RURAL WATER SUPPLY PROJECT AT

KUARMUNDA AND NUAGAON

DISTT. SUNDERGARH ODISHA

Document No.: MS-GENERAL-001/Rev. A Date : 21 -09- 2020

QAP

QUALITY ASSURANCE PLAN

.

A 12-09-2020

Quality Manager Piping Manager Safety Manager Project Manager

Rev. Date
Reviewed By Approved By

A 12-09-2020 Approval

Rev. No Date Issued for Prepared By Checked By Reviewed By

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TABLE OF CONTENTS Page

I. GENERAL 4

1.1. SERVICE 4
1.2. QUALITY 4
1.3. QUALITY ASSURANCE 4
1.4. QA PLAN 4
1.5. QA SYSTEM 4
1.6. QUALITY CONTROL 4
1.7. INSPECTION LEVEL 4

II. QUALITY ASSURANCE POLICY 5

III. ORGANISATION CHART 5

IV. MAN POWER CONTROL & QA/QC MANAGER RESPONSIBILITIES 5

4.1. PROJECT MANAGER 5
4.2. QA/QC MANAGER 6
4.3 ENGINEER 6
4.4 PROJECT CONTROL 6
4.5 CONSTRUCTION MANAGER 6
4.6 PROCUREMENT 6
4.7. SAFETY, HEALTH AND ENVIRONMENT (HES) OFFICER 6
4.8. LOGISTIC 6
9.9. DOCUMENT CONTROL 6

V. WORK ASSIGNMENT 6

VI WORKING PROCEDURE 7

VII. TESTING AND INSPECTION 8

7.1 GENERAL 8
7.2 TESTING IN THE CONTRACTOR'S FIELD LABORATORY 8
7.3 INSTRUMENT / EQUIPMENT CALIBRATION AND FREQUENCY 8
7.4 ADITIONAL TEST 8

VIII NONCONFORMANCE 9

8.1 NON-CONFORMANCE REPORT ITEMS 9

8.2 WHEN TO ISSUE A NON-CONFORMANCE REPORT 9
8.3 NCR ISSUING AUTHORITY 9
8.4 NCR CLOSE OUT 9

IX DOCUMENT CONTROL, RECORD CONTROL & FILLING SYSTEM 10

9.1 NUMBERING OF DOCUMENTS 10

9.2 LIST OF DOCUMENTS 10

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9.3 REVISION 10
9.4 DOCUMENT APPROVAL 10
9.5 DISTRIBUTION 10

X RECORD CONTROL 10

XI FILLING SYSTEM 11

XII PROCUREMENT CONTROL 11

XIII MATERIAL CONTROL 11

XIV IDENTIFY PROCEDURE 11

14.1 PHYSICAL IDENTIFICATION 11

14.2 IN-PROCESS IDENTIFICATION 11

XV RECORD 12

XVI INSPECTION AND TESTING PLAN 12

16.1 INSPECTOR 12
16.2 INSPECTION AND TEST EXECUTION CONTROL 12

XVII LOGISTIC 13

17.1 PLANNING, CONTROLLING GENERAL 13

17.2 HANDLING AND STORAGE 13

XVIII QUALITY RECORDS 13

XIX AUDIT 13

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I. GENERAL
Scope

This Quality Assurance and Quality Plan is to establish control procedures that to be executed
properly and effectively in order to assure the reliability in procurement, inspection, and
construction in compliance with the requirements specified in the contract documents. If there
is any conflict between this plan and contract documents, the last revision of the contract
documents shall be favour.

1.1 SERVICE

The performance of activities: such as, fabrication, inspection, repair or installation.

1.2 QUALITY

Fitness for use; means intended purpose, performs satisfactory in service for a special time.

1.3 QUALITY ASSURANCE

Is an included system or program of activities involving planning, quality control,

implementation, quality assessment, reporting, and quality improvement to ensure that a
product or service meets defined standards of quality with a stated level of confidence.

