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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
This is to notice all the project employees that the Project quality policy is:
1. Strictly observe the rules and regulations of the project quality management system,
enhance leadership, participate in by all employees, use method of management of
system and process to exercise scientific management on project quality work, complete
the project to the satisfaction of CUSTOMER , perform audit, continually improve the
quality of the project.
2. Prepare quality management documents covering the entire project, enhance internal
audit, fill in and maintain process record, promote effective implementation of quality
system, pass the audit performed by CONTRACTOR.
The quality policy and quality objectives embody the quality goal and direction, and are
important part of project general policy and objectives. It constitutes a framework for quality
review and continual improvement.
All employees shall study them conscientiously and observe them strictly.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
TABLE OF CONTENTS
1.0 INTRODUCTION.....................................................................................................................5
1.1SCOPE............................................................................................................................... 5
1.2DEFINITION & ABBREVIATION.............................................................................................. 5
2.0 REFERENCE...........................................................................................................................6
3.0 QUALITY POLICY OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD............7
4.0 QUALITY PURPOSE OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD.......7
5.0 CONTROL OF QUALITY PLAN.............................................................................................8
5.1EXPLANATION..................................................................................................................... 8
5.2CONTROL OF QUALITY PLAN..............................................................................................8
5.3IMPLEMENTATION OF QUALITY PLAN...................................................................................8
6.0 QUALITY MANAGEMENT SYSTEM......................................................................................9
6.1GENERAL REQUIREMENT.................................................................................................... 9
6.2OVERALL REQUIREMENT.....................................................................................................9
6.3DOCUMENT CONTROL.......................................................................................................10
6.4CONTROL OF RECORD......................................................................................................12
6.5MANAGEMENT RESPONSIBILITY & COMMITMENTS..............................................................13
6.6DESIGN & ENGINEERING QUALITY PLAN............................................................................18
6.7PROCUREMENT QUALITY PLAN & PROCEDURE..................................................................21
6.8CONSTRUCTION QUALITY PLAN & PROCEDURE.................................................................28
6.9CONTROL OF MONITORING AND MEASURING DEVICES.......................................................31
6.10 MEASUREMENT, ANALYSIS & IMPROVEMENT................................................................32
7.0 ANNEXURES........................................................................................................................40
7.1PROJECT QUALITY ASSURANCE & CONTROL CERTIFICATIONS...........................................41
7.2QMS RESPONSIBILITY MATRIX..........................................................................................42
7.3PROJECT QA ACTIVITY FLOWCHART.................................................................................44
7.4PROJECT SITE QC ACTIVITY FLOWCHART.........................................................................46
7.5NON CONFORMANCE REPORT...........................................................................................48
7.6QUALITY AUDITS PLAN SCHEDULE....................................................................................50
7.7Technical Query Form......................................................................................................52
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
1.0 INTRODUCTION
For the detail of the Project profile, completion time and main workload, please see relevant
EPC Scope of Work.
1.1 Scope
The project quality plan describes the requirements of quality management system and the
activities stipulated. It provides the basic document used for the quality management system,
and supplies the information that is identical with the quality management system.
The Plan is applicable for the Rehabilitation , structural & piping construction works for (4)
Thermal units at Mussaib Power Plant Including Boiler, Steam Turbine, Generator, and BOP.
2.0 REFERENCE
3.0 QUALITY POLICY OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD
The policy is adapted to the purpose of CONTRACTOR, and is an important integrated part of
business policy of CONTRACTOR.
The policy shows the CONTRACTOR will meet the requirements of CUSTOMERon the
products and the continual improvement.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
The policy provides a range used for establishing and reviewing the quality objective of
CONTRACTOR.
The leaders at all levels shall communicate the quality policy to all management departments,
professional offices, teams and branches in order to enable the staff of CONTRACTOR to
understand correctly the policy and insist on putting into effect.
The reviews of the quality policy shall be carried out continuously by CONTRACTOR, to ensure
the continual compatibility, sufficiency and effectiveness; the policy shall be revised to be
adapted to the change of environment in the CUSTOMER , if necessary.
4.0 QUALITY PURPOSE OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD
Ensure the finished products are 100% qualified, set up the consciousness of providing product
with high quality, and devote major efforts to developing the activity of creating the excellence
products.
Do the good job during the construction and do the good improvement work after the project put
into operation.
Carry out comprehensive project management, and make great efforts to keep the project
management to be connected with the orbit of international universal management model.
Carry out comprehensive quality management and insist on the continual improvement of the
quality management system.
All staff shall recognize and implement seriously the quality objective, establish the
correspondent quality objective with the departments related to the quality together, to enable
more detailed and to be measurable, and to permit to be identical with the quality policy, in order
to ensure the implementation of the quality objective.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
5.1 Explanation
The Quality plan defines and stipulates the quality objectives, organization, responsibility,
resources management, process control, quality requirement, measurement, analysis and
continual improvement of quality management system. For the general content, Quality plan will
directly quote them from Albilal Group Quality Management System Procedures.
