Project Quality Plan Rev 2

8/11/2019 Project Quality Plan Rev 2

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Project Quality Plan

Petrodar Contract No. PDOC/31/05-237BDocument No.

Issue and Revision Record

RevNo.

Date Description Prepare by Revie by !pproved by

B 25-07-06 FOR REVIEW

Oner "Petrodar Operatin# Co$pany%i$ited

&PCC Contractor "'i#(ei# ) C*ina +ian#s,Consorti,$

&n#ineerin# ,b-Contractor "C*ina Petro(e,$ &n#ineerin#

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HIGLEIG PTROLEUM SERVICES&INVESTMENT CO.LTD&CHINA

JIANGSU- CONSORTIUMEPCC FOR PDOC NEW OFFICE

BUILDINGPROJECT


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PROJECT QUALITY PLAN

INDEX

i. Cover Page

ii. Revision Control Sheet

iii. Controlled Document Distribution List

1.0 Introduction, Definitions & bbreviations

!.0 "ualit# Polic#

$.0 "ualit# %bectives

'.0 %rgani(ation, uthorit# & Res)onsibilit#

*.0 "ualit# Planning

+.0 Product Reali(ation

*.0 easurement, nal#sis and Im)rovement

-.0 List of ))endies

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'ontro((ed Document Distri)ution *istDoc,$ent 4"+++++++++++++++++++++++++++++++++++++

Doc,$ent it(e, ++++++++++++++++++++++++++++++++++Doc,$ent ype, +++++++++++++++++++++++++++++++

Docu%ent ol&er i#n.Date

receivedss,e /6

CopyN,$ber

! *eader -!DO' #

!ro/ect 'onstruction ana"er - !' 2

!ro/ect ana"er-'onsortium &

Deut1 !ro/ect ana"er-'onsortium

'3ie$ En"ineerin" -'onsortium 5

'onstruction ana"er- 'onsortium 64E-ana"er- 'onsortium 7

!ro/ect 'ontro( ana"er- 'onsortium

!ro/ect En"ineerin" ana"er- 'onsortium %

!ro/ect !rocurement ana"er- 'onsortium #0

!ro/ect *o"istic ana"er- 'onsortium ##

!ro/ect 8' ana"er- 'onsortium #2

!ro/ect ite O$$ice - 'onsortium #&

roved )1 ana"ement Reresentative, +++++++++++

'!( INTRODUCTION)

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7his PROJECT QUALITY PLAN of the Consortium Partner is based onguidance from IS% 80019!000 2 "ualit# anagement S#stems Re:uirements& s)ecificall# )re)ared for an EPCCContract for P;7R%DR %P;R7I


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Re$re#entati"e6 as )er "ualit#anagement S#stem anual

Quality Re$re#entati"e2 or the Proect, the )osition of 5QA1QCEn:ineer6 is 5Quality Re$re#entati"e6 atsite for the CONSORTIUM.

Site O22ice2 CONSORTIUM2site office

Project 7ana:e%ent Re"ie;2 7his is conducted in Site %ffice 4eel# 6fortnightl# or as decided b# the Proectanager 6 Proect Control anager6Construction anager6 7his 4ill alsoinclude "ualit# anagement Revie4)ertaining to site 4ors.

Quality 7ana:e%ent Re"ie;2 7his is conducted in %ffice and the meetingis held at least once in * months to chec5Quality Sy#te% I%$le%entation6 as )erCor)orate "ualit# anagement S#stemanual.

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1.!.! )art from this a number of abbreviations are used in this PROJECT QUALITYPLAN4hich are e)lained belo4 for clarit#.1. Proect anager 2 P!. De)ut# Proect anager 2 D>P$. Construction anager 2 C'. /arrantee anager 2 /

+. Proect Control anager 2 PC

*. ;ngineering anager 2 ;

-. Procurement & Subcontract anager 2 PS

8. Chief Engineer - CE

8. "ualit# Re)resentative 2 "R

10.Planning ;ngineer 2 P;

11. Personnel & dministration 2 P &

1!.Logistic anager 2 L

1$.Gealth, Safet# & ;nvironment 2 GS;

1'.onitoring & easuring Devices 2 D

1+."ualit# ssurance 2 "..

1*."ualit# Control 2 ".C.

1-.ethod Statement 2 .S.

H1. Ins)ection & 7est Plan 2 I.7.P.

18.7hird Part# Ins)ector 2 7.P.I.

!0.


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UALITY POLICY

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'.1.$ "ualit# Polic# is communicated to all em)lo#ees b# dis)la#ing on ill#through training and )rovision of resources.

'.1.H 7o ensure that the Su$$lier6# a&3ere to Quality 7ana:e%ent Sy#te%Procedures, ethod Statements and Ins)ection & 7est Plans, as a )art of theSubcontract )hiloso)h# to the entire satisfaction of the Consortium and o4ner

'.1.8 7o en#ure -ee&9ac> from Au&it#, Noncon2or%ance Re$ort# and res)ectiveCorrecti"e Action# and Pre"enti"e Action# and those %4ner com)laints*SN+are brought to the notice of anagement during "ualit# anagementRevie4 eeting for effective and efficient revie4 and resolutions sought, areincor)orated in net generation )rocedures and im)lemented throughout theorgani(ation.


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'.!.1 7o ensure that the %bectives of the %4ner are fulfilled in re:uired se:uence,schedule and time for our sco)e of 4ors for the Proect b# com)l#ing 4iththe re:uirements of 7echnical S)ecifications & Dra4ings.

s a Contractor, 4e are res)onsible for erification, confirmation andcom)letion of ;ngineering, construction, )rocurement, Pre2Commissioning &commissioning of the )roect & deliver it for usage as a )roduct of ourindustr#.

7his 4ill be achieved b# follo4ing "ualit# S#stem and Procedures, GS;Re:uirements and other Statutor# & Regulator# re:uirements.

'.!.! 7o ;nsure Safet# 4areness of all )ersonnel irres)ective of 7rade andunderstand the J?ero Acci&entJ Polic# and im)lement the safet# )rogram 6

)ractices in each )hase of 4or carried out.

'.!.$ 7o eecute the said 4ors for the PDOC Ne; O22ice .uil&in: 4ithinbudgetar# )rovisions, simultaneousl# meeting or im)osing u)on ProectSchedule and "6"C re:uirements for the Proect and 4or shall beeecuted strictl# in accordance 4ith the Proect "ualit# Plan & Safet# Planand in accordance 4ith the %4ner Fs s)ecified rule and meeting theregulations.

7he revision to this Project Quality Plan @to meet contract re:uirementsand6or comments from %4nerA 4ill be issued b# Con#ortiu% QA8QC7ana:eror QA8QC En:ineerat site, 4ho is authori(ed to amend the samein line 4ith document control )rocedure.

ethod Statements, Ins)ection & 7est2Plans and Procedures are to be)re)ared and amended to meet the %4ner re:uirements through the Contract7hese shall be $re$are& b# QC En:ineer# 8 Di#ci$line En:ineer#,re"ie;e& b# QA8QC En:ineer and a$$ro"e& b# Project 7ana:er beforesending to O;ner for re"ie;8a$$ro"al.

'.$.! If %ajor changes in an# document are re:uired, i.e., Change in themethodolog# or a))roach, then it 4ill be i##ue& 2or re"ie; as Rev. , 5, Cand so on. Go4ever, necessar# entries shall be made in re"i#ion control$a:eof the corres)onding document.

/hen %inor amendments are to be carried out in an# document, i.e.,7#)ogra)hical errors, reordering the contents etc, the same 4ill be issued fora$$ro"alunder Issue No! *(+ and so on.

