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Mechanical/Electrical
Field Inspection Guidelines
Table of Contents
Number
Construction Inspections
Construction Safety
Equipment Tag/Lockout
Receiving and Storage
Design Document Control
Material Control
Measuring and Testing Equipment
Control of Deficient Items
Records Retention
Field Welding
G-31
G-32
G-33
G-34
General Welding
Code Welding
Nondestructive Examination
Heat Treatment
Piping Systems
P-1
General Piping
Table of Contents
Number
Title
General
G-1
G-2
G-3
G-4
G-5
G-6
G-7
G-8
G-9
Mechanical/Electrical
Field Inspection Guidelines
P-2
P-3
P-4
P-5
P-6
P-7
P-8
Title
Large Pipe
Small Pipe
Embedded Piping
Storm and Sanitary Sewer
HDPE Piping
Valves
Hangers and Supports
Lined Piping
P-11
P-12
P-13
P-14
P-15
Plastic-Lined Pipes
Lined Pipe Gaskets
Kynar-Lined Pipe
PTFE-Lined Pipe
Lined PipeSaran or Polypropylene
TOC-2
Mechanical/Electrical
Field Inspection Guidelines
Table of Contents
Number
M-8
Title
Table of Contents
Number
Mechanical Equipment
M-11
M-12
M-13
M-14
M-15
M-16
M-17
M-18
M-19
Mechanical/Electrical
Field Inspection Guidelines
Boilers
Condensers
Heat Exchangers
Columns and Vessels
Steam Turbines
Combustion Gas Turbines
Diesel Engines
Furnaces and Heaters
Water Treatment Equipment
HVAC Installation
Ductwork
HVAC Fans
Air Conditioning Equipment
Forced Draft Cooling Fans
M-31
M-32
E-7
E-8
E-9
E-10
Title
Electrical Installations (continued)
Lighting Systems
Grounding
Batteries
Cathodic Protection
Instrumentation Installations
J-1
J-2
J-3
J-4
J-5
J-6
Hoisting Systems
Electrical Installations
E-1
E-2
E-3
E-4
E-5
E-6
TOC-3
TOC-4
Guideline G-1
Construction Inspections
Construction Inspections
Guideline G-1
Immediately advise supervision and/or the contractor of any unacceptable work and the corrective action required to correct the deficiencies.
Follow up on all rejected work after corrective actions have been
implemented to ensure that the work is acceptable.
File all inspection records in the project files per procedure requirements.
B. During Inspections
G-1-2
Guideline G-2
Construction Safety
Construction Safety
B. Emergency Preparedness
Check that medical personnel are available for advice and consultation on occupational health matters and that employees understand the reporting requirements and process.
Check that equipment for prompt transportation of injured personnel to a physician or hospital is available and that a communication
system for calling an ambulance is provided.
Check that the telephone numbers for physicians, hospitals, and
ambulance 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 and
unobstructed.
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 and
operational.
C. Hazardous Materials
Check that employees are knowledgeable of the hazards and control measures associated with all chemicals in use.
Guideline G-2
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 from
intakes.
G-2-2
Construction Safety
Guideline G-2
I.
Compressed Gases
J. Ionizing Radiation
Check that persons using x-rays or radioactive materials are qualified or licensed where necessary.
K. Nonionizing Radiation
L. Illumination
G-2-3
Construction Safety
Guideline G-2
Work areas
All walkways including, ramps, runways, corridors, and stairways
Offices, shops, and storage areas
Parking lots, security, and access points.
O. Respiratory Protection
G-2-4
Construction Safety
Guideline G-2
G-2-5
Construction Safety
Guideline G-2
Check that scaffold is secured to the building every 26 ft (8 m) vertically and every 30 ft (9 m) horizontally.
Check anchorage on two point suspension scaffolds. Anchorage
must be redundant and capable of supporting 6 times the intended
load.
Check working load of suspended scaffold. A maximum of 500 lbs
(227 kg) for two workers and a maximum of 750 lbs (340 kg) for
three workers.
Check that each employee has a separate independent lifeline.
U. Housekeeping
G-2-6
Construction Safety
Guideline G-2
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.
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 of
platforms, scaffolds, ladders, temporary floors, safety lines, or body
harnesses are impractical.
Check that nets extend 8 ft (2.5 m) beyond work edge where workers are exposed.
Check that nets are installed as close as possible to the work and
no more than 25 ft (7.6 m) below working level over ground or
water.
X. Sanitation
G-2-7
Guideline G-3
Equipment Tag/Lockout
A. Establishing 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.
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 isolating devices.
