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Piling Works for South Side of Paradip Refinery Project Site for Group Area – I
Page 1 of 16
CONTRACT NUMBER-205/4200
PROJECT QUALITY PLAN
1.0
25.05.2010
Revision
Date
For Information or review Reason for Issue / Remark
Prepared
Checked
ITD CEM Project No.: ITD CEM Project Code.:
Approved
17610CF Piling, FW-IOCL, Paradip
Contractor Doc. No.:
Company Doc. No.:
PJ/CC/PDRP/PILE/GA-1/09-10/FOA/04 Dated 20-02-2010
ITD Cem/Div.3/PQP/Piling - 1
Paradip Refinery Project
South Side of Project Site for Group Area-I
Page 2 of 17
PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
REVISION HISTORY REV.
DATE
DESCRIPTION
01
25/05/10
Project quality plan
Paradip Refinery Project
South Side of Project Site for Group Area-I
Page 3 of 17
PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
* Notes:
This page records all revisions of the project quality plan.
Paradip Refinery Project
South Side of Project Site for Group Area-I
Page 4 of 17
PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
INDEX Sr. No.
Description
Page No.
1.
GENERAL
04 to 09
2.
QUALITY OBJECTIVES
10 to 10
3.
ORGANOGRAM
17 to 17
4.
LIST OF PRESONNEL FOR SITE ORGANIZATION
18 to 18
5.
DETAILS OF CONSTRUCTION ACTIVITY
19 to 19
6.
TIME PROGRAM FOR PROJECT EXECUTION
7.
MATERIAL PROCUREMENT PROGRAM
20 to 20
8.
INSPECTION AND TEST PLAN
21 to 27
9.
PLAN FOR CALIBRATION OF INSTRUMENTS
28 to 28
10.
PLANT REQUIREMENT PROGRAM
11.
QUALITY RECORDS
Refer to DOC.No.17610CF/Foster Wheeler /planning 2010—01 dated 18.05.10
Refer to ITD/17610CF/2010/FW/EDS
29 to 52
Paradip Refinery Project
1.0
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
GENERAL 1.1. • • • • • • • • • • • • • • • • • • • • • 1.2. • • • • • 1.3.
ABBREVIATIONS ITD Cem IOCL FW PMC EPCM PQP IMS-Procedures QR R MS WI DS ITP P IS QAQC QS QMS EMS
ITD Cementation India Ltd. M/s. Indian Oil Corporation Limited Foster Wheeler GB limited Project Management Consultant Engineering Procurement & Construction Management Project Quality Plan Integrated Management System Procedures Quality Record Record Method Statement Work Instruction Data Sheet Inspection Test Procedure / Plan Procedure Indian Standard Quality Assurance & Quality Control Quantity Survey Quality Management System Environment Management System
OHSAS ESH
Occupational Health and Safety Assessment Series Environment, Safety Health
EXECUTION DETAILS Contractor Owner Consultant Date of Commencement Date of Completion
ITD Cementation India Ltd. M/s. Indian Oil Corporation Limited Foster Wheeler GB limited April 20th, 2010 December 19th 2010
SCOPE The scope includes Bored Cast-in-situ and Driven Cast-in-situ Piling Works for South Side of Paradip Refinery Project Site for Group Area – I. The activities in this contract are separately discussed in method statement.
1.4.
QUALITY SYSTEM
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
ITD Cem operates an Integrated Management System certified by DNV as per the requirements of ISO-9001, ISO-14001 and OSHAS-18001 termed as “Integrated Management System.” ITD Cem ensures that all employees whose activities are related to IMS performance are assigned responsibilities and given authority to ensure proper implementation through their motivation, active involvement, and commitment. The Project shall be executed by the ITD Cem under IMS Manual, IMS Procedures, Method Statements, Work Instructions pertaining to the scope of work.
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
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1.5.
PURPOSE OF PQP
The purpose of this PQP is to execute the work in an organized manner and provide clear procedure for each part of the execution with proper recording & monitoring system. This PQP has been prepared in accordance with the guidelines provided in IMSProcedure P-11 Project Execution. The PQP shall be a live document till the end of the project. This PQP shall be reviewed, amended and re-issued as mentioned in IMS-Procedure, P-1 (Control of Documents.) If required QA/QC procedures, QC Plans, Method Statements and Work Instructions shall be prepared and issued as per IMS Procedure P-1, Document Control.
