1 In process examination shall meet the following: A. B. C. D. E. All base materials shall be identified as to type and grade (i.e.; 6061, 6063, etc.). Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualification, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Tack welds shall be made by qualified welders. Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. F. G. H. I. J. K. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 46 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 1.2 Final Visual Examination shall be in accordance with the following: A. B. No porosity. No linear indications such as cracks or cold lap or other indications that would compromise weld quality. Undercut shall not exceed 1/32 inch (0.8 mm). Fillet weld sizes shall meet drawing requirements. Perform visual weld examination prior to other nondestructive examinations. Weld reinforcement shall not exceed the following. MAXIMUM HEIGHT OF REINFORCEMENT ABOVE PLATE SURFACE 3/32" (2.4 mm) 1/8" (3 mm) 3/16" (5 mm) C. D. E. F. PLATE THICKNESS, INCHES 3/8 inch (9.5 mm)or less Greater than 3/8 inch to 3/4 inch (9.5-19 mm) Greater than 3/4 inch (19 mm) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 47 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 13 - API 620 Acceptance Criteria 1.0 API 620, "DESIGN AND CONSTRUCTION OF LARGE WELDED LOW PRESSURE STORAGE TANKS" 1.1 In process examination shall meet the following: A. All base materials shall be identified as to thickness, type, and grade (i.e., A53B, A516 GR70, etc.), and identified by the mill heat number. Prior to cutting, the heat number shall be transferred by steel stamping. On plates less than 1/4 inch (6.3 mm) thick steel stamping shall not be used. CMTR’s are required for plate material. Review drawing to determine if CVN testing is required. Joint preparation and cleanliness shall be in accordance with the WPS. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Tracing by AWS Classification, heat and let number to the weld joints is required for CVN applications. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up, shall be in accordance with the WPS except misalignment of butt welds shall not exceed 1/16” (1.5 mm) for <=1/4” (6.3 mm) and 1/8” (3 mm) (or 25% plate thickness whichever is less) for plates over ¼” (6.3 mm). Do not taper plate joints. Tack welds shall be made by qualified welders. Tack welds in butt joints to be welded manually shall be removed before welding. Tack welds in lap and fillet welded joints need not be removed provided they are free of cracks, slag, porosity, lack of fusion, cold lap, and the ends prepared by grinding for incorporated into the next weld pass. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. B. C. D. E. F. G. H. I. J. K. L. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 48 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 2.0 Final Visual Examination shall be in accordance with the following: A. Surface porosity does not exceed one cluster (one or more pores) in each 4 inches (10 cm) of length and the maximum diameter of each cluster or pore does not exceed 3/32 inch (2.4 mm). No linear indications such as cracks or cold lap or other indications that would compromise weld quality. Undercut does not exceed: 1. 1/64 inch (0.4 mm) for longitudinal butt joints and for welds that attach nozzles, manholes, and clean out openings. 1/32 inch (0.8 mm) for circumferential butt joints. B. C. 2. D. E. F. G. No lack of fusion. No overlaps or abrupt ridges or valleys. No underfilled (weld cap) areas. Weld reinforcement (internal or external), where RT is not required, shall meet the following: PLATE THICKNESS (INCHES) MAXIMUM THICKNESS OF REINFORCEMENT (INCHES) 1/2 inch (12 mm) or less Over 1/2 inch to 1 inch (12-25 mm) Over 1 inch (25 mm) H. Vertical Joints 3/32 (2.4 mm) 1/8 (3 mm) 3/16 (5 mm) Horizontal Joints 1/8 (3 mm) 3/16 (5 mm) ¼ (6.3 mm) Where RT is required, weld reinforcement shall not exceed 1/16” (1.5 mm) for plates <=1/2” (12 mm), 3/32” (2.4 mm) for plates over ½” (12 mm) through 1” (25 mm), and 1/8” (3 mm) for plates over 1” (25 mm) thickness. Weld repairs shall be feathered to a 4:1 taper. I. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 49 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 14 - API 650 Acceptance Criteria 1.0 API 650 "Welded Steel Tanks for Oil Storage" 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.) and identified by the mill heat number if CMTR’s are required by drawing or purchase order. Review drawing to determine if CVN testing is required, (if so, CMTR’s are required). Joint preparation and cleanliness shall be in accordance with the WPS. Edges of Plates to be welded shall not be manually gas cut. Vertical joints shall be staggered a minimum of five times the plate thickness. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Tracing by AWS Classification heat and lot number to the weld joint is required for CVN applications. Low Hydrogen electrodes are required for SMAW when welding: 1. 2. 3. Attachment of the first shell course to the bottom or annular plates. For shell courses over ½” (12 mm) thick made from material Groups I – III. For all welds, including temporary and permanent attachments, in shell courses made of material from Groups IV – VI. B. C. D. E. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up shall be in accordance with the WPS except misalignment of vertical buttwelds for plates over 5/8” (16 mm) shall not exceed the lesser of 1/8” (3 mm) or 10% of the plate thickness, and shall not exceed 1/16” (1.5 mm) for plates 5/8” (16 mm) or less. For horizontal butt joints, the upper plate shall not project over the lower plate by more than the lesser of 1/8” (3 mm) or 20% of the plate thickness for plates 5/16” (8 mm) and over. For plates under 5/16” (8 mm), the projection shall not exceed 1/16” (1.5 mm). Do not taper plate joints. Tack welds shall be made by qualified welders. Tack welds in vertical butt joints to be manually welded shall be removed before welding. Tack welds in horizontal butt joints, lap and fillet welded joints need not be removed. Provided they are free of cracks, slag, porosity, lack of fusion, cold lap and the ends prepared by grinding for incorporation into the next weld pass. F. G. H. I. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 50 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 J. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. K. L. 1.2 Final Visual Examination shall be in accordance with the following: A. B. No porosity. No linear indications such as cracks or cold lap or other indications that would compromise weld quality. Undercut does not exceed: 1. 1/64 inch (0.4 mm) for vertical butt joints and for welds that attach nozzles, manholes, clean out openings and permanent attachment. 1/32 inch (0.8 mm) for horizontal butt joints. C. 2. D. Surface porosity does not exceed one cluster (one or more pores) in any 4 inches (10 cm) of length and the diameter of each cluster or pore does not exceed 3/32 inch (2.4 mm). No lack of fusion. No under-filled (weld cap) areas. Weld reinforcement (internal or external) shall meet the following: PLATE THICKNESS (INCHES) MAXIMUM THICKNESS OF REINFORCEMENT (INCHES) E. F. G. 1/2 inch (12 mm) or less Over 1/2 inch to 1 inch (12-25 mm) Over 1 inch (25 mm) H. Vertical Joints 3/32 (2.4 mm) 1/8 (3 mm) 3/16 (5 mm) Horizontal Joints 1/8 (3 mm) 3/16 (5 mm) ¼ (6.3 mm) Where RT is required, weld reinforcement shall not exceed 1/16” (1.5 mm) for plates <= ½” (12 mm), 3/32” (2.4 mm) for plates over ½” (12 mm) through 1” (25 mm), and 1/8” (3 mm) for plates over 1” (25 mm) thickness. Areas where temporary attachments have been removed shall be ground smooth and visually inspected. Peaking at vertical joints and banding at horizontal joints shall not exceed ½” (12 mm) when using a 36” (1 m) sweep board (for vertical joints, the sweep board must meet tank curvature). Page 51 of 58 I. J. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 15 - AWWA D100 (Identical to AWS D5.2) Acceptance Criteria 1.0 AWWA D100 (identical to AWS D5.2) "Welded Steel Elevated Tanks, Standpipes, and Reservoirs for Water Storage" 1.1 In process examination shall meet the following: A. All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.). Joint preparation and cleanliness shall be in accordance with the WPS. Straight edges of plates to be welded shall not be manually cut with oxy-fuel methods. Check welder qualifications, base material for conformance to the WPS. Welding filler materials shall be in accordance with the WPS. Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Fit-up shall be accordance with WPS except misalignment of vertical (and other primary stress joints) butt-welds for plates over 5/8” (16 mm) shall not exceed the lesser of ¼” (6.3 mm) or 10% of the plate thickness, and shall not exceed 1/16” (1.5 mm) for plates 5/8” (16 mm) or less. For horizontal (and other secondary stress joints) butt joints for plates over 5/8” (16 mm) shall not exceed the lesser of 3/8” (9.5 mm) or 20% of the plate thickness. And shall not exceed 1/8” (3 mm) for plates 5/8” (16 mm) and less. Do not taper plates. Tack welds shall be made by qualified welders and visually inspected. The separation between lap joints shall not be greater than 1/16 inch (1.5 mm). Where separation occurs, the weld size shall be increased by the amount of separation. The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding. Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality. Arc strikes shall be properly removed and areas visually examined. B. C. D. E. F. G. H. I. J. K. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 52 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 1.2 Final Visual Examination shall be in accordance with the following: A. B. C. No cracks. No porosity. Undercut does not exceed: 1. 2. D. E. 1/64 inch (0.4 mm) for vertical joints (lap or butt weld). 1/32 inch (0.8 mm) for horizontal joints (lap or butt weld). No lack of fusion. No linear indications such as cracks or cold lap or other indications that would compromise weld quality. No underfilled (weld cap) areas. Weld reinforcement, internal and external, shall not exceed the following: F. G. Plate Thickness (Inches) ½ inch (12 mm) and less Over 1/2/ inch to 1 inch (12-25 mm) Over 1 inch (25 mm) Maximum Thickness of Reinforcement (Inches) Vertical Joints Horizontal Joints 3/32” (2.4 mm) 1/8” (3 mm) 1/8” (3 mm) 3/16” (5 mm) 3/16” (5 mm) 1/4” (6.3 mm) H. Welder’s identification shall be stamp (low stress stamps) adjacent to the weld at intervals not to exceed 3 feet (1 m)or the constructor may supply a record of welders employed on each joint. Peaking at vertical joints and banding at horizontal joints shall not exceed ½” (12 mm) when using a 36” (1 m) sweep board (for vertical joints, the sweep board must meet tank curvature). I. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 53 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 16 - ANSI/AWS D1.1 / D1.6 Acceptance Criteria 1.0 ANSI/AWS D1.1, STRUCTURAL WELDING CODE-STEEL (STATICALLY LOADED) ANSI/AWS D1.6, STRUCTURAL WELDING CODE-STAINLESS STEEL (STATICALLY LOADED) 1.1 In process weld examination shall meet the following: A. Joint preparation shall be in accordance with the WPS. Full and complete information regarding location, type, size, and extent of all welds shall be clearly shown on the drawings. The drawings shall clearly distinguish between shop and field welds. Fit-up, cleanliness and alignment of butt welds shall be in accordance with the WPS. Backing bar gap shall not exceed 1/6 inch (1.5 mm). Fillet weld fit-up gap shall meet the WPS unless otherwise specified on the drawing. If the gap is greater than 1/16 inch (1.5 mm), the leg of the fillet weld shall be increased by the amount of the root opening. Check welder qualification, filler material for conformance with the WPS. For butt welding parts of unequal thickness, the joint preparation shall provide for a transition at a taper not-to-exceed 1:2 1/2. Chamfering of the parts shall be a specified on the drawing, otherwise the taper shall be accomplished across the weld joint. Parts to be butt welded shall not exceed a mismatch of 10% of the thinner of the two members being joined, but in no case more than 1/8" (3 mm). In correcting misalignment, the parts shall be drawn in to a slope not greater than 1/2 inch (12 mm) in 12 inches (30 cm). In addition, where the thicknesses of the two members being joined differ, the weld and/or base materials are to be tapered to a smooth transition with slop not-to-exceed 1 inch 2 1/2 inches. B. C. D. E. F. 1.2 Final Visual Weld Examination shall be in accordance with the following: A. B. C. D. E. F. No porosity. No linear indications such as cracks, lack of fusion, cold laps. No slag or weld spatter (including base material). No craters except for ends of intermittent fillet welds outside their effective length. No under filled areas. Undercut: AWS D1.1 – For material less than 1” (25 mm) thick, undercut shall not exceed 1/32” (0.8 mm) except a maximum of 1/16’ (1.5 mm) is permitted for an accumulated length of 2” (50 mm) in any 12” (30 cm). For material equal to or greater than 1’ (30 cm), undercut shall not exceed 1/16” (1.5 mm) for any length of weld. AWS D1.6 – For material less than 3/16” (5 mm), undercut shall not exceed Page 54 of 58 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 .010” (0.25 mm). For material equal to 3/16” (5 mm) and less than 1” (25 mm), undercut shall not exceed 1/32” (0.8 mm). 1/16” (1.5 mm) undercut is permitted for an accumulated length of 2” (50 mm) in any 12” (30 cm) for material greater than ½’ (15 cm) thick. G. H. Butt weld reinforcement shall not exceed 1/8 inch (3 mm). Convexity of a fillet weld shall not exceed .07 times the actual width, plus .06 inch (1.5 mm). Any offset of outside surfaces shall be faired to a 1:2 1/2 taper over the width of the weld. In any single continuous fillet weld the actual size may be less than the specified size by not more than 1/16 inch (1.5 mm) provided that the undersize portion does not exceed 10 percent of the weld length. On web-to-flange welds on girders, no under-run is permitted at the ends for a length equal to twice the width of the flange. NOTE: Visual examination for A514 and A517 steels shall be performed not less than 48 hours after completion of the weld. I. J. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 55 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 Attachment 17 - Numbering of Pipe Weld Joints All pressure retaining welds and attachment welds to pressure piping shall be given a unique number which will serve to identify all data concerning the weld. 1.0 Field Welds - All pressure retaining piping welds and attachment welds shall be numbered. Upon receipt of the isometric drawings or layout piping plans, the Site Quality Manager shall (if possible) pre-number all field welds. If this pre-numbering proves impractical, the Welding Inspector shall assign weld numbers as the welds are made. A Log may be used to identify the weld numbers already assigned to ensure that no duplication of weld numbers occurs. Certain things need to be emphasized: Remember that it is of primary importance to assign a unique weld number to all field welding. Once this number is assigned, do not change it for any reason. Do not renumber isometrics to keep the weld numbers consecutive in the direction of flow. Use the next available number for any alterations or additional welds. If a portion of piping containing assigned welds is cut out of a system and discarded do not reuse these weld numbers but note on the isometric that these welds are void and show the new welds on the current isometric revision. Cut shop welds will be assigned field weld numbers. If the shop weld and mark piece can be identified, note this in the remarks portion of the Daily Welding Report. 1.1 SOCKET WELDS, HALF COUPLINGS, WELDOLETS (UNDER 2" or 5 cm) All socket welds shall be numbered by isometric drawing. Each sheet shall start with weld 1 and be numbered with the flow. In the event that additional welds are added, use the next numbers not previously used on each sheet for the new welds. In this manner all socket welds will have a single digit or two digit weld number. Half couplings and weldolets (under 2" or 5 cm) shall also have a single digit or two digit weld number assigned by isometric drawing. In other works, the numbering of a series of half coupling on a header will be welds 1, 2, 3 etc. on the main header line number which shows these welds. The socket welds on lines running from these half couplings will be numbered as described above, for each line number. 