Professional Documents
Culture Documents
MANAGEMENT SERVICES
Discipline Code:
General
Bid. No.:
STC-1030
Doc. No:
004/AI-TQ-QMS-16
Rev.0
CLIENTS :
PT PHE ONWJ
PROJECT TITLE :
TECHNICAL SERVICES
CONTRACT
FOR PROJECT
ENGINEERING
AND
CONSTRUCTION
MANAGEMENT
SERVICES
PHE TOWER, Jl. TB Simatupang Kav. 99, Jakarta
LOCATION :
PT ALDABERTA INDONESIA
REV.
DESCRIPTION
IFA
CLIENT
DATE
BY
CHKD
APVD
25/09/2016
JR
RP
ESA
CHKD
APVD
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TABLE OF CONTENTS
INTRODUCTION.........................................................................................................................................9
PROJECT OVERVIEW ................................................................................................................................ 9
SCOPE AND PURPOSE OF THE QUALITY PLAN ............................................................................... 10
REFERENCES ............................................................................................................................................ 10
DEFINITIONS ............................................................................................................................................ 11
Contract ........................................................................................................................................... 11
Project.............................................................................................................................................. 11
Procedure ......................................................................................................................................... 11
Product............................................................................................................................................. 11
Quality Plan ..................................................................................................................................... 11
Quality System ................................................................................................................................ 11
CONTRACTORS PROJECT QUALITY POLICY .................................................................................. 12
PROJECT QUALITY POLICY OBJECTIVE ............................................................................................ 13
GENERAL .................................................................................................................................................. 13
ORGANIZATION CHART ........................................................................................................................ 14
MANAGEMENT REPRESENTATIVES................................................................................................... 14
PROJECT MANAGEMENT ON QUALITY ACTIVITIES ...................................................................... 15
Responsibility and Authority ........................................................................................................... 15
Delegation and Authority ................................................................................................................ 17
PROJECT PERSONNEL AND TRAINING .............................................................................................. 17
PROJECT COORDINATION .................................................................................................................... 17
GENERAL .................................................................................................................................................. 18
CONTRACT REVIEW ............................................................................................................................... 18
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Review .......................................................................................................................................... 18
Management of Changes (MOC)..................................................................................................... 19
QA PROGRAM DEVELOPMENT ............................................................................................................ 20
MANAGEMENT REVIEW ....................................................................................................................... 21
GENERAL .................................................................................................................................................. 21
Scope ............................................................................................................................................... 21
Policy and Objective ........................................................................................................................ 21
DOCUMENT CONTROL GENERAL REQUIREMENTS ....................................................................... 22
Responsibility .................................................................................................................................. 22
Document Approval and Issue......................................................................................................... 22
Document Changes/Revision........................................................................................................... 22
Document Numbering and Revision Status ..................................................................................... 22
Listing of Documents ...................................................................................................................... 22
Distribution of Documents .............................................................................................................. 23
Document Filing .............................................................................................................................. 23
Handling of Obsolete Documents .................................................................................................... 23
CONTROL OF COMPANY SUPPLIED DOCUMENTS .......................................................................... 24
CONTROL OF DOCUMENTS PREPARED BY VENDOR ..................................................................... 24
CONTROL OF OUDATED DOCUMENTS .............................................................................................. 24
CONTROL OF DESIGN DOCUMENTS AT THE SITE .......................................................................... 24
GENERAL .................................................................................................................................................. 25
Scope ............................................................................................................................................... 25
Policy and Objective ........................................................................................................................ 25
RECORD CONTROL REQUIREMENTS ................................................................................................. 25
Identification of Quality Record ...................................................................................................... 25
Maintenance and Storage of Records .............................................................................................. 26
Retention and Disposition of Records ............................................................................................. 26
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GENERAL .................................................................................................................................................. 27
Scope ............................................................................................................................................... 27
Policy and Objective ........................................................................................................................ 27
ESTABLISHMENT OF DESIGN INTERFACE ....................................................................................... 27
Design Interface between the COMPANY and the CONTRACTOR ............................................. 27
Design Interface among CONTRACTORS ..................................................................................... 28
Design Interface between Contractor and Vendor ........................................................................... 28
CONTROL OF DESIGN PROCESS .......................................................................................................... 28
Review of Design Input from Company .......................................................................................... 28
Preparation of Design/Engineering's Documents ............................................................................ 29
Review and Approval of Design/Engineering's Documents ............................................................ 29
DESIGN VERIFICATION ......................................................................................................................... 30
CONTROL OF DESIGN CHANGES ........................................................................................................ 30
ENGINEERING HOLD .............................................................................................................................. 31
DESIGN DEVIATION AND/OR ALTERNATIVE .................................................................................. 31
GENERAL .................................................................................................................................................. 31
Scope ............................................................................................................................................... 31
Policy and Objectives ...................................................................................................................... 31
CONTROL OF REQUISITION PREPARATION ..................................................................................... 32
Requisition Preparation ................................................................................................................... 32
Review of Requisition ..................................................................................................................... 33
Selection of Vendor ..................................................................................................................................... 33
EVALUATION AND VERIFICATION OF VENDOR'S PERFORMANCE ............................................ 34
Review and Approval of Vendor's Documents ................................................................................ 34
Control and Verification of Vendor/Subcontractor Performance .................................................... 34
CONTROL OF SUB-VENDORS ............................................................................................................... 35
GENERAL .................................................................................................................................................. 35
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Scope ............................................................................................................................................... 35
