ABU DHAB I OIL REFINING COMPANY (TAKREER) RUWAIS REFINERY EXPANSION (RRE) PROJECT PROJECT NO. 5578 / AGREEMENT NO. 09-5578-E-4 EPC PACKAGE - 4 : TANKAGE AND ASSOCIATED INTERCONNECTING PIPING
DOCUMENT / DRAWING COMMENTS SHEET COMMENTS TO BE RETURNED TO: COMPANY/PMC FAX NO.:
FAX NO.:
BY DATE:
BY DATE:
Contractor Transmittal No.
T-DH-5578-E4-5806
Recd. Date
25 Jul 2011
Document No.
5578-E4-1041-QC-CC-304
Rev. Date
21 Jul 2011
Document Title
Project Quality Plan for Civil Work
Rev
0
COMMENTS:
RUWAIS REFINERY EXPANSION PROJECT EPC-4 TANKAGE AND ASSOCIATED INTERCONNECTING PIPING AGREEMENT No. 09-5578-E-4
PROJECT No. 5578
Doc. No. 5578-E4-1041-QC-CC-304
PROJECT QUALITY PLAN for Civil Work
Rev. 0
Page 1/3
RUWAIS REFINERY EXPANSION PROJECT EPC-4 TANKAGE AND ASSOCIATED INTERCONNECTING PIPING AGREEMENT No. 09-5578-E-4
PROJECT No. 5578
Doc. No. 5578-E4-1041-QC-CC-304
PROJECT QUALITY PLAN for Civil Work
Rev. 0
Page 1/3
RUWAIS REFINERY EXPANSION PROJECT EPC-4 TANKAGE AND ASSOCIATED INTERCONNECTING PIPING
TAKREER
AGREEMENT No. 09-5578-E-4
DAEWOO E&C
PROJECT QUALITY PLAN for Civil Work
352-(&71R
'RF1R(4&&&
REVISION INDEX
$ Rev
$% %&
5HY
DETAILS
Location of Change 6HFDQG
)LUVWLVVXH
6HF
$GGHG([KLELW %DSSOLFDEOHSURMHFWVSHFLILFDWLRQ &RPPHQW ZDV LQFRUSRUDWHG
Brief Description of Change
$GGHGFRGHDQGVWDQGDUGDQGSURMHFWVSHFLILFDWLRQ )LUVW,VVXH
,VVXHG IRU &RQVWUXFWLRQ
3DJH
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
2 of 30
Rev. :
00
Date:
18 Apri l 2011
Amendment Form
SN
Section / Item
Current Statement
Amended Statement
Rev.
Date
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
3 of 30
Rev. :
00
Date:
18 Apri l 2011
Distribution Log
Controlled copies of this System Operating Procedure have been issued as follows:
Copy No.
Issued to:
1
Project Management
2
Workshop
3
QA/QC Central Unit
4
QA/QC Site Unit
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
4 of 30
Rev. :
00
Date:
18 Apri l 2011
Table of Contents KETTANEH STATEMENT OF QUALITY POLICY AND OBJECTIVE ..................................................................... 6 Project Quality Policy………………………………………………………………………………………………….......6 Project Quality Objective…………………………………………………………………………………………………..6 1.
SCOPE ........................................................................................................................................................................ 7
2.
APPLICABLE STANDARDS AND PROCEDURE .................................................................................................. 7
3.
TERMS AND DEFINITIONS .................................................................................................................................... 7
4.
PROJECT QUALITY MANAGEMENT SYSTEM ................................................................................................... 7 4.1. GENERAL REQUIREMENTS ............................................................................................................................. 7 4.1.1 General......................................................................................................................................................... 7 4.1.2 Outsourcing processes ................................................................................................................................. 8 4.2 DOCUMENTATION ........................................................................................................................................... 8 4.2.1 Project Quality M anagement System Documents ....................................................................................... 8 4.2.2 Document and Data Control ........................................................................................................................ 8 4.2.3 Control of Quality Record ........................................................................................................................... 9
5.
MANAGEMENT RESPONSIBILITY ....................................................................................................................... 9 5.1 GENERAL ........................................................................................................................................................... 9 5.2 ORGANIZATION ................................................................................................................................................ 9 5.2.1 Project Organization.................................................................................................................................... 9 5.2.2 Project Quality Organization ...................................................................................................................... 9 5.2.3 Function and Responsibility ........................................................................................................................ 9
6.
