Specification for Quality Assurance Specification for Quality Assurance GME-QS-L2-202 R1 27-09-2016 Page 6 of 37 Users are responsible for ensuring the use of correct revision of this

Specification for Quality Assurance

GME-QS-L2-202 R1 27-09-2016 Page 2 of 37

Users are responsible for ensuring the use of correct revision of this document

CONTENTS PAGE NO.

1. Purpose 3

2. Scope 3

3. Definitions and Abbreviations 3

4. Standard/Specification/Guidelines content 5

5. References 24

6.

7.

Records 24

Appendices 25


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1. PURPOSE

The purpose of this Specification is to specify the Company's minimum requirements for

Quality Assurance in all Contracts and Purchase Orders (Consultants, Contractors,

manufacturers and Vendors). This specification is intended to set Company Quality Assurance

Standards during design, procurement, construction, commissioning and maintenance phase

of facilities.

2. SCOPE

This specification presents the Company's minimum requirements for Quality Assurance in all

Contracts and Purchase Orders with their nominated Suppliers (Consultants, Contractors,

manufacturers and Vendors). The requirements are based on the use of the BS EN ISO 9000

Series of Quality Management and Quality Assurance Standards.

The body of this specification is the Quality Assurance Specification and forms part of the

Contract or Purchase Order. Definitions and abbreviations used are defined in section 3 and

referenced standards are listed in section 5.

Appendix A, Contract Quality Plan Guidelines and Appendix D, Quality Control Plan

Guidelines, offers Suppliers (Consultants, Contractors, manufacturers and Vendors)

guidelines on the contents and development of a Contract Quality Plan and Quality Control

Plan, that will meet the requirements of this specification.

This specification is not applicable to ex-stock items.

3. DEFINITIONS AND ABBREVIATIONS

API

ANSI

American Petroleum Institute

American National Standards Institute

ASME

ASNT

ASTM

AWS

American Society of Mechanical Engineers

American Society for Non Destructive Testing

American Society for Testing of Materials

American Welding Society

BSI British Standards Institution

BV Bureau Veritas

CAR

CEP

Corrective Action Request

Contract Execution Plan

CFDH Corporate Functional Discipline Head


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CQP Contract Quality Plan

CV

CSWIP

Curriculum Vitae

Certified Scheme for Welding Inspection Pesonnel

DNV Det Norske Veritas

EPC

FCAW

GME

GTAW

Engineering, Procurement and Construction

Flux Cored Arc Welding

General Manager Engineering Gas Tungston Arc Welding

LRQA Lloyds Register Quality Assurance

IRCA International Register of Certificated Auditors

ISO International Organisation for Standardisation

ITP

MESC

MT

Inspection and Test Plan

Materials and Equipment Standards Code

Magnetic Particle Testing

NCR

NDT

Non-Conformance Report

Non Destructive Testing

PMI

PQR

PT

RT

Positive Material Identification

Procedure Qualification Records

Penetrant Tesing

Radiography Testing

QA Quality Assurance

QC Quality Control

QCP

SAW

SMAW

Quality Control Plan / Inspection Test Plan (ITP)

Submerged Arc Welding

Shielded Metal Arc Welding

SP

SUPPLIER

Specification

Shall refer to the Company's appointed Contractors, Manufacturers and Vendors.

TA

ToFD

Technical Authority

Time of Flight Defraction

TPI

UT

VT

WPS

Third Party Inspection

Ultrasonic Testing

Visual Testing

Welding Procedure Specification


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4. STANDARD/SPECIFICATION/GUIDELINE CONTENT

4.1 Quality Management System

The Supplier (Consultant, Contractor, Manufacturer and Vendor) shall implement and use a

Quality Management System that complies with the Standard ISO/TS 29001 or ISO 9001

(latest edition), as listed below, and the requirements of this specification.

ISO/TS 29001: Petroleum, Petrochemical and Natural Gas Industries – Sector specific

quality management systems --- Requirements for product and services supply

organizations

or

BS EN ISO 9001: Quality Systems - Model for Quality Assurance in design

development, production, installation and servicing.

Suppliers shall attain Third Party Registration of their Quality Management System.

Certification to ISO 9001 is acceptable. The registration shall be from an Accredited Certifying

Body (for example, BSI, BV, DNV, Velosi, TUV, and LRQA etc), who are themselves

accredited by a National Accreditation Authority to assess Quality Management Systems.

Where Suppliers are not yet certified to ISO 9001, they shall demonstrate that they have a

Quality Management System that complies with any of the above. Consideration should be

given to attaining Third Party Registration as a means of maintaining the Quality System and

verifying compliance with this specification.

The Standard shall be selected to cover all work activities (consultancy, project management,

procurement, construction, and provision of goods, products or services), associated with the

Contract or Purchase Order.

If any part of the Contract is Sub-Contracted, the Supplier shall comply with Clause 4.1 in ISO

9001, which requires the Sub-Contractor to maintain an appropriate Quality System. The Sub-

Contractor shall implement a Quality System that meets the requirements of ISO 9001 /

ISO/TS 29001, as appropriate for the sub-contracted work. The Supplier shall remain

ultimately responsible for the quality of the Sub-Contractor's work.

4.2 Quality Management during the Contract Execution

4.2.1

For Contract Activities :

Quality management System as described in the CQP shall be implemented for EPC

projects, Engineering Contracts, Maintenance Contracts etc., and no work shall start

unless the Company approves CQP. ITPs, procedures and verification personnel

appropriate to work being executed shall be approved by the Company. This shall also

apply to sub-contractor activities.


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4.2.2 Contract Quality Plan

As a minimum, the requirements specified in Appendix A shall be fulfilled. The Supplier

shall have a nominated Management Representative (MR), who shall have defined

responsibility for the Corporate Quality System, in accordance with ISO/TS 29001 /

ISO 9001. The roles and responsibilities of the MR shall be stated in the Contract

Quality Plan.

4.2.3 Inspection and Test Plans

Construction / manufacturing activities shall be clearly identified and the supplier shall

prepare quality control plans and submit for review and company approval.

Subcontracted activities shall be clearly identified and subcontractors shall prepare

quality control plans for review by the contractor and approval by the company.

A pre-commissioning quality control plan shall be submitted to company for approval

not less than three month prior to commencement of pre-commissioning.

Subcontractor’s activities, where involved for pre-commissioning shall be clearly

defined in the QCP. For all Package and bulk products (including MESC items), ITPs

shall be approved by the Company. The requirements specified in Appendix D shall be

fulfilled. The Company has the right to identify in the ITP the review, surveillance,

witness and hold points.

4.2.4 Contract Quality Management System Review

In major EPC contracts, the supplier shall ensure that the Contract Quality

Management System is reviewed at frequency of not more than three months till the

end of the contract. The frequency of such review shall be based on nature and type of

contract, duration etc. and shall be agreed during Quality kick off meeting. The

Corporate Quality Manager shall participate in the review meeting. Areas of concern or

weakness are to be identified in the Quality Management System and actions

recommended to be recorded in minutes of meeting.