1.4 QA PLAN

A detailed scheme is developed and documented, for achieving the desired level of quality in
completion facilities.

1.5 QA SYSTEM

The procedures, equipment, activities, organization and personnel use implement quality
assurance plan

1.6 QUALITY CONTROL

It Is the overall system of routine technical activities whose purpose is to measure and control
the quality of a product or service so that it meets the needs of the user or standards.

1.7 INSPECTION LEVEL

The specified amount of inspection is deemed necessary to ensure that the product of service
conform to specification.

II. QUALITY ASSURANCE POLICY

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2.1 In “Anwesha Engineering & Projects Limited” quality assurance policy shall be
formulated to achieve procurement, construction, and test which are defined as time schedule,
project cost, safely execution. A part of the quality assurance is to satisfy the contractor at all
stage of the project. Executive management “Anwesha Engineering & Projects Limited” shall
be required to confirm their commitments to implement this plan by signing the Quality
Assurance Policy Statement.

2.2 Project Manager and each relevant manager are responsible for assure that all phases
of the program which is his responsible are operate strictly in accordance to the quality
assurance. The QA/QC Manager has authority to delegate the inspection, identify quality
problems and problem solving to all inspectors in every discipline.

III. ORGANISATION CHART

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IV. MAN POWER CONTROL INCLUDING QA/QC MANAGER RESPONSIBILITIES

The organization and its authority and responsibility in activity performance which is affecting
the quality to satisfy the requirements. The level of the responsibility and assigned authority of
these personnel shall be clearly indicated.

4.1 PROJECT MANAGER

Project Manager has overall authority and responsibility to execute the project regarding
contractual condition, establishment of project organization and coordination, implementation
and maintenance of QA Plan, monitoring the job quality, effective cost and schedule, and the
entire project management.

4.2. QA/QC MANAGER

In order to ensure the implementation of the QA Plan, QA/QC manager will be assigned in the
project organization. He will report directly to the project manager.

4.3. ENGINEER

Engineer is responsible to report to construction Manager for all engineering aspects of the
project and assure that the work is compliance with the applicable documents.

4.4. PROJECT CONTROL

PC is responsible to report to Project Manager for the control of cost, Schedule, documents,
materials and loss prevention control on the planning.

4.5. CONSTRUCTION MANAGER

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Construction Manager is assist Project Manager in handling the construction activities and
ensure that the activities are in accordance with the requirements of this plan.

4.6. PROCUREMENT

Procurement is responsible for all aspect of the procurement of equipment, materials and
service, including purchasing, expediting and shipping. He shall establish the procurement
policy including the activities specified by the QA plan.

4.7. SAFETY, HEALTH AND ENVIRONMENT (HES) OFFICER

Safety Manager / Health and Environment Officer shall assist to the Construction Manager in
conducting the safety, health and environment program under the direction of the project
manager. HES Officer shall check the concept of each work plan or procedure and report his
conclusion to the construction manager.

7.8. LOGISTIC

Logistic shall responsible to the construction manager for overall control materials, including
receiving, checking, inspection, storing, issuing, and handling over and disposal materials.

7.9. DOCUMENT CONTROL

Document Control shall responsible to Identify and Control of Document affecting quality to
assure that documents are processed properly, and that the latest applicable documents are
available to the personnel or organization concerned on schedule.

V. WORK ASSIGNMENT

This Work assignment describes a QA/QC contribution from Planning Stage until
Project have finished.

5.1 When Contract Awarded, QA/QC Manager held a Contract Review Meeting with all of
project Management Team. Reviewing project requirement, ensuring that contract have not
noncompliance, job sharing to develop a planning.

