You are on page 1of 55

Rehabilitation of 4 Thermal units at Mussaib Power Plant

Including Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN

REV DATE STATUS ISSUE PURPOSE ISSUED BY CHECKED BY APPROVED BY


Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 2 Of 56

DOCUMENT REVISION HISTORY SHEET

REV STATUS DATE ISSUED DESCRIPTION

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 3 Of 56

QUALITY POLICY & QUALITY OBJECTIVES

This is to notice all the project employees that the Project quality policy is:

Quality orientation, Continual improvement, Top-ranking project, Sincere service.

The project quality objectives are:

(a) Quality Management Objectives:

1. Strictly observe the rules and regulations of the project quality management system,
enhance leadership, participate in by all employees, use method of management of
system and process to exercise scientific management on project quality work, complete
the project to the satisfaction of CUSTOMER , perform audit, continually improve the
quality of the project.
2. Prepare quality management documents covering the entire project, enhance internal
audit, fill in and maintain process record, promote effective implementation of quality
system, pass the audit performed by CONTRACTOR.

(b) Project/Product Quality Objective:


1. Design Input Review Rate 100%;
2. Purchased Material Inspection Rate 100%;
3. Welding Repair Rate less than 2%;
4. One-time Put into Operation Successful Rate 100%.

The quality policy and quality objectives embody the quality goal and direction, and are
important part of project general policy and objectives. It constitutes a framework for quality
review and continual improvement.

All employees shall study them conscientiously and observe them strictly.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 4 Of 56

TABLE OF CONTENTS
1.0 INTRODUCTION.....................................................................................................................5
1.1SCOPE............................................................................................................................... 5
1.2DEFINITION & ABBREVIATION.............................................................................................. 5
2.0 REFERENCE...........................................................................................................................6
3.0 QUALITY POLICY OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD............7
4.0 QUALITY PURPOSE OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD.......7
5.0 CONTROL OF QUALITY PLAN.............................................................................................8
5.1EXPLANATION..................................................................................................................... 8
5.2CONTROL OF QUALITY PLAN..............................................................................................8
5.3IMPLEMENTATION OF QUALITY PLAN...................................................................................8
6.0 QUALITY MANAGEMENT SYSTEM......................................................................................9
6.1GENERAL REQUIREMENT.................................................................................................... 9
6.2OVERALL REQUIREMENT.....................................................................................................9
6.3DOCUMENT CONTROL.......................................................................................................10
6.4CONTROL OF RECORD......................................................................................................12
6.5MANAGEMENT RESPONSIBILITY & COMMITMENTS..............................................................13
6.6DESIGN & ENGINEERING QUALITY PLAN............................................................................18
6.7PROCUREMENT QUALITY PLAN & PROCEDURE..................................................................21
6.8CONSTRUCTION QUALITY PLAN & PROCEDURE.................................................................28
6.9CONTROL OF MONITORING AND MEASURING DEVICES.......................................................31
6.10 MEASUREMENT, ANALYSIS & IMPROVEMENT................................................................32
7.0 ANNEXURES........................................................................................................................40
7.1PROJECT QUALITY ASSURANCE & CONTROL CERTIFICATIONS...........................................41
7.2QMS RESPONSIBILITY MATRIX..........................................................................................42
7.3PROJECT QA ACTIVITY FLOWCHART.................................................................................44
7.4PROJECT SITE QC ACTIVITY FLOWCHART.........................................................................46
7.5NON CONFORMANCE REPORT...........................................................................................48
7.6QUALITY AUDITS PLAN SCHEDULE....................................................................................50
7.7Technical Query Form......................................................................................................52

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 5 Of 56

1.0 INTRODUCTION

For the detail of the Project profile, completion time and main workload, please see relevant
EPC Scope of Work.

1.1 Scope

The project quality plan describes the requirements of quality management system and the
activities stipulated. It provides the basic document used for the quality management system,
and supplies the information that is identical with the quality management system.

The Plan is applicable for the Rehabilitation , structural & piping construction works for (4)
Thermal units at Mussaib Power Plant Including Boiler, Steam Turbine, Generator, and BOP.

1.2 Definition & Abbreviation

Rehabilitation of 4 Thermal units at Mussaib Power Plant Including Boiler,


PROJECT
Steam Turbine, Generator, and BOP
CUSTOMER MOE
PMC Project Management Consultant
CONTRACTOR AlBilal Group For General Contracts Co. Ltd
QUALITY Compliance with the specification and requirement of CONTRACT
Activity where the characteristics of item(s) or service(s) are subject to
INSPECTION examination, and/or measurement, and/or testing to determine
compliance with the specification
QUALITY Activity where the characteristics of item(s) or service(s) are subject to
inspection and correction to ensure compliance with the specification. QC
CONTROL (QC) includes inspection
QUALITY
Activity where a proactive, planned and systematic program is used to
ASSURANCE
ensure the item(s) or service(s) are in compliance with the specification.
(QA)
QUALITY Activity that provides for managing the integration of QA with cost and
MANAGEMENT schedule to ensure the item(s) or service(s) are reliable and safe.
Activity that provides management with a method to monitor performance
QUALITY AUDIT
of QA
QUALITY Documents that are prepared and utilized for the purpose of verifying and
recording compliance of any operation directly related to the product
RECORDS quality. The record may be in the form of hard copy or electronic media
HSE Health, Safety, Environment
PQP Project Quality Plan
QMS Quality Management System
ITP Inspection Test Plan
TDR Technical Document Register
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 6 Of 56

LLI Long Lead Item


FOB Free on Board
RFQ Request for Quotation
CAD Computer-Aided Design
ISO International Standardization Organization
WPS Welding Procedure Specification
PQR Procedure Qualification Report
NDE Non Destructive Examination
TPI Third Party Inspection
NCR Non Conformance Report
PO Purchase Order
MR Material Requisition
FOC Fiber Optical Cable
EPCC Engineering, Procurement, Construction and Commissioning

2.0 REFERENCE

2.1.1 ISO 9001: 2008 Quality Management System

3.0 QUALITY POLICY OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD

“Insisting on adopting the advanced applicable technique and scientific management


CONTRACTOR will supply the satisfactory product and service to the CUSTOMER and carry
out, maintain and improve continued the quality management system.”

The policy is adapted to the purpose of CONTRACTOR, and is an important integrated part of
business policy of CONTRACTOR.

The policy shows the CONTRACTOR will meet the requirements of CUSTOMERon the
products and the continual improvement.
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 7 Of 56

The policy provides a range used for establishing and reviewing the quality objective of
CONTRACTOR.

The leaders at all levels shall communicate the quality policy to all management departments,
professional offices, teams and branches in order to enable the staff of CONTRACTOR to
understand correctly the policy and insist on putting into effect.

The reviews of the quality policy shall be carried out continuously by CONTRACTOR, to ensure
the continual compatibility, sufficiency and effectiveness; the policy shall be revised to be
adapted to the change of environment in the CUSTOMER , if necessary.

4.0 QUALITY PURPOSE OF ALBILAL GROUP FOR GENERAL CONTRACTS CO. LTD

Ensure the finished products are 100% qualified, set up the consciousness of providing product
with high quality, and devote major efforts to developing the activity of creating the excellence
products.

Achievement rate of contract execution is 100%.

Do the good job during the construction and do the good improvement work after the project put
into operation.

Carry out comprehensive project management, and make great efforts to keep the project
management to be connected with the orbit of international universal management model.
Carry out comprehensive quality management and insist on the continual improvement of the
quality management system.

All staff shall recognize and implement seriously the quality objective, establish the
correspondent quality objective with the departments related to the quality together, to enable
more detailed and to be measurable, and to permit to be identical with the quality policy, in order
to ensure the implementation of the quality objective.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 8 Of 56

5.0 Control Of Quality Plan

5.1 Explanation

The Quality plan defines and stipulates the quality objectives, organization, responsibility,
resources management, process control, quality requirement, measurement, analysis and
continual improvement of quality management system. For the general content, Quality plan will
directly quote them from Albilal Group Quality Management System Procedures.

