00-ZA-E-G09600_00A

HASBAH & ARABIYAH OFFSHORE & ONSHORE FACILITIES Contract No (OOK) 6600026283 / (IK) 6600026284 Document No. 00-ZA-E-G09600 PROJECT QUALITY PLAN

Rev. 00A

Date 06 June 2013

Sheet 2 of 64

AMENDMENTS AND REVISIONS Amendment and rev.

Date

Page

Description

Project Director

X01

27.03.2011

All pages

Issued for IDC

GS

A

04.04.2011

All pages

First Issue to COMPANY for Approval

GS

Second issue to Company with comments incorporated (ref AOC –OPMD-SL0175) :  00

22.10.2011

All pages as appl

 

Included document numbers for documents as referenced in the PQP (all pages as applicable) Added a list of controlled copy holders as per SAEP-1154 Para 4.1.7 (page 37) Included the BI # ‘s (main / cover sheet)

GS

Note: Document Number changed from GN00-A-A-Q-PG-00001 of previous rev into 00-ZA-E-G09600 in accordance with Document Control and review Procedure 00-ZA-E-G09805 last appl. revision Third issue to Company . Re issued for Construction (previous rev 00 Company approved) 00A

06 June 2013

All pages Revised scope to include portion of 36” CLAD Offshore Trunkline as appl Replacement Revised for general update as appropriate to reflect changes on the Project, Quality practices and as per QMS review outputs.

CC


Rev. 00A

Date 06 June 2013

Sheet 3 of 64

INDEX AMENDMENTS AND REVISIONS .................................................................................................................... 2 INDEX................................................................................................................................................................. 3 1.

INTRODUCTION ...................................................................................................................................... 6

2.

SCOPE AND PURPOSE ......................................................................................................................... 6

3.

PROJECT DESCRIPTION ...................................................................................................................... 7

4.

PROJECT DEFINITIONS, ABBREVIATIONS, AND ACRONYMS ...................................................... 10 4.1

DEFINITIONS ................................................................................................................................... 10

4.2

ABBREVIATIONS AND ACRONYMS ............................................................................................. 12

5.

REFERENCE RULES, CODES AND STANDARDS ............................................................................ 15 5.1

CODES AND STANDARDS ............................................................................................................. 15

5.2

COMPANY DOCUMENTS ............................................................................................................... 15

5.3

CONTRACTOR DOCUMENTS ........................................................................................................ 17

6.

QUALITY MANAGEMENT SYSTEM .................................................................................................... 18 6.1

GENERAL ........................................................................................................................................ 18

6.2

CONTRACTOR’S QMS APPLICABLE PROCESSES .................................................................... 19

6.3

QUALITY SYSTEM DOCUMENTS (QSD) ....................................................................................... 37

6.4

CONTROL OF DOCUMENTS .......................................................................................................... 37

6.5 7.

6.4.1

Control of Project Quality Plan ............................................................................................... 37

6.4.2

Quality System Documents .................................................................................................... 38

6.4.3

Document & Data Control ....................................................................................................... 38

CONTROL OF RECORDS ............................................................................................................... 39 MANAGEMENT RESPONSIBILITY ...................................................................................................... 39

7.1

MANAGEMENT COMMITMENT ...................................................................................................... 39

7.2

COMPANY FOCUS ......................................................................................................................... 39


Rev. 00A

Date 06 June 2013

Sheet 4 of 64 7.3

PROJECT QUALITY POLICY .......................................................................................................... 41

7.4

PLANNING ....................................................................................................................................... 42

8.

7.4.1

Quality Objectives ................................................................................................................... 42

7.4.2

Quality Management System Planning .................................................................................. 42

7.4.3

Document & Data Control - Control of Records .................................................................... 43

ORGANIZATION ................................................................................................................................... 44 8.1

CONTRACTOR ORGANIZATION ................................................................................................... 44

8.2

RESPONSIBILITIES AND AUTHORITIES ...................................................................................... 44

9.

INTERNAL COMMUNICATION ............................................................................................................ 47

10.

MANAGEMENT REVIEW ...................................................................................................................... 47

11.

RESOURCE MANAGEMENT ............................................................................................................... 48 11.1 PROVISION OF RESOURCES ........................................................................................................ 48 11.2 HUMAN RESOURCES ..................................................................................................................... 48 11.2.1

General ................................................................................................................................... 48

11.2.2

Competence, Awareness, and Training ................................................................................. 49

11.3 INFRASTRUCTURE ......................................................................................................................... 49 11.4 WORK ENVIRONMENT ................................................................................................................... 50 12.

PROJECT EXECUTION ........................................................................................................................ 50 12.1 PLANNING OF PROJECT EXECUTION ......................................................................................... 50 12.2 CUSTOMERS RELATED PROCESSES ......................................................................................... 50 12.2.1

Determining Project Requirements......................................................................................... 50

12.2.2

Reviewing Project Requirements ........................................................................................... 51

12.2.3

Customer Communication ...................................................................................................... 51

12.3 DESIGN AND DEVELOPMENT ....................................................................................................... 51 12.3.1

Design and Developing Planning ........................................................................................... 52

12.3.2

Design and Development Inputs ............................................................................................ 52

12.3.3

Design and Development Outputs.......................................................................................... 53

12.3.4

Design and Development Review .......................................................................................... 53

12.3.5

Design and Development Verification .................................................................................... 54

12.3.6

Design and development validation........................................................................................ 54


Rev. 00A

Date 06 June 2013

Sheet 5 of 64 12.3.7

Control of Design and Development Changes ....................................................................... 54

12.4 PROCUREMENT .............................................................................................................................. 54 12.4.1

Material & Equipment ............................................................................................................. 55

12.4.2

Services .................................................................................................................................. 55

12.4.3

Procurement Information ........................................................................................................ 56

12.4.4

Verification of Purchased Product / Services ......................................................................... 56

12.5 PRODUCTION AND SERVICE PROVISION ................................................................................... 56 12.5.1

Control of Production and Service Provision .......................................................................... 56

12.5.2

Validation of Processes for Production and Service .............................................................. 57

12.5.3

Identification and Traceability ................................................................................................. 57

12.5.4

Saudi Aramco Property. ......................................................................................................... 58

12.6 CONTROL OF MONITORING AND MEASURING DEVICES ......................................................... 58 13.

MEASUREMENT, ANALYSIS AND IMPROVEMENT .......................................................................... 59 13.1 GENERAL ........................................................................................................................................ 59 13.2 MONITORING AND MEASURING ................................................................................................... 59 13.2.1

Customer Satisfaction ............................................................................................................ 59

13.2.2

Internal Audit........................................................................................................................... 59

13.2.3

Monitoring and Measuring of Processes ................................................................................ 60

13.2.4

Monitoring and Measuring of the Work .................................................................................. 60

13.3 CONTROL OF NON-CONFORMING PRODUCT ............................................................................ 61 13.3.1

Control of Non-Conformance during design phase ................................................................ 62

13.3.2

Control of Non-Conformance during Procurement ................................................................. 62

13.3.3

Control of Non-Conformance during Fabrication.................................................................... 62

13.4 ANALYSIS OF DATA ....................................................................................................................... 62 13.5 IMPROVEMENTS ............................................................................................................................. 63 13.5.1

Continual Improvement .......................................................................................................... 63

13.5.2

Corrective Action and Preventative Action ............................................................................. 64


Rev. 00A

Date 06 June 2013

Sheet 6 of 64

1.

INTRODUCTION

Saudi Arabian Oil Company (Saudi Aramco) has awarded the Contract to Saipem group for Detail Design, Procurement, Fabrication, Transportation, Installation, Hook-up and Pre-commissioning of Arabiyah and Hasbah offshore facilities. This Project will provide grass root facilities to produce 2,500 MMSCFD of Hasbah and Arabiyah non-associated raw Khuff gas. Processing Hasbah and Arabiyah gas is expected to produce 1,700 MMSCFD of sales gas. The facilities to be provided with these budget items include new offshore gas production and tie-in platforms as well as the associated power supply, pipelines, and telecommunication system. The Arabiyah and Hasbah offshore fields are located approximately 150 kilometers northeast of Jubail and 250 kilometers north of Dhahran. The new facilities will be installed in medium depth waters of 40-60 meters and at some 150 -180 kilometers north east of Wasit Gas Plant. Offshore facilities are unmanned and control/monitoring is at the central control room of Manifa processing facility (MPF) with monitoring at Wasit Gas Plant (WGP). Design Engineering and Procurement will be carried out at Saipem Sharjah offices (Main and Design Offices) as well as at Saipem Fano Offices (Italy) – specifically to Pipelines & Cables E& P programme. Fabrication works will be carried out in STAR fabrication yard in Dammam, approximately 400 kilometers north east of Riyadh, Saudi Arabia, CONTRACTOR Dammam Base located 40 kilometers far from the STAR yard and P.T. Saipem Indonesia yard located in Karimun island (OOK). The offshore activities for Transport and Installation of facilities will be performed by the vessel Castoro II and Castoro 8 and relevant marine spread in support.

2.

SCOPE AND PURPOSE

This document defines the Project Quality Management system applied by CONTRACTOR for the realization of ARABIYAH & HASBAH OFFSHORE and ONSHORE FACILITIES PROJECT” through Engineering, Procurement, Construction and pre commissioning phase encompassing development of the offshore Arabiyah and Hasbah fields, located in the Arabian Gulf. This PQP applies to the entire scope of work of the OOK CONTRACT # 6600026283 and the IK CONTRACT #6600026284, as described in at clause 2 below. This PQP applies as well to the entire scope of the IK CONTRACT # 6600029102 which has been awarded to CONTRACTOR at later stage for the design, procurement of material including the CLAD linepipe required for the WORK, fabrication, transportation, installation, tie-in, cleaning and testing of the below portion of submarine pipelines:


Rev. 00A

Date 06 June 2013

Sheet 7 of 64 ARABIYAH Field 

One (1) 36” Trunk line section from the flange at the end of Arabiyah Platform tie-in spool up to where the gas temperature is lower than 48.9° C (120° F) (approximately 7km long). HASBAH Field 

One (1) 36” Trunk line section plus 4” piggy back HDO line from the flange at the end of Hasbah Platform tie-in spool up to where the gas temperature is lower than 48.9° C (120° F) (approximately 10km long).

The integration of the two main contracts with the “36” CLAD lines” Contract is considered a key factor for their successful completion.

The project quality system shall comply with contractual obligations and conform to the requirements of:  Schedule Q  Saudi Aramco Standards as applicable  the ISO 9001:2008 International Standard

3.

PROJECT DESCRIPTION

Arabiyah and Hasbah are offshore fields located in Arabian Gulf approximately 150 kilometers northeast of Jubail, 250 kilometers north of Dhahran. The fields lay in medium-depth waters in range of 40-60 meters. The new Arabiyah-Hasbah gas offshore platforms will be installed some 150-180 kilometers north-weast of the Wasit Gas Plant. Each of the single well offshore platforms will connect to a field Tie-in Platform (one Tie-in platform will be installed for each field). The Arabiyah gas field comprises one tie-in platform, six wellhead platforms, pipelines and onshore receiving facilities. Intra-field flowlines connect wellhead platforms to the Tie-in Platform ARBI-TP-1 and the commingled production is exported via a 36” trunk-line to Wasit Gas Plant. The trunkline is approximately 128.5 km offshore and 30 km onshore buried. The first 7 km of trunkline, after the TP’s corridor spools, shall be internally cladded with CRA and the remainder of the trunkline to the onshore plant shall be internally FBE coated. The Hasbah gas field comprises one tie-in platform, seven wellhead platforms, pipelines and onshore receiving facilities. Intra-field flowlines connect wellhead platforms to the Tie-in Platform HSBH-TP-1 and the commingled production is exported via a 36” trunk-line to Wasit Gas Plant. The trunkline is approximately 125.5 km offshore and 30 km onshore buried. The first 10 km of trunkline, after the TP’s corridor spools, shall be internally cladded with CRA and the remainder of the trunkline to the onshore plant shall be internally FBE coated The CONTRACTOR shall be responsible for developing the offshore and onshore facilities for Arabiyah and Hasbah Field. The primary facilities of Arabiyah and Hasbah Offshore/Onshore Facilities are divided into two main Packages as part of the Invitation for Proposal (IFP) based on Lump Sum Turn Key (LSTK) Contract Requisitions to cover the


Rev. 00A

Date 06 June 2013

Sheet 8 of 64 design, procurement, transportation, fabrication and installation of the Arabiyah and Hasbah offshore platforms, pipelines, submarine cables and Wellhead Hook up and pre-commissioning and are listed as follows: 

Offshore facilities:

   

One (1) tie-in platform (ARBI TP-1) including; jacket, deck, bridge, flare and bridge support jackets;



One (1) 12”OD (5L X-65) offshore internally coated MEG injection pipeline from beach valve station to IIP (Intermediate injection platform) (with a total length of 75 km). The Work including the dredged shore pull trenches;



One (1) 10.75”OD (5L X-65) internally coated MEG injection pipeline from II-P (Intermediate injection platform) to the ARBI TP-1 (approx. length of 50 km);



Six (6) internally clad 12”OD (5L X65) high pressure gas flowlines from the wellhead platforms to ARBI TP-1 (with a total length of 25 km);

 

One (1) 4” OD flexible and subsea valve skid connecting II-P to 36” OD Arabiyah trunkline;



One (1) composite submarine cable (15-kV power with an internal fiber optic core) from shore at Abu Ali to II-P (approx. length of 43 km). Work includes a dredged shore approach and onshore cable tie-in at Abu Ali GOSP;



One (1) composite submarine cable (15-kV power with an internal fiber optic core) from ARBI TP-1 to IIP (with a total length of 50 km long);

    

Six (6) ICCP systems for each wellhead platforms;



One (1) 10.75”OD (5L X-65) internally coated MEG injection pipeline from II-P (Intermediate injection platform) to the HSBH TP-1 (approx. length of 50 km);

One (1) Intermediate MEG injection platform (II-P) including jacket and deck; Six (6) Decks for new wellhead platforms (jackets built and pre-installed by others); One (1) 36”OD (5L X-65) offshore internally coated Arabiyah trunkline from beach valve station to ARBI TP-1 (approx. length of 130 km). The Work including the dredged shore pull trenches; the section from the flange at the end of Arabiyah Platform tie-in spool up to where the gas temperature is lower than 48.9° C (120° F) (approximately 7km long) shall be made of Internally CLAD linepipe and not Internally coated.

