mechanical and electrical field inspection guideline

© 1997, 2001 Bechtel—.qxd-6263-03/03 (old 5709-11/01)

© 2002 Bechtel CorporationAll Rights Reserved.

No parts of this publication may be reproducedin any form without the prior written orexpressed permission of the publisher.

Printed in the United States of America.

Mechanical/ElectricalField Inspection Guidelines

Table of Contents

Number TitleP-2 Large PipeP-3 Small PipeP-4 Embedded PipingP-5 Storm and Sanitary SewerP-6 HDPE PipingP-7 ValvesP-8 Hangers and Supports

Lined PipingP-11 Plastic-Lined PipesP-12 Lined Pipe GasketsP-13 Kynar-Lined PipeP-14 PTFE-Lined PipeP-15 Lined Pipe—Saran or Polypropylene

Flushing, Testing, and InsulatingP-21 Flushing and CleaningP-22 Leak TestingP-23 Pipe InsulationP-24 Vibration Isolation and Control

General Mechanical InspectionsM-1 General Equipment SettingM-2 Rotating EquipmentM-3 Coupling AlignmentM-4 Belt-Driven EquipmentM-5 Non-Rotating EquipmentM-6 PumpsM-7 Elevated Steel Tanks

TOC-2


Table of Contents

Number Title

GeneralG-1 Construction InspectionsG-2 Construction SafetyG-3 Equipment Tag/LockoutG-4 Receiving and StorageG-5 Design Document ControlG-6 Material ControlG-7 Measuring and Testing EquipmentG-8 Control of Deficient ItemsG-9 Records Retention

Heavy Lift RiggingG-21 Rigging Method SelectionG-22 Rigging PerformanceG-23 Movement by TransportG-24 Mobile CranesG-25 Bridge CranesG-26 Base-Mounted CranesG-27 Rigging ComponentsG-28 Suspended Personnel Work Platforms

Field WeldingG-31 General WeldingG-32 Code WeldingG-33 Nondestructive ExaminationG-34 Heat Treatment

Piping SystemsP-1 General Piping

Field Inspection Guidelines © 1997, 2001 BechtelTOC-1


Table of Contents

Number TitleElectrical Installations (continued)

E-7 Lighting SystemsE-8 GroundingE-9 BatteriesE-10 Cathodic Protection

Instrumentation InstallationsJ-1 Instrument Installation ReviewJ-2 Instrument Piping and TubingJ-3 Instrument Mounting SupportsJ-4 Instrumentation CleanlinessJ-5 Instrumentation TestingJ-6 Instrumentation System Release

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Table of Contents

Number TitleM-8 Underground Storage Tanks

Mechanical EquipmentM-11 BoilersM-12 CondensersM-13 Heat ExchangersM-14 Columns and VesselsM-15 Steam TurbinesM-16 Combustion Gas TurbinesM-17 Diesel EnginesM-18 Furnaces and HeatersM-19 Water Treatment Equipment

Heating, Ventilating, and Air Conditioning

M-21 HVAC InstallationM-22 DuctworkM-23 HVAC FansM-24 Air Conditioning EquipmentM-25 Forced Draft Cooling Fans

Hoisting SystemsM-31 Crane and Hoist InstallationM-32 Testing Hoisting Equipment

Electrical InstallationsE-1 Embedded Rigid ConduitE-2 RacewayE-3 Electrical Panels and SwitchgearE-4 Electrical EquipmentE-5 Wire and CableE-6 Terminations

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Construction Inspections Guideline G-1

C. After Performing Inspections❏ Immediately advise supervision and/or the contractor of any unac-

ceptable work and the corrective action required to correct the defi-ciencies.

❏ Follow up on all rejected work after corrective actions have beenimplemented to ensure that the work is acceptable.

❏ File all inspection records in the project files per procedure require-ments.

G-1-2

Guideline G-1Construction InspectionsA. Before Performing any Inspections❏ Review the contract, specifications, drawings, industry standards,

vendor requirements, and other project agreements on the work tobe inspected.✔ Determine what is required to be inspected.✔ Determine the frequency of inspection required.✔ Determine the method of inspection.✔ Determine requirements for third-party inspections.✔ Develop a formal plan for project inspection activities.

❏ Check all approved design drawings including any approvedchanges associated with the work to be inspected.

❏ Review material requirements for the materials to be used andobtain material samples for use in inspection activities whereappropriate.

❏ Review project procedures and/or the contractor quality plan todetermine requirements before starting any inspection activities.

❏ Identify which forms or documents must be completed to documentfield inspection activities.

B. During Inspections❏ Check that only approved materials have been used.

✔ For materials that cannot be visually verified after installation,establish controls to ensure that the correct materials havebeen used.

✔ Use material samples to verify that the in-place materialsmatch submitted samples, when appropriate.

❏ Check key dimensional requirements including location, size, clear-ances, spacing, and other key dimensions for the installation.

❏ Perform any required inspection verification testing such as slumptesting, torque verifications, and pressure test verifications.✔ Ensure that properly controlled and calibrated materials and

testing equipment (M&TE) devices are used for verificationtesting.

❏ When worker qualification requirements exist, ensure that qualifiedpersonnel have performed the work.

❏ Document all inspections per project procedure requirements.✔ If a formal quality control program is implemented on the proj-

ect, document all inspections performed on the required form.

Field Inspection Guidelines © 1997, 2001 BechtelG-1-1

Construction Safety Guideline G-2

❏ Check that materials being used and structures, coatings, ormaterials being worked on have been assessed for healthhazards.

D. Gases, Vapors, Fumes, and Mists❏ Check that employees are not exposed to amounts in excess of

threshold limit values. Have an industrial hygienist evaluate anyconcerns.

❏ Ensure that equipment or protective measures intended to reduceor control exposure are approved by a competent industrial hygien-ist and are being used properly.

E. Ventilation❏ Check that threshold limit values are not exceeded when fumes,

mists, or dusts are removed by ventilation.❏ Ensure that exhaust systems do not draw harmful substances

through work area.❏ Check that exhaust systems operate continually if needed and are

shut down when required.❏ Check that all ventilation systems for dusts, fumes, mists, vapors,

or gases are discharged to outside atmosphere and away fromintakes.

F. Flammable and Combustible Liquids❏ Check that only approved and properly labeled containers, portable

tanks, and metal safety cans are used for the storage and handlingof flammable liquids.

❏ Check that temporary buildings, fire hazards, equipment, or mate-rials are not placed where they obstruct exits.

❏ Check that temporary buildings placed inside another building arenoncombustible or have a 1-hour fire resistant rating.

❏ Check that outside buildings are at least 10 ft (3 m) from otherstructures.

❏ Check temporary heating devices for clearance from combustiblematerial.

❏ Check that heaters on wood floors are placed on noncombustiblematerial, extending a minimum of 2 ft (0.5 m) on all sides.

❏ Check that clearance between heaters and tarpaulins, canvas, orsimilar coverings is at least 10 ft (3 m). Coverings must be secure-ly fastened to prevent contact with heater.

❏ Check that temporary heating devices are equipped with pilot andautomatic shutoff valve to prevent flow of fuel if flame goes out.

❏ Check that fluid used in hydraulic powered tools is fire-resistant.❏ Check that covers are used on containers with hazardous or flam-

mable wastes.

G-2-2

Guideline G-2Construction SafetyA. Personal Safety and General Crew Safety❏ Check that energy potentials such as excavations, confined

spaces, pressurized systems, electrical, chemical, physical agentshave been identified and are properly controlled.

❏ Check that the required personal protective equipment has beeninspected and is ready for use when needed.✔ Is head, eye, ear, hand, foot, lung, or body protection

required?❏ Check that safe access is provided to the work area.❏ Check that required permits are issued and encompass inspection

activities.✔ Examples of permits include: cold work, hot work, ignition

source, lockouts, confined space entry, area entry, excavation,hole watch, and fire watch.

❏ Check that a colleague or supervisor is knowledgeable of area ofinspection and time duration when working alone or with energypotentials

❏ Check compliance with site safety and health procedures such ascompleted job safety analysis, scaffold tagging, lockout/tagout,safety eye wash/shower test, hot work containment, stand-by per-sonnel, barricades, and signs.

B. Emergency Preparedness❏ Check that medical personnel are available for advice and consul-

tation on occupational health matters and that employees under-stand the reporting requirements and process.

❏ Check that equipment for prompt transportation of injured person-nel to a physician or hospital is available and that a communicationsystem for calling an ambulance is provided.

❏ Check that the telephone numbers for physicians, hospitals, andambulance service are conspicuously posted.

❏ Check that emergency procedures are understood for medical, fire,and natural emergencies.

❏ Check that emergency exit routes and staging areas are clear andunobstructed.

❏ Check that fire protection equipment such as fire hydrants, hoses,extinguishers, and sprinklers is readily available and serviceable.

❏ Check that emergency eye wash and showers are available andoperational.

C. Hazardous Materials❏ Check that employees are knowledgeable of the hazards and con-

trol measures associated with all chemicals in use.


Construction Safety Guideline G-2✔ Work areas✔ All walkways including, ramps, runways, corridors, and stair-

ways✔ Offices, shops, and storage areas✔ Parking lots, security, and access points.

M. Worker Activity Checklist❏ Is the employee watching what he/she is doing?❏ Is the employee watching where he/she is going?❏ When ascending/descending, is the employee following three point

rule?✔ A combination of feet and hands adding to three at all times.

❏ Is the employee twisting, overextending, or jerking?❏ Is the employee lifting correctly?❏ Are employee body parts positioned to avoid pinch or pinned posi-

tions?❏ Is the employee in the line of fire?

✔ Can an energy source contact, strike, or hit the employee?❏ Do employees communicate their actions, concerns, or warnings?

Do they request assistance?❏ Do employees preplan their work? Do they anticipate, recognize,

evaluate, and control hazards? ❏ Are the correct tools being used for the task? Are they being used

correctly? Are the tools in good repair?❏ Are walking and working surfaces free of hazards?❏ Are vehicles operated at safe speed and do they have appropriate

alarms?❏ Are employees trained to operate equipment?N. Head, Eye, and Face Protection❏ Ensure that appropriate head protection is provided and used by all

employees.❏ Check that eye and face protection devices are provided and used.❏ Check that adequate eye and face protection equipment is provid-

ed to prevent injury from physical or chemical agents.❏ Check that eye-wash devices are properly located adjacent to haz-

ardous chemical storage or use areas.O. Respiratory Protection❏ Check that respirators are an approved type (e.g., U.S. Bureau of

Mines or other local standard) and are designed to protect for thespecific type and concentration of contaminant in the work environ-ment.

❏ Check that employees required to use respirators are trained intheir use and are clean shaven.

❏ Ensure that respiratory equipment is regularly inspected and is ingood condition.✔ Interchanging components from different manufacturers is

prohibited.❏ Ensure that used respiratory equipment is cleaned and disinfected

before reissue.

G-2-4


G. Fire Prevention Measures❏ Ensure that a fire prevention and protection program is in place at

the site.❏ Check that combustible materials are isolated from hot work either

by distance or fire-resistant covers.❏ Check that slag and hot materials are properly contained.❏ Check that hot work permits are properly executed.❏ Check that scrap wood, cartons, and other combustibles are

promptly and properly disposed.H. Welding and Cutting Operations❏ Check that hot work permits are being used.❏ Ensure that fire extinguishers are present during all welding and

cutting operations.❏ Check that oxygen and fuel cylinders are stored at least 20 ft (6 m)

apart.❏ Ensure that only trained personnel operate welding and cutting

equipment.I. Compressed Gases❏ Check that cylinders are segregated in well-ventilated areas.❏ Ensure that smoking is prohibited in cylinder storage areas.❏ Check that cylinders are stored in a secure and upright position.J. Ionizing Radiation❏ Check that persons using x-rays or radioactive materials are quali-

fied or licensed where necessary.K. Nonionizing Radiation❏ Check that only qualified, trained personnel operate laser equip-

ment.❏ Check that laser safety goggles are provided when power exceeds

0.005 watts and that employees are not exposed to intensities overallowable limits.

❏ Check that areas are posted with warning signs when laser equip-ment is used.

❏ Check that lasers are turned off when not in use.❏ Check that laser beams are not directed at employees.❏ Check that lasers are not used when it is raining or snowing or

when there is heavy fog or dust in the air.❏ Check that labels indicating power are shown on laser equipment.❏ Check that laser beams are used in controlled areas and/or isolat-

ed from employee contact.L. Illumination❏ Check that illumination is provided and is adequate for the task

being performed. Particular attention should be given to the fol-lowing areas:✔ Exits and egress routes

G-2-3


❏ Check that scaffold is secured to the building every 26 ft (8 m) ver-tically and every 30 ft (9 m) horizontally.

❏ Check anchorage on two point suspension scaffolds. Anchoragemust be redundant and capable of supporting 6 times the intendedload.

❏ Check working load of suspended scaffold. A maximum of 500 lbs(227 kg) for two workers and a maximum of 750 lbs (340 kg) forthree workers.

❏ Check that each employee has a separate independent lifeline.S. Excavation, Shoring, and Trenching❏ Check for underground structures such as gas, water, electric, and

utilities before performing any excavation.❏ Check excavation depth. If greater that 4 ft (1.2 m), identify com-

petent person.❏ Check atmospheric testing.❏ Check that burden is at least 2 ft (0.6 m) from excavation and

machine loading.❏ Check groundwater and groundwater control.❏ Check adjacent structures for shoring stability.❏ Check adequacy of shoring or angle of repose for soil and depth

conditions.❏ Check support and protection of roads and sidewalks.❏ Check for adequate access. Ladders or stairs are required for

every 25 ft (7.6m) of lateral travel.❏ Check that equipment ramps are adequate and that slope is not too

steep.T. Hoists, Cranes, and Derricks❏ Check cables and sheaves for excessive wear and abrasion.❏ Check slings, chains, hooks, and eyes for defects, excessive wear,

or damage.❏ Check overhead utility potentials to ensure that lines are inactivat-

ed or removed or that work is at safe distance from the lines asrequired by local regulations.

❏ Check barricades or lift area isolation.❏ Check lift plan and verify weights calculations.U. Housekeeping❏ Make sure that general site housekeeping is up to standards.❏ Ensure that scrap with protruding nails such as crates and boards

are removed and properly disposed from work areas.❏ Check that combustible scrap and debris is removed at least once

each shift or more frequently as required.❏ Verify that separate labeled containers are provided for waste,

trash, and oily rags.

G-2-6


P. Safety Harnesses/Lifelines/Retractable Reels❏ Check that safety equipment is used for employee safety only.

Items used otherwise should be destroyed.❏ Check that lifeline systems (anchorage points, cable size, clamps)

and safety harnesses have a minimum breaking strength of 5,400lbs (2,450 kg).

❏ Check for proper safety equipment inspection and storage.Q. Occupational Noise Exposure❏ Ensure that employees are provided with hearing protection when

noise levels may exceed limits.❏ Check that an effective hearing conservation program is adminis-

tered when noise levels continuously exceed limits.❏ Check that devices for hearing protection are worn properly.R. Scaffolds and Ladders❏ Check that portable ladders are tied, blocked, or otherwise secured

to prevent displacement.❏ Check that ladders placed in passageways, doorways, or in other

areas where they may be displaced are protected by barricades orguards.

❏ Check that job-made ladders providing the only means of exit for25 or more employees are double cleated and not more than 24 ft(7.3 m) in length.

❏ Check that ladder cleats are inset into side rails 1/2 inches (12mm), or filler blocks are placed between cleats.

❏ Check that ladders have been inspected and are properlylabeled/marked.

❏ Check that scaffold and ladders are placed or constructed on solidfoundations. Adjustable or plane bases are required for scaffoldlegs.

❏ Check that scaffolding is properly tagged.❏ Check that standard guard rails and toe boards are provided on all

scaffolds that are 10 ft (3 m) or more above ground or floor.Standard guard rails shall be minimum 42 inches (1 m) high, con-structed with 2 inch x 4 inch posts and rails (or equivalent), 1 inchx 6 inch mid-rail and 4 inch high toe boards (minimum). Sizes referto nominal or dressed lumber dimensions.

❏ Check that scaffolds that must be passed or worked under are pro-vided with screen from toe board to midrail.

❏ Check that overhead protection is provided for workers on a scaf-fold exposed to overhead hazards.

❏ Check that scaffold planks extend between 6 and 12 inches (15and 30 cm) and are of scaffold grades material.

G-2-5

Guideline G-3Equipment Tag/LockoutA. Establishing A Tag/Lockout Condition❏ Ensure that an authorized/affected worker completes a tag/lockout

request defining work or testing to be performed.❏ Before the equipment is turned off, ensure that the

authorized/affected worker understands:✔ Type and magnitude of energy involved✔ The potential hazards of the energy being controlled✔ The method of controlling the energy

❏ Shut down the equipment per procedures avoiding hazards toworkers and equipment as a result of the equipment stoppage.

❏ Physically locate, tag, and lock (install and try) all boundary energydevices that will control and isolate the equipment from all energysource(s).

❏ Release, disconnect, and render safe all residual or stored energyin the equipment.

❏ Establish a method to monitor and verify equipment isolation ifthere is a potential for residual or stored energy buildup.✔ Continue monitoring until equipment lockout is removed or the

potential for residual or stored energy buildup no longerexists.

B. Working in a Tag/Lockout Condition❏ Ensure that an authorized/affected worker verifies that isolation or

de-energizing is complete before starting the work covered by theequipment tag/lockout request.

❏ Ensure that a test is performed on normally energized or cyclicalequipment parts exposed to the worker during the work operationto verify that these parts are de-energized.

C. Temporary Removal of Tag/Lockout Devices for Testingor Positioning

❏ Inspect the work area, remove all nonessential items, and verifythat the equipment is operationally intact.

❏ Inspect the work area and position all workers away from danger.❏ Notify all affected workers of the pending energization.❏ Remove the tag/lockout device.❏ Energize the equipment and proceed with testing or positioning.❏ Shut down the equipment per procedures avoiding hazards to

workers and equipment as a result of the equipment stoppage.❏ Reinstall tag/lockout devices and physically check all energy isolat-

ing devices.❏ Check all residual or stored energy sources to ensure that energy

has been released, disconnected, or rendered safe.



❏ Ensure that scrap with protruding nails such as crates and boardsare removed and properly disposed from work areas.

❏ Check that combustible scrap and debris is removed at least onceeach shift or more frequently as required.

❏ Verify that separate labeled containers are provided for waste,trash, and oily rags.

V. Safety Nets❏ Ensure that safety nets are provided when the work place is more

than 25 ft (7.6 m) above the ground or water and when the use ofplatforms, scaffolds, ladders, temporary floors, safety lines, or bodyharnesses are impractical.

❏ Check that nets extend 8 ft (2.5 m) beyond work edge where work-ers are exposed.

❏ Check that nets are installed as close as possible to the work andno more than 25 ft (7.6 m) below working level over ground orwater.

W. Miscellaneous Safety and Health Issues❏ Check that covers are on hazardous or flammable waste contain-

ers.❏ Check that employees working over or near water use life jackets.❏ Check that floor openings are guarded with standard handrails. A

floor opening is a hole 12 inches (30 cm) or more in its least dimen-sion.

❏ Check that runways are provided with standard rails and toe boardswhen they are 4 ft (1.2 m) or more above the ground.

❏ Ensure that an entry permit is issued and that the atmosphere istested and found safe or forced ventilation is provided beforeemployees enter a manhole or nonvented vault.

❏ Check that an employee is available in the immediate vicinity forassistance when work is being done in a manhole or nonventedvault.

X. Sanitation❏ Check that containers for drinking water are so labeled.❏ Check that outlets for non-potable water are labeled.❏ Verify that no connection exists between potable and non-potable

water supplies.❏ Check that toilets are adequate and in proper working order.❏ Check that adequate washing facilities are provided for employees

handling hazardous materials.❏ Check that workers do not have to work in unsanitary conditions.

G-2-7

Guideline G-4Receiving and StorageA. Receiving❏ Maintain a daily receiving log.❏ Check for loading and shipping damage to material and equipment.

✔ Verify that items are free of damage caused by fire or hightemperatures, excessive weather exposure, environmentaldamage, tie down failure, or rough handling.

❏ Avoid contamination of the materials and components duringreceipt inspection.

❏ Check that material and equipment conform to size, type, quantity,and configuration specified in the purchase order and on the detaildrawings.

❏ Verify that all required supplier documentation is received with theshipment.✔ Verify that Material Safety Data Sheets (MSDSs) are provided

for all chemicals.❏ Review supplier documentation for special identification, marking,

and tagging required by the purchase order or contract.✔ Make this review when the shipment is received to avoid the

added cost and schedule impacts.❏ Promptly identify and expedite all shortage items and initiate repair

or replacement of damaged items.❏ Avoid double handling by checking shipping and erection sched-

ules.✔ Unload and transport directly to erection areas, where possi-

ble.❏ Follow manufacturer instructions and/or approved procedures

when unloading, rigging, handling, and transporting components toand from rail cars or trucks.

B. Storage❏ Verify that good housekeeping practices are used in storage areas.❏ Systematize and record storage locations so that materials can be

located easily.✔ Provide full crane, truck, and rail access to storage areas.✔ Segregate and control access to damaged or rejected materi-

als.❏ Provide dry indoor storage for instruments, electrical equipment,

weld rod, insulation, and other items, requiring protection from theelements.✔ Provide numbered bin storage, where appropriate.

❏ Identify and control items with a specified shelf life.❏ Perform user acceptance tests, where required.❏ Perform preventive maintenance for equipment per manufacturer

instructions.❏ Check that manufacturer storage and preservation requirements

are followed.❏ Ensure that flammable and hazardous materials are properly

stored.

G-4-1

Equipment Tag/Lockout Guideline G-3

❏ Establish a method to monitor and verify equipment isolation ifthere is a potential for residual or stored energy buildup.✔ Continue monitoring until equipment lockout is removed or the

potential for residual or stored energy buildup no longerexists.

D. Release of a Tag/Lockout Condition❏ Inspect the work area, remove all nonessential items, and verify

that the equipment is operationally intact.❏ Inspect the work area and position all workers away from danger.❏ Notify all affected workers of the pending energization.❏ Ensure that the worker who initiated the control removes the

tag/lockout device returning tags and/or locks to the appropriatecustodian.

❏ Energize the equipment.

G-3-2

Guideline G-6Material ControlA. Preplanning❏ Make sure that material availability and delivery are considered in

work scheduling.✔ Track critical procurements.✔ Expedite orders when required.✔ Establish priorities for material receipt and issue.

❏ Check that a process/procedure is in place to control material pro-curement, receiving, storage, maintenance, and issue.✔ Define technical and quality requirements in purchase orders.✔ Identify and properly handle hazardous materials.✔ Perform receipt inspection for damage and purchase order

requirements.✔ Identify and implement storage and maintenance require-

ments.✔ Control material storage and issue.

❏ Check that site personnel are knowledgeable of site material con-trol process.

B. Implementation of Site Material Control❏ Check that required receipt inspection documentation is completed.❏ Check that material is properly handled from off loading through

installation.✔ Use proper handling practices.✔ Implement special handling requirements.