5.2 Control Of Quality Plan

The Quality Assurance/ Quality Control Department (QA/QC department) shall be responsible
for the preparation of the quality plan. Deputy project director (DPD) shall be responsible for
review of the quality plan.
Other departments concerned of CONTRACTOR shall jointly review it. Quality plan will not
come into effect until authorized person of CONTRACTOR approves it.
The quality plan shall be reviewed by the management representative and approved by the
General Manager, then issued to CUSTOMER for approval.
The quality plan shall be divided into two editions i.e. controllable and non-controllable.
Controllable edition shall be issued to the leaderships of CONTRACTOR and the departments,
personnel related to quality responsibility as well as the center of quality system review.
The non-controllable edition (existing effective edition) are issued to CUSTOMER for introducing
the brief of the quality management system of CONTRACTOR, and the evidences for the quality
guarantee shall be provided.
The replacing of the edition for the quality Plan or the partial change thereof shall be prepared
by the QA/QC department and reviewed by the Management Representative as well as
approved by the General Manager.
After completion of the replacing or change of the edition the “Notice Of Document Change” and
the new edition of quality Plan or the revised pages shall be issued to the holders of the quality
plan, and the cancelled editions shall be returned back, the document control procedure shall
be carried out.
The holder of the quality Plan shall be responsible for management of the quality plan, any
alterations outside the CONTRACTOR are not to be permitted.
5.3 Implementation Of Quality Plan

Project director shall organize all the departments of the Project and Subcontractors to
implement and maintain the quality plan. All the departments and Subcontractors shall observe
it strictly. QA/QC department shall supervise and inspect the implementation of the quality plan
with other departments concerned. QA/QC department is responsible for the interpretation of
the quality plan.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 9 Of 56

6.0 QUALITY MANAGEMENT SYSTEM

6.1 General Requirement

The CONTRACTOR top management has established quality management system and, QA/QC
Department has developed the quality plan according to ISO 9001-2008 standards and
CONTRACTOR. quality system documents. All staff of the project shall implement and maintain
the quality management system and continually improve its effectiveness. The project will
exercise control on processes based on the following requirements.
a) Identity the processes needed for the quality management system.
b) Determine the sequence and interaction of these processes.
c) Determine methods and criteria needed to ensure that both the operation and
control of these processes are effective.
d) Ensure the availability of resources and information necessary to support the
operation and monitoring of these processes.
e) Monitor, measure and analyze these processes.
f) Perform actions necessary to achieve planned results and continual
improvement of these processes. Subcontractors shall establish their own quality management
system and prepare quality plan accordingly based on the requirement of the project quality
plan and their scope of work to be carried out.

6.2 Overall Requirement

CONTRACTOR is committed to develop, document, implement, maintain and continuously


improve the Quality Management System.

This project’s Quality Management System meets the ISO 9001:2008 Quality Management
Systems and able to ensure that project is completed to provide safe, reliable, and operability
meets the project requirements.

According to ISO 9001: 2008 “Quality Management System”, the quality management system,
shall perform the relative quality management to meet the following requirements.

a) The quality management system covers the detailed process required by the contract
document, for managing the quality of engineering, procurement, construction, commissioning
and warranty of project.

b) In order to guarantee the above-mentioned process and the operation and control of the
external contract process the quality management system is set up to ensure the
implementation of Quality Assurance and Quality Control and supply all the relevant quality
assurance requirements to its Subcontractors & suppliers etc. involved in the project for
compliance.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 10 Of 56

c) The necessary resource and information shall be provided to ensure the operation of
process and the effectiveness of the supervision.

d) With the aid of analyzing the information which come from the supervising and measuring
process the corrective and preventive measures shall be taken for the continual improvement of
these processes, to realize the quality policy and quality objective of CONTRACTOR.

6.3 Document Control

CONTRACTOR set up and carry out strict control of quality records and documents required by
the quality management system, in order to ensure that the holders of the documents can make
good use and prevent the misuse of the invalid or scrap documents.

6.3.1 Administration department shall be responsible for the control of quality system
document,
technical documents, correspondence and the documents from out-side, for example,
regulatory and statutory documents. It shall also direct, monitor and inspect the document
control of other departments.

6.3.1.1 Each department shall appoint a person as document controller who is responsible for
receiving, dispatching, registering, numbering and filing the document within scope of work of
his own department.

6.3.1.2 The numbering system of project quality system document shall observe the
requirements of the project document control procedure.

6.3.2 Control of quality management system documents.

Scope of quality management system documents:


 Controlled quality system documents issued by CONTRACTOR.
 Project quality plan, project procedures and management instruction.
 Contract documents, procurement documents, correspondence and records.
6.3.3 Control of technical documents.

Scope of the technical document

a) Drawing,

b) Project execution plan,

c) Construction plan,

d) Construction instruction,

e) Standards and specifications,


Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 11 Of 56

f) Inspection and test procedures for different disciplines,

g) Pre-commissioning and commissioning plan,

h) Design change order,

i) Work interface record.

6.3.3.1 Distribution of construction drawings :

a) According to contract requirement and project internal procedure, engineering drawings


shall be made available to Administration Department and logged by Administration
Department.

b) A distribution matrix shall be prepared by document controller. After the matrix is approved
by Deputy Project Director the drawings can be distributed and the recipient shall sign his name
on Distribution log.

c) The document controller in each department and the Subcontractor shall be responsible for
control and distribution of the drawings received. After completion of the project, drawings shall
be returned to administration department for hand-over or destroy except the drawings must be
kept for future use.

6.3.3.2 The Administration department shall register and file project specification and
standards. The obsolete specifications may be kept by document controller for the purpose of
knowledge preservation, but they must be marked with the stamp “For Reference Only”.

6.3.3.3 The technical documents prepared by each department or Subcontractor shall be


jointly reviewed by related departments and distributed by administration department after
approval by Deputy project director (DPD) in-charge.

6.3.3.4 The control of as- built technical documents and data shall observe requirement of the
project contract and as-built drawing of detail design procedure manual.

6.3.4 Correspondence.

6.3.4.1 A letter is prepared when the giving or issuing of approvals, certificates, consents,
determinations, notices and request, which shall be type-written, printed or electronically made
and signed by project management or the authorized representative. The letter number is
assigned by administration department.
6.3.4.2 A transmittal is used to convey technical documents and drawings. All transmittal shall
be numbered and prepared by using approved transmittal coversheet. The transmittal number
is assigned by administration department. For the numbering system of letter and transmittal,
see the project document and control procedure and relevant internal management stipulations
prepared by administration department.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 12 Of 56

6.3.4.3 Each department shall prepare their own list of quality system documents and list of
technical document. Document shall be distributed by use of distribution record of documents.

6.3.4.4 Changes to documents and data shall be reviewed and approved by the same
department that performs the original review and approval. The invalid and/or obsolete
document shall be promptly removed from all points of issue or use, or otherwise assured
against unintended use.

6.3.4.5 Other content not mentioned here shall observe the project document and data control
procedure and relevant internal management stipulations prepared by administration
department.

6.4 Control Of Record

CONTRACTOR shall set up and carry out the record control, as well as the controls of mark,
storage, protection, index and preservation period, and provide evidences in which the product
has satisfied the requirement and the quality management system has been operated
effectively.

6.4.1 QA/QC department is a responsible department of controlling QA/QC records. It


shall be in charge of quality records including but not limited to records of quality
management review, quality audit, corrective and preventive actions, non-conformance
report (NCR), site inspection and test and so on. It shall monitor and audit quality records
prepared and controlled by each department.

6.4.2 Each department shall be responsible for development, control and management
of quality records required by responsible processes of QMS process function distribution
chart (See Attachment III-1). Each department shall also prepare the numbering system of
the records. “Records List” used in each department shall be established and maintained
by each department. Records shall be legible, readily, identifiable and retrievable.

6.4.3 Except the records and formats that shall be handed over to CUSTOMER or
placed in CONTRACTOR archive, Project records shall be retained till the end of
commissioning. Quality system implementation records shall be retained till the
completion of the project.

6.4.4 The records that need to be handed over or filed shall follow the contract and
CONTRACTOR regulation and rules.

6.4.5 The detailed requirements of control of record shall refer to quality record control
procedure.

6.5 Management Responsibility & Commitments

CONTRACTOR consists of leadership planning layer, function department management layer


and execution layer.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 13 Of 56

6.5.1 Project Quality Management Organization & Information Flow Chart

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 14 Of 56

6.5.2 Management Commitment

The authorities and responsibilities of Project Manager and Main Department Managers,
especially their duties to the QAQC activities in the Project, are described as below:

6.5.2.1 Project Manager

Project Manager makes commitment to: observing CONTRACTOR President’s commitment,


focusing on quality, executing the contract strictly, satisfying CUSTOMER contract requirement,
developing and implementing the quality management system, exercising effective control on
various processes that impact project quality and various processes developed from the project,
providing to CUSTOMER the satisfactory project.

The following activities shall be done to keep the commitment:


6.5.2.1.1 Communicating to all employees in the project the requirements and
importance of CUSTOMER ’s and local regulations, statutes and laws.

6.5.2.1.2 Establishing the project quality objectives. The status of


implementation and fulfillment of project objectives shall be considered as the basis of
evaluating the effectiveness of project quality management system.

6.5.2.1.3 Providing the necessary resource for implementation, establishment


and improvement of quality management system.