1.2 BUTT WELDS, BRANCH CONNECTIONS (2" or 5 cm AND OVER), WELDOLETS (2" or 5 cm AND OVER) ETC. All butt welds, mitre welds, branch connections (2" or 5 cm and over), weldolets (2" or 5 cm and over) and slip-on flanges shall have a three digit weld number running consecutively throughout all lines contained in the modification. Each modification shall begin with weld 001 and numbered with the flow to the end of the line. Additional lines should continue with the next number and progress until all such welds are numbered. A log attached to the field welding isometric package should readily identify the last weld number used. If additional welds are needed, the next unused numbers will be assigned and logged. On modifications where it is not practical to pre-number the welds, the next consecutive number, as determined by the log, shall be used as the welding progresses. 1.3 ATTACHMENT WELDS Attachment welds shall be numbered using the nearest (upstream) piping weld as a part of the weld number with the suffix "X1". In other words, a shoe welded between welds 021 and 022 will be numbered 021X1. Additional attachment welds in this area will be W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 56 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 numbered 021X2 and 021X3, etc. In the common case of a reinforcing pad, all welds will refer to the field weld number joining the pipe-to-branch pipe. The pad-to-branch pipe weld will be "X1". In other words, the stub-in weld will be a three digit weld number, say 007, with the pad-to-branch pipe weld 007X1 and the pad-to-main pipe weld 007X2. 1.4 DOUBLE-JOINTED PIPE When straight run pipe is being double jointed on the ground, and it is not certain which line it belongs t, then use the prefix "DJ" before these field welds. Maintain a separate log of "DJ" welds that is unique to the "DJ" number using Exhibit 9-7R, Welding/NDE Status Log (Double Joints). In other words, there will only be on DJ-1 on the entire job. Ensure each "DJ" weld is marked twice at 120 intervals. Weld maps shall accurately show the final location of all "DJ" welds. Each isometric drawing shall have Exhibit 9-6R, Welding/NDE Status Log, attached over the Bill of Material section. This log must be maintained on a daily basis as it will serve as a complete summary of all NDE/PWHT performed on that portion of the line. This information is essential when the time comes to provide NDE clearance for test packages. 2.0 Pipe Shop Welding - All welds on piping fabricated in the Site Pipe Shop shall be given a unique number by the Pipe Shop Supervisor prior to fabrication. All mark pieces shown on an isometric drawing shall be assigned consecutive numbers beginning with the lowest numbered mark piece and numbered with the flow until all shop welds on all mark pieces on the isometric have been identified. Any additional welds on any mark piece shall be given the next unassigned number on the isometric. In other words the first weld on the first mark piece will be "SW1" and continuing throughout all mark pieces on the isometric drawing. Thus the unit number, line number sheet number, mark piece number and weld number will constitute an unique weld identification as required. 2.1 Double Jointed Welds - All random length piping being welded by the Site Pipe Shop into double (or triple) lengths for ease in field erection shall be given a unique number. If the line number and line class are unknown at the time of fabrication these welds shall be given consecutive four digit weld numbers prefixed by "DJ". A log shall be maintained by the Pipe Shop Supervisor of the "DJ" weld numbers used to prevent duplication of weld numbers. All "DJ" weld numbers shall be hard stamped or etched across the weld in two locations 120 degrees apart, 60 either side of the welders stamp. These "DJ" welds shall be radiographed 100 % and stockpiled for eventual use. These welds will be tracked as "Unassigned Welds" and transferred when the actual modification, line number and class are known. All random length piping being double (or triple) jointed in the Site Pipe Shop where the modification number, line number and line class are known at the time of fabrication shall be given consecutive three digit shop weld numbers beginning with SW100 and numbered consecutively within that particular modification. These welds will be subject to the normal shop weld NDE requirements and welder control based on the line class requirements. These weld numbers shall be hard stamped or etched as described above with the exception of "DJ" prefix which will be "SW" in this case. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 57 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7910 Revision 0, 10 June 2013 All random length piping double (or triple) jointed in the field for installation on a particular modification where the line number and line class are known shall be given consecutive field weld numbers within the modification. These numbers shall be hard stamped or etched by the Piping Supervisor for eventual location in the piping system. These welds shall be subject to the normal NDE and welder control for the line class at the time of production. 2.1.1 Piping Drawings All field welds on pressure piping (both pressure retaining and attachment welds) shall be accurately located on the isometric drawing (or plot plan). Since other records will show the welder and the date or production (Daily Welding Report, Line Welding and NDE Record) this information is not necessary to include on the drawing. Double joint ("DS") random length pipe welds shall be accurately shown on the isometric, rack, or plot plan drawings in relation to the field tie-in welds. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7910 Rev 0 Welding Inspection.doc Page 58 of 58 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 SURVEILLANCE REPORT Location Subcontractor/Activity Date Completed Work Yes No ID A02201 Report No. Inspection Checklist, Specification, Or Drawing Used As Reference: RESULTS: Follow-up Required Description Of Item/Work Inspected/Observed: Satisfactory Observations/Deficiency: Surveillance Personnel/Date Site Quality Manger/Date Person Notified Of Deficiency Name Recommended Corrective Action: Title Corrective Actions Implemented/Accepted: Surveillance Personnel/Date Site Quality Manager/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F02201 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F02201 Rev 0 Surveillance Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79001 Revision 0, 10 June 2013 DAILY WELDING REPORT Subcontractor Unit Line No. Line Class Sheet No. Weld No. Type Weld Area Size Wall Thick. Welder Symbol Process Root Bal Fit-Up Visual Inspected ID W79001 Remarks Foreman Welding Inspector Date Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79001 Rev 0 Daily Welding Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79001 Rev 0 Daily Welding Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79002 Revision 0, 10 June 2013 POST WELD HEAT TREATMENT LOG Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID W79002 Client Other Sub – System: Location: Log No. Line No. Line Class Sheet No. Mark No. Weld No. Weld Type Circuit No. Completion Date Initials Welding Supervisor: Inspector: Subcontractor Name Signature Date Name Signature Date Date: Date: Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79002 Rev 0 Post Weld Heat Treatment Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79002 Rev 0 Post Weld Heat Treatment Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7920 Revision 0, 10 June 2013 NONDESTRUCTIVE EXAMINATION SCOPE This procedure describes the activities and controls for performing nondestructive examination of weldments when specified by project requirements. Methods within the scope of this procedure include radiographic testing (RT), ultrasonic testing (UT), magnetic particle test (MT), liquid penetrant test (PT), positive material identification test (PMI) and hardness test (HT). RESPONSIBILITY - Self-Perform ACTIVITY Perform RT, UT, MT, PT, PMI, HT Technical Supervision of NDE Selection for NDE and