QualityPlan FPSO Topside

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REVISION CHANGE NOTICES

Rev. Location of Changes Brief Description of ChangeR01 Initial issue for comment/use A01 Issued for Design Incorporation of comments resulting

from internal review. Also change indocument number from BON-AME-399-Q-PRC001.

A02 Re-issued for Design Changes as discussed withSNEPCO 6 th/7 th March 2001. ReferMinutes of Meeting No:

L00802/AME/SNEPCO/R1/015 plusother minor comments. Also changein document number from BON-

AME-3GN-G-000199-007.


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CONTENTS

1.0 GENERAL

1.1 Introduction1.2 Issue and Distribution 1.3 Terms and Definitions 1.4 Project Quality Policy Statement1.5 Quality Objectives1.6 Organisation and Resources1.7 Management Reviews 1.8 Performance Standards and Contract Control Assessments1.9 Sub-Contractors1.10 Audit by SNEPCO1.11 Quality Improvement1.12 Integration with other Management Systems

2.0 PROJECT QUALITY MANAGEMENT SYSTEM

2.1 Project Quality Management System Structure2.2 General2.3 Contract Review2.4 Design Control2.5 Document and Data Control2.6 Purchasing2.7 Process Control2.8 Inspection and Testing2.9 Inspection, Measuring and Test Equipment2.10 Inspection and Test Status2.11 Non-Conformance and Corrective Action2.12 Handling, Storage, Packaging, Preservation and Delivery2.13 Quality Records2.14 Quality Audits2.15 Training2.16 Servicing2.17 Statistical Techniques

APPENDICES

APPENDIX I Organisation Charts APPENDIX II Audit and Review Strategy


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1.1 INTRODUCTION

The contents of this Project Quality Plan are based on, or interface with, the applicable

requirements of the following Specifications:

ISO 9001:1994

SHELL NIGERIA EXPLORATION AND PRODUCTION COMPANY LIMITEDContract, (No: L00802).

Shell International Exploration and Production INC. Bonga Construction QualityPlan, SDS 99-1007 (Rev A1)

Bonga-SPEC-GL-001, Shell Deepwater Development Systems, Inc. GlobalTechnical Specification - Quality Assurance/Quality Control, (Rev C).

AMEC Services Ltd, London, Quality Manual (Rev A9).

Project Execution Plan, BON-AME-3GN-G-00199-001

Key Quality Activities Matrix, BON-AME-3GN-Q-00190-002

QA/HS&E Project Audit & Review Schedule, BON-AME-3GN-Q-00190-003

HSE Plan, BON-AME-3GN-G-00199-005

The purpose of the Project Quality Plan is to provide the first tier of the overall projectquality management system structure and to provide means by which projectmanagement shall derive confidence that the Project is being executed in accordancewith the requirements of the contract and related regulatory requirements.

The Project Quality Plan will be supported by the Key Quality Activities Matrix (Doc No:BON-AME-3GN-Q-00190-002), as referenced above, which will be used to facilitateimplementation of the project quality management system. The Matrix will define the keyquality activities, procedures, responsibilities etc, for the contracted scope of work.

This Quality Plan, and revisions thereto, shall be submitted to SHELL NIGERIAEXPLORATION AND PRODUCTION COMPANY LIMITED (SNEPCO) for review andapproval.

This Project Quality Plan is a 'live' document and as such will be subject to periodicreview/change in line with identified and agreed amendments and improvements to theProject Quality Management System during the course of the Project. The ProjectQuality Plan will also be reviewed and updated to accommodate any additions orchanges to the contracted scope of work.


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1.2 ISSUE AND DISTRIBUTION

The Project Quality Plan will be made available electronically, on read only basis, onthe Project M drive.

Limited controlled hard copies will be issued as authorised by the Project QualityManager on an as required basis to nominated individuals who shall be heldresponsible for its implementation and update within their functions. All other hardcopies, including those hard copies down-loaded from AMECnet and the Project Mdrive, shall be deemed to be uncontrolled.

Hard copies requested by SNEPCO shall be formally transmitted via the ProjectDocument Control function who shall retain records of recipients.

Project personnel will be responsible for reporting to Project Management anydeficiencies or problems and suggesting improvements resulting from the use of theProject Quality Plan and related procedures.

Revisions

The Project Quality Assurance Manager will update and revise the Project Quality Planwhenever changes, additions or deletions are found to be necessary.

When a revision to the text results in a change, addition or deletion, the area of thecurrent revision shall be identified in the left hand margin of the page adjacent to wherethe change/addition/deletion was made. All previous revision identification shall beremoved.

1.3 TERMS AND DEFINITIONS

For the purpose of this Project Quality Plan and supporting procedures the following

definitions shall apply.

TERMS DEFINITIONS

Quality The totality of features and characteristics of a product or servicethat bear on its ability to satisfy stated or implied needs.

Quality Management That aspect of the overall management function that determines

and implements the quality policy.

Quality Assurance All those planned and systematic activities and functionsnecessary to provide adequate confidence that a product orservice shall satisfy given requirements for quality.

