Engineering Procedure SAEP-383 5 December 2012 Approving Third Party Testing Laboratories, Geotechnical Engineering Offices and Batch Plants Document Responsibility: Inspection Engineering Standards Committee
Saudi Aramco DeskTop Standards Table of Contents 1
Scope............................................................. 2
2
Conflicts and Deviations................................. 2
3
Purpose.......................................................... 2
4
Applicable Documents.................................... 3
5
Definitions and Acronyms............................... 4
6
Evaluation and Certification Procedures........ 5
7
Responsibility and Authority........................... 6
8
Approval, On-Hold and Withdrawal of Approval Procedures.......................... 8
Appendix A: Third Party Testing Laboratory Approval Process – Permanent Basis….. 12 Appendix B: Third Party Testing Laboratory Approval Process – One-Time Basis….... 13 Appendix C: Batch Plant Approval Process Permanent Basis…...….....……………..... 14 Appendix D: Batch Plant Approval Process One-Time Basis........................................ 15
Previous Issue: New
Next Planned Update: 5 December 2017 Page 1 of 13
Primary contact: Albarillo, Rodolfo Celino at 966-3-8801496 Copyright©Saudi Aramco 2012. All rights reserved.
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
1
Scope This procedure provides minimum requirements for the approval of companies that intend to qualify as Saudi Aramco approved Third Party Testing Laboratories, Geotechnical Engineering Offices and Batch Plants. This procedure does not cover approval of agencies engaged in non-destructive testing (NDT) as described in SAEP-1140 and related standards and procedures. Commentary Note: This procedure does not cover on-site pre-cast yards used for fabricating small foundations and other similar non-prestressed pre-cast elements. Such pre-cast yards are subject to the evaluation and approval of the respective Area Project Inspection Units/Inspection Department.
2
Conflicts and Deviations 2.1
Conflicts Any conflict between this SAEP and other applicable Mandatory Saudi Aramco Engineering Requirements (MSAERs) shall be resolved in writing by the Company through the Manager, Inspection Department and/or Consulting Services Department of Saudi Aramco, Dhahran.
2.2
Deviations and Waivers Any required deviation from the requirements of this procedure shall be reviewed and approved by the Inspection Department Manager. Direct all requests to deviate or waive the requirements of this Procedure in writing to the Manager, Inspection Department, Dhahran, according to the internal company procedure SAEP-302, Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.
3
Purpose The purpose of this SAEP is to specify the accreditation requirements of Saudi Aramco and approval procedure of Third Party Testing Laboratories, Geotechnical Engineering Offices and Batch Plants. This procedure also clarifies the following processes: 3.1
Process of QMS/technical assessments
3.2
Process of putting an approved entity on ‘On-Hold Status’ and, Page 2 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
3.3 4
Process of withdrawing approvals from approved entities.
Applicable Documents The latest edition of the following applicable references shall be applied: 4.1
Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-301
Instruction for Establishing and Maintaining Saudi Aramco Engineering Requirements
SAEP-302
Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement
SAEP-1150
Inspection Coverage on Projects
Saudi Aramco Engineering Standards SAES-A-110
Surveying Coordinates and Datum
SAES-A-112
Meteorological and Seismic Design Data
SAES-A-113
Geotechnical Engineering Requirements
SAES-A-114
Excavation and Backfill
SAES-Q-001
Criteria for Design and Construction of Concrete Structures
SAES-Q-005
Concrete Foundations
SAES-Q-006
Asphalt and Sulfur Extended Asphalt Concrete Paving
SAES-Q-012
Criteria for Design and Construction of Precast and Prestressed Concrete Structure
Saudi Aramco Materials System Specification 09-SAMSS-097
Ready-Mixed Portland Cement Concrete
Saudi Aramco General Instruction GI-0400-001
Quality Management Roles and Responsibilities Saudi Aramco Construction Safety Manual
PID Work Instruction 7.5-WI-PID-BP&CTU-01 Batch Plants and Civil Testing Laboratories Inspection Coverage
Page 3 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
4.2
Industry Standards and Codes Process Industry Practice PIP CVS02010
Geotechnical Engineering Investigation Specification
International Standardization Organization ISO/IEC 17025:2005
General Requirements for the Competence of Testing and Calibration Laboratories
ISO 9001:2008
Quality Management Systems-Requirements
American Society for Testing and Materials
5
ASTM C94
Standard Specification for Ready Mix Concrete
ASTM C1077
Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation
ASTM D2850
Test Method for Unconsolidated, Undrained Compressive Strength of Cohesive Soils in Triaxial Compression
ASTM D3666
Standard Specification for Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials
ASTM D3740
Practice for Minimum Requirement of Agencies Engaged in the Testing of Soils and Rocks
ASTM D4428
Standard Test Method for Crosshole Seismic Testing
ASTM D5778
Standard Test Method for Electronic Friction Cone and Piezocone Penetration Testing of Soil
ASTM E329
Standard Specifications for Agencies Engaged in Construction Inspection and/or Testing
Definitions and Acronyms Assessment: Systematic evaluation of the Saudi Aramco approved Third Party Testing Laboratories, Geotechnical Engineering Offices and Batch Plants at planned frequencies using the minimum guidelines of ISO 19011 or ISO/IEC 17025 Batch Plants: Ready-Mix Concrete Batch Plants, Precast Plants and Asphalt Batch Plants BP&CTU: Batch Plants and Civil Testing Unit – Inspection Department (ID) approving authority for Third Party Testing Laboratories and Batch Plants Page 4 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
CEU: Civil Engineering Unit CSD: Consulting Services Department DPIS: Dhahran Projects Inspection Section Geotechnical Engineering Office (GEO): A Saudi Aramco approved agency performing geotechnical engineering calculations on Saudi Aramco projects Geotechnical Third Party Testing Laboratory (GTPTL): A Saudi Aramco approved Third Party Testing Laboratory with specific approval in the Geotechnical Category IAU: Inspection Assessment Unit ID: Inspection Department ISSD: Inspection Support Services Division P&SPD: Projects and Strategic Purchasing Department PID: Projects Inspection Division QMS: Quality Management System Survey: Evaluation of compliance with Saudi Aramco requirements and vendor’s quality management system of new Third Party Testing laboratories, Geotechnical Engineering Offices and Batch Plants for Saudi Aramco approval Third Party Testing Laboratory (TPTL): A Saudi Aramco approved service provider to perform testing for Saudi Aramco projects 6
Evaluation and Certification Procedures 6.1
Third Party Testing Laboratories In order to be qualified as a Saudi Aramco approved Third Party Testing Laboratory (any material), an entity shall have ISO/IEC 17025 or SASO/ISO 17025 accreditation. The approval of each laboratory shall be based on the Test Standards listed in its ISO 17025 accreditation. Commentary Note: In situations where a test standard is not listed in the accreditation certificate of any of the Saudi Aramco approved third party testing laboratory and if required by a Saudi Aramco proponent, additional testing capabilities may be added on onetime basis only to its approval list based on recommendations from subjectmatter-experts (SME) or Responsible Standardization Agent (RSA) from either Inspection Department or Consulting Services Department.
Page 5 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
6.2
Geotechnical Third Party Testing Laboratories In order to be qualified as a Saudi Aramco approved Geotechnical Third Party Testing Laboratory, an entity shall have ISO/IEC 17025 accreditation showing under the scope of accreditation the standards listed below, including the tests required to support these standards.
6.3
ASTM D 2850
Test Method for Unconsolidated, Undrained Compressive Strength of Cohesive Soils in Triaxial Compression
ASTM D 4428
Standard Test Method for Crosshole Seismic Testing
ASTM D5778
Standard Test Method for Electronic Friction Cone and Piezocone Penetration Testing of Soil
Geotechnical Engineering Offices In order to qualify as Saudi Aramco approved Geotechnical Engineering Office, an entity shall be ISO 9001:2008 certified. The GEO shall utilize only a Saudi Aramco-approved Geotechnical Third Party Testing Laboratory for obtaining field data and other soil engineering properties.
6.4
Batch Plants Batch Plants shall be ISO 9001:2008 accredited in order to be considered as Saudi Aramco approved entity. Furthermore, all aggregate stockpiles or other ingredients and plant equipment inside the perimeter fence of a Saudi Aramco approved Batch Plant shall be in compliance with Saudi Aramco requirements or Saudi Aramco equivalent Industry Standards.
6.5
Re-assessment and Renewal of Accreditation
Re-survey Re-survey every two years shall be carried out by ID for TPTLs, GTPTLs & BPs and by CSD for GEOs to confirm that the quality system and technical capabilities remain in compliance with the accreditation requirements.
7
Responsibility and Authority 7.1
Third Party Testing Laboratories The following are Inspection Department (ID) responsibilities: 7.1.1
Survey and approve/disapprove Third Party Testing Laboratories based on Section 6.1. Page 6 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
7.2
7.1.2
Spot check Technical and QMS implementation.
7.1.3
Administer issuance and withdrawal of Civil Testing Technician Approval card.
7.1.4
Conduct unannounced focus assessments.
Geotechnical Third Party Testing Laboratories 7.2.1
The following are Consulting Services Department (CSD) responsibilities: 7.2.1.1
Provide technical assistance/consultancy services during field and laboratory processes, as requested by a Saudi Aramco organization.
