REQUISITION NO. 3000027795 SCHEDULE “Q” QUALITY ASSURANCE AND CONTROL, INSPECTION AND TESTING TABLE OF CONTENTS 1
General
2
Contractor Quality System Requirements
3
Contractor Quality Plan(s)
4
Personnel and Resources
5
Management Review
6
Contractor Quality Control Requirements
7
Procedures for the Control Of Non-Conformance
8
Quality Management Reports
Attachment I
CONTRACTOR and Subcontractor Quality Personnel Qualification Requirements
Attachment II
SAUDI ARAMCO Standards and Procedures Containing Quality Requirements
Attachment III Attachment IV
QA/QC Requirements for Contractor Supplied Materials QA/QC Requirements for the Construction Phase
Attachment V
Summary of Quality System Deliverables
Attachment VI
Project Specific Quality Requirements
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REQUISITION NO. 3000027795 SCHEDULE “Q” QUALITY ASSURANCE AND CONTROL, INSPECTION AND TESTING 1.
GENERAL 1.1.
For the purposes of this Schedule “Q”, SAUDI ARAMCO shall have the same meaning as COMPANY for contracts with Aramco Services Company and Aramco Overseas Company.
1.2.
This Schedule describes SAUDI ARAMCO’s minimum requirements for CONTRACTOR’s Quality System.
1.3.
CONTRACTOR shall be totally responsible for the quality of WORK required by this Contract. Except as provided in Paragraph 4.5 of this Schedule “Q”, CONTRACTOR’s responsibilities as described herein may not be delegated without the express written consent of the Company Representative.
1.4.
CONTRACTOR shall inspect, test and accept all parts of the WORK as defined in Schedule “B”, including its subcontractors' work, in conformance with all drawings, specifications and standards applicable to the WORK.
1.5.
CONTRACTOR shall perform Quality Assurance and Quality Control ("QA/QC") functions for all parts of the WORK, including its subcontractors', vendors', manufacturers' and suppliers' WORK as specified in the CONTRACTOR's Quality Manual and approved Quality Plan(s).
1.6.
SAUDI ARAMCO shall be entitled to have the Company Representative or his nominee present at all locations where CONTRACTOR or its subcontractors and suppliers are engaged in the performance of the WORK, at any and all times, to review all aspects of CONTRACTOR's QA/QC activities and to witness whatever inspection and testing is required by this Contract. SAUDI ARAMCO retains the right to conduct whatever additional tests or inspections it deems necessary to assure itself that the materials meet the requirements of the Contract. CONTRACTOR shall not refuse access to technical or other data which CONTRACTOR considers proprietary or confidential, and which is reasonably required to inspect CONTRACTOR's performance of the WORK, except where the nominee of SAUDI ARAMCO’s Company Representative is a competitor of CONTRACTOR in the sale, engineering, or installation of systems similar to the FACILITIES or is related to or affiliated with such a firm, in which event the Company Representative may nominate an alternate.
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REQUISITION NO. 3000027795 1.7.
SAUDI ARAMCO will complete its review of CONTRACTOR’s QA/QC documents and personnel qualifications no more than thirty (30) calendar days after submittal of a document or its subsequent modifications. Following its initial review, SAUDI ARAMCO will approve or provisionally approve the submitted document or personnel qualification, or it will reject the document with comments.
1.8.
For any inspection or any test required to be witnessed by SAUDI ARAMCO, including any required by applicable laws, rules and regulations of Saudi Arabia, CONTRACTOR shall provide sufficient notice of said inspection or test as specified in the approved Inspection and Test Plans (ITP’s) to enable the Company Representative to attend. If any part of the WORK or the FACILITIES is closed or covered before the required inspection or witnessing has been performed or without agreement by SAUDI ARAMCO, it must, if required by SAUDI ARAMCO, be opened or uncovered for inspection or witnessing and reclosed or recovered at CONTRACTOR's expense.
1.9.
If any inspection or test directed or performed by SAUDI ARAMCO, or by another party at the direction of SAUDI ARAMCO, reveals any defect in CONTRACTOR-supplied materials or in the WORK, CONTRACTOR shall bear the cost of such inspection and testing and shall promptly correct such defect at CONTRACTOR's expense.
1.10. If CONTRACTOR does not adhere to the QA/QC requirements of this schedule, SAUDI ARAMCO may, after two weeks notification to CONTRACTOR, supply sufficient inspection and testing services to assure that the WORK is being done as required by this Contract. CONTRACTOR shall bear the cost of such inspection and testing. 2.
CONTRACTOR QUALITY SYSTEM REQUIREMENTS CONTRACTOR shall implement for this Contract a Quality System according to this Schedule “Q” and the latest version of ISO 9001 (Quality systems – Model for quality assurance in design, development, production, installation and servicing), which is incorporated herein by reference. Definitions contained in the latest versions of ISO 9001and ISO 8402 (Quality management and quality assurance – vocabulary) Section 3, (Terms related to the quality system) apply to the terms in this Schedule ‘“Q”.’
3.
CONTRACTOR QUALITY PLAN(S) 3.1.
CONTRACTOR shall plan, organize, control and execute all WORK in accordance with CONTRACTOR’s Quality Plan(s), Inspection and Test Plans (ITP) and documented procedures. The Quality Plan(s) shall be developed to ensure that quality personnel and processes, Q-2 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 including those of subcontractors, are effective and that the WORK is completed in strict compliance with all provisions of schedule “B” of this Contract. 3.2.
CONTRACTOR shall prepare Quality Plan(s) as specified in ISO 10005:1994 (Quality management – Guidelines for quality plans) and this Schedule for the fulfillment of the requirements of this Contract. CONTRACTOR shall submit Quality Plan(s) to the Company Representative for review and approval not more than fifteen (15) calendar days prior to the start of WORK or forty-five calendar (45) days after the effective date of this Contract, whichever is earlier. ".
3.3.
CONTRACTOR shall modify its Quality Plan(s) to reflect any significant changes identified by CONTRACTOR or SAUDI ARAMCO. CONTRACTOR’s revised Quality Plan(s) shall then be resubmitted for SAUDI ARAMCO’s approval.
3.4.
CONTRACTOR shall not place purchase orders for any equipment or materials assigned an inspection level in Attachment VI of this Schedule “Q” prior to SAUDI ARAMCO’s approval of the Procurement Quality Plan.
3.5.
CONTRACTOR shall not start any construction or precommissioning activities prior to SAUDI ARAMCO’s approval of the applicable Quality Plan. CONTRACTOR shall not start specific construction or precommissioning activities prior to SAUDI ARAMCO’s approval (as required by Attachments IV of this Schedule “Q”) of the applicable ITP.
3.6.