Quality Control The techniques and activities that demonstrate compliance with


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Quality Plan Document setting out the specific quality practices, resources,and sequence of activities relevant to a particular product, projector contract.

Quality ActivityControl Plan

A key document which supports the Project Quality Plan and listsin a logical sequence key activities such as contract review,engineering, procurement, etc. It identifies individual activities,controlling procedures/ standards, verifying documentation andmethod by which compliance is assured (i.e. audit).

Inspection and TestPlan

A document relating to purchased / subcontracted products andservices which lists in a logical sequence key activities such aspurchase order review, manufacturing, construction, inspection,

test and verification activities. It identifies individual activities,controlling procedures / standards, characteristics to be verified,acceptance criteria, verifying documentation, inspection and testrequirements, etc.

Quality Audit A systematic and independent examination to determine whetherquality activities and related results comply with planned and/ordocumented arrangements and whether these arrangements areimplemented and effective in achieving stated objectives.

Supplier Organisation that provides a product to the customer. Thereference to "supplier" includes for vendors.

Product Result of activities or processes and encompasses hardware,software, processed materials and services or any combination ofthese.

SNEPCO Shell Nigeria Exploration and Production Company Limited

AMEC AMEC Services Ltd, Offshore Business Unit.


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1.4 PROJECT QUALITY POLICY STATEMENT

It is the policy of AMEC to provide products and services that fulfil the quality, reliability,safety and specified requirements and stated expectations of the Project.

In order to achieve this policy for the SHELL NIGERIA EXPLORATION ANDPRODUCTION COMPANY LIMITED (SNEPCO) Bonga Project, the project team shallbe committed to establishing and maintaining an effective Project Quality ManagementSystem complying with the requirements of ISO 9001: 1994, the Contract specificationsand related regulatory requirements.

Compliance with the Project Quality Management System and the supporting systems,procedures, work instructions etc is mandatory and shall be adhered to by all personnelemployed on the project in order to achieve a common approach to Quality Assurance.

The Project Quality Assurance Manager will have overall responsibility for ensuring thatthe contents of this Project Quality Plan are satisfactorily implemented across theProject, including within key sub-contractors. As part of this responsibility the ProjectQuality Assurance Manager shall also ensure, as far as practicable, the alignment ofsub-contractors quality management system with that described within this Project

Quality Plan.The Project Quality Assurance Manager shall ensure that any problems or disputesarising from such are brought to the attention of the AMEC Project Manager, SNEPCOand/or senior management as appropriate.

Wherever possible the recommendations and "learning resulting from AMECsapproach to continuous performance improvement shall be fully integrated into the wayof working on the Project to ensure that an efficient and cost effective approach isachieved. This approach considers that everyone involved with the Project has aresponsibility for contributing towards continuous improvement and for benefiting fromlessons learned from previous projects/work.

A joint working relationship with SNEPCO shall be cultivated to enable an open and freeexchange of information in order to ensure that the Project is safe and reliable,completed on time, within target cost and to the required quality.

AMEC Project Manager


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1.5 QUALITY OBJECTIVES

The quality objectives of the Project are to ensure that all activities are:

- Planned and performed in such a manner that all facilities provided within theContracted Scope of Work are safe, reliable and free of errors and deficiencies.

- Planned and performed to achieve required quality, in accordance with agreedrequirements of the Contract and related specifications, within target cost andschedule requirements.

- In accordance with contractual and regulatory requirements.

- Performed correctly the first time to ensure cost effectiveness and efficiency.- Undertaken within an environment of Continuous Performance Improvement.

1.6 ORGANISATION AND RESOURCES

1.6.1 Project Organisation

The overall organisation for the Project shall be as per the organisation charts includedwithin the Project Execution Plan (Document No: BON-AME-003-G-00001). Theorganisation chart for the London QA & Certification/Classification team together withthe chart showing interfaces with the key sub-contractors are shown in Appendix 1. Alsoto be included within this Appendix will be the QA/QC organisations for the individualsub-contractors.

1.6.1.1 Job Description for Key Personnel

Job descriptions shall be available for all project personnel and shall include thefollowing as a minimum:

Function description Responsibilities, including for safety and quality. Accountability

Each key Project team member shall hold or have access to a copy of his/her jobdescription. The responsible manager for each area shall also hold or have access torelevant copies. The Project M drive shall contain those job descriptions applicable to

AMEC London based personnel. Non- AMEC personnel shall work according to therequirements of their respective management systems which are required to comply withthe AMEC project quality management system.

1.6.2 Quality Assurance Functi on


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Assurance Function shall also be responsible for monitoring sub-contractors and majorvendors to verify that they are complying with their own individual quality managementsystems applicable to their contracted scopes of work/supply.

1.6.3 QA Job Function and Accoun tability

1.6.3.1 Quality Assurance Manager

Function :

To plan, co-ordinate and report the day to day functions of the QA requirementsdictated by the Contract and the Project Quality Management System.

To monitor the implementation of the Project Quality Plan and assess itsoperation by review and audit and manage the QA activities defined by thecontract workscope. To liaise with SNEPCO on all matters relating to Quality

Assurance.

