PROJECT QUALITY PLAN
2 Approved for Implementation (ref.Transmittal 45283-KS-T-00350) F.Menichini A.Castagna G.Raimondi 23.11.10 1 Re issued for approval -revised as indicated (ref.Transmittal 45283-KS-T-00201
& letter 45283/KS/L/00103 )
F.Menichini A.Castagna G.Raimondi 19.10.10 0 Approved for Implementation (ref.Transmittal 45283-KS-T-00116) F.Menichini A.Castagna G.Raimondi 21.09.10 B Re-issued for Approval-Incorporated comments (ref. letter 45283/KS/T/00021) F. Menichini A.Castagna G. Raimondi 16.08.10
A Issued for Approval F. Menichini A.Castagna G. Raimondi 15.07.10
CONTENTS
1. SCOPE AND FIELD OF APPLICATION 4
1.1. General 4
1.2. Work Scope 4
2. REFERENCE 5
2.1. CONTRACTOR’s Reference Documents 5
2.2. Contractual Reference Documents 5
3. TERMS AND DEFINITIONS 6
3.1. Definitions 6
3.2. Abbreviations 6
4. QUALITY MANAGEMENT SYSTEM 8
4.1. Processes in project activities 8
4.2. Documentation requirements 8
5. MANAGEMENT RESPONSIBILITY 12
5.1. Management commitment 12
5.2. COMPANY focus 13
5.3. Project quality policy 13
5.4. Project Quality objectives 14
5.5. Project organisation: functions and responsibilities 14
5.6. Project Management review 14
6. RESOURCE MANAGEMENT 15
6.1. Human resources 15
6.2. Personnel training & Induction 15
6.3. Training of Company Personnel 16
7. PROJECT EXECUTION 17
7.1. Planning of project execution 17
7.2. COMPANY-related processes 20
7.3 Design and development 21
7.4. Procurement 23
7.6. Subcontracts qualification & control 30 7.7. Quality Control and inspection activities during construction
phase 30
7.8. Control of monitoring and measuring equipment 32
7.9. Constructability review 33
8. MEASUREMENT, ANALYSIS AND IMPROVEMENT 35
8.1. General requirements 35
8.2. Monitoring and measurement 35
8.3. Control of nonconforming products 36
8.4. Data analysis 37
8.5. Improvement 37
ANNEXURE 1 – LIST OF CORPORATE CONTRACTOR’S PROCEDURES 39
ANNEXURE 2 – LIST OF PROJECT PROCEDURES (TO BE SUBMITTED
FOR KOC REVIEW AND APPROVAL) 40
1. SCOPE AND FIELD OF APPLICATION 1.1. General
This document defines the project Quality management system applied by the CONTRACTOR for realisation of Building New Booster Station BS-171 in West Kuwait.
This Project Quality Plan is base referenced on Contractor's corporate Quality Management System Manual:
• to provide consistent product that meets Company requirements,
• to address Company satisfaction through the effective implementation of the system with operations for continual improvement and prevention of non conformity.
In particular it specifies the Quality requirements to be applied to the project activities, the organisational structure (functions and responsibilities) implemented for the project, the multidisciplinary design reviews and the Quality audits to be conducted both in the home office and at site to achieve the Quality objectives of the project. Every control will be exercised by the project management to achieve the Quality objectives and to focus attention on prevention of nonconformities.
1.2. Work Scope
The Contractor shall construct the Facilities and supply all Materials, manpower and other resources; provide quality assurance services and all other requirements to provide the Company with complete operable Facilities in accordance with the
Contract.
The detailed work scope will be in accordance to the contract and is appendix:
“APPENDIX E Scope Of Work and Description of Services”
The Works shall include all necessary operations and services to complete and commission the Facilities and any associated work in accordance with the Contract
2. REFERENCE
ISO 9000 ed. 2005 Quality management systems - Fundamentals and vocabulary; ISO 9001 ed. 2008 Quality management systems - Requirements.
Applicable industry KOC Contract documents and Company Standards, Project specifications and applicable International Codes & Standards. 2.1. CONTRACTOR’s Reference Documents
POL-SPA-QUAL-001 Quality Policy
GP-SPA-QUALON-005 BU ONSHORE (QUALITY) MANAGEMENT SYSTEM
MANUAL
Doc. NO. KOC-Q-014 – Project QA/QC Requirements
The complete list of documents is given in Annexures -1 and 2. 2.2. Contractual Reference Documents
General Conditions of Contract for Lump Sum Turnkey Projects Appendix D, Project Administration and Coordination Procedure Appendix E, Scope of Work and Description of Services
Doc. NO. KOC-Q-014 – Project QA/QC Requirements
3. TERMS AND DEFINITIONS 3.1. Definitions
(the below definition are in respect the term established on General Condition of Contract clause 1)
• COMPANY: as defined on GCC clause 1 )
• CONTRACTOR: as defined on GCC clause 1 )
• Contract: Contract between COMPANY and CONTRACTOR with all Annexure and Attachments (GCC clause 1 )
• Construction subcontractor: organisation that is engaged by the CONTRACTOR to perform the erection and construction works with relevant inspections, examinations and tests
• Work: All the work and services to be performed by the CONTRACTOR as set out in the Contract. (GCC clause 1 )
3.2. Abbreviations
Project positions (
*
Key personnel indicated on attachment 14 of Technical Proposal clause 4), due to the split between Home office and Site the sub clause are not in sequence. The abbreviations don’t represent the totality of Project’s role.PM - Project Manager (Project Manager clause 4.1*) DPM - Deputy Project Manager
TM - Technical Manager (Engineering Manager clause 4.2*) PE1 - Project Engineer (clause 4.3*)
PCM - Project Control Manager (taking duty also of Planning and scheduling Engineer clause 4.4*)
HSEM - Project HSE Manager (clause 4.6*) PQM - Project Quality Manager (clause 4.7*) PPRM - Project Procurement Manager (clause 4.8*)
CA - Contract Administrator (Contracts Manager clause 4.10*) COM - Commissioning &Training Manager (Pre-commissioning/ commissioning engineer clause 4.14*; Training Manager clause
4.5*)
DC - Document Controller
DCC - Document Control Coordinator DTM - Deputy Technical Manager
MM - Material Manager (Material Control Manager clause 4.9*) PLE - Project Planning and scheduling Engineer
PLL - Project Loss Prevention and Environment Leader (Lead discipline Engineer clause 4.12 *)
PPL - Project Process Leader (Lead discipline Engineer clause 4.12 *) PSL - Project Specialist Leader (Lead discipline Engineer clause 4.12*)
Site organisation
CM - Construction Manager clause 4.11*
DS - Discipline Superintendant
FEM - Field Engineering Manager (Lead construction Engineer clause 4.13*) FMMS - Field Material Management Superintendent (Material Control
Manager clause 4.9*)
QCS - Field Quality Control Supervisor WES - Welding Supervisor
Other abbreviations
EPC - Engineering, Procurement, Construction IDS - Inspection data Sheets
ITP - Inspection and Test Plans CAR - Corrective action request WBS - Work Breakdown structure TQ - Technical Query CR - Concession Request DR - Deviation Request VO - Variation Order Organisation Departments PROC2 - Procurement
HSE - Health, Safety and Environment
QUAL - Quality
CONSTR Construction
ICT - Information and Communication Technology PCON - Project Control
CAON - Contract Administration
4. QUALITY MANAGEMENT SYSTEM 4.1. Processes in project activities
The work processes defined for the project activities are as per “APPENDIX E- Scope of work and description of services” :
• Project Management Services
• Design Engineering Services
• Procurement Services
• Subcontracting Services
• Construction Services
• Quality Assurance Services
• Temporary Services for Company
• Training of Company Personnel
• Health, Safety and Environmental (HSE) Services
4.2. Documentation requirements
4.2.1. General requirements
The documentation includes: • Contractual documents;
• Project planning and control documents; • Technical and construction documents; • Purchasing and subcontracting documents; • Quality records;
• Correspondence with the COMPANY, Vendors, subcontractors, etc. • Internal communication;
• Minutes of meetings and reports.