Six (6) composite submarine cables (15-kV power with an internal fiber optic core) from ARBI TP-1 to Wellhead platforms (with a total length of 25 km);

Six (6) Wellhead Hook ups, pre-commissioning and SCADA integration for Arabiyah Wellhead Platforms; One (1) tie-in platform (HSBH TP-1) including; jacket, deck, bridge, flare and bridge support jackets; Seven (7) Decks for new wellhead platforms (jackets will be built and pre-installed by others); One (1) 36”OD (5L X-65) offshore internally coated Hasbah trunkline from beach valve station to HSBH TP-1 (approx. length of 130 km). The Work including the dredged shore pull trenches; the section from the flange at the end of Arabiyah Platform tie-in spool up to where the gas temperature is lower than 48.9° C (120° F) (approximately 7km long) shall be made of Internally CLAD linepipe and not Internally coated.


Rev. 00A

Date 06 June 2013

Sheet 9 of 64





Seven (7) internally clad 12”OD (5L X65) high pressure gas flowlines from the wellhead platforms to HSBH TP-1;

 

One (1) 4” OD flexible and subsea valve skid connecting IIP to 36” OD Arabiyah trunk line;



One (1) composite submarine cable (15-kV power with an internal fiber optic core) from MRJN GOSP-2 to HSBH TP-1 (approx. length of 45 km);



One (1) composite submarine cable (15-kV power with an internal fiber optic core) from HSBHI TP-1 to II-P (approx. length of 50 km);

 

Seven (7) ICCP systems for each wellhead platforms;



One (1) 6” offshore elemental sulfur solvent injection pipeline from beach valve station to II-P (intermediate injection platform) (approx. length of 75 km). The Work includes the dredging of the shore pull trenches. Pipeline shall be piggybacked on the 36” Hasbah Trunkline;



One (1) 4” elemental sulfur solvent injection pipeline from II-P (intermediate injection platform) to the HSBH TP-1 (approx. length of 50 km). Pipeline shall be piggybacked on the 36” Hasbah Trunkline.

Seven (7) composite submarine cables (15-kV power with an internal fiber optic core and tubes for elemental sulfur solvent injection) from HSBH TP-1 to Wellhead platforms (with a total length about 35 km);

Seven (7) Wellhead Hook ups, pre-commissioning and SCADA integration for Hasbah Wellhead Platforms.

Onshore facilities:



Two (2) 36”OD (5L X-65) onshore trunklines for Arabiyah and Hasbah from shoreline to Wasit Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP (approx. length of 60 km);



One (1) 12”OD (5L X-65) MEG onshore pipeline from shoreline to Wasit Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP (approx. length of 30 km);

 

DCS at Manifa CCR; One (1) 6” elemental sulfur solvent onshore pipeline from shoreline to Wasit Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP (approx. length of 30 km). Pipeline shall be buried 1.0 m deep and parallel to the route of 36” HSBH Trunkline.


Rev. 00A

Date 06 June 2013

Sheet 10 of 64

4. 4.1

PROJECT DEFINITIONS, ABBREVIATIONS, AND ACRONYMS DEFINITIONS

CONTRACT

Contract No. IK 6600026284 Procurement, Fabrication, Transportation and Installation for ARABIYAH & HASBAH Platforms, Pipelines, Cables, Hookups, and Pre-commissioning Contract No. OOK 6600026283 Detailed Design. Materials Procurement, Fabrication, Transportation of ARABIYAH & HASBAH Platforms, Pipelines, Cables, Hookups, and Pre-commissioning Contract No. 6600029102 ARABIYAH & HASBAH 36” Offshore Trunkline CLAD Section Replacement

COMPANY

SAUDI ARABIAN OIL COMPANY (IK) / ARAMCO Overseas Company B.V. (OOK)

CONTRACTOR

Snamprogetti Saudi Arabia Ltd (IK) and Saipem S.p.A. (OOK)

SUBCONTRACTOR

Company selected by CONTRACTOR to perform some work described in this document.

Appraisal

Assessment of a supplier’s capability of controlling quality, carried out before placing orders

Certification

The authoritative act of documenting compliance with requirements

Compliance

An indication or judgment that the product or service meets the requirements of the relevant specification or regulation; also the state of meeting the requirements

Corrective Action

Action taken to eliminate the causes of an existing nonconformity, defect or other undesirable situation in order to prevent recurrence.

Defect

Non-fulfillment of an intended usage requirement or reasonable expectation, including one concerned with safety.

Documentation

Any recorded or pictorial information describing, defining, procedures or results.

Hold Point

Work will be held until the inspection or test has been satisfactorily completed.

Improvement

Actions taken by CONTRACTOR to increase the effectiveness and efficiency of activities and processes in order to provide added benefits to both CONTRACTOR and its SUBCONTRACTOR’s.


Rev. 00A

Date 06 June 2013

Sheet 11 of 64 Inspection

An activity such as measuring, examining, testing or gauging one or more characteristics of an entity and comparing the results with specified requirements in order to establish whether conformity is achieved for each characteristic.

Non-conformity

Non-fulfillment of a specified requirement

Procedure

A specified way to perform an activity

Process

Set of inter-related resources and activities which transform inputs into outputs.

Product

Result of activities or processes

PROJECT

The execution of the contractual scope of work awarded.

Quality

The totality of characteristics of an entity that bear on its ability to satisfy stated and implied needs

Quality Assurance

All the planned and systematic activities implemented within CONTRACTOR’s quality system, and demonstrated as needed to provide adequate confidence that an entity will fulfill requirements for quality.

Quality Audit

A systematic and independent examination to determine whether quality activities and related results comply with planned arrangements and whether these arrangements are implemented effectively and are suitable to achieve objectives.

Quality Control

CONTRACTOR employs operational techniques and activities that are used so that its operations and services conform to the quality requirements as laid down in Company’s documents

Quality Management

All activities of the overall management function that determine the quality policy, objectives and responsibilities, and implement them by means such as quality planning, quality control, quality assurance and quality improvement with CONTRACTOR’s Quality System

Quality Plan

A document setting out the specific quality practices, resources and sequence of activities relevant to a particular project, service, contract or product

Quality Policy

The overall intentions and direction of an organization with regard to quality, as formally expressed by top management

Quality Surveillance

The continuous monitoring and verification of the status of an entity and analysis of the records to ensure that specified requirements are being fulfilled.

Quality System

CONTRACTOR’s organizational structure, procedures, processes and resources needed to implement quality management

Repair

Action taken on a non-conforming product so that it will fulfill the intended usage requirements although it may not conform to the originally specified requirements


Rev. 00A

Date 06 June 2013

Sheet 12 of 64 Review

An independent assessment undertaken by an individual or group, of the area under review.

Rework

Action taken on a non-conforming product so that it will fulfill the original requirement

Safety-related

Pertaining to those items of plant, the satisfactory performance of which is important to the prevention of consequences of such accidents

Service

The results generated, by activities at the interface between the supplier and the customer and by supplier internal activities to meet customer needs

Service delivery

Those supplier activities necessary to provide the service

Specification

The document that prescribes in detail the requirements with which the product or service has to comply

Standard

A document approved by a generally recognized body which results from the process of formulating and applying rules for an orderly approach to a specific activity

Supplier

Any individual or organization that furnishes items or services to a procurement document (PO)

Test

The determination or verification of the capability of an item to meet specified requirements by subjecting the item to a set of physical, chemical, environmental or operating conditions

Traceability

The ability to trace the history, application or location of an entity by means of recorded identifications

Waiver

Written authorization to use or release a product or service which does not conform to the specified requirements

Witness Point

The inspection will be witnessed by inspection of QC staff

4.2

ABBREVIATIONS AND ACRONYMS

CAR

Corrective Action Request

CR

Contract Requisition

CTR

CONTRACTOR

EIM

ENGINEERING INTEGRATION MANAGER (the system to share, harmonize and manage documents inside a global repository)

DC

Document Controller

DPQP

Discipline Project Quality Plan


Rev. 00A

Date 06 June 2013

Sheet 13 of 64 EIL

Exception Items List

EDRs

Equipments/Material Delivered Reports to Site

HR

Human Resources

KOM

Kick Off Meeting

IK

In Kingdom

ICCP

Impressed Current Cathodic Protection for Large Structure

LBE

Log Book Entry

OOK

Out of Kingdom

MEG

Mono Ethylene Glycol

MDR

Master Document Register

PAR

Preventive Action Request

PCP

Process Control Procedures

PD

Project Director

PE

Project Engineer

PMT

Project Management Team

PO

Purchase Order

PQI

Project Quality Index

PQMP

Project Quality Management Procedures

PQP

Project Quality Plan

PQM

CONTRACTOR Project QA Manager

QCP

Quality Control Plan

QMS

Quality Management System

QSD

Quality System Documents

RTFI

RT Films Interpreter

SA

Saudi Aramco

SAIC

Saudi Aramco Inspection Checklist

SATIP

Saudi Aramco Typical Inspection Plan

SATR

Saudi Aramco Test Report

SOW

Scope of Work


Rev. 00A

Date 06 June 2013

Sheet 14 of 64 SUBC

SUBCONTRACTOR

T&I

Transport and Installation

TBA

To Be Advised

TBC

To Be Confirmed

TPI

Third Party

VO

Variation Order (Change Order)

WI

Work instruction


Rev. 00A

Date 06 June 2013

Sheet 15 of 64

5.

REFERENCE RULES, CODES AND STANDARDS

5.1

CODES AND STANDARDS

Ref

Document Number

Title

1. ISO 9001:2008

Quality Management System – Requirements

2. ISO 9000:2005

Quality Management System – Fundamentals And Vocabulary

3. ISO 10005:2005

Quality Management – Guidelines For Quality Plans

5.2

COMPANY DOCUMENTS

Ref

Document Number

Title

1. 6600026284

Contract (IK)

2. 6600026283

Contract (OOK)

3. 6600029102

Contract ARABIYAH & HASBAH 36” Offshore Trunkline CLAD Section Replacement

4. Schedule A

General Terms and Conditions

5. Schedule B

Job Specification

6. Schedule D

Safety, Health and Environmental Requirements

7. Schedule G

Materials, Tools and Equipment

8. Schedule H

Special Terms and Conditions

9. Schedule Q

Quality Requirements

10. SA Desktop Standards

Saudi Aramco Engineering Standards and Procedures (SAEPs, SAESs, SAERs, SAMSSs, SABPs), June 2010

11. SA Desktop Standards

Saudi Aramco SATIPs, SAICs and SATRs, June 2010

12. PE-GTH386

Arabiyah and Hasbah Platforms, Power and Subsea Pipelines – Project Summary


Rev. 00A

Date 06 June 2013

Sheet 16 of 64 Ref

Document Number

Title

13. PE –GTP999

Engineering Requirements

14. PE-GTP327

Engineering, Design and Procurement of Offshore Platform, Jackets, Decks, Pipelines and Cables - SoW

15. PE-GIP028

Fabrication, Transportation and Installation of Jackets, Decks, Flare Platforms and Bridges - SoW

16. PE-GIP026

Fabrication, Transportation and Installation of Offshore Pipelines, Submarine Composite Power Cables, Impressed Current Cathodic Protection (ICCP) Anode Sleds/Cables - SoW

17. RE-COM010

Communication Systems

18. RE-COM020

Communication Systems for ARBI-TP-2

19. PE-GTP109

Well Hook-up - SoW

20. SAEP-1154

Guidelines for CONTRACTOR's Quality Plan

21. SAEP-103

Metric Units of Weight and measure

22. SAEP-127

Security and Control of Saudi Aramco Engineering Data

23. SAEP-202

Saudi Aramco Engineering Drawing Preparation

24. SAEP-302

Instructions for Obtaining a waiver of a mandatory Saudi Aramco Engineering Requirements

25. SAEP-303

Engineering Reviews of Project Proposal and Detail Design Documentation

26. SAEP-334

Retrieval, Certification & Submittal

27. SAEP-122

Project Records

28. SAEP-14

Project Proposal

29. SAER-1972

Saudi Aramco Materials Inspection and Testing


Rev. 00A

Date 06 June 2013

Sheet 17 of 64

5.3

CONTRACTOR DOCUMENTS

Ref

Document Number

Title

1. 00-ZA-E-G09000

Project Work Execution Plan and Procedures

2. 00-ZA-E-G09601

Procurement Quality Plan

3. 00-ZA-E-G09694

QA/QC Requirements for Suppliers of Materials and Equipments

4. 00-ZA-E-G09695

QA/QC Plan for Procurement

5. 00-ZA-E-G09700

Procurement Plan

6. 00-ZA-E-G09701

Subcontracting Plan

7. 00-ZA-E-G09805

Document Control and Review Procedure

8. 00-ZA-E-G09806

Coordination Procedure

9. 00-ZA-E-G09801

Planning and Scheduling Procedure

10. 00-ZA-E-G09802

Project Reporting Procedure

11. 00-ZA-E-G09803

Progress Measurement Procedure

12. 00-ZA-E-G09602

Audit Procedure

13. 00-ZA-E-G09603

Corrective and Preventive Action Procedure

14. 00-ZA-E-G09604

Non Conformance Management Procedure

15. 00-ZA-E-G09609

Material Management and Control

16. 00-ZA-E-G09622

Pipe Tracking system Procedure

17. 00-ZA-E-G09607

Control and Monitoring of Measurement Devices


Rev. 00A

Date 06 June 2013

Sheet 18 of 64

6.