1.6. •
REFERENCE DOCUMENTS Applicable IS Codes- Indian codes and standards
Paradip Refinery Project
South Side of Project Site for Group Area-I
Page 11 of 17
PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
IS-456 IS-1489 IS-2911 Part-1,sec 1 IS-2911 Part-1,sec 2 IS-383
Plain and Reinforced concrete Specification for Portland pozzolana cement Driven Cast in situ concrete pile Bored Cast in situ concrete pile Specification of coarse and fine aggregate from natural sources for concrete IS-516 Method of Test for strength for concrete IS-1199 Method of sampling and analysis of concrete IS-1786 Specification for High strength Deformed steel Bars &wire for concrete reinforcement IS-2386 Methods for sampling of aggregates for concrete IS-4031 Method of physical Tests of Hydraulic cement IS-4032 Method of Chemical Tests of Hydraulic cement IS-4925 Specification of concrete batching and mixing plant IS-6461 Glossary of Terms relating to cement concrete IS-8112 Specification for 43 grade ordinary Portland cement IS-9013 Method of making, curing & Determining compressive strength of accelerated cured concrete test specifications IS-9103 Specification of concrete admixtures IS-10262 Recommended guidelines for concrete mix design IS-13311 Method of non-Destructive testing of concrete IS-14000 Quality Systems-Guidelines for selection and use of standards on quality systems IS-14858 Compressive testing machine used for testing of concrete and Mortar-requirements SP-23 Handbook on concrete mixes SP-34 Handbook on concrete reinforcement and Detailing • Relevant Contract Specificationsa. General Specification for pilling(PDRP-8310-Sp-0006) b. General Specification for concrete work (PDRP-8310-Sp-0005)
2.0
QUALITY OBJECTIVE 2.1 2.2 2.3
3.0
The work shall be performed throughout the execution period in accordance with the applicable standards and specifications as per the contract document, QC Plans, Method Statements and Work Instructions wherever applicable. Project In-charges shall maintain the IMS-Procedures, Method Statements, Work Instructions and PQP. The work shall be performed in accordance with quality requirements to the satisfaction of the Owner & PMC and shall be completed within the scheduled contract duration.
SITE ORGANOGRAM 3.1
The organization structure indicating various functional and administrative relationships together with lines of communication for effective management and execution of the project is shown in Annexure-A to this PQP.
Paradip Refinery Project
4.0
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
ALLOCATION OF RESPONSIBILITIES 4.1
The responsibilities allocated herein are specified to this project. In case of conflict of responsibilities between this PQP and the IMS Manual, the former shall prevail in addition to those identified in the IMS Manual.
4.1.1 Project Manager • • • • • • • • • •
Overall execution and administration of the project as per the contract requirements and Approved drawings. Ensure Quality Management System is effectively implemented in the project. Continuously assess the actual progress of work against planned program and initiate recovery program in a case of slippage in progress. Ensure that all approved drawings are available at the pertinent locations. Ensure firm control over the subcontractor to meet the end product quality requirements as per the contract requirements. Coordinate with involved functions for obtaining the necessary resources for the project and deploy as required. Submit Project reports as per contractual requirements. Perform initial post-award and periodical contract review along with Project QS as and when required throughout the execution of the project. Identify the training needs and coordinate with appropriate function for fulfilling the training requirements. Analyze deviations, change of contract scope, incorporate it and if necessary, reschedule to meet target dates and maintain records for changes incorporated.
4.1.2 Project In-Charge • • • • • •
Review of drawings received from the customer in co-operation with Project Manager. Co-ordinate with Project Manager for mobilization of manpower, equipment and material for execution of works. Monitor the subcontractors activity to ensure quality and timely completion of the work. Laise with the sub-ordinate staff and execute the works as per planned schedule in conformance with applicable standards. Laise with customer representative for day-to-day quality related activities. Responsible for any survey activity to be carried out.
4.1.3 Project Engineer • • •
Co-ordinate with Execution Engineers, Site Supervisors for the execution of the work. Receive instructions from Project manager / In-charge regarding priority of the work & implementation of the planned programme at field. Liasoning with Owner / consultant for approval of the routine works.
Paradip Refinery Project
• •
South Side of Project Site for Group Area-I
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Responsible for ensuring quality & safety at work site with required progress of the work. Ensure fulfillment of time to time documentation requirement for the execution part of the work.