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'.$.$ 7he QA8QC En:ineershall )re)are a list of DOCU7ENTS OLDERF. 7he#shall receive the Controlled Co)iesF of this Project Quality Plan and)ertinent issues of other "ualit# S#stem Documents through Docu%entControl o22ice. 7his 4ill be clearl# sho4n on controlle& &ocu%ent&i#tri9ution li#t.

'.$.' 7he controlle& co$y 3ol&er shall be res)onsible for &e#troyin:o9#oleteco)ies of the :ualit# s#stem documents 6 Dra4ings 6 an# other Documents oridentif#ing the same as Su)ersededF and ee)ing it under safe custod# if thedocument is deemed necessar# for an# future reference or financial claim)ur)oses.

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B!( OR/ANISATION AUTORITY AND RESPONSI.ILITY

B!' %verall Proect %rgani(ation is included as A$$en&i01@, 4hich sho4s theoverall organi(ation structure.

B!4 /eneral State%ent on Quality A##urance

+.!.1 It shall be the in&i"i&ual &e$art%ent %ana:er6#, res)onsibilit# to ensurethat the )rocedures are im)lemented and regularl# revie4ed to reflect current%4ner re:uirements & )hiloso)h#.

+.!.! It shall be the res)onsibilit# of the QA8QC En:ineerto %onitor continuousl#the im)lementation of the current Project Quality Plan. In order to verif# a+the necessar# s#stems and )rocedures eist and 9+ )lanned &im)lementation Au&it# b# QA8QC 7ana:er QA En:ineer 4ill beconducted on )roect site office.

B!@ Con#truction 7ana:e%ent

CONSORTIUM 7ANA/E7ENThas overall authorit# and res)onsibilit# for allactivities related to the /ors for com)letion of the )roect

B!< QA8QC Re#$on#i9ility 1CONSORTIU7+

@QA8QC+ 7ana:er Con#ortiu%, 4ho are connected 4ith the )roect forbasic in)uts lie technical data, material, man)o4er, regulator# a))rovals andfinance are referred to in this Project Quality Plan.

+.'.1 QA8QC 7ana:er

@"6"CA anager has overall authorit# and res)onsibilit# for "ualit#anagement S#stem Program. Ge is also 57ana:e%ent Re$re#entati"e6forConsortium. Gis )rimar# res)onsibilities include9

2 Re)resenting Consortium on all "ualit# matters )ertaining to the "ualit#ssurance Program and he re)orts directl# to Proect S)onsor.

2 Structuring Project Quality Plan to ensure com)liance 4ith "ualit#re:uirements.

2 Revie4ing the Con#ortiu% or:ani=ation relationshi)s and develo)ing)ro)osals for im)rovement.

2 Determining and re)orting )rinci)le causes of "ualit# losses andnon2conformances.

- uditing various areas and De)artments of the Consortium and itsSubcontractorFs "ualit# S#stems as )er udit Plans & Schedule.

2 ;nsure that all #$ecial $roce##e# are e22ecti"ely controlle& an&%onitore&to ensure better :ualit# and im)roved reliabilit#.

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2 onitoring ConsortiumFs "ualit# ssurance Program to &eter%ine ;3erei%$ro"e%ent# are nee&e& and recommending a))ro)riate correctiveaction.

2 ;nsure that all "ualit# Re:uirements are met through udit and e)editeclose out of non2conformance, if an#, b# clo#e %onitorin:of correctiveactions taen to ensure better :ualit# and im)roved reliabilit#.

2 Present overall status of "ualit# ssurance S#stem Im)lementationthrough Quality 7ana:e%ent Re"ie; 7eetin:#F on a regular basis andtae corrective actions in ".. S#stem 6 Procedure as )er "..Rresolutions.

B!

/ith regard to "ualit#, each De)artment 6 Disci)line anager shall beres)onsible for9

2 7he "ualit# of 4or carried out b# all )ersonnel 4ithin their de)artment.

2 erif#ing the a))roved )rocedures are ado)ted 4ithin their de)artmentand that an# necessar# additional )rocedures are established,im)lemented, revie4ed and u)dated as re:uired.

2 ;nsuring that all staff are ade:uatel# :ualified and e)erienced in theirdisci)line to )erform the duties of their )osition in a satisfactor# manner.7rain them if needed to meet technological advancement.

2 ;nsuring that all staff are familiar 4ith Proect "ualit# )rocedures, haveread# access and im)lement them in the da# to da# 4ors.

B!B Aut3ority Re#$on#i9ility *Project+

7he authorit# and res)onsibilit# of e# )ersonnel for "ualit# ssuranceactivities for the Proect 4ill be defined in this Project Quality Plan.

+.+.1 Project S$on#or

7he 7o) anagement of the 7o4 Com)anies cor)orate to form a Con#ortiu%.oar& 4hich 4ill be the Proect S)onsor for the Proect on behalf ofConsortium. 7he# shall be res)onsible for fulfilling %4nerFs obectives torealise the Proect b# com)leting our ESco)e of /orF in a se:uential, timel#and efficient manner b# maintaining :ualit# assurance, GS; s#stem, Planningand Co2ordination.

+.+.' Project 7ana:er

P7shall be re#$on#i9le tothe Con#ortiu% .oar&for successful eecutionof the )roect from a4ard until final com)letion. T3e ;or> area# o2%ana:e%ent directl# under his control & management shall be9 Proect

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anagement Integration. , Proect 7ime anagement, Proect Sco)eanagement, Proect "ualit#, GS; anagement, Proect Cost, Ris,Procurement, Communications & Guman resource anagement.

Gis res)onsibilit# shall include but not limited to 9

2 Re)resent Consortium and liaise 4ith %4ner on da#2to2da# matters.

2 %rgani(e a Proect 7eam and assign authorit# and res)onsibilities to hissu))orting anagers 6 ;ngineers 6 Su)ervisors in consultation 4ith theConstruction anager @CA 6 Proect Control anager @PCA6 /arranteeanager.

2 7imel# com)letion 4ithin the budgetar# )rovisions.

2 Revie4 )eriodicall# %verall /or Plans, S2Curve and detailed schedulesalong 4ith Consortium mobili(ation )lans, and revie4 them )eriodicall# toensure that )roect )erformance matches 4ith Proect schedulere:uirements.

2 Providing technical 6 financial in)uts, timel# mobili(ation of man)o4er ande:ui)ment to )roect site.

2 obili(e and utili(e the re:uired services of construction )ersonnel ors)ecialist Subcontractors.

2 Revie4 ConsortiumFs 4or schedule, man)o4er, machiner#, )roduction,)roductivit# and :ualit#.

- Co2ordinate bet4een various functions lie administration, )rocurement,)roect control, design & develo)ment, construction and commissioningand finance, so as to ensure that target dates are set for various actions 6)rograms and im)lemented in timel# manner to meet the ProectSchedule.

2 ;nsure meeting contractual re:uirements for "ualit#, Gealth, Safet#,;nvironment and other legal matters.

- Regularl# revie4 the )erformance of "ualit# anagement, Safet# &/elfare anagement, ;nvironmental "ualit# anagement b# conductingrevie4 meetings 6 obtaining 4eel# re)orts and a))raise the managementof the status of im)lementation and ensure corrective actions, if an#, tomaintain 6 im)rove these s#stems.

2 ;nsure that subcontractors6su))liers are scrutini(edK short2listed andrelevant a))rovals are obtained from %4ner.

2 %btaining necessar# and relevant a))rovals from Regulator# 5odies

through the Local uthorit# Coordinator.

