1171 V1.0

Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID : SP-1171 (ERD 84-02)April 2000 Filing key :

Specification for Quality Assurance of Design, Construction and Engineering

Works

Keywords:

BS EN ISO 9000Organisational StructureQuality ManualQuality SystemQuality PolicyQuality AssuranceQuality ControlQuality ManagementQuality PlanQuality Control PlanQuality AuditProcess ControlProcedures

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

Specification for Quality Assurance of Design, Construction and Engineering Works Version 1.0

Authorised For Issue

Signed :........................................................UER (OTT/1)CFDH Materials and Corrosion

The following table lists the four most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No. Date Author Checked Scope / RemarksVersion 1.0 24/04/2000 OTT/151 OTT/15 Revision and re-formatting of ERD 84-02

(September 1995 issue).

April 2000 SP-1171i

Version 1.0Specification for Quality Assurance of Design, Construction and Engineering Works

Contents

1. Introduction.................................................................................................................... 11.1 Purpose....................................................................................................................... 11.2 Changes to the Specification.......................................................................................11.3 Specification Owner's Responsibility..........................................................................11.4 Effective period.......................................................................................................... 11.5 Review and Improvement...........................................................................................1

2. Specification Requirements............................................................................................22.1 Scope.......................................................................................................................... 22.2 Quality System............................................................................................................ 22.3 Documents to be Submitted.........................................................................................4

2.3.1 Quality System.................................................................................................42.3.2 Quality Manual................................................................................................52.3.3 Contract Quality Plan (CQP)............................................................................6

2.4 Quality Management during the Contract..................................................................122.5 Documentation..........................................................................................................122.6 Quality Assurance, Inspection (Quality Control) and Verification Personnel.............122.7 Qualifications and Duties of The Supplier’s Quality Assurance, Inspection (Quality Control)

and Verification Personnel........................................................................................142.7.1 Corporate Quality Assurance Manager............................................................142.7.2 Quality Assurance Engineer............................................................................152.7.3 Quality Control Inspector - Multi-Discipline (Welding, Painting, NDE).........162.7.4 QC Inspectors - Civil and Structural...............................................................162.7.5 Q C Inspectors - Instrumentation....................................................................17

2.8 Quality Assurance Auditing.......................................................................................172.9 Purchasing................................................................................................................ 182.10 Inspection, Measuring and Test Equipment..........................................................182.11 Third Party Certification......................................................................................192.12 Pressure Vessels...................................................................................................20

2.12.1 Vessels Manufactured Outside Oman.............................................................202.12.2 Vessels Manufactured in Oman.....................................................................21

2.13 Static Equipment.................................................................................................212.14 Quality System Certification:...............................................................................22

Appendix A - Glossary of Definitions, Terms and Abbreviations....................................23

Appendix B – References...................................................................................................25

Appendix C - Contract Quality Plan and Contract Quality Plan Guidelines..................26

User Comment Form......................................................................................................... 36

SP-1171 April 2000ii


1. Introduction

1.1 Purpose

This specification revises and replaces ERD 84 -02, 1995, Quality Assurance Engineering Reference Document, issued in September 1995. The purpose of this Specification is to specify the Company's minimum requirements for Quality Assurance in all Contracts and Purchase Orders with their nominated Suppliers (Consultants, Contractors and Vendors). This specification is intended to set Company Quality Assurance Standards during design, procurement and construction phase of facilities

1.2 Changes to the Specification

This specification shall not be changed without approval from the Custodian, the Materials and Corrosion Functional Discipline Head (CFDH), UER (OTT/1), who owns this specification. Any user of this specification, who encounters an inaccuracy or ambiguity, is requested to notify OTT/15, using the User Feedback page provided at the end of this specification and send the copy with comments and personal details to DCS.

1.3 Specification Owner's Responsibility

The owner of this specification, OTT/1, as CFDH Materials and Corrosion, is responsible for authorising all proposed deviations or amendments to the specification and for the instigation of periodic reviews and updates in accordance with Clauses 1.2 and 1.5.

1.4 Effective period

The requirements of this specification shall remain in force indefinitely unless superseded by an authorised revision.

1.5 Review and Improvement

This specification will be reviewed and updated once every three years. The review authority will be UER (OTT/1, CFDH Materials and Corrosion). Any revision and updates before three years period, is at the discretion of the reviewing authority, UER (OTT/1).

April 2000 Page 1 SP-1171

Version 1.0 Specification for Quality Assurance of Design, Construction and Engineering Works

2. Specification Requirements

2.1 Scope

This specification presents the Company's minimum requirements for Quality Assurance in all Contracts and Purchase Orders with their nominated Suppliers (Consultants, Contractors and Vendors). The requirements are based on the use of the BS EN ISO 9000 Series of Quality Management and Quality Assurance Standards.

The body of this specification is the Quality Assurance Specification and forms part of the Contract or Purchase Order. Terms and abbreviations used are defined in Appendix A and referenced standards are listed in Appendix B.

Appendix C, Contract Quality Plan and Quality Control Plan Guidelines, offers Suppliers (Consultants, Contractors and Vendors) guidelines on the contents and development of a Contract Quality Plan and Quality Control Plan, that will meet the requirements of this specification.

2.2 Quality System

The Supplier (Consultant, Contractor, Manufacturer and Vendor) shall implement and use a Quality System that complies with the appropriate Standard from the ISO 9000 Series, (latest edition), as listed below, and the requirements of this specification.

BS EN ISO 9001: Quality Systems - Model for quality assurance in design development, production, installation and servicing.

or

BS EN ISO 9002 : Quality Systems - Model for quality assurance in production, installation and servicing.

The Standard shall be selected to cover all work activities (consultancy, project management, procurement, construction, and provision of goods, products or services), associated with the Contract or Purchase Order.

Where the Contract includes design work, ISO 9001 shall be used. Where the Contract is purely for production, construction, installation, commissioning and hand over, then ISO 9002 shall be used.

If any part of the Contract is Sub-Contracted, the Supplier shall comply with Clause 4.6.2 in ISO 9001/9002, which requires the Sub-Contractor to maintain an appropriate Quality System. The Sub-Contractor shall implement a Quality System that meets the requirements of ISO 9001 or ISO 9002, as appropriate for the sub-contracted work. The Supplier shall remain ultimately responsible for the quality of the Sub-Contractor's work.

The term Process Control in ISO 9000, shall be considered to embrace all work activities from Tendering and Contract Award to Completion of the Contract. Activities such as; Contract Management, Cost Control, Planning and Scheduling, Progress Measurement, Reporting, 'As Built' Documentation etc. shall have properly documented Procedures or Work Instructions.

Suppliers in selected Work Categories may be required to attain Third Party Registration of their Quality System. The registration shall be from an Accredited Certifying Body (for example, BSI, BV, DNV, Lloyds etc.), who are themselves accredited by a National Accreditation Authority to assess Quality Systems. Work Categories required to attain registration will be informed by the Work Category Custodian (see clause 2.14).

SP-1171 Page 2 April 2000


Where Suppliers are not required to attain Third Party Registration, they shall demonstrate that they have a Quality System that complies with ISO 9001 or 9002, as appropriate for the contract or purchase order scope. Consideration should be given to attaining Third Party Registration as a means of maintaining the Quality System and verifying compliance with this specification.



2.3 Documents to be Submitted

The following documents shall be submitted with the Tender. Post Contract, the following documents shall be submitted within 14 days of Contract award, and the Quality System shall be implemented at the Work site, within 3 to 4 weeks of the award of the Contract.

