Anoh Gas Plant Project (agpp) Project Quality Plan: Agp-gps-anogp-e02-0201

ANOH Gas Processing Company Limited

Security Classification: Restricted

AGP-GPS-ANOGP-E02-0201

ANOH GAS PLANT PROJECT (AGPP) Project Quality Plan Jul, 2019

Rev

Date

Description

Issued by

Mirza R Baig 2019.07.09 08:48:03 +04'00'

A02

9-Jul-19

Issued for Approval

MRB

A01

25-Jun-19

Issued for Approval

MRB

GPS DOC NO. D1034-01-QA-PL-0201

Checked by

Approved by

Asif Badal 2019.07.09 09:04:44 +04'00'

Asif Badal 2019.07.09 09:04:22 +04'00'

AB AB

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ADDITIONAL APPROVAL / REVISION HISTORY TABLE

Party

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Sign

Date

Revision Philosophy All documents for approval will be issued at A01 as required. If the document is for information, it will also be issued as A01. All revisions re-Issued for approval will be issued as A02, with subsequent A03, A04, etc as required. Documents approved for Construction will be issued at C01, C02, and C03 respectively. Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc. Previous revision highlighting to be removed at subsequent issues Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by the use of a triangle containing the revision status.

Revision History Revision No. A02

Date of issue 9-Jul-19

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Reason for change Revised as per AGPC comments

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TABLE OF CONTENTS 1

GENERAL.....................................................................................................................5 1.1 1.2 1.3

Purpose ................................................................................................................................5 Scope ...................................................................................................................................5 Project Quality Objectives ...................................................................................................5

2

ABBREVIATIONS ..........................................................................................................6

3

QUALITY MANAGEMENT .............................................................................................7 3.1 3.2

4

PROJECT TEAM AND KEY RESPONSIBILITES ..................................................................7 4.1 4.2 4.3 4.4 4.5 4.6 4.7

5

Resource Planning .............................................................................................................10 Inspection and Test Plan (ITP) ...........................................................................................10

REVIEW OF QUALITY MANAGEMENT SYSTEM ............................................................ 11 6.1 6.2 6.3 6.4

7

Project Manager ..................................................................................................................7 Project Engineering Manager ..............................................................................................8 Project Quality Manager .....................................................................................................8 Deputy QAQC Manager .......................................................................................................9 Procurement Manager ........................................................................................................9 Project/Package Manager & Engineers ...............................................................................9 Fabrication Manager .........................................................................................................10

QUALITY PLANNING .................................................................................................. 10 5.1 5.2

6

QMS Layout .........................................................................................................................7 QMS Certification ................................................................................................................7

General ..............................................................................................................................11 Quality Audits ....................................................................................................................11 Audit Arrangements ..........................................................................................................11 Audit Reports.....................................................................................................................11

QUALITY EXECUTION ................................................................................................. 11 7.1 7.2

7.3

Quality Management System Awareness .........................................................................11 Engineering ........................................................................................................................12 7.2.1 Engineering Documents ...................................................................................12 7.2.2 Material Requisition.........................................................................................12 7.2.3 Criticality Rating ...............................................................................................13 7.2.4 Supplier Data Requirement List (SDRL)............................................................13 7.2.5 Technical Bid Evaluation ..................................................................................13 Procurement......................................................................................................................14 7.3.1 Supplier Approval & Evaluation .......................................................................14 7.3.2 Procurement of Project Items..........................................................................14 7.3.3 Control of Purchased Materials .......................................................................15

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7.3.4 Factory Acceptance Test ..................................................................................15 Construction ......................................................................................................................15 7.4.1 Control of Inspection Activates........................................................................15 7.4.2 Identification and Control of Materials ...........................................................16 7.4.3 Control of Inspection, Measuring & Test Equipment’s ....................................16 7.4.4 Visual and Dimensional Control .......................................................................17 7.4.5 Control of Special Processes ............................................................................17 7.4.6 Control of Welders, Inspectors & Testing Personnel .......................................18 7.4.7 Control of Consumables...................................................................................18 7.4.8 Inspection & Test Records ...............................................................................18 7.4.9 Manufacturers Data Record Book ...................................................................18

QUALITY MEASUREMENT .......................................................................................... 19 8.1 8.2

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Document No.

Control of Non-Conforming Product .................................................................................19 Client Feedback .................................................................................................................19

QUALITY IMPROVEMENT .......................................................................................... 20 9.1 9.2 9.3 9.4

Quality Management System Review ...............................................................................20 Key Performance Indicators ..............................................................................................20 Continual Improvement ....................................................................................................21 Lessons Learnt ...................................................................................................................21

Attachments: A. Project organization Chart B. Project QAQC Organization Chart C. Copies of GPS Credentials: ISO 9001-2015, ASME U, U2, R & NB

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GENERAL

1.1

Purpose

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The purpose of this Project Quality Plan (PQP) is to define the Project Quality System, activities, procedures, practices, responsibilities, resources and sequence of activities relevant to the execution of Engineering, Procurement and Construction (EPC) phases of the ANOH Gas Plant Project (AGPP). The Project Quality Management System complies with the requirements of ISO 9001:2015 and Company Quality Management Requirements. This PQP details the methodology that will be applied by GPS to deliver the Detailed Design Engineering, Procurement, Fabrication, Assembly, Construction and Completion phases associated with delivery of the Project Scope. GPS will ensure that all work scopes are efficiently defined and integrated, all interfaces well managed and that a common suite of Project standards for Quality Assurance / Quality Control (QA/QC) are applied effectively throughout all phases of the Project and at all levels.

