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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001

Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

SUMMARY OF DOCUMENT REVISIONS


Rev. Date Section
No. Revised Revised Revision Description
0 3 Jan. ‘12 All Initial Issue

1 20 Feb. ‘12 All Revision of procedure including following was done.


- Section 2.0 Added document reference.
- Section 3.4 deleted.
- Section 6.1 1) revised as Company comments.
- Section 6.1. 2), 4) added as Company comments.
- Section 6.2. 4) added Format of ITP.
- Section 6.3.1 deleted and revised as Company
comments.
- Section 6.3.3 revised as Company comments.
- Section 6.3.4 2) added as Company comments.
- Attachment 1 Work Flow revised as as Company
comments.
- Attachment 3 added KOM(Kick Off Meeting) List
- Attachment 4 added Format of ITP for Company

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

TABLE OF CONTENTS

Section Topic

1.0 PURPOSE AND SCOPE ...................................................................................... 4

2.0 REFERENCES ..................................................................................................... 4

3.0 TERMS AND DEFINITIONS ................................................................................. 4

4.0 RESPONSIBILITY AND AUTHORITY ................................................................. 5

5.0 GENERAL ............................................................................................................ 7

6.0 PROCEDURE ....................................................................................................... 7

ATTACHMENT 1 WORK FLOW

ATTACHMENT 2 FORMAT OF REQUEST FOR INSPECTION (RFI)

ATTACHMENT 3 KOM (KICK OFF MEETING) LIST

ATTACHMENT 4 RFI FORMAT FOR COMPANY

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

1.0 PURPOSE AND SCOPE

1.1 This procedure is provided for control of the site inspection and test of SADARA MFC
Project to verify that equipment and materials are installed, assembled and adjusted
in accordance with the latest construction drawings, instructions, procedures and
other applicable documents.

2.0 REFERENCES

1) Schedule Q: Quality Requirement


2) Project Quality Plan (A554-E-103-QA-GEN-PLN-001)
3) Inspection and Testing Control Procedure (P-MS-301E)
4) Materials Management Plan (A554-E-103-MM-GEN-PLN-001)

3.0 TERMS AND DEFINITIONS

3.1 Inspection point

The inspection point is defined as hold point, witness point, spot witness point, and
review point.

3.2 Hold point

A designated stopping point in the process of fabrication or installation activity at


which inspection or test is required before further work can be performed. The hold
point shall not be by-passed without designator's concurrence.

3.3 Witness point

A point which is required to be witnessed by the QC Inspector and/or Client for


inspection and test to verify quality. Even if the designator is not present at the
inspection and test, further work may proceed.

3.4 Spot Witness point

A point which is required to be witnessed randomly or partially by the QC Inspector


and/or Client for inspection and test to verify quality. Even if the designator is not
present at the inspection and test, further work may proceed.

3.4 Review point

A point which is required to review documents in accordance with project


requirements and specification and relative standard.

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

3.5 Inspection

Activity such as measuring, examining, test, or gauging one or more characteristics


of service or production and comparing the results with specified requirements to
establish whether conformity is achieved for each characteristic.

3.6 Test

An element of verification for the determination of the capability of any product to


meet specified requirements by subjecting the product to a set of physical, chemical,
environmental, or operation conditions.

4.0 RESPONSIBILITY AND AUTHORITY

4.1 Site QC Manager (SQCM)

1) Planning and managing site inspection and test at site.

2) Approving the Site Inspection and Test Plan.

3) Coordinating Company for the quality matters.

4) Holding weekly Quality meeting with Company and Subcontractors

5) Mobilizing and managing inspectors for site inspection and test.

4.2 Site Quality Engineer (SQE)

1) Assisting Site QC Manager for site inspection and test.

2) Reviewing quality documents for technical justification such as the


nonconformance disposition, corrective action, WPS & PQR, welding control and
etc..

3) Preparing weekly, a two week look ahead schedule of all planned quality
activities.

4) Preparing weekly the status report for inspection and test.

5) Controlling measuring and test equipment for site inspection and test.

6) Coordinating subcontractors for site inspection and test.