CONTRACTOR’s Quality Plan(s) shall address in detail the Quality System implementation plan for all suppliers and subcontractors, including all levels of services to be provided to CONTRACTOR and subcontractors. In this regard, CONTRACTOR’s Quality Plan(s) shall include the CONTRACTOR’s required quality submittals by all suppliers and subcontractors. Each ITP shall include CONTRACTOR required witness and hold points for all equipment purchases and construction activities.
3.7.
CONTRACTOR’s Quality Plan(s) shall include a system of document control and change management for insuring that, for any change, all affected work is identified and all required modifications are made to the design, procurement and construction documents supplied by SAUDI ARAMCO, CONTRACTOR, or its agents.
3.8.
The Quality Plan(s) shall contain organization charts that show reporting relationships from the inspector through the level above the CONTRACTOR’s project manager for this Contract, internal and external lines of communication, as well as the interfaces between Q-3 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 the CONTRACTOR and its subcontractors and suppliers, and between CONTRACTOR and SAUDI ARAMCO. 3.8.1. CONTRACTOR’s QA/QC personnel shall be dedicated to the WORK described in this Schedule “Q” and shall perform no other function. The CONTRACTOR’s QA/QC Managers shall have organizational authority at least equal to that of the line manager directly responsible for execution of the WORK. CONTRACTOR’s QA/QC personnel shall have sufficient and well-defined responsibility, qualifications, authority, and organizational freedom to identify quality problems and areas of non-conformance and to initiate, recommend and substantiate corrective actions. 3.8.2. During all phases of the WORK, CONTRACTOR’s QC personnel shall functionally report to the CONTRACTOR QA or QC Manager and shall be supported by qualified personnel to effectively accomplish their functions detailed in the Quality Plan. 3.9.
CONTRACTOR shall include in all Quality Plan(s) a detailed procedure for gathering the information necessary to complete the Project Inspection Record Books as specified in SAEP-122 “Project Records” and Schedule “B”.
3.10. The latest revision of CONTRACTOR’s Quality Manual and applicable Quality Plans and all referenced documentation shall be available for SAUDI ARAMCO’s use at the CONTRACTOR's procurement, fabrication and installation or construction locations. Reference documents include all those contained in drawings, specifications and procedures for the inspection of equipment and materials to be fabricated or constructed at the applicable site. 4.
PERSONNEL AND RESOURCES 4.1.
4.2.
CONTRACTOR shall provide resources to implement the Quality System as set forth in this Schedule. For all procurement, construction, and precommissioning activities, sufficient SAUDI ARAMCO accepted QA/QC personnel shall be on-site prior to the start of the applicable WORK.
CONTRACTOR shall provide resumes of all CONTRACTOR and subcontractor QA/QC personnel to SAUDI ARAMCO for review and approval prior to the start of work for each individual. SAUDI ARAMCO shall have the right to interview and/or test assigned Q-4 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 inspectors. SAUDI ARAMCO has the right to reject proposed candidates if they do not comply with the requirements in Attachment I or if SAUDI ARAMCO has had prior poor experience with such candidates. 4.3.
5.
Within seven calendar days of the effective date of this Contract, CONTRACTOR shall designate the QA or QA/QC Manager for this Contract. The QA Manager shall be assigned to the WORK through Mechanical Completion. 4.4.
CONTRACTOR’s, subcontractor’s and third party agency’s QA/QC personnel assigned to the WORK shall meet the minimum qualification requirements of Attachment I of this Schedule “Q”, and must be technically competent to perform their duties. Records must be maintained for SAUDI ARAMCO’s review that documents the qualifications of CONTRACTOR’s QA/QC Personnel.
4.5.
CONTRACTOR may subcontract inspection services, subject to SAUDI ARAMCO’s review and approval.
4.6.
CONTRACTOR shall submit a listing of QA/QC personnel, sorted by discipline for each WORK Phase, to the Company Representative within thirty (30) calendar days of the effective date of this Contract and shall update the list monthly (with changes noted).
4.7.
CONTRACTOR shall make QA/QC personnel changes required due to vacations, illness, temporary assignments, emergency leave, resignations or other reasons as necessary to maintain required QA/QC coverage. CONTRACTOR shall advise the Company Representative of such personnel and QA/QC coverage at least thirty (30) calendar days in advance of scheduled absences or changes and as soon as possible for other changes.
MANAGEMENT REVIEW 5.1.
In accordance with ISO 9001, CONTRACTOR's senior management shall review the project specific Quality System on a regular basis to ensure that the system is suitable and effective. Senior Management Reviews shall be scheduled events included in the quality audit schedule approved by the Company Representative as provided in Paragraph 5.3.2 of this Schedule “Q”.. At a minimum, CONTRACTOR’s senior Management Reviews shall be conducted every six months. Q-5 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 5.2.
CONTRACTOR shall make a presentation of the results and recommended actions of such reviews to the Company Representative within three (3) weeks after the scheduled review date. Changes to the Quality System that result from CONTRACTOR’s senior Management Reviews shall be incorporated in the project Quality Plan(s), with the approval of the Company Representative. 5.3.
Internal Audits
5.3.1. CONTRACTOR shall develop and implement an internal audit program covering all WORK Phases. This shall include audits of the CONTRACTOR's quality function and obligations as described in this Schedule ”Q”. This program shall also include scheduled Quality System audits for all subcontractors. 5.3.2. CONTRACTOR shall submit a quality audit schedule to the Company Representative for review and approval with the Quality Plan(s) submittal. As a minimum, audits shall be carried out at twenty-five percent (25%) and seventy-five percent (75%) of completion stage for the Procurement and Construction WORK Phases. CONTRACTOR’s audits may be rescheduled only with the approval of the Company Representative. 5.3.3. All audits shall be executed by Quality Assurance (QA) personnel (qualified in accordance with Attachment I of this Schedule “Q”) not directly responsible for the area being audited or by an approved third party agency. Audits shall be performed in accordance with pre-established written procedures and checklists. 5.3.4. CONTRACTOR shall initiate corrective actions for items identified in each audit. CONTRACTOR shall verify implementation of corrective actions prior to the next scheduled audit. 5.3.5. CONTRACTOR shall submit to the Company Representative a copy of each audit report within fourteen (14) calendar days of its completion. 5.4.
The Company Representative or its nominee shall be invited to participate in all audits and reviews. Audit and review notifications shall be submitted to the Company Representative fourteen (14) calendar days in advance. Q-6 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 6.
CONTRACTOR QUALITY CONTROL REQUIREMENTS 6.1.
Procurement Phase Quality Control Activities 6.1.1. CONTRACTOR shall define the Procurement Phase Quality Control (QC) activities in its Quality Plan to ensure that qualified personnel properly monitor procurement activities and supplier performance. The Quality Plan shall include identification of all materials that will require specific preinspection meetings and ITPs. CONTRACTOR shall define activities and methods used to assure that procured equipment, materials and services conform to the Contract requirements. 6.1.2. Refer to Attachment III of this Schedule “Q” for other procurement phase QA/QC activity requirements. 6.2.