❏ Check that material is properly stored.✔ Ensure that storage meets project and manufacturer require-

ments.✔ Control access to storage areas.✔ Maintain storage areas in a neat and orderly manner.✔ Ensure that materials can be easily located.

❏ Check that material issue is controlled and documented.❏ Check that correct material is installed.

✔ Material markings are correct.✔ Materials meet design requirements.✔ Material installation documentation is complete.

G-6-1

Guideline G-5Design Document ControlA. Preplanning❏ Check that a site procedure exists to control project design docu-

ments and design document changes. This procedure mustaddress:✔ Verification of the documents received against project engi-

neering, vendor, or subcontractor transmittals✔ Maintenance of document control logs (registers) listing the

current revision to each document✔ Control stamping of the documents✔ Field distribution of design documents using controlled distri-

bution lists✔ Logging and transmittal of field changes such as Field

Change Requests (FCRs) and Field Change Notices (FCNs)for approval

✔ Receipt, control, and distribution of approved field generatedchanges such as FCRs and FCNs

❏ Check that personnel responsible for controlling and using designdocuments are knowledgeable of the requirements.

❏ Check that the central filing system is neat and well organized.B. Central Document Control ❏ Check that newly received documents conform to the applicable

project engineering, vendor, or subcontractor transmittal listing. ❏ Check that the pertinent information for newly received documents

is entered into control logs or registers.❏ Check that newly received documents are stamped per site proce-

dure requirements.❏ Check that newly received documents are distributed per the site

procedure.❏ Check that the document control system is regularly audited as

required by site procedures.C. Implementation of Design Document Control❏ Check that documents are obtained from controlled sources per the

site procedure.❏ Check that the document has the appropriate stamp for the appli-

cation.❏ Check for interim field changes to design documents per site

requirements.D. Document Turnover❏ Check that a project procedure exists for the turnover of records to

the client per contract requirements.



Guideline G-8Control of Deficient ItemsA. Preplanning❏ Check that a site procedure exists to control deficient items.

This procedure must address methods to:✔ Identify, document, and evaluate deficient items.✔ Prevent inadvertent use of deficient items.✔ Segregate deficient items, where necessary.✔ Control deficient items released for installation before the

deficiency is resolved.✔ Ensure that the final resolution of the deficiency is obtained.✔ Determine the cause of the deficiency and the appropriate

corrective action.✔ Notify appropriate functions of the deficiency and corrective

action.❏ Ensure that responsibility for review and disposition deficient items

is defined.❏ Verify that site personnel are knowledgeable of deficient item

control requirements.B. Implementation of Deficiency Control❏ Check that deficient items are documented by the use of:

✔ Receipt Inspection Reports✔ Punchlists✔ Deficiency Reports

❏ Check that items released for installation before the final resolutionof the deficiency can be traced and retrieved from the installedlocation.

❏ Ensure that the deficiency is resolved before the item is turned overor the deficiency is noted as an exception.

❏ Check that dispositions have the required level of approval.❏ Check that all specified rework, repair, and verifications are per-

formed and documented.❏ Check that measures are taken to prevent the inadvertent use of

rejected items by scraping, discarding, or destroying the rejecteditems.

❏ Check that the cause of the deficiency is determined and appropri-ate corrective action is taken.

❏ Check that repaired or reworked items are reinspected as required.


Guideline G-7Measuring and Testing EquipmentA. Preplanning❏ Review contract requirements, codes, standards, specifications,

drawings, procedures, and other site requirements to determine thetype, size, and range of equipment required to fall under the cali-bration control program.

❏ Check that a site procedure exists to control Measuring and TestingEquipment (M&TE) at the site. The procedure must address:✔ Usage control✔ Storage and maintenance of M&TE✔ M&TE labeling✔ Calibration expiration recall✔ Evaluation of M&TE that is lost, damaged, or found to be out

of calibration❏ Check that personnel responsible for using and controlling the

M&TE are knowledgeable of the requirementsB. Implementation of M&TE Control❏ Check that the M&TE appears to be functioning properly.❏ Check that the M&TE is labeled properly.❏ Check that the M&TE is not past the calibration due date.❏ Check that the M&TE has been properly withdrawn identifying:

✔ Where will the M&TE is to be used✔ On what items the M&TE will be used✔ The value or range of values that the M&TE will be used to

verify✔ The name of the person who checked out the M&TE

❏ Check that the M&TE is being used within the acceptable range.❏ Check that any required pre-usage or post-usage functional tests

are performed❏ Check that the required documentation is completed and that it

records:✔ M&TE identification✔ Value measured✔ Name of the person using the M&TE

❏ Check that M&TE is returned to the designated storage location


Guideline G-21Rigging Method SelectionA. Preplanning❏ Preplan all heavy lifts and prepare a formal rigging plan for:

✔ All lifts of more than 10 tons✔ All lifts of critical equipment or lifts over critical equipment

regardless of weight.❏ Obtain certified rigging engineer rigging plan review and approval

for all lifts of more than 50 tons.B. Heavy Lift Rigging Plans❏ Determine configuration and dimensions of the items to be

handled.❏ Locate the center of gravity and determine weight using certified

vendor drawings.✔ Double check vessel weight with shipping scale weights.

❏ Verify that the vessel is empty and drained of hydrostatic test water.❏ Determine if temporary shipping skids must be left in place for the

lift and if so, include the skid weight in the load evaluation.❏ Determine the method of attachment.

✔ If attachment points are provided on the equipment, makecertain that they are intended to handle the entire weight andnot just a component.

❏ Comply with fabricator handling requirements to prevent damage.❏ Determine necessity and availability of special handling devices.❏ Account for all rigging component weights in determining the load

to be lifted including the boom jib, wire rope, hooks and shackles,and spreader beams.

❏ Make appropriate crane capacity deductions per manufacturercrane chart.

C. Work Site Evaluation❏ Determine the path of movement from receipt of final setting;

identify areas of restricted movement, including both lateral andoverhead clearances.

❏ Check proximity of electrical power lines and maintain the minimumrequired clearance in all transport and rigging operations.

❏ Determine the adequacy of work areas.❏ Check floors, structures, and access roads for design-imposed load

restrictions.✔ Anticipate load distribution change during upending and other

handling operations.


Guideline G-9Records RetentionA. Preplanning❏ Check that a site procedure exists to control construction quality

records. This procedure must address:✔ Which construction quality records must be retained✔ Requirements for control of in-process construction quality

records✔ Requirements for filing and storage of completed construction

quality records✔ Appropriate fire protection✔ Provisions for supplementing or correcting completed records✔ Method for turning over completed construction records to the

client✔ Method of turning over completed construction records for

Bechtel archives❏ Check that personnel responsible for controlling construction

quality records are knowledgeable of the requirements.B. Implementation of Construction Quality Record Retention ❏ Check that construction quality records are complete and legible.❏ Check that records that are light, pressure, or temperature

sensitive are handled per manufacturer instructions.❏ Check that precautions are taken with electronic records to ensure

that only authorized personnel can access and make changes tothe records.

❏ Check that the in-process construction quality records are storedas required.

❏ Check that completed quality records are filed as required.❏ Check for interim field changes to design per site requirements.

Guideline G-22Rigging PerformanceA. Preplanning❏ Recheck clearance in path of lifting operations.❏ Check that the crane and/or equipment are on stable level ground

and that mats are used as shown on drawings.❏ Verify the type of crane.❏ Ensure that outriggers are fully extended before making the lift.❏ Check that the crane is positioned per the heavy lift rigging plan.❏ Verify that accessories, such as slings and shackles, have been

properly examined and inspected.❏ Verify that test certificates are available for all lifting equipment.❏ Verify that boom length, working radius, load line reeving are per

rigging plan.❏ Check that accessories are the size, capacity, and quality specified.❏ Check that nondestructive examination is performed on lifting lugs.❏ Check that softeners are placed over sharp corners and objects for

protection.❏ Verify that hydrostatic test water has been completely drained from

vessels before lifting operations.❏ Ensure that heavy lift rigging plan requirements are reviewed with

the superintendent, crane operator, ground crew, and competentsignal person(s) before making the lift.

B. Work Operations❏ Monitor rigging operations for compliance with the heavy lift rigging

plan.❏ Perform a preliminary lift by slowly raising and lowering load slightly

to ensure that all equipment is functioning properly and is suspended at correct altitude.

❏ Check that slings and load have equalized as required.❏ Ensure that walk loads are as close to the ground as possible.❏ Check that chain slings are not used.❏ Check that tag lines are used.❏ Hoist, traverse, and rotate the item as required for placement.


Rigging Method Selection Guideline G-21

D. Equipment Handling❏ Determine the proper orientation of the equipment in its final

location.❏ Place a matching orientation mark (e.g., plant north) on both the

equipment and the equipment support that can be matched duringsetting operations.

❏ Determine the proper handling sequence for equipment with severalcomponents.

❏ Determine whether wind, temperature, humidity, or rain will requirespecial handling restrictions.

G-21-2

Guideline G-24Mobile CranesA. Preplanning❏ Note the boom model and number of parts of load line required by

the manufacturer load chart.❏ Determine whether a jib is to be used.

✔ If so, note the mode, capacity, length, and offset required forthe lift.

❏ Determine whether the crane will remain stationary and/or levelduring all phases of the operation.

❏ If load must be walked with the crane, verify that crawler cranes arerated at 75 percent of tip-up.

❏ Truck cranes are normally rated at 85 percent of tip-up.✔ Most manufacturers do not furnish information on conditions

for use.✔ Charts are normally based on capacity without outriggers.✔ Do not overload tires and running gear.✔ Critical loads must be carried over rear of crane on firm level

ground.❏ Check slings and fittings to ensure a safety factor of 5.

✔ To determine safety factor, consider angle of sling, efficiencyof end connections, type of hitch, and reduction due to bend-ing around corners and small radius pins.

❏ Verify that softeners are in place if required to protect slings aroundsharp corners or to protect the surface.

❏ If a four sling lift is to be made, verify that any two slings are capable of handling the entire load.

❏ Verify that the rated capacity of the spreader bar (if used) is adequate.

❏ Verify that hand lines are used to control the load during lift operation, if required.


Guideline G-23Movement by TransportA. Transport Vehicles❏ Ensure that the transport vehicle complies with local motor vehicle

regulations.❏ Make sure that special conditions and equipment required for safe

transport of hazardous materials are identified and planned.❏ Determine the combined weight of the transport vehicle and trailer.❏ Verify that drivers and operators are licensed, qualified, and

certified as required to operate assigned equipment.❏ Develop an emergency plan for the transport effort.❏ Ensure that the height, width, and length of the load complies with

local regulations.❏ Preplan requirements for escort vehicles, transport signs, and

transport hours and verify compliance with local regulations.❏ Inspect transport vehicle and trailer to verify working condition of

horn, back-up alarm, lights, turn signals, tires, brakes, emergencybrake, ball and hitch, safety chains, reflectors, electrical wiring andconnections, and fire extinguishers.

❏ Ensure that adequate tie downs and chocking are provided.B. Load Evaluation❏ Confirm the weight of the component(s) to be transported by check-

ing manufacturer documents and certified scale weights whenavailable.✔ Ensure that shipping skids are included in the weight determi-

nation.✔ Check for water that may be trapped in the component to be

transported and may increase the transported load.❏ Verify that the weight of the component to be moved is within the

design capability of the transport vehicle.❏ Verify that configuration and structure of the transport vehicle or

trailer bed will accommodate the component(s) to be moved.❏ Determine the combined weight of the transported component(s)

and transport vehicle.❏ Plan transport vehicle load distribution to avoid exceeding axle load

limits.C. Travel Route Evaluation❏ Verify that axle loadings do not exceed floor or access road

limitations.❏ Verify that vehicle maneuverability is compatible with the access

route.❏ Determine whether assistance is required to negotiate grades.❏ Verify that adequate clearance is available along access route.


Guideline G-26Base-Mounted CranesA. Preplanning❏ Before a base-mounted crane is used for rigging operations, the

entire system should be inspected by the person-in-charge or theresponsible field engineer.

❏ Verify that the total load to be lifted includes the weight of the pieceplus an allowance of 10 percent for impact.

❏ Verify that the hoist provides adequate line pull on one drum (ortwo, if simultaneously) to make the lift. Line pull decreases as thenumber of wraps on the drum increases.

❏ Check the hoist to verify that it has adequate capacity to spool thelength of rope required for the lift with no less than two wraps onthe drum at all times. ✔ Verify that proper anchorage installation of the rope to the

drum.❏ Ensure that the hoist is located at a sufficient distance from the lead

sheave to provide the proper fleet angle to ensure that the rope willspool evenly on the drum.

❏ Verify that the hoist anchorage provides a safety factor of 2 basedon the total line pull at any time, not including the weight of thehoist.

❏ Check whether the angle at which the rope leaves the drum willproduce a vertical or side force on the hoist. ✔ Anchorage must be provided to resist these forces.

❏ Select a load line that will provide a safety factor of 31/2 for themost heavily loaded rope based on the maximum load to be liftedby a set of falls. ✔ Take into account end connection and friction from sheaves.✔ Verify that the size of rope used is adequate for the number of

parts of line used.❏ Select load blocks compatible with the load line whose rated capac-

ity is equal to or greater than the maximum load they must hoist.❏ Select lead sheaves compatible with the load line and with a rated

capacity equal to or greater than the resultant of the load line enter-ing and leaving the sheave. ✔ The resultant is the bisector of the angle between the two

lines.B. In-Process Inspections❏ Verify that the lead sheave is free to move its loaded position with-

out interference and make provisions to prevent movement alongthe member to which it is anchored. ✔ Wire rope used to anchor lead sheaves must provide a safety

factor of 3.❏ Verify that load lines enter and leave sheaves squarely and not at

an angle that would cause the rope to bear on the lip of the sheave.

G-26-1

Guideline G-25Bridge CranesA. PreplanningNote: Handling construction loads with bridge cranes permitshandling up to the rated capacity of the crane within the entirearea of coverage.❏ Check slings and fittings to ensure that they have a safety factor

of 5.✔ To determine safety factor, consider angle of slings, efficiency

of end connections, type of hitch, and reductions due to bend-ing around corners and small radius pins.

❏ Verify that softeners are in place if required to protect slings aroundsharp corners or to protect the surface.

❏ If four slings are used, verify that any two are capable of handlingthe entire load.

❏ Verify that the rated capacity of the spreader bar is adequate.❏ Verify that hand lines are used to control the load during lifting

operation, if required.❏ When handling loads through an access hatch, complete a clear-

ance study to determine that sufficient drift is provided with thehook in the upper limit position.

G-25-1

Guideline G-27Rigging ComponentsA. General❏ Have a competent person inspect components each day before

use for damage or defects.❏ Do not use hardware in other than intended use.❏ Do not exceed rated capacities.❏ Check for load capacity identification markings on the component.B. Wire Rope Clips❏ Ensure that the U-bolt is applied over the dead end of wire rope and

live end rests in saddle; never saddle a dead horse.❏ Ensure that clip nuts are tightened evenly.❏ With a single clip, apply one base width from dead end of rope.❏ When two clips are required, ensure that the second clip is applied

as near to the loop or thimble as possible.❏ When three or more clips are required, ensure that clips are spaced

evenly with no slack in the wire rope.C. Hooks❏ Visually inspect hooks for cracks, nicks, wear, gouges, and defor-

mation.❏ Periodically perform non-destructive examination of hooks used in

frequent load cycles.❏ Inspect hooks to ensure that throat opening has not opened, that

tip is not bent more than 10 degrees out of plane, or that hook isnot distorted in any way.

❏ Remove hooks from service that have excessive wear.❏ Do not repair, alter, rework, or reshape hooks by welding, heating,

burning, or bending.❏ For threaded shanks, the minimum thread engagement should not

be less than one thread diameter.D. Eye Bolts❏ Do not use an eye bolt if it shows signs of wear or damage or if it

is bent or elongated.❏ For regular nut and shoulder eye bolts, apply load in the plane of

the eye–not at an angle.E. Swivel Hoist Rings❏ Do not use swivel hoist rings if ring shows sign of corrosion, wear,

or damage or if the bail is bent or elongated.❏ Check already installed rings with a torque wrench before use.❏ Remove any spacers or washers installed between bushing flange

and mounting surface and retorque before use.❏ Ensure bail freely pivots 180° and swivels 360°.

G-27-1

Base-Mounted Cranes Guideline G-26

❏ Verify that suspended from structural steel supporting the upperload block is designed per AISC or other applicable design code.

❏ Verify that the slings and spreader bars used to attach the loadblock meet the same requirements designed for those used onmobile cranes.

❏ Verify that line speeds are slow enough to permit complete controlat all times.

G-26-2


Guideline G-28Suspended Personnel Work PlatformsA. General❏ Verify that suspended work platform use is the safest and most

practical way to accomplish the task.❏ Ensure that all crane inspections are current.❏ Check that all hooks have a current inspection and have positive

locking type hook latches.❏ Ensure that the load chart is in the crane and that the operator is

familiar with all special chart requirements.❏ Verify that crane operational aids and safety devices are function-

ing and that the operator knows how to use them.❏ Ensure that the crane is on firm footing and the crane outriggers are

extended, down, and locked as applicable.❏ Check that the crane is level within 1% and is on a firm surface.

✔ Verify stability of the footing during the full cycle of operationtest.

❏ Ensure that the operator is able to verify that the crane is level.❏ Ensure that a firm, level "runway" or travel path has been prepared

for the weight and configuration of the crane used.❏ Ensure that counterweights are per crane manufacturer require-

ments.❏ Ensure that load lines are properly reeved and laying on drums.❏ Ensure that all drum hoists have full control load lowering and that

free fall is not used.❏ Check that the boom angle and radius indicator operates properly.❏ Check that the boom length indicator on telescoping booms oper-

ates properly.❏ Ensure that the positive anti two block device operates properly.B. Rigging Requirements❏ Ensure that each bridle leg is connected to the master link or

shackle and that the load is evenly shared by all bridle legs.❏ Ensure that all rigging, wire rope, shackles, rings, master links, and

other rigging hardware have a safety factor of 5.✔ When non-spin cable is used, a safety factor of 10 is required.

❏ Check that all wire rope eye fittings have thimbles.❏ Ensure that all load hooks are closed with locking type latches.❏ Ensure that all suspended work platform rigging equipment is

exclusive for that use.❏ Inspect all rigging for kinks and damage.❏ Check that all shackle pins are nut with pin retainer type.

Rigging Components Guideline G-27

F. Block and Tackle❏ Do not use if block and tackle show signs of permanent deforma-

tion, significant wear, or damage.❏ Inspect swivel fittings for shoulder running clearance, lateral

movement, wear, and deformation.❏ Inspect and refurbish bearings on sheaves that are loose or

wobbly.❏ Make sure the sheave groove matches the wire rope diameter.❏ Check sheaves for signs of deep or unusual channeling, rutting, or

corrugating along the walls and at the bottom of its groove.❏ Periodically inspect sheaves for groove diameter, bent or cracked

flanges, worn hubs, cracked welds, or cracked spokes.❏ Avoid excessive fleet angles–the angle between the wire rope and

the sheave as it enters or leaves the sheave.✔ Fleet angles in excess of 2° can cause excessive wear and

rope twisting.G. Slings❏ Do not use if damaged or defective.❏ Do not shorten with knots, bolts, or other makeshift devices.❏ Do not kink sling legs.❏ Balance basket hitch sling loads to prevent slippage.❏ Pad or protect slings from damage from sharp edges on the load.❏ Do not apply shock loadings.❏ Do not pull slings from under a load when the load is resting on the

sling.H. Shackles❏ Identify load rating on the shackle.❏ Apply angle loads in the plane of the bow.❏ Do not side load round pin shackles.❏ Do not exceed 120° including angle between slings connected to a

shackle.❏ Reduce shackle working load limit per manufacturer requirements

when pad eye is less than shackle opening.

G-27-2

Suspended Personnel Work Platforms Guideline G-28

❏ Ensure that the load and boom hoist drum brakes, swing brakes,and locking devices are engaged when the occupied platform is ina stationary working position.

❏ Ensure that employees keep all body parts inside the platform dur-ing operations.

❏ Ensure that the operator remains at the controls when the craneengine is running and the platform is occupied.

❏ Make sure that platform use is discontinued when there is an indi-cation of dangerous weather conditions or other danger.

❏ Make sure that the operator and signal person are in constant handsignal or voice communications during operations.

❏ Make sure that employees remain in sight or in direct communica-tion with the operator or signal person.

❏ Ensure that all employees on the platform wear a properlyanchored body belt or harness system.

❏ Ensure that materials and tools are secured to prevent movementduring the lift.

❏ Make sure that no other object is lifted using any of the crane loadlines while the platform is suspended.

❏ Verify that a trial lift calculation sheet has been completed, signed,and dated.

G-28-3

Suspended Personnel Work Platforms Guideline G-28

C. Suspended Work Platform Requirements❏ Ensure that the platform is designed with a safety factor of 5.❏ Ensure that the maximum rated load and personnel capacity is

posted on the platform.❏ Ensure that the platform is provided with a perimeter grabrail,

guardrail, mid-rail, and toeboard.❏ Ensure that body harness anchorage points are provided.❏ Ensure that the access gate opens inward and is positively

prevented from swinging outward while the platform is in use.❏ Ensure that the access gate has positive locking to prevent

accidental opening during operation.❏ Ensure that employees can stand upright in the platform.❏ Ensure that overhead protection is provided on the platform when

there is a potential of falling objects.D. Proof-Testing, Trial Lift, Inspection, and Pre-Lift Meeting❏ Ensure that a pre-lift meeting is held with the operator, signal per-

son(s), employee(s) to be lifted, and the person responsible for thework.

❏ Ensure that employees will be protected from special hazards suchas electrical hazards and power lines and in operations where theplatform will be out of the operator's view.

❏ Ensure that a suspended work platform use authorization has beenissued, dated, and approved for the work.

❏ Verify that the platform and rigging are proof-tested to 125% of theplatform rated capacity.

❏ Verify that an unoccupied trial lift is performed with the platformloaded to the anticipated lift weight.✔ Perform a trial lift each time the crane is moved.

❏ Perform a post-trial lift crane inspection and correct any deficien-cies.

❏ Ensure that actual loads are less than 50% of the crane rating.❏ Verify that all systems, controls, and safety devices are functioning

properly and that no interferences exist.❏ Before lifting personnel, hoist the platform slightly to verify it hangs

level.❏ Check that all hoist ropes are free of kinks.❏ Check that multi-part lines are not twisted around each other.❏ Check that the hook is centered over the load.❏ Recheck the crane bearing surface and relevel the crane as

required.❏ Reinspect crane safety components, dogs, pawls, and brakes after

the trial lift.

G-28-2

General Welding Guideline G-31

❏ Verify that no rust, burning slag, grease, paint, moisture, or otherforeign matter is present on joint before welding.

❏ Verify that proper pre-heat is applied before welding.❏ Check that each layer of the weld is free from flux, slag, and

surface defects.❏ Verify that welds are of the full shape and section required.❏ For full penetration welds, verify that proper back gouging or

grinding of root to sound metal before second side welding.❏ Check that an adequate shrinkage allowance is made so that

distortions will not result.❏ Verify that completed welds are inspected/examined as specified.