The Quality Assurance/ Quality Control Department (QA/QC department) shall be responsible
for the preparation of the quality plan. Deputy project director (DPD) shall be responsible for
review of the quality plan.
Other departments concerned of CONTRACTOR shall jointly review it. Quality plan will not
come into effect until authorized person of CONTRACTOR approves it.
The quality plan shall be reviewed by the management representative and approved by the
General Manager, then issued to CUSTOMER for approval.
The quality plan shall be divided into two editions i.e. controllable and non-controllable.
Controllable edition shall be issued to the leaderships of CONTRACTOR and the departments,
personnel related to quality responsibility as well as the center of quality system review.
The non-controllable edition (existing effective edition) are issued to CUSTOMER for introducing
the brief of the quality management system of CONTRACTOR, and the evidences for the quality
guarantee shall be provided.
The replacing of the edition for the quality Plan or the partial change thereof shall be prepared
by the QA/QC department and reviewed by the Management Representative as well as
approved by the General Manager.
After completion of the replacing or change of the edition the “Notice Of Document Change” and
the new edition of quality Plan or the revised pages shall be issued to the holders of the quality
plan, and the cancelled editions shall be returned back, the document control procedure shall
be carried out.
The holder of the quality Plan shall be responsible for management of the quality plan, any
alterations outside the CONTRACTOR are not to be permitted.
5.3 Implementation Of Quality Plan
Project director shall organize all the departments of the Project and Subcontractors to
implement and maintain the quality plan. All the departments and Subcontractors shall observe
it strictly. QA/QC department shall supervise and inspect the implementation of the quality plan
with other departments concerned. QA/QC department is responsible for the interpretation of
the quality plan.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
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The CONTRACTOR top management has established quality management system and, QA/QC
Department has developed the quality plan according to ISO 9001-2008 standards and
CONTRACTOR. quality system documents. All staff of the project shall implement and maintain
the quality management system and continually improve its effectiveness. The project will
exercise control on processes based on the following requirements.
a) Identity the processes needed for the quality management system.
b) Determine the sequence and interaction of these processes.
c) Determine methods and criteria needed to ensure that both the operation and
control of these processes are effective.
d) Ensure the availability of resources and information necessary to support the
operation and monitoring of these processes.
e) Monitor, measure and analyze these processes.
f) Perform actions necessary to achieve planned results and continual
improvement of these processes. Subcontractors shall establish their own quality management
system and prepare quality plan accordingly based on the requirement of the project quality
plan and their scope of work to be carried out.
This project’s Quality Management System meets the ISO 9001:2008 Quality Management
Systems and able to ensure that project is completed to provide safe, reliable, and operability
meets the project requirements.
According to ISO 9001: 2008 “Quality Management System”, the quality management system,
shall perform the relative quality management to meet the following requirements.
a) The quality management system covers the detailed process required by the contract
document, for managing the quality of engineering, procurement, construction, commissioning
and warranty of project.
b) In order to guarantee the above-mentioned process and the operation and control of the
external contract process the quality management system is set up to ensure the
implementation of Quality Assurance and Quality Control and supply all the relevant quality
assurance requirements to its Subcontractors & suppliers etc. involved in the project for
compliance.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
c) The necessary resource and information shall be provided to ensure the operation of
process and the effectiveness of the supervision.
d) With the aid of analyzing the information which come from the supervising and measuring
process the corrective and preventive measures shall be taken for the continual improvement of
these processes, to realize the quality policy and quality objective of CONTRACTOR.
CONTRACTOR set up and carry out strict control of quality records and documents required by
the quality management system, in order to ensure that the holders of the documents can make
good use and prevent the misuse of the invalid or scrap documents.
6.3.1 Administration department shall be responsible for the control of quality system
document,
technical documents, correspondence and the documents from out-side, for example,
regulatory and statutory documents. It shall also direct, monitor and inspect the document
control of other departments.
6.3.1.1 Each department shall appoint a person as document controller who is responsible for
receiving, dispatching, registering, numbering and filing the document within scope of work of
his own department.
6.3.1.2 The numbering system of project quality system document shall observe the
requirements of the project document control procedure.
a) Drawing,
c) Construction plan,
d) Construction instruction,
b) A distribution matrix shall be prepared by document controller. After the matrix is approved
by Deputy Project Director the drawings can be distributed and the recipient shall sign his name
on Distribution log.
c) The document controller in each department and the Subcontractor shall be responsible for
control and distribution of the drawings received. After completion of the project, drawings shall
be returned to administration department for hand-over or destroy except the drawings must be
kept for future use.
6.3.3.2 The Administration department shall register and file project specification and
standards. The obsolete specifications may be kept by document controller for the purpose of
knowledge preservation, but they must be marked with the stamp “For Reference Only”.
6.3.3.4 The control of as- built technical documents and data shall observe requirement of the
project contract and as-built drawing of detail design procedure manual.
