TUCK SIN Engineering & Construction Sdn. Bhd.

(153842-K)

PROJECT QUALITY PLAN

PREPARED BY
QA / QC DEPARTMENT
License No. 153842-k

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

TABLE OF CONTENT

1.)

INSPECTION TEST PLANT ( ITP ) & Q.C/Q.A . STANDARD MANUAL

2.)

QUALITY ASSURANCE MANUAL

3.)

CALIBRATION CERTIFICATE

4.)

WELDING PROCEDURE SPECIFICATION (WPS)

WELDER QUALIFICATION TEST ( WQT )

5.)

WELDING PROCEDURE

6.)

CLIENT SPECIFICATION

7.)

NDT

8.)

PAINTING PROCEDURE

PREPARED BY:

CHECKED BY :

APPOVERD BY :

LIZAWATI BT SAMSUDIN
QA/QC Representative

( RAYMUND N.LING )
QA/QC MANAGER

(CLIENT REPRESENTATIVE)

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

TUCK SIN PROJECT POLICY STATEMENT

TUCK SIN is fully committed to the high quality level objective of the Work Package for
the STEEL STRUCTURE for the fabrication and erection of the structure steel in following with
the requirements of standard coats and the Contractual Specification.
Tuck Sins combined experience, expertise and capability places particular emphasis on Safety,
Reliability and Quality.
The objective of Tuck Sin is provide these services in a manner, which conforms to the specified
requirements of the Client and all applicable Statutory and Regulatory requirements.
In order to achieve this objective, it is the policy of Tuck Sin to establish and maintain an effective
and efficient Quality Management System planned and developed in conjunction with other
management functions.
The assurance of Quality is fundamental to all work undertaken by Tuck Sin on the Project and is
practised by all of our staff.
The defined commitment of each member of Tuck Sin is work as a Team to achieve the objectives
of our Client.

RAYMUND N.LING
QA/QC MANAGER

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

1.0

INTRODUCTION

This Project Quality Plan has been developed by Tuck Sin in following with the basis
Quality requirements of ISO 9002 Standard. This Quality Plan is tailored to satisfy the
specific requirements in the fabrication and erection of the Work Package for the
fabrication and erection of the Steel Structure.

1.1

Management Policy Statement

The Management of Tuck Sin having Executive responsibility have fully endorsed this
Project Quality Plan as fully meeting the expectations of the client.
The policy of Tuck Sin is that an effective and efficient Quality System shall be utilised
throughout all levels of the organisation in the executive of the Work Package.

1.2

Objective of the Project Quality Plan

The objective of the Project Quality Plan is ensuring that all phases of the Project are
executed with the highest level of Quality and efficiency satisfying the Clients
requirements.
In this regard Tuck Sins Management has appointed a Project Quality Manager with
the defined authority to ensure that the Project Quality Plan is implemented and
maintained throughout all phases of the project.
The Quality Plan shall be implemented with the full support of all personnel engaged
on the Project. Included in the Tuck Sins objectives is a commitment to execute the
Project in accordance with all applying Regulatory Standards and Codes applying to
the Project, on schedule and within the Contracted Budget.
That the completed STEEL STRUCTURE facility are turned over to the Client as a
Safe, reliable and fully satisfying to the Specification for the Steel Structural according
to Client or Standard Code.

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

2.0 ORGANISATION AND RESPONDSIBILITY

2.1

Scope

Executive Management has delegated responsibilities to Management levels of the

Project staff with complete authority to take the necessary actions to ensure
conformance by all staff members to the Quality System.
A detailed description of the duties to be performed by the positions shown in
Attachment A identified as the ORGANISATION CHART and in the Responsibility
Matrix shown in Paragraph 2.2 of this Plan.
To satisfy the purpose of this Project Quality Plan, the word Responsibility shall
mean:

The actions which nominated personnel are responsible and accountable for .

The assignment of responsibilities is enhanced by the identification of four basic

functions, which apply to each element of the Quality System.
The four basic functions of the System are:
a.)

To Authorises and Approve is preliminarily a Quality Assurance Management

function associated with the development and the Continuous Improvement
Process of the Quality System.

b.)

Prepare and Issue also a Quality Assurance Management function associated

with the development and Communication of the procedures required for the
Quality control of the various elements of the Project Quality System.

c.)

Implementation and Co-ordination is jointly a Quality Control (QC), Operations

Management and Site Project Management function associated with the
ongoing use and implementation of the Project Quality System.

d.)

Quality Reporting is a Quality Assurance function associated with

documentation and monitoring the work process for conformance to the Project
Quality System.

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

2.2

1.

Responsibility Matrix

TITLE
Operations

General Manager
(Reports to Tuck
Sin
Managing
Director)

2.