RESOURCE MANAGEMENT ................................................................................................................................ 10
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
5 of 30
Rev. :
00
Date:
18 Apri l 2011
7.3.2 Identification of Traceability ..................................................................................................................... 18 7.3.3 Client Supplied Material............................................................................................................................ 19 7.3.4 Handling, Receiving, Storing, Preservation and Delivery......................................................................... 19 7.4 CONTROL OF INSPECTION, MEASUREMENT AND TEST EQUIPMENT ........................ ................. .......... 20 8.
MEASUREMENT, ANALYSIS AND IMPROVEMENT ........................................................................................ 21 8.1 GENERAL ......................................................................................................................................................... 21 8.2 MONITORING AND MEASUREMENT ........................................................................................................... 21 8.2.1 Client’s Satisfaction ................................................................................................................................... 21 8.2.2 Internal Quality Audit ............................................................................................................................... 22 8.2.3 Monitoring and Measurement of Processes............................................................................................... 22 8.2.4 Monitoring & Measurement of Manufacturing Products & Construction Work.................................... 22 8.3 CONTROL OF NONCONFORMING PRODUCT........................ ................ ........................ ....................... ....... 23 8.4 ANALYSIS OF DATA....................................................................................................................................... 24 8.4.1. Client Satisfaction ...................................................................................................................................... 24 8.4.2 Nonconformity to project requirements.................................................................................................... 24 8.4.3 Characteristics and trends of processes and products .............................................................................. 24 8.4.4 Subcontractors ........................................................................................................................................... 24 8.5 IMPROVEMENT ............................................................................................................................................... 25 8.5.1 Continual Improvement ............................................................................................................................ 25 8.5.2 Corrective Action ....................................................................................................................................... 25 8.5.3 Preventive Action ...................................................................................................................................... 25 8.6 HANDOVER OF CIVIL WORKS ...................................................................................................................... 25 8.7 INSPECTION AND TEST ................................................................................................................................. 25
Appendix 1-1 Overall Organization Chart Rev. 01 .............................. .................... ................... ...................... ................ ... 26 Appendix 1-2 Field QA/QC Organization Rev. 01 ............................ .................. .................. ...................... ................. ....... 27
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
6 of 30
Rev. :
00
Date:
18 Apri l 2011
KETTANEH STATEMENT OF QUALITY POLICY AND OBJECTIVE
Project Quality Policy
Kettaneh Construction Emirates (KCE) is committed to provide, in realizing the Ruwais Refinery EPC4 Project located at Ruwais Industrial City, services to the satisfaction of M/s. CB&I ANSTALT under DAEWOO E&C as per specifications and agreed conditions. To meet its challenges KCE shall: - Maintain a high level of technical capabilities through professiona l, experienced, skilled and trained employees. - Use of relevant equipment and modern technologies. - Respect and comply with all relevant national and international codes and standards. - Continue the pursuit of improving the quality of services. General Guidelines
In realizing this project with regard to the quality policy above, the Project Management states the project goals hereunder: KCE shall comply with the project quality plan in order to handover this project to the satisfaction of
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
7 of 30
Rev. :
00
Date:
18 Apri l 2011
1. SCOPE
This “Project Quality Plan” identifies & describes the Quality Management System (QMS) processes needed for the construction activities conducted by Kettaneh Construction Emirates for M/s CB&I ANSTALT under DAEWOO E&C to realize the RUWAIS REFINERY EXPANSION EPC-4 PROJECT. 2. APPLICABLE STANDARDS AND PROCEDURE