Status Maintenance Coordinate Weld Repairs RESPONSIBILITY NDE Coordinator NDE Coordinator DOCUMENTATION Report as specified in the approved NDE Procedure _____ Welds: 000.509.F79201 000.509.F79204 FREQUENCY OF ACTIVITY Per specifications _____ NDE Coordinator or NEWS program. Other than welds: 000.509.F79204 Per specifications Welding Specialist _____ Each rejected weld Responsibility - Subcontracted Work ACTIVITY Perform RT, UT, MT, PT, PMI, HT Technical Supervision of NDE Selection for NDE and Status Maintenance Coordinate Weld Repairs Surveillance NOTE 1: RESPONSIBILITY Subcontractor Subcontractor DOCUMENTATION Report as specified in the approved NDE Procedure _____ Welds: 000.509.F79201 000.509.F79204 or NEWS program. Other than welds: 000.509.F79204 _____ 000.509.F02201 FREQUENCY OF ACTIVITY Per specification _____ NDE Coordinator (Note 1) Per specification Subcontractor QC Inspector Each rejected weld Daily during life of activity. This activity may be delegated to the Installation Subcontractor W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7920 Rev 0 Non Destructive Examination.doc Page 1 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7920 Revision 0, 10 June 2013 GENERAL • Fluor personnel performing RT, UT, MT, PT, and PMI are to be qualified and certified to the requirements of NDE Practice 000.511.0101 "Certification of Nondestructive Examination Personnel", found in the Nondestructive Examination (NDE) Manual – Fluor Enterprises, Inc., 000.511.0000. Personnel performing hardness tests must be trained in the use of the equipment and procedure but do not require certification. Fluor self-performed NDE will be performed in accordance with the referenced NDE procedures. Perform RT, UT, MT, PT, PMI, HT Volumetric Nondestructive Tests should be completed and results reported within 24 hours after the welds are reported as complete. For special circumstances, such as the start of the welding program, or when the NDE Contractor does not have a jobsite laboratory, welds requiring radiography may be accumulated, but in these cases there should not be a backlog of more than ten (10) welds. Other NDE methods should be completed as soon after the NDE request as practical. • • • Technical Supervision of NDE includes: The activities listed under Technical Supervision of procedure 000.509.0090and activities listed under the NDE Coordinator responsibilities of 000.509.0040. • Weld Selection and Status Maintenance includes: Obtain a weld map (developed by 000.509.7910) and post the status of NDE for line classes requiring 100% NDE by a specific method or for individual welds requiring NDE by specification. Also post the status of welds that have been postweld heat treated. Alternately, Form 000.509.F79204 may also be kept for each isometric sheet. Either of these documents is to provide for accountability that all welds on the line were examined and accepted. Using the "Daily Welding Report" and the Post Weld Heat Treatment Log (000.509.F79001 and 000.509.F79002), select the welds for NDE as they are completed. Examine the selected welds for surface contour that may interfere with the NDE method. Notify the NDE Contractor or the inspector if self-performed, of the required NDE, by submission of a copy of the Nondestructive Examination Request/Record (000.509.F79202). Maintain the original to verify completion of NDE. Maintain a tickler file of rejected welds. The Site NDE Coordinator's copy of the NDE Report shall remain in the tickler file until the repair for that weld is noted as accepted on a subsequent report. At that time, the reports of the original and repaired weld and the radiographic film for both welds, shall all be placed together in the file. The acceptance date shall be logged on the isometric sheet or line sketch. - - - W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7920 Rev 0 Non Destructive Examination.doc Page 2 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7920 Revision 0, 10 June 2013 - The data on 000.509.F79202, Nondestructive Examination Request /Record, the NDE Reports (annotated with Fluor Site NDE Coordinator review) and the Radiographic film shall be traceable to the weld location shown on the spool drawing or pipeline sketch. • Selection of Welds under a random radiographic program includes: Select welds for random radiography to satisfy ASME B31 requirements from individual welder histories established on the "Welder B31.3 Random Radiography Control Log "Form 000.509.F79201. Welds to be radiographed for random radiography must be selected from sample lots established from the data on Form 000.509.F79201. For simplicity, it is suggested that sample lots be established as 20 welds for 5% radiography. Select the first two welds made by a welder on a system requiring random radiography to confirm the welder's proficiency in production. These two production welds shall not be counted as part of the random radiography sample lot. This should be waived if other welds made by the welder were radiographed. Identify the welds to be radiographed. Notify the Foreman of the welds selected for radiography. Log the radiographic examination results for random radiography on Form 000.509.F79201"Welder B31.3 Random Radiography Control Log". Post the completed welds reported by the foreman, the date reported, and the results of radiography on the Weld Map. Notify the Foreman and Welding Specialist of the results. For random radiography, when a weld is rejected, select two previous similar welds by the same welder, from a specified sample lot, for additional radiography, in compliance with ANSI B31.3. The selection shall be made from the welder's history on Form 000.509.F79201 "Welder B-31.3 Random Radiography Control Log. The welds are to be selected from the sample lot used to select the initial weld. Selection of welds and maintenance of status can be performed using the computer program NEWS. In this case, the forms for manual weld tracking (000.509.F79201and 000.509.F79204) do not need to be maintained. It is recommended that the NEWS program be used for projects with 200 or more joints to be radiographed. Issue periodic weld reject rate reports for welds examined by radiography using Form 000.509.F79203, "Radiographic Rejectable Defects Statistics". When statistical data indicates high or increasing reject rates, the Site Manager, the Welding Specialist, and the Quality Manager shall be informed. A copy of the weld reject rate reports should be sent to the Construction Technology Welding Engineer. This section also applies if UT is substituted for RT. - - - - - - NOTE: Informative RT shall not be performed on welds that have been capped out. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7920 Rev 0 Non Destructive Examination.doc Page 3 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7920 Revision 0, 10 June 2013 • Coordination of Weld Repairs includes: For those welds which have been rejected, determine the exact location, extent, and nature of the defect. Consult with the welder and foreman on defect cause and prevention and repair technique. When the weld has been repaired, have the weld reported on the "Daily Welding Report" to schedule radiography of the repair. Identify the repaired weld with the identification number previously assigned, except the subscript R1 shall be added after the designation. Subscripts shall designate subsequent repairs of the same welds, such as R2 and R3, until the weld is determined to be acceptable by examination. - - FORMS Quality Control Forms: 000.509.F79201 000.509.F79202 000.509.F79203 000.509.F79204 000.509.F79205 000.509.F79001 000.509.F79002 Welder B31.3 Random Radiography Control Log Nondestructive Examination Request/Record Radiographic Rejectable Defects Statistics Welding/NDE Status Log Ferrite Test Report Daily Welding Report Post Weld Heat Treatment Log Fluor Nondestructive Examination Procedures: (See the Nondestructive Examination (NDE) Manual – Fluor Enterprises, Inc., 000.511.0000) Practice: 000 511 0101 Practice: 000 511 0104 Practice: 000 511 0106 Practice: Practice: Practice: Practice: 000 511 0108 000 511 0109 000 511 0116 000 511 0117 Certification of Nondestructive Examination Personnel Liquid Penetrant Examination of Weldments and Materials - ASME Code (Visual Dye/Solvent Removable) Magnetic Particle Examination of Weldments and Materials (Dry Particles - Continuous Method) Radiographic Examination of Weldments Ultrasonic Examination Methods Positive Material Identification Testing using X-Ray Diffraction Hardness Testing of Weldments ATTACHMENTS Attachment 1 – ASME B31.3 Random Radiography Requirements Reference W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7920 Rev 0 Non Destructive Examination.doc Page 4 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7920 Revision 0, 10 June 2013 Attachment 1 – ASME B31.3 Random Radiography Requirements Reference If ACCEPTABLE, all welds in this welder's lot are considered to be acceptable Select weld from welder's lot of welds ** ** Note: The first two pressure piping butt welds radiographed for each welder are not to be included in the welder's lot. Radiograph 4th Weld 2nd Weld Acceptable 3rd Weld Rejected Radiograph 5th Weld If BOTH additional welds are ACCEPTABLE, consider the balance of the welds in this lot to be acceptable. Radiograph Weld Radiograph 2nd Weld Radiograph 3rd Weld 2nd Weld Rejected 3rd Weld Acceptable If EITHER of these welds are REJECTED, all welds by this welder in this lot shall be 100% Radiographed.