Check all residual or stored energy sources to ensure that energy
has been released, disconnected, or rendered safe.
Equipment Tag/Lockout
Guideline G-3
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 appropriate
custodian.
Energize the equipment.
Guideline G-4
B. Storage
G-3-2
G-4-1
Guideline G-5
Guideline G-6
Material Control
A. Preplanning
Check that a site procedure exists to control project design documents and design document changes. This procedure must
address:
Verification of the documents received against project engineering, 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 distribution 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 generated
changes such as FCRs and FCNs
Check that personnel responsible for controlling and using design
documents are knowledgeable of the requirements.
Check that the central filing system is neat and well organized.
Check that documents are obtained from controlled sources per the
site procedure.
Check that the document has the appropriate stamp for the application.
Check for interim field changes to design documents per site
requirements.
A. Preplanning
D. Document Turnover
G-6-1
Guideline G-8
Guideline G-7
A. Preplanning
A. Preplanning
G-8-1
Guideline G-9
Guideline G-21
Records Retention
A. Preplanning
A. 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.
Guideline G-21
D. Equipment Handling
Guideline G-22
Rigging Performance
A. Preplanning
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.
G-21-2
Guideline G-23
Guideline G-24
Movement by Transport
Mobile Cranes
A. 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, emergency
brake, ball and hitch, safety chains, reflectors, electrical wiring and
connections, 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 checking manufacturer documents and certified scale weights when
available.
Ensure that shipping skids are included in the weight determination.
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.
A. 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 for
the lift.
Determine whether the crane will remain stationary and/or level
during all phases of the operation.
If load must be walked with the crane, verify that crawler cranes are
rated 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, efficiency
of end connections, type of hitch, and reduction due to bending around corners and small radius pins.
Verify that softeners are in place if required to protect slings around
sharp 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-25
Guideline G-26
Bridge Cranes
Base-Mounted Cranes
A. Preplanning
A. Preplanning
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 bending around corners and small radius pins.
Verify that softeners are in place if required to protect slings around
sharp corners or to protect the surface.
If four slings are used, verify that any two are capable of handling
the 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 clearance study to determine that sufficient drift is provided with the
hook in the upper limit position.
B. In-Process Inspections
Verify that the lead sheave is free to move its loaded position without interference and make provisions to prevent movement along
the 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-25-1
G-26-1
Base-Mounted Cranes
Guideline G-26
Guideline G-27
Rigging Components
A. General
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 deformation.
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 is
not 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 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-26-2
G-27-1
Rigging Components
Guideline G-27
Do not use if block and tackle show signs of permanent deformation, 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 anglesthe 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
H. Shackles
G-27-2
Guideline G-28
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 functioning 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 operation
test.
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 requirements.
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 operates properly.
Ensure that the positive anti two block device operates properly.
B. Rigging Requirements
G-28-1
Guideline G-28
Ensure that a pre-lift meeting is held with the operator, signal person(s), employee(s) to be lifted, and the person responsible for the
work.
Ensure that employees will be protected from special hazards such
as electrical hazards and power lines and in operations where the
platform will be out of the operator's view.
Ensure that a suspended work platform use authorization has been
issued, dated, and approved for the work.
Verify that the platform and rigging are proof-tested to 125% of the
platform rated capacity.
Verify that an unoccupied trial lift is performed with the platform
loaded 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 deficiencies.
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
Guideline G-28
Ensure that the load and boom hoist drum brakes, swing brakes,
and locking devices are engaged when the occupied platform is in
a stationary working position.
Ensure that employees keep all body parts inside the platform during operations.
Ensure that the operator remains at the controls when the crane
engine is running and the platform is occupied.
Make sure that platform use is discontinued when there is an indication of dangerous weather conditions or other danger.
Make sure that the operator and signal person are in constant hand
signal or voice communications during operations.
Make sure that employees remain in sight or in direct communication with the operator or signal person.
Ensure that all employees on the platform wear a properly
anchored body belt or harness system.
Ensure that materials and tools are secured to prevent movement
during the lift.
Make sure that no other object is lifted using any of the crane load
lines while the platform is suspended.
Verify that a trial lift calculation sheet has been completed, signed,
and dated.
G-28-3
Guideline G-31
General Welding
General Welding
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, regulators, and support tools for welding activities are in good working
condition.
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 weld
splatter, 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 configuration before welding.
Verify the type and size of rod used.
Verify that root openings do not exceed specified tolerance.