4.1.4 QA/QC Engineer • • • • • •
Responsible for all the lab tests and field tests including coordination for the third party testing of required materials during the course of execution. Maintain all relevant test records which are being used for recording the results. Focal point of Inspection, Monitoring and Measurement Devices used in the project and responsible for the proper implementation of the ITD Cem’s IMS System Procedures. Responsible for preparation, maintenance and retention of Lab/Field test records. Inform Project engineer regarding any non conformance observed in the material in use during the project execution. Shall be worked as IMS Coordinator for co-coordinating the QMS related issues & implementation of QMS during the entire period of the project execution.
4.1.5 Site Supervisor • • •
Ensure that the work in their respective area is carried out in accordance with the contract document and procedures as directed by the discipline Engineers. Proper and optimum utilization of available resources. Liaise with the QA/QC Engineer for effective implementation of Procedures.
4.1.6 Planning Engineer • • • • • •
Responsible for preparation of detail time program for the smooth execution of the project. Responsible for evaluation of resources required. Responsible for preparation of weekly progress report. Review the actual progress of work against the scheduled program. Monitor the progress including sub-contractor’s activity. Laise with Project In-charge for the reasons of delay in completion of the project in time.
4.1.7 Commercial Engineer/QS • • •
Responsible for preparation of invoices in terms of contract. Responsible for the cost-value reconciliation on the basis of invoices on monthly/ Quarterly basis. Responsible for preparing claims towards extra/additional works undertaken.
4.1.8 Plant Engineer / Equipment Engineer
Paradip Refinery Project
• • • • •
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
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Responsible for maintaining list of equipments available at site. Responsible for maintenance of vehicles / equipment periodically. Responsible for maintaining all records as per the IMS-Procedure P-15 Plant. Co-Ordinate with Project In-charge in smooth running of plant and machinery. Attend the break downs immediately to avoid in delay of progress.
4.1.9 ESH Officer • • • • • • •
5.0
LIST OF PERSONNEL FOR SITE ORGANIZATION . 5.1
6.0
The construction activity in this project is shown in Annexure – C to this PQP along with applicable Method Statements and relevant Quality records that are to be maintained during the execution of the project.
TIME PROGRAM FOR PROJECT EXECUTION 7.1
8.0
The details of personnel for the site organization are shown in Annexure-B to this PQP.
DETAILS OF CONSTRUCTION ACTIVITY . 6.1
7.0
He will be accountable to the Project Manager / Project Incharge for fulfilling the duties assigned to him and ensures implementation of ESH Plan. Monitor and advise relevant personnel on compliance with ESH statutory obligations at the site. Provide copies of site / office inspection report to relevant managers / engineers. Monitor incident reporting procedure. Attend and participate in Site ESH Management Review Meetings. Access and advise PM on the perceived ESH training needs of project personnel. Organise and conduct training for site and
A detail activity wise time program for smooth execution of this project is shown in Annexure –D to this PQP.
MATERIAL PROCUREMENT 8.1 8.2 8.3 8.4
ITD Cem has developed a procedure P-8 (Purchase) for procurement of materials and P-18 (Stores) for preservation, transportation, handling, storage of materials. Manufacturer’s Test certificates for major direct materials e.g. Cement & Reinforcement Steel shall be collected with every lot & same shall be kept with QAQC In-charge. Record of the same shall be maintained in the stock register. A detail material requirement at various stages of project is shown in Material Procurement Plan attached as Annexure –E to this PQP. If any non-conformity observed during procurement of materials, it shall be either rejected or disposed as detailed in P- 16 (Control of NC Product) and corrective &
Paradip Refinery Project
8.5
9.0.
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
preventive action shall be taken as per P-17 (Corrective and Preventive Action).The record of the same shall be maintained in R-1/16 – Record of non-confirming product and corrective & preventive action taken attached herewith as Annexure - L Receipt of Customer Complaint with respect to the quality, progress of the work, legislative safety & environmental issues shall be recorded in R-2/17 – Customer Complaint Record attached herewith as Annexure – M.
INSPECTION AND TEST PLAN. 9.1 A detailed Inspection and Test Plan for controlling the Quality of the product including incoming & in process materials at various stages of construction and responsibility lies with shown as Annexure F 10.1 The QA/QC Engineer shall be the focal point for all Monitoring and Measurement devices used in the project. A detail plan for calibration of instruments used in this project is shown in Annexure-G to this PQP.