QUALITY MANAGEMENT SYSTEM

6.1

GENERAL

CONTRACTOR PQM in collaboration with the CONTRACTOR’s PMT, is responsible for the preparation and review of the Project Quality Plan in accordance with the CONTRACTOR’s standard criteria and the Contract. CONTRACTOR PQM is responsible for the issue, distribution and up-dating of the Project Quality Plan for the duration of the Project. CONTRACTOR PQM and the Project Director, assisted by the Quality Personnel, shall ensure that the content of this Plan is well understood and adhered to by all Project personnel. The Project Quality Personnel shall verify the implementation of this Plan and evaluate its adequacy, by means of monitoring and auditing the work performance in respect to the established quality objectives. Whenever necessary, the Project Quality Personnel will recommend corrective actions to the Project Management and verify their implementation and effectiveness. Quality Assurance activities shall be considered as normal working practices, assuring that the technical requirements of a Project are satisfactorily accomplished in accordance with approved procedures and work instructions. In order to satisfy the established objectives, the Quality Department shall carry out the following main activities. 

Development of Project Quality System Documents



Ensure that Saudi Aramco specification e.g. SAES, SAMSS, Form-175 etc is integrated in the procedures and specifications prepared for the purchase orders.



Ensures that procedures and instruction are issued for the performance of all procurement activities



Verify Supplier selection



Verify Pre-qualification of supplier and it’s specific manufacturing site, in case of a non-approved supplier



Ensures by qualified inspection that the work is carried out to required quality level



Ensures through document records that the work has been carried out and inspected satisfying the specified prescriptions.



Coordinate Internal Quality audits on Project to verify implementation of the corporate work instructions, Project quality requirements and follow-up of Corrective Actions



Supervise the planning of Quality Inspections of procurement, construction and pre-commissioning activities.



Prepare non-conformance reports as and when applicable.



Submit all documentation required by Projects Engineering and Project Management, to complete the Project Inspection record book as per SAEP-122.


Rev. 00A

Date 06 June 2013

Sheet 19 of 64 CONTRACTOR PQM or his nominee shall attend the scheduled work progress meeting. Any outstanding inspection concerns, including a review of outstanding logbook entries and NCR items shall be discussed. The Contactor has assigned PQM as the Management Representative for quality management system on this Project. He shall ensure that the Quality Management System is established, maintained and implemented and shall report to top management on six month basis – as minimum, and makes recommendations for quality system improvements whenever applicable. The management representative for quality shall assure that the Project team is aware of customer requirements regarding the Project.

6.2

CONTRACTOR’S QMS APPLICABLE PROCESSES

Refer to Matrix in the next pages.

ARABIYAH & HASBAH OFFSHORE/ONSHORE FACILITIES Contract No.: IK 6600026284; OOK 6600026283 Doc. No.: 00-ZA-E-G09600 PROJECT QUALITY PLAN

Rev.: 00A

Date: 06.06.2013 Sheet 20 of 64

Procedure / Activities / Responsibilities Matrix QA System requirement ISO 9001/ 2008

No

Resulting Document

Activity

Responsibility Prepare / Approve Act

Method to assure Compliance

Document of reference Project Documents

COMPANY DOC/ CONTRACTOR DOCUMENT

QUALITY MANAGEMENT SYSTEM 4.1 General Requirements

4.2.3 Documentation Requirements

1

Establish and CONTRACTOR Project Program

2

1


Implementatio n / review

QAM

PD

00-ZA-E-G09600 Project Quality Plan

Approval of CONTRACTOR Project specific Procedures

Project Control Procedures

Approval Review

PLE / PCM

PD

00-ZA-E-G09805 Document Control and Review Procedure

Establish CONTRACTOR Project documents control system for: - Contract documents - Project technical documents - Project correspondence - Project procurement documents - Certification inspection records -subcontracted engineering documents

Document Control and Review Procedure

Review / Document Control / Audit

DC / PE / / PC /QAM

PD


2

Log, file, distribute in / out CONTRACTOR Project documents

Transmittal forms in / out Correspondence Log

Periodical verification

SECR / DC

PD

3

Up-date CONTRACTOR Project documents list


DC

PD

4

Sign outgoing Project correspondence, review incoming correspondence and establish documents distribution

SECR

PD

PD – Project Director QAM - Project Quality Manager PCM – Project Control Manager DC - Document Controller

PE – Project Engineer SECR - Secretary PLE – Planning Engineer PQE – Project Quality Engineer

approve Quality

/


Index of Project files and registers

Electronic file

QCS – Quality Control Supervisor HSEM – Project HSE Manager HSE - Project HSE Engineer CA – Contract Administrator


ICT – Information Communication & Technology QCM – Quality Control Manager CM – Contract Manager

00-ZA-E-G09805 Document Control and Review Procedure 00-ZA-E-G09805 Document Control and Review Procedure 00-ZA-E-G09805 Document Control and Review Procedure

OM – Operation Manager CC - Cost Controller PC – Procurement Coordinator

PM - Project Manager NDE – Non-destructive examination ASS – Asset IM – Interface Mngr.

FC – Construction Coordinator QCI – Quality Control Inspector PEM – Project Engineering Mngr. PSL – Project Specialist Leader


Rev.: 00A

Date: 06.06.2013 Sheet 21 of 64


No

Resulting Document

Activity

5

Log in/out, file, distribution of Project correspondence and technical documents Collection of superseded documents

6

Preparation, control and approval of Project quality records Identification and collection of Quality Records

Index of Project Files List of quality records





SECR / DC

PD


Review

QAM

QAM


00-ZA-E-G09802 Project Reporting Procedure Quality Control Plans to cover all items / phases of the Supply or of the Work will be developed. Samples of such QCP are listed below: - Quality Control Plan for Dredging & Backfilling - Quality Control Plan for Diving Activities - Quality Control Plan for Positioning Services - QCP for Pile Dynamic Monitoring System - QCP for Jacket Grouting, Free Span Correction & Pipeline Crossing - QCP for WHP Installation - QCP for TIP Installation - QCP for Pipelay CII - QCP for Pipelay C8 - Quality Control Plan for Survey - Quality Control Plan for Pre-commissioning Activities - Quality Control Plan for Hook up Activities








Dedicated SATIP, WI-SMS-QUAL-107-E Project Quality Control Plan development WI-SPA-OOFS-203-E Management and execution of offshore construction operations WI-SMS-QUAL-115-E Quality records in Offshore Construction Operations



Rev.: 00A

Date: 06.06.2013 Sheet 22 of 64


No

7

Resulting Document

Activity

Establish Project Reporting System Approval of Project Reporting Documents

Project Reporting Procedure / Monthly Reports


Verification


PLE

PD


00-ZA-E-G09801 Planning and Scheduling Procedure 00-ZA-E-G09803 Progress Measurement Procedure

8

Collection of records and preparation of As-Built Dossier

Final as-Built Dossier

Verification

QCS / DC / QAM

PD


WI-SMS-PCON-102-E Offshore Project Progress Planning and Monitoring WI-SMS-PCON-103-E SUBCONTRACTOR Progress and Planning WI-SMS-OOFS-111-E Offshore Site “As-Built” Documentation

MANAGEMENT RESPONSIBILITY 1

Establish overall project quality policy and objectives

Project Quality policy and objectives

Review / audit

QAM

PD

Project Quality Policy 00-ZA-E-G09600 Project Quality Plan

Schedule B, Q DE 119885

2

Establish CONTRACTOR HSE management commitment and motivation

HSE Project policy

Review

HSEM

PD

Loss Prevention Plan for: 00-ZA-E-G85816 – Onshore Construction Activ 00-ZA-E-G85818 – Offshore Activities 00-ZA-E-G85816 – Fabrication Activities (and other relevant Project HSE Procedures)

WI-SMS-HSE-201-E Management commitment and motivation

5.2 Customer Focus

1

Establish compliance with contractual, statutory and regulatory requirements


Review / audit

QAM

PD

Project Quality Policy 00-ZA-E-G09600 Project Quality Plan

5.3 Planning

1

Establish overall Project Execution Plan

Project Execution Plan

Review

PEM/PM

PD

00-ZA-E-G09000 Project Work Execution Plan and Procedures

5.1 Management Commitment









Rev.: 00A

Date: 06.06.2013 Sheet 23 of 64


No



Verification of Minutes of meeting

PD/ team members

PD

Project Planning Procedure

Review

PLE / PCM

PD

00-ZA-E-G09801 Planning and Scheduling Procedure 00-ZA-E-G09803 Progress Measurement Procedure 00-ZA-E-G09000 Project Work Execution Plan and Procedures

WI-SMS-PCON-101-E Work breakdown structure development WI-SMS-PCON-002-E Offshore project progress planning and monitoring

Monitoring of progress planned for the Project

Planning schedule

Review

PLE / PCM

PD

00-ZA-E-G09801 Planning and Scheduling Procedure 00-ZA-E-G09803 Progress Measurement Procedure 00-ZA-E-G09000 Project Work Execution Plan and Procedures

WI-SMS-PCON-102-E Offshore project progress planning and monitoring

Approval of the overall Project Work Schedule

Project Work Schedule(s)

PLE/PCM

PM’s/ PD

3

Organize the internal kick off meeting

Presentation Minutes of Meeting

4

Establish overall Project Planning System

5


Responsibility Prepare / Approve Act PD

Project Organization charts

1


All PM’s / Discipline Mgr’s and PLE

Define overall Project organization

2

5.4 Responsibility, authority and communications

Resulting Document

Activity



Periodical review


Project Organization Charts

00-ZA-E-G09801 Planning and Scheduling Procedure 00-ZA-E-G09803 Progress Measurement Procedure





Rev.: 00A

Date: 06.06.2013 Sheet 24 of 64


5.5 Management Review

No

1

Resulting Document

Activity

Project Review meeting

Minute of meeting

Method to assure Compliance Review

Responsibility Prepare / Approve Act PEM/IM

PD




Schedule Q WI-SMS-OOFS-109-E Organisation of the Project Operational Meetings

2

Periodical review of the overall Project Quality system

3

HSE Management System review

4

Project close-out report

Audit

QAM

PD

00-ZA-E-G09600 Project Quality Plan 00-ZA-E-G09602 Audits Procedure

Project H&S and EMP Plan

Review/Audit

HSEM / HSE

PD

Loss Prevention Plan for: 00-ZA-E-G85816 – Onshore Construction Activ 00-ZA-E-G85818 – Offshore Activities 00-ZA-E-G85816 – Fabrication Activities (and other relevant Project HSE Procedures) 00-ZA-E-G85809 Project HSE Audit Plan

Close-out

Review

PLE / PCM / QAM / CA

PD

WI-SMS-HSE-216-E HSE management system revision

WI-SMS-OOFS-110-E Preparation of End of Project Data and CloseOut

Report

RESOURCE MANAGEMENT 6.1 Human Resources

1

Selection of trained and qualified key Project personnel

Personnel Resumes HR Plan

Training Control

HR

PD

6.2 Provision of resources

1

Training of personnel on safety and quality aspects

Training control

Training Control

HSE

PD





-

WI-SMS-HR-111-E Personnel Recruitment

00-ZA-E-G85807 Project HSE Training and Induction Plan

Schedule D Schedule Q


WI-SMS-HSE-203-E Development of HSE





Rev.: 00A

Date: 06.06.2013 Sheet 25 of 64


No

Resulting Document

Activity




COMPANY DOC/ CONTRACTOR DOCUMENT training program WI-SMS-HSE-109-E Firsts Aids training Program

6.3 Infrastructure

6.4 Work Environment

2

Training and qualification of welders and NDT inspectors (when applicable)

Welders Qualification Records N.D.T. Personnel Certificates

Inspection/ Review

1

Establish a Project main office & site offices

Office & camp layouts

Verification

PD

2

Provision and Maintenance of process equipment, workspace and associated utilities

Request of Consumables & computer assignation

Verification / Assets Audits

PD

Establish overall Project HSE and Environmental Plan

Project HSE & Environmental Plan

Review / Audits

1

QCS

QAM

Welders Qualification Procedures NDT Procedures

-

HSE

PD Loss Prevention Programmes and other relevant Project HSE Procedures Environmental Management Plan

2 PD – Project Director QAM - Project Quality Manager PCM – Project Control Manager DC - Document Controller

Approval of the Project HSE Plan PE – Project Engineer SECR - Secretary PLE – Planning Engineer PQE – Project Quality Engineer

Project HSE plan


Verification

HSE /


PD OM – Operation Manager CC - Cost Controller PC – Procurement Coordinator

WI-SMS-WELD-101-E Identification System for qualified welders WI-SMS-WELD-110-E Qualification and certification of NDT personnel

Schedule B Schedule B WI-SMS-HSE-211-E Safety Regulations WI-SMS-HSE-208-E Project HSE organization WI-SMS-HSE-303-E Project Environmental Management Plan




Rev.: 00A

Date: 06.06.2013 Sheet 26 of 64


No

Resulting Document

Activity





HSEM Preparation and approval of the overall Environmental Plan

1

1

3

Environmental Management Plan

Review / HSE Audits

HSE / HSEM

PD

Planning and execution of work

Project procedures Project Plan

Verification

IE/PEM

PM


WI-SMS-OOFS-101-E Project Manager and Job number assignment to an offshore construction project WI-SMS-OOFS-103-E Preparation of the Project Initial Execution Plan WI-SMS-OOFS-105-E Planning and Co-ordination of Offshore Contruction Engineering

Review of contractual documentation for: work scope contract specifications COMPANY philosophies regulatory requirements standards and codes clarifications

Contract Review Comments

Review

CA/PEM /CM

PD


WI-SMS-COFS-108-E Transfer of a contract for complex or non-complex projects WI-SMS-COFS-106-E Negotiation the offer for Offshore Construction Work WI-SMS-QUAL-110-E

PRODUCT REALISATION

7.1 Planning of product realisation

7.2 Customer related process









Rev.: 00A

Date: 06.06.2013 Sheet 27 of 64


No

Resulting Document

Activity




COMPANY DOC/ CONTRACTOR DOCUMENT Contract Review

7.3 Design & Development

2

Control of queries and concession requests (CONTRACTOR level) Change orders request

Variation order

Answer review

PE / CM / OM

PD


WI-SMS-OOFS-107-E Monitoring the project and contractual variations in offshore construction work

3

Complaints management

Complaints Reports

Review

QAM / PE / OM

PD


WI-SMS-QUAL-112-E Customer Climate Analysis

1

Establish engineering organization

Project Organization charts

Verification

PM

PD


2

Planning & management of technical project documents.

