Project Quality Plan Rev 2

HIGLEIG PTROLEUM SERVICES &INVESTMENT CO.LTD&CHINA JIANGSU- CONSORTIUM EPCC FOR PDOC NEW OFFICE BUILDING PROJECT

Project Quality Plan Petrodar Contract No.

PDOC/31/05-237B

Document No. Issue and Revision Record Rev No.

Date

Description

B

25-07-06

FOR REVIEW

Prepare by

Review by

Approved by

A Owner : Petrodar Limited

Operating

Company

EPCC Contractor : Higleig – China Jiangsu Consortium

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Engineering Sub-Contractor : China Petroleum Engineering

HIGLEIG PETROLEUM SERVICES INVESTMENTS CO.

PROJECT QUALITY PLAN INDEX

i.

Cover Page

ii.

Revision Control Sheet

iii.

Controlled Document Distribution List

1.0

Introduction, Definitions & Abbreviations

2.0

Quality Policy

3.0

Quality Objectives

4.0

Organization, Authority & Responsibility

6.0

Quality Planning

5.0

Product Realization

6.0

Measurement, Analysis and Improvement

7.0

List of Appendixes

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REVISION CONTROL SHEET Sr. No.

Rev. No.

Issue No.

1

A

1

2

B

2

Issue Date

Description With Kick -of meeting – Post award submission Incorporated the following comments from Owner/Client and resubmitted for review.

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Controlled Document Distribution List

Document #: _____________________________________ Document Title: __________________________________ Document Type: _______________________________ Document Holder

Sign.

Date received

PMT Leader -PDOC Project Construction Manager - PMC Project Manager-Consortium Deputy Project Manager-Consortium Chief Engineering -Consortium Construction Manager- Consortium HSE-Manager- Consortium Project Control Manager- Consortium Project Engineering Manager- Consortium Project Procurement Manager- Consortium Project Logistic Manager- Consortium Project QA/QC Manager- Consortium Project Site Office - Consortium

Copy Number 1 2 3 4 5 6 7 8 9 10 11 12 13

Approved by Management Representative: ___________

1.0

Issue X/Y

INTRODUCTION:

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This PROJECT QUALITY PLAN of the Consortium Partner is based on guidance from ISO 9001:2000 - Quality Management Systems Requirements & specifically prepared for an EPCC Contract for PETRODAR OPERATING COMPANY LTD (PDOC) - PDOC NEW OFFICE BUILDING. Our Quality Management System is certified to ISO 9001-2000 since June 2005 and a copy of the certificate is attached herewith as Appendix-1. The purpose of this Plan is to determine and document the Management policy and Quality objectives to illustrate how the Quality Management system and practices will be followed, to achieve the objectives in line with Corporate Quality Management System Manual --------------------- (latest revision). Uncontrolled Copy of the QMS Manual Index & List of QMS Procedures attached herewith as Appendix-2. Also this PQP Illustrate the instructions to be followed by the staff to control & assure of product compliance with requirements& determine the approaches of project set-up & operated The quality Management system requirements for this project will documented with the entire system being subdivided into 4 parts. 1.

Project Quality Plan (This manual).

2. Project Method Statements – as Required. 3 Inspection and Test Plans – ITP for specific scope of work- as required. 4 Project QA procedures – as per QA procedures List. 1.1

This PQP addresses all QA/QC activities as required and provides details of Quality Assurance and Quality Control program for the Work.

1.2

DEFINITIONS AND ABBREVIATIONS:

1.2.1

Following words utilized in this PROJECT QUALITY PLAN are defined below: OWNER

The word ‘OWNER’ utilized in this document refers to ‘PETRODAR OPERATING COMPANY LTD (PDOC)’.

CONTRACTOR

The word ‘CONTRACTOR’ in this document refers to ‘HIGLEIG-CHINA JIANGSU CONSORTIUM’

Supplier/Subcontractors

The word `Supplier’ in this document refers to CONSORTIUM Suppliers / Subcontractors

Management Representative -

‘Quality Assurance / Quality Control’ Manager is defined as ‘Management Page 5 of 69

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Representative’ as per Management System Manual

Quality

Quality Representative -

For the Project, the position of ‘QA-QC Engineer’ is ‘Quality Representative’ at site for the CONSORTIUM.

Site Office -

CONSORTIUM -site office

Project Management Review -

This is conducted in Site Office weekly / fortnightly or as decided by the Project Manager / Project Control Manager/ Construction Manager/ This will also include Quality Management Review pertaining to site works.

Quality Management Review -

This is conducted in Office and the meeting is held at least once in 6 months to check ‘Quality System Implementation’ as per Corporate Quality Management System Manual.

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1.2.2

Apart from this a number of abbreviations PLAN which are explained below for clarity. 1. Project Manager 2. Deputy Project Manager 3. Construction Manager

are used in this PROJECT QUALITY -

PM DYPM CM

4. Warrantee Manager

-

WM

5. Project Control Manager

-

PCM

6. Engineering Manager

-

EM

7. Procurement & Subcontract Manager

-

PSM

8. Chief Engineer

-

CE

9. Quality Representative

-

QR

10. Planning Engineer

-

PE

11. Personnel & Administration

-

P&A

12. Logistic Manager

-

LM

13. Health, Safety & Environment

-

HSE

14. Monitoring & Measuring Devices

-

MMD

15. Quality Assurance

-

Q.A.

16. Quality Control

-

Q.C.

17. Method Statement

-

M.S.

81. Inspection & Test Plan

-

I.T.P.

19. Third Party Inspector

-

T.P.I.

20. Non-Conformance Report

-

N.C.R.

21. Correction Action Request 22. Preventive Action

-

C.A.R. P.A

23. Front End Engineering Design

-

FEED

24. Material Takeoff

-

MTO

25. Technical Query

-

TQ

26. Request for Quotation

-

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RFQ

HIGLEIG PETROLEUM SERVICES INVESTMENTS CO.

QUALITY POLICY

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4.0

QUALITY OBJECTIVES

4.1

General Statement of Quality Objectives

4.1.1 The purpose of this statement is to inform all our work force and our Customer, of our effort to assure quality as stipulated in our Corporate Quality Management System Manual, Latest Revision. 4.1.2 To emphasize that Quality Management is a fundamental requirement for all contracts undertaken by the Corporat, shall be practiced by all personnel including Suppliers in their respective activities. 4.1.3 Quality Policy is communicated to all employees by displaying on Notice Boards / Offices and is reflected in all work performed.

4.1.4 To promote uniformity in work methodology throughout the organization, irrespective of Customer requirements through procedures, which will be implemented at all times, with a view to enhancing Quality, Standard and Overall Performance of the Organization. 4.1.5 To ensure continuous Improvement by working in a systematic manner by employee participation with the formalized procedures, to eliminate / reduce defect, repair or rework. 4.1.6 To enhance Owner satisfaction by effective utilization of resources, procedures and ensure time bound completion. 4.1.7 To promote leadership skills through training and provision of resources. 4.1.8 To ensure that the Supplier’s adhere to Quality Management System Procedures, Method Statements and Inspection & Test Plans, as a part of the Subcontract philosophy to the entire satisfaction of the Consortium and owner 4.1.9 To ensure Feedback from Audits, Nonconformance Reports and respective Corrective Actions and Preventive Actions and those Owner complaints (SN) are brought to the notice of Management during Quality Management Review Meeting for effective and efficient review and resolutions sought, are incorporated in next generation procedures and implemented throughout the organization.

4.2

The project specific Quality Objectives are:

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4.2.1

To ensure that the Objectives of the Owner are fulfilled in required sequence, schedule and time for our scope of works for the Project by complying with the requirements of Technical Specifications & Drawings. As a Contractor, we are responsible for Verification, confirmation and completion of Engineering, construction, procurement, Pre-Commissioning & commissioning of the project & deliver it for usage as a product of our industry. This will be achieved by following Quality System and Procedures, HSE Requirements and other Statutory & Regulatory requirements.

4.2.2

To Ensure Safety Awareness of all personnel irrespective of Trade and understand the "Zero Accident" Policy and implement the safety program / practices in each phase of work carried out.

4.2.3

To execute the said works for the ‘PDOC New Office Building within budgetary provisions, simultaneously meeting or imposing upon Project Schedule and QA/QC requirements for the Project and work shall be executed strictly in accordance with the Project Quality Plan & Safety Plan and in accordance with the Owner ’s specified rule and meeting the regulations.

4.3

Control of Project Quality Plan and Quality System Documentation (Preparation, Review, Approval and Revision )

4.3.1

Quality Representative(QR), (Q.A) Engineer, will review, record and inform QA/QC Manager of the Consortium about the adequacy of this Project Quality Plan/ Document and Drawing Registers including Engineering Deliverables and suggest necessary amendment. The revision to this Project Quality Plan (to meet contract requirements and/or comments from Owner) will be issued by Consortium QA/QC Manager or QA/QC Engineer at site, who is authorized to amend the same in line with document control procedure. Method Statements, Inspection & Test-Plans and Procedures are to be prepared and amended to meet the Owner requirements through the Contract These shall be prepared by QC Engineers / Discipline Engineers, reviewed by QA/QC Engineer and approved by Project Manager before sending to Owner for review/approval.

4.3.2

If major changes in any document are required, i.e., Change in the methodology or approach, then it will be issued for review as Rev. A, B, C and so on. However, necessary entries shall be made in revision control page of the corresponding document. When minor amendments are to be carried out in any document, i.e., Typographical errors, reordering the contents etc, the same will be issued for approval under Issue No. (0) and so on. Page 10 of 69

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4.3.3

The QA/QC Engineer shall prepare a list of ‘DOCUMENTS HOLDER ’. They shall receive the ‘Controlled Copies’ of this Project Quality Plan and pertinent issues of other Quality System Documents through Document Control office. This will be clearly shown on controlled document distribution list .

