QualityPlan FPSO Topside

DOCUMENT NO.

BON-AME-3GN-Q-00190-001

CONTRACT NO. :

CONTRACT NO. : P0001

L00802

SNEPCO BONGA FPSO TOPSIDES, COMMISSIONING AND OPERATIONS HANDOVER

DOCUMENT TITLE :

Project Quality Plan

A02 A01 R01 REV.

Re-issued for Design Issued for Design For comment/use ISSUE OR REVISION DESCRIPTION

EA

15/03/ 01

RA

15/03/01

DMH

15/03/01

EA EA ORIG. BY

Feb 01 Feb 01 DATE

RA RA CHKD. BY

Feb 01 Feb 01 DATE

DMH DMH APPD. AMEC

Feb 01 Feb 01 DATE

Page 1 of 37

APPD Client

DATE

____________________________________________________________________________________

REVISION CHANGE NOTICES Rev. R01 A01

Location of Changes Initial issue for comment/use Issued for Design

A02

Re-issued for Design

Brief Description of Change Incorporation of comments resulting from internal review. Also change in document number from BON-AME399-Q-PRC001. Changes as discussed with SNEPCO 6th/7th March 2001. Refer Minutes of Meeting No: L00802/AME/SNEPCO/R1/015 plus other minor comments. Also change in document number from BONAME-3GN-G-000199-007.

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CONTENTS

1.0

GENERAL 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12

2.0

Introduction Issue and Distribution Terms and Definitions Project Quality Policy Statement Quality Objectives Organisation and Resources Management Reviews Performance Standards and Contract Control Assessments Sub-Contractors Audit by SNEPCO Quality Improvement Integration with other Management Systems

PROJECT QUALITY MANAGEMENT SYSTEM 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17

Project Quality Management System Structure General Contract Review Design Control Document and Data Control Purchasing Process Control Inspection and Testing Inspection, Measuring and Test Equipment Inspection and Test Status Non-Conformance and Corrective Action Handling, Storage, Packaging, Preservation and Delivery Quality Records Quality Audits Training Servicing Statistical Techniques

APPENDICES APPENDIX I APPENDIX II

Organisation Charts Audit and Review Strategy


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1.1

INTRODUCTION The contents of this Project Quality Plan are based on, or interface with, the applicable requirements of the following Specifications: 

ISO 9001:1994



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



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



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



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



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



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



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



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

The purpose of the Project Quality Plan is to provide the first tier of the overall project quality management system structure and to provide means by which project management shall derive confidence that the Project is being executed in accordance with the requirements of the contract and related regulatory requirements. The Project Quality Plan will be supported by the Key Quality Activities Matrix (Doc No: BON-AME-3GN-Q-00190-002), as referenced above, which will be used to facilitate implementation of the project quality management system. The Matrix will define the key quality activities, procedures, responsibilities etc, for the contracted scope of work. This Quality Plan, and revisions thereto, shall be submitted to SHELL NIGERIA EXPLORATION AND PRODUCTION COMPANY LIMITED (SNEPCO) for review and approval. This Project Quality Plan is a 'live' document and as such will be subject to periodic review/change in line with identified and agreed amendments and improvements to the Project Quality Management System during the course of the Project. The Project Quality Plan will also be reviewed and updated to accommodate any additions or changes to the contracted scope of work. This Project Quality Plan is supported by the individual quality plans of AMEC’ fabrication division, other major fabrication subcontractors and the Nigerian engineering design facility. The supporting plans, as referenced within Section 2.1 of this Project Quality Plan, will be reviewed by the Project QA function for alignment and compliance with the AMEC Project Quality Management System.


____________________________________________________________________________________ 1.2

ISSUE AND DISTRIBUTION The Project Quality Plan will be made available electronically, on ‘read only’ basis, on the Project ‘M’ drive. Limited “controlled” hard copies will be issued as authorised by the Manager on an ‘as required’ basis to nominated individuals who responsible for its implementation and update within their functions. copies, including those hard copies down-loaded from AMECnet and drive, shall be deemed to be “uncontrolled”.

Project Quality shall be held All other hard the Project ‘M’

Hard copies requested by SNEPCO shall be formally transmitted via the Project Document Control function who shall retain records of recipients. Project personnel will be responsible for reporting to Project Management any deficiencies or problems and suggesting improvements resulting from the use of the Project Quality Plan and related procedures. Revisions The Project Quality Assurance Manager will update and revise the Project Quality Plan whenever changes, additions or deletions are found to be necessary. When a revision to the text results in a change, addition or deletion, the area of the current revision shall be identified in the left hand margin of the page adjacent to where the change/addition/deletion was made. All previous revision identification shall be removed. 1.3

TERMS AND DEFINITIONS For the purpose of this Project Quality Plan and supporting procedures the following definitions shall apply. TERMS

DEFINITIONS

Quality

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

Quality Management

That aspect of the overall management function that determines and implements the quality policy.

Quality Assurance

All those planned and systematic activities and functions necessary to provide adequate confidence that a product or service shall satisfy given requirements for quality.

Quality Control

The techniques and activities that demonstrate compliance with specified requirements. This includes inspection, test, etc.

Quality System

The aspect of the Quality Management System, setting out the quality practices, policies and procedures demonstrating compliance with ISO 9001.