Policy and Objective ........................................................................................................................ 35
IDENTIFICATION PROCEDURE ............................................................................................................ 35
RECORD OF MATERIAL ......................................................................................................................... 36
Positive Material Identification ................................................................................................................... 36
GENERAL .................................................................................................................................................. 37
Scope ............................................................................................................................................... 37
Policy and Objective ........................................................................................................................ 37
GENERAL CONTROL OF FABRICATION AND INSTALLATION ..................................................... 37
SPECIAL PROCESS CONTROL............................................................................................................... 38
Welding Process Control ................................................................................................................. 38
Control of Other Special Processes ................................................................................................. 40
Training ........................................................................................................................................... 40
GENERAL .................................................................................................................................................. 41
Scope ............................................................................................................................................... 41
Policy and Objective ........................................................................................................................ 41
ESTABLISHMENT OF INSPECTION AND TEST PROGRAM ............................................................. 41
Inspection Personnel ................................................................................................................................... 43
Inspection Coordinator .................................................................................................................... 43
Inspector .......................................................................................................................................... 43
Vendor Inspector ............................................................................................................................. 43
NDE personnel ................................................................................................................................ 43
CONTROL OF INSPECTION AND EXECUTION .................................................................................. 43
CONTROL OF CRITICAL DIMENSION ................................................................................................. 44
RECORD OF INSPECTION ...................................................................................................................... 45
Scope ............................................................................................................................................... 45
Policy and Objective ........................................................................................................................ 45
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GENERAL .................................................................................................................................................. 50
Scope ............................................................................................................................................... 50
Policy and Objectives ...................................................................................................................... 50
CONSTRUCTION WORK CONTROL PLANNING ................................................................................ 50
SUBCONTRACTOR CONTROL .............................................................................................................. 50
Selection .......................................................................................................................................... 50
Coordination .................................................................................................................................... 51
QC Activities ................................................................................................................................... 51
MATERIAL AND EQUIPMENT RECEIVING INSPECTION ................................................................ 52
ENVIRONMENTAL CONTROL .............................................................................................................. 53
GENERAL .................................................................................................................................................. 53
Scope ............................................................................................................................................... 53
Policy and Objective ........................................................................................................................ 53
STATIC AND DYNAMIC COMMISSIONING ........................................................................................ 54
PRE-COMMISSIONING VERIFICATION ............................................................................................... 54
PLANT COMMISSIONING ...................................................................................................................... 54
COLLECTION OF DATA, EVALUATION AND RECORD ................................................................... 55
GENERAL .................................................................................................................................................. 55
Scope ............................................................................................................................................... 55
Policy and Objective ........................................................................................................................ 55
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GENERAL .................................................................................................................................................. 56
Scope ............................................................................................................................................... 56
Policy and Objective ........................................................................................................................ 57
NON-CONFORMANCE CONTROL & CORRECTIVE ACTION........................................................... 57
GENERAL .................................................................................................................................................. 59
Scope ............................................................................................................................................... 59
Policy and Objective ........................................................................................................................ 59
HANDLING OF CUSTOMER COMPLAINT ........................................................................................... 59
GENERAL .................................................................................................................................................. 60
Scope ............................................................................................................................................... 60
Policy and Objective ........................................................................................................................ 60
INTERNAL AUDIT ................................................................................................................................... 60
EXTERNAL AUDIT .................................................................................................................................. 60
HANDLING OF AUDIT RESULTS .......................................................................................................... 61
GENERAL .................................................................................................................................................. 61
Scope ............................................................................................................................................... 61
Policy and Objective ........................................................................................................................ 61
CORRECTIVE AND PREVENTIVE ACTION ......................................................................................... 61
LESSONS LEARNED ................................................................................................................................ 62
GENERAL .................................................................................................................................................. 62
Scope ............................................................................................................................................... 62
Policy and Objective ........................................................................................................................ 62
MANAGEMENT REVIEW MEETING ..................................................................................................... 62
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GENERAL .................................................................................................................................................. 63
Scope ............................................................................................................................................... 63
Policy and Objective ........................................................................................................................ 63
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GENERAL
INTRODUCTION
Project Quality Plan conforms to the applicable requirements of BS EN ISO
9001:2000 and Aldaberta Corporate Quality Manual.
The objective of defining a quality plan is as following:
A quality plan may be used within an organization to ensure that specific requirements
for quality are being appropriately planned and addressed for identified products
during production.
A quality plan may be used to indicate the specific application of a quality system to a
given development project.
PROJECT OVERVIEW
COMPANY intends to optimize, maintain, and enhance its current production
facilities and development of new production facilities for the near future in order to
meet new management policy in relation with maintaining production rate for oil and
gas demand, production cost optimization, and minimize environmental pollution
from production process.