4.3 Documentation

4.3.1 Contract Documentation Requirements (General)

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

The Supplier shall maintain the latest revision of the relevant Contract Documents, Drawings, Technical Specifications, International Standards, CQP, ITPs, Procedures and Work Instructions, etc. at the location where work is being carried out.

The Contract Quality Plan, quality control plans, WPS, PQR, and NDT, painting procedures for individual parts of the work shall be submitted for approval not less than two months prior to commencement of work.

Procedures, work instructions and checklists to be used in a contract is listed in Aneexure C. The following documents shall be approved by the Company authorities as stated below:


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Sl No:

Document Description Approval Authority

1 CQP, ITPs & NDT Procedures QA Specialist / QA Engineer

2 CVs of NDT Engineer, Welding Engineer, QA Engineer and QA Manager

QA Specialist or QA Engineer

3 CVs of other Quality Verification personnel QA Specialist / QA Engineer

4 WPS/PQRs & Welding related procedures QA Specialist / QA Engineer

5 Method statements (Site related) & Procedures

Relevant discipline Engineer

6 Engineering Drawings & Deliverables Discipline Engineer

7 Non-standard MESCs Engineering & Quality Discipline

8 Deviations from Contract technical specifications

GME

9 Material selection reports, painting/coating procedure and ITPs,

Materials & Corrosion Engineer

10 Design Basis Discipline Engineer

11 Project material specifications Materials & Corrosion Engineer

12

13

Deviation from Company approved Manufacturers, Suppliers, Stockists & Vendors

Commissioning Procedures, ITPs and Manuals

GME

Head of Commissioning & QA Engineer

4.3.3 Transmittal of Documents All documents shall be submitted to company under cover of transmittal forms and

the company shall return documents likewise. The sequential numbering of these

transmittal forms shall be agreed by both parties.

4.3.4 Document Control Register

The document register shall list all drawings, documents and other deliverables related to the work and including documents prepared and submitted by vendors and subcontractors. Document Control Register shall update on a regular basis and shall form part of the monthly progress report.

4.3.5 Documents For Approval One copy of FOR APPROVAL documents and letters which contractor submits to

authorities, third parties shall be submitted to company FOR INFORMATION and all

subsequent correspondence regarding such approvals shall also be submitted for

information to company.


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The contractor shall submit to company FOR INFORMATION and update every two

weeks a report indicating contractor’s forecast dates of issue FOR APPROVAL of

all relevant documents.

4.3.6 Submission and Approval of Design Deliverables

Company review and approval of design deliverables shall be based on the

agreed/approved design deliverable matrix.

4.3.7 As Built Documents

Contractor shall keep accurate records of changes made in the field. Drawings

required to be AS BUILT shall be continuously updated during construction,

commissioning, and initial operations and guarantee period. The AS BUILT

exercise shall be performed at the contractor’s construction site offices.

Pipelines (including spur lines) as built alignment survey work shall be completed by

a qualified surveyor. The as built revision of pipelines, and spur lines shall include

and not limited to all design drawings complete with clear details and dimensions

before trenches are filled to allow top of line and coordinates to be accurately

reflected and to mark-up AS BUILT information of underground piping, trenches and

foundation locations.

Pipeline survey methods shall be as such that positioning accuracy of +/-10cm and

elevation accuracy of better than +/-20cm. The survey work shall be done using

either Real Time Kinematic (RTK) GPS survey technique or conventional survey

equipment. Survey techniques and equipment shall be approved by Company

before commencement of survey.

Copies of all documents required to be AS BUILT shall be submitted by contractor

to company in an agreed format.

4.3.8 Final Documentation Final documentation shall be provided following completion of the AS BUILTs. As

minimum, final documentation shall include the latest revision of all design,

construction, operating and maintenance manuals, drawings and documents. Prior

approval shall obtained for the final document dossier index.

4.3.9 Vendor Drawings and Equipment Files Vendor Documents requiring Suppliers approval shall be stipulated in the purchase

order and it is the responsibility of supplier to submit the vendor documents for

Company review/approval. Supplier also shall ensure that vendor and sub-

contractors comply with the requirements specified in OGC procedure for Drawing,

Document Numbering & Equipment tagging Procedure (GME-QS-L3-312). Supplier

shall provide each vendor document with proper company drawings number,

requisition number and unit/equipment numbers.


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4.3.10 Drawing and Equipment Files

Supplier shall maintain files of all drawings, requisitions and SPIR lists in numerical

order. The organization of both drawing and equipment files shall be as per OGC

procedure for Drawing, Document Numbering & Equipment tagging Procedure

GME-QS-L3-312.

Where deemed necessary, documentation related to the Quality Management

System shall be available at the location where work is being carried out.

The Supplier shall maintain the latest revision of the relevant Contract Documents,

Drawings, all Contract Technical Specifications, International Standards (BS, DIN,

ASME, API etc.), Procedures and Work Instructions, at the location where work is

being carried out.

4.3.11 Quality Assurance The contract quality plan shall cover all phases of the contract and describe how the

supplier shall interpret, implement, execute and maintain the project specific

requirements into his, his subcontractors and vendors quality assurance system.

Subcontract quality plans should be submitted within 30 days from the award of

subcontract and shall be reviewed and approved by the company. The plan is to

include details how Supplier will manage subcontractors and vendors.

Supplier shall identify high risk quality issues specific to the work and describe

measures to eliminate/control these focused areas. All critical quality issues/risks

shall be identified in the contract quality plan.

The supplier shall compile a comprehensive quality audit schedule for the work

which shall cover all phases of the work and including all audits on contractor,

subcontractor and vendor.

The supplier shall submit detailed proposals for the quality audits, including the

commencement and completion date for each audit. The Company reserves the

right to attend any or all of these audits. The audit report should be submitted

within two weeks and any alteration in commencement date shall be subject to ten

working days prior notice.

The supplier should clear all audit action items within 21 working days of the issue

of the report. Status of close out and follow-up shall be reported in the normal

project progress reports.

4.3.12 Procedures for Suppliers The supplier shall develop a communication plan taking company’s requirements into account. The plan must include a document and information flow matrix.


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4.3.13 Meetings and Records Formal meetings at discipline and company representative level shall be held

regularly on a weekly basis. A weekly progress meeting will be held to allow the

supplier to present and discuss the weekly and overall status of the project.

Progress review meetings will be held between the parties or as requested by the

Company. MOM shall be prepared by the supplier representative and forwarded to

the Company Representative within two working days after the meeting. Frequency,

format of Minutes of Meeting and numbering system shall be agreed during project

kick-off meeting.