6.3.4 Correspondence.
6.3.4.1 A letter is prepared when the giving or issuing of approvals, certificates, consents,
determinations, notices and request, which shall be type-written, printed or electronically made
and signed by project management or the authorized representative. The letter number is
assigned by administration department.
6.3.4.2 A transmittal is used to convey technical documents and drawings. All transmittal shall
be numbered and prepared by using approved transmittal coversheet. The transmittal number
is assigned by administration department. For the numbering system of letter and transmittal,
see the project document and control procedure and relevant internal management stipulations
prepared by administration department.
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6.3.4.3 Each department shall prepare their own list of quality system documents and list of
technical document. Document shall be distributed by use of distribution record of documents.
6.3.4.4 Changes to documents and data shall be reviewed and approved by the same
department that performs the original review and approval. The invalid and/or obsolete
document shall be promptly removed from all points of issue or use, or otherwise assured
against unintended use.
6.3.4.5 Other content not mentioned here shall observe the project document and data control
procedure and relevant internal management stipulations prepared by administration
department.
CONTRACTOR shall set up and carry out the record control, as well as the controls of mark,
storage, protection, index and preservation period, and provide evidences in which the product
has satisfied the requirement and the quality management system has been operated
effectively.
6.4.2 Each department shall be responsible for development, control and management
of quality records required by responsible processes of QMS process function distribution
chart (See Attachment III-1). Each department shall also prepare the numbering system of
the records. “Records List” used in each department shall be established and maintained
by each department. Records shall be legible, readily, identifiable and retrievable.
6.4.3 Except the records and formats that shall be handed over to CUSTOMER or
placed in CONTRACTOR archive, Project records shall be retained till the end of
commissioning. Quality system implementation records shall be retained till the
completion of the project.
6.4.4 The records that need to be handed over or filed shall follow the contract and
CONTRACTOR regulation and rules.
6.4.5 The detailed requirements of control of record shall refer to quality record control
procedure.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
The authorities and responsibilities of Project Manager and Main Department Managers,
especially their duties to the QAQC activities in the Project, are described as below:
Deputy Project Manager (DPM) Shall be responsible to execute the CONTRACT of the project.
He shall take charge of the Quality Assurance, the Schedule Control and the Cost Control in
implementing the CONTRACT. Interfacing and coordinating with CUSTOMER and General
Superintendent, handling daily managements of the Project, the Deputy Project Manager (DPM)
timely reports to the Project Manager (PM) directly.
In addition to the above Deputy Project Manager (DPM) shall perform the works assigned by
the Project Manager (PM) ensuring the effective implementation of quality management within
his responsible department. For the quality management responsibilities of each functional
department and the quality responsibility of each post, refer to “Project Quality Management
System Processes and Function Distribution Chart”. Project Manager (PM) may appoint a
Deputy Project Manager (DPM) to do routine work for quality management system.
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Under the leadership of the project top management CONTRACTOR, QA/QC Manager shall
exercise quality management on their quality processes listed at PROJECT’s QUALITY
DELIVERABLES Documents. Project management has provided sufficient QA/QC engineers
with different professional background to perform audits, inspections on quality work.
Subcontractor shall provide its own QC inspectors, whose qualification shall be identified and
the work be supervised by main CONTRACTOR..
QA/QC Manager shall be reporting to and receiving Project direction from the Project Manager.
Communicating the QA/QC events with the Deputy Project Manager. In case of quality related
concerns which cannot be resolved by the Deputy Project Manager (DPM) , the QA/QC
Manager can communicate with the Project Manager, The Vice President and the President of
CONTRACTOR.
The QAQC Manager is responsible for the development and maintenance of Project Quality
Plan for assuring that the project activities are performed and accomplished in accordance with
the Project Quality Plan and approved procedures.
6.5.2.3.1 Strictly observe the rules and regulations of the project quality
management system, enhance leadership, participate in by all employees, use method of
management of system and process to exercise scientific management on project quality work,
complete the project to the satisfaction of CUSTOMER , perform audit, continually improve the
quality of the project.
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Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP
Reporting to and receiving operational guidance from the Project Manager. The Procurement
Manager is responsible for all procurement activities and Quality Activities related for the Project
and take direct responsibility for Project procurement performance.
Reporting to and receiving technical and administrative direction from the Project Manager. The
Construction Manager is responsible for all construction activities and Quality Activities related
for the Project.
Reporting to and receiving Project direction from the Project Manager. The Control Manager is
also responsible for the overall monitoring of the Project's performance against the approved
budget and schedule.
Reporting to and receiving the direction from Deputy Project Manager for project related issue
but directly refer to the HSE department for the implementation of the safety criteria with the
project.
The HSE Manager is responsible for the safety, environment protection and health of the Project
and also for safety of construction personnel and equipment on site which will be protected and
prevented with the applicable safe facilities and makes the overall construction in safe and
sound condition.