____________________________________________________________________________________ Quality Plan

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

Quality Activity Control Plan

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

Inspection and Test Plan

A document relating to purchased / subcontracted products and services which lists in a logical sequence key activities such as purchase order review, manufacturing, construction, inspection, test and verification activities. It identifies individual activities, controlling procedures / standards, characteristics to be verified, acceptance criteria, verifying documentation, inspection and test requirements, etc.

Quality Audit

A systematic and independent examination to determine whether quality activities and related results comply with planned and/or documented arrangements and whether these arrangements are implemented and effective in achieving stated objectives.

Supplier

Organisation that provides a product to the customer. The reference to "supplier" includes for “vendors”.

Product

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

SNEPCO

Shell Nigeria Exploration and Production Company Limited

AMEC

AMEC Services Ltd, Offshore Business Unit.


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1.4

PROJECT QUALITY POLICY STATEMENT

It is the policy of AMEC to provide products and services that fulfil the quality, reliability, safety and specified requirements and stated expectations of the Project. In order to achieve this policy for the SHELL NIGERIA EXPLORATION AND PRODUCTION COMPANY LIMITED (SNEPCO) Bonga Project, the project team shall be committed to establishing and maintaining an effective Project Quality Management System complying with the requirements of ISO 9001: 1994, the Contract specifications and related regulatory requirements. Compliance with the Project Quality Management System and the supporting systems, procedures, work instructions etc is mandatory and shall be adhered to by all personnel employed on the project in order to achieve a common approach to Quality Assurance. The Project Quality Assurance Manager will have overall responsibility for ensuring that the contents of this Project Quality Plan are satisfactorily implemented across the Project, including within key sub-contractors. As part of this responsibility the Project Quality Assurance Manager shall also ensure, as far as practicable, the alignment of sub-contractors quality management system with that described within this Project Quality Plan. The Project Quality Assurance Manager shall ensure that any problems or disputes arising from such are brought to the attention of the AMEC Project Manager, SNEPCO and/or senior management as appropriate. Wherever possible the recommendations and "learning” resulting from AMEC’s approach to continuous performance improvement shall be fully integrated into the way of working on the Project to ensure that an efficient and cost effective approach is achieved. This ‘approach’ considers that everyone involved with the Project has a responsibility for contributing towards continuous improvement and for benefiting from “lessons learned” from previous projects/work. A joint working relationship with SNEPCO shall be cultivated to enable an open and free exchange of information in order to ensure that the Project is safe and reliable, completed on time, within target cost and to the required quality.

AMEC Project Manager


____________________________________________________________________________________ 1.5

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

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

-

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

-

In accordance with contractual and regulatory requirements.

-

Performed correctly the first time to ensure cost effectiveness and efficiency.

-

Undertaken within an environment of Continuous Performance Improvement.

1.6

ORGANISATION AND RESOURCES

1.6.1

Project Organisation The overall organisation for the Project shall be as per the organisation charts included within the Project Execution Plan (Document No: BON-AME-003-G-00001). The organisation chart for the London QA & Certification/Classification team together with the chart showing interfaces with the key sub-contractors are shown in Appendix 1. Also to be included within this Appendix will be the QA/QC organisations for the individual sub-contractors. 1.6.1.1 Job Description for Key Personnel Job descriptions shall be available for all project personnel and shall include the following as a minimum:   

Function description Responsibilities, including for safety and quality. Accountability

Each key Project team member shall hold or have access to a copy of his/her job description. The responsible manager for each area shall also hold or have access to relevant copies. The Project ‘M’ drive shall contain those job descriptions applicable to AMEC London based personnel. Non- AMEC personnel shall work according to the requirements of their respective management systems which are required to comply with the AMEC project quality management system. 1.6.2

Quality Assurance Function The Quality Assurance function shall be headed by the Project Quality Assurance Manager, supported by the Lead Quality Assurance Engineer who shall manage and ensure that the principles of Quality Assurance and Quality Control are actively practised by all project personnel in their daily activities throughout the duration of the project. The Project Quality Assurance function shall be responsible for ensuring that the requirements of this Project Quality Plan, associated procedures and work instructions are integrated into the working methods of project personnel, and that objective evidence of compliance with specified requirements is generated. The Project Quality


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

1.6.3

QA Job Function and Accountability 1.6.3.1 Quality Assurance Manager Function: To plan, co-ordinate and report the day to day functions of the QA requirements dictated by the Contract and the Project Quality Management System. To monitor the implementation of the Project Quality Plan and assess its operation by review and audit and manage the QA activities defined by the contract workscope. To liaise with SNEPCO on all matters relating to Quality Assurance. Accountability: Reports directly to the AMEC Project Manager regarding day to day project activities but also has a reporting line to the AMEC Corporate Director responsible for quality, in particular, in those instances where there may be quality related problems which cannot be resolved at Project level. 1.6.3.1.1

Responsibilities of the Project Quality Assurance Manager

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

To issue, revise and control the Project Quality Plan.

-

To perform QA activities against the Project Quality Plan and Project Programme.

-

To review the contract with regard to Quality related activities.

-

To convene, attend and minute QA related meetings with SNEPCO as necessary.

-

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

-

To plan, perform and report audits and reviews in accordance with the agreed Audit and Review Programme assisted where necessary by AMEC Corporate specialist discipline personnel.