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2 ;nsure )ro)er indents of consumables and Subcontractors 6 Su))lierFssu))lied materials and do necessar# follo42u) 4ith ProcurementDe)artment through Proect Control ;ngineer.

- Revie4 that ade:uate resources @man)o4er, e:ui)ment, tools andtacles, etc.A are available as $er Project E0ecution Plan and ensurethat necessar# mobili(ation arrangement is made through the Proectanager.

2 Revie4 the )erformance of the 4or, on dail# basis 4ith Proect anager 6Proect Control 7eam and Proect Services =rou) and ensure thatcorrective action is taen to ensure Construction Schedule is maintained.

- Periodicall# chec 4ith GS; ;ngineer for im)lementation of )rogram,revie4 safet# returns and audit 6 ins)ection re)orts. ;nsure that ade:uate)ersonnel )rotective e:ui)ment is )rovided as )er trade, )ro)erl# utili(edand the morale of the )ersonnel is maintained b# )rovision of ade:uatehealth, safet# and 4elfare conditions.

+.+.* Project Control 7ana:er

Proect Control anager @PCA shall be res)onsible to the C for)lanning6scheduling, engineering materials control services and re)orting.

Ge 4ill be assigned to the )roect site from the )eriod from commencement ofthe )roect through to com)letion of commissioning and 4ill be the )erson4ho 4ill be contacted b# the %4ner in the absence of P, D>P and C.

Ge shall92

- Im)lement and maintain the s#stems and )rocedures for )roectscheduling, monitoring and re)orting )roect eecution throughout theduration of the Contract. Provide overall and detailed )lans and schedulesof activities and resources, 4hich are ade:uate and are in accordance4ith the )roect eecution )lans .

- Pre)are the different level of Proect Planning for activities and monitorProect Progress on onthl#6/eel# schedules.

- Pre)are Proect ;ecution Schedules, SM curve, obili(ation Plan forresources, loo ahead schedule etc. and monitor that the mobili(ation,construction is being done as )er )lan and revise the schedule as )erProect In)ut @including 7%A from %4ner after raising alert to P.

2 onitor area of interface 4ith %4ner, Subcontractors and other third)arties for com)liance 4ith a))roved schedules and general eecutionintent. A&"i#e P7 o2 any &e"iation# an& tren, 4hich %ay a&"er#elye22ect $roject e0ecution!

2 Pre)are and maintain s#stems and )rocedures for control of free issuematerials from %4ner 3 if an# 2. Direct and manage material control

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services for com)liance 4ith a))roved )rocedures and in a manner thatensures ade:uate su))ort of effective )roect eecution.

- Pre)are and maintain s#stems and )rocedures for control of sco)edeviations and administration of contract terms and condition in relation to4or eecution. ;nsure ade:uate and timel# identification, :uantificationand documentation of contract variations and etra 4or instructionsthroughout )roect eecution and at Proect closeout.

2 ;nsure )ro)er co2o)eration of activities 4ithin sco)e of res)onsibilit# 4ithother eecution and services grou)s for effective 4oring.

- ;nsure that the )urchase of )roect materials i.e. consumables, structuralsteel etc. for various /ors are correctl# s)ecified 4ith regard to sco)e,technical and :ualit# matters and made available as )er Proect Schedule.

- Revie4 deliverables submitted b# Subcontractors and confirm that the#match 4ith Proect re:uirements b# organi(ing technical revie4 through"6"C ;ngineers 6 Disci)line ;ngineers and distribution to all concernedthrough Document Control.

- Revie4 aterial Receiving StatisticsF for Purchased Items @)ermanentmaterialsA and e)edite deliver# of long deliver# items and dela#eddeliver# items through Proect Control ;ngineer 6 D>P.

2 Control of C%P6C through PC4henever there is sli))age in an# front.

- Resolution of technical :ueries, concession notes, design deviationre:uest from Su))liers b# re)resentation to the %4ner and u)dating thestatus of such matters.

- %riginate and control the overall schedule for construction includingverification of resources Subcontractor 6 Services 6 man)o4er loading inconsultation 4ith C6D>P and inform P for necessar# mobili(ation.

+.+.- En:ineerin: 7ana:er

7he ;ngineering anager *E7+shall be re#$on#i9le to the CE Ge shallensure "ualit# ssurance in Design, Develo)ment, Production6abricationInstallation and Commissioning of facilities. Ge shall be res)onsible toensure the im)lementation of ;ngineering SubcontractorFs Design Control

Procedure during all stages of Design & Develo)ment.

Ge shallK

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- 5e res)onsible to )rovide formal and s#stematic guidelines to allconcerned to control and verif# design and detailed engineering relatedactivities of )roect in order to meet %4ner stated and im)lied needs.

- 5e res)onsible for activit# assignment to Consortium )ersonnel for initialsurve# and site data collection, 4hich 4ill form the basis of designin)uts.

- Plan and %rgani(e technical interface co2ordination.

- Identif# design in)ut, design out)uts, design revie4, design verification,design validation and design change control.

- Pre)aration of Proect Co2ordination Procedure 4ith %4ner- 5e res)onsible for Document, Dra4ing control and Su))lier data control.

- 5e res)onsible for Progress Re)ort for Design and Detailed ;ngineeringactivities indicating areas of concern, )rogress statistics, )rogresscurve, dra4ings & documents status re)ort, baclog activities and theirantici)ated date of com)letion.

- 5e res)onsible for revie4 of all material re:uisitions and )acagesubcontract documents )re)ared b# Design & Develo)mentSubcontractor2if an# for on4ard a))roval b# %4ner and issue to

Subcontractor6Su))liers.

- 5e res)onsible for revie4 of all documents, dra4ings, data, andtechnical evaluations, )re)ared b# Design & Develo)mentSubcontractor before issue for a))roval of %4ner and6or )urchaseorder.

- 5e res)onsible for maing s)ecific setches, 4rite2u)s for obtaining4or )ermits, statutor# a))rovals etc., as re:uired during theconstruction of )roect.

- 5e res)onsible for ensuring technical conformit# for materials thatre:uired @7A, su))lied to )roect site 4ith necessar# third )art#ins)ection re)orts as a))licable and 4itness factor# acce)tance test andsite acce)tance test 4ith disci)line engineers.

- 5e res)onsible for )re)aration of necessar# documentation 6constructions)ecifications for s)eciali(ed 4or.

- Resolve da# to da# matters )ertaining to incom)lete information or

ambiguit# in s)ecifications 6 dra4ings and field )roblems and if

necessar#, for4ard unsolved )roblems to C; 6 D>P & P for taing u)in %4nerFs Progress eeting for resolution& mae a re:uiredcoordination to raise @S7"A 4ith C , )re)ared b# Su))orting technical)ro)osals .

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- mend s)ecifications6dra4ings etc. in line 4ith a))roved designconcession6deviation re:uests a))roved b# %4ner and maintainnecessar# and relevant data for submission on s25uiltF documentation.

- 5e res)onsible for maing s)ecific setches, 4rite2u)s for obtaining4or )ermits, statutor# a))rovals etc., as re:uired during theconstruction.

- mend s)ecifications6dra4ings etc. in line 4ith a))roved designconcession6deviation re:uests a))roved b# %4ner and maintainnecessar# and relevant data for submission.

+.+.-.1 En:ineerin: Con#truction Coor&ination

7he ;ngineering & Construction Coordination shall be res)onsible to theDYP7 for coordinating bet4een the ;ngineering Subcontractor throughChief Engineering CE and the con#truction 7ana:er C7 for mattersrelated to their disci)line 4ithin the sco)e of 4or shall be res)onsible forRevie4, e)editing and coordination of the engineering dra4ings6s)ecifications and the )rocurement of material for ensuring timel# deliver#and conformance to )roect C @a))roved for constructionA dra4ings6functional s)ecifications.