1.2

Scope The provisions of this PQP apply to all engineering, procurement, construction and completion activities for the Project including supervision/surveillance of all Suppliers and Sub-Contractors. The work covered by this plan will be the supply and administration of project management services, materials and equipment’s pertaining to agreed elements of the ANOH Gas Plant Project as defined within the scope matrix, Contract and related documents. The Project Quality System addressed by this PQP applies to all project activities from the effective date of the project award. The PQP shall apply to the entire GPS scope of work of the project. The PQP shall also apply to all work carried out for the project by suppliers and subcontractors, and sub-tiers thereof, under the control of Global Process System. The source documents, which provide the basis for the scope of the PQP, are as follows:• • •

1.3

Contract documents, including standards, codes and specifications ISO 9001:2015 Quality Management System - Requirements GPS Project Quality Control Plans and Procedures

Project Quality Objectives •

To ensure Design activities are organized, controlled, audited and executed in line with project requirements and process defined in GPS Integrated Management System (IMS).

•

To ensure that Procurement activities are organized, controlled, and effectively implemented in line with the GPS IMS.

•

To ensure that Construction & fabrication activities are organized, controlled and effectively supervised in line with the Project QMS.

•

Timely completion of project in-line with required standards of Quality, Health, Safety and Environment.

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ABBREVIATIONS The following definitions / abbreviations are used throughout the body of this document: ASL

Approved Supplier List

GPS

Global Process Systems

ISO

International Organization for Standardization

ITP

Inspection & Test Plan

MDR

Manufacturers Data Record Book

NDT

Non Destructive Testing

PEP

Project Execution Plan

PQP

Project Quality Plan

QA/QC

Quality Assurance / Quality Control

QMS

Quality Management System

SDRL

Supplier Document Requirements List

TC

Test Certificate

IMS

Integrated Management System

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3

QUALITY MANAGEMENT

3.1

QMS Layout This PQP is based on the foundation set out in GPS’s IMS Manual. GPS IMS documents are separated into four levels as shown below: GPS QMS DOCUMENTS LAYOUT

3.2

IMS Manual

The IMS Manual defines the Quality Management System in accordance with the requirements of ISO 9001. It provides an overview of the QMS and associated documentation which include the statements of the GPS’s Vision, Policies and Objectives.

QMS Procedures

Procedures are documents that describe the activities required to implement Quality Management System based on ISO 9001:2015. A procedure outlines how to perform a process, they define the Who, What, How and When of various core functions to meet set objectives.

QMS Department Procedures

Work Instructions are documents that describe the detailed sequence and interaction of the processes necessary for individual function. These are very function specific and are referenced in the core QMS procedures where applicable.

QMS Forms, Flow Charts, Records etc.

Supporting documents include both blank and filled in forms and charts. They provide evidence that the requirements for the desired quality have been met, thus demonstrating the effectiveness of a system and providing a means to measure the continual improvement of its operation.

QMS Certification GPS has an established QMS, which is certified to ISO 9001:2015. All phases of the works will be performed in strict compliance to the procedures and requirements contained within the QMS.

4

PROJECT TEAM AND KEY RESPONSIBILITES

4.1

Project Manager Reporting to: Operations Manager Responsibilities: • Coordinate with all departments involved in the development of engineering drawings, technical studies etc.

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Co-ordination of all production activities and the maintenance of production schedules. Ensuring availability of adequate and suitably qualified personnel and resources. Supervision of material control, logistics and shipping staff. Ensuring the provision of adequate resources to maintain an effective plant and equipment maintenance program. Maintenance of good house-keeping standards within company’s fabrication facility. Administration of the Contract and its Budget control. Developing project schedule to meet client requirements and its monitoring. Coordination and Monitoring of project material procurement. Monitoring of overall progress of the project and its control. Studying cost status and report to the management if there is deviation in project budget. Reporting to the Project Managers are Project Engineer and other Production personnel.

Project Engineering Manager Reporting to: Group Engineering Manager (Functional) & Project Manager Responsibilities: • Overall control on Engineering Department encompassing of Process, Mechanical, Piping, Structural, Electrical and Instrumentation disciplines. • Assist with the development of Tender/Bid Packages. • Advise and assist client engineering personnel on technical matters. • Resolving all internal technical queries. • Carryout Design reviews at appropriate stages throughout the design cycle. • Perform and manage Design verification and where applicable design validation activities. • Reporting to the Project Engineering Manager are Discipline Lead Engineers.

