2.0 Project Quality Control Plan

QUALITY MANAGEMENT SYSTEM DOCUMENT QUALITY DETAIL PROCEDURE

DOC. NO : EJ/SSB/B11LQ/1.4.2/08 DATE

: 13/04/10

REV. NO

: 0

SAMPLE PROJECT QUALITY PLAN PROCEDURES

PROVISION OF HOOK-UP AND COMMISSIONING SERVICES FOR B11 LIVING QUARTERS MODULE AND HELIDECK

THIS DOCUMENT PRESCRIBES COMPANY PRACTICE AND IS FOR INTERNAL USE ONLY. IT SHALL NOT BE REPRODUCED IN WHOLE OR IN PARTS OR RELEASED TO A THIRD PARTY WITHOUT PRIOR CONSENT FROM THE HEAD OF RESPONSIBLE DEPARTMENT.

PREPARED BY

:

COMMISSIONING ENGINEER CONTROLLED COPY

REVIEWED BY

:

MANAGER, COMMISSIONING

NO. :

APPROVED BY

:

PROJECT MANAGER

UNCONTROLLED COPY

RESPONSIBLE DEPARTMENT: HOOK-UP & COMMISSIONING

C : B11 LQ /Sec.1.4.2 Project Quality Plan Procedure

Page 1 OF 24

QUALITY MANAGEMENT SYSTEM DOCUMENT QUALITY DETAIL PROCEDURE

DOC. NO : EJ/SSB/B11LQ/1.4.2/08 DATE

: 13/04/10

REV. NO

: 0

REVISION

PURPOSE OF ISSUE

DATE ISSUE

ISSUED BY

A B 0

Issued for review Re-issued for approval Issued for Construction

02/04/2008 06/06/2008 07/06/2008

Hook-up and Commissioning Hook-Up and Commissioning Hook-Up and Commissioning

AGREED BY SSB AUTHORISED REPRESENTATIVE

...................................................................

(SIGNATURE)

...................................

(DATE)

NOTE : Please return approved copy to :

BROOKE DOCKYARD ENGINEERING & WORKS CORPORATION HOOK-UP AND COMMISSIONING DEPARTMENT ENGINEERING DIVISION SEJINGKAT, JALAN BAKO 93050 KUCHING, SARAWAK


Page 2 OF 24

B11 LIVING QUARTERS MODULE AND HELIDECK TABLE OF CONTENTS SECTION

DESCRIPTION

PAGE

1.0

PURPOSE

4 OF 24

2.0

SCOPE

4 OF 24

3.0

REFERENCES

4 OF 24

4.0

PROJECT QUALITY ORGANIZATION

4 OF 24

5.0

DUTIES AND RESPONSIBILITIES 5.1 Project Team Leader 5.2 Lead Commissioning Engineer 5.3 Technical / Document Clerk 5.4 Planning Engineer 5.5 Cost Engineer / Estimator 5.6 HSE Engineer 5.7 Material Planner/ Coordinator 5.8 Designer / Draftsman 5.9 QA / QC Engineer

5-9 OF 24

6.0

PQP REVIEW

10 OF 24

7.0

APPLICABLE QUALITY MANAGEMENT SYSTEM (QMS) ELEMENTS 7.1 Project Contract Review 7.2 Document Control

10-12 OF 24

8.0

PRODUCT IDENTIFICATION AND TRACEABILITY 8.1 Process Control 8.2 Interfacing Controls 8.3 Procedures and Work Instructions 8.4 Variance Order Controls 8.5 Special Process Control 8.6 Commissioning 8.7 Inspection and Testing 8.8 Control of Inspection and Testing Equipment 8.9 Control of Inspection and Testing Equipment 8.10 Control of Non-conforming Products Corrective Action 8.11 Handling, Storage, Packaging, Preservation and Delivery 8.12 Quality Records 8.13 Quality Assurance Audits and Quality Awareness Program 8.14 Training 8.15 Project Statistical Data

13-22 OF 24


Page 3 OF 24

1.0

PURPOSE This Project Quality Plan (PQP) intends to provide the control methods in all the work processes involved in the engineering, offshore fabrication, installation, pre-commissioning and commissioning phases of B11LQ Modules and Helideck.