4.2.2. Quality Manual
The CONTRACTOR’s ‘BU Onshore (Quality) Management System Manual’ (GP-SPA-QUALON-005) constitutes the base reference for the Project Quality Plan which defines how the CONTRACTOR’s Quality management system finds application in operational projects.
The Quality Plan issuing methods are described in chapter 7.1.7. 4.2.3. Control of documents
Reference documents like codes. Standards, specifications. Project specification Documents, etc. which controls activities effecting quality shall be readily
available to related personnel. The latest revision of the applicable Project documents shall be made available at all activity locations.
a) Document management during engineering phase
The methods for preparing and identifying project documents, including those produced by the vendors of material and services, are indicated in the project procedure 000-ZA-E-09003 “Project coding and numbering procedure”.
Project documents (specifications and drawings) are managed according to OPR.GM.XE.5013 “Project Documents Control” utilising a software application called Engineering Integration Manager (EIM).
The above software application manages both the issue and the revision of all project documents and the storage of electronic files.
Any changes to documents are formalised according to 000-ZA-E-09003 “Project coding and numbering procedure”.
Changes to documents shall be verified and approved by the same functions that performed the original review and approval, using the same work instructions as described in Chapter 7.3.5.
b) Document management during construction phase.
On site, technical documents are managed according to the instruction given in project procedure 000-ZA-E-09000 “Project coordination/administration procedure between Company and Contractor”.
c) Document management during Pre-commissioning and Commissioning and Close-out phase.
The CONTRACTOR shall keep a copy of “as-built” drawings as indicated in the project procedure 000-AZ-E-02018 “As-built drawings procedure”.
d) Document Control processes
Document control processes will be manage in accordance to the requirements of Appendix “D”.
Explanation of the document control processes is explained on Document Control Project procedure 000-ZA-E-09806 and monitored by the Document List and Drawing Register Status Report 000-ZA-E-09804 which as an extraction of EIM EDMS system gives the status on update time of the handover of project documentation
The procedure 000-ZA-E-09806 outline the measures that has be established by the Contractor to control the issuance, retrieval and revision of documents (e.g. drawings, procedures and instructions) including changes to such documents and in which way the Participating organizations, site included, shall have in their possession procedures for control and revision of such documents to preclude the possibility of using outdated or inappropriate documents in the performance of the Works.
4.2.4. Project record Books
Project record book will be manage in accordance to the “Appendix D, clause 10 & 11”.
A complete set of Project records and books shall be prepared by the Contractor during the period between the Date for Commencement and the date of Turnover. These documents shall be prepared to represent the Facilities in the as-built condition and shall be supplied to the Company sixty (60) days prior to Construction Completion of the whole or a Portion of the Facility. The Contractor shall prepare approved Vendor prints and data for inclusion into the Project Records Books as required by Clause 10 entitled “Project Records and Manuals.”
Project records are managed according to the following table: Normative reference
(UNI EN ISO 9001:2008)
Document Responsibility 6.2.2 – Competence, awareness
and Training
Curriculum Vitae – Training Induction and participants’ lists
PM 7.1 – Planning of product realization Engineerining Programme – Construction programme – Procurement programme TM/ PPRM/ PCL
7.4 – Purchasing Process Vendor list - Vendor prints and data PPRM / PSL 7.2.2 – Review of requirements
related to the product
Project Execution Plan PM 7.3.2 – Design and development
inputs
General Design Criteria TM 7.3.4 – Design and development
review
Minutes of design review meeting PPL/PSL/PLL 7.3.5 – Design and development
verification
Calculation printouts, check lists PPL/PSL/PLL 7.3.6 – Design and development
validation
Final project report PM
7.3.7 – Control of design and development changes
Design change record TM
7.5.2 –Validation of processes for production and service provision
Specifications for special process recording requirements
PSL
7.5.3 – Identification and traceability
Material traceability list Spool and traceability map
DS WES 7.5.4 – COMPANY property Anomaly records PM 7.6 – Control of monitoring and
measuring devices
Monitoring and measurement device records
MM/DS 8.2.2 – Internal audits Audit report PQM 8.2.4 – Monitoring and
measurement of products
Quality control report MM/DS/QCS 8.3 – Control of nonconforming products Nonconformity reports: • Materials (QCF NC register) • Audit report (RNC) • Site (NC register) MM PQM QCS 8.5.2 – Corrective actions Audit report, non conformity report MM/PQM
Normative reference (UNI EN ISO 9001:2008)
Document Responsibility 8.5.3 – Preventive actions Lessons learnt, Audit report
HAZOP study
Corporate Depts. HSE
The PM keeps a record of the COMPANY complaints. Once the complaint has been examined and the necessary corrective action implemented, both the complaint and the corrective action records are filed together with the project documentation.
5. MANAGEMENT RESPONSIBILITY 5.1. Management commitment
The Management shows its commitment by developing the activities through PM and DPM. The Management responsibility are defined on Contract document: Appendix “E” clause 2 , Project management Services
• Communicating to the functions involved in the project, the importance of complying with contractual and applicable regulatory requirements;
• Establishing the Project Quality policy;
• Provide all necessary fully qualified and experienced personnel to interface with the COMPANY and manage the Works including, but not limited to, the following:
- Pursuant to Clause 33.6 of the General Conditions of Contract provide a fully qualified and experienced project manager acceptable to the Company who shall not be changed without prior written consent of the Company.
- Establish an organisation acceptable to the Company fully capable of performing the Works. Office Organisation Charts shall be provided to the Company, as specified in Clause 33.3 of the General Conditions of Contract within fourteen (14) days from Date for Commencement of the Contract. Site Organisation Chart shall be provided to the Company, as specified in Clause 33.4 of the General Conditions of Contract no later than thirty (30) days prior to assigning construction personnel to the Site (including its design support team in Kuwait)
- Develop and provide to the Company an acceptable execution plan which shall clearly illustrate the Contractor’s understanding of the Works and the timely completion of the Facilities. This Plan shall include complete Coordination Procedures within the Contractor’s organization and with the Company for each phase of the Works and incorporate all requirements of Appendix D (Project Administration and Coordination Procedure).