-

To monitor by audit and review, the compliance of sub-contractors with the requirements of this Project Quality Plan including overseeing the implementation of their own individual project quality management systems.

-

To perform supplier quality audits as agreed with the AMEC Project Manager.

-

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


____________________________________________________________________________________

1.6.5

-

To monitor the application of quality assurance requirements for requisition packages.

-

To review sample enquiry and purchase requisitions to ensure quality related requirements have been adequately specified.

-

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

-

To review supplier Inspection & Test Plans.

-

To facilitate development of QA procedures identified by the Project Quality Plan and review other procedures to ensure applicability to the Project.

-

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

-

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

-

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

-

To monitor and review the Certification/Classification programme implemented for the Project.

-

To provide QA input to project induction sessions.

-

To direct the Lead QA Engineer in the performance of the above as required.

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

1.6.6

Certification/Classification Job Function and Accountability 1.6.6.1 Lead Certification/Classification Engineer Function: Focal point responsible for the co-ordination of the Certification/Classification effort on behalf of AMEC and the principal sub contractors. The Lead Certification/Classification Engineer shall be responsible for maintaining records


____________________________________________________________________________________ of submissions made via SNEPCO to the various authorities and for the coordination of Project team responses to queries resulting from such submissions. Accountability: The Lead Certification/Classification Engineer shall report directly to the Project Quality Assurance Manager but will also be the focal point with SNEPCO who in turn shall have direct contact with the various regulatory bodies

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

1.7

-

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

-

To perform activities against the Certification/Classification Plan and Project Programme.

-

To issue, revise and control the Regulatory Permits and Consents Compliance Plan.

-

To convene, attend and minute Certification/Classification related meetings with SNEPCO as necessary.

-

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

-

To monitor the application of Certification/Classification requirements for requisition packages.

-

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

-

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

-

To provide Certification/Classification input to Project Reports.

-

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

-

To monitor and review the Certification/Classification programme implemented for the Project.

-

To provide Certification/Classification input to project induction sessions.

MANAGEMENT REVIEWS The AMEC Project Manager shall sponsor periodic (i.e. six monthly) Management Reviews of the Project Quality Management System. The Reviews shall be attended by the senior project personnel, typically Project Manager, Engineering Manager, Procurement Manager etc, and principal sub-contractors.


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

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



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



Identified deficiencies are corrected in a proper and expeditious manner.



All other matters of any concern are examined.

These reviews shall be identified on the Audit and Review Programme and shall compliment the ongoing feedback and improvement of the Project Quality Management System in its day to day implementation. Findings and recommendations arising from these reviews shall be reported to Bonga Project and AMEC Corporate Management and SNEPCO. Follow-up, verification and close-out of actions arising from such reviews shall be performed and reported by the Project Quality Assurance Manager.

1.8

PERFORMANCE STANDARDS & CONTRACT CONTROL ASSESSMENTS AMEC Company policy is that all projects use performance standards as the base document in formulating their Management System arrangements, including customer and sub-contractor interfaces. The ten performance standards are: -

Management leadership, commitment and accountability

-

Risk assessment and management

-

Design and construction

-

Operations and maintenance

-

Employee competency and involvement

-

Occupational health

-

Third party management

-

Impact upon the community and emergency planning

-

Incident investigation and analysis

-

Measurement, audit and review

The Project shall carry out an annual self-assessment of the status of the Management System with a resulting improvement plan, which will advance performance towards a set of defined targets. Improvement plans shall take account of any common or joint aspirations of the customer, AMEC and sub-contractors etc, as applicable. The performance standards and self-assessment results shall also form the basis of major internal audits (termed Contract Control Assessments) performed by persons independent of the Project.


____________________________________________________________________________________ The self-assessment tool considers several related criteria under each of the defined performance standards and this lends itself to focussed improvement targets. Information on self-assessments for projects and contracts is published on AMECnet together with the related contract improvement plans.

1.9

SUB- CONTRACTORS All subcontractors employed on the Project shall be required to demonstrate capability in operating formal quality management systems in accordance with ISO 9001 or ISO 9002 as appropriate and to work in accordance with approved Quality Plans and Procedures. Subcontract documents shall specify all relevant standards and shall define the quality assurance and control requirements to be complied with by the subcontractor throughout the duration of the Project. Close liaison shall be maintained by the QA function with key subcontractors, typically through site visits, management reviews, audits etc, throughout applicable phases of the Project to ensure efficient sub-contract completion. This however shall not absolve the subcontractor from his responsibility in monitoring and auditing his scope of work in accordance with approved audit/review programmes. All subcontractors shall be required to produce their own Quality Plans that shall be submitted to the Project team for review and approval by the Project QA Manager. Each subcontractor, in addition to undertaking their own audits in accordance with their procedures and programme, shall be subject to periodic audit and/or review by AMEC in accordance with the agreed Project Audit and Review Plan. Planned audits of main subcontractors may, at the discretion of the Project Quality Assurance Manager, be treated as “healthcheck” reviews. Where possible such reviews shall be timed to coincide with any audits to be undertaken by the subcontractor. The degree of monitoring shall generally be dependant upon the level of performance of the subcontractor and the type of product subcontracted. Increased monitoring shall be implemented in those instances where defects with the subcontractors quality management system or defective performance have been identified.