Accountability:

Reports directly to the AMEC Project Manager regarding day to day projectactivities but also has a reporting line to the AMEC Corporate Directorresponsible for quality, in particular, in those instances where there may bequality related problems which cannot be resolved at Project level.

1.6.3.1.1 Responsibilities of the Project Quality Assurance Manager

The overall responsibilities of the Quality Assurance Manager, supported by theLead Quality Assurance Engineer, are as follows:

- To issue, revise and control the Project Quality Plan.

- To perform QA activities against the Project Quality Plan and ProjectProgramme.

- To review the contract with regard to Quality related activities.

- To convene, attend and minute QA related meetings with SNEPCO asnecessary.

- To report promptly to Corporate Quality Management any quality relatedproblems that cannot be resolved on the project.

- To plan, perform and report audits and reviews in accordance with theagreed Audit and Review Programme assisted where necessary by

AMEC Corporate specialist discipline personnel.


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- To monitor the application of quality assurance requirements forrequisition packages.

- To review sample enquiry and purchase requisitions to ensure qualityrelated requirements have been adequately specified.

- To attend bid clarification meetings with suppliers and sub-contractors asnecessary.

- To review supplier Inspection & Test Plans.

- To facilitate development of QA procedures identified by the ProjectQuality Plan and review other procedures to ensure applicability to theProject.

- To establish the requirements for project quality records and to ensure byaudit and review that they are adequately maintained.

- To provide QA input to Project Reports. Such inputs shall include detailsof reviews and audits undertaken and highlight any adverse trends andrequired amendments to the document quality system.

- To co-ordinate and provide input to the periodic Management Reviews ofthe Project Quality Management System.

- To monitor and review the Certification/Classification programmeimplemented for the Project.

- To provide QA input to project induction sessions.

- To direct the Lead QA Engineer in the performance of the above asrequired.

1.6.5 Certification/Classification

The project shall utilise the services of a Lead Certification/Classification Engineer,reporting to the Project Quality Assurance Manager, who shall be responsible for the co-ordination of the Certification/Classification effort on behalf of AMEC and the principalsub contractors. The Lead Certification/Classification Engineer shall be the focal pointwith SNEPCO who in turn will have direct contact with the various regulatory bodies. TheLead Certification/Classification Engineer shall be responsible for maintaining records ofsubmissions made via SNEPCO to the various authorities and for the co-ordination ofProject team responses to queries resulting from such submissions.


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of submissions made via SNEPCO to the various authorities and for the co-ordination of Project team responses to queries resulting from such submissions.

Accountability:

The Lead Certification/Classification Engineer shall report directly to the ProjectQuality Assurance Manager but will also be the focal point with SNEPCO who inturn shall have direct contact with the various regulatory bodies

1.6.6.1.1 Responsibilities of the Lead Certification Engineer

The key responsibilities of the Lead Certification Engineer are as follows:

- To issue, revise and control the Certification/Classification Plan.

- To perform activities against the Certification/Classification Plan andProject Programme.

- To issue, revise and control the Regulatory Permits and ConsentsCompliance Plan.

- To convene, attend and minute Certification/Classification relatedmeetings with SNEPCO as necessary.

- To record and monitor the resolution of non-conforming activities.

- To monitor the application of Certification/Classification requirements forrequisition packages.

- To review sample enquiry and purchase requisitions to ensureCertification/Classification requirements have been adequately specified.

- To attend bid clarification meetings with suppliers and sub-contractors asnecessary.

- To provide Certification/Classification input to Project Reports.

- To co-ordinate and provide input to the periodic Management Reviews ofthe Project Quality Management System.

- To monitor and review the Certification/Classification programmeimplemented for the Project.

- To provide Certification/Classification input to project induction sessions.


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These reviews shall be formal, and recorded in detail, to monitor the effectiveness of theProject Quality Management System to ensure that:

The Project Quality Management System is, and shall remain, appropriate to theProject objectives and is effective.

Audit activities are pertinent and that findings and recommendations arising areproperly evaluated and actioned.

Identified deficiencies are corrected in a proper and expeditious manner.

All other matters of any concern are examined.

These reviews shall be identified on the Audit and Review Programme and shallcompliment the ongoing feedback and improvement of the Project Quality ManagementSystem in its day to day implementation.

Findings and recommendations arising from these reviews shall be reported to BongaProject and AMEC Corporate Management and SNEPCO.

Follow-up, verification and close-out of actions arising from such reviews shall beperformed and reported by the Project Quality Assurance Manager.

1.8 PERFORMANCE STANDARDS & CONTRACT CONTROL ASSESSMENTS

AMEC Company policy is that all projects use performance standards as the basedocument in formulating their Management System arrangements, including customerand sub-contractor interfaces.

The ten performance standards are:

- Management leadership, commitment and accountability- Risk assessment and management- Design and construction- Operations and maintenance- Employee competency and involvement- Occupational health

- Third party management- Impact upon the community and emergency planning- Incident investigation and analysis- Measurement, audit and review


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The self-assessment tool considers several related criteria under each of the definedperformance standards and this lends itself to focussed improvement targets.

Information on self-assessments for projects and contracts is published on AMECnettogether with the related contract improvement plans.