Guideline G-31
E. Weld Repairs
G-31-2
Guideline G-32
Nondestructive Examination
Code Welding
Note: Code welding requirements are specified in the projectspecific Special Processes Manual (SPM), and all field inspections
must be based on these requirements. The following guidelines
are typical of the requirements included in the SPM.
A. Code Requirements
Magnetic particle
Monitor method, sequence of operations, examination medium, 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.
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 metal
cleanliness)
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 G-33
G-33-2
Guideline P-1
Guideline G-34
General Piping
Heat Treatment
Note: Postweld heat treatment requirements are specified in
the project-specific Special Processes Manual (SPM),
and all field inspections must be based on these requirements. The following guidelines are typical of the
requirements included in the SPM.
A. Pre-Process
B. In-Process
C. Post-Process
A. Preplanning
B. Receiving Inspection
D. Fabrication
G-34-1
P-1-1
General Piping
Guideline P-1
I.
Guideline P-2
Large Pipe
A. Preplanning
B. Installation
C. Testing
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
Guideline P-4
Guideline P-3
Small Pipe
Embedded Piping
A. Preplanning
A. Preplanning
B. Installation
B. Installation
C. Testing
P-3-1
P-4-1
Guideline P-5
Guideline P-6
HDPE Piping
A. Preplanning
Ensure that requisitions and quotation requests for reinforced concrete pipe (RCP) to be used in refinery or chemical plant applications specify the intended application.
Even though material specifications are the same, RCP manufacturers often provide a better quality, more leaktight product to refinery and chemical plant applications.
B. Installation
P-5-1
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
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 included in the bend.
Check that the pipe is slightly snaked in the trench to accommodate
for pipe expansion and contraction due to temperature changes.
In warm weather, make sure that the pipe is allowed to fully contract by allowing the pipe cool to ground temperature before trimming and joining adjacent sections.
Make sure that gas pipe is buried the required distance from steam
lines, hot water lines, power lines, and other sources of heat to
avoid temperatures in excess of 140F (60C) or as required by
local codes.
Check that protective sleeves are provided at all gas pipe service
branches and transition fittings to protect against bending and
shear forces.
If tracer wires or metallic tape are installed to assist in locating
buried gas lines, make sure that they are installed at least 4 inches
(10 cm) from the pipe.
HDPE Piping
Guideline P-6
D. Pipe Fusion
Guideline P-7
Valves
A. Preplanning
B. Installation
C. Testing
Check valve pressure capacity and ensure that it is greater than the
required piping pressure test. Review Leak Testing Guideline.
P-6-2
Guideline P-8
Make sure that shock suppresser internals and reservoir are protected when disassembling for repair or refilling.
Check that supports and hangers not designated as anchors do not
restrict the free expansion and contraction of piping due to temperature changes.
Check that pipe anchors and pipe guides are installed at locations noted in the contract documents.
C. Checkout
Verify that hanger and support checkout is performed per applicable contract documents.
D. Temporary Supports
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 document 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 apply
unless otherwise specified in the contract documents, by the manufacturer, 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 concrete
expansion 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 strap
material is not used for piping supports.
Verify that the most current approved drawing revision is being
used for hanger fabrication, installation, and checkout.
Check that P&ID and piping drawing changes are incorporated on
applicable hanger support drawings.
Ensure that all required exception reports are properly prepared
and processed.
P-8-1
Guideline P-8
MAXIMUM SPACING
STEEL
GASES
COPPER
WATER
PIPE SIZE
WATER
1/2"
5'-0"
6'-0"
3/4"
5'-0"
6'-0"
1"
7'-0"
9'-0"
5'-0"
4'-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-12
Guideline P-11
Plastic-Lined Pipes
A. Handling/Assembly
A. Materials
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 connections, where flow changes direction, and in areas of high load concentrations such as clusters of valves or fittings.
B. Painting/Preparation
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-code
band).
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 that
leaves burrs and causes severe stress risers in the plastic
liner.
Check that cut-off length of pipe and finished, face-to-face
length 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 surface
of 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 the
importance of these tolerances, ensure that a steel scale is
used to layout the 3/16" dimension.
Carefully cut the plastic liner to achieve the proper outside
diameter dimension. Make sure that the stops on hand cutter
are 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, imperfections
must be removed.
Ensure that cracks, nicks, and gouges are filed or lightly
sanded away.
Check that the feather at the beginning of the standard tapered
pipe thread on the steel pipe is removed to prevent interference
with proper joint makeup because it will tend to curl over the liner
stub.
Check that the flange or union fitting is screwed on the pipe until the
end of the 3/16" plastic liner projection is flush with the face of the
flange or union.