10.0
PLANT & MAINTENANCE 11.1 ITD Cem has developed a procedure P- 15, for maintenance of plant & machineries and maintenance of records. 11.2 A detail requirement of plant and equipment for execution of project is shown in Annexure –H in this PQP.
11.0
QUALITY RECORDS 12.1 All Quality records shall be compiled, stored and retained in such a manner that they are readily retrievable, prevented from damage, deterioration and loss. 12.2 All Quality records shall have unique identification no. as mentioned in the Details of Construction Activity sheet.
13.0
MEASUREMENT AND MONITORING Report on numbers of NCR to be reported at weekly progress meeting Performance of the project shall be monitored in the monthly Site Review Meeting at site level and by the Internal Audits at Division level. 13.1 ITD Cem has developed a Procedure P- 20 (Internal Audit), for Internal Auditing systems & maintaining records of the internal audits. 13.2 Internal as well as external (on sub-contractors) Quality Audits shall be carried out as per the Internal Audit program by respective HOD-Engineering. 13.3 HOD Engineering in consultation with Corporate Environmental and Safety Head shall be responsible for implementing the audits including follow-up. Qualified auditors nominated by Chief Internal Auditor will carry out the audits. 13.4 Frequency of Internal Audit shall be once in a six month. DNV selects the projects for External Audit. 13.5 Customer Satisfaction shall be taken in Customer Satisfaction Form attached herewith
Paradip Refinery Project
South Side of Project Site for Group Area-I
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Revision : 1.0 Date : 25.05.2010
as Annexure – I. 13.6 Audit Program and Audit reports to be copied to Foster wheeler
14 TRAINING Training shall be conducted for employees & workers deputed at project sites to improve the awareness & skills of the employees & workers in their respective fields. 14.1 Environment & Safety Trainings for all shall be conducted by EHS officer at project sites. 14.2 For specialized training on technical subjects, environment & safety, training needs shall be identified by concerned Corporate/Div. Head. 14.3 Project Manager / In-charge in consultation with respective functional heads shall identify the training needs for employees & subcontractors personnel. 14.4 Training record shall be maintained in R-1/19 record sheet enclosed herewith as Annexure – J.
15 RESOURCE MANAGEMENT 15.1 Requirement of resources such as manpower, materials, plant & equipments, etc. shall be identified & shall be procured / deployed according to requirements of the project. 15.2 Records related to workmen deployed shall be maintained by HR & Administration Officer in accordance with the applicable Rules & Regulation of the State Government and shall be maintained in the format prescribed by them. 15.3 Facilities in terms of accommodation, drinking water, urinals & latrines, rest room, etc. shall be provided as per the applicable contract specifications. 15.4 Temporary Site Installations such as Site Office, Stores, Workshops, Batching Plant, and Cement Godown shall be constructed / erected as per site requirements.
16 AS-BUILTS 16.1 Receipt of the drawings & all amendments shall be recorded in the Drawing Register attached herewith as Annexure – K 16.2 As Built drawing shall be prepared in accordance with applicable contractual requirements and shall be submitted after completion & handing over of the structures. 16.3 Quality and method of markine up As –Built drawing to be as shown on F/W procedure 17 Panning Engineer in consultation with Surveyor shall be responsible for record of drawing receipt & submission of as built drawings.
18 ENCLOSURES Following enclosures are attached herewith along with this PQP for ease of reference of the documents. • • •
Annexure – A Annexure – B Annexure – C
Site Organogram List of Personnel for Site Organization Details of Construction Activity
•
Annexure – D
Time Programme for Project Execution (Refer to -DOC.No.17610CF/Foster
Paradip Refinery Project
• • • • • • • • •
South Side of Project Site for Group Area-I
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Wheeler /planning 2010—01 dated 18.05.10 Annexure – E Material Procurement Plan Annexure – F Inspection and Test Plan Annexure – G Plan for Calibration of Instruments Annexure – H Plant Requirement Plan ( Refer. ITD/17610CF/2010/FW/EDS) Annexure – I Customer Satisfaction Form Annexure – J Training Record Annexure – K Drawing Register Annexure – L Record of non-confirming product and corrective & preventive action taken Annexure – M Customer Complaint Record
Page 1 of 16
CONTRACT NUMBER-205/4200
PROJECT QUALITY PLAN
1.0
25.05.2010
Revision
Date
For Information or review Reason for Issue / Remark
Prepared
Checked
ITD CEM Project No.: ITD CEM Project Code.:
Approved
17610CF Piling, FW-IOCL, Paradip
Contractor Doc. No.:
Company Doc. No.:
PJ/CC/PDRP/PILE/GA-1/09-10/FOA/04 Dated 20-02-2010
ITD Cem/Div.3/PQP/Piling - 1
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
REVISION HISTORY REV.
