Specification for Quality Assurance

Transcription

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2 Page 2 of 37 CONTENTS PAGE NO. 1. Purpose 3 2. Scope 3 3. Definitions and Abbreviations 3 4. Standard/Specification/Guidelines content 5 5. References Records 24 Appendices 25

3 Page 3 of PURPOSE The purpose of this Specification is to specify the Company's minimum requirements for Quality Assurance in all Contracts and Purchase Orders (Consultants, Contractors, manufacturers and Vendors). This specification is intended to set Company Quality Assurance Standards during design, procurement, construction, commissioning and maintenance phase of facilities. 2. SCOPE This specification presents the Company's minimum requirements for Quality Assurance in all Contracts and Purchase Orders with their nominated Suppliers (Consultants, Contractors, manufacturers and Vendors). The requirements are based on the use of the BS EN ISO 9000 Series of Quality Management and Quality Assurance Standards. The body of this specification is the Quality Assurance Specification and forms part of the Contract or Purchase Order. Definitions and abbreviations used are defined in section 3 and referenced standards are listed in section 5. Appendix A, Contract Quality Plan Guidelines and Appendix D, Quality Control Plan Guidelines, offers Suppliers (Consultants, Contractors, manufacturers and Vendors) guidelines on the contents and development of a Contract Quality Plan and Quality Control Plan, that will meet the requirements of this specification. This specification is not applicable to ex-stock items. 3. DEFINITIONS AND ABBREVIATIONS API ANSI ASME ASNT ASTM AWS BSI BV CAR CEP CFDH American Petroleum Institute American National Standards Institute American Society of Mechanical Engineers American Society for Non Destructive Testing American Society for Testing of Materials American Welding Society British Standards Institution Bureau Veritas Corrective Action Request Contract Execution Plan Corporate Functional Discipline Head

4 Page 4 of 37 CQP CV CSWIP DNV EPC FCAW GME GTAW LRQA IRCA ISO ITP MESC MT NCR NDT PMI PQR PT RT QA QC QCP SAW SMAW SP SUPPLIER TA ToFD TPI UT VT WPS Contract Quality Plan Curriculum Vitae Certified Scheme for Welding Inspection Pesonnel Det Norske Veritas Engineering, Procurement and Construction Flux Cored Arc Welding General Manager Engineering Gas Tungston Arc Welding Lloyds Register Quality Assurance International Register of Certificated Auditors International Organisation for Standardisation Inspection and Test Plan Materials and Equipment Standards Code Magnetic Particle Testing Non-Conformance Report Non Destructive Testing Positive Material Identification Procedure Qualification Records Penetrant Tesing Radiography Testing Quality Assurance Quality Control Quality Control Plan / Inspection Test Plan (ITP) Submerged Arc Welding Shielded Metal Arc Welding Specification Shall refer to the Company's appointed Contractors, Manufacturers and Vendors. Technical Authority Time of Flight Defraction Third Party Inspection Ultrasonic Testing Visual Testing Welding Procedure Specification

5 Page 5 of STANDARD/SPECIFICATION/GUIDELINE CONTENT 4.1 Quality Management System The Supplier (Consultant, Contractor, Manufacturer and Vendor) shall implement and use a Quality Management System that complies with the Standard ISO/TS or ISO 9001 (latest edition), as listed below, and the requirements of this specification. ISO/TS 29001: Petroleum, Petrochemical and Natural Gas Industries Sector specific quality management systems --- Requirements for product and services supply organizations or BS EN ISO 9001: Quality Systems - Model for Quality Assurance in design development, production, installation and servicing. Suppliers shall attain Third Party Registration of their Quality Management System. Certification to ISO 9001 is acceptable. The registration shall be from an Accredited Certifying Body (for example, BSI, BV, DNV, Velosi, TUV, and LRQA etc), who are themselves accredited by a National Accreditation Authority to assess Quality Management Systems. Where Suppliers are not yet certified to ISO 9001, they shall demonstrate that they have a Quality Management System that complies with any of the above. Consideration should be given to attaining Third Party Registration as a means of maintaining the Quality System and verifying compliance with this specification. 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. If any part of the Contract is Sub-Contracted, the Supplier shall comply with Clause 4.1 in ISO 9001, which requires the Sub-Contractor to maintain an appropriate Quality System. The Sub- Contractor shall implement a Quality System that meets the requirements of ISO 9001 / ISO/TS 29001, as appropriate for the sub-contracted work. The Supplier shall remain ultimately responsible for the quality of the Sub-Contractor's work. 4.2 Quality Management during the Contract Execution For Contract Activities : Quality management System as described in the CQP shall be implemented for EPC projects, Engineering Contracts, Maintenance Contracts etc., and no work shall start unless the Company approves CQP. ITPs, procedures and verification personnel appropriate to work being executed shall be approved by the Company. This shall also apply to sub-contractor activities.