Minutes of meeting, transmittals, reports

Verification

PEM

PD


3

Establish list of authorized signatories

List of authorized signatories

Verification

PEM

PD

Technical document Distribution Matrix

4

Perform Design Verification of Technical documents

Self Check Check Print IDC check

Verification

PSL

PEM


5

Carry out Design Review as per schedule B – 4.10 Formalize relevant records in accordance with schedule.

Design Reviews MOM and reports.

Review

PEM

PD










Rev.: 00A

Date: 06.06.2013 Sheet 28 of 64


7.4 Purchase

No

Resulting Document

Activity




6

Design changes control Contract changes control

List of Engineering Changes / VO’s

Review

CA

PD

00-ZA-E-G09806 Coordination Procedure

7

Establish management of technical clarifications

Technical queries / concession request form

Verification

PEM/ QAM

PD

00-ZA-E-G09806 Coordination Procedure

1

Establish list of items to be procured

Material Take Off

Review

PE / PC

PD

00-ZA-E-G09700 Procurement Procedure 00-ZA-E-G09701 Subcontracting Plan 00-ZA-E-G09695 QAQC Plan for Procurement 00-ZA-E-G09694 QAQC Requirements for Suppliers of Materials and Equipments

Pre-qualification of suppliers / SUBCONTRACTORs Technical, commercial / logistic quality and safety requirements

Pre-qualification report External audits report

Review / external audits

PC / QAM / HSEM

PD

3

Establish list of vendors

Vendors List

Verification

PC

PD

4

Establish technical & quality requirements for vendors:

Procurement plan

Verification

PC / PE / QAM

PD

2





00-ZA-E-G09701 Subcontracting Plan

COMPANY DOC/ CONTRACTOR DOCUMENT WI-SMS-OOFS-107-E Monitoring the project and contractual variations in offshore construction work

WI-SMS-OOFS-106-E Planning & co-ordination of Purchasing and Contracts for Offshore construction work

List of SAUDI ARAMCO Approved Vendor STD-COR-PROC-001-E Vendor Management STD-COR-PROC-001-E Vendor Management

00-ZA-E-G09602 Audits Procedure SPC-COR-QUAL-001-E Quality Requirements for Vendors and Subcontractors – Low Criticality SPC-COR-QUAL-002-E Quality Requirements for Vendors and



STD-COR-QUAL-002-E Management of Quality Specifications for Vendors / SUBCONTRACTORs WI-SMS-QUAL-108-E Management of FC – Construction Coordinator QCI – Quality Control Inspector PEM – Project Engineering Mngr. PSL – Project Specialist Leader


Rev.: 00A

Date: 06.06.2013 Sheet 29 of 64


No

Resulting Document

Activity


Subcontractors – Medium Criticality SPC-COR-QUAL-003-E Quality Requirements for Vendors and Subcontractors – High Criticality

Vendors/SUBCONTRACT ORs Quality Specification SPC-SMS-HSE-401/402-E HSE Requirements for SUBCONTRACTORs

00-ZA-E-G09700 Procurement Procedure 00-ZA-E-G09701 Subcontracting Plan

STD-COR-PROC-002-E Requisitioning definition – Purchase Request Management STD-COR-PROC-004-E Purchase Order - Contract

6

Selection of SUBCONTRACTOR / supplier

Approved vendor list

Review

PE / PC

PD



7

Preparation of Purchase Order Verification of Purchase Order Approval of Purchase Order Preliminary check of sub-contracting plan Issue of Purchase Order to SUBCONTRACTOR / supplier

Purchases Order (PO)

Review/ Approval

PE / PC / QAM / HSE/CC

PD



8

Control of supplier performance Control of work program

Daily reports Corrective,

Inspection / Audits

QAM / PC / PE /

PD

00-ZA-E-G09603 Corrective and Preventive Action Procedure

STD-COR-PROC-007-E Inspection - testing


PD


Purchases request


PE / QAM / HSE


Issue of purchase requests: Review of Purchase Request: technical commercial / logistic quality requirements

5

Verification


00-ZA-E-G09695 QAQC Plan for Procurement







Rev.: 00A

Date: 06.06.2013 Sheet 30 of 64


No

9

10

Resulting Document

Activity

Control of progress Verify the completion of the order Monitor application of penalties Vendor performance evaluation Management of claims with SUBCONTRACTORs.

preventive action request

Inspection and testing Prepare / Submit Inspection level matrix Monitor scheduled inspection activities

Material / Inspection report

Verification of handling, Transport and Storage of materials

Packing List





PM/CA

Review

QCS Inspectio n Agency

PC

2-weeks Look Ahead Inspection Schedule Inspection and testing plans

STD-COR-PROC-007-E Inspection - testing

00-ZA-E-G09695 QAQC Plan for Procurement Review

Logistic Manager

PD

00-ZA-E-G09609 Material Management and Control Procedure

PE-GTH325; DE 119892 WI-SMS-OOFS-106-E Planning and Coordination of Purchasing and Contracts for Offshore Construction Works

7.5 Production and service provision

1

2


Issue process control and operations procedures for normal processes in fabrication phase and in installation phase

Project Procedures / Installation Construction / Operations Manuals

Review

Issue procedures for special processes in fabrication phase and in installation phase and perform

Project W.P.S., Welders Performance

Inspection / Review



PE / QAM

PD

NDE / QCS

QAM / PD


- Project Installation Manuals - Project Pre-commissioning Manuals (set of documents to be produced before work execution)

SATIPs, SAICs, SATRs

Fabrication Phase Procedures: Fabrication Welding Procedure NDT Procedures (RT Procedure, UT procedure,

PE-GTH325; DE 119886



WI-SMS-QUAL-115-E Quality records in Offshore Construction Operations



Rev.: 00A

Date: 06.06.2013 Sheet 31 of 64


No

Resulting Document

Activity

relevant qualifications:  Welding  Non Destructive Testing



Qualification Records, N.D.T. Procedures


MT procedure) Jacket Installation Procedures Welding procedure qualifications records for jacket inst. (welding book ) NDT Procedures (RT Procedure, UT procedure, MT procedure, if different from above NDT Procedures) Decks Installation Procedures Welding procedure qualifications records for deck inst. (welding book ) NDT Procedures (RT Procedure, UT procedure, MT procedure, if different from above NDT Procedures)


DE 119895; SAEP 1142 STD-COR-WELD-010-E Welding Procedure Qualification Activities STD-COR-WELD-009-E Project welding summary – including proposed and approved WPSs

Pipelines items Project Welding Summary for Sealines Welding Procedure Qualifications Record for Sealines (Welding Book - As Built) Automatic Ultrasonic Testing (AUT) Procedure for Sealines NDT Acceptance Criteria for AUT for 36” Sealines NDT Procedure for Sealines (RT Procedure, UT procedure, MT procedure)

3


Perform qualifications for personnel assigned to special processes in fabrication phase and in installation phase: PE – Project Engineer SECR - Secretary PLE – Planning Engineer PQE – Project Quality Engineer

Welders Performance Qualification Records Welders I.D. Tags


Review / verification of certificates

NDE / QCS


QAM / PD

Welders Qualification Procedures NDT Procedures



WI-SMS-WELD-101-E Identification System for qualified welders WI-SMS-WELD-110-E FC – Construction Coordinator QCI – Quality Control Inspector PEM – Project Engineering Mngr. PSL – Project Specialist Leader


Rev.: 00A

Date: 06.06.2013 Sheet 32 of 64


No

Resulting Document

Activity





Welders N.D. T. operators / Inspectors

N.D.T. Personnel Certificates

4

Verification if infrastructure for performance of operations is adequate

Audits reports

HSE Audits

HSE

PD

00-ZA-E-G85809 Project HSE Audit Plan 00-ZA-E-G85806 Project Event Reporting and Investigation Procedure

5

Management of Project materials in fabrication phase and in installation phase

Material Log

Review

PC

PD

Separate for the project specific activities and all procedures listed for fabrication and for T & I

WI-SMS-OOFS-106-E Planning and Coordination of Purchasing and Contracts for Offshore Construction Works

6

Management of suitable equipment in fabrications phase and in installation phase

Assets Register

Review

ASS

PD

7

Verification of adequate use of monitoring and measurement devices in fabrications phase and in installation phase

Instrument log Calibration log

Review

QCS

QAM

00-ZA-E-G09607 Control and Monitoring of Measuring Devices

WI-SMS-OOFS-108-E Control of Offshore Construction Project Documents

8

Availability of Project document and work instruction

Master Document register

Review / audits

DC/PE/

PCM/ QAM

Document Progress Register

9

Establish pipe tracking system

Pipe Tracking System Records

Review

PE/QAM

QAM

PTS Procedure




Qualification certification personnel



of

and NDT

WI-SMS-HSE-211-E Safety Regulations

WI-SPA-OOFS-205-E Handling projects materials for Offshore construction works PM - Project Manager NDE – Non-destructive examination ASS – Asset IM – Interface Mngr.



Rev.: 00A

Date: 06.06.2013 Sheet 33 of 64


7.6 Control of monitoring and measuring devices

No

Resulting Document

Activity




10

Establish weld and N.D.T. Plans

Welds and N.D.T. Plans

Review

QCS

PD

11

Identification, handling packing, storage and protection of Project materials

Materials packing list

Review

QCM

PD


12

Inspect, log of materials on receipt

Materials inspection Records

Inspection / Review

FC/ DC / QCS / QCI

PD


13

Verification of materials supplied from COMPANY are in compliance with requirements

Event Reports

Inspection / Review

1

Selection of equipment to be calibrated

Calibration Log

Review

QAM / QCM

PD


2

Perform Laboratory calibrations

Calibration certificates

Review

QAM / QCM

PD





COMPANY DOC/ CONTRACTOR DOCUMENT WI-SMS-OOFS-106-E Planning and Coordination of Purchasing and Contracts for Offshore Construction Works

PD




STD-COR-QUAL-003-E Management and Control of the Measuring Equipment WI-SMS-QUAL-104-E Control of Measuring Equipment FC – Construction Coordinator QCI – Quality Control Inspector PEM – Project Engineering Mngr. PSL – Project Specialist Leader


Rev.: 00A

Date: 06.06.2013 Sheet 34 of 64


No

Resulting Document

Activity





3

Perform Site Calibrations in fabrication phase and in installation phase

Calibration Reports

Review

QCS

QAM


STD-COR-QUAL-003-E Management and Control of the Measuring Equipment WI-SMS-QUAL-104-E Control of Measuring Equipment

4

Collate Calibration Records/Certificates and logs

Calibration book certificates

Verification

DC/PC

QAM


STD-COR-QUAL-003-E Management and Control of the Measuring Equipment WI-SMS-QUAL-104-E Control of Measuring Equipment

Establish measurement of COMPANY satisfaction

Customer satisfaction questionnaire

Meetings / permanent verification

QAM

PD


WI-SMS-QUAL-112-E Customer Complaints analysis

Planning and preparation of Project Audits Perform Project Audits (including follow-up) and issue Audit Report

Project Quality Plan Audit Report(s)

Review

QAM

PD

00-ZA-E-G09602 Audits Procedure

Perform Project audits (including follow-up) to SUBCONTRACTORs

Audit Report

Review

QAM

PD

00-ZA-E-G09602 Audits Procedure

MEASUREMENT, ANALYSIS AND IMPROVEMENT 8.1 General

1

8.2 Monitoring 1 and Measurement

2 PD – Project Director QAM - Project Quality Manager PCM – Project Control Manager DC - Document Controller








Rev.: 00A

Date: 06.06.2013 Sheet 35 of 64


8.3 Control of nonconforming products

No

Resulting Document

Activity





3

Establish and approval of Q.C. Plans for site process control activities performed and subject to inspection and testing

Q.C. Plan(s)

Review / audit

QAM / QCM

PD

Specific Quality Control Plans

4

Implementation of relevant Q.C. Plan

Quality Records

Review

QCS/ SUBCO NTRACT ORs

QAM/H SE


SATIPs

5

Perform in-progress inspections and witness tests at suppliers premises

Supplier Q.C. Plan(s) Supplier Inspection Reports

Review / audits

QCS

QAM


SATIPs

1

Identify, report and classify Nonconformances in fabrication phase and in T & I phase

Non-conformance Log & Report, Monthly Quality Management Report

Review

QC / QCM

QCM / QAM

00-ZA-E-G09604 Non-Conformity Management

2

Issue and follow up Non-conformance Report (NCR) in fabrication phase and in T & I phase

NCR Report, Monthly Quality Management Report

Review

QCS / QAM

PD


3

Review, log and process NCR issued in fabrication phase and in T & I phase

NCR Log

Review

DC/QCS

QAM


4

Identification, issue and log of Corrective Action Requests (CAR)

Corrective action reports

QAM

PD





WI-SMS-QUAL-107-E Project Quality Control Plan development

STD-COR-PROC-007-E Inspection - Testing






Rev.: 00A

Date: 06.06.2013 Sheet 36 of 64


No

Resulting Document

Activity





relevant to CONTRACTOR Quality System

8.4 Analysis of Data

1

Collection of Records and data base of Project information for improvement of overall system

QMR

QAM / PQE/ QCS

PD


8.5 Improvement

1

Identification, issue and log of Corrective Action Requests (CAR) relevant to CONTRACTOR quality system

Corrective action reports

QAM

PD


2

Identification, issue and log of Preventive Action Requests (PAR)

Preventive action Reports

QAM

PD








WI-SMS-QUAL-113-E Preventive Actions and Improvement Actions


HASBAH & ARABIYAH OFFSHORE & ONSHORE FACILITIES Contract No (OOK): 6600026283 / (IK) 6600026284 Document No. 00-ZA-E-G09600 PROJECT QUALITY PLAN DOCUMENT

Rev. 00A

Date 06-06-2013

Sheet 37 of 64

6.3

QUALITY SYSTEM DOCUMENTS (QSD)

The project quality system documents consist of the following documents. 