The following Codes and Standards will be applied for this project: ISO 9001:2008 : Quality Management Systems - Requirements ISO 9000:2005 : Quality Management Systems – Fundamentals and vocabulary BSI : British Standard Institution ASTM : American Society for Testing and Materials ACI : American Concrete Institute Corporate Quality Manual: KCE-QM-101 Issue 01, 25 Nov 2010 3. TERMS AND DEFINITIONS
For the purposes of this Project Quality Plan, the terms and definitions given in the International Standard, ISO 9001:2008 “Quality Management Systems – Fundamentals and Vo cabulary” shall apply. The following definitions will be applied in this document.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
8 of 30
Rev. :
00
Date:
18 Apri l 2011
4. PROJECT QUALITY MANAGEMENT SYSTEM 4.1. GENERAL REQUIREMENTS 4.1.1
General
The Project Quality Plan is prepared in accordance with KCE “Quality Manual” based on ISO 9001:2008, as well as the Client’s requirements specified in the Tender Documents. 4.1.2
Outsourcing processes
KCE will use Third Party Independent Testing Laboratory to conduct laboratory quality tests, at site or off site, when and where applicable. The Project Management shall appoint the Field QA/QC Manager to monitor the testing laboratory to ensure that their activities and documentation are in line with the Project Requirement. 4.2 DOCUMENTATION 4.2.1
Project Quality Management System Documents
Project Specific procedures and method statements for all aspects of the Works will be prepared based on the Project requirements and KCE’s Corporate Standard. Applicable documents for the Project specific Quality Management System is listed in Appendix-3 “Applicable Document List”.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
9 of 30
Rev. :
00
Date:
18 Apri l 2011
The applicable documents for this chapter are TAK-CQP-S-GEN-PDRC-0003 REV. 00 “Control Quality Procedure Drawing Control” and TAK-CQP-S-GEN-PDOC-0002 REV. 00 “Control Procedure for General Document Control”. All formats to be used shall be approved under its respective Master Document (Attachment No.5) 4.2.3
Control of Quality Record
Project Management maintains quality records to provide evidence of conformity to requirements and of the effective operation of the QMS. The “Control of Records Procedure” defines the controls needed for identification, storage, protection, retrieval, retention time and disposition of records. The applicable document for this chapter is Quality Procedure for Control of Records”.
TAK-CQP-S-GEN-PCOR-0004 REV. 00
“Control
5. MANAGEMENT RESPONSIBILITY 5.1 GENERAL
The Project Management established the “Project Quality Objective” herewith attached ( Attachment No.1) and which shall be communicated by all concerned and will be instructed to perform their duties strictly in accordance with this Project Quality Plan and thereby contribute to the realization of the Project Quality Objective.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008 5.2.3
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
10 of 30
Rev. :
00
Date:
18 Apri l 2011
Function and Responsibility
Please refer to Appendix 2 “ Job Description” for the Roles and Responsibilities of Key Persons in this Project. 6. RESOURCE MANAGEMENT 6.1 PROVISION OF RESOURCES
The Project Management ensures the meeting of Client’s requirements by providing the resources needed to implement and maintain the QMS and continually improve its effectiveness. 6.2 HUMAN RESOURCES 6.2.1
General
The General Manager assigned for this Project competent personnel, on the basis of appropriate education, training, skills and experience, for the management and implementation of the Works as well as their inspection including internal audits. 6.2.2 Competence, Training and Awareness
1) Qualification of Project Management Team Members
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
11 of 30
Rev. :
00
Date:
18 Apri l 2011
The Project Management maintains records of training of project office personnel on an individual basis, Attachment No. 6 “Training Record ”, which shall be kept confidential at the Project Management disposition. The applicable document for this chapter is TAK-CQP-S-GEN-PCTA-0008 Procedure for Competence, Training & Awareness” 6.3 INFRASTRUCTURE AND WORK INVIRONMENT
REV. 00 ,
“Control Quality
6.3.1 Infrastructure
Project Management provides the infrastructure needed in the project. includes the following temporary items as follows:
Infrastructure
1. project office and associated utilities, warehouse, stockyard, temporary car park, 2. materials, machine and process equipment (both hardware and software), and 3. supporting services such as t ransport, communication and/or information system 6.3.2 Work Environment
Project Management provides Work Environment to include the following temporary items as follows: 1. temporary safe and healthful facilities, 2. places of communication in the Project Site, and
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
12 of 30
Rev. :
00
Date:
18 Apri l 2011
The realization process in KCE is done in three stages: • • •
Pre-award Estimation Stage Award Stage Post-award Execution Stage
This PQP shall describe only the stages related specifically to this Project. 7.1.2.1 1)
Post-Award Stage Contract Budget and Cost Control