6.5.2.1.4 Analyzing the quality at regular interval, evaluating the suitability,


effectiveness and adequacy of the quality system

6.5.2.1.5 Administration Department Secretary Group shall perform practical


works to assist project management in taking on commitment.

6.5.2.2 Deputy Project Manager

Deputy Project Manager (DPM) Shall be responsible to execute the CONTRACT of the project.
He shall take charge of the Quality Assurance, the Schedule Control and the Cost Control in
implementing the CONTRACT. Interfacing and coordinating with CUSTOMER and General
Superintendent, handling daily managements of the Project, the Deputy Project Manager (DPM)
timely reports to the Project Manager (PM) directly.

In addition to the above Deputy Project Manager (DPM) shall perform the works assigned by
the Project Manager (PM) ensuring the effective implementation of quality management within
his responsible department. For the quality management responsibilities of each functional
department and the quality responsibility of each post, refer to “Project Quality Management
System Processes and Function Distribution Chart”. Project Manager (PM) may appoint a
Deputy Project Manager (DPM) to do routine work for quality management system.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 15 Of 56

6.5.2.3 QA/QC Manager

Under the leadership of the project top management CONTRACTOR, QA/QC Manager shall
exercise quality management on their quality processes listed at PROJECT’s QUALITY
DELIVERABLES Documents. Project management has provided sufficient QA/QC engineers
with different professional background to perform audits, inspections on quality work.

Subcontractor shall provide its own QC inspectors, whose qualification shall be identified and
the work be supervised by main CONTRACTOR..

QA/QC Manager shall be reporting to and receiving Project direction from the Project Manager.
Communicating the QA/QC events with the Deputy Project Manager. In case of quality related
concerns which cannot be resolved by the Deputy Project Manager (DPM) , the QA/QC
Manager can communicate with the Project Manager, The Vice President and the President of
CONTRACTOR.

The QAQC Manager is responsible for the development and maintenance of Project Quality
Plan for assuring that the project activities are performed and accomplished in accordance with
the Project Quality Plan and approved procedures.

QA/QC Manager specific responsibilities include, but not limited to:

6.5.2.3.1 Strictly observe the rules and regulations of the project quality
management system, enhance leadership, participate in by all employees, use method of
management of system and process to exercise scientific management on project quality work,
complete the project to the satisfaction of CUSTOMER , perform audit, continually improve the
quality of the project.

6.5.2.3.2 Prepare quality management documents covering all the project,


enhance internal audit, fill-in and maintain process record, promote effective implementation of
quality system, pass the audit performed by CONTRACTOR.

6.5.2.3.3 QA/QC Manager shall be responsible for development of project


quality objectives and resolve the objectives into each department. Each department heads and
Subcontractor shall establish its own quality objectives. QA/QC Manager will check and review
the status of implementation.

6.5.2.3.4 QA/QC Manager shall be responsible for Quality management system


planning and continual improvement is an important part of planning quality management
system.

6.5.2.3.5 The integrity of the quality management system is maintained where


changes to the quality management system are planned and implemented.

6.5.2.3.6 QA/QC Manager shall be responsible to oversee all aspects of quality


for works managed, designed, and constructed by CONTRACTOR and assigned
Subcontractors.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 16 Of 56

6.5.2.4 Procurement Manager

Reporting to and receiving operational guidance from the Project Manager. The Procurement
Manager is responsible for all procurement activities and Quality Activities related for the Project
and take direct responsibility for Project procurement performance.

Procurement Manager specific responsibilities include, but not limited to:

6.5.2.4.1 Functional and operational direction and coordination of the Project


Management Organization.

6.5.2.4.2 Interfacing with Project Management Organization for the


development, implementation, and control of procurement policies and procedures.

6.5.2.4.3 Procurement of equipment, materials, and services; vendor


evaluation and shop inspection.

6.5.2.4.4 The Procurement Manager is also responsible for material receiving


and warehousing at each site and maintains a full control of materials issued for construction.

6.5.2.5 Construction Manager

Reporting to and receiving technical and administrative direction from the Project Manager. The
Construction Manager is responsible for all construction activities and Quality Activities related
for the Project.

Construction Manager specific responsibilities include, but not limited to:

6.5.2.5.1 Construction direction.

6.5.2.5.2 Material control during construction.

6.5.2.5.3 Design document constructability review/input.

6.5.2.5.4 Implementation of construction plan and procedures.

6.5.2.6 Control Manager

Reporting to and receiving Project direction from the Project Manager. The Control Manager is
also responsible for the overall monitoring of the Project's performance against the approved
budget and schedule.

Control Manager specific responsibilities include, but not limited to:

6.5.2.6.1 Administration and maintenance of the Project schedule.


Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 17 Of 56

6.5.2.6.2 Cost control, accounting, trending and estimating services and


progress reporting.

6.5.2.7 HSE Manager

Reporting to and receiving the direction from Deputy Project Manager for project related issue
but directly refer to the HSE department for the implementation of the safety criteria with the
project.

The HSE Manager is responsible for the safety, environment protection and health of the Project
and also for safety of construction personnel and equipment on site which will be protected and
prevented with the applicable safe facilities and makes the overall construction in safe and
sound condition.

6.5.2.8 Document Control Manager

Reporting to and receiving Project direction from the Deputy Project Manager. The Document
Control Manager is responsible for the reception, classifying, numbering, issuance, callback of
quality documents, and, takes part in reviewing of as-built documents, organizes translation and
typing of notices, records and documents of quality conference.

6.5.2.9 QA/QC Engineer - I

QA/QC Engineers is assigned for each activity of quality management. Reporting to and
receiving Project direction from the QA/QC Manager. He shall be responsible for overall quality
control activities of construction and related activities.

Instructing and training the Inspector from construction teams with their task, The QAQC
Engineers are fully responsible for implementing the Project Quality Plan at sites.

QAQC Engineer shall be responsible for preparing all the procedures of Quality Management
System of the Project.

6.5.2.10 Quality Inspector - II

Report to QAQC Engineers, Quality Inspector’s responsibilities is included as below:

6.5.2.10.1 Receive Instructions from QA/QC Engineers and feedback quality


information timely.

6.5.2.10.2 Strictly execute & follow inspection plans and procedures.

6.5.2.10.3 Conduct quality control and quality inspection according to regulation


and requirement.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 18 Of 56

6.5.2.10.4 Fill and keep records of site inspection, tracking and urging
reclamation of quality deficiency.

6.5.2.10.5 Feedback quality information at sites to QAQC Engineers should be


in time.

Through various meetings, reports, documents internal publications and computer compiler
network, the horizontal and vertical connection between various different layers and function of
CONTRACTOR will be kept to link up the information in relation to the QMS to ensure the
effectiveness of the process of QMS.

6.6 Design & Engineering Quality Plan

Engineering department is responsible for engineering control and part of engineering work, it
shall conducts supervision on all engineering and design work. QA engineer in engineering
department shall perform QA audit to the design work at different stages. QA engineers working
in QA/QC department shall also make audit to the design work according to annual QA plan.

6.6.1 Design & Engineering Planning:

Under the guidance of Engineering Manager, Engineering department shall carefully study the
Main Contract, especially about the technical part, identify the customer’s requirement and
ensure that engineering shall satisfy the requirement and achieve the expected objectives.
6.6.1.1 During the design and development planning, the engineering department
shall determine:

a) The design and development stages, for example, intermediate design and final design,
basic design and detailed design.

b) The review, verification and validation that are appropriate to each design and development
stage. The records of the review, verification and validation shall be maintained.

c) The responsibilities and authorities for design and development. For detailed information,
please see relevant design procedure manual.

6.6.1.2 The Engineering Manager shall manage the interfaces between different
groups involved in design and development to ensure effective communication and clear
assignment of responsibility.

6.6.1.3 If there are some changes to the requirement of engineering, the planning
output shall be updated, as appropriate, as the design and development progresses.

6.6.2 Design & Engineering Inputs.

6.6.2.1 Engineering department shall identify and document the design and
development inputs. These inputs of the project include:

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 19 Of 56

a) Contract document: there are a lot of basic technical requirement, data and drawings in the
documents. It describes the project facilities, operation and control philosophy, scope of work,
technical specifications of different disciplines and survey data.

b) Functional and performance requirements of the project. They specify the quality of design
documents. Designers shall pay attention to the suitability, safety, economy, construction
easiness of the design document.

c) Applicable statutory and regulatory requirement of local authorities and international


associations.

d) Environment protection, forestation and other potential social requirement.

6.6.2.2 The inputs shall be reviewed for adequacy. Requirements shall be complete,
unambiguous and not in conflict with each other.