Site
Project
Manager
(Reports to the
Operations
Manager)

3.

4.

Safety Officer

(Reports to the
Managing
Director)
Quality

Assurance
Manager

(Reports to the
Managing

Director)

5.

QC
and

Supervisor
the

MAIN FUNCTION
Project Management
Direction
to
Project
Engineers
Control
of
Project
Activities
Response
for
Site
Quality/Safety
Control of Project Costs
Liaison with Government
Authorities
Management
of
all
erection activities
Review
of
Proposed
Contract Change
Manpower and Equipment
Resource Audits
Fabrication and erection
Controls
Scheduling
and
Work
Controls
Worker Training Program
Approvals
Liaison
with
Clients
Representative
Responsible for site Safety
Monitoring
for
Safety
Procedures
Responsible for Quality at
all areas of Project Activity
Internal Quality Audits on
PQP
Guidance
to
Site
Inspectors
Monitor all site Quality
System
Implementation
Interpret
Project
Specifications
Responsible for inspection
of work both in the shop

SECONDARY FUNCTION
Liaison
with
Client
Representative
Safety management
Reporting
to
the
managing Director

Supervision
in
Implementation of Work
Instructions
Enforcement of Safety
Rules
Welding Supervision
Supervision
of
Site
Activities
Supervision of erection
work

Liaison
with
Safety Manager

Quality Training
Development of Quality
plans and Procedures
Supplier
Audits
as
necessary
Preparation of new work
instruction
Liaison with engineering

Clients

Assistance to the Safety

Officer Conduction QA
QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

6.

Inspectors
(Reports to QA
Manager)
Design Engineer

(Reports to the
Managing

Director)

and at site
Responsible
for
the
engineering
Design in all aspects of
the Project.
The
review
of
shop
drawings
and
Site
erection drawings

Audits

7.

Welding Engineer
(Reports
to
Design Engineer)

Develop
Welding
Procedures

Resolve welding problems

8.

Document

Controller
(Reports to the
QA Manager)
Material

Controller
(Reports to the
QA Manager)

Responsible
for
the
control and filing of all
Quality
related
documentation
Responsible for material
receipt
Recording
issue
of
materials
Monitoring
material
quality

9.

Provide
guidance
to
engineers
Develop
monthly
engineering Reports
Provide guidance to site
Erection in engineering
matters

Assists design to engineer

Monitors material analysis
and
Metallurgical
problems
Assist
the
Material
Controller
Assist the QC Inspector at
site

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

2.3

Quality Assurance Manager

2.3.1 Scope of Responsibilities

The Project Quality Assurance Manager reports to the Managing Director. His
responsibilities and authority with regard to Quality matters are directly delegated
from Management on all the Project activities. His specific responsibilities are: The preparation and issue Method Statements, Work Procedures and Work Instructions
in the following with the Project Specification

2.4

Take follow-up action on unresolved problems areas.

To review the qualifications of all inspection and Test Personnel.
Develop action Plans on reoccurring problems.
Monitor/Supervise Third Party Inspection activities.
Issue reports to the Managing Director on the implementation of the Project Quality
Plan, the Quality System and Method Statements.
Conduct periodic Internal Audits to ensure conformance to all applying BS
Standards referenced in the Project Specification approved Project Quality Plan.
Ensure the complete identification and traceability of structural steel used on the
work.
Review all Non-Conformance Reports and expedite the resolutions for corrective
action.

Design Engineer

2.4.1 Scope of Responsibilities

The Design Engineer is responsible for aspects for engineering activities as follows:

The preparation of design drawings and calculations in accordance with BS 5950.

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

The preparation of shop drawings as built drawings

Identify any steel member greater than 30mm for testing in accordance with
Specification.

Keep the Operations Manager fully advised on all design activities.

Prepare erection plans and erection instructions in following with regard to

dimensions and tolerances.

Anticipate erection problems before they occur and implement corrective actions.

Maintain close liaison with the Operations and QA Managers to avoid erection
problems or delays in the work.

Provide guidance in the resolutions of Non-Conformance and recommend

corrective actions.
To incorporate all Quality and Safety features into the design work.

To liase with the Client any engineering problems that may arise during the design
stage.

2.0

QUALITY SYSTEM

2.1

General

The Project Quality Plan is supported by Tuck Sins Quality Manual and Internal
Company Procedures.

3.2

Quality System Procedures

This Quality Plan applies to all Suppliers and Sub-Contractors where need the relevant
in regard to Quality aspects of the for Structural Steel Work.

3.3

Project Quality Control Plans

Quality Control Plans shall provide details of actual work related activities that shall be
performed to fulfil the requirements of the contract. The activities shall be in a logical
sequence covering all erection phases.