The contract quantities and budget are prepared for operational purposes (procurement, accounting, cost control etc). Copy of the budget is checked by the ETM and VP Business Development, Estimation & IT. VP Business Development, Estimation & IT will forward the same to the General Manager for his review, if the former finds it necessary. This is done prior to distribution to the Area Procurement Department for reference, Finance and Accounts Unit (FAU) for control and PCSM for follow-up. 2)
Contract Document Distribution
Copies of the contract document will be distributed to :
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
13 of 30
Rev. :
00
Date:
18 Apri l 2011
Area Administrative & Commercial Manager (ACM) The ACM will be basically involved in payment terms and the relevant cash flow including monthly expenses vs. income. The ACM Shall be involved in procurement of site needs for various categories of staff and labours and their accommodation, transportation and travel, visas, residency cards, work permits, etc. Area Quality Assurance / Quality Control Manager (AQAQCM) The Area QA/QC Manager will review the Contract and highlight all Quality related issues. At a later stage, he will be responsible to define the processes and procedures required by the Contract in order to implement them for this specific Project. Contracts Manager (CM) The CM will review the Contract and highlight all the specifically contractual rights and duties of both KCE and the Client, in order to be able to follow them up at a later stage. 3)
Transfer of Data
Upon signing the contract, the AMD shall invite all concerned to an internal kick off meeting, whereby the AMD will transfer the following basic elements/data to
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008 4)
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
14 of 30
Rev. :
00
Date:
18 Apri l 2011
Construction Operations: •
Material Delivery
The Site Procurement Coordinator (SPC) in conjunction with the Site Planning Engineer (SPE) will regularly review material delivery dates with respect to construction activities and completion dates so as to meet the overall project completion schedule date. •
Procurement
The Area Procurement Department (based in our Head Office, Abu Dhabi) will review the contract schedule in relation to the material requirements of the project: as to when the material is required on s ite, and the relevant specification of that material •
Shop Drawings
The Technical Office (TO) reviews the contract requirement for shop drawings envisaged to be prepared, in due course, for submittal to avoid any delays in material procurement or project execution of the relevant works.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008 7.1.2.2
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
15 of 30
Rev. :
00
Date:
18 Apri l 2011
Amendment of Contract Variations to the Contract:
During the process of execution, should the Client introduce changes in Specifications to certain items or changes in the scope of Work, the Technical Office (TO) will evaluate with the assistance of the ESD, the price effect resulting from these changes. The TO will also evaluate any effect on the terms of the contract and in particular, on the execution schedule of the project as a whole or part thereof and also price effect of items related to the “indirect cost”. In case of any amendment, the said amendment are resolved and properly documented and the relevant personnel and company departments concerned are made aware of the changes for implementation. Originals are added to the original Contract document retained by AMD. Contract review records are maintained with the Project Manager. 7.1.2.3
Communication with Client
The Project Management determines and implements effective arrangements for communicating with Client in relation to: 1)
Product information
Upon request from Client, KCE shall submit relevant technical sheets, samples
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
16 of 30
Rev. :
00
Date:
18 Apri l 2011
7.2 PURCHASING 7.2.1
General
The Area Procurement / Procurement Manager based in the KCE Abu Dhabi head office has overall responsibility for all purchasing activities to ensure purchasing will be implemented in accordance with the Client’s requirements and Corporate Standard Practices. The applicable document for this chapter is Quality Procedure Purchasing”. 7.2.2
TAK -CQP-S-GEN-PPUR-0007 REV. 00 ,
“Control
Sub-Vendor list
The Project Manager with the coordination of the Area Procurement / Procurement Manager shall prepare and submit to the Client the Sub-vendor list for approval as per the Contract requirements. This list shall be prepared based on the return of experience from previous similar projects and related activities which had materialized vide the periodical evaluation. 7.2.3
Assessment and Selection of Sub-vendors
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008 7.2.6
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
17 of 30
Rev. :
00
Date:
18 Apri l 2011
operation & maintenance manuals, and warranty
Verification of Purchased Product