- Provide a project controls team which shall develop the necessary schedules and plans for all phases of the Works and accurately monitor progress against the schedules and plans in accordance with the requirements of Appendix D (Project Administration and Coordination Procedure). The Team shall coordinate with the Company’s project controls team to ensure compatibility of reporting with that of the Company.
- Prepare Monthly Progress Reports for presentation to and discussion with the Company. The Reports shall highlight all critical issues. Monthly Progress Reports shall be issued no later than the seventh (7th) day of the following month and shall incorporate all the requirements of Appendix D, Clause 6, “Project Reports.”
- Responsibility for all management of its Vendors, and Subcontractors, as necessary, to achieve expeditious completion of the Facilities in accordance with the Contract.
- Assist the Company in the coordination with other Company’s contractors whose scope of work directly relates to the Works.
- Designate an Executive Sponsor for the Project. The Executive Sponsor shall be an executive of the Contractor, from the Contractor’s home office, who will be available to the Superintendent for the resolution of problems. The Executive Sponsor shall not be the Project Manager.
5.2. COMPANY focus
The needs and expectations of the COMPANY are satisfied by means of:
• Compliance with contractual requirements defined by the COMPANY, with the regulatory, safety and environmental requirements and with those requested by other partners of the CONTRACTOR;
• Communication to the functions concerned regarding the above requirements and their involvement in the same;
• Focusing on the improvement of work processes. 5.3. Project quality policy
The Quality policy implemented by the CONTRACTOR during project execution aims to ensure that the products and services meet the needs and expectations of the COMPANY and conform to the Quality requirements established for the project, including applicable norms, specifications, legislation, instructions and regulations, particularly those concerning occupational health, safety and environmental conservation.
This Project Quality Plan is issued in compliance with the requirements of the COMPANY and the ISO 9001:2008 standard and is in conformity with the CONTRACTOR’s Quality management system.
The Quality objectives defined herein can be measured and reviewed by the Management for continual improvement of the project work processes.
The CONTRACTOR shall define the responsibilities and authorities of key personnel and assign qualified and competent resources to achieve Project Quality objectives. The PM of the CONTRACTOR shall take all the necessary actions to implement the Project Quality policy throughout project execution.
This Project Quality Plan documents the Project Quality Management System, resources and the work processes to be adopted in the project.
The responsibility of preparation of the Project Quality Plan is entrusted to PQM, to whom the Management has awarded the necessary authority, freedom and support. The PM, in cooperation with the permanent organisation, is responsible for the implementation of continual improvement of the system in order to achieve COMPANY satisfaction and the established objectives.
5.4. Project Quality objectives
The Project Quality objectives are:
• Comply with KOC International Codes Standards and Specification as well the Industry Good Practices;
• Absence of COMPANY complaints;
• Absence of serious nonconformities;
• Schedule Compliance
The achievement of Quality objectives is entrusted to all the persons involved in the project.
5.5. Project organisation: functions and responsibilities
In accordance to COMPANY requirements expressed onKey personnel indicated on attachment 17 of Tender Document, clause 4, CONTRACTOR will provide all the necessary key project positions.
The key project positions, while remaining under the direction of their department manager, shall operate to achieve the project objectives, according to the instructions of the PM.
The PM supervises all aspects of project execution and represents the CONTRACTOR in front of the COMPANY.
The departments of the permanent structure of the CONTRACTOR are responsible for ensuring the conformance of their activities/products to Quality standards. They are also responsible for the technical accuracy of documents and for all the activities within their discipline such as technical assistance to inspections and tests, construction, pre-commissioning, commissioning, etc.
The home office and site organisations, along with the functions and responsibilities, are detailed in the project procedure 000-ZA-E-09602 “Project office and site organisation charts with job descriptions”, this include also Project QA/QC function and responsibilities and Charts showing the compliance for personnel mobilization. List of QA/QC personal is shown in annex 3.
Construction Subcontractor detailed QA/QC organization chart will be included on document 000-ZA-E-09606 Subcontractor Project Quality Plan issued by Construction Subcontractor and subject to CONTRACTOR and COMPANY approval. 5.6. Project Management review
The Project Quality management system is reviewed regularly by the Management and recorded for future reference and actions.
The review is based on feedback from the projects in terms of problems encountered, inconsistencies and their causes, conformity of purchased products, effectiveness of work methods and organisational structures, audit reports and project records.
6. RESOURCE MANAGEMENT 6.1. Human resources
All personnel assigned to the project shall have correct profile in terms of skills and capabilities as per clause 5.3 of KOC-Q-014.
The Responsibility of assigning adequate resources to the project is with the CONTRACTOR’s department managers. The responsibly of mobilizing adequate resources required by all the subcontractors to execute the contract Scope of work is whit the contractor.
Employee's performance evaluation shall be conducted regularly to identify the necessary training requirements to meet the skill levels required for their designated works.
The records attesting the competence, responsibilities and authority of the resources assigned to the project are filed by the CONTRACTOR’s department managers. 6.2. Personnel training & Induction
CONTRACTOR’s Department Managers ensure that positions within the CONTRACTOR are filled by resources with the correct profile in terms of skills and capabilities. This activity is achieved by implementing dedicated personnel training and education of the individual, consistently with the professional development objectives defined. Training records shall be maintained.
At the beginning of Project a specific Induction to the Quality System applied to the project with the explanation of content of the Quality Project Plan is given to all the personnel involved in the project, who shall fully comply with the requirements and procedures indicated herein.
The competence, responsibilities and authority of the resources assigned to the project are guaranteed through quality audits scheduled in the “Quality Assurance activities and Audit Plan” Doc N. 000-ZA-E-09603.
CONTRACTOR will include specific Project Quality requirements in Subcontractors contract, in order to made resources aware that their work activities contribute to the achievement of quality objectives.
6.2.1. Competence, awareness and training
All personnel assigned to the project will have received professional training and have experience in accordance with corporate operating procedure OPR.RD.XB.5020 – “Personnel training”.
It is the responsibility of the PM to ensure that all personnel assigned to the Project are qualified by training and/or experience and are familiar with COMPANIES to perform the tasks assigned to them.
The personnel awareness of the relevance and importance of their activities, it is guaranteed with the specific project quality training. In the beginning of the Project a quality training is held with all the Project team to illustrate all the aspects treated on the Project Quality Plan for the fully understanding of the information contained, particular attention is given to all the Contract requirements that may be constitute a deviation from the normal practice of works or Corporate Procedures and for these a
specific Project procedures are issued. For this reason a training program is developed and relative Attendee records maintained.
6.3. Training of Company Personnel
The Contractor shall in accordance with Clause 36.0 of the General Conditions of Contract and the requirements expressed on Appendix E clause 9 prepare a training programme, “000-ZA-E-79002 Training of Company personnel programme”.