1.10

AUDIT BY SNEPCO SNEPCO and/or its authorised representatives shall be afforded access at all reasonable times for the purpose of audit, review and surveillance of aspects that are subcontracted subject to all such parties complying with the subcontractors current HSE and security regulations applicable to the worksite(s) to be visited. AMEC shall liaise with subcontractors to ensure that any arising corrective actions are satisfactorily actioned and closed-out within a mutually agreed timescale.

1.11

QUALITY IMPROVEMENT All work associated with the Project shall be undertaken within an environment of continuous performance improvement.


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

the for the the

The Project will strive for a consistency for quality measurements across the contracted scope of work in order to identify possible opportunities for improvement. All project personnel shall be responsible for reporting quality deficiencies and suggested improvements. Ad-hoc improvement teams/groups shall be established, as required, to tackle particular problem areas and to identify/facilitate solutions for improvement. The Q-Pulse ISO 9000 Records Management System will be the vehicle for registering and monitoring of formal recommendations for improvement.

1.12

INTEGRATION WITH OTHER MANAGEMENT SYSTEMS AMEC recognise the similarities between Quality, Safety, Health, Environmental and other management systems and shall ensure that integration of key quality management system activities with those other systems is achieved without conflict or duplication.


____________________________________________________________________________________ 2.0

PROJECT QUALITY MANAGEMENT SYSTEM

2.1

PROJECT QUALITY MANAGEMENT SYSTEM STRUCTURE The Quality Management System structure for the Project shall be established in four levels as follows: 1st Tier Document - Project Quality Plan The Project Quality Plan shall be the 1st Tier Document of the project quality management system and is based on the requirements of ISO 9001: 1994. The objective being to employ a system of control so that systems, components, structures etc., are designed, procured and manufactured and constructed in accordance with the applicable contract requirements, codes, specifications and drawings. The Project Quality Plan provides the interface with the content of the individual quality plans to be developed and utilised by AMEC’s fabrication division and each of the major subcontractors as follows: AMEC Wallsend – Doc No: tba Heerema Zwijndrecht – Doc No: tba Heerema Hartlepool – Doc No: tba Fabrication facility (Nigeria) – Name of facility and Q Plan Number tba Netco Nigeria – Doc No: tba 2nd Tier Document - Key Quality Activities Matrix The Key Quality Activities Matrix, (Document No: BON-AME-3GN-Q-00190-002), issued as a supporting document to this Project Quality Plan, shall tabulate the activities and identify the controlling procedures which shall describe in detail the quality activities to be executed in order to satisfy the contract requirements. The Key Quality Activities Matrix will also provide an interface to key activities relating to subcontracted scopes of work. 3rd Tier Documents – Control Procedures These control procedures are those which are identified within Key Quality Activities Matrix. It is the intention of the Project to utilise as far as possible those procedures which are AMEC standard. Where necessary, existing procedures shall be amended, or new versions developed, to take cognisance of those business processes which may be specific to the project. Co-ordination procedures shall also be developed as necessary to address those systems and business processes which shall be common across the project, e.g. document control, cost reporting etc. Sub-contractors procedures shall be identified within their own individual quality plans as identified above.

4th Tier Documents - Inspection and Test Plans


____________________________________________________________________________________ Inspection and Test Plans (also referred to as Quality Control Plans) shall be developed as required by AMEC and its suppliers and subcontractors to cover specific products, services or scopes of work. The Inspection and Test Plans shall identify the quality related activities, the controlling procedure/specification/drawing, the acceptance criteria, verifying documentation and inspection and surveillance requirements. The requirements of such Inspection and Test Plans shall relate to the criticality of the purchased/subcontracted product or scope of work.

2.2

GENERAL The following subsections explain briefly how the applicable clauses of ISO 9001: 1994 will be addressed by the Quality Management System established for the Project. The relevant clause of ISO 9001 is shown in brackets against each sub-section title. Also included within the following subsections are those key procedures applicable to that subject. For a more detailed explanation of control procedures reference shall be made to the Key Quality Activities Matrix, (Document No: BON-AME-3GN-Q-00190-002) which is issued as a supporting document to this Project Quality Plan.

2.3

CONTRACT REVIEW (4.3) Contract reviews shall be performed in order to verify contract documents, and authorised amendments thereto, in order to familiarise project personnel with Scope of Work, contract documentation and requirements, and to identify and resolve errors/ inconsistencies / ambiguities as well as deviations from tender documentation and Bid Clarification agreements. Applicable Procedures: 3319-300

2.4

Contract Review

DESIGN CONTROL (4.4) The following describes the general requirements for the control of design activities and review of engineering information to ensure compatibility with the Contract requirements. Design Development and Planning Established procedures shall be utilised to cover the control and verification of the design. Design interfaces shall be established where necessary and shall be generally in the form of document transmittals, technical queries, meetings, reviews, letters etc.

Organisation and Technical Interfaces Design documents shall be circulated to associated disciplines for review and comment based on the Project document distribution schedule (or as additionally required by the originating discipline).