4.3.4

The controlled copy holder shall be responsible for destroying obsolete copies of the quality system documents / Drawings / any other Documents or identifying the same as ‘Superseded’ and keeping it under safe custody if the document is deemed necessary for any future reference or financial claim purposes.

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5.0

ORGANISATION, AUTHORITY AND RESPONSIBILITY

5.1

Overall Project Organization is included as Appendix-3, which shows the overall organization structure.

5.2

General Statement on Quality Assurance

5.2.1

It shall be the individual department manager’s, responsibility to ensure that the procedures are implemented and regularly reviewed to reflect current Owner requirements & philosophy.

5.2.2

It shall be the responsibility of the QA/QC Engineer to monitor continuously the implementation of the current Project Quality Plan. In order to verify a) the necessary systems and procedures exist and b) planned & implementation Audits by QA/QC Manager & QA Engineer will be conducted on project site office.

5.3

Construction Management CONSORTIUM MANAGEMENT has overall authority and responsibility for all activities related to the Works for completion of the project

5.4

QA/QC Responsibility -CONSORTIUM) (QA/QC) Manager –Consortium, who are connected with the project for basic inputs like technical data, material, manpower, regulatory approvals and finance are referred to in this Project Quality Plan.

5.4.1

QA/QC Manager (QA/QC) Manager has overall authority and responsibility for Quality Management System Program. He is also ‘Management Representative’ for Consortium. His primary responsibilities include: -

Representing Consortium on all Quality matters pertaining to the Quality Assurance Program and he reports directly to Project Sponsor.

-

Structuring Project Quality Plan to ensure compliance with Quality requirements.

-

Reviewing the Consortium organization relationships and developing proposals for improvement.

-

Determining and reporting principle causes of Quality losses and non-conformances. Auditing various areas and Departments of the Consortium and its Subcontractor’s Quality Systems as per Audit Plans & Schedule.

-

Ensure that all special processes are effectively controlled and monitored to ensure better quality and improved reliability. Page 12 of 69

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5.4.2

-

Monitoring Consortium’s Quality Assurance Program to determine where improvements are needed and recommending appropriate corrective action.

-

Ensure that all Quality Requirements are met through Audit and expedite close out of non-conformance, if any, by close monitoring of corrective actions taken to ensure better quality and improved reliability.

-

Present overall status of Quality Assurance System Implementation through ‘Quality Management Review Meetings’ on a regular basis and take corrective actions in Q.A. System / Procedure as per Q.M.R resolutions.

Departmental Heads With regard to Quality, each Department / Discipline Manager shall be responsible for:

5.5

-

The Quality of work carried out by all personnel within their department.

-

Verifying the approved procedures are adopted within their department and that any necessary additional procedures are established, implemented, reviewed and updated as required.

-

Ensuring that all staff are adequately qualified and experienced in their discipline to perform the duties of their position in a satisfactory manner. Train them if needed to meet technological advancement.

-

Ensuring that all staff are familiar with Project Quality procedures, have ready access and implement them in the day to day works.

Authority & Responsibility (Project) The authority and responsibility of key personnel for Quality Assurance activities for the Project will be defined in this Project Quality Plan.

5.5.1

Project Sponsor The Top Management of the Tow Companies corporate to form a Consortium Board which will be the Project Sponsor for the Project on behalf of Consortium. They shall be responsible for fulfilling Owner’s objectives to realise the Project by completing our `Scope of Work’ in a sequential, timely and efficient manner by maintaining quality assurance, HSE system, Planning and Co-ordination.

5.5.4

Project Manager PM shall be responsible to the Consortium Board for successful execution of the project from award until final completion. The work areas of management directly under his control & management shall be: Project Page 13 of 69

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Management Integration. , Project Time Management, Project Scope Management, Project Quality, HSE Management, Project Cost, Risk, Procurement, Communications & Human resource Management. His responsibility shall include but not limited to : -

Represent Consortium and liaise with Owner on day-to-day matters.

-

Organize a Project Team and assign authority and responsibilities to his supporting Managers / Engineers / Supervisors in consultation with the Construction Manager (CM) / Project Control Manager (PCM)/ Warrantee Manager.

-

Timely completion within the budgetary provisions.

-

Review periodically Overall Work Plans, S-Curve and detailed schedules along with Consortium mobilization plans, and review them periodically to ensure that project performance matches with Project schedule requirements.

-

Providing technical / financial inputs, timely mobilization of manpower and equipment to project site. Mobilize and utilize the required services of construction personnel or specialist Subcontractors.

-

Review Consortium’s work schedule, manpower, machinery, production, productivity and quality.

-

Co-ordinate between various functions like administration, procurement, project control, design & development, construction and commissioning and finance, so as to ensure that target dates are set for various actions / programs and implemented in timely manner to meet the Project Schedule.

-

Ensure meeting contractual requirements for Quality, Health, Safety, Environment and other legal matters.

-

Regularly review the performance of Quality Management, Safety & Welfare Management, Environmental Quality Management by conducting review meetings / obtaining weekly reports and appraise the management of the status of implementation and ensure corrective actions, if any, to maintain / improve these systems.

-

Ensure that subcontractors/suppliers are scrutinized; short-listed and relevant approvals are obtained from Owner.

-

Obtaining necessary and relevant approvals from Regulatory Bodies through the Local Authority Coordinator.

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5.5.4.1

Deputy Project Manager Deputy Project Manager (DYPM) is Consortium’s Project Representative and shall be responsible to the Consortium PM and shall have the authority and responsibility for execution of Consortium’s Scope of Work including coordination between contractor and CONTRACTOR for design engineering and construction management, QA/QC, Health, Safety, Environmental Quality Control, and schedule control for a successful completion of the Project. His responsibility shall include but not limited to: -

5.5.5

Represent the Consortium and liaise with Owner on day-to-day matters. He will manage the project coordination between the Engineering Subcontractor and the construction Team through the Chief engineering & construction Manager. Co-ordinate between various functions like procurement dept., construction dept., technical dept., QA/QC dept. & site office Ensure meeting contractual requirements for Quality, Health, Safety, Environment matters.

-

Regularly review the performance of Quality Management, Safety & construction Management, by conducting review meetings / obtaining weekly reports and appraise the management of the status of implementation and ensure corrective actions, if any, to maintain / improve these systems.

-

Ensure that subcontractors/suppliers are scrutinized; short-listed and relevant approvals are obtained from Owner.

Construction Manager (CM) Construction Manager (CM) is Consortium’s Site Representative and shall be responsible to the DYPM and he shall have overall authority and responsibility for field execution of all CMEI activities. He shall: -

Represent Consortium in the absence of PM / DYPM on site with the sole exception of QA/QC activities.

-

Ensure drawings are properly studied and field checks are made before work is undertaken. Prepare (site) Technical Queries for discrepancies in drawings with Engineering subcontractor after field check or discrepancies/clarification in the specification/s if any.

-

Ensure ‘As-Built’ documentation and ‘Field Design Modifications is prepared by Design & Engineering Subcontractor.

.

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-

Ensure proper indents of consumables and Subcontractors / Supplier’s supplied materials and do necessary follow-up with Procurement Department through Project Control Engineer. Review that adequate resources (manpower, equipment, tools and tackles, etc.) are available as per Project Execution Plan and ensure that necessary mobilization arrangement is made through the Project Manager. - Review the performance of the work, on daily basis with Project Manager / Project Control Team and Project Services Group and ensure that corrective action is taken to ensure Construction Schedule is maintained.

-

5.5.6

Periodically check with HSE Engineer for implementation of program, review safety returns and audit / inspection reports. Ensure that adequate personnel protective equipment is provided as per trade, properly utilized and the morale of the personnel is maintained by provision of adequate health, safety and welfare conditions.

Project Control Manager Project Control Manager (PCM) shall be responsible to the CM for planning/scheduling, engineering materials control services and reporting. He will be assigned to the project site from the period from commencement of the project through to completion of commissioning and will be the person who will be contacted by the Owner in the absence of PM, DYPM and CM. He shall:-

Implement and maintain the systems and procedures for project scheduling, monitoring and reporting project execution throughout the duration of the Contract. Provide overall and detailed plans and schedules of activities and resources, which are adequate and are in accordance with the project execution plans .

-

Prepare the different level of Project Planning for activities and monitor Project Progress on Monthly/Weekly schedules.

-

Prepare Project Execution Schedules, “S” curve, Mobilization Plan for resources, look ahead schedule etc. and monitor that the mobilization, construction is being done as per plan and revise the schedule as per Project Input (including MTO) from Owner after raising alert to PM.

-

Monitor area of interface with Owner, Subcontractors and other third parties for compliance with approved schedules and general execution intent. Advise PM of any deviations and trends, which may adversely effect project execution.

-

Prepare and maintain systems and procedures for control of free issue materials from Owner – if any -. Direct and manage material control Page 16 of 69

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services for compliance with approved procedures and in a manner that ensures adequate support of effective project execution.

5.5.7

-

Prepare and maintain systems and procedures for control of scope deviations and administration of contract terms and condition in relation to work execution. Ensure adequate and timely identification, quantification and documentation of contract variations and extra work instructions throughout project execution and at Project closeout.

-

Ensure proper co-operation of activities within scope of responsibility with other execution and services groups for effective working.

-

Ensure that the purchase of project materials i.e. consumables, structural steel etc. for various Works are correctly specified with regard to scope, technical and quality matters and made available as per Project Schedule.

-

Review deliverables submitted by Subcontractors and confirm that they match with Project requirements by organizing technical review through QA/QC Engineers / Discipline Engineers and distribution to all concerned through Document Control.

-

Review ‘Material Receiving Statistics’ for Purchased Items (permanent materials) and expedite delivery of long delivery items and delayed delivery items through Project Control Engineer / DYPM.