DATE
DESCRIPTION
01
25/05/10
Project quality plan
Paradip Refinery Project
South Side of Project Site for Group Area-I
Page 3 of 17
PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
* Notes:
This page records all revisions of the project quality plan.
Paradip Refinery Project
South Side of Project Site for Group Area-I
Page 4 of 17
PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
INDEX Sr. No.
Description
Page No.
1.
GENERAL
04 to 09
2.
QUALITY OBJECTIVES
10 to 10
3.
ORGANOGRAM
17 to 17
4.
LIST OF PRESONNEL FOR SITE ORGANIZATION
18 to 18
5.
DETAILS OF CONSTRUCTION ACTIVITY
19 to 19
6.
TIME PROGRAM FOR PROJECT EXECUTION
7.
MATERIAL PROCUREMENT PROGRAM
20 to 20
8.
INSPECTION AND TEST PLAN
21 to 27
9.
PLAN FOR CALIBRATION OF INSTRUMENTS
28 to 28
10.
PLANT REQUIREMENT PROGRAM
11.
QUALITY RECORDS
Refer to DOC.No.17610CF/Foster Wheeler /planning 2010—01 dated 18.05.10
Refer to ITD/17610CF/2010/FW/EDS
29 to 52
Paradip Refinery Project
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GENERAL 1.1. • • • • • • • • • • • • • • • • • • • • • 1.2. • • • • • 1.3.
ABBREVIATIONS ITD Cem IOCL FW PMC EPCM PQP IMS-Procedures QR R MS WI DS ITP P IS QAQC QS QMS EMS
ITD Cementation India Ltd. M/s. Indian Oil Corporation Limited Foster Wheeler GB limited Project Management Consultant Engineering Procurement & Construction Management Project Quality Plan Integrated Management System Procedures Quality Record Record Method Statement Work Instruction Data Sheet Inspection Test Procedure / Plan Procedure Indian Standard Quality Assurance & Quality Control Quantity Survey Quality Management System Environment Management System
OHSAS ESH
Occupational Health and Safety Assessment Series Environment, Safety Health
EXECUTION DETAILS Contractor Owner Consultant Date of Commencement Date of Completion
ITD Cementation India Ltd. M/s. Indian Oil Corporation Limited Foster Wheeler GB limited April 20th, 2010 December 19th 2010
SCOPE The scope includes Bored Cast-in-situ and Driven Cast-in-situ Piling Works for South Side of Paradip Refinery Project Site for Group Area – I. The activities in this contract are separately discussed in method statement.
1.4.
QUALITY SYSTEM
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
ITD Cem operates an Integrated Management System certified by DNV as per the requirements of ISO-9001, ISO-14001 and OSHAS-18001 termed as “Integrated Management System.” ITD Cem ensures that all employees whose activities are related to IMS performance are assigned responsibilities and given authority to ensure proper implementation through their motivation, active involvement, and commitment. The Project shall be executed by the ITD Cem under IMS Manual, IMS Procedures, Method Statements, Work Instructions pertaining to the scope of work.
Paradip Refinery Project
South Side of Project Site for Group Area-I
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Revision : 1.0 Date : 25.05.2010
Paradip Refinery Project
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PROJECT QUALITY PLAN
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Paradip Refinery Project
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1.5.
PURPOSE OF PQP
The purpose of this PQP is to execute the work in an organized manner and provide clear procedure for each part of the execution with proper recording & monitoring system. This PQP has been prepared in accordance with the guidelines provided in IMSProcedure P-11 Project Execution. The PQP shall be a live document till the end of the project. This PQP shall be reviewed, amended and re-issued as mentioned in IMS-Procedure, P-1 (Control of Documents.) If required QA/QC procedures, QC Plans, Method Statements and Work Instructions shall be prepared and issued as per IMS Procedure P-1, Document Control.