____________________________________________________________________________________ Inter-discipline design co-ordination shall be undertaken in accordance with established procedures. In addition, regular design reviews shall be convened to identify and resolve any design restraints and interface queries. Interfaces between the AMEC and related sub contractors shall be controlled on the Project via an external interface procedure which shall cover both technical interfaces and reporting paths. Design Input Contract Specifications shall be reviewed to establish that all applicable design inputs, such as process information, data, codes, standards and specifications are available. Design input shall be subject to an initial review of the information/data received, including that received in electronic form. Subsequent information/data shall be reviewed and any inconsistencies, ambiguities or conflicting requirements shall be referred back to the originator who may be AMEC, SNEPCO, main sub-contractor or a supplier. Design Output Design output shall be verified by a formal system of checking, review and approval to ensure that design input requirements are met, contain or reference applicable acceptance criteria, conform to the regulatory requirements. Also to ensure that all characteristics of the design which are crucial to the safe and proper functioning of the supplied product are incorporated. Design Review Design reviews shall be accomplished at specific stages during the life of the Project, in accordance with formal procedures, by a number of methods including:      

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

As part of design review activity AMEC shall also perform a Safety and Operability Study of Electrical Systems (SAFOP) study in accordance with Shell Global solution document SIOP-OGBE/3. The reviews shall ensure, among other things, that the design:   

can be constructed, inspected, tested, operated and maintained. complies with weight and space requirements. complies with the specific safety, environmental, availability, operability and maintainability requirements.

Participating in these reviews shall be SNEPCO and representatives from each discipline whose function shall have a direct effect on quality appropriate to the design phase reached in the progress of the contract. In addition this shall apply to main subcontractors and key suppliers as applicable.


____________________________________________________________________________________ The timing of these reviews shall be dependent on the progress of the project and the interfaces associated with different disciplines. Records of these reviews shall be documented and maintained. Design Verification Design documents generated within the Contract work-scope shall be subject to verification checks by independent checkers, within the Bonga design team, in accordance with relevant project procedures to ensure that:    

it is correct, clear and unambiguous. it complies with the technical, format and presentation requirements. it is adequately substantiated by calculation. all interfaces have been identified and addressed.

The level of verification shall generally relate to the importance/complexity etc of the related product or system. Design documentation shall also be subject to inter-discipline review by other engineering disciplines in accordance with formal procedures. Design documentation shall be checked by competent personnel to ensure that it incorporates applicable information and feedback from suppliers and subcontractors, SNEPCO and any third parties and regulatory bodies. The output from computer calculations shall be verified as for design documentation and shall be checked by alternative calculation methods. Computer data shall be secured from loss or damage by regular back-up and protected from unauthorised access. All design software shall be subject to validation prior to use on the project. Such validation shall be completed either corporately or on the Project. The suitability of software packages for use with American Specifications and Standards shall be formally assessed/verified prior to use. Design Validation The Project shall utilise design validation to ensure that supplied product conforms to Contract requirements. Such needs and requirements shall be established through contract review and shall be translated into design input requirements e.g. Job Design Specifications etc. The comparison of the design against contract requirements shall be achieved by a number of means such as feedback from contract review activities, technical audits, safety audits, project review meetings, FAT’s, performance tests etc. Design Change Controls Design change control procedures shall ensure that:

Design changes are reviewed and approved, where possible, by the same personnel who performed the original design.



Information concerning design changes is transmitted to all personnel affected by the design change, in a controlled and timely manner.


____________________________________________________________________________________ 

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



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

Where it is not possible for the originator of the design to perform the design change, then another responsible person or organisation will be appointed to conduct the review. Reliability, Maintainability and Operability Reliability, maintainability and operability activities shall be performed in accordance with approved project procedures. In addition, formal assessments such as reviews, studies, functional tests etc, shall be performed to demonstrate compliance with the specified reliability, maintainability and operability requirements. Weight Control Weight control activity shall be co-ordinated by a dedicated Project Lead Weight Control Engineer who shall report to the Bonga AMEC Engineering Manager. Weight control shall be undertaken in accordance with approved procedure(s) and shall include, but not necessarily be limited to: -

Weight estimation, with estimate refining as more accurate data becomes available.

-

Calculation of centres of gravity, with calculation refining as more accurate data becomes available.

-

Issue weight control reports plus update of the equipment list.

-

Incorporation of weight control in change procedure.

-

Liaison between topsides weight control and vessel stability calculations.

Applicable Procedures: BON-AME-3GN-G-00190-003 BON-AME-3GN-Q-00190-004 BON-AME-3GN-G-00190-002 BON-AME-3GN-W-00190-001 3318-000 3212-030 3305-000 3319-100 3319-200 3320-300 3319-400 3324-320 3324-322 3322-282 3322-290 3322-250 3323-200

External Interface Procedure Supplier Concession Request Procedure Procedure for Use of SI Units Project Weight Control Procedure Engineering Administration Project Variations Produce Project Design Basis Checking & Approval of Design Documents Inter-Discipline Reviews Detailed Design Execution Design Reviews Interface Control (Internal) Client Interfaces Change Control Operability & Maintainability Studies Reliability & Availability Studies Technical Audits