Guideline P-12
P-12-2
Guideline P-13
Kynar-Lined Pipe
A. 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 sized
forming tool into flange bolt holes.
Check that guide pins fit freely in the bolt holes with the
clamping dogs behind the flange.
Loosen adjusting nuts, center tool, and retighten nuts if
adjustment is needed.
Remove tool, attach hydraulic hose, and set aside.
Check preheating:
Lightly grease aluminum flaring die with a high temperature
grease.
Preheat die to 280F - 300F (138C - 149C) with hot plate,
oven, or torch.
Use 300F (149C) temperature-sensing crayon or a pyrometer to monitor to monitor preheating.
Do not heat preformer cone die; it is used at room temperature.
Check heating:
Attach heat cup to hot air gun, set heater dials per manufacturer recommendation, and allow gun to preheat for 15 to 20
minutes.
Place the proper locking collar over the plastic stub and place
tight against the flange face, with curved crimped edge
inward, fitting into flange chamfer.
For forming faces of Kynar, be sure to only use locking collar
with 5/32" diameter holes; do not use collar with 1/16" or
3/32" diameter holes, which is designed for PTFE-lined pipe.
For 1" - 2" pipe, place heat gun and heat cup to flange and
heat plastic stub to 200F - 230F (93C - 110C). Use a
230F (110C) 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 and
heat plastic stub to 240F - 250F (116C - 121C). Use a
250F (121C) temperature-sensing crayon to monitor.
Rotate hot air gun frequently to ensure uniform heating.
Kynar-Lined Pipe
Guideline P-13
Kynar-Lined Pipe
Guideline P-13
Make sure that a plywood cover is bolted to the flange to protect the
plastic face and to prevent the face from remembering its preformed shape and pulling away from flange.
P-13-2
P-13-3
Guideline P-14
PTFE-Lined Pipe
PTFE-Lined Pipe
A. 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 holes
with 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 edge
inward 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, which
are designed for Kynar-lined pipe.
C. Field Forming
P-14-1
Guideline P-14
D. Preforming
Check the insertion of the cone-shaped preformer tool into translucent plastic stub and that a gradual rocking motion is used to
enlarge the opening in the plastic.
Verify that the preformer is then fully inserted into the flange face to
quench 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 the
forming tool guide pins are placed into the flange holes and that the
clamping dogs are locked in place.
Ensure that the forming die is cranked snug to the flange and that
cool air or water is used to speed cooling of the plastic to room temperature.
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 preformed shape and pulling away from the flange.
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:
P-14-2
PTFE-Lined Pipe
Guideline P-14
P-14-3
Guideline P-15
Check that all cutting oil, shavings, and dirt are wiped from exposed
plastic stub of the clamped prepared pipe using a nonflammable
cleaning 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 the
bolt holes with the clamping dogs behind the flange.
Loosen adjusting nuts, center tool, and retighten nuts if
adjustment 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 the
heat to warm the molding die.
Check that the heat gun and cup are placed against the flange and
that 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 plastic
back to face of flange with gloved hand.
Quickly align molding tool and forming die assembly to plastic
and crank the molding die tight to the flange.
Allow plastic to cool several minutes before removing forming
tool.
Guideline P-15
If plastic face appears distorted, one side normal and the other side
erratic and not fully formed, one of the following may have
occurred:
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 allowing 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 is
applied.
Excessive flash at outer diameter and center of plastic face
allowed to heat to excess, lower heat setting, and/or shorten
heating time
Too much force was applied to molding die, thus forcing hot
plastic into tooling allowances.
If excessive flash occurs on the inside diameter of the plastic after
the molding tool is removed, one of the following may have
occurred:
The heated plastic was not properly hand formed before
molding, allowing forming die mandrel to push soft plastic
inside 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 to
engage soft plastic and push it inside pipe.
P-15-2
Guideline P-15
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 laminate
if mixed with grease.
P-15-3
Guideline P-21
D. Refrigeration Piping
A. Preplanning
Guideline P-21
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.
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 components
have been removed.
Check that all high points are vented to ensure that the cleaning
solution will contact all inside surfaces of the pipe.
Check that sufficient bypasses are installed to ensure the flow of
the 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.
P-21-2
Guideline P-22
Leak Testing
Leak Testing
A. Preplanning
Make sure that system identification and test boundaries are
defined early.
Perform a pre-test inspection by walking down the system and verifying accessibility for inspection, completeness per P&ID, tightness
of flanged joints, and chalking of joints, as applicable.