Construction Phase Quality Control Activities
6.2.1. CONTRACTOR shall define the Construction Phase QC activities in its Quality Plan to ensure that qualified personnel properly monitor construction, fabrication and subcontractor performance. The Quality Plan shall include identification of all construction processes that will require ITPs and specific SAUDI ARAMCO approvals. CONTRACTOR shall define activities and methods used to ensure that all CONTRACTOR, subcontractor, and supplier construction processes and services conform to the Contract requirements. 6.2.2. Refer to Attachment IV of this Schedule “Q” for other construction phase QA/QC activity requirements 6.3.
Pre-Commissioning Phase Quality Control Activities. Prior to SAUDI ARAMCO’s acceptance of the WORK, CONTRACTOR shall perform the inspections required by Schedule “B” to complete pre-commissioning activities, and correct any nonconformances in accordance with Paragraph 7 of this Schedule “Q”. A copy of the inspection results and status of the correction of nonconformances shall be submitted to the Company Representative each week until the acceptance of the applicable system or facilities.
6.4.
Inspection Schedules CONTRACTOR shall submit each week a two-week look ahead schedule of all planned QA/QC activities to the Company Q-7 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 Representative during the Procurement, Construction and Precommissioning WORK Phases as specified in Schedule “A”. The schedule shall be sent electronically in a format acceptable to SAUDI ARAMCO. 6.5.
Material Identification and Traceability 6.5.1. CONTRACTOR shall maintain an identification procedure for all documents, materials, parts and components, including partially fabricated assemblies. Traceability shall be maintained on equipment, materials, parts and components, as specified in SAUDI ARAMCO standards and manufacturer’s specifications. Identification of an item shall be addressed either by using tags, stamps, color coding, stencils or labels or by records traceable to an item throughout fabrication, erection, installation, repair, modification and use of the item. 6.5.2. The location and the method of identification shall not affect the function or quality of the item being identified. The procedure shall require that verification of correct identification of material, parts and components be made and documented prior to installation. 6.5.3. Material not in compliance with these requirements shall be rejected by the CONTRACTOR, reported and resolved in accordance with Paragraph 7 of this Schedule.
6.6.
Control of SAUDI ARAMCO Supplied Material and Equipment CONTRACTOR shall implement a documented control system for all SAUDI ARAMCO supplied material or equipment. The written procedure shall provide for receiving inspection, proper storage, and maintenance of such material and equipment. This procedure shall have provisions for dealing with losses, damage or other problems discovered with such material and equipment.
6.7.
Waivers 6.7.1. CONTRACTOR shall not waive the requirements of any CONTRACTOR Quality Plan or ITP previously accepted by the Company Representative without the express written consent of the Company Representative. 6.7.2. The CONTRACTOR shall maintain a log detailing all waivers from SAUDI ARAMCO or CONTRACTOR QA/QC and inspection requirements obtained during all WORK phases. Q-8 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 This log must indicate the status of the waiver, a brief description and details of the applicable purchase order and equipment or construction process. 6.7.3. The CONTRACTOR shall also maintain a log detailing all technical waivers to SAUDI ARAMCO’s standards, including those initiated by SAUDI ARAMCO (during or prior to the start of WORK) or CONTRACTOR. This log must indicate the status of the waiver, a brief description and details of the applicable purchase order and equipment or construction process. 7.
PROCEDURES FOR THE CONTROL OF NON-CONFORMANCE 7.1.
CONTRACTOR shall include in the Quality Plan(s) procedures to prevent inadvertent use of design documents, materials, parts, components, services, or workmanship not conforming to requirements of the Contract. Quality Plan(s) shall require the identification and documentation of non-conformances, corrective actions and waivers of Contract requirements.
7.2.
CONTRACTOR shall issue Non-Conformance Reports (NCRs) for all violations of Contract requirements and SAUDI ARAMCO approved CONTRACTOR procedures by the CONTRACTOR, subcontractors, manufacturers or suppliers. CONTRACTOR shall submit a copy of each NCR to the Company Representative within 48 hours to document specific Contract scope, standards and specification violations observed. CONTRACTOR shall maintain a summary of the open NCRs, and submit it at the regular project progress meetings. CONTRACTOR shall notify the Company Representative prior to final closure of each NCR for inspection by SAUDI ARAMCO.
7.3.
CONTRACTOR shall respond to all NCRs issued by SAUDI ARAMCO in writing within 48 hours of receiving notification of nonconformance, including proposed corrective action.
7.4.
CONTRACTOR shall investigate the causes of non-conforming items, and initiate corrective actions to prevent recurrence of nonconformities. 7.5.
DISPOSITION OF NON-CONFORMING MATERIALS
CONTRACTOR shall control CONTRACTOR and subcontractor supplied materials and fabricated assemblies that do not conform to requirements as indicated in 7.5.1, 7.5.2 and 7.5.3 below. Controls to restrict further processing or installation of non-conforming or Q-9 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 defective items, pending decisions on disposition, shall be established and maintained. 7.5.1. CONTRACTOR shall re-inspect repair and rework items in accordance with applicable procedures. Those items accepted after re-inspection may be used in the WORK. Those items rejected will be managed as stated in 7.5.2 or 7.5.3 below. 7.5.2. CONTRACTOR shall submit an application for a waiver to SAUDI ARAMCO standards to the Company Representative for items that do not comply with SAUDI ARAMCO standards but are still considered usable. The item may be used in the WORK only if SAUDI ARAMCO approves the waiver. 7.5.3. CONTRACTOR shall segregate all other non-conforming materials and assemblies to a clearly designated rejection site. CONTRACTOR shall track and control all rejected equipment or materials until it is reused, exported, or otherwise disposed of. All imported rejected materials shall be disposed of in accordance with Schedule “G”. CONTRACTOR shall notify the Company Representative of the disposition of all rejected materials on a monthly basis as part of the Quality Management Report. 8.
QUALITY MANAGEMENT REPORTS
CONTRACTOR shall prepare and submit a monthly quality management report in a format acceptable to SAUDI ARAMCO to demonstrate effective implementation of the CONTRACTOR's Quality System. The CONTRACTOR shall include the following items as a minimum: 8.1.
Listing of supplier surveys performed with a summary of findings
8.2.
Listing of Pre-inspection Meetings conducted
8.3.
Listing of supplier inspections performed versus scheduled inspections
8.4.
Non-conformance reports issued to vendors: number issued, closed out, and pending for the month
8.5.
Non-conformance reports issued during Construction: number issued, closed out, and pending for the month
8.6.