Reporting to and receiving Project direction from the Deputy Project Manager. The Document
Control Manager is responsible for the reception, classifying, numbering, issuance, callback of
quality documents, and, takes part in reviewing of as-built documents, organizes translation and
typing of notices, records and documents of quality conference.
QA/QC Engineers is assigned for each activity of quality management. Reporting to and
receiving Project direction from the QA/QC Manager. He shall be responsible for overall quality
control activities of construction and related activities.
Instructing and training the Inspector from construction teams with their task, The QAQC
Engineers are fully responsible for implementing the Project Quality Plan at sites.
QAQC Engineer shall be responsible for preparing all the procedures of Quality Management
System of the Project.
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6.5.2.10.4 Fill and keep records of site inspection, tracking and urging
reclamation of quality deficiency.
Through various meetings, reports, documents internal publications and computer compiler
network, the horizontal and vertical connection between various different layers and function of
CONTRACTOR will be kept to link up the information in relation to the QMS to ensure the
effectiveness of the process of QMS.
Engineering department is responsible for engineering control and part of engineering work, it
shall conducts supervision on all engineering and design work. QA engineer in engineering
department shall perform QA audit to the design work at different stages. QA engineers working
in QA/QC department shall also make audit to the design work according to annual QA plan.
Under the guidance of Engineering Manager, Engineering department shall carefully study the
Main Contract, especially about the technical part, identify the customer’s requirement and
ensure that engineering shall satisfy the requirement and achieve the expected objectives.
6.6.1.1 During the design and development planning, the engineering department
shall determine:
a) The design and development stages, for example, intermediate design and final design,
basic design and detailed design.
b) The review, verification and validation that are appropriate to each design and development
stage. The records of the review, verification and validation shall be maintained.
c) The responsibilities and authorities for design and development. For detailed information,
please see relevant design procedure manual.
6.6.1.2 The Engineering Manager shall manage the interfaces between different
groups involved in design and development to ensure effective communication and clear
assignment of responsibility.
6.6.1.3 If there are some changes to the requirement of engineering, the planning
output shall be updated, as appropriate, as the design and development progresses.
6.6.2.1 Engineering department shall identify and document the design and
development inputs. These inputs of the project include:
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a) Contract document: there are a lot of basic technical requirement, data and drawings in the
documents. It describes the project facilities, operation and control philosophy, scope of work,
technical specifications of different disciplines and survey data.
b) Functional and performance requirements of the project. They specify the quality of design
documents. Designers shall pay attention to the suitability, safety, economy, construction
easiness of the design document.
6.6.2.2 The inputs shall be reviewed for adequacy. Requirements shall be complete,
unambiguous and not in conflict with each other.
d) Specify the characteristics of the project that are essential for its safe and proper use.
6.6.3.2 The type of output may be documents, specifications, drawings and data
sheets.
6.6.4.1 The purpose of the review is to ensure the suitability of stage and final design
results to the internal and external resources, the adequacy of conformity with general design
inputs, and the effectiveness of achieving established effects.
6.6.4.3 The type of review may be meeting review, expert review, review at different
levels, trade review.
6.6.4.5 Records of the results of the reviews and any necessary actions shall be
maintained.
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6.6.5.3 Especially when new structure, new material and new technology are
adopted in the project, verification activities shall be determined in design planning and must be
conducted.
6.6.5.4 Records of the results of the verification and necessary actions shall be
maintained.
6.6.6.1 The validation shall be performed to ensure that the resulting project is
capable of meeting the requirements for the specified application or intended use.
6.6.6.3 Records of the results of validation and any other necessary actions shall be
maintained.
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6.6.7.1 Lead Engineer is responsible for collection of all design change requests and
raises formal “Design Change Request (DCR)” for modification to all approved or issued
engineering documents.
6.6.7.2 DCR shall be registered and distributed to the engineers concerned for their
review of the impact on the work.
6.6.7.3 Engineering manager shall authorize the DCR and seek the approval from
customer, then forward a copy of the DCR to responsible engineer to modify the design.
6.6.7.5 Records of the results of the review of changes and any necessary actions
shall be maintained.
The purpose of control over the purchasing process is to ensure that the purchasing product
conforms to specified purchase requirement.
6.7.1.1 The project shall establish the criteria for selection, evaluation and re-
evaluation of suppliers. It shall evaluate and select suppliers based on their ability to supply
product in accordance with the project requirement.
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Its work at this stage shall include but be not limited to the following:
6.7.1.6 Contract department shall prepare terms and conditions of the ITB document
according to the main contract, law and other related regulatory and statutory requirements and
monitor the observation of the above.
6.7.1.7 Records of the results of monitoring and any necessary actions taken shall
be maintained.
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6.7.2.6 The content of the purchase order includes the vendor's quotation number,
quotation date, the RFQ package that was issued to solicit the bid, the equipment specification
number and drawing numbers issued with the RFQ, all inspection notices, hold points for
witness and notification requirements, and all vendor documentation and data required. The
equipment specification refers to all codes, standards, and stamps to which the CONTRACTOR.
must adhere.