4.3.14 Site / Engineering Queries and Deviation Requests

A Query or Deviation Request shall be routed through the suppliers Engineering or

Project/Construction Manager. Deviation request shall comply to the requirements

identified in Company procedure for Technical Deviation (GME-QS-L3-311) and all

Query and Deviation Request shall itemize the relevant document references,

supplemented with justification and shall provide all details of the query/request

concerned and all supporting drawings, sketches, calculations shall be attached.

The query or Deviation Request may be submitted by e-mail to company discipline

engineer. The formal request shall be submitted to the company document

controller. The company should provide a response to the supplier within 15 working

days from the day Document Controller has received it.

The supplier shall maintain a register for all engineering queries and deviation

requests. All outstanding queries and deviation requests shall be reported by the

supplier in the weekly and monthly report until closed out by Company.

4.3.15 Progress and Reporting

The detailed format and content of progress report on a specified frequency shall be

developed by supplier and approved by the company.

All pivotal project reports shall include a section where current risk management is

reported in an open and transparent manner. Risk management reporting shall

include key project objectives including HSE, Quality, Schedule, Cost, and

Reputation.

Auditable progress measurement procedure for calculating both planned and actual

physical progress shall be developed by supplier. The progress is measured by

physical measurable criteria for each work packages and shall be based on

assigning weightings to each activity or sub-activity.

4.4 Qualification and Duties of the Suppliers Quality Assurance, Inspection (Quality

Control) and verification personnel

4.4.1 Competency of verification personnel

Verification personnel working for the supplier at during contract execution shall


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be approved by the company as stated in Table-1.

The verification personnel should have previously worked on similar Contracts in

similar capacities and shall have formal qualifications (e.g. CSWIP, AWS, and British

Gas or equivalent which is acceptable to Company) as appropriate.

Supplier shall establish and maintain the records to demonstrate that all verification

personnel are competent.

4.4.2 Quality Verification Personnel

The Supplier shall assign and deploy competent Verification Personnel for the

Contract to ensure that the Quality Management System and Quality Control are

effectively established, implemented and maintained throughout the Contract. There

shall be sufficient verification personnel to cover all disciplines work and activities, all

Sub-Contractor's work at the site and off site facilities. This shall be clearly

documented along with their responsibilities and authorities in the CQP. They shall be

independent of the work being performed and shall have no other duties or

responsibilities.

The Supplier shall assign at least one dedicated QA/QC Engineer for each contract

and located at work site. The QA/QC Engineer shall functionally report to the

Supplier’s Corporate QA Manager on all Quality and technical matters and report to

the Site Manager on day to day activities.

The actual staffing levels will depend on the work load, complexity of the work, number

of disciplines working on the Contract at any one time, number of Sub-Contractors,

the number of locations where work is being carried out on site/off site and the quality

performance of the contractor.

The Supplier shall prepare a QA/QC personnel resource plan on a monthly basis to

cover all verification activities as required by ITP. The use of multi-disciplined

Inspectors is acceptable provided they have appropriate qualifications in each of the

disciplines they are required to inspect. The adequacy of the QA/QC resources shall

be reviewed by the Company representatives at sites during progress review

meetings. Company decision regarding QA/QC staffing shall be final and binding on

the Supplier and its Sub-Contractors.

The minimum qualification & experience requirements of QA/QC personnel shall be as

detailed below, unless otherwise stated in the contract/purchase order:

4.4.2.1

Table - 1 QA/QC Manager (Head Office/Site)

Qualifications Duties

Shall be a Graduate Engineer (B.Sc. Eng. / BE/B.Tech.) either in Mechanical / Metallurgical / Welding / Electrical / Instrumentation/Civil engineering as appropriate.

Shall be an IRCA, UK Registered Lead Assessor or equivalent (where equivalent is proposed, Supplier

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

Shall be responsible for implementation, operation and maintenance of project Quality Management System in compliance with ISO 9001.


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shall provide evidence of equivalence from International Accreditation Body (ies)).

Shall have minimum of 15 years of relevant experience in onshore oil and gas facility construction, including live installations. Out of 15 years of experience, 5 years of experience shall have gained in the Middle East. He shall have a minimum of 5 years management experience in establishment, operation and maintenance of quality management system in accordance with ISO/TS 29001 / ISO 9000 with the capability of developing quality system, quality plans, work procedures and inspection plans.

Shall have sound knowledge in quality management aspects within various technical disciplines and shall be familiar with standards and codes used in oil and gas industries.

Shall have sound technical knowledge in materials, welding, coating/painting, NDE inspection and general construction activities involving civil, electrical and instrumentation works.

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

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

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

4.4.2.2 Welding Engineer


A post graduate qualification in Welding Engineering or shall be registered as European Federation Welding Engineer.

Demonstrated sound technical knowledge and extensive experience in welding processes (SMAW, SAW, GTAW, GMAW, and FCAW etc.), materials, welding and fabrication methods in onshore oil and gas industry. Expert knowledge in welding of high strength pipeline steels used in oil and gas industry is must.

Sound technical knowledge of corrosion / fracture / fatigue / creep / embrittlement behaviour of welded joints and materials used in oil and gas industry.

Demonstrated capability in preparation of WPS, selection of welding consumables; ability to undertake weldment failure analysis; welding related problems diagnosis and solutions; qualification of welding procedures. Welding Inspection Personnel qualifications such as CSWIP/AWS shall not substitute as an acceptable qualification for Welding Engineer in lieu of the requirements given above.

At least 6 years relevant experience in the construction of onshore oil & Gas or Petrochemical industries facilities (pressure vessels, tanks, mechanical fabrication, pipelines, piping etc.) including live installations. Out of 6 years’

Review and approve vendor’s/ contractors proposed welding procedure specifications, construction welding procedure specifications and procedure qualification records.

Guiding Corrosion and materials departments on the material selection with respect to welding

Advising and guiding Contractor’s in developing and qualifying welding procedure specifications

Developing Welding specifications to ensure integrity of equipment and facilities used in OGC.

Review and modification of existing welding specifications based on field experience and developments taking place in oil and gas industry.

Carrying out failure analysis and finding solutions to welding related problems.


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experience, 2 years of experience should have gained in the Middle East preferably in Oman environment.

Experience of working to and fully conversant with international codes (ANSI/ASME, ASTM, API, BS, EN, MSS, ISO, etc.) used in oil and gas industry.

4.4.2.3

QA/QC Engineer (QA/QC in-charge at head office or construction site)


Shall be a Graduate Engineer in relevant discipline

Shall have qualification as Lead Assessor (IRCA Registered or equivalent that is acceptable to Company Quality Management Services)

Shall have minimum of 6 years of relevant experience in oil and gas facility construction. He shall have a minimum of 2 years management experience in establishment, operation and maintenance of a quality management system in accordance with ISO/TS 29001 / ISO 9000 or equivalent with the capability of developing quality system, quality plans, work procedures and inspection plans.