6.6.3 Design & Engineering Output.

6.6.3.1 Design & Development outputs shall:

a) Meet the input requirements for design and development.

b) Provide ER (Engineering Requisition) document used for purchasing, drawings, operation


and maintenance manual.

c) Contain or reference project acceptance criteria.

d) Specify the characteristics of the project that are essential for its safe and proper use.

6.6.3.2 The type of output may be documents, specifications, drawings and data
sheets.

6.6.3.3 The outputs of design and development shall be approved by engineering


department manager, project director and customer (if required) prior to release.

6.6.4 Design & Engineering Review.

6.6.4.1 The purpose of the review is to ensure the suitability of stage and final design
results to the internal and external resources, the adequacy of conformity with general design
inputs, and the effectiveness of achieving established effects.

6.6.4.2 Engineering department shall determine the review requirements and


perform review for the design at appropriate design stages.

6.6.4.3 The type of review may be meeting review, expert review, review at different
levels, trade review.

6.6.4.4 Participants in such review shall include representatives of function


Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 20 Of 56

concerned with the design and development stages being reviewed.

6.6.4.5 Records of the results of the reviews and any necessary actions shall be
maintained.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 21 Of 56

6.6.5 Design & Engineering Verification.

6.6.5.1 Verification shall be performed in accordance with planned arrangement to


ensure that the design and development outputs have met the design and development input
requirement.

6.6.5.2 Design verification may take activities such as:

a) Perform alternative calculations.

b) Comparing the new design with a similar proven design, if available.

c) Undertaking test and demonstration.

6.6.5.3 Especially when new structure, new material and new technology are
adopted in the project, verification activities shall be determined in design planning and must be
conducted.

6.6.5.4 Records of the results of the verification and necessary actions shall be
maintained.

6.6.6 Design & Engineering Validation.

6.6.6.1 The validation shall be performed to ensure that the resulting project is
capable of meeting the requirements for the specified application or intended use.

6.6.6.2 Wherever practicable, validation shall be completed prior to the delivery or


implementation of the project.

6.6.6.3 Records of the results of validation and any other necessary actions shall be
maintained.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 22 Of 56

6.6.7 Control Of Design & Engineering Changes.

6.6.7.1 Lead Engineer is responsible for collection of all design change requests and
raises formal “Design Change Request (DCR)” for modification to all approved or issued
engineering documents.

6.6.7.2 DCR shall be registered and distributed to the engineers concerned for their
review of the impact on the work.

6.6.7.3 Engineering manager shall authorize the DCR and seek the approval from
customer, then forward a copy of the DCR to responsible engineer to modify the design.

6.6.7.4 The design changes cannot be implemented prior to review, verification,


validation and approval.

6.6.7.5 Records of the results of the review of changes and any necessary actions
shall be maintained.

6.7 Procurement Quality Plan & Procedure

The purpose of control over the purchasing process is to ensure that the purchasing product
conforms to specified purchase requirement.

6.7.1 Purchasing Process:

6.7.1.1 The project shall establish the criteria for selection, evaluation and re-
evaluation of suppliers. It shall evaluate and select suppliers based on their ability to supply
product in accordance with the project requirement.

6.7.1.2 Procurement department, engineering department, construction department


and contract department are all responsible departments of the purchase process.

6.7.1.3 Procurement department shall develop procurement manual to define the


criteria of selection, evaluation and re-evaluation of suppliers.

a) Evaluation of supplier about qualification, certification, history, reputation, financial status.

b) Product quality status and experience of suppliers.

c) Supplier’s quality management system and its assurance ability.

d) Degree of customer ‘s satisfaction.

e) Service and support ability after delivery by supplier.

f) Establish a short name-list for qualified suppliers.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 23 Of 56

6.7.1.4 Engineering department, together with relevant departments, shall evaluate


the qualification, certification, experience and quality assurance ability of design Subcontractor
for selection of qualified design Subcontractor.

6.7.1.5 Construction department, together with other relevant departments, shall be


responsible for development of ITB document (Invitation Bidding Document) for construction
Subcontractor, in which criteria of evaluation and selection shall be defined.

Its work at this stage shall include but be not limited to the following:

a) Evaluating the qualification, certification, experience, quality assurance ability, etc.

b) Evaluating competence of management staff and skilled workers.

c) Evaluating the equipment ability.

d) Forming a short name- list of construction Subcontractor.

6.7.1.6 Contract department shall prepare terms and conditions of the ITB document
according to the main contract, law and other related regulatory and statutory requirements and
monitor the observation of the above.

6.7.1.7 Records of the results of monitoring and any necessary actions taken shall
be maintained.

6.7.2 Purchasing Information:

6.7.2.1 Procurement department shall define the goods requirement about


specification, quality, acceptance, delivery, price and quantity in the Purchasing order.

6.7.2.2 Engineering department shall prepare design sub-contract document, in


which design requirements and design scope shall be defined.

6.7.2.3 Construction department, together with relevant departments, shall prepare


the documents about project subcontract and labor service subcontract. In these documents,
construction department shall provide the following information:

a) Work-scope, characteristics of subcontract project.

b) Requirement of work period, quality and safety of subcontract project.

c) Requirement of product and service supplied.

d) Requirement of acceptance and delivery of the subcontract project.

e) Requirement of equipment and personnel supplied by supplier.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 24 Of 56

f) Requirement of work processes and quality management system of supplier.

6.7.2.4 Contract department shall prepare legal content of the subcontract.

6.7.2.5 The adequacy of specified purchase requirement shall be confirmed and


approved prior to communication to the supplier.

6.7.2.6 The content of the purchase order includes the vendor's quotation number,
quotation date, the RFQ package that was issued to solicit the bid, the equipment specification
number and drawing numbers issued with the RFQ, all inspection notices, hold points for
witness and notification requirements, and all vendor documentation and data required. The
equipment specification refers to all codes, standards, and stamps to which the CONTRACTOR.
must adhere.

6.7.2.7 Procurement and project teams should review and approve purchasing
documents for accuracy to the specifications prior to their release. To eliminate any delays
caused by the vendor not having a hard copy of the Purchase Order in his possession, a
Purchase Order Authorization Letter can be faxed to the vendor, which allows him to process
the order without any delays. An acknowledgement copy of the purchase order is also issued to
the successful CONTRACTOR. to sign and return, acknowledging their agreement with pricing,
description, delivery, and the commercial terms of the sale.

6.7.3 Purchased Product & Services Verification:

CUSTOMER or authorized Third Party Representative may verify at the source or upon receipt
that the purchased products and service conform to requirements. Verification by CUSTOMER
or Third Party Representative does not reduce the CONTRACTOR.'s responsibility.

a) QC Department shall be responsible for quality control in the all processes of procurement.
It shall prepare product inspection and test plan/ procedure, which shall be approved by
customer, and conduct the verification of purchased product.

b) The QC group shall review the procurement documents and ensure the suitability, adequacy
and effectiveness of these documents.

c) The QC group shall conduct inspection and test for delivered material and equipments.

d) If necessary, the QC group can perform verification at the supplier’s premises and make
verification arrangements and method of product release in the purchasing information before
verification.

e) Engineering department shall verify the achievements of design Subcontractor at different


design stages.

f) Construction department shall verify that the construction progress and quality of
subcontracted work meet the requirements of Subcontract.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 25 Of 56

g) All the records of the verification shall be maintained.

6.7.3.1 Source Inspection

CONTRACTOR. shall inspects the work of vendors, sub-vendors, and manufacturers as


necessary to obtain equipment and materials conforming to project specifications.

CONTRACTOR. shall develop source inspection and surveillance program including quality
surveillance schedule to ensure quality of procurement.

6.7.3.2 Inspection & Test Plans

CONTRACTOR.'s Vendors shall prepare and use the Inspection and Test Plans which give
detailed instructions for the inspectors. These Inspection & Test Plans are approved by
CONTRACTOR. And CUSTOMER prior to any inspection activity being performed.

Procurement inspection for designated items begins with the award of the purchase order and
concludes when the inspector has duly released the equipment from the vendor's shop after
successful completion of all inspections.

6.7.3.3 Inspection Coordination & Responsibilities

The Procurement Inspection Supervisor coordinates inspection activities. After receiving the
assignment from the Procurement Inspection Supervisor, the source inspector reviews the
order and conducts a pre-inspection meeting, followed by an initial inspection visit.

Progressive inspection visits will be conducted to perform the required equipment inspection as
outlined in the Inspection and Test Plans. The Source Inspector maintains the field file and
reports the results to the responsible office. The Procurement Inspection Supervisor also
coordinates source inspection activities with CUSTOMER 's Inspection personnel. The third
party inspector selection and approval shall be endorsed by CUSTOMER .

6.7.3.4 Criticality Rating Of Equipment & Materials

CONTRACTOR. will perform, as a minimum, equipment inspection according to required


inspection levels. CONTRACTOR. may deviate from these recommendations upon approval
from CUSTOMER according to work requirements.