1.9 SUB- CONTRACTORS

All subcontractors employed on the Project shall be required to demonstrate capability inoperating formal quality management systems in accordance with ISO 9001 or ISO 9002as appropriate and to work in accordance with approved Quality Plans and Procedures.

Subcontract documents shall specify all relevant standards and shall define the qualityassurance and control requirements to be complied with by the subcontractor throughoutthe duration of the Project.

Close liaison shall be maintained by the QA function with key subcontractors, typicallythrough site visits, management reviews, audits etc, throughout applicable phases of theProject to ensure efficient sub-contract completion. This however shall not absolve thesubcontractor from his responsibility in monitoring and auditing his scope of work inaccordance with approved audit/review programmes.

All subcontractors shall be required to produce their own Quality Plans that shall besubmitted to the Project team for review and approval by the Project QA Manager.

Each subcontractor, in addition to undertaking their own audits in accordance with theirprocedures and programme, shall be subject to periodic audit and/or review by AMEC inaccordance with the agreed Project Audit and Review Plan.

Planned audits of main subcontractors may, at the discretion of the Project Quality Assurance Manager, be treated as healthcheck reviews. Where possible such reviewsshall be timed to coincide with any audits to be undertaken by the subcontractor.

The degree of monitoring shall generally be dependant upon the level of performance ofthe subcontractor and the type of product subcontracted. Increased monitoring shall beimplemented in those instances where defects with the subcontractors qualitymanagement system or defective performance have been identified.

1.10 AUDIT BY SNEPCO

SNEPCO and/or its authorised representatives shall be afforded access at allreasonable times for the purpose of audit, review and surveillance of aspects that aresubcontracted subject to all such parties complying with the subcontractors current HSEand security regulations applicable to the worksite(s) to be visited. AMEC shall liaisewith subcontractors to ensure that any arising corrective actions are satisfactorily


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This involves the continuous search for improving the way work is carried out, theestablishment of relationships, the breaking down of barriers, the search forbreakthroughs and 'what's possible'. CPI is aimed at creating a culture that enables theimprovement process to be readily accepted as a way of life throughout all levels of theProject Organisation.

The Project will strive for a consistency for quality measurements across the contractedscope of work in order to identify possible opportunities for improvement.

All project personnel shall be responsible for reporting quality deficiencies andsuggested improvements.

Ad-hoc improvement teams/groups shall be established, as required, to tackle particularproblem areas and to identify/facilitate solutions for improvement.

The Q-Pulse ISO 9000 Records Management System will be the vehicle for registeringand monitoring of formal recommendations for improvement.

1.12 INTEGRATION WITH OTHER MANAGEMENT SYSTEMS

AMEC recognise the similarities between Quality, Safety, Health, Environmental andother management systems and shall ensure that integration of key quality managementsystem activities with those other systems is achieved without conflict or duplication.


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2.0 PROJECT QUALITY MANAGEMENT SYSTEM

2.1 PROJECT QUALITY MANAGEMENT SYSTEM STRUCTURE

The Quality Management System structure for the Project shall be established in fourlevels as follows:

1st Tier Document - Project Quality Plan

The Project Quality Plan shall be the 1st Tier Document of the project qualitymanagement system and is based on the requirements of ISO 9001: 1994. Theobjective being to employ a system of control so that systems, components, structuresetc., are designed, procured and manufactured and constructed in accordance with theapplicable contract requirements, codes, specifications and drawings.

The Project Quality Plan provides the interface with the content of the individual qualityplans to be developed and utilised by AMECs fabrication division and each of the majorsubcontractors as follows:

AMEC Wallsend Doc No: tba

Heerema Zwijndrecht Doc No: tba

Heerema Hartlepool Doc No: tba

Fabrication facility (Nigeria) Name of facility and Q Plan Number tba

Netco Nigeria Doc No: tba

2nd Tier Document - Key Quality Act iviti es Matrix

The Key Quality Activities Matrix, (Document No: BON-AME-3GN-Q-00190-002), issuedas a supporting document to this Project Quality Plan, shall tabulate the activities andidentify the controlling procedures which shall describe in detail the quality activities tobe executed in order to satisfy the contract requirements.

The Key Quality Activities Matrix will also provide an interface to key activities relating tosubcontracted scopes of work.

3rd Tier Documents Control Procedures

These control procedures are those which are identified within Key Quality ActivitiesMatrix. It is the intention of the Project to utilise as far as possible those procedureswhich are AMEC standard. Where necessary, existing procedures shall be amended, ornew versions developed, to take cognisance of those business processes which may bespecific to the project. Co-ordination procedures shall also be developed as necessary


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Inspection and Test Plans (also referred to as Quality Control Plans) shall be developedas required by AMEC and its suppliers and subcontractors to cover specific products,services or scopes of work. The Inspection and Test Plans shall identify the qualityrelated activities, the controlling procedure/specification/drawing, the acceptance criteria,verifying documentation and inspection and surveillance requirements.

The requirements of such Inspection and Test Plans shall relate to the criticality of thepurchased/subcontracted product or scope of work.