-

Control of CONTRACTOR / Subcontractors work schedule, manpower, machinery, production and quality by regular review of reports and monitoring Inspection and Test Status. Inform DYPM/CM through PCM whenever there is slippage in any front.

-

Resolution of technical queries, concession notes, design deviation request from Suppliers by representation to the Owner and updating the status of such matters.

-

Originate and control the overall schedule for construction including verification of resources Subcontractor / Services / manpower loading in consultation with CM/DYPM and inform PM for necessary mobilization.

Engineering Manager The Engineering Manager (EM) shall be responsible to the CE He shall ensure Quality Assurance in Design, Development, Production/Fabrication Installation and Commissioning of facilities. He shall be responsible to ensure the implementation of Engineering Subcontractor’s Design Control Procedure during all stages of Design & Development. He shall; Page 17 of 69

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-

Be responsible to provide formal and systematic guidelines to all concerned to control and verify design and detailed engineering related activities of project in order to meet Owner stated and implied needs.

-

Be responsible for activity assignment to Consortium personnel for initial survey and site data collection, which will form the basis of design inputs.

-

Plan and Organize technical interface co-ordination.

-

Identify design input, design outputs, design review, design verification, design validation and design change control.

-

Preparation of Project Co-ordination Procedure with Owner Be responsible for Document, Drawing control and Supplier data control.

-

Be responsible for Progress Report for Design and Detailed Engineering activities indicating areas of concern, progress statistics, progress curve, drawings & documents status report, backlog activities and their anticipated date of completion.

-

Be responsible for review of all material requisitions and package subcontract documents prepared by Design & Development Subcontractor-if any for onward approval by Owner and issue to Subcontractor/Suppliers.

-

Be responsible for review of all documents, drawings, data, and technical evaluations, prepared by Design & Development Subcontractor before issue for approval of Owner and/or purchase order.

-

Be responsible for making specific sketches, write-ups for obtaining work permits, statutory approvals etc., as required during the construction of project.

-

Be responsible for ensuring technical conformity for materials that required (FAT), supplied to project site with necessary third party inspection reports as applicable and witness factory acceptance test and site acceptance test with discipline engineers.

-

Be responsible for preparation of necessary documentation /construction specifications for specialized work.

-

Resolve day to day matters pertaining to incomplete information or ambiguity in specifications / drawings and field problems and if necessary, forward unsolved problems to CE / DYPM & PM for taking up in Owner’s Progress Meeting for resolution& make a required coordination to raise (STQ) with CM , prepared by Supporting technical proposals . Page 18 of 69

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-

Amend specifications/drawings etc. in line with approved design concession/deviation requests approved by Owner and maintain necessary and relevant data for submission on ‘As-Built’ documentation.

-

Be responsible for making specific sketches, write-ups for obtaining work permits, statutory approvals etc., as required during the construction.

Amend specifications/drawings etc. in line with approved design concession/deviation requests approved by Owner and maintain necessary and relevant data for submission. Engineering & Construction Coordination -

5.5.7.1

The Engineering & Construction Coordination shall be responsible to the DYPM for coordinating between the Engineering Subcontractor through Chief Engineering CE and the construction Manager CM for matters related to their discipline within the scope of work shall be responsible for Review, expediting and coordination of the engineering drawings/ specifications and the procurement of material for ensuring timely delivery and conformance to project AFC (approved for construction) drawings/ functional specifications. 5.5.8

Procurement Manager The Procurement Mang.shall report directly to Project Manager (PM) with Cc to CM. He shall be responsible for timely procurement of materials and arranging subcontracts / services as per the schedule requirements of the project. He shall: -

Be responsible for RFQ in consultation with Engineering Manager.

-

Be responsible for preparation of Procurement Schedule in consultation with Planning department as per project specification.

-

Be responsible for evaluation and pre-qualification of vendors and submit the technical evaluation in consultation with Engineering Manager and Project Manager for approval.

-

Be responsible for floating of enquiries and receiving quotations.

-

Be responsible for Techno-commercial evaluation in consultation with project team.

-

Be responsible for cost effectiveness of procurement of all materials.

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5.5.9

-

Be responsible for placing of orders and expediting for effective and realistic delivery.

-

Be responsible for ORGANISING and scheduling Third Party Shop Inspections at vendor’s shop and keeping track of inspection status and informing QA/QC Manager.

-

Organize third party inspection / audit on vendors of products depending on criticality class and inspection level given in technical specifications and Material Requisition.

-

Be responsible for arranging all shop test certificates from vendors.

-

Be responsible for the release of materials for transportation and handling, shipping and custom clearance at sea port / airport and delivery to site.

-

Be responsible for providing timely input to all sub-contracts or services and monitoring their performance and cost.

Logistic Manager –Material Control Manager Logistic Manager (LM) shall be responsible to Project Control Manager (PCM) and shall have the authority and responsibility for material control at construction site and reports to CM & PCM for Non-availability, shortage, and damage of receipt. He shall: -

Coordinate with PCM/PE/CM and QA/QC Manager to get necessary procedures, data sheets and formats for material control at construction site for purchased material for permanent installation.

-

Supervise storage including preservation as deemed necessary as per Project Specification or Manufacturer’s recommendation. Make arrangement of field material control and handling plan depending upon availability storage area and facilities and job requirements.

-

Provide report and request as to anticipate material shortage to PCM and CM to avoid possible delay of construction work.

-

Prepare indents of the consumables, services required for execution of the project and send to the Procurement Group through CM.

-

Co-ordinate with purchasing Section to get necessary material requisitioned for the project execution, e.g. tools / tackles, consumables.

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-

Visually inspect and co-ordinate regarding technical matters with Q.C. Inspector QA/QC Engineer and / or discipline engineer and segregate non-confirming material in quarantine area. Maintain material receipt inspection records.

-

Maintain records of receipt, issue and certificates of conformity, calibration data and batch test certificates for various material received by him, certification, wherever necessary. Copies of necessary records mentioned above are handed over to Q.C. Department / Discipline Engineer for review / records.

-

Inspect visually and report damage, deficiency / Non-conformance in the material receipts and consumables and other local purchase items to CM.

-

Make arrangement of Material Control and Handling plan depending upon job requirements and organize suitable storage facilities, closed storage, air-condition storage, open shed or free-hold level plot, pipe dump, etc.

-

Organize for Receipt, Inspection, Storage, Preservation and issue of equipment, pipes/fittings and other materials.

-

Supervise storage / stacking including preservation of specified components like Instrumentation Control items.

-

Coordinate with applicable specialist for inspection all incoming supplier equipment / materials visually and report damage, deficiency / Nonconformance in the material receipts, consumables and other local purchase items to PE/PCM/PM.

-

Ensures Product Identification and Traceability of materials till items are fabricated or erected and maintain relevant data till final hand over in consultation with QA/QC Manager.

-

Maintain records of receipt / issue, Certificates of Conformity, Calibration Data, Batch Test Certificates and Material Safety Data sheets for materials like paints, resin and various other materials received by him as applicable. Prepare indents of the consumables, services required for execution of the project and send to PCM after approval by CM/Field Engineers.

-

5.5.10

Coordinate with purchasing function to get necessary material requisitioned for the project execution, e.g. tools/tackles and consumables.

HSE Manager HSE Manager shall be responsible to (PM) and he shall have overall authority and responsibility for Safety, Health and Welfare at site. He shall: Page 21 of 69

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-

Coordinate with Owner, Discipline Engineers, Subcontractors and the workforce in general for overall safety practices to be followed during execution of this Project. Formulate Site Safety Committee with representatives from all working group and conduct regular meetings.

-

Plan, organize and co-ordinate basic induction training and orientation given by Safety supervisor and maintain status report of each individual.

-

Ensure that the supervisory staff and workers are adequately trained in the process of implementation of Environmental Control by lectures and constantly reminded by the use of Signs and Posters displayed at prominent places of work.

-

Direct and supervise Safety, Health, Welfare and Environment related matters as per local regulations, COMPANY’s Project (HSE) Procedures and Contractor’s approved HSE Plan for Contractor’s personnel and for Subcontractors.

-

To confirm that all plant lifting equipment, tools / tackles and lifting belts for use at work are examined and tested by competent authorities and periodically checked for validity of certificates to ensure reliability and Safety.

-

Necessary and adequate information about the use of personal protective equipment are available to the concerned operators.

-

Co-ordinate, conduct and report site safety related Induction Training; organize weekly Tool Box Talks to improve understanding of workforce about risk-potential / control / elimination.

- Ensure that ‘Material Safety Data sheets’ for paints, resin and other chemicals utilized in the Project are obtained and necessary copies are available to the concerned supervisory personnel for use to understand possible potential hazards / mitigating measures and emergency response scheme. - Initiate and supervise safety drills - fire prevention / fire extinguisher / electrical safety, etc. -

Monitor and report site safety activities, and investigate incident / accident whether ‘major’, ‘minor’ or ‘near-miss’ condition.

-

Attend regular meetings with Owner’s representative to discuss and coordinate interface / safety related problems with other Subcontractors working within the same area.

-

Explore all possibilities of improving on safe conduct of work by discussion, surveillance, site audit and inspection. Inform Supervisory and Management personnel during weekly safety review meetings about

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the past mistakes and future plan to improve and secure the safety, health and welfare of persons at work.

5.5.11

-

Prepare Emergency / Contingency Plan for HSE .

-

Obtain necessary approval from Owner and/or other regulatory bodies and ensure that work is not held up for work of permits / approvals.

-

Regular safety inspection and audits are carried out at work places and necessary corrective action are taken on priority basis.

-

Necessary medical facilities / clinic / first aid, if required are set up for site and regularly inspected for implementation of Health and Welfare Plan.