Contractor in conjunction with its Subcontractors and approved manufacturers and Vendors, prepare, develop and carry out a specialist training programme to impart all necessary skills and knowledge to a certain number and category of the Company’s Operation and Maintenance personnel. Any request for quotations and purchase orders shall stipulate the training requirements to be provided by the Vendor in fulfilment of the Contractor training responsibilities.
The training shall be carried out in Kuwait as specified in Appendix E in accordance with the approved training programme and shall be completed prior to, and as a condition precedent to, the issue of the Construction Completion Certificate of the relevant Portion or the whole of the Facilities
7. PROJECT EXECUTION
7.1. Planning of project execution
7.1.1. General requirements
The Contractor shall arrange the Project pre Inspection meeting (PPIM), Construction Pre-Inspection Meeting (CPIM) and Vendor Pre-Inspection Meetings (VPIM) requirements in accordance with the agenda detailed in c1ause 6.0 of KOC-Q-014 Rev 1
The project planning and project control strategy are the responsibilities of the PM. The DPM verifies all the project control documents, the PM approves all the project control documents.
The PCM reviews the requirements contained in the contractual and tender documents regarding project control, and participates in defining the strategies for project execution and control.
In cooperation with all the project positions and in consultation with CONTRACTOR’s permanent structure of PCON, the PCM defines the “Work Breakdown Structure” (WBS) that takes into account the contractual aspects and the constraints involved in the development of the activities. The WBS is transversal to all project activities and is defined to meet the fundamental needs of all the involved functions.
The PCM prepares the document that defines the WBS and submits it to the PM for check and approval before issue.
During this activity, the basic considerations for the project realisation plan are finalised and the project procedure 000-ZA-E-09800 “Planning and scheduling procedure” is issued.
The detailed “Project overall contract CPM Schedule (LEV 3)” 000-ZA-E-09853, based on the contractual dates, is prepared by the PCM with the assistance of all discipline leaders; then it is verified by DPM and approved by the PM and transmitted to the COMPANY.
After verifying the contractual requirements and the project development plan, CONTRACTOR also prepares the following project procedures:
• 000-ZA-E-09801 “Project physical progress measurement procedure”; • 000-ZA-E-09802 “Reporting procedure”;
• 000-ZA-E-09803 “Progress measurement system for invoicing procedure” • 000-ZA-E-09002 “Variation order procedure”;
7.1.2. Occupational health and safety requirements
The project procedure 000-ZA-E-85822 “HSE manual for construction” is issued by HSE department
7.1.3. HSE
CONTRACTOR shall issue a " Overall Project HSE Management plan" doc. No. 000-ZA-E-85800, in compliance with the project requirements, regarding health, safety and environmental conservation.
The plan, prepare by HSE Manager and approved by Project Manager, describes the HSE activities to be performed for the project under the HSEM responsibility; it is a “living document” and will remain in force throughout the complete project cycle. A Projects HSE Philosophy specification, doc No. 000-ZA-E-85820 shall be issued for the project, containing contractual requirements, international standards to comply with during the project design.
According to contract, the following review, under HSE responsibility, is foreseen: Hazard & Operability (HAZOP) review, to be led by a third party Chairmen, with the participation by COMPANY and CONTRACTOR.
Project HSE Reviews, to be led a third party Chairmen, on the design solutions versus HSE requirement compliance.
7.1.4. Technical-organisational coordination
The exchange of documentation and information between the Contractor and the COMPANY takes into account the following:
• Contractual clauses;
• Type of contract and scope of work;
• Project complexity.
Particular attention is paid to the contractual clauses that affect the relationship among the parties.
All the key positions of the project organisation take part in this activity. Finally all contractual communication shall vetted by CA before final issuance.
In the project procedure 000-ZA-E-09000 “Project coordination/administration procedure between COMPANY and CONTRACTOR” the following points are defined:
• General information (project name, job number, parties involved specifying their tasks and mutual relationship, documents to be considered, names of persons representing the parties involved, choice of language);
• Method of communication used in the correspondence (letters, fax, transmittal), verbal messages and telephone calls, meetings and possible electronic connections;
• Design documents (method of identification, recording, management, transmission for approval, comments or information, filing and delivery to the COMPANY);
• Purchasing documents;
• Quality management documents;
• Commercial and Contractual documents;
• Variation request;
• Documents related to Notification and COMPANY approval
• Information (unless specified in other items) related to planning, cost control, order changes, etc;
• Confidentiality requirements. 7.1.5. Material inspection and testing plan
All purchased equipment, machineries, material and components are classified according to their inspection level.
This activity is carried out immediately after the Process Flow Diagram (PFD) for primary and secondary systems and the Heat & Material Balance have been issued. This classification is required to produce the Inspection Data Sheet (IDS) and to optimise the resources to be employed in control and surveillance activities during the manufacturing of the purchased product. It is defined in the project procedure 000-ZA-E-09001 “Project material classification ”.
7.1.6. Project “Information & Communication Technology” (ICT) System
The ICT system is defined following contract review and during project planning. It defines the methods and responsibilities for the implementation of information activities and voice/data transmission.
The ICT resources (processing and communication systems, base and application software) and ICT standards (for example, file formats) to be used in the project and in relations with the COMPANY and third party organisations such as Vendors, Construction subcontractors and Partners, shall be identified and included in the project procedure 000-ZA-E-09005 “General specification for project information and communication technology (ICT) system”.
7.1.7. Project quality plan
All planned project activities are documented in the Project Quality Plan which is defined after the review of contractual documents.
The PQM, assisted by the competent positions of the project organisation, prepares and issues the Project Quality plan based on the PM instructions.
PQM ensures its conformity with applicable elements of the CONTRACTOR’s Quality management system and with the contractual requirements,
The Project Quality Plan is verified by the QUAL Department manager, approved by the PM and distributed to everybody in the project organisation, distribution to all the project organization and Subcontractor is performed, as all the other documentations, in accordance to the project procedure 000-ZA-E-09806 “Document Control procedure” EIM and in accordance to the distribution matrix defined in EDMS system. Once approved by Company a general review of the PQP will take place every six month, if not significant modification arouse in the meantime, PQP will always revise in case of modification that may need after Audits results which clearly define a better assessment of the Plan.
7.2. COMPANY-related processes 7.2.1. Determination of project requirements
The project requirements are specified by the COMPANY in the contract including the regulatory ones.
7.2.2. Review of contractual documents
In the initial phase of the project, the contractual documents are reviewed by the project positions within their specific competence.
The contractual documents include:
a) documents related to management, economic and financial aspects such as: contract, scope of work, prices, penalties, financing, insurance, legal aspects, obligations of the CONTRACTOR and COMPANY, commercial agreements such as joint ventures, pre-bidding agreements, letters of intent, licensing agreements, confidentiality agreements, etc.;
Following the review of the management, economic and financial documents, the document “Project Management Data” is issued; the document details the contractual requirements and constraints, and indicates the problems, criticalities, choices, fundamental strategies and operating plans defined for the project. This document shall be prepared by PM. It shall be issued for internal use only and hence shall not be recorded in the project documents.
b) Technical documents: drawings and specifications block diagrams, other diagrams, technical data, environmental information, programs, codes, standards, regulatory laws and regulations.