Establish the test medium, test pressures, and test boundaries for
each 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 master
gauge before testing.
Ensure that the maximum test pressure is within 30% to 70% of
gauge range.
Identify components not capable of safely withstanding the required
system test pressure and ensure that those components are
removed or isolated from the system.
Identify systems that must be laid up after testing and that the
required layup medium is available for use before the start of the
test.
Determine if the system will or will not require draining after the
hydrostatic test.
Verify that all required test vents and drains are installed and that
fill points are established.
Make sure that required testing equipment, relief valves, pressure
regulators, valves, strainers, temporary piping, and temporary fittings 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, as
required.
Check that the system is adequately supported for expected
loading during hydrostatic testing.
Check that test equipment and temporary piping have been flushed
before connection to system.
Guideline P-22
B. Pneumatic Testing
Ensure that a project procedure is prepared summarizing pneumatic 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).
Verify that testing is limited to only those systems released for testing.
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.
P-22-2
Guideline P-23
Guideline P-24
Pipe Insulation
A. Storage
B. Preplanning
C. Installation
P-23-1
A. Material
P-24-1
Guideline P-24
P-24-2
Guideline P-24
P-24-3
Guideline M-1
Guideline M-2
Rotating Equipment
A. Installation
A. Preplanning
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 component 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 construction or layup. Make sure that manufacturer instructions are
followed.
C. Anchor Installation
Verify accuracy of embedments, anchor bolt layout, size, dimensions, and elevation, before and after placing concrete and foundation.
Protect anchor bolt threads from dirt, rust, and mechanical damage.
D. Equipment Installation
M-1-1
M-2-1
Rotating Equipment
Guideline M-2
F. Piping Connections
M-2-2
Guideline M-3
Coupling Alignment
A. Preplanning
M-3-1
Guideline M-4
Belt-Driven Equipment
Belt-Driven Equipment
A. Preplanning
Guideline M-4
Verify that the outer edge of the sheave hub does not extend
beyond equipment shaft. Also, verify that the inner edge does not
touch the equipment. If sheaves are not same thickness, it will be
necessary 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 driven equipment are secured to their respective shafts per manufacturer instructions. Check belt tension per manufacturer instructions.
Verify that the driven equipment has been securely bolted and doweled to the baseplate as specified.
Verify that the driver is securely bolted to the equipment baseplate
by holddown bolts and however, remains adjustable (i.e., no dowels) for belt tensioning adjustments during maintenance.
Monitor shaft alignment when piping connections to driven equipment are made (if any).
Repeat above step after piping connections are completed.
M-4-1
M-4-2
Guideline M-5
Non-Rotating Equipment
Non-Rotating Equipment
E. Equipment Grouting
A. Preplanning
B. General
C. Embedded Equipment
D. Anchor Installation
M-5-1
Guideline M-5
F. Equipment Installation
M-5-2
Non-Rotating Equipment
Guideline M-5
Ensure that all valves, instruments, tubing, gauge lines, control air
components, and capillary tubing are effectively protected from all
construction activity.
Check that small pipe design does not encroach on clear space left
for tube bundle withdrawal.
Check that all system flush requirements are compatible with manufacturer procedures for equipment maintenance.
Guideline M-6
Pumps
A. Receipt Inspection
B. Installation
Check that equipment pads, platforms, or hangers required to support 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 supports 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 documents.
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 cleaned
before final acceptance.
Check wet and dry sump elevations, access gratings, and safety
devices 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
M-5-3
M-6-1
Guideline M-7
Guideline M-8
A. 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 no
harmful gases, vapors, fumes, or mists present in the tank
and proper ventilation is provided or proper respirator and
protective 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 setting operations. Review Rigging Guideline.
Check for correct orientation of tank and nozzles.
Ensure that the following conform to specification and code requirements:
Erection
Welding
Nondestructive examination
Testing
Cathodic protection, as applicable
Outside painting
Disinfection
A. Preplanning
B. Tank Setting
M-7-1
M-8-1
Guideline M-8
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
M-8-2
Guideline M-11
Boilers
A. Preplanning
Check vendor data, installation procedures, specifications, and layout 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 alignment clips for component handling and assembly.
Ensure that vendor has specified preservative and paint requirements.
Check that all bolts, studs, and nuts are the proper material.
B. Anchor Installation
Check anchor bolts for correct location, free length, sleeve condition, thread projection and protection before foundation concrete is
placed.
C. Boiler Installation
Check that all rigging and handling equipment is safe and will properly 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 by
local codes.
Check that spare parts and installation/maintenance tools are available for turnover to owner.
