Construction management and quality control

Construction management and quality control

From approved plans to ready-to-launch facilities

A successful fountain is the result of coordination between design, equipment procurement, construction operations, facility installation and performance control. The quality of each part affects other parts: the level difference in the structure can disturb the uniformity of a water curtain; Improper placement of a pod may make it difficult to seal the pond; And the correct installation of equipment without proper access for repair will make future operation difficult.

Runtime management should detect these connections before they become errors. Quality control must also be present during manufacturing; Measure and modify while components are still visible.

In the introduction of GSO services, consulting, design, equipment manufacturing, training and support are placed together. To organize project implementation, this service chain must be translated into clear responsibilities, trackable documents, and clear acceptance criteria. Introducing services and urban fountains of GSO ^[200]

The templates and tables in this chapter are compilation suggestions for project management and should be completed according to the contract, fountain type, approved design, and site requirements.

29–1. Defining success before starting operations

Before equipping the workshop, the main members of the project must have a common understanding of the expected result.

Words like "beautiful water feature", "quality execution" or "proper equipment" are not enough to manage execution. Every important expectation should be turned into a reviewable feature.

For example, fountain height acceptance criteria should clarify wind conditions, water level, number of active circuits, and measurement method. Without this information, the results of two visits may not be comparable.

The WBDG guide also emphasizes on recording the employer's needs and turning them into the basis of design and acceptance documents. This general facility management approach can be applied to the water fountain project. WBDG setup and acceptance documentation guide ^[201]

29–2. Determining responsibilities and delivery boundaries between groups

In the fountain project, many problems occur at the intersection of responsibilities. It is possible that the structural contractor is waiting for the sheath dimensions, the equipment manufacturer is waiting for the final drawing, and the electrical contractor is running the cable route based on an old drawing.

For prevention, each joint activity should have three specific officers:

• Responsible for providing information or executing work.

• Responsible for review and acceptance according to the contract.

• Responsible for receiving the result to continue the next activity.

The following example should be completed with the actual project structure:

In the start-up meeting minutes, it should be specified who can issue a technical change order and who is authorized to release a stopped phase to continue. The presence of a representative in the workshop alone does not indicate the authority to accept all courses.

29–3. The package of necessary documents to start any work front

The start of the operation must be done based on the valid documents of the same activity. For example, starting the installation of a collector requires a coordinated drawing, connection specifications, support details and connected equipment information.

The package of executive documents, tailored to the project, includes the following:

1. Maps with execution license and specific revision number. 2. Technical specifications and acceptance criteria. 3. List of approved equipment and technical sheets. 4. Calculations and related design principles. 5. Method of implementing sensitive activities. 6. Inspection and test program. 7. Coordination map of fields. 8. List of open questions and official answers.

Document version control

A map with correct geometry but an old revision can be the source of the error. The version used in the workshop should be identifiable, and obsolete drawings should be removed from the execution cycle.

Implemented changes should also be recorded at the same time. Preparing a construction plan from memory at the end of the project is not reliable, especially for buried pipes and cables.

Figure 29–1 — Pre-implementation coordination

Suggested image: Photo of the workshop session next to the location map, along with a close-up of the marking of the axis of the nozzles and the path of the pods.

Caption: "Coordination of levels, routes, and buried components prior to construction allows for less costly remediation."

29–4. coordination map; The meeting place of architecture and facilities

Coordination map should show how different components fit together in real space.

The important topics are:

• The axis and alignment of nozzles, lights, floors and valves.

• Thickness of structural layers, sealing, mortar and final coating.

• The path of pipes, cables and passing through walls.

• The location of connections and the space required to open them.

• The way to remove the pump, filter or heavy equipment.

• Access to valves and sampling points.

• The path of overflow, discharge and disposal of water from maintenance.

• Place of installation of sensors and the possibility of their service.

Executive example

Suppose the position of a floor nozzle is determined relative to the concrete of the structure, but the thickness of the final layers is not included in the installation plan. After the stone work is completed, the nozzle may be set too low or protrude beyond the desired level.

The way to prevent it is to determine a common height basis and insert the exact relationship between the concrete of the structure, the finished floor and the reference point of the equipment installation. The possibility of adjusting the equipment should also be extracted from the real information of the manufacturer.

Allowable tolerance of each component must be determined before implementation. The sensitivity of alignment on a continuous overflow edge is not the same as the sensitivity of the location of a valve in the engine room.

29–5. Provision of equipment and consideration of alternatives

The purchase of equipment should be done after checking the technical specifications affecting the performance. Brand name, power rating or connection diameter alone are not sufficient for verification.

For each major equipment, the supply file can include:

The replacement of a model should be accompanied by a review of its effect on the entire system. Changing the pump may change the operating point, current or time response of the display. Changing the lamp may also affect the power supply, addressability or color uniformity.

Substitute approval must be filed prior to final order and update related drawings and settings.