* Radiograph 4th Weld Radiograph 5th Weld If ALL FOUR of these welds are ACCEPTABLE, consider the balance of the welds in this lot to be acceptable. 2nd Weld Rejected 3rd Weld Rejected Radiograph 6th Weld Radiograph 7th Weld If ANY of these four welds are REJECTED, all of the welds by this welder in this lot shall be 100% Radiographed.* If REJECTED, select two additional welds from same lot If BOTH additional welds are acceptable, the balance of welds in this welder's lot are considered to be acceptable. ALL REJECTED WELDS MUST BE REPAIRED OR REPLACED AS NECESSARY TO MEET APPLICABLE QUALITY *NOTE: WELDER MAY BE REQUIRED TO DEMONSTRATE HIS ABILITY TO PRODUCE WELDS QUALITY STANDARDS. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7920 Rev 0 Non Destructive Examination.doc Page 5 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7920 Revision 0, 10 June 2013 This page is intentionally blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7920 Rev 0 Non Destructive Examination.doc Page 6 of 6 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79201 Revision 0, 10 June 2013 WELDER B31.3 RANDOM RADIOGRAPHY CONTROL LOG Weld Identification Cumulative Butt Welds Date Welded Date Examined Weld Number Examination Data Two B31.3 Tracer Welds Selected For Each Reject Accepted (A) Rejected (R) ID W79201 Drawing Number (Line And Sheet) Defects And Disposition Defects and Disposition Symbols B31.3 Interpretation Defects CK IP LF UC P S CR EL Crack Incomplete Penetration Lack of Fusion Undercutting Porosity Slag Concave Root Surface Elongated Indication GO GS CW R1 R2 Welder’s Name Welder’s Symbol Prepared By: Repair Instructions Grind Out, remove area with defect Grind Surface Cutout Weld, slice in weld plane First Repair Second Repair W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79201 Rev 0 Welder B31.3 Random Radiography Control Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79202 Revision 0, 10 June 2013 NONDESTRUCTIVE EXAMINATION REQUEST/RECORD Type Examination Radiographic Liquid Penetrant Magnetic Partical Examination Data Line No./Spool Sheet: Location: P No./Material: Pipe Size/Schedule: Acceptance criteria (code): Weld No. Welder Symbol P No. / Material Pipe Size/ Schedule ID W79202 Ultrasonic Hardness Testing PMI Date: Requested by: Site NDE Coordinator Location Line No/Sheet Date NDE Completed Note: The Following Identification Shall Be Plainly And Permanently Included On The Radiographic Film: Project No., Line No., Weld No., Welder Symbol, Date Of Radiography. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79202 Rev 0 Non Destructive Examination Request Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. 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Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79203 Revision 0, 10 June 2013 RADIOGRAPHIC REJECTABLE DEFECTS STATISTICS Process Reporting Period From To ID W79203 Rejectable Butt Welds This Reporting Period Number Of Butt Welds Radiographed Number Of Butt Welds Rejected Percent Rejected Accumulative Job Totals Number Of Butt Welds Radiographed Number Of Butt Welds Rejected Percent Rejected Rejectable Defect Classification This Reporting Period Lack of Fusion Cracks Undercut Incomplete Penetration Concave Root Slag Inclusions Porosity Elongated Indication Remarks Lack of Fusion Cracks Undercut Incomplete Penetration Concave Root Slag Inclusions Porosity Elongated Indication Accumulative Job Totals General Notes: 1. This exhibit is to be used to track weld quality levels as determined by butt weld radiography. 2. Keep separate records for each weld process, controlling code, random or 100% radiography. 3. Report high or increasing defect rates or repetitive defect types to the Jobsite Welding Specialist and the Construction Project Manager. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79203 Rev 0 Radiographic Rejectable Defects Statistic.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79203 Revision 0, 10 June 2013 This page is intentionally blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79203 Rev 0 Radiographic Rejectable Defects Statistic.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79204 Revision 0, 10 June 2013 WELDING/NDE STATUS LOG Line No. Welder Symbol Line Class Date Welded RT/UT Accept Date Sheet No. PT/MT Accept Date PWHT Date Revision BH Date ID W79204 Weld No. Remarks NDE Technician : Fluor QA Inspector: Date: Date: W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79204 Rev 0 Welding-NDE Status Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79204 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79204 Rev 0 Welding-NDE Status Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79205 Revision 0, 10 June 2013 FERRITE TEST REPORT Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Acceptable FN No. Equipment Number or Isometric Drawing Number Weld Number Base Material Welder’s ID Stamp Location ID W79205 Tag No.: Turnover System: Client Other Sub – System: Location: 00 900 1800 2700 AVG Remarks NDE Technician/Date Fluor QA Inspector/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79205 Rev 0 Ferrite Test Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79205 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79205 Rev 0 Ferrite Test Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79001 Revision 0, 10 June 2013 DAILY WELDING REPORT Subcontractor Unit Line No. Line Class Sheet No. Weld No. Type Weld Area Size Wall Thick. Welder Symbol Process Root Bal Fit-Up Visual Inspected ID W79001 Remarks Foreman Welding Inspector Date Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79001 Rev 0 Daily Welding Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79001 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79001 Rev 0 Daily Welding Report.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79002 Revision 0, 10 June 2013 POST WELD HEAT TREATMENT LOG Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID W79002 Client Other Sub – System: Location: Log No. Line No. Line Class Sheet No. Mark No. Weld No. Weld Type Circuit No. Completion Date Initials Welding Supervisor: Inspector: Subcontractor Name Signature Date Name Signature Date Date: Date: Fluor Field Engineering Name Signature Date Fluor QA W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79002 Rev 0 Post Weld Heat Treatment Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79002 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79002 Rev 0 Post Weld Heat Treatment Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 POSITIVE MATERIAL IDENTIFICATION EXAMINATION SCOPE This procedure describes the activities and controls for performing Positive Material Identification (PMI) examination of specified alloy and other special materials in accordance with the requirements of project specifications. RESPONSIBILITY – Materials Supplied by Fluor to Subcontractors ACTIVITY Warehouse Receiving Receiving Inspection Perform PMI Identification Document Results Technically Supervise PMI Resolve Accept and Rejects RESPONSIBILITY Warehouse Manager/Supervisor