Upon COMPANY's issuance of Work Order, CONTRACTOR shall provide personnel
to support Project Management, Construction Engineering Services, Construction
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works
related
to
Engineering,
Procurement,
Construction/Fabrication,
REFERENCES
AI-QC-GG-002 : QA/QC Procedure
AI-QC-GG-003 : Inspection and Test Plan at Shop
AI-QC-GG-004 : Inspection and Test Plan at Field
AI-QC-GG-008 : Fabrication Quality Control Plan
AI-MN-GG-008 : Filing Procedure
AI-MN-GG-010 : Quality Audit Procedure
COMPANY'S Requirements;
CONTRACTOR' S Quality Management System Requirements;
Codes and Specifications:
ASME -American Society of Mechanical Engineers code;
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DEFINITIONS
Terms which are repeated here for clarity but have been defined in other International
Standards are:
Contract
Agreed requirements between a supplier and customer transmitted by any
means [ISO 9001)
Project
Unique process consisting of a set of coordinated and controlled activities
with start and finish dates, undertaken to achieve an objective conforming to
specific requirements, including the constraints of time, cost and resources
Procedure
Specified way to perform an activity
Product
Result of activities or processes
Quality Plan
Document setting out the specific quality practices, resources and sequence
of activities relevant to a particular product, project or contract
Quality System
Organizational structure, procedures, processes and resources needed to
implement quality management
Abbreviations used in this document are :
DC
ENG
PC
PE
PM
QM
Document Controller
Engineering
Project Controls
Project Engineer
Project Manager
Quality Manager
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Vendor quality assurance policy shall be formulated to achieve the product and
services, which are defined as on time schedule, competitive project cost, safely
execution and operation, are compliance with the PT. Aldaberta Indonesia
requirements. As a part of quality assurance is to satisfy the PT. Aldaberta
Indonesia at all stage of project, from design until commissioning. Vendor
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Project Manager and each relevant manager are responsible for assuring that
all phases of the program for which he is responsible are operating strictly in
accordance with the quality assurance. The Quality Control (QC) Manager and
his delegates have organizational freedom from disciplines, being directly
responsible for performing the work, and have the authorities to conduct audit,
identify quality problems and to guide solutions.
The work merits Company satisfaction by meeting targets for HSE, quality and
schedule.
All deliverables including drawings are clearly documented, and is consistent with the
requirements of Company and the needs of the project.
All project work is required to be performed in compliance with the plan, however, to
facilitate exceptional circumstances, deviations are allowed on the written authority
of the Project Manager, if such deviations will not affect the contractual requirements.
ORGANIZATION
GENERAL
This section covers the organization, project coordination and its authority and
responsibility in the performance of activities affecting quality related to the project.
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ORGANIZATION CHART
This section covers the organization and its authority and responsibility in the
performance of activities affecting quality related to the Project. Vendor shall
establish a Project Organization, which shall satisfy PT. Aldaberta Indonesia
requirements. The level of the responsibility and assigned authority of these
personnel shall be clearly indicated. In addition, it is Vendor responsibility to ensure
that its Vendor/Sub Contractor also comply with these requirements. The following
is Aldaberta Indonesia organization chart.
MANAGEMENT REPRESENTATIVES
Under responsibility of PT ALDABERTA INDONESIA a single project team
consisting of personnel from different organizations including vendor/suppliers and
subcontractors will manage and perform the project. Corporate management working
in committee will be responsible for safety and quality management, demonstrating
the CONTRACTOR's commitment to the safety and quality of the project. The Quality
Manager as the representative of the committee has the overall authority and
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QC Manager (QM)
In order to ensure the implementation of the QA Plan, QC Manager will
be assigned in the project organization. He will report directly to the
Project Manager. QC Manager will have sufficient authorities,
organization freedom, and direct access to all managers to perform his
duties.
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PROJECT COORDINATION
To ensure that CONTRACTOR can complete the project satisfactorily within the
project period, general progress and weekly activities completed, including the next
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scheduled activities will be reviewed during the project coordination meeting and as
reflected on the Project Coordination Procedure.
Integral to successful project execution is coordination between parties:
Between
the
control
of
the
Between the CONTRACTOR and other contractors for split of supplies, works
and responsibilities, and interface coordination.
MANAGEMENT REVIEW
GENERAL
Project Quality Plan will be established in compliance with the COMPANY's
requirements, specified codes and standards to offer an integrated approach, in
which specific practices relevant to project QA activities will be identified.
CONTRACT REVIEW
Review
At the award of the contract, as applicable, the project team shall arrange
and conduct a preliminary review of the contract package to ensure that:
-
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Based on the contract review, the PM will prepare job instructions for the
project which contain the necessary information to start the job, and
distribute the copies to all relevant disciplines and draw up the project
execution practice.
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Time limitations;
Approval
and
implementation
of
change
including
adequate
communication as necessary;
QA PROGRAM DEVELOPMENT
The PM, at both offices of CONTRACTOR's offices, will calf for a kick-off
meeting to which all relevant Discipline Managers shall attend. The contents of
job instruction are explained for overall understanding of the project, and each
Manager is requested to assign an Appointed Engineer (AE) for the project.