CONTRACTOR. will perform the inspection and test work to different vendor according to the
Risk Number (RN) (1-18), and finalize the Rating Classification (CR) (I , II , III or IV) of
equipment and material, finalize the frequency of inspection according to RN and CR.

6.7.3.5 Work Process Control

CONTRACTOR. identifies and plans the production and, where applicable, installation
processes which directly affect quality and ensures that these processes are carried out under
controlled conditions.
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 26 Of 56

These include:

a) Documenting work instructions defining production and installation, where the absence of
such instructions would adversely affect quality.

b) Monitoring and control of suitable process and product characteristics during production and
installation.

c) Approval of processes and equipment.

d) Stipulated criteria for workmanship in written standards or representative samples of same.

6.7.3.6 Special Processes

When results of certain processes cannot be fully verified by subsequent inspection and testing
of the product (e.g., heat treating, NDE, cleaning, etc.) Processing deficiencies may become
apparent only after the product is in use. Then continuous monitoring and/or compliance with
documented procedures is required to ensure that the specified requirements are met.

6.7.3.7 Receiving Inspection & Testing

CONTRACTOR. ensures that incoming items are not used or processed until they are
inspected and conformance to requirements is verified according to the quality plan or
documented procedures.

6.7.3.8 In-Process Inspection & Testing

CONTRACTOR. inspects, test and identifies the work as required and uses process monitoring
and control methods to conform to requirements.

CONTRACTOR. holds the work until the required inspection and testing are complete or
necessary reports have been received and verified.

6.7.3.9 Final Inspection & Testing

No work will be released or delivered to CUSTOMER until all inspection and testing of the
activities specified in the Quality Plan has been satisfactorily completed and the associated
data and documentation are available and properly authorized.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 27 Of 56

6.7.3.10 Inspection & Test Records

CONTRACTOR. will maintain records which give evidence that the work has passed inspection
and/or testing with defined acceptance criteria.

6.7.3.11 Non-Conformance Control

CONTRACTOR. procedures ensure that nonconforming products are not used or installed.
Control provides:

a) Identification, documentation, evaluation, segregation (when practical).

b) Disposition of nonconforming work.

c) Notification to the functions concerned.

The Quality Plan defines responsibility for review and authority for the disposition of
nonconforming work. Where required by the contract, the proposed repair of nonconforming
work is reported to CUSTOMER or representative. Repaired and repeated work will be re-
inspected using the same inspection method that discovered the defect in accordance with
documented procedures.

6.7.3.12 Corrective Action

CONTRACTOR. takes the following action to correct nonconforming work:

a) Establishes, documents, and maintains procedures for investigating the cause.

b) Takes corrective action needed to prevent recurrence.

c) Detects and eliminates the root cause(s) by analyzing all processes, work operations,
deviations, quality records, service reports and complaints.

d) Initiates preventive action, commensurate with the risks encountered, to deal with problems.

e) Verifies that corrective action is taken and that it is effective.

f) Implements and records change in procedures resulting from corrective action, if any .

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 28 Of 56

6.7.3.13 MATERIAL CONTROL


(1) General

Material control refers to the various measures adopted to reduce the amount of loss
of materials at the time of receiving, storing and issuing the designated materials.
Material control in practice is exercised through periodical records and reports relating
to purchase, receipt, inspection, storage and issuing direct and indirect materials.
Proper control over material can contribute substantially to the efficiency of a job
activities.

(2) Objectives
 To enable uninterrupted progress of work.
 To ensure requisite quality of materials.
 To minimize wastage.
 To provide information and traceability.

6.7.3.14 Handling, Storage, Packing & Delivery


Handling, storage, packaging, preservation, and delivery of material is on a per project basis
appropriate to satisfy the requirements of the quality system and contract specifications. Major
equipment and materials are handled according to procedure in a manner that prevents the loss
of product value.

Equipment and material are stored according to procedure in a manner to prevent the loss of
value, preventing damage or deterioration. Equipment/material easily affected by adverse
conditions such as moisture, radiation and windstorm will be stored in an appropriate secured
warehouse. Any special storage preparations or ongoing maintenance will be performed upon
receipt of such material (i.e., electric motor bumped and kept dry with lights, desiccant installed
in crates or boxes as required, etc.) and throughout storage as required.

Packing or crating of equipment/material will be performed by reputable packager and may be


witnessed by an experienced CONTRACTOR. employee if required. Each crate/package will be
marked as is required by customs for exit of the country of origin and for entrance to the country
of end use.

Each crate will also be marked with numbers (e.g. crate 1 of 24) to alert the receiver as to how
many crates should be received. An itemized report is created which lists the contents of each
crate by crate number, vendor, cost, and date shipped. This report is provided to the receiver to
assist with receipt of material. Like items are crated together to ensure ease of receipt of
material, as well as the ability to track the material during shipment.

Shipments of equipment/material may include a CONTRACTOR. representative at the receiving


end (foreign port) to witness the loading of the material onto local trucks, clearing local customs,
and acCUSTOMER ing the material to the destination to ensure proper receipt of material. The
freight forwarder will also be present to ensure that there are not time delays due to paperwork
or language difficulties when clearing customs.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 29 Of 56

6.7.3.15 Quality Records

CONTRACTOR. maintains procedures for identifying, collecting, indexing, accessing, and


storage of quality records such as material test records, pressure test certificates, compliance
certificates, FAT inspection etc which shall be available by CONTRACTOR..

Quality records are maintained to demonstrate conformance to specified requirements and the
effective operation of the quality system. Pertinent vendor quality records are included. Each
project contract specifies the disposition and/or the retention time required for the various
documents.

The requirement for maintaining these records to demonstrate achievement of the required
quality and the effective operation of the quality system become part of the job completion as
witnessed and accepted by CUSTOMER . All quality records are turned over to CUSTOMER as
part of the Project Records Books as required by the Contract.

6.7.3.16 Internal Quality Audits

CONTRACTOR. Quality Assurance department performs internal quality audits which include
CONTRACTOR. and Subcontractor activities.

All audits are planned and scheduled. However, unscheduled audits may also be performed in
the situations where there may be serious quality problems for the activities performed by
CONTRACTOR. or the Subcontractors.

All audits are performed by the qualified and certified auditors. Audit results will be documented
and provided to the audited organization.

6.7.3.17 Training & Qualifications

CONTRACTOR. maintains procedures for identifying the training needs and provides for
training of all personnel performing activities affecting quality. Personnel performing specific
assigned tasks are qualified on the basis of appropriate education, training and/or experience,
as required. Appropriate records of training are maintained.

6.8 Construction Quality Plan & Procedure

6.8.1 Levels Of Quality Surveillance

Levels of quality surveillance will be generated to suit the project requirements and will be
specified in the Quality Plan.

6.8.2 Inspector Qualifications

For pipeline, mechanical, electrical, instrument and FOC disciplines, CONTRACTOR. describes
what type of personnel in the organization will perform in-process and final inspections.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 30 Of 56

All inspectors covering assignments for critical welded fabrications will be certified by The
American Welding Society, The American Petroleum Institute, or similar international institutions
approved by CONTRACTOR. and CUSTOMER .
All inspectors witnessing or evaluating non-destructive testing will be certified to SNT-TC-1A,
Level II. As with engineering and procurement, CUSTOMER will review and approve
Construction staffing.

6.8.3 Control Of Production & Services Provision.

6.8.3.1 Control department shall prepare overall progress schedule according to the
requirement of the contract and construction characteristics. It shall prepare the procedures for
progress controlling and monitoring. These procedures and documents shall be based on level-
3 schedule, which shall be duly filled by authorized field engineers, verified by construction
department, and then put into the databank of the progress monitoring system.

6.8.3.2 Construction department shall prepare or request Subcontractor to prepare


“Construction Procedure” or “Work Instruction” for these key/special processes. These
documents shall be reviewed by related department and submitted to CUSTOMER for
approval.

6.8.3.3 Construction department shall check and inspect the material and equipment
provided by sub-contractor for their conformity of quality requirements. It shall also check and
review the qualification of the personnel who engages in the key/ special process.

6.8.3.4 For the covered work, construction department shall fill in “Covered Work
Record” and invite customer’s representative, QC inspector to the jobsite to jointly inspect the
covered work. If acceptable, countersign “Covered Work Record”, then cover the work. The
covered work record shall be maintained.

6.8.3.5 Based on workload, work schedule and work characteristics, construction


department shall develop a “Construction Equipment Plan” and “Work Force Balance Plan” and
implement by itself or urge Subcontractor to implement these plans.
Construction department or Subcontractor shall also provide or use sufficient monitoring and
measuring devices whose precision and accuracy shall meet the requirement of specification,
standards and codes.