With Tender Within 14 Days of Contract Award

2.3.1 Quality System Additional information that has changed since the tender.

2.3.1.1

2.3.1.2

Where the Supplier’s Quality System is to be certified to ISO 9001 or 9002 by an Accredited Certifying Body, a copy of ISO 9001 or 9002 Certificate shall be submitted.

If the Supplier’s Quality System is not certified to ISO 9001 or 9002, the Supplier shall submit evidence, that an acceptable Quality System, complying with either ISO 9001 or ISO 9002, as appropriate, is in operation. This requirement can be fulfilled by submitting any of the following:

1. Copies of System and Compliance Audit Reports prepared by the Company on other Contract.

2. The Supplier shall arrange for an Accredited Certifying Body to carry out a baseline System Audit of the Supplier’s Quality System against ISO 9001 or 9002. A copy of the Audit Report shall be submitted with the tender.




2.3.2 Quality Manual An updated Quality Manual, which shall indicate any revisions to the manual since submitting the tender.

This shall include, but shall not be limited to :

1. Quality Policy statement.2. Brief description of the Supplier’s company and the business activities.3. Quality objectives and scope of the Quality System.4. Details of how the Quality System addresses the requirements of the ISO

9001 or ISO 9002 System Elements. Cross-reference to Corporate Quality System Procedures should be included.

5. Description of the Quality System documentation (Quality Manual, Quality System Procedures, Work Procedures, Work Instructions, Contract Quality Plans etc.), and how it is controlled.

6. Corporate Organisation Chart, highlighting the Quality Assurance, Quality Control, Inspection and Verification personnel.

7. Typical Contract Organisation Chart, showing the relationship to the Corporate Organisation.

8. Appendices to the Quality Manual. (Note: These items are included as Appendices to enable them to be revised independently of the Quality Manual, to show current status). Index of Corporate Quality System Procedures / Work Instructions

etc., encompassed by Quality System documentation, implemented and used by the Supplier to control work activities, showing the current revision status and issue date. The Company shall have access to the Procedures / Work Instructions.

List of positional/functional Job Descriptions showing the Responsibilities and Authority of all personnel whose work has a quality function. The Company shall have access to the Job Descriptions on request.




2.3.3 Contract Quality Plan (CQP) The Contract Quality Plan shall be approved by the Company, (QA & QC section) prior to work commencing. This plan shall be an updated revision of the Tender issue plan. The CQP shall include and address all the relevant and applicable elements of ISO 9001 or 9002 as appropriate.

This shall include:

2.3.3.1 Control of Contract Quality Plan

1. Index.2. Revision Status.3. Distribution List.

1. Index.2. Revision Status, together with the Control Mechanism of the CQP and a

Distribution List. The Company distribution shall be as the Contract documents, with a minimum of:- Company Representative.- Head of Quality Assurance Services, OTT/15- Company Site Representative.- In-charge Interior QA & QC Services - OTT/151

3. Details of the Supplier’s Procedures for preparing, reviewing, revising and re-issuing the Contract Quality Plan during the Contract shall be stated in the CQP.

2.3.3.2 General

1. Outline of how the Supplier’s corporate Quality System shall be applied and implemented on the Contract.

2. A brief description of all Quality related aspects of the Contract, related to the Scope of Work. Identify all main work activities and sub-activities to be controlled by the Contract Quality Plan.

3. Identify which activities will be carried out by Sub-Contractors. Include details of Sub-Contractor’s Quality System and how it will be monitored and controlled by the Supplier.

1. Details of how the Corporate Quality System documentation shall be applied and implemented on the Contract. The CQP shall include contract specific quality system structure.

2. Detailed Scope of Work of the Contract, together with a detailed description of the Quality related aspects of the Contract. Inclusion of copy of sheets from Contract shall not be acceptable.

3. Identify all work activities and sub-activities, including those performed by Sub-Contractors, to be controlled by the CQP.

4. Detailed methodology how quality system and work performed by Sub-Contractor shall be monitored and controlled by the Supplier.

5. Details of how Quality Planning shall be undertaken and controlled.




2.3.3.3 Quality Assurance Objectives

1. Reference to the Contract and other documents whose requirements are to be met.

1. Detailed list of the Contract and other documents whose requirements are to be met, together with their revision status.

2. Indicate the location where these documents are available, the Procedures for controlling and revising them and the person responsible.

3. Include a Distribution Matrix for all documents.

2.3.3.4 Organisational Structure

1. A Contract specific Organisation Chart, identifying by Name and Job Title all personnel down to Foreman level. Highlight the Quality Assurance, Quality Control, Inspection and Verification personnel. Show their reporting relationships for the Contract and in the Corporate organisation. Show the relationship between office and site based staff. Indicate if personnel are full or part time on the Contract.

2. Establish a detailed schedule of responsibilities (may be in the form of Job Description), for all functions carrying out quality related activities. Define the authority level for each function and reporting responsibilities.

3. Curriculum Vitae of the QA and QC personnel viz. Corporate Quality Assurance Manager, the Senior Quality Assurance Engineer(s), Welding Engineer and Q C Inspector(s) (MDIs and other disciplines) for the Contract, together with copies of their qualifications, including any Training courses attended. Photocopies of qualifications must be attested. All QA and QC personnel shall be subject to approval by Company QA / QC section prior to mobilisation on contract and to site. The Company shall review the CVs and reserve the right to interview and or submit all QA and QC personnel to an examination to determine their suitability for the work they are required to perform and reject unsuitable candidates.

Note: The qualification, training and experience of QA and QC personnel shall be appropriate to the nature and scope of the Contract and to be read in conjunction with clause 2.7 of this SP.

1. A final Contract specific Organisation Chart, highlighting Quality Assurance, Quality Control, and Inspection and Verification personnel. Confirm mobilisation dates for all staff down to Foreman level.

2. Provide a Corporate Organisation Chart identifying by Name and Job Title all personnel who will interface with the Contract personnel, Sub-Contractors, Vendors or the Company. Define roles, responsibilities and reporting relationships of all personnel identified in the Contract specific organisation with interface with Corporate personnel.

3. Where duties other than Quality Assurance and Inspection are to be carried out by Quality Assurance / Inspection personnel, details of other duties shall be submitted, together with the times to be spent on each activity.

4. Details of any Sub-Contractor’s Quality Assurance / Inspection personnel, indicating how the Supplier will monitor and control the Sub-Contractor’s Quality System.

5. Details of the training schedule for all persons to be employed on the Contract (include all training, not just Quality training). Include all personnel requiring formal certification for the Contract, for example, Welders.

6. Submit CVs of QA and QC personnel together with copies of qualifications including training, for review and approval by Company QA / QC section.




2.3.3.5 Service Contract Work Orders

Indicate how the Contract Quality Plan and specific Quality Assurance requirements will be applied to individual Work Orders issued under a Service Contract. This may be in the form of a Project Quality Plan, developed from the Contract Quality Plan.

Details of how specific Quality Assurance requirements will be formulated for individual Work Orders in Service Contracts, how they relate to the Contract Quality Plan and who will be responsible for identifying the requirements and implementing them at the Work site.

2.3.6.6. Applicable Procedures, Work Instruction & Checklists

1. List of Corporate Quality System Procedures, Work Procedures and Work Instructions, with current Revision Status and Issue Date that shall be used on the Contract without revision.

2. List of Corporate Quality System Procedures, Work Procedures and Work Instructions, with current Revision Status and Issue Date, that require revision before they meet the Contract requirements. Denote who is responsible for revising the documentation and the date when it shall be completed.

3. List of Contract Specific Procedures and Work Instructions required to be developed for the Contract. Denote who is responsible for developing and approving the documentation and the date when it shall be completed.