Shall have supervisory skills

Shall have in depth technical knowledge of inspection and exposed to multi discipline works of oil and gas construction field.

Shall be fully familiar with relevant codes used in oil and gas industries.

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

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

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

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

Preparation, implementation, revision and monitoring Quality Control Plans (QCP/ITP).

Maintaining of Quality records.

Reporting Quality activities.

Liaison with the Company on matters related to Quality.

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

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

4.4.2.4 NDT Engineer * * If requested in the contract


A graduate qualification in Engineering and shall have qualifications as NDT Level III in accordance with ISO 9712 in methods, RT, UT, PT, MT and VT.

Demonstrated sound technical knowledge and extensive experience in methods RT, UT, PT, MT and VT.

Shall have sound technical knowledge of TOFD, Phased array UT, long range UT, digital radiography, radioscopy etc. Qualification on above techniques required when project is using any of these techniques.

Shall be fully familiar with B scan, C scan and D scans (Computer image techniques) of UT

Review and approve vendor’s/ contractors proposed NDT procedures

Advising and guiding Contractor’s in developing and qualifying NDT procedures

Witnessing of NDT

Developing NDT specifications to ensure integrity of equipment and facilities used in OGC.

Review and modification of existing NDT specifications based on field experience and developments taking place in oil and gas industry.


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Shall be fully familiar with corrosion mapping using MFL, UT etc

Knowledge of application of UT on coarse grained materials.

Demonstrated capability of preparation and qualification of NDT procedures

At least 6 years relevant experience in the construction of onshore Oil & Gas or Petrochemical industries facilities (pressure vessels, tanks, mechanical fabrication, pipelines, piping etc.) including live installations. Out of 6 years’ experience, 2 years of experience should have gained in the Middle East preferably in Oman environment.

Experience of working to and fully conversant with international codes (ANSI/ASME, ASTM, API, BS, EN, MSS, ISO, etc.) used in oil and gas industry.

Analysis of NDT data and reporting results.

4.4.2.5

Quality Control Inspector - (Welding/ Painting/ NDT/GRE)


Shall be Diploma or Graduate Engineer in Mechanical or Metallurgical Engineering. and shall have a minimum of 4 years of inspection experience in construction industries out of which 2 years shall be gained in oil and gas facility construction.

Welding Inspector shall possess CSWIP 3.1 / AWS for welding inspection or equivalent acceptable to Company Quality Management Services and Certified to ASNT level II in RT, PT, MT and UT techniques.

Painting Inspector shall possess BGAS / ERS III or equivalent in NACE for painting inspection or equivalent acceptable to Company Quality Management Services.

NDT Inspector shall be Certified to ASNT level II in RT, PT, MT and UT techniques.

For Fusion Bonded Epoxy (FBE) or Shrink Sleeve or Glass Reinforced Epoxy materials works, Supplier shall mobilise and deploy personnel appropriately qualified, suitably trained and formally certified (contractor’s established certification schemes may be accepted if agreed by Company) for verification of these works.

GRE Inspector shall have worked as GRE fitter/bonder or supervisor for a minimum of 1 year.

Implementation of QA/QC activities including those of sub-contractors works in accordance with approved QCP /ITPs and Procedures, method statements and other contract documents.

Maintaining records of calibration, inspection and testing equipment.

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

Witness procedures, tests and certify the results.

Provide sufficient feed back to QA/QC Engineer on the day to day quality issues

4.4.2.6 QC Inspectors - Civil and Structural


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

Shall have a minimum of 4 years of quality control and inspection experience in construction industries. The experience shall include works involving soil excavation



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and earth works, concrete works, block works, structural steel works and roofing, roads and paving, tank pads and bunds and general activities associated with civil and building works.

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

Witnessing tests and maintaining records of tests, calibration, inspection and testing equipment.


Provide sufficient feed back to QA/QC Engineer on the day to day quality issues

4.4.2.7 QC Inspectors - Instrumentation


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

Shall have a minimum of 4 years of quality control and inspection experience in construction industries. The experience shall include electronic and pneumatic equipment including analogue and digital control

systems, relay based and solid state logic systems, transmitters, control valves and accessories.

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


Witnessing tests and maintaining records of tests, calibration, inspection / testing equipment.


Provide sufficient feed back to QA/QC engineer on the day to day quality issues

4.4.2.8 Q C Inspectors - Electrical


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

Shall have a minimum of 4 years of quality control and inspection experience in construction industries.

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


Witnessing tests and maintaining records of tests, calibration, inspection and testing equipment.


Provide sufficient feed back to QA/QC engineer on the day to day quality issues.

4.4.3

Auditors

The auditors shall possess the following qualifications and shall have conducted minimum 10 relevant audits.

For External Audits – 5 day course, IRCA, UK registered. or equivalent acceptable to Company

For Internal Audits - 2 day course IRCA, UK registered. or equivalent


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4.4.4

acceptable to Company

Company’s Inspector Roles & Responsibilities.

Inspector (QA/QC Inspector & TPI) roles and responsibilities shall be as follows but not limited to:

Qualification and experience shall be in the same discipline/field to the product/service getting inspected.

Verify the product conformance to contractual requirements at various stages of the fabrication/manufacturing as stated in Company approved ITP and applicable technical specifications.

Review quality documentation to verify product conformance to contractual requirements.

Carry out surveillance inspections to verify processes and procedures compliance.

Issue Release Note of Product/ Sign test packs (QA/QC dossier).

The role of the company’s Inspector/TPI shall be limited to surveillance role, unless stated otherwise in the Company approved ITP.

To monitor manufacturers/contractors’ activities with respect to quality performance.

The signature of the Company’s (QA/QC Inspector/TPI) shall be taken as he/she verified and accepted the details in the document reviewed. The signature of the Company’s (QA/QC Inspector/TPI) shall not absolve the supplier’s responsibilities to supply the product that meets contractual requirements.

4.5 Procurement Requirement

4.5.1 Criteria for Vendor selection, evaluation and re-evaluation

Generally the Supplier shall only purchase products and services from Company approved sources. Lists of approved sources (Contractors/Suppliers and Vendors) are available from the Company. The Supplier shall be accountable for procurement of materials that fully comply with the Company specifications and shall be able to demonstrate the material complied to Company specifications at all stages by having a quality management system, vendor scrutiny, and inspection. Records shall be established and maintained to demonstrate the ability of vendors to supply such items meeting Company technical specifications.

The Company reserves the right to inspect products or services purchased by the Supplier from Sub-Contractors (or Vendors). Verification or Inspection by the Company is not a substitute for verification by the Supplier nor absolve the Supplier of its contractual obligations. Hold, Review and Witness Points shall be identified in the Quality Control Plans for Supplier, Sub-Vendor, Third Party Inspector / Authorised inspector and Company. Company shall be given at least 15 working days’ notice to attend such verifications. Company will not be responsible and will not accept any delay due to the rejection of items during the verification process.