2.2 GENERAL

The following subsections explain briefly how the applicable clauses of ISO 9001: 1994will be addressed by the Quality Management System established for the Project.The relevant clause of ISO 9001 is shown in brackets against each sub-section title.

Also included within the following subsections are those key procedures applicable tothat subject.

For a more detailed explanation of control procedures reference shall be made to theKey Quality Activities Matrix, (Document No: BON-AME-3GN-Q-00190-002) which isissued as a supporting document to this Project Quality Plan.

2.3 CONTRACT REVIEW (4.3)

Contract reviews shall be performed in order to verify contract documents, andauthorised amendments thereto, in order to familiarise project personnel with Scope ofWork, contract documentation and requirements, and to identify and resolve errors/inconsistencies / ambiguities as well as deviations from tender documentation and BidClarification agreements.

Appl ic able Procedures:

3319-300 Contract Review

2.4 DESIGN CONTROL (4.4)

The following describes the general requirements for the control of design activities andreview of engineering information to ensure compatibility with the Contract requirements.

Design Development and Planning

Established procedures shall be utilised to cover the control and verification of thedesign.

Design interfaces shall be established where necessary and shall be generally in the


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Inter-discipline design co-ordination shall be undertaken in accordance with establishedprocedures. In addition, regular design reviews shall be convened to identify andresolve any design restraints and interface queries.

Interfaces between the AMEC and related sub contractors shall be controlled on theProject via an external interface procedure which shall cover both technical interfacesand reporting paths.

Design Input

Contract Specifications shall be reviewed to establish that all applicable design inputs,such as process information, data, codes, standards and specifications are available.

Design input shall be subject to an initial review of the information/data received,including that received in electronic form. Subsequent information/data shall bereviewed and any inconsistencies, ambiguities or conflicting requirements shall bereferred back to the originator who may be AMEC, SNEPCO, main sub-contractor or asupplier.

Design Output

Design output shall be verified by a formal system of checking, review and approval toensure that design input requirements are met, contain or reference applicableacceptance criteria, conform to the regulatory requirements. Also to ensure that allcharacteristics of the design which are crucial to the safe and proper functioning of thesupplied product are incorporated.

Design Review

Design reviews shall be accomplished at specific stages during the life of the Project, inaccordance with formal procedures, by a number of methods including:

P & ID Reviews HAZOP/HAZAN Reviews Layout Reviews Plot Plan Reviews Hazardous Area Reviews Operability Review

As part of design review activity AMEC shall also perform a Safety and Operability Studyof Electrical Systems (SAFOP) study in accordance with Shell Global solution documentSIOP-OGBE/3.

The reviews shall ensure, among other things, that the design:

can be constructed, inspected, tested, operated and maintained. complies with weight and space requirements.


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The timing of these reviews shall be dependent on the progress of the project and theinterfaces associated with different disciplines. Records of these reviews shall bedocumented and maintained.

Design Verific ation

Design documents generated within the Contract work-scope shall be subject toverification checks by independent checkers, within the Bonga design team, inaccordance with relevant project procedures to ensure that:

it is correct, clear and unambiguous. it complies with the technical, format and presentation requirements. it is adequately substantiated by calculation.

all interfaces have been identified and addressed.The level of verification shall generally relate to the importance/complexity etc of therelated product or system.

Design documentation shall also be subject to inter-discipline review by otherengineering disciplines in accordance with formal procedures.

Design documentation shall be checked by competent personnel to ensure that it

incorporates applicable information and feedback from suppliers and subcontractors,SNEPCO and any third parties and regulatory bodies.

The output from computer calculations shall be verified as for design documentation andshall be checked by alternative calculation methods. Computer data shall be securedfrom loss or damage by regular back-up and protected from unauthorised access.

All design software shall be subject to validation prior to use on the project. Suchvalidation shall be completed either corporately or on the Project.

The suitability of software packages for use with American Specifications and Standardsshall be formally assessed/verified prior to use.

Design Validation

The Project shall utilise design validation to ensure that supplied product conforms toContract requirements.

Such needs and requirements shall be established through contract review and shall betranslated into design input requirements e.g. Job Design Specifications etc. Thecomparison of the design against contract requirements shall be achieved by a numberof means such as feedback from contract review activities, technical audits, safetyaudits, project review meetings, FATs, performance tests etc.

Design Change Controls


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The technical impact of such changes are considered and the relevant actionsperformed and documented.

All changes out-with the Contract are subject to formal variation approval.

Where it is not possible for the originator of the design to perform the design change,then another responsible person or organisation will be appointed to conduct the review.

Reliability, Maintainability and Operability

Reliability, maintainability and operability activities shall be performed in accordance withapproved project procedures. In addition, formal assessments such as reviews, studies,functional tests etc, shall be performed to demonstrate compliance with the specifiedreliability, maintainability and operability requirements.

Weight Contro l

Weight control activity shall be co-ordinated by a dedicated Project Lead Weight ControlEngineer who shall report to the Bonga AMEC Engineering Manager.

Weight control shall be undertaken in accordance with approved procedure(s) and shallinclude, but not necessarily be limited to:

- Weight estimation, with estimate refining as more accurate data becomesavailable.