Project Quality Plan (PQP)



Project Quality Management Procedures (PQMP) (note 1)



Project Quality Control Plans (PQCP)



Saudi Aramco Typical Inspection Plans (SATIPs)



Process Control Procedures (PCP)



Project Quality Records



An exhaustive and updated list of Project QSD will be maintained by the Document Controller in an electronic file.

(Note: if a Saipem system level QMS document (WI) exists for the specific subject, it will be used at project level) 6.4 6.4.1

CONTROL OF DOCUMENTS CONTROL OF PROJECT QUALITY PLAN

This Project Quality Plan shall be prepared, checked (verify), reviewed and accepted for adequacy (discipline Approved) and approved as indicated in the below matrix, identifying as well the list of controlled copies holders. Function

Controlled Copy Holder

Project Director



PQM (Management Representative)



Project Managers



Project Engineering Managers – Technical managers



Project Specialist Leaders (PSL)



Procurement Manager



Material Manager



Project Control Manager



Project Document Administrator



Project HSE Manager



Project QC Managers – QC Procurement Manager



Project Quality Engineers / QC Proc Supervisors

Prepare

Verify

Discipline Approved

Approve

 








Rev. 00A

Date 06-06-2013

Sheet 38 of 64 Any revision of This Project Quality Plan shall be transmitted to COMPANY in accordance with provisions of 00-ZA-E-G09805 Document Control and review Procedure. 6.4.2

QUALITY SYSTEM DOCUMENTS

The PQP, PQMP, PQCP, SATIP & PCP are controlled documents. PQM is responsible to ensure that the initial issue and subsequent changes are acknowledged by those authorized to receive the Quality Plan. This will be redistributed through Project Document Controller. The PQM is responsible for the preparation and the updating of PQP, PQMP, PQCP, & SATIP. QA/QC personnel or a person competent in the relevant activity may prepare Process Control Procedures (PCP). The Original of the approved PQP, QPOL, PQMP, QCP, SATIP & PCP shall be filed at the Project Document Control Centre. The document controller shall distribute controlled copies of the approved documents as per the distribution matrix. When a document is revised or changes made to it for any reason, it shall be submitted to Saudi Aramco for approval. The approved revised document shall be distributed as per the controlled copy distribution matrix. 6.4.3

DOCUMENT & DATA CONTROL

Document and data control is the formal control of all documents and data related to the Quality process within the Scope of Work. Controlled and uncontrolled documents shall be identified for their development, approval, issue, revision, distribution, maintenance, use, storage, security, obsolescence or disposal. Authorized personnel shall be authorized to approve certain documents; such personnel shall be named and recorded accordingly. Documents issued by CONTRACTOR shall be controlled in accordance with Project specific procedures that ensure the following: 

Relevant statutory and regulatory and COMPANY’s requirements are referenced and addressed.



Controlled distribution of internally generated and externally supplied documents.



Review and approval of documents.



Formal removal and/or identification of obsolete or superseded documents.



Formal revision of documents.



Archiving, retention and retrieval of stored documents and data.

Electronic copy of Project Document and Records shall be maintained in the main Server in Saipem Sharjah main offices and subjected to Back Up and storage in accordance to provisions of Saipem Work Instruction WI-SCNSH-ICT-006E “Back up Management Procedure” . A Master Document Register (MDR) shall be developed and implemented. Identification, recording and tracking of all controlled Project documents shall be implemented. Nominated Document Controller for the Project shall maintain up-to-date document registers detailing current revision, issue status and document holders. Changes to controlled documents and data are subject to the same review and approval cycle as the original issue. Obsolete and/or superseded documents shall be removed from circulation to preclude their use. Refer to Document Control and Review Procedure 00-ZA-E-G09805 Refer to WI-SCNSH-ICT-006E “Back up Management Procedure” .


Rev. 00A

Date 06-06-2013

Sheet 39 of 64 6.5

CONTROL OF RECORDS

Project records are to be managed in accordance to SAEP 122. Records shall be generated and maintained to adequately support and substantiate inspections and tests performed. These records shall provide evidence of the quality of the item and testify directly and indirectly its compliance with the contractual requirements. Quality records shall be retained as to provide evidence of the conformance to requirements and the effectiveness of the quality management system. All quality records have to remain legible, easily traceable as to comply with COMPANY and CONTRACTOR requirements, contractual requirements and/or international standard as applicable. Inspection records shall identify their subject, applicable requirements, inspection or test method, inspections performed, dates of inspections and inspector’s name, results obtained, and the feedback of corrective action generated by previous inspections. Electronic copy of Project Document and Records shall be maintained in the main Server in Saipem Sharjah main offices and subjected to Back Up and storage in accordance to provisions of Saipem Work Instruction WI-SCNSH-ICT-006E “Back up Management Procedure” . Project Records shall be kept for the minimum period 5 years and shall be made available upon request to the Customer representatives. Records shall be stored in a suitable environment to minimize deterioration or damage and to prevent loss. Refer to Document Control and Review Procedure 00-ZA-E-G09805 Refer to WI-SCNSH-ICT-006E “Back up Management Procedure” . 7.

MANAGEMENT RESPONSIBILITY

7.1

MANAGEMENT COMMITMENT

CONTRACTOR’s Project Top Management Team has a committed attitude towards quality and customer service. Quality is not just another goal; it is our basic strategy for survival and future growth. It is recognized that the achievement of a satisfactory standard of quality is the responsibility of all those assigned to the work and not solely of the personnel within the Quality Department. The Project top management is committed to the development and improvement of the quality management system by:  Communicating the importance of meeting COMPANY, regulatory, and legal requirements by Contract Review, Weekly Meetings & Internal Audits.  Implementing the Quality Policy by identifying & monitoring measurable Objectives.  Conducting management reviews  Ensuring the availability of necessary resources, taking into account also local content  Compliance with Company requirements, inclusive of regulatory safety and environmental 7.2

COMPANY FOCUS

CONTRACTOR shall ensure COMPANY satisfaction by the following:  Reviewing contractual requirements, Quality Management System, and procedures for consistency and submit modifications as appropriate.


Rev. 00A

Date 06-06-2013

Sheet 40 of 64          

Allocating trained and qualified staff resources in accordance with Contractual requirements (and with Attachment I of Schedule Q for Quality Personnel) to perform project tasks. Scheduling and reporting progress in sufficient detail to control project cost. Training personnel as required Performing management reviews and internal quality audits. Performing external audits on SUBCONTRACTORs and vendors as applicable Performing Design Reviews, HAZOP and any other Engineering Study as per contractual requirements Establish a program for problem identification and resolution and prevention. Maintaining data control systems and records of project activities. Responding to COMPANY complaints Achieve effective evaluation of Customer Satisfaction throughout entire project execution at defined frequencies as per contractual requirements, and in any at the completion of each project phase or once per year in case phases are shorter. (issue Customer Satisfaction Questionnaire, analyze the results & take promptly improvement actions as necessary)


Rev. 00A

Date 06-06-2013

Sheet 41 of 64

7.3

PROJECT QUALITY POLICY PROJECT QUALITY POLICY and objectives

In accordance with SAIPEM Quality Policy, the Project Director is committed to establish, implement and maintain an affective Project Quality Program for the duration of the Project as described in this Project Quality Plan and associated work procedures and instructions. The Plan complies with the contractual requirements and as well with Saipem Company Management Manual, based on the ISO 9001: 2008 Quality Standards. The main macro objectives within the actual policy that have been defined for the Wasit Project are: x Ensure that the work is accurately planned and organized. x Ensure, by qualified inspection, that all activities and relevant tests are carried out to the required level of quality. x Ensure compliance to Statutory and Regulatory requirements at all Project work locations, either IK or OOK x Obtain quality performance continuous improvement by monitoring the results and defining those actions than can allow increasing performance effectiveness. x Ensure that procedures and instructions are issued for the performance of all quality affecting activities. x Ensure that QMS will be subject to periodical review to establish that the QMS remains relevant to project needs. x Ensure that the personnel involved in the project activities are adequately trained and qualified, and that tasks and responsibilities have been correctly assigned. x Guarantee, by means of documented quality records, that the work has been carried out and inspected to the required level of quality. x Delivery of the project within agreed cost and schedule. x Obtain Company satisfaction throughout all activities and phases of project execution. It is recognized that the achievement of a satisfactory standard of Quality is the responsibility of all those assigned to the work and not solely of the personnel of the Quality Organization. All CONTRACTORs personnel involved in the project shall therefore follow the requirements of this Project Quality Plan, including suppliers and subcontractors providing material/equipment and services for the project, which shall be controlled be CONTRACTOR accordingly. Furthermore all measures shall be taken in order to ensure safety, safeguard to all personnel and environment during performance of the works. It is firm commitment of the Project Management to maintain the above policy throughout the execution of the project activities Sign: Camillo CERESA Project Director

Date: 06 June 2013


Rev. 00A

Date 06-06-2013

Sheet 42 of 64

7.4 7.4.1

PLANNING QUALITY OBJECTIVES

Quality Objectives are required in order to:  Ensure that quality requirements are determined and satisfied throughout all phases of contract performance, including, engineering, procurement, construction and pre-commissioning.  Maintain an effective program for quality and to satisfy Saudi Aramco quality requirements as defined in Schedule “Q” of contract and Saudi Aramco Standards. Top management of CONTRACTOR has identified the quality objectives for the project. The objectives are measurable, consistent with policy, relevant to the successful completion of the project, and attainment of objectives is considered as part of our effort for improvement.  Project Quality Performance Index* - each month > 88%  Project Quality Performance Index* – cumulative > 85%  Equipment / material arriving on site: zero rejection (for which material can not be incorporated, either as is after downgrade or after rework at site)  Weld Rejection Rate: max 2% (Linear) & max 5% (Joint basis)  NCR ratio (SAUDI ARAMCO vs. CONTRACTORs) 1:15  Worksheets: zero  RTFI disagreement less than 5%  Pre-commissioning Test acceptance: > 90%  Building on previous experience lesson learned (minimization of repeated violations) *(combined Procurement and Construction PQI) 7.4.2

QUALITY M ANAGEMENT SYSTEM PLANNING

The elements that comprise the quality planning process are PQP, PQCPs, Project organization charts supported by HR plans that prescribe personnel allocations and mobilizations, titles of individuals, SUBCONTRACTORs necessary to complete the Work, and the integration of quality improvement initiatives described in section 10 (Management Review) and 13.1 (Measurement Analysis and Improvement). When conditions require change, the process is controlled and the integrity of the quality management system is maintained. Any change in the Quality System Documents shall be done as stated in “Document Control and Correspondence Procedure”. Any major change in the scope of work will require changes in resources, procedures & milestone dates.


Rev. 00A

Date 06-06-2013

Sheet 43 of 64 This change shall be documented by the use of “Change Requests” as described in section 12.2. of this document. At project level, the Project Quality Plan is prepared addressing the Quality Management System application at Project to attend the Client specific requirements. 7.4.3

DOCUMENT & DATA CONTROL - CONTROL OF RECORDS

Document and data control is the formal control of all documents and data related to the Quality process within the Scope of Work. Controlled and uncontrolled documents shall be identified for their development, approval, issue, revision, distribution, maintenance, use, storage, security, obsolescence or disposal. Authorized personnel shall be authorized to approve certain documents; such personnel shall be named and recorded accordingly. Documents issued by CONTRACTOR shall be controlled in accordance with Project specific procedures that ensure the following: 

Relevant statutory and regulatory and COMPANY’s requirements are referenced and addressed.



Controlled distribution of internally generated and externally supplied documents.



Review and approval of documents.



Formal removal and/or identification of obsolete or superseded documents.



Formal revision of documents.



Archiving, retention and retrieval of stored documents and data.

A Master Document Register (MDR) shall be developed and implemented. Identification, recording and tracking of all controlled Project documents shall be implemented. Nominated Document Controller for the Project shall maintain up-to-date document registers detailing current revision, issue status and document holders. Changes to controlled documents and data are subject to the same review and approval cycle as the original issue. Obsolete and/or superseded documents shall be removed from circulation to preclude their use. Records shall be generated and maintained to adequately support and substantiate inspections and tests performed. These records shall provide evidence of the quality of the item and testify directly and indirectly its compliance with the contractual requirements. Quality records shall be retained as to provide evidence of the conformance to requirements and the effectiveness of the quality management system. All quality records have to remain legible, easily traceable as to comply with COMPANY and CONTRACTOR requirements, contractual requirements and/or international standard as applicable. Inspection records shall identify their subject, applicable requirements, inspection or test method, inspections performed, dates of inspections and inspector’s name, results obtained, and the feedback of corrective action generated by previous inspections. Project Records shall be kept for the minimum period 5 years and shall be made available upon request to the Customer representatives. Records shall be stored in a suitable environment to minimize deterioration or damage and to prevent loss. Refer Document Control and Review Procedure 00-ZA-E-G09805 Refer coordination Procedure 00-ZA-E-G09806


Rev. 00A

Date 06-06-2013

Sheet 44 of 64

8.