2.0

SCOPE This PQP shall be applied during the entire duration of this project and shall be complied by EJ Joint Venture Sdn Bhd (EJJV) to perform works or services and to supply consumables materials for the project.

3.0

REFERENCES QUALITY ASSURANCE MANUAL QUALITY ASSURANCE AND CONTROL PROCEDURES MANUAL COMPANY PROJECT MANAGEMENT GUIDE AND PRACTICE COMPANY PROJECT DEVELOPMENT GUIDELINE PETRONAS TECHNICAL SPECIFICATION ASME/ANSI B31.3 AWS Dl.1 API 1104

4.0

PROJECT QUALITY ORGANIZATION Refer to Appendix 1 for the various proposed Organization Charts respectively. There are three major engineering services to be utilized for the project namely: -

Project Workpack and Cost Control Fabrication and Commissioning Quality Assurance

The scope of work and responsibilities of each group is mentioned in the Project Execution Plan.


Page 4 OF 24

5.0

DUTIES AND RESPONSIBILITIES 5.1

Project Team Leader 5.1.1 Reporting directly to client Project Manager for the development of the commissioning workpack. 5.1.1.1

Development of pre-commissioning / commissioning testing plans and priorities, that will be applied for onshore and offshore works.

5.1.1.2

Manage and coordinate testing pre-commissioning and commissioning interfaces with construction, design engineering, procurement and vendor services.

5.1.1.3

Development of testing and pre-commissioning & commissioning procedures in accordance with the specification, drawing, codes and standards and vendor recommendations and coordinate endorsement by operation. He has to liaise with client Operations Department and personnel in establishing commissioning procedures.

5.1.1.4

To coordinate and update client in respect to the preparation and progress of the commissioning workpack and development.

5.1.1.5

During the workpack and project implementation offshore he shall be responsible to client operation the following a) b) c) d) e) f) g) h)


Implementation of safety program for offshore testing and commissioning. Timely completion of testing and commissioning activities. Offshore testing and commissioning requirements i.e testing consumables, equipments, manpower and support services from other parties. Preparation of MTO, commissioning spares, testing equipment, shiploose list for the Hook up and Commissioning phase and coordinate timely deliveries. Vendor assistance requirement and mobilization as and when required. Testing and Commissioning progress control and reporting. Coordinate with Operation on system priorities, and sub-system ready for witnessing and handover. Compilation of Testing and Commissioning documentations, redline as-built drawings, equipment dossiers, etc.

Page 5 OF 24

5.2

Lead Commissioning Engineer 5.2.1

Prepare system overview and Commissioning Testing Plan (CTP).

5.2.2

Review and finalize testing procedure and checksheets.

5.2.3

Able to determine vendor assistance requirement and mobilization, to be able to incorporate in the workpack.

5.2.4

Leads the team in preparing procedure for testing and commissioning of subsystem / system in accordance with the procedure and schedule of priorities. Ensure testing and commissioning procedure meets design criteria and intent purpose. He shall be supported by Electrical and Instrument Engineers and Mechanical / Rotary Commissioning Engineers.

5.2.5

Preparation of the definition of Mechanical completion.

5.2.6

During the workpack and project implementation offshore, he has to undertake the overall coordination of the commissioning activities with client Operation supervision.

5.2.7

Advise operation personnel commissioning on sub-system / system ready for testing.

5.2.8

Identifying need of third party inspectors and vendors.

5.2.9

Ensuring timely development compilation of the Commissioning Workpack and preparation of final documentation.

5.2.10

Clarifying inquiries on operations and maintenance of the system and/or equipment.

5.2.11

Preparing the relevant documentation for requisition of test equipment and tools.

5.2.12

Liaise with QA/QC for compliance to requirements prior Commissioning and Testing (i.e weld test, NCR clearance, etc.).

5.2.13

Monitoring, control, documentation and compilation of site changes and variation orders.

5.2.14

Monitoring, Control Documentation and Compilation of site changes and variation orders.


and

pre-commissioning/commissioning

to

Pre-

Page 6 OF 24

5.3

5.4

5.5

Technical Writer / Document Clerk 5.3.1

To assist in contract document compilation i.e. final document workpack etc.