4.3 NDE Engineer (NE)

1) Controlling NDE 3’rd party agency for NDE activities.

2) Reviewing NDE report and reporting to SQCM.

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

3) Coordinating NDE activities with subcontractors and NDE 3’rd party agency.

4.4 QC Supervisor (QS)

1) Leading and guiding his discipline inspectors for inspection and test activities.

2) Monitoring inspection and test activities on each construction stage of his


discipline and issuing surveillance report.

3) Carrying out witness for the hold point on ITP of his discipline.

4) Reviewing documents of inspection and test of his discipline.

4.5 QC inspector (QI)

1) Carrying out inspection and test in accordance with approved ITP.

2) Initiating the NCR for nonconformance item.

3) Proposing the corrective action plan and disposition of NCR.

4) Confirming the disposition of nonconformance item.

5) Monitoring construction activities of his discipline and issuing surveillance report.

4.6 Document Controller (DC)

1) Planning document control for quality document.

2) Coordinating subcontractors for document control.

3) Receiving, filing and distributing quality documents.

4.7 Site Manager (SM)

1) Approving ITP and inspection/test procedure and submitting to Company.

4.8 Superintendent (SI)

1) Preparing ITP in cooperation with Subcontractor with incorporating quality


project requirement.

4.9 Field Material Controller (FMC)

1) Checking that quantity and condition of equipment and materials for receiving
inspection at site.

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

2) Submitting RFI of receiving inspection to QA/QC Team for Contractor and


Company supply equipment and materials.

3) Preparing OSI & D report, if discrepancies, damages, overages and shortages


are found.

4.10 Field Material Control Manager (FMCM)

1) Approving and issuing OSI & D report, if discrepancies, damages, overages and
shortages are found.

4.11 Subcontractor

1) Cooperating with Contractor for establishing ITP and maintaining approved ITP.

2) Implementing inspection and test in accordance with approved ITP.

3) Submitting inspection and test records and documents required to verify


conformance to project requirement.

4) Implementing Qualification of personnel for inspection and test, as required.

5) Controlling the inspection, measuring and test equipment for inspection and test.

5.0 GENERAL

1) Contractor shall submit weekly, a two week look ahead schedule of all planned
quality activities to the Company.

2) Calibration validity of the measuring and test equipment shall be confirmed prior
to starting first inspection and test.

3) When non-conformance is found during inspection and test, NCR shall be issued
and non-conformance label/sticker shall be attached to the non-conformance
item in accordance with non-conformance control procedure.

6.0 PROCEDURE

6.1 Kick-Off Meeting (KOM)

1) KOM shall be held by SM of Contractor between Company, Contactor and


Subcontractor for all major construction activities prior to starting initial work.

2) Major construction activities are referred to KOM List(Attachment 3)

3) The quality requirement of Project shall be explained by QA/QC Team of


Contractor and major concerning quality matters of subcontractor shall be
discussed during the KOM.

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

4) Each Subcontractor shall arrange KOM with Contractor and Company in


accordance with KOM List(Attachment 3)

6.2 Inspection and Test Plan (ITP)

1) Discipline Superintendent of Contractor shall prepare ITP in cooperation with


Subcontractor with incorporating quality project requirement 45 days prior to
starting initial work of Subcontractor.

2) ITP shall be reviewed by SQCM and approved by of SM and submitted to


Company 30 days prior to starting initial work of Subcontractor.

3) ITP shall include provisions to ensure that inspection and test prerequisites have
been met such as adequate calibrated instruments is available and the
necessary inspection and test is performed.

4) The ITP shall include the following information as a minimum. (See attached
Format of ITP)
• Process description
• Quality control requirements
• Notification requirements for Requests For Inspections (RFI)
• Responsibilities
• Applicable procedures
• Acceptance criteria
• Percentage of tests to be done (including increased inspection levels when
performance requirements are not met.)
• Review, Witness and Hold points
• Verifying documents

5) Revision Control - Contractor shall revise each ITP and obtain approval for such
revisions from the Company Representative throughout the work, if any.
Contractor and Subcontractor shall maintain copies of latest approved ITP.