Ensure that the boiler flushing and/or chemical cleaning requirements are satisfied.
M-11-1
Guideline M-12
Guideline M-13
Condensers
Heat Exchangers
A. Submittals
Check vendor data, installation procedures, specifications, and layout 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 deoxaluminite 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 replacement 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
M-12-1
A. Preplanning
B. Installation
M-13-1
Guideline M-14
M-14-1
Guideline M-14
Before columns and vessels are headed up, ensure that they are
cleaned out and the internals are inspected.
G. Trays
M-14-2
Guideline M-14
Ensure that bubble caps and tray valves are installed and that
valves are free on valve trays.
Check all trays for cleanliness.
Check weep hole requirements on seal pan trays.
H. Nozzles
I.
Distributors
Guideline M-15
Steam Turbines
A. Preplanning
J. Mist Eliminators
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
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.
B. Installation
C. Alignment
as required.
M-15-1
Steam Turbines
Guideline M-15
M-15-2
Steam Turbines
Guideline M-15
M-15-3
Guideline M-16
Guideline M-17
Diesel Engines
A. Preplanning
B. Installation
M-16-1
A. Preplanning
B. Installation
C. Checkout
M-17-1
Guideline M-18
D. Burners
A. General
B. Heater Casing
M-18-1
Guideline M-18
Check that installed burners are protected from mechanical damage 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
F. Burner Piping
M-18-2
Guideline M-18
H. Soot Blowers
I.
Guideline M-18
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 operation.
Monitor the thermal movement of tubes, tube support systems, and
refractory during dryout for evidence of problems.
Air Preheaters
J. Fans
M-18-3
M-18-4
Guideline M-19
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
Guideline M-21
HVAC Installation
A. Preplanning
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 vibration or pulsation during operation.
Check that access doors in insulated casings and housings have
frames of heavy galvanized structural steel members and inspection windows constructed of two sheets of plexiglass with air space
between.
Check that access doors open to the outside of the housing on the
fan suction side and to the inside of the housing on the fan discharge 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 specifications.
C. Testing
M-19-1
M-21-1
Guideline M-22
Ductwork
Ductwork
A. Installation
Inspect ductwork for correct gauge material, overall size, cross sectional area, reinforcement, use of correct flexible connections,
alignment without undue deformation of flexible connections, and
use of specified hangers.
Check that pilot tube access holes with threaded plugs have been
provided in the ducts and plenums for taking air flow measurements used in system balancing.
Ensure that chambers or casings attached to masonry at louvers or
registers are secured with expansion bolts with mastic grout
between 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 welded
flanges as specified and are properly reinforced at the joints and
between the joints.
Ensure that sealants conform to specified fire hazard classification.
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 with
duct 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-resistant
adhesive and are secured with welded pins or welding cup head
pins as specified.
Verify installation and operation of control, fire, and smoke
dampers.
M-22-1
Guideline M-22
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
Ductwork
Guideline M-22
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 and
dust.
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 been
vacuum cleaned.
Make sure that the completed system is maintained in a clean condition until final acceptance.
M-22-3
Guideline M-23
HVAC Fans
A. Preplanning
B. Installation
Inspect equipment when installed for damage including bent members, dents in panels, broken or deformed motor mounts, damaged
roll filter and controls, and deformed vibration isolator assemblies.
Check equipment installation for location, level, plumbness, and
anchorage per manufacturer requirements.
Check all rooftop fan decks to ensure that all flashing and sealing
are completely effective.
Check that vibration isolators are installed per manufacturer
requirements.
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 the
fan discharge side.
Check that required acoustical lining is installed where required
and that the material satisfies fire rating requirements.
Verify that the equipment lines up with duct installation without
excessive deformation of flexible connections.
Check that piping, controls, and structural supports for the equipment are installed as required.
Check all motors for mounting, line-up, ease of turning, sufficient
and suitable belts in drive (if applicable), belt guard mounting, and
lubrication 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.
M-23-1
HVAC Fans
Guideline M-23
Check that the equipment is identified with a fixed label per contract
requirements.
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 system.
Verify that belt guards are arranged to permit oiling, testing, and
use 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, is
cleaned before final acceptance.
C. Testing
Guideline M-24
M-24-1
Guideline M-24
Guideline M-25
C. Pre-Operational Checkout
B. Testing
M-24-2
A. Preplanning
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 another 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.
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.
M-25-1
Guideline M-31
Guideline M-32
A. Runway
A. Preplanning
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 manufacturer instructions and as specified. Check that vendor representative 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.