1.6. •
REFERENCE DOCUMENTS Applicable IS Codes- Indian codes and standards
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
IS-456 IS-1489 IS-2911 Part-1,sec 1 IS-2911 Part-1,sec 2 IS-383
Plain and Reinforced concrete Specification for Portland pozzolana cement Driven Cast in situ concrete pile Bored Cast in situ concrete pile Specification of coarse and fine aggregate from natural sources for concrete IS-516 Method of Test for strength for concrete IS-1199 Method of sampling and analysis of concrete IS-1786 Specification for High strength Deformed steel Bars &wire for concrete reinforcement IS-2386 Methods for sampling of aggregates for concrete IS-4031 Method of physical Tests of Hydraulic cement IS-4032 Method of Chemical Tests of Hydraulic cement IS-4925 Specification of concrete batching and mixing plant IS-6461 Glossary of Terms relating to cement concrete IS-8112 Specification for 43 grade ordinary Portland cement IS-9013 Method of making, curing & Determining compressive strength of accelerated cured concrete test specifications IS-9103 Specification of concrete admixtures IS-10262 Recommended guidelines for concrete mix design IS-13311 Method of non-Destructive testing of concrete IS-14000 Quality Systems-Guidelines for selection and use of standards on quality systems IS-14858 Compressive testing machine used for testing of concrete and Mortar-requirements SP-23 Handbook on concrete mixes SP-34 Handbook on concrete reinforcement and Detailing • Relevant Contract Specificationsa. General Specification for pilling(PDRP-8310-Sp-0006) b. General Specification for concrete work (PDRP-8310-Sp-0005)
2.0
QUALITY OBJECTIVE 2.1 2.2 2.3
3.0
The work shall be performed throughout the execution period in accordance with the applicable standards and specifications as per the contract document, QC Plans, Method Statements and Work Instructions wherever applicable. Project In-charges shall maintain the IMS-Procedures, Method Statements, Work Instructions and PQP. The work shall be performed in accordance with quality requirements to the satisfaction of the Owner & PMC and shall be completed within the scheduled contract duration.
SITE ORGANOGRAM 3.1
The organization structure indicating various functional and administrative relationships together with lines of communication for effective management and execution of the project is shown in Annexure-A to this PQP.
Paradip Refinery Project
4.0
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
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ALLOCATION OF RESPONSIBILITIES 4.1
The responsibilities allocated herein are specified to this project. In case of conflict of responsibilities between this PQP and the IMS Manual, the former shall prevail in addition to those identified in the IMS Manual.
4.1.1 Project Manager • • • • • • • • • •
Overall execution and administration of the project as per the contract requirements and Approved drawings. Ensure Quality Management System is effectively implemented in the project. Continuously assess the actual progress of work against planned program and initiate recovery program in a case of slippage in progress. Ensure that all approved drawings are available at the pertinent locations. Ensure firm control over the subcontractor to meet the end product quality requirements as per the contract requirements. Coordinate with involved functions for obtaining the necessary resources for the project and deploy as required. Submit Project reports as per contractual requirements. Perform initial post-award and periodical contract review along with Project QS as and when required throughout the execution of the project. Identify the training needs and coordinate with appropriate function for fulfilling the training requirements. Analyze deviations, change of contract scope, incorporate it and if necessary, reschedule to meet target dates and maintain records for changes incorporated.
4.1.2 Project In-Charge • • • • • •
Review of drawings received from the customer in co-operation with Project Manager. Co-ordinate with Project Manager for mobilization of manpower, equipment and material for execution of works. Monitor the subcontractors activity to ensure quality and timely completion of the work. Laise with the sub-ordinate staff and execute the works as per planned schedule in conformance with applicable standards. Laise with customer representative for day-to-day quality related activities. Responsible for any survey activity to be carried out.
4.1.3 Project Engineer • • •
Co-ordinate with Execution Engineers, Site Supervisors for the execution of the work. Receive instructions from Project manager / In-charge regarding priority of the work & implementation of the planned programme at field. Liasoning with Owner / consultant for approval of the routine works.
Paradip Refinery Project
• •
South Side of Project Site for Group Area-I
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Responsible for ensuring quality & safety at work site with required progress of the work. Ensure fulfillment of time to time documentation requirement for the execution part of the work.