Following the review of the technical documentation, the documents “General “Design Criteria” are issued; these documents compile the input basic design data to carry out project engineering activities (see par. 7.3.2).
7.2.3. Contract amendments
As the outcome of Contract Technical Review any amendments to the contract shall be treated according to the contract specifications and with the project procedure 000-ZA-E-09002 “Variation order procedure”.
Following COMPANY approval, the amendment becomes an integral part of the contract and the PM informs the parties involved and gives the authorisation to proceed accordingly.
In case of disputes between the CONTRACTOR and the COMPANY, the matter is treated according to provision of Contract.
7.2.4. COMPANY communication
The tools used to communicate with the COMPANY, including the documents to be submitted for approval, review and information, are listed in the project procedure 00-ZA-E-09000 “Project coordination/administration procedure between COMPANY and CONTRACTOR”.
7.3 Design and development
7.3.1 Design and development planning
The design and development phases are identified on the basis of:
• Design input;
• Design output;
• Design review;
• Design verification;
• Design validation;
• Control of design changes;
as detailed in the following paragraphs.
7.3.2. Design input
Following the contract review, the project procedures
• 171-ZA-E-8001 “Process design basis- BS 171”
• 171A-ZA-E-08050 “Process design basis- ISC”
• 016-ZA-E-08062 “Process design basis – GC 16”
• 017-ZA-E-08070 “Process design basis – GC 17”
• 027-ZA-E-08081 “Process design basis – GC 27”
• 028-ZA-E-08092 “Process design basis – GC 28”
are prepared, which gathers all the general technical data needed as a basis for project engineering.
7.3.3. Design output
The work processes for engineering and development are described in the Quality management system procedures, as indicated in the relevant section of the Quality manual. In addition to defining the methods for project documents issue and project data, these procedures provide the work instructions needed for the verification and, whenever applicable, the validation of design outputs according to input data, to provide objective evidence of their conformity to the product’s requirements.
The PSL’s are in charge of the design activities, under the coordination of the TM. Design outputs include: drawings, specifications, operational and maintenance manuals, Process Flow Diagrams (PFD), Piping & Instrument Diagrams (P&ID), data sheets, Bill of Quantities (BOQ), etc.
7.3.4. Design review
The purpose of design review is to identify and solve the critical aspects of the project, taking into account the project objectives and the COMPANY requirements. Each department shall conduct a design review according to the respective department Work Instructions.
In accordance with the design planning, at least the following interdisciplinary reviews are performed:
• Review of Piping and Instrument Diagrams according to OPR.MO.XE.5012 “Piping and Instrument Diagrams (P&ID)”
• Review of plot plans and model according to OPR.GS.XE.5060 “Plot Plans and Design Model”;
• Review of HSE (see para. 7.1.3).
Individual disciplines shall carry out the respective design reviews in accordance with the departmental technical instructions.
7.3.5. Design verification
The verification and approval of project documents in Home office are carried out according to the methods and responsibilities defined in GP-SPA-ENGON-007 Verification, checking, review and approval of project document.
The project outputs are approved by the concerned project function only if the verification has met the necessary requirements.
The project functions performing the verification activities are authorised by their respective department managers.
In addition to ensuring the conformance to specific project requirements, the verifications are carried out to guarantee an adequate safety level of engineering and to evaluate the risk associated to the plants.
The Interdisciplinary review will be done in accordance to the ILA.GG.EDM.0030 and the associated distribution matrix as a reference to the IDC procedure applied to BS-171. The IDC distribution list will be prepared by projects and Document Controller on the basis of inputs from PSLs.
The activities applicable to the project are performed according to the OPR.RS.XE.5015 “Safety and Reliability Activities for Plant Design”, and to the project procedure 000-ZA-E-85800 “Overall Project HSE management plan”.
7.3.6. Design validation
The final design validation is carried out, whenever applicable, after the successful completion of test runs of the plant or parts of it.
The above validation is formalised by the PM in the “Final Project Report”.
This report states the results achieved, the problems encountered and the adopted solutions, and is distributed to the department managers.
7.3.7. Control of design changes
The identification and indication of the need for a design change can be made by anyone involved in the project.
The design changes can be originated by the following causes:
• Requests from the COMPANY and/or Licensor;
• Work processes or operating methods different from the established program;
• Changes or delays in the activities of a department that could impact the activities of other departments. Such changes shall be communicated to COMPANY for approval.
Activities regarding the change cannot start before the COMPANY’s approval. On completion of the design change, the TM updates the “Design change record”. Design changes and modification will be carried out and documented in accordance with the relevant procedure GP-SPA-ENGON-006 “ Design change management” and the following project procedure:
• 000-ZA-E-09320 “Management of change procedure”
7.4. Procurement
7.4.1. Procurement process
The procurement work process is detailed through the following phases:
• Definition of purchasing strategies and development procedures
• Bidder list definition
• Receipt of purchase request
• Floating request for quotations and invitation to tenders
• Management and closing of bidding phase
• Bid evaluation and negotiation
• Contract/Purchase order assignment and signature and verification of Vendor’s order acceptance
• Management of contract and order changes
• Expediting
• Inspection and testing
• Logistics and customs
• Delivery at site
• Reporting
• Vendor assistance for site activities (Installation and commissioning) The purchasing activities are documented in the following project procedures: • 000-ZA-E-09700 “Procurement execution Plan”
• 000-ZA-E-09701 “Material Acquisition and Management Plan” • 000-ZA-E-09702 “Purchasing Procedure-Materials and Equipment” • 000-ZA-E-09703 “Purchasing Procedure-Services (Subcontracts)” • 000-ZA-E-73004 “Logistics and Shipping Procedure”
• 000-ZA-E-73003 “Expediting Procedure” • 000-ZA-E-73001 “QC requirement for Vendors”
• 000-ZA-E-73002 “Project shop inspection test procedure” • 000-ZA-E-09705 “Spare Parts management Procedure”
In detail, the procurement QA/QC activities, including the identification of critical materials that will require specific Inspection and Testing Plans and pre Inspection Meeting, are documented in the following project procedure:
• 000-ZA-E-09001 “Project material classification” (contains material classification and inspection level as per Appendix D attachment 15, KOC Standard KOC-Q-014)
• 000-ZA-E-09604 “QA requirement for Vendor” (contains requirement for ITP and PIM as per Appendix D attachment 15, KOC Standard KOC-Q-014)
• 000-ZA-E-73001 “QC requirement for Vendors” (contains requirement for ITP and PIM as per Appendix D attachment 15, KOC Standard KOC-Q-014)
• 000-ZA-E-73002 “Project shop inspection test procedure”
The above procedures are produced by the Procurement Department or by the relevant project function, according to the CONTRACTOR’s Quality management system procedures and to the KOC requested project procedure as defined on Contract documents: Appendix E clause 7.8, Appendix D clause 16 and attachment 15, KOC Standard KOC-Q-014.