B. Test ProcedureCranes
M-31-1
M-32-1
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-1
Verify that conduits and fittings to be embedded are of the size indicated on the drawings, are galvanized rigid steel, and are per specification requirements.
Verify that conduit and stub up locations are per drawing requirements.
Check that there are no running threads on conduit (not allowed per
the National Electric Code).
Check that approved expansion couplings are installed at all
expansion 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 bituminous
compound or tape in areas of possible contact with reinforcing
bar.
Where practicable, avoid contact between dissimilar metals to eliminate the possibility of galvanic action.
Ensure that open conduit ends are capped and pull boxes sealed
to prevent the entry of foreign materials.
Ensure that all conduit is swabbed, rodded, or balled after installation to remove any foreign material and is then capped.
Verify that the number of bends in a run of conduit between pull
points does not exceed a total of four 90 degree bends or 360
degrees total unless cable pulling calculations indicate the conduit
installation is acceptable.
Check that threads are coated with an approved corrosion-resistant
material where conduit galvanizing has been removed for field
threading.
Verify that conduit bends meet the minimum bend radius requirements listed in the table unless otherwise specified in the contract
documents.
Ensure that installed conduit is checked for obstructions (mandrel
pulled through embedded conduit to remove foreign material)
before installing cable.
E-1-1
Guideline E-1
Ensure that conduits and fittings are of the size and type as
indicated in the drawings and manufactured per specification
requirements. Check that all field bends are free of cuts, dents, or flats.
Ensure that each length of nonmetallic conduit is clearly marked
with material identity (type) at least every 10 ft (3 m).
Ensure that nonmetallic conduit is not used in hazardous (classified) 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 requirements 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 pull
points 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 conduit
installation 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.
Guideline E-2
Raceway
A. Receiving and Storage
B. Installation
C. Documentation
Check that raceway card system, if used, or other system is functioning correctly.
E-2-1
Guideline E-3
A. Preplanning
Check that switchgear tools such as levers and earth sticks are
received with the equipment and are either properly secured to the
equipment or have a separate tool box that can be installed near
the switchgear.
Check that the size and spacing of terminal blocks conform to the
type of cables, lugs, and voltage level specified.
Check that the switchgear name plate is received along with the
equipment and includes all required information.
B. Inspection
C. Final Acceptance
E-3-1
E-3-2
Guideline E-3
Guideline E-4
Electrical Equipment
Electrical Equipment
A. Preplanning
B. Installation
Guideline E-4
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 damage.
Verify that bolted bus joints are torqued per manufacturer instructions using a calibrated torque wrench.
Witness electrical continuity checks of all current, potential, and
control circuits using wiring diagrams as a reference.
E-4-1
E-4-2
Guideline E-5
Guideline E-5
E. Documentation
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.
E-5-1
E-5-2
Guideline E-6
Terminations
Terminations
A. Low Voltage
Guideline E-6
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 semiconductor are compatible with the termination kit.
Check that semiconductor paints, tapes, or extruded layers are completely removed from the insulation.
Ensure that insulation is thoroughly cleaned using an approved solvent.
Check that conductor strands are not nicked or cut when the insulation 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.
E-6-1
E-6-2
Guideline E-7
Lighting Systems
Lighting Systems
A. General
Verify that installed lighting systems, including panels, transformers, raceway, lights, wiring, and receptacles, conform to drawing,
specification, and applicable electrical code requirements.
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 contract 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 holder with clear window on the inside of the panel door.
E-7-1
Guideline E-7
Verify that branch circuit breaker ratings comply with lighting panel
schedule and are installed in the correct location shown on the
schedule.
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
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 fixtures 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 system is operational.
Verify that the exit fixtures are installed over doorways as specified.
E-7-2
Guideline E-8
Grounding
Grounding
A. Preplanning
B. Equipment Review
Check that all normally non-current-carrying metal parts of electrical equipment, enclosures, building steel, and other specified structures are grounded as follows:
Steel columns are grounded to the grounding grid as specified.
Motors are grounded to the ground grid or to a grounded
structural member as specified.
Metallic raceway (tray, conduit, and junction boxes) is grounded 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 piles
unless otherwise specified.
Check that ground rods are driven into the ground until the top of
the rod is 6" (15 cm) above the elevation of the grounding conductor unless otherwise specified.
Verify that buried ground cables crossing buried metallic structures
are either installed a minimum of 36" (90 cm) apart or are insulated as specified.
Check that buried ground cables installed parallel to electrically isolated underground metallic piping are separated by at least 10 ft (3
m).