Then, the PM shall call a launch meeting for AEs to give basic data for the
preparation of required documents.
On the basis of the above information and QA policy for the project, the QA
engineer will prepare the QA plan. The plan will be reviewed and approved by
the Quality Assurance
Manager and with acknowledgment by the PM, submitted to the COMPANY for
approval.
The plan will optimize the control of quality in relation to risk and cost and
incorporate specific requirements imposed by the contract. The plan will provide
for, as appropriate:
-
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MANAGEMENT REVIEW
The review results will be distributed by the PM to the relevant disciplines for
proper execution and for corrective actions with directions, as required.
In the event that any deficiency is found in the QA plan by the management
review, the PM will propose the change to the Quality Manager, and the plan will
be revised the same way as for the original.
DOCUMENT CONTROL
GENERAL
Scope
Document control is the formal control of all documents related to the project
processes within the Scope of Work.
Policy and Objective
Controlled documents Will be specified for development, approval, issue,
revision, distribution, maintenance, use, storage, security, obsolescence or
disposal. Authorized personnel will be identified to approve documents; such
personnel shall be named and recorded accordingly.
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instructions,
drawings
checklist,
including
and/or
revisions
are
frequently
repeated
and
where
misunderstandings are likely to occur, the issuing discipline will revise the
originals entirely and reissue the revised documents.
Document Numbering and Revision Status
Each document prepared by the relevant disciplines will be assigned a unique
number in accordance with the document numbering system established for
the project. In the event of revisions, revision numbers will be given.
Listing of Documents
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Distribution of Documents
Documents approved by the relevant discipline lead engineer and/or
discipline manager will be sent to the project team, which shall be signed off
and distributed by the Engineering Manager. The document controller will
enter these documents into the document list and the specified numbers of
copies sent along with the document transmittal sheet.
The receipt acknowledgement signature will be obtained on the transmittal
sheet. Special care will be taken on revised documents.
Document Filing
Document Controller will establish a filing system of project documents to
facilitate the availability and retrieval of documents and to keep the
documents updated.
Each discipline files project documents in accordance with the standard filing
system.
Handling of Obsolete Documents
The obsolete document copies will be first marked as obsolete I superseded
and then shredded by the responsible person in accordance with the
instruction contained in the document transmittal sheet, after its substitution
with the latest version.
The document controller will check the receivers' acknowledgements to
confirm that the latest approved documents are used at proper locations.
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When any discrepancies are found through the design checking or review, the
responsible AE for the document will notify and propose the change request by
following the approved MOC procedures for COMPANY approval.
Manufacturing work specified in vendor's design documents will proceed only after
obtaining contractor's approval.
CONTROL OF OUDATED DOCUMENTS
The obsolete document copies shall be destroyed by the responsible person in
accordance with the instruction contained in the document transmittal sheet, after
the substitution with the latest version. Document Controller shall check the receiver
acknowledgement to confirm that the latest approved documents are used at proper
locations.
CONTROL OF DESIGN DOCUMENTS AT THE SITE
Design documents required for field construction will be prepared by the
CONTRACTOR and distributed to the site by the EM.
The field document controller designated by the Site Manager is responsible for the
document control at the site. The Site Manger will establish a site document control
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system on the basis of the home office system, taking into consideration special
conditions of the site.
The field document controller will identify the documents transmitted from home
office and control distribution using the site document list.
If it becomes necessary to change the design, the chief field engineer will contact the
home office through the Site Manager to obtain direction. In an urgent case or when
judged possible or practicable to change at the site, the change will be made with
COMPANY approval. However, the change should be reported to home office for
record as established in the Field Change Notice Procedure.
GENERAL
Scope
This section covers the control procedure for the preparation and
maintenance of the evidence of quality.
Policy and Objective
All the quality records shall be legible, easy to retrieve, and be stored in a
manner and location to prevent deterioration or loss in accordance with the
relevant Document Control Procedures.
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The EM will establish the filing code of documents and prepare a quality
record index to identify all the records to be collected with the cooperation
of relevant AEs.
The size of record, format of record, contents of file will also be defined.
AEs are responsible for collecting and filing of relevant quality records
and the EM will check them with the record index.
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Design input will be coordinated and confirmed by the PE, considering the
past experiences of the similar plants and the feedback data. When
incomplete, ambiguous or conflicting inputs are found in the course of the
engineering review, the PM will discuss them with the COMPANY. The result
will be documented and immediately informed to all AEs.
On the basis of the design inputs, AEs will prepare design and engineering
documents, such as data sheets, specifications, instructions, drawings, and
procedures.
These documents will meet design input requirements, contain or reference
product and/or acceptance criteria and conform to applicable statutory
requirements.
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3. Internal Screening
Screening meetings will be held prior to the issuance stages of IFA (Issue
for Approval) and AFD (Approved for Design) of PFD, P&ID, Plot Plan,
etc. At several stages of the design, as required, the EM will contact the
relevant engineers to confirm design coordination. The results will be
agreed upon and incorporated into the design documents.
4. For the documents to be submitted to COMPANY, refer to section 4
above.