6.8.3.6 QA/QC department shall develop quality control plan for key/special
processes and conduct inspection and surveillance for these processes.
QA/QC department shall check the calibration status of monitoring and measuring devices to
make sure that their precision, accuracy and validity meet the project requirement.

6.8.3.7 Construction department shall prepare “Construction Record” and QA/QC


department shall fill in the “QC inspection and test records”. One process cannot be passed to
next process until the required inspection and tests have been completed or necessary reports
have been received and verified.

6.8.3.8 The project cannot be delivered until final inspection and test have been
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 31 Of 56

done and associated data and documentation are handed over and approved.

6.8.3.9 If non-conforming product is found out, it shall be reviewed in accordance


with documented procedure. It may be:

a) Reworked to meet the specified requirements.

b) Accepted with or without repair by concession.

c) Re-graded for alternative applications.

d) Rejected or scrapped.

For the detail, see 6.10.4 Control of non-conforming product.

6.8.4 Validation Of Process For Production & Service Provision.

6.8.4.1 Some processes for production and service provision shall be validated
because the resulting output cannot be verified by subsequent monitoring or measurement, or
their deficiencies become apparent only after the product is in use or the service has been
delivered.

6.8.4.2 Construction department shall identify the special processes, prepare


“Construction Procedure” or “Work Instruction”, define criteria of review and approval, and
provide suitable equipment and qualified personnel for performance of these processes.

6.8.4.3 Process review, equipment status, personnel qualification etc, shall be


recorded and maintained.

6.8.4.4 If there are some changes to important material /product parameter, the
process shall be revalidated.

6.8.5 Identification & Traceability.

6.8.5.1 In order to preclude the product or its status from confusion or misuse during
the product realization and achieve the purpose of traceability of product or service, a suitable
means shall be taken to identify the product, product status and the unique identification of the
product where traceability is a requirement.

6.8.5.2 Procurement, construction and QA/QC department are all responsible


departments of the process.

6.8.5.3 Procurement department shall maintain the original identification No. on


purchased material and equipment. When marking by itself is necessary, the type and content
shall conform to the requirement of documentation and product.
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 32 Of 56

6.8.5.4 The records of identification shall be registered in a list.

6.8.5.5 Construction department shall check the identification No. before withdrawing
material from warehouse.

6.8.5.6 Construction department shall mark the sub-projects and construction


processes, for example, pipeline No., weld No., welder No.

6.8.5.7 Construction Record may be an identification of installation work.

6.8.5.8 QA/QC department shall be responsible for identification of product status,


for example, the status of inspection and test (Hold for inspection, acceptance, reject, valid,
invalid…).

6.8.5.9 Where traceability is a requirement, all the responsible departments shall


take the responsibilities to control and record the unique identification of the product.

For example, when material shall be separated or covered, the worker or warehouse keeper
shall transfer the identification marking. Construction engineer shall monitor and document the
marking transfer to assure the traceability of the material. QC inspector shall supervise the
process of identification transfer.

6.8.6 Customer Property:

This Project is an EPC (Engineering, Procurement, Construction) project. When the customer
property is transferred to CONTRACTOR., CONTRACTOR. shall exercise care with them,
protect the existing property of customers and restore to original profile after installation.
Construction department shall record the status of the customer property and report happenings
to customer or related department.

6.8.7 Preservation Of Product.

6.8.7.1 Preservation shall be controlled in accordance with approved Preservation


Procedure.

6.8.7.2 Preservation records shall be maintained by Procurement and Construction


team till final handover to CUSTOMER .

6.8.7.3 Procurement department shall set up warehouse and material yard for
storage of material and equipment. The type and size of warehouse or yard shall meet the
quality and quantity requirements of material. The method of control over the material or
equipment shall observe the normal practice and Vender’s recommendation. Care shall be
taken for identification, handling, package and storage.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 33 Of 56

6.8.7.4 Construction department shall be responsible for product preservation during


construction. Safety measures shall be taken to protect the products from damage, loss and
deterioration.

6.9 Control Of Monitoring And Measuring Devices

6.9.1 Based on project characteristics, progress and workload, Construction


department shall prepare “Monitoring and Measuring Devices (MMD) Requisition Plan” in which
the number, type, category shall be defined.

6.9.2 Construction department shall get these devices calibrated at specific intervals or
prior to use against measurement standards traceable to international and national
measurement standards.

6.9.3 Procurement department shall provide the devices (buy or rent) used in the
course of procurement and protect the devices from damage and deterioration during handling
and storage. For the monitoring and measuring devices provided by supplier or used at jobsite
by supplier, construction department shall review the list of MMD and check the records of
calibration status prior to use.

6.9.4 QA/QC department shall spot-check and keep track of the calibration status of
these devices.

6.9.5 When the devices are found to be out of calibration, the validity of the previous
measuring results shall be assessed and recorded. Construction and QA/QC departments shall
take appropriate actions for the devices and any product affected.

6.9.6 Records of the results of calibration and verification shall be maintained.

6.9.7 When used in the monitoring and measurement of specified requirements, the
ability of computer software to satisfy the intended application shall be confirmed. This shall be
undertaken prior to initial use and reconfirmed as necessary.

6.10 Measurement, Analysis & Improvement

6.10.1 General

6.10.1.1 The project shall demonstrate conformity of product and quality management
system(QMS) and continually improve the effectiveness of QMS through customer satisfaction,
internal audit, monitoring and measurement of processes and product, control of nonconforming
product and analysis of data.

6.10.1.2 Applicable methods, including statistical techniques, shall be applied to the


planning and implementation of monitoring and measurement needed in the project.

6.10.2 Monitoring & Measurement

6.10.2.1 Customer satisfaction


Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 34 Of 56

1) Scope of Application
CONTRACTOR shall monitor information and the perception of CUSTOMER ’s
satisfaction. The methods for obtaining information on such perception may include
letters and correspondences, CUSTOMER ’s complaints, claim analysis, direct
communication, compliments, electronic communication systems, comments during
meetings, etc.
2) Responsibility and Authority

The Project Manager shall be responsible for:


 Deciding the primer monitoring methods considering the above information sources,
and implementing effective survey and analysis.
The Quality Manager shall be responsible for:
 Following up internal issues that may affect the CUSTOMER satisfaction.

Obtaining feedback from the assigned auditor over the CUSTOMER ’s satisfaction.
Such information shall be collected during the quality audits.
3) Development
The investigation and analysis of CUSTOMER ’s satisfaction shall consider the following:
 The quality of the service supplied, and the CUSTOMER ’s satisfaction over the final
product.
 The level of cooperation and reliability with regards to CUSTOMER ´s expectations.
 Major aspects from the CUSTOMER ´s point of view.
 CUSTOMER satisfaction / dissatisfaction may be subjective and perceived in several
ways, and if necessary, it may be described in the Interface / Coordination Procedure.
 CUSTOMER ’s satisfaction shall be measured in accordance with the performance
rating included in the Key Performance Indicator Procedure, which shall be
developed and issued to the CUSTOMER for its approval. This procedure shall
include a list of all performance indicators for the Engineering, Procurement and
Construction stages and the weight value for each indicator (or index) giving as a
result the performance rating of the Project

6.10.2.2 Contract department is responsible for monitoring and measurement of


customer satisfaction, working out customer satisfaction index in order to carry out effective
monitoring and measurement. Every half year, contract department shall collect, analyze and
evaluate project monthly reports, fill in “ Statistic Form of Customer Satisfaction” and report to
CONTRACTOR..

6.10.2.3 Contract department is responsible for analysis and evaluation of information


collected from implementation, amendment and change of the contract and routine
communication with customer, the result shall be the input of continual improvement. Other
departments (including engineering department, procurement department, construction
department, control department and QA/QC department) shall establish effective approach to
communication with customer in order to obtain, monitor, collect the information as to whether
CONTRACTOR. has met customer requirements.
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 35 Of 56

6.10.2.4 Main source of customer information:

a) Feedback from customer to product or service

b) Customer requirement, service information and contract information;

c) Change of market requirement;

d) Information related to rivals;

e) Survey to customer;

f) Complaint of customer.

g) Information from monitoring and measurement.

6.10.2.5 Customer visitation shall be conducted by the form of technical review


meeting and weekly progress review meeting. It shall inspect and check construction progress,
quality, service and other items to ensure conformity to contract requirements. Visitation can be
implemented by the method of visitation meetings. The minutes of the meeting shall be signed
by Customer (CUSTOMER ) and CONTRACTOR..

6.10.2.6 Other aspects about customer satisfaction shall observe CONTRACTOR.


Procedure “Monitoring and Measurement of Customer Satisfaction”.