5.3.2

To assist engineers in preparing the "Workpack" such as data encoding of jobcards using in-house jobcard system, typing the scope of work, summaries, work scoping / site visit report etc. for both Onshore and Offshore preparation job.

5.3.3

To keep proper filling for all contract documents / final documentation and workpack.

5.3.4

Involve directly with Engineering Department, Safety QA/QC, Procurement and Safety Department to provide clerical support such updating status report.

Planning Engineer 5.4.1

Develop planning bar chart, CPN, manpower histogram and S-Curve for the project.

5.4.2

Develop progress monitoring package and updating for reporting

5.4.3

Prepare daily and weekly progress report.

5.4.4

Preparing progress reports, analyses and areas of concern.

Cost Engineer / Estimator 5.5.1

Developing the Cost Control Strategy

5.5.2

Estimation of the required resources

5.5.3

Monitoring of cost and resources

5.5.4

Coordination and follow-up of the required resources

5.5.5

Coordinating of contractual issues

5.5.6

To prepare and estimate cost for additional works and up-date the status

5.5.7

Coordination of punchlist line items and follow up / up-date the status


Page 7 OF 24

5.6

5.7

5.8

5.9

HSE Engineer 5.6.1

To prepare safety jobcard analysis in every task Mechanical, Electrical and Instrument, pre-commissioning and commissioning

5.6.2

To liaise and coordinate with client representative on matters pertaining to safety.

5.6.3

To establish and coordinate safe working method.

Material Planner/Coordinator 5.7.1

Performs receipt inspection of incoming materials. Coordinate client inspection.

5.7.2

Document materials inspection by using the Materials Receipt Inspection Report. Filing of reports and material mill/test certificates.

5.7.3

Updating of the Material Status Report.

Designer/Draftsman 5.8.1

To check the completeness of the issue drawings based on the quantity and number of copies against the list in the drawing transmittal from client.

5.8.2

To update Drawing Control List which indicate the drawing and revision number.

5.8.3

To issue a relevant copy of the drawings to the workpack team, which consist of Discipline Engineers, Material Planner and QA/QC Engineer for workpack preparation.

QA/QC Engineer 5.9.1

Responsible for the implementation and documentation of the project quality procedures.

5.9.2

To ensure that inspection and testing are performed and documented in accordance with the inspection and test plans.

5.9.3

Performs periodic audit on fabrication, installation, testing and commissioning activities. Monitoring and implementation of corrective actions.

5.9.4

To develop specific quality control procedures when needed.


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5.10

5.9.5

To ensure that the documentation of all inspection records is properly done by the discipline engineers and inspectors.

5.9.6

To perform inspection when the need arises

5.9.7

Coordination with the client's inspector on inspection and testing activities.

5.9.8

Perform welder evaluation on a weekly basis.

5.9.9

To provide direction to inspectors on a daily basis to clarify assignments and activities to be met and performed.

5.9.10

Responsible for the final documentation of the project.

Commissioning Engineers 5.10.1

Develop specific commissioning procedures.

5.10.2

Implement and document commissioning activities.

5.10.3

Ensure that client is informed on the tests that required client's presence. Coordinate by sending notice of inspection.

5.10.4

He shall complete the required checksheets prior to submission to the client for approval.

5.10.5

Preparation and compilation of inspection records, drawings and commissioning checksheets into a System Handover Document for client approval.

5.10.6

Initiate "red-line" marking on drawings and diagrams with regards to actual changes from the construction drawings.

5.10.7

Provide updates of activities to the Planning Engineer to be included in the daily progress reporting.


Page 9 OF 24

6.0

7.0

PQP REVIEW 6.1

This Project Quality Plan shall be reviewed monthly to determine its effectiveness in the implementation of the Company quality objectives for the project.

6.2

The review is to be performed based on audits and feedbacks by the client and the Company's Quality Management Team. The review shall be documented and copied to the client.

APPLICABLE QUALITY MANAGEMENT SYSTEM (QMS) ELEMENTS 7.1

Project Contract Review 7.1.1

Review of the contract shall be performed prior to the award of the work to define and clear the scope of work in terms of its various requirements.