Listing of quality audits completed (internal and subcontractor) Q-10 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 8.7.
Listing and disposition of all defective or rejected material or equipment received at jobsite by CONTRACTOR and subcontractor
8.8.
Welding rejection rate, reported on a per joint basis for piping, structural, and alloy welds. A chart showing the historical performance during the project shall be included.
8.9.
Listing and status of all engineering waivers
8.10. QA/QC Personnel Listing by Discipline as specified in Paragraph 4.6.
END OF SCHEDULE “Q”
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REQUISITION NO. 3000027795 ATTACHMENT I TO SCHEDULE “Q” CONTRACTOR and SUBCONTRACTOR QUALITY PERSONNEL QUALIFICATION REQUIREMENTS At a minimum, personnel employed by CONTRACTOR or its subcontractors or suppliers to perform the WORK described in this Schedule “Q” shall have 10 years of relevant industrial experience, including 6 years experience in a given inspection specialty, four of which have been in oil and gas or petrochemical industries; shall be a High School graduate, or equivalent; shall be fully conversant with applicable Industry Standards and Specifications; and shall perform a variety of complex inspection functions with minimal supervision. SAUDI ARAMCO shall be the final authority for the determination of equivalency for all qualifications, certifications, or experience. Additional requirements shall apply for specific disciplines as follows: 1.
Welding/Mechanical Inspector: Inspector shall be certified as an American Welding Society CWI, CSWIP Certified Welding Inspector, or SAUDI ARAMCO approved equivalent. Inspector shall have a demonstrated background and thorough knowledge of codes such as ANSI B 31.3, 31.4 and 31.8, ASME Section V and IX, API 620 and 650, AWS D1.1, required for the execution of the WORK. Where Nondestructive Testing (NDT) forms part of the WORK, and Inspector is required to review, audit or ensure NDT programs and results, he shall have been previously qualified and certified to a minimum ASNT Level II in the relevant method(s). When performing, reviewing, ensuring or auditing Nondestructive Testing in VT, MT, PT, RT or UT, he shall be certified in the specific method(s). When performing, reviewing, ensuring or auditing Radiographic Testing Film Interpretation (RTFI), Inspector shall be certified in RTFI.
2.
Plant and Equipment Inspector: Inspector shall demonstrate working knowledge of codes such as ASME Sec I, V, VIII and IX. He shall be able to perform all types of equipment inspection such as inspections that require the use of calipers, micrometers, infrared camera, boroscope, pit gauges etc. to ensure continued safe operation; tests and inspections on equipment that has been repaired or modified to assure that the equipment meets the manufacturers and ASME Code requirements; inspections for the installation of hot tap, weld plus ends, repair sleeves, or any welding that is required on equipment while in service; and inspections on vessels and equipment heat treatments.
3.
Heat Treatment Inspector: Inspector shall have five years direct work experience as a heat treatment technician (preferably with some supervisory Q-I-1 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 experience) working directly for an industry recognized heat treatment contractor(s). Inspector shall have direct knowledge of all aspects of heat treatment with the types of equipment that will be used on the construction project such as electrical resistance heating elements, induction coils, or gas fired heaters. Related experience in any of these areas qualifies Inspector to also inspect all types of shop or site erected heat-treating furnaces for batch heat treatment of parts and vessels that are internally fired to stress relieve them. Inspector shall also be thoroughly familiar with the heattreating requirements of ASME B31.3 and ASME Section VIII Division 1. 4.
Civil Inspector: Inspector shall demonstrate a thorough working knowledge of recognized building codes such as the Uniform Building Code (UBC) or equivalent standards.
5.
Coating Inspector: Inspector shall demonstrate a thorough working knowledge and proven ability of all phases and types of critical coating applications and methods and recognized industry standards and Inspector shall be qualified to NACE Level II Critical Coatings Certification, CSWIP Level I, or equivalent.
6.
Plumbing Inspector: Inspector shall demonstrate a thorough knowledge of codes such as the Uniform Plumbing Code or equivalent standards.
7.
HVAC Inspector: Inspector shall demonstrate a thorough working knowledge of codes such as the Sheet Metal and Air Conditioning Contractors National Association (SMACNA) codes and/or equivalent standards.
8.
Crane Inspector: Inspector shall demonstrate a thorough working knowledge of codes such as ANSI-A17.1 and 17.2, ANSI-B30.1 through B30.16, or equivalent standards.
9.
Electrical Inspector: Inspector shall demonstrate a thorough working knowledge of the National Electric Code/NFPA 70, or equivalent standards. He shall also have working knowledge of electrical installations including materials, methods, specifications, and hazardous location identification for oil and gas or petrochemical industries.
10.
Communication Inspector: Inspector shall demonstrate a thorough working knowledge of telecommunications, and be familiar with North American or International Telecommunications Standards; Building Industry Consulting Services International - Telecommunications Distribution Methods Manual (BICSI-TDMM); National Electrical Codes; and National Electrical Safety Codes, or their equivalents. Q-I-2 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 11.
Instrumentation Inspector: Inspector shall satisfy the requirements of a fully qualified Instrument Technician/ Engineer meeting the requirements laid out by the Instrument Society of America or the Institute of Measurement and Control. He shall also have applicable working knowledge of instrument and electrical installations including materials, methods, specifications, and hazardous location identification for oil and gas or petrochemical industries in accordance with the National Electric Code, NEC/NFPA 70, or equivalent standards.
12.
Nondestructive Testing (NDT) Personnel: All CONTRACTOR and subcontractor personnel located in Saudi Arabia responsible for performing NDT operations, or interpreting, reviewing, ensuring or auditing NDT operations shall meet SAUDI ARAMCO’s requirement as listed in SAEP1142. All CONTRACTOR and subcontractor NDT and personnel shall hold current certification where outlined below attesting to their NDT qualifications.
12.3.
12.1.
Nondestructive Testing NDT Level III personnel: such personnel shall have been tested and certified by ASNT (or equivalent nationally recognized program as approved by SAUDI ARAMCO) in the required NDT method(s) specified by the Contract and shall be required to fulfill the full scope of a practicing Level III including, but not limited to: method application, interpretation of results, interpretation of codes and standards, preparation of procedures, and training of Level I and Level II personnel.
12.2.
Radiographic Examination Personnel: such personnel shall be qualified to perform X and Gamma Ray radiographic examinations.
Radiograph Film Interpretation Technician: such personnel shall be certified by SAUDI ARAMCO in Radiographic Testing Film Interpretation (RTFI) when performing, reviewing, ensuring or auditing RTFI. 12.4.
Ultrasonic Examination Technician: such personnel shall be qualified to perform longitudinal and shear wave ultrasonic examination of welds utilizing A-Scan ultrasonic flaw detection equipment.