____________________________________________________________________________________ 2.5

DOCUMENT AND DATA CONTROL (4.5) Document Control procedures shall ensure that all correspondence, drawings and technical data received or generated is recorded, distributed, filed and stored in an efficient and controlled manner. The Project Document Control function shall be the focal point for co-ordinating control and issue of project documentation. Control activities exercised on the documentation shall include the following: Review of documents, including drawings, prior to release to ensure that all applicable requirements are clearly stated and that they are authorised for issue.  Identification of documents to be controlled.  Review and approval of changes to documents and drawings.  Control of documents, including approved changes, to preclude inadvertent use of obsolete or superseded documents.  Filing and storage control. All revisions to drawings and technical documents shall be handled in a manner as described within the project procedure for the receipt, issue and control of documentation. Formal procedures shall be implemented for control of CD Rom usage, particularly for the archiving of project records. Virus checking procedures shall be implemented for individual PC’s and remote laptops to guard against the import of viruses, particularly from the Website, emails and boughtin software packages. Also to protect against the spread of potential viruses within electronic documentation. This shall be particularly important with respect to ‘e’ data transfer between Project and suppliers and sub-contractors. Applicable Procedures: 3319-500 3216-010 3318-200

2.6

Validation of Engineering Software Control of Engineering Documentation Filing & Archiving of Documents

PURCHASING (4.6) General Products shall only be purchased from suppliers who can demonstrate an ability to comply with the relevant Project Procurement Quality requirements. This shall be achieved by one or a number of the following as appropriate: -

Satisfactory performance profile within the First Point Assessment Ltd (FPAL) database. Included on SNEPCO "Acceptable Vendors Lists".


____________________________________________________________________________________ -

Approved by a recognised third party (e.g. DNV, BSI, LRQA etc.) to a national or international quality standard covering the scope of intended work. Successfully demonstrating second party audit compliance. Successful Project QA assessment/audit.

In addition, the qualification of suppliers shall be dependent upon other criteria such as product capability, safety, capacity, on-time delivery etc, as appropriate. Purchasing Data Purchasing data shall be kept to a level appropriate to the importance and complexity of the product or service being purchased and shall be clearly identified within the requisition package. Supplier Audits Where, due to lack of third party quality system approvals or previous knowledge of unsatisfactory performance or other concerns, a pre-award audit of the supplier may be deemed necessary, such audits shall be formally carried out, following agreement with the AMEC Project Manager. Similarly, those audits identified after award shall be formally undertaken following agreement with the AMEC Project Manager. Such audits shall be identified on the Project Audit and Review Programme. SNEPCO shall be provided with ten working days notice of those audits that are to be carried out by AMEC at suppliers works. Analysis of Tenders Documentation received from suppliers in respect of bids shall be formally assessed by the relevant disciplines in accordance with established procedures. Deviations and Concessions Supplier deviations and concession requests shall be reviewed by the appropriate discipline(s) in accordance with established procedures. Accepted deviations and concessions shall be formally recorded so that the circumstances under which and the specification against which the concession, waiver or deviation was approved can be readily identified. Waivers and concessions that have an impact on contract requirements shall be subject to SNEPCO agreement. Applicable Procedures: BON-AME-3GN-Q-00190-004 3321-100 3321-112 3321-120 3428-100 3429-000 3430-000 2.7

Supplier Concession Request Procedure Procurement of Equipment Requisition Packages Technical Bid Analysis Purchasing of Materials and Equipment Expediting Inspection

PROCESS CONTROL (4.9) All processes affecting quality of delivered product, including special processes, shall be accomplished under specified and controlled conditions by qualified and experienced personnel using approved procedures.


____________________________________________________________________________________

Qualifications of special processes such as welding, heat treatment, non-destructive testing, coating etc, personnel performing special processes, and equipment shall be maintained current and records thereof shall be maintained. Procedures and personnel qualifications for special processes shall be subject to review by SNEPCO. Applicable Procedures: 4506-100 3321-100 TBA 2.8

Supplier Quality Plans Procurement of Equipment Subcontractors Quality Plans

INSPECTION AND TESTING (4.10) Inspection and testing by subcontractors and suppliers shall be carried out in accordance with approved and valid test procedures that shall be identified within the Inspection and Test Plans (Quality Control Plans) approved by AMEC. Each subcontractor and supplier involved in the Project shall provide its own Q.C./inspection arrangements but the adequacy and effectiveness of such arrangements shall be assessed by means of audit, review, surveillance or inspection by the Project Quality Assurance Function and/or project inspectors. Levels of quality surveillance by AMEC and SNEPCO shall be defined within the subcontractor and supplier Inspection and Test Plans (Quality Control Plans) and , where relevant, will reflect the specific requirements of Bonga-SPEC-GL-001. Where appropriate, provision shall be made for the independent checking of critical dimensions, including interfaces, before proceeding with work that would increase the cost of correcting possible errors or that would lengthen the construction schedule if errors were discovered later in the construction sequence. The level of inspection may also be influenced by the complexity of the product or service being purchased and also to the suppliers past and current performance. Verification that an item offered as complete has undergone the required inspections and tests shall be achieved by the review of the Inspection and Test Plans and quality records generated during all phases of the project. Any products found to be non-conforming shall be identified as such in accordance with the applicable project procedure(s). The subcontractor or supplier shall be required to inform AMEC in advance for agreed witness points in advance of the activity. AMEC in turn shall advise SNEPCO of any required witness points in accordance with documented process. Work may proceed beyond a witness point if AMEC/SNEPCO do not attend. Applicable Procedures: BON-AME-3GN-Q-00190-004 3430-000 3321-100 TBA

Supplier Concession Request Procedure Inspection Procurement of Equipment Subcontractor Quality Plans