4.3

Project Quality Manager Project Quality Manager (PQM) to ensure implementation of Quality Management System in accordance to ISO 9001-2015 across all processes within GPS, at Vendor & Sub-contracted works. PQM reports to Project Manager. He shall ensure all quality related roles are performed in accordance with this PQP and to meet ANOH Gas Plant Project requirements. QAQC Engineers/Inspectors in Dubai Office / stationed at sub-contractor works will report to PQM and Project Manager for all project related activities. PQM is accountable for all bought out tagged components/packages and subcontracted works. QAQC Engineers/Inspectors reporting to PQM together are responsible for: • • • • • • • • • •

Selection process of Vendor/ subcontractor. Conduct Pre-inspection Meetings at vendor/subcontractor works. Assist and review all vendor offers for compliance to project requirements. Ensure quality documents from vendors/subcontractors are reviewed & approved. Perform internal and external audits as per audit plan. Manage/perform Inspections at vendor & subcontracted works. Manage non-conformity reports (NCR) and provide appropriate resolutions to close-out NCRs. Ensure proper coordination with AGPC and TPI agencies for arranging inspections as per approved Inspection and Test Plan (ITP). Manage the quality management interfaces between GPS and sub-contractors. Initiate and facilitate management review in line with ISO 9001-2015 section 9.3.1

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Ensure resources needed for quality management system are available Ensure compilation of final MDR from all vendors and/or sub-contractors as per agreed index. Assist Project Document Controller for preparation of Final Manufacturers Data Record Book.

Deputy QAQC Manager Deputy QAQC Manager is responsible for implementation and management of Quality Management system across all processes during the project execution/fabrication phase at GPSYard (Mafraq- Abu Dhabi). Welding Engineer and relevant discipline inspectors at yard reporting to Deputy QAQC Manager are responsible for producing relevant welding procedures, maintaining proper welder records and performing inspections as per approved ITP and relevant procedures. ITP for the scope of GPS-Yard shall be prepared and submitted for AGPC approval by the quality team at GPS-Mafraq yard. Quality team at GPS-Yard (Mafraq) are responsible for: • • • • • • • •

4.5

Conducting Pre-inspection Meetings at GPS-Yard (Mafraq- Abu Dhabi). Prepare and submit ITPs, welding documents and test procedures. Perform internal audits as per audit plan. Perform Inspections as per approved ITP at GPS-Yard. Manage non-conformity reports (NCR) and provide appropriate resolutions to close-out NCRs. Coordination with AGPC inspection team for arranging inspections as per approved Inspection and Test Plan (ITP). Prepare of final MDR for the scope of works performed at GPS-Yard. Assist Project Document Controller for preparation of Final Manufacturers Data Record Book.

Procurement Manager Reporting to: Commercial Manager (Functional) & Project Manager Responsibilities: • Procurement Manager is responsible for procurement of project materials as per request from Project Team. • Recommend and select prospective suppliers or sub-contractors with consideration of Quality, Delivery Punctuality, Cost effectiveness etc. • Maintain Approved Supplier list (ASL) • Obtain Quotations from suppliers and prepare Purchase Order (PO) for selected supplier, suppliers/vendors selected shall comply to project specific Approved Vendor List. • Obtain approval from General Manager and expedite the delivery schedule. • In conjunction with QA/QC Department shall resolve issues related to Material Discrepancy • In conjunction with Project Quality Manager shall review Suppliers evaluations and performances. • Reporting to the Procurement Manager are Procurement Engineers.

4.6

Project/Package Manager & Engineers Reporting to: Project Manager Responsibilities:

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Assist project manager to review project scope and associated Cost Time Resources. Prepare invoice and coordinate with project services for timely issuance and approvals. Oversee and endorse the evaluation of tenders/bids for technical and delivery compliance including recommendation prior to approval of project manager. Project/Package Engineers (PE) are responsible for all the interface between vendors/subcontractors and Engineering. PE are responsible to closely monitor progress and expedite for all works related to long lead/critical packages with vendors or sub-contractors. Review and manage sub-contract production schedules with the overall project schedule. Address and resolve issues with vendor / subcontractors to achieve delivery schedule. Close coordination with GPS Engineering/Quality, Procurement and sub-contractor to resolve all issues.

Fabrication Manager Reporting to: General Manager Responsibilities: • Provides insights for additional resources and approves manpower requirements at GPS fabrication yard. • Ensures timely completion of activities at GPS fabrication yard. • Manages the production team at GPS fabrication yard. • Collaborates with HSE manager and ensures all activities are performed safely. • Responsible to closely monitor progress and expedite for all works. • Review and manage production schedules with the overall project schedule. • Close coordination with project manager to resolve resource issues for timely completion.

5

QUALITY PLANNING

5.1

Resource Planning QA/QC resources shall be allocated to the Engineering, Procurement and Construction (EPC) phases to ensure that the Quality aspects pertaining to Project Management, Fabrication, Mechanical, Coating, Electrical and Instrumentation works at all related sites, including any commissioning assistance, are identified and suitably controlled.

5.2

Inspection and Test Plan (ITP) This PQP shall be supplemented by Inspection and Test Plans developed in accordance with GPSQA-PR-3601 “Development of Inspection & Test Plan procedure” addressing all prime inspections pertaining to all various components/equipment’s in Project, e.g. Mechanical Fabrication, Piping, coating, electrical and instrumentation etc. All Hold, Witness and Inspection points throughout the project are identified on the Project Inspection & Test Plan. This ITP is produced by PQM and approved for use by the GPS Project Manager. Prior to implementation of the ITP, comments from AGPC shall be sought and incorporated. PQM & Deputy QAQC Manager shall be responsible for issuing all Inspection Notifications to AGPC and Certification Authority throughout the Project cycle.