6.10.3 Internal Audit

6.10.3.1 QA/QC department is responsible for internal audit, preparing “Quality


Assurance Audit Plan”, helping the audited departments to correct the nonconformity and
verifying the corrective actions. The audit document shall be maintained. For the QA work flow,
see the attachment IV “Project QA Activity Flow Chart”.

6.10.3.2 QA/QC department shall prepare internal audit plan at the beginning of each
year and get the approval of project leader in charge. The plan shall define the requirement of
the audit criteria, scope, frequency, methods, audit implementation, audit report,
corrective/preventive action, verification and documentation.

6.10.3.3 Internal audit should be conducted once a year. For a department, the audit
interval shall be less than 12 months. For each internal audit, all the procedures and sites
involved in the quality management system shall be covered. Regular internal audit may involve
the whole quality system or parts of it. Random internal audit can be conducted at any time
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 36 Of 56

when special condition occurs (e.g. there is a great change to the function ).

6.10.3.4 QA/QC department shall select and appoint qualified auditors to conduct
audits. Auditors shall not audit activities related to their own work to ensure the objectivity and
impartiality of the audit process.

6.10.3.5 Auditors shall objectively describe the nonconformity, communicate with the
audited department who shall analyze the causes of nonconformity and bring forward correction
methods and finish correction within limited time.

6.10.3.6 The lead auditor shall prepare audit report which can be used as input to
evaluate project quality management system and continual improvement. The audit results shall
be handed over to the departments having been audited.

6.10.3.7 For the internal audit control, refer to the procedure “Internal Audit Control
Procedure”.

6.10.3.8 Monitoring and measurement of processes

6.10.3.9 QA/QC department is responsible for monitoring and measurement of the


processes. It shall develop QC plan and procedures, which define the processes of quality
management system and the methods to monitor and measure them.

6.10.3.10 The main methods to monitor and measure processes are process audit,
process review, routine process supervision and inspection, data analysis and so on. These
methods shall demonstrate the ability of the processes to achieve planned result.

6.10.3.11 Construction department shall conduct related monitoring and measurement


of the construction processes according to relevant procedures.

6.10.3.12 Monitoring and measurement shall be taken for:

a) Special processes;

b) Processes controlled with parameters;

c) Processes needed for approval;

d) Related releases.

6.10.3.13 Corrective actions shall be taken to the nonconformity discovered in


monitoring and measurement of processes. The collected data and information shall be
analyzed. If necessary, preventive actions shall be taken.

6.10.3.14 Monitoring and measurement of product

6.10.3.15 QA/QC department is responsible for the monitoring and measurement of


in-process and final products, preparing “Process control procedure” and “Control procedure of
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 37 Of 56

in-process and final inspection and test”, determining the appropriate stages to monitor and
measure the products.

6.10.3.16 QA/QC Department shall prepare QC Plan in which “H”, “W”, “C” points (Hold
point, Witness point, Certification point) shall be inserted. When works reach these points,
Construction department shall issue IN (Inspection Notification) attached with checklist and
relating documents to QA/QC inspectors to engage in joint inspection. For the QC work flow,
see the attachment V “Project Site QC Activity Flow Chart”.

6.10.3.17 Procurement department is also the responsible department of this process,


it shall monitor and measure the purchased products, prepare inspection and test procedure for
purchased products, determine the appropriate stages of monitoring and measurement,
verification method, acceptance criteria and suggestions for nonconformity. The monitoring and
measurement of the purchased products shall observe the procedure “Quality Control
Procedure” prepared by procurement department.

6.10.3.18 All functional departments shall maintain records of monitoring and


measurement. Evidence of conformity with the acceptance criteria shall be maintained. The
persons authorizing release of product shall be determined.

6.10.3.19 Product release and service delivery shall not proceed until the planned
arrangements have been satisfactorily completed, unless otherwise approved by a relevant
authority (where applicable, by the customer). For emergency release, see the procedure of
inspection and test for delivered material.

6.10.3.20 Supervision and control shall be taken on the material purchased by


CONTRACTOR. or supplied by suppliers, and irregular supervision or tour inspection shall be
taken on construction processes. The results shall be recorded and maintained.

6.10.4 Control Of Nonconforming Product

6.10.4.1 The project ensures that product which does not conform to product
requirements is identified and controlled to prevent its unintended use and delivery.

6.10.4.2 Procurement department is responsible for control and management of


nonconformity of purchased products. QA/QC Department is responsible for control and
management of nonconforming product found in construction and maintaining the records.

6.10.4.3 QA/QC department shall prepare QCP-8.3 “Nonconforming Product Control


Procedure”

6.10.4.4 Nonconforming products include purchased products, in-process products


and finished products. Control of nonconforming product shall observe CONTRACTOR. quality
management system procedure QCP-8.3 “Non-conforming Product Control procedure”.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 38 Of 56

6.10.4.5 CONTRACTOR. shall deal with nonconforming product by one or more the
following ways:

6.10.4.5.1 By taking action to eliminate the detected nonconformity;

6.10.4.5.2 By authorizing its use, release or acceptance under concession by a


relevant authority and, where applicable, by the customer;

6.10.4.5.3 By taking action to preclude its original intended use or application.

6.10.4.5.4 The main methods to control nonconforming products are as follows:


marking, recording, isolating and quarantining (as appropriate), reviewing and disposing.

6.10.4.5.5 Records of the nature of nonconformity and any subsequent actions


taken, including concessions obtained shall be maintained.

6.10.5 Analysis Of Data

6.10.5.1 QA/QC department is responsible for collection, filing and statistical analysis
of data.

6.10.5.2 The collected data shall include:

a) Customer satisfaction (suggestion, complaint).

b) Data related to quality system implementation: information of monitoring and measurement


of process, the ability of product realization, the results of quality analysis meeting, internal audit
conclusion, output of top management review in head office of CONTRACTOR..

c) Data related to product: quality records, non-conforming information of product.

6.10.5.3 The project shall demonstrate suitability and effectiveness of the quality
management system and evaluate the opportunities of improvement through data analysis. This
mainly includes:

a) The present status and trend of customer satisfaction. Analyzing the main customer
complaints and improving quality management system.

b) Conformity to quality management system. Analyzing problems according to data statistic,


analyzing the processes in which the problems lie and then improve them.

c) The present status and trend of change to processes and products. Analyzing if potential
problems exist, determining the necessity to take preventive action.

d) Suppliers. Analyzing suppliers’ products, production processes and quality management


system, determining the necessity to enforce the control on them.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 39 Of 56

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 40 Of 56

6.10.6 Improvement

6.10.6.1 Continual improvement

6.10.6.1.1 The project shall continually improve the effectiveness of the quality
management system through implementation of the quality policy, quality objectives, audit
results, data analysis, corrective and preventive actions and management review.

6.10.6.1.2 QA/QC department is responsible for continual improvement of


quality management system.

6.10.6.1.3 The project shall plan for improvement when:

a) Any information indicating unsatisfied result arise;

b) Rational suggestions from employees are accepted;


c) The customer requirements cannot be met properly;

d) Wide scope or not only one department is involved in corrective or preventive actions.

6.10.6.1.4 Processes and methods of continual improvement

a) Seek the opportunities and ways of improvement by monitoring and measurement of quality
management system, product, and customer satisfaction, and by means of internal/external
audit, control of nonconformance and data analysis.

b) Realize improvements through preparation and implementation of corrective and preventive


actions, this is the main and effective method to continually improve quality management
system.

c) Determine new improvement target by the output of management review from head office of
CONTRACTOR..

6.10.6.1.5 QA/QC department shall collect, analyze information to prepare the


project quality information sheet and report to CONTRACTOR. Head Office at the end of each
month.

6.10.6.2 Corrective action

6.10.6.2.1 QA/QC department is responsible for monitoring, inspection, check,


following-up and verification of corrective action, preparing QCP-8.5 “Corrective and preventive
action control procedure”. The relevant functional departments are responsible for
implementation of corrective action in their own departments.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 41 Of 56

6.10.6.2.2 The following requirements shall be defined in the corrective action


procedure.

a) Reviewing nonconformities (including customer complaints);

b) Analyzing and determining the causes of nonconformities;

c) Evaluating the need for action to ensure that nonconformities do not recur;

d) Determining and implementing action needed;

e) Records of the results of action taken;

f) Reviewing corrective action taken.

6.10.6.2.3 All departments concerned of the project shall actively take corrective
actions, eliminate the causes of nonconformity to prevent recurrence. If the nonconformity is
caused by CONTRACTOR. or Subcontractors, they shall take corrective actions and implement
them separately, the responsible department of the project shall verify the implementation
results.

6.10.6.2.4 The information of corrective action shall be the input of management


review in head office.

6.10.6.3 Preventive action

6.10.6.3.1 QA/QC is responsible for monitoring, inspection, check and following-


up and verification of preventive action. Relevant functional departments are responsible for
implementation of preventive action in their own departments.