4. List of procedures and work instructions that shall be used on the Contract by Sub-Contractor(s) for assigned work activities, including those to be developed or revised.

1. List of all Corporate Quality System Procedures, Work Procedures and Contract Specific Procedures, Work Instructions, Checklists and Standard Forms, with current Revision Status and Issue Date, that shall be used on the Contract without revision. Documentation requiring revision to meet Contract requirements, shall be listed indicating dates when shall be issued and the person(s) responsible for revision and implementation. The listing shall follow the normal workflow. Indicate dates when Contract specific Procedures and Work Instructions shall be issued and the person(s) responsible for developing, reviewing and implementing them.

2. The Supplier shall provide the Company on request, all-Corporate Quality System Procedures, Work Procedures, Work Instructions, Checklists and Standard Forms applicable and required for the Contract. They shall be issued as ‘Controlled Copies’ to the Company within 2 weeks of Contract award or whenever demanded by Company. This may be in the form of a separate Contract Procedures Manual or separate volume of the Contract Quality Plan.

3. Copies of Contract Specific Procedures, Work Instructions, Checklists and Standard Forms shall be issued to the Company within 4 weeks of Contract award (or at least 2 weeks before the work activity commences, for Contracts of less than 6 weeks duration.

4. List of procedures and work instructions that shall be used on the Contract by Sub-Contractor(s) for assigned work activities, including those to be developed or revised by dates.




2.3.3.7 Quality Control Plans (Inspection &Test Plans)

1. List of Corporate Quality Control Plans, with current Revision Status and Issue Date, that will be used on the Contract without revision. They shall be grouped by discipline (for example, Contract Management, Civil, Mechanical, Piping, Electrical, Instrumentation, Commissioning, Handover, ‘As Builts’ etc.)

2. List of Corporate Quality Plans, with current Revision Status and Issue Date that require revision before they meet the Contract requirements. Denote who is responsible for revising the documentation and the date when it will be completed.

3. List of Contract Specific Quality Control Plans, required to be developed for the Contract. Denote who is responsible for producing the documentation and the date when it will be completed.

4. List of Quality Control Plan(s) that shall be used on the Contract by Sub-Contractor(s) for assigned work activities, including those to be developed or revised.

1. List of QCP, with current Revision Status and Issue Date, to be used on the Contract. Indicate dates when Contract specific QCP will be issued and the person(s) responsible for developing, reviewing and implementing them. All QCPs shall be approved by the Company prior to work commencing. Above include QCP(s) from Sub-Contractor(s).

2. ‘Controlled Copies’ of all Corporate and Contract Specific QCPs, including those from Sub-Contractor, to be used on the Contract shall be included in the CQP.

- The Quality Control Plans shall include:- List of Activities and Sub-Activities requiring Quality Control and or stage

inspection.- Controlling Document (Supplier’s Procedure / Work Instruction, Contract

Specification, Specifications (SP), Procedures (PR), ERD, DEP, International Code or Standard).

- Specified Acceptance / Rejection Criteria and Actual Value(s). When it is practically not possible to indicate or accommodate Actual Value(s) in QCP, then cross reference to source providing such information shall be shown in QCP(s) (for example, Clause Reference, Table in SP, PR, ERD, DEP, Code or Standard etc.).

- Supplier’s Verification Personnel responsible for the Quality Control activity.- Verifying Document / Quality Control Record, where test results are recorded

and endorsed by the Supplier’s Verification Personnel.- Hold, Witness, Surveillance, Monitoring and Review points by the Supplier,

Third Party or Company, shall be identified. Appropriate legends for 'Hold', 'Witness', 'Review', 'Surveillance' and 'Monitoring' shall be used in the QCP(s).

- Sub-Contractor(s) QCP(s) and quality document(s) shall be reviewed and endorsed by Contractor, before submitting for Company approval.

- When TPI is a Contract requirement, the QCP(s) and Quality document(s) shall also be reviewed and endorsed by the nominated TPI Agency.




2.3.3.8 Quality Records

1. None.

1. Include details of all Quality Records and their formats and Test Packs to be used on the Contract, either by the Supplier and or Sub-Contractors. Where new documentation is required, denote who is responsible for developing and approving the documentation and the date when it will be completed.

2. The Verifying Document / Quality Record shall show the specified value and the measured value. Where it is reasonably difficult to show specified value, adequate details of reference standard/code/ERD/SP/DEP shall be provided for specified value.

3. Verifying Documents that shall be issued to the Company as Quality Records shall be identified and given a reference number.

4. Include a Distribution Matrix for all Quality Records, which shall include the following as a minimum:- Records to be reviewed by the Company during the Contract.- Records requiring Approval / Hold & Witness by the Company.- Records to be handed to the Company.- Records to be kept for use by the Supplier only.- Define the content and format of Test Packs, per discipline, and shall be agreed

with the Company Representative in advance. Records of Company approval shall be maintained by the Supplier.

2.3.3.9 Audit Schedule

1. Include a preliminary Internal Audit Schedule.2. Include a preliminary External Audit Schedule of Sub-Contractors.

1. Include a detailed Audit Schedule for the Contract. The schedule shall identify the Internal Audits the Supplier will conduct on the Quality System throughout the Contract.

2. The schedule shall also include details of External Audits the Supplier will carry out on Sub-Contractors and Vendors.

3. A Compliance Audit shall be carried out at least once per month on all work activities that have recently commenced.

4. External and internal audits shall be carried out by trained, qualified and experienced auditors. Auditors shall possess IRCA, UK or equivalent auditing qualification. (Note: Also see clause 2.8 of this SP).

5. Supplier shall provide a copy of their internal and external audit notification to Company QA / QC section at least five working days in advance of the planned audit date. Company reserves the right to join the audit as an observer.

6. Supplier shall provide Company QA / QC section copies of all internal and external audit reports along with audit check list used during audits.




2.3.3.10 Third Party Certification of the Contract

1. Where Third Party Certification of the Contract is required in the Scope of Work, include details of the Third Party Certification Authority. Include details of the services they will provide to the Supplier, in the form of a draft Sub-Contractor’s Quality Plan. Provide details of the personnel they will employ on the Contract.

1. Include a detailed monitoring programme in the form of a Sub-Contractor’s Quality Plan showing all auditing, monitoring, surveillance, inspection, witnessing and acceptance testing to be carried out by the Third Party Certification Authority.

2. Include Curriculum Vitae of all personnel for approval by the Company QA / QC section.



2.4 Quality Management during the Contract

The following Quality matters shall be reported in the Contract Weekly / Fortnightly / Monthly Report:

Summary of Contract Quality Plan development and Procedure development and approvals.

Summary of Internal and External Audits carried out, reported against the Audit Schedule.

Listing of Corrective Actions for each Audit, the current status and the planned dates for follow up and closeout.

Areas of concern or weakness identified in the Quality System.

Details of any investigations into non-conformance and action to prevent recurrence of any Quality System failures.

Summary of Tests and Inspections carried out ‘on site’ and ‘off site’ and on Sub-Contractors.

During Weekly / Fortnightly / Monthly meeting with Company, the Supplier shall furnish details on the following items:

Number of Customer Complaints raised during the preceding period and the cumulative total, action taken to address complaints and close out.

Quality issue raised by Company QA / QC, details of action taken to address the issues and close out.

Number and nature of variance raised, cumulative numbers, approval status, implementation and documentation of the variance.