6.7.2.7 Procurement and project teams should review and approve purchasing
documents for accuracy to the specifications prior to their release. To eliminate any delays
caused by the vendor not having a hard copy of the Purchase Order in his possession, a
Purchase Order Authorization Letter can be faxed to the vendor, which allows him to process
the order without any delays. An acknowledgement copy of the purchase order is also issued to
the successful CONTRACTOR. to sign and return, acknowledging their agreement with pricing,
description, delivery, and the commercial terms of the sale.
CUSTOMER or authorized Third Party Representative may verify at the source or upon receipt
that the purchased products and service conform to requirements. Verification by CUSTOMER
or Third Party Representative does not reduce the CONTRACTOR.'s responsibility.
a) QC Department shall be responsible for quality control in the all processes of procurement.
It shall prepare product inspection and test plan/ procedure, which shall be approved by
customer, and conduct the verification of purchased product.
b) The QC group shall review the procurement documents and ensure the suitability, adequacy
and effectiveness of these documents.
c) The QC group shall conduct inspection and test for delivered material and equipments.
d) If necessary, the QC group can perform verification at the supplier’s premises and make
verification arrangements and method of product release in the purchasing information before
verification.
f) Construction department shall verify that the construction progress and quality of
subcontracted work meet the requirements of Subcontract.
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CONTRACTOR. shall develop source inspection and surveillance program including quality
surveillance schedule to ensure quality of procurement.
CONTRACTOR.'s Vendors shall prepare and use the Inspection and Test Plans which give
detailed instructions for the inspectors. These Inspection & Test Plans are approved by
CONTRACTOR. And CUSTOMER prior to any inspection activity being performed.
Procurement inspection for designated items begins with the award of the purchase order and
concludes when the inspector has duly released the equipment from the vendor's shop after
successful completion of all inspections.
The Procurement Inspection Supervisor coordinates inspection activities. After receiving the
assignment from the Procurement Inspection Supervisor, the source inspector reviews the
order and conducts a pre-inspection meeting, followed by an initial inspection visit.
Progressive inspection visits will be conducted to perform the required equipment inspection as
outlined in the Inspection and Test Plans. The Source Inspector maintains the field file and
reports the results to the responsible office. The Procurement Inspection Supervisor also
coordinates source inspection activities with CUSTOMER 's Inspection personnel. The third
party inspector selection and approval shall be endorsed by CUSTOMER .
CONTRACTOR. will perform the inspection and test work to different vendor according to the
Risk Number (RN) (1-18), and finalize the Rating Classification (CR) (I , II , III or IV) of
equipment and material, finalize the frequency of inspection according to RN and CR.
CONTRACTOR. identifies and plans the production and, where applicable, installation
processes which directly affect quality and ensures that these processes are carried out under
controlled conditions.
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These include:
a) Documenting work instructions defining production and installation, where the absence of
such instructions would adversely affect quality.
b) Monitoring and control of suitable process and product characteristics during production and
installation.
When results of certain processes cannot be fully verified by subsequent inspection and testing
of the product (e.g., heat treating, NDE, cleaning, etc.) Processing deficiencies may become
apparent only after the product is in use. Then continuous monitoring and/or compliance with
documented procedures is required to ensure that the specified requirements are met.
CONTRACTOR. ensures that incoming items are not used or processed until they are
inspected and conformance to requirements is verified according to the quality plan or
documented procedures.
CONTRACTOR. inspects, test and identifies the work as required and uses process monitoring
and control methods to conform to requirements.
CONTRACTOR. holds the work until the required inspection and testing are complete or
necessary reports have been received and verified.
No work will be released or delivered to CUSTOMER until all inspection and testing of the
activities specified in the Quality Plan has been satisfactorily completed and the associated
data and documentation are available and properly authorized.
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CONTRACTOR. will maintain records which give evidence that the work has passed inspection
and/or testing with defined acceptance criteria.
CONTRACTOR. procedures ensure that nonconforming products are not used or installed.
Control provides:
The Quality Plan defines responsibility for review and authority for the disposition of
nonconforming work. Where required by the contract, the proposed repair of nonconforming
work is reported to CUSTOMER or representative. Repaired and repeated work will be re-
inspected using the same inspection method that discovered the defect in accordance with
documented procedures.
c) Detects and eliminates the root cause(s) by analyzing all processes, work operations,
deviations, quality records, service reports and complaints.
d) Initiates preventive action, commensurate with the risks encountered, to deal with problems.
f) Implements and records change in procedures resulting from corrective action, if any .
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Material control refers to the various measures adopted to reduce the amount of loss
of materials at the time of receiving, storing and issuing the designated materials.
Material control in practice is exercised through periodical records and reports relating
to purchase, receipt, inspection, storage and issuing direct and indirect materials.
Proper control over material can contribute substantially to the efficiency of a job
activities.