7.2.1.2
Perform basic site and/or laboratory evaluation on non-routine geotechnical tests, as requested by a Saudi Aramco organization. Commentary Note: This evaluation may be limited to reviewing and observing test procedures, calibration certificates and general condition of the testing equipment.
7.2.1.3 7.2.2
7.3
Research on current equipment or tools that could be added to upgrade field testing.
The following are Inspection Department (ID) responsibilities: 7.2.2.1
Survey and approve/disapprove Geotechnical Third Party Testing Laboratories based on Section 6.2.
7.2.2.2
Monitor technical and QMS implementation.
7.2.2.3
Conduct unannounced focus assessments.
Geotechnical Engineering Offices 7.3.1
The following are Consulting Services Department (CSD) responsibilities: 7.3.1.1
Evaluate, survey and approve/disapprove Geotechnical Engineering Offices (GEO).
7.3.1.2
Verify internal quality assurance system in report preparations.
7.3.1.3
Review and approve organizational charts and manpower levels to ensure compliance with PIP CVS02010 and SAES-A-113. Page 7 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
7.3.2
7.4
7.3.1.4
Review CVs and approve geotechnical/design personnel to ensure compliance with PIP CVS02010 and SAES-A-113.
7.3.1.5
Review and evaluate geotechnical analyses tools (software), geotechnical engineering references and codes.
7.3.1.6
Review and evaluate geotechnical reports to determine geotechnical office capability to produce a geotechnical report in compliance with PIP CVS02010 and SAES-A-113.
The following are Inspection Department (ID) responsibilities: 7.3.2.1
Verify compliance with ISO 17025/ISO 9001:2008 or SASO/ISO 17025 accreditation.
7.3.2.2
Monitor compliance with ISO 17025/ISO 9001:2008 or SASO/ISO 17025 QMS implementation.
Batch Plants The following are Inspection Department (ID) responsibilities:
8
7.4.1
Survey and approve/disapprove Batch Plants.
7.4.2
Spot check technical and QMS implementation.
7.4.3
Conduct periodic technical and quality assessments.
7.4.4
Administer issuance and withdrawal of Batch Plant Internal QC Technician Approval Card.
Approval, On-Hold and Withdrawal of Approval Procedures 8.1
Approval 8.1.1
Third Party Testing Laboratory (TPTL) Workflow Chart 8.1.1.1
Workflow chart in Appendix A shall be followed for Third Party Testing Laboratory Approval Process - Permanent Basis approval.
8.1.1.2
Workflow chart in Appendix B shall be followed for Third Party Testing Laboratory Approval Process - One-Time Basis approval.
Page 8 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
8.1.2
Third Party Testing Laboratory (TPTL) Evaluation Report BP&CTU shall issue evaluation report to TPTL management. The report shall be approved by the Sr. Supervisor/DAPIS.
8.1.3
Geotechnical Third Party Testing Laboratory (GTPTL) Evaluation Report BP&CTU, in coordination with CSD shall issue evaluation report to GTPTL management. The report shall be approved by the Sr. Supervisor/DAPIS.
8.1.4
Geotechnical Engineering Office (GEO) Evaluation Report CSD, in coordination with BP&CTU shall issue evaluation report to GEO management. The report shall be approved by CSD/Civil Engineering Unit Supervisor.
8.1.5
8.1.6
Batch Plant Workflow Chart 8.1.5.1
Workflow chart in Appendix C shall be followed for Batch Plant Approval Process - Permanent Basis approval.
8.1.5.2
Workflow chart in Appendix D shall be followed for Batch Plant Approval Process - One-Time Basis approval.
Batch Plant Overall Evaluation/Approval BP&CTU, in coordination with IAU is responsible for the overall evaluation/approval of Batch Plants. BP&CTU shall evaluate the technical aspects while IAU shall evaluate quality management systems. BP&CTU shall issue Batch Plant evaluation report through P&SPD. The report shall be approved by responsible Project Inspection Division Head.
8.1.7
ID/SHAREK Update Responsibility for the update of the List of Approved TPTLs, GTPTLs, Batch Plants and GEOs in the ID/SHAREK web page shall be as follows: 8.1.7.1
ID is responsible for the update of the List of Approved TPTLs, GTPTLs and Batch Plants (http://sharek.aramco.com.sa/orgs/30003279/Shared%20Docm ents/Forms/AllItems.aspx).