+.+.H Procure%ent 7ana:er

7he Procurement ang.shall re)ort directl# to Proect anager @PA 4ith Ccto C.

Ge shall be res)onsible for timel# )rocurement of materials and arrangingsubcontracts 6 services as )er the schedule re:uirements of the )roect.

Ge shall9

- 5e res)onsible for R" in consultation 4ith ;ngineering anager.

2 5e res)onsible for )re)aration of Procurement Schedule in consultation4ith Planning de)artment as )er )roect s)ecification.

2 5e res)onsible for evaluation and )re2:ualification of vendors andsubmit the technical evaluation in consultation 4ith ;ngineeringanager and Proect anager for a))roval.

2 5e res)onsible for floating of en:uiries and receiving :uotations.

2 5e res)onsible for 7echno2commercial evaluation in consultation 4ith)roect team.

2 5e res)onsible for cost effectiveness of )rocurement of all materials.

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2 5e res)onsible for )lacing of orders and e)editing for effective andrealistic deliver#.

2 5e res)onsible for %R=


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2 isuall# ins)ect and co2ordinate regarding technical matters 4ith ".C.Ins)ector "6"C ;ngineer and 6 or disci)line engineer and segregatenon2confirming material in :uarantine area. aintain material recei)tins)ection records.

2 aintain records of recei)t, issue and certificates of conformit#,calibration data and batch test certificates for various material receivedb# him, certification, 4herever necessar#. Co)ies of necessar# recordsmentioned above are handed over to ".C. De)artment 6 Disci)line;ngineer for revie4 6 records.

2 Ins)ect visuall# and re)ort damage, deficienc# 6


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2 Coordinate 4ith %4ner, Disci)line ;ngineers, Subcontractors and the4orforce in general for overall safet# )ractices to be follo4ed duringeecution of this Proect. ormulate Site Safet# Committee 4ithre)resentatives from all 4oring grou) and conduct regular meetings.

2 Plan, organi(e and co2ordinate basic induction training and orientationgiven b# Safet# su)ervisor and maintain status re)ort of each individual.

2 ;nsure that the su)ervisor# staff and 4orers are ade:uatel# trained inthe )rocess of im)lementation of ;nvironmental Control b# lectures andconstantl# reminded b# the use of Signs and Posters dis)la#ed at)rominent )laces of 4or.

2 Direct and su)ervise Safet#, Gealth, /elfare and ;nvironment relatedmatters as )er local regulations, C%PFs Proect @GS;A Proceduresand ContractorFs a))roved GS; Plan for ContractorFs )ersonnel and forSubcontractors.

2 7o confirm that all )lant lifting e:ui)ment, tools 6 tacles and lifting beltsfor use at 4or are eamined and tested b# com)etent authorities and$erio&ically c3ec>e& 2or "ali&ity o2 certi2icate#to ensure reliabilit# andSafet#.

2 ly #a2ety re"ie; %eetin:# about

!a"e 22 o$ 6%


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the )ast mistaes and future )lan to im)rove and secure the safet#, healthand 4elfare of )ersons at 4or.

2 Pre)are ;mergenc# 6 Contingenc# Plan for GS; .

2 %btain necessar# a))roval from %4ner and6or other regulator# bodiesand ensure that 4or is not held u) for 4or of )ermits 6 a))rovals.

2 Regular safet# ins)ection and audits are carried out at 4or )laces andnecessar# corrective action are taen on )riorit# basis.

2


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2 %rgani(e and monitor the Stage Ins)ections re:uired at ;:ui)mentSubcontractorFs 4ors as )er the a))roved I7P.

2 %rgani(e third )art# ins)ection 6 audit on SubcontractorFs of )roductsde)ending on criticalit# class and ins)ection level given in technicals)ecifications and aterial Re:uisition.

2 Schedule & conduct Internal udits and ;ternal udits on Su))liers.

2 Coordinate for 7hird Part# Ins)ection @if an#A at SubcontractorFs sho) andensure )ro)er certifications as )er ins)ection levels and ProectS)ecification re:uirements 6 material re:uirements.

2 Inform %4nerFs "6"C De)artment regarding "ualit# anagement S#stem calls for the )resence of " ;ngineer forensuring com)liance to the "ualit# s#stem. 7he " ;ngineer @uditsA shallre$ort to t3e QA8QC 7ana:er.

Ge shall9

- Revie4 the )roect s)ecifications on regular basis, es)eciall# 4henrevisions are made, to assess the effect on cost and time 4.r.t )resentProcedures and raise 7echnical "ueries @7"A and associate him toresolve the same.

- %rgani(e s)ecial training )rogramme related to IS% 80019!000 34areness and Im)lementation on regular basis and monitoreasurement, nal#sis and Im)rovement Programme including ContinualIm)rovement .

- %rgani(e s)ecial surveillance on Customer )ro)ert# and sort out

discre)ancies, if an#, b# raising 7echnical "ueries and discussion 4ithCustomerFs re)resentative.

!a"e 2 o$ 6%


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- Pre)are Internal udit Schedule & conduct audits 4ithin theorgani(ation as 4ell as on Subcontractors as )er )rogramme, )rovidefeedbac to the anagement on audit findings and follo4 u) on closeoutof


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2 Collect, segregate, file and maintain "ualit# records throughDocumentation Cler and )re)are Ins)ection & 7est Status on regularbasis.

+.+.1* Document Controller

Document Controller 4ors on site office shall be res)onsible for Recei)t,onitor, ile, and Inde, distribute and maintain a database 4ith the revisionstatus of various documents received6issued and to6from ;ngineeringSubcontractor, Subcontractors, Su))liers and %4ner.

Ge shall also res)onsible for internal distribution of all :ualit# documents,Dra4ings, S)ecifications, Su))lier documents etc., as )er the DocumentDistribution matri. ll the corres)ondence to 6 form the %4ner andSu))liers, i.e., Letters, 7ele faes etc. 4ill be handled, monitored anddistributed b# the Proect anager #ecretary. n Incoming and %utgoingcorres)ondence log shall be maintained either in the form of a soft co)# orhard co)#.

+.+.1- ;ngineer, Su)ervisor, oreman

;ngineer, Su)ervisor, oreman shall be res)onsible to the C and the# shallhave authorit# and res)onsibilit# for schedule control, :ualit# control andGS; control on assigned 4or at )roect sites. 7hese are direct su)ervisor#)ositions and the s)an of control in each case 4ill be as defined in this Plan,but the )rimar# functions are similar. Disci)line ;ngineers in )articular haveto liaise 4ith "C ;ngineer 6 Ins)ectors in the )re)aration of Ins)ection and7est Plans.

Ge shall9

2 Pre)are and eecute detailed construction )lan including detailedschedule, manning )lan, construction e:ui)ment )lan, etc. for da#2to2da#activities and advise PC6P; accordingl#.

2 Revie4 and )lan according to the Level III Construction Plan for his

disci)line @Sco)eA for the 4ee6fortnight.

2 Direct and su)ervise subcontractor, if an#.

2 Perform :ualit# control of the assigned 4or in line 4ith ethodStatements & Ins)ection and 7est Plans a))roved b# %4ner.

2 Direct and su)ervise Subcontractors in their area of 4or.

2 7ae corrective action on


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2 Pre)are technical :ueries for discre)ancies in dra4ing after field chec ordiscre)ancies or clarification in the s)ecification as 4ell.