(2) Objectives
To enable uninterrupted progress of work.
To ensure requisite quality of materials.
To minimize wastage.
To provide information and traceability.
Equipment and material are stored according to procedure in a manner to prevent the loss of
value, preventing damage or deterioration. Equipment/material easily affected by adverse
conditions such as moisture, radiation and windstorm will be stored in an appropriate secured
warehouse. Any special storage preparations or ongoing maintenance will be performed upon
receipt of such material (i.e., electric motor bumped and kept dry with lights, desiccant installed
in crates or boxes as required, etc.) and throughout storage as required.
Each crate will also be marked with numbers (e.g. crate 1 of 24) to alert the receiver as to how
many crates should be received. An itemized report is created which lists the contents of each
crate by crate number, vendor, cost, and date shipped. This report is provided to the receiver to
assist with receipt of material. Like items are crated together to ensure ease of receipt of
material, as well as the ability to track the material during shipment.
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Quality records are maintained to demonstrate conformance to specified requirements and the
effective operation of the quality system. Pertinent vendor quality records are included. Each
project contract specifies the disposition and/or the retention time required for the various
documents.
The requirement for maintaining these records to demonstrate achievement of the required
quality and the effective operation of the quality system become part of the job completion as
witnessed and accepted by CUSTOMER . All quality records are turned over to CUSTOMER as
part of the Project Records Books as required by the Contract.
CONTRACTOR. Quality Assurance department performs internal quality audits which include
CONTRACTOR. and Subcontractor activities.
All audits are planned and scheduled. However, unscheduled audits may also be performed in
the situations where there may be serious quality problems for the activities performed by
CONTRACTOR. or the Subcontractors.
All audits are performed by the qualified and certified auditors. Audit results will be documented
and provided to the audited organization.
CONTRACTOR. maintains procedures for identifying the training needs and provides for
training of all personnel performing activities affecting quality. Personnel performing specific
assigned tasks are qualified on the basis of appropriate education, training and/or experience,
as required. Appropriate records of training are maintained.
Levels of quality surveillance will be generated to suit the project requirements and will be
specified in the Quality Plan.
For pipeline, mechanical, electrical, instrument and FOC disciplines, CONTRACTOR. describes
what type of personnel in the organization will perform in-process and final inspections.
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All inspectors covering assignments for critical welded fabrications will be certified by The
American Welding Society, The American Petroleum Institute, or similar international institutions
approved by CONTRACTOR. and CUSTOMER .
All inspectors witnessing or evaluating non-destructive testing will be certified to SNT-TC-1A,
Level II. As with engineering and procurement, CUSTOMER will review and approve
Construction staffing.
6.8.3.1 Control department shall prepare overall progress schedule according to the
requirement of the contract and construction characteristics. It shall prepare the procedures for
progress controlling and monitoring. These procedures and documents shall be based on level-
3 schedule, which shall be duly filled by authorized field engineers, verified by construction
department, and then put into the databank of the progress monitoring system.
6.8.3.3 Construction department shall check and inspect the material and equipment
provided by sub-contractor for their conformity of quality requirements. It shall also check and
review the qualification of the personnel who engages in the key/ special process.
6.8.3.4 For the covered work, construction department shall fill in “Covered Work
Record” and invite customer’s representative, QC inspector to the jobsite to jointly inspect the
covered work. If acceptable, countersign “Covered Work Record”, then cover the work. The
covered work record shall be maintained.
6.8.3.6 QA/QC department shall develop quality control plan for key/special
processes and conduct inspection and surveillance for these processes.
QA/QC department shall check the calibration status of monitoring and measuring devices to
make sure that their precision, accuracy and validity meet the project requirement.
6.8.3.8 The project cannot be delivered until final inspection and test have been
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done and associated data and documentation are handed over and approved.
d) Rejected or scrapped.
6.8.4.1 Some processes for production and service provision shall be validated
because the resulting output cannot be verified by subsequent monitoring or measurement, or
their deficiencies become apparent only after the product is in use or the service has been
delivered.
6.8.4.4 If there are some changes to important material /product parameter, the
process shall be revalidated.
6.8.5.1 In order to preclude the product or its status from confusion or misuse during
the product realization and achieve the purpose of traceability of product or service, a suitable
means shall be taken to identify the product, product status and the unique identification of the
product where traceability is a requirement.
6.8.5.5 Construction department shall check the identification No. before withdrawing
material from warehouse.
For example, when material shall be separated or covered, the worker or warehouse keeper
shall transfer the identification marking. Construction engineer shall monitor and document the
marking transfer to assure the traceability of the material. QC inspector shall supervise the
process of identification transfer.
This Project is an EPC (Engineering, Procurement, Construction) project. When the customer
property is transferred to CONTRACTOR., CONTRACTOR. shall exercise care with them,
protect the existing property of customers and restore to original profile after installation.
Construction department shall record the status of the customer property and report happenings
to customer or related department.