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Similarly, to overall Project ITP, each equipment or package item shall have a dedicated ITP which shall be developed by vendors/subcontractors. This will be submitted for approval immediately upon award of PO and shall be approved by GPS prior to implementation. The contents of the ITP and extent of scope shall be largely driven by the Criticality Rating that is assigned to the particular package or equipment item. This is determined by the Package Engineer through the use of a matrix scoring system in line with GPS QMS procedures. Criticality Ratings range from one (01) through to four (04). A Criticality Rating of one (01) is the highest rating that can be assigned and ensures the most stringent ITP is in place for the particular package or equipment item.

6

REVIEW OF QUALITY MANAGEMENT SYSTEM

6.1

General A formal review of all elements of GPS’s QMS shall be carried out during the project to ensure the continuing suitability and effectiveness of the QMS.

6.2

Quality Audits The effectiveness of GPS's QMS shall be monitored by quality surveillances performed by Quality Assurance personnel in accordance to ISO 9001-2015. The surveillance program shall be utilized to demonstrate compliance to Project QMS in-line with the requirements of ISO 9001:2015 and to verify compliance with Project specific systems and procedures based on Project requirements and work schedules throughout the project duration.

6.3

Audit Arrangements Audit notice shall be followed for all the audits as planned, formal notice shall be issued on agreed dates with auditee prior to conducting audits. GPS intends to perform Internal audits twice during the project cycle (30% and 70% project progress) covering major processes at GPS Engineering, PMT, Procurement, Fabrication and as required at vendors/sub-contractors to ensure compliance with Project QMS and contract as applicable.

6.4

Audit Reports Any findings as discussed during close-out meeting with auditee shall be reported together with any improvements that can be implemented. Audit reports shall be issued by GPS Lead Auditor. Audit findings if any shall be closed by agreed dates, which shall be verified and accepted by the auditor.

7

QUALITY EXECUTION

7.1

Quality Management System Awareness All project personnel are made aware of GPS’s QMS requirements to execute their responsibilities in accordance with applicable project procedures and specifications. Quality Engineers and Department Managers are responsible to conduct QMS awareness training and inductions for all the new employees for implementation of process and procedures in accordance with GPS-HR-PR-3800 “Recruitment, Induction & Mobilization Procedure”.

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7.2

Engineering

7.2.1

Engineering Documents GPS shall ensure that Engineering and Design documents correctly reflect the Project requirements and comply with the relevant specifications. The basis of design, the design criteria and standards, as well as the legislative requirements, shall be properly documented and accessible to the people performing the work. Compliance of Design and Engineering to GPS’s QMS / Project requirements shall be controlled by Internal and Intra discipline checks, verifications and design reviews. Verification, Checking and Approval of Engineering and Design documents shall be performed in accordance with GPS QMS Procedures as below: • • • •

GPS-EG-PR-3301 GPS-EG-PR-3302 GPS-EG-PR-3303 GPS-EG-PR-3305 Documents

Design & Development Planning Procedure Design Review Procedure Design Validation Procedures Procedure for Preparation, Checking & Approval of Design

Engineering documents produced by all the disciplines throughout the project shall be categorized for consistency and document numbering shall be in accordance with GPS-DC-PR-3272 “Project Document Numbering procedure”. Project documents produced by GPS personnel shall be controlled with Master Document Schedule in accordance with GPS-PL-PR-3202 “Engineering Progress Measurement Procedure” (EPMS) by the project Document Controller. Document progress on EPMS is closely monitored by Planning Engineer and Project Manager. Supplier Documents shall be controlled in accordance with GPS-DC-PR-3271 Supplier Document Control Procedure and Vendor document control system (VEPMS). Document Distribution Matrix shall be developed based on project Master Document Schedule to guide the Document Controller for Internal and External distribution of all the project documents. This will ensure effective Inter Discipline Review before approving any project document.

7.2.2

Material Requisition Material/Technical Requisitions shall be prepared by Project Engineering team in accordance with GPS-EG-PR-3306 Procedure for preparation of Technical Requirements for RFQ/ITB packages. As a minimum, Material/Technical Requisition shall address and include the following: • • • • • • •

Scope and Deliverables Hardware Items Services Exclusions Document Precedence Criticality Rating Applicable Documents List

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Inspection & Test Plan SDRL

After completion of the technical evaluation of received bids and prior to the placement of a Purchase Order by Procurement Team, the Requisition Engineer shall be responsible for updating the requisition referenced documents, and requisition itself to incorporate any agreed changes and / or clarifications to the original documents and their requirements. The Purchase Order requisition may also include a list of any agreed deviations or clarifications to Project specifications.

7.2.3

Criticality Rating The Criticality Rating provides a method for determining the relative importance of services to be provided, or items to be manufactured, constructed and installed for the Project. The Item / Service Criticality shall be measured in accordance with GPS-EG-PR-3304 “Criticality Rating Procedure”. Criticality Rating calculated against defined and weighted performance and potential loss parameters and this subsequently determines the Supplier’s requirements relating to producing a PQP, an Inspection and Test Plan, and whether Quality Audits are required and to what extent. The Criticality Rating system evaluates goods within a requisition, or equipment packages etc. in accordance with following six criteria, each with levels which increase in score based on relative impact. • • • • • •

Safety Product Service Characteristics Design Maturity and Complexity Schedule and Cost Manufacturing / Construction Process Complexity Economics

The Criticality Rating is assessed against each of the criteria listed above and a numerical point score value (ranging from 0 through to 6) for the various sub-sections within each criterion shall be recorded in the Criticality Rating Assessment column and then tallied. The tallied figure will dictate the Supplier’s requirements relating to producing a PQP, an Inspection and Test Plan, and whether Quality Audits are required and to what extent.