5.2 When Engineering personnel submit constructability review from drawing and
execution method then QA/QC inspector have to follow Inspection and Testing Plan and as
per project requirement.( Subcontractor will follow Contractor Inspection and Test Plan)

5.3 When Procurement want to procure material, QA/QC Manager have to review the
compliance before submission Purchase Order to Vendor and ensuring that appropriate
document such as mill certificate, MSDS, Inspection Manual, Heat Number have described on
Purchase Order.

5.4 At Material Receiving, QA/QC Inspector have to make inspection material compliance,
and ask for a Material Verification from Contractor‘s Inspector.

5.5 All of Material must have identification, in order traceability more easy. QA/QC Officer
and Logistic have to make identification for all material.

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4.6 QA/QC inspector have to ensure that storage process satisfy with work order,
Maintained, placed on safe area in warehouse.

5.7 Material will not be damaged then process handling and delivery satisfy with
procedure. QA/QC Manager have to give explanation to Logistic the essential of
implementation correct delivery and handling method.

5.8. All of non-conformance since material receiving until final inspection must be corrected
and prevented to increase performance of Work. Non conformance control system have to be
applied by QA/QC Manager and will get Corrective and Preventive Action by personnel whose
responsible for Corrective and preventive action.

5.9 All Correction and preventive action have to be monitored in order the cause of non
conformance have eliminated and can be prevented for next time.

5.10 When QA/QC wants to conduct Audit, then Audit prepared by QA/QC Manager. The
implementation of audit is responsible QA/QC Manager. All of Non-conformances have to be
eliminated by auditor. The result of audit has to be reported to Project Manager and then all
PMT will involve the management review to make plan of system improvement.

5.11 Project Director, Project Manager, Construction Department, HES Department,

Material Department must to support QAQC during execution of work to guarantee that
product according to quality expected by “CONTRACTOR” and according to existing standard.

VI. WORKING PROCEDURE

Working of procedure is a reference or guidance of subcontractor to do work so that as

according to standard and contract spec. Work shall be done accordingly Working Procedure.
Subcontractor will submit working procedure to contractor for approval and use at site. This
working procedure has to be distributed to field. Type of Working procedure includes cover all
discipline for example: Mechanical (Piping), Civil etc.

VII. TESTING AND INSPECTION:

7.1 GENERAL

To ensure that all required testing is properly identified, planned, documented and performed
under controlled and suitable environmental conditions, including cleanliness.

6.1.1 “Anwesha Engineering & Projects Limited” will perform all required testing and
will provide all the necessary labour, materials and testing equipment as per project
requirements and scope of work.

6.1.2 All tests will be performed in the presence of Contractor representative.

6.1.3 Sub contractor will produce and submit fabrication and construction / errection
procedure, WPS, PQR, Qualified Personnel List, Inspection Test Records (Mill Test
Certificate), QA/QC Plan, Special Process Records Technical Documents, and MSDS
etc to Contractor.

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6.1.4 As early as possible Subcontractor will submit all test report to Contractor
which will carried out at site. All tests will be recorded on standard tests reports format
agreed with or supplied by contractor

6.1.5 Sub-contractor is responsible to provide any test report or inspection report to

Company which will make available at construction site.

7.2 TESTING IN THE CONTRACTOR'S FIELD LABORATORY

Sub-Contractor shall established material testing laboratory at site, equipped and adequately
staffed to carry out the field laboratory tests as per requirements defined in the Contract.

This Field Laboratory established by the sub-contractor and supervised by the Contractors
Quality Control / Assurance staff will carry out the required tests and maintain a systematic
and retrievable record.

The Sub-Contractor will be responsible for providing and transporting the test specimens to
the laboratory under the guidance and supervision of the Contractors representative.

7.3 INSTRUMENT / EQUIPMENT CALIBRATION AND FREQUENCY

Instruments and equipment shall be calibrated prior to each use or on a scheduled, periodic
basis. The calibrations performed and the standards used will be recorded. Calibration
certificate will be available at work site.