The relevant compliance with the KOC requested procedure is shown on Annexure 2 of this document.
The activities and methods used to assure that the procured equipment, material and service will be conform to the Contract requirements are detailed in the next chapters. Project vendor list
The CONTRACTOR may purchase material, equipment and services only from Vendors included in the COMPANY vendor list.
Other Vendors can be added to the said list subject to COMPANY approval. Vendor qualification
The requirement for Vendor qualification is coordinated by the Procurement department, by means of other competent departments in the CONTRACTOR. Procurement department also ensures the recording of qualification in the corporate information system and the filing in specific archives.
The target is to evaluate and qualify the capability of Vendors to satisfy the CONTRACTOR’s requirements, through the acquisition and management of information on the Vendors themselves, according to objective and documented criteria.
The evaluations are based on information gathered from questionnaires and visits, according to the CONTRACTOR’s applicable procedures, and are updated based on feedback of the material and services delivered by Vendors and subcontractors. The equipment, materials and construction activities to be purchased are grouped into product classes and the list of Vendors qualified by the CONTRACTOR is regularly updated.
7.4.2. Purchasing information Purchasing data
The purchasing documents shall contain information on the product to be purchased, such as:
• Inspection Data Sheets (IDS) issued by the PSL, according to Project Material Classification for material supplies (see 7.1.5);
• specifications, drawings, reference codes and standards indicating the applicable edition;
• requirements for Quality management of Vendors.
• Field quality control plan for site activities;
The IDS provide the list of tests and inspections to be performed on the products and indicate those which the CONTRACTOR and the COMPANY may attend and the level of Surveillance.
They also list the Quality records and the material certifications to be issued by the Vendor. Based on the IDS, the Vendor prepares the Inspection and Test Plans (ITP) for approval by the CONTRACTORs involved. The implementation methods for the ITP are documented in the project procedure 000-ZA-E-73002 “Project Shop Inspection procedure”
Materials purchasing
The “QA requirements for Vendors” are specified in the project document 000-ZA-E-09604; the “QC requirements for Vendors” are specified in the project document 000-ZA-E-73001. The PSL shall include a copy of the above documents in the purchasing documentation.
Construction services purchasing
The “QA requirements for Construction subcontractors” are specified in the project document 000-ZA-E-09609; the “QC requirements for Construction subcontractors” are specified in the project document 000-ZA-E-09610. The CM shall include a copy of the above documents in the purchasing documentation.
Purchase requisition and technical bid evaluation
The material purchase requisition and the technical bid evaluation are prepared and verified by the technical department involved, and approved by the PM according to the following procedure:
STD-COR-PROC-003: “Request for Quotation – Bid Management – Tabulation”. During Purchase requisition issue, the PSL indicates to the Procurement department the need to obtain conformance certificates from the Vendors, that shall be included in the “Final Test Certificate”.
Spare parts
The preparation of bid requests for spare parts is defined in the project document 000-ZA-E-09705 “Spare Parts Management Procedure”.
7.4.3. Verification of purchased product Materials purchasing
The inspection and testing activities on supplies are defined according to Project Material Classification. See para. 7.1.5.
The inspections and tests at the Vendor’s premises are conducted as indicated in the technical documents attached to the orders and in the inspection and testing plans. The above activities are documented in the following:
• Inspection report;
• Non-conformity report;
• Release note;
• Final test certificate;
• Quality statement.
The agreements for verifications, the coordination with other involved parties, including assigned third parties, and the methods for product release, shall be arranged according to the following project procedures:
• 000-ZA-E-73003 “Expediting procedure”
• 000-ZA-E-73002 “Project Shop Inspection procedure”.
The inspections and tests are conducted in accordance with the ITP, drawings, specifications and any other contractual requirement as expressed on Appendix “D” Construction services purchasing
The site quality control activities are carried out by the Construction subcontractors for the as indicated in the document 000-ZA-09610 “QC requirements for Construction subcontractors” and specific Quality Control Standards (QCSs) issued by the technical departments, under the coordination of the PQM.
QCSs will be endorsed by Construction subcontractors by issuing Quality Control Plans (QCPs); QCPs with CONTRACTOR review comments will be forwarded to the COMPANY for review and for mark up of COMPANY involvement in site QC inspection activities.
All Quality Managers of the Construction subcontractors shall have a reporting line to CONTRACTOR Field Quality Coordinator.
7.5. Production and service provision
7.5.1. Control of work process during site activities
The planning, coordination and control of site activities is ensured by the following project procedures:
• 000-AZ-E-02332 “Site security plan”
• 000-ZA-E-02003 “Temporary site facilities for Company & Contractor” • 000-ZA-E-09801 “Project physical progress measurement procedure”.
The site coordination procedure illustrates the methods to be followed for the coordination between the COMPANY, CONTRACTOR and Construction subcontractor’s representatives on site. The following aspects are detailed:
• Organisation;
• Correspondence;
• Meetings;
• Work planning and coordination;
• Material delivery;
• Daily reports;
• Quality control;
• HSE compliance;
• As-built drawings.
Baseline data Collection
The Contractor will arrange for and undertake all baseline data activities including isometric drawings of the fabricated and installed piping ne\work. The baseline data will provide as a minimum the following information:
(a) the equipment and piping materials of construction;
(b) the joining I welding type, NDT and pressure testing made;
(c) the actual measured wall thickness of ali pipe spools, filtings, connections and static equipment
(d) static equipment and line specifications, design and operating data and reference to P&IDs
(e) painting or coating type and the dry film thickness and reference specification I standard used.
- The Contractor will submit for Company review and approval its "Baseline Data Preparation Procedure" , doc 000-ZA-E-02020 well in advance of the start of the work,
- Completed baseline data records will be submitted to Company in stages
commensurate with the progress of work. The records shall be provided in MS Office Excel sheets so that it could be integrated with the existing Risk Based Inspection (RBI) KOC records and software under the control of Inspection & Corrosion Teams. - Equipment to be included in the baseline data are those newly installed ones by the Contractor within the Scope of the project I Contract. These equipments include the stationary pressure vessels, heat exchange equipment, storage tanks (shop
fabricated or site erected), scraper traps, heaters, tiare stacks, tiare tips, slug
catchers, etc. All drawings for equipment and piping isometrics shall be submitted in soft copy in both AUTOCAD and PDF formats.
Control of mechanical completion and commissioning.
The operating methods for the completion of plant construction, erection and commissioning are based on the following project procedures:
• 000-AZ-E-02019 “Mechanical completion & pre commissioning procedure”; • 000-ZA-E-79001 “Commissioning & start up procedure”.
The above documents are issued according to the relevant procedures of the Quality management system and according to the contractual requirements.