✔ Temporary welds have the same requirements as final welds.D. Visual Inspection of Completed Welds❏ Check fillet welds for leg and throat size.❏ Check butt/grove welds for excessive or insufficient reinforcement.❏ Check for defects such as undercut, overlap, slag inclusions, and

excessive porosity.E. Weld Repairs❏ Report any weld defects to the Field Welding Engineer for

disposition.❏ Verify that removal of weld metal for the full length of any cracks as

specified by the contract documents before re-welding.F. Do not allow the following:❏ Cut-off of anchor bolts or rebar without approval.❏ Use of grinding wheels, files, or tools on stainless, inconel, or

monel base metal alloys that were previously contaminated by useon mild steel or iron.

❏ Unapproved tack welds to rebar, anchor bolts, or structural steel.❏ Unapproved heating or cutting structural steel.❏ Welding on crane booms without prior authorization of the Field

Welding Engineer.❏ Unapproved use of heat to align piping and equipment.❏ Welding unprotected from wind, rain, snow, or blowing sand.

G-31-2

Guideline G-31General WeldingNote: Welding requirements are specified in the project-specificSpecial Processes Manual (SPM), and all field inspections mustbe based on these requirements. The following guidelines aretypical of the requirements included in the SPM.A. Preplanning❏ Verify that welding procedures are approved for use and available

at the site.❏ Verify that welders are qualified for position and welding process.❏ Ensure that adequate facilities are available for welder testing on

site and that lighting and ventilation are adequate.❏ Check that welding machines, welding leads, flowmeters, regula-

tors, and support tools for welding activities are in good workingcondition.

B. Weld Rod Storage❏ Verify that new rods are stored in unopened, hermetically (airtight)

sealed containers.❏ Check that loose rods are stored in holding ovens until withdrawn

for use.❏ Verify that un-used weld rods that have been exposed to the atmos-

phere are returned to a holding oven for re-drying before re-issueas required by the contract documents.

❏ Make sure that a system is in place to ensure that weld rods are notre-dried more than one time.

❏ Verify that weld rods that have been wet are not used.C. Field Welding Inspection❏ Verify that all work is performed per the applicable welding code or

standard as required by the contract documents.❏ Verify that welders assigned to the work are qualified for the

process and applicable code.❏ Make sure that a protective cover or shelter is provided to protect

the welder and welding process from wind and rain.❏ Check that welding screens and/or blankets are provided to protect

personnel, material, and equipment from weld flashes and weldsplatter, as necessary.

❏ Check that edges or surfaces to be welded are correctly prepared,shaped, and cleaned.

❏ Verify that members are tacked together in the specified joint con-figuration before welding.

❏ Verify the type and size of rod used.❏ Verify that root openings do not exceed specified tolerance.


Nondestructive Examination Guideline G-33

❏ Magnetic particle✔ Monitor method, sequence of operations, examination medi-

um, surface temperature, and lighting.✔ Check magnetizing current, prod spacing, and direction of

magnetization.✔ Check examination coverage.✔ Review indication evaluation.

❏ Liquid penetrant✔ Verify penetrant material type/group.✔ Check lighting, surface cleaning, penetrant application, and

penetrant dwell time.✔ Check temperature, penetrant removal, and drying.✔ Check developer application and developer time.✔ Review indication evaluation.

C. Post-process❏ Verify that radiographic film is properly identified (both film and film

jacket).❏ Verify that NDE subcontractor evaluation for film quality (technique,

density, sensitivity) and report.❏ Verify that Bechtel Level II or III evaluation of weld quality and

report.❏ Verify that weld and base metal surface conditions and external

cleanliness are restored.

G-33-2

Guideline G-32Code WeldingNote: Code welding requirements are specified in the project-specific Special Processes Manual (SPM), and all field inspectionsmust be based on these requirements. The following guidelinesare typical of the requirements included in the SPM.A. Code Requirements❏ As required by the contract, verify that welding and other related

criteria meet the requirements of the following or other codesand/or standards specified:✔ ASME Boiler and Pressure Vessel Code, Sections I, V, VIII,

and X✔ ANSI B31.1, Power Piping; B31.3, Refinery Piping; and

B31.9, Building Piping✔ API 650, Welded Steel Tanks for Oil Storage; and API 620,

Recommended Rules for Design and Construction of LargeWelded Low Pressure Storage Tanks

✔ AWWA, Water Storage Tanks✔ AWS 1.1, Structural Steel

❏ Verify that the following have been submitted and approved, whenapplicable:✔ Quality control program✔ Welding and brazing procedures✔ Welding procedure qualification test records✔ Postweld heat treatment procedure✔ Nondestructive examination and inspection procedures

❏ Verify that the approved filler material control procedure is availableat the site and is being followed.

B. Work Operations❏ Check that the proper type and size of welding electrode is used.❏ Ensure that welders are qualified for the welds being made.❏ Check in-process welding techniques, including:

✔ Base metal surface preparation (bevel preparation and metalcleanliness)

✔ Fit-up and preheat temperature✔ Correct filler material, interpass temperature, and interpass

cleaning✔ Machine setting and shielding gas

❏ Verify weld quality. Review General Welding Guideline.❏ Verify that code nondestructive examination and postweld heat

treatment requirements are satisfied.


Guideline P-1General PipingA. Preplanning❏ Review applicable contract documents, codes, and standards

applicable to the piping system installation and identify specificrequirements.

B. Receiving Inspection❏ Check that material is properly packaged and free of damage.❏ Check material for proper identification.

✔ Check that permanent tags are attached to valves as speci-fied.

❏ Verify that quantities, sizes, material, surface preparation, weight,type of joint material and/or gaskets, bolt sizes and types, hangersizes and types, finish or cleanliness, and end closures of receivedpiping materials.

❏ Verify that the required documents are received with shipment.✔ Segregate and document items not conforming to specified

requirements.❏ Verify that required code data reports and documentation are

received with code piping materials.❏ Verify that required heat stamping or code stamps are on code pip-

ing material.C. Storage and Handling❏ Review need for any special processing.❏ Ensure that storage and handling are per procedures, specifica-

tions, and/or special instructions.❏ Provide for segregated storage of code piping materials.❏ Verify that cleanliness is maintained during storage.D. Fabrication❏ Before fabrication, check installation area and resolve interferences

with structural steel, electrical raceway, HVAC ductwork, and othercommodities.

❏ Verify that current revision of drawings are being used for fabrica-tion.

❏ Verify that proper material has been requisitioned from storage.❏ Inspect fabricated pipe spools to verify cleanliness, dimensions,

and configuration.❏ Verify that proper storage and identification of fabricated pipe

spools.E. General Piping Installation❏ After cutting or beveling, ensure that piping is cleaned and reamed

to full size.❏ Ensure that proper depth shoes or spacers are provided on pipe

supports and racks to accommodate required insulation.❏ Verify that specified protective coatings have been applied.

P-1-1

Guideline G-34Heat TreatmentNote: Postweld heat treatment requirements are specified in

the project-specific Special Processes Manual (SPM),and all field inspections must be based on these require-ments. The following guidelines are typical of therequirements included in the SPM.

A. Pre-Process❏ Determine the location, size, and quantities of welds to be treated.❏ Select the temperature monitoring equipment and the number and

location of thermocouples to be used.❏ Select the heating, controlling, and recording devices to be used.❏ Determine the required preparation of surfaces to be heat treated.B. In-Process❏ Monitor the following during the heat treatment:

✔ Heating and cooling rates✔ Holding temperatures✔ Time and temperature controlled, measured, and recorded

❏ Record the type, number, and location of temperature measuringand recording devices.

❏ Verify that temperature of weldment and adjacent base material isat proper level before protective insulation is stripped off.

C. Post-Process❏ Check that thermocouples and other temporary attachments are

removed and affected areas are visually examined.❏ Verify that weld and base metal external and internal surface clean-

liness is restored.

G-34-1

Guideline P-2Large PipeA. Preplanning❏ Review design drawings for constructability, interferences,

problems for erection, and scheduling.❏ Preplan piping installation. Review General Piping Guideline.❏ Perform receiving inspection of piping materials.❏ Ensure that material is properly stored and maintained.❏ Perform periodic material inventories and reorder required materi-

als as necessary.❏ Check building areas for possible interferences.❏ Check that required piping sleeves and openings are installed in

walls and floors before concrete placement.B. Installation❏ Monitor required field changes in piping systems and obtain

required engineering approvals before performing the work.❏ Ensure that the work is performed per applicable project proce-

dures.❏ Ensure that pipe connections do not transmit stress to equipment

flanges and nozzles.❏ Ensure that exception reports are properly prepared and

processed.❏ Ensure that changes that may result in interferences or that may

cause delays are coordinated with other disciplines.❏ Review other discipline design drawings for possible interferences

and schedule impacts.C. Testing❏ Ensure that installed pipe has been released for testing.❏ Ensure that post-test punchlists are completed and that pipe is

released for painting and/or insulation, as specified.❏ Release the completed system to Startup.

Field Inspection Guidelines © 1997, 2001 BechtelP-2-1

General Piping Guideline P-1

❏ Check that non-ferrous to ferrous piping connections are made withdielectric unions/couplings.

❏ Verify correct installation by checking configuration, orientation,location, and dimensions of the installed piping system.

❏ Verify correct installation of low point drains, high point vent assem-blies, expansion loops, and expansion joints.

❏ Verify that pipe, openings, valves, and fixtures are protected fromdirt, foreign objects, and damage during construction.✔ Ensure that all open pipe and valve ends are capped to pre-

vent entry of dust, dirt, and moisture.❏ Ensure that pipe connections do not transmit stress to equipment

flanges and nozzles.F. Welded Piping Installation❏ Check that pipe ends are square before beveling.❏ Check fit-up and beveling before welding piping joints.❏ Verify that pipe completed welds are free of metal "icicles," loose

material, or other obstructions that could retard the flow of gasesand fluids through the piping system.

❏ During construction, ensure that open ends of piping are protectedwith temporary closure plugs.

G. Screwed Piping Installation❏ Check that cut pipe ends are reamed to full size.❏ Check that threads are clean cut and free of burrs.❏ Ensure that joints in screwed piping are made up with joint com-

pound or teflon tape. H. Flanged Piping Installation❏ Ensure that flanged joints are faced true and square.❏ Check that gasket material is suitable for the intended application,

including temperature, pressure, and working medium.❏ Check that bolting material is properly lubricated before torquing.❏ Verify that flange bolts are properly torqued.I. Rack Piping Installation❏ Check that rack piping is neatly installed in common racks and runs

parallel in both vertical and horizontal planes.✔ Check that piping is pitched for venting or draining.✔ Check that adjacent lines are grouped in common vertical and

horizontal planes.J. System Punchlist❏ Walkdown assigned system(s) using system and design drawings

to verify completion status.❏ Prepare a punchlist by listing:

✔ Items that do not conform to contract requirements✔ Items that are not complete

❏ Verify completion of punchlist items when reported complete.❏ Update and reissue as necessary.

P-1-2


Guideline P-4Embedded PipingA. Preplanning❏ Verify that the embedded piping installation schedule is compatible

with the concrete placement schedule.❏ Verify that material receiving inspections have been performed.❏ Check that embedded pipe, fittings, and associated material are

properly marked, identified, and stored.❏ Make sure that material that does not conform to design require-

ments is segregated and documented.❏ Identify embedded piping that must be coated and wrapped.❏ Check for potential interferences with reinforcing bar, structural

steel, and formwork and ensure that adequate space is availablefor embedded piping installation before starting the work.

B. Installation❏ Verify that piping is physically located per the design drawings.❏ Document any dimensional installation deviations on "as-built"

drawings.❏ Verify that piping is adequately supported and secured against

movement during concrete or backfill placement.❏ Verify that system or partial system pressure tests have been con-

ducted and accepted before embedding any piping.❏ Ensure that adequate space is available to erect and pressure test

connection piping.❏ Make sure that all openings in the system, such as floor drains,

equipment drains, and connecting piping joints, have been sealedand that any valves in the vicinity of the concrete placement orbackfill have been protected for cleanliness against damage.


Guideline P-3Small PipeA. Preplanning❏ Preplan the piping installation. Review General Piping Guideline.❏ Determine the small pipe to be field routed.❏ Determine the small pipe to be detailed on field-prepared

isometrics.❏ Prepare small pipe layout and isometric drawings.❏ Check building areas for interferences before preparation of

isometrics.❏ Perform required receiving inspection.❏ Ensure that pipe and pipe fittings are properly marked, identified,

and stored.❏ Check that required piping sleeves and openings are installed in

walls and floors before concrete placement.❏ Monitor drawing changes and ensure that they are incorporated in

the field drawings.❏ Check that required project procedures have been prepared. ❏ Review other discipline design drawings for possible interferences

and schedule impacts.❏ Ensure that changes that may result in interferences or that may

cause delays are coordinated with other disciplines.B. Installation❏ Monitor required field changes in field-routed piping systems and

update field drawings accordingly.❏ Ensure that the work is performed per applicable project proce-

dures.❏ Ensure that pipe connections do not transmit stress to equipment

flanges and nozzles.❏ Ensure that exception reports are properly prepared and

processed.❏ Ensure that changes that may result in interferences or that may

cause delays are coordinated with other disciplines.❏ Review other discipline design drawings for possible interferences

and schedule impacts.C. Testing❏ Ensure that installed pipe has been released for testing.❏ Ensure that post-test punchlists are completed and that pipe is

released for painting and/or insulation, as specified.❏ Release the completed system to Startup.

Guideline P-6HDPE PipingHDPE A category of high-density polyethylene piping products

used in water, waste, electrical conduit, slurry lines, andgas pipe services. Pipe joining is performed by plasticwelding, socket connections, or butt heat fusion.

A. Material Handling❏ Make sure that the pipe is not handled with chains or drug over

sharp rocks or other abrasive materials.✔ Use canvas slings and pad forklifts where they directly contact

the pipe.❏ Check that material is stored to avoid crushing or piercing.B. Trenching❏ Ensure that the pipe trench provides a continuous bedding of

undisturbed or well-compacted soil free of rocks and other debris.❏ Provide a 4-inch (10 cm) minimum bedding of sand or other fine-

grained fill material over rock, ledge, hardpan, or boulders.❏ To minimize the width of the trench required, join piping above-

ground before lowering the pipe into the trench.❏ Verify that minimum burial depth is provided for the piping as

specified in the project specification or as required by local codes.C. Pipe Placement❏ Make sure that the piping is handled with care to avoid buckling and

twisting.❏ Check that the piping is not bent to a radius smaller than that

permitted by the manufacturer.✔ Typically 20 times the outside diameter of the pipe for regular

bends and 125 times the outside diameter is a fitting is includ-ed in the bend.

❏ Check that the pipe is slightly snaked in the trench to accommodatefor pipe expansion and contraction due to temperature changes.

❏ In warm weather, make sure that the pipe is allowed to fully con-tract by allowing the pipe cool to ground temperature before trim-ming and joining adjacent sections.

❏ Make sure that gas pipe is buried the required distance from steamlines, hot water lines, power lines, and other sources of heat toavoid temperatures in excess of 140°F (60°C) or as required bylocal codes.

❏ Check that protective sleeves are provided at all gas pipe servicebranches and transition fittings to protect against bending andshear forces.

❏ If tracer wires or metallic tape are installed to assist in locatingburied gas lines, make sure that they are installed at least 4 inches(10 cm) from the pipe.



Guideline P-5Storm and Sanitary SewerA. Preplanning❏ Ensure that requisitions and quotation requests for reinforced con-

crete pipe (RCP) to be used in refinery or chemical plant applica-tions specify the intended application.✔ Even though material specifications are the same, RCP man-

ufacturers often provide a better quality, more leaktight prod-uct to refinery and chemical plant applications.

B. Installation❏ Verify that the piping installation is properly aligned and sloped.

✔ Check that horizontal sanitary soil, storm, and drainage pipingis installed at a uniform grade as required by the contract doc-uments or local code requirements.

✔ Check that vent piping is graded to provide venting of plumb-ing fixtures and freedom from condensation.

❏ Check locations of all existing crosslines.❏ Make sure that required shoring or excavation shields are used as

required and that ladders are properly located for emergencyegress.

❏ Determine the correct testing equipment, procedures, and accept-ance criteria to be used.

❏ Monitor the excavation of trenches for correct alignment and elevations. Review Excavation Guideline.

❏ Check that pipe is properly bedded.❏ Check that soil and waste system connections are made correctly

and that each fixture or piece of equipment is equipped with a code-accepted trap.

❏ Check that cleanouts are located to provide easy rodding.✔ To ensure that cleanouts are accessible, verify that cleanouts

are extended to grade, floor, or wall.❏ Check that each plumbing vent penetrating the roof is provided with

flashing per contract document requirements.❏ Ensure that backfill placement and compaction procedures will pro-

tect piping from breakage or movement.❏ Verify that backfill meets compaction requirements.

Guideline P-7ValvesA. Preplanning❏ Preplan the valve installation. Review General Piping Guideline.❏ Perform required receiving inspection.❏ Check that valves are properly handled, stored, and maintained.❏ Check building areas for interferences with valves installation and

operation.❏ Verify that valves are the correct size, type, and pressure rating and

are installed in their correct location and orientation. ✔ Read the manufacturer tags and not the vendor tags to verify

valve information.❏ Perform required valve installation in-process inspections.❏ Complete valve installation progress reporting.❏ Perform periodic valve inventories and initiate field purchases of

valves if necessary.❏ Monitor P&ID deviations and obtain required design approvals for

changes.❏ Ensure that extra valve stem packing, bonnet gaskets, pressure

seals, plugs, and flange gaskets needed for repairs are available.❏ Review piping design drawings and vendor valve detail sheets for

compatibility, including material and end preps.❏ Ensure that required operating and setting instructions and proce-

dures are available.❏ Check that operating and setting activities are performed per appli-

cable instructions, procedures, and valve/operator manufacturerinstructions.

❏ Ensure that changes that may result in interferences or that maycause delays are coordinated with other disciplines.

B. Installation❏ Ensure that required exception reports are prepared and

processed.❏ Verify that required valve operator supports are installed.❏ Make sure that measures are taken to protect valve bodies and

internals from heat effects of welding.C. Testing❏ Check valve pressure capacity and ensure that it is greater than the

required piping pressure test. Review Leak Testing Guideline.


HDPE Piping Guideline P-6

D. Pipe Fusion❏ Check that fusion equipment is in proper working order and perform

a trial fusion at the start of each day.❏ Check that fusion tools, pipe, and fittings are free of contaminants

before use.❏ Remove sections of pipe with cuts, gouges, and deep scratches

before fusing.❏ Square pipe ends to remove any damaged or necked down

surface.❏ Check that the pipe ends are wiped with a clean cotton rag to

remove any foreign substance and cuttings from the inside diameter.✔ Avoid synthetic fiber rags because they may melt and char

against the heater.❏ Ensure that joined surfaces are simultaneously heated by the

fusion tool for the specified time.❏ Check that the two heated surfaces are brought together to form a

smooth, continuous seal and are held in that position until solidified.❏ Clean heater surfaces after every joint with a wooden implement.

✔ Do not use metal tools.❏ Check that transition fittings are used when HDPE pipe is joined to

other materials.E. Backfilling and Compaction❏ Provide the greater of 4 inches (10 cm) or one pipe diameter of

compacted fill over the buried pipe.❏ Ensure that fill is free of large rocks, dirt clods, frozen earth, and

decomposable debris such as wood.❏ Verify that fill is compacted as specified density.❏ Check that voids beneath service connections and transitions are

filled and compacted by hand or with a tamper as appropriate.❏ Check that the fill is placed in successive layers and spread uni-

formly to fill the trench completely without voids.❏ When heavy equipment is used to consolidate the final backfill,

ensure that care is taken to avoid damage to the pipe and that 24 inches (60 cm) of previously compacted cover is in place.

P-6-2

Hangers and Supports Guideline P-8

❏ Make sure that shock suppresser internals and reservoir are pro-tected when disassembling for repair or refilling.

❏ Check that supports and hangers not designated as anchors do notrestrict the free expansion and contraction of piping due to temper-ature changes.✔ Check that pipe anchors and pipe guides are installed at loca-

tions noted in the contract documents.C. Checkout❏ Verify that hanger and support checkout is performed per applica-

ble contract documents.D. Temporary Supports❏ Use the following table for temporary pipe support spacing:

MAXIMUM SPACING

STEEL COPPERPIPE SIZE WATER GASES WATER

1/2" 5'-0" 6'-0" 4'-0"

3/4" 5'-0" 6'-0" -

1" 7'-0" 9'-0" 5'-0"

11/2" 9'-0" 11'-0" 7'-0"

2" 10'-0" 13'-0" 8'-0"

21/2" 11'-0" 14'-0" 8'-0"

3" 12'-0" 15'-0" 9'-0"

31/2" 13'-0" 16'-0" -

4" 14'-0" 17'-0" 10'-0"

6" 17'-0" 21'-0" -

8" 19'-0" 24'-0" -

10" 22'-0" 28'-0" 17'-0"

P-8-2

Guideline P-8Hangers and SupportsA. Preplanning❏ Verify that the material receiving inspection has been performed

and that hangers and supports are acceptable for installation.❏ Determine which hangers will be field fabricated and which will be

vendor supplied.❏ Survey and locate hanger structural attachment locations.❏ Check installation areas for possible interference.❏ Make sure that hanger fabrication and installation are scheduled to

precede piping installation.❏ Ensure that spring hanger travel stops remain in place during

installation, testing, and system hanger checkout.B. Installation❏ Check that hangers and supports are installed per detail drawings

and within the tolerances allowed in contract documents.❏ Check that hanger and support spacing comply with contract doc-

ument requirements. Unless otherwise specified:✔ Support intervals will prevent sagging of the line.✔ Spacing will prevent excessive loading on any one hanger.✔ Piping will not be supported from other piping.✔ Hangers will be installed at valve and equipment locations.

❏ For fire protection piping, the following NFPA 13 requirements applyunless otherwise specified in the contract documents, by the man-ufacturer, or in local codes:✔ Maximum hanger spacing not to exceed 10 feet (3 m).✔ Maximum hanger spacing may be increased to 15 feet (4.5

m) for steel pipe that does not use vertically installed concreteexpansion anchors as structural attachments.

✔ Maximum unsupported end pipe section not to exceed 2 feet(0.6 m).

❏ Verify that perforated metal bands, wire, or punched hole strapmaterial is not used for piping supports.

❏ Verify that the most current approved drawing revision is beingused for hanger fabrication, installation, and checkout.

❏ Check that P&ID and piping drawing changes are incorporated onapplicable hanger support drawings.

❏ Ensure that all required exception reports are properly preparedand processed.

P-8-1

Guideline P-12Lined Pipe GasketsA. Materials❏ Ensure that gasketed joints are fabricated only for pipe lined with

Saran or thermally stabilized polypropylene resins.✔ They cannot be used for pipe lined with Kynar PVDF or PTFE

resins.❏ Ensure that polypropylene-lined pipe utilized for gasketed joints is

thermally stabilized (light gray liner color; blue color-code band).✔ Do not use non-thermally stabilized polypropylene-lined pipe

for gasketed joints (off-white liner color; white color-codeband).

