QA QC PLAN for CNG

7/24/2019 QA QC PLAN for CNG..

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QA / QC PLAN

Rev.No. Date Description Reference No. Approved

0 October 2015 Issued for Approved

CLIENT :

PROJECT :PROJECT NO.:

WORK/SCOPE

:

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TABLE OFCONTENTS

PART TI TLEPAGE

1 PART-1 GENERAL. 3

1.1 Purpose. .. 4

1.2 Extent . .. 4

1.3 Definition of Term 4-6

2 PART-2 ORGANIZATION . 7

2.1 Project Organization . 8

3 PART-3 DESIGN .. 9

3.1 Design and Relevant Quality Control ... 10

3.2 Changes Control 10

4 PART-4 PROCUREMENT CONTROL . 11

4.1 General . 12

4.2 Vendors Evaluation .. 12

4.3 Purchasing Control .. 12-13

4.4 Shop Inspection and Control 13-14

4.5 Non-Conformance Control .. 14-15

4.6 Sub contracting .. 15-16

5 PART 5 SITE CONSTRUCTION AND INSTALLATION 17

5.1 Scope . 18

5.2 Document Control . 18-19

5.3 Material Receipt, Storage and Trace ability ... 19

5.4 Field Quality Control 20

5.5 Construction Equipment and Test/Inspection Equipment Control 205.6 Non-Conformance Control 20-21

5.7 Final Documentation and Records 21


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1. PART 1 - GENERAL

1.1. PURPOSE

1.2. EXTENT

1.3. DEFINITION OFTERMS


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1.1. PURPOSE

The main purpose on this QA/QC Plan is to ensure in achieving the desired level of

quality of a completed facility.

1.2. EXTENT

1.2.1. The requirements in this QA/QC Plan pertains to the contract activities effecting

quality including Design, Procurement .Fabrication, Transportation, Storage,

Installation and Testing.

1.2.2. Any organization, firm, sub-contractor or party who carries-out any of the above

activity shall conform to the requirement of this QA/QC Plan. In such cases, the

interfacing between different parties shall be defined and controlled.

1.3. DEFINITION OF TERMS

In this QA/QC Plan the following term are mentioned and defined as follows;

Acceptance Criteria - Specified limits mentioned which characterizedan item, process, or service defined codes,

standards or other requirement document.

Approval - An act of endorsing or adding positive

authorization of both.

Certificate of Conformance - A document signed by an authorized individual,

certifying the degree to which items or services

meet specified requirements at the time of

assessment.

Certification - The authoritative act of documenting compliance

with requirements.

Contractor -

Client -

Document - Any written or pictorial information describing,

defining, specifying, reporting, or certifying

activities, requirements, procedures, or result.

Inspection - Examination of measurement to verify whether

an item or activity conforms to specified

requirement

Inspection Authority - Clients own inspection department and or


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Nationality or internationally recognized Inspecification agency.

Inspection Level - Specified amount of inspection coverage deemednecessary to assure that a product or services

conforms to specifications.

Interface (Interfacing) - Interrelationship between the different

organization participating to the same project and

also relating to define communication and

physical boundary.

Item - Any level of unit assembly, including structure

system, subassembly, component, part or

material.

Non Conformance - A deficiency in characteristics documentation of

procedure that renders the quality of an item or

activity unacceptable or indeterminate.

Objective Evidence - Any documented statement or fact, information

or record, quantitative or qualitative, pertaining to

the quality of an item or activity, based on

observations, measurements, or tests which can

be verified.

Procedure - A document that specifies or describes show an

activity is to be performed.

It may include methods to be employed or

materials to be used and sequence of operations.

Qualification (Personnel) - The characteristics or abilities gained through

education, training, or experience as measured,

such as standards or tests, that quality of an

individual to perform a required function.

Quality Assurance (QA) - All these planned, systematic actions, and

detailed schemes developed and documented

before hand necessary to provide adequate

confidence that a product, processor service will

be satisfied.

Quality Control (QC) - That pasta QA which through checks, review,

measurements, tests, and inspection determines

that specifications are met.


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Repair - The process of correcting and/or rectifying aNon conforming characteristics to a condition

such that the capability of an item to functionreliably and safety is unimpaired even conform to

the original requirement.

Surveillance - The act if monitoring or observing to verify

whether any item or activity conforms to

specified requirements.

Testing - An element of verification for the determination

of the capability of an item to meet specified

requirements by subjecting the item to set of

physical, chemical, environmental or operating

conditions.

Traceability - The ability to trace the history, application, or

location of an item an like items or activities by

means of recorded identification.