ORGANIZATION

8.1

CONTRACTOR ORGANIZATION

CONTRACTOR fulfils the scope of work through the deployment of a dedicated Project Management Team, lead by fully dedicated Project Director, Project Managers and Project Team. The Project Team is made up of key personnel, all specifically dedicated to the project as task force, and with the support of CONTRACTOR’S permanent staff structure. CONTRACTOR staff organization is formed by Discipline Managers. Discipline managers appointed at CONTRACTOR organization level shall further grant continuity of the activities performed by the Project Team organization. PQM will be focal point for all quality related issues, including the duties of Management Representative. Project HSE Manger will be the focal point for all HSE related issues. CONTRACTOR overall Project Organization Charts are developed and kept updated throughout Project execution life at care of each relevant Project Manager / Discipline / Function Manager and collected by Project Control Department for inclusion on regular basis in the Monthly Progress Report and whenever any change occurs both within CONTRACTOR’s Project Organization With Respect to Quality Organizational Charts, in addition to the high level Overall Chart for the Project Quality Team, at each Project Working Location shall be developed and maintained updated specific Quality Organization Charts with level of details in accordance to requirements of Schedule Q 5.9.

8.2 



RESPONSIBILITIES AND AUTHORITIES Project Director, CONTRACTOR Representative -

Single point of contact with COMPANY for all matters pertaining to the CONTRACT

-

Authorize all external communications

-

Ensures that the level of performance is in accordance with the CONTRACT requirements and with all the stakeholders’ expectations.

-

Authorize all Expenditures and Procurement Requests related to the PROJECT

-

Has the ultimate responsibility for the correct implementation of the Quality and HSE programs within the Project with the cooperation of all functions, specifically with Project Quality Manager.

Management Representative, appointed by top management shall have responsibility and authority that includes -

Ensuring that processes needed for quality management system are established, implemented and maintained

-

Reporting to top management on the performances of the quality management system and any need for improvement


Rev. 00A

Date 06-06-2013

Sheet 45 of 64 











Ensuring promotion of awareness of customer requirements within the Project

Project Manager -

Coordinate the engineering and constructions activities liaising with relevant disciplines’ managers

-

Support the Project Director in the coordination of the procurement activities

-

Manage subcontracts

-

Involved in Interface management both external and internal

Project HSE Manager -

Responsible for all HSE related activities in cooperation with Project Director and all functions

-

Prepares all HSE documentation

-

Ensures continual improvement through the preparation and execution of audits;

-

Manage on site HSE personnel

-

Has the authority to halt operations if not performed in compliance with required HSE requirements.

Project HR Manager -

Responsible for the implementation of the agreed HR Plan

-

Responsible for personnel logistic including Visas, Resident Permits, Seamen Books,….., Transport and Accommodation

-

Responsible for IT related processes, infrastructure, equipment, training

-

Responsible for facilities management

Project QA Manager -

Responsible for definition, documentation, control and implementation of CONTRACTOR QMS at project level, in cooperation with Project Director and all functions.

-

Responsible for ensuring the awareness on customer’s requirements regarding the project

Contract Administrator -

Support the Project Team in the CONTRACT and SUBCONTRACT management

-

Coordinate Quantity Surveyors

-

Implement COMPANY invoicing procedure

-

Prepare Invoices to COMPANY defining the needs of back up documentation and liaising with Project Control function;

-

Liaise with Corporate legal department in case of legal disputes related to the CONTRACT.

Project Control Manager -

Manage planning, cost control, risk management and document control activities.

-

Prepare the Progress Control and Monitoring Procedure defining planning scheme, WBS and weighting in accordance to the CONTRACT


Rev. 00A

Date 06-06-2013

Sheet 46 of 64









-

Prepare weekly and monthly reports

-

Prepare and keep updated the control budget

-

Collect and provide back up documentation for all projects related costs.

-

Control progress against baseline schedule providing estimates to completion;

-

Collects information and statistical data on the completed project to increase the Project Management and Engineering database.

Project Procurement Manager -

Issues the project procurement procedure in accordance to the CONTRACT;

-

Prepare and keep updated the procurement plan.

-

Define vendor lists and subcontracting strategy

-

Manage and implement the procurement process granting competitive solutions; Manage procurement of material until the material is delivered to site (incl. expediting, logistic and quality) and subcontracting till the signature of the subcontract;

-

Prepare Procurement Packages for COMPANY approval;

-

Issue Purchase Orders and Subcontracts CONTRACTOR’s Proxy of Authorities

gathering

authorization

in

accordance

to

Project Technical Manager / Project Engineering Interface Coordinator -

Verification of COMPANY data completeness and definition of Technical Queries

-

Design activities in accordance to contractual requirements, including Preliminary Design Verification, Design Reviews and Studies;

-

Development of engineering documentation for Detail engineering and material / packaged equipment procurement (calculation notes, IFC & As Built drawings, procedures, reports, MR, data sheets, project specifications)

-

Coordination of Engineering Internal Interfaces between the relevant facilities within the PROJECT, in liaison with relevant Project Managers

-

Coordination of Engineering external interfaces with other parties / facilities and interaction with Company

-

Consolidation of internal and external interface matrix

Construction Manager -

Management of on site personnel

-

On site implementation of engineered solutions

-

SUBCONTRACTORs management on site

-

Liaison with on site COMPANY Rep.

Fabrication Manager -

Management and Coordination of relevant Fabrication Yard activities

-

Direct Management of relevant dedicated Yard for on site implementation of engineered solutions


Rev. 00A

Date 06-06-2013

Sheet 47 of 64 -

SUBCONTRACTORs management on site

-

Liaison with on site COMPANY Rep.

9.

INTERNAL COMMUNICATION

PQM ensures the processes of the quality management system and their effectiveness are communicated throughout the organization by the following. 

Distribution of Quality System Documents as per the distribution matrix.



Conducting Internal Audits and distributing audit reports



Organizing Management review Meetings & distributing management reviews reports



Internal training on QMS & Processes

10.

MANAGEMENT REVIEW

The CONTRACTOR top management shall review the Quality Management System at least once every six months for design, procurement and construction phases to ensure its suitability, adequacy, and effectiveness. The QMS, quality policy, and quality objectives will be evaluated for any needed change. Participants in the meeting includes (but not limited to) the following members of the Project Management: 

Project Director



Project Managers



Discipline / Function Managers



PQM (Management Reperesentative)

PQM will outline to the Committee the current status of the Quality System, its achievements and shortfalls. The evaluation of the Quality Management System shall embrace (but not limited to) the following aspects: Results of the Quality Audits performed the project, and consequently, the degree of implementation of the Company Quality program. Sufficiency of the present Quality System in respect of the current Customers expectations and of the quality objectives set by the Company; need for modification/improvement of the system. Need for further indoctrination and training of the personnel in regard of the Company Quality Program. Decisions undertaken by the CONTRACTOR Management during the meeting, recorded in the respective Minutes of Meeting, shall constitute the guideline for further activities of the Quality Department. The results and recommendations of the management review will be issued representative within two weeks after the scheduled review date.

to Saudi Aramco


Rev. 00A

Date 06-06-2013

Sheet 48 of 64 All management review results and recommendation actions shall be recorded and any change to the Project quality system resulting from management reviews will be incorporated in the PQP for SAUDI ARAMCO approval.

11.

RESOURCE MANAGEMENT

11.1 PROVISION OF RESOURCES CONTRACTOR considers the process of finding resources as the most important factor in deciding the success of a project. The responsibilities are as follows; The Human Resource department is responsible for the provision of Manpower The Operation Asset department is responsible for the provision of buildings, equipment and other infrastructure. Project Director in coordination with the department managers is responsible to assess organizational and project needs including oversight functions and develop resource requirements. This is in order to assure that resources necessary to implement and improve the QMS processes and Saudi Aramco satisfaction issues are provided in a timely manner. 11.2 HUMAN RESOURCES 11.2.1

GENERAL

The various processes in human resource management are: 

Quantifying manpower needs and planning resources



Recruitment



Manpower development & performance evaluation

The CONTRACTOR shall assign QA/QC personnel to the Project in accordance with Schedule Q, Attachment VI that is competent on the basis of applicable education, training, skills, and experience. All personnel assigned to this project shall meet the minimum qualification and experience levels specified in Schedule Q, Attachment I. The PD & QAM are responsible to review the contract to determine any customer requirement for competency level of personnel assigned to the project and ensure that assignment of personnel including SUBCONTRACTORs meet the requirements. Resumes of all quality personnel including sub-CONTRACTOR quality personnel shall be submitted to Saudi Aramco for review and approval at least two weeks prior to the starting of the work. CONTRACTOR shall provide on a monthly basis a listing of approved Quality personnel forecast to be mobilized in the next 60 days as well as list of personnel to be demobilized in the next sixty days. The planned staffing levels shall comply with the Saudi Aramco approved Quality Plan. Reduction from required level of quality personnel specified in Schedule Q shall require Saudi Aramco written approval. Anticipated changes in QC personnel due to vacation, temporary assignments or resignations shall be advised to Saudi Aramco at least 30 days in advance of the scheduled absence. All other changes such as for illness and emergency leaves will be advised as soon as possible.


Rev. 00A

Date 06-06-2013

Sheet 49 of 64 11.2.2

COMPETENCE, AWARENESS, AND TRAINING

CONTRACTOR has developed position descriptions for those personnel performing activities affecting quality that identify competency requirements. HR Manager maintains the latest issue of position descriptions. Each Head of the Department is responsible to identify training needs and assure training is performed. Personnel lacking required competencies should receive training such as formal, informal, or on-the-job. CONTRACTOR will provide training as deemed appropriate to satisfy competency needs or utilize external training sources. CONTRACTOR shall evaluate the effectiveness of the training through periodic internal audits, review and analysis of employee generated errors and omissions. CONTRACTOR employees and sub-CONTRACTORs shall be made aware of the project quality requirements and how their work activities contribute to the achievement of quality objectives. This is done through awareness presentations to CONTRACTOR personnel and SUBCONTRACTORs, project kick-off meetings, Project position descriptions, Project organization charts, and toolbox meetings. CONTRACTOR shall maintain records of education, training skills, and experience for personnel affecting quality. The CONTRACTOR HR&ICT Manager is responsible to ensure appropriate record including records of training activities and subject matter of the training are maintained. Functions requiring specific skills and those functions which could be adversely affected by the lack of such skills, are identified as follows: 

QA Manager (PQM)



QC Manager



QC Supervisor



QC Inspectors



Internal Auditors

CONTRACTOR management shall assess, through review, examination or other means, whether personnel carrying out such activities are sufficiently qualified, and when required, shall provide for additional training. The head of the department shall verify competence of relevant personnel by monitoring their activities. The relevant records shall substantiate all training and qualification activities. 11.3 INFRASTRUCTURE CONTRACTOR provides a work environment suitable for it to achieve its business objective and satisfy project requirements. Workplaces and associated facilities will be constructed as necessary for the employees. Offices will be provided with air-conditioning facilities. Office equipments such as computers, fax machines, photocopy machines, telephones etc will be provided as required to ensure smooth and efficient operation. It is the responsibility of Project Director to provide the necessary infrastructure for all personnel to facilitate an efficient and economical working environment. All infrastructures shall meet minimum requirement of Schedule “B”.


Rev. 00A

Date 06-06-2013

Sheet 50 of 64 11.4 WORK ENVIRONMENT This section is addressed in the HSE Management Program. Refer to specific Loss Prevention Programmes. 12. PROJECT EXECUTION 12.1 PLANNING OF PROJECT EXECUTION The development of project execution process is defined in the Project execution Plan 00-ZA-E-G09000. Project Execution Plan shall be established and submitted to Company within 35 days after the effective date of the Contract. The quality objectives for the design, procurement, fabrication, construction, transportation and installation activities are identified in accordance with schedule Q (attachment IV) of the contract as internal quality objectives as defined in 7.4.1 of this PQP. The main processes are defined in section 6.2 (CONTRACTOR’S QMS APPLICABLE PROCESSES – Matrix) of this PQP. The documentation for project execution is stated in paragraph 5.3 of this PQP. Facilities required for the execution of the project will be identified in the project execution plan. Verification and validation are incorporated into the planning process as follows: 

Acceptance testing



Planned inspections



Approval

Acceptance criteria for the work will be developed where appropriate. PQM or his subordinates shall maintain records attesting to conformity of process and resulting Work. Records include: 

Material Disposition Reports



Internal quality audit results and close out of relevant findings



Records of management reviews



Mechanical Completion Certificate(s) (MCC) shall be the document to prove Saudi Aramco acceptance of the project.

12.2 CUSTOMERS RELATED PROCESSES 12.2.1

DETERMINING PROJECT REQUIREMENTS

CONTRACTOR shall review the contract documents to determine customer requirements. Project Director and Contract Administrator will evaluate these requirements and determine any additional requirements including regulatory and legal ones, which may not have been identified by the Saudi Aramco, and need to be implemented to support the delivery of the Work. The identifications which may not have been identified


Rev. 00A

Date 06-06-2013

Sheet 51 of 64 by Saudi Aramco shall be notified. 12.2.2

REVIEWING PROJECT REQUIREMENTS

The responsibility to review the contract lies on the Project Director with the Contract Administrator collaboration. He shall ensure that the requirements are understood, and that inside the organization there is the capability of performing the work. The review shall also ensure that agreed changes (if any) have been incorporated. A contract review meeting will be performed after the Contract Award, and then periodically at frequencies set by the PMT. Record of Contract review and subsequent amendments to Contract are maintained within appropriate discipline. Project Director shall be responsible for organizing the contract review process. All department heads shall be invited to participate in the process. During all phases of project, from design & procurement up to construction and commissioning phase, if a change from the contractual scope is required, the respective department will initiate a request for change. This change request shall be approved by Project Director and shall be forwarded to Saudi Aramco for further processing. 12.2.3

CUSTOMER COMMUNICATION

CONTRACTOR Project Director is responsible to establish and maintain communication with the Saudi Aramco Representative regarding Contract execution activities. This shall be done either by weekly communication meetings or formal written communication. Project Director is responsible for evaluation of Saudi Aramco feedback/complaints and responding to them. A monthly quality management report will be submitted to Saudi Aramco, to demonstrate the effective implementation of the quality system. The following items will be included in the report. 