B. Fabrication❏ Check the cutting of the pipe to the desired length, using a parting

or square-end cutter.✔ Make sure that hacksaws or wheel-type cutters are not used.

Hacksaws tend to lead, which produces non-right-angle cuts.Wheel-type cutters also produce a slightly beveled cut thatleaves burrs and causes severe stress risers in the plasticliner.

✔ Check that cut-off length of pipe and finished, face-to-facelength are the same.

❏ Check pipe end preparation:✔ Cut the metal 3/16" from the end of the pipe using the same

parting or square-end cutter, cutting through until the surfaceof the plastic liner is reached.

✔ The 3/16" cutback dimension is the same for all sizes of pipe.Tolerances for the cutback are +0" / -1/64". Because of theimportance of these tolerances, ensure that a steel scale isused to layout the 3/16" dimension.

✔ Carefully cut the plastic liner to achieve the proper outsidediameter dimension. Make sure that the stops on hand cutterare accurately set to achieve this dimension.

❏ Inspect the end and outside surface of the plastic liner stub.✔ Because the quality of the completed joint depends partly on

the surface condition of the plastic liner stub, imperfectionsmust be removed.

✔ Ensure that cracks, nicks, and gouges are filed or lightlysanded away.

❏ Check that the feather at the beginning of the standard taperedpipe thread on the steel pipe is removed to prevent interferencewith proper joint makeup because it will tend to curl over the linerstub.

❏ Check that the flange or union fitting is screwed on the pipe until theend of the 3/16" plastic liner projection is flush with the face of theflange or union.


Guideline P-11Plastic-Lined PipesA. Handling/Assembly❏ Ensure that protective end caps on the piping are left in place until

the piping is ready for installation.❏ Check that the piping is assembled with clean, new machine bolts.❏ Check that a bolt lubricant is applied to the full length of the bolt

threads.❏ Ensure that over-torquing which may cause damage to the plastic

sealing surface is avoided.❏ Verify that tightening of the flange bolts with a torque wrench, using

a crisscross pattern that alternately tightens the bolts located 180°apart.

❏ Check that hanger supports are located near the flange connec-tions, where flow changes direction, and in areas of high load con-centrations such as clusters of valves or fittings.

B. Painting/Preparation❏ Ensure that sandblasting and painting is done with care to protect

the raised plastic face.❏ Make sure that protective end caps are in place at all times during

sandblasting operations, and that sandblast grit is directed awayfrom the flange face.

❏ If the exterior of the pipe is to be treated with a heat-curable pro-tective coating, ensure that caution is exercised during the heatingprocess. ✔ Never apply heat in excess of the liner's rated maximum

temperature limit.



Guideline P-13Kynar-Lined PipeA. Forming Flared Faces❏ Check that cutting oil, shavings, and dirt are wiped from exposed

plastic stub, using a nonflammable cleaning solvent and clean rag.❏ Check setup:

✔ Check alignment and centering by dry running proper sizedforming tool into flange bolt holes.

✔ Check that guide pins fit freely in the bolt holes with theclamping dogs behind the flange.

✔ Loosen adjusting nuts, center tool, and retighten nuts ifadjustment is needed.

✔ Remove tool, attach hydraulic hose, and set aside.❏ Check preheating:

✔ Lightly grease aluminum flaring die with a high temperaturegrease.

✔ Preheat die to 280°F - 300°F (138°C - 149°C) with hot plate,oven, or torch.

✔ Use 300°F (149°C) temperature-sensing crayon or a pyrome-ter to monitor to monitor preheating.

✔ Do not heat preformer cone die; it is used at room tempera-ture.

❏ Check heating:✔ Attach heat cup to hot air gun, set heater dials per manufac-

turer recommendation, and allow gun to preheat for 15 to 20minutes.

✔ Place the proper locking collar over the plastic stub and placetight against the flange face, with curved crimped edgeinward, fitting into flange chamfer.

✔ For forming faces of Kynar, be sure to only use locking collarwith 5/32" diameter holes; do not use collar with 1/16" or3/32" diameter holes, which is designed for PTFE-lined pipe.

✔ For 1" - 2" pipe, place heat gun and heat cup to flange andheat plastic stub to 200°F - 230°F (93°C - 110°C). Use a230°F (110°C) temperature-sensing crayon to monitor.Rotate hot air gun frequently to ensure uniform heating.

✔ For 3" - 8" pipe, place heat gun and heat cup to flange andheat plastic stub to 240°F - 250°F (116°C - 121°C). Use a250°F (121°C) temperature-sensing crayon to monitor.Rotate hot air gun frequently to ensure uniform heating.

Lined Pipe Gaskets Guideline P-12

✔ Determine the flush position by placing a straight-edge acrossthe face of the flange or union; the plastic liner must contactthe straight edge.

✔ When flanges are used, they should be adjusted by a slightamount of further tightening to align flange bolt holes at eitherend of the pipe spool.

❏ If the thread chasers are badly worn or if the die is set to cut anoversize thread, it may be impossible to screw on a flange as far asnecessary. Should this occur, remove the flange, set the die to cuta slightly deeper thread, rechase the thread, then screw on theflange and adjust it as required.

❏ Check that the proper gasket is inserted into the recess formedbetween the projecting plastic liner and the chamfer at the face ofthe flange or union fitting.✔ Whether a half or full gasket should be used is determined by

the type of connection being made.✔ The choice of gasket elastomer type is based on temperature

and chemical service.❏ Check that a color-coded plastic band is attached to the spool.

✔ Use a blue band for gasketed polypropylene-lined pipe.✔ Use a green band for pipe lined with Saran.

❏ Make sure a plywood cover is bolted to the spool to protect theplastic projection.

P-12-2

Kynar-Lined Pipe Guideline P-13

❏ Make sure that a plywood cover is bolted to the flange to protect theplastic face and to prevent the face from remembering its pre-formed shape and pulling away from flange.

B. Troubleshooting–Kynar Face Forming❏ If the plastic face is smashed flat, thin on one side, or distorted on

one side while the other side appears normal, one of the followingmay have occurred:✔ The reaction frame may not be adjusted parallel to the flange

face causing the forming die to bear more heavily on one sideof the flare than on the other.

✔ The plastic liner extension may not have been heated evenly.One side of the liner may have been hot, the other cold.Ensure that the hot air gun is rotated while heating the liner.

❏ If the flare face raises up from the flange, one of the following mayhave occurred:✔ The flaring die may have been removed before cooling was

complete.✔ The plastic was not heated sufficiently.

❏ If the flare face is folded or wrinkled, one of the following may haveoccurred:✔ The plastic may have been overheated.✔ The molding die may have been incorrectly applied. Make

sure that the liner end does not catch on face of flaring die,causing buckling instead of smooth outward flaring

P-13-3

Kynar-Lined Pipe Guideline P-13

❏ When field forming, use adequate ventilation (indoors, use exhaustfans). Avoid breathing vapors resulting from overheating and possible degradation of plastic.

❏ Check face forming:✔ Engage hydraulic forming tool to flange and lock into position.✔ Place preformer die on cylinder pin of tool and advance for-

ward into plastic stub.✔ Hold in place for approximately 10 seconds at gauge pressure

of 1,000 psi (70 kg/cm2).✔ For 3" - 8" (8 cm - 20 cm) pipe, attach the preheated forming

die to the hydraulic cylinder on the forming tool. ✔ With die centered in plastic stub, insert tool reaction arms

through flange holes and insert locking pins in arms, makingsure that the pins do not bear on the raised lettering of theflange.

✔ Apply hydraulic pressure to form face. Because the pressurewill drop as the plastic flows, repeatedly pump pressure backup again until constant pressure is maintained for 2 minutes.

✔ Avoid excessive force on the preformer cone, causing thin-ning of liner against end of steel shell.

✔ Release pressure and retract cylinder.✔ Immediately replace preformer die with preheated aluminum

flaring die and again extend cylinder forward to completeforming of face.

✔ Maintain pressure on flaring die at 3,000 psi (210 kg/cm2) for2 minutes.

✔ Clamp flaring die to flange and retract and remove formingtool assembly.

✔ Leave die in place until plastic, steel pipe shell, and flangehave been properly cooled to room temperature by air coolingor water bath.

✔ For 3" - 8" (8 cm - 20 cm) pipe, attach bolts through freeflange holes and secure flaring die to flange. Retract thehydraulic cylinder; remove locking pins and forming tool. Coolthe plastic to room temperature using cooling air or water.Then remove die from flange.

✔ To assure properly flared face, it is extremely important tocool plastic and flange to room temperature.

❏ To identify Kynar liner, check that a black color-coded plastic bandis attached to lined pipe spools.

P-13-2

P-14-2

PTFE-Lined Pipe Guideline P-14

❏ If a heat gun is used for heating:✔ Make sure that the proper size heat cup is used.✔ Check that heat gun is allowed to preheat for 15 to 20 min-

utes.✔ When gun is ready, check that the gun with heat cup is placed

against the flange and heated until the plastic stub becomestranslucent.

✔ Check that the heat gun is frequently rotated to balance theheat over the plastic surface.

✔ When field forming by either method, use adequate ventilation(indoors, use exhaust fans). Avoid breathing vapors resultingfrom overheating and possible degradation of plastic.

D. Preforming❏ Check the insertion of the cone-shaped preformer tool into translu-

cent plastic stub and that a gradual rocking motion is used toenlarge the opening in the plastic.

❏ Verify that the preformer is then fully inserted into the flange face toquench the inner side wall.

❏ When in the translucent (gel) state, PTFE is very shock sensitive.Make sure the force is applied gently with the preformer.

❏ With the forming die centered in the plastic stub, check that theforming tool guide pins are placed into the flange holes and that theclamping dogs are locked in place.

❏ Ensure that the forming die is cranked snug to the flange and thatcool air or water is used to speed cooling of the plastic to room tem-perature.

❏ After cooling, make sure that the tool is removed.❏ To assure properly flared face, it is extremely important to cool the

plastic and flange to room temperature.❏ Verify that a color-coded plastic band is attached to the spool to

identify the PTFE liner.❏ Make sure that a plywood cover is bolted to the flange to protect the

plastic face and to prevent the face from remembering its pre-formed shape and pulling away from the flange.

E. Troubleshooting PTFE Face Forming❏ If small cracks or splits develop around the edge of the formed face,

one of the following may have occurred:✔ Torch flame was allowed to dwell on the edge of the PTFE

stub, causing overheating and degradation of the liner.✔ Liner ends were not smoothed properly after the cutoff

operation.❏ If the liner splits during the flaring operation:


Guideline P-14PTFE-Lined PipeA. Joining Preparation❏ Check that any notches on end of exposed plastic stub are filed or

sanded away.❏ Check that cutting oil, shavings, and dirt are wiped away from the

pipe stub, using a nonflammable cleaning solvent and clean rag.B. Joining❏ Make sure that the proper size flaring die and forming tool are used.❏ Check that the clamping block assembly guide pin matches the

flange bolt holes.❏ With the molding die centered in the extended liner and the drive

screw retracted, check that the guide pins fit freely in the bolt holeswith the clamping dogs behind the flange.✔ Loosen the adjusting nuts, center the tool, and retighten the

nuts if adjustment is needed.❏ Check that the proper locking collar is placed over the plastic stub

and tightened against the flange face with the curved crimped edgeinward fitting into the flange chamfer.

❏ For the PTFE face, check that the locking collar has 1/16" or 3/32"diameter holes. Do not use collars with 5/32" diameter holes, whichare designed for Kynar-lined pipe.

C. Field Forming❏ If a torch is used for heating:

✔ Make sure that a MAPP/air or LPG/air torch is used with anaspirating nozzle (#3 tip) to provide flooding type heat.

✔ Check that the torch is held at a 90° angle to the pipe so thatflame tip barely touches plastic.

✔ Check that the torch is continuously moved around the plasticuntil one-half of the stub thickness turns translucent.

✔ Ensure that the inside of the stub is then heated with the torchheld at a 45° angle and the torch is moved continually aroundthe plastic.

✔ Ensure that the process is repeated from outside to insideuntil the entire stub has become translucent.

✔ Verify that the torch flame is kept just inside the cut edge ofthe plastic stub and is not allowed to directly contact thisedge.

Guideline P-15Lined Pipe–Saran or PolypropyleneA. Installation❏ Check that all cutting oil, shavings, and dirt are wiped from exposed

plastic stub of the clamped prepared pipe using a nonflammablecleaning solvent and clean rag.

❏ Check proper fit-up:✔ Spring compressed on forming tool while attaching molding

die.✔ Guide pin fit in clamping block assembly to match the flange

bolt holes.✔ With the molding die centered in the extended liner and the

drive screw retracted, check that guide pins fit freely in thebolt holes with the clamping dogs behind the flange.

✔ Loosen adjusting nuts, center tool, and retighten nuts ifadjustment is needed.

✔ Remove forming tool.❏ Check that proper size heat cup attached to hot air gun

✔ Use standard heat cup for 1" to 4" pipe.✔ Use special baffle heat cup for 6" or 8" pipe.

❏ Ensure that the heat gun is preheated for 15-20 minutes using theheat to warm the molding die.

❏ Check that the heat gun and cup are placed against the flange andthat the cup position is rotated periodically to balance heat over surface of plastic stub.✔ Heating time will vary with ambient conditions. ✔ Heat until the plastic stub appears to be uniformly wet and

glossy, checking softness with clean glove. ✔ If pipe is clamped in horizontal position and excessive plastic

droop occurs, rotate pipe to control.✔ When field forming, use adequate ventilation (indoors, use

exhaust fans). Avoid breathing vapors resulting from overheating and possible degradation of the plastic.

❏ Check flange to pipe adhesion process:✔ Plastic is ready for adhesion when saran feels like putty or

polypropylene feels like rubber and looks shiny.✔ Remove hot air gun, fold end of sagging plastic stub out

toward the outside diameter of the flange, and form plasticback to face of flange with gloved hand.

✔ Quickly align molding tool and forming die assembly to plasticand crank the molding die tight to the flange.

✔ Allow plastic to cool several minutes before removing formingtool.


PTFE-Lined Pipe Guideline P-14

✔ Excessive force may have been used during the preformingstep. While in the gel state, PTFE is extremely shock sensi-tive. Exercise care to avoid jarring the PTFE in this state.Carefully insert the preformer fully to the flange face toquench the inner side of the wall completely before continuingwith the preforming step.

❏ If the flare face raises up from the flange, one of the following mayhave occurred:✔ The flaring tool may have been removed before cooling was

complete.❏ The liner may not have been heated sufficiently.

P-14-3

P-15-3

Lined Pipe—Saran or Polypropylene Guideline P-15✔ Inside diameter was undersized due to over-compression of

pipe by flanging with too much force.C. Final Joint Surfacing❏ Excessive flash may be cut from molded end with any properly

sharpened knife.❏ Surface of plastic face may be reshaped with flat file, preferably in

rotary motion on face (seal area).❏ Surface of plastic face may be reheated and remolded to improve

one of poor quality.❏ Do not use grease on aluminum molding dies where contact is

made with plastic molding surface; the plastic will tend to laminateif mixed with grease.

Lined Pipe—Saran or Polypropylene Guideline P-15

✔ The plastic face diameter on field-formed spools may besomewhat smaller than that on factory-supplied spools. Thiswill not, however, affect pipe performance.

❏ Verify that plastic-lined pipe is correctly identified:✔ Green plastic band for saran-lined pipe spools✔ White plastic band for polypropylene-lined pipe spools

❏ Make sure that a plywood cover is bolted to the flange to protect theplastic face.

B. Troubleshooting Saran and Polypropylene Face Forming❏ If plastic face appears distorted, one side normal and the other side

erratic and not fully formed, one of the following may haveoccurred:✔ The hot air gun was not properly rotated to ensure uniform

heating.✔ The heat setting was too high for conditions, thereby not

allowing plastic resin to heat uniformly.✔ Not enough pressure on forming die to fill out molding cavity.

❏ If the plastic face has rough laminar pattern molded in the surface,one of the following may have occurred:✔ Soft plastic was not properly rolled back and preformed with

gloved hands before molding.✔ Too much time was taken to hand form soft plastic, thus allow-

ing air-hardened skin to form before molding tool is applied.❏ If plastic face is well molded but has flow lines in surface, one of the

following may have occurred:✔ Molding die was not preheated before forming operation.✔ Too much time was taken to hand form soft plastic, thus

allowing air hardened skin to form before molding tool isapplied.

✔ Excessive flash at outer diameter and center of plastic faceallowed to heat to excess, lower heat setting, and/or shortenheating time

✔ Too much force was applied to molding die, thus forcing hotplastic into tooling allowances.

❏ If excessive flash occurs on the inside diameter of the plastic afterthe molding tool is removed, one of the following may haveoccurred:✔ The heated plastic was not properly hand formed before

molding, allowing forming die mandrel to push soft plasticinside pipe.

✔ Excessive pressure was applied to die causing very soft plastic to flow past die mandrel.

✔ Molding tool was not properly centered causing die mandrel toengage soft plastic and push it inside pipe.

P-15-2

Flushing and Cleaning Guideline P-21

D. Refrigeration Piping❏ Check that installation of cleaning of refrigeration piping and

accessories is per manufacturer requirements.E. Domestic Water Piping❏ Check that all lines are flushed with fresh, clean, potable water

before disinfection.❏ Verify that piping is disinfected before final acceptance per AWWA

C601 unless other required in contract documents or local codes.

P-21-2Field Inspection Guidelines © 1997, 2001 Bechtel

P-21-1

Guideline P-21Flushing and CleaningA. Preplanning❏ Verify that procedures are developed and approved indicating

flushing and cleaning sequence and the steps to be performed.❏ Check that all welded connections are complete and that the piping

system is released for flushing and cleaning operations.❏ Make sure that flushing is not carried out through any machinery or

equipment that may be damaged by flushing.❏ Ensure that line debris is not flushed into dead ends or associated

vessels.❏ Make sure that heat exchangers are isolated wherever possible

until initial flushing is complete.❏ If a cleaning solvent is used, check that no materials in the system

will be damaged by its use.❏ Preplan the disposal of all flushing and passivating materials and

ensure that the disposal meets applicable regulation requirements.B. Work Operations❏ Check that orifice plates and flow nozzles are removed from the

line.❏ Check that temporary spacers or spool pieces are provided where

necessary to avoid straining the pipe where in-line componentshave been removed.

❏ Check that all high points are vented to ensure that the cleaningsolution will contact all inside surfaces of the pipe.

❏ Check that sufficient bypasses are installed to ensure the flow ofthe cleaning solution through all desired parts of the system.

❏ Ensure that adequate venting is provided to prevent vacuums forming in the system.

❏ Maintain continuous surveillance of the flushing and cleaning operations to ensure compliance with procedure requirements.

C. After Cleaning, Passivating, and Flushing is Complete and the System has been Drained and Dried

❏ Inspect all accessible points of the system to ensure that it is freeof scale, rust, loose paint, and film and is of correct surface appear-ance. This is usually done at the end of the flush and before fluidre-entry into holding tanks.

❏ Check that all removed items are correctly reinstalled.❏ If testing is not to be performed immediately, ensure that the piping

is sealed.❏ Make regular inspections after cleaning to ensure that the piping is

kept sealed.❏ Where specified for critical components or systems, verify that

nitrogen blanket is re-established per manufacturer instructionsand project procedures.

Leak Testing Guideline P-22

❏ Check that the system to be tested has been flushed before testing, if required.

❏ Verify that required test witnesses, such as the quality controlinspector, the authorized code inspector, or the client representa-tive, have been notified in advance of scheduled test.

B. Pneumatic Testing❏ Ensure that a project procedure is prepared summarizing pneu-

matic pressure testing requirements.❏ Make sure that the immediate area surrounding the system test is

roped off and that personnel are kept out of the roped off area during pneumatic test.

❏ Verify that test pressure is maintained for the specified period.✔ If a pressure drop is observed, check for audible air leaks in

the system.❏ Verify that the system is gas tight by applying an approved soap

bubble solution to all joints (pneumatic test only).C. Pressure Piping Testing❏ Verify that testing is limited to only those systems released for test-

ing.❏ Confirm that testing is performed to approved procedures and

specifications.❏ Ensure that qualified personnel perform the testing.❏ Make sure that personnel safety is exercised throughout the testing

process.❏ Verify that the proper test medium is used.❏ Verify that the test medium is at proper temperature, as applicable.❏ Check that system pressurization stages are maintained, if

required.❏ Verify that the system is held for the specified time at the required

test pressure before inspecting for leaks.❏ Ensure that testing documentation is maintained, completed, and

accepted by the responsible field engineer and required witnesses.❏ Make sure that tested systems are properly vented and drained for

layup and/or properly restored for turnover.D. Fire Protection Piping Testing❏ Determine local code requirements for leak testing including

minimum pressure, hold time, allowable pressure drop, and testcertification requirements.

P-22-2Field Inspection Guidelines © 1997, 2001 Bechtel

P-22-1

Guideline P-22Leak TestingA. Preplanning❏ Make sure that system identification and test boundaries are

defined early.❏ Perform a pre-test inspection by walking down the system and ver-

ifying accessibility for inspection, completeness per P&ID, tightnessof flanged joints, and chalking of joints, as applicable.

❏ Establish the test medium, test pressures, and test boundaries foreach test, including blind flange thickness determinations.

❏ Tag test boundaries per approved procedures and as required.❏ Sample and test hydrostatic test medium to determine if it is

acceptable or detrimental to the vessel internals and alloy piping.❏ Verify that test gauges have been calibrated per project procedures

and that the calibration due date is shown on the test gauge.✔ To validate that test gauges are still within the prescribed

calibration period, check the test gauges against a mastergauge before testing.

❏ Ensure that the maximum test pressure is within 30% to 70% ofgauge range.

❏ Identify components not capable of safely withstanding the requiredsystem test pressure and ensure that those components areremoved or isolated from the system.

❏ Identify systems that must be laid up after testing and that therequired layup medium is available for use before the start of thetest.

❏ Determine if the system will or will not require draining after thehydrostatic test.

❏ Verify that all required test vents and drains are installed and thatfill points are established.

❏ Make sure that required testing equipment, relief valves, pressureregulators, valves, strainers, temporary piping, and temporary fit-tings are available before the start of hydrostatic testing.

❏ Check that all system valves are positioned as required.✔ All system valves are typically placed in the open position.

❏ Confirm that system relief valves have been blinded or removed, asrequired.

❏ Check that the system is adequately supported for expected loading during hydrostatic testing.

❏ Check that test equipment and temporary piping have been flushedbefore connection to system.