7.2.4

Supplier Data Requirement List (SDRL) The SDRL is the comprehensive master listing of all Supplier data that can be expected to be submitted and covers all disciplines. The listing is for inclusion in all requisitions and defines the documentation required to be forwarded by Suppliers with the associated document submission schedule, together with the quantities and format of these submissions. Each Requisition Engineer shall create a specific SDRL for the equipment, goods, items or services being requisitioned.

7.2.5

Technical Bid Evaluation Bids received in response to Request for Quotation (RFQ) packages shall be assessed both technically and commercially to arrive at a technically acceptable bid at the lowest cost in accordance with GPS-EG-PR-3307 Technical Bid Evaluation Procedure.

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For a bid to be acceptable, it shall meet all the requirements of the RFQ. The reviewing engineer shall be responsible for evaluating the following: • • • • • • • • • •

The offered scope of supply against the RFQ The reliability and suitability of the system, equipment or goods The performance of the system, equipment or goods Standards, Statutory and certification requirements Specific equipment requirements Termination details Delivery schedule Supplier data / documentation submissions against the SDRL QA requirement Any deviations from the RFQ.

A clarification meeting if required will be held with shortlisted bidders for each package, service, equipment item or material to ensure that all technical and commercial matters are adequately covered and that the offer remains both technically acceptable and commercially viable.

7.3

Procurement

7.3.1

Supplier Approval & Evaluation Project Materials shall be procured from only GPS Approved Suppliers and Sub-Contractors. Any suppliers or sub-contractor not in the Approved Supplier List (ASL) shall be selected and approved in accordance with the GPS-PG-PR-3401 Supplier Approval and Evaluation Procedure. The Procurement department is responsible for the maintenance of an Approved Supplier List to facilitate the ongoing evaluation of supplier performance. This register is a live document and is updated at regular intervals. Approval of suppliers shall relate to supplier's QHSSE Management Systems and capabilities and shall be based on one or more of the following: • • • •

Evidence of accredited approval of supplier quality system by an independent Certification Body. Company Assessments and/or Audits carried out at supplier's works. Historical data based upon supplier's previous performance capability involving similar work and/or specification requirements. As Per Client's Advice/Requirements

The Procurement Manager or his nominee shall obtain the records of selection and evaluation of suppliers and sub-contractors.

7.3.2

Procurement of Project Items Procurement shall be controlled by the project Procurement Manager in accordance with the GPSPG-PR-3403 “Purchase Process Procedure”. All purchase orders shall contain data clearly describing the product/services to be ordered including as applicable; • •

Type, class, style, grade, quantity and any other precise identification. Title or other positive identification, applicable specifications, drawings, relevant technical

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data, inspection and certification requirements. Title, number and issue of any quality standard to be applied to the product, and where applicable, requirements for approval or qualification of product, procedures and personnel. Provision for inspection at supplier's premises by Company and/or client representative to verify that product conforms to specified requirements

Originators of Material Requisitions are responsible for ensuring that adequate detail is given to ensure compliance of ordered goods with relevant controlling specifications, and to ensure that Company requirements are fully understood by the supplier. Company's authorized signatories shall be responsible for reviewing Purchase Order documents & verify adequacy of information prior to approving the Purchase Order.

7.3.3

Control of Purchased Materials Warehousing and Quality Control personnel shall ensure received materials, components, assemblies and services conform to purchase requirements necessary inspection and tests are performed in accordance with GPS-CM-PR-3501 Material Control Procedure. The resource for inspection and expediting services is by a combination of dedicated personnel operating within the Project and/or by using competent Third Party Inspector (TPI). Company’s established receiving inspection control systems will verify the conformance of received goods with the specified requirements of the purchase order documents and appropriate verification records shall be maintained.

7.3.4

Factory Acceptance Test As per each individual equipment item ITP, a Factory Acceptance Test (FAT) will be conducted at the manufacturer’s or supplier’s premises as applicable. The Criticality Rating assigned to each RFQ package or equipment item will dictate the Supplier’s requirements relating to testing, amongst others. This will be detailed in the associated ITP and reflected on the overall Project ITP. As detailed or as agreed within the PQP and Project ITP, AGPC representatives will be invited to attend and witness any such tests that may be required. GPS inspection team together with package engineers will attend these tests as necessary.

7.4

Construction

7.4.1

Control of Inspection Activates The co-ordination of inspection will be carried out by GPS QAQC Engineer/inspector for all the inspections at GPS yard or sub-contracted works. All inspection personnel will be vetted to ensure they have suitable competency and experience of the equipment which they are inspecting. All inspection activities will be formally recorded and submitted for review and approval. Liaison with verification bodies will be handled with appropriate control to ensure that appropriate notification is provided and that verification activities are completed and documented. Project Engineers will closely follow-up with sub-contractors/vendors and expedite activities to meet the project schedules.