+.+.1H Co%%i##ionin: 7ana:er

7he commissioning manager shall be res)onsible to the )roect manager. Geshall be overall res)onsible for )lanning the commissioning activities in coordination 4ith the PC and the C in the se:uential manner.

Ge shall9

- erif# all the com)letion records before taing u) s#stems6e:ui)ments forcommissioning.

- erif# the com)liance to the design of the s#stems and )re)are )ro)ercommissioning schedule.

-


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F!( QUALITY PLANNIN/

*.1 Consortium 4ill submit " Procedures 6 ethod Statements 6 /orInstructions that are referenced in I7P and 6"ualit# Plan 4hich define ho4individual elements of the 4or are undertaen, the )ersonnel res)onsible,the im)lementation of ins)ection6verification activities and testingre:uirements.

7he Proect S)ecific Procedures and Ins)ection & 7est Plans @"ualit# PlansA4ill be )re)ared after stud#ing all Proect S)ecifications, Codes andStandards s)elled out in I.7.P., Proect S)ecifications and Dra4ings for theContract and good engineering )ractice.

Res)onsibilit# for )re)aration, revie4 and a))roval @including revisionA hasbeen identified in Para '.$.1 of this Project Quality Planthe same 4ill befollo4ed.

Proect S)ecifications, Documents and Dra4ings listed in the Documents &Dra4ings RegisterM 4ill be used in conunction 4ith C%


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Consortium 4ill maimi(e utili(ation 6 modification of e0i#tin: e#ta9li#3e&&ocu%entrather than )re)aring ne4 ever# time. ccordingl# the documentslisted shall be )re)ared to suit the )roect s)ecific re:uirements.

*.!.! 7he " Procedures, ethod Statements and corres)onding Ins)ection and7est Plan 4ill be )re)ared b# "6"C ;ngineer6Disci)line ;ngineers revie4edb# "6"C anager and a))roved b# Proect anager before submitting forrevie4 of %4ner. T3e In#$ection an& Te#t 2or%at# 5Reue#t 2orIn#$ection6or any ot3er 2or%at 2or 5In#$ection Te#t Statu#6 a# reuire&9y t3e contractual reuire%ent an& Project tec3nical reuire%ent al#o;ill 9e #u9%itte& 2or a$$ro"al!

*.$ QUALITY 7ANA/E7ENT

*.$.1 S#stem %utlines

7he follo4ing are summari(ed re:uirements of "ualit# anagement S#stemand details of /G%, /G7 and G%/ are defined in GPSICFs 4ritten "ualit#anagement S#stem Procedures or %)erational or " Procedures, ethodStatements @.SA and Ins)ection & 7est Plans @I.7.PA as a))licable.

*.$.! Quality 7ana:e%ent Re#$on#i9ility

*.$.!.1 "ualit# Polic#, "ualit# obective have been defined in )revious )aragra)hs inthis Project Quality Plan.

*.$.!.! 7he organi(ation structure, res)onsibilities and authorit# of )roect2based)ersonnel have been defined in this Project Quality Plan.

*.$.!.$ %verall "ualit# Planning for the Proect is being done in line 4ith theguidelines given as )er "ualit# Planning )hiloso)h# in "ualit# anagementS#stem anual

*.$.!.' Re#ource 7o9ili=ation In2ra#tructure

Identification of Resources re:uired for eecution of a contract shall be doneb# Proect anager in consultation 4ith Consortium Proect anagement7eam and documented in92

7he PR%?;C7 "BLI7> PL


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2 Cor$orate Guman Resources De)artment *RD+ for silled6unsilled)ersonnel, including )rovision of )ro)er 4or environment meeting thestatutor# & regulator# re:uirements @Labor La4, Contract Re:uirementsetc.,A

2 Proect Control =rou) for infrastructure re:uirements such as9 Storage &abrication acilities, Cam)s and associated utilities,

2 aintenance De)artment for mobili(ation of Plant and e:ui)ment,certification, refurbishment as )er the )reventive maintenance scheduleand breado4n maintenance.

2 Purchase =rou) for

Identification & obili(ation of Su))liers

Permanent materials

Consumables


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Recor& o2 all trainin:carried out and certificate issued 4ill be e)t inconcerned de)artments and a co)# 4ill be maintained b# dminstratoranager in the corres)onding em)lo#eeFs )ersonnel file.

%nl# )ersonnel 4ith valid certificates 6 :ualification shall be allo4ed to)erform the s)eciali(ed sill 4or.

Si%ilarly QA8QC anager on site shall en#ure that all oremen and;ngineers 4oring on site are a;areof our "ualit# Polic#, "ualit# %bectivefor this )roect and " & "C re:uirement of the )roect b# carr#ing outlectures 6 discussion of "ualit# ssurance )rocedures 6 ins)ection and test)lans and e)laining the needs 6 s)ecified re:uirement of the Proect,organi(ing "ualit# 4areness Programs organi(ed internall# .

*.$.!.* Quality 7ana:e%ent Sy#te% I%$le%entation

"ualit# anagement S#stem im)lementation :ui&eline# are covered underA$$en&i01F. "ualit# Re)resentative at )roect site shall tae cogni(ance ofthis re:uirement and ensure effective im)lementation.

*.$.!.- 7ana:e%ent Re"ie; *Project Le"el+

Proect anagement Revie4 7eetin: conducted e"ery %ont3 4illinclude onthl# Progress, "ualit# anagement, Gealth & Safet# and;nvironmental "ualit# functions.


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ll incoming corres)ondence from %4ner & Su))liers, i.e. Letters, 7elefaesetc. shall be recei"e& 9y the P7 #ecretary, verified, date stam)ed and entr#made in the Incoming register and circulated to all concerned a# %ar>e& 9yP7 8 C7 8 PC7 as Documented in the Document Control Procedure. llincoming documents shall be recei"e& 9y t3e DC &e$art%ent, verified,stam)ed and logged in to the Incoming document register and distributed as)er the )redefined Internal Dra4ing & Document Distribution List. DocumentDi#tri9ution Li#t 2or%at i# inclu&e& a# Attac3%ento2 A$$en&i01G!

aster Dra4ings & Document Register 4ill be )re)ared including the;ngineering Deliverable generated for the reali(ation of the )roect. T3eDra;in: Docu%ent Re:i#ter -or%at attac3e& 3ere;it3 a#A$$en&i01H./henever ne4 or revised s)ecification 6 dra4ings are received, the# 4ill beentered in aster to reflect revision number, date of issue @on documentA,date of recei)t at site and issued to the relevant disci)line manager 6engineers 6 ins)ectors and "6"C ;ngineer as )er distribution matri forstud# and im)lementation.

ll the co)ies of su)erseded s)ecifications 6 dra4ings 6 )rocedures, etc., shallbe destro#ed or be mared %IDM or SBP;RC;D;DM and the# ma# be e)tin se)arate files if re:uired for future reference.

ll outgoing documents shall be issued 4ith a uni:ue serial number, revisiondesignator 4ith date of )re)aration 6 revie4 6 a))roval and listing of alldocuments shall be maintained in the Document Control Log 6 Dra4ingInde 6 Procedure Inde 6 ethod Statement Inde 6 Ins)ection and 7estPlans matri. 7he numbering s#stem for document is to be identified in theDocumentControl Proce&ure!

n# re:uest for change to the "ualit# S#stem Documents shall be made tothe original a))rover, unless authori(ed or delegated in line 4ith Para +.*.18and all subse:uent revisions have to be authori(ed. 7he res)onsibilities for)re)aration, revie4, and a))roval including revision have been outlined inthis Project Quality Plan.