QA/QC Manager QA/QC Manager (also called Management Representative) shall be full time and responsible to Project Manager (PM) and he shall have overall authority and responsibility for QA/QC programs at site. He will have sufficient authority and organizational freedom to achieve ‘Quality Objectives’ on site and his responsibility will be so placed that the Project Schedule shall not compromise quality. Consortium shall identify the location of its quality organization, the degree of independence from the performing organization, and the authority of the individuals assigned quality functions. He Shall: -

Coordinate with Owner’s QA/QC representative and QC Inspectors, Subcontractors, Third Party Inspection Agencies and Mechanical Testing Laboratories.

-

Prepare and obtain Owner approval of Method Statements, Inspection and Test Plans and Procedures as per Quality Management requirement of the contract.

-

Review Controlled Document Distribution List at site office and ensure document distribution through Document Control section.

-

Check periodically that pertinent issues are available to those responsible for carrying out the work and its quality.

-

Monitor proper distribution of relevant procedures as Document Distribution Matrix, drawings, specifications / method statements to discipline engineer / superintendent / foreman periodically.

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-

Organize and monitor the Stage Inspections required at Equipment Subcontractor’s works as per the approved ITP.

-

Organize third party inspection / audit on Subcontractor’s of products depending on criticality class and inspection level given in technical specifications and Material Requisition.

-

Schedule & conduct Internal Audits and External Audits on Suppliers.

-

Coordinate for Third Party Inspection (if any) at Subcontractor’s shop and ensure proper certifications as per inspection levels and Project Specification requirements / material requirements.

-

Inform Owner’s QA/QC Department regarding NCR Status, Audit and Audit Deficiencies and required Corrective Action, on a regular basis.

- Review QA/QC requirements periodically, check Inspection and Test status and ensure that corrective actions are taken on NCR conditions effectively (leading to NCR close-out) and these conditions do not re-occur during the Project duration. -

Continuously update all Quality System records &confirm that Quality Program is being effectively implemented and appropriate actions are taken to correct deficiencies.

The Monthly reporting Format attached as Appendix-4. 5.5.12

(QA) Engineer Quality Management System calls for the presence of QA Engineer for ensuring compliance to the Quality system. The QA Engineer (Audits) shall report to the QA/QC Manager. He shall: -

Review the project specifications on regular basis, especially when revisions are made, to assess the effect on cost and time w.r.t present Procedures and raise Technical Queries (TQ) and associate him to resolve the same.

-

Organize special training programme related to ISO 9001:2000 – Awareness and Implementation on regular basis and monitor Measurement, Analysis and Improvement Programme including Continual Improvement .

-

Organize special surveillance on Customer property and sort out discrepancies, if any, by raising Technical Queries and discussion with Customer’s representative.

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5.5.15

-

Prepare Internal Audit Schedule & conduct audits within the organization as well as on Subcontractors as per programme, provide feedback to the Management on audit findings and follow up on closeout of Non-conformities (if any), that will be done with coordination of QA/QC Manager .

-

Carry out surveillance on various activities during execution of the project and ensure implementation of Quality Management System in order to meet Quality requirements for the project and cross check on QA/QC activities carried out by Quality Inspectors.

-

Ensure that Non-conformance reports raised are followed up until final Corrective actions are closed out of NCR.

-

Inform QA/QC Manager regarding NCR Status, Audit and Audit Deficiencies and required Corrective Action, on regular basis.

-

Assist QA/QC Manager in External Audits.

Quality Control Engineers ( QC ) The Project Quality Requirements call for presence of QC Engineers / Inspectors and they shall report to QA/QC Engineer –site. As such responsibility for Quality rests with Engineers and Supervisors as first line and with QC Engineers / Inspectors as second line. The QC Engineers / Inspectors shall be fully aware of Project Specifications, latest approved quality documents like Q.C. Procedures, Method Statements, Inspection and Test Plan, i.e. Project Requirements and have sufficient experience in the field of work undertaken. They shall -

Issue RFI for in process activity .

-

Random check on incoming materials to check proper certification / verification, inspection records to ensure product identification and traceability to confirm that (LM) is following the system and involving concerned discipline engineers.

-

Assure that all inspection and test outlined in the Inspection and Test Plan are carried out. They shall coordinate Inspection and Test activities with Owner’s Engineer / Inspectors and ensure that all requirement of ITP’s like Hold, Witness, Monitoring or review point are satisfied and the necessary certification is signed by all. The original shall be given in QA/QC department and copy handed over to Discipline Engineer /Owner Representative as applicable.

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-

5.5.16

Collect, segregate, file and maintain Quality records through Documentation Clerk and prepare Inspection & Test Status on regular basis.

Document Controller Document Controller works on site office shall be responsible for Receipt, Monitor, File, and Index, distribute and maintain a database with the revision status of various documents received/issued and to/from Engineering Subcontractor, Subcontractors, Suppliers and Owner. He shall also responsible for internal distribution of all quality documents, Drawings, Specifications, Supplier documents etc., as per the Document Distribution matrix. All the correspondence to / form the Owner and Suppliers, i.e., Letters, Tele faxes etc. will be handled, monitored and distributed by the Project Manager secretary. An Incoming and Outgoing correspondence log shall be maintained either in the form of a soft copy or hard copy.

5.5.17

Engineer, Supervisor, Foreman Engineer, Supervisor, Foreman shall be responsible to the CM and they shall have authority and responsibility for schedule control, quality control and HSE control on assigned work at project sites. These are direct supervisory positions and the span of control in each case will be as defined in this Plan, but the primary functions are similar. Discipline Engineers in particular have to liaise with QC Engineer / Inspectors in the preparation of Inspection and Test Plans. He shall: -

Prepare and execute detailed construction plan including detailed schedule, manning plan, construction equipment plan, etc. for day-to-day activities and advise PCM/PE accordingly.

-

Review and plan according to the Level III Construction Plan for his discipline (Scope) for the week/fortnight.

-

Direct and supervise subcontractor, if any.

-

Perform quality control of the assigned work in line with Method Statements & Inspection and Test Plans approved by Owner.

-

Direct and supervise Subcontractors in their area of work.

-

Take corrective action on “NCR” and audit deficiency as soon as the same is known and ensure that the action is completed along with necessary documentation required for NCR CLOSE-OUT. Also ensure that the conditions / practices leading to NCR are checked and controlled so that these will not be repeated.

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5.5.18

Prepare technical queries for discrepancies in drawing after field check or discrepancies or clarification in the specification as well.

Commissioning Manager The commissioning manager shall be responsible to the project manager. He shall be overall responsible for planning the commissioning activities in co ordination with the PCM and the CM in the sequential manner. He shall:

5.5.19

-

Verify all the completion records before taking up systems/equipments for commissioning.

-

Verify the compliance to the design of the systems and prepare proper commissioning schedule.

-

Nominate the responsibilities to the commission team for managing the handover and take over for commissioning of systems.

-

Organize for startup / checkout testing and Owner training along with the commissioning activities.

-

Control the total commissioning operation through co ordination with the various subcontractors.

-

Carry out pre functional and functional testing of all equipment and system to be commissioned using the procedures designed for each system / equipment.

-

Control the preparation of commissioning documentation required for operation and maintenance of the systems/ equipments.

-

Review the design against the performance efficiency designed to be delivered by the system/ equipment

Delegation of Authority As mentioned above and in this paragraph of PROJECT QUALITY PLAN each personnel have authority and responsibility for the functions assigned to him. However, he may delegate his duties to assigned individuals within his relevant Section as appropriate. “The Responsibility for Quality rests with you and not only with the staff operating the Inspection System. It is the total commitment of the group that makes the Quality Management - 100 percent successful.”

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6.0

QUALITY PLANNING

6.1

Consortium will submit QA Procedures / Method Statements / Work Instructions that are referenced in ITP and /Quality Plan which define how individual elements of the work are undertaken, the personnel responsible, the implementation of inspection/verification activities and testing requirements. The Project Specific Procedures and Inspection & Test Plans (Quality Plans) will be prepared after studying all Project Specifications, Codes and Standards spelled out in I.T.P., Project Specifications and Drawings for the Contract and good engineering practice. Responsibility for preparation, review and approval (including revision) has been identified in Para 4.3.1 of this Project Quality Plan the same will be followed. Project Specifications, Documents and Drawings listed in the “Documents & Drawings Register” will be used in conjunction with CONSORTIUM's Project Quality Plan for effective execution of the project and maintaining high standards of Quality in all operations.

6.2

Quality System Documentation

6.2.1

As explained in the introductory paragraph, CONSORTIUM’s organization is certified to ISO 9001 – 2000 with Quality Management System implemented through their corporate Quality Management System At the project site the following documents will be generated for effective implementation of QMS. (a) Project Quality Plan It is the master document that addresses the project specific quality requirement. (b) Index of Quality System Procedures (Including Quality Assurance Method Statements / Work Instructions to be submitted ).

/

(c) Inspection and Test Plans - (For Project specific scope of Work to be submitted ). Project Specific activity-wise proposed QA Procedures, Method Statements / Inspection and Test Plans for this Project has been prepared and given in Appendix-5. However some of these documents may be combined or renamed as per the actual project requirements, after the award of contract. All Quality documents for the activities to be started after award of contract shall be submitted on priority. The update of actual submission and approval status shall be incorporated as part of the “Document and Drawing Register”

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Consortium will maximize utilization / modification of existing established document rather than preparing new every time. Accordingly the documents listed shall be prepared to suit the project specific requirements. 6.2.2

6.3 6.3.1

The QA Procedures, Method Statements and corresponding Inspection and Test Plan will be prepared by QA/QC Engineer/Discipline Engineers reviewed by QA/QC Manager and approved by Project Manager before submitting for review of Owner. The Inspection and Test formats, ‘Request for Inspection’ or any other format for ‘Inspection & Test Status’ as required by the contractual requirement and Project technical requirement also will be submitted for approval. QUALITY MANAGEMENT System Outlines The following are summarized requirements of Quality Management System and details of WHO, WHAT and HOW are defined in HPSIC’s written Quality Management System Procedures or Operational or QA Procedures, Method Statements (M.S) and Inspection & Test Plans (I.T.P) as applicable.