Site Quality Manager Fluor NDE Coordinator/ Subcontractor Subcontractor Fluor NDE Coordinator/ Subcontractor Site Quality Manager Site Quality Manager DOCUMENTATION FREQUENCY On-going _____ Project Specifications _____ Form 000.509.F79301 Form 000.509.F79302 Form 000.509.F79304 _____ Project Specifications On-going Per Specification On-going Each test _____ Per Rejects RESPONSIBILITY – Subcontractor Supplied Materials and Alloy Welds ACTIVITY Receiving Inspection Perform PMI PMI of Welds Identification Document Results Technically Supervise PMI Resolve Accept and Rejects RESPONSIBILITY Subcontractor Quality Manager NDE Subcontractor Subcontractor Quality Manager Subcontractor Subcontractor Subcontractor Quality Manager Subcontractor Quality Manager DOCUMENTATION _____ Project Specifications Project Specifications _____ Form 000.509.F79301 Form 000.509.F79302 Form 000.509.F79304 _____ Project Specifications _____ Per Rejects FREQUENCY On-going Per Specification Per Specification On-going W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 1 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 GENERAL • Warehouse Receiving Inspection The Warehouse Supervisor shall be responsible for receiving inspection to confirm that all incoming alloy and special materials are received with the required positive material identification (PMI) performed, with PMI identification coding in place, and, when specified, with PMI documentation confirming identity verification conformance. (Note: material test reports do not satisfy the requirement for PMI documentation.) Nonconforming items (alloy or special materials for which the required PMI has not been performed, items without the required PMI identification coding in place, and/or items without PMI documentation) shall be placed in a “Quarantine” area or tagged “Hold” until such time as the nonconformance is resolved. The Material Manager shall be responsible for obtaining disposition for incoming items found to be nonconforming. The Site Quality Manager shall be notified of any alloy or special materials identified at initial Warehouse Receiving as nonconforming. NOTE: Do Not release nonconforming or indeterminate materials, components, or equipment for use in the facilities being constructed. Provide notification to the NDE Coordinator when alloy or special materials are received at the construction site. Request PMI analysis for alloy and special materials received at warehouse by notification to the NDE Coordinator. Provide an area in the warehouse for receiving inspection. Palletize piping components or other small items for Receiving Inspection and place in a “Hold” area. Identify the location of alloy pipe, plate, or large fabrication and equipment items that have been received and require Receiving Inspection confirmation of prior PMI. - - - • Subcontractor Receiving Inspection Each Subcontractor is responsible to ensure that all items supplied to him by Fluor or the subcontractor’s own vendors/suppliers meets the requirements of the project specifications. Nonconforming items (alloys for which the required PMI has not been performed, items without the required PMI identification coding in place, and/or items without PMI documentation) shall be placed in a “Quarantine” area until such time as the nonconformance is resolved. The Subcontractor Quality Manager shall be responsible for obtaining disposition for incoming items found to be nonconforming. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 2 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 • Perform Positive Material Identification PMI will be performed by trained personnel whose ability to successfully operate the PMI test equipment has been documented by test. Non-destructive methods used for PMI testing shall be capable of identifying the material quantitatively. Acceptable test equipment for non-destructive PMI testing is listed below: Portable x-ray fluorescence analyzers. Use is limited to the following instruments or their equivalents unless Fluor Engineer gives prior approval. The Engineer may designate another instrument as equivalent based on demonstrated and documented performance testing. TN Technologies Alloy Analyzer 9266, 9277 (The metallurgist XR) or Metallurgist Pro. Metorex – X-MET 880, X-MET 960 or X-MET 2000. Portable optical emission analyzers. Use is limited to the following instruments or their equivalent unless Fluor Engineer gives prior approval. Care shall be taken not to damage critical surfaces (e.g., bearings) when using optical emission analyzers. SpectroPORT Model TP-07 or TFO-02, Specto Test F. Metroex ARC-MET 900 or ARC-MET 930. Extent of PMI shall be per the project specifications. - • PMI of Alloy Piping All field installed alloy piping will be 100% PMI verified in the “as installed” position. Each spool and the weld will be verified and results documented on the fabrication spool drawing/isometric, listed on the PMI point sheet and marked with the appropriate verification color by the PMI Technician as each point is analyzed. See Attachment 1 for complete instruction. • PMI of Welding Wire (Bare) Bare wire shall be purchased in unopened manufacturer’s containers. Each container must have the AWS Classification, heat and lot number clearly marked. Filler metal certification is required. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 3 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 • The greatest of 5% or 5 pieces of welding wire shall be PMI checked from each container. Coated electrodes do not require PMI checks prior to use. Deposited filler metal (SMAW) must be PMI checked in the “as welded” condition. Identification Each item (pipe spool, plate, weld, fitting, valve, etc.) that has been verified shall be marked using project specifications (See Attachment 2). Items which cannot accommodate this identification shall be individually tagged with the above. Paints/Markers used for applying color code for PMIV are controlled by the Site Quality Manager. Each fabricated spool must have verification marks applied to each component and weld by the PMI Technician. Pipe and fittings should be painted with a stripe that is parallel with the axis of the pipe. Welds should be marked along their circumference perpendicular to the axis of the pipe so that the verification markings will be visible when the pipe spool is installed. Small connections and short branches should be painted through their entire length. - - - • Document Results Document PMI test results on the appropriate Positive Material Identification (PMI) Inspection Reports Form 000.509.F79301, 000.509.F79302 or 000.509.F79303. • Technically Supervise PMI will include: Ensuring that only properly trained personnel conduct PMI testing in accordance with a procedure which has been reviewed and approved by the Fluor NDE Level III. The Site Quality Manager shall have overall responsibilities for the implementation of this PMI Program. Verification of PMI A Fluor Quality Representative must witness initial calibration/standardization of the PMI equipment at the start of each work period and observe PMI testing randomly during the work period to assure compliance with this procedure. A Fluor Quality Representative must witness a minimum of 5% of all PMI testing randomly during the work period. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 4 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 - These observations must be noted on the PMI isometrics by initialing and dating the drawing and listing test points that are witnessed by the Fluor Quality Representative. A Weekly PMI log, Form 000.509.F79304 will be maintained by the Fluor Quality Representative to verify the percentage of PMI testing observed. • Resolved Accept and Rejects If the PMI test results fall outside of the acceptable ranges, the item will be rejected. All rejected materials shall be isolated in a "Quarantine" area, tagged "REJECTED", and a Nonconformance Report initiated. When an item from a representative sample is rejected: a) 100% of the remaining components from which the sample was taken shall be examined. b) 100% of the components from the next two lots shall be examined. c) If no further components are rejected in a) or b), above, the extent of examination shall return to that specified in project specifications. Rejected items shall be returned to the original source of supply at no cost to the Fluor. - REFERENCES Quality Control Forms: 000.509.F79301 000.509.F79302 000.509.F79303 000.509.F79304 ATTACHMENTS Attachment 1 Attachment 2 Project Specifications: 000 285 85012 – General Specification for Positive Material Identification (PMI) PMI Procedure for the Field Color Code for Metal Identification PMI Inspection Record Bulk Material Positive Material Identification Record Pipe Spool Positive Material Identification Record “Point” Sheet Weekly PMI Log W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 5 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 Attachment 1 PMI Procedure for the Field 1.0 (a) Piping: PMI Verification is dependent on the ability of Inspection to see the verification marking on each component and to compare visual verification with the listing of each component on a point sheet and spool drawing or field/shop isometric. These “point sheets” must be signed by the PMI technician who performed the tests and a Fluor Quality Representative. The verification marking should be a color that is not associated with other activities, (i.e. material color code, dismantling, blinding, etc.). Attachment 2 has designated colors to be used as verification markings on the most widely used alloys. These colors shall be listed in the PMI plan as per this attachment. In cases where an alloy is to be used that are not listed in Attachment 2, the alloy should be assigned a predetermined color and included in the PMI plan as such. All PMI locations must have PMI verification color markings and the PMI Technician must apply the markings at the time of actual PMI testing. Each component should be marked with a ½” (12 mm) dot of the appropriate color marking. The markers used for PMIV are controlled by the Site Quality Manager and shall not be issued for any other application. The Site Quality Manager representative will issue them to the PMI technician at the fabrication facility or job site. All fabricated alloy spools shall be PMI checked at the time of receipt. PMI shall be performed at the, job-site or designated lay-down area by a qualified PMI Technician under the direct supervision of an the Site Quality Manager. Each check must be sequentially recorded, as each point is analyzed, not after the fact. The procedure for PMI should be as follows: 1. 2. 3. Obtain or make the drawing. Make the point sheet. Compare the drawing to point sheet while performing PMI to verify all components are listed. (If the PMI technician finds a point not listed on the point sheet, he should PMI the point and list it on the bottom of the point sheet as a sub-listing of the previous point. Example: a weld between points 5 and 6 would be numbered 5a). PMI the component and record results on the point sheet. Color-code the component. Repeat sequentially for the next component. (b) (c) (d) (e) (f) 1.1 1.2 1.3 4. 5. 6. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 6 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 2.0 2.1 2.2 Drawings: Shop spool drawings of field isometric drawings must indicate all components. The spool drawings, isometrics and point sheets must be signed off as follows: 1. 2. 3. 4. 5. PMI Company PMI Technician name in print and date PMI Technician signature Site Quality Representative name in print and date Site Quality Mechanical Representative signature 2.3 2.4 Any alteration of shop spools must be noted on as-built shop spool drawings or isometrics and this information must be recorded on the primary point sheet. Completed spool drawings, isometrics and point sheets must be attached to Inspection isometrics. Number of PMI points for Piping Welds: Welds requiring PMI shall be inspected according to the following: 1. 2. 3. 4. 5. Automated welding---one sample from each girth or long seam. Manual welding---one sample from each girth seam < 24 in. (60 cm) diameter. Manual welding---two samples from each girth seam equal to or > 24 in. (60 cm) diameter. Autogenous welded pipe and fittings---PMI verification of base metal only. Semi-automatic welding in the 1 G (rotated) position---one sample from each girth seam. 3.0 3.1 4.0 4.1 4.2 4.3 4.4 Ring Joint Gaskets: Ring joint gaskets (alloy) must be PMI tested and marked prior to installation. The PMI Technician should place a single ¼” (6.3 mm) diameter paint mark on each ring adjacent to the alloy designation of the ring gasket. All ring joint gaskets must be checked out of the designated holding facility by the piping job supervisor or foreman. PMI Verification will be dependent upon the placement of the ring gasket in the flange so that the Inspector can see the paint marking and the alloy designator for the ring. Valves: All alloy valves will be PMI tested in two (2) locations (Valve body and Bonnet). The PMI Technician will mark each location with the designated verification color. 5.0 5.1 5.2 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 7 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 6.0 6.1 6.2 6.3 6.4 6.5 Welding Wire (Bare): Bare wire shall be purchased in unopened manufacturer’s containers. Each container must have the AWS Classification, heat and lot number clearly marked. Filler metal certification is required. The greatest of 5% or 5 pieces of welding wire shall be PMI checked from each container. Coated electrodes do not require PMI checks prior to use. Deposited filler metal (SMAW) must be PMI checked in the as welded condition. Non-Conformances: If there is a component in a PMI system that does not meet the necessary chemistry, that component must be flagged with a color of flagging tape that does not conflict with other colors designated for NDE or PWHT. The PMI Technician must inform the Site Quality Manager immediately of any non-conformances and these must be corrected by the fabricator/erector as a matter of priority. Verification/Audit of PMI Procedure The Site Quality Representative must witness initial calibration/standardization of the PMI equipment at the start of each work period and observe PMI testing randomly during the work period to assure compliance with this procedure. These observations must be noted on the PMI point sheets by initialing the test points that are witnessed by the Site Quality Representative. The Site Quality Representative during the PMI operation must witness a minimum of 5% of all PMI testing. A weekly log will be maintained by the Site Quality Representative to verify the percentage of PMI testing observed. 7.0 7.1 8.0 W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 8 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 Attachment 2 Color Code for Metal Identification SINGLE STRIPE MAGNETIC METALS Plain Carbon Steel Carbon Steel for LowTemperature Service (Below 20 F) Carbon-Moly Steel AISI 4140 Steel 1-1/4 Cr - 1/2 Mo steel, B-16 Studs 2-1/4 Cr - 1/2 Mo steel 5 Cr - 1/2 Mo steel 9 Cr - 1 Mo 12 Cr - 2 Mo Steel, Type 410S, 405 17 Cr Steel, Type 430 3-1/2 Ni Steel Ductile, Nodular Iron COLOR None Yellow White Red Gray Orange Green Purple Black Pink Blue Brown DOUBLE OR BROKEN STRIPE NONMAGNETIC METALS Aluminum - All Grades Type 304 (18 Cr - 8 Ni) Type 316 (16 Cr - 10 Ni- 3 Mo) Alloy 20 (20 Cr - 29 Ni) Red Brass (85 Cu - 15 Zn) Incoloy 800 (20 Cr -32 Ni) R.A. 330 (19 Cr -35 Ni - 1-1/4 Si) Type 304-L, Low-Carbon (16 Cr - 10 Ni - 3 Mo) Type 316-L Low Carbon (16 Cr - 10 Ni - 3 Mo) Hastelloy "B: (65 Ni - 30 Mo) Inconel 600 (72 Ni - 15 Cr) Monel (67 Ni - 30 Cu) Hastelloy "C" (60 Ni - 15 Cr - 17 Mo) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 9 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7930 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7930 Rev 0 Positive Material Identification Examination.doc Page 10 of 10 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79301 Revision 0, 10 June 2013 PMI INSPECTION RECORD Tag Description: P. O. No.: Subcontractor: PMI Request By: Signature: Date: PMI Performed By: Signature: Date: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: ID W79301A Client Other Sub – System: Location: PMI Equipment Used: Purchase Order Number: PMI Performed By: Signature: Company Performing PMI: PMI Will Be/Was Performed At: Examination Results/By