DESIGN VERIFICATION
In the event that an inconsistency or inadequacy is found, the finder will request
the originating design group to change the document, using design change
request sheet.
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The changed parts will be marked for easy identification and the revision date,
revision number and the reason for the change will be noted on the document.
ENGINEERING HOLD
Engineering hold which may result from design uncertainties will be identified on the
document by the AEs. The relevant work involved in such engineering hold will not
go ahead without a clear solution given by the responsible AE.
If it is judged by the AE that any alterations to, or deviations from the contract
package or engineering documents supplied by the COMPANY are necessary, the
proposed deviations and/or alternatives will be submitted to the COMPANY through
the PM for approval with the explanatory data.
PROCUREMENT CONTROL
GENERAL
Scope
This section will cover the procedure to control all the purchased
products and services in this project.
Policy and Objectives
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Scope of supply;
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Review of Requisition
A review of requisition and changes will be made to assure the adequacy of
specified requirements. The project procurement coordinator will check the
requisition and attach the necessary documents for the inquiry or for the
purchase order. The PM will give final approval.
Selection of Vendor
Contractor will select potential vendors in principle among 'vendor list' which will
be established between the COMPANY and the CONTRACTOR.
The project procurement coordinator will issue requests for quotation to potential
vendors.
Upon request of the PM, the QA Supervisor will perform QA/QC surveillance to
vendors and their facilities in accordance with the QA levels of products and
services to be made and the result will be reported to PM with the QA rating.
The selection of vendor and the extent of control will be dependent upon the
type of products and services, vendor's demonstrated capacity and past
performance of the similar work, the evaluation of vendor's quotation, QA
evaluation and the capability on schedule and cost.
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The new approved vendor list will be submitted to the COMPANY for approval.
and
the
vendor
for
coordination
and
mutual
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CONTROL OF SUB-VENDORS
At the pre-inspection meeting between contractor and vendor, the Senior QAQC
Engineer will check the quality requirements of vendor to the sub vendor.
GENERAL
Scope
This section will cover the identification and control procedure for all
materials, parts and components in this project.
Policy and Objective
The materials, parts and components control will be conducted to assure the
correctness of products, maintenance of traceability and the prevention of
inadvertent use of incorrect products including field activities.
IDENTIFICATION PROCEDURE
1. Marking Procedure
For identification control, the document controller will provide vendors with the
CONTRACTOR's specifications, in which the marking method, marking location,
marking items and color coding are specified. Items to be marked for permanent
identification are shown in the inspection program as material test (mill sheet).
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2. Physical Identification
Physical identification using tow stress dye stamping will be used to the
maximum extent possible. Where physical identification on the item is
impractical, physical separation procedure control by tagging, labels and records
will be employed.
3. In-process identification
a. Transfer of marking will be controlled.
b. Identification during storage will be controlled (separation, tag, etc.)
c. Nonconforming items will be identified and separated.
d. Inspection status (accepted, rejected, not yet inspected) will be identified.
4. Marking
Marking will be applied in a manner and at a location that would not leave
detrimental effects on the items.
RECORD OF MATERIAL
The record will be traceable to the item and will be checked by an inspector. Where
required the vendor will submit 'As-built Sketch of Material Allocation' in which the
marking location including weld line numbers are shown to the CONTRACTOR.
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To prevent the installation of incorrect materials of construction for low chrome and
alloy materials in process or pressure containing duty, PT.ALDABERTA INDONESIA
shall attach " Alloy Verification Procedure" to the Purchase Order for the relevant
Vendors and Sub Vendor, in which the requirements or examination methods, the
qualification of inspectors, sampling methods, acceptance criteria, identification
marks, record, etc. are defined.
The Vendor's procedure shall be reviewed and approved by PT. Aldaberta Indonesia.
1. Environmental Control
a) The vendor/subcontractor will establish the control measures to keep the
working area clean and under suitably controlled conditions to prevent the
infiltration of foreign materials and not to cause detrimental effects on products.
b) The CONTRACTOR will check the controlled status of the working area using
witness inspection or by patrolling as appropriate and give recommendations
for correction, if any.
2. Fabrication and Installation Planning
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a) The AEs and Site QC Manager will identify applicable regulations, codes and
standards for fabrication and installation, inspection and monitoring points, and
acceptance criteria, as appropriate in the procurement documents.
b) For major products, the AE will request the vendor/subcontractor to submit
procedures in which the process sequence, inspection and/or monitoring items
and the methods are made clear.
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The relevant Welding Engineer will review and approve WPSs and PQRs. The
Site QC manager will confirm them and specify the inspection items, witnessing,
and required records in the inspection and test program.
Offsite piping spool prefabrication shops for fabricating exotic alloys and DSS/
SDSS / SS alloys are to be inspected and approved after a joint inspection with
COMPANY personnel.
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The CONTRACTOR's inspector will check and confirm the work and the results
through the work records.
Training
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In the event that qualifications are required for special processes and/or
personnel performing specific work, CONTRACTOR shall specify the
qualification in the purchase specification, as appropriate.
Vendor shall establish and perform necessary training to obtain the qualification
and to maintain the required skill.
CONTRACTOR shall confirm the qualification and monitor the performance, and
when any degradation is found, require Vendor to do re- training.