4.1.4 QA/QC Engineer • • • • • •
Responsible for all the lab tests and field tests including coordination for the third party testing of required materials during the course of execution. Maintain all relevant test records which are being used for recording the results. Focal point of Inspection, Monitoring and Measurement Devices used in the project and responsible for the proper implementation of the ITD Cem’s IMS System Procedures. Responsible for preparation, maintenance and retention of Lab/Field test records. Inform Project engineer regarding any non conformance observed in the material in use during the project execution. Shall be worked as IMS Coordinator for co-coordinating the QMS related issues & implementation of QMS during the entire period of the project execution.
4.1.5 Site Supervisor • • •
Ensure that the work in their respective area is carried out in accordance with the contract document and procedures as directed by the discipline Engineers. Proper and optimum utilization of available resources. Liaise with the QA/QC Engineer for effective implementation of Procedures.
4.1.6 Planning Engineer • • • • • •
Responsible for preparation of detail time program for the smooth execution of the project. Responsible for evaluation of resources required. Responsible for preparation of weekly progress report. Review the actual progress of work against the scheduled program. Monitor the progress including sub-contractor’s activity. Laise with Project In-charge for the reasons of delay in completion of the project in time.
4.1.7 Commercial Engineer/QS • • •
Responsible for preparation of invoices in terms of contract. Responsible for the cost-value reconciliation on the basis of invoices on monthly/ Quarterly basis. Responsible for preparing claims towards extra/additional works undertaken.
4.1.8 Plant Engineer / Equipment Engineer
Paradip Refinery Project
• • • • •
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
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Responsible for maintaining list of equipments available at site. Responsible for maintenance of vehicles / equipment periodically. Responsible for maintaining all records as per the IMS-Procedure P-15 Plant. Co-Ordinate with Project In-charge in smooth running of plant and machinery. Attend the break downs immediately to avoid in delay of progress.
4.1.9 ESH Officer • • • • • • •
5.0
LIST OF PERSONNEL FOR SITE ORGANIZATION . 5.1
6.0
The construction activity in this project is shown in Annexure – C to this PQP along with applicable Method Statements and relevant Quality records that are to be maintained during the execution of the project.
TIME PROGRAM FOR PROJECT EXECUTION 7.1
8.0
The details of personnel for the site organization are shown in Annexure-B to this PQP.
DETAILS OF CONSTRUCTION ACTIVITY . 6.1
7.0
He will be accountable to the Project Manager / Project Incharge for fulfilling the duties assigned to him and ensures implementation of ESH Plan. Monitor and advise relevant personnel on compliance with ESH statutory obligations at the site. Provide copies of site / office inspection report to relevant managers / engineers. Monitor incident reporting procedure. Attend and participate in Site ESH Management Review Meetings. Access and advise PM on the perceived ESH training needs of project personnel. Organise and conduct training for site and
A detail activity wise time program for smooth execution of this project is shown in Annexure –D to this PQP.
MATERIAL PROCUREMENT 8.1 8.2 8.3 8.4
ITD Cem has developed a procedure P-8 (Purchase) for procurement of materials and P-18 (Stores) for preservation, transportation, handling, storage of materials. Manufacturer’s Test certificates for major direct materials e.g. Cement & Reinforcement Steel shall be collected with every lot & same shall be kept with QAQC In-charge. Record of the same shall be maintained in the stock register. A detail material requirement at various stages of project is shown in Material Procurement Plan attached as Annexure –E to this PQP. If any non-conformity observed during procurement of materials, it shall be either rejected or disposed as detailed in P- 16 (Control of NC Product) and corrective &
Paradip Refinery Project
8.5
9.0.
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
preventive action shall be taken as per P-17 (Corrective and Preventive Action).The record of the same shall be maintained in R-1/16 – Record of non-confirming product and corrective & preventive action taken attached herewith as Annexure - L Receipt of Customer Complaint with respect to the quality, progress of the work, legislative safety & environmental issues shall be recorded in R-2/17 – Customer Complaint Record attached herewith as Annexure – M.
INSPECTION AND TEST PLAN. 9.1 A detailed Inspection and Test Plan for controlling the Quality of the product including incoming & in process materials at various stages of construction and responsibility lies with shown as Annexure F 10.1 The QA/QC Engineer shall be the focal point for all Monitoring and Measurement devices used in the project. A detail plan for calibration of instruments used in this project is shown in Annexure-G to this PQP.