Document Submittal log for )rocedures, ethod statements, I7Ps etc., 4ill beu)dated 4eel# to confirm the status of submission, comments and a))rovaletc.

ll documents issued for construction )ur)ose shall be mared JCJ6 ICM.7hese shall be a))roved b# the P 6 PC. 7he numbering s#stem anda))roving authorit# for various documents 6 dra4ings shall be as establishedb# Consortium accor&in: to nu%9erin: #y#te% $roce&ure

7ransmission of Dra4ings 6 Data Sheets 6 Procedures and other "ualit#S#stem Documents 6 S)ecification shall be done 4ith a Document

7ransmittalN orm, a co)# of 4hich shall be signed b# the receiver andreturned to the originator.

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F!B Quality Recor

7he Con#ortiu%4ill )re)are )rocedure for identification, collection, indeingaccess, filing storage, maintenance and dis)osition of "ualit# Records todemonstrate the effectiveness of the :ualit# s#stem and the :ualit# of the)roduct.

ll batch certificates, Lab certificates, Dail# Ins)ection Re)orts,


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G!( PROJECT REALI?ATION PROCESS

-.1 Plannin: 2or Pro&uct Reali=ation Proce##

7he Con#ortiu%4ill )re)are the Proect obili(ation Schedules, Proect SFcurve, Level2III & Level2I Schedules etc., identif#ing the resources re:uiredfor ;ngineering, aterial anagement, Construction and Commissioningactivities to meet the scheduled com)letion date as )er Contract.

7he Procurement anagement, "ualit# anagement, and GS; management4ill be organi(ed b# 7he Con#ortiu%. 7he Design & ;ngineering 4ill bemanaged b# 7he Con#ortiu%.

7he schedules 4ill be submitted to the %4ner for their revie4 and comments.%n the a))roval of the Schedule and the )ro)osed SF curve, 7heCon#ortiu%4ill monitor the )roect )rogress.

7he )roect schedule and )rogress 4ill be revie4ed on 4eel# basis andnecessar# actions 4ill be initiated to adhere or eceed the )lanned )rogressre:uirements.

s this is an EPCC Proect, meeting the schedules and achieving the)rogress is full# de)end u)on the Design & Develo)ment, Procurement anddeliver# schedule of the Long Lead Critical items.

"ualit# s#stem documents 4ill be )re)ared. Stage 4ise , ins)ection 4ill becarried out as )er the a))roved Ins)ection and test )lans.

ll ins)ection records, necessar# & relevant documents generated 6 identifiedin various stages of )roduct reali(ation 4ill be com)iled )rogressivel# for finalDocumentation submission.

-.! Cu#to%er Relate& Proce## Co%%unicationfter a4ard of the contract, a )ost2a4ard revie4 4as )erformed b# Proect=rou) i.e. Proect anager @PA, Construction anager @CA, ProectControl anager @PCA, "6"C anager and an# other functions asre:uired to get familiarit# and understanding 4ith the re:uirements s)ecifiedin the contract.

PC has full access to the )re2a4ard contract revie4s, bidding stagedocumentation, clarifications and :ualifications etc. during )roect handingover to ;ecution =rou). PC has the res)onsibilit# of coordinating theresult of the Contract Revie4 and submit an# findings to %4ner throughP6C.

/hen resolution of technical :uer# @7"A, Site Instructions @SIA or letter forclarification, confirms that additional material, man)o4er, e:ui)ment hours

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4ill be s)ent to carr# out the 4or as against sti)ulated in bid, thenamendment to contract ma# be re:uired. s a))licable b# the contractconditions, PC has to substantiate claims for variation order 2 direct costim)act 6 time im)act for the ConsortiumFs sco)e of 4or to %4ner. 7he etra4or ma# be due to ConsortiumFs increase sco)e of 4or or %4nerFs changeof Process Design 6 7echnical s)ecification etc. %btaining Change Re:uestFfrom %4ner is the res)onsibilit# of Proect Control anager.

ll documents )roduced during the )ost2a4ard contract2revie4 shall be filedb# PC and accessible for all concerned )ersonnel.

G!@ De#i:n De"elo$%ent

-.$.1 CP; has been assigned as the ;ngineering, Design & Develo)mentSubcontractor, 4ho has a certified "S conforming to IS% 80012!000. co$y o2 t3e Certi2icate attac3e& 3ere;it3 a# A$$en&i01'! 7he;ngineering, Design and Develo)ment Sub Contractor is res)onsible tocarr#out, Design & Develo)ment, Process Design and Detail Design.

-.$.! Proect S)ecific ;ngineering Contract "ualit# PlanM develo)ed b#;ngineering, Design & Develo)ment Subcontractor 4ill be submitted to

Com)an# for Revie4 and a))roval.

-.$.$ Design ;ngineering Subcontractor shall also be res)onsible to stud# thecriticalit# rating for all Proect Permanent materials used on this contract as)er C%P Proect s)ecification.

Design ;ngineeringSubcontractor4ill cover this as)ect under En:ineerin:Project Quality Plan Pre)ared after the a4ard of the Contract. 7hisProcedure 4ill be revie4ed and submitted for C%P a))roval.

-.$.$.1 7he Criticalit# Rating derived shall be used to determine the ins)ection, testand 4itness re:uirements. 7he Criticalit# Rating shall be used to determinethe re:uirements for the follo4ing9

dditional endor "ualit# ))raisal

endor Design ))roval

endor "ualit# Plan re:uirement

Reliabilit# and maintainabilit#

"ualit# control surveillance

Ins)ection and tests

Documentation

aterial 7raceabilit#

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7he Criticalit# Rating for each )rocurement )acage shall be assigned b# theDesign ;ngineering De)artment 6 contractor and authori(ed b# the ContractorRe)resentative. /hen the Criticalit# Rating has been determined it shall benormall# remain fied throughout the )roect c#cle. Go4ever, an# designchanges shall be revie4ed to assess if the Criticalit# Rating re:uiresamendment. n# decisions concerning the acce)tabilit# of nonconformingitems shall tae account of the Criticalit# Rating assigned.

-.$.$ C3ie2 En:ineer *CE + t3rou:3 t3e En:ineerin: 7ana:er *E7+ isres)onsible for Coordination & liaise 4ith the Design ;ngineeringSubcontractor as 4ell as the %4ner for Design Control i.e. Design &Develo)ment Planning, In)ut, %ut)ut, Revie4, Design erification.

or )re)aration of as built dra4ing, construction surve#ors and draftsmenshall red mar the dra4ing and get them a))roved b# eecution team of the%4ner and send them to Design ;ngineering Subcontractor for )re)aringfinal s25uilt ;ngineering Dra4ings.

!a"e &7 o$ 6%


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G!< Purc3a#in: Proce##

-.'.1 Proect Control anager at site 4ill co2ordinate 4ith Procurement andSubcontract anager at site. Ge shall be res)onsible for im)lementation ofthe s#stem and 4ould be re)orting to Proect anager.

-.'.! ll material received shall be visuall# checed b# L%=IS7IC


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P;6"2"C for the )roect are checed b# Disci)line ;ngineers to confirm thatthese are meeting Proect 7echnical re:uirements, )roect standard for eacht#)e of item, re:uirements of 5atch 7est Certificate or Certificate of conformit#and calibration certificate and the same should be incor)orated in thematerial 6 )urchase re:uisition )urchase order.

-.'.8 ;ach Subcontractor utili(ed in the )roect shall be re:uired to develo) a"ualit# anagement S#stem and conform to the Con#ortiu%6# 5ProjectQuality PlanF and de)ending on his sco)e of 4or, he shall be ased to)re)are ethod Statements and Ins)ection & 7est Plans in accordance 4ith)roect :ualit# re:uirements and technical s)ecifications.

the Con#ortiu%shall ensure that all necessar# and )ertinent re:uirementsestablished b# the a))roved " )rogram are im)osed on all su))liers andsubcontractors and acce)ted b# these )arties.