7.1.2

Ambiguities and exceptions shall be notified and cleared with the client through a clarification meeting. Deviations shall be documented and discussed with CLIENT for approval.

7.1.3

During the execution of work, site changes shall be documented and forwarded to CLIENT for approval. Variation orders are to be controlled in accordance with the applicable procedure and guideline provided by CLIENT.

7.1.4

All contract reviews, technical clarifications/queries, tender clarifications, minutes of meetings and other contract documents shall be retained in the Company's Document Control Section for retrieval. Reference Procedures: EJJV.QP.CN.001, REV. 0 : Contract Review EJJV.QP.CN.002, REV. 0 : Change Order Control

7.2

Document Control 7.2.1

Project Filing System 7.2.1.1


All communication, correspondence and data in hard copy shall be filed in accordance with the Project Files List. This does NOT apply to manuals, procedures, and drawings (technical documents) which are covered below.

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7.2.2

7.2.1.2

Technical documents received from the client, consultants, subcontractors and suppliers and documents produced by EJJV shall be controlled in accordance with EJJV.QP.QA.001, "Document Control Procedure".

7.2.1.3

Documents shall be distributed by the Project Document Controller in accordance with the matrix prepared by the Project Team Leader in concurrence with the Project Document Controller and the Quality Assurance Manager. This matrix shall be held in the Document Control Section.

Project Documents Procedures, codes and specifications are to be controlled by the Quality Assurance Engineer/Inspector. These documents are to be kept and maintained at EJJV facilities. This includes the following

7.2.3

7.2.2.1

Company Standard QA/QC Procedures

7.2.2.2

Project Specific Procedures

7.2.2.3

Commissioning Procedures

7.2.2.4

Project Work Instructions

7.2.2.5

Welding Procedure Specifications

7.2.2.6

Procedure Qualification. Records

7.2.2.7

CLIENT General Specifications

7.2.2.8

Codes and Standards, i.e. ASME IX, ANSI B31.3, API 1104

Document Review, Approval and Issuance 7.2.3.1

Project specific procedures are to be reviewed and approved by the Project Team Leader. Procedures are controlled as defined in the Document Control Procedure.

7.2.3.2

Only the latest revision is to be used. Obsolete drawings, procedures or specifications shall be identified, segregated and shall not be used in the project.


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7.2.3.3

7.2.4

Document transmittals shall be filed by the Document Controller. There shall be a Project Document Register which is updated whenever a document is developed, revised and distributed.

Project Revisable Technical Documents All project revisable documentation shall be controlled by the Company Document Controller in accordance with the Document Control Procedure. The project Document Controller shall revise the project Document Register periodically and forward the markup to the Company Document Controller office in KL for updating of the Master Document Register and issue of reports.

7.2.5

Standards and Codes The Project Team Leader shall obtain the required standards and codes for the project

7.2.6

Drawing Control 7.2.6.1

AFC drawings shall be distributed in accordance with the Drawing Distribution Matrix prepared by the Project Team Leader in conjunction with the Document Controller and the Quality Assurance Engineer.

7.2.6.2

Use Document Transmittals whenever drawings are to be furnished. Ensure that, transmittal copies are forwarded by the recipients to the Document Controller to acknowledge receipt.

7.2.6.3

A Project Drawing Register is to be drawn up by the project Document Controller. It is to be updated whenever new revisions are received.


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8.0

PRODUCT IDENTIFICATION AND TRACEABILITY -

Upon acceptance receipt inspection, project materials, i.e. pipes, plates, flanges, valves, fittings, etc, and all load-bearing structural components as well as pressure-containing parts, shall be identified by color coding which denotes a specific type of material. These color codes are as per CLIENT's specification for each type of material.

-

Each type of material shall be stored or stacked separately into racks. Materials such as duplex stainless steel shall be protected from any contamination caused by mixing with other type of steels.

-

Mill Certificates shall be denotes with the Material Receiving Inspection Report number for an efficient retrieval of information.

-

When required by the contract, the project materials shall be identified with the specific area or location to which these are intended for construction or erection. Forms of identification, i.e. color code, tagging, marking, etc., are in accordance with the applicable client specification.