Procurement of material by the Supplier from Company approved vendor list does not absolve the responsibility of the Supplier from supplying material meeting relevant specification.


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4.5.2 Verification of purchased product

Inspection level based on criticality rating of purchased materials shall be included in all purchase specifications and purchase orders.

The Supplier is responsible for ensuring material certification of all pressure retaining and non-pressure pressure retaining materials, component, items meet the requirements of applicable design code.

4.5.3 Material Group Standardization The Supplier shall ensure that material group standardization is enforced on all vendors of purchased equipment and also ensure that vendors also standardizes on his sub-contractors across the same material groups. Supplier shall specify standardized components to the package vendor, such that they conform to the standardized selection of tagged items and field bulk materials. This approach shall equally apply to the Main Automation scope of supply also.

4.5.4 Approved Vendor List (AVL) Company shall reject any materials that have been supplied by an un-approved

vendor on the AVL list. Any amendments to the AVL list shall be subject to company

approval. Suppliers who proposing a new vendor other than available ones from AVL,

then they need to approach company well in advance with sufficient details for

vendor approval. Company reserve the right to accept or reject the proposal.

4.5.5 Materials and Equipment Standards and Codes (MESC) Types, sizes and quantities of Materials recognized as “Standard” by company are listed and coded in the MESC code numbers. Contractor/Supplier/vendor shall comply with the MESC standards for the procurement of materials. Any deviation from MESC shall be submitted to company for approval together with proposed alternative.

4.5.6 Life Cycle Cost Methodology For EPC contracts having major procurement scope, “Total life cycle cost analyses” concept shall be employed to all rotating equipment. The contractor shall maintain an auditable system, which demonstrates that all life cycle costs have been evaluated and that bids have been awarded on the basis of lowest overall life cycle cost.

4.5.7 Procurement Management Manual For EPC contracts having major procurement scope, the Supplier shall produce and maintain a Project Procurement Management Manual which shall contain method statement, detailed procedure specific to the contract and specimens of all standard forms. The procedures must fully reflect the requirements of the contract with respect to standardization and the use of Omani goods and services.


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4.5.8 Criticality Rating For EPC contracts having major procurement scope, the Suppliers shall establish and document Control measures for establishing criticality rating of purchased materials, items or components. Criticality rating of purchased materials, items or components shall be included in all buying descriptions.

The criticality rating procedure shall be approved by Company.

4.5.9 Project Procurement Control Contractor/Supplier shall develop an Integrated Materials Planning and Tracking system. The system shall form the basis for all procurement tracking and reports. The company may review the system for its applicability

4.5.10 Requisitions All requisitions shall be prepared in accordance with applicable drawings, specifications and standards. Requisitions shall be clearly marked or stamped with status, for comments, for enquiry or for purchase.

4.5.11 Purchase Orders and Agreements Purchase orders for all tagged items of equipment, packaged or skid units shall

include the following requirements (production/delivery schedule, quality manual and

quality control plan, manufacturing report, SPIRS, completed data/requisition sheets,

drawings, calculations and design documentation, equipment installation, operation

and maintenance manuals.

Supplier shall ensure that all vendor documents have the company project reference

in front page company drawing number, and purchase order, requisition number,

unit/equipment tag numbers which meet the requirements of OGC procedure for

Drawing, Document Numbering & Equipment tagging Procedure GME-QS-L3-312.

4.5.12 Assignment of major equipment Purchase Order

The Supplier shall engage a third party to perform inspection of the major equipment

packages. Selection of third party shall be from Company approved list and approval

shall obtain from company prior to mobilization. All costs for the third party inspection

shall be included in the contract price.

The supplier shall appoint one person within his organization who shall be

responsible for managing the execution of the Purchase Order.

4.5.13 Expediting Supplier shall submit a written expediting report to company following visits to sub-

contractors/vendors within five working days.

Supplier shall maintain and issue weekly a critical materials list for information. The

list shall be covered by a narrative report which shall highlight the important changes

from the previous report.


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4.5.14 Packing and Transportation All packing of equipment and materials shall be in accordance with Company approved procedure.

4.5.15 Receipt, Inspection and Storage Inspection shall be undertaken by qualified personnel and shall include verification of

dimensional correctness and material certification, and a check for shortage and

damage.

All materials and equipment shall be fully identified showing identification number and

abbreviated description. All piping/fitting shall be colour coded and shall strictly

segregate material groups.

The contractor shall maintain storage conditions for all materials as per specification /

supplier recommendations.

4.6 Third Party Certification

Where Third Party Certification is specified in the Supplier’s Scope of Work in the Contract, the Supplier shall use one of the following Third Party Certification Authorities as a Sub-Contractor: The Supplier shall ensure that the TPI agency is suitable for the scope of work and personnel deployed to certify are competent.

AIB Vincotte International Ltd.

American Bureau of Shipping Services Inc.

Bureau Veritas

Det Norske Veritas

Germanischer Llyod

Lloyds Register of Shipping

TUV

Applus Velosi

Where the Company will deploy a Third Party Inspection agency to represent the Company in addition to the Supplier’s TPI, the Supplier shall not use the same Inspection agency as the one used by the Company

In order to assure conformance to the order requirements, the Supplier shall ensure that the Third Party Inspection Agency carries out the following activities as a minimum:

Endorse the Supplier’s Quality Management System and Inspection & Test Plan as and when required.

Endorse the Supplier processes, procedures are effective in meeting product requirements as and when required.

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

Ensure the Supplier personnel including QA/QC personnel are suitably qualified and competent as and when required

Ensure Purchase Order technical requirements are met


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

Endorse inspection certificates

Comply with the ITP requirement with respect to review/witness/hold points process

Where the Company employs the Inspection Agency, they shall act on behalf of the Company and shall have the same access to the Supplier’s Quality System as the Company for the above documentation and reports for certification purposes.

Components certified by TPI, shall be issued as 3.2 certificates in accordance with BS EN 10204 or equivalent certification in accordance with ISO 10474. Pressure Vessels shall be coded and constructed to in accordance with ASME Section VIII.

4.7 Project/Construction Management

4.7.1 Project Management Organization

The contract management team shall include one representative each from engineering, procurement, construction, commissioning, operations, HSE, quality assurance and project services. The contractor shall provide a project manager who shall be required to move to the construction site during construction. The contractor’s project organization shall be documented in the Contract Execution Plan (CEP).

4.7.2 Key Personnel In the case of key personnel replacement the contractor shall ensure that there shall be

a two week hand-over period. All leave greater than five (5) consecutive days of key

personnel shall be subject to company approval.

4.7.3 Contract Execution Plan

The requirement of CEP shall be based on size, nature, type and duration of contract.

At least 60 calendar days prior to the start of site mobilization the CEP shall be re-

submitted with a detailed construction plan which is similarly required to be approved by

the company. A typical Contract Execution Plan index is attached as Annexure – B with

this specification.