1.) The Project Management established documented procedures for receiving, inspecting and testing of materials and equipment which are carried out, inside and outside of the Project Site and verifies that such materials and equipments complies with the relevant Specifications provided in the Contract. The documented procedures established include the measures to prevent such materials and equipment from being used by mistake prior to being inspected or tested. 2.) The Project Management determined and included in the documented procedures the items, frequency and sampling rate of the receiving inspection and testing for such materials and equipment considering the condit ions described below. a) The extent of quality of such material and equipments supplied by the manufacturer are the quality records provided by the manufacturers’ and suppliers. Where such information is not available or such information seems to be unreliable, the sampling and testing frequency shall be as per Client requirements, as well as applicable local and international Standards. Subsequently, the increase or decrease of testing frequency, depending on the results of such sampling t esting.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008 7.2.7
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
18 of 30
Rev. :
00
Date:
18 Apri l 2011
Shipping and Custom Clearance
The shipping activities for equipment and materials for the Project will be performed in accordance with Project shipping and packing instruct ions and applicable UAE law. 7.3 PRODUCTION AND SERVICE PROVISION 7.3.1 Control of Product and Service Provision
Project Management had clearly defined construction plan including construction processes on the project schedule and/or work procedures as needed and shall carry out construction under controlled conditions. Controlled conditions shall include as applicable. 1) The availability of information that describes the characteristics of the product, such as Design Drawings, Specifications, Design Instruction, etc. (7.1.2 Review of Project requirements) 2) The availability of work instructions such as work procedures etc., as necessary and the use of suitable equipment which are needed for the work; (6.3.1: Infrastructure) 3) The availability and use of monitoring and measuring devices, as necessary;
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008 3)
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
19 of 30
Rev. :
00
Date:
18 Apri l 2011
Traceability for the state of inspection.
The applicable document for this chapter (Civil works) is TAK-CQP-S-GEN-PRET-0004 REV. 00 “Control Quality Procedure for Rebar Traceability” and approved concrete pour card. 7.3.3 Client Supplied Material
Project Management performs regarding this section t he following actions: 1) Where the Client’s property is to be incorporated in the Work as provided in the Contract, the Project Management determined the process of handling these items and verification on receipt, storage and release from storage until incorporation in the work of such Client’s property, and 2) Where the Client’s property is found visually unacceptable or partly and/or entirely missing, the Project Management shall report the fact to the Client and agrees with him how to recover. The applicable document for this chapter is TAK -CQP-S-GEN-PHRM-0005 REV. 00 “Control Quality Procedure for Handling and Receiving Permanent Mat erials” 7.3.4 Handling, Receiving, Storing, Preservation and Delivery
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
20 of 30
Rev. :
00
Date:
18 Apri l 2011
b) The Procedure shall be identified for the materials and equipment which could easily deteriorate during storage and a matrix of inspection as applicable shall be established with the frequency of inspection and assess the extent of any deterioration and take necessary actions to prevent damage and/or deterioration, and c) Establish the materials “entry and release control procedure” including approval of release. 3) Protection
The procedure for the protection methods for the completed portions of the Work, identification for the items, which need rust-inhibiting treatment or sealing of desiccant, and a practical method for prevention are included in the construction procedure for the specific work items. 4) Delivery
The Project Management establishes documented procedures for the care of the completed structure after in-house inspection and testing on completion and maintains them until handing over to t he Client in conformance with the procedures. The applicable documents for this chapter is TAK-CQP-S-GEN-PHRM-0005 REV. 00 “Control Quality Procedure for Handling and Receiving Per manent Materials” 7.4 CONTROL OF INSPECTION, MEASUREMENT AND TEST EQUIPMENT
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
21 of 30
Rev. :
00
Date:
18 Apri l 2011
6) Pressure Gauges 7) Concrete Moisture Tester 8) Nuclear Density Gauge 9) Electrode Drying Oven 10) Welding Rectifier 11) Welding Generator Set 12) Electrical Digital Multi Meter 13) Electrical Digital Clamp Meter 14) Cable Insulation Tester In addition, Project Management shall assess & record the validity of the previous measuring results when the equipment is found not conforms to the requirements. Project Manager shall take appropriate action o n the equipment & any product affected. Records of the results of calibration & verification shall be maintained. The applicable documents for this chapter are KCQ-QM-101-7.6.3 “Procedure for Control of Inspection, Measurement and Test Equipment ”, of the Corporate Quality Manual.