12.5.
Liquid Penetrant Examination Technician: such personnel shall be qualified to perform visible and fluorescent liquid penetrant examination. Q-I-3 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 12.6.
Magnetic Particle Examination Technician: such personnel shall be qualified to perform wet and dry visible and wet fluorescent magnetic particle examination.
13.
Quality Assurance Manager: Shall have demonstrated knowledge and training in the ISO-9000 Series international standards, or equivalent; a university degree or equivalent with a minimum of 10 years of direct experience in Quality Assurance system activities in the oil, gas and petrochemical industries.
14.
Quality Control Manager: Shall have demonstrated knowledge and training in the use of measuring and test equipment routinely used in conducting inspections. He shall have a university degree or equivalent and seven years inspection experience or a high school diploma with ten years inspection experience directly relating to supervision of construction activities in the oil, gas and petrochemical industries.
15.
Procurement Quality Control Supervisor: Shall have demonstrated knowledge and training in the use of measuring and test equipment routinely used in conducting inspections at manufacturing and fabrication sites. He shall have a university degree or equivalent and seven years inspection experience or a high school diploma with ten years inspection experience directly relating to supervision of vendor inspection activities in the oil, gas and petrochemical industries.
16.
Vendor Inspector: Shall have 10 years Quality Assurance/Quality Control (QA/QC) inspection experience in manufacturing plants, including 4 years of this inspection experience in the specific commodity and processes to be inspected. He must understand national codes and fabrication methods; and shall be qualified to perform specialized inspection and testing of petrochemical processing materials, plant surveys as required to verify supplier compliance with purchase order and SAUDI ARAMCO’s Engineering Standards. Where NDT forms part of the WORK, and Inspector is required to review, audit or ensure NDT programs and results, he shall have been previously qualified and certified to a minimum ASNT Level II in the relevant method(s). When performing, reviewing, ensuring or auditing Nondestructive Testing in VT, MT, PT, RT or UT, he shall be certified to a minimum ASNT Level II in the relevant method(s). When performing, reviewing, ensuring or auditing Radiographic Testing Film Interpretation (RTFI), Inspector shall be certified in RTFI.
17.
Quality System Auditors: Shall have 10 years Quality Assurance/Quality Control (QA/QC) inspection or auditing experience in manufacturing plants. Auditors shall be qualified as stated in ISO-10011 and competent in the discipline being audited, familiar with Quality System standards and be able Q-I-4 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
REQUISITION NO. 3000027795 to exercise judgment against the criteria of the standards. Auditors must be able to communicate clearly in writing and orally. Auditors shall have satisfactorily completed a training course and passed the course examination. Auditors shall have participated in a minimum of four audits for a total of at least 20 days including documentation review, actual audit activities and audit reporting. END OF SCHEDULE “Q” ATTACHMENT I
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ATTACHMENT II TO SCHEDULE “Q” SAUDI ARAMCO STANDARDS AND PROCEDURES CONTAINING QUALITY REQUIREMENTS CONTRACTOR shall comply with all applicable SAUDI ARAMCO Material System Specifications (SAMSS), SAUDI ARAMCO Engineering Standards (SAES), and other SAUDI ARAMCO standards and specifications including, but not limited to the following: 1. SAEP-122 2. SAEP -124
Project Records Producing, Processing and Controlling CADD Drawings Within Saudi Aramco 3. SAEP-128 Security and Control of Saudi Aramco Engineering Data outside of Saudi Aramco 4. SAEP-302 Instructions for Obtaining a Waiver of a Saudi Aramco Engineering Requirement 5. SAEP-303 Engineering Reviews of Project Proposal and Detail Design Documentation 6. SAEP-311 Installation of Hot Tapped Connections 7. SAEP-316 Performance Qualification of Coating Personnel 8. SAEP-318 Pressure Relief Valve Program Authorization for Installation, Deletion and Changes 9. SAEP-324 Certification Review and Registration of Project Welders and Brazers 10. SAEP-334 Certification and Submittal of Saudi Aramco Engineering Drawings 11. SAEP-1101 through SAEP 1117: Welding and Brazing Test Supplements for Welder Performance Qualification 12. SAEP-1131 Pressure Relief Valve Program Use of Form 3099A, RV Authorization 13. SAEP-1133 Form 3750, Pressuring Relieving Device Test Report 14. SAEP-1141 Industrial Radiation Safety 15. SAEP-1142 Qualification of Non-Saudi Aramco NDT Personnel 16. SAEP-1143 Radiographic Examination 17. SAEP-1144 Magnetic Particle Examination 18. SAEP-1145 Liquid Penetrant Examination 19. SAEP-1634 Factory Acceptance Test 20. SAEP-1636 Installation And Checkout Plan 21. SAEP-1638 Site Acceptance Test Plan 22. SAEP-3101 Spare Parts Data Requirements for Contractor Procured Equipment 23. SAER 1972 SAUDI ARAMCO Inspection Requirements (Form 175) 24. SAUDI ARAMCO Drafting Manual END OF SCHEDULE “Q” ATTACHMENT II Q-II-1 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
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ATTACHMENT III TO SCHEDULE “Q” QA/QC REQUIREMENTS FOR CONTRACTOR SUPPLIED MATERIALS 1.
CONTRACTOR shall provide and document QA/QC activities in the procurement of equipment and material to be used or installed during the construction and installation of the facilities as specified in the requirements of the Contract.
2.
CONTRACTOR or its SAUDI ARAMCO approved third party inspector shall perform QA/QC activities at the supplier and sub-supplier locations as required by the inspection level assigned for the materials and equipment identified in this Schedule “Q” Attachment VI - Project Specific Quality Requirements. Subject to SAUDI ARAMCO approval, CONTRACTOR may change the assigned level of inspection, upward or downward, during the course of the work as a result of supplier performance.
3.
CONTRACTOR shall prepare detailed Inspection and Test Plans (ITPs) for all equipment and materials assigned a level 2, 3, or 4 in Attachment VI of this Schedule “Q, and for any other equipment deemed necessary by CONTRACTOR. CONTRACTOR shall review the QA/QC requirements in all applicable SAUDI ARAMCO standards and procedures listed in Attachment II to this Schedule “Q” and include appropriate QA/QC requirements in the ITPs. Each ITP shall identify the inspection level and detail all witness, hold and certification review points as specified in the each SAUDI ARAMCO Form175 (Inspection Requirements). 3.1.
As a minimum, each ITP shall include the following information: 3.1.1. Process description 3.1.2. Quality control requirements 3.1.3. Notification requirements for supplier inspection witness and hold points (minimum 5 working days.) 3.1.4. Responsibilities 3.1.5. Applicable procedures 3.1.6. Acceptance criteria 3.1.7. Verifying documents 3.1.8. Inspection points 3.1.9. Hold points
4.