Material Identification Item Or Tag No. Sample Size Material Mill Cert. No. Heat Number Description Item Or Tag No. Sample Size Examination Results/Analyzed Material Chemical Composition Percentage Material Mill Cert. No. Heat Number Cr Mo Ni Mn Ti V Fe Co Cu Nb W Address Of Supplier Responsible For Rejection (s) Additional Information Manhours And Loss Incurred From Rejections, Etc. PMI Supervisor Signature/Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79301 Rev 0 PMI Inspection Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79301 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79301 Rev 0 PMI Inspection Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79302 Revision 0, 10 June 2013 BULK MATERIAL POSITIVE MATERIAL IDENTIFICATION RECORD Calibration/Standardization Witnessed: Company: Standard Analyzed Purchase Order Number: Fabricator’s Pipe Spool Drawing (s): Location Where PMI Performed Item No. Line Item Description Type, Size, Rating Material Type PMI Performed by (Print Name): Signature/Date: PMI Analyzer Manufacturer & Model: Material Verified PMI Accept Reject Chemical Composition Percentage Cr Mo Ni MN Ti V FE Co Cu Nb W Print Name: Signature: Date: ID W79302A Site Quality Representative: QTY Body Bonnet Stem Remarks W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79302 Rev 0 Bulk Material PMI Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79302 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79302 Rev 0 Bulk Material PMI Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79303 Revision 0, 10 June 2013 PIPE SPOOL POSITIVE MATERIAL IDENTIFICATION RECORD “POINT” SHEET Tag Description: P. O. No.: Subcontractor: Inspection Classification Subcontractor Fluor Tag No.: Turnover System: Client Other ID W79303A Ni Ti V Sub – System: Location: Calibration/Standardization Witnessed: Company: Standard Analyzed PMI Points Line Number and Class Chemical Composition Percentage Cr Mo MN FE Co Cu Nb W Site Quality Representative: Print Name: Signature: Date: MK # Sheet # Rev. # PMI Results Accepted Rejected Print PMI Technician Signature Site Quality Representative Date Print Signature of of of of of of of of of of of of of W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79303 Rev 0 Pipe Spool PMI Record.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79303 Revision 0, 10 June 2013 PIPE SPOOL POSITIVE MATERIAL IDENTIFICATION RECORD “POINT” SHEET PMI Points Line Number and Class MK # Sheet # Rev. # PMI Results Accepted Rejected Print PMI Technician Signature ID W79303A Site Quality Representative Date Print Signature of of of of of of of of of of of of of of of of of of of W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79303 Rev 0 Pipe Spool PMI Record.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79304 Revision 0, 10 June 2013 WEEKLY PMI LOG Calibration/Standardization Witnessed Start of Work Period Date Number of Points Witnessed # of # of of of of of of of of of of of of of of of of of of Job # Sketch # PMI Technician ID W79304A Site Quality Representative of of W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79304 Rev 0 PMI Log.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79304 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79304 Rev 0 PMI Log.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7950 Revision 0, 10 June 2013 HARDNESS TESTING SCOPE This procedure describes the functions to be performed in the performance of hardness testing. RESPONSIBILITIES ACTIVITY Review Job Specification for Hardness Testing Requirements Hardness Testing Equipment Personnel Training & Vision Test Preparation of Surface to be Tested Perform Hardness Testing & Report Results PROCEDURE • Review Job Specification for Hardness Testing Requirements • Obtain a copy of the Code/Job Specification requirements prior to the start of work. RESPONSIBILITY Site Quality Manager Site Quality Manager Site Quality Manager Piping Superintendent QC Inspector/NDE Technician 000.509.F79503 000.509.F79501 000.509.F79502 DOCUMENTATION FREQUENCY OF ACTIVITY Prior to start of work Prior to start of work Yearly or each applicable. Yearly Each test location As required by code or specification Hardness Testing Equipment Obtain the hardness testing equipment required or contract with a supplier of hardness testing services. • Personnel Training & Vision Test Assure that the personnel performing the hardness testing have been trained in the use of the equipment or have used the equipment within one (1) year and have a current vision test (Jaeger 2 at 12 inches (30 cm) minimum within one (1) year). • Preparation of the Surface to be Tested Assure that the surface to be tested is buffed/filed to a relatively flat smooth texture to avoid erroneous measurements which may result from a coarse surface. Care must also be taken to assure that any grinding or other mechanical working does not generate sufficient heat to affect the material hardness. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7950 Rev 0 Hardness Testing.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 7950 Revision 0, 10 June 2013 • Perform Hardness Testing & Report Results Perform the hardness testing in accordance with the equipment manufacturer's written procedure as required by the code or job specification. For hardness testing in the weld heat affected zone (HAZ), the test instrument indenter shall not be greater than three (3) millimeters across the tip. Report hardness testing results. For local hardness testing on welded joints, three tests shall be conducted at each location required by code or job specification. Each reading shall be reported and the average for the three shall be computed and reported on Form 000.509.F79503. - FORMS Quality Control Forms: 000.509.F79501 000.509.F79502 000.509.F79503 Verification of Training For Hardness Testing Report of Vision Test Hardness Testing Report W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Procedures\509-7950 Rev 0 Hardness Testing.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79501 Revision 0, 10 June 2013 VERIFICATION OF TRAINING FOR HARDNESS TESTING ID W79501 This is to verify that has been trained in the use of the Hardness Testing Equipment described below or has successfully used this equipment within the past year. Description of Equipment: Site Manager/Site Quality Manager Date W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79501 Rev 0 Verification of Training for Hardness Testing.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79501 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79501 Rev 0 Verification of Training for Hardness Testing.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79502 Revision 0, 10 June 2013 REPORT OF VISION TEST Employee Name: Social Security Number: ID W79502 Type Chart Used: Jaeger J1 @ 30 cm min. Snellen Equivalent to J1 @ cm min. Jaeger J2 @ 30 cm min. Snellen Equivalent to J2 @ 30 cm min. Near Vision Results: Left Eye Passed Failed Corrected Uncorrected Remarks/Comments: Right Eye Printed Name, Signature And Title Of Test Administrator Date Of Test (Month (Day) (Year) W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79502 Rev 0 Report of Vision Test.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79502 Revision 0, 10 June 2013 This page intentionally left blank. W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79502 Rev 0 Report of Vision Test.doc Page 2 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79503 Revision 0, 10 June 2013 HARDNESS TESTING REPORT Project Drawing No. Weld No. Weld Type Applicable Code/Spec Material Base Mat'l Weld Metal Project No. Test Equipment Type/Proc. Size And Thickness ID W79503A Date PWHT Before After Hardness Test Results Reading #1 #2 #3 Ave. BM HAZ WM HAZ BM BM HAZ WM HAZ BM BM HAZ WM HAZ BM BM HAZ WM HAZ BM BM HAZ WM HAZ BM BM HAZ WM HAZ BM Remarks EQUIPMENT OPERATOR (PRINT)/DATE QC INSPECTOR (SIGN)/DATE W:\103_PROJ_ADMIN\109_ENG DOCS\109.12R_OT\05-Construction\240K-C2-OT-05-002_SiteQualityManual\Forms\F79503 Rev 0 Hardness Testing Report.doc Page 1 of 2 Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV 240K-C2-05-002 Site Quality Manual 000 509 F79503 Revision 0, 10 June 2013 This page intentionally left blank. 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