Guideline P-24Vibration Isolation and ControlA. Material❏ Review contract documents to determine installation and accept-

ance criteria.✔ Determine pipe isolator sizes, hardware, and installation loca-

tions.❏ For freestanding spring isolators, check the following materials on

receipt for shipping damage and completeness:✔ Sound-deadening pads✔ Leveling and connecting bolts for both the equipment and the

structural base✔ Adjustable stops, both up and down✔ Hot dip galvanized steel components✔ Cadium-plated and neoprene-coated springs✔ Lateral limit stops on springs where required✔ Type and model of isolator identified on component✔ Springs clamped to bases and not welded

❏ For rubber shear isolators, check the following materials on receiptfor shipping damage and completeness:✔ Confirm if single and/or double isolator(s) provided.✔ Verify that the isolator is properly housed with bolt holes for

attaching equipment and structural base.✔ Hot dip galvanized steel components.

❏ For suspended pipe and equipment isolators, check the followingmaterials on receipt for shipping damage and completeness:✔ Hot dip galvanized steel components.✔ Ensure that the isolator is adjustable to transfer the load to

the spring.✔ For suspended piping support, confirm that the isolator is a

combination rubber-in-shear and spring type.✔ Confirm that a rubber grommet is provided surrounding the

bottom suspension rod as required by the contract docu-ments.

❏ Check inertia block framing:✔ Check that reinforcing bar is included with the vendor-sup-

plied isolator frame.✔ Check that the block is framed to provide support for base

pipe elbow supports.✔ Check the quality and completeness of frame welding and

bracing.



Guideline P-23Pipe InsulationA. Storage❏ Maintain surveillance of the storage conditions of the insulation

materials.❏ Check that material drawn from storage for application is dry and

undamaged.B. Preplanning❏ Verify that all required hydrostatic and nondestructive testing has

been performed before application of insulation.❏ Ensure that any required surface coating has been applied.❏ Ensure that pipe surface is free of moisture before application of

insulation.C. Installation❏ Check that correct type and thickness insulation is applied.❏ Check that the support fittings (banding straps, "S" and "J" clips,

etc.) are of the proper material.❏ Where a vapor barrier is required, check that it is correctly applied

to the proper thickness and that its integrity is maintained through-out.

❏ Check that protective metal coverings are applied so that underly-ing insulation or vapor barrier is undamaged.

❏ Ensure that piping or equipment supports do not damage the insu-lation.

❏ To isolate the effects of a break-in insulation or vapor barrier, thebarrier should be sealed to the pipe at every fitting and at supports.

❏ All removable vessel heads and manways should be fitted withremovable insulation.

❏ When abrasive insulation material such as cellular glass is used onlines or equipment subject to vibration, coat the inside surface toprevent damage to the lines or equipment.

❏ When more than one layer is to be applied, check that:✔ All joints of the previous layer are sealed before application of

the next layer.✔ All joints between one layer and another are "offset."

Vibration Isolation and Control Guideline P-24

C. Ductwork Supports❏ Verify that vibration isolators are used:

✔ With duct hangers where specified✔ To connect ductwork with equipment with flexible duct con-

nectors✔ To segment ductwork using flexible duct connectors where

specified❏ Check that isolation pads are provided at the base support and on

lateral struts for duct riser supports.

P-24-3

Vibration Isolation and Control Guideline P-24

B. Installation❏ Verify the installation of vibration isolation system on mechanical

equipment, piping, and ductwork per contract documents to preventthe transmission of objectionable vibration and structure born noiseto the building and occupied spaces.

❏ Check that suitable holddowns and limit stop devices have beeninstalled to maintain equipment isolators at correct static deflectionwhile connecting piping and ducts.✔ After installation and adjustment, check that the equipment is

allowed to float free and that limit stops are out of contact dur-ing startup and operation.

❏ Check that the installed isolation system will not interfere with theoperation of the mechanical equipment.

❏ Check that flexible isolator systems are adjusted to match equip-ment weight distribution to provide a stable mounting decoupledsystem.✔ The isolation system frequency shall not differ by more than

10%.❏ The following units typically are installed with vibration isolators:

✔ Floor-mounted air handlers✔ Ceiling-mounted air handlers and fans✔ Duct-mounted fans✔ Chilled water, hot water, and cooling water pumps✔ Pump to boiler nozzle connections✔ Air-cooled condensing packages

❏ Check loaded and unloaded isolator heights to verify that the loadis correctly spread and that the difference in height is about equalto the specified deflection.

❏ Check that spring isolators have 50% capacity remaining afterloading.

❏ Check that rubber shear isolators are not splitting or cracking or arebeing cut by attached bases or adjacent equipment.

❏ Verify that equipment is level and not transmitting substantial load-ing to adjacent piping or ducts through the equipment flanges. Todo this:✔ Observe pipe-to-equipment alignment before bolt-up✔ Randomly test by disconnecting flanged connections at

equipment and determining if alignment remains.❏ Verify that the isolators are attached to structurally sound locations

on the equipment frame.❏ Check that isolators are attached to equipment and structural

supports using hot-dipped or plated fasteners.❏ Verify that the isolators are plumb when loaded.

P-24-2

Field Inspection Guidelines © 1997, 2001 BechtelM-2-1

Guideline M-2Rotating EquipmentA. Preplanning❏ Review the equipment specifications and the approved plans,

methods, procedures and sequence of operations. Major items tobe considered:✔ Equipment manufacturer installation instructions✔ Accuracy of anchor bolt layout✔ Grouting techniques

B. General❏ Ensure that rotating equipment is the correct size, type, and rating

as specified.❏ Verify that vendor has provided lifting lugs as required for compo-

nent handling.❏ Ensure that proper handling and storage techniques are employed.❏ Verify that rotating elements turn freely before installation.❏ Verify that rotating elements are turned periodically during con-

struction or layup. Make sure that manufacturer instructions arefollowed.

C. Anchor Installation❏ Verify accuracy of embedments, anchor bolt layout, size, dimen-

sions, and elevation, before and after placing concrete and foun-dation.

❏ Protect anchor bolt threads from dirt, rust, and mechanical damage.D. Equipment Installation❏ Verify that the equipment bed plate is installed per manufacturer

instructions and that vendor representative is present when settingcritical items such as sole plates where required.

❏ Verify that grout and air release holes are provided in each compartment of the equipment bed plate.

❏ Ensure that foundation surface preparation is complete.❏ Check that all rigging and handling equipment is safe and will

properly handle component loads. Review Rigging Guideline.❏ Take care when transporting, handling, and setting rotating

equipment.❏ Check that equipment location coordinates and elevations are

correct.❏ Ensure proper equipment lubrication before installation including:

✔ Shipping and/or field storage lubricants drained✔ Lubricant reservoirs flushed and cleaned✔ Reservoirs filled with correct quantities of approved lubricants


Guideline M-1General Equipment SettingA. Installation❏ Check that embedded anchor bolts are installed per design.❏ Verify that adequate anchor bolt projection has been provided.❏ Verify that baseplates are level.❏ If more than one baseplate, verify that the baseplates are all on the

same plane.❏ If shims are required, determine correct size, thickness, and shape

of shims required.❏ Make sure that no undue stresses are created when the equipment

is connected to piping, ductwork, or conduit.❏ Check rotation of motors before energizing.

✔ Make sure that coupling is not energized when checkingmotor rotation.

❏ Verify manufacturer lubrication requirements before energizing.❏ Check that grouting or dry-packing of foundation plates are com-

plete and cured before energizing.


Guideline M-3Coupling AlignmentA. Preplanning❏ Check equipment for proper location/orientation and elevation.❏ Before coupling work is started, ensure that lockout procedures are

followed and safety tags are posted as applicable on the following:✔ Breakers to electric motor drivers✔ Air or steam supply valves to mechanical drivers✔ Pump suction and discharge shutoff valves

❏ Ensure that required electrical testing such as motor rotation orbump test is completed before coupling the equipment.

B. Before Connecting Piping but after Shimming and Anchor Bolt Tightening

❏ With coupling bolts removed, check coupling halves of both driverand driven machinery to ensure concentricity of coupling rim andcomponent axes. Use manufacturer alignment recommendations.

❏ Check coupling halves for parallel alignment to ensure that equip-ment center lines are coaxial. Correct parallel displacement beforenext step.

❏ Check coupling halves for angular alignment to ensure that cou-pling faces are parallel. Correct angular displacement before finalalignment.

C. Alignment Work Operations❏ Monitor coupling alignment when piping connections to driven

machinery are made.❏ Repeat alignment check after piping connections are complete.❏ Rework piping or supports, as required.❏ Recheck alignment and record final readings on alignment data

sheet, when satisfactory.❏ Make up coupling after correct direction of rotation of driver has

been established.❏ Ensure that coupling bolts and set screws are tight and secured

against accidental loosening.❏ Recheck alignment during initial startup/operation, as required.

Rotating Equipment Guideline M-2

E. Alignment, after equipment is set, shimmed, and bolted down, before grout and before making piping connections.

❏ Do not allow holddown nuts to be pulled down so strongly that bedplate is distorted.

❏ Provide tapered spacers for anchor bolt nuts bearing againsttapered bed plate flanges.

❏ Verify that grout is mixed and placed per manufacturer instructions.Review Equipment Grouting Guideline.

❏ Recheck alignment after grouting.F. Piping Connections❏ Visually check the suction and discharge before pipe hook-up.

Verify that rotating elements turn freely.❏ Check that all welders engaged in the equipment installation are

qualified to AWS, ASME, AWA, and/or ANSI codes as applicableunless otherwise required in the contract or local codes.

❏ Make pipe connections after grout is cured.❏ Do not allow pipe connections to transmit stress to equipment

flanges and nozzles.❏ Re-check alignment. Relieve stresses, as required.❏ Check that gland leak-offs are properly piped to drains.❏ Verify that glands and seals have proper packing correctly tightened.❏ Check that lube oil and bearing cooling water piping is correctly

installed.✔ Verify that sleeves are installed for this piping where necessary.

❏ Determine that supports for piping, tubing, and instruments do notcause interference.

❏ Check that the doweling is done after acceptable coupling align-ment or after hot alignment, if applicable.

❏ Check that thermocouple leads, capillary tubing and pressure tub-ing are neatly and conveniently run and that all instrument connec-tions properly penetrate covers, lagging, and other sheet metal.

❏ Make sure that all vents and drains are properly installed and areclear.

❏ Determine that proper provisions are made for installing protectivestrainers during system flushing.

❏ Re-check alignment as required to ensure that no additional stress-es are imposed on the equipment.

❏ Ensure that coupling alignment is performed per manufacturerinstallation instructions and as specified. Review CouplingAlignment Guidelines.

M-2-2

Belt-Driven Equipment Guideline M-4

❏ Rework piping or supports if required.❏ Recheck alignment per the above step. Record final readings on

data alignment sheet, when satisfactory.❏ Recheck belt tension per belt manufacturer recommendations.❏ Check belt guards for proper clearance, alignment and security.❏ Recheck belt tension and alignment during initial startup/operation,

as required.❏ Determine that all data required by startup are properly coordinated.❏ Make sure that thermocouple leads, capillary tubing, and pressure

tubing are neatly and conveniently run and that all instrument con-nections properly penetrate covers, lagging, and other sheet metal.

❏ Verify that rotating elements are turned periodically during con-struction or layup. Make sure that manufacturer instructions arefollowed.

❏ Make sure that all vents and drains are properly installed and areclear.

❏ Determine that proper provisions are made for installing the pro-tective strainers during system flushing.

❏ Check alignment as required to ensure that no additional stressesare imposed on the equipment.

M-4-2Field Inspection Guidelines © 1997, 2001 Bechtel

M-4-1

Guideline M-4Belt-Driven EquipmentA. Preplanning❏ Check vendor data, specifications, layout drawings for interface

with other disciplines.❏ Check equipment for proper location, orientation and elevation.❏ Before any sheave alignment work is started, ensure that lockout

procedure is followed and safety tags are posted as applicable onthe following:✔ Breakers on electric motor drivers✔ Pump/compressor suction and discharge shutoff valves

❏ Ensure that the equipment baseplate grout is complete and accept-ed. ✔ For fans, ensure that base vibration dampeners are properly

installed.❏ Check foundation bolts and nuts for proper size and tightness

(including vibration mounts, if applicable).❏ Before installing the belts, check the following:

✔ Sheave of both driving and driven equipment to ensure con-centricity of sheave rim and equipment

✔ Damaged or dirty sheave(s)✔ V-groove alignment of sheaves on driving and driven equip-

ment; V-belts must enter and leave sheaves without side bind-ing.

B. Belt Installation and Alignment❏ Verify that the outer edge of the sheave hub does not extend

beyond equipment shaft. Also, verify that the inner edge does nottouch the equipment. If sheaves are not same thickness, it will benecessary to align center lines.

❏ Verify that shafts of both driving and driven equipment are parallel.❏ Check for matched sets on multi-belt units.❏ Ensure that all belts are installed with the slack on the same side.❏ After installation of belts, ensure that sheaves on driving and driv-

en equipment are secured to their respective shafts per manufac-turer instructions. Check belt tension per manufacturer instruc-tions.

❏ Verify that the driven equipment has been securely bolted and dow-eled to the baseplate as specified.

❏ Verify that the driver is securely bolted to the equipment baseplateby holddown bolts and however, remains adjustable (i.e., no dow-els) for belt tensioning adjustments during maintenance.

❏ Monitor shaft alignment when piping connections to driven equip-ment are made (if any).

❏ Repeat above step after piping connections are completed.

Non-Rotating Equipment Guideline M-5

E. Equipment Grouting❏ Verify that equipment bed plate is installed per manufacturer

instructions and that vendor representative is present when settingcritical components such as soleplates.

❏ Check grouting preparation including removal of laitance, cleanup,wet down, grout dams, and provisions for grout and air releaseholes in bed and foundation plates.

❏ Verify that sole plates meet manufacturer requirements and areinstalled in correct location, elevation, and slope and have therequired anchor bolt clearance.

❏ Verify that grout is mixed and placed per manufacturer require-ments. Review Equipment Grouting Guideline.

F. Equipment Installation❏ Take care during transportation, handling, and setting equipment.

Review Rigging Guideline.❏ Check the centerline and elevation of each piece of equipment.

✔ Verify that the accuracy and tolerance of all locating dimen-sions satisfy final requirements.

❏ Allow for proper insulation clearance around equipment.❏ Check all insulation for proper thickness.❏ Check that all fixed points for thermal expansion are at designated

location and expansion is in the required direction.❏ Check that all bolts, studs, and nuts are the proper material.❏ Verify that flange bolt torquing is performed to manufacturer and

specification requirements. ✔ Verify that required bolt tightening sequences are followed.

❏ Ensure that all piping connections are properly aligned and are nottransmitting stress to the equipment.

❏ Check manufacturer data before welding attachments to equip-ment.

❏ Consult manufacturer before welding on vessels and piping thathave special coating, lining, or paint.

❏ Check that all welders engaged in the equipment installation arequalified to AWS, ASME, AWA, and/or ANSI codes as applicableunless otherwise required in the contract or local codes.

❏ Properly support all pipe, tubing, conduit, and ductwork and checkthat connections to equipment are performed as specified.

❏ Check all piping, particularly drains, to verify that design slope, P-traps, or air breaks are maintained throughout runs.

❏ Check that all required pressure taps, thermowells, thermocouples,test connections, vents and drains are in proper locations.


M-5-1

Guideline M-5Non-Rotating EquipmentA. Preplanning❏ Review the equipment specifications and the approved plans,

methods, procedures, and sequence of operations. Major items tobe considered include:✔ Equipment manufacturer installation instructions✔ Accuracy of anchor bolt layout✔ Grouting techniques✔ Manufacturer storage and layup procedures ✔ Inspection and maintenance for corrosion and cleanliness

control before, during, and after assemblyB. General❏ Check that equipment is correct size, type, and rating as specified. ❏ Ensure that correct equipment manuals and drawings are avail-

able.❏ Verify that vendor has provided lifting lugs as required for compo-

nent handling.❏ Check that all rigging and handling equipment for offloading and

moving meets requirements. Review Rigging Guideline.❏ Ensure that all rigging and handling equipment is engineered for

conditions of all specific moves to the final location of the equip-ment.

❏ Check that miscellaneous steel and concrete block walls that mayobstruct setting of equipment are omitted until after setting. ✔ Confirm any steel framing omission with design engineering.

❏ Ensure that curbs, piping projecting above the floor, cable trays, orother similar items will not interfere with rigging or skidding theequipment into place.

❏ Ensure that all accessories supplied by the equipment vendor, suchas piping, level indicators, temperature indicators, pressuregauges, and switches, are installed.

C. Embedded Equipment❏ Ensure that all embedded equipment drains, conduit, grounding

cables, and other below floor level facilities are in place before plac-ing concrete.

D. Anchor Installation❏ Check anchor bolt layout, elevation, projection, and thread length:

✔ Determine if anchor bolt sleeves are required.✔ Ensure that bolt threads are protected.


Guideline M-6PumpsA. Receipt Inspection❏ Ensure that pumps are inspected on board vehicle on arrival at the

site.✔ Inspect for visual evidence of shipping damage.✔ Carefully check any associate piping bundles for complete-

ness or damage.B. Installation❏ Check that equipment pads, platforms, or hangers required to sup-

port the equipment are complete before starting the installation.❏ Verify that the equipment is installed per contract documents.❏ Verify that vibration isolators and flexible connections are installed

as required.❏ Check that all piping, check valves, controls, and structural sup-

ports for the equipment are installed as required.❏ Verify that all required electrical connections are complete.❏ Verify that belt guards are arranged to permit oiling, testing, and

use of a tachometer with the guard in place.✔ Ensure that a belt guard access door is provided to measure

belt tension.❏ Verify that the pump has been aligned to operate without noticeable

vibration.❏ Ensure that the equipment is protected from dirt, foreign objects,

and damage during the installation period.❏ Witness all balancing and testing required by the contract docu-

ments.❏ Witness required equipment performance tests demonstrating that

the equipment functions as intended.❏ Verify that all debris is removed from the work site and that all

equipment including castings, sumps, and motors are cleanedbefore final acceptance.

❏ Check wet and dry sump elevations, access gratings, and safetydevices for proper installation.

❏ Verify that in-flow drains are clear of any obstruction.❏ Check that inlet and discharge line flanges are correctly installed

and securely gasketed.❏ Ensure that equipment lubrication fittings can be accessed easily.❏ Verify that unit controls are installed per contract documents and

function properly.C. Testing❏ Verify that fire pump test satisfies the requirements of NFPA 20 or

specified code.

Non-Rotating Equipment Guideline M-5

❏ Ensure that all valves, instruments, tubing, gauge lines, control aircomponents, and capillary tubing are effectively protected from allconstruction activity.

❏ Check that small pipe design does not encroach on clear space leftfor tube bundle withdrawal.

❏ Check that all system flush requirements are compatible with man-ufacturer procedures for equipment maintenance.

M-5-3


Guideline M-8Underground Storage TanksA. Preplanning❏ Verify that tank is manufactured in conformance with applicable

local codes.✔ U.S. Environmental Protection Agency requirements require

nonpermeable liners for hydrocarbon or hazardous materialunderground storage tanks.

❏ Verify that all required shop testing has been completed and datasheets, test reports, and certifications are submitted.

❏ Inspect for obvious damage to the tank.❏ Make sure that chocks are used to prevent the tank from rolling

while in temporary storage at the site.❏ Inspect internally for cleanliness and proper internal coating sys-

tem.✔ Conduct holiday tests on any coating repair areas.✔ No one shall enter a "confined space" until safety inspection

has been performed and determinations made that there areno harmful gases, vapors, fumes, or mists present in the tankand proper ventilation is provided or proper respirator andprotective clothing is worn as required.

❏ If double walled tank is provided with a vacuum in the interstice,check vacuum level and compare with the level when the tank leftthe factory.✔ Advise manufacturer of any difference.

❏ Pressurize single wall steel tanks and fiberglass reinforced plastic(FRP) tanks to 5 psi and soap bubble test for leaks:✔ Weld seams of steel tanks✔ The entire surface of FRP tanks

❏ Check that bedding is of acceptable material, thickness, and com-pacted according to specification requirements. Review Cut andCover Excavation and Backfill Guideline.

B. Tank Setting❏ Check that care is taken to prevent damage during movement,

handling and setting operations. Review Rigging Guideline.✔ Only use designated lift lugs to move the tank.

❏ Ensure that the installation is according to shop drawings, applica-ble code requirements, and manufacturer instructions. Check thefollowing as applicable:✔ Welding✔ Nondestructive examination✔ Testing✔ Cathodic protection✔ Painting


Guideline M-7Elevated Steel TanksA. Preplanning❏ Verify that all required shop testing has been completed and data

sheets, test reports, and certifications are submitted.❏ Inspect for obvious damage to the tank.❏ Verify that there are no unrelieved welds on stress-relieved tanks,

e.g., ladder clips, pipe supports, etc.❏ Inspect internally for cleanliness and proper internal coating

system.✔ No one may enter a "confined space" until safety inspection

has been performed and determination made that their are noharmful gases, vapors, fumes, or mists present in the tankand proper ventilation is provided or proper respirator andprotective clothing is worn as required.

❏ Ensure that concrete foundations have been sufficiently cured.❏ Check anchor bolts for correct location, elevation, and protection.B. Tank Erection❏ Take care to prevent damage during movement, handling, and set-

ting operations. Review Rigging Guideline.❏ Check for correct orientation of tank and nozzles.❏ Ensure that the following conform to specification and code require-

ments:✔ Erection✔ Welding✔ Nondestructive examination✔ Testing✔ Cathodic protection, as applicable✔ Outside painting✔ Disinfection


Guideline M-11BoilersA. Preplanning❏ Check vendor data, installation procedures, specifications, and lay-

out drawings for corrections and interface with other disciplines.❏ Ensure that all boiler erection and assembly drawings are approved

for installation.❏ Check that a detailed vendor shipping list is available before any

components are received at the site.❏ Determine the number, location, and schedule or erection "hold

points" and coordinate with the "Authorized Inspector."❏ Thoroughly check all shipping lists and bills of material against the

drawings.❏ Ensure that vendor has provided lifting lugs, lift beams, and align-

ment clips for component handling and assembly.❏ Ensure that vendor has specified preservative and paint require-

ments.❏ Check that all bolts, studs, and nuts are the proper material.B. Anchor Installation❏ Check anchor bolts for correct location, free length, sleeve condi-

tion, thread projection and protection before foundation concrete isplaced.

C. Boiler Installation❏ Check that all rigging and handling equipment is safe and will prop-

erly handle component loads. Review Rigging Guideline.❏ Take care during transport, handling, and setting operations. ❏ Ensure that vendor representative is available during installation

operations, as required.❏ Check for insulation clearance around pipe and equipment.❏ Check that all required pressure taps, thermowells, thermocouples,

rest connections, vents, and drains are provided in proper locations.❏ Verify that piping, instrumentation, and equipment are protected

from freeze-up.❏ Drill and fill all dowels, as required.❏ Check that all welders engaged in boiler erection are qualified to

applicable AWS, ASME, AWA, and/or ANSI codes or as required bylocal codes.

❏ Check that spare parts and installation/maintenance tools are avail-able for turnover to owner.

❏ Ensure that the boiler flushing and/or chemical cleaning require-ments are satisfied.

Underground Storage Tanks Guideline M-8

❏ Check bedding and backfill for acceptable material, uniformity, andcompaction per specification and applicable codes.✔ Ensure that backfill and bedding are of the same material.