Use-as-is - A disposition permitted for a non conforming

item when it can be established that the item is

satisfactory for its intended use.

Verification - The act of reviewing, inspecting, testing,

looking, auditing or other wise determining and

documenting whether items, process, services, or

documents conform to specified requirements.

Waiver - Documented authorization to deviate from

specified requirements.


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2. PART2 - ORGANIZATION

2.1. PROJECT ORGANIZATION


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2.1. PROJECT ORGANIZATION

2.1.1. The Project Organization, de line at as the authority and responsibility of theappointed persons and parties performing project activities.

The Organization Chart indicates the key positions both at home office and on

site engaged in the project. While other engineering groups from the permanent

organization will be assigned to the project team in relation to the needs defined

and scheduled by the Project Management.

2.1.2. The structure of the Quality Assurance team in the Project Organization and the

relation ship with the Project Management, the QA/QC team and the other

functions.

2.1.3. The overall responsibility for site construction is of the Site Manager who reports

to the Project Manager.

The execution of the works is the responsibility of the Construction Manager

while field it the responsibility of the Construction Manager while field quality

control activities are the responsibility of Field QC Engineer.

2.1.4. The execution of the work on site in accordance with the drawings and

specifications shall be ensured by the Field Erection Superintendents and

Supervisors who report to the Construction Manager.

2.1.5. At Site, the engineering activities shall be carried out be the Engineering Team

headed by the Field Engineering Manager. On Site, the quality control activities

shall be ensured by the QC team under the coordination of the Field QC

Engineer who reports to the Site Manager.

The Site Quality Control is included but not limited to the activities for materials

and equipment at their arrival at Site. Special process used during construction

and completed testing and examination of items and systems during and after

installation.

2.1.6. The Field QC Team will act as a separate entity from construction team and

therefore free of conflicts with progress and construction restraints.

2.1.7. The Clients representative and Inspection Authority, acting on be half of the

Client, witness to ensure that the project is carried out in accordance with the

contract requirements. The Quality Assurance Plan, system or program which

either during site construction clearly shows the relevant witnessing points.


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3. PART3 - DESIGN

3.1. DESIGN AND RELEVANT QUALITY CONTROL

3.2. CHANGES CONTROL


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3.1. DESIGN AND RELEVANT QUALITY CONTROL

3.1.1. Measures are established to ensure that the Design activities are planned, carriedand reviewed in a controlled manner in accordance with the established project

requirements. The Engineering documents to be produced in the project will be

controlled with document list which indicate the date of issuing for project use

(inquiry, purchase, construction, etc.) and those which are subject to clients, etc.)

And those which are subject to clients approval/comment.

3.1.2. Responsibilities for preparation, checking, reviewing, and approval of technical

documents shall be clearly defined. Design reviews are planned, performed and

recorded under the coordination of the Project Engineering Manager.

3.1.3. The drawings and specifications to be issued must be approved and signed by the

responsible Engineer concerned or other relevant position after verification that

the established checks and design review shave been satisfactorily performed.

When a document needs to be modified following a design/field change, the

revisions shall be signed for approval by the same positions the approved the

original document.

Status and reason for document revisions is to be clearly indicated in the

document front sheet.

3.2. CHANGES CONTROL

3.2.1. The design document may be revised for completion or for change purpose.

The changes may result mainly from Client request, design requirements, shop or

site exigencies. In any case it must be basic solution previously established or the

project quality requirements.

3.2.2. The document from required change shall be sent by the Engineer concerned to

the Project Management for evaluation. If accepted copies of the change order

are sent to all the involved persons and organizations. The technical documentsreflecting the design change shall be approved using the same procedure and by

the same personnel as ones who approved the original design documents.

3.2.3. Changes with multi disciplinary implications shall be examined by all the

positions concerned. If necessary design review meetings shall be repeated as

appropriate.


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4. PART4 - PROCUREMENT CONTROL

4.1. GENERAL

4.2. VENDOR EVALUATION

4.3. PURCHASING CONTROL

4.4. SHOP INSPECTION AND TESTING

4.5. NON- CONFORMANCE CONTROL

4.6. SUB CONTRACTING


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4.1. GENERAL

4.1.1. The Procurement Control System is organized to give assurance that purchaseditems, whether directly or through vendors, meet the contractual requirements for

quality, delivery schedule and economy.

4.1.2. This system requires that Vendors meet the standards and specifications of the

contract.

4.1.3. The Procurement Control System includes provisions for source evaluation and

selection, surveillance of the vendors and inspection of items and examination of

documentation upon delivery.

4.2. VENDOR EVALUATION

4.2.1. Inquiries shall only be sent to qualified Vendors included in the Project Vendor

Lists.

4.2.2. For the vendors not included in the Project Vendor List, a prevention evaluation

and qualification shall be carried out before the purchase order issue. The

qualification is carried out by the Procurement Group in cooperation with the

relevant technical and QA group as required.

4.3. PURCHASING CONTROL

4.3.1. The established procedures shall be implemented to make sure that all the

applicable prescription, regulatory requirements, design basis and inspection

requirements necessary to assure adequate quality of the bids are included or

referenced in the documents for requisition of items and service. A said

procedure defines the type documentation to be included in the inquiries and the

responsibilities for their preparation, control and approval.

4.3.2. Bid Evaluation

The evaluation of the received bids shall be performed according to the

established procedure. All the bids are compared in a bid summary.

Technical bid evaluation is carried out buy the Engineering Group concerned to

assess the adherence to the inquiring documents, the soundness of the proposed

solutions and to evaluate the proposed deviations. Bid clarification meeting will

be held with the Bidder son the short List. A survey may be carried out in

connection with bid clarification meeting depending on previous experience with

theBidder.


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4.3.3. Purchase Orders

The preparation and issuance of the purchase orders to the selected vendors/

subcontractors shall follow the established procedures. Before orders for major

items are issued, verifications will be carried out by the Engineering Group on

the purchase order documentation to check that the following conditions are met;

a. The Technical Bid Evaluation has been properly carried out by the

Engineering Group concerned according to the procedures.

b. The selected Vendor is included in the Project Vendor List and/or has been

duly qualified.

c. The documents attached there to are complete, updated, consistent to each

other and include the approved drawing sand specifications.

4.3.4. Vendor Documentation

Vendors drawing sand data will be described in a Vendor Document List

included in the Inquiry. Such list will specify in detail which documents will be

apart of the supply and those to be submitted to Contractor (for

approval/review/information) according to the delivery program.

4.4. SHOP INSPECTION AND TESTING

4.4.1. The vendor shall carry out the checks, inspection and tests required by the

purchase order and inspection requirements.

4.4.2. The minimum requirements for shop inspections and test for main equipment are

detailed in the Inspection Requirements of the Contract.

4.4.3. The Inspection will perform, as specified in the appropriate procedure;

a. Pre inspection meeting with Vendors of major or critical equipment to clarifycontract requirement, coordination procedures and interfaces.

b. Approval of the shop fabrication.

c. Qualification of Welding Procedures.

d. Qualification of Welders.

e. Verification of Material Identification and Traceability.

f. Check of material source certificates.


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g. Witness shop inspection and testing and/or review relevant results in

accordance with contract and/or relevant specification requirements.

h. Check and validation of examination and test reports and certificates.

4.4.4. The Project QA personnel will at tend the pre-inspection meetings with major

supplies to verify their quality organization to clarify, Final Test Report will be

prepared by vendor.

4.4.5. On completion of inspection, Final Test Report will be prepared by vendor.

4.4.6. Only after checking that all the established inspections, examinations and tests

have been properly carried out, witnessed, evaluated documented, incompliance

with the P.O., the inspector will review and approve with signature on the final

inspection report to release for shipment.

4.4.7. A final check of the documentation of inspections and test shall be carried out by

the Project QA Team to verify completeness and adequacy.

4.5. NON-CONFORMANCECONTROL

4.5.1. Materials, components, equipment or system at deviate from approved

specifications, drawings or other applicable documents or due to document

deficiencies are indeterminate are considered as Non-Conforming Items andshall be properly marked and/or segregated in order to avoid the in advertent use.

The Non-Conformance shall be documented by the inspector and the due course

of action shall be initiated according to the concerned procedure.

4.5.2. A Non-Conformance will be classified as;

a. Minor Non-ConformanceWhen it can be solved with in the contractors

QA Group, such as accepting;

- Item replacement which affects the Project Schedule.

- Complete repair in compliance with the applicable codes andspecifications.

- Additional documentation (in case of document deficiency).

b. Major Non-ConformanceWhen it is necessary to involve other Group such

as;

- Repair with a procedure to be approved.- Repair not leading to full conformance.

- Replacement delaying the project schedule.

- Use-as-is of the item.


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4.5.3. There solution of major non-conformance shall involve all concerned Project

function sand the Project QA Manager. The later will verify that all implications

concerning the quality are duly considered and that there solution of the non-conformance is effective and documented.

The above shall be applied also is the case of vendor, should propose a change

not in compliance with the requirements of purchase specifications.

4.5.4. The Non-conformance resolution such as Use-as-is or a Repair not leading to

full conformance to governing specifications, drawings or Contract

Documents but not effecting the suitability for service of materials, shall be

exhaustively documented in the non-conformance report by the Contractors

Inspector.

In both cases the documents non-conformance resolution shall be submitted to

the Project Manager for evaluation and disposition.

4.5.5. As soon as a major non-conformance is found, a copy of the relevant Quality

Control Report shall be sent to the Project QA Manager who will verify the

effectiveness of the corrective action.

4.5.6. There solution of a major non-conformance shall be documented by the Project

QA Manager and the relevant report shall be signed by all individual concerned,

A copy of this report will be filed by the Project QA Manager as QA Record.

4.6. SUBCONTRACTING

4.6.1. General

This describes the measures which are established and documented to assure that

services, complete assemblies or constructions are supplied in a controlled way

with the aim to satisfy the Project requirements for quality, delivery schedule and

cost.

4.6.2. Instructions of Tendering Subcontractors

The Contracts Department is responsible for collecting all documents to be

included in the Tender Invitation such as;

- Scope of Work.

- Technical Requirement (including Inspection and Test Requirements).- Commercial Conditions.


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4.6.3. Tender Evaluation

The Evaluation of the received tenders shall be preformed by the Engineeringgroup concerned to assess the adherence to the inquiry documents.

The Final Tender Evaluation will end up with a Tender Evaluation Report where

the contractors are ranked and all necessary documents to be included in the

contract are listed.

4.6.4. Contract Award

Contract commitments are made only the Tender Evaluation Report has been

approved according to the Project provisions. The Procurement Group in

cooperation with the Engineering Group shall prepare the Contract clearly

stating all the requirements of quality related, technical and commercial nature,

including what has been agreed upon during the clarification meetings.


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5. PART5 - SITE CONSTRUCTION AND INSTALLATION

5.1. SCOPE

5.2. DOCUMENT CONTROL

5.3. MATEIALRECEIPT, STORAGE AND TRACEABILITY

5.4. FIELD QUALITY CONTROL

5.5. CONSTRUCTION EQUIPMENT AND TEST INSPECTIONEQUIPMENT CONTROL

5.6. NON - CONFORMANCE CONTROL

5.7. FINAL DOCUMENTATION AND RECORDS


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5.1. SCOPE

5.1.1. The purpose of this section is to provide a formalized and systematic means for

the implementation of the Quality Control for Construction to ensure that the

contracted facilities installed by the Field Project Organization are fully

compliant with are relevant specifications, procedures, drawings, applicable

codes, rules and regulations.

5.1.2. The working procedures state the activities, for the relevant responsibilities, the

quality control activities, the reports to be prepared, the communication lines to

be maintained and the required recording system.

5.1.3. This section includes the requirements pertaining to the administration and control

of the technical documentation on site.

5.1.4. It is also specified how the same requirements are imposed on subcontractors.

5.1.5. Although the construction subcontractor is responsible for the execution, testing

and documentation of the work, the Site Organization has as advisory function

and is given the responsibility to provide a close follow-up subcontractor

activities.

5.2. DOCUMENT CONTROL

5.2.1. Recording, filing and distribution of design documentation received from home

office shall been sure by the Site Drawing Controller.

5.2.2. The document will be distributed to the personnel concerned so as to be available

at the location where the activity is to be performed prior to commencement of

the activity it self.

All obsolete documents must be marked OBSOLETE to prevent their

misapplication.

5.2.3. On working site, the Field Engineer concerned receives the construction

specifications and drawings and review them, also taking into account any field

requirements. Where necessary, he will ensure that modifications/additions to

said documents are performed in compliance with the procedures.

In case of change effecting the basic design, he ensures through the Field

Engineering Manager the approval of home office Engineer concerned and,

when necessary of the Customer Representative. The data necessary for the As

Built Drawings will be collected by the Field Engineers.

5.2.4. The documents which are prepared on site (or modified without needing the homeoffice approval as per part5.2.3) will be signed by the Field Engineer concerned

and by the Field Engineering Manager for check and approval.


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A copy of said documents will be sent to the relevant home office the Engineer

who provides for the relevant recording, distribution and filing.

5.2.5. Documentation relevant to fabrication and testing of purchased items and

materials (mill certificates, test reports, manufacturers drawings, specifications,

data reports, instruction manuals) will be received and filed by the Site Drawing

controller.

5.2.6. Recurrent in sections will be carried out at the working are as by the Field

Engineers, to as certain that the latest revisions of construction drawings and

specifications are be ingused.

5.3. MATERIAL RECEIPT, STORAGE AND TRACEABILITY

5.3.1. Material receipt, unloading, check registration, storage and traceability will be

ensured by the material controller in accordance with the relevant procedure.

5.3.2. Only after a satisfactory check, the received material may be release for the final

registration and storage.

Irregularity on the concerning document be found such as to identify anon-

conformity, the Construction Manager shall be informed.

He shall evaluate the non-conformity, informing when necessary, the concerned

Engineer at home office.When contractual requirements are effected the client representative is to be

informed.

5.3.3. The Construction Managers evaluation of a non-conformity can be Rejection

or Repair or Use-as-is and shall in any case be documented.

In case of Repair, the relevant repair procedure is the responsibility of the

Construction Manager concerned which, after repair will evaluate the results and

issues the acceptance certificate.

Should any deviation from design documents be accepted, the written approval

of the concerned Engineer is necessary, before the acceptance certificate.

Incase of deviations from contractual requirements, the customer writtenapproval will be required.

These reports are to be filed as Quality Control Records.

5.3.4. All the materials which have not passed the receiving control are to be marked

HOLD and held being separated from the others, until they are accepted or

rejected. In case rejection they must be marked REJECTED and kept

segregated.

5.3.5. For the released items or materials the Material Controller will provide for the

project registration, storage, preservation and maintenance (to prevent any

damage or deterioration) ensuring the traceability of stored items and materialsby painting or stamping project, identification symbols or marks, all in

accordance with the procedures.


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5.4. FIELD QUALITY CONTROL

5.4.1. The site installation and construction work shall be performed in a planned andcoordinated manner using construction drawings and specifications.

5.4.2. The inspection and test activities shall be planned in order to maintain overall

project scheduling and shall be supported by the applicable procedures.

The status of inspections and tests in every stage of the construction work shall

be maintained by the Quality Control Engineer.

5.4.3. The purpose of the Field Quality Control Plan is to define all the mandatory tests

and examination to be carried out during the installation work to verify the work

is carried out in conformity to specify prescriptions and to provide for the

relevant documentary evidence.

TheplanwillalsoshowthewitnesspointsandthetimingwhenQualityControl

Engineer shall notify the customer and/or the Inspection Authority.

5.4.4. Quality Control Team Construction Team will have meetings when ever QC

Matter requires coordination or instruction prior to installation activity.

5.4.5. The Client Inspection Group may witness the inspections and tests made in

accordance with the Field QA Plan.

This Plan will show the Clients witnessing points while the coordination between

the Contractor and the Client is defined in the established procedure.

5.5. CONSTRUCTION EQUIPMENT AND TEST/ INSPECTION EQUIPMENT

CONTROL

5.5.1. In general, using equipment (i.e. welding equipment, grinder etc.) the supervisor

and warehouse staff confirm the condition of equipment and make a proper

suggestion to prevent damage and maintain its original quality.

5.5.2. The Field QC engineer nominates for a test and inspection equipment controller

and let him control these equipment.

5.6. NON - CONFORMANCECONTROL

5.6.1. Any deficiency or deviation in characteristic, documentation, procedure or work

which renders the quality of an item or work un acceptable or in determinate

shall be considered as anon-conforming.A defined course of action shall be applied according to the concerned

procedure.

5.6.2. The finding of a Non-conforming may occur at any time during the installation

work or routine inspection and may be made by any one. All field staff are awarethat it must be reported both to the Construction Manager and Field QC

Engineer.


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5.6.3. The Construction Manager and Field QC Engineer convene a discussion with the

relevant personnel, to discuss the counter measures and make the final decision.

5.6.4. When the disposition plan of non-conformities is considered to effect the original

design, the Field Engineer shall re-evaluate and inform the result to the

Construction Manager and Field QC Engineer.

5.6.5. If repaired, Field QC Engineer confirms the passing of the Final Inspections,

removes the non-conformities identification and sends it to next process.

5.6.6. If scrapping the non- conformities product, the Construction Manager, together

with relevant personnel, separate it from others.

5.7. FINAL DOCUMENTATION AND RECORDS

5.7.1. All reports of examination, inspection, tests, non-conformities and changes issued

during installation works will be collected, checked and signed by the concerned

Field QC Engineer and/or Superintendent.

The documents are to be prepared shall be taken to prevent deterioration,

damages and losses.

5.7.2. The above documents will be checked by the Field QC Team for completeness

and adequacy with the QA Plan prescription and Contract requirements.