6.3.2

Quality Management Responsibility

6.3.2.1

Quality Policy, Quality objective have been defined in previous paragraphs in this Project Quality Plan.

6.3.2.2

The organization structure, responsibilities and authority of project-based personnel have been defined in this Project Quality Plan.

6.3.2.3

Overall Quality Planning for the Project is being done in line with the guidelines given as per Quality Planning philosophy in Quality Management System Manual

6.3.2.4

Resource Mobilization & Infrastructure Identification of Resources required for execution of a contract shall be done by Project Manager in consultation with Consortium Project Management Team and documented in:

 

The PROJECT QUALITY PLAN. Project HSE Plan. Project Planning Process group for Project Schedule (Manpower, Equipment) &Project Time schedule Execution Plan & method statement Commissioning procedure

These documents determine the Project input and resources. The responsibility for mobilization rests with: Page 29 of 69

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6.3.2.5

-

Corporate Human Resources Department (HRD) for skilled/unskilled personnel, including provision of proper work environment meeting the statutory & regulatory requirements (Labor Law, Contract Requirements etc.,)

-

Project Control Group for infrastructure requirements such as: Storage & Fabrication Facilities, Camps and associated utilities,

-

Maintenance Department for mobilization of Plant and equipment, certification, refurbishment as per the preventive maintenance schedule and breakdown maintenance.

-

Purchase Group for  Identification & Mobilization of Suppliers  Permanent materials  Consumables  New tools and tackles  Hire / Purchase of equipment.

-

Co-ordination of all these is done by PM to ensure proper / timely mobilization of resources / infrastructure.

-

Status of mobilization of manpower (category-wise) and equipment will be maintained, updated and monitored by PCM.

Training Consortium maintains a system of training staff and workers. Consortium shall ensure that personnel performing activities affecting quality are trained, qualified or certified based on education, training, experience or examination, including training on the applicable projectspecific Quality Plan. Records will be maintained to demonstrate that personnel are qualified or certified. All staff and workers will have specialist training according to trade. They will receive appropriate instructions and will be tested in accordance with the recognized standards or by recognized institutions e.g. – -

Safety Induction course by Safety Officer Emergency Safety Procedure by Safety Officer, if any Tool Box Topics by Safety Officer / Supervisors Crane driver, Operators, Heavy Vehicle Driver etc. by regulatory authorities. Welders by Consortium in the presence of Owner Representative. Training of process/commissioning for operation and maintenance staff shall be provided to consortium & Owner personnel’s –if required during installation and commissioning stages . Page 30 of 69

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Record of all training carried out and certificate issued will be kept in concerned departments and a copy will be maintained by Adminstrator Manager in the corresponding employee’s personnel file. Only personnel with valid certificates / qualification shall be allowed to perform the specialized skill work. Similarly QA/QC Manager on site shall ensure that all Foremen and Engineers working on site are aware of our Quality Policy, Quality Objective for this project and QA & QC requirement of the project by carrying out lectures / discussion of Quality Assurance procedures / inspection and test plans and explaining the needs / specified requirement of the Project, organizing Quality Awareness Programs organized internally . 6.3.2.6

Quality Management System Implementation Quality Management System implementation guidelines are covered under Appendix-6. Quality Representative at project site shall take cognizance of this requirement and ensure effective implementation.

6.3.2.7

Management Review (Project Level) A Project Management Review Meeting conducted every month will include Monthly Progress, Quality Management, Health & Safety and Environmental Quality functions. Necessary corrective and preventive actions will be taken as per guidelines in individual plan and decisions/resolutions made during meeting.

6.4

Document Control The Consortium shall establish and maintain a system, which shall provide for the control of approval and issue of all documents, together with methods of changing/modifying of this system. The Consortium shall be responsible for operating a Library established for the storage of all records such as drawings, specifications, procedures, and all other relevant reference documents. The Library shall consist of suitable secure cabinets that prevent deterioration or damage to documents.

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All incoming correspondence from Owner & Suppliers, i.e. Letters, Telefaxes etc. shall be received by the PM secretary, verified, date stamped and entry made in the Incoming register and circulated to all concerned as marked by PM / CM / PCM as Documented in the Document Control Procedure. All incoming documents shall be received by the DC department, verified, stamped and logged in to the Incoming document register and distributed as per the predefined Internal Drawing & Document Distribution List. Document Distribution List format is included as Attachment of Appendix-7. A Master Drawings & Document Register will be prepared including the Engineering Deliverable generated for the realization of the project. The Drawing & Document Register Format attached herewith as Appendix-8. Whenever new or revised specification / drawings are received, they will be entered in Master to reflect revision number, date of issue (on document), date of receipt at site and issued to the relevant discipline manager / engineers / inspectors and QA/QC Engineer as per distribution matrix for study and implementation. All the copies of superseded specifications / drawings / procedures, etc., shall be destroyed or be marked “VOID” or “SUPERCEDED” and they may be kept in separate files if required for future reference. All outgoing documents shall be issued with a unique serial number, revision designator with date of preparation / review / approval and listing of all documents shall be maintained in the Document Control Log / Drawing Index / Procedure Index / Method Statement Index / Inspection and Test Plans matrix. The numbering system for document is to be identified in the Document Control Procedure. Any request for change to the Quality System Documents shall be made to the original approver, unless authorized or delegated in line with Para 5.6.19 and all subsequent revisions have to be authorized. The responsibilities for preparation, review, and approval including revision have been outlined in this Project Quality Plan. Document Submittal log for procedures, Method statements, ITPs etc., will be updated weekly to confirm the status of submission, comments and approval etc. All documents issued for construction purpose shall be marked "AFC"/ “IFC”. These shall be approved by the PM / PCM. The numbering system and approving authority for various documents / drawings shall be as established by Consortium according to numbering system procedure Transmission of Drawings / Data Sheets / Procedures and other Quality System Documents / Specification shall be done with a ‘Document Transmittal' Form, a copy of which shall be signed by the receiver and returned to the originator.

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6.5

Quality Records The Consortium will prepare procedure for identification, collection, indexing access, filing storage, maintenance and disposition of Quality Records to demonstrate the effectiveness of the quality system and the quality of the product. All batch certificates, Lab certificates, Daily Inspection Reports, NDT Inspection Report if any, Performance / Procedure Specification records, Audit Reports, NCR Status log, etc., constitute as Quality Records. The records will be produced in line with specified requirement of the project specifications and Inspection and Test Plan for each discipline as per scope of work. Such records signed by Discipline Foreman / QC Engineer and certified by Owner constitute as Quality Records. Each form utilized shall be uniquely identified and bear the appropriate authorization signatures by Discipline Engineer / QC Engineer. List of Formats to be used for the project will be attached to the method statement. Quality Records shall be filed and Indexed at a centralized location under the control of QA/QC Manager, The Original Quality Records shall be kept safely in an orderly manner and shall be accessible to the personnel authorized by QA/QC Manager. The records shall be compiled in accordance with requirement of final submission by Owner. Compilation of Reports shall be performed on a daily basis. All inspection reports shall be checked and filed accordingly. The Inspection reports shall clearly state, whether the subjected activity is accepted or rejected. The reports shall be available for Owner Verification/review at their discretion. Final package and handover shall be agreed by Owner. Systems Operations Manual shall be developed as part of the Engineering Deliverables (if stated in the contract) by the Consortium.

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7.0

PROJECT REALIZATION PROCESS

7.1

Planning for Product Realization Process The Consortium will prepare the Project Mobilization Schedules, Project ‘S’ curve, Level-III & Level-IV Schedules etc., identifying the resources required for Engineering, Material Management, Construction and Commissioning activities to meet the scheduled completion date as per Contract. The Procurement Management, Quality Management, and HSE management will be organized by The Consortium. The Design & Engineering will be managed by The Consortium. The schedules will be submitted to the Owner for their review and comments. On the approval of the Schedule and the proposed ‘S’ curve, The Consortium will monitor the project progress. The project schedule and progress will be reviewed on weekly basis and necessary actions will be initiated to adhere or exceed the planned progress requirements. As this is an EPCC Project, meeting the schedules and achieving the progress is fully depend upon the Design & Development, Procurement and delivery schedule of the Long Lead Critical items. Quality system documents will be prepared. Stage wise , inspection will be carried out as per the approved Inspection and test plans. All inspection records, necessary & relevant documents generated / identified in various stages of product realization will be compiled progressively for final Documentation submission.

7.2

Customer Related Process & Communication After award of the contract, a post-award review was performed by Project Group i.e. Project Manager (PM), Construction Manager (CM), Project Control Manager (PCM), QA/QC Manager and any other functions as required to get familiarity and understanding with the requirements specified in the contract. PCM has full access to the pre-award contract reviews, bidding stage documentation, clarifications and qualifications etc. during project handing over to Execution Group. PCM has the responsibility of coordinating the result of the Contract Review and submit any findings to Owner through PM/CM. When resolution of technical query (TQ), Site Instructions (SI) or letter for clarification, confirms that additional material, manpower, equipment hours Page 35 of 69

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will be spent to carry out the work as against stipulated in bid, then amendment to contract may be required. As applicable by the contract conditions, PCM has to substantiate claims for variation order - direct cost impact / time impact for the Consortium’s scope of work to Owner. The extra work may be due to Consortium’s increase scope of work or Owner’s change of Process Design / Technical specification etc. Obtaining ‘Change Request’ from Owner is the responsibility of Project Control Manager. All documents produced during the post-award contract-review shall be filed by PCM and accessible for all concerned personnel.

7.3

Design & Development

7.3.1

CPE has been assigned as the “Engineering, Design & Development Subcontractor, who has a certified QMS conforming to ISO 9001-2000. A copy of the Certificate attached herewith as Appendix-1. The Engineering, Design and Development Sub Contractor is responsible to carryout, Design & Development, Process Design and Detail Design.