In the introduction of OASE Professional services, project engineering, system review, component supply, installation, expert supervision, and display testing are placed in an executive chain. This example shows that the purchase plan should be coordinated with the installation plan. OASE Professional specialized services ^[202]

29–6. Prototyping and pre-installation testing

In parts where the visual or functional outcome depends on sensitive details, prototyping can reduce design ambiguity.

Suitable items for prototyping are:

• Part of a water curtain or spillway edge.

• Combination of nozzle and lamp in conditions close to the project.

• Set of floor nozzle, valve and peripheral cover.

• Special sealing connection at the facility passage.

• A representative control circuit to check equipment compatibility.

The sample should clarify the answer to a specific question; Such as the uniformity of the water curtain, access for repairs or acceptable glare from the spectator's place.

Dimensions, materials, working conditions and generalization limits of sample results should be recorded. The favorable performance of a short piece of water curtain alone does not prove the performance of the entire length of the project.

Crystal Fountains also introduces prototyping, installation detailing and inspection of critical execution steps in its technical services. Crystal Fountains technical support and prototyping ^[203]

29–7. Quality program and inspection and test program

The quality plan specifies how project quality will be managed, reviewed and documented. The ISO 10005 standard is a guide for compiling and revising quality programs; This document does not specify the specific technical requirements of the fountain. Official introduction of ISO 10005:2018 ^[204]

One of the implementation tools of this program is the inspection and test program or ITP. For each activity, the subject of control, time of control, acceptance criteria, responsible person and proof of result should be specified.

Three common symptoms in such programs are:

• H - stop point: the continuation of the dependent activity requires the documented release of the step.

• W - point of presence: the designated party is invited to observe the inspection or test; The conditions for continuing work in case of non-attendance are subject to the project agreement.

• R - document review: the relevant report, certificate or document is reviewed.

Suggested example:

This table must be completed for the project. The phrase "conforms to the standard" does not establish a clear acceptance reference without specifying the relevant document, revision, and criteria.

29–8. Schedule based on activity dependencies

The implementation plan should show what prerequisites each activity depends on to complete. Increasing the number of forces does not remove all limitations; Supply time, substrate preparation, material processing and tests are also effective.

Educational example

In the table below, the durations are hypothetical and according to working days. This program is not an estimate of the duration of a real fountain.

Assuming the possibility of simultaneous implementation of independent branches and the absence of common resource limitations:

Total duration = 5 + maximum 〔20 + 8, 30 + 10〕 + 5 + 7 + 3 = 60 working days

The duration determining path in this example:

A ← C ← E ← F ← G ← H

The supply and assembly branch reaches the junction 12 days earlier than the infrastructure preparation and installation branch. Therefore, a delay of 15 days in the same branch, other things being equal, increases the total duration by three days.

In a real application, buried tasks must be placed within the corresponding build sequence. The times required for preparation, processing and testing of materials should also be extracted from the approved implementation method.

Place Figure 29–2 — Implementation dependency diagram

Suggested form: two parallel branches "supply and assembly" and "construction and site preparation", with connection at the final installation stage. The path that determines the duration should be marked with a different color.

Caption: "Project completion time is a function of the longest chain of dependent activities and resource constraints."

29–9. Access control, storage and equipment tracking

The control of the arrival of goods should go beyond the counting of packages. The specifications of the delivered equipment should be compared with the approved documents and checked for transport damage, missing accessories and the protection status of the connections.

For original equipment, it is recommended to record the following information:

• Equipment ID in the project.

• Manufacturer, model and serial number, if applicable.

• Date of receipt and result of inspection.

• Storage location and storage conditions.

• Date and place of installation.

• Number of related test report.

Suspicious or non-conforming equipment should be separated from ready-to-install items with a clear condition.

Its storage conditions should be subject to product instructions. The protection of the opening of pipes, cables, seals, boards and sensitive parts continues until installation. The safe delivery of a piece of equipment does not guarantee its quality against subsequent improper maintenance.

29–10. Control the tasks that are hidden

Hidden works are difficult to detect after they are covered. Therefore, they should be controlled and recorded before pouring concrete, pouring soil or installing the cover.

Important items include:

• The location of buried pods and parts.

• Route of pipes and cables.

• Details of leaks and passage of facilities.

• Buried components of protection and connection, according to the electrical plan.

• Supports and connections to which access is closed.

• Sealing layers and repaired points.

The photo must match the location, direction, date and component ID. The existence of a measurement scale or reference increases the value of documentation; However, the photo is not a substitute for the test.

In the implementation of sealing, the state of the substrate, the materials used, the implementation conditions, the details of corners and penetrations, and the protection of the applied layer are recorded. Experimental dewatering and emptying should also be done with the approved method and structural considerations.

Fig. 29–3 — Registration before masking

Suggested image: three photos of a fixed location; Before covering the facility, when completing the sealing and after applying the final coating.

Caption: "A step-by-step recording of a specific situation illuminates the path of future investigation and repair."