8. MEASUREMENT, ANALYSIS AND IMPROVEMENT 8.1 GENERAL
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
22 of 30
Rev. :
00
Date:
18 Apri l 2011
2) Requests and complaints upon the completion of wo rks; - on the in-house final inspection and/or the handing over of the Project 3) Other information such as business development matters and Customer Survey Form etc. This information mentioned above shall be utilized for the Corrective and Preventive action, Management Review Meeting, and also spread within all the organization of KCE as necessary. 8.2.2
Internal Quality Audit
The Area QA/QC Manager or his delegate shall conduct internal audits at planned intervals; usually the first audit will be conducted when the project reaches a twenty percent (20%) progress accomplishment, to determine whether the Pro ject Quality Plan is effectively implemented and maintained. Succeeding internal audits will be conducted at a planned interval as practicable and applicable for a minimum of 2 audits per 12 months project duration. The General Manager will submit the relevant audit and/or surveillance reports, including findings and observations, areas of concern and required corrective actions, if any, on completion to the Client through the Project Management whenever requested by M/s. DAEWOO E&C or to be shown as requested during an audit conducted by M/s. DAEWOO E&C.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
1)
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
23 of 30
Rev. :
00
Date:
18 Apri l 2011
Inspection during construction Project Management establishes and implements the procedure for inspection and testing of the work described in the relevant approved ITP including the measures to prevent works from being progressed to the subsequent stage prior to inspection and testing for conformance, except the process work which can be identified and tested for conformance, from the subsequent work. a) Information from the monthly reports which are pro vided by Project Management.
2)
In-house inspection and testing and completion Project Management carries out the in-house inspection and testing on completion in order to verify that the Works conform to specified requirements and records the results. Project Management shall deliver the work to the Client after he confirms the completion of the works complies with the Client requirements.
The applicable Document for this chapter is TAK -CQP-S-GEN-PPLP-0009 REV. 00 “Control Quality Procedure Punch List Procedure” 8.3 CONTROL OF NONCONFORMING PRODUCT
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
24 of 30
Rev. :
00
Date:
18 Apri l 2011
The controls and related responsibilities and authorities for dealing with nonconforming product shall be defined in TAK-CQP-S-GEN-PNCP-0010 REV. 00 “Control Quality Procedure for Control of Nonconforming Product”. 8.4 ANALYSIS OF DATA
The Project Management with close coordination with the Corporate QA/QC Manager shall collect and analyze appropriate data to demonstrate the suitability and effectiveness of the QMS and to evaluate where continual improvement of the effectiveness of the QMS can be made. The analysis of data shall provide information relating to: 8.4.1. Client Satisfaction Project Management analyses claims and request s from Client through their regular meetings during construction as well as the “customer satisfaction survey”, and then takes measures against them. Where necessary, Project Management discusses the matter with the Corporate QA/QC Manager. The Corporate QA/QC Manager shall then report to Top Management vide the VP Projects Control, Safety & Quality and utilize the data to ensure Client satisfaction through Continual Improvement of QMS, and such information shall also be included as one of the inputs during Management Review Meeting.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
25 of 30
Rev. :
00
Date:
18 Apri l 2011
8.5 IMPROVEMENT 8.5.1
Continual Improvement
KCE continually improves the effectiveness of the Quality Management System through the use of the Quality Policy, Quality Objectives, Audit Results, Analysis of Data, Corrective and Preventive act ions and Management Review. 8.5.2
Corrective Action
Project Management takes action to eliminate t he cause of nonconformities in order to prevent reoccurrence. Corrective action shall be appropriate to the effects of the nonconformities encountered. A documented procedure has been established to define the requirements as mentioned below; a. b. c. d. e. f. g. 8.5.3
evaluating the need for action to ensure that non-conformities do not reoccur, reviewing nonconformities (including Client complaints), determining the root causes of nonconformities, determining and implementing action needed, correction of the nonconformity, records of the results of action taken, and reviewing corrective action and analyze the e ffectiveness of action taken
Preventive Action
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
26 of 30
Rev. :
00
Date:
18 Apri l 2011
8.6 HANDOVER OF CIVIL WORKS 8.6.1
The handover of CIVIL WORK will be in accordance with a DAEWOO procedure to be agreed with COMPANY.