-.'.10 ll material received shall be visuall# checed b# *L7+against the order andan ins)ection )erformed either b# himself or concerned disci)line engineer or"C Ins)ector to establish conformance to Purchase %rder 6 PurchaseRe:uisition.


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;ngineering anager along 4ith necessar# bac2u) data )rovidedb# Su))liers, Design ;ngineeringSubcontractorFs revie4 etc. andfollo4 u) for clarification or resolution.

@ii iA %nce clarified or a))roved b# the %4ner, the loo) shall becom)leted b# Design ;ngineering anager 3 b# sending thedocuments to Design ;ngineeringSubcontractor for incor)oratingnecessar# and relevant changes in the aterial Re:uisition 67echnical S)ecification etc.

@ivA 7he revised material re:uisition 6 technical s)ecification and 6 orthe clarified 6 a))roved concession re:uest and technical :ueriesshall be for4arded to su))lier through Procurement ;ngineer. Ifnecessar#, the Purchase %rder ma# be revised accordingl# andissued to su))lier for com)liance.

.+ Su$$lier &ra;in:# &ocu%ent an& &ata

7his shall follo4 the same route as done in the su))lier concessionre:uest and technical :ueries, ece)t for follo4ing.

/hen the# significantl# affect other )rocurement or construction

activities.

In this case, the co)# of the documents shall also be sent for revie4 ofsite conditions, cost and time. 7he comments from them shall be includedin the for4ard to Design ;ngineering Subcontractoras 4ell as internalrevie4.

urther )rocess of resolution, discussion and clarification 4ill be on thesame lines as )ara @A. 7he detailed flo4 sheet 4ill be )re)ared inconsultation 4ith Design & ;ngineering Subcontractor on a4ard of thecontract.

-.'.1$ inimum Sho) Ins)ection and Certification re:uirements shall be s)ecified toSu))lier as mentioned in basis of offer. Su))lier shall )re)are the I7Psdetailing all stage 4ise Ins)ection and 7esting re:uirements and submit to theC%


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G!B Con#truction Proce##

list of Construction Procedures, ethod Statements, I7PFs to be develo)edfor the )roect 4ere listed in the "ualit# S#stem Procedures Inde.7he data regarding the Ins)ection & test status and Records 4ill be u)datedand maintained in com)uter database.

-.+.1 Vali&ation o2 Proce##e#

7he validation of the )rocess shall demonstrate the abilit# of the )roductout)ut to achieve )lanned results.

Some of the eam)les for Process alidation are detailed belo49

2 G#drostatic Lea 7est 6 Pneumatic Lea 7est for verif#ing of the Integrit#of installed )i)ing net4or before commissioning.

2 ;lectrical and Instrumentation loo) checing for the validation of the;lectrical and Instrumentation Circuits before energi(ing and charging theCircuits.

- Procedure "ualification Records for alidation of /elding Procedures,P/G7 Procedures,


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If material has been )reviousl# tagged b# a Su))lier, then these shall remainfor traceabilit# to su))lierFs documentation. If re:uired, the# shall be taggedb# ConsortiumFs aterials ;ngineer 4ith an in2house tag and referenced onthe relevant documentation. Color2coding of materials shall be noted inaterial Control Procedures as a means of identification.

7ags or other means of identification shall remain on e:ui)ment untilfabrication or installation.

T3e Con#ortiu%shall identif#, segregate, control and certif# materials ande:ui)ment that 4ill be incor)orated into the 5uilding.

ll reected material shall be stored in a designated area a4a# fromacce)table material and mared ReectM. ll material that has been reectedshall be removed from the store as soon as )ossible. 7he aterial & S)oolController shall maintain records of such materials and its de)arture from thestorage area.

-.+.!.! Ins)ection & 7est records, 4hich give evidence that the )roduct has )assed 6failed ins)ection and 6 or test 4ith defined acce)tance criteria, 4ill bemaintained on various activities 4ithin the Sco)e of /or.

-.+.$ Cu#to%er Pro$erty

If an# customer )ro)ert# is su))lied during the )roect eecution stageConsortium shall verif#, )rotect and safe guard the )ro)ert# for an# damage.

-.+.' Stora:e Pre#er"ation o2 Pro&uct

suitable shed 6 containers 6 o)en s)ace are assigned for storage )ur)oseb# Logistic anager and the material shall be stored )ro)erl# and )reservedas )er t#)e of materials in coordination 4ith "C ;ngineers 6 Disci)line;ngineers and guidance from su))liers6manufacturers & GS; dvisor./elding Consumables shall be stored in com)liance 4ith the manufacturerFsrecommendations, and )re)ared in accordance 4ith "C Procedures.

ll material received and dis)atched from stores shall be recorded on bincard and ;cess 6 Shortage shall be checed b# @LA on regular basis. n#s)ecial re:uirements of material s)ecified b# su))liers shall be adhered to.

7he s)ecific conditions of storage shall be informed b# disci)line engineer to@LA b# referring to 7echnical Data Sheet6"C Procedures. In case of doubthe should consult "C ;ngineer 6 Disci)line ;ngineer on site and )re)are thestorage facilit# accordingl#, e.g. air2condition storage or de2humidifier etc.

7he )rogram for )reventive maintenance of e:ui)ment shall be in accordance4ith the manufacturerFs recommendations and shall )rovide a sufficient level

!a"e 2 o$ 6%


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of maintenance acce)table for 4arrant# )ur)oses.


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H!( 7EASURE7ENT ANALYSIS I7PROVE7ENT

H.1 %rgani(ational Performance and Customer Satisfaction are :ualitativemeasurements. 7he )rocess for measurement shall include9

aA Data for )roduct or )rocess converted into information and no4ledgebase.

bA 7he format and method of measurement shall be revie4ed and u)dated.cA Customer Satisfaction or com)liant 3 customer 4ise or )roect 4ise or

countr# 4ise.dA udit %bservations 6


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Su))liers as a))licable. %4ner and the auditee 6 organi(ation 4ill be notifiedabout the audits in advance.

ll uditees shall be informed of im)ending audits b# " De)artment. %4nerma# be informed of the audit if the# 4ish to 4itness the audit as an observerand as re:uired b# the contract. 7he audits 4ill be conducted b# :ualifiedauditors .

udit Chec lists shall be )re)ared 6 utili(ed to ensure that all relevant to)icsare covered. Go4ever, the checlist shall not restrict uditors from raisingfurther :uestions, not included in the checlist.

n audit re)ort shall be issued b# "6"C anager to P6C indicating an#

observations, non2conformance found and it ma# )rovide recommendeddis)osition as 4ell as corrective action to be taen. 7he co)# of the uditre)ort shall be issued to the uditee through the de)artment head and to the%4ner, if re:uired.

ll non2conformances including those issued b# %4ner shall be acted u)on,and a resolution agreed 4ith the "6"C anager2"6"C ;ngineer and Cas )er agreed time frame and corrective actions 4ill be taen accordingl#.

log of non2conformances and their status shall be maintained b# "6"Canager for the Proect and discussed during monthl# Proect anagement

revie4 meeting. ll the


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7he consortium shall notif# the %4nerFs Re)resentative sufficientl# inadvance to allo4 %4nerFs Re)resentative an o))ortunit# for 4itnessingIns)ection 6 7esting activities.

))roved Procedures, ))licable S)ecification, "ualification Records &dra4ing shall be issued to res)onsible )erson, as )er Document Distributionatri.