-

Prior to cutting of plates or pipes, an inspection shall be conducted to verify the Material Specification, Heat Number and Size of the material. Result of the inspection shall be recorded into the Material Verification Report. The Material Specification and the Heat Number of the material shall be transferred prior to cutting.

-

A weld summary shall be developed to indicate the history of each joint throughout the stages of fabrication. The summary shall contain the report numbers of inspection performed during material verification, fit-up, visual, NDT, PWHT, hydrostatic testing and painting. The QC Inspector shall update the summary whenever an inspection is performed.

-

Welding Visual Inspection Reports shall indicate the welding process, the joint number, drawing number, WPS number, and the welder number.

-

Each inspection point/joint shall be marked with joint number, line number welder number and the applicable NDT performed. Color coding using GREEN is to indicate the acceptance of the applicable NDT. This is to facilitate a faster verification especially when a succeeding test, such as hydrotest, is to be performed.

-

The Lot Number or Heat Number of all welding electrodes, filter wires, or fluxes, shall be recorded into the Welding Consumable Register which is maintained by the QC Section. -

Scrap or surplus materials shall be identified by the color code for each type of material, with the material specification and the heat number clearly stamped.


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As required by the contract, a Positive Material Identification shall be performed of specific incoming materials, and weldments. The process shall be in accordance with GS 18-10-1 and the reference procedure below. All materials or joints inspected by PMI shall be identified by color code as provided by the GS mentioned above

-

Reference Procedures: EJJV.QP.MT.001, REV. 0 : Material Control EJJV.QP.MT.002, REV. 0 : Control of Customer Supplied Materials EJJV.QP.MT.003, REV. 0 : Positive Material Identification. 8.1

Process Controls 8.1.1

8.2

Planning and Scheduling 8.1.1.1

Level 1, Level 2 and Level 3 planning packages shall be developed and submitted for approval by the client.

8.1.1.2

The Project Plan and Schedule should be able to monitor the actual progress against planned targets.

8.1.1.3

The planning package shall specifically mention and capture manpower and equipment loading and schedules.

8.1.1.4

Progress reporting shall be made on the daily basis using the report format provided by the contract. The Project Team shall formulate corrective actions in order to maintain the achievement of planned targets.

Interfacing Controls 8.2.1

Resources for each discipline shall be determined and prepared on hand prior to the start of the project. Manpower and equipment are sourced, hired or purchased.

8.2.2

Weekly meeting with CLIENTS shall be conducted to discuss and monitor performance, progress and compliance to the requirements of this PQP.

8.2.3

Internal coordination meetings shall be conducted to the discuss inter-phases activities between various disciplines. It shall be encouraged to hold informal brainstorming sessions to seek clarifications and agreements.


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8.3

Procedures and Work Instructions 8.3.1

Procedures and Work Instructions shall be developed to cover the various fabrication stages as follows: 8.3.1.1 8.3.1.2 8.3.1.3 8.3.1.4 8.3.1.5 8.3.1.6 8.3.1.7 8.3.1.8 8.3.1.9

8.4

8.5

Material Cutting Fit-up Welding Repair of Duplex Steel Inspection and Testing Painting Erection Pre-commissioning Commissioning

8.3.2

Each discipline engineer i.e. QC, Mechanical, Electrical and Instrument shall be responsible in the development of procedures and work instructions.

8.3.3

Flowcharts shall be used to supplement work instructions and procedures to establish a user-friendly approach.

8.3.4

Translation to Bahasa Malaysia of procedures and instructions are done as some of the company workers may not be conversant with the English language.

Variance Order Controls 8.4.1

Change orders shall either be client or EJJV generated. Each site change may be initiated by CLIENT through a site instruction or by EJJV issuing a change order notice.

8.4.2

Variance orders are to be documented by relevant drawings and diagrams when submitting to the client for approval.

8.4.3

EJJV-issued Variance Order Notice shall be signed by the Project Team Leader prior to being sent to CLIENT for approval.

Special Process Control 8.5.1

EJJV shall generate procedures to verify the accuracy and quality of product or process which is termed as a special process. The procedures is also able to rectify on the usage of the special equipment to be used for inspection.


Page 15 OF 24

8.6

8.5.2

Equipment to used shall be reliable by having a valid calibration and traceable to a calibration standard.

