QA / QC
IN OIL & GAS projectsENJEUX & OUTILS
1ORIGIN OF NON QUALITYORGANISATIONLOGISTICSPROCUREMENTBREAKDOWN RATEDEFAULTSPLANNING
OPERATORPOOR ATTENTIONLACK OF TRAINING
70 80 %20 30 %2Quality Basis
by paying attention totheir qualificationsby a periodic and systematic approch by looking to their performances
QA/QC WHY ?
The objective of implementing a quality assurance approach for work done by suppliers / contractors / vendors is to:ensure that the equipment or service supplied complies with specification or contract requirements.reinforce the Contractor's awareness to his responsibility for the workminimise Company's involvement and hence Company's costsminimise delays to schedule caused by the use of excessive Hold pointsproduce evidence of compliance (the 'audit trail') and measure Contractor/Supplier performance.
The purpose of this procedure is to specify the Company's minimum requirements for Quality Assurance/Quality control during design, procurement and construction phase of HelM facilities.
This procedure presents the Sarost's minimum requirements for QA/QC in all Contracts and Purchase Orders with their nominated Suppliers (Consultants, Contractors and Vendors).
The requirements are based on the use of the ISO 9000 Series of Quality Management and Quality Assurance Standards.
6NOW LETS SEE MNT HAS EVOLVED OVER TIME.Scope
This procedure forms a part of the Contract or Purchase Orders. Contract Quality Plan and Quality Control Plan Guidelines, offers Suppliers (Consultants, Contractors and Vendors) guidelines on the contents and development of a Contract Quality Plan and Quality Control Plan that will meet the requirements of this procedure.
A system or equipment item will be critical if it safeguards the integrity of the facility or impacts upon its ability to meet performance objectives.
An activity can be critical by reason of its importance to the success of the project or through risks associated with it.
QA/QC for Critical activities / Equipments
Quality Assurance of Design
List of all the types of deliverable produced by the design contractor.
Identify which deliverables requires Sarost review / approval to ensure the technical integrity of the design.
Design QA Plan
Project Engineer shall prepare and approve authorisation matrix defining the required technical authorisation (TA) level for each type of project documents for review and approval.
The Design Deliverables Matrix The matrix specifies the discipline TA approval required for each deliverable depending on the criticality level.
A default criticality has been assigned to each deliverables.
DELIVERABLE REVIEW LEVELSTechnical Autorisation LevelsLevel 1Corporate Functional Discipline Head. Sets the boundaries wherein the discipline operates.
Level 2Experienced Professional. Can handle himself without outside support in almost all discipline situations.
Level 3Engineer with specialised but yet incomplete skills in one or more areas of the discipline.
Design QA PlanThe design contractor produces and verifies the deliverables according to its own ISO 9001 approved QA system before issuing to the Sarost engineer.
The deliverable(s) is then issued to the Sarost engineer who is responsible for obtaining the correct level of review and approval in accordance with the approved design QA plan.
Once the necessary approvals have been obtained the Sarost engineer returns the deliverable(s) back to the design contractor.
Process flowchart for design deliverables is shown in Appendix 3.
Process flowchart for design deliverables(Same as PQP)
Deliverable Criticality Rating
Quality SystemThe Supplier (Consultant, Contractor, Manufacturer and Vendor) shall implement and use a Quality System that complies with the appropriate Standard from the ISO 9000 Series, (latest edition), as listed below, and the requirements of this procedure. ISO 9001: Quality Systems - Model for quality assurance in design development, production, installation and servicing.orISO 9002 :Quality Systems - Model for quality assurance in production, installation and servicing.The Standard shall be selected to cover all work activities (consultancy, project management, procurement, construction, and provision of goods, products or services), associated with the Contract or Purchase Order.
16CONDITIONAL PROBABILITY OF FAILURE:-THIS ASSUMES THAT WHEN A PIECE OF EQUIPMENT IS NEW IT WILL NOT FAIL FROM NEW BUT WILL REACH A POINT WHERE IT WILL START TO WEAR OUT.