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Identification and Control of Materials GPS shall be responsible for the supply of such labor, plant and equipment to ensure that all Project materials are suitably and adequately controlled. The control systems shall be applied to both freeissued materials and materials purchased by GPS. The control and movement of materials to and within GPS facilities, including shipment of prefabricated items from GPS's facilities, will be such as to ensure that installation is accomplished in compliance with overall Project planning. Material and/or equipment shall be received initially into assigned on-site storage areas. The materials will then be checked against the Purchase Order and delivery note by Material Control personnel. The Material Controller shall record the receipt of materials and route it to appropriate storage areas. The Material Controller shall forward all supporting documentation and certificates, to the appointed QC Inspector who shall verify that delivery conforms to specified requirements. Acceptable deliveries shall be logged on the Material Inspection Report and advised warehouse personnel to store the components as appropriate. Throughout the storage period, any preventive maintenance requirements shall be observed, whilst awaiting transportation within the jobsite in accordance with GPS-CM-PR-3502 Preservation Procedure. Any damaged or non-conforming material shall be resolved in accordance with GPS-IMS-PR-2016 Control of Non-Conforming Product. Non-Conforming product shall be identified as being noncompliant against the relevant specifications. Products shall be clearly identified and, where practicable, moved to a designated quarantine area. If the material remains "in-situ" it shall be suitably identified and recorded on associated documentation until the non-conformance is resolved or the material is returned to the supplier. Material traceability shall be accomplished and maintained for all component parts and materials incorporated in the works. Full material traceability shall be maintained for all Structural (primary & Secondary), Pressure retaining parts and for materials that are welded directly to pressure components. Transfer of TC heat numbers prior to material cutting shall ensure positive identification is maintained throughout all stages of the work and final as-built drawings shall record the location of all materials and equipment in accordance with GPS-QA-PR-3605 Material Inspection & Traceability Procedure.

7.4.3

Control of Inspection, Measuring & Test Equipment’s Established control procedures at GPS and sub-contractors works will ensure that all relevant equipment including, where applicable, test software is subject to regular maintenance and calibration. The calibrated equipment shall be traceable to national/International standards. The calibration status of all inspection, measuring and test equipment used by GPS/vendors/subcontractors for the Project shall be readily identifiable and supporting certification and records shall be held on file and on request shall be presented for review during audits/inspection visits. The appointed Project QC Engineers/inspectors shall be responsible for ensuring all required certification is in place for any inspection, measuring or test equipment, which may be delivered direct to the job sites.

GPS Doc No. D1034-01-QA-PL-0201

7.4.4

Document No.

AGP-GPS-ANOGP-E02-0201

Rev.

A02

Document Title

Project Quality Plan

Page

17 of 21

Visual and Dimensional Control Visual & Dimensional Control shall be performed during all stages of fabrication and shall be implemented by the QC Department using suitably qualified personnel in accordance to approved procedures to ensure compliance to approved drawings/contract. Dimensional inspections will be carried out at specific stages of fabrication development as per the respective equipment ITP / Project ITP. Instrumentation used for Dimensional Control shall be suitably calibrated and reports made available for review when requested. For each dimensional inspection, a report will be issued in order to demonstrate compliance and/or deviation from specified tolerances identified within the specifications, drawings and/or relevant procedures. All complete reports will be readily transposed onto red line as-built drawings to facilitate final as-built drawings at completion of the Works.

7.4.5

Control of Special Processes All special processes to be utilized in the performance of the Project shall be carried out in accordance with prescribed practicable procedures duly approved by GPS. Special processes may include, but not be limited to: • • • • •

Welding Painting Post weld heat treatment Pressure testing NDE etc.

Specified requirements shall be translated into procedures, sufficiently detailed to prescribe clearly the manner in which the work will be performed and the required quality acceptance criteria. All Project specific documentation shall be prepared based on GPS Standard QMS Procedures including project specific requirements if any. All these procedures are subjected to AGPC review and comments as identified in MDS, prior to implementation. Process Control Instructions may be in the form of: • • • • •

Written Standards Project Specific Procedures Quality Control Plans Drawings Specifications

GPS recognizes that monitoring and inspection control is an essential part of process control and engages only qualified personnel in the verification process. Any or all of the following inspection stages may be utilized: • • • • • •

Process Control Stage Inspection Sample Inspection Final Inspection Test and Function Commissioning

GPS Doc No. D1034-01-QA-PL-0201

7.4.6

Document No.

AGP-GPS-ANOGP-E02-0201

Rev.

A02

Document Title

Project Quality Plan

Page

18 of 21

Control of Welders, Inspectors & Testing Personnel The control and certification of all welding personnel assigned to the Project scope shall be monitored by Quality Engineers/inspectors in accordance with GPS-QA-PR-3603 Qualification of Welders and Welding Operators, and established procedures of sub-contractors. The QA/QC Department shall be responsible for ensuring that all requisite qualification tests have been undertaken prior to deployment of welding personnel and that all necessary certification is in place and valid to cover assigned work scopes. The same will be verified by deputed QC Engineers/Inspectors/AGPC Inspectors visiting works during inspections. Welder Qualification Certificates shall be approved by GPS’s appointed Quality representative and submitted to AGPC for similar endorsement as/if required. NDT activities at GPS are sub-contracted and all activities of NDT are monitored and coordinated by GPS NDT coordinator. NDT operators shall be qualified in accordance to ASNT or equivalent and approved written practice, copies of proficiency certificates shall be submitted for approval and/or quality engineers/inspectors visiting facilities/works may randomly verify for qualification records.