3.4

Fabrication Quality Control Plan

The Fabrication Quality Control Plan consist of two sections as applied to the
fabrication process at the factory as follows:

Section 1

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

An index of procedures or instructions giving the document number and descriptive

title for each procedure to be employed by the factory during the various stages of
fabrication, shop inspection and testing.
The shop foreman shall be advised of all witness points at the various stages of the
work while it is in progress.

Section 2
The Project Inspection and Test Plan shall list all activities involved from testing of
materials to shop fabrication and despatch at site. Particular attention shall be given
to Final Inspection and the testing to be performed prior to despatch.
The Quality Assurance Manager shall specify the Inspection Activities, which shall be
considered as Hold Points both during fabrication and erection.
For each Quality activity the appropriate specification or procedure shall be identified
together with how the result is recorded and stages where specific records, reports or
certificates are produced.

3.5

Format and Approved Inspection and Test Plan

The content and format of all Fabrication/Site Inspection and Test Plan shall not be
revised without prior consultation and approval of the Client.
Deviations from approved Plans shall be subject to discussion and agreement by the
Client prior to implementation.

3.6

Preparation of Inspection and Test Plans

Inspection and Test Plans shall be submitted to the Client for approval prior to
implementation.
Test Plans shall reference any relevant working instruction such as weld procedure
number, assembly procedure reference number, etc.
National Standards and Codes shall be listed, together with reference to any particular
relevant sections or tables.
Verifying documents produced and signed off, as proof of acceptance by the Project
Inspector shall be listed, e.g. material test certificates, NDT results (MPI, UT, PT, etc.).
Where necessary, separate procedures shall be developed for special processes that
are not covered by routine procedures. Such procedures shall be subject to approval
by the Quality Assurance Manager.
QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

The procedure shall then become part of the Project Quality System and Project
Quality Records.
All Inspection and Test Plans shall reference, where necessary, the applying paragraph
of the Project Specification.

4.0

PROCESS CONTROLS

4.1

General

The Site Project Manager shall ensure that all site erection activities are performed in
accordance with the requirements of:
a.)
b.)
c.)
d.)
e.)

Relevant sections of the Specification

Approved fabrication and construction drawings (Latest Revision).
Approved Fabrication/Construction Procedures and Specifications (Latest).
The Project Quality Plan, relevant Inspections and Test Plan and Supporting
Procedures.
When necessary, special Quality procedures.

4.2

Erection Quality Plan

As early as possible, prior to the commencement of any construction work, the

Operations Manager shall prepare an Erection Plan along with any necessary
supporting Construction Instructions.

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

Immediately upon approval of the Erection Quality Plan, all members of the erection
Team shall be instructed in the implementation of the Plan. All personnel subsequently
assigned to the team shall undergo the same instruction prior to commencement of
work on the project.

4.3

Control Over Erection

Control over the erection work shall be governed by Method Statements, procedures
and approved drawings, which define the parameters of the work to be performed in
accordance with standards, and defined work practices. Suppliers documents shall
subsequently be checked to ensure specifications, etc. is being followed. When
surveillance checks during erection.
Erection of material at site shall be performed to documented Work Instructions which
defines the work activity, the personnel responsible, any special equipment involved
and the verifications checks and the quality Records to be produced,
Where critical work processes and equipment are in use, these shall be evaluated by
authorised personnel and formally approved.

4.4Special Process
Special processes, such as welding, non-destructive testing, protective coating
testing, etc. shall require Special Procedures to be developed and approved by the
Client. Where necessary the operators shall be qualified in accordance with the
applicable standards.
Qualification Test Records or results for special processes, equipment and personnel
(e.g. welding, non-destructive testing, etc.) shall be kept current and available for
verification by authorised personnel.
All NDT procedures and personnel shall be approved by the QA Manager and the
Client prior to starting NDT work.
All control gauges for special processes, e.g. measuring equipment, shall be certified
and approved and thereafter included in a calibration programme.

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

The overall responsibility for the control of all major processes at site is that of the
Site Project Manager who shall maintain close contact with the QA Manager so that
any required qualification tests for a Special Process can be conducted.

5.0

PRODUCT IDENTIFICATION AND TRACEABILITY

5.1

All items of equipment and materials shall have an identification number for
traceability purposes. Tuck Sin procedures require that these item numbers and
other relevant identification numbers are stated on the design and procurement
documents as such traceability is imposed on Suppliers and Site Construction
staff as necessary.

5.2

Materials and items identified as requiring traceability are positively identified

at all times during manufacture, fabrication, storage, handling, transport,
construction, commissioning and use. This allows traceability to a specified
source and to relevant Certification.
QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

5.3

Identification is maintained by heat number, part number, serial number, etc.

on the material or item or on a tag securely attached and always on documents
and records traceable to the material and item. Physical identification is used
wherever possible within the limits of requirements imposed by relevant codes,
standards or specification.