6.3 Inspection and Test

6.3.1 Receiving Inspection

1) Field material controller of Contractor and Subcontractor shall check that quantity
and condition of product is delivered in accordance with purchase order
specification and drawing.

2) Subcontractor shall submit RFI of receiving inspection for equipment and


materials to QA/QC Team of Contractor in accordance with approved ITP.

3) The receiving inspection shall be carried out with witness of Material Receiving
Inspector of Contractor/Company as per approved ITP.

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

4) All incoming equipment and materials shall be inspected for damage and quantity
and for conformance to all applicable requirements, including the supplier
inspection release sheet with verified Material Test Reports (MTR).

5) If the equipment and materials are delivered without required inspection release
sheet and MTR, it shall be verified at site for the compliance of the equipment
with applicable standards and specifications prior to release to be installed.

6) OSI & D report shall be issued to supplier by Field Material Manager, if


discrepancies, damages, overages and shortages are found.

7) Equipment and Materials shall be stored after receiving inspection is completed


so that equipment and materials are not deteriorated.

Site Receiving Inspection shall be carried out in accordance with article “6.3
Unpacking and Inspection of Material Management Plan (A554-E-103-MM-GEN-
PLN-001)” and approved ITP.

6.3.2 Company Supplied Products

1) Field Material Controller shall take measures to control the Company supplied
products
such as the manner of separate logging and placing in accordance with contract
requirement.

2) Immediately upon receipt of Company’s Supplied equipment and materials at site,


all delivered equipment and materials shall be inspected in compliance with
delivery document. OSI &D report shall be reported immediately to the Company,
if any overages, shortages or damages are found.

3) Equipment and materials subject to an OSI &D report and NCR shall be
quarantined during pending period of verification or disposition.

6.3.3 Request for Inspection and Test

Request for Inspection(RFI) shall be submitted to Contractor/Company by


Subcontractor 24 hours before inspection for work days, until every day 15:00 after
self inspection of subcontractor. For weekend inspection, RFI shall be submitted 48
hours before. Contractor shall check the work before Company Inspection.

The Numbering of RFI shall follow the numbering sequence listed below:

RFI No: MFC – DLM – XXX – XX – 000

Serial Number

Discipline(CI for Civil, PI for PipingSee Note 1)

Sub – Con. Name

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

Note 1: CI for Civil, PI for Piping, BU for Building, ME for Mech., EL for Elec., IN for
Instrument, IS for Insulation, PA for Painting, HV for HVAC, SS for Steel
Structure, RE for Refractory.

6.3.4 Control of Inspection and Test

1) Subcontractor shall perform the self inspection and test required to verify
conformance with project quality requirements and submit RFI with record of
inspection and test to Contractor QC inspector and Company, if applicable.

2) In a format acceptable to the Company Representative, Contractor must have an


electronic RFI system to send, record, track, and report all issued RFI s for all
inspection points on the Project ITPs. This system must enable classification of
inspections by discipline and identification of repetitive defects or deficiencies.

3) QC Inspector shall review record of inspection and test of Subcontractor before


witness of inspection and test.

4) QC Inspector of Contractor and Company, if applicable, shall perform witness of


inspection and test in accordance with approved ITP and sign on the inspection
and test record, if accepted.

5) NDT Engineer shall witness/review NDT performed by Third Party NDT


Subcontractors in accordance with approved ITP and NDT requirement and sign
on the NDT report, if accepted.

6) NDT Engineer shall prepare NDT status report in every weeks including RT reject
rate of field and RT reject rate per Welder and report to Company.

7) SQE shall prepare the 14 days look ahead schedule of all planned quality
activities during construction and pre-commissioning on each week and get review
of SQCM and approval of SM and submit to Company Quality Representative.

8) The status report for inspection and test shall be prepared weekly by SQE for
traceability and identification of all inspection and tests of Contractor and
Subcontractor and any non-conformances discovered during the inspection and
test and get review of SQCM and approval of SM and submit to Company Quality
Representative.

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

ATTACHMENT 1 WORK FLOW

Subcontractor Contractor Company

Submitting RFI for Receiving RFI for receiving inspection


receiving inspection

Check the Materials

Performing receiving
inspection Witness and verify receiving inspection

If discrepancies,
overages and
shortages found.