6.10.6.3.2 The following requirements shall be defined in the preventive action


procedure.

a) Determining the potential nonconformities and their causes;

b) Evaluating the need for action to prevent occurrence of nonconformities;

c) Determining and implementing action needed;

d) Records of the results of action taken;

e) Review of preventive action taken.

6.10.6.3.3 Different types of quality analysis meeting shall be held for solution of
the problems about product quality and quality system. For example, weekly meeting between
CONTRACTOR. and CUSTOMER , project internal weekly meeting, technical meeting, etc.
These meetings shall analyze the status of product quality and quality system implementation
Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 42 Of 56

and determine the preventive actions.

6.10.6.3.4 All departments of the project shall actively take actions to prevent
nonconformity occurrence by collecting and analyzing information and eliminating the causes of
nonconformities.

6.10.6.3.5 The information of preventive action shall be the input of management


review.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 43 Of 56

7.0 ANNEXURES

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 44 Of 56

7.1 Project Quality Assurance & Control Certifications

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 45 Of 56

7.2 QMS Responsibility Matrix

QMS Responsibility Matrix

Procurement dept.

Professional office
Market dev. dept
Project Manager
Project Director

Labor resource

Administration.
Deputy Project

Project control

planning dept.
manage dept
Construction
QAQC dept.

Files office
Enterprise
manager
Functional dept.post

dept.

dept

dept
System requirement

★ △ General requirements ▲
★ General ▲ △
★ △ Quality Plan ▲ △
Control of documents △ △ △ ▲ △ △ △ △ ▲ ▲ △
Control of record △ △ △ ▲ △ △ △ △ △ ▲ △
★ ▲ Management commitment ▲
★ ▲ CUSTOMER focus △ △ ▲ △ △ △
★ △ Quality policy △ △ ▲ △ △ △
★ △ Quality objective △ △ △ ▲ △ △ △ △ △ △ △
★ △ QMS planning ▲ △
★ △ Responsibility & authority △ △ △ ▲ △ △ △ △ △ △ △
★ Management representative
★ △ Internal communication △ △ △ △ △ △ △ △ △ △ △
★ ▲ Management review △ △ △ △ △ △ △ △ △ △ △
★ Provision of resources ▲ ▲ ▲
★ Human resources △ ▲
★ Infrastructure △ ▲ ▲ △
★ Working environment ▲
★ Planning of product realization ▲ ▲ △ ▲ ▲ △
★ CUSTOMER - related processes ▲ △ △ △ △ △ △
Purchase ▲ △ ▲ ▲ △
★ Production & service provision △ ▲ △ △ △ △ △ △
Control of monitoring & measurement
▲ △ △
devices
★ △ CUSTOMER satisfaction △ △ △ ▲ △ △ △
★ Internal audit △ △ △ ▲ △ △ △ △ △ △ △
★ Monitoring & measurement of process △ △ △ ▲ △ ▲ △ △ △ △ △
★ Monitoring & measurement of product ▲ △ ▲ △ ▲ △ ▲
★ Control of nonconforming product ▲ △ ▲ ▲ ▲ △ ▲
★ Analysis of data △ △ △ ▲ △ △ △ △ △
★ △ Improvement △ △ △ ▲ △ △ △ △ △ △ △

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 46 Of 56

★ stands for Overseeing


▲ stands for Executing
△ stands for Assisting

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 47 Of 56

7.3 Project QA Activity Flowchart


PROJECT QA ACTIVITY FLOW CHART

QA Plan Audit ISO 9001, Contract,


Schedule Project QC Plan and
Procedure

QA Department Issue Relevant


Audit Notification Departments
Prepare Checklist

Project Director

QA Reject
Auditee
Acknowledgement NO

Auditee takes QA Follow


Corrective Preventive. up and
Actions Verify

QA Issue Audit Report YES


with NCR & CAR

QA NO QA Accept
Department Finding Exists Observe
Perform
Yes Non Conformance
Audit

YES

Satisfactory or only
Suggestions

Audit Report

Filing Audit Report &


NCR Closed Report

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 48 Of 56

7.4 Project Site QC Activity Flowchart

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 49 Of 56

PROJECT SITE QC ACTIVITY FLOW CHART

Contract Specification QC Dept Verification and


Engineering Document QC Dept Surveillance Acceptance
Project QA/QC Plan

Site QC Plan I &TP QC Comments enter Log


QC Procedure Book

Construction Construction Dept.


Department Issue IN Response Action
at W or H Point

Project Director or
QC Dept receive IN NCR His Deputy

QC Dept. Reject
Notice owner for Joint No
Inspection
NO

YES QC 2nd
Inspection
QC 1st
Inspection
NO

YES
Construction Dept Issue Engineering
New IN After Corrective Department
Action
QC Dept. Accept (or Joint
Signature)

QC Dept. Reject
Make Note on FIN

QC Dept. File Record

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 50 Of 56

7.5 Non Conformance Report

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 51 Of 56

NON CONFORMANCE REPORT


(NCR)
NCR No: DATE:
1. DESCRIPTION OF NON CONFORMANCE:

ORIGINATOR SIGN:
DATE:
NAME: (print)
2. CONTRACTOR RESPONSE:

CONTRACTOR SIGN:
DATE:
NAME: (print)
COMMENTS:

3. IMPLEMENTATION OF THE CORRECTION:

AUTHORIZED SIGN:
DATE:
NAME: (print)
4. VERIFICATION AFTER IMPLEMENTATION OF THE CORRECTION

REMARKS:

CONTRACTOR
ENGINEER SIGN: DATE:
NAME: (print)
CUSTOMER ENGINEER
SIGN: DATE:
NAME: (print)

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 52 Of 56

7.6 Quality Audits Plan Schedule

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 53 Of 56

Quality Audits Schedule


DESCRIPTION OF
FREQUENCY AND
AUDIT SUBJECT OR TYPE OF AUDITOR
AUDIT CRITERIA DURATION OF REMARKS
NUMBER ACTIVITY TO BE AUDIT TITLES
PLANNED AUDITS
AUDITED
Internal Audits for Procurement
Project Procurement Contract, Contractor System Project
System Procedures, Project Compliance Quality
ABP-001 30%, & 60% of
Execution Plan Quality Manager &
ABP-002 Procurement Procurement Progress
Discipline Execution Plan Objectives Audit Team
Deliverables Procurement Execution Plan Compliance
Internal Audits for Construction (including Construction Subcontractors)
Contract, Contractor
ABC-001 Construction System 15% , & 50% of
Procedures, Construction Audit Team
ABC-002 Management System Compliance Construction Progress’s
Plan
Contract, Subcontractor Subcontractor
Subcontractor Quality 30% of Construction
ABS-001 Construction Plan & System
Management System Manager Progress
Quality Organization Compliance
Construction Procedures,
Process Audit
Pre-commissioning
Construction & Quality 70% of Construction
ABC-003 Procedures,
Deliverables Surveillance Manager Progress
Mechanical Completion
of Work
Hand-over Management

 ABP: For Project Procurement


 ABC: For Project Construction
 ABS: For Subcontractor

Note: QA/QC manager will modify the audits schedule in accordance with the revised schedule
of the Project progress when necessary. In accordance with the importance of the work, times of
audits could be modified to suit the conditions of the Project. Additional audits shall be
considered in preparation of the schedule. All audit schedules or changes shall be informed to
CUSTOMER 7 days before the change takes effect.

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 54 Of 56

7.7 Technical Query Form

Doc Size : A4
Rehabilitation of 4 Thermal units at Mussaib Power Plant Including
Boiler, Steam Turbine, Generator, and BOP

PROJECT QUALITY PLAN Rev.: Status:


Document No.: Page : 55 Of 56

TECHNICAL QUERY (TQ)


Contract No: Sheet 1 of ____
Contract Title:
Contractor:
Multi-Discipline:

Ref. No: Date:


To:

From:

TQ Title:

Criticality: □ - URGENT □ - ROUTINE


Classification: □ - ESSENTIAL □ – NON - ESSENTIAL
Requirement: □ - CLARIFICATION □ – DEVIATION
Documentation attached:

Query:

Signed for and on behalf of CONTRACTOR: Name:

Signature: Date:

CUSTOMER Response: (attach additional sheets if required)

□ – CUSTOMER review complete. CONTRACTOR may proceed.


□ – CONTRACTOR may proceed subject to implementation of CUSTOMER comments.
□ – CONTRACTOR may not proceed. Resubmission required.

Response prepared by: Position:

Signature: Date:
Response reviewed by: Position:

Signature: Date:
Signed for and on behalf of CUSTOMER : Name:

Signature: Date:

Doc Size : A4