7.4.7

Control of Consumables Welding consumables for the project shall be purchased, stored and controlled in accordance to procedure GPS-CM-PR-3514. Store keeper is responsible for proper storing & handling of welding consumables including the Baking and Holding ovens as per above mentioned procedure or as recommended by consumable manufacturers. Welding supervisor/foreman and Quality Inspectors shall monitor the consumable register maintained by the store keeper. All painting consumables are safely stored in a controlled environment to safeguard the paints from direct heat and fire hazards. All paint consumables are either stored at GPS premises or subcontractor facilities under the control of sub-contractor. Random surveillance of paint storage area at GPS yard shall be carried out by GPS safety officer and/or painting inspector.

7.4.8

Inspection & Test Records Project-specific Inspection and Testing procedures shall be developed based on project requirements and tests as applicable, Approved Procedures are required to ensure that all necessary inspection and tests are carried out in accordance with relevant codes and standards. Verification activities shall be performed by suitably qualified personnel in accordance with approved procedures and as required by Project Inspection & Test Plan. The approved Project Procedures shall specify all inspection and test techniques and acceptance criteria for each discipline and shall identify records required for retention. The inspection status of all works shall be readily demonstrated via documented systems and registers, etc., under the control of Project QA/QC personnel. Documentary methods for recording all test and inspection activities shall be in accordance with Project-specific procedures.

7.4.9

Manufacturers Data Record Book A Manufacturer’s Data Record (MDR) book shall be created, maintained, populated and controlled in accordance with approved MDR index.

GPS Doc No. D1034-01-QA-PL-0201

Document No.

AGP-GPS-ANOGP-E02-0201

Rev.

A02

Document Title

Project Quality Plan

Page

19 of 21

Prior to population of the MDR, the MDR index shall be reviewed and agreed to by AGPC. MDR Index for the project is prepared by DCC/Quality Engineers under supervision of PQM. The index is designed to ensure has a proven track record for practicality, usability and completeness. Throughout the fabrication, assembly and construction phases of the Project, the MDR shall be progressively reviewed and accepted by Quality Engineers/inspectors/AGPC and/or Certification Authority (as required). This will ensure a swift issuance of final documentation upon completion of the Project and Delivery. It shall be a Project objective to issue the final MDR to AGPC within Sixty days (60) following Delivery. Project Quality Manager and Package Engineers are responsible to communicate and/or control the Suppliers and Sub-Suppliers to ensure submission of MDR covering their scope of work while adhering to the procedure.

8

QUALITY MEASUREMENT

8.1

Control of Non-Conforming Product The control method for the identification reporting and processing of non-conformances, revealed through either systems auditing or process surveillance activities, shall be done as per GPS-IMS-PR2016 Control of Non-Conforming Product. The procedure provides for the processing of non-conforming product as below: • • • • • • • •

8.2

Identification of non-conformances Segregation of materials (if applicable) Reporting methods Corrective action Disposition of materials Close-out/Approvals Registering of non-conformance reports Analysis of non-conformance and preventive actions

Client Feedback GPS will regularly collect feedback from AGPC on Project performance through structured feedback which includes: •

Meetings;

•

Client Audits

•

GPS audits

•

Client Satisfaction Surveys/Questionnaire

It is inherent to all GPS employees that they take responsibility to effectively solicit Client feedback and engage with the Clients across their organization taking accountability for pursuing improvement actions where required. The results of this feedback, both positive and negative, will be acted upon in a timely manner. Positive feedback and achievements should be communicated by the Project Manager to the team including progress in meeting the Client’s expectations.

GPS Doc No. D1034-01-QA-PL-0201

Document No.

AGP-GPS-ANOGP-E02-0201

Rev.

A02

Document Title

Project Quality Plan

Page

20 of 21

Equally areas of negative feedback, which require corrective action to improve the relevant methods, process and procures applied which failed internally and led to Client dissatisfaction shall be acted upon accordingly clearly identifying root causes, action party agreed action and action date. This data shall form the basis of input to Quality Management System review.

9

QUALITY IMPROVEMENT

9.1

Quality Management System Review Quality Management System Reviews will be required when any issue incites repeated nonconformities on similar root causes or when total failure of Quality Management System. Requirement for review of Quality Management System will be determined from results of internal audits and or inspections. The review shall be executed in accordance with the Quality Management System Review process as per ISO 9001-2015 and will ensure the continued effectiveness of the quality policy, management system audit program, Client satisfaction, supplier feedback, employee feedback, etc. Review of Quality Management System shall include: results of audits [including internal audits and evaluations of compliance with legal requirements communications from external interested parties including Clients process performance including performance of the organization status of preventive and corrective actions follow-up actions from previous management reviews changing circumstances that could affect the management system [including developments in legal and other requirements related to environmental aspects; the extent to which objectives and targets have been met; recommendations for improvement

• • • • • • • •

Actions arising from the Management System Review will be captured and monitored by Project Quality Manager till its effective resolution. These actions may be in the form of Opportunities for Improvement or Non-conformities (for system non-conformances) recording the corrective action(s) as appropriate.