6.8.7.3 Procurement department shall set up warehouse and material yard for
storage of material and equipment. The type and size of warehouse or yard shall meet the
quality and quantity requirements of material. The method of control over the material or
equipment shall observe the normal practice and Vender’s recommendation. Care shall be
taken for identification, handling, package and storage.
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6.9.2 Construction department shall get these devices calibrated at specific intervals or
prior to use against measurement standards traceable to international and national
measurement standards.
6.9.3 Procurement department shall provide the devices (buy or rent) used in the
course of procurement and protect the devices from damage and deterioration during handling
and storage. For the monitoring and measuring devices provided by supplier or used at jobsite
by supplier, construction department shall review the list of MMD and check the records of
calibration status prior to use.
6.9.4 QA/QC department shall spot-check and keep track of the calibration status of
these devices.
6.9.5 When the devices are found to be out of calibration, the validity of the previous
measuring results shall be assessed and recorded. Construction and QA/QC departments shall
take appropriate actions for the devices and any product affected.
6.9.7 When used in the monitoring and measurement of specified requirements, the
ability of computer software to satisfy the intended application shall be confirmed. This shall be
undertaken prior to initial use and reconfirmed as necessary.
6.10.1 General
6.10.1.1 The project shall demonstrate conformity of product and quality management
system(QMS) and continually improve the effectiveness of QMS through customer satisfaction,
internal audit, monitoring and measurement of processes and product, control of nonconforming
product and analysis of data.
1) Scope of Application
CONTRACTOR shall monitor information and the perception of CUSTOMER ’s
satisfaction. The methods for obtaining information on such perception may include
letters and correspondences, CUSTOMER ’s complaints, claim analysis, direct
communication, compliments, electronic communication systems, comments during
meetings, etc.
2) Responsibility and Authority
e) Survey to customer;
f) Complaint of customer.
6.10.3.2 QA/QC department shall prepare internal audit plan at the beginning of each
year and get the approval of project leader in charge. The plan shall define the requirement of
the audit criteria, scope, frequency, methods, audit implementation, audit report,
corrective/preventive action, verification and documentation.
6.10.3.3 Internal audit should be conducted once a year. For a department, the audit
interval shall be less than 12 months. For each internal audit, all the procedures and sites
involved in the quality management system shall be covered. Regular internal audit may involve
the whole quality system or parts of it. Random internal audit can be conducted at any time
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when special condition occurs (e.g. there is a great change to the function ).
6.10.3.4 QA/QC department shall select and appoint qualified auditors to conduct
audits. Auditors shall not audit activities related to their own work to ensure the objectivity and
impartiality of the audit process.
6.10.3.5 Auditors shall objectively describe the nonconformity, communicate with the
audited department who shall analyze the causes of nonconformity and bring forward correction
methods and finish correction within limited time.
6.10.3.6 The lead auditor shall prepare audit report which can be used as input to
evaluate project quality management system and continual improvement. The audit results shall
be handed over to the departments having been audited.
6.10.3.7 For the internal audit control, refer to the procedure “Internal Audit Control
Procedure”.
6.10.3.10 The main methods to monitor and measure processes are process audit,
process review, routine process supervision and inspection, data analysis and so on. These
methods shall demonstrate the ability of the processes to achieve planned result.
a) Special processes;
d) Related releases.
in-process and final inspection and test”, determining the appropriate stages to monitor and
measure the products.
6.10.3.16 QA/QC Department shall prepare QC Plan in which “H”, “W”, “C” points (Hold
point, Witness point, Certification point) shall be inserted. When works reach these points,
Construction department shall issue IN (Inspection Notification) attached with checklist and
relating documents to QA/QC inspectors to engage in joint inspection. For the QC work flow,
see the attachment V “Project Site QC Activity Flow Chart”.
6.10.3.19 Product release and service delivery shall not proceed until the planned
arrangements have been satisfactorily completed, unless otherwise approved by a relevant
authority (where applicable, by the customer). For emergency release, see the procedure of
inspection and test for delivered material.
6.10.4.1 The project ensures that product which does not conform to product
requirements is identified and controlled to prevent its unintended use and delivery.
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6.10.4.5 CONTRACTOR. shall deal with nonconforming product by one or more the
following ways:
6.10.5.1 QA/QC department is responsible for collection, filing and statistical analysis
of data.
6.10.5.3 The project shall demonstrate suitability and effectiveness of the quality
management system and evaluate the opportunities of improvement through data analysis. This
mainly includes:
a) The present status and trend of customer satisfaction. Analyzing the main customer
complaints and improving quality management system.
c) The present status and trend of change to processes and products. Analyzing if potential
problems exist, determining the necessity to take preventive action.
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6.10.6 Improvement
6.10.6.1.1 The project shall continually improve the effectiveness of the quality
management system through implementation of the quality policy, quality objectives, audit
results, data analysis, corrective and preventive actions and management review.
d) Wide scope or not only one department is involved in corrective or preventive actions.
a) Seek the opportunities and ways of improvement by monitoring and measurement of quality
management system, product, and customer satisfaction, and by means of internal/external
audit, control of nonconformance and data analysis.
c) Determine new improvement target by the output of management review from head office of
CONTRACTOR..