Check that ground cable is #4/0 AWG stranded bare copper cable
unless otherwise noted.
Check that earth connections are protected with an approved
greasing compound
Check that thermal weld ground branch joints are properly completed and that earthing tape is applied per specifications
E-8-1
Guideline E-8
fault return path and require no conductor with the conduits. However, the tray ends of rigid steel conduits
should be jumpered to the tray's ground fault conductor.
Metallic tubing carrying power cables have a ground fault
conductor in the conduit.
Flexible conduits 1-1/2 inch (38 mm) and larger carrying
power cables have a ground fault conductor (jumper).
Embedded nonmetallic conduits carrying power cables
have a ground fault conductor.
Duct banks have a ground fault conductor embedded in
the top center surface of the duct bank concrete or on top
of the duct bank. Power conduits branching off also
require the ground fault conductor to follow. The ground
fault conductor must be continuous inside manholes.
Ground fault conductors should be installed to both ends
of the ground bus for MCCs, switchgear, or load centers.
E-8-2
Guideline E-9
Guideline E-10
Batteries
Cathodic Protection
A. 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 applicable code) with instruments, indicating lights, and control devices
mounted on front door.
Check installation and wiring for compliance with specifications,
drawings, and manufacturer instructions.
Verify that batteries and battery chargers have been shop tested
and data sheets submitted, as required.
Verify that field testing has demonstrated that the equipment functions over the entire range of operation.
Verify that battery rooms have adequate forced ventilation to preclude the build-up of an explosive mixture of hydrogen gas gassed
from the batteries during charging.
Verify that battery rooms not having forced ventilation have explosion-proof electrical installations for raceway, light fixtures, light
switches, receptacles, telephones, and equipment.
Check that completed battery Installation allows enough space for
maintenance
Check that batteries, MCCBs, and cables are correctly identified
B. Testing
E-9-1
A. 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 welded 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 selenium
surge plates and lightening arresters.
Check impressed current anodes and sacrificial anodes, if any, for
correct type and configuration.
Verify that cable terminations are made with acceptable type terminal and crimping tools.
Check anodes and cathodic protection cables for correct type and
size.
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 backfill, 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
E-10-1
Guideline J-1
Ensure that vendor packages are complete and conform to purchase 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, operation and maintenance.
Check that instruments are located as close as practical to the primary 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 allowance
made for movement of equipment by seismic loading, vibrations, or
expansion or contraction caused by temperature changes.
Ensure that lines or connections open to atmosphere are protected
against ingress of foreign matter.
Unprotected openings should have a gooseneck, or equivalent, 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 are
installed clear of mainline insulation.
Ensure that manufacturer installation requirements, including those
relating to unsupported span and minimum bend-radius of capillary
tubing, are followed.
Check that sensing lines have a continuous slope to promote their
being 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.
J-1-1
Guideline J-1
J-1-2
Guideline J-2
Ensure that instrument system is fabricated and installed per drawings and specifications.
Verify that brazing and soldering are per specifications and procedures.
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.
J-2-1
Guideline J-3
B. Installation
Check that supports are located and oriented per instrument location drawings and sensing line isometrics.
Ensure that concrete fasteners are the correct size (length and
diameter) and type as specified. Review Concrete Expansion
Anchor Guideline.
Check that concrete fasteners are properly located and installed
per manufacturer instructions.
Ensure that instrument mounting supports requiring welding, are
welded per approved procedures and examined as specified.
Review Welding Guideline.
Check that weld materials and welder identification numbers are
stamped or etched on instrument mounting supports, where specified.
Ensure that instrument mounting supports requiring documentation
are stamped or etched with identification number.
Check that instrument valves and bypass manifold valves are rigidly mounted to mounting structure.
Ensure that open-end pipe supports are properly sealed.
Check that mounting baseplates are grouted per drawings, specifications, and grout manufacturer's instructions. Review Equipment
Grouting Guideline.
Ensure that mounting supports are painted, as specified. Review
Painting Guideline.
J-3-1
Guideline J-4
Instrumentation Cleanliness
A. Work Operations
J-4-1
Guideline J-5
Instrumentation Testing
A. Preplanning
Perform a pre-test inspection by walking down the line and verifying 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 calibration period, check the test gauges against a master gauge
before testing.
Ensure that the maximum test pressure is within 30% to 70% of
gauge range.
Check that test gauges are calibrated by a qualified instrument laboratory.
Make sure that items not capable of safely sustaining test pressures are removed or isolated from the system.
B. Testing
J-5-1
Guideline J-6
J-6-1