10.0
PLANT & MAINTENANCE 11.1 ITD Cem has developed a procedure P- 15, for maintenance of plant & machineries and maintenance of records. 11.2 A detail requirement of plant and equipment for execution of project is shown in Annexure –H in this PQP.
11.0
QUALITY RECORDS 12.1 All Quality records shall be compiled, stored and retained in such a manner that they are readily retrievable, prevented from damage, deterioration and loss. 12.2 All Quality records shall have unique identification no. as mentioned in the Details of Construction Activity sheet.
13.0
MEASUREMENT AND MONITORING Report on numbers of NCR to be reported at weekly progress meeting Performance of the project shall be monitored in the monthly Site Review Meeting at site level and by the Internal Audits at Division level. 13.1 ITD Cem has developed a Procedure P- 20 (Internal Audit), for Internal Auditing systems & maintaining records of the internal audits. 13.2 Internal as well as external (on sub-contractors) Quality Audits shall be carried out as per the Internal Audit program by respective HOD-Engineering. 13.3 HOD Engineering in consultation with Corporate Environmental and Safety Head shall be responsible for implementing the audits including follow-up. Qualified auditors nominated by Chief Internal Auditor will carry out the audits. 13.4 Frequency of Internal Audit shall be once in a six month. DNV selects the projects for External Audit. 13.5 Customer Satisfaction shall be taken in Customer Satisfaction Form attached herewith
Paradip Refinery Project
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
as Annexure – I. 13.6 Audit Program and Audit reports to be copied to Foster wheeler
14 TRAINING Training shall be conducted for employees & workers deputed at project sites to improve the awareness & skills of the employees & workers in their respective fields. 14.1 Environment & Safety Trainings for all shall be conducted by EHS officer at project sites. 14.2 For specialized training on technical subjects, environment & safety, training needs shall be identified by concerned Corporate/Div. Head. 14.3 Project Manager / In-charge in consultation with respective functional heads shall identify the training needs for employees & subcontractors personnel. 14.4 Training record shall be maintained in R-1/19 record sheet enclosed herewith as Annexure – J.
15 RESOURCE MANAGEMENT 15.1 Requirement of resources such as manpower, materials, plant & equipments, etc. shall be identified & shall be procured / deployed according to requirements of the project. 15.2 Records related to workmen deployed shall be maintained by HR & Administration Officer in accordance with the applicable Rules & Regulation of the State Government and shall be maintained in the format prescribed by them. 15.3 Facilities in terms of accommodation, drinking water, urinals & latrines, rest room, etc. shall be provided as per the applicable contract specifications. 15.4 Temporary Site Installations such as Site Office, Stores, Workshops, Batching Plant, and Cement Godown shall be constructed / erected as per site requirements.
16 AS-BUILTS 16.1 Receipt of the drawings & all amendments shall be recorded in the Drawing Register attached herewith as Annexure – K 16.2 As Built drawing shall be prepared in accordance with applicable contractual requirements and shall be submitted after completion & handing over of the structures. 16.3 Quality and method of markine up As –Built drawing to be as shown on F/W procedure 17 Panning Engineer in consultation with Surveyor shall be responsible for record of drawing receipt & submission of as built drawings.
18 ENCLOSURES Following enclosures are attached herewith along with this PQP for ease of reference of the documents. • • •
Annexure – A Annexure – B Annexure – C
Site Organogram List of Personnel for Site Organization Details of Construction Activity
•
Annexure – D
Time Programme for Project Execution (Refer to -DOC.No.17610CF/Foster
Paradip Refinery Project
• • • • • • • • •
South Side of Project Site for Group Area-I
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PROJECT QUALITY PLAN
Revision : 1.0 Date : 25.05.2010
Wheeler /planning 2010—01 dated 18.05.10 Annexure – E Material Procurement Plan Annexure – F Inspection and Test Plan Annexure – G Plan for Calibration of Instruments Annexure – H Plant Requirement Plan ( Refer. ITD/17610CF/2010/FW/EDS) Annexure – I Customer Satisfaction Form Annexure – J Training Record Annexure – K Drawing Register Annexure – L Record of non-confirming product and corrective & preventive action taken Annexure – M Customer Complaint Record
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