5.4

The location and method of identification does not affect the function or quality
of the material and the identification will be unambiguous, legible and clear.
Material identification that is hidden or obliterated during manufacture,
assembly or installation is transferred to a more suitable location. When a
material is sub-divided, its identification is transferred to its daughter materials.
Operations involving transfer or identification are itemised on Quality Plans and
are verified.

5.5

Correct identification of materials and items and traceability to their documents

and records is verified prior to acceptance and use.

6.0

NON-DESCTRUCTIVE TESTING

The frequency of non-destructive examination shall be in accordance with BS 5135 :

1984

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

TYPE OF WELD
Full Penetration Welds
Fillet Welds and Partial Penetration
Weld

6.1

6.2

6.3

7.0
7.1

INSPECTION
100% ultrasonic testing for each welder.
Random 20%Dye penetration Examination on
fabricated items.

Test and examinations of all the welds shall be performed in accordance with the
AWS D1.1.
The NDT inspector shall be an independent licensed agency.

Identification and Traceability

Each assembled truss shall be given a unique numbering system for tracebility

Painting Inspection and Tolerance

Minimum Protective coating shall be a three coat protective system.
Surface conciliation frequency 100% as per SIS 05 5900 SA25.
Paint systems to be applied as per manufacturers specification.
Humidity shall not more than 85% for each application.
Final paint inspection to be recorded as per specification.

Final Inspection/Delivery
QA/QC personnel shall ensure that all inspection process pertaining to outgoing
products has been performed and documented.
Final Release Note shall be performed before any delivery.

INSPECTION AND TEST STATUS

General
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TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

The Site Inspector shall be responsible for monitoring the status of all Inspection and
Test that are required to be performed throughout the different phases of the erection
work. The system for identifying the status of inspection and/or Testing shall be by
reference to the documented inspection records. The records shall be maintained in
accordance with Project Specifications.
For the purpose of controls a Master Chart shall be developed by the Inspection
Department showing Inspection and Test Status and the due dates of each Inspection
or Test.

7.2

Inspection and Test Plan

The QA Manager shall develop and issue Inspection Check Lists or Inspection and Test
Plans show inspection requirements during fabrication and erection. Inspection status
shall be indicated by the inspectors signature and date adjacent to the operation on
the List or Plan.
Where possible visible identification labels, tags or other suitable identification shall
be placed on the product on acceptance by the Inspector.

8.0

CONTROL OF NON-CONFORMING PRODUCTS

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

8.1

Purpose

The purpose of this Section is to ensure that Non-Conforming items or processes are
clearly and easily recognised by all concerned so that they are not inadvertently used
on the project. It is the responsibility of site QC to ensure that the necessary controls
are in place to satisfy the requirements of this Section and Project Specifications.

8.2

Methodology

When detected, non-conforming products shall be identified by clear physical marking,

tagging and, if possible, segregated to prevent unauthorised use, shipment or mixing
with conforming material.
No further work shall be progressed on the product pending a decision on its further
disposition by QA Manager in consultation if necessary with Engineering, Construction
of the Client as necessary.

8.3

Disposition

According to the circumstances, disposition decisions shall include:

Scrap and Replacement

Repair
Rework
Use-as-is

Quality Control is responsible for ensuring that all Non-Conformance Reports are
recorded. All disposition decisions shall be properly recorded and filed with the Project
Quality records.
Objective evidence shall be maintained to substantiate that repair and reworked items
have been re-inspected or re-tested and found acceptable.
The QA Manager shall be informed of all incidents of non-conformance for monitoring
purposes and the assessment of trends.

8.4

Re-inspection

It is responsibility of site QC to ensure that all Non-Conforming products are reinspected by the same method that detected the original discrepan

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TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

9.0
9.1

QUALITY RECORDS
General

It is the responsibility of the Site QC Manager or his designated Inspector to ensure

that all site developed Quality Records are complied, maintained and collated as the
work is performed throughout the duration of the Project. These records provide
objective evidence of the Quality of work produced and testifies that the work is in
compliance with contractual requirements.

9.2

Records

Such Quality records shall contain all data and information required by the Project
Specifications, Codes, Standards and the PQP.
Records shall be legibly hand written Inspection Forms other acceptable material
Certificates, which shall comprise of the original documents or authenticated copies.
Records shall be retained for the minimum period specified in the procedures, or as
required by law.
The Document Controller is responsible for maintaining the Quality Record System.

9.3

Quality Records

It is the responsibility of the site QC Manager to ensure that copies of all Quality
Records are sent to the Document Controller for compilation into the Quality Record
Dossier.

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TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

QA & QC DEPARTMENT