Supplier internal NCRs raised, corrective and preventive action and close out. Welder performance and repair rates based on radiography. Status of deployment of QA and QC resources and their Company approval status.Supplier shall ensure that the site Quality Management System is reviewed at least once in a quarter

2.5 Documentation

Documentation related to the Quality System shall be available at the location where work is being carried out.

The Supplier shall maintain the latest revision of the relevant Contract Documents, Drawings, all Contract Technical Specifications (SPs, PRs, ERDs, DEPs, HSE Manual), Standards (BS, DIN, ASME, etc.), Procedures and Work Instructions, at the location where work is being carried out.

A Document Control procedure shall control the issue, distribution, change, review and withdrawal of all documentation.

2.6 Quality Assurance, Inspection (Quality Control) and Verification Personnel

The Supplier shall nominate. a Senior Manager (Management Representative), who shall have defined responsibility for the Corporate Quality System, in accordance with Clause 4.1.2.3 of ISO 9001/2.

The Supplier shall assign sufficient Quality Assurance / Inspection (Quality Control) and Verification Personnel to the Contract to ensure that the Quality Management System, Quality Assurance and Quality Control are effectively established, implemented and maintained throughout the Contract. There shall be sufficient personnel to cover all disciplines work and activities, all Sub-Contractor's work and off site facilities.



The Supplier shall assign a Q A Engineer at each construction site. The Senior Quality Assurance Engineer and Quality Control Inspector(s) (MDIs and discipline) shall be assigned / based at each construction site / location where work is being carried out. They shall be independent of the work being performed and shall have no other duties or responsibilities, unless prior approval in writing is granted by the Company.

Where elements of Quality Control are part of the responsibilities of production staff and workers, the Supplier shall identify independent verification requirements and document in the QCPs and provide adequate resources. Quality control responsibilities of production staff shall be adequately documented in their job descriptions.

The Quality Assurance Engineer shall functionally report to the Supplier's Corporate Q A Manager on all Quality and technical matters and liaise with Site Manager on day to day activities. The Q C Inspectors shall report to Q A Engineer.

The Supplier shall provide the following minimum QA / QC staff at each construction site. The actual staffing levels will depend on the work load, complexity of the work, number of disciplines working on the Contract at any one time, number of Sub-Contractors, and most importantly, the number of locations where work is being carried out on site and off site, but shall not be less than that is specified below in any case. Company decision regarding QA / QC staffing shall be final and binding on the Supplier and its Sub-Contractors. The use of multi-disciplined Inspectors is acceptable provided they have appropriate qualifications in each of the disciplines they are required to inspect. The Management Representative is not included and is additional to the numbers below.

Supplier shall ensure that Inspection (Quality Control) and Verification Personnel are provided to cover activities and works in all disciplines areas.

Deployment of Inspection (Quality Control) and Inspection personnel by Supplier does not absolve nor relieve Sub-Contractor(s) of their responsibility to provide their Inspection and Verification personnel in adequate numbers to cover works and activities performed by them.

Size of Contractor’s Overall Workforce (at each location, (including Sub-Contractors)

Minimum Number of QA Engineer & QC Inspectors at each Construction Site

(excluding personnel employed by any Sub-Contract Certification Authority)

Up to 25 1 QA Engineer Part Time (Minimum 50% of time on QA function)1 QC Inspector Full Time

26 - 75 1 QA Engineer Full Time2 QC Inspector Full Time

76 – 150 1 QA Engineer Full Time3 QC Inspectors Full Time

151 – 250 1 QA Engineer Full Time4 QC Inspectors Full Time

> 2511 QA Engineer Full Time5 QC Inspectors Full Time1 Additional QC Inspector for every 75 employees.

Notes: The above numbers exclude any personnel employed either by the Supplier or Company from a

Third Party Certification Authority. Numbers specified in the above Table do not include Corporate QA Personnel.



2.7 Qualifications and Duties of The Supplier’s Quality Assurance, Inspection (Quality Control) and Verification Personnel

All persons nominated by the Supplier for work within the Quality Assurance, Inspection and Verification function shall be properly qualified, trained and experienced in the aspects of the work for which they will be employed. They shall have previously worked on similar Contracts in similar capacities and shall have formal Quality Assurance / Inspection qualifications.

Supplier's all QA, Inspection (Quality Control) and Verification personnel shall be subject to approval Company QA / QC section prior to mobilisation on Contract and to site.

Company reserves the right to interview and or submit all QA, Inspection (Quality Control) and Verification Personnel to an examination to determine their suitability for the work they are required to carry out and to reject any personnel found unsuitable, at Company's sole discretion.

The duties of the Quality Assurance, Inspection and Verification personnel shall include, but not be limited to the following activities:

2.7.1 Corporate Quality Assurance Manager

Qualifications Duties

1

2

3

4

5

Shall be a Graduate Engineer (B.Sc. Eng./ BE/B.Tech.) either in Mechanical or Metallurgical or Welding engineering.

Shall be an IRCA, UK Registered Lead Assessor or equivalent (where equivalent is proposed, Supplier shall provide evidence of equivalence from International Accreditation Body (ies)).

Shall have minimum of 18 years of relevant experience in onshore oil and gas facility construction, including live installations. Out of 18 years of experience, 5 years of experience shall have gained in the Middle East. He shall have a minimum of 7 years management experience in establishment, operation and maintenance of a quality management system in accordance with ISO 9000 with the capability of developing quality system, quality plans, work procedures and inspection plans.

Shall have sound technical knowledge in materials, welding, coating/painting, NDE inspection and general construction activities

Shall have experience of working to and fully familiar with ANSI, ASME, ASTM, API and BS codes used in oil and gas industries.

1

2

3

4

Shall be responsible for advising, guiding and motivating site line management on all QA and QC activities and related technical matters.

Shall be responsible for implementation, operation and maintenance of Quality Management System in compliance with ISO 9000.

Shall be responsible for relevant QA and QC training for all site personnel and overseeing all personnel understand and effectively deliver their QA and QC responsibilities as per quality plan procedures.

Shall report to highest executive management with in the organisation to ensure authority and freedom to execute assigned responsibilities.

Notes: For Design Consultancy contracts, the candidate shall have appropriate technical qualifications on above lines and possess same number of years of relevant experience as per serial 3 above in the design organisation involved in oil and gas facility design.



2.7.2 Quality Assurance Engineer

Qualifications Duties1

2

3

4

5

6

Shall be a Graduate Engineer (B.Sc.Eng. / BE / B.Tech.) either in Mechanical or Metallurgical or Welding engineering.

Shall be an IRCA, UK Registered Lead Assessor or equivalent (where equivalent is proposed, Supplier shall provide evidence of equivalence from International Accreditation Body (ies)). If the candidate is in the process of obtaining the registration with IRCA, UK, then it is mandatory to have an audit log that is verifiable indicating having performed at least ten external (2nd party) Quality SYSTEM audits, with more than fifteen compliance audits.

Shall have minimum of 12 years of, site based, relevant experience in onshore oil and gas facility construction, including live installations. He shall have a minimum of 4 years management experience in establishment, operation and maintenance of quality management system in compliance with ISO 9000. Shall have demonstrable capability of developing quality system, quality plans, quality control procedures, inspection plans and contract specific work procedures.

Shall have in depth technical knowledge in materials, welding, coating/painting, NDE inspection and exposed to multi discipline works of oil and gas construction field.

Shall be fully familiar with ANSI, ASME, ASTM, API and BS codes used in oil and gas industries.

Shall be completely familiar with Supplier's Corporate Quality System.

1

2

3

4

5

6

7

8

9

Preparation, implementation, monitoring, revision and updating of the Supplier’s Contract Quality Plan.