Supplier Selection
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4.1.
Except as provided in Paragraph 4.3 of this Attachment III to Schedule “Q”, for all equipment and materials for which inspection requirements are specified on the applicable SAUDI ARAMCO Form 175, CONTRACTOR shall prequalify each supplier and its specific manufacturing site as described in 4.1.1 through 4.1.3 of this Attachment III to Schedule “Q”. Evidence of the prequalification shall be provided to SAUDI ARAMCO for its review at least two weeks prior to placement of the purchase order. 4.1.1. CONTRACTOR shall evaluate supplier’s capabilities to meet the technical and quality requirements of the WORK. Such evaluation shall include technical review of products to ensure compliance with applicable SAUDI ARAMCO standards. 4.1.2. CONTRACTOR shall evaluate suppliers’ Quality System, which shall meet the appropriate ISO 9000 system requirements. Reliance solely on certification to ISO Quality Systems is unacceptable. CONTRACTOR's prior audit findings are considered current if completed within 24-months prior to the proposed equipment purchase and do not include any major technical or quality deficiencies. 4.1.3. CONTRACTOR shall complete a physical survey of proposed suppliers for any equipment requiring an inspection level of 2, 3, or 4 as specified in Attachment VI to this Schedule “Q”. CONTRACTOR supplier evaluations shall, at a minimum, be carried out by a QA/QC representative and a technical expert for the equipment under consideration.
5.
4.2.
CONTRACTOR shall notify SAUDI ARAMCO at least two weeks ahead of all planned supplier surveys.
4.3.
Quality System evaluations are not required for manufacturers or suppliers currently specified in SAUDI ARAMCO Engineering Standards (SAES) or in Schedule “G”. For equipment and materials manufactured within Saudi Arabia, Quality System evaluations are not required if the supplier is listed on the SAUDI ARAMCO Industrial Development Group IDG-4a Report current as of the effective date of this Contract.
Requisitions and Purchase Orders 5.1.
CONTRACTOR quality personnel shall review requisitions and purchase orders prior to placement to ensure that all technical and quality requirements are included as specified in Schedule “G”. Q-III-2 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
5.2.
The CONTRACTOR shall review its supplier's sub-orders to ensure that all relevant SAUDI ARAMCO technical and inspection requirements are passed on to sub-suppliers.
5.3.
CONTRACTOR shall complete and submit a weekly inspection/fabrication status report to the Company Representative in an electronic format acceptable to SAUDI ARAMCO. The report shall include, as a minimum, the following information for each purchase order: 5.3.1. 5.3.2. 5.3.3. 5.3.4.
Purchase Order Number and Date Material Description Vendor Name and Location Inspection Assignment Package submittal date as specified in Paragraph 8.1 of this Attachment III. 5.3.5. Level of Inspection as specified in Attachment VI of Schedule “Q” 5.3.6. Pre-inspection Meeting Date 5.3.7. Fabrication Start Date 5.3.8. Scheduled and Forecast Delivery Date 5.3.9. Inspection Agency and Inspector (qualified as specified in Attachment I of Schedule “Q”) 5.3.10. Special Process Procedures (approved as specified in Paragraph 7.3 of this Attachment III) 5.3.11. Open and Closed NCR’s 5.3.12. Closeout Date 5.3.13. Disposition Report submittal date 5.4. 6.
SAUDI ARAMCO shall have access to all purchase order inspection report files. Verification of Purchased Materials
6.1.
CONTRACTOR’s Quality Plan(s) shall include a procedure to review and approve supplier submittals for conformance to SAUDI ARAMCO designs, specifications and standards. These procedures shall include required reviews of supplier proposals prior to purchase order placement and supplier submittals purchase order in accordance with the purchase order after placement.
6.2.
CONTRACTOR’s Quality Plan(s) shall include a procedure to ensure that all shop drawings originated by CONTRACTOR or its agents are accurately incorporated into the SAUDI ARAMCO supplied designs and approved by SAUDI ARAMCO prior to construction. Q-III-3 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
6.3.
CONTRACTOR shall maintain an effective system for continuity of order identification that ensures drawings, specifications, and inspection requirements are properly transmitted to suppliers at all tiers of order placement.
6.4.
CONTRACTOR shall ensure that all suppliers and manufacturers have and maintain acceptable QA/QC programs as identified in the relevant ISO-9000 Series standards.
7.
Control of Manufacturing Processes During Procurement
7.1.
When required by SAUDI ARAMCO’s standards, and prior to start of the applicable WORK, CONTRACTOR shall submit for SAUDI ARAMCO’s review and approval all supplier procedures for refractory installation, welding, welding repair, NDT, heat treatment, and alloy verification.
7.2.
Supplier and subsupplier personnel for NDT, Positive Material Identification, and welding shall be qualified as specified by SAUDI ARAMCO’s Standards and Attachment I of this Schedule “Q”. CONTRACTOR shall review and approve such qualifications prior to the start of manufacturing.
7.3.
The qualification and certification of Out of Kingdom Nondestructive Testing (NDT) personnel shall be in accordance with a nationally recognized program as listed in SAEP-1142. CONTRACTOR’s designated Level III Inspector shall review and approve all supplier and subsupplier NDT personnel qualification and certification programs, as well as all NDT procedures prior to commencement of any NDT operations.
7.4.
CONTRACTOR shall make supplier and sub-supplier NDT personnel records and Welder Qualification Records available to the Company Representative on request.
8. 8.1.
Inspection and Testing CONTRACTOR shall compile and forward to the Company Representative no later than twenty-one (21) calendar days prior to the pre-inspection meeting and start of any fabrication, either at the prime supplier or a major sub-supplier, three (3) sets of the CONTRACTOR's Inspection Assignment Package, which shall include:
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8.1.1. A complete copy of the CONTRACTOR's unpriced purchase order or subcontract, material requisition, and attachments. 8.1.2. Copies of sub-supplier's unpriced purchase orders. 8.1.3. Inspection requirements as specified in the applicable SAUDI ARAMCO Form 175 8.1.4. Inspection assignment sheet specifying the inspector(s) that will perform the inspections. 8.1.5. Inspection and Test Plan 8.1.6. The level of CONTRACTOR inspection (as required by Attachment VI to this Schedule “Q”.) 8.1.7. Agenda for appropriate
each
pre-inspection
meeting
where
8.2.
CONTRACTOR or its approved third party inspector shall schedule and perform source inspection at supplier and sub-supplier fabrication sites as specified in the approved Inspection and Test Plans.
8.3.
Contractor shall provide Pre-inspection Meeting Reports and subsequent Vendor Inspection Reports to the Company Representative within 10 calendar days of each shop visit.
8.4.