____________________________________________________________________________________ 2.9

INSPECTION, MEASURING AND TEST EQUIPMENT (4.11) Control procedures shall ensure that inspection measuring and testing devices used in activities affecting quality are properly controlled and calibrated. Selection of the measuring and test equipment shall be controlled to ensure that such items are of the proper type, range, accuracy and tolerance to conform with the specified requirements. The method and interval of calibration shall be determined by the items intended use. Measuring and test equipment shall be properly handled and stored to maintain accuracy. Applicable Procedures: 3430-000 TBA

2.10

Inspection Subcontractor Quality Plans

INSPECTION AND TEST STATUS (4.12) Records shall be compiled and documents maintained in a logical, progressive sequence, to enable the current inspection and test status during manufacture to be determined. Suppliers and subcontractors engaged on the Project shall be subject to their own Quality Control surveillance and inspection activities and shall progressively record the inspection and test status of the product or service provided. A positive recall system shall be required for those instances of release of product to the workplace, prior to clearance of inspection. Applicable Procedures: 3430-000 TBA

2.11


NON- CONFORMANCE AND CORRECTIVE ACTION (4.13, 4.14) All project personnel have the responsibility for ensuring that any deficiencies, ambiguities and problems are resolved to the satisfaction of the project team. Non-Conformities regarding the Project Quality System as identified by Quality Assurance Audits and Reviews shall be formally recorded on Corrective Action Requests and progressively monitored and closed out. Consistency in the use of non-conformance reports shall be established for the Project. Non-conformance reports initiated internally, at the subcontractors or suppliers works shall be referred to SNEPCO, who shall have the right, but not the obligation, of concurrence with the proposed corrective action.


____________________________________________________________________________________ Formal internal audits shall be performed in accordance with approved procedures by personnel independent of the process, and any non-conformities identified shall be resolved by the project lead engineers to the satisfaction of the Project Management. Deviations to contract requirements shall only be allowed with SNEPCO formal approval. Identified deviations to specification(s) that relate to purchased or sub contracted services shall be subject to rejection, rework or acceptance with concession approval in accordance with procedures. Applicable Procedures: 3430-000 TBA BON-AME-3GN-Q-00190-004 4502-000 2.12

Inspection Subcontractor Quality Plans Supplier Concession Request Procedure QA Audits

HANDLING, STORAGE, PACKAGING, PRESERVATION AND DELIVERY (4.15) Products shall be subject to receipt inspections as detailed within the applicable quality control plans and procedures to verify compliance with the contract specifications, including for loss, damage, overage and shortage. Any product that is found to be non-conforming shall be identified and marked as such and, where practical, removed to a segregated holding area. Product traceability, where required, shall be maintained in accordance with applicable specifications and procedures. Fabricators and suppliers procedures shall provide for verification of correct identification of materials, parts and components prior to release for fabrication, assembly, shipping or installation. Materials and equipment shall be stored in such a manner as to prevent damage and contamination during the period of storage. Where appropriate, such storage requirements shall be specified by the supplier. Compliance with SNEPCO procedures and specifications relating to preservation and storage shall also be required. Applicable Procedures: 3430-000 TBA

2.13


QUALITY RECORDS (4.16) Records that furnish documentary evidence that the quality of items produced and activities affecting quality are consistent with the applicable procedures, codes and specifications shall be systematically collated, stored and maintained in accordance with the requirements of the applicable procedures. Documentation shall be progressively collated and filed throughout the period of work in accordance with the quality records procedure(s). Such records shall be made available for review by SNEPCO as required during execution of the contracted scope of work.


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A system shall be in place that determines the handover status of records to SNEPCO and regulatory bodies at any time relative to the project schedule and contract requirements. A central document management system shall include a record indexing system which shall enable easy reference and retrievability of quality records. Quality records shall be legible and traceable to the item or activity involved. The Project shall also utilise a Projects Completions System (WinPCS) which will be the process by which systems hand-over will be managed and controlled from mechanical completion through to ready for safe commissioning and start-up Applicable Procedures: 3318-200 3216-010 4505-000

2.14

Filing and Archiving of Documents Control of Engineering Documentation Archiving & Retrieval

QUALITY AUDITS (4.17) Compliance with the Project Quality Management System shall be verified by a planned programme of quality audits and reviews. An Audit and Review Schedule (BON-AME-3GN-Q-00190-003) is issued as a separate document in support of this Project Quality Plan. In addition to identifying planned formal audits the Schedule shall identify “healthcheck” reviews to be undertaken on those main sub-contractors as identified within Section 2.1 of this Project Quality Plan. AMEC project and SNEPCO auditing functions will be aligned to facilitate joint auditing where practicable. AMEC shall utilise the Q-Pulse ISO 9000 Records Management System for the management of the audit and review programme and for the retention of electronic audit reports and corrective action requests. Quality Audits are an additional means of gauging the progress towards the required objectives and should be seen as assisting the overall workscope activity. Quality Audits are required to be carried out in order to verify that the requirements of ISO 9001: 1994 and the documented Quality Management Systems are being complied with. Quality audits as well as providing assurance that the activities are being carried out in accordance with prescribed procedures shall also be proactive in identifying and facilitating solutions for any omissions or deficiencies discovered within the established procedures and working methods and for identifying opportunities for improvement. All audits shall be carried out by persons who are trained and experienced Assessors or Lead Assessors. Audits and reviews shall be re-scheduled as necessary during the course of the project to align with any future changes to the Project Master Schedule. Where possible, internal audits of a similar nature across more than one discipline shall be scheduled to