Development, preparation, implementation and monitoring of all Contract Specific Procedures and Work Instructions.

Monitoring Sub-Contractor’s Quality Systems and quality performance.

Preparation, implementation, revision and monitoring Quality Control Plans.

Records of Quality activities.

Reporting Quality activities.

Liaison with the Company on matters related to Quality.

Auditing - internal and external, and follow up of Corrective Actions.

Overall control, supervision and implementation of Contract quality and technical requirements; resolution of quality problems; preparation and maintenance of Contract quality records.

Note 1: For Design Consultancy contracts, the candidate shall have relevant and appropriate technical qualifications on above lines and possess same number of years of relevant experience as per serial 3 above in the design organisation involved in oil and gas facility design.

Note 2:For Electrical and Civil contracts, the candidate shall have relevant and appropriate technical qualifications on above lines and possess same number of years of relevant experience as per serial 3 above in oil and gas facility construction



2.7.3 Quality Control Inspector - Multi-Discipline (Welding, Painting, NDE)


1

2

3

4

5

6

.

HND or Graduate (B.Sc. Eng./ BE / B.Tech.) in Mechanical or Metallurgical Engineering.

Shall possess CSWIP / AWS (*) for welding inspection.

Shall possess BGAS / ERS II or equivalent in NACE for painting inspection

Certified ASNT level II in all NDE techniques.

Shall have a minimum of 8 years of quality control and inspection experience in construction industries out of which 5 years shall be gained in onshore oil and gas facility construction.

For Fusion Bonded Epoxy (FBE) or Shrink Sleeve or Glass Reinforced Epoxy materials works, Supplier shall mobilise and deploy appropriately qualified and suitably trained (from TWI) personnel for quality control and inspection of these works.

(*) For DCMEI and EPC Contracts, at least one inspector shall possess CSWIP 3.2 / AWS SCWI for welding, BGAS / ERS II or equivalent in NACE for painting and ASNT level II in all NDE techniques and shall function as Senior QC Inspector.

1

2

3

4

5

Implementation, and supervision of all Procedures and Work Instructions.

Implementation and supervision of all Sub-Contractor’s Quality Plans, Inspection Plan, Procedures and Work Instructions.

Maintaining records of calibration, inspection and testing equipment.

Maintaining the latest revision of all Contract Documents, Drawings, Specifications, SPs, PRs, ERDs, DEPs and Standards, required for Quality Assurance, Quality Control and inspection.

Control, management and execution of all specified inspection activities as per inspection, specification and codes, witness procedures and tests and interpret results accurately.

Note:For Certification of QC Personnel to ASNT levels, Supplier shall establish and maintain written practice in compliance with SNT - TC - 1A, which shall be duly certified by ASNT level III.

2.7.4 QC Inspectors - Civil and Structural

Qualifications Duties1

2

3

Shall be HND or Graduate Engineer (B.Sc. Eng. / BE / B.Tech) in Civil engineering.

Shall have a minimum of 8 years of quality control and inspection experience in construction industries. The experience shall include works involving soil excavation and earth works, concrete works, block works, structural steel works and roofing, roads and paving, tank pads and bunds and general activities associated wit civil and building works.

Shall be thoroughly familiar with civil construction materials and construction methods, testing of civil construction materials, international codes and standards for civil design, construction and testing of materials and works.

1

2

3

4

Development and implementation of inspection plan and work related procedures

Preparation and maintenance of inspection reports and records.

Control, management and execution of all specified inspection activities as per inspection plan, specifications and codes.

Witnessing of inspection, testing and interpretation of results.



2.7.5 Q C Inspectors - Instrumentation


1

2

3

Shall be Graduate Engineer (B.Sc. Eng. / BE / B.Tech) in Electronics / Instrumentation engineering.

Shall have a minimum of 8 years of quality control and inspection experience in construction industries. The experience shall include electronic and pneumatic equipment including analogue and digital control systems, relay based and solid state logic systems, transmitters, control valves and accessories.

Shall be thoroughly familiar with instrument construction materials and construction methods, testing of instrumentation and installations, international codes and standards for instrumentation design, construction and testing of facilities and works.

1

2

3

4

Development and implementation of inspection plan and work related procedures

Preparation and maintenance of inspection reports and records.

Control, management and execution of all specified inspection activities as per inspection plan, specifications and codes.

Witnessing of inspection, testing and interpretation of results.

2.8 Quality Assurance Auditing

The Supplier shall carry out Internal Audits of the Quality System and External Audits of Sub-Contractors throughout the Contract. An Audit Schedule shall be included in the Contract Quality Plan, which shall be approved by the Company.

The Audit Schedule shall include External Audits carried out by the Supplier on Sub-Contractors.

Compliance Audits shall be carried out at least once per month on all ongoing activities.

For Contracts of less than 4 months duration the Supplier shall include the annual Corporate Audit Schedule of the Quality System, together with details of supplementary audits planned for the Contract. Supplementary audits shall include the following as a minimum:

Document and Data Control. Process Control. Inspection and Testing Control of Inspection, Measuring and Test Equipment Control of Quality Records. Internal Quality Audits

Audits shall be carried out in accordance with ISO 10011-1, Part 1.

The Company QA / QC shall be included on the distribution for the entire Supplier’s Internal and External Audit Notifications and shall be invited to participate in the audits, as Team Members or Observers. The audit notification shall be delivered to Company QA / QC section at least five working days in advance of the audit date.

The Company reserves the right to carry out scheduled or unscheduled External Audits, Reviews and Surveillance of the Supplier, Sub-Contractors and Vendors. These audits will be carried out by the Company or Third Party auditors appointed by the Company.

The Supplier shall carry out the following actions: Assign a Lead Auditor and Audit Team for each audit. Establish a Distribution Matrix for Audit Reports. Reports shall be issued to the Company not

more than 2 weeks after the audit.

The audit report distribution to Company shall include;

Company Representative,



Company Site Representative, Head of Quality Assurance Services, OTT / 15, In-Charge Interior QA and QC Services, OTT / 151.

The Supplier shall ensure that their Auditors possess following qualifications and experience:

For External Audits - Passed IRCA, UK registered Five days Lead Assessor / Assessor course and have done minimum 10 external audits (at least 5 as lead auditor).

For Internal Audits - Passed IRCA, UK registered Two days Internal Auditor course and have done minimum 10 internal audits (at least 5 as lead auditor).

Audit Reports shall include:

Front Cover with details of the Audit. Report with Conclusion. Corrective Action Requests (CAR), stating any Non-conformance, signed by the Auditee, stating

Corrective Action and Action to Prevent Recurrence and Date for Completion of Corrective Action.

Log of CARs showing Follow Up and Close Out status. Audit checklist covering each process and applicable elements.

The Supplier shall maintain a summary log of all Corrective Action Requests raised during Internal and External Audits. The log shall show:

Title and reference number of the audit. Corrective action request number and brief description. Brief description of the corrective action to be taken and date for completion. Follow up and close out status and dates.

2.9 Purchasing

The Company reserves the right to inspect products or services purchased by the Supplier from Sub-Contractors (or Vendors). Such inspection shall take place at the source, in the Supplier's premises, on site or at the Sub-Contractor's premises. Verification or Inspection by the Company is not a substitute for verification by the Supplier nor absolve the Supplier of its contractual obligations. Hold, Review and Witness Points shall be identified in the Quality Control Plans for Supplier, Sub-Vendor, Third Party Inspector / Authorised inspector and Company. Company shall be given at least 10 working days notice to attend such verifications.