- Calculation of centres of gravity, with calculation refining as more accurate databecomes available.

- Issue weight control reports plus update of the equipment list.

- Incorporation of weight control in change procedure.

- Liaison between topsides weight control and vessel stability calculations.

Appl icable Procedures:

BON-AME-3GN-G-00190-003 External Interface ProcedureBON-AME-3GN-Q-00190-004 Supplier Concession Request ProcedureBON-AME-3GN-G-00190-002 Procedure for Use of SI Units

BON-AME-3GN-W-00190-001 Project Weight Control Procedure3318-000 Engineering Administration3212-030 Project Variations3305-000 Produce Project Design Basis3319-100 Checking & Approval of Design Documents3319-200 Inter-Discipline Reviews3320 300 Detailed Design Execution


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2.5 DOCUMENT AND DATA CONTROL (4.5)

Document Control procedures shall ensure that all correspondence, drawings andtechnical data received or generated is recorded, distributed, filed and stored in anefficient and controlled manner.

The Project Document Control function shall be the focal point for co-ordinating controland issue of project documentation.

Control activities exercised on the documentation shall include the following:-

Review of documents, including drawings, prior to release to ensure that allapplicable requirements are clearly stated and that they are authorised for issue.

Identification of documents to be controlled.

Review and approval of changes to documents and drawings.

Control of documents, including approved changes, to preclude inadvertent useof obsolete or superseded documents.

Filing and storage control.

All revisions to drawings and technical documents shall be handled in a manner asdescribed within the project procedure for the receipt, issue and control ofdocumentation.

Formal procedures shall be implemented for control of CD Rom usage, particularly forthe archiving of project records.

Virus checking procedures shall be implemented for individual PCs and remote laptopsto guard against the import of viruses, particularly from the Website, emails and bought-in software packages. Also to protect against the spread of potential viruses withinelectronic documentation.This shall be particularly important with respect to e data transfer between Project andsuppliers and sub-contractors.


3319-500 Validation of Engineering Software3216-010 Control of Engineering Documentation

3318-200 Filing & Archiving of Documents

2.6 PURCHASING (4.6)

General


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- Approved by a recognised third party (e.g. DNV, BSI, LRQA etc.) to a national orinternational quality standard covering the scope of intended work.

- Successfully demonstrating second party audit compliance.- Successful Project QA assessment/audit.

In addition, the qualification of suppliers shall be dependent upon other criteria such asproduct capability, safety, capacity, on-time delivery etc, as appropriate.

Purchasing Data

Purchasing data shall be kept to a level appropriate to the importance and complexity ofthe product or service being purchased and shall be clearly identified within therequisition package.

Supplier Audits

Where, due to lack of third party quality system approvals or previous knowledge of un-satisfactory performance or other concerns, a pre-award audit of the supplier may bedeemed necessary, such audits shall be formally carried out, following agreement withthe AMEC Project Manager. Similarly, those audits identified after award shall beformally undertaken following agreement with the AMEC Project Manager. Such auditsshall be identified on the Project Audit and Review Programme. SNEPCO shall beprovided with ten working days notice of those audits that are to be carried out by AMECat suppliers works.

Analysi s o f Tenders

Documentation received from suppliers in respect of bids shall be formally assessed bythe relevant disciplines in accordance with established procedures.

Deviations and Concessions

Supplier deviations and concession requests shall be reviewed by the appropriatediscipline(s) in accordance with established procedures.

Accepted deviations and concessions shall be formally recorded so that thecircumstances under which and the specification against which the concession, waiveror deviation was approved can be readily identified.

Waivers and concessions that have an impact on contract requirements shall be subjectto SNEPCO agreement.


BON-AME-3GN-Q-00190-004 Supplier Concession Request Procedure3321-100 Procurement of Equipment3321-112 Requisition Packages3321-120 Technical Bid Analysis


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Qualifications of special processes such as welding, heat treatment, non-destructivetesting, coating etc, personnel performing special processes, and equipment shall bemaintained current and records thereof shall be maintained.

Procedures and personnel qualifications for special processes shall be subject to reviewby SNEPCO.


4506-100 Supplier Quality Plans3321-100 Procurement of EquipmentTBA Subcontractors Quality Plans

2.8 INSPECTION AND TESTING (4.10)

Inspection and testing by subcontractors and suppliers shall be carried out inaccordance with approved and valid test procedures that shall be identified within theInspection and Test Plans (Quality Control Plans) approved by AMEC.

Each subcontractor and supplier involved in the Project shall provide its ownQ.C./inspection arrangements but the adequacy and effectiveness of such arrangementsshall be assessed by means of audit, review, surveillance or inspection by the Project

Quality Assurance Function and/or project inspectors.

Levels of quality surveillance by AMEC and SNEPCO shall be defined within thesubcontractor and supplier Inspection and Test Plans (Quality Control Plans) and ,where relevant, will reflect the specific requirements of Bonga-SPEC-GL-001.

Where appropriate, provision shall be made for the independent checking of criticaldimensions, including interfaces, before proceeding with work that would increase thecost of correcting possible errors or that would lengthen the construction schedule if

errors were discovered later in the construction sequence.