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cA aintenance of scheduled dates.dA Revenue 3 actual v6s budget.eA Safet# Satisfaction, Lost 7ime Incidents @L7IA6Lost 7ime Incidents

re:uenc# @L7IA.

etc. as a )art of anagement Information s#stem @ISA 4ithin theorgani(ation.

7he communication flo4 4ithin the follo4ing de)artments 4ill be ensured as a)art of monitoring the Product 6 )roduction and have better controls.

rom Proect Control to Construction9

aA /eel# Plan for an activit#

bA onthl# Plan for an activit#cA $ onthl# Plan for an activit#dA /eel# summar# 3 )lanned v6s actualeA onthl# summar# 3 )lanned v6s actual and

rom Construction to PC

aA Dail# Re)ort 3 activit#, man)o4er, e:ui)mentbA Dail# Discre)anc# Re)ort 3 maintenance, e:ui)ment or

material shortage.cA Reason for dela# or loss of )roductivit# etc.

7his is to be evaluated and fed bac in the )lan for net 4ee.

Proect team 4ill finali(e corrective action b# revie4 of the situation,mobili(ation of resources and other necessar# actions. Such and similaractions could be taen on all o)erations lie recei)t of )urchased items,)reservation of all )rocured )roduct, testing and reinstatement or an# activit#4ithin ContractorFs sco)e.

rom the )roect team, a similar re)ort is sent to Consortium anagement ona dail# 6 4eel# and monthl# basis for revie4, clarification.

7he acce)tance and reection of a )roduct, normall# monitored 4ith "Cs#stem, could be an indicator of )rogress and status re)orts shall bemaintained for information to customers6colleagues from Proect or ProectCor)orate %ffice as 4ell. 7his shall also be a))licable to Su))liers @vendorsAof )roducts.

.2 Control o2 Non Con2or%in: Pro&uct

/henever the )roduct or material is found not conforming to the ProectS)ecification 6 Code Re:uirements, a 4ritten


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shall be decided b# "C ;ngineer 6 Disci)line ;ngineer in consultation 4iththe O;neras necessar#.


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Procurement9

2 Res)onse trends for an en:uir# in the local or International arets2 Processing time of a )urchase order2 7rends in failure to meet the deliver# schedule2 Performance level of su))liers of various categories

Corrective action could be e)editing, reinforcement of resources orformation of s)ecial team etc. Root cause of the )otential )roblems shall befound and necessar# corrective and )reventive action 4ill be decided oncase2to2case basis.

H!< Continual I%$ro"e%ent

H.'.1 7he continual effectiveness and efficienc# of the )rocesses decide theachievement of the )roect obectives. Consortium shall set the targets to beachieved based on the )erformance in the )revious )roects. Some of suchtargets are9

a. Com)letion of the )roect 4ithout an# L7I,). chieving the 4eld re)air )ercentage belo4 !.+ targeting (ero defect,

2if an#c. inimi(ing the Punch list 4hile mechanical com)letion to a maimum

of 10 itemsd. Start )re)aring and handover documentation s#stemM as soon as +0O

test )acs are tested.

Similar Programs 4ill be develo)ed 4ithin the Proect anagement 7eam andConstruction =rou). Sam)le Programs are9

- Productivit# targets for /elders 6 itters 6 Instrumentation7echnicians etc.,

- Planning & %)timum utili(ation of the resources due to the 4ides)read of ob locations.

- Com)letion of the )roect ahead of the schedule to tae advantageof the )rovided bonus clause of the contract2 if an#.

)art from the above listed areas, )roect management aims for the continualim)rovement in other as)ects also such as Performance im)rovement of theresources.

7his 4ill be achieved b# )roviding )ro)er 4orenviroment 4ith im)rovedhealth and 4elfare conditions to create better 4oring environment forem)lo#ees. aintaining the necessar# s)ares and )erforming the )reventive

maintenance according to the )reventive maintenance schedule 4ill enable toutili(e the e:ui)ment at their o)timum ca)acit# levels.

H.'.! Correcti"e an& Pre"enti"e Action

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7he Consortium shall maintain a s#stem to ensure that all non2conformancesare revie4ed b# "6"C anager.

ll re)orts )roduced on non2conformance found during testing andins)ection, surveillance audits, Customer audits shall be inde)endentl#revie4ed, b# "6"C anager and Disci)line ;ngineer of the Consortium.7he course of action to be undertaen is determined, onl# after checing rootcause of the defect or deficienc# and actions 6 results shall be recorded.

Corrective action shall be onl# )roceed after authori(ed 4ritten instructionshave been )roduced and a))roved b# the " 6 "C manager. 7he dis)osition2 Re4orF, Re)airF, ReectF or BseF as it is shall be carried out./hen non2conforming conditions re2occurs, detailed eamination shall be

made b# "6"C anager, to determine 4hat )reventing action is necessar#based on stud# of available data, re)orts and methodolog# and then rootcause of the non2conformance i.e. 4hether 4or man 6 )rocess 6 machiner#shall be identified 6 the situation rectified to ensure re)etition shall not occur.

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!( LIST O- APPENDIX)

))endi21 IS% 80012!000 Certificate))endi2! Inde of "S anual & List of Cor)orates "S Procedures))endi2$ Proect %rgani(ation chart))endi2' "6"C onthl# Re)ort ormat for R))endi2+ List of Pro)osed "6"C Documents @)rocedures6S6I7PA))endi2* "ualit# management s#stem im)lementation guideline.))endi2- ormat of document distribution list.))endi2H ormat of Document Control Register))endi28 Internal udit Schedule

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APPENDIX '

ISO ((' 4((( CERTI-ICATE

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APPENDIX 1 4

INDEX O- CORPORATE QUALITY 7ANUAL

CORPORATE QUALITY 7ANA/E7ENT SYSTE7PROCEDURE LIST

7ANUAL In&e09ENER* !a"e

0.# Inde: #

0.2 Introduction &

0.& E:c(usions 7

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E'ION - ;*I< N9EEN


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LIS7 % C%RP%R7; "S PR%C;DBR;

!-2-0# 'ontro( o$ Documents

!-2-02 ua(it1 1stem Documentation

!-2-0& 'ontro( o$ ua(it1 Records

!-2-0 Documentation aster *ist

!-5-0# ua(it1 !o(ic1 ua(it1 O)/ectives

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!-56-0# ana"ement Revie?

!-62-0# rainin" and ?areness

!-6&-0# ervices Bui(din" aintenance

!-7#-0# !ro/ects !(annin" and Bud/etin" Be$ore E:ecution

!-72-0# '(ient 'ontract Revie? Estimates

!-72-02 '(ient 'ommunication

!-72-0& '3an"e Orders

!-7-0# u(ier Eva(uation and e(ection

!-7-02 !urc3asin"

!-7-0& 'ustoms

!-75-0# !rocess 'ontro(

!-75-02 E=uiment aintenance

!-75-0& ateria( 4and(in"@ tora"e@ and 'ontro(.

!-75-0 est and insection status

!-75-05 '(ient su(ied ro/ects

!-76-0# estin" E=uiment 'a(i)ration

!-2-0# Interna( ua(it1 udits

!-2-02 Incomin" ateria( Insection and estin"

!-2-0& Insection and estin" $or In-rocess WorAs

!-2-0 Insection and estin" $or t3e 'om(eted !ro/ects

!-&-0# 'ontro( o$ Noncon$ormin" ateria(s

!-5-0# 'ontinua( Imrovement

!-5-02 'orrective and !reventive ction

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APPENDIX @TE PROJECT OR/ANI?ATION CART

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APPENDIX