The purchase of products and the associated Quality documentation shall be co-ordinated with the Contract Schedule (programme), to ensure timely delivery. Special attention shall be given to long lead items.

Generally the Supplier shall only purchase products and services from Company approved sources. Lists of approved sources (Contractors and Vendors) are available from the Company.

2.10 Inspection, Measuring and Test Equipment

The Supplier shall supply all inspection, measuring and test equipment required for inspection and testing. All equipment shall be robust and suitable for the working environment. The equipment shall be calibrated at the start of the Contract and re-calibrated as required by the manufacturer, contract specification(s), international codes and standards or, job conditions. All calibration shall be carried out against certified equipment having a known valid relationship to internationally or nationally recognised standards and records shall be available for inspection by the Company and maintained by Supplier at construction site / work location. Instructions on the use and maintenance of the equipment shall be available at the Work Site. Supplier shall ensure proper and adequate handling, preservation and storage condition such that the accuracy and fitness for use are maintained.



The Supplier shall establish and maintain documented procedures to control, calibrate and maintain inspection, measuring and test equipment in accordance with clause 4.11.1 of ISO 9001 / 9002.

2.11 Third Party Certification

Where Third Party Certification is specified in the Supplier’s Scope of Work in the Contract, the Supplier shall use one of the following Third Party Certification Authorities as a Sub-Contractor:

AIB Vincotte International Ltd.

American Bureau of Shipping Services Inc.

Bureau Veritas

Det Norske Veritas

Germanischer Llyod

Lloyds Register of Shipping

TUV Bayern Sachesen

Velosi TUV Bayern LLC.

The Third Party Certification Authority shall issue the following certification to provide assurance and evidence that the Works are in conformance with the Contract.

Certificate of Compliance (with all Contract specified requirements).

Certificate of Acceptance (that all pre-commissioning and commissioning is complete).

Certificate of Safe Operation (that all plant and equipment is safe for normal operation).

Certificate of Completion (that the Contract can be handed over to the Company for normal operation).

The Certification shall apply to all design, procurement, on and off site construction, pre-commissioning, commissioning and hand over activities, included in the Scope of Work of the Supplier.

The Certification shall also apply to all materials and consumables procured by the Supplier (Purchased Product – ISO 9000) and materials issued free to the Supplier by the Company (Purchaser Supplied Product – ISO 9000). In the later case the Certification shall be limited to ensuring material certification data is supplied with the material and that the delivered materials as detailed on the material certification data complies with the requisition and drawings. It shall not include inspection of Company supplied material outside Oman.

In order to assure conformance to the Contract requirements the following activities shall be considered as a minimum to be carried out by the Third Party Certification Authority:

Endorse the Supplier’s Quality System and Contract Quality Plan to ensure they meet the requirements of this specification and ISO 9000.

Endorse the Supplier’s Procedures and Work Instructions to ensure they meet the specified requirements.



Ensure all supporting documentation and Standards, Codes, Specifications are available at the Work site.

Carry out audits, surveillance, inspection and witnessing sufficient to ensure specified requirements are met and to enable Certification to be issued.

Ensure the Supplier’s QA/QC staffs are suitably qualified as specified.

Ensure proper test & inspection equipment is used, calibrated and certified.

Endorse Quality Records, Commissioning Plans, Operation & Maintenance Manuals and As Built information.

Report directly to the Company any Non-conformance and Close out the Non-conformance.

Provide monthly Quality Assurance Report directly to the Company.

Issue Certificate of Compliance, Acceptance, Safe Operation and Completeness, directly to the Company.

Provide a bond, insurance or guarantee directly to the Company to support the Certification.

Personnel employed by the Third Party Certification Authority shall have qualifications and experience at least equal to that specified for the Supplier’s Quality Assurance Engineer and Inspection personnel.

Where the Company employs the Third Party Certification Authority, they shall act on behalf of the Company and shall have the same access to the Supplier’s Quality System as the Company.

2.12 Pressure Vessels

Vendors shall implement a Quality System as described in Section 2.2 of this specification, which shall incorporate all Inspection &Test requirements specified in the Purchase Order and Specifications (DEP, SP, PR, ERD, Codes & Standards).

Vessels shall be inspected and certified by an independent Inspection Agency / Authorities, in accordance with the Code requirements. All costs associated with the testing, inspection, coding and certification of the vessel, either by the Vendor or by an independent Third Party, shall be borne by the Vendor.

2.12.1 Vessels Manufactured Out Side Oman

Vessels manufactured outside Oman shall be designed and fabricated in accordance with ASME VIII – Division 1 as amended by DEP 31.22.20.31-Gen. or BS 5500 as amended by DEP 31.22.10.32-Gen, unless specifically stated otherwise in the Specifications. The following shall apply:

Item Design /Fabrication CodeASME VIII BS 5500



Information to be supplied with tender

1. Valid Current Certificate of Authorisation from the ASME Boiler & Pressure Vessel Committee.

2. Details of the Authorised Inspection Agency.

3. Requirements of Section 2.3 of this specification.

1. Details of the designated independent Inspection Authority, for approval by the Company, prior to any work commencing.

2. Requirements of Section 2.3 of this specification.

Inspection & testing

In accordance with Sections UG-90 to UG-103

In accordance with BS 5500 Section 5.

Certification By Authorised Inspection UG-90 to UG-103. Completed Form X, Certificate of Compliance, signed by the Inspection Authority.

Vessel Marking Code U or UM Symbol (as appropriate), in accordance with Sections UG-115 to UG-119 (AS-130 Div.2)

Name plate in accordance with Section 5.8.9.

Note:Where section numbers are given they relate to the 1999 edition of ASME VIII and 1997 edition of BS 5500 (re-designated PD 5500). If a later edition or addenda exist, the equivalent sections in the latter edition shall take precedence.

2.12.2 Vessels Manufactured in Oman

Vessels manufactured inside Oman (by local Vendors), shall be designed and manufactured in accordance with ASME VIII – Division 1 as amended by DEP 31.22.20.31-Gen. or BS 5500 as amended by DEP 31.22.10.32-Gen, unless specifically stated otherwise in the Specifications.

All vessels designed and manufactured to ASME VIII, shall be Coded, requiring Supplier / Vendor to hold a Valid Current Certificate of Authorisation from ASME Boiler & Pressure Vessel Committee.

The Company reserves the right to carry out their own inspection, testing and auditing.

2.13 Static Equipment

Static equipment shall refer to all other manufactured static items, other than pressure vessels (for example, tanks, heat exchangers, spools, manifolds and skids).

Vendors shall implement a quality system as described in section 2.2 of this specification, which shall incorporate all test & inspection requirements specified in the purchase order and specifications ( DEP, ERD, SP, PR, codes & standards).

The scope of work (design and fabrication) for all static equipment shall include for third party certification of the finished product. All work shall be inspected and certified in accordance with section 2.11 of this specification, by an independent third party certification authority, as listed therein and approved by the company, prior to any work commencing.

All costs associated with the testing, inspection and certification of the static equipment, either by the vendor or by the independent third party, shall be borne by the vendor.

The certification authority shall issue the certification detailed in section 2.11, directly to the company. Copies shall be included in any quality records / test & inspection packs issued by the vendor to the company.

Third party certification shall not relieve the vendor of responsibility for compliance with the requirements of the purchase order and specifications (DEP, SP, PR, ERD, CODES & Standards).



Manufactured static equipment shall not be dispatched from the place of manufacture until the certificate of compliance has been signed by the third party certification authority. The quality control plan (test & inspection plan), shall include this activity as a ‘hold point’ for both the third party certification authority and the company.

The company reserve the right to carry out their own inspection, testing and auditing.