4.7.4 Contract Monthly Reports – Quality Statistics

The following Quality matters shall be reported in the Contract Monthly Report for EPC projects as well as other Contracts:

Summary of Contract Quality Documents development and Procedure

development and approvals.

Contract Quality Management review minutes of meeting

Summary of Internal and External Audits carried out and reported against the

Audit Schedule.

Up-dated audit tracking system

Listing of Corrective Actions for each Audit, the current status and the planned

dates for follow up and closeout.


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Details of any investigations into non-

conformance and action to prevent recurrence of any Quality System failures.

KPI/project objective reviews

Summary of Tests and Inspections carried out ‘on site’ and ‘off site’ including

those on Sub-Contracted activities.

Shall include statistics that indicate quality trend from the start of contract for the

following as a minimum:

a) Number of Customer Complaints.

b) Deviations raised.

c) Product NCRs.

d) Welder performance and repair rates based on radiography.

e) Status of deployment of QA and QC resources against the resource plan.

f) Rework and repairs carried out.

g) Measuring and monitoring Equipment register with calibration details

4.7.5

4.7.6

Process Control and Monitoring

All welding, QA and related activities (e.g. PWHT, NDT) shall satisfy the requirements of ISO 3834-1/2 as appropriate. Guidance is given in ISO3834-6.

Special processes (e.g. welding, painting, coating, NDE, GRE bonding, Concreting, grouting, HDPE fusion bonding, cable jointing, glass flake lining etc.) shall be carried out under supervision of a person, who has the experience and qualifications. All special processes shall be executed in accordance with documented and qualified procedures that ensure work is complying with company technical specifications.

The Supplier shall keep a card index or register of all approved welders/jointers. The register shall give information on training of the welders/jointers and date and results of qualification tests. The Company shall be allowed to examine the register at any time.

The procedure qualification tests for special processes, welder, jointer, NDT technician, painter etc. performance qualification tests shall be witnessed by Company representative or by company approved Third party inspection agency as identified in clause 4.6 of this specification.

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

Where the Company employs the Third Party Certification Authority, they shall act on behalf of the Company and shall have the same access to the Supplier’s Quality System as the Company. Process control documents as required by the Contract shall be submitted well in advance prior to commencement of the activities for review and approval (as applicable and as stated in the Contract). They shall be available at the location where the activities are carried out.

Identification and Traceability

Identification and traceability of materials, component and equipment shall be

maintained and documented throughout the pre-fabrication and installation process for

all pressure retaining components and non-pressure retaining components welded to


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pressure retaining components including welding consumables, paints, coatings,

adhesives etc.

The Supplier is responsible for ensuring identification, colour coding and material

traceability including Positive Material Identification (PMI) meeting the project standards

and specifications.

4.7.7

4.7.8

Control of monitoring and measuring equipment

Measuring and test equipment used to monitor special processes shall have documented calibration status.

Internal / external audit

For major projects (where duration is more than a year) The Supplier/Contractor shall carry out audits on major sub-contractors/vendors, where applicable on every project at the following project phase stages covering all activities at all work locations:

30% of project completion but before completion of design phase

65% of project completion but before completion of procurement phase

90% of project completion but before completion of construction phase

For projects having less than twelve month’s duration, one audit covering all activities may be sufficient.

The Company’s project representative may participate in all Suppliers’ internal audit specific to Company’s contracts as an observer.

An Audit Schedule shall be included in the Contract Quality Plan, which shall be approved by the Company. The Audit Schedule shall include External Audits carried out by the Supplier on Sub-Contractors.

The Supplier shall ensure that the Auditors are qualified and have sufficient experience in the areas audited.

The Company Quality section and Project team shall be notified to participate in internal audits, external audits on subcontractors/vendors and third party certification audits on the Company’s contracts as an observer. The audit notification shall be delivered to Company Quality section at least two weeks in advance of the audit date. The audit reports shall be issued to the Company not more than 2 weeks after the audit.

The audit report distribution to Company shall include;

Project Manager / Project Engineer

Company Site Representative

Engineering Services Manager

The Company reserves the right to carry out scheduled or unscheduled External Audits, Reviews and Surveillance of the Supplier, Sub-Contractors and Vendors.

The Supplier shall maintain a tracking system of all Corrective Action Requests / Non Conformance Reports raised during Internal and External Audits and Third party certification audits including audits carried out by the Supplier on subcontractors. The


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audit tracking system shall be updated monthly and a copy is issued to the Company on monthly basis. The Supplier shall ensure that their Auditors qualifications and experience are as stated in clause 4.4.3.

4.7.9 Company Audits Company will conduct regular compliance audit on the supplier. The audit will be notified

via audit notification at least one week prior to the audit. Supplier need to coordinate

with Company for making the required facility/arrangements for the audit.

4.7.10 Submission of action plans

Classification criteria and response times shall be as follows:

High risk if significant effect on HSE or technical integrity of production facilities (immediate action is required)

Medium risk if significant effect on integrity of production facilities and negligible effect on HSE (action required within 14 days)

Low risk Conditions other than high risk and medium risk (action required within 30 days but before close-out of project)

4.7.11 Release or acceptance of non-conforming product under concession

A copy of non-conformances shall be submitted to Company within 24 hours of noticing it and shall be classified as high /medium/low risk. Upon closeout of nonconformity, closed out non-conformance report shall be submitted to the Company.

4.7.12 Analysis of data

Data analysis report showing quality performance trends shall be reported, monthly

(refer clause 4.7.4). The report shall include root causes, actions, and their

effectiveness. Recurring nonconformities shall be highlighted.

4.7.13 Corrective action response times The response time with actions taken shall be as given in clause 4.7.10. The effectiveness of corrective actions taken shall be demonstrated through quality performance trends (refer clause 4.7.4).

4.7.14 Preventive action The response time with actions taken shall be as given in clause 4.7.10. The effectiveness of preventive actions taken shall be demonstrated through quality performance trends (refer clause 4.7.4).


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5. REFERENCES

1. ISO/TS 29001- Petroleum, petrochemical and natural gas industries—Sector specific quality management systems-Requirements for product and services supply organizations. 2. ISO 3834-1 - Criteria for the selection of the approval level of Quality Requirements. 3. ISO 3834-2 - Comprehensive Quality – Requirements. 4. ISO 3834 - Quality Requirements for fusion welding of metallic materials. 5. ISO 19011 - Guidelines for Quality and/or Environmental Management Systems auditing. 6. ISO 10005 - Quality Management Systems- Guidelines for quality plans. 7. ISO/TR 10013 - Guidelines for Quality Management System documentation. 8. ISO 9001 - Quality Management Systems- Requirements. 9. ISO 9712 - Non-destructive Testing – Qualification and Certification of Personnel.