7.3.2

A Project Specific “Engineering Contract Quality Plan” developed by Engineering, Design & Development Subcontractor will be submitted to Company for Review and approval.

7.3.3

Design Engineering Subcontractor shall also be responsible to study the criticality rating for all Project Permanent materials used on this contract as per COMPANY Project specification. Design Engineering Subcontractor will cover this aspect under Engineering Project Quality Plan Prepared after the award of the Contract. This Procedure will be reviewed and submitted for COMPANY approval.

7.3.3.1

The Criticality Rating derived shall be used to determine the inspection, test and witness requirements. The Criticality Rating shall be used to determine the requirements for the following:        

Additional Vendor Quality Appraisal Vendor Design Approval Vendor Quality Plan requirement Reliability and maintainability Quality control surveillance Inspection and tests Documentation Material Traceability

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7.3.3

The Criticality Rating for each procurement package shall be assigned by the Design Engineering Department / contractor and authorized by the Contractor Representative. When the Criticality Rating has been determined it shall be normally remain fixed throughout the project cycle. However, any design changes shall be reviewed to assess if the Criticality Rating requires amendment. Any decisions concerning the acceptability of nonconforming items shall take account of the Criticality Rating assigned. Chief Engineer (CE ) through the Engineering Manager (EM) is responsible for Coordination & liaise with the Design Engineering Subcontractor as well as the Owner for Design Control i.e. Design & Development Planning, Input, Output, Review, Design Verification. For preparation of as built drawing, construction surveyors and draftsmen shall red mark the drawing and get them approved by execution team of the Owner and send them to Design Engineering Subcontractor for preparing final As-Built Engineering Drawings.

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7.4

Purchasing Process

7.4.1

Project Control Manager at site will co-ordinate with Procurement and Subcontract Manager at site. He shall be responsible for implementation of the system and would be reporting to Project Manager.

7.4.2

All material received shall be visually checked by LOGISTIC MANAGER (LM) against the order and an inspection performed either by himself or concerned discipline engineer or QC Inspector to establish conformance to Purchase Order / Purchase Requisition. Necessary documents received with the material shall be kept by (LM) and copy sent to PCM and Procurement & Sub-contractor Manager through PM. The Original Batch Test Certificates / Certificate of Conformity or Calibration Certificates are handed over to QA/QC Engineer, Copy of it retained in the stores for onward submission / approval by the Owner, if any.

7.4.3

Supplier shall be informed immediately of any discrepancies such as excess, shortage and damage or non-conformance found between the supplies and order.

7.4.4

Evaluation and selection of Supplier The basis of this aspect is covered under the Quality Management System Procedures.

7.4.5

All sources of permanent project installation materials purchased by the Consortium and used on the project shall be approved by the Owner or selected from the Approved Supplier List provided / Approved by the Owner, before any purchasing is done.

7.4.6

New Supplier’s capability to supply Product / Services shall be reviewed based on his company profile, Owner’s approved supplier lists, Quality & Environment Management System Certification. Qualified Suppliers’ names shall be included in ‘Approved Suppliers List’ after techno-commercial review as required.

7.4.7

Request for Quotation issued to supplier by Purchase Manager shall include three requirements e.g. Material Requisition, Quality Requirement, and Technical requirements, apart from commercial, contractual requirements. For standard components, the certificate of conformity / batch test certificate etc. will be issued depending on criticality level of the item supplied and Inspection and Test requirement.

7.4.8

Consumables, tools / instruments other than permanent plant installation materials requisitioned by (LM) on behalf of various discipline engineers, Page 38 of 69

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PE/QA-QC for the project are checked by Discipline Engineers to confirm that these are meeting Project Technical requirements, project standard for each type of item, requirements of Batch Test Certificate or Certificate of conformity and calibration certificate and the same should be incorporated in the material / purchase requisition purchase order. 7.4.9

Each Subcontractor utilized in the project shall be required to develop a Quality Management System and conform to the Consortium’s ‘Project Quality Plan’ and depending on his scope of work, he shall be asked to prepare Method Statements and Inspection & Test Plans in accordance with project quality requirements and technical specifications. the Consortium shall ensure that all necessary and pertinent requirements established by the approved QA program are imposed on all suppliers and subcontractors and accepted by these parties.

7.4.10

All material received shall be visually checked by (LM) against the order and an inspection performed either by himself or concerned discipline engineer or QC Inspector to establish conformance to Purchase Order / Purchase Requisition. Necessary documents received with the material shall be kept by (LM) and copy sent to PCM and Procurement & Sub-contractor Manager through PM. The Original Batch Test Certificates / Certificate of Conformity or Calibration Certificates are handed over to QA/QC Engineer, Copy of it retained in the stores for onward submission / approval by the Owner, if any.

7.4.11

The Supplier shall be informed immediately of any discrepancies such as damage, shortage or overage or non-conformance found between the supplies and order.

7.4.12

Procurement QC Co-ordination A) Supplier concession request and technical queries These requests and queries will be received by Procurement and Subcontract Manager, who shall forward them to the Engineering Manager, who shall review and send them to Engineering Subcontractor for technical review, clarification or resolution. Based on their output, (i)

Either supplier will be asked to check his query / request in the light of alternative suggested by Design Engineering Subcontractor and resubmit the proposal for review and final approval.

(ii)

Or when the Design Engineering Subcontractor accepts them as “essential” or “necessary” for resolution with Owner, the concession request and technical queries will be forwarded to the Owner by Page 39 of 69

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Engineering Manager along with necessary back-up data provided by Suppliers, Design Engineering Subcontractor’s review etc. and follow up for clarification or resolution. (iii)

Once clarified or approved by the Owner, the loop shall be completed by Design Engineering Manager – by sending the documents to Design Engineering Subcontractor for incorporating necessary and relevant changes in the Material Requisition / Technical Specification etc.

(iv)

The revised material requisition / technical specification and / or the clarified / approved concession request and technical queries shall be forwarded to supplier through Procurement Engineer. If necessary, the Purchase Order may be revised accordingly and issued to supplier for compliance.

B) Supplier drawings, document and data This shall follow the same route as done in the supplier concession request and technical queries, except for following.  When they significantly affect other procurement or construction activities. In this case, the copy of the documents shall also be sent for review of site conditions, cost and time. The comments from them shall be included in the forward to Design Engineering Subcontractor as well as internal review. Further process of resolution, discussion and clarification will be on the same lines as para (A). The detailed flow sheet will be prepared in consultation with Design & Engineering Subcontractor on award of the contract. 7.4.13

Minimum Shop Inspection and Certification requirements shall be specified to Supplier as mentioned in basis of offer. Supplier shall prepare the ITPs detailing all stage wise Inspection and Testing requirements and submit to the CONTRACTOR for review and approval. Supplier shall furnish material certificates in accordance with the requirements of Project specification or as specified in the Purchase Order. The stage wise inspection & Test status and the progress of works at Supplier shops till the dispatch with site delivery schedule shall be provided to the Site Management on a regular basis. This is very critical to enable the Project Management to revisit the project executions plans and take necessary actions accordingly. The Procurement & Subcontract Manager at site shall prepare a project specific Procurement, Expediting and Subcontract procedure.

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7.5

Construction Process A list of Construction Procedures, Method Statements, ITP’s to be developed for the project were listed in the Quality System Procedures Index. The data regarding the Inspection & test status and Records will be updated and maintained in computer database.

7.5.1

Validation of Processes The validation of the process shall demonstrate the ability of the product output to achieve planned results. Some of the examples for Process Validation are detailed below: -

Hydrostatic Leak Test / Pneumatic Leak Test for verifying of the Integrity of installed piping network before commissioning.

-

Electrical and Instrumentation loop checking for the validation of the Electrical and Instrumentation Circuits before energizing and charging the Circuits.

-

Procedure Qualification Records for Validation of Welding Procedures, PWHT Procedures, NDT Procedures etc.

-

When Process Validation is required, Pre-qualified Procedure will be used by the Consortium wherever possible. New procedures shall be qualified whenever such previous records are not available. This will be applicable, but not limited to- if any - the Welding Procedure Specification, and Welder Performance Qualifications, Concrete / Grout Mix designs and similar specialized trades.

For the pre commissioning and commissioning activities as per contract, wherever applicable Suppliers shall be contacted for their availability based on the schedule dates. After the confirmation of availability of the supplier representatives the information will be provided to the Owner for the confirmation on the suitability of the proposed dates. On the confirmation from the Owner, Consortium will prepare a detail plan of Training, pre commissioning and commissioning activities. Applicable Training, O&M & Job Manuals, Commissioning procedures & Check Lists will be prepared and made available to all the concern. 7.5.2

Identification & Traceability

7.5.2.1

All incoming products and materials shall be tagged, or individually identified, and a record kept of its location by (LM) in line with the requirement of the project specification and approved Inspection and Test Plans (as applicable) and material requisition prepared by LOGISTIC MANAGER.

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If material has been previously tagged by a Supplier, then these shall remain for traceability to supplier’s documentation. If required, they shall be tagged by Consortium’s Materials Engineer with an in-house tag and referenced on the relevant documentation. Color-coding of materials shall be noted in Material Control Procedures as a means of identification. Tags or other means of identification shall remain on equipment until fabrication or installation. The Consortium shall identify, segregate, control and certify materials and equipment that will be incorporated into the Building. All rejected material shall be stored in a designated area away from acceptable material and marked “Reject”. All material that has been rejected shall be removed from the store as soon as possible. The Material & Spool Controller shall maintain records of such materials and its departure from the storage area. 7.5.2.2

Inspection & Test records, which give evidence that the product has passed / failed inspection and / or test with defined acceptance criteria, will be maintained on various activities within the Scope of Work.