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Quality control plan at shop for the project developed along with proceeding
detail engineering. The sample format to be used for the project is attached
below.
The inspection and test program will be reviewed by the COMPANY. The
approved program will be confirmed at a pre-inspection meeting.
Acceptance criteria;
In the event that the inspection of processed items is not practical due to a
number of reasons, indirect control by monitoring the processing method,
equipment and personnel will be defined (e.g. welding, personnel, welding
electrode used, ampere, voltage, heat treatment chart).
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Inspection Personnel
Inspection Coordinator
Inspector
Inspection Coordinator selects inspector on the basis of prior experience and
qualification from PT.ALDABERTA INDONESIA's Inspection Section and
from inspection agencies.
Inspection Agency is selected from nominated agencies. The nominated
Inspection Agency shall have :
Vendor Inspector
PT.ALDABERTA INDONESIA shall review and evaluate Vendor's inspectors
to ensure their qualification and skill, as required.
NDE personnel
NDE personnel shall have qualification obtained from the authorised
organization. When Vendor performs NDE, he shall submit an Qualified NDE
Personnel List in which kinds and level of NDE, terms of validity, and the
organization by which they are qualified are made clear.
A pre-inspection meeting will be held for major items or when deemed necessary
by the Senior QA / QC Engineer for coordination and for mutual understanding
prior to fabrication.
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The status of inspection and test schedule will be controlled by the Senior QAQC
Engineer.
For the hold point items, the vendor must not proceed with the work until it has
been inspected by the representative or a written approval of waiver is obtained.
Final inspection will include a record review of the results and resolution of non
conformance identified by prior inspections. The Senior QAQC Engineer will
check the inspection record and when the record is found to meet purchase
order's requirements, the inspection release will be prepared.
The vendor will establish and control the suitable status identification measures
of inspections and tests on items.
The AE will specify the critical dimensions of the product in charge with the
required tolerances in the design document.
Vendors will pay special attention to these dimensions and show them in the
fabrication drawings and dimensional inspection record forms appropriately
(preferably with care marks). During fabrication at the machining stage, the
assembling and aligning stage and at the final inspection stage, these
dimensions will be checked and recorded.
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At the final inspection, the critical dimensions will be confirmed by the witness
and actual dimensions recorded. Special care will be taken with the cantering,
alignment, flatness, and distortion.
'As-Built' conditions of the work in the drawings. 'As built' drawings will be
submitted to the CONTRACTOR for the permanent records.
RECORD OF INSPECTION
Record of inspection for main items will identify as a minimum:
Inspection procedure;
Acceptance criteria;
Results.
The inspection records will be signed or stamped and dated by vendor and
contractor's representative.
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Where required, Vendor shall submit the procedures for review and
approval. Vendor shall implement the work in accordance with the
approved procedures, and shall generate the work records.
The CONTRACTOR and its subcontractors and suppliers will clearly define
the methods for handling, storage, packaging, transportation and installation
of all materials relevant to the entire project's Scope of Work such that the
following is achieved:
Records for the above activities shall be generated and maintained in the
data base.
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The CONTRACTOR and its subcontractors will ensure all chemical and
hazardous substances Material Safety Data Sheets (MSDS) are
provided, for all chemicals and hazardous substances used during the
execution of the Work.
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The vendor will control the packing, preservation and marking process in
order to satisfy the CONTRACTOR's requirements.
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Any sensitive or delicate items which are likely to get damaged during
transportation shall be additionally protected.
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Scope
This section will cover control of all construction activities in this project.
Assurance
requirements
specified
in
Construction
Quality
SUBCONTRACTOR CONTROL
Selection
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requirements, right to access and extension of requirements to subtiers, at least, are specified.
The bid evaluation will be dependent upon the type of products and
services, resources, demonstrated capability and past performance of
similar work, proposed quality control activities and capability on
schedule and cost. The PM will make the final determination and the
subcontractor list will be submitted for approval.
Coordination
The
coordination
procedure
between
the
COMPANY,
the
QC Activities
Document Control
Construction Superintendent designates Site Document Controller. He
shall control site documents as follows:
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Receiving Control Site Material Controller (MC) is responsible for site receiving
as follows:
-
deterioration
during
transportation,
quantities,
required
documents, etc;
-
The relevant Assigned Engineer will review and specify the requirements
for products that may require special environmental conditions or
maintenance;
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ENVIRONMENTAL CONTROL
The work environment should be kept clean and tidy to assure that the work is
performed under well controlled conditions for work and safety.
Scope
This section refers to the pre-commissioning and commissioning activities.
Policy and Objective
The SCCM will keep close communication with the COMPANY and
the Site Manager and report to the PM.
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The SCCM will prepare and arrange the following plans and procedures with the
cooperation of the commissioning staff and relevant subcontractors:
PRE-COMMISSIONING VERIFICATION
Pre-installation verification:
-
Identification check;
Installation verification:
Equipment verification for operational readiness and confirmation of satisfactory
disposition of pending problem, system check cleaning, pressure-leak test, flow
direction check, and in-line instrumentation check.