6. RECORDS Nil


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Appendices


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Appendix A - Contract Quality Plan and Contract Quality Plan Guidelines

Introduction

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

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

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

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

1. Control of Contract Quality Plan

1.1 Index.

1.2. Revision Status, together with the Control Mechanism of the CQP and a Distribution List. The Company distribution shall be as the Contract documents, with a minimum of: - Company Representative. - Project Manager., - Company Site Representative. - Engineering Services Manager - Site QA In charge

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

2. General

2.1 Details of how the Corporate Quality System documentation shall be applied and

implemented on the Contract. The CQP shall include contract specific quality system structure.

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

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

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

2.5 Details of how Quality Planning shall be undertaken and controlled. 3. Quality Assurance Objectives

3.1 Detailed list of the Contract and other documents whose requirements are to be met,

together with their revision status. 3.2 Indicate the location where these documents are available, the Procedures for controlling

and revising them and the person responsible. 3.3 Include a Distribution Matrix for all documents.

4. Organisational Structure


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4.1 A final Contract specific Organisation Chart, highlighting Quality Assurance, Quality

Control, and Inspection and Verification personnel. Confirm mobilisation dates for all staff down to Foreman level.

4.2. Provide a Corporate Organisation Chart identifying by Name and Job Title all personnel who will interface with the Contract personnel, Sub-Contractors, Vendors or the Company.

4.3. Define roles, responsibilities and reporting relationships of all personnel identified in the Contract specific organisation with interface with Corporate personnel.

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

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

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

Note: The qualification, training and experience of QA and QC personnel shall be appropriate to the nature and scope of the Contract.

5. Applicable Procedures, Work Instruction & Checklists

5.1 List of all Corporate Quality System Procedures, Work Procedures and Contract Specific Procedures, Work Instructions, Checklists and Standard Forms, with current Revision Status and Issue Date, that shall be used on the Contract. Indicate dates when Contract specific Procedures and Work Instructions shall be issued and the person(s) responsible for developing, reviewing and implementing them.

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

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

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

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

6. Quality Control Plans (Inspection &Test Plans)

6.1 List of QCP, with current Revision Status and Issue Date, to be used on the Contract.

Indicate dates when Contract specific QCP will be issued and the person(s) responsible for developing, reviewing and implementing them.

6.2 All QCPs shall be approved by the Company prior to work commencing. Above include QCP(s) from Sub-Contractor(s).

6.3 ‘Controlled Copies’ of all Corporate and Contract Specific QCPs, including those from Sub-Contractor, to be used on the Contract shall be included in the CQP. - The Quality Control Plans shall include: - List of Activities and Sub-Activities requiring Quality Control and or stage inspection. - Controlling Document (Supplier’s Procedure / Work Instruction, Contract Specification,

Specifications, Procedures, International Code or Standard).


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

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

endorsed by the Supplier’s Verification Personnel.

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

7. Quality Records

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

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

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

7.4 Include a Distribution Matrix for all Quality Records, which shall include the following as a minimum: - Records to be reviewed by the Company during the Contract. - Records requiring Approval / Hold & Witness by the Company. - Records to be handed to the Company. - Records to be kept for use by the Supplier only.

7.5 Define the content and format of Test Packs, per discipline, and shall be agreed with the Company Representative in advance. Records of Company approval shall be maintained by the Supplier.

8. Audit Schedule

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

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

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

8.4 External and internal audits shall be carried out by trained, qualified and experienced auditors. Auditors shall possess IRCA, UK or equivalent auditing qualification. (Note: Also see clause 4.4.2.9 of this specification).

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

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

Contract/Project Quality Plan Index


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( Typical Example – Contract Issue )

Contents of Contractor’s Contract Quality Plan: Contents of the CQP should follow the following structure and contents (where applicable).

A. Purpose and Scope

B. Special Terms, Definitions, Acronyms and Abbreviations

C. References

D. Requirements

1. Project Codes and Standards

2. Regulatory, Legislation, Permits and Consents Compliance

E. Quality Policy, Objectives and strategy

F. QMS Structure

G. Management Responsibility

1. Management Commitment

2. Management Review

H. Quality Organization

1. Roles and Responsibilities and Accountabilities

2. Project Quality Organization and Quality Function Organization Charts

3. Quality Resources

4. Training and Competency

I. Information Management

1. Document Control

2. Quality Records Management and Certification

3. Control of Software

J. Communication and Interface Control

K. Management of Change

L. Continuous Improvement

1. Audits

2. Health Checks

3. Corrective and Preventive Actions

4. Lessons Learned

5. KPIs


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M. Interrelated Systems

1. Operations Readiness and Assurance

2. Technical Integrity Verification

3. Flawless Project Delivery

N. Project/Product Realization

1. Quality Planning

2. Quality Risk Assessment

3. Equipment Criticality Rating

4. Design/Engineering Management (If applicable)

I. Design Planning

II. Engineering Deliverables

III. Design Reviews

IV. Technical Assurance

a) Design Verification

b) Design and Novel Technology Validation

V. Technical Deviations

5. Contracting and Procurement (If applicable)

I. Prequalification Requirements

II. Contract Quality Requirements

III. Tender Documentation and Assessment

IV. Post Contract Award Requirements

V. Performance Monitoring

6. Fabrication, Construction, Assembly, Mechanical Completion (if applicable)

I. Material Management

a) Control of Company Supplied Materials

b) Packaging and Preservation requirements

7. Inspection and Testing

I. Inspection and Test Plan

II. Inspection and Test Execution and Monitoring

III. Verification Activities by Company


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IV. Inspection Function and Competency

V. Pre-inspection and Quality Alignment

VI. Inspection and Test Records

VII. Control of Measuring and Testing Equipment

8. Hook-Up, Commissioning, Start-up and Handover (If applicable).

I. Commissioning Planning

II. Commissioning Execution

III. Completion and Handover

O. Non-Conformance Management and Control

P. Appendices (ISO certifications, audit schedules, Document Distribution Matrix, Training Matrix, Organograms etc.)


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Appendix B - Contract Execution Plan Index

( Typical Example – Contract Issue )

1 Introduction 1.1 Document Purpose 1.2 Intended Audience 1.3 Scope of Work 1.4 Project Objectives and Priorities 2 Management Plan 2.1 Management 2.2 Risk Management 2.3 Provision of Facilities and Equipment 2.4 Skills and Resource Requirement 2.5 Organization Roles & Responsibilities 2.6 Communications 2.7 Output Review and Acceptance 2.8 Updating this Plan 3 Project Controls 3.1 Change Management 3.2 Schedule Management 3.3 Cost/value Management 3.4 Quality Assurance and Quality Control 3.5 Administrative System and Procedures 3.6 Safety and Environment 3.7 Progress Reporting 4 Design Development 4.1 Design and Development Activities 4.2 Organization and Staffing 4.3 Interface with OGC Departments, consumers & other agencies 4.4 Design Methodology 4.5 Design Input 4.6 Design Output 4.7 Inspection and Review 4.8 Approval and Acceptance 4.9 Authorization and Distribution 4.10 Updating and Changing 5 Design Development 5.1 Purchasing Specification 5.2 Selection of Suppliers 5.3 Subcontractor Management 5.4 Inspection and Testing of Purchased Goods & Services 5.5 Records Required 6 Construction Plan 6.1 Construction Strategy 6.2 Initial Mobilization 6.3 Milestones 6.4 Interface Management 6.5 Process Inspection & Testing 6.6 Records Required