8.5.2

Operators or skilled technicians to perform the verification are to be selected by virtue of qualification and experience.

Commissioning 8.6.1

As EJJV will commission systems the following shall be considered in the commissioning plans: 8.6.1.1 8.6.1.2 8.6.1.3 8.6.1.4 8.6.1.5 8.6.1.6

commissioning responsibilities of EJJV scope of commissioning activities interfaces with hook-up group resources required preparation of checksheets and procedures criteria for handover

8.6.2

CLIENT shall be consulted and presented with the plans for review and approval prior to the start of the commissioning activities.

8.6.3

Make use of the construction group's resources. Tie up with the construction activities in order to minimise the time of handover.

8.6.4

If required, the planning shall include the order and timetables of deliveries for commissioning spares like lubricating oils, filters, greases, chemicals, packing materials, etc.

8.6.5

List down the commissioning spares for one year and two years.

8.6.6

Set up system of checksheets, ensure that results of tests are recorded in the checksheets and signed by CLIENT upon completion.

8.6.7

Ensure that commissioning resources are present, such as: 8.6.7.1 8.6.7.2 8.6.7.3


Supervision personnel Client engineers to witness the tests Vendor's representatives

Page 16 OF 24

8.6.8

Check the availability of commissioning documentation which include: 8.6.8.1 8.6.8.2 8.6.8.3 8.6.8.4

8.6.9

Equipment inventory Equipment record cards System and equipment manuals Procedures

Commissioning activities will be monitored by the Q.C. Engineer or Inspector to ensure that procedures and work instructions are implemented. Reference Procedures: EJJV.O.P.09-0, REV. 0 EJJV.QP.QC.001, REV. 0 EJJV.O.P.04-0, REV. 0 EJJV.O.G.06-1, REV. 0 EJJV.QP.QC.005, REV. 0 EJJV.O.G.02-2, REV. 0 EJJV.QP.QC.007, REV. 0 EJJV.O.G.02-2, REV. 0 EJJV.QP.QC.009, REV. 0 EJJV.QG.02-3, REV. 0 EJJV.QP.QC.01 1, REV. 0 EJJV.QP.PJ.001, REV. 0 EJJV.QP.PJ.002, REV. 0 EJJV.QP.PJ.003, REV. 0 EJJV.QP.PJ.004, REV. 0

8.7

-

Change Order Control Welding and Fabrication Qualification and Evaluation Of Welders Control of Welding Consumables Surface Preparation and Coating Pressure Testing Repair of Valves Valves Leak Test Post Weld Heat Treatment Hardness Testing Insulation Project Management Monitoring and Control Planning and Scheduling Piping and Mechanical Pre-Commissioning Electrical and Instrument PreCommissioning

Inspection and Testing 8.7.1

Inspection and testing are to be conducted in accordance with clientapproved Inspection and Test Plan (ITP). See attached Inspection and Test Plan for Piping, mechanical, electrical and instrument works.

8.7.2

The inspection activities are performed during the following stages: material receiving, in-process and final inspection. Each of these stages are to have distinct ITP's to be adhered to during the fabrication.

8.7.3

In-process inspection utilizes checksheets or checklists. It is to be ensured that the preceding inspection activity is completed prior to conducting the next step of fabrication.


Page 17 OF 24

8.7.4

Final inspection and testing is performing line checking and system check to verify that the system is not having outstanding non-conformances or incomplete inspection/test.

8.7.5

When all tests and works. have been completed, a System Handover is carried out. The System Handover Package is composed of the test records, drawings and diagrams for the whole system. This shall be forwarded upon the discipline engineer's approval, to the client for acceptance.

8.7.6

All inspection records and certificates are to be maintained by the QC Department. However, each discipline is responsible for the updating and filing of their records. These records shall form the Final Project Documentation.

8.7.7

The Final Documentation Index is to be submitted to the client for approval upon award of the contract. Reference Procedures: EJJV.QP.02-0, REV. 0 : Inspection and Test Status

8.8

Control of Inspection and Testing Equipment 8.8.1

The QC Department is to maintain and update an Equipment Register to indicate the calibration status of all the test equipment to be used.