7.5.2. Validation of production work process
The work process validation is required when work process integrity could not be verified by subsequent monitoring or measurement.
The CONTRACTOR shall validate any processes for product and service provision where the resulting output cannot be verified by subsequent monitoring or measurement.
These include the activities regarding welding, thermal treatments, non-destructive controls and qualification of operators.
All these processes are validated by the CONTRACTOR prior to the beginning of works.
The validation activities are:
• qualification of work processes;
• qualification of equipment and personnel;
• use of specified methodologies and procedures.
7.5.3. Product identification and traceability
During all phase of project realisation, the products are identifiable and traceable through well defined numbering and identification systems.
For the bulk piping material, when required by contract, its unique identification is recorded to ensure it can be traced back to the certificate of origin and/or inspection documents.
This activity is addressed to tracing each single component or lot of components for their eventual repair and/or replacement, to identify the Vendor, and to acquire feedback on the damaged, nonconforming or inadequate components.
Identification methods have been established, such as the colour code and/or verification of alloy elements “Positive Material Identification” of piping material, to avoid errors in linking the piping components, which could have a negative impact on the safety or reliability of the plant.
These activities are defined for each project and documented in dedicated specifications. For the Project Material Identification, in the event of critical circuits, the project procedure 000-AZ-E-02014 “Positive material identification procedure” is issued.
7.5.4. COMPANY property
With the purpose of identifying responsibilities related to COMPANY property and in order to protect its value, the CONTRACTOR manages the following in compliance with contract specifications:
• parts or components provided by the COMPANY that will be incorporated in the final product;
• the COMPANY’s intellectual property including specifications, drawings and confidential information.
Therefore, the CONTRACTOR shall carry out the following:
• identify the COMPANY’s property;
• verify if the COMPANY’s property is damaged;
• keep records of the damage and notify the COMPANY;
• protect the COMPANY’s property (as set out in the following procedures: 000-AZ-E-02013 “Material management, storage and handling procedure”).
7.5.5. Product preservation
The handling, storage, packaging, preservation and delivery of material to the established destination specified in the order shall conform to the SPC.IB.GEN.0001 “Packaging and delivery of material and equipment”, and to the general purchasing conditions.
In compliance with KOC standard KOC-Q-014, the CONTRACTOR will ensure a proper material management in order to:
• To ensure proper transportation and handling equipment during loading, offloading and handling of equipment and materials
• To consider preservation of materials during site handling, transportation and storage
• To consider timely use of material with limited life
• To ensure material inspection and identification on receipt • To ensure accurate identification of material on issue
• To ensure non-conforming and undefined materials will be held in quarantine until they are rectified, replaced or accepted by concession
The following project procedure shall be produced 000-ZA-E-73003 “Expediting procedure”.
The material and equipment on site is managed according to the project procedure 000-AZ-E-02013 “Material management, storage and handling procedure”. The project procedure will be in compliance with KOC standard KOC-Q-014 clause 7 The following checks will be made periodically (for stored materials and equipment) and when any new equipment or materials are received:
• Inspection for completeness and proper type as per the Contract requirements and purchase order specifications
• Periodic inspection and precautions to assure adequate storage conditions and to guard against damage for handling and deterioration during storage
• Functional testing, either prior to or after installation, or both, as required to determine satisfactory operation
• Identification and protection from improper use or disposition • Verification of quantity
7.6. Subcontracts qualification & control
Preparation of subcontracts, approvals of Subcontractor selections, and administration procedures for subcontracts shall be per the requirements of Clause 7.0 of the General Conditions of Contract and Clause 17.0 of Appendix D (Project Administration and Coordination Procedure) The Qualification process for Subcontractor is governed by Corporate procedure STD-COR-PROC-001 Vendor Management. During request for Bid phase the complete set of Company Quality requirements requested by KOC-Q-014 is given to subcontractor.
Moreover to define more in detail the managing aspect to be implemented by the Subcontractor and the control operated by Contractor Two project procedure are issued, the two document set the requirements and planning for Control subcontractor Quality activities: 000-ZA-E-09609 “Quality Assurance General Specification for Subcontractor” and 000-ZA-E-09610 “Quality Control General Specification for Subcontractor”, these two documents are part of Contractor Project Quality System and are issued to Company for approval.
Contractor will manage the subcontracting aspects with dedicated Project procedure 000-AZ-E-02005 Sub-Contract Administration Procedure”
Subcontractor will issue all the require Management/Technical Project documentations in order to demonstrate their compliance and understanding of the relevant assigned job and the requested Contractor requirements. The Subcontractor documentations will be subject to Contractor approval and to Companies approval. 7.7. Quality Control and inspection activities during construction phase
All construction and installation activities will be made in accordance with KOC approved procedures, the Project procedure will be in compliance with KOK-Q-014 appendix G &H.
In accordance to Company requirements contained on Appendix E clause 7.10, KOC-Q-014 clause 6.6 Contractor will provide a resident organization for QC activities, a resident QA/QC manager (FQM) will be on charge for all the QC activities and relation with the Companies for all the aspects related to QC activities, for each discipline work a dedicate QC Supervisor/Inspector will be put in place in order to monitor and control all the inspection and test foreseen on the ITP, more specific task is clearly defined on document “Project organization, function, responsibilities and charts” 000-ZA-E-09602
The site quality control activities are carried out by the CONTRACTOR (direct hiring works) and by Construction subcontractors for the subcontracted works.
Direct hiring
The quality control activities will be carried out by CONTRACTOR as indicated in the Quality Control Plans (QCPs) issued by the technical departments, under the coordination of the PQM
QCPs will be forwarded to the COMPANY for review and for mark up of COMPANY involvement in site QC inspection activities.
Requirements for execution of QC activities related working processes are defined in the specification 000-ZA-E-09610 “Quality Control Requirement for Construction Subcontractor”, it is valid also for direct hiring works.
The specification 000-ZA-E-09610 is in accordance to KOC standard KOC–Q-014 clause 6.6
More in detail, it outlines the requirements for:
Quality control planning and implementation, (KOC –Q-014 clause 6.6.2.1)
Quality verifications (initial, in-process, final, Third Party Inspection – TPI - and by CONTRACTOR and COMPANIES), (KOC –Q-014 clause 6.6.2.2)
Control of construction processes (including special processes), (KOC –Q-014 clause 6.6.6 & 6.6.7)
QA/QC co-ordination (including Inspection Notification), (KOC –Q-014 clause 6.6.2.4)
Inspection and Test Reporting (KOC –Q-014 clause 6.6.2.3)
Quality Control Specifications applicable to the Project (KOC –Q-014 clause 6.6.1.2)
QCP/ITP (Inspection and test Plan) To be issued (KOC –Q-014 clause 6.6) Subcontracted work
A dedicated Specifications for subcontracting requirements for QA/QC are issued for COMPANY approval: 000-ZA-E-09609 “Quality Assurance Requirement for Construction Subcontractors & 000-ZA-E-09610 “Quality Control Requirement for Construction Subcontractor”.