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c) Evaluating the need for action to ensure that nonconformities do not recur;
6.10.6.2.3 All departments concerned of the project shall actively take corrective
actions, eliminate the causes of nonconformity to prevent recurrence. If the nonconformity is
caused by CONTRACTOR. or Subcontractors, they shall take corrective actions and implement
them separately, the responsible department of the project shall verify the implementation
results.
6.10.6.3.3 Different types of quality analysis meeting shall be held for solution of
the problems about product quality and quality system. For example, weekly meeting between
CONTRACTOR. and CUSTOMER , project internal weekly meeting, technical meeting, etc.
These meetings shall analyze the status of product quality and quality system implementation
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6.10.6.3.4 All departments of the project shall actively take actions to prevent
nonconformity occurrence by collecting and analyzing information and eliminating the causes of
nonconformities.
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7.0 ANNEXURES
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Procurement dept.
Professional office
Market dev. dept
Project Manager
Project Director
Labor resource
Administration.
Deputy Project
Project control
planning dept.
manage dept
Construction
QAQC dept.
Files office
Enterprise
manager
Functional dept.post
dept.
dept
dept
System requirement
★ △ General requirements ▲
★ General ▲ △
★ △ Quality Plan ▲ △
Control of documents △ △ △ ▲ △ △ △ △ ▲ ▲ △
Control of record △ △ △ ▲ △ △ △ △ △ ▲ △
★ ▲ Management commitment ▲
★ ▲ CUSTOMER focus △ △ ▲ △ △ △
★ △ Quality policy △ △ ▲ △ △ △
★ △ Quality objective △ △ △ ▲ △ △ △ △ △ △ △
★ △ QMS planning ▲ △
★ △ Responsibility & authority △ △ △ ▲ △ △ △ △ △ △ △
★ Management representative
★ △ Internal communication △ △ △ △ △ △ △ △ △ △ △
★ ▲ Management review △ △ △ △ △ △ △ △ △ △ △
★ Provision of resources ▲ ▲ ▲
★ Human resources △ ▲
★ Infrastructure △ ▲ ▲ △
★ Working environment ▲
★ Planning of product realization ▲ ▲ △ ▲ ▲ △
★ CUSTOMER - related processes ▲ △ △ △ △ △ △
Purchase ▲ △ ▲ ▲ △
★ Production & service provision △ ▲ △ △ △ △ △ △
Control of monitoring & measurement
▲ △ △
devices
★ △ CUSTOMER satisfaction △ △ △ ▲ △ △ △
★ Internal audit △ △ △ ▲ △ △ △ △ △ △ △
★ Monitoring & measurement of process △ △ △ ▲ △ ▲ △ △ △ △ △
★ Monitoring & measurement of product ▲ △ ▲ △ ▲ △ ▲
★ Control of nonconforming product ▲ △ ▲ ▲ ▲ △ ▲
★ Analysis of data △ △ △ ▲ △ △ △ △ △
★ △ Improvement △ △ △ ▲ △ △ △ △ △ △ △
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Project Director
QA Reject
Auditee
Acknowledgement NO
QA NO QA Accept
Department Finding Exists Observe
Perform
Yes Non Conformance
Audit
YES
Satisfactory or only
Suggestions
Audit Report
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Project Director or
QC Dept receive IN NCR His Deputy
QC Dept. Reject
Notice owner for Joint No
Inspection
NO
YES QC 2nd
Inspection
QC 1st
Inspection
NO
YES
Construction Dept Issue Engineering
New IN After Corrective Department
Action
QC Dept. Accept (or Joint
Signature)
QC Dept. Reject
Make Note on FIN
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ORIGINATOR SIGN:
DATE:
NAME: (print)
2. CONTRACTOR RESPONSE:
CONTRACTOR SIGN:
DATE:
NAME: (print)
COMMENTS:
AUTHORIZED SIGN:
DATE:
NAME: (print)
4. VERIFICATION AFTER IMPLEMENTATION OF THE CORRECTION
REMARKS:
CONTRACTOR
ENGINEER SIGN: DATE:
NAME: (print)
CUSTOMER ENGINEER
SIGN: DATE:
NAME: (print)
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Note: QA/QC manager will modify the audits schedule in accordance with the revised schedule
of the Project progress when necessary. In accordance with the importance of the work, times of
audits could be modified to suit the conditions of the Project. Additional audits shall be
considered in preparation of the schedule. All audit schedules or changes shall be informed to
CUSTOMER 7 days before the change takes effect.
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From:
TQ Title:
Query:
Signature: Date:
Signature: Date:
Response reviewed by: Position:
Signature: Date:
Signed for and on behalf of CUSTOMER : Name:
Signature: Date:
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