29–11. Mechanical installation control, electricity and control

In mechanical installation, in addition to the adaptation of routes, the possibility of draining, ventilation, opening of equipment and access to valves should be checked. The pipe connection should not force the equipment to accept undue stress or displacement.

The test of each circuit must be done with the appropriate method of pipe material, connections and equipment. The pressure, duration, test environment and acceptance criteria are determined from the approved documents of the same circuit.

In the electrical and control sector, the inspection includes installation compliance, cable identification, connection protection, panel plan, protection circuits and equipment compatibility. Specialized tests must be performed by qualified people and respecting the limitations of electronic equipment.

Chain of command to equipment

For each control output, it must be specified which physical device the software command reaches. It is not enough to match the name of the circuit on the display with the label of the panel; Actual performance should also be observed or checked with valid feedback.

Likewise, the display of a "low water level" warning alone does not prove that the expected protective action has been implemented. This relationship will be investigated in the performance test.

Power-up and water entry should be staged so that the status of each section is clear to all groups present.

29–12. Protecting completed work and preparing for launch

After installation, the activity of other groups can damage the equipment. Cutting dust, mortar, shavings, material washing and tool impact should be kept away from circuits and sensitive components.

The responsibility for the protection and cleaning of each front should be clear. Before starting, the following are checked:

• Removal of waste from ponds and tanks.

• Cleaning the circuits with the appropriate method.

• Preparation of filters and purification equipment.

• Closure of infiltrators and remaining connections.

• Completion of the authorized water drainage route.

• Preparation of water quality monitoring and control equipment.

• Clarity of the authorized access range of people.

Taking water for construction test does not prove the sanitary readiness of water for use. Water preparation should be in harmony with the type of use and the operation plan.

29–13. Non-conformance and change management

Non-conformity means that the result of implementation or equipment received does not match the specified requirement.

Each case must be recorded with an objective description, the exact location and reference of the dispute. The term "improper performance" is not sufficient for follow-up.

Sample training form for registration of non-compliance

The decision about correction, replacement or acceptance of the deviation must be made by the authorized authority and by examining its effects.

The intentional change of the plan should also have a separate and trackable path: description of the change, cause, effect on performance and maintenance, time and financial effect, modified documents and recorded decision.

For recurring errors, it is important to fix the cause. If several devices are installed in the wrong direction, in addition to correcting the installations, the ambiguity of the map or identification method should also be resolved.

29–14. Measuring real progress and preparation

The progress report should distinguish between "purchase", "installation", "testing" and "acceptance". Most of the equipment may be installed, but the absence of a sensor or the failure of a connection will stop a full test of the system.

For example, if out of 100 similar devices, 90 devices are installed, 60 devices are tested and 55 devices are accepted:

• Installation progress: 90%.

• Test coverage: 60 percent.

• Final acceptance of equipment: 55%.

This simple calculation is for educational equivalent items only. The progress of the entire project should be measured based on the defined weights.

The weekly report should answer the following questions:

1. What works have been done and accepted? 2. What activities are waiting for information, goods or stage release? 3. Which delay affects the completion date? 4. What non-conformances remain open? 5. Who should make the next decision and by what date?

29–15. Phased delivery and quality file

The internal delivery of each section should make its status clear to the next group. Delivery of the basin for equipment installation, delivery of the circuit for testing and delivery of the entire system to the operator are three different points.

At each stage, the scope of the deliverables, completed tasks, limitations, and the person responsible for the protection of the deliverables are recorded.

The final quality file, according to the contract, will include the following:

A defect that makes testing or safe operation impossible must be fixed before entering that phase. Other remaining items should also be assigned according to the contract; Registering in the list of defects is not in itself a license to operate.

Control system access information and backup copies must be delivered to authorized persons through a clear and secure route.

Figure 29-4 — from equipment to test history

Suggested image: a photo of a device with a label, next to a sample ID card of the same device and its test report page; Remove confidential information.

Caption: "Common ID between equipment, map and test report simplifies quality tracking and maintenance."

29–16. Gateway to launch

Before the integrated performance tests, a preparatory meeting is held. In this meeting, there must be enough evidence to enter the next stage:

• Necessary documents and settings are available.

• Effective installations have been completed and checked on the test.

• Relevant preliminary tests are accepted.

• Water, electricity, evacuation and necessary environmental conditions are provided.

• The appropriate measurement tool is ready.

• The person in charge of directing the test and the person in charge of emergency stop are known.

• The test area is protected from unwanted public access.

• Restrictions and open cases are registered and assigned.

• The method of recording the result and the conditions for repeating the test are clear.

The output of the meeting is a documented decision about the readiness of each department. One circuit may be ready for testing and the other still needs modification.

Chapter 30 is dedicated to commissioning, performance testing and final delivery of the fountain; From the first controlled switching on of the circuits to actual performance measurement, error status testing and project document acceptance.