❏ For steel tanks, check that:✔ Sand, crushed stone, or pea gravel is used for bedding and

backfill.✔ Bedding and backfill is free of large, sharp rocks that could

damage coatings.❏ For FRP tanks, check that:

✔ Pea gravel is used for bedding and backfill material.✔ Crushed stone or sand is only used where specifically permit-

ted.❏ Check for minimum bedding depth of 12 inches (30 cm) unless oth-

erwise specified.❏ Check that required tank buoyancy anchors are installed.❏ Make sure that standard buried reference cells provided for cathod-

ic protection are installed level with the bottom of the tank.❏ Check backfill compaction under the tank's lower quadrants to pre-

vent settlement after burial.C. Piping Connections❏ Make sure that sealants are compatible with both tank and piping

materials.❏ Check that piping is well inserted into the tank flange.❏ Test both tank and piping for integrity.❏ Conduct cathodic protection tests to make sure that the tank is

electrically isolated from other structures.D. Tank Deflection❏ Check FRP tanks for deflections and verify that it is less than the

maximum diameter change allowed by the manufacturer.E. Installation Documentation❏ Maintain checklists of all installation activities.❏ Maintain photographs of all installations for future reference.

M-8-2


Guideline M-13Heat ExchangersA. Preplanning❏ Check that nitrogen blanket pressure is within prescribed limits

when vessels arrive at site.❏ Follow manufacturer and code requirements before any repair work

on the vessel or its appurtenances.❏ Ensure that all steel, equipment, and piping that prevent rigging

and placement of the vessels are not erected until after setting.❏ Check all critical layout dimensions between vessels and main tur-

bine, then between vessels and building steel.❏ Check that anchor bolts (pedestal-supported vessels) are accu-

rately set to line and line grade and within tolerance.❏ Check that support hangers and support steel (hanger-supported

vessels) are accurately set to line and grade within tolerance.❏ Check that benchmarks are established to verify line and grade and

are provided so that accurate line of sight is preserved the comple-tion of work.

❏ Plan large cross-around piping placement at most advantageoustime.

❏ Check that all equipment and structures in vicinity will permitdesigned expansion of vessel and its piping.

❏ Do not block vessel manway doors or other critical access itemswith permanent components.

❏ Ensure that no work is done inside the vessel until it is effectivelyvented and purged. Review the manufacturer suggested proce-dure. Satisfy all state, federal, and jobsite safety requirements.

B. Installation❏ Follow the manufacturer requirements and specifications when

removing temporary covers and internal shipping braces.❏ Verify that at frequent intervals that all vessel internals are effec-

tively protected from contamination when factory-supplied coversare removed.

❏ If welding is required, check that manufacturer-approved specifica-tions, materials, and procedures are used.

❏ Verify that welding is performed by qualified welders.❏ Ensure that nondestructive examination is performed as specified.❏ Check that all touchup painting of vessel interior uses only that

paint supplied and/or specified by the manufacturer.


Guideline M-12CondensersA. Submittals❏ Check vendor data, installation procedures, specifications, and lay-

out drawings for interface with other disciplines.❏ Verify that vendor has provided lifting beams as required by the

specifications.❏ Verify that waterboxes are hydrostatically tested at the vendor shop

before delivery to site.❏ Verify that weld footage, weld configurations, and a weld distortion

control procedure is available from the vendor.B. General❏ Verify that vendor has coated shop-prepared weld ends with deox-

aluminite to preclude corrosion before field welding.❏ Verify that the vendor has provided lifting lugs and alignment clips

for component handling and assembly.❏ Ensure that all shortage items are promptly identified and replace-

ment is expedited.❏ Check that torque values and tightening sequence for waterbox

bolts/nuts are available from the vendor.❏ If waterboxes are rubber lined, check that lining is not separating

due to shipping damage, storage, and handling.❏ Check that space gaskets and/or "O" rings are available.❏ Check that blank nozzles are capped off.C. Installation❏ Verify that condenser concrete foundation pad (piers) and anchor

bolts are in proper location, orientation, and elevation.❏ Take care during transportation, handling, and setting condenser.

Review Rigging Guideline.❏ Ensure that vendor representative is available during installation

operations, as required.❏ Ensure that equipment grouting is performed per manufacturer

instructions. Review Equipment Grouting Guideline.❏ Check nozzle protrusions for clearances before skidding in pre-

assembled condensers.❏ Verify that welding is performed by qualified welders.❏ Ensure that nondestructive examination is performed as specified.

Columns and Vessels Guideline M-14

✔ After checking, locally grout the shims to prevent removal.❏ Check that protective lattice, lubricants, and paint are removed and

surfaces cleaned where grouting is required.❏ Before removal of lifting equipment, make a final check of plumb-

ness and correct alignment.❏ Maintain an equipment settlement survey record and review the

results of each elevation check.E. Column and Vessel Testing❏ Inspect internally for cleanliness and any debris.

✔ No one may enter a "confined space" until safety inspectionhas been performed and determination made that their are noharmful gases, vapors, fumes, or mists present in the tankand proper ventilation is provided or proper respirator andprotective clothing is worn as required.

❏ Verify that a written procedure has been prepared for testing largecolumns and vessels.

❏ Ensure that testing is performed per the correct procedure and document the results.

❏ Testing of columns and vessels that have been shop tested maynot be required.✔ For convenience in testing piping, however, most columns

and vessels are included in the piping tests.❏ Ensure that trays are tested as required by the contract and

document the results.F. Final Inspection of Columns and Vessels❏ Before columns and vessels are headed up, ensure that they are

cleaned out and the internals are inspected.G. Trays❏ Check trays for levelness.❏ If levelness tolerance is not specified, use the following:

✔ All trays 12 ft (3.5 m) diameter and smaller should not bemore than 1/4" (6 mm) out of level.

✔ All trays larger than 12 ft (3.5 m) in diameter should not bemore than 3/8" (9 mm) out of level.

❏ Check orientation of trays with the vessel drawings.❏ Check that downcomers are sealed by weirs of the proper height.❏ Check downcomer and weir height dimensions against the vessel

drawings.❏ Check that trays are securely anchored to the vessel and that all

tray manways are properly installed following the inspection.❏ Check for proper gasket installation to ensure tightness.


M-14-1

Guideline M-14Columns and VesselsA. Preplanning❏ Inspect equipment at time of receipt for damage and/or shortages.

✔ Document any shipping or erection damage by photograph.❏ Check that stress-relieved vessels are stenciled. DO NOT WELD.❏ On large diameter equipment, it is desirable to have anchor bolt

templates made by the fabricator and shipped early to site beforepouring foundation.

B. Field-Fabricated Columns and Vessels❏ Perform dimensional, orientation and plumbness checks as work

progresses.❏ Where mating flanges occur, check horizontal and vertical align-

ment and also alignment of bolt holes.❏ Check that all welding is performed per contract and code require-

ments.❏ Inspect internals and externals for correct configuration and

completeness.C. Before Column or Vessel Erection❏ Prepare a heavy lift rigging plan per Bechtel rigging standards.❏ Check anchor bolt and skirt hole orientation and anchor bolt

projection.❏ Inspect anchor bolts for damage.❏ Establish elevations for setting leveling blocks.❏ Check large diameter columns for ovality before erection to identify

possible tray installation problems.❏ Ensure that the concrete foundation has been sufficiently cured.❏ Ensure that grading, timber mats, and track spurs are complete per

the heavy lift rigging plan.❏ Perform compaction tests on structural fill placed to accommodate

the heavy lift.❏ Verify that slide plates are installed and that lubrication, teflon, and

double nuts are used where required.❏ Verify that all welds on stress-relieved vessels have been stress

relieved.✔ Specifically check ladder, instrument, and pipe support attach-

ment welds.❏ Verify that there is no obvious damage to the vessel and no obvi-

ous misalignment or bow in the shell.❏ Check that suitable drainage is available to protect the tank pad.D. Column and Vessel Setting❏ Make a final check of the elevations of the leveling blocks and

anchor bolt locations and projections, before final setting.


Guideline M-15Steam TurbinesA. Preplanning❏ Inspect equipment at time of receipt for damage and/or shortages.❏ Remove shaft movement stops.❏ Inspect bearings.❏ Apply approved rust preservative to exposed machined surfaces

and machined surfaces inside bearing housings.✔ Apply an approved oil treatment to the journal bearings.

❏ Rotate shaft weekly if shaft stops have been removed.❏ Verify that foundation anchor bolts match baseplate anchor bolt

locations.❏ Prepare foundation surfaces for grouting.❏ Prepare baseplate bottom surfaces with approved primer for epoxy

grouting.B. Installation❏ Set baseplate on foundation.❏ Level baseplate.❏ Prepare grout forms.❏ Grout baseplate and cure grout.❏ Remove leveling screws and tighten anchor bolts to specified

torque.❏ Install coupling hub and verify pull-up.❏ Set equipment shafts level by adjusting shims at support feet.❏ Check distance between shaft ends with shafts in normal running

positions.✔ If necessary, move equipment positions.

C. Alignment❏ Align equipment shafts.❏ Make cold offset adjustment required by manufacturer to allow for

thermal growth of the equipment to a hot running condition withshafts level.

❏ Check cold alignment and adjust as necessary.❏ Temporary dowel equipment feet.

✔ Set clearance on equipment holddown bolts and spacersas required.

✔ Set centerline alignment key clearances.✔ Set radial growth key clearances as required.

❏ Install steam supply and exhaust piping.✔ Make last field weld well away from turbine.

❏ Break main piping flanges one at a time and monitor shaft align-ment for position changes indicating pipe strain.

Columns and Vessels Guideline M-14

❏ Ensure that bubble caps and tray valves are installed and thatvalves are free on valve trays.

❏ Check all trays for cleanliness.❏ Check weep hole requirements on seal pan trays.H. Nozzles❏ Check the orientation of vessel nozzles.❏ Verify that process nozzles are located on the proper trays.❏ Check thermowell locations and projections into vessels.I. Distributors❏ Check the orientation and location of distributors.❏ Check that distributors are properly supported and anchored to the

vessel.❏ Check drilled holes and/or spray nozzle for size, number, and

orientation.✔ Make certain that none of the holes or nozzles are plugged.

J. Mist Eliminators❏ Check orientation and location of mist eliminators.❏ Make certain that the pads are firmly supported and anchored.❏ Ensure that eliminators can maintain wash if located in an atmos-

phere where choking or plugging would be expected.K. Miscellaneous❏ Check that all internal bolts are stamped with the correct material

symbol.❏ Check weirs for proper orientation, height, and weep holes.❏ Check that davits are installed and working properly.❏ Inspect vortex breakers.❏ Check that leak testing nipples in nozzle-reinforcing pads extend

beyond insulation.❏ Check location of level control nozzles.❏ Ensure that name plates are readable and are securely fastened.❏ Check overall cleanliness.❏ Verify that all other internals are complete.L. Catalyst Loading❏ Check all elevations marked in vessels for catalyst levels.❏ Request frequent client inspections and approvals.❏ Obtain client signed Inspection Reports for record and filing.❏ Review and retain copies of equipment settlement survey records.M. Documentation❏ Verify that all reports and records are retained in the project files.❏ Verify that all code reports and inspection reports are retained in

the project files.

M-14-3

Steam Turbines Guideline M-15

F. System Restoration and Startup❏ Remove temporary jumpers and screens and reconnect oil piping

for normal service.✔ Drain reservoir and clean out all debris.✔ Replace filter cartridges and refill reservoir with clean oil.

❏ Verify that lube system pump start/stop and test system pressurecontrols during upset.

❏ Verify lube system rundown tank functionality.❏ Static test governor and governor actuator.

✔ Program governor as required.❏ Check governor valves, prepilot, pilot, and main servomotor linkage.

✔ Ensure that total travel of valves agrees with prepilot travel.❏ Verify that governor actuator/prepilot action on trip and action of

emergency shutdown cylinder for valve closure.❏ Blowdown main steam supply, exhaust steam header, leakoff and

sealing steam headers, gland ejector steam supply, and air removalsystem steam supply.

❏ Test exhaust pressure relief valve and install in exhaust pipingbetween turbine and first downstream block valve.

❏ Verify operation of main condenser condensate pumps and levelcontrol loop.

❏ Verify operation of air removal system ejectors, inter/after con-denser, drain traps or drain piping loops, and vent system.✔ Check relief valve operation for each stage.✔ Verify that hogger is able to achieve vacuum in reasonable

time.❏ Connect all piping while monitoring for piping strains.❏ Verify that all alarms and trips are functional.

✔ Test local panel and control room emergency stop button.❏ Verify trip and throttle valve operation during simulated trip.

✔ Verify action of trip and throttle valve exercising system.❏ Verify operation of extraction/induction non-return valve shutdown

cylinder and valve disk closure system.✔ Check that disk counterweight is fixed and adjusted properly.

M-15-3

Steam Turbines Guideline M-15

✔ Do not use come-a-longs to pull piping into position for bolt upor to hold piping while checking for pipe strain.

❏ Make up lube oil interconnecting piping for oil console.❏ Clean interconnecting and other field-fabricated oil piping.D. Lube Oil Flushing❏ Install flushing screens at each equipment oil connection.

✔ Alternatively, jumper each oil connection to drain and cover toprotect from entrance of foreign material.

❏ Flush oil system.❏ Fabricate auxiliary piping and ensure that piping has room for ther-

mal expansion.❏ Connect all instruments and electrical signals.E. Instrument Calibration and Checkout❏ Calibrate all instruments:

✔ Vibration probes, proximeters, and panel readouts.✔ RTDs and T/Cs✔ Trip and throttle valve position micro switches✔ Pressure switches, differential pressure switches, and

temperature switches✔ Sealing and leak off steam pressure control loops and valves✔ Bearing and control oil pressure control loops and valves✔ Bearing oil temperature control loop and valve✔ Level switches✔ I/P transducer calibrations

❏ Verify that all restricted orifices are installed.❏ Set tachometer and governor magnetic pickup clearances.❏ Set mechanical overspeed trip clearance.❏ Verify total shaft float.❏ Verify radial and thrust bearing clearance.❏ Check governor drive gear backlash, bearing clearance, and

coupling.❏ Check turning gear, adjust engagement, verify motor direction,

adjust disengagement mechanism, and adjust indicating microswitch.

❏ Check instrument and electrical loops between local panel andcontrol room.

❏ Verify that governor remote speed set point signal loop.

M-15-2


Guideline M-17Diesel EnginesA. Preplanning❏ Inspect equipment at time of receipt for damage and/or shortages.❏ Check that certification documentation has been received.❏ Check nameplate data.B. Installation❏ Check installation location per design requirements.❏ Verify that resilient mounting is fitted.❏ Verify that coupling and coupling bolts are fitted.❏ Check cold alignment.❏ Ensure that dowels are properly installed and hold down bolts are

tightened as required.❏ Check that shims are installed correctly.❏ Check that coupling guard is properly installed.❏ Verify that air inlet filter is installed and is accessible for mainte-

nance.❏ Check that exhaust silencer is installed including personnel

protection.❏ Check expansion joints for free movement.C. Checkout❏ Check engine lubrication including oil type and level.❏ Verify that new lube filter installed.❏ Check that cooling radiator is accessible for fill and drain.❏ Verify that crankcase and oil relief vents are installed.❏ Check that all instruments are installed.❏ Check that theoretical rotation is the same as the driven equipment.❏ Verify that starting system is properly installed and ready for start.❏ Verify that cooling system is charged with the correct coolant

mixture.❏ Check gauge board against P&IDs.❏ Verify that the emergency shutdown and/or fuel shutoff valves at

the unit are operational.


Guideline M-16Combustion Gas TurbinesA. Preplanning❏ Inspect equipment at time of receipt for damage and/or shortages.B. Installation❏ Check cold alignment as required.❏ Verify that baseplate is properly grouted.❏ Check that jacksrews are removed and foundation bolts are

tightened.❏ Recheck cold alignment.❏ Check installation of special spool pieces and verify that no piping

strain is applied to equipment.❏ Verify installation of fuel filters.❏ Check that pipe supports are properly installed.❏ Recheck cold alignment.❏ Flush lube and seal oil systems, refill reservoir with new oil, and

change oil filters.❏ Check reservoir oil heater.❏ Check instrumentation loops.❏ Verify that grounding strap is installed.❏ Check starter motor and direction of rotation.❏ Check that coupling and guard are installed.❏ Check inlet plenum and verify vacuum is cleaned.❏ Inspect clean air house.❏ Verify that all site-fabricated piping pressure was tested as

required.❏ Verify that all site-fabricated piping was chemically cleaned as

required.❏ Verify oil protection unit setup.

Furnaces and Heaters Guideline M-18

D. Burners❏ Check that installed burners are protected from mechanical dam-

age and that all refractory material is kept dry.❏ Make sure that there is no serious refractory damage and that

burner internals are clear of debris.❏ Check for adequate clearance between burner tiles and floor

refractory.❏ Check gun size, position, and alignment.❏ Ensure that suitable ignition equipment has been provided.

✔ Check that spares have been provided.❏ Make sure that both ignitor guns and the burner assembly can be

removed while the heater is in operation.❏ Check that the burner support is adequate to ensure that burner

alignment does not change while in service.❏ Ensure that suitable flame scanners are provided and that spares

are available.E. Dampers❏ Check operability of all dampers.

✔ Check critical dampers such as flue gas/combustion airbypass dampers both internally and externally.

✔ Verify that tight closure and ease of operation for all dampers.✔ Check for the potential of thermal growth problems.

❏ Check that stack damper indicator corresponds with damper posi-tion and that stops have been provided.

❏ Make sure that forced draft heaters cannot be over pressured byimproper damper operation.

❏ Check that hot service mechanical bearings are properly installedand are adequate for expected operating conditions.✔ Outboard installation is preferred to reduce operating temper-

ature.❏ Check for shaft leakage in forced or induced draft systems.❏ Check that individual burner dampers are capable of locking in the

fully open or fully closed position.F. Burner Piping❏ Inspect burner fuel valving system to ensure that burner startup,

operating, and shutdown requirements are met.❏ Inspect ignitor fuel valving system to ensure that ignitor startup,

operating, and shutdown requirements are met.❏ Check that required insulation and steam tracing is properly

installed.❏ Check that piping flexibility and support are adequate for gun height

repositioning.


M-18-1

Guideline M-18Furnaces and HeatersA. General❏ Check that nameplate is correctly installed and that nameplate

information is correct and legible.❏ Check erection for compliance with specification requirements and

verify that any deviations are documented.❏ Verify that welding procedures are approved for use.❏ Verify that field welding, heat treatment, and stress relieving are

performed per approved procedures and are properly documented.❏ Verify that nondestructive examination has been performed and

documented on field welds as required.❏ Check that hydrostatic testing is performed per contract and

applicable code requirements.❏ Ensure that exposed surfaces, easily accessible by operators,

with surface temperatures over 150°F (65°C) are insulated for personnel protection.

❏ Ensure that safe access is provided to all valves and instruments.❏ Check that all spare parts have been provided and are available.B. Heater Casing❏ Check sources of air infiltration:

✔ Sealing devices provided at entry and exit points for all tubes✔ Packing provided around convection section tubes at the end

of tube sheets✔ Convection section header boxes gasketed as required

❏ Check that large panels are adequately supported.✔ Additional stiffening may be required to prevent bowing.

❏ Check that rainwater cannot accumulate in arches, angles, orchannels.

C. Access and Observation Doors❏ Check that adequate radiant section observation doors have been

provided for the tubes, supports, walls, arch, and burner flames.❏ Make sure that convection section observation doors have been

installed to view representative tubes, extended surface, and tubesheets.

❏ Make sure that doors fit properly to minimize air infiltration.❏ Make sure that any explosion on pressure release doors will not

discharge flue gas in a direction where personnel exposure couldoccur.


K. Refractory Placement and Insulation❏ Verify that the installation, curing, and drying of refractory are

performed per manufacturer requirements.❏ Inspect completed refractory and insulation installation and

document any deviations.❏ Check that all expansion joint packing is installed and that no

thermal expansion problems are evident.❏ Make sure that convection section setting will not impose forces on

the arch noise area.❏ Ensure that all required field testing is complete including produc-

tion, cold crushing, and density tests.L. Dryout❏ Make sure that hydrostatic test water is removed from coils to the

maximum extent possible.❏ Ensure that fuel lines are steam blown dry but not through the

burner guns.✔ Check the performance of all burners during the dryout opera-

tion.❏ Monitor the thermal movement of tubes, tube support systems, and

refractory during dryout for evidence of problems.

M-18-4


✔ Make sure that only minor thermal growth forces will beimposed at the burner gun to piping junctions.

❏ Check that fuel piping has been properly seal welded.G. Radiant and Convection Section Coils❏ Review support and guide system for freedom of movement.

✔ Make sure that inlet and outlet piping does not impose excessive force on the coil assemblies.

❏ Check for adequate thermal movement clearances inside heater, attube entry and exit points, and at crossover piping.

❏ Inspect the operability of piping spring and counterweight supports.H. Soot Blowers❏ Check that steam piping is properly sloped and trapped.❏ Ensure that blowers are properly serviced for startup per manufac-

turer recommendations.❏ Conduct blower run-in test per manufacturer recommendations.

✔ Ensure that limit switches are positioned correctly.✔ Ensure that the lance has adequate clearances when in the

soot blower cavity.✔ Adjust poppet valves to provide required lance steam

pressure.I. Air Preheaters❏ Check installation per manufacturer instructions.

✔ Check instrumentation to ensure that thermal performance ofthe air preheater is controlled and enables safe operation.

✔ Make sure that cleaning facilities are adequate to maintainthermal performance.

✔ Make sure that air/flue gas dampers will provide for satisfacto-ry operation of the fired heater with the air preheat systembypassed.

J. Fans❏ Check instrumentation installation per design requirements.❏ Check bearing lubrication and cooling systems.❏ Check operability of forced draft fan inlet guide vane assembly.❏ Make sure that ductwork does not impose loads on fans.❏ Check operability of automatic backflow check for forced draft fans

operating in parallel.

M-18-3


Guideline M-21HVAC InstallationA. Preplanning❏ All ductwork, frames, connections, stiffeners, and access doors are

hot dipped galvanized steel unless otherwise specified.❏ Check that temporary test facilities are provided for leak testing of

ductwork, where specified.B. Installation❏ Check all rooftop fan decks to ensure that all flashing and sealing

are completely effective.❏ Ensure that damper and filter mounting frames are not distorted

during assembly.❏ Verify that sheet metal plenums, casings, and blank-offs are

smooth and even inside, airtight, and reinforced to eliminate vibra-tion or pulsation during operation.

❏ Check that access doors in insulated casings and housings haveframes of heavy galvanized structural steel members and inspec-tion windows constructed of two sheets of plexiglass with air spacebetween.

❏ Check that access doors open to the outside of the housing on thefan suction side and to the inside of the housing on the fan dis-charge side.

❏ Check all turning vanes for proper materials and installation.❏ Check that all joints are sealed and leak tested, as required, before

insulating or covering.❏ Check all ductwork, duct hangers, duct joint details, and equipment

supports for compliance with the project drawings and specifica-tions.