7.5.3

Customer Property If any customer property is supplied during the project execution stage Consortium shall verify, protect and safe guard the property for any damage.

7.5.4

Storage & Preservation of Product A suitable shed / containers / open space are assigned for storage purpose by Logistic Manager and the material shall be stored properly and preserved as per type of materials in coordination with QC Engineers / Discipline Engineers and guidance from suppliers/manufacturers & HSE Advisor. Welding Consumables shall be stored in compliance with the manufacturer’s recommendations, and prepared in accordance with QC Procedures. All material received and dispatched from stores shall be recorded on bin card and Excess / Shortage shall be checked by (LM) on regular basis. Any special requirements of material specified by suppliers shall be adhered to. The specific conditions of storage shall be informed by discipline engineer to (LM) by referring to Technical Data Sheet/QC Procedures. In case of doubt he should consult QC Engineer / Discipline Engineer on site and prepare the storage facility accordingly, e.g. air-condition storage or de-humidifier etc. The program for preventive maintenance of equipment shall be in accordance with the manufacturer’s recommendations and shall provide a sufficient level

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of maintenance acceptable for warranty purposes. verifying the maintenance performed will be kept. 7.6

Necessary records

Pre-Commissioning, Commissioning After completion of the construction activities, Pre-commissioning activities will follow with Flushing & reinstatement and commissioning will follow as per the approved commissioning procedure, system wise, under the strict control of the commissioning team

7.7

Control of Monitoring and Measuring Devices The Consortium shall operate a system, which ensures control over Monitoring and Measuring Devices (MMD). All Measuring Devices shall be calibrated prior to use, in accordance with standard procedures and traceable to International Standards in line with Owner’s project specific requirement by Discipline Engineers / QC Engineer either through an independent laboratory or by using standard master set on site. QC Engineer shall surveillance check for validity of measuring Devices like temperature & pressure gauges, Vernier calipers, thickness gauges tools, instruments used for activities controlling quality. The date of calibration and date of validity shall be incorporated in the Calibration Register and technician shall know the periodicity of calibration and recall the equipment before expiry date for re-calibration and identified by a sticker on each instrument separately. Records and log of all test equipment calibration shall be maintained in the QA/QC Manager’s office. QC Engineer should periodically review to check the need for recalibration, if any.

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8.0

MEASUREMENT, ANALYSIS & IMPROVEMENT

8.1

Organizational Performance and Customer Satisfaction are qualitative measurements. The process for measurement shall include: a) Data for product or process converted into information and knowledge base. b) The format and method of measurement shall be reviewed and updated. c) Customer Satisfaction or compliant – customer wise or project wise or country wise. d) Audit Observations / NCR’s from Clients e) Suggestion for communication / improvement.

8.1.1

Monitoring & Measurement of Owner satisfaction Owner’s Satisfaction about the execution of the said contract is Monitored & Measured on regular basis. This will be done by Project Control Engineer by gathering the information from various points, where the Conortium has interaction with the Owner. The main sources of such information is from the Weekly and Monthly Progress review meetings, information from all employees who are having point of contacts with the Owner Representatives or employees during the course of contract execution, Feed back from the Consortium’s top management. All such information will be reviewed on regular basis during the Consortium’s internal monthly Project Management Review Meetings to assess the perception / satisfaction of the Owner about the works carried out by The Consortium. Apart from the scheduled reviews, any feedback / complaints / comments from the Owner during any stage of the contract execution will be taken positively & reviewed by the Consortium project management and wherever necessary immediate necessary corrective and preventive actions will be initiated to increase the satisfaction level of the customer, limited to the awarded contract scope of works.

8.1.2

Quality Audits (Internal & External) The Consortium maintains a system of auditing to ensure the quality system is being properly administered. This shall be in joint responsibility of QA/QC Manger & QA/QC Engineer. Audit Schedule will be prepared in the form of Matrix - Project Activity vs. Time and Quality system element to be audited vs. time. Internal Audit schedule has been attached in Appendix-9.

Every effort will be made to meet the planned Audit Schedule i.e. internal as well as external audits (will be prepared at later date) on subcontractors and Page 44 of 69

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Suppliers as applicable. Owner and the auditee / organization will be notified about the audits in advance. All Auditees shall be informed of impending audits by QA Department. Owner may be informed of the audit if they wish to witness the audit as an observer and as required by the contract. The audits will be conducted by qualified auditors . Audit Check lists shall be prepared / utilized to ensure that all relevant topics are covered. However, the checklist shall not restrict Auditors from raising further questions, not included in the checklist. An audit report shall be issued by QA/QC Manager to PM/CM indicating any observations, non-conformance found and it may provide recommended disposition as well as corrective action to be taken. The copy of the Audit report shall be issued to the Auditee through the department head and to the Owner, if required. All non-conformances including those issued by Owner shall be acted upon, and a resolution agreed with the QA/QC Manager-QA/QC Engineer and CM as per agreed time frame and corrective actions will be taken accordingly. A log of non-conformances and their status shall be maintained by QA/QC Manager for the Project and discussed during monthly Project Management review meeting. All the NCR reports shall be closed out by the agreed corrective action. External Audit Schedule will be decided after the Project Team is in place, Subcontractors & Suppliers are finalized. An External Audit Schedule will be decided by QA/QC Manager in consultation with the Procurement & Subcontracts Manager –if required. 8.1.3

Monitoring & Measurement of Processes The necessary preparation and submittal plan for the Procedures, Method Statement and Inspection and Test Plans shall be prepared to ensure that processes are carried out under controlled conditions and in a systematic manner. The Consortium and its Subcontractors shall not start work in the field until the Consortium has received quality programs that have been reviewed and accepted by the Owner. All special process shall be carried out by Qualified Operators and required continuous monitoring and control of process parameters to ensure that specified requirements are met. Project Specific Procedures-if required e.g. Welding / NDT / PWHT shall be approved by Owner , followed by Procedure Qualification Test and Performance Qualification Test of the Operators, if required. Page 45 of 69

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The consortium shall notify the Owner’s Representative sufficiently in advance to allow Owner’s Representative an opportunity for witnessing Inspection / Testing activities. Approved Procedures, Applicable Specification, Qualification Records & drawing shall be issued to responsible person, as per Document Distribution Matrix. Necessary and relevant inspection and test records shall be prepared, reviewed and approved by Owner as per Inspection & Test Plans. 8.1.4

Monitoring and Measurement of Product

8.1.4.1

The Consortium shall operate a system to ensure that all the necessary, relevant inspection and testing is carried out stage wise to meet contractual commitment. The Inspection and Test Plan prepared to meet technical specification and approved by the Owner becomes guide. Notification shall be issued to the Owner as per agreed program. The Inspection & Test Plan shall be used by each responsible person when the activity is started and followed up till completion. This shall also be the responsibility of Supplier/Subcontractor for supply of manufactured product and also for Specialty Subcontractors (Implementation of program will be verified during scheduled inspection visit by Consortium / and/or the Owner representative or third party inspector as per mutually agreed Inspection Plan. Necessary Quality records of inspection and test shall be prepared, reviewed, signed and maintained. Identification shall be provided in the Inspection Test Plan (I.T.P) as to the Inspection requirements for various stages of inspection such as material receipt, procedure/welder qualification, fit-up inspection, weld visual inspection etc. The concerned personnel as defined in the ITP shall carry out the inspection activities. QA/QC Manager shall carry out surveillance on these activities. Final Inspection of each system shall be independently verified and recorded and reviewed by QA/QC Engineer / Inspectors to confirm compliance with all Project Specification. Then the same will be jointly reviewed with the Owner’s Engineer / representative along with Discipline Engineer / Superintendent / Foreman of Subcontractor, as and when necessary. The performance of the personnel doing the following Specific activities will be monitored by Quality Control. The rejection percentage is assigned and corrective action is sought by the person as well as supervisory staff. Similar measurement can be made for: a) b)

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c) d) e)

Maintenance of scheduled dates. Revenue – actual v/s budget. Safety Satisfaction, Lost Time Incidents (LTI)/Lost Time Incidents Frequency (LTIF).

etc. as a part of Management Information system (MIS) within the organization. The communication flow within the following departments will be ensured as a part of monitoring the Product / production and have better controls. From Project Control to Construction: a) b) c) d) e)

Weekly Plan for an activity Monthly Plan for an activity 3 Monthly Plan for an activity Weekly summary – planned v/s actual Monthly summary – planned v/s actual and

From Construction to PCM a) b)

Daily Report – activity, manpower, equipment Daily Discrepancy Report – maintenance, equipment or material shortage. c) Reason for delay or loss of productivity etc. This is to be evaluated and fed back in the plan for next week. Project team will finalize corrective action by review of the situation, mobilization of resources and other necessary actions. Such and similar actions could be taken on all operations like receipt of purchased items, preservation of all procured product, testing and reinstatement or any activity within Contractor’s scope. From the project team, a similar report is sent to Consortium Management on a daily / weekly and monthly basis for review, clarification.

The acceptance and rejection of a product, normally monitored with QC system, could be an indicator of progress and status reports shall be maintained for information to customers/colleagues from Project or Project Corporate Office as well. This shall also be applicable to Suppliers (vendors) of products. 8.2

Control of Non Conforming Product Whenever the product or material is found not conforming to the Project Specification / Code Requirements, a written Non-Conformance Report (NCR) shall be produced and necessary disposition and corrective action Page 47 of 69

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shall be decided by QC Engineer / Discipline Engineer in consultation with the Owner as necessary. Necessary NCR Register and close-out Log has to be maintained to monitor / overview of all non-conformances enabling trends to be identified and corresponding corrective action undertaken. The non-conforming product shall be reviewed in accordance with the documented procedures. Disposition of Non-conforming product shall be decided as per Procedure. All non-conformances, upon both initiating and final disposition shall be submitted to the Owner for their review. 8.3

Analysis of Data The data collected from the Audits, Nonconformance Reports (NCR or CAR), data generated during the Monitoring and Measurement of Process and Products as detailed previously, the Owner satisfaction levels and the Suppliers performance shall be analyzed to evaluate where continual improvement of effectiveness of the quality management system can be made. The basic data, which can be analyzed by some of the departments, are outlined below: QA/QC: -

% documentation approved by the Owner without Major Comments in the first attempt. Welder Performance, Weld Repair Percentage.- if any No. of times failure in meeting inspection schedules. Acceptance of an activity in the First Inspection. Weld repair % Trends-if any No. of Test Packs or Electrical & Instrumentation Loop – Checking are cleared without Punch Lists. Trends of Concrete and Grout test results No. of NCRs, Observations, repeated areas of concern & trends. Rejections in Painting & Coating.