If SAUDI ARAMCO waives a plant visit, CONTRACTOR shall obtain from suppliers and sub-suppliers such inspection records as may be required to meet the requirements of Paragraph 8.2, and include the inspection records in the Inspection Disposition Reports (Paragraph 10). Such waiver shall not release CONTRACTOR from any other obligations contained in this Schedule “Q”.
9.
Procurement Inspection and Test Records
CONTRACTOR shall require its Subcontractors / suppliers to submit manufacturing and test reports as specified on each form SA-175. The CONTRACTOR shall review and indicate its acceptance of these inspection records prior to issuing the inspection (or shipping) release. A copy shall be provided to SAUDI ARAMCO with the Inspection Disposition Report. 10.
Inspection Disposition Reports Q-III-5 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
10.1. Within two weeks of acceptance of material or equipment, the CONTRACTOR shall prepare and issue to the Company Representative a final disposition report. This report shall be based upon CONTRACTOR's review of the inspection file and shall provide narrative details of QA/QC activities performed during manufacturing and fabrication of the equipment or material. The report shall provide as a minimum: 10.1.1. Copies of SAUDI ARAMCO approved waivers to SAUDI ARAMCO’s requirements. 10.1.2. All SA-175 CONTRACTOR witnessed inspections. 10.1.3. Copies of supplier quality records as specified in SA-175. 10.1.4. Copies of all NCR's with final dispositions and resolutions. 10.2. In cases where the supplier is responsible for export packing, the final disposition report shall be prepared after export packing has been inspected and accepted by CONTRACTOR. END OF SCHEDULE “Q” ATTACHMENT III
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ATTACHMENT IV TO SCHEDULE “Q” QA/QC REQUIREMENTS FOR THE CONSTRUCTION PHASE 1.
CONTRACTOR shall include in the Construction Phase Quality Plan procedures for controlling all fabrication and construction processes, clearly identifying key parameters and variables affecting quality, as specified in the appropriate WORK specifications or instructions. All of the WORK execution steps shall be inspected or witnessed as documented by the CONTRACTOR in the SAUDI ARAMCO approved Inspection and Test Plan. 2.
Inspection and Test Plans
2.1.
One month prior to the start of the applicable WORK, CONTRACTOR shall submit for review and approval a detailed Inspection and Test Plan (ITP) for all construction processes to be executed by CONTRACTOR or subcontractors. CONTRACTOR shall review the quality requirements in all applicable SAUDI ARAMCO standards and procedures listed in Attachment II to this Schedule “Q” and include appropriate QA/QC requirements in each ITP. Each ITP shall detail all review, witness, hold and certification review points for SAUDI ARAMCO, CONTRACTOR, and subcontractors as specified in this Contract. It shall also include the methods, extent and timing for examinations, measurements or tests.
2.2.
As a minimum, each ITP shall include the following information: 2.2.1. Process description 2.2.2. Quality control requirements 2.2.3. Notification requirements for Requests For Inspections (RFI) (minimum 24 hours for site work, 48 hours for weekend inspections, except when SAUDI ARAMCO personnel will require special qualifications.) 2.2.4. Responsibilities 2.2.5. Applicable procedures 2.2.6. Acceptance criteria 2.2.7. Percentage of tests to be done (including increased inspection levels when performance requirements are not met.) 2.2.8. Verifying documents 2.2.9. Review, Witness and Hold points
2.3.
Inspection and Test Plans and related procedures shall include provisions to ensure that test prerequisites have been met, that adequate Q-IV-1 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
calibrated instrumentation is available and used, and that the necessary inspection is performed. 2.4.
3.
Revision Control – CONTRACTOR shall revise each ITP and obtain approval for such revisions from the Company Representative as needed throughout the WORK. CONTRACTOR and subcontractor inspectors shall maintain copies of every currently approved subcontractor ITP.
Control of Construction Processes The following special processes require SAUDI ARAMCO’s review and/or approval of work procedures, personnel qualifications, or personnel qualification procedures. CONTRACTOR shall ensure that these special processes are accomplished under controlled conditions as specified in all applicable standards and specifications. All process parameters shall be identified with acceptance criteria specified and monitored. All Procedures and Personnel Qualification shall be submitted for review and/or approval at least thirty (30) calendar days prior to the start of the applicable WORK. Work Procedure Approval (A) or Review (R) Required
Personnel Qualification Procedure Approval Required
Personnel Qualification Approval Required
Welding
A
Yes
Yes
Nondestructive Testing/examination
A
Yes
Yes
High Voltage (>1000V) Cable splicing/termination
R
Yes
Yes
Alloy verification
A
Yes
Yes
Coatings
A
Yes
Yes
Concrete Mix Design
A
No
No
Cable and Conduit Seal Installation
R
No
No
Gasket Installation
R
No
No
Concrete Installation
R
No
No
Special Process
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Structural Bolt Tensioning
R
No
No
Gap Control for socket weld and back welded threaded fittings.
R
No
No
Hydro-testing
A
No
No
Heat Treatment
A
No
No
Hot Tap Procedures (Calculation Sheets)
A
No
No
Refractory Installation
A
No
No
4.
Calibration of Inspection, Measuring and Test Equipment
4.1.
CONTRACTOR shall include procedures for the control of inspection, measuring and testing equipment. Specific tools and equipment shall be identified to make and perform tests in the field with instructions for their use, calibration, and storage. The CONTRACTOR shall identify, maintain, control, adjust, and calibrate tools, gauges, instruments and other measuring and testing devices used for activities controlling quality. Calibration shall be performed at established periods as specified in SAUDI ARAMCO or other applicable standards; in no case shall the calibration cycle exceed six months.
4.2.
CONTRACTOR shall audit and document the validity of previous inspection and test results when inspection, measuring and test equipment is found to be out of calibration.
5.
Construction Inspection and Test Records 5.1.
5.2.
CONTRACTOR shall submit its test reports and its subcontractors test reports to the Company Representative as specified by the applicable SAUDI ARAMCO standards. The CONTRACTOR shall review and approve its subcontractor’s test reports prior to submittal.
CONTRACTOR shall include in the Construction Phase Quality Plan procedures to identify inspection and test status. The status report shall Q-IV-3 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
identify all CONTRACTOR and subcontractor required inspection and tests for each system, when it is scheduled, when it was completed, and any non-conformances discovered during the test or inspection. Inspection status reports shall be kept current and shall be available for SAUDI ARAMCO’s review at all times. 6.
Receiving Inspections
CONTRACTOR shall inspect all incoming equipment for damage and for conformance to all applicable requirements, including the supplier inspection release with verified Material Test Reports (MTR). If the equipment does not have the required inspection release and MTR, CONTRACTOR shall verify and document the compliance of the equipment with applicable standards and specifications prior to release to be used as part of the WORK. Data concerning receiving inspections shall be included on the Monthly Materials Procurement Status Report as specified in Schedule “G”. 7.