C. Testing❏ Witness all balancing and testing required by the contract docu-

ments.


Guideline M-19Water Treatment EquipmentA. Receipt Inspection❏ Check that tanks and vessels are inspected onboard vehicle at

arrival.✔ Inspect top of load for damage; determine degree of pre-

assembly.✔ Carefully check bundled piping for completeness.

❏ Check the lining and interior of all vessels or tanks on arrival.B. Installation Preplanning❏ Ensure that overhead and side clearances are adequate for tanks

and vehicle, both inside and outside building.❏ Ensure that construction activities do not block access for charging

tanks with resin or filter bed material.C. Installation❏ Do not allow welding or burning on lined tanks, vessels, or piping

unless vendor instructions are followed exactly.❏ Check that system flushes do not disrupt filter beds or resin beds.❏ Check that drains and flush down effluent from acid and alkali stor-

age tanks go only to drain lines provided for that service.

Ductwork Guideline M-22

❏ Check the operation of each damper✔ All damper motors are protected before and after mounting.✔ Dampers are easy working and provided with steel shafts and

end bearings.✔ Key-operated regulators are provided where damper fixing or

locking devices are not exposed or accessible.✔ Mounting brackets for damper motors or other duct supported

equipment have not been broken, removed, or damaged.✔ Damper motors are adequate for service intended.✔ Nylon or teflon bushing and seals on damper units are not

damaged by heating, metal chips, or misalignment.❏ Ensure that volume dampers and splitters are installed where

shown and in the following locations:✔ Provide a splitter for each safety branch✔ Provide a volume damper for each horizontal supply and

exhaust branch from vertical risers serving two or more floors.✔ Provide instrument test holes where required for balancing

system❏ Ensure that manual dampers, splitters, and deflectors are installed

where required for proper air flow and balancing of the air handlingsystems.

❏ Verify that the space between the duct or duct insulation and thesleeved or framed opening in fire-rated wall and floor penetrationsis sealed as specified.

❏ Check that removable handholes are installed:✔ Where necessary to reset fire or smoke dampers✔ Where required to adjust extractors✔ Where other devices inside ducts require service

❏ Verify that handholes at fire or smoke dampers are of heat-retar-dant wire glass and located so that the damper position is visible.

❏ Check that access doors or panels are provided adjacent to auto-matic dampers, at fire dampers, and where required for propermaintenance and servicing.

❏ Verify that fire damper fusible links are not defaced, missing, mixed,or placed in the wrong fire damper.

❏ Check that the entire fire damper is outside the air stream while inthe open position.

❏ Verify that ductwork turning vanes are correctly installed.B. Testing❏ Check plenum drains before system testing to ensure that they are

not plugged and that traps are water sealed.❏ Check for any undue vibration or movement in the ductwork during

pre-operational testing.

M-22-2

Guideline M-22DuctworkA. Installation❏ Inspect ductwork for correct gauge material, overall size, cross sec-

tional area, reinforcement, use of correct flexible connections,alignment without undue deformation of flexible connections, anduse of specified hangers.

❏ Check that pilot tube access holes with threaded plugs have beenprovided in the ducts and plenums for taking air flow measure-ments used in system balancing.

❏ Ensure that chambers or casings attached to masonry at louvers orregisters are secured with expansion bolts with mastic groutbetween angles and construction.

❏ Make sure that duct openings are capped during construction to prevent entry of dust and debris.

❏ Check that riser supports allow free vertical movement of the duct.✔ Supports shall only be attached to structural framing members

and structure concrete.✔ Do not anchor supports to metal decking unless specifically

detailed.✔ Do not use friction beam clamps.

❏ Check that duct joints are made with gasketed flanges or weldedflanges as specified and are properly reinforced at the joints andbetween the joints.✔ Ensure that sealants conform to specified fire hazard classifi-

cation.✔ Check that negative pressure safety relief valves are provided

as specified.❏ Check that spiral lock seam duct and flat oval duct are locked with

a minimum of three equally spaced drive screws and sealed withduct tape unless otherwise specified.✔ Verify that there are no dents in the male portion of the slip

fitting collar.❏ Check that fibrous glass duct installation is per manufacturer

requirements.✔ Check that supports are provided as specified.✔ Check that leakage rates do not exceed maximum allowed.✔ Ensure that sealants are per manufacturer requirements.

❏ Check that acoustical duct linings are installed with fire-resistantadhesive and are secured with welded pins or welding cup headpins as specified.

❏ Verify installation and operation of control, fire, and smokedampers.



Guideline M-23HVAC FansA. Preplanning❏ Inspect equipment on receipt at the site for completeness and

visible damage.B. Installation❏ Inspect equipment when installed for damage including bent mem-

bers, dents in panels, broken or deformed motor mounts, damagedroll filter and controls, and deformed vibration isolator assemblies.

❏ Check equipment installation for location, level, plumbness, andanchorage per manufacturer requirements.

❏ Check all rooftop fan decks to ensure that all flashing and sealingare completely effective.

❏ Check that vibration isolators are installed per manufacturerrequirements.✔ Verify that the spring in the isolator is not fully compressed.

❏ Check access doors and hatches:✔ Verify that they have been provided with tightly fitted seals.✔ Check for interference with other equipment or structures

when the doors or hatches are opened.❏ Verify that the access doors and panels are large enough for the

inspection and maintenance.✔ Check that access is adequate to permit personnel access

and for removal of internal equipment.✔ Verify that access doors open to the outside of the housing on

the fan suction side and to the inside of the housing on thefan discharge side.

❏ Check that required acoustical lining is installed where requiredand that the material satisfies fire rating requirements.

❏ Verify that the equipment lines up with duct installation withoutexcessive deformation of flexible connections.

❏ Check that piping, controls, and structural supports for the equip-ment are installed as required.

❏ Check all motors for mounting, line-up, ease of turning, sufficientand suitable belts in drive (if applicable), belt guard mounting, andlubrication fitting installation.✔ Lubrication fittings should be installed in easily accessible

locations.❏ Check power wiring, control wiring, and control piping for proper

installation.❏ Check all control panels for location, mounting, and completeness.

Ductwork Guideline M-22

✔ Verify that the system is substantially airtight with no audibleleaks.

✔ Verify that the maximum leakage rate is no more than 5% ofsystem operating air flow at system static pressure beforecovering the ductwork with insulation or concealing it behindmasonry or drywall.

❏ Leak test duct risers and branch ducts for high pressure ductworkincluding all flexible metal hose runouts to the joints where the ductrisers tie into the main.✔ Verify that the maximum leakage rate is no more than 1% of

system operating air flow at 1.25 times system operating pres-sure before covering the ductwork with insulation or conceal-ing it behind masonry or drywall.

✔ Identify each orifice tube used in the leak test with a uniqueidentification number that can be correlated to the calibrationcurve.

✔ Leak test the mains after the vertical duct risers or branchducts have been tested and accepted and after the centralstation air handling apparatus has been installed.

❏ Check that all flexible connections in the system are jumpered withcopper cable bolted to each side of connectors to the ductwork orframe of major equipment. ✔ Verify that a continuous ground is provided for all ductwork

through installed jumpers via grounded equipment.C. Cleaning❏ Verify that the interior of all ducts, plenums, and casing is cleaned

of all debris and is blown free of all small particles of rubbish anddust.✔ Before installing outlet faces, verify that interior of the system

is provided with a final vacuum cleaning.❏ Check that all equipment is wiped clean to remove oil, dust, dirt,

and paint spots.❏ Make sure that temporary filters are provided for all fans that are

operated during construction.❏ Verify that new filters are installed after all construction debris has

been removed from the structure and all duct systems have beenvacuum cleaned.

❏ Make sure that the completed system is maintained in a clean con-dition until final acceptance.

M-22-3


Guideline M-24Air Conditioning EquipmentA. Installation❏ Check that equipment pads, platforms, or hangers required to sup-

port the equipment are complete before starting the installation.❏ Verify that cooling and heating coils are properly located away from

permanent equipment for ease of access and removal.❏ Verify that tube fins on heat exchanger coils are not flattened or

defaced or plugged with dirt.❏ Check for visible damage to the HVAC system including bent mem-

bers, dents in panels, and broken glass.❏ Check for completeness of the system installation using the latest

revision of the contract documents.❏ Verify that all panels are identified with a fixed label per contract

document requirements.❏ Check for equipment line-up for level and plumbness using shims

as required.❏ Check that the line-up is securely fastened after leveling and align-

ment.❏ Check for interferences with other plant equipment or structures:

✔ Doors can be opened fully✔ Easy access to interior of line-up✔ Cable connections accessible✔ Conduit entry accessible

❏ Check that breakers, transformers, and other electrical devices canbe easily be removed from the line-up for maintenance, repair, orreplacement.

❏ Verify that the ground bus is complete for the entire length of theline-up and is connected at both ends to the station ground bus.

❏ Verify that all conduits entering the equipment room are sealed toprevent the entry of water into the room.

❏ Check that all wall and floor penetrations are fire sealed asrequired.

❏ Check that room doors and door frames have a Class B fire ratinglabel.

❏ Check that the roof, cable trench penetrations, and other areassubject to water leaking are waterproofed and that all leaks havebeen stopped.

❏ Check all electrical cables for damage, during and after installation.❏ Verify that the ground bus is connected to the station ground sys-

tem.❏ Verify that bus bar connecting bolts are properly tightened.

HVAC Fans Guideline M-23

❏ Check that the equipment is identified with a fixed label per contractrequirements.

❏ Check filters for type, cleanliness, and operation.❏ Check that electrical equipment and metal portions of installation

are bonded and securely connected to the station grounding sys-tem.

❏ Verify that belt guards are arranged to permit oiling, testing, anduse of a tachometer with the guard in place.✔ Verify that an access door has been provided in the belt

guard to measure belt tension.❏ Verify that the fan has been adjusted to operate without noticeable

vibration.❏ Make sure that the equipment is protected from dirt, foreign

objects, and damage during the installation period.❏ Check that all debris is removed from the work site and that all

equipment, including fan scrolls, housings, blades, and motors, iscleaned before final acceptance.

C. Testing❏ Verify that system balancing and testing are completed as required

and that the equipment performs as intended.

M-23-2


Guideline M-25Forced Draft Cooling FansA. Preplanning❏ Inspect equipment at time of receipt for damage and/or shortages.❏ Check that fan and motor bearings are lubricated while equipment

is in pre-installation storage per manufacturer recommendations.❏ Ensure that shaft is rotated weekly.B. Fan Installation❏ Check fan shaft at two locations 90° apart to verify that the shaft is

vertical and plumb.❏ Verify that fan shaft to hub bolting is torqued correctly.❏ Check fan blade to shroud clearance and concentricity.❏ Verify that all blade pitch angles are set.❏ Check that the maximum blade tip deviation relative to one anoth-

er does not exceed the maximum allowed by the manufacturer.❏ Check the fan blade holding screw/bolt torque.❏ Verify that the blade control is installed and functional.❏ Verify that the pitch angle is set (fixed or auto).❏ Check that the lube lines are installed.❏ Verify that the fan guard is installed.❏ Check that the motor and sheaves are installed.❏ Verify that the sheaves are aligned.❏ Verify that the fan belts are installed and tensioned.❏ Verify that the belt guard is installed.C. Pre-Operational Checkout❏ Check that the vibration switch is set.❏ Verify that the grounding strap is installed.❏ Check the operation of the start-stop switch at the motor, grade,

and control room.❏ Check the direction of fan rotation.❏ Verify that indicating lights are functional.❏ Ensure that the 4-hour motor run test is completed.❏ Check vibration level at vibration switch.❏ Re-check shaft and sheave alignment after run test.❏ Check motor amperage during operation at minimum, maximum,

and normal fan pitch.❏ Verify that exchanger bundle tie rods are loose.

Air Conditioning Equipment Guideline M-24

❏ Verify that vibration isolators and flexible connections have beeninstalled as required.

❏ Verify that belt guards are arranged to permit oiling, testing, anduse of a tachometer with the guard in place.✔ Verify that an access door has been provided in the belt

guard to measure belt tension.❏ Check that multiple type fan belts are machine-matched sets.❏ Verify that pressure gauges have been provided across filter banks

to indicate pressure drop.❏ Check that coils on rails are adequately supported and can be eas-

ily removed.✔ Make sure that the coils are not used to support piping.✔ Ensure that all coil vents and drains are properly terminated.✔ Check that piping connections to coil header to obtain counter

flow of air and water are complete.✔ Check that condensate drain pipe is routed from each unit

drain pan to nearest floor drain.❏ Make sure that equipment is protected from dirt, foreign objects,

and damage during the installation period.❏ Check that all debris is removed from the work site and that all

equipment including housing, coils, supports, fan and damperblades, belts, guards, and motors are cleaned before final accept-ance.

B. Testing❏ Witness required equipment performance tests demonstrating that

the equipment functions as intended.✔ Make sure new air filters are installed after the completion of

the performance test.

M-24-2


Guideline M-32Testing Hoisting EquipmentA. Preplanning❏ Verify that nondestructive examination (NDE) has been performed

and accepted on the crane hook.❏ Verify that cables and sheaves are free of excessive wear and

abrasions.❏ Verify that slings and chains, hooks, and eyes have no evidence of

defects, excessive wear, or damage.B. Test Procedure–Cranes❏ Monitor the actual test and indicate acceptance of each operation

before proceeding to the next operation.❏ Assemble proper test weights as specified on the crane test data

sheet, and use proper rigging for the test tag lines.❏ Position crane to make an over-the-rear lift, on level ground, with

extended outriggers, if so equipped.❏ Adjust boom to proper initial radius per crane test data.❏ Attach rigging devices so that the head of the boom and the center

of the test load are near plumb.❏ Tension load, and hold before initial lift off; confirm that all riggings

devices are in their proper positions.❏ Lift load approximately 12 to 18 inches (30 to 46 cm) from grade

and hold for short period to observe stability. ✔ Stability will be determined by observation of the bearing of

the crane outriggers or tracks that maintain the load from 11/2to 2 minutes.

❏ Lower load back to, but not in contact with, the grade; this loweringmust be performed and controlled at a slow rate.

❏ Lift load approximately 5 ft (1.5 m) above grade.❏ Observe stability.❏ Lower load by repeating initial load lowering.❏ Observe stability.❏ Lift load to approximately 10 ft (3 m) above grade.❏ Lower load by repeating load lowering operation.❏ Lift load to slightly less than "two block" position, and hold approx-

imately 10 to 15 seconds.❏ Observe stability.❏ Lower load at a reasonable rate of speed with control of the plane-

tary lowering system of the crane and brake load to a complete stopapproximately 4 to 8 inches (10 to 20 cm) from grade.


Guideline M-31Crane and Hoist InstallationA. Runway❏ Ensure that runway beam(s) and (girders) are straight and level

and within specification tolerances.❏ Ensure that runway rails are straight, level, and parallel within

specification tolerances.❏ Ensure that runway end stops and trolley bumpers are installed.B. Installation❏ Ensure that crane and hoist installation is performed per manufac-

turer instructions and as specified. Check that vendor representa-tive is present during erection operations, as required.

❏ Ensure that wire rope is of correct material, diameter, lay, and pitch.❏ Check that hoist controls are supplied per specifications.❏ Adjust all hoist holding, hoist control, bridge, and trolley brakes as

required.❏ Satisfy lubrication requirements before operating the crane or hoist.❏ Check that test weights (based on heaviest weight to be lifted) are

available for field testing, as required.❏ Ensure that vendor representative is present during operational

testing and/or certification and final acceptance.

Guideline E-1Embedded Rigid ConduitA. Rigid Steel Conduit❏ Verify that conduits and fittings to be embedded are of the size indi-

cated on the drawings, are galvanized rigid steel, and are per spec-ification requirements.

❏ Verify that conduit and stub up locations are per drawing require-ments.

❏ Check that there are no running threads on conduit (not allowed perthe National Electric Code).

❏ Check that approved expansion couplings are installed at allexpansion joints and in conduit runs greater than 300 ft (90 m)and/or as required by the contract documents.

❏ Ensure that installed couplings are listed as "concrete tight." ❏ Check that threads are coated with conductive sealing material to

seal and ensure electrical continuity of conduit installation.❏ Check that conduit runs crossing contraction or expansion joints

are at 90 degrees to the joint.❏ Check that conduits are rigid and will adequately maintain correct

location and spacing during concrete placement.❏ Check that conduit is supported clear of reinforcing bar.

✔ Ensure that conduit is coated or wrapped with a bituminouscompound or tape in areas of possible contact with reinforcingbar.

❏ Where practicable, avoid contact between dissimilar metals to elim-inate the possibility of galvanic action.

❏ Ensure that open conduit ends are capped and pull boxes sealedto prevent the entry of foreign materials.

❏ Ensure that all conduit is swabbed, rodded, or balled after installa-tion to remove any foreign material and is then capped.

❏ Verify that the number of bends in a run of conduit between pullpoints does not exceed a total of four 90 degree bends or 360degrees total unless cable pulling calculations indicate the conduitinstallation is acceptable.

❏ Check that threads are coated with an approved corrosion-resistantmaterial where conduit galvanizing has been removed for fieldthreading.

❏ Verify that conduit bends meet the minimum bend radius require-ments listed in the table unless otherwise specified in the contractdocuments.

❏ Ensure that installed conduit is checked for obstructions (mandrelpulled through embedded conduit to remove foreign material)before installing cable.

Field Inspection Guidelines © 1997, 2001 BechtelE-1-1

Testing Hoisting Equipment Guideline M-32

❏ Observe stability.❏ Lower boom to final radius, with load no higher than approximately

12 inches (30 cm) from grade.❏ Observe stability.❏ Rotate crane 90 degrees at a slow rate of speed.❏ Observe stability.❏ Rotate crane 180 degrees via the rear of the crane. Note: avoid

rotation of load beyond either of the forward outriggers.❏ Observe stability.❏ Return crane to initial lift radius and set down load.❏ Complete test report and all supporting documentation and forward

to records.

M-32-2

Guideline E-2RacewayA. Receiving and Storage❏ Check that material received is of the type and quantity specified

and bears a UL label where applicable.❏ Check that raceway is stored where it will be kept clean and pro-

tected against damage.B. Installation❏ Verify that installations are per project plans, raceway schedules,

specifications, notes, and details.❏ Check embedded conduit for correct installation before concrete is

placed.❏ Verify that raceway installation meets the requirements for cable

installation, such as:✔ Conduit radius and number of bends between pull points✔ Location of pull points✔ Access for pulling equipment and cable reels as adequate at

pull points❏ Check that protective end caps or plugs are installed in the ends of

embedded conduits and ducts to keep foreign material from enter-ing the raceway.

❏ Verify that raceway is properly:✔ Grounded✔ Supported✔ Identified

C. Documentation❏ Check that raceway card system, if used, or other system is func-

tioning correctly.


Embedded Rigid Conduit Guideline E-1

❏ Check that conduits terminating in cable trays are securely connected to the tray to provide a good electrical bond.

❏ Document conduit installation deviations on as-built drawings.B. Rigid Nonmetallic Conduit❏ Ensure that conduits and fittings are of the size and type as

indicated in the drawings and manufactured per specificationrequirements. Check that all field bends are free of cuts, dents, or flats.

❏ Ensure that each length of nonmetallic conduit is clearly markedwith material identity (type) at least every 10 ft (3 m).

❏ Ensure that nonmetallic conduit is not used in hazardous (classi-fied) locations.

❏ Check that cut ends of conduit are reamed to remove rough edges.❏ Ensure that location of conduits and stub outs are as shown on the

drawings.❏ Check that all joints between lengths of conduits and between

conduit couplings, fittings, and boxes are made by approved methods.❏ Check that conduit bends meet the minimum bend radius require-

ments as shown in the table included in the guideline or as otherwise approved by the engineer.

❏ Ensure that the number of bends in a run of conduit between pullpoints does not exceed the equivalent of four quarter bends (360 degrees total) including bends located immediately at the outlet or fitting unless cable pulling calculations indicate the conduitinstallation is acceptable.

❏ Check that "as built" conduit locations are noted on drawings.❏ Ensure that conduit bends meet the minimum bend radius as

follows or as otherwise specified.

MINIMUM CONDUIT BEND RADIUSCONDUIT SIZE (IN.) MINIMUM RADIUS (IN.)

1/2 43/4 5

1 611/4 811/2 10

2 1221/2 15

3 183 1/2 21

4 245 306 36

E-1-2

Electrical Panels and Switchgear Guideline E-3

❏ Witness insulation resistance test at 1,000 volts dc on all controlwiring. Minimum insulation resistance shall be 1,000,000 ohms.

❏ Verify that the proper type, range, and connections of all instrumenttransformers.✔ Confirm correct polarity of all current transformers electroni-

cally.❏ Verify that short-circuiting links have been removed from current

transformers after checking that secondary circuits are complete.❏ Verify that all meter connections are complete and that the meters

have been properly calibrated.❏ Verify that all protective relays, auxiliary relays, trip coils, trip circuit

seal-in and target coils, and fuses are the correct type and range.❏ Verify that all wedges, ties, and blocks installed by the manufactur-

er to prevent damage during shipment have been removed.❏ Check all relays per manufacturer instructions.

✔ Set all relays per provided settings.✔ Check time-current characteristics with a test kit approved by

the relay manufacturer.❏ Measure battery system charging voltage and each individual cell

voltage, verifying that measured values are within manufacturer tol-erances.

❏ Ensure that all changes of connection, insertion, and removal ofmeters, relays, and other devices are made so that the secondarycircuits of energized current transformers are not opened evenmomentarily.

E-3-2

Guideline E-3Electrical Panels and SwitchgearA. Preplanning❏ Check that switchgear tools such as levers and earth sticks are

received with the equipment and are either properly secured to theequipment or have a separate tool box that can be installed nearthe switchgear.

❏ Check that the size and spacing of terminal blocks conform to thetype of cables, lugs, and voltage level specified.

❏ Check that the switchgear name plate is received along with theequipment and includes all required information.

B. Inspection❏ Verify that mounting channels and brackets are located as speci-

fied.❏ Check that embedded floor mounting channels are level and on the

same plane.❏ Make sure that there are no high spots between mounting channels

to cause warping of switchgear panels.❏ Verify that the panels have not been racked or warped during tran-

sit.❏ Make sure that all jacks are raised evenly when jacking switchgear

to remove shipping skids.❏ Ensure that embedded conduit and ground cables are not dam-

aged when setting switchgear.❏ Make sure that panels and switchgear are adequately protected

from dust, dirt, moisture, water, and mechanical damage duringconstruction.

❏ Ensure that switchgear and instrument shipping blocks are kept inplace until heavy cables are installed.

❏ Check that wall-mounted panels are level and set off the wallenough to ensure that unevenness of wall will not warp panels.

❏ Check that embedded wall panels are adequately braced beforeconcreting to prevent warping.

C. Final Acceptance❏ Compare actual wiring connections with wiring diagrams.❏ Inspect all devices and equipment for shipping or handling dam-

age.❏ Verify that bolted bus joints are torqued per manufacturer instruc-

tions using a calibrated torque wrench.❏ Verify that the performance of all mechanical operators by con-

ducting contact alignment tests on breakers and operating mecha-nisms per manufacturer instructions.