Construction: -

Actual progress vs. Planned

Project Controls: -

Utilization of Resources Analyze the trends of rejection Discipline wise productivity and trends

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Procurement: -

Response trends for an enquiry in the local or International Markets Processing time of a purchase order Trends in failure to meet the delivery schedule Performance level of suppliers of various categories

Corrective action could be expediting, reinforcement of resources or formation of special team etc. Root cause of the potential problems shall be found and necessary corrective and preventive action will be decided on case-to-case basis.

8.4

Continual Improvement

8.4.1

The continual effectiveness and efficiency of the processes decide the achievement of the project objectives. Consortium shall set the targets to be achieved based on the performance in the previous projects. Some of such targets are: a.

Completion of the project without any LTI, Achieving the weld repair percentage below 2.5 targeting zero defect, -if any c. Minimizing the Punch list while mechanical completion to a maximum of 10 items d. Start preparing and handover documentation “system” as soon as 50% test packs are tested. b.

Similar Programs will be developed within the Project Management Team and Construction Group. Sample Programs are: -

Productivity targets for Welders / Fitters / Instrumentation Technicians etc., Planning & Optimum utilization of the resources due to the wide spread of job locations. Completion of the project ahead of the schedule to take advantage of the provided bonus clause of the contract- if any.

Apart from the above listed areas, project management aims for the continual improvement in other aspects also such as Performance improvement of the resources. This will be achieved by providing proper workenviroment with improved health and welfare conditions to create better working environment for employees. Maintaining the necessary spares and performing the preventive maintenance according to the preventive maintenance schedule will enable to utilize the equipment at their optimum capacity levels. 8.4.2

Corrective and Preventive Action Page 49 of 69

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The Consortium shall maintain a system to ensure that all non-conformances are reviewed by QA/QC Manager. All reports produced on non-conformance found during testing and inspection, surveillance audits, Customer audits shall be independently reviewed, by QA/QC Manager and Discipline Engineer of the Consortium. The course of action to be undertaken is determined, only after checking root cause of the defect or deficiency and actions / results shall be recorded. Corrective action shall be only proceed after authorized written instructions have been produced and approved by the QA / QC manager. The disposition - ‘Rework’, ‘Repair’, ‘Reject’ or ‘Use’ as it is shall be carried out. When non-conforming conditions re-occurs, detailed examination shall be made by QA/QC Manager, to determine what preventing action is necessary based on study of available data, reports and methodology and then root cause of the non-conformance i.e. whether work man / process / machinery shall be identified / the situation rectified to ensure repetition shall not occur.

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9.0

LIST OF APPENDIX: Appendix-1 Appendix-2 Appendix-3 Appendix-4 Appendix-5 Appendix-6 Appendix-7 Appendix-8 Appendix-9

ISO 9001-2000 Certificate Index of QMS Manual & List of Corporates QMS Procedures Project Organization chart QA/QC Monthly Report Format for MR List of Proposed QA/QC Documents (procedures/MS/ITP) Quality management system implementation guideline. Format of document distribution list. Format of Document Control Register Internal Audit Schedule

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APPENDIX – 1 ISO 9001 – 2000 CERTIFICATE

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APPENDIX - 2 INDEX OF CORPORATE QUALITY MANUAL & CORPORATE QUALITY MANAGEMENT SYSTEM PROCEDURE LIST

MANUAL – Index GENERAL

Page

0.1

Index

1

0.2

Introduction

3

0.3

Exclusions <>

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SECTION 4 - QUALITY MANAGEMENT SYSTEM 4.1

General Requirements

9

4.2

Documentation and Records

12

SECTION 5 - MANAGEMENT RESPONSIBILITY 5.1

Management Commitment

15

5.2

Client Focus

17

5.3

Quality Policy

19

5.4

Quality System Planning

21

5.5

Organization and Communication

24

5.6

Management Review

30

SECTION 6 - RESOURCE MANAGEMENT 6.1

Provision of Resources

32

6.2

Competence, Awareness and Training

34

6.3

Infrastructure and Work Environment

37

SECTION 7 - PROJECT REALIZATION 7.1

Planning of Project Realization

39

7.2

Client-related Processes

42

7.3

Design Control

46

7.4

Purchasing

47

7.5

Operations

49

7.6

Monitoring and Measuring Equipment

54

SECTION 8 - MEASUREMENT, ANALYSIS AND IMPROVEMENT 8.1

Planning of Monitoring and Measurement

56

8.2

Monitoring and Measurement

58

8.3

Control of Nonconforming Project

63

8.4

Analysis of Data

65

8.5

Continual Improvement

67

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LIST OF CORPORATE QMS PROCEDURE QP-42-01

Control of Documents

QP-42-02

Quality System Documentation

QP-42-03

Control of Quality Records

QP-42-04

Documentation Master List

QP-54-01

Quality Policy & Quality Objectives Page 56 of 69

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QP-56-01

Management Review

QP-62-01

Training and Awareness

QP-63-01

Services & Building Maintenance

QP-71-01

Projects Planning and Budjeting Before Execution

QP-72-01

Client Contract Review & Estimates

QP-72-02

Client Communication

QP-72-03

Change Orders

QP-74-01

Supplier Evaluation and Selection

QP-74-02

Purchasing

QP-74-03

Customs

QP-75-01

Process Control

QP-75-02

Equipment Maintenance

QP-75-03

Material Handling, Storage, and Control.

QP-75-04

Test and inspection status

QP-75-05

Client supplied projects

QP-76-01

Testing Equipment Calibration

QP-82-01

Internal Quality Audits

QP-82-02

Incoming Material Inspection and Testing

QP-82-03

Inspection and Testing for In-process Works

QP-82-04

Inspection and Testing for the Completed Projects

QP-83-01

Control of Nonconforming Materials

QP-85-01

Continual Improvement

QP-85-02

Corrective and Preventive Action

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APPENDIX – 3 THE PROJECT ORGANIZATION CHART

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APPENDIX – 4 QA/QC MONTHLY REPORT FORMAT

QA/QC STATUS REPORT FOR : Month:

Year

Document No.

CONS/PDOC/31/05 -237B/QA-RPT-

CONTRACT TITLE: PDOC NEW OFFICE Revision No. BUILDING Date CONTRACTOR: HPSIC-JIANGSU CONSORTIUME Page of CONTRACT NO.: PDOC/31/05-237B 1. SITE INSPECTION STATUS REQUEST FOR INSPECTIO N

CIVIL

MECH

ELECT

INST

Issued Accepted Hold Rejected Total

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MATERIALS/ EQUIPMETN S ON SITE

OTHER S (IF ANY)

TOTAL

HIGLEIG PETROLEUM SERVICES INVESTMENTS CO.

2. NON-CONFORMANCE REPORT (NCR) ISSUED BY PMC: NCR QAQC

CIVIL

MECH

EXECUTION ELECT

INST

OTHERS

TOTAL

REMARK S

Issued Closed Outstandin g Total

3. NON-CONFORMANCE REPORT (NCR) ISSUED BY CONTRACTOR(INTERNAL AUDIT ) AUDIT NO. ISSUED

NCR CLOSED

OBSERVATION

REMARKS

OUTSTANDING

TOTAL

4. SITE NOTIFICATION (SN) - By PMC SN

TOTAL

Issued Closed Converted to NCR Outstanding

- By contractor on Sub-contractor SN

TOTAL

Issued Closed Converted to NCR Outstanding

5. PROCEDURES AND INSPECTION & TEST PLANS TYPE OF DOCUMENT Total Required Approved Resubmit Outstanding

ITP

PROCEDURE

6. COMPLIANCE QUALITY AUDIT(By PMC)

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TOTAL

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AUDIT NO. ISSUED

NCR CLOSED

OBSERVATION

REMARKS

OUTSTANDING

TOTAL

7. SITE TECHNICAL QUERY (STQ) ISSUED BY CONTRACTOR Total No. Issued To PMC Responded by PMC Approved Rejected Pending Outstanding by PMC

NUMBER

REMARKS

8. MECHANICAL COMPLETION STATUS (SYSTEM WISE ) SYSTEM NO.

TITLE

REQUESTE D DATE

SUBMIT

RE-SUBMIT

APPROVED

REMARKS

9. PERFRMANCE TEST- IF ANY (SYSTEM WISE) SYSTEM NO. REQUIRED

TEST PACKAGE SUBMITTED

ACCEPTED

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TEST COMPLETED %

REMARKS

HIGLEIG PETROLEUM SERVICES INVESTMENTS CO.

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APPENDIX – 5 LIST OF PROPOSED QA/QC DOCUMENTS (PROCEDURES/MS/ITP)

APPENDIX - 6 QUALITY MANAGEMENT SYSTEM IMPLEMENTATION GUIDELINE Page 65 of 69

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APPENDIX - 7 DOCUMENT DISTRIBUTION LIST FORMAT

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APPENDIX – 8 DOCUMETS CONTROL REGISTER FORMAT Page 67 of 69

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APPENDIX – 9 INTERNAL AUDIT SCHEDULE

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