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7 Commissioning Plan 7.1 Commissioning Strategy 7.2 Unit Testing 7.3 System & Subsystem Testing 7.4 Pre-Commissioning 7.5 Commissioning 7.6 Guarantee Run 8 Project Evaluation Review(s) 9 Project Plan 9.1 Overall Project Plan 10 Final Documentation 10.1 Engineering 10.2 Operation 11 Appendices


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Appendix C - Procedures, Work Instructions and Checklists

The following Procedures / Work Instructions shall be used on the Contract: (Note: The following listing is purely for example purposes and is not intended to be a definitive list of Procedures for a particular type of Contract). Title Rev. Date Contract Management

Contract Review Contract Quality Plan HSE Plan Planning & Scheduling Document Control Labour, Materials & Plant Resourcing Interim & Final Payment Certification Contract Reporting to OGC Training Quality Auditing HSE Auditing & Inspection Technical Queries Change Orders & Variations Control of Non-Conforming Product Corrective Action Third Party Certification (if required in Scope of Work) Design

Design control Drawing control Design Verification & Technical Reviews HAZOP/SAFOP Control of Specifications, Codes & Standards Preparation of Requisitions Materials Tracking & Reporting Reviewing Vendor Documentation As Built Information Operation & Maintenance Manuals Operating Philosophies Procurement

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

Surveying & Setting Out Earthworks, Trenching, Excavation & Backfilling


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Concrete Work Structural Steelwork Brick work & Block work General Building & Architectural Work Building Services (Plumbing, Electrical, A/C) Roads & Paving Mechanical Engineering

On Plot Piping Off Plot Piping Welding Installation of Static Equipment Installation of Rotating Equipment Painting & Coating Non-Destructive Examination NDE Electrical Engineering

Protection & Isolation Installation of Electrical Equipment Installation of Underground Cables Installation of Overhead Lines HV & LV Switch gear Cathodic Protection As Built Drawings Vendor Manuals Instrumentation Engineering & Telecommunications

Safeguarding Installing Instrumentation Instrument Air Supply System Cabling DCS Systems SCADA Factory & Site Acceptance Testing Installation of Telecommunication Equipment As Built Drawings Vendor Manuals Commissioning, Handover, As Builts, Operation & Maintenance Manuals

Pre-commissioning Commissioning As Built Documentation Operation & Maintenance Manuals Spare Parts for Initial Running & Operation Pre-satrtup Audit Close out Report Regulatory Permits (Environment, Municipality etc.) Project-Operation Certificates.


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

Quality Control Plan Ref.: Contract: Contract No.:

Discipline Element: Procedure Ref.:

Activity Controlling Document Acceptance Criteria.

Frequency of Test.

Supplier’s

Verification

Personnel

Verification Document Hold, Witness & Review

Points

List the activity to be controlled. Ideally prepare

a QCP for each Procedure by Discipline, for

example:

Contract Management - Contract Review - Contract Quality Plan

- HSE Plan, etc.

Design - Design Control

- Drawing Control, etc.

Procurement – Approved Contractors & Vendors – Requisitions, etc.

Civil Engineering

– Surveying & setting Out

– Earthworks, etc.

Mechanical Engineering

Electrical Engineering

Instrumentation Engineering

Commissioning & Handover, etc.

Identify the documents that

control the activity.

This will be the Supplier’s

Procedure, Contract

Specifications, BS, ASME, etc.

Identify the Quality Control requirements in these

documents.

Identify the Clause reference

that stipulates the

requirements.

Identify the actual value of

the specified requirement if

this is a simple measurement. Alternatively

cross reference to the clause,

table, figure, etc. in the relevant specification, BS,

ASME, etc.

Verification Documents and

Checklists can be used to

show the specified Acceptance Criteria, if it is

not practical to show details

in the QCP. This enables easy comparison with

measured values.

State the specified frequency

of testing.

Identify the

Supplier’s

personnel responsible for

verifying the test

results.

This will usually

not be the same person that carried

out the Quality /

Control Activity / Measurement.

Identify the document that

verifies the Quality Control

has taken place, for example, signed Quality Control Form,

Checklist, NDT X-Ray, Test

Results Records, etc.

Often examples of completed

Verification documents are included in the relevant

Procedure.

Should have a numbering

system in accordance with a

Document Control Procedure.

Identify any Hold & Witness

points.

Some are specified in the

Contract, requiring inspection

by the Client or Third Party Inspector.

Some may be required by the Supplier to monitor the work

and measure the performance

of the process with respect to Quality.


GME-QS-L2-202 R1 27-09-2016

Page 37 of 37


Appendix D - Quality Control Plan - Typical Example for ‘Hydro Testing’

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

Discipline: For example,

‘Mechanical Engineering’ Element: For example, ‘On Plot Hydro Testing’

Procedure Ref.: For example, ‘Pre Commissioning Pressure Testing of On-Plot

Mechanical Equipment & Pipework Procedure.

Activity

Controlling Document

(Supplier’s Procedure, Contract

Specification, Standard)

Acceptance Criteria, (Specified

Test Requirements etc.)

+

Frequency of Test

Supplier’s

Verification

Personnel

Verification Document.

(Quality Control Form,

Inspection Record etc)

Supplier’s Hold,

Witness &

Review

Company Hold,

Witness &

Review

H W R H W R

Pressure testing schedule

Supplier Procedure (in this

example) ASME 31.3

Approved Testing Schedule QC Eng. Approved Schedule H H

Permit to Work

Supplier Procedure

OGC HSE Manual

Approved Permit to Work Mech. Sup. Approved Permit H H

Pre-test documentation. Test Pack

Folder

Supplier Procedure

ASME 31.3

Cl. 5.2.1 to 5.2.4. Shown on

Checklist Every Test

Mech. Sup. Checklist W H

Pre-test mechanical site inspection

Supplier Procedure

Cl. 5.2.5. Shown on Checklist Every Test

Mech. Sup. Checklist R R

Hydro testing

Supplier Procedure

ASME 31.3

Cl. 5.3.1 to 5.3.6. Shown on

Checklist Every Test

Mech. Sup. Checklist R W

Pressure Test Certificate

Supplier Procedure

Cl. 5.3.11. Shown on Checklist Every Test

QC Eng. Checklist H H