Pre-operational testing:
-
PLANT COMMISSIONING
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Plant commissioning will be carried out to verify and ensure the compatibility of
systems, sequential operation, plant performance and capacity, plant safety, from
start-up to cool-down.
Data taken at each stage will be analyzed and evaluated for the validity, integrity
and completeness. If any incompleteness is found, the SCCM will take corrective
action such as requesting additional tests and making procedure change. '
Records will be collected and compiled by the relevant engineers with prior
agreement.
Records will include the results of analysis and evaluation, corrective actions,
changes and modifications, and calibration records.
Scope
This section will cover all the measuring and test equipment used in this
project.
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The control methods will be as per the relevant Inspection, Measuring and Test
Equipment Control Procedure.
The measures will include records and control logs, the identification of validity
to show the calibration status, and handling and storing to prevent damage and
deterioration.
The CONTRACTOR will confirm the control status of surveillance, audit, witness
inspection, on a timely basis.
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In the event that the non-conformance is serious I major enough to fall into one
or more of the following items, the non-conformance report will be prepared by
the inspector or the vendor/subcontractor, and be sent to the QC Manager with
details.
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The Quality Managers will circulate the report to the Assigned Engineers in
charge of review and comments and send the copies to the PM.
The PM will discuss with key personnel of the relevant organizations (Assigned
Engineers, Engineering Manager, Procurement Manager, Quality Manager, and
specialists, where necessary) and report to the COMPANY to obtain approval
and direction.
Disposition:
-
For non-conformances that may hinder the final use or integrity of the product,
the relevant CONTRACTOR'S engineering discipline shall make an evaluation
in order to determine its final disposition.
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The results will be confirmed, entered in the confirmation column, and reported
by the responsible organization to the COMPANY, PM and the Quality
Manager.
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QUALITY AUDIT
GENERAL
Scope
This section will cover internal and external audit activity that will be
conducted in the project.
Policy and Objective
The CONTRACTOR will conduct the audit to ensure the proper execution of
quality related activities and to evaluate the effectiveness of QA program.
INTERNAL AUDIT
Internal audits will be performed in accordance with the approved audit schedule,
which includes audits for the site work at appropriate stages, and as per IS019011 Guidelines for quality and I or environmental management systems auditing.
The Quality Manager may deem additional internal audits necessary through routine
monitoring of QA/QC activities. Audits will be performed by the appointed Audit Team
or personnel designated by him on the particular areas. COMPANY will be notified
of all internal and external audits for witnessing and I or participating.
EXTERNAL AUDIT
The Quality Manager will establish an external audit plan for vendors, giving
consideration to the importance of items and services for which they received orders
and to their past performance.
With the agreement of the PM, the Quality Manager will designate audit personnel
out of the QA staff.
Audits will be performed in accordance with appropriate procedures, schedules and
checklists by audit personnel.
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LESSONS LEARNED
The Project Manager shall be responsible for the implementation of the lessons
learned and best practices for this Project, in order to strive for continual
improvement of the Project.
Lessons learned refer to the defined positive and negative knowledge and
experience gained through the execution of previous Projects. Lessons learned will
be used as a preventive management tool that can be utilized in managing risk
factors and best practices that may occur during the Project execution. They may
include: lessons learned and experiences, Trouble and Errors which may be defined
as the loss of opportunity due to factors like lack of experience, technology,
management, etc; non-conformances and best practices.
CONTRACTOR will implement its own lessons learned procedures, as well as
lessons learned shared by COMPANY.
MANAGEMENT REVIEW
GENERAL
Scope
This section will cover Management Review activities which shall be
conducted in this project.
Policy and Objective
CONTRACTOR'S Project Management shall conduct the Management
Review at regular basis to review the performance of the Project. The
Management Review meeting shall be chaired by the Project Manager by
arrangement of Project QA Manager.
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CONTINUAL IMPROVEMENT
GENERAL
Scope
This section will cover continual improvement which is implemented in this
project.
Policy and Objective
The Project Manager shall ensure that Quality improvement on the Project
implemented within all function and level of the Project Organization. Lessons
Learned shaII be tools for quality improvement, to be registered and taken
the corrective and preventive actions to avoid a repetitive problem. Method
of continual improvement shall always in accordance with ISO 9001 :2008
requirements.
APPENDIX
CONFIDENTIAL
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
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Bid. No.:
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Rev. 0
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
Activity Description
1.
PROJECT MANAGEMENT
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Control
Document
Reference
Responsible
Deliverable/
Documentation
Produced
Organisation Chart
Responsibilities Interface
Chart
PM
Contract Review
PM/QM
Contract Scope
PM/QM
Quality Objectives
PM/QM
Training Record
Quality/HSE Audits
Audit Schedule
Audit Reports
Corrective Action Requests
Variation Requests
Variation Orders
Contract Review
Monitor Performances
PM
PM/QM
PM
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
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Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
2.
2.1
2.2
3.
3.1
3.2
3.3
3.4
4.