7.4 ADDITIONAL TESTS.

Additional tests, not covered on this specification may be required for projects. These tests in
general shall be in accordance with the equipment manufacturer’s recommendation or
Contractors recommendation. Such field tests that are necessary for this equipment shall be
performed by the Contractor Engineer, Manufacturer’s test engineer, or Third-party Inspectors
with agreement between Sub-Contractor and Contractor and results shall be submitted to the
Contractor.

VIII. NONCONFORMANCE

A non-conformance report, or non-conformity report or NCR, is a construction-related

document that addresses specification deviation or work that fails to meet quality standards.
The report is used as part of quality control processes by detailing the problem, how it
occurred, and how to prevent it from happening again. An NCR also is used in determining a
resolution with a customer and documenting any corrective changes made.

8.1 NON-CONFORMANCE REPORT ITEMS

A non-conformance report must include at a minimum the following information:

7.1.1 What is the main reason for the NCR or what went wrong
7.1.2 Why the work doesn't meet specs
7.1.3 What can be done to prevent the problem from happening again

8.2 WHEN TO ISSUE A NON-CONFORMANCE REPORT

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7.2.1 Work that was not built as indicated in the approved Issued for Construction
drawings
7.2.2 Work that fails to meet specified tolerances as established in the project
specifications
7.2.3 Work that is being performed using non-approved methods or standards
7.2.4 Failure to follow the approved testing and inspection plan
7.2.5 Testing results demonstrate that the product does not meet established and
approved standards
7.2.6 Material used that has not been approved as a substitute (equal or similar)

8.3 NCR ISSUING AUTHORITY

A non-conformance report can be issued by any of the project team members. The report
must present a non-debatable fact and include clear and sufficient backup information that
supports the claim. The NCR follows agreed-upon conditions for tracking and closing the
report after appropriate corrections are made. Non-conformance reports often are used as
training tools for team leaders to train other employees to help prevent similar situations from
happening again.

8.4 NCR CLOSE OUT

Meet with the person issuing the NCR.

Implement the corrective action and make sure through an inspection process that the issue
has been solved adequately.
Respond with a formal letter or another document, outlining the process that led to the action
that triggered the NCR, documenting the action to solve the issue, and explaining the steps
taken to prevent the problem from recurring.
Make sure that your counterpart agrees and signs off on your action plan for closeout the
NCR

IX. DOCUMENT CONTROL, RECORD CONTROL AND FILLING SYSTEM

Documents controller controls all documents affecting quality to assure that documents are
processed properly, and that the latest applicable documents are available to the personnel or
organization concerned on schedule.

9.1 Numbering of Documents

Each documents prepare by the relevant discipline shall assigned a unique number in
accordance with the document numbering system established for the project numbering
system shall be approve by Contractor.

9.2 List of documents

Document controller shall list up the document, and shall be updated for issuance, receipt and
approval to identify the current document status.

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9.3 Revision

Each document conduct to revise have to be marked with number revise. And Document old
ones pulled from circulation to be kept or annihilate.

9.4 Document Approval

All documents to be submitted to Contractor for Approval and issue to use. If document have
got approval from contractor hence can be distributed to field.

9.6 Distribution

All Documents have to be distributed according to request. Document control has to record all
of document distribution. Document that distributed have to be marked CONTROLLED
DOCUMENT, UNCONTROLLED DOCUMENT, CONFIDENTIAL, RECEIVED, OBSELENCE.

XI RECORD CONTROL

10.1 Record is evidence of procedure implementation, so all record have to meet

requirement.

10.2 All of record from field operation or execution process must be maintained by
Construction Manager.

10.3 Company Record for process business have to be maintained under responsibility of
manager.

10.4 All record is maintained by filling system

XI. FILLING SYSTEM

11.1 All of Document have to saved on File.

11.2 Each File content code in order to be easy to trace.

11.3 All of Superintendent have to maintain document through filling system assisted
document control.

XII. PROCUREMENT CONTROL