8.8.2

Equipment requiring calibration shall be calibrated by an authorized third party. Calibration is to be traceable to standard practices. Records of calibration are to be maintained by the QC Department for retrieval and verification purposes.

8.8.3

Inspection and test equipment are to be maintained by competent technicians and stored in controlled conditions to maintain the accuracy of measurements when in use.

8.8.4

Each equipment shall be assigned a unique Identification Tag Number for traceability purpose. Reference Procedure: EJJV.QP.05-2, REV. 0 : Control Measuring and Testing Equipment


of

Page 18 OF 24

8.9

Control of Inspection and Testing Equipment 8.9.1

Materials received from CLIENT are inspected by the Material Coordinator/QC Inspector shall be tagged to classify whether they are: 8.9.1.1 8.9.1.2 8.9.1.3 8.9.1.4

Awaiting Inspection Rejected Accepted On hold

8.9.2

Rejected materials shall be segregated and identified to ensure that these are not used for whatever purposes.

8.9.3

The inspection shall be conducted in accordance with the relevant specifications and standards. The Material Coordinator/QC Inspector shall indicate the status and date of inspection on the items inspected.

8.9.4

Inspection conducted during offshore fabrication shall be recorded and documented using the standard Company formats contained in the applicable procedures. Results of inspection are to be indicated on the inspected items by using tag, permanent marker, label or color code.

8.9.5

Items which have undergone final inspection shall be tagged to facilitate an identification for future processing or opening, i.e. opening of flanges, vessels, etc. after the final inspection. Reference Procedure: EJJV.QP.08-0, REV. 0 : Material Handling, Storage Packaging & Delivery


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8.10

Control of Non-conforming Products and Corrective Action 8.10.1

Non-conforming products shall be segregated and identified. The nature of non-conformance will be recorded in the Non-conformance Report. When necessary, drawings or illustration shall be attached to provide the details and extent of the non-conformity.

8.10.2

The Non-conformance report shall be forwarded to the Project team Leader and copied to the client for approval of the proposed repair or disposition. The discipline engineer is to provide the necessary corrective action to be taken and the corresponding preventive measure.

8.10.3

The implementation of the proposed corrective action shall be monitored by the QA/QC Department in order to subject the item to the applicable inspection and testing. Only when the outcome of the test is satisfactory that the Hold tag on the item is removed and the item is released for use.

8.10.4

A Non-conformance Log shall be maintained by the QA/QC Department. The trend of non-conformities shall be recorded and monitored in order to develop preventive action to minimize the recurrence of a non-conformity.

8.10.5

For issues where a formal NCR is unnecessary, a punchlist shall be compiled and resolved progressively.

8.10.6

For non-conformance reports from the client, the NCR shall be registered first and then copied to the Project Quality Assurance Engineer and Project Lead Commissioning Engineers to determine the necessary corrective action.

8.10.7

Corrective and preventive action arising from the Company's audits shall be registered as project Corrective Action Requests, implemented and followedup to verify effectiveness. Reference Procedures: EJJV.QP.07-0, REV. 0 : Control of Non-conforming Products EJJV.QP.03-0, REV. 0 : Corrective and Preventive Action EJJV.QP.04-0, REV. 0 : Corrective and Preventive Action


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8.11

Handling, Storage, Packaging, Preservation and Delivery 8.11.1 Project Materials shall be stored, released and used in a controlled manner. Appropriate preservation methods and practice shall be used to maintain the integrity of the materials. 8.11.2 Materials shall be identified with the methods provided by the client specifications. Storage is carried out on racks and bins separating the materials b y location numbers and material color coding. 8.11.3 Accepted and issued materials shall be updated in the Material Inventory List. The Material Coordinator shall provide a copy of the list on a weekly basis. 8.11.4 Different types of materials are stored and preserved according to the Company relevant procedure. Special type of materials and products are to be separated and protected from the rest to avoid contamination, i.e. duplex steels. 8.11.5

The handling personnel and end-users shall be briefed with the appropriate methods of handling and use of certain type of materials thru Tool Box Meetings and Mobilization Briefing.