Activity Description
PLANNING
Control
Document
Reference
Responsible
Deliverable/
Documentation
Produced
PC
Progress Reports
Cost Control
Manhour Estimate
Filing System
Numbering of Projects
Document Register
Drawing Register
Document Control
Document Register
Drawing Register
DOCUMENT CONTROL
DESIGN CONTROL
DC
ENG
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Control
Document
Reference
Deliverable/
Documentation
Produced
Act
Ref
Activity Description
4.1
Design Control
Site Surveys
Survey Data
Design Control
Design Control
Environmental Design
Legislation Register
Aspects Table
Design Checklists
Validation Certificate
4.2
4.3
4.4
4.5
4.6
Responsible
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
4.7
4.8
4.9
Activity Description
Control
Document
Reference
Responsible
Deliverable/
Documentation
Produced
Drawing Control
Drawings
Specifications
Specifications
Specifications
Calculations
Calculations
Calculations
Studies/Reports
Manuals
Data Books
Technical Requisitions
Control of Requisitions
Technical Requisitions
Design Verification
Design Check (IDC)
ENG
Design Control
IDC Records
Design Reviews
ENG
HAZOP
ENG
HAZOP Study
System Audit
QM
Quality/HSE Audits
Audit Reports
Freeze Design
ENG
Master Copies
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
4.10
Activity Description
Control Design Changes
PM
ENG
4.11
5.
Co-ordinate Concessions
ENG/PU
Deliverable/
Documentation
Produced
Master Copies
Technical Concessions
Concession Register
Concession Request
Procurement
Bid Lists
PROCUREMENT
5.1
5.2
5.3
Control
Document
Reference
Responsible
PU
ENG
Control of Requisitions
Technical Requisitions
Supplier Data
Requirements List (SDRL)
Package QA Requirements
QM
Procurement
Supplier Quality
Requirements
Commercial Requirements
PU
Procurement
Contract Conditions
ENG
Technical Evaluation
Engineering Evaluation
Report
QM
Procurement QA
QA Evaluation Report
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
5.4
5.5
5.6
5.7
5.8
5.9
Activity Description
Control
Document
Reference
Responsible
Deliverable/
Documentation
Produced
Clarify Ambiguities
PU
Procurement
Clarification Records
PU
Procurement
Purchase Orders
Supplier KO Meetings
PU
Supplier KO Meetings
Minutes of Meeting
Supplier Inspection
PU
Inspection Records
Technical Concessions
Concessions Request
Inspection Waivers
Inspection Waivers
Expediting
P
Expediting Report
Expedite Progress
Monitor Performance
6.
6.1
PU
PU/QA
DCC
Procurement
Procurement QA
Audit Reports
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
7.
7.1
7.2
Activity Description
7.4
7.5
7.6
7.7
7.8
Deliverable/
Documentation
Produced
CONTRACTS
Identify Contract to be Placed and Establish Bid List
Identify
Scope of Contract
7.3
Control
Document
Reference
Responsible
PM
Contract Scope
QA Requirements
QA
QC/Inspection Requirements
PM
QA Obligations
Commercial Requirements
PM
Invite Tenders
CA
Invitation to Tender
CA
Tender Register
PM
CA
Evaluation Reports
Raise Contract
CA
Contract
Monitor Performance
QA
Procurement QA
QA Reports
PM
CA
QC Requirements
Commercial Terms
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
8.
8.1
Activity Description
CONSTRUCTION ADMINISTRATION
8.3
8.4
8.5
8.6
9.
Control
Document
Reference
Deliverable/
Documentation
Produced
CM
CM/QA
Work Instructions
CM/QA
Method Statements
8.2
Responsible
Construction Administration
Procedure Register
Work Instruction
CM/A
Method Statement
Register
CM
Construction Administration
Registers, Files,
Transmittals
CM
Construction Administration
P
CM
Material Records
Preservation Log
Movement Tickets
Site Training
CM
Construction Administration
Training Records
CM
Construction Administration
Job Specifications
CM
Construction Administration
Project Records
CONSTRUCTION
CM
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
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QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
9.1
9.2
9.3
9.4
9.5
10.
11.
12.
13.
14.
Activity Description
Responsible
Control
Document
Reference
Deliverable/
Documentation
Produced
CM
Material Records
Preservation Log
Movement Tickets
CM
Equipment Calibration
Records
CM
Tagging Records
Material Certificates
CM
Non-Conformance Reports
Quarantine Records
ENG
Construction Administration
Clarifications Records
CM
CM
INSTALLATION - INSTRUMENT
CM
INSTALLATION - ELECTRICAL
CM
TESTING
CM
Test Certificates
CONFIDENTIAL
Approval/Inspection
Authority
TECHNICAL SERVICES CONTRACT FOR PROJECT ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES
Discipline Code:
General
Doc. No.:
005/AI-TQ-ENG-16
Bid. No.:
STC-1030
Rev. 0
Page:
73 of 73
QUALITY PLAN
Client:
Project:
PHE ONWJ
Act
Ref
15.
16.
17.
Activity Description
Control
Document
Reference
Responsible
Deliverable/
Documentation
Produced
COMMISSIONING
PM
Commissioning Manual
PM
PM
Document Handover
Handover Package
Project Archives
Archive Records
CONFIDENTIAL
Approval/Inspection
Authority