8.1.7.2
CSD is responsible for the update of the List of Approved GEOs (http://sharek/orgs/30003036/30012126/SitePages/SA%20Approved %20Geotechnical%20Offices.aspx). Page 9 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
8.1.8
One-Time Basis Approval 8.1.8.1
Remote Locations (TPTLs and GEOs) Approval by ID and/or CSD as described in sections 6.1 to 6.3, may be granted in locations where there are insufficient Saudi Aramco approved TPTLs and GEOs. In such cases, a letter from permanently approved entities confirming they cannot be accommodated shall be secured by Contractor.
8.1.8.2
Remote Locations (Batch Plants) One-Time Basis Approvals for Batch Plants in remote areas shall be as per 09-SAMSS-097 Section 12.
8.1.8.3
On-site TPTL Branch For On-site TPTL branch, only those with Saudi Aramco permanently approved TPTLs shall be considered for one-time basis approval.
8.2
On-Hold and Withdrawal of Approval Procedures 8.2.1
8.2.2
Grounds for Putting On-Hold and Withdrawal of Approval 8.2.1.1
TPTLs, GTPTLs, GEOs and Batch Plants shall be subjected to be put “On-Hold” or approval removed, due to, but not limited to violations with potential severe impact to product/service.
8.2.1.2
For committing serious violations such as unethical business action, Health, Safety and Environmental violations, etc., immediate “On- Hold” status shall be implemented.
Duration of On-Hold Penalty The duration of “On-Hold” penalty shall be determined by the Sr. Supervisor, DPIS for TPTLs, GTPLs, & Batch Plants and by the Supervisor, CEU/CSD for GEOs.
8.2.3
Removal from Saudi Aramco ID/CSD webpage/SHAREK Approval List Any TPTL, GTPTL, GEO or Batch Plant that have been put ON-HOLD for more than six (6) months without any corrective action on violations mentioned above after the “Hold” period had elapsed, shall be removed
Page 10 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
from the Saudi Aramco list of approved TPTLs, GTPTLs, GEOs or Batch Plants in the ID/CSD webpage/SHAREK. A letter for withdrawal of approval notification shall be sent by the Supervisor of CEU/CSD for GEOs and by the Sr. Supervisor of DPIS for the other service providers under this Procedure.
5 December 2012
Revision Summary New Saudi Aramco Engineering Procedure.
Page 11 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
Appendix A: Third Party Testing Laboratory Approval Process – Permanent Basis Third Party Testing Laboratory
Contracting
Secure Vendor Number from Contracting Dept
Issue Vendor Number
BP&CTU
Submits Required Documentation Package for Approval
Yes
Civil Testing Lab?
Evaluate Documentation Package (Civil Testing Lab)
No
Evaluate Documentation Package (Other Testing Lab)
No
ISO 17025 Compliant? Yes
Rectify Corrective Action
ISO 17025 Compliant?
Yes
Conduct Lab Survey No
Issue Corrective Action
No
Compliant?
Yes
Approves 3rd Party Laboratory / Agency
Update ID Website & Issue Lab Approval
Page 12 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
Appendix B: Third Party Testing Laboratory Approval Process – One-Time Basis Third Party Testing Laboratory
SAPMT
Responsible Project Inspection Section
BP&CTU
Page 13 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
Appendix C: Batch Plant Approval Process – Permanent Basis
Vendor
Submit “REQUEST FOR PLANT APPROVAL”
P&SPD (Purchasing)
BP&CTU
Process “REQUEST FOR PLANT APPROVAL”
Evaluates “REQUEST FOR PLANT APPROVAL”
“REQUEST FOR PLANT APPROVAL” acceptable?
No
Yes
Conducts Site / Plant Evaluation / Survey
Site / Plant Evaluation / Survey Acceptable?
Yes No
Rectify Corrective Action
Plant Approved
Notify Vendor of Corrective Action Required
Notify Vendor of Approval
Issue Corrective Action
Update ID Website & Issue “Plant Approval”
Page 14 of 15
Document Responsibility: Inspection Engineering Standards Committee SAEP-383 Issue Date: 5 December 2012 Approving Third Party Testing Laboratories, Next Planned Update: 5 December 2017 Geotechnical Engineering Offices and Batch Plants
Appendix D: Batch Plant Approval Process – One-Time Basis Contractor
Conduct Initial Plant Survey
SAPMT
Process Request for Approval
Responsible Project Inspection Section
BP&CTU
Evaluate Package
Review Package
Submit Request for Approval Yes
Comply with requirements?
Complete? No
Yes
Conducts Plant Survey / Evaluation
No
Compliance
No Yes Rectify Corrective Action
Plant Approved
Notify Contractor of Corrective Action Required
Notify SAPMT of Corrective Action Required
Issue Corrective Action
Notify Contractor of Plant Approval
Notify SAPMT of Plant Approval
Update ID Website & Issue Plant Approval
Page 15 of 15