8.11.6

Fabricated pipe spools are to be protected by ends caps (plywood or rubber) prior to shipment at site. Duplex pipes shall be and covered with plastic sheets. Reference Procedure: EJJV.QP.08-0, REV. 0 : Material Handling, Storage Preservation and Delivery


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8.12

Quality Records 8.12.1

Project quality records comprise essential documentation that each department of the project team is maintaining. This includes but not limited to the following: 8.12.1.1

Contract documents, including contract review minutes of meeting, clarifications, change orders 8.12.1.2 Specifications 8.12.1.3 Company and Project quality procedures 8.12.1.4 Constructions, installation and commissioning procedures 8.12.1.5 Work instructions 8.12.1.6 Standards and codes 8.12.1.7 Field inspection reports 8.12.1.8 Equipment calibration reports 8.12.1.9 Human resources personnel records 8.12.1.10 Drawings (AFC & As-built) 8.12.1.11 Vendor's catalogues and data 8.12.1.12 Checksheets and handover records 8.12.1.13 Work package 8.12.2

Project records shall be retained and stored in the project files. They shall be archived in accordance with the procedures.

8.12.3

The Project Document Controller shall assign a unique index file code for each department to correspond with the type and names of records to be maintained, filed and updated.

8.12.4

Records shall be in A4 size sheet but those larger, as in drawings and catalogues may be reproduced or just filed as they are, provided the filing space is not restricted.

8.12.5

Audits shall be performed to verify the timely updating and completeness of records as mentioned above.

8.12.6

Upon the completion of the project, the QA/QC Department shall initiate the compilation and classification of project documents to be included in the final documentation. An index of the Final Documentation is to be submitted to the client for approval.

8.12.7

Back-up copies of electronic data shall be taken once a week and stored at the project document room for safekeeping. Latest anti-virus software shall be utilized.


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8.12.8

Mechanical binders for final documentation shall comply with the client's specification. The number of copies to be forwarded to the client is dictated by the contract. Reference Procedures: EJJV.QP.09-0, REV.O :

8.13

Control of Quality Records

Quality Assurance Audits and Quality Awareness Program 8.13.1

Audits shall be conducted during the project duration to verify compliance to this PQP. Auditing is to, be carried out as per the audit schedule which is submitted to the client at the start of the project.

8.13.2

Notice of audits shall be sent to the auditees and CLIENT shall be informed of the planned audit. The client may join the audit as observer. See attached Audit Schedule.

8.13.3

Non-conformance reports and Corrective Action Requests are compiled with the audit reports. Trends analysis of non-conformities shall be established and the QA/QC Department shall conduct follow-up audits to verify the implementation of corrective and preventive actions.

8.13.4

Tool box meetings, briefings, Quality suggestion scheme, and Quality slogan contests shall be initiated by the management. Reference Procedure: EJJV.QP.10-0, REV.0 : Quality Assurance Auditing

8.14

Training 8.14.1

Tool box meetings shall be conducted daily to explain and impart quality requirements to engineers and workforce. Topics of meetings are planned ahead and forwarded to CLIENT for information.

8.14.2

Attendance during tool box meetings is to be recorded. Action items and discussions shall be minuted and copied to CLIENT.

8.14.3

The Project Team Leader is responsible for the identification of all training and ensuring that appropriate training is made available.


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8.14.4

During the site phase of work, all personnel shall be inducted to safety and general project requirements. The Project Team Leader shall retain the following records relating to above: 8.14.4.1 A list of staff who have been inducted into the operation of the above procedures. 8.14.4.2 A list of all site personnel inducted into the site/vessel. Reference Procedure: EJJV.QP.HR.001, REV.O : Training and Personnel Develop

8.15

Project Statistical Data 8.15.1

The QA/QC Department shall submit the following reports to CLIENT on a weekly basis: Welder Repair Rate Welder's Repair Rate Non-conformance Breakdown Report Non-conformance Trend Analysis Report

8.15.2

Welding Repair rate for piping is calculated on "as per weld basis", which is the number of weld joints repaired divided by the total joints tested. For structural welding, the repair rate is the length of repair divided by the total length of weld tested

8.15.3

The maximum allowable repair rate for welders shall be 3%. Welders who exceed shall be sent a first warning. Failure to improve after one week shall require the welder to re-qualify.


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2.0 Project Quality Control Plan

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