8.6.2
KCE shall be totally responsible for handover of all its WORK related to the construction of the PLANT as per Scope of Work. KCE procedure will typically include the following handover steps: -Discipline Acceptance -Systems Acceptance -Unit Acceptance -CIVIL COMPLETION
8.6.3
Each of these handover steps will be a “Hold Point i.e., progress from one step to the next requires written approval from DAEWOO E&C. ‟,
8.7 INSPECTION AND TEST
KCE will inspect and test not only as per COMPANY approved field Inspection & Test Plan but also as per Contract Requirements.
Appendix 1-1 Overall Organization Chart Rev. 01
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
27 of 30
Rev. :
00
Date:
18 Apri l 2011
Appendix 1-2 Field QA/QC Organization Rev. 0 CORPORATE QA/QC MANAGER Toni Hamouche KETTANEH CONSTRUCTION EMIRATES
OFF SITE ORGANIZATION SITE ORGANIZATION
PROJECT MANAGEMENT
CB&I QA/QC MANAGER TBA
Field QA/QC MANAGER TBA
Coordination Communication
SECRETARY & DOCUMENT CONTROLLER
TANK 1
TANK 2
TANK 3
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
28 of 30
Rev. :
00
Date:
18 Apri l 2011
Appendix 2: “Job Description” 1) Project Manager
a. Having full charge of all operations and full authority to represent the project and to control the Safety, Quality, Schedule and Cost. b. Has the overall responsibility for the Project HSE and Quality Plans functioning within the Company & Client policies. This responsibility and authority shall be delegated to responsible project personnel with instructions to maintain and verify compliance to the system throughout the duration of the project. c. Approving the Project Plan and appraising the performance of the project WORKS and submit monthly progress reports to the Client and highlighting any adverse trend with counter measures to be taken. d. Implementing the Project Safety / Quality Plan for procurement, construction / commissioning work etc. e. Detecting non-conformities / incidents and initiating and/or approving corrective actions, intervening as to resolve outstanding safety & Quality issues and ensuring documenting of all changes to project specification. f.
Fulfilling Contractor’s requirements specified in the Contract.
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
29 of 30
Rev. :
00
Date:
18 Apri l 2011
3) Section Engineer
a. Responsible for the general progress of the section construction work b. Controlling work schedule, Quality, Work packages subcontract works and construction. c. Implement method statements / work procedure. d. Reporting to the Site / Construction Manager 4) Technical Office Manager
a. Responsible for the preparation, review of method statement and shop drawings, technical queries, etc. b. Responsible for the preparation of monthly progress reports c. Responsible for the schedule control d. Review contracts and change orders with coordination of the Contract Manager e. Attend project review meeting f.
Reporting to the Site Manager
5) Field QA/QC Manager
QUALITY MANAGEMENT SYSTEM PROJECT QUALITY PLAN
ISO 9001: 2008
Doc. No.:
TAK -PQP-S-GEN-0000-0001
Page:
30 of 30
Rev. :
00
Date:
18 Apri l 2011
e. Major administrative issues reported to Area Administrative and Commercial Manager. Appendix 3: “Applicable Document List” Doc. No.
Title
1
TAK-CQP-S-GEN-PCOW-0001 REV. 00
Control Quality Procedure for Concrete Works
2
TAK -CQP -S-GEN-PGDC-0002 REV. 00
Control Quality Procedure for General Document Control
3
TAK -CQP -S-GEN-PDRC-0003 REV. 00
Control Quality Procedure for Drawing Control
4
TAK -CQP -S-GEN-PCOR-0004 REV. 00
Control Quality Procedure for Control of Records
5
TAK -CQP -S-GEN-PRET-0005 REV. 00
Control Quality Procedure for Rebar Traceability
6
TAK -CQP -S-GEN-PHRM-0006 REV. 00
Control Quality Procedure for Handling and Receiving Permanent Materials
7
TAK -CQP -S-GEN-PPUR-0007 REV. 00
Control Quality Procedure Purchasing
8
TAK -CQP -S-GEN-PCTA-0008 REV. 00
Control Quality Procedure for Competence, Training & Awareness