Verification Issuing OSI & D report

If accepted

Performing installation

Performing self
inspection If rejected

Submitting RFI for


Receiving RFI for receiving inspection
inspection and test

Check the Work


Performing inspection Witness and verify inspection and test
and test

Verification Sing on inspection and test record


If accepted

If accepted

Filing inspection and test record

Contains Confidential Information of Both Dow and Saudi Aramco


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SADA
ARA Mixed Feed Crack
ker Document No:
N A554-E--103-QA-GEN-PRO-001
Revision:
R 1
Issue Pu
urpose: IFA
Docu
ument Title: Site Inspec
ction and Te
est Procedurre

ATTA
ACHMENT 2 FORMAT
T OF REQU
UEST FOR INSPECTIO
ON (RFI)

Issue
e Date : REQUE
EST FOR INSPECTION RFI N
No.:
Project Name : SA
ADARA MFC AND TESST Subccon. Name :

No. Inspection
n/Test In
nspection/Tes
st ITP Insp. Grade Location Date & Remarks
Item Activity No. (H/W/R) /Area Time

Rema
arks :

We w
would like to
o request yo
our witness for above in
nspection/te
est items as above.
Issue
ed by Subcoontractor SQ
QCM :
Receeived by Con
ntractor SQCM :
Receeived by Com
mpany Quallity Represe
entative :

nfidential Infformation of
Contains Con o Both Dow and Saudi A
Aramco
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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

ATTACHMENT 3 KOM (Kick Off Meeting) List

Major Activities for Attendee


No. Remarks
KOM Subcontractor Contractor Company
1 Earth Work

2 U/G Piping

3 Concrete Work

4 Paving

5 Building

6 HVAC
SM,CM, SQCM
7 Refractory SM,CM, SQCM and KOM shall
and responsible Quality
responsible be held
personnel for Representative
8 Fire Proofing personnel for before
Engineering, / responsible
Construction and starting
Construction Inspector
9 Steel Structure Quality work.
and Quality
10 Stationary Equipment

11 Rotating Equipment

12 A/G Piping

13 Coating and Insulation

14 Electrical Work

15 Instrument Work

Contains Confidential Information of Both Dow and Saudi Aramco


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SADARA Mixed Feed Cracker Document No: A554-E-103-QA-GEN-PRO-001
Revision: 1
Issue Purpose: IFA
Document Title: Site Inspection and Test Procedure

ATTACHMENT 4 RFI FORMAT FOR COMPANY

SADARA PROJECT

REQUEST FOR INSPECTION RFI NO.: ______________________________

Project Title: ………………………………………………. Asset Group Name: ……………………………

Plant/Unit No. : ..……………………………………… Plant/Unit Name: ……………………………………

To: Sadara Inspection Team/Mr.: ………………………………………………………………………………….

□ Civil/Structural □ Mechanical □ Piping □ Plumbing □ HVAC □ Elect. □ Inst. □ Telecom. □ Other: …………

Inspection is required on (date): ………….. At (time): …………. Item to be inspected: ………………………

Location and/or Equipment: ………………………………………………………………………………………

Inspection Activity and Test Plan/Checklist: ……………………………………………….. □ Witness □ Hold

Work Permit required □ Yes □ No

Contractor has verified that the work is complete and Contractor: …………………………………….
inspected in compliance with the following Specifications:
QA/QC Name: …………………………………

Specs./Stands: ……………………………………………… Signature: ………………………………….…..

Drawing(s): ………………………………………………… Date: …………. Phone number: ………………

This RFI was received by the undersigned QA/QC person.

Name: ……………………… Signature: ………………………Date: ………………… Time: …………………

Attended □ Yes □ No

□ Accepted □ Accepted partially □ Rejected □ Not ready Log Book Entry No: ……………

Inspector’s Comments:

……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………

Date of Inspection: ……………… Inspector Name: ………………………… Badge #: ……………………

QA-F-001 Rev.01

Contains Confidential Information of Both Dow and Saudi Aramco


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