Listing of supplier surveys performed with a summary of findings



Listing of supplier inspections performed versus scheduled inspections



Non-conformance reports issued to vendors: Number issued, closed out and pending for the month



Listing of quality audits completed



A chart showing the historical performance during the project will be included



Listing of status of engineering waivers requested

12.3 DESIGN AND DEVELOPMENT Detail Design Engineering activities are carried out by CONTRACTOR Main Design Office in Sharjah – UAE and Design offices in Fano – Italy (specific to pipelines, cables and umbilicals) to provide all management, supervision and other qualified engineering, drafting, inspection, QA QC and procurement services, software and FACILITIES as necessary to : 

Complete all basic engineering designs, analysis, calculations, field surveys, approved IFC


Rev. 00A

Date 06-06-2013

Sheet 52 of 64 drawings, data sheets, specifications, design reviews, HAZOP review, constructability review and other reviews related to the basic design of the FACILITIES 

Produce purchase specifications, quotations documents, technical bid evaluations and purchase orders as required to procure all permanent FACILITY engineered and bulk materials and to evaluate and record all vendor information before and after purchase order placement.



Perform basic engineering to confirm the acceptability of CONTRACTOR’s fabrication procedures and the IK construction contract, installation procedures before the notice to proceed for the Fabrication and Transportation program is issued



Perform all other basic engineering functions required under the job specifications and this contract as required to define the basic design of the FACILITIES

The Project Technical Managers under direction of relevant Project Managers are responsible for the control and coordination of the engineering activities. During the Design and Procurement phase, PQM or by him appointed Project quality related person shall perform the following to ensure proper control of the activities of the Engineering activities. 

Perform audits at 15% and 60% progress of Engineering and Procurement Phase



Attend weekly progress meetings



Participate in Design Reviews



Monitor activities of document management as to ensure that documents are controlled and distributed to the relevant personnel.

12.3.1

DESIGN AND DEVELOPING PLANNING

The design and development phases are identified on the basis of: 

Design input;



Design output;



Design review;



Design verification;



Design validation;



Control of design changes

as detailed in the following paragraphs.

12.3.2

DESIGN AND DEVELOPMENT INPUTS

The Design developed for Wasit Project will include the verification and correction of the preliminary design, with the Investigation of “interface points” between said preliminary design and any existing facilities and/or the design interfaces with the other related projects being designed and constructed by COMPANY’s other CONTRACTORs, including those interfaces that have not been specifically completed or detailed in the preliminary design.


Rev. 00A

Date 06-06-2013

Sheet 53 of 64 

Development of detailed design documents and drawings and provide all necessary materials and equipment necessary for the FACILITIES to perform in full compliance with Project specifications.



Design Input requirements, including customer specified product functional and performance requirements, as well as codes and standards, are identified. Incomplete, ambiguous or conflicting information are pursued and resolved.



Agreements / clarifications reached during contract review from part of the Design Input



All the project stakeholders, in accordance with the requirements of SAEP-14 and SAEP-303, will review these design inputs starting from project proposal stage.

12.3.3

DESIGN AND DEVELOPMENT OUTPUTS

Engineering department shall make sure that the design and development outputs meet the input requirements and that it provides appropriate information for purchasing and for service provision, containing product acceptance criteria. The Engineering Managers will ensure that the COMPANY Engineering Data are protected against loss, unauthorized disclosure, reproduction and disclosure, according SAEP-127, par.4. The design drawing listing and book shall be conform to SAEP-122 requirements. Design output, in the form of calculations, specifications, drawings, data sheets or studies reports, are checked for conformance prior to release. The design output documents identify product acceptance criteria and characteristics essential for its safe and proper use. Project Management Team shall make available, control, and maintain a copy of all project documents such as specification, drawings and data available at work place for use by the project team. Development of construction schedules and estimated construction costs shall be under the direction of Project Director, Project Managers and Contract Manager. The methodology used to develop construction schedules and estimates of construction costs are described in written procedure. Format shall conform to Saudi Aramco standards as required in the contract. Project Director shall review the schedules and estimates prior to their issue to Saudi Aramco. 12.3.4

DESIGN AND DEVELOPMENT REVIEW

CONTRACTOR shall conduct three different design review meetings when the actual engineering and procurement progress has reached 30%, 60% and 90% of completion stage, which will be shown in the PROJECT work schedule. The preparation and submittals for the design reviews will comply with SAEP303. These three formal Design reviews are in addition to the routine engineering and design document reviews which will be conducted at Design offices throughout the duration of the Contract. Records of the results of the reviews and necessary actions shall be maintained. HAZOP Studies will be performed after 60% of Design Review meeting has been completed and all comments from the 60% design review have been incorporated and at least 60 days before the 90% design review package release. All findings of the HAZOP study must be implemented in the project documents before the 90% design review package is submitted to COMPANY.


Rev. 00A

Date 06-06-2013

Sheet 54 of 64 12.3.5

DESIGN AND DEVELOPMENT VERIFICATION

Project Engineering Managers shall: 

Ensure preparation of drawings and documents in accordance with SAEP -334 & SAES-A-202.



Review and approve Vendor and SUBCONTRACTOR drawings, design and specification of conformity to this Job Specification



Institute an effective internal controls for their prompt receipt, review , approval and return



Incorporate all applicable Vendor and SUBCONTRACTOR information into the design of the FACILITIES



Perform verification to ensure that the design outputs have satisfied the input requirements

CONTRACTOR shall maintain records of the verification results. 12.3.6

DESIGN AND DEVELOPMENT VALIDATION

Design and development validation shall be performed as required and validation records will be maintained. The scope of design validation is agreed with Client at contract review stage and built into the design input requirements. Since the final design validation cannot be carried out after the completion of test runs, validation of the Design will be performed during the Project Close Out meeting.

12.3.7

CONTROL OF DESIGN AND DEVELOPMENT CHANGES

Design and development changes shall be identified and records maintained. The changes shall be reviewed, verified as appropriate and approved before implementation. The Project Engineering Managers shall coordinate these activities. As-built documents shall be developed as per contract requirements. As-built documents shall be reviewed to ensure field-marked prints and other sources of as-built information have been correctly translated onto the original document. The activity shall meet SAEP-334, par.6.1 requirements. CONTRACTOR shall establish a procedure for “Control of Design and Development Changes” and shall ensure that current revisions of design outputs are the working copies and all obsolete or old revisions are withdrawn and destroyed according to the applicable procedures. In accordance with SAEP-122, CONTRACTOR will submit to the Company required Drawing Books.

12.4 PROCUREMENT Procurement process includes the procurement of material, equipment or service. This includes the subcontracting of work for the project. Refer Procurement Procedure 00-ZA-E-G09700 Refer Subcontracting Plan 00-ZA-E-G09701


Rev. 00A

Date 06-06-2013

Sheet 55 of 64 12.4.1

M ATERIAL & EQUIPMENT

Where suppliers are engaged to provide material or equipment for this Project, their capability to perform the assigned scope of work is evaluated by CONTRACTOR Procurement Manager in coordination with PQCS, in accordance with Schedule Q, Attachment III. Physical surveys, when needed or required, shall be performed by a Lead Auditor suitable qualified as per requirements of Schedule Q. Except as provided in Schedule Q, Attachment III, paragraph 1.3.6, evidence of qualification of manufacturers and suppliers shall be provided to Saudi Aramco. The Supplier quality program in accordance with ISO 9001:2008 shall be verified by the vendor inspector who will perform the job on behalf of CONTRACTOR. CONTRACTOR Procurement Manager shall maintain records of supplier performance. Suppliers with a record of poor performance shall be excluded from future consideration. Evaluation of supplier performance shall take place on a yearly basis or after hand-over of the materials, whichever comes earlier. CONTRACTOR Procurement Coordinator is responsible to follow up on identified areas of poor performance. Refer Procurement Quality Plan 00-ZA-E-G09601 Refer QA/QC Plan for Procurement 00-ZA-E-G09695. 12.4.2

SERVICES

Where SUBCONTRACTORs are engaged to provide services (work) on this project, their capability to perform the assigned scope of work is evaluated by the CONTRACTOR Procurement Manager in coordination with Project Team. The CONTRACTOR Procurement Manager shall maintain records of SUBCONTRACTOR performance. SUBCONTRACTORs with a record of poor performance shall be excluded from future consideration. Evaluation criteria are defined by CONTRACTOR’s COR-STD-PROC-014-E (Vendor Management Procedure). Evaluation of SUBCONTRACTOR performance shall take place on a yearly basis or at the end of their service, whichever comes earlier. CONTRACTOR Procurement Coordinator and Project Director are responsible to follow up on identified areas of poor performance. The site superintendent shall control the construction SUBCONTRACTORs to ensure that they comply with the requirements of the subcontract, main contract, Saudi Aramco Standards and Project quality program. The PQM / QC Manager / QC Supervisors shall ensure that the work performed by the SUBCONTRACTORs are tested, verified and accepted as per the requirements of this Project Quality Plan and relevant QCP’s / ITP’s. SUBCONTRACTORs providing inspection services will be controlled and closely monitored by the QC Manager and QC Supervisor. The NDT SUBCONTRACTOR will be controlled as follows. 

Ensure that NDT procedures are approved prior to start work



Ensure that NDT personnel resume & qualifications are verified and accepted prior to work



Ensure that the RTFI certificate, Radiation safety Cards and level 2 certificate are valid



Ensure that any change in the NDT personnel are with prior approval only



Ensure that the daily activities of NDT personnel are planned to avoid backlogs



Ensure that the results of NDT are impartial and the records are legible


Rev. 00A

Date 06-06-2013

Sheet 56 of 64  12.4.3

Ensure that all NDT results are securely filed PROCUREMENT INFORMATION

Purchase Orders or Contracts with SUBCONTRACTORs and suppliers will define service or product requirements, Quality management system requirements, HSE requirements, applicable procedures, and processes, equipment, and personnel qualifications in sufficient detail to ensure the work performed meets the purchase order/contract requirements. Quality requirements shall be clearly specified in all purchase orders or subcontract agreements. The PQCS (Procurement QC Supervisor) shall review all material requests including revisions and purchase orders for permanent Project materials. Refer to Procurement Procedure 00-ZA-E-G09700 Refer Procurement Quality Plan 00-ZA-E-G09601 Refer QA/QC Plan for Procurement 00-ZA-E-G09695 Procurement Information shall meet minimum requirements of Sch. Q, attachment III. 12.4.4

VERIFICATION OF PURCHASED PRODUCT / SERVICES

Products (Material or equipment) supplied by vendors shall be inspected to ensure that the purchased product meets the specified purchase requirements. Saudi Aramco approved third party inspectors will do this inspection. The PQCS will coordinate inspections. Saudi Aramco Form SA-175 and approved ITP (QCP) shall be the basis for all inspection and tests. Supplier suborders shall be reviewed for conformance to the original purchase order requirement and document. Once fabrication starts, progress shall be reported on a weekly inspection/fabrication status report to Saudi Aramco. Records of supplier inspections shall be prepared following each inspection or weekly for resident inspectors and submitted to Saudi Aramco as per Schedule Q. Inspection Disposition Reports shall be prepared within two weeks following release to ship material and submitted to Saudi Aramco. Procurement Information shall meet minimum requirements of Sch. Q, attachment III. Refer Procurement Quality Plan 00-ZA-E-G09601 Refer QA/QC Plan for Procurement 00-ZA-E-G09695 12.5 PRODUCTION AND SERVICE PROVISION 12.5.1

CONTROL OF PRODUCTION AND SERVICE PROVISION

The sequence of activities are planned and scheduled. CONTRACTOR has established the controls applicable to Project management activities. Detailed controls of construction activities are reflected in the Saudi Aramco supplied SATIP and SAICs (Checklists) that form part of the Fabrication Quality Control Plans. Acceptance criteria are defined. Project Director and Project Managers are to ensure that adequate resources (tools, equipment, and trained personnel) are available to perform the work.


Rev. 00A

Date 06-06-2013

Sheet 57 of 64 Project Director and Project HSE Manager are responsible to ensure that the work environment is safe and conforms to health and safety requirements in the contract. PQM, QC Managers and QC Supervisors are responsible to ensure that procedures, work instructions, and/or construction/installation instructions are available to the workforce. PQM and QC Manager are responsible to ensure that codes, standards and other references, including portions of the contract are available to the workforce. Site Superintendents and QC Inspectors are responsible to ensure that standards of workmanship are implemented. Where required, only licensed or certified personnel are assigned to the Project to perform activities requiring such license or certification. A program to monitor the effectiveness of these process controls is in place and implemented. Criteria for approval and acceptance of work are established. Requirements of Saudi Aramco Standards, Specifications, and inspection, testing or examination requirements may be waived only with the written approval from Saudi Aramco. The request for waiver shall be submitted to Saudi Aramco according SAEP-302 Instruction and copy shall be transmitted to the Project QA Manager. 12.5.2

VALIDATION OF PROCESSES FOR PRODUCTION AND SERVICE

The validation of the design is the constructed project that satisfies the Saudi Aramco requirements. The validation of certain construction processes can only be ascertained when operation is initiated. For the project, these processes are referenced in Schedule Q, Attachment 4 “Special Processes” in paragraph 2.1, as applicable. CONTRACTOR assures these processes can achieve planned results through: 

Process qualification



Equipment and personnel qualification



Defined methods and procedures

Records shall be maintained and revalidation performed as necessary. Applicable construction Process Control Procedures (PCP) and personnel qualifications as identified in Schedule Q, Attachment IV will be submitted for Saudi Aramco review at least 30 days prior to start of the construction activity. The results of Qualification Tests concerning processes, equipment and personnel shall be kept up to date and available for inspection. Extent of inspection required for each special process shall be established case by case by the PQM in agreement with ARAMCO. 12.5.3

IDENTIFICATION AND TRACEABILITY

PQM will ensure that the CONTRACTOR will take care that all materials and/or components requiring individual identification and traceability shall be selected at the beginning of the project, prior to the fabrication and/or installation phases. The identification and marking systems shall be developed on a case-by-case basis in accordance with the governing Project specifications, drawings or other documents.