The level of inspection may also be influenced by the complexity of the product orservice being purchased and also to the suppliers past and current performance.

Verification that an item offered as complete has undergone the required inspectionsand tests shall be achieved by the review of the Inspection and Test Plans and qualityrecords generated during all phases of the project.

Any products found to be non-conforming shall be identified as such in accordance withthe applicable project procedure(s).

The subcontractor or supplier shall be required to inform AMEC in advance for agreedwitness points in advance of the activity. AMEC in turn shall advise SNEPCO of anyrequired witness points in accordance with documented process. Work may proceedbeyond a witness point if AMEC/SNEPCO do not attend


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2.9 INSPECTION, MEASURING AND TEST EQUIPMENT (4.11)

Control procedures shall ensure that inspection measuring and testing devices used inactivities affecting quality are properly controlled and calibrated.

Selection of the measuring and test equipment shall be controlled to ensure that suchitems are of the proper type, range, accuracy and tolerance to conform with the specifiedrequirements.

The method and interval of calibration shall be determined by the items intended use.

Measuring and test equipment shall be properly handled and stored to maintainaccuracy.


3430-000 InspectionTBA Subcontractor Quality Plans

2.10 INSPECTION AND TEST STATUS (4.12)

Records shall be compiled and documents maintained in a logical, progressivesequence, to enable the current inspection and test status during manufacture to bedetermined.Suppliers and subcontractors engaged on the Project shall be subject to their ownQuality Control surveillance and inspection activities and shall progressively record theinspection and test status of the product or service provided.

A positive recall system shall be required for those instances of release of product to theworkplace, prior to clearance of inspection.



2.11 NON- CONFORMANCE AND CORRECTIVE ACTION (4.13, 4.14)

All project personnel have the responsibility for ensuring that any deficiencies,ambiguities and problems are resolved to the satisfaction of the project team.

Non-Conformities regarding the Project Quality System as identified by Quality Assurance Audits and Reviews shall be formally recorded on Corrective ActionRequests and progressively monitored and closed out.


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Formal internal audits shall be performed in accordance with approved procedures bypersonnel independent of the process, and any non-conformities identified shall beresolved by the project lead engineers to the satisfaction of the Project Management.

Deviations to contract requirements shall only be allowed with SNEPCO formal approval.Identified deviations to specification(s) that relate to purchased or sub contractedservices shall be subject to rejection, rework or acceptance with concession approval inaccordance with procedures.


3430-000 InspectionTBA Subcontractor Quality PlansBON-AME-3GN-Q-00190-004 Supplier Concession Request Procedure

4502-000 QA Audits

2.12 HANDLING, STORAGE, PACKAGING, PRESERVATION AND DELIVERY (4.15)

Products shall be subject to receipt inspections as detailed within the applicable qualitycontrol plans and procedures to verify compliance with the contract specifications,including for loss, damage, overage and shortage.

Any product that is found to be non-conforming shall be identified and marked as such

and, where practical, removed to a segregated holding area.

Product traceability, where required, shall be maintained in accordance with applicablespecifications and procedures.

Fabricators and suppliers procedures shall provide for verification of correct identificationof materials, parts and components prior to release for fabrication, assembly, shipping orinstallation.

Materials and equipment shall be stored in such a manner as to prevent damage andcontamination during the period of storage. Where appropriate, such storagerequirements shall be specified by the supplier.

Compliance with SNEPCO procedures and specifications relating to preservation andstorage shall also be required.



2.13 QUALITY RECORDS (4.16)

Records that furnish documentary evidence that the quality of items produced and


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A system shall be in place that determines the handover status of records to SNEPCOand regulatory bodies at any time relative to the project schedule and contractrequirements.

A central document management system shall include a record indexing system whichshall enable easy reference and retrievability of quality records. Quality records shall belegible and traceable to the item or activity involved.

The Project shall also utilise a Projects Completions System (WinPCS) which will be theprocess by which systems hand-over will be managed and controlled from mechanicalcompletion through to ready for safe commissioning and start-up


3318-200 Filing and Archiving of Documents3216-010 Control of Engineering Documentation4505-000 Archiving & Retrieval

2.14 QUALITY AUDITS (4.17)

Compliance with the Project Quality Management System shall be verified by a plannedprogramme of quality audits and reviews.

An Audit and Review Schedule (BON-AME-3GN-Q-00190-003) is issued as a separatedocument in support of this Project Quality Plan.

In addition to identifying planned formal audits the Schedule shall identify healthcheckreviews to be undertaken on those main sub-contractors as identified within Section 2.1

of this Project Quality Plan. AMEC project and SNEPCO auditing functions will be aligned to facilitate joint auditingwhere practicable.

AMEC shall utilise the Q-Pulse ISO 9000 Records Management System for themanagement of the audit and review programme and for the retention of electronic auditreports and corrective action requests.

Quality Audits are an additional means of gauging the progress towards the requiredobjectives and should be seen as assisting the overall workscope activity. Quality Audits are required to be carried out in order to verify that the requirements of ISO 9001:1994 and the documented Quality Management Systems are being complied with.