2.14 Quality System Certification:

WORK CATEGORIES REQUIRING CERTIFICATION OF SUPPLIER QUALITY SYSTEM TO ISO 9000

Suppliers in the Work Categories below are required to attain Third Party Certification of their Quality System by an Accredited Certification Body. The Accredited Certifying Body shall themselves be accredited by a National Accreditation Authority to assess Quality Systems.

The SCOPE of the Supplier's ISO 9000 Quality System Certificate shall encompass all disciplines, areas and activities that are covered, involved and included in the following Work Categories.

Ref. Work Category Title

C01 Oil & Gas Facilities Design C10 Civil, Mechanical, Electrical & Instrumentation Contractors (CME&1)C12 Oil & Gas Engineering, Procurement & Construction (EPC)

For other Work Categories, the Supplier shall be required to attain Third Party Certification of their Quality System by an Accredited Certification Body if specified by the Work Category Custodian.



Appendix A - Glossary of Definitions, Terms and Abbreviations

Definitions

Company The term Company shall refer to Petroleum Development Oman L.L.C.

Supplier The term Supplier, as used in ISO 9000, shall refer to the Company's appointed Consultants, Contractors, Manufacturers and Vendors.

Contract The term Contract, as used in ISO 9000, shall refer to the Company's Contracts and Purchase Orders with Suppliers (Consultants, Contractors, Manufacturers and Vendors.

Sub-Contractor The term Sub-Contractor, as used in ISO 9000, refers to any Third Party or Sub Vendor employed by the Supplier to perform part of the Contract

Third Party Certification The term Third Party Certification refers to services provided by an independent Third Party Certification Authority, employed by the Supplier or Company, to assure the Company that work is in accordance with the Contract and to issue Certificates of Compliance, Completeness, Safe Operation and Acceptance.

Work Category The term Work Category, refers to a specific work activity for which the Company awards Contracts, and maintains a list of qualified Contractors. The list is maintained by a Work Category Custodian.

Contract Quality Plan The term Contract Quality Plan, is used to describe a Contract-specific Quality Plan for the Contract, as referred to in ISO 9004-1 - 1994 Clause 3.4 and 5.3.3.

Quality Control Plan The term Quality Control Plan (Inspection and Test Plan), is used to identify activities that are to be controlled, the controlling specification and the control mechanisms. .

shall The word 'shall' used throughout this specification indicates a Contract requirement.

should The word 'should' used throughout this specification indicates a recommendation.

may The word 'may' used throughout this specification indicates a possible course of action.

Contractor The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility.

Manufacturer The party, which fabricates and manufactures equipment and provide services to perform duties specified by Company or contractor.

User The Company or Supplier who uses this Specification.



Abbreviations

BS British Standard

CQP Contract Quality Plan

CV Curriculum Vitae

GU Guidelines

ISO International Organisation for Standardisation.

ITP Inspection and Test Plan

MDI Multi-Discipline Inspector (Welding, Painting, and NDE)

QA Quality Assurance.

PQR Procedure Qualification Record

PR Procedure

QC Quality Control.

QCP Quality Control Plan

SP Specification

TPI Third Party Inspection

WPS Welding Procedure Specification



Appendix B – ReferencesIn this specification, reference is made to the following publications. Unless specifically designated by date, the latest edition of each publication shall be used together with any amendments.

Shell Group StandardsPressure Vessels (Amendments/Supplements to BS 5500)

Pressure Vessels (Amendments/Supplements to ASME Section VIII Division 1 and Division 2)

DEP 31.22.10.32-Gen

DEP 31.22.20.31-Gen

National and International StandardsASME Boiler and Pressure Vessel Code

Unfired Fusion Welded Pressure Vessels

Quality Systems - Model for quality assurance in design development, production, installation and servicing

Quality Systems - Model for quality assurance in production, installation and servicing

Quality Management and System Elements

Guidelines for Auditing Quality Systems

ASME VIII Division 1

BS 5500 (PD 5500)

BS EN ISO 9001

BS EN ISO 9002

BS EN ISO 9004

ISO 10011



Appendix C - Contract Quality Plan and Contract Quality Plan Guidelines

Introduction

A Contract Quality Plan is required for each Contract. This is a Contract specific document outlining how the Supplier’s corporate Quality System will be utilised on the Contract and what, if any, additional Contract specific Quality documentation is required.

The Tender issue Contract Quality Plan (normally Revision 0), will only include selected sections. The Contract issue Contract Quality Plan (normally Revision 1), will include full details.

The following pages offer guidelines on the content of some of the elements of a Supplier’s Contract Quality Plan. Where the Supplier has standard formats they may be used instead of the formats offered here.

The numbering is as the Typical Index to the Contract Quality Plan and as some sections are not included in these guidelines, the numbering is not sequential.



Contract Quality Plan Front Page

Contract Quality Plan

Contract :

P.D.O Contract No. :

Contractor :

Contractor’s Contract Ref. :

Document Ref. :

Controlled Copy No. :

Revision No. :



Contract Quality Plan Index

( Typical Example – Contract Issue )

1.0 Control of Contract Quality Plan

1.1 Revision Status1.2 Controlled Copy Distribution List1.3 Preparation, Approval, Issue and Revision of the Contract Quality Plan

2.0 General Contract Information

2.1 Corporate & Contract Specific Quality System Documentation2.2 Scope of Work2.3 Sub-Contractors' Quality Systems and Monitoring2.4 Activities to be controlled by the Contract Quality Plan, including Sub contractors

3.0 Quality Assurance Objectives

3.1 Contract Documentation with Quality Requirements3.2 Control of Documentation with Quality Requirements3.3 Certification of the Contract by Third Party Certification Authority

4.0 Organisational Structure

4.1 Contract Organisation Chart and Mobilisation Dates4.2 Corporate Organisation Chart and Relationship with Contract Organisation4.3 Job Descriptions, Authority Levels and Reporting Relationships4.4 Curriculum Vitae of Quality Assurance personnel, including Sub-Contractors4.5 Training Schedule

5.0 Project Quality Plans (Service Contracts Only)

5.1 Preparation, Approval, Issue and Revision of the Project Quality Plans

6.0 Procedures, Work Instructions & Checklists (Corporate & Contract Specific)

6.1 Contract Management6.2 Design6.3 Procurement6.4 Civil Engineering6.5 Mechanical Engineering6.6 Electrical Engineering6.7 Instrumentation Engineering6.8 Commissioning, Handover, As Built, Operation & Maintenance Manuals

7.0 Quality Control Plans (Test & Inspection Plans)

7.1 Contract Management7.2 Design7.3 Procurement7.4 Civil Engineering7.5 Mechanical Engineering7.6 Electrical Engineering7.7 Instrumentation Engineering7.8 Commissioning, Handover, As Built, Operation & Maintenance Manuals

8.0 Quality Records



8.1 Identification of Quality Records8.2 Quality Records & Test Pack Formats

9.0 Audit Schedule

9.1 Internal & External Audit Schedule9.2 Audit Team Members9.3 Distribution Matrix for Audit Notification and Audit Reports

10.0 Other Measures

10.1 To be identified by Supplier



Control of Contract Quality Plan

Revision Status

RevNo. Date Description Prepared

ByApproved

By Approved by PDO

0 1.1.99 Tender Issue Project.Engineer

Quality AssuranceManager

1 1.3.99 Contract Issue Project.Engineer

Quality AssuranceManager

Contractor to define who prepares and approves the CQP. This is only an example.

Review by PDO is for overall format, not detailed checking.