Rev. 00A

Date 06-06-2013

Sheet 58 of 64 And such identifications shall be maintained during all stages of fabrication and/or installation and recorded on all relevant Quality Records. All materials and equipment supplied by the Customer for incorporation in a given project shall be inspected receipt for identification, quantity, damage, and completeness from the Construction department. They shall be stored, transported and handled in accordance with the appropriate Customer instructions. Relevant procedures (mentioned in ‘References’ below) will be established and submit to Company for review and approval. References:

Material Management and Control Procedure 00-ZA-E-G09609

References: Pipe Tracking System Procedure 00-ZA-E-G09622 (specific to Offshore Pipelines) 12.5.4

SAUDI ARAMCO PROPERTY.

CONTRACTOR will ensure that a system is be maintained on two levels a) Project offices for the intellectual property b) Site level - Construction dept. for the preservation, warehousing and handling of materials and equipment Throughout the entire project management, engineering, procurement, construction and/or installation process until handover to COMPANY, as specified in the contract and construction specifications. All precautions shall be taken to protect intellectual property and materials from abuse, misuse, damage, deterioration and unauthorized use. This system shall be applicable to the SUBCONTRACTORs too. Particular care will be required by CONTRACTOR to Construction and SUBCONTRACTORs for all materials subject to deterioration or corrosion due to environment. This one shall be kept cleaned and fully protected at all times in accordance with approved preservation procedures or equipment maintenance manuals. Suspect items shall be placed on “Hold” and marked properly until acceptability is established or other disposition arranged. Reference: Material Management and Control Procedure 00-ZA-E-G09609 12.6 CONTROL OF MONITORING AND MEASURING DEVICES PQM, QC Managers with the support of respective Quality Departments at the various contruction locations will ensure that all the devices, which are essential to ensure the quality of construction and inspection activities, are verified within appropriate intervals to assure conformity of work as required by the contract. The verifications can be carried-out by Construction QC dept. or a recognized laboratory, having calibration standards traceable to the “National Standard”. The verification will include for the calibrated equipment, the presence of the relevant certificates and the tag or sticker indicating the calibration status, moreover a Calibration Log listing the identification details of calibrated equipment, shall be maintained by the Construction and SUBCONTRACTORs. PQM, QC Managers will ensure that an established written program to identify, control, and calibrate measurement and monitoring devices is implemented by Construction and SUBCONTRACTORs QC dept. Reference: Control and Monitoring of Measuring Devices 00-ZA-E-G09607


Rev. 00A

Date 06-06-2013

Sheet 59 of 64 13. MEASUREMENT, ANALYSIS AND IMPROVEMENT 13.1 GENERAL CONTRACTOR has defined, planned and implemented the following measurement, monitoring, analysis and improvement activities to assure conformity and achieve improvement. 

Customer satisfaction surveys (LBE, PQI)



Internal audits



In-process reviews/inspections/tests



Control of nonconformities



Data analysis



Corrective, preventive, and improvement activities

13.2 MONITORING AND MEASURING 13.2.1

CUSTOMER SATISFACTION

CONTRACTOR takes care about the data related to customer satisfaction. The data shall also include the COMPANY Complaints. COMPANY satisfaction will be measured by collecting the following data. 

Documented COMPANY Complaints



Work Performance Evaluation Methods



Customer Satisfaction Questionnaire

In addition to the above, COMPANY satisfaction will be evaluated based on the number of NCR and Worksheets issued by COMPANY. 13.2.2

INTERNAL AUDIT

CONTRACTOR has established, and will maintain, and implement an internal quality audit program to verify that quality activities and related results comply with planned contractual arrangements and to determine the effectiveness of the quality program and associated procedures. Internal audits shall be scheduled based on requirements in Schedule Q Para 7.2. The Audit schedule shall be transmitted to the Saudi Aramco Representative and then kept updated on regular basis throughout all project execution lifespan. Personnel conducting internal audits are capable of objectivity and impartiality in conducting audits. All audits shall be executed by Quality Assurance Personnel qualified in accordance with attachment-I of schedule Q of contract. They will not audit their own area. Audits shall be performed in accordance with established Audit procedure, which identify essential items to be investigated. Each non-conformity found during the Audit shall be addressed by means of “Corrective Action Request”. Reports of internal audit results shall be generated and issued to audited departments. CONTRACTOR management and Saudi Aramco shall receive copies of report within two weeks of audit completion. Corrective action shall be monitored and followed up for closure. The Management functions responsible


Rev. 00A

Date 06-06-2013

Sheet 60 of 64 for the area audited shall review agrees and correct deficiencies revealed in the Audit report. Follow-up internal audits shall be conducted as appropriate, to ensure implementation of corrective action, and the results reported to CONTRACTOR management and Saudi Aramco. The activities of SUBCONTRACTORs working for this Project and under its quality management system will be included in the audit program, if their activity lasts more then 6 months. An Audit Plan shall be established, documented and implemented in order to evaluate objectively the adequacy of the functions, systems and procedures subject to Auditing activities. Internal audit will be carried out at 15% and 60% completion stage of Design, Procurement and Construction phases. The Audit plan shall define: 

Functions, organizations, activities to be audited



Audit criteria (reference procedures and standards)



Personnel allocated to perform Audits.



Dates of Audits

Audits may include an evaluation of: 

Activities, processes, work areas and services



Quality practices, systems, procedures and instructions



Certification, documents and records

The Contractor management will evaluate the results of audits during Management Review meeting. Reference: Audits Procedure 00-ZA-E-G09602 13.2.3

MONITORING AND MEASURING OF PROCESSES

The project execution processes, described in Section 12 of this document, necessary to achieve Saudi Aramco requirements are measured and monitored as follows: 

Internal audits



Punch lists



COMPANY Complaints (including LBE’s issued by Company at site)



Non-conformance reports

These methods shall confirm the continuing ability of each process to satisfy its intended purpose. When planned results are not achieved, corrective preventive actions shall be taken to assure conformity. 13.2.4

MONITORING AND MEASURING OF THE WORK

The inspections and tests related to manufacturing of the ordered material/equipment shall be carried out by the Procurement QC Team in accordance with the Vendor’s pre-established Inspection & Test Plans. Third Party Vendor Inspectors acting on behalf of CONTRACTOR Organization may be used joining Aramco Inspectors for the inspections as per the requirements of the approved ITP and vendor performance. Generally, materials and equipment purchased for incorporation in a given project, shall be identified, inspected, tested and released at source, and subsequently issued with all required supporting


Rev. 00A

Date 06-06-2013

Sheet 61 of 64 documentation. Only after a satisfactory result of inspection the material can be released for the shipping at the construction site. Than all materials and equipment received shall be inspected for identification, quantity, damages, and completeness. They shall be stored, transported and handled in accordance with appropriate instructions. The QC Procurement Manager and QC Procurement Supervisors shall ensure that the equipment and materials are inspected and accepted for project use prior to shipment to construction / fabrication site. Testing shall be performed by qualified personnel to written procedures, with acceptance criteria defined and results identified and transmitted to Saudi Aramco, such as follows: 

Non-Destructive testing of welds



Welder Qualification Tests



Hydro test



Valve Seat Test



Instrument Calibration

All test results shall be documented on forms appropriate for the tests, and dated and signed by the test personnel. Results shall be issued as required by the contract. QC Procurement Mgr and Supervisor is responsible to supervise and accept or reject all CONTRACTORperformed inspections and tests. In case of material is received at site without Inspection Release, the Material Receiving Inspector shall perform inspection against the purchase order requirements and verify that the equipment and material meets the specified standards. A Material Receiving Inspection Report shall be prepared to indicate the acceptance status. Inspection and test status of all material and work within the contract scope shall be known and verifiable at all times. This is to ensure that only product that has passed the required inspection and tests is dispatched, used or installed. 13.3 CONTROL OF NON-CONFORMING PRODUCT Products that fail to meet the specified requirements shall be identified and controlled to prevent its unintended use or delivery. This event shall be documented by the use of non-conformance reports. During procurement, any conditions that do not meet contract requirements and that cannot be corrected by the end of the workday shall be rejected and documented. The assigned QC Inspector shall track the condition by further inspection until restoration to the designed conditions or until the "as-installed" condition is accepted by Saudi Aramco. All violations of Saudi Aramco standards and specifications that result in "as-installed" or "use-as-is" recommendations shall be documented as Waiver in accordance with SAEP-302 (Instruction for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement. Evidences of the remedial action and corrective action implementation shall be recorded and maintained to substantiate that repaired; reworked or corrected items have been re-inspected and/or re-tested according to the applicable procedures. Applicable forms shall be completed, identifying the non-conforming item or activity, deviation or


Rev. 00A

Date 06-06-2013

Sheet 62 of 64 discrepancy and forwarded to the involved functions for registration and coordination of further processing. Saudi Aramco shall be copied of all (CONTRACTOR and SUBCONTRACTOR) non-conformance reports within 48 hours of issue and Saudi Aramco shall be notified prior to closing of the NCR. Reference: NCR Procedure 00-ZA-E-G09604 CONTROL OF NON-CONFORMANCE DURING DESIGN PHASE Any non conformance or deficiency identified during Design activities will be managed in accordance to the grounds of CONTRACTOR Project Quality Management System with initiation of Corrective Action Procedure. 13.3.1

Reference: Preventive and Corrective Action 00-ZA-E-G09603 13.3.2

CONTROL OF NON-CONFORMANCE DURING PROCUREMENT

Non-conformance or deficiency detected during inspection at vendors premises during relevant manufacturing processes will be initiated at care of PQCS / assigned Inspector according to the grounds 00-ZA-E-G09601 QC Procurement Plan. 13.3.3

CONTROL OF NON-CONFORMANCE DURING FABRICATION

PQM shall ensure that the non-conformance control system pertains to the management of nonconforming items and practices is existing and implemented at all construction sites. This is applicable to any work carried out by CONTRACTOR, and it’s SUBCONTRACTORs, and may regard (but may not be limited to) the following: 

Material defects



Process failure



Missing/unavailable documentation



Non implementation of existing procedure or work instructions



Unsafe equipment or practice

Non-conforming items and relevant activities shall be identified and properly marked as appropriate to prevent unauthorized use of implementation, shipment, or mixing with conforming items. Reference: NCR Procedure 00-ZA-E-G09604 13.4 ANALYSIS OF DATA CONTRACTOR collects and analyzes appropriate data to determine the suitability and effectiveness of its quality management system and to identify where improvements can be made in the quality management system. The following data are gathered and analyzed. Project Director and PQM are responsible for the effort and to ensure closure where QMS improvements are warranted. 

COMPANY Satisfaction



COMPANY Complaints



Non-conformances


Rev. 00A

Date 06-06-2013

Sheet 63 of 64 

Performance Evaluation



Corrective Action Requests



Preventive Action Requests



Material Conformance (Material Rejected during Vendor Inspection)

13.5 IMPROVEMENTS 13.5.1

CONTINUAL IMPROVEMENT

CONTRACTOR facilitates continual improvement of the quality management system. The results of data analysis will be used to make improvements in the Quality Management System. 

Results of COMPANY Satisfaction Analysis will provide information about the satisfaction or dissatisfaction of customer towards the performance of a department or activity. The results of the analysis will be provided to the head of the departments to take improvement actions.



Results of COMPANY Complaints Analysis will provide information about the day-to-day complaints generated during the ongoing activities of the project. This information will indicate the subject of the complaints, which area is responsible and the frequency of complaints. The results of the analysis will be provided to the Responsible of the area in order to take improvement actions.



Results of Non-conformance Analysis will be used to monitor the type of non-conformances, for the responsibility and the reason. Based on this result, improvement action will be taken.



Results of Performance Evaluation Analysis will be used to monitor the capability and achievements of personnel. Based on this result, improvement action will be taken.



Results of Corrective Action Requests Analysis will indicate the type of violations, for the responsibility and the reason. Based on this result, improvement action will be taken.



Results of Preventive Action Requests Analysis will indicate which area is more prone to mistakes and what is the reason. Based on this result, improvement action will be taken.



Results of Material Non Conformance Analysis will be used to monitor the quantity of material rejected during receiving inspection, which manufacturer or supplier is responsible and what is the reason. Based on this result, improvement action will be taken (change manufacturer/vendor, increase inspection level, provide additional inspection etc.)



Results of the Overall Analysis will provide information about the overall quality of the project. The results of the analysis will be provided to the head of the departments to take improvement actions.

In addition to taking immediate improvement actions (where possible), the issues and action taken will be discussed during the Management Review Meeting to ensure full participation of management in the improvement actions and to ensure that the improvement actions are transmitted to different levels of the Contractor organization. When required, the Quality policy and Quality Objectives will be revised to indicate the changes. Monitoring of these objectives will be included in the internal audit scope and the results will be presented to the management to take appropriate action. PQM is responsible to assure implementation of this planning for improvement effort. Reference: Preventive and Corrective Action 00-ZA-E-G09603


Rev. 00A

Date 06-06-2013

Sheet 64 of 64 13.5.2

CORRECTIVE ACTION AND PREVENTATIVE ACTION

CONTRACTOR has established a corrective action program to eliminate the causes of the nonconformity and prevent its recurrence. Corrective action will be appropriate to the severity of the nonconformity identified. A documented procedure for corrective action has been established. The procedure addresses nonconformity identification (including COMPANY complaints), cause determination, action to prevent recurrence, identifying and implementing the corrective action, recording results, determining if the corrective action was implemented and effective in resolving the nonconformity. Corrective action for non-conformances identified during audits shall be addressed through the “Corrective Action Request” form. Reference: Preventive and Corrective Action 00-ZA-E-G09603

00-ZA-E-G09600_00A

Recommend Documents