Quality audits as well as providing assurance that the activities are being carried out inaccordance with prescribed procedures shall also be proactive in identifying and


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____________________________________________________________________________________

occur at the same time in order to minimise inconvenience. The resulting reports shallthus be of a multi-discipline nature.

The hierarchical approach to auditing and review for the Project is indicated by theProject Audit and Review Strategy included as Appendix II of this Project Quality Plan.

Corporate Audits

These audits shall be carried out by persons independent from the Project and whorepresent AMEC Corporate management. Copies of the reports and any related findingsshall be issued to the AMEC Project Manager who shall arrange distribution asappropriate. These audits will be carried out annually.


BON-AME-3GN-Q-00190-003 QA/HS&E Audit & Review Schedule4502-000 QA Audits3322-280 Safety Audits3323-200 Technical Audits

2.15 TRAINING (4.18)

The Project Quality Assurance Manager shall provide input to induction sessions as

necessary for project personnel at which time the contents/requirements of this ProjectQuality Plan and supporting procedures shall be explained and discussed as well as anychanges to the normal method of working which may have been identified for thecontract.

A further aspect of training shall involve any "team building" that may be held during thecourse of the project.

Where specialist skills/qualifications are required e.g. Welding/N.D.T.etc, the skill level

proficiency shall be monitored and if any needs are identified, appropriate action shall betaken.

The Project QA function shall, during audits and reviews, verify that personnel arequalified as appropriate to their job functions, that they have received required trainingand that effective methods are in place to ensure that additional training needs aresatisfied.


4210-000 Training4209-000 Induction

2.16 SERVICING (4.19)

____________________________________________________________________________________


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2.17 STATISTICAL TECHNIQUES (4.20)

Statistical Techniques shall be used as required for establishing, controlling andverifying process capability, execution proficiency and product characteristics. Individualapplications are described within appropriate procedures and are used during theinspection of bulk materials and items etc.

Project quality measures shall also be supported by statistical techniques whereappropriate.

____________________________________________________________________________________


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APPENDIX I

ORGANISATION CHARTS


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Revision A02 ____________________________________________________________________________________

______________________________________________________________________________________________________Page 29 of 34

ChartOverall Management Organisation

- Certification/classification- QM- QC Inspection

QualityManagerE Abbott

(see chart 2)

HSE Manager

N Beesley

- AMEC SMS/EMS-Subcontractors

SNEPCOProject

Manager

AMEC

ProjectManager

D M Harwood

EngineeringManager

RE Austin

BusinessServicesManagerS Hope

Construction& Integration

Managertba


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Revision A02 ____________________________________________________________________________________

______________________________________________________________________________________________________Page 31 of 34

ChartLondon QA & Certification/Classification Organisation

Lead Certification/Classification

EngineerB. Barton

Lead QAEngineer

W. Davies

AMECProject

ManagerD. Harwood

AMECProject QAManagerE. Abbott


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Revision A02 ____________________________________________________________________________________

______________________________________________________________________________________________________Page 33 of 34

AMECProject Manager

AMECProject QA Manager

QualityRepresentative


HU&C(Onshore/Offshore)

Fabrication/Integration(Wallsend)

Design Office(Nigeria)

Fabrication(Nigeria)

Fabrication(Zwijndrecht)




Project QA &Classificatio/Certifica

tion(London)

Procurement(London)

ProcurementQC/Inspection

Fabrication(Hartlepool)


Full Line = Direct Responsibility to Project ManagerDotted Line = Functional Responsibility to Project QA Manager

QA/QC Organisation Interfaces

Chart


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Revision A02 ____________________________________________________________________________________

______________________________________________________________________________________________________Page 34 of 34

ON HOLD

(Awaiting Charts from Wallsend and Sub-contractors)

QA/QC Organisations for Wallsend and Sub-Contractors

Bonga FPSO Topsides, Commissioning Project Quality Planand Operations Handover BON-AME-3GN-G-00199-007

Revision A01


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Revision A01 ____________________________________________________________________________________

APPENDIX II

AUDIT AND REVIEW STRATEGY


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Revision A01 ____________________________________________________________________________________

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Internal Audits

PROJECT QUALITY AUDIT STRATEGY

ProjectQuality

Plan

Hereemahartlepool

Heerema Zwijndrecht

Internal Audits

Internal Audits

ExternalSub-Supplier

and/or Sub-Contractor

Audits

Sub-Suppliersand/or

Subcontractors

Internal Audits

External Sub-Supplier


Audits

AMECLondon

Design Office(tba)

Nigeria

Internal

Quality Audits

Sub-Suppliersand/or

Subcontractors

Internal Audits

Internal Audits

Fabricator (tba)

Nigeria

Sub-Suppliersand/or

Subcontractors

Internal Audits

Internal Audits

Spare

Sub-Suppliersand/or

Subcontractors

Internal Audits

Internal Audits

AMECWallsend

Sub-Suppliersand/or

Subcontractors

Internal Audits

Quality Audits& Reviews

Internal Audits



Audits



Audits

External Sub-Supplier


Audits