❏ Witness minimum pickup voltage tests on all trip and closing coils.❏ Review electrical continuity checks of all current, potential, and

control circuits.


Electrical Equipment Guideline E-4

❏ Witness insulation resistance test at 1,000 volts dc on all controlwiring. Minimum insulation resistance shall be 1,000,000 ohms.

❏ Verify that the proper type, range, and connections of all instrumenttransformers.✔ Confirm correct polarity of all current transformers electroni-

cally.❏ Verify that short-circuiting links have been removed from current

transformers after checking that secondary circuits are complete.❏ Verify that all meter connections are complete and that the meters

have been properly calibrated.❏ Verify that all wedges, ties, and blocks installed by the manufactur-

er to prevent damage during shipment have been removed.❏ Verify functional testing of equipment to demonstrate performance

per the manufacturer specifications.❏ Retain copies of test results for project records.❏ Ensure that changes of connection, insertion, and removal of

meters, relays, and other devices are made so that the secondarycircuits of energized current transformers are not opened evenmomentarily.

E-4-2Field Inspection Guidelines © 1997, 2001 Bechtel

E-4-1

Guideline E-4Electrical EquipmentA. Preplanning❏ Verify that temporary storage is provided for protection against

moisture, blowing dust, temperature extremes, and other environ-mental elements per manufacturer instructions.

❏ Make sure that manufacturer representative is available duringinstallation as required by the contract.

❏ Make sure that foundation grades and bolt locations are correctbefore installing equipment.

❏ Check that the size and spacing of terminal blocks conform to thetype of cables, lugs, and voltage level specified.

❏ Check that the equipment name plate is received along with theequipment and includes all required information.

B. Installation❏ Check that equipment is installed per manufacturer instructions.❏ Verify that electrical service conforms to the requirements of the

applicable electrical code or standard such as NEC, NFPA, orANSI.

❏ Check leveling and alignment of equipment to specified tolerances.❏ Check torquing of mounting bolts.❏ Verify that baseplates or equipment is shimmed, leveled, and

aligned before grouting.❏ Verify that grout mixing and placement are performed per manu-

facturer requirements. Review Equipment Grouting Guideline.❏ Verify that welding conforms to specified structural welding codes.❏ Verify that the equipment is correctly and permanently identified as

required by contract documents.❏ Verify that power, instrumentation, and control cables are identified

at each end.C. Testing❏ Check that all test equipment used for testing is calibrated and

operating properly.❏ Compare actual connections with wiring diagrams.❏ Inspect all devices and equipment for shipping or installation dam-

age.❏ Verify that bolted bus joints are torqued per manufacturer instruc-

tions using a calibrated torque wrench.❏ Witness electrical continuity checks of all current, potential, and

control circuits using wiring diagrams as a reference.

Wire and Cable Guideline E-5

❏ Verify that cable is temporarily coiled after installation and properlysupported to preclude cable damage.

❏ Verify that cable routing is correct.❏ Check that the length of the cable route conforms to the specified

cut length plus a reasonable allowanceE. Documentation❏ Retain cable pulling records in SETROUTE™.


E-5-1

Guideline E-5Wire and CableA. General❏ Verify that cable voltage rating, insulation type, conductor size,

number of conductors, shielding, cable and conductor identifica-tion, and reel markings are correct.

❏ Verify that cable and reels are free of damage.❏ Verify that cable ends are properly sealed to preclude water and

moisture damage.❏ Ensure that proper equipment and unloading methods are used to

prevent damage to cable during handling operations.❏ Verify that cable reels are tagged or color coded, as required.B. Storage❏ Check that the cable storage area is properly fenced, well lighted,

and level, with adequate drainage.❏ Check that reels are on chocks or timbers and properly spaced.❏ Verify that a running inventory of reel numbers by location and color

code is maintained.C. Before Installing Cable❏ Verify that duct lengths are in field before cutting cable.❏ Check that material and cable pulling equipment is available and

adequate.❏ Ensure that there is a method of communication when pulling

cable.❏ Review manufacturer recommendations for cable installation.❏ Verify that pulling compound is compatible with the cable being

installed.❏ Check if the cable will be pulled from the correct drum number per

the SETROUTE™ scheduleD. Installing Wire and Cable in Raceways❏ Check ambient temperature and weather conditions before pulling

cable outdoors and ensure that temperature is not below recom-mended minimum.

❏ Verify that raceway, conduit, and ductbank are complete and cleanand that cable can be installed.

❏ Ensure that craft have required SETROUTE™ pull cards and tags.❏ Verify that cable pulling calculations have been performed as

required.❏ Check pulling tensions and direction of pull.❏ Check dynamometer reading when necessary.❏ Check pulling set ups and equipment for compliance with safety

requirements.❏ Ensure that cables rated at more than 15 kV are pulled down grade.❏ Verify that temporary cable identification tags are installed.

Terminations Guideline E-6

❏ Ensure that minimum installed radius is not violated.❏ Check that cables meet megger or hypot testing, if required.❏ Ensure that connections to bus bars or motor leads are correctly

torqued.❏ Check that connections are properly insulated.❏ Ensure that ground leads are connected to ground bus and prop-

erly routed.❏ Check that cables are properly supported.❏ Ensure that sleeves, conduits, and cutouts are sealed after cables

are terminated and tested, where specified.C. Installing Cable❏ check if the length of the route conforms to the cut length plus a

reasonable allowance.


E-6-1

Guideline E-6TerminationsA. Low Voltage❏ Ensure that connection diagrams used are the latest revision.❏ Ensure that cable jacket strippers do not cut the insulated conduc-

tors.❏ Ensure that cable jackets are stripped reasonably close to the point

of termination.❏ Ensure that insulated conductors are stripped to the required length.❏ Ensure that strippers do not cut or nick the conductor strands.❏ Ensure that terminal lugs are the proper conductor range and stud

size.❏ Ensure that correct crimping tool is used.❏ Ensure that the ratchet on the crimping tool is in good working order.❏ Check that no more than two connectors are terminated under each

terminal screw.❏ Check that no two conductors are crimped in the same compression

connector unless shown on a drawing or allowed by specification.❏ Check that thermocouple terminations have the proper lugs and

tools.❏ Ensure that cables are properly supported.❏ Ensure that cables are correctly and permanently identified after ter-

mination.❏ Where specified, ensure that sleeve, block-outs, or slots are proper-

ly sealed.B. Medium Voltage❏ Ensure that the correct termination kits are used and installed per

manufacturer instructions.❏ Check that cable jackets are cut squarely without jagged edges.❏ Ensure that metallic shielding tape is not cut when the jacket is

removed.❏ Check that metallic shielding tape is cut without jagged edges.❏ Ensure that semi-conducting shield is cut squarely without cutting

the insulation.❏ Check that there are not cuts or gouges in the insulation.❏ Ensure that dimensions of the jacket, shielding tape, and semicon-

ductor are compatible with the termination kit.❏ Check that semiconductor paints, tapes, or extruded layers are com-

pletely removed from the insulation.❏ Ensure that insulation is thoroughly cleaned using an approved sol-

vent.❏ Check that conductor strands are not nicked or cut when the insula-

tion is removed.❏ Ensure that correct size and type of lug are used.❏ Check that correct crimping tool and die are used.❏ Ensure that shield cable termination is correctly grounded.❏ Check that stress relieving material is heated completely to shrink

tubing.❏ Ensure that cables are correctly and permanently identified.

Lighting Systems Guideline E-7

❏ Verify that branch circuit breaker ratings comply with lighting panelschedule and are installed in the correct location shown on theschedule.

❏ Verify that the lighting panel enclosure is properly grounded.❏ Verify that tags and name plates provided are per purchase order

and contract requirements.F. Lighting Transformers❏ Verify that the type, size, and rating of transformers are per single

line diagrams, drawings, and/or specifications.❏ Check that transformer "equipment" and "neutral grounds" are

properly installed.G. Pole-Mounted Fixtures❏ Verify that concrete base complies with design drawing require-

ments.❏ Double nut pole to mounting bracket or base and verify that the

pole is plumb.❏ Grout void between concrete base and panel, if required.❏ Verify that luminaries and photoelectric controls are installed per

manufacturer requirements.❏ Verify that lighting standards are properly grounded.H. Tunnel Lighting❏ Verify that required fixture supports are installed and that fixtures

and supports are not mounted on or in contact with ducts or pipes.❏ Verify that the lighting fixtures are installed at the required locations

and in the proper alignment specified.❏ Ensure that fixture vent holes are not blocked and permit free air

flow to the fixture.❏ Verify that fixtures are properly aligned by aiming adjustable fix-

tures to provide the required illumination.✔ Do this just before final acceptance.

❏❏ Verify final cleaning of the lighting system:✔ Clean lighting fixture bottoms, trim, reflecting surfaces, lenses,

baffles, louvers, and reflector cones during installation.✔ Mask lighting fixture trims and bottoms to protect them during

installation.❏ Verify that the correct lamp is installed in each fixture.❏ Ensure that temporary lighting fixtures, lamps, and associated

wiring, conduit, and boxes are removed after the permanent sys-tem is operational.

❏ Verify that the exit fixtures are installed over doorways as specified.


E-7-1

Guideline E-7Lighting SystemsA. General❏ Verify that installed lighting systems, including panels, transform-

ers, raceway, lights, wiring, and receptacles, conform to drawing,specification, and applicable electrical code requirements.

B. Fixtures and Switches❏ Verify that installed fixture and switch locations, mounting methods,

and mounting heights are per lighting layout drawings.❏ Check that conduit and boxes are properly installed and supported.❏ Ensure that local lighting switches (single pole or 3-way) are

installed per layout drawings.❏ Verify that switch mounting heights conform with the specification

requirements.❏ Verify that installed fixtures and switches are the type, voltage, and

wattage specified.❏ Verify that fixtures and switches are connected to the correct elec-

trical panel circuit.❏ Check that the lighted area illumination level is acceptable by visu-

al inspection or by the use of a light meter to verify specified footcandle level.

❏ Verify that lighting fixtures are properly grounded.❏ Verify that fixtures and switches are tagged per contract require-

ments.C. Convenience Outlets❏ Verify that installed receptacles are the type and rating specified.❏ Verify that receptacles are installed in the required locations and at

the correct height.❏ Verify that receptacles are correctly phased and grounded.❏ Verify that receptacles are properly terminated and connected to

the correct branch circuit.❏ Verify that receptacles are tagged per contract requirements.D. Wiring❏ Verify that type, size, and color code of lighting wires are per con-

tract requirements.❏ Check that fixture terminations are properly installed.E. Lighting Panel❏ Verify that lighting panel and circuit breaker type, size, and rating

are per lighting panel schedule.❏ Check panel mounting height per design requirements.❏ Verify that lighting panels name plates show lighting panel number

and location per contract requirements.❏ Ensure that a typed circuit directory is provided in a protected hold-

er with clear window on the inside of the panel door.

Grounding Guideline E-8

D. Ground Fault Return Path❏ Check that all electrical equipment energized from a low-resistance

or solidly grounded system operating at greater than 120 volts hasa continuous ground fault return patch using the following methods:✔ Trays carrying power cables require a bare conductor

along the outside of the tray.✔ Rigid steel conduits are considered an effective ground

fault return path and require no conductor with the con-duits. However, the tray ends of rigid steel conduitsshould be jumpered to the tray's ground fault conductor.

✔ Metallic tubing carrying power cables have a ground faultconductor in the conduit.

✔ Flexible conduits 1-1/2 inch (38 mm) and larger carryingpower cables have a ground fault conductor (jumper).

✔ Embedded nonmetallic conduits carrying power cableshave a ground fault conductor.

✔ Duct banks have a ground fault conductor embedded inthe top center surface of the duct bank concrete or on topof the duct bank. Power conduits branching off alsorequire the ground fault conductor to follow. The groundfault conductor must be continuous inside manholes.

✔ Ground fault conductors should be installed to both endsof the ground bus for MCCs, switchgear, or load centers.


E-8-1

Guideline E-8GroundingA. Preplanning❏ Review job drawings and specifications for grounding require-

ments.B. Equipment Review❏ Check that all normally non-current-carrying metal parts of electri-

cal equipment, enclosures, building steel, and other specified struc-tures are grounded as follows:✔ Steel columns are grounded to the grounding grid as speci-

fied.✔ Motors are grounded to the ground grid or to a grounded

structural member as specified.✔ Metallic raceway (tray, conduit, and junction boxes) is ground-

ed as specified.✔ Electrical equipment such as transformers, switchgear, motor

control centers, and control panels are grounded as specified.C. Grounding Grid❏ Check that ground cable, stub-ups, and ground pads are properly

located.❏ Check that the grounding grid is installed not less than 30" (76 cm)

below finished grade unless otherwise specified.❏ Ensure 24" (60 cm) minimum separation between grounding rods

and/or bare grounding conductors, concrete structures, or pilesunless otherwise specified.

❏ Check that ground rods are driven into the ground until the top ofthe rod is 6" (15 cm) above the elevation of the grounding conduc-tor unless otherwise specified.

❏ Verify that buried ground cables crossing buried metallic structuresare either installed a minimum of 36" (90 cm) apart or are insulat-ed as specified.

❏ Check that buried ground cables installed parallel to electrically iso-lated underground metallic piping are separated by at least 10 ft (3m).

❏ Check that ground cable is #4/0 AWG stranded bare copper cableunless otherwise noted.

❏ Check that earth connections are protected with an approvedgreasing compound

❏ Check that thermal weld ground branch joints are properly com-pleted and that earthing tape is applied per specifications

Guideline E-10Cathodic ProtectionA. Installation❏ Check that the type, size, and rating of transformers and rectifiers

are as required by specifications and drawings.❏ Verify that enclosures are sheet metal per NEMA IS1.1 with weld-

ed seams and hinged doors.❏ Check mounting of circuit breakers, ammeters, and voltmeters on

inside panel of enclosures.❏ Check that rectifier semiconductors are high-current silicon diodes

with input and output sides protected by zeener type seleniumsurge plates and lightening arresters.

❏ Check impressed current anodes and sacrificial anodes, if any, forcorrect type and configuration.

❏ Verify that cable terminations are made with acceptable type termi-nal and crimping tools.

❏ Check anodes and cathodic protection cables for correct type andsize.

❏ Check the installation of rectifiers panels.❏ Check installation of test stations for location, terminations, and

that they are correctly identified. ❏ Check buried rectifiers cables for correct depth, bedding, and back-

fill, as specified.❏ Check anode installations.❏ Verify that the cathodic protection systems are electrically isolated

from the grounding system and reinforced concrete foundations.❏ Check bonding of waterline joints to ensure electrical continuity.❏ Verify continuity of conductors after backfill.❏ Verify that all test results are included in the final survey report.❏ Check that rectifier cables and anode cables are properly identified

and numbered on both sides❏ Verify that the as-built location of anodes and the ring are identified

on the design drawings


Guideline E-9BatteriesA. Installation❏ Check that batteries, racks, and accessories are the type, size, and

rating required by specifications and drawings.❏ Verify that battery chargers are of specified type and constructed

per NEMA or per applicable code.❏ Verify that enclosures are NEMA Type 1 (or as required by appli-

cable code) with instruments, indicating lights, and control devicesmounted on front door.

❏ Check installation and wiring for compliance with specifications,drawings, and manufacturer instructions.

❏ Verify that batteries and battery chargers have been shop testedand data sheets submitted, as required.

❏ Verify that field testing has demonstrated that the equipment func-tions over the entire range of operation.

❏ Verify that battery rooms have adequate forced ventilation to pre-clude the build-up of an explosive mixture of hydrogen gas gassedfrom the batteries during charging.

❏ Verify that battery rooms not having forced ventilation have explo-sion-proof electrical installations for raceway, light fixtures, lightswitches, receptacles, telephones, and equipment.

❏ Check that completed battery Installation allows enough space formaintenance

❏ Check that batteries, MCCBs, and cables are correctly identifiedB. Testing❏ Witness the following field testing:

✔ Insulation resistance tests✔ Performance test of each battery per IEEE 450 or as specified


Instrument Installation Review Guideline J-1

❏ Ensure that instrument primary taps are correctly oriented andsized and provide sufficient elevation for correct sensing line slope.

❏ Ensure that flareless type fittings are installed only where specified.❏ Ensure that dissimilar metals are not joined directly in socket weld-

ing but by other approved methods.

J-1-2

Guideline J-1Instrument Installation ReviewA. Submittals❏ Ensure that vendor packages are complete and conform to pur-

chase order, requisitions, drawings, P&IDs and specifications.❏ Check that vendor and/or subcontract drawings and specifications

are accurate, complete, and conform to codes.B. Installation Review❏ Ensure that racks, panels, instruments, and sensing lines are free

of interferences.❏ Ensure that instrument locations are accessible for mounting, oper-

ation and maintenance.❏ Check that instruments are located as close as practical to the pri-

mary tap.✔ Locate locally mounted instruments near the most convenient

point of use consistent with good measuring practice. ✔ Sensing lines should be as short as practical.

❏ Check that all instruments and connecting lines have allowancemade for movement of equipment by seismic loading, vibrations, orexpansion or contraction caused by temperature changes.

❏ Ensure that lines or connections open to atmosphere are protectedagainst ingress of foreign matter. ✔ Unprotected openings should have a gooseneck, or equiva-

lent, attached to protect against falling particles.❏ Check that process connections and root valves are located so that

they are accessible. Ensure that root valve stem and handle areinstalled clear of mainline insulation.

❏ Ensure that manufacturer installation requirements, including thoserelating to unsupported span and minimum bend-radius of capillarytubing, are followed.

❏ Check that sensing lines have a continuous slope to promote theirbeing kept either full or free of liquid, as appropriate.

❏ Ensure that flareless type fittings are harder than tubing they grip.❏ Check that flareless versus socket welding fittings are installed in

systems and areas per instrument piping specifications.❏ Ensure that instruments are properly oriented and mounted per

instrument manufacturer instructions and as specified.❏ Check that instruments are not subject to excessive vibration or

shock to impair proper operation.❏ Ensure that instrument primary taps are located per instrument

connection details.

Field Inspection Guidelines © 1997, 2001 BechtelJ-1-1


Guideline J-3Instrument Mounting SupportsA. Fabrication❏ Check that instrument mounting supports are fabricated from

approved materials.❏ Ensure that instrument mounting supports are fabricated and

installed per instrument mounting details.B. Installation❏ Check that supports are located and oriented per instrument loca-

tion drawings and sensing line isometrics.❏ Ensure that concrete fasteners are the correct size (length and

diameter) and type as specified. Review Concrete ExpansionAnchor Guideline.

❏ Check that concrete fasteners are properly located and installedper manufacturer instructions.

❏ Ensure that instrument mounting supports requiring welding, arewelded per approved procedures and examined as specified.Review Welding Guideline.

❏ Check that weld materials and welder identification numbers arestamped or etched on instrument mounting supports, where speci-fied.

❏ Ensure that instrument mounting supports requiring documentationare stamped or etched with identification number.

❏ Check that instrument valves and bypass manifold valves are rigid-ly mounted to mounting structure.

❏ Ensure that open-end pipe supports are properly sealed.❏ Check that mounting baseplates are grouted per drawings, specifi-

cations, and grout manufacturer's instructions. Review EquipmentGrouting Guideline.

❏ Ensure that mounting supports are painted, as specified. ReviewPainting Guideline.


Guideline J-2Instrument Piping and TubingA. Installation❏ Ensure that instrument system is fabricated and installed per draw-

ings and specifications.❏ Verify that brazing and soldering are per specifications and proce-

dures.❏ Ensure that Instrument system contains isolation and blowdown

valves at each elevation as required.❏ Verify that instrument lines are sized per instrument and piping

specifications.❏ Ensure that required tubing slopes are provided.❏ Verify that instrument tubing bends are free of wrinkles and flat

spots.❏ Ensure that instrument tubing is properly supported and protected

from potential damage.


Guideline J-5Instrumentation TestingA. Preplanning❏ Perform a pre-test inspection by walking down the line and verify-

ing inspection accessibility, completeness, flanged joints tightness,and joint chalking.

❏ Ensure that test boundaries are properly tagged site procedures.❏ Verify that test gauges are calibrated per project procedures and

that the calibration due date is shown on the test gauge.✔ To validate that test gauges are still within the prescribed cali-

bration period, check the test gauges against a master gaugebefore testing.

❏ Ensure that the maximum test pressure is within 30% to 70% ofgauge range.

❏ Check that test gauges are calibrated by a qualified instrument lab-oratory.

❏ Make sure that items not capable of safely sustaining test pres-sures are removed or isolated from the system.

B. Testing❏ Verify that only systems released for testing are tested.❏ Verify that testing is performed per approved procedures and spec-

ifications.❏ Ensure that testing is performed by qualified personnel.❏ Check that the proper test medium is used.❏ Check that the test medium is at proper temperature.❏ Verify that the system is tested between the minimum and maxi-

mum test procedures specified.❏ Verify that the test pressures are held for specified time limit.

✔ Typically a 10 minute minimum holding time is required.❏ Ensure that testing progress charts are maintained when required.❏ Verify that documentation forms are accurately completed per proj-

ect procedures.❏ Ensure that documented tests are witnessed when required and

that documentation forms are signed by the authorized witness.❏ Verify that the system is gastight by applying an approved soap

bubble solution to all joints (pneumatic test only).


Guideline J-4Instrumentation CleanlinessA. Work Operations❏ Ensure that installed instruments, racks, and panels are protected

with temporary covers, enclosures, or barriers.❏ Verify that instrument port openings are sealed from dirt, moisture,

and other contaminates.❏ Ensure that tools, such as files, grinders, and brushes, used in fab-

rication and installation of stainless steel materials have not beenused previously on other materials.

❏ During pipe fabrication, ensure that openings are plugged beforeleaving area unattended.

❏ Ensure that material storage areas are inspected periodically forgood housekeeping practices.

❏ Visually check material for unsealed openings subject to dirt andmoisture during receiving, storage, fabrication, and installation;seal as required.

❏ Ensure that all material remains clean during handling, receiving,storage, fabrication and installation including after installation perinstrument manufactures procedures and as specified.


Guideline J-6Instrumentation System ReleaseA. Preplanning❏ Visually check instrument installation by walking down system and

verifying conformance to latest revision of sensing line isometric orinstrument installation detail.

❏ Visually check that instrument installation conforms to P&ID design.❏ Visually check that sensing line and instrument supports conform to

drawings.❏ Visually check that instrument root valves are installed with stems

in the proper position.❏ Visually check instrument sensing lines for correct vents and

drains.❏ Check sensing lines for correct slope.❏ Visually check instrument installations for damage and missing

parts.❏ Visually check pipe and tubing for smooth wrinkle-free bends and

that bend radii are per drawings and specifications.❏ Visually check that instrument racks and panels are properly grout-

ed.❏ Visually check instruments for protective coverings.❏ Visually check that hanger rack and tray mounting bolts and nuts

are tight.

mechanical and electrical field inspection guideline

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