The Contractor will deliver to the Subcontractor a complete set of Quality Control Standards (QCS) to enable the Subcontractor to prepare the QCPs applicable to the Project, (list of QCP/ITP is given on Appendix 1 of 000-ZA-E-09610 “Quality Control Requirement for Construction Subcontractor), each QCS is issued for each main discipline work. The QCS contains several ITS (Inspection and test Standard) and related Check List to be used as base for ITP, the ITS’s and check lists covers all the test and control foreseen to the works related to the discipline of the mentioned QCS. The Subcontractors will issue the QCP, (which contains the related ITP to be used for construction), with the Project code number already assigned.
The specification 000-ZA-E-09609 “Quality Assurance Requirement for Construction Subcontractor” provide requirements for the organisation, the procedures and the tools to be set up by Subcontractor to fulfil the COMPANY quality requirements (KOC-Q-014, clause 6.6.3) in terms of:
Quality Management System implementation, Procedures to be prepared and submitted, Personnel mobilisation and qualification
Construction processes to be controlled, Quality auditing activities
Quality meetings,
Management of nonconformities, Reporting to CONTRACTOR Continual improvement
The specification 000-ZA-E-09609 is in accordance to KOC standard KOC–Q-014 clause 6.6
The specification 000-ZA-E-09610 “Quality Control Requirement for Construction Subcontractor” provides requirements for the execution of QC activities related working processes.
More in detail, it outlines the requirements for:
Quality control planning and implementation, (KOC –Q-014 clause 6.6.2.1)
Quality verifications (initial, in-process, final, Third Party Inspection – TPI - and by CONTRACTOR and COMPANIES), (KOC –Q-014 clause 6.6.2.2)
Control of construction processes (including special processes), (KOC –Q-014 clause 6.6.6 & 6.6.7)
QA/QC co-ordination (including Inspection Notification), (KOC –Q-014 clause 6.6.2.4)
Inspection and Test Reporting (KOC –Q-014 clause 6.6.2.3)
Quality Control Specifications applicable to the Project (KOC –Q-014 clause 6.6.1.2)
QCP/ITP (Inspection and test Plan) To be issued (KOC –Q-014 clause 6.6) CONTRACTOR will review and approve the QCP/ITP before transmission to the COMPANY for approval and insertion of Company W/H point, CONTRACTOR will forward the QCP/ITP 14 days prior the start of the relative works.
Baseline data
All the information regarding the welding traceability as: piping materials,
joining/welding type, NDT and pressure testing made,
measured wall thickness of pipe spools, fitting, connection and static equipment static equipment and line specifications, design and operating data and reference
to P&IDs
painting or coating type and the dry film thickness are listed in the Welding summary list.
The modality to management the Welding summary list and the Welding summary list form are described into Quality Control Plan for Welding.
7.8. Control of monitoring and measuring equipment 7.8.1. Control of monitoring and measuring tools, instrument
As per KOC-Q-014 clause 6.6.8 requirements, the project specification 000-ZA-E-09610 “QC requirements for Construction subcontractors” par. 4.4, defines the
the calibration and preservation of testing, (KOC –Q-014 clause 6.6.8.2)
identification and calibration of measuring and inspection equipment (KOC –Q-014 clause 6.6.8.2)
calibration records (KOC –Q-014 clause 6.6.8.3) and indicates the certificates to be issued.
The prescriptions apply to direct hiring and to subcontracted works
Records of calibration and control sheets shall be maintained by the Contractor; FQM will be responsible for the management of the updating and disposition of control sheets.
7.8.2. Laboratory qualification
All testing laboratories that will be utilized by the Contractor, sub-Contractors will be competent in accordance with the requirements of clause 8.0 of KOCQ-014 Rev 1 & BS EN ISO/IEC17025. Contractor and subcontractors will use laboratory as Intrex and Gulf Inspection.
7.9. Constructability review
Constructability program, applicable to the Project, is performed according to project document “000-ZA-E-09022 Constructability Procedure”.
The CII (Construction Industry Institute) defines constructability as the optimum use of construction knowledge and experience in planning, design, procurement and field operation, to achieve overall project objective.
As part of its policy of continuous improvement in job management, Saipem considers the systematic application of Project Management methodologies (Best Practices) to be an element of fundamental importance for achieving first-rate results in projects. The application of Best Practices also contributes to the spread and rise of the Project Management culture at all levels
Constructability rests on three fundamental pillars: Project Planning, Site Layout and application of the so-called Major Construction Methods.
In reality, it is necessary to pay extra attention to certain additional points:
Develop and maintain a strong will to achieve maximum project cost effectiveness Make use of specific constructability techniques (e.g. standardization,
modularization etc.) to achieve the set objectives Involve the construction experts “early on” Plan construction activities with care
Insist on obtaining the receptivity of design engineers to construction needs
- G
WORK PROCESS: The work process is divided into the following phases Setting up of Constructability Team
Information collection
Preparation and issue of Project Constructability Procedure Constructability Implementation Schedule
Kick-off meeting
Discipline review of constructability checklist
Objectives definition and constructability plan preparation Constructability plan review meetings
During construction at planned stages established inside the constructability procedure a dedicated Constructability reviews will be performed in order to assure the correct conformance to the programs and to foreseen and correct eventual future loss of time.
8. MEASUREMENT, ANALYSIS AND IMPROVEMENT 8.1. General requirements
The activities that contribute to the measurement, analysis and improvement process are aimed at:
• demonstrating the conformity of the product by means of design reviews and verifications, tests and inspections conducted at the Vendor’s premises and during construction, controls and final tests during plant start-up;
• ensuring the conformity of the Quality management system by means of project reviews and internal audits;
• continually improving the effectiveness of the Quality management system by reviewing the work processes.
8.2. Monitoring and measurement
The monitoring and measurements activities enable decision-making based on objective evidence.
The feedback obtained from the project and updated continuously constitutes the base of improvement for the CONTRACTOR’s services through the involvement of all parties concerned.
8.2.1. COMPANY satisfaction
The degree of COMPANY satisfaction is monitored by the BM, both during project development with the assistance of the PM, and during post-sales activities.
The COMPANY’s complaints are formally communicated to the PM who verifies if the complaint is justified. If so, he then proceeds to solving the COMPANY’s complaint, both directly and by involving the managers of the departments concerned.
All the COMPANY complaints are documented and managed by means of internal or external correspondence and minutes of meetings (MOM) to identify adequate corrective action.
The above-stated correspondence and minutes are recorded and filed.
8.2.2. Project audits
Project audits are planned and conducted in the Contractor home office at Contractor and Subcontractor site on Vendors and on testing laboratories with the following objectives:
• verify that the activities are performed in accordance with the provisions of the project Quality system;
• assess the adequacy and effectiveness of the project Quality management system in relation to established Quality objectives, particularly considering the congruence and integration among activities;
• identify possible deficiencies, determine the causes of such and, where necessary, promote appropriate corrective action;