6 Page 6 of Contract Quality Plan As a minimum, the requirements specified in Appendix A shall be fulfilled. The Supplier shall have a nominated Management Representative (MR), who shall have defined responsibility for the Corporate Quality System, in accordance with ISO/TS / ISO The roles and responsibilities of the MR shall be stated in the Contract Quality Plan Inspection and Test Plans Construction / manufacturing activities shall be clearly identified and the supplier shall prepare quality control plans and submit for review and company approval. Subcontracted activities shall be clearly identified and subcontractors shall prepare quality control plans for review by the contractor and approval by the company. A pre-commissioning quality control plan shall be submitted to company for approval not less than three month prior to commencement of pre-commissioning. Subcontractor s activities, where involved for pre-commissioning shall be clearly defined in the QCP. For all Package and bulk products (including MESC items), ITPs shall be approved by the Company. The requirements specified in Appendix D shall be fulfilled. The Company has the right to identify in the ITP the review, surveillance, witness and hold points Contract Quality Management System Review 4.3 Documentation In major EPC contracts, the supplier shall ensure that the Contract Quality Management System is reviewed at frequency of not more than three months till the end of the contract. The frequency of such review shall be based on nature and type of contract, duration etc. and shall be agreed during Quality kick off meeting. The Corporate Quality Manager shall participate in the review meeting. Areas of concern or weakness are to be identified in the Quality Management System and actions recommended to be recorded in minutes of meeting Contract Documentation Requirements (General) All documentation related to the Quality Management System shall be available at the location where work is being carried out. The Supplier shall maintain the latest revision of the relevant Contract Documents, Drawings, Technical Specifications, International Standards, CQP, ITPs, Procedures and Work Instructions, etc. at the location where work is being carried out. The Contract Quality Plan, quality control plans, WPS, PQR, and NDT, painting procedures for individual parts of the work shall be submitted for approval not less than two months prior to commencement of work. Procedures, work instructions and checklists to be used in a contract is listed in Aneexure C. The following documents shall be approved by the Company authorities as stated below:

7 Page 7 of 37 Sl No: Document Description Approval Authority 1 CQP, ITPs & NDT Procedures QA Specialist / QA Engineer 2 CVs of NDT Engineer, Welding Engineer, QA Engineer and QA Manager QA Specialist or QA Engineer 3 CVs of other Quality Verification personnel QA Specialist / QA Engineer 4 WPS/PQRs & Welding related procedures QA Specialist / QA Engineer 5 Method statements (Site related) & Relevant discipline Engineer Procedures 6 Engineering Drawings & Deliverables Discipline Engineer 7 Non-standard MESCs Engineering & Quality Discipline 8 Deviations from Contract technical specifications 9 Material selection reports, painting/coating procedure and ITPs, GME Materials & Corrosion Engineer 10 Design Basis Discipline Engineer 11 Project material specifications Materials & Corrosion Engineer Deviation from Company approved Manufacturers, Suppliers, Stockists & Vendors Commissioning Procedures, ITPs and Manuals GME Head of Commissioning & QA Engineer Transmittal of Documents All documents shall be submitted to company under cover of transmittal forms and the company shall return documents likewise. The sequential numbering of these transmittal forms shall be agreed by both parties Document Control Register The document register shall list all drawings, documents and other deliverables related to the work and including documents prepared and submitted by vendors and subcontractors. Document Control Register shall update on a regular basis and shall form part of the monthly progress report Documents For Approval One copy of FOR APPROVAL documents and letters which contractor submits to authorities, third parties shall be submitted to company FOR INFORMATION and all subsequent correspondence regarding such approvals shall also be submitted for information to company.

8 Page 8 of 37 The contractor shall submit to company FOR INFORMATION and update every two weeks a report indicating contractor s forecast dates of issue FOR APPROVAL of all relevant documents Submission and Approval of Design Deliverables Company review and approval of design deliverables shall be based on the agreed/approved design deliverable matrix As Built Documents Contractor shall keep accurate records of changes made in the field. Drawings required to be AS BUILT shall be continuously updated during construction, commissioning, and initial operations and guarantee period. The AS BUILT exercise shall be performed at the contractor s construction site offices. Pipelines (including spur lines) as built alignment survey work shall be completed by a qualified surveyor. The as built revision of pipelines, and spur lines shall include and not limited to all design drawings complete with clear details and dimensions before trenches are filled to allow top of line and coordinates to be accurately reflected and to mark-up AS BUILT information of underground piping, trenches and foundation locations. Pipeline survey methods shall be as such that positioning accuracy of +/-10cm and elevation accuracy of better than +/-20cm. The survey work shall be done using either Real Time Kinematic (RTK) GPS survey technique or conventional survey equipment. Survey techniques and equipment shall be approved by Company before commencement of survey. Copies of all documents required to be AS BUILT shall be submitted by contractor to company in an agreed format Final Documentation Final documentation shall be provided following completion of the AS BUILTs. As minimum, final documentation shall include the latest revision of all design, construction, operating and maintenance manuals, drawings and documents. Prior approval shall obtained for the final document dossier index Vendor Drawings and Equipment Files Vendor Documents requiring Suppliers approval shall be stipulated in the purchase order and it is the responsibility of supplier to submit the vendor documents for Company review/approval. Supplier also shall ensure that vendor and subcontractors comply with the requirements specified in OGC procedure for Drawing, Document Numbering & Equipment tagging Procedure (GME-QS-L3-312). Supplier shall provide each vendor document with proper company drawings number, requisition number and unit/equipment numbers.