____________________________________________________________________________________ occur at the same time in order to minimise inconvenience. The resulting reports shall thus be of a multi-discipline nature. The hierarchical approach to auditing and review for the Project is indicated by the Project Audit and Review Strategy included as Appendix II of this Project Quality Plan. Corporate Audits These audits shall be carried out by persons independent from the Project and who represent AMEC Corporate management. Copies of the reports and any related findings shall be issued to the AMEC Project Manager who shall arrange distribution as appropriate. These audits will be carried out annually. Applicable Procedures: BON-AME-3GN-Q-00190-003 4502-000 3322-280 3323-200 2.15

QA/HS&E Audit & Review Schedule QA Audits Safety Audits Technical Audits

TRAINING (4.18) The Project Quality Assurance Manager shall provide input to induction sessions as necessary for project personnel at which time the contents/requirements of this Project Quality Plan and supporting procedures shall be explained and discussed as well as any changes to the normal method of working which may have been identified for the contract. A further aspect of training shall involve any "team building" that may be held during the course of the project. Where specialist skills/qualifications are required e.g. Welding/N.D.T.etc, the skill level proficiency shall be monitored and if any needs are identified, appropriate action shall be taken. The Project QA function shall, during audits and reviews, verify that personnel are qualified as appropriate to their job functions, that they have received required training and that effective methods are in place to ensure that additional training needs are satisfied. Applicable Procedures: 4210-000 4209-000

2.16

Training Induction

SERVICING (4.19) Where there is a requirement to include for servicing, including during post commissioning, operational support etc, then the methods and controls for this activity shall be planned and identified. The methods and servicing schedules shall generally be identified in the operating/ maintenance manuals for the product, which include such items as lubrication schedules, recommended spares lists, installation drawings/instructions, final certified drawings etc. for the product.


____________________________________________________________________________________

2.17

STATISTICAL TECHNIQUES (4.20) Statistical Techniques shall be used as required for establishing, controlling and verifying process capability, execution proficiency and product characteristics. Individual applications are described within appropriate procedures and are used during the inspection of bulk materials and items etc. Project quality measures shall also be supported by statistical techniques where appropriate.


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APPENDIX I ORGANISATION CHARTS


Bonga FPSO Topsides, Commissioning and Operations Handover

Project Quality Plan BON-AME-3GN-Q-00190-001 Revision A02

____________________________________________________________________________________

SNEPCO Project Manager

AMEC Project Manager D M Harwood

Quality Manager E Abbott (see chart 2)

HSE Manager N Beesley

- Certification/classification - QM - QC Inspection

- AMEC SMS/EMS -Subcontractors

Business Services Manager S Hope

Engineering Manager

Construction & Integration Manager tba

RE Austin

Overall Management Organisation ______________________________________________________________________________________________________ Page 29 of 34

Chart



____________________________________________________________________________________

AMEC Project Manager D. Harwood

AMEC Project QA Manager E. Abbott

Lead QA Engineer W. Davies

Lead Certification /Classification Engineer B. Barton

London QA & Certification/Classification Organisation ______________________________________________________________________________________________________ Page 31 of 34

Chart



____________________________________________________________________________________

AMEC Project Manager

AMEC Project QA Manager

Procurement (London)

Project QA & Classificatio/Certifica tion (London)

Procurement QC/Inspection

HU&C (Onshore/ Offshore)

Fabrication/ Integration (Wallsend)

Design Office (Nigeria)

Fabrication (Nigeria)

Fabrication (Zwijndrecht)

Fabrication (Hartlepool)

Quality Representativ e (tba)






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

Chart

QA/QC Organisation Interfaces ______________________________________________________________________________________________________ Page 33 of 34



____________________________________________________________________________________

ON HOLD

(Awaiting Charts from Wallsend and Sub-contractors)

QA/QC Organisations for Wallsend and Sub-Contractors ______________________________________________________________________________________________________ Page 34 of 34


Project Quality Plan BON-AME-3GN-G-00199-007 Revision A01

____________________________________________________________________________________

APPENDIX II AUDIT AND REVIEW STRATEGY

______________________________________________________________________________________________________ Page 35 of 36


Project Quality Plan BON-AME-3GN-G-00199-007 Revision A01

____________________________________________________________________________________

PROJECT QUALITY AUDIT STRATEGY

Project Quality Plan

Internal Quality Audits

AMEC London

Quality Audits & Reviews

Internal Audits

Internal Audits

Internal Audits

AMEC Wallsend

Hereema hartlepool

External Sub-Supplier and/or Sub-Contractor Audits


Sub-Suppliers and/or Subcontractors

Internal Audits

Internal Audits

Internal Audits


Heerema Zwijndrecht

Internal Audits Design Office (tba) Nigeria

External Sub-Supplier and/or Sub-Contractor Audits Internal Audits

Internal Audits


______________________________________________________________________________________________________ Page 36 of 36

Internal Audits Fabricator (tba) Nigeria

Spare




Internal Audits


QualityPlan FPSO Topside

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