Material Handling, Storage and Preservation
CONTRACTOR shall include in the Construction Phase Quality Plan procedures for handling, storage, and preservation of material as specified in all applicable specifications, manufacturer recommendations and SAUDI ARAMCO’s standards. The procedure shall list all WORK and inspection schedules for maintaining the quality of the material or equipment as well as provide for documentation that the required activities have been performed. Individuals responsible for special handling, storage and preservation shall be fully qualified to do so, and supplied with predetermined WORK and inspection instructions. Data concerning handling, storage and preservation shall be included on the Monthly Materials Procurement Status Report as specified in Schedule “G”. END OF SCHEDULE “Q” ATTACHMENT IV
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ATTACHMENT V TO SCHEDULE “Q” SUMMARY OF QUALITY SYSTEM DELIVERABLES No. 1.
2.
3. 4. 5. 6. 7. 8. 9.
10. 11. 12.
Title Quality Plan. Paragraph 3.2 of Schedule “Q”
QA/QC Personnel or Agency Qualifications Paragraph 4.4 of Schedule “Q” Quality Audit Schedule. Paragraph 5.3.2 of Schedule “Q” Audit Report Paragraph 5.3.5 of Schedule “Q” Inspection Schedules Paragraph 6.4 of Schedule “Q” CONTRACTOR, Vendor and Subcontractor NCR’s Paragraph 7.2 of Schedule “Q” NCR Summary Paragraph 7.2 of Schedule “Q” Quality Management Report Paragraph 8 of Schedule “Q” Inspection/Fabrication Status Report Paragraph 5.3 of Attachment III Inspection Assignment Package Paragraph 8.1 of Attachment III Preinspection Meeting Reports Paragraph 8.3 of Attachment III Vendor Inspection Reports Paragraph 8.3 of Attachment III
First Submittal to SAUDI ARAMCO
Subsequent submittals to SAUDI ARAMCO
15 calendar days prior to the start of WORK or 45 calendar days after the effective date of this Contract, whichever is earlier
Within 7 calendar days of each revision
Prior to assignment of personnel on the project
Prior to bringing new QA/QC personnel on the project.
Submitted with Quality Plan
Within 7 calendar days of revisions
Within fourteen (14) calendar days of completion of the scheduled audit and re-audit. Fourteen (14) calendar days before the start of any related activities
Updated Weekly
Within 48 hours of reporting each non-conformance
Notification of clearance required
After the first NCR is issued
Weekly for the Project Progress Meeting
Sixty (60) calendar days after the effective date of the Contract
Monthly
One week after the first purchase order is awarded for the Contract
Weekly
Twenty one (21) calendar days prior to pre-inspection meeting Ten (10) calendar days after preinspection meeting Ten (10) calendar days after the first inspection visit for each supplier
Ten (10) calendar days after each inspection visit
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13. 14.
15.
Inspection Disposition Report Paragraph 10 of Attachment III Special Process Procedures and Personnel Qualification Procedures Paragraph 7 of Attachment III Paragraph 3 of Attachment IV Construction Inspection and Test Plans Paragraph 2 of Attachment IV
Whenever materials are released for shipment Thirty (30) calendar days prior to operation or test
Revision Approval prior to execution
One month prior to start of applicable WORK
Revision Approval prior to execution
END OF SCHEDULE “Q” ATTACHMENT V
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ATTACHMENT VI TO SCHEDULE “Q” PROJECT SPECIFIC QUALITY REQUIREMENTS 1.
Procurement Phase Project Specific Quality Requirements 1.1.
The following system of coding the level of planned inspections shall be used to define the inspection requirements. The inspection levels specify the minimum amount of inspection coverage deemed necessary by SAUDI ARAMCO to ensure that a product or service conforms to specifications at a specific supplier’s and/or sub-supplier’s factory or fabrication site. The following five levels of inspection shall be used: 1.1.1. Level 0: required.
Documentation requirements only; no inspection
1.1.2. Level 1:
Only final inspection required prior to shipping.
1.1.3. Level 2: Includes, as a minimum, pre-inspection meetings, one or more unspecified "in progress" surveillance visit/s, all witness and hold points, final inspection, and release for shipment. 1.1.4. Level 3: Same as Level 2, except that "in progress" surveillance inspections shall be on a regular basis (daily, weekly or bi-weekly). 1.1.5. Level 4: 1.2.
Resident inspector continuously monitoring the work.
Minimum inspection levels for CONTRACTOR supplied equipment and materials are indicated below or listed on the Master Equipment List provided in Schedule “B”. CONTRACTOR shall submit its supplier inspection and test plans according to these minimum inspection levels. 1.2.1. For equipment items the following inspection levels apply: Pressure vessels /columns /separators/Preheater Level 3 Fin-Fan steam condensers Level 2 Control valves, switching valves Level 3 Motor Control Centers/Starters Level 2 Power and Control Cables (above 300 volts) Level 1 BTX analyzer Level 2 Locally fabricated electrical junction / terminal / splice boxes Level 1 DCS hard ware, control processor etc. Level 0 Pumps with drive motors and accessories Level 1 Q-VI-1 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
2.
1.2.2. For pipe, valves , fittings &fire protection items
Level 0
1.2.3. For fabrication of pre-cast foundations/structural steel/ roof trusses, and miscellaneous civil/structural items
Level 2
1.2.4. Any field fabrication requires
Level 4
Construction and Precommissioning Phase Project Specific Quality Requirements 2.1.
As a minimum, CONTRACTOR shall assign, or require its subcontractor to assign, SAUDI ARAMCO approved Inspectors to the WORK in accordance with the following table. With SAUDI ARAMCO approval, inspectors may be qualified to inspect more than one discipline; in such a case, however, any individual inspector may not fill more than one full time position at any time. Construction Phase Inspector Requirements
Construction Discipline
Earth work, foundations, concrete, asphalting and steel work.
Primary Inspectors CONTRACTOR (CONTRACTOR or Supervising subcontractor) Inspectors Civil/Structural One Inspector full time
Precommissioning Inspectors
N/A
One Inspector full time
N/A
Two Inspectors full time
N/A
One Inspector part time
N/A
One Inspector part time
Electrical Two Inspectors full time
Electrical
Mechanical Plumbing / piping
One Inspector part time Welding
Welding 2.2.
One Inspector part time
Other Project Specific Requirements: Two Q/C Survey full time END OF SCHEDULE “Q” ATTACHMENT VI Q-VI-2 CR, MP-IK-LS, MP-IK-LSPB OFF-IK-LSPB, OFF-OK-LSPB OFF-IK-LS, OFF-OK-LS 09/00