BUT AS ENGS WILL INCLUDE A COMFORTABLE FACTOR OF SAFETY WHICH REDUCES THE USEFUL LIFE SPAN,Q? HOW CAN YOU MAXIMISE THE USEFUL LIFE: CONDITION MONITORING.TYRE EXAMPLE:-Where the Contract includes design work, ISO 9001 shall be used.
Where the Contract is purely for production, construction, installation, commissioning and hand over, then ISO 9002 shall be used.Quality System
Elements of a Quality Management System
The term Process Control in ISO 9000, shall be considered to embrace all work activities from Tendering and Contract Award to Completion of the Contract.
Activities such as; Contract Management, Cost Control, Planning and Scheduling, Progress Measurement, Reporting, 'As Built' Documentation etc. shall have properly documented Procedures or Work Instructions. Quality System
Suppliers in selected Work Categories may be required to attain Third Party Registration of their Quality System.
Work Categories required to attain registration will be informed by the project Manager.
20Quality SystemWhere Suppliers are not required to attain Third Party Registration, they shall demonstrate that they have a Quality System that complies with ISO 9001 or 9002, as appropriate for the contract or purchase order scope.Quality Management during tender processDocuments to be Submitted
23Quality system documentation
QA/QC Procedure Organisational StructureSubject to Approval byCompany andSarost
Office basedSite basedFull orpart time ?
Mobilisation Dates ?
quality system shall embody for design, production and distributionquality system shall embody for design, production and distributionDocuments to be Submitted with the tender
If not availableDocuments to be Submitted Within 14 Days of Contract Award Quality ManualContract Quality Plan (CQP)Control Quality Plan3.Identify all work activities and sub-activities, including those performed by Sub-Contractors, to be controlled by the CQP.
4.Detailed methodology how quality system and work performed by Sub-Contractor shall be monitored and controlled by the Supplier.
5. Details of how Quality Planning shall be undertaken and controlled.
Quality Control Plan (Test and Inspection Plan) - Typical Format
Quality Control Plan - Typical Example for Hydro Testing
Service Contract Work Orders
Indicate how the Contract Quality Plan and specific Quality Assurance requirements will be applied to individual Work Orders issued under a Service Contract. This may be in the form of a Project Quality Plan, developed from the Contract Quality Plan.
Service Contract Extra Work Orders
Subject to Company & SarostsApproval before workstartsApplicable Procedures, Work Instruction & Checklists
QUALITY CONTROL What is Quality Control ?
Quality Control is a process to measure and analyze project results from specific operational activities using specialized operational monitoring and verification tools and techniques to determine if the results in compliance to established quality standards or requirement.
This process shall also include identification and elimination of nonconforming products and identifying ways to eliminate the causes of non-conformances.
The quality control activities shall include the following:
Conduct general surveillance on engineering deliverables Conduct required inspection at SUPPLIERs manufacturing/fabrication facilities
Lead specific data analysis works for quality improvement Conduct third party inspection verification Conduct general surveillance on construction and commissioning activities Witness and approve Welding Procedure / Welder qualification Witness and approve validation other special construction and commissioning work processes Monitor construction process traceability Monitor punch list program Conduct verification on mechanical completion and commissioningcompletion readiness Lead specific data analysis works for quality improvement Final DocumentationQuality Control Plan shall include *Specified Acceptance / Rejection Criteria*List of Activities and Sub-Activities requiring Quality Control and or stage inspection.
*Hold, Witness, Surveillance, Monitoring and Review points *When Third Party Inspection (TPI) is a Contract requirement, the QCP(s) and Quality document(s) shall also be reviewed and endorsed by the nominated TPI Agency.*Sub-Contractor(s) QCP(s) and quality document(s) shall be reviewed and endorsed by Contractor, before submitting for Company approval. *Inspection &Test PlansQC Inspectors (Location Site Office)The QC inspector shall operate independent of the personnel performingthe work and report to the QA/QC Engineer for the Contract. He shall beresponsible for: Surveillance of all specified construction activities as per inspectionplan, specifications and codes. Witnessing all checks/ tests, as per ITP and interpretation of results. Reporting of non-conformance to QA/QC Engineer. Pr