9.2

Key Performance Indicators The Project Management Team shall consistently monitor below activities to ensure performance is being maintained across the project to meet overall project schedule. • • • •

Development & issuance of Key documents On time issuance of purchase orders On time delivery of materials/components/equipment’s Monitor progress of fabrication, sub-contracted works for main packages and long lead items.

Regular review of performance against these performance indicators shall be undertaken during weekly/monthly project meetings to ensure Project Milestones and Deliverables are met. This will be carried out in accordance with the Project Schedule, Budget and Quality Requirements.

GPS Doc No. D1034-01-QA-PL-0201

9.3

Document No.

AGP-GPS-ANOGP-E02-0201

Rev.

A02

Document Title

Project Quality Plan

Page

21 of 21

Continual Improvement GPS Project Quality Manager is responsible to capture all positive and negative results from: • • • • • •

surveillance/verification activities supplier feedback non-conformance reports Client feedback opportunities for improvement audit findings

The Project Management team will regularly review their corrective & preventive actions and assess the applicability of new best practices, lessons learned, Opportunities for Improvement, etc. that may have raised on other Projects provided it is beneficial on ANOH Project. Regular review of non-conformities and preventive actions will be presented at management meetings with individuals held accountable for effective closure of remedial actions.

9.4

Lessons Learnt A detailed Lessons Learned session to be conducted at the beginning of Project, with learning’s from previous projects with similar work scopes being examined. Briefing of lessons learnt shall include both positive and negative. The lessons learned process will be applied at specific periods throughout the Project life cycle but specifically at Project closeout and incident investigation phases.

GPS Doc No. D1034-01-QA-PL-0201

ATTACHMENT -A GPS PROJECT ORGANISATION CHART - ANOH

PROJECT MANAGER Asif Badal

Project Engineering Manager Vihang Joshi

Chief EngineerProcess Reddy Madhava

Chief EngineerMechanical Saravanan Muthusamy

Chief EngineerStructural Dipayan Chakraborty

Chief EngineerPiping Boddu Prasad

Chief Engineer- E &I Greg Zieman

Commercial Manager TBC

Lead Process Engineer

Lead Mechanical Engineer

Lead Structural Engineer

Lead Piping Engineer

Lead E&I Engineer

Quantity Surveyor

Process Engineers & Designers Team

Mechanical Engineers & Designers Team

PMT – Interface Engineer

Project Engineer – Mech Packages

Procurement Manager Jitendra Ramtekkar

Project Quality Manager Mirza Baig

HSE Manager Harrison Kidd

Planning Manager Venkat K

Procurement/ Expediting Team

QA/QC Team

HSE Team

Planning/Cost Controls Team

Commissioning Manager E Venkatesh

Project Engineer – E& I Packages

Structural Engineers & Designers Team

Piping Engineers & Designers Team

E&I Engineers & Designers Team

GPS Fabrication Manager Marco Bruni

Project Engineers

HSE Mafraq Shop Project Engineer – Mech Packages

Project Engineer – Subcontracts (UAE)

Superintendents

Project Engineer – Subcontracts (UAE)

Yard Supervisors

Lead Document Controller

Lhynn Dichosa

Document Controllers Team

Foremen

Yard Personnel

GPSLLC PROJECT 06/2019REV01

Author: Asif Badal Status: Confirmed Date: 01JUNE 2019

ATTACHMENT -B

ANOH MIDSTREAM GAS PROCESSING PLANT QAQC ORGANIZATION Operations Manager Martin Brownhill

Project Manager Asif Badal

Fabrication Manager Marco Bruni

Project Quality Manager Mirza R Baig

Deputy QC Manager Anna Durai

Bought-out / subcontracted equipments

QAQC Engineer-Mech TBA

QAQC Engineer-E&I TBA

QAQC Engineer-Mech TBA

QC Inspector at Subcontractors / TPI Inspectors

QC Inspector at Subcontractors / TPI Inspectors

NDE Coordinator Saravanan

NDE Inspectors (Subcon)

QC Inspectors Mech & Piping

Welding Engineer Bharani DUBAI MAFRAQ

Document Controller Farook

Author: Mirza R Baig Date: 30 Jun 2019

NIGERIA

ATTACHMENT -C, Page 1/6

ATTACHMENT -C, Page 2/6

ATTACHMENT -C, Page 3/6

ATTACHMENT -C, Page 4/6

Certificate of Authorization

This is to certify that GLOBAL PROCESS SYSTEMS LLC Plot 325, Tarif Road Mafraq, Abu Dhabi United Arab Emirates

is authorized to use the R Symbol in accordance with the provisions of the National Board Inspection Code and NB-415, Accreditation of "R" Repair Organizations. All activities within the scope of this Authorization shall be controlled by the above location. The scope of this Authorization is limited to: Metallic Repairs and Alterations At Shop and Field Locations

Certification Number:

7117

Issue Date:

February 12, 2019

Expiration Date:

March 2, 2022

Executive Director

ATTACHMENT -C, Page 5/6

ATTACHMENT -C, Page 6/6