Controlled Copy Distribution List

CopyNo. Copy Holder Name Position Location Tel. No.

1 Contract Manager Head Office

2 Contractor Representative Head Office

3 Contractor Site Representative Site

4 Quality Assurance Manager Head Office

5 Quality Assurance Engineer Site

6 PDO Company Representative MAF

7 PDO Company Site Representative Site

8PDO Quality Assurance /Quality Control MAF

Contractor to decide on internal distribution.



2. General Contract Information

Corporate & Contract Specific Quality System Documentation

The Quality System should be based on the following documentation:



Procedures, Work Instructions and Checklists

The following Procedures / Work Instructions shall be used on the Contract:

(Note: The following listing is purely for example purposes and is not intended to be a definitive list of Procedures for a particular type of Contract).

Title Rev. Date

Contract Management

Contract ReviewContract Quality PlanHSE PlanPlanning & SchedulingDocument ControlLabour, Materials & Plant Resourcing Interim & Final Payment Certification Contract Reporting to PDOTrainingQuality AuditingHSE Auditing & InspectionTechnical QueriesChange Orders & VariationsControl of Non-Conforming ProductCorrective ActionThird Party Certification (if required in Scope of Work)

Design

Design controlDrawing controlDesign Verification & Technical ReviewsHAZOP/SAFOPControl of Specifications, ERDs, DEPs, Codes & Standards Preparation of RequisitionsMaterials Tracking & ReportingReviewing Vendor DocumentationAs Built InformationOperation & Maintenance Manuals

Procurement

Approved Contractors & Vendors List Requisitions, Purchasing Data & Purchase Orders Materials Tracking & ExpeditingInspection & Testing (in process & Final)Control of Customer Supplied Product Handling, Storage, Packing & TransportationGoods Inward Inspection

Civil Engineering

Surveying & Setting OutEarthworks, Trenching, Excavation & BackfillingConcrete WorkStructural SteelworkBrickwork & BlockworkGeneral Building & Architectural Work



Building Services (Plumbing, Electrical, A/C)Roads & Paving

Mechanical Engineering

On Plot PipingOff Plot PipingWeldingInstallation of Static EquipmentInstallation of Rotating EquipmentPainting & CoatingNon-Destructive Examination NDE

Electrical Engineering

Protection & IsolationInstallation of Electrical Equipment Installation of Underground Cables Installation of Overhead Lines HV & LV Switch gearCathodic Protection

Instrumentation Engineering & Telecommunications

SafeguardingInstalling InstrumentationInstrument Air SupplySystem CablingDCS SystemsSCADAFactory & Site Acceptance TestingInstallation of Telecommunication Equipment

Commissioning, Handover, As Builts, Operation & Maintenance Manuals

Pre-commissioningCommissioningAs Built DocumentationOperation & Maintenance ManualsSpare Parts for Initial Running & Operation



Quality Control Plan (Test and Inspection Plan) - Typical Format

Quality Control Plan Ref.: Contract: Contract No.:Discipline Element: Procedure Ref.:

Activity Controlling Document Acceptance Criteria.Frequency of Test.

Supplier’sVerification Personnel

Verification Document Hold, Witness & Review Points

List the activity to be controlled. Ideally prepare a QCP for each Procedure by Discipline, for example:

Contract Management- Contract Review- Contract Quality Plan- HSE Plan, etc.

Design- Design Control- Drawing Control, etc.

Procurement– Approved Contractors & Vendors– Requisitions, etc.

Civil Engineering– Surveying & setting Out– Earthworks, etc.

Mechanical Engineering Electrical Engineering Instrumentation Engineering Commissioning & Handover, etc.

Identify the documents that control the activity.

This will be the Supplier’s Procedure, Contract Specifications, DEP, ERD, BS, ASME, etc.

Identify the Quality Control requirements in these documents.

Identify the Clause reference that stipulates the requirements.

Identify the actual value of the specified requirement if this is a simple measurement. Alternatively cross reference to the clause, table, figure, etc. in the relevant specification, ERD, DEP, BS, ASME, etc.

Verification Documents and Checklists can be used to show the specified Acceptance Criteria, if it is not practical to show details in the QCP. This enables easy comparison with measured values.

State the specified frequency of testing.

Identify the Supplier’s personnel responsible for verifying the test results.

This will usually not be the same person that carried out the Quality / Control Activity / Measurement.

Identify the document that verifies the Quality Control has taken place, for example, signed Quality Control Form, Checklist, NDT X-Ray, Test Results Records, etc.

Often examples of completed Verification documents are included in the relevant Procedure.

Should have a numbering system in accordance with a Document Control Procedure.

Identify any Hold & Witness points.

Some are specified in the Contract, requiring inspection by the Client or Third Party Inspector.

Some may be required by the Supplier to monitor the work and measure the performance of the process with respect to Quality.



Quality Control Plan - Typical Example for ‘Hydro Testing’

Quality Control Plan Ref.: Contract: ‘Contract Name’ Contract No.: ‘Contract Number’

Discipline: For example, ‘Mechanical Engineering’ Element: For example, ‘On Plot Hydro Testing’ Procedure Ref.: For example, ‘Pre Commissioning Pressure Testing of On-Plot

Mechanical Equipment & Pipework Procedure. Ref. PIPEWORK / 3’

Activity

Controlling Document (Supplier’s Procedure, Contract Specification, Standard, ERD,

DEP)

Acceptance Criteria, (Specified Test Requirements etc.)

+Frequency of Test

Supplier’s Verification Personnel

Verification Document. (Quality Control Form, Inspection Record etc)

Supplier’s Hold, Witness &

Review

Company Hold, Witness &

Review

H W R H W R

Pressure testing schedule Supplier Procedure PIPEWORK/3 (in this example) Approved Testing Schedule QC Eng. Approved Schedule H H

Permit to Work Supplier ProcedurePIPEWORK/3 Approved Permit to Work Mech. Sup. Approved Permit H H

Pre test documentation. Test Pack Folder

Supplier ProcedurePIPEWORK/3ERD 84-01

Cl. 5.2.1 to 5.2.4. Shown on Checklist PIPE 01. Every Test

Mech. Sup. Checklist PIPE 01 W H

Pre test mechanical site inspectionSupplier ProcedurePIPEWORK/3ERD 84-01

Cl. 5.2.5. Shown on Checklist PIPE 02.Every Test

Mech. Sup. Checklist PIPE 02 R R

Hydro testingSupplier ProcedurePIPEWORK/3ERD 84-01

Cl. 5.3.1 to 5.3.6. Shown on Checklist PIPE 03.Every Test

Mech. Sup. Checklist PIPE 03 R W

Pressure Test CertificateSupplier ProcedurePIPEWORK/3ERD 84-01

Cl. 5.3.11. Shown on Checklist PIPE 06.Every Test

QC Eng. Checklist PIPE 06 H H



User Comment Form

User Comment Form If you find something that is incorrect, ambiguous or could be better in this document, write your comments and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets DCS or the CFDH ask you about your comments and tell you about the decision.

Procedure Details Title: Issue Date:Number:

Page Number: Heading Number: Figure Number:

Comments:

Suggestions:

User’s personal detailsName: Ref.

Ind.:Signature: Date:

Phone:Document Control Section ActionsCommentNumber:

Date: CFDHRef. Ind.:

Recd.: To CFDH:CFDH ActionsRecd.Date:

Decision:

Reject:Accept, revise at next issue:Accept, issue temporary amendment

Inits.: Ref.Ind.:

Date:

Comments:

OriginatorAdvised:

Date: Inits.: Document ControlSection Advised:

Date: Inits.:
