Sie sind auf Seite 1von 18

01 SCOPE

This section identifies how quality will be managed during all phases of the Work associated with the execution of the scope of work. The Quality System Policies and QA/QC Procedures applicable to this project are defined in this Quality Plan. This system of policies, procedures, and practices ensure the fulfillment of the requirements of ISO 9001and provides customers with assurance that quality processes are maintained. The master and controlled versions of the Quality Management System is maintained by the project QA/QC Manager. An uncontrolled copy of the Quality Management System documentation will be made available upon request by the members of the project team.

02 ADMINISTRATIONS Project Quality Plan Control


This Project Quality Plan will be subject to amendments when necessitated by changes in working procedures, policy and customer approved contract revisions. The controlled copy of this Project Quality Plan and associated quality management system documentation will be controlled by the Quality Assurance Manager. All applicable sections, as appropriate, will be revised when amendments take place. The designated project QA/QC Manager is responsible for the administration and maintenance of the relevant project quality management system documentation. Paper copies of the Project Quality Plan and quality management system documentation are uncontrolled copies.

03 Standard Quality definitions shall be used as indicated below:


QCITP Quality Control Acceptance & Test Plan AFI Application for Inspection PQE Project Quality Assurance and Quality Control Manager QMS Quality Management System SAT Site Acceptance Test FAT Factory Acceptance Test QAP Quality Assurance Procedures QCP Quality Control Procedures DCC Document Control Centre

NCR Nonconformance Report CAR Corrective Action Request

04 PROJECT QUALITY MANAGEMENT SYSTEMS


4.1 Quality system All pertinent QA/QC Procedures and Quality Control Inspection Check Sheets shall be identified and indexed in this Project Quality Plan. The application of these procedures is detailed in this Project Quality Plan. Project specific information is included in the Project Execution Plan. 4.2 Quality Objectives

The application of the quality management system has the following overall objectives:

Ensure that the requirements of all applicable Customers Project specifications are satisfied, particularly with regard to quality assurance (QA) and quality control (QC) as it pertains to design, procurement, construction and testing. Effectively manage quality throughout all phases of project execution, including those activities conducted by Subcontractor, Vendor/Sub vendors, Suppliers, Fabricators and Installation Contractors. Provide assurance that the completed work associated with the facilities will conform to the project specifications, design codes, regulatory requirements, and sound engineering and construction practices. The following key project goals shall take precedence:

Ensure quality transparency is observed throughout the project Measure quality performance and identify positive and negative trends. Identify and resolve discrepancies relating to contractual project specifications, piping, instrumentation diagrams (P&IDs), network drawings, loop diagrams, and calculations. This objective is accomplished primarily during the Planning Phase of the project. Complete a full and objective 3D Model and constructability reviews in the design phase of the project ensuring that all stake holders are invited and advised of the status of outstanding issues. Ensure that the equipment is installed according to approved specifications, design, and installation drawings. Ensure that procured items delivered to the site comply with the Contract and customers project specifications and that they are controlled, distributed to prevent inadvertent use. Demonstrate that all systems functions have been implemented in accordance with design requirements.

Develop and maintain as-built documentation in the procurement, construction mechanical completion, pre commissioning and turnover stages of the project. 4.3 Quality Plan The project quality manager shall establish a Quality Plan to ensure all the Quality assurance activities are fully identified, auctioned, and meet the Contract requirements. 4.4 Control of quality records The Project Manager shall establish a project filing system in accordance with the project requirements while implementing the customers contract requirements. The designated document controller shall control all the project documents and data bases. The document data base shall conform to the customers contract requirements All files shall be clearly identified with the project reference number.

5. MANAGEMENT RESPONSIBILITY
5.1 Responsibilities The project manager has the responsibility to ensure these actions are planned, documented, and implemented in the sequence that will ensure customer satisfaction by meeting project requirements and expectations. The Project QA/QC Manager is responsible for the implementation of the Quality System on the project. A Project Execution Plan will be developed by the project management team this will provide the basis for the execution of each project. This document shall be maintained current in order to reflect any changes in the project requirements and scope for the duration of the project. A project Organization Chart will be completed and maintained (updated) for the duration of the project to show the interrelation of the different disciplines associated with the execution of the project. The Contractors Site Manager is accountable to the Project Manager for the controlled execution for the scope of work at site as per contract requirements.

The Project Execution Plan will detail the job descriptions for the project team members. The Project site QA/QC Manager reports to the corporate Quality Assurance Manager. The Project site QA/QC Manager is responsible for monitoring the implementation of the Project Quality Plan through a program of quality audits and project surveillances. The QA/QC Manager is responsible for reviewing the project audit reports and ensuring that corrective and preventive actions are completed in a timely manner. Any requests to deviate from the requirements of the Project Quality Plan and associated procedures shall require the authorization of the Project Manager, Quality Assurance Manager. The Project site QA/QC Manager shall establish and complete a monthly QA/QC Management report. 6. RESOURCE MANAGEMENT 6.1. Interfaces Project Task force. It is the project QA/QC Managers responsibility to explain in a prearranged QA meeting(s) the QA activities and requirements of the project.

Quality Control Plans covering engineering, procurement and construction disciplines. The implementation the project Work Packages shall be explained. The project Quality Management Systems shall be explained. Subcontractor Point of Contact. The Project QA/QC Manager will be the interface and the point of contact with all subcontractors vendors, suppliers and customer representatives regarding all quality issues. 6.2. Competence, Awareness The Contractor is committed to complete appropriate training, documentation and guidance. Training covers topics in the following areas:-

Product transparency, code of ethics Contractors policies, objectives.

Quality awareness. HSE training.

7. PRODUCT REALIZATION 7.1. Contract Review


The project team shall complete Contract Review meetings with the sales team and ensure that all ambiguities and anomalies are cleared and verified.

Applicable procedure:

7.10. Control of Monitoring and Measuring Devices 7.10.1. Calibration Equipment This procedure shall apply to all Instruments used for calibration and test purposes. Applicable Procedure: Project Procedure: Calibration Equipment 7.10.2. Calibration Records Contractor shall request Subcontractor and Suppliers to provide their Calibration records.

7.10.3. Faulty Test Equipment When a piece of test equipment has been found faulty, it is the responsibility of the Principal Lead Engineer to identify the work the unit has been used on and assess the consequences. Re-visits to customer site may be required. Faulty test equipment is normally identified by the engineers service report or the calibration certificate after re-certification. It is the responsibility of the Principal Lead engineer to record any faults and actions taken.

Reference Procedure: Project Procedure: Non-Conforming Material 7.2. Order Confromation The Project Manager shall formally acknowledge the project order from Sales team. Applicable procedure: Project procedure: Order booking 7.3. Project Kick-off Project Manager shall conduct a Kick-off meeting with the Customer. The following shall be discussed and agreed during the Kick-off meeting:

Communication Protocols Non-Conformance management Project Organization charts Designated Points of Contact Project Schedules Quality Assurance requirements Project Progress Reporting HSE Requirements Change Management Applicable procedure: Project procedure Project Kick Off 7.4. Design Control 7.4.1. Project Planning / Review Meetings The basis of design, and contract shall be highlighted in the contractors Project Execution Plan. Quality Control Plan for the engineering/design disciplines defines for each activity the applicable controlling procedure, responsibility and the resultant deliverables. Design deliverables are subject to review and approval prior to issue in accordance with the established procedure or detailed description.

Applicable procedure: Project procedure: Project Planning Additional information: Project Execution Plan project Meetings, Reports and Correspondence. 3D Model Reviews Constructability Reviews

7.4.2. System Design implementation

Implementation of design shall proceed as prescribed and scheduled in the project review meetings. The Customers Design specifications will be complied with:

Functional Design Specification Detailed Design Specification


7.4.3. Design changes Design Changes are controlled in accordance with established procedures to ensure that all changes are recorded, evaluated and reviewed prior to their implementation. All design changes shall be recorded and tracked.

Applicable procedure Project procedure: Change Control

7.4.4. Application Engineering Project team shall utilize the approved engineering tools during the project engineering. New software shall be evaluated and approved as required prior to use.

Project Software Control system shall be established per the procedure and have a regular back-up and revision controls. The Project team shall follow the project records procedure established and shall maintain traceability.

7.4.5. Off-site Engineering

Applicable external staging sources: Quality Plan, Inspection & Test Plan and Factory Acceptance Test procedures from external vendors and suppliers shall be obtained by the Contractor prior to the execution of factory testing. The order shall be reviewed with the Customer in accordance with project requirements.

Responsible: Project Manager, Engineering Manager.

7.5. Document Control 7.5.1. Document Deliverables All project deliverables are identified in the customers Project Specifications and contract. Project deliverableds will be defined in the project specific Document Control Index (DCC). All deliverables will be provided per the customers Project Schedule. The deliverables for this project are listed in the DCC and will be maintained by the Project Principal Lead Engineer and Document Engineer. These will be kept with the rest of the project documentation. The master document index will be located in the Contractors database. Once an item is delivered, it is assumed frozen and any further updates will require change management. The completion of these deliverables marks the end and acceptance of that project phase (less any future Change Management that will be tracked until completed). Applicable Procedure: -Document Control Quality assurance procedures will be followed for receiving, transmitting, filing and retention of the documents. 7.5.2. As-Built Documentation

The Contractor will develop and maintain the system design drawings as well as databases and revision logs throughout the project. The contractor will ensure that the master set of working drawings is complete, properly marked with changes, and reflects

current status. All as-built system drawings for the systems, and relevant databases will be turned over to the Customer at the end of the project. Applicable Procedure: -Document Control 7.5.3. System Documentation Applicable procedure: Project Procedure: Standard System Manuals 7.5.4. Other Project Documentation

The contractor will create other documents during the course of the project intended to facilitate the successful completion of its work. Some of these documents will relate to quality issues and, as such, will be maintained and made available as required by the contract these may include the following:

Contractual documents Project correspondence Change orders Nonconformance reports Design specifications, drawings, and calculations Procurement documents Material receipt and inspection records Field change orders and variance authorizations Applicable Procedure: -Document Control 7.5.6. Archiving According procedure: Archiving 7.6. Project Software Control The term Software includes all project related correspondence files, documentation, engineering data and programs. The following Control activities will be documented: Software Control Activities

Working Copy (WC) Working Master / Daily Backup (WM) Weekly Backup (WB) System and Project Specific Software media Project Software generation and control Storage of media Labeling of media Responsibilities Associated forms The qualification of software in use on the project is subject to routine verification during internal audits. Quality records are maintained. The project server will continuously monitor viruses by special embedded programs running in the background in the main server. Software imported from outside the project will be scanned for viruses before use. Applicable procedure: Project procedure: Project software Control Procedure

Options: Tracking register: to be maintained by DCC. The computer software can automatically track Office Documents (per category etc.), and also email associated with a contact.

Activities Tab in contact Tracking of Email Tracking of Email shall be subject to routine verification during internal audits. The IT Administrator is responsible to use agreed application Software, troubleshoot PC failures in Software and Hardware. Employees are not allowed to install Software in their PC which is not on the list of approved product available with the IT Administrator. The standard Operating system on every Contractors computer is Windows. A PC may have other Operating Systems (Dual Boot) this should be agreed with the IT Administrator.

IT Administrator may monitor the contractors PCs from the project team without prior notice to the concerned personnel. He has the authority to delete programs which are not identified by Corporate as a valid approved product. All employees shall have access to the Contractors Intranet and Area Network (Internet). The standard browser to be used is Internet Explorer as per Corporate guidelines. Internet traffic will be monitored. 7.8. Procurement All purchased material and services will comply with the specified requirements. To achieve this, all purchase order requisitions will contain adequate and precise descriptions of the material and services required. These will be supported by relevant specifications and technical data as appropriate. Contract conditions will be stipulated in all purchase orders which will secure for the Contractor the right to verify that purchased material and services comply with specified requirements and to reject those which do not. This will also include the right for Contractor to verify the products and services at the suppliers premises. Purchasing is carried out in two different ways: a) Purchasing from approved subcontractors (customers approved suppliers lists) b) Purchasing from outside vendors and suppliers (minimum value products under an agreed contract sum). c) Sole source vendors and suppliers. The contractors Purchasing Manager will review and approve all orders in conjunction with the engineering manager. Maintenance of the Approved Vendor List, vendor approval and monitoring is also carried out by the Purchasing Manager. Applicable Procedure: Project Procedure: Cost Control General QA procedure: Purchasing 7.8.2. Assessment of Subcontractor

The scope of work is defined in work packages as referenced in the Project Execution Plan. Contractor will manage and control the Sub-contractor on the basis of an accepted Project Execution Plan prepared by the sub-contractor including deliverables, review points and records to be produced. Copies of relevant sub-contractor quality records and safety records will be obtained and will form part of the Over all Project Quality Records. Contractor will review the Corrective & Preventive actions Control of activities: Refer to the attached appendix: Project Audit Plan. Contractors terms and conditions will be applied to all subcontracts for the relevant scope of the subcontractors or sub vendors supply. Applicable Procedure: General QA Procedure: Subcontractor Selection, Evaluation and Monitoring Control of activities: 3rd party inspector company shall carry out an audits at suppliers premises. Contractor nominated engineer shall conduct inspections at suppliers premises. Applicable Procedure: General QA Procedure: Supplier Evaluation & Selection Supporting documents: Project Quality Manual; section 3.4 Quality Assurance Procedures: Purchasing Goods & Services Receipt Quality Assurance Forms: Observation/Inspection form 7.8.3. Supplier Evaluation Applicable Procedure: General QA procedure: Purchasing 7.8.4. Procurement of Items from contractors suppliers Applicable Procedure: General QA procedure: Purchasing

7.9. Production and Service Provision 7.9.1. Control of Production and Service Provision Contractor controls production and service activities by employing suitably qualified personnel, giving them the appropriate training and guidance. 7.9.2. Identification and Traceability

Applies to material utilized in the delivery of hardware, software and systems in Project Operations during implementation, delivery and installation. Components, assemblies, modules, subsystems, software and technical documentation are defined in accordance with applicable drawings, specifications, subcontractors identifying part number or code, or other unique identifiers. QA/QC Procedures ensure identification, traceability and status where applicable. Identification and traceability is normally achieved by one or more of the following:

Proposal number

Job number Project number Part number Model and/or serial number

Applicable Procedures and Documentation: Project Procedure: Project Software Control Project Procedure: Material Identification and Traceability 7.9.3. Customer Property Contractor ensures that customer owned product is protected from loss, damage or unauthorized use. Detailed records of customer-supplied product are made upon receipt. If any damage is noted appropriate action is taken as in standard practice for all other material received.

Prior to integration the customer supplied product is clearly labeled using a suitable method and identifiers. Upon integration or loading into the system the customer supplied product is checked for suitability to perform the specified service. An inventory check is made of all customer supplied products and repackaged in original packaging prior to making arrangement for shipping. None conforming material shall be segregated marked until final disposition is agreed. Applicable Procedure: Project Procedure : Customer Supplied Material 7.10. Control of Monitoring and Measuring Devices 7.10.1. Calibration Equipment his procedure shall apply to all Instruments used for calibration and test purposes. Applicable Procedure: Project Procedure: Calibration Equipment 7.10.2. Calibration Records Contractor shall request Subcontractor and Suppliers to provide their Calibration records. 7.10.3. Faulty Test Equipment When a piece of test equipment has been found faulty, it is the responsibility of the Principal Lead Engineer to identify the work the unit has been used on and assess the consequences. Re-visits to customer site may be required. Faulty test equipment is normally identified by the engineers service report or the calibration certificate after re-certification. It is the responsibility of the Principal Lead engineer to record any faults and actions taken. Reference Procedure: Project Procedure: Non-Conforming Material 8. MEASUREMENTS, ANALYSIS AND IMPROVEMENT 8.1. Measurement and Monitoring 8.1.1. Customer Satisfaction

Customer satisfaction surveys shall be completed to ensure that quality improvement can be achieved. A survey format is operated at six monthly intervals. The process shall be initiated, measured by the Contractors head office. 8.1.2. Internal Audit The Contractors work will be subject to internal quality audits to ensure that the required ISO policies, procedures, and practices are being properly followed. Audit reports and other quality records will be made available to the customer upon request. Internal Quality Audits will be scheduled on the basis of the status and importance of the activity to be audited. At a minimum, each project will be audited once per year. Audits will be carried out by personnel independent of those having direct responsibility for the activity being audited. The results of audits will be recorded and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area will take timely corrective action on deficiencies found during the audit. Follow-up activities will verify and record the implementation and effectiveness of the corrective action taken. Reference Documents: The internal audit procedure for projects is described in:General Quality Assurance procedure: 8.1.3. Contractor Tests Inspection: Any deficiencies observed during inspection and testing will be rectified by corrective measures. Internal contractor testing QC Check Sheets as built-documentation, manufacturing Record Books will be maintained and made available to the customer as per contract. Applicable Documentation: Project Procedures: Factory Acceptance Test 8.1.5. Site Acceptance Test

The Site QC Acceptance Tests shall be carried out against a Site Acceptance Test Procedures. These documents will be developed during the detailed engineering phase. Tests will be carried out per phase per installed equipment. Vendor specialists will attend the Site Acceptance testing as required. The Site Acceptance Test shall be witnessed and signed off for acceptance by the customer any punch list items recorded during the test shall be attended by the contractor and signed off by the customer. Applicable Documentation: Project Procedures: Site Acceptance Test 8.1.6. Testing After completion of installation and commissioning activities, the rotating machinery will be started. As soon as the machinery attains the temperature and pressure conditions (with in 2 hours), a surge test will be carried out and the machinery will be handed over for operations. Applicable Documentation: Inspection & Test Plan 8.1.7. Installation The Contractor shall ensure that any system or part of the system is installed in accordance with the Contractors quality management procedures, subcontractors QA plan, Subcontractor QC Test and Inspection plan, such quality documentation should comply with the customers requirements. Inspection: The contractor shall witness the installation process. Any deficiencies observed during these tests will be rectified by corrective measures. Test documentation will be maintained and made available to the customer upon request Applicable Procedure: Project Procedure: Installation. 8.1.9. Handover

On completion of construction activities and prior to mechanical turnover Site Acceptance Tests, shall completed and shall handed over to the customer. Applicable procedure: Project Procedure Handover 8.1.8. Commissioning Support The contractor will provide post-commissioning assistance as required by the contract. Applicable Procedure: Project Procedure: System Commissioning 8.2. Control of Non-Confirming Product Any product non-conformity found is reviewed and all actions taken to deal with it are controlled and recorded. Occurrences of non-conformity shall be monitored and analyzed on a regular basis in order to identify opportunities for improvement. Applicable procedures: Project procedure: Project Procedure Non-Conformity Material General Assurance procedure: Project Procedure Complaints Management System 8.3. Analysis of Data The Project site QA/QC Manager is responsible to report any deficiencies to the Project Manager. Based on these reports, the Management Team shall complete Management review meetings to analyze any non-conformity that repeats itself during the execution of this project. Applicable procedures: Project procedure: Management Reporting Cost Control Project Close Out 8.4. Improvement

According procedures: Corrective / Preventive Action