9 Page 9 of Drawing and Equipment Files Supplier shall maintain files of all drawings, requisitions and SPIR lists in numerical order. The organization of both drawing and equipment files shall be as per OGC procedure for Drawing, Document Numbering & Equipment tagging Procedure GME-QS-L Where deemed necessary, documentation related to the Quality Management System shall be available at the location where work is being carried out. The Supplier shall maintain the latest revision of the relevant Contract Documents, Drawings, all Contract Technical Specifications, International Standards (BS, DIN, ASME, API etc.), Procedures and Work Instructions, at the location where work is being carried out Quality Assurance The contract quality plan shall cover all phases of the contract and describe how the supplier shall interpret, implement, execute and maintain the project specific requirements into his, his subcontractors and vendors quality assurance system. Subcontract quality plans should be submitted within 30 days from the award of subcontract and shall be reviewed and approved by the company. The plan is to include details how Supplier will manage subcontractors and vendors. Supplier shall identify high risk quality issues specific to the work and describe measures to eliminate/control these focused areas. All critical quality issues/risks shall be identified in the contract quality plan. The supplier shall compile a comprehensive quality audit schedule for the work which shall cover all phases of the work and including all audits on contractor, subcontractor and vendor. The supplier shall submit detailed proposals for the quality audits, including the commencement and completion date for each audit. The Company reserves the right to attend any or all of these audits. The audit report should be submitted within two weeks and any alteration in commencement date shall be subject to ten working days prior notice. The supplier should clear all audit action items within 21 working days of the issue of the report. Status of close out and follow-up shall be reported in the normal project progress reports Procedures for Suppliers The supplier shall develop a communication plan taking company s requirements into account. The plan must include a document and information flow matrix.

10 Page 10 of Meetings and Records Formal meetings at discipline and company representative level shall be held regularly on a weekly basis. A weekly progress meeting will be held to allow the supplier to present and discuss the weekly and overall status of the project. Progress review meetings will be held between the parties or as requested by the Company. MOM shall be prepared by the supplier representative and forwarded to the Company Representative within two working days after the meeting. Frequency, format of Minutes of Meeting and numbering system shall be agreed during project kick-off meeting Site / Engineering Queries and Deviation Requests A Query or Deviation Request shall be routed through the suppliers Engineering or Project/Construction Manager. Deviation request shall comply to the requirements identified in Company procedure for Technical Deviation (GME-QS-L3-311) and all Query and Deviation Request shall itemize the relevant document references, supplemented with justification and shall provide all details of the query/request concerned and all supporting drawings, sketches, calculations shall be attached. The query or Deviation Request may be submitted by to company discipline engineer. The formal request shall be submitted to the company document controller. The company should provide a response to the supplier within 15 working days from the day Document Controller has received it. The supplier shall maintain a register for all engineering queries and deviation requests. All outstanding queries and deviation requests shall be reported by the supplier in the weekly and monthly report until closed out by Company Progress and Reporting The detailed format and content of progress report on a specified frequency shall be developed by supplier and approved by the company. All pivotal project reports shall include a section where current risk management is reported in an open and transparent manner. Risk management reporting shall include key project objectives including HSE, Quality, Schedule, Cost, and Reputation. Auditable progress measurement procedure for calculating both planned and actual physical progress shall be developed by supplier. The progress is measured by physical measurable criteria for each work packages and shall be based on assigning weightings to each activity or sub-activity. 4.4 Qualification and Duties of the Suppliers Quality Assurance, Inspection (Quality Control) and verification personnel Competency of verification personnel Verification personnel working for the supplier at during contract execution shall

11 Page 11 of 37 be approved by the company as stated in Table-1. The verification personnel should have previously worked on similar Contracts in similar capacities and shall have formal qualifications (e.g. CSWIP, AWS, and British Gas or equivalent which is acceptable to Company) as appropriate. Supplier shall establish and maintain the records to demonstrate that all verification personnel are competent Quality Verification Personnel The Supplier shall assign and deploy competent Verification Personnel for the Contract to ensure that the Quality Management System and Quality Control are effectively established, implemented and maintained throughout the Contract. There shall be sufficient verification personnel to cover all disciplines work and activities, all Sub-Contractor's work at the site and off site facilities. This shall be clearly documented along with their responsibilities and authorities in the CQP. They shall be independent of the work being performed and shall have no other duties or responsibilities. The Supplier shall assign at least one dedicated QA/QC Engineer for each contract and located at work site. The QA/QC Engineer shall functionally report to the Supplier s Corporate QA Manager on all Quality and technical matters and report to the Site Manager on day to day activities. The actual staffing levels will depend on the work load, complexity of the work, number of disciplines working on the Contract at any one time, number of Sub-Contractors, the number of locations where work is being carried out on site/off site and the quality performance of the contractor. The Supplier shall prepare a QA/QC personnel resource plan on a monthly basis to cover all verification activities as required by ITP. The use of multi-disciplined Inspectors is acceptable provided they have appropriate qualifications in each of the disciplines they are required to inspect. The adequacy of the QA/QC resources shall be reviewed by the Company representatives at sites during progress review meetings. Company decision regarding QA/QC staffing shall be final and binding on the Supplier and its Sub-Contractors. The minimum qualification & experience requirements of QA/QC personnel shall be as detailed below, unless otherwise stated in the contract/purchase order: QA/QC Manager (Head Office/Site) Qualifications Table - 1 Duties Shall be a Graduate Engineer (B.Sc. Eng. / BE/B.Tech.) either in Mechanical / Metallurgical / Welding / Electrical / Instrumentation/Civil engineering as appropriate. Shall be an IRCA, UK Registered Lead Assessor or equivalent (where equivalent is proposed, Supplier Shall be responsible for advising, guiding and motivating site line management on all QA and QC activities and related technical matters. Shall be responsible for implementation, operation and maintenance of project Quality Management System in compliance with ISO 9001.

12 Page 12 of 37 shall provide evidence of equivalence from International Accreditation Body (ies)). Shall have minimum of 15 years of relevant experience in onshore oil and gas facility construction, including live installations. Out of 15 years of experience, 5 years of experience shall have gained in the Middle East. He shall have a minimum of 5 years management experience in establishment, operation and maintenance of quality management system in accordance with ISO/TS / ISO 9000 with the capability of developing quality system, quality plans, work procedures and inspection plans. Shall be responsible for relevant QA and QC training for all site personnel and overseeing all personnel understand and effectively deliver their QA and QC responsibilities as per quality plan and procedures. Shall report to highest executive management within the organisation to ensure authority and freedom to execute assigned responsibilities. Shall have sound knowledge in quality management aspects within various technical disciplines and shall be familiar with standards and codes used in oil and gas industries. Shall have sound technical knowledge in materials, welding, coating/painting, NDE inspection and general construction activities involving civil, electrical and instrumentation works. Shall have experience of working to and fully familiar with codes and standards such as from ANSI, ASME, ASTM, API and BS codes used in oil and gas industries Welding Engineer Qualifications Duties A post graduate qualification in Welding Engineering or shall be registered as European Federation Welding Engineer. Demonstrated sound technical knowledge and extensive experience in welding processes (SMAW, SAW, GTAW, GMAW, and FCAW etc.), materials, welding and fabrication methods in onshore oil and gas industry. Expert knowledge in welding of high strength pipeline steels used in oil and gas industry is must. Sound technical knowledge of corrosion / fracture / fatigue / creep / embrittlement behaviour of welded joints and materials used in oil and gas industry. Demonstrated capability in preparation of WPS, selection of welding consumables; ability to undertake weldment failure analysis; welding related problems diagnosis and solutions; qualification of welding procedures. Welding Inspection Personnel qualifications such as CSWIP/AWS shall not substitute as an acceptable qualification for Welding Engineer in lieu of the requirements given above. Review and approve vendor s/ contractors proposed welding procedure specifications, construction welding procedure specifications and procedure qualification records. Guiding Corrosion and materials departments on the material selection with respect to welding Advising and guiding Contractor s in developing and qualifying welding procedure specifications Developing Welding specifications to ensure integrity of equipment and facilities used in OGC. Review and modification of existing welding specifications based on field experience and developments taking place in oil and gas industry. Carrying out failure analysis and finding solutions to welding related problems. At least 6 years relevant experience in the construction of onshore oil & Gas or Petrochemical industries facilities (pressure vessels, tanks, mechanical fabrication, pipelines, piping etc.) including live installations. Out of 6 years

13 Page 13 of 37 experience, 2 years of experience should have gained in the Middle East preferably in Oman environment. Experience of working to and fully conversant with international codes (ANSI/ASME, ASTM, API, BS, EN, MSS, ISO, etc.) used in oil and gas industry QA/QC Engineer (QA/QC in-charge at head office or construction site) Qualifications Shall be a Graduate Engineer in relevant discipline Shall have qualification as Lead Assessor (IRCA Registered or equivalent that is acceptable to Company Quality Management Services) Shall have minimum of 6 years of relevant experience in oil and gas facility construction. He shall have a minimum of 2 years management experience in establishment, operation and maintenance of a quality management system in accordance with ISO/TS / ISO 9000 or equivalent with the capability of developing quality system, quality plans, work procedures and inspection plans. Shall have supervisory skills Shall have in depth technical knowledge of inspection and exposed to multi discipline works of oil and gas construction field. Duties Preparation, implementation, monitoring, revision and updating of the Supplier s Contract Quality Plan. Development, preparation, implementation and monitoring of all Contract Specific Procedures and Work Instructions. Review and Monitoring Sub-Contractor s Quality Systems and quality performance. Preparation, implementation, revision and monitoring Quality Control Plans (QCP/ITP). Maintaining of Quality records. Reporting Quality activities. Liaison with the Company on matters related to Quality. Shall be fully familiar with relevant codes used in oil and gas industries. Auditing - internal and external, and follow up of Corrective Actions. Shall be completely familiar with Supplier's Corporate Quality System. Overall control, supervision and implementation of Contract quality and technical requirements; resolution of quality problems; preparation and maintenance of Contract quality records NDT Engineer * Qualifications * If requested in the contract Duties A graduate qualification in Engineering and shall have qualifications as NDT Level III in accordance with ISO 9712 in methods, RT, UT, PT, MT and VT. Demonstrated sound technical knowledge and extensive experience in methods RT, UT, PT, MT and VT. Review and approve vendor s/ contractors proposed NDT procedures Advising and guiding Contractor s in developing and qualifying NDT procedures Witnessing of NDT Shall have sound technical knowledge of TOFD, Phased array UT, long range UT, digital radiography, radioscopy etc. Qualification on above techniques required when project is using any of these techniques. Shall be fully familiar with B scan, C scan and D scans (Computer image techniques) of UT Developing NDT specifications to ensure integrity of equipment and facilities used in OGC. Review and modification of existing NDT specifications based on field experience and developments taking place in oil and gas industry.

14 Page 14 of 37 Shall be fully familiar with corrosion mapping using MFL, UT etc Analysis of NDT data and reporting results. Knowledge of application of UT on coarse grained materials. Demonstrated capability of preparation and qualification of NDT procedures At least 6 years relevant experience in the construction of onshore Oil & Gas or Petrochemical industries facilities (pressure vessels, tanks, mechanical fabrication, pipelines, piping etc.) including live installations. Out of 6 years experience, 2 years of experience should have gained in the Middle East preferably in Oman environment. Experience of working to and fully conversant with international codes (ANSI/ASME, ASTM, API, BS, EN, MSS, ISO, etc.) used in oil and gas industry Quality Control Inspector - (Welding/ Painting/ NDT/GRE) Qualifications Duties Shall be Diploma or Graduate Engineer in Mechanical or Metallurgical Engineering. and shall have a minimum of 4 years of inspection experience in construction industries out of which 2 years shall be gained in oil and gas facility construction. Implementation of QA/QC activities including those of sub-contractors works in accordance with approved QCP /ITPs and Procedures, method statements and other contract documents. Welding Inspector shall possess CSWIP 3.1 / AWS for welding inspection or equivalent acceptable to Company Quality Management Services and Certified to ASNT level II in RT, PT, MT and UT techniques. Painting Inspector shall possess BGAS / ERS III or equivalent in NACE for painting inspection or equivalent acceptable to Company Quality Management Services. Maintaining records of calibration, inspection and testing equipment. Maintaining the latest revision of all Contract Documents, Drawings, Specifications, and Standards, required for Quality Assurance, Quality Control and inspection. NDT Inspector shall be Certified to ASNT level II in RT, PT, MT and UT techniques. Witness procedures, tests and certify the results. For Fusion Bonded Epoxy (FBE) or Shrink Sleeve or Glass Reinforced Epoxy materials works, Supplier shall mobilise and deploy personnel appropriately qualified, suitably trained and formally certified (contractor s established certification schemes may be accepted if agreed by Company) for verification of these works. GRE Inspector shall have worked as GRE fitter/bonder or supervisor for a minimum of 1 year. Provide sufficient feed back to QA/QC Engineer on the day to day quality issues QC Inspectors - Civil and Structural Qualifications Duties Shall be Diploma or Graduate Engineer (B.Sc. Eng. / BE / B.Tech/ ) in Civil engineering. Shall have a minimum of 4 years of quality control and inspection experience in construction industries. The experience shall include works involving soil excavation Implementation of QA/QC activities including those of sub-contractors works in accordance with approved QCP /ITPs and Procedures, method statements and other contract documents.

15 Page 15 of 37 and earth works, concrete works, block works, structural steel works and roofing, roads and paving, tank pads and bunds and general activities associated with civil and building works. Shall be thoroughly familiar with civil construction materials and construction methods, testing of civil construction materials, international codes and standards for civil design, construction and testing of materials and works. Witnessing tests and maintaining records of tests, calibration, inspection and testing equipment. Maintaining the latest revision of all Contract Documents, Drawings, Specifications, and Standards, required for Quality Assurance, Quality Control and inspection. Provide sufficient feed back to QA/QC Engineer on the day to day quality issues QC Inspectors - Instrumentation Qualifications Duties Shall be Diploma or Graduate Engineer (B.Sc. Eng. / BE / B.Tech) in Electronics / Instrumentation engineering. Shall have a minimum of 4 years of quality control and inspection experience in construction industries. The experience shall include electronic and pneumatic equipment including analogue and digital control systems, relay based and solid state logic systems, transmitters, control valves and accessories. Shall be thoroughly familiar with instrument construction materials and construction methods, testing of instrumentation and installations, international codes and standards for instrumentation design, construction and testing of facilities and works. Implementation of QA/QC activities including those of sub-contractors works in accordance with approved QCP /ITPs and Procedures, method statements and other contract documents. Witnessing tests and maintaining records of tests, calibration, inspection / testing equipment. Maintaining the latest revision of all Contract Documents, Drawings, Specifications, and Standards, required for Quality Assurance, Quality Control and inspection. Provide sufficient feed back to QA/QC engineer on the day to day quality issues Q C Inspectors - Electrical Qualifications Duties Shall be Diploma or Graduate Engineer (B.Sc. Eng. / BE / B.Tech) in Electrical engineering. Shall have a minimum of 4 years of quality control and inspection experience in construction industries. Shall be thoroughly familiar with electrical construction materials and construction methods, testing of electrical equipment and installations, international codes and standards for electrical design, construction and testing of facilities and works. Implementation of QA/QC activities including those of sub-contractors works in accordance with approved QCP /ITPs and Procedures, method statements and other contract documents. Witnessing tests and maintaining records of tests, calibration, inspection and testing equipment. Maintaining the latest revision of all Contract Documents, Drawings, Specifications, and Standards, required for Quality Assurance, Quality Control and inspection. Provide sufficient feed back to QA/QC engineer on the day to day quality issues Auditors The auditors shall possess the following qualifications and shall have conducted minimum 10 relevant audits. For External Audits 5 day course, IRCA, UK registered. or equivalent acceptable to Company For Internal Audits - 2 day course IRCA, UK registered. or equivalent

16 Page 16 of 37 acceptable to Company Company s Inspector Roles & Responsibilities. Inspector (QA/QC Inspector & TPI) roles and responsibilities shall be as follows but not limited to: Qualification and experience shall be in the same discipline/field to the product/service getting inspected. Verify the product conformance to contractual requirements at various stages of the fabrication/manufacturing as stated in Company approved ITP and applicable technical specifications. Review quality documentation to verify product conformance to contractual requirements. Carry out surveillance inspections to verify processes and procedures compliance. Issue Release Note of Product/ Sign test packs (QA/QC dossier). The role of the company s Inspector/TPI shall be limited to surveillance role, unless stated otherwise in the Company approved ITP. To monitor manufacturers/contractors activities with respect to quality performance. The signature of the Company s (QA/QC Inspector/TPI) shall be taken as he/she verified and accepted the details in the document reviewed. The signature of the Company s (QA/QC Inspector/TPI) shall not absolve the supplier s responsibilities to supply the product that meets contractual requirements. 4.5 Procurement Requirement Criteria for Vendor selection, evaluation and re-evaluation Generally the Supplier shall only purchase products and services from Company approved sources. Lists of approved sources (Contractors/Suppliers and Vendors) are available from the Company. The Supplier shall be accountable for procurement of materials that fully comply with the Company specifications and shall be able to demonstrate the material complied to Company specifications at all stages by having a quality management system, vendor scrutiny, and inspection. Records shall be established and maintained to demonstrate the ability of vendors to supply such items meeting Company technical specifications. The Company reserves the right to inspect products or services purchased by the Supplier from Sub-Contractors (or Vendors). Verification or Inspection by the Company is not a substitute for verification by the Supplier nor absolve the Supplier of its contractual obligations. Hold, Review and Witness Points shall be identified in the Quality Control Plans for Supplier, Sub-Vendor, Third Party Inspector / Authorised inspector and Company. Company shall be given at least 15 working days notice to attend such verifications. Company will not be responsible and will not accept any delay due to the rejection of items during the verification process. Procurement of material by the Supplier from Company approved vendor list does not absolve the responsibility of the Supplier from supplying material meeting relevant specification.

17 Page 17 of Verification of purchased product Inspection level based on criticality rating of purchased materials shall be included in all purchase specifications and purchase orders. The Supplier is responsible for ensuring material certification of all pressure retaining and non-pressure pressure retaining materials, component, items meet the requirements of applicable design code Material Group Standardization The Supplier shall ensure that material group standardization is enforced on all vendors of purchased equipment and also ensure that vendors also standardizes on his sub-contractors across the same material groups. Supplier shall specify standardized components to the package vendor, such that they conform to the standardized selection of tagged items and field bulk materials. This approach shall equally apply to the Main Automation scope of supply also Approved Vendor List (AVL) Company shall reject any materials that have been supplied by an un-approved vendor on the AVL list. Any amendments to the AVL list shall be subject to company approval. Suppliers who proposing a new vendor other than available ones from AVL, then they need to approach company well in advance with sufficient details for vendor approval. Company reserve the right to accept or reject the proposal Materials and Equipment Standards and Codes (MESC) Types, sizes and quantities of Materials recognized as Standard by company are listed and coded in the MESC code numbers. Contractor/Supplier/vendor shall comply with the MESC standards for the procurement of materials. Any deviation from MESC shall be submitted to company for approval together with proposed alternative Life Cycle Cost Methodology For EPC contracts having major procurement scope, Total life cycle cost analyses concept shall be employed to all rotating equipment. The contractor shall maintain an auditable system, which demonstrates that all life cycle costs have been evaluated and that bids have been awarded on the basis of lowest overall life cycle cost Procurement Management Manual For EPC contracts having major procurement scope, the Supplier shall produce and maintain a Project Procurement Management Manual which shall contain method statement, detailed procedure specific to the contract and specimens of all standard forms. The procedures must fully reflect the requirements of the contract with respect to standardization and the use of Omani goods and services.

18 Page 18 of Criticality Rating For EPC contracts having major procurement scope, the Suppliers shall establish and document Control measures for establishing criticality rating of purchased materials, items or components. Criticality rating of purchased materials, items or components shall be included in all buying descriptions. The criticality rating procedure shall be approved by Company Project Procurement Control Contractor/Supplier shall develop an Integrated Materials Planning and Tracking system. The system shall form the basis for all procurement tracking and reports. The company may review the system for its applicability Requisitions All requisitions shall be prepared in accordance with applicable drawings, specifications and standards. Requisitions shall be clearly marked or stamped with status, for comments, for enquiry or for purchase Purchase Orders and Agreements Purchase orders for all tagged items of equipment, packaged or skid units shall include the following requirements (production/delivery schedule, quality manual and quality control plan, manufacturing report, SPIRS, completed data/requisition sheets, drawings, calculations and design documentation, equipment installation, operation and maintenance manuals. Supplier shall ensure that all vendor documents have the company project reference in front page company drawing number, and purchase order, requisition number, unit/equipment tag numbers which meet the requirements of OGC procedure for Drawing, Document Numbering & Equipment tagging Procedure GME-QS-L Assignment of major equipment Purchase Order The Supplier shall engage a third party to perform inspection of the major equipment packages. Selection of third party shall be from Company approved list and approval shall obtain from company prior to mobilization. All costs for the third party inspection shall be included in the contract price. The supplier shall appoint one person within his organization who shall be responsible for managing the execution of the Purchase Order Expediting Supplier shall submit a written expediting report to company following visits to subcontractors/vendors within five working days. Supplier shall maintain and issue weekly a critical materials list for information. The list shall be covered by a narrative report which shall highlight the important changes from the previous report.

19 Page 19 of Packing and Transportation All packing of equipment and materials shall be in accordance with Company approved procedure Receipt, Inspection and Storage 4.6 Third Party Certification Inspection shall be undertaken by qualified personnel and shall include verification of dimensional correctness and material certification, and a check for shortage and damage. All materials and equipment shall be fully identified showing identification number and abbreviated description. All piping/fitting shall be colour coded and shall strictly segregate material groups. The contractor shall maintain storage conditions for all materials as per specification / supplier recommendations. Where Third Party Certification is specified in the Supplier s Scope of Work in the Contract, the Supplier shall use one of the following Third Party Certification Authorities as a Sub-Contractor: The Supplier shall ensure that the TPI agency is suitable for the scope of work and personnel deployed to certify are competent. AIB Vincotte International Ltd. American Bureau of Shipping Services Inc. Bureau Veritas Det Norske Veritas Germanischer Llyod Lloyds Register of Shipping TUV Applus Velosi Where the Company will deploy a Third Party Inspection agency to represent the Company in addition to the Supplier s TPI, the Supplier shall not use the same Inspection agency as the one used by the Company In order to assure conformance to the order requirements, the Supplier shall ensure that the Third Party Inspection Agency carries out the following activities as a minimum: Endorse the Supplier s Quality Management System and Inspection & Test Plan as and when required. Endorse the Supplier processes, procedures are effective in meeting product requirements as and when required. Carry out audits, surveillance, inspection and witnessing sufficient to ensure specified requirements are met and to enable Certification to be issued as and when required. Ensure the Supplier personnel including QA/QC personnel are suitably qualified and competent as and when required Ensure Purchase Order technical requirements are met

20 Page 20 of 37 Ensure proper test & inspection equipment is used, calibrated and certified. Endorse inspection certificates Comply with the ITP requirement with respect to review/witness/hold points process Where the Company employs the Inspection Agency, they shall act on behalf of the Company and shall have the same access to the Supplier s Quality System as the Company for the above documentation and reports for certification purposes. Components certified by TPI, shall be issued as 3.2 certificates in accordance with BS EN or equivalent certification in accordance with ISO Pressure Vessels shall be coded and constructed to in accordance with ASME Section VIII. 4.7 Project/Construction Management Project Management Organization The contract management team shall include one representative each from engineering, procurement, construction, commissioning, operations, HSE, quality assurance and project services. The contractor shall provide a project manager who shall be required to move to the construction site during construction. The contractor s project organization shall be documented in the Contract Execution Plan (CEP) Key Personnel In the case of key personnel replacement the contractor shall ensure that there shall be a two week hand-over period. All leave greater than five (5) consecutive days of key personnel shall be subject to company approval Contract Execution Plan The requirement of CEP shall be based on size, nature, type and duration of contract. At least 60 calendar days prior to the start of site mobilization the CEP shall be resubmitted with a detailed construction plan which is similarly required to be approved by the company. A typical Contract Execution Plan index is attached as Annexure B with this specification Contract Monthly Reports Quality Statistics The following Quality matters shall be reported in the Contract Monthly Report for EPC projects as well as other Contracts: Summary of Contract Quality Documents development and Procedure development and approvals. Contract Quality Management review minutes of meeting Summary of Internal and External Audits carried out and reported against the Audit Schedule. Up-dated audit tracking system Listing of Corrective Actions for each Audit, the current status and the planned dates for follow up and closeout.

21 Page 21 of 37 Details of any investigations into nonconformance and action to prevent recurrence of any Quality System failures. KPI/project objective reviews Summary of Tests and Inspections carried out on site and off site including those on Sub-Contracted activities. Shall include statistics that indicate quality trend from the start of contract for the following as a minimum: a) Number of Customer Complaints. b) Deviations raised. c) Product NCRs. d) Welder performance and repair rates based on radiography. e) Status of deployment of QA and QC resources against the resource plan. f) Rework and repairs carried out. g) Measuring and monitoring Equipment register with calibration details Process Control and Monitoring All welding, QA and related activities (e.g. PWHT, NDT) shall satisfy the requirements of ISO /2 as appropriate. Guidance is given in ISO Special processes (e.g. welding, painting, coating, NDE, GRE bonding, Concreting, grouting, HDPE fusion bonding, cable jointing, glass flake lining etc.) shall be carried out under supervision of a person, who has the experience and qualifications. All special processes shall be executed in accordance with documented and qualified procedures that ensure work is complying with company technical specifications. The Supplier shall keep a card index or register of all approved welders/jointers. The register shall give information on training of the welders/jointers and date and results of qualification tests. The Company shall be allowed to examine the register at any time. The procedure qualification tests for special processes, welder, jointer, NDT technician, painter etc. performance qualification tests shall be witnessed by Company representative or by company approved Third party inspection agency as identified in clause 4.6 of this specification. Personnel employed by the Third Party Certification Authority shall have qualifications and experience at least equal to that specified for the Supplier s Quality Assurance Engineer and Inspection personnel. Where the Company employs the Third Party Certification Authority, they shall act on behalf of the Company and shall have the same access to the Supplier s Quality System as the Company. Process control documents as required by the Contract shall be submitted well in advance prior to commencement of the activities for review and approval (as applicable and as stated in the Contract). They shall be available at the location where the activities are carried out Identification and Traceability Identification and traceability of materials, component and equipment shall be maintained and documented throughout the pre-fabrication and installation process for all pressure retaining components and non-pressure retaining components welded to

22 Page 22 of 37 pressure retaining components including welding consumables, paints, coatings, adhesives etc. The Supplier is responsible for ensuring identification, colour coding and material traceability including Positive Material Identification (PMI) meeting the project standards and specifications Control of monitoring and measuring equipment Measuring and test equipment used to monitor special processes shall have documented calibration status Internal / external audit For major projects (where duration is more than a year) The Supplier/Contractor shall carry out audits on major sub-contractors/vendors, where applicable on every project at the following project phase stages covering all activities at all work locations: 30% of project completion but before completion of design phase 65% of project completion but before completion of procurement phase 90% of project completion but before completion of construction phase For projects having less than twelve month s duration, one audit covering all activities may be sufficient. The Company s project representative may participate in all Suppliers internal audit specific to Company s contracts as an observer. An Audit Schedule shall be included in the Contract Quality Plan, which shall be approved by the Company. The Audit Schedule shall include External Audits carried out by the Supplier on Sub-Contractors. The Supplier shall ensure that the Auditors are qualified and have sufficient experience in the areas audited. The Company Quality section and Project team shall be notified to participate in internal audits, external audits on subcontractors/vendors and third party certification audits on the Company s contracts as an observer. The audit notification shall be delivered to Company Quality section at least two weeks in advance of the audit date. The audit reports shall be issued to the Company not more than 2 weeks after the audit. The audit report distribution to Company shall include; Project Manager / Project Engineer Company Site Representative Engineering Services Manager The Company reserves the right to carry out scheduled or unscheduled External Audits, Reviews and Surveillance of the Supplier, Sub-Contractors and Vendors. The Supplier shall maintain a tracking system of all Corrective Action Requests / Non Conformance Reports raised during Internal and External Audits and Third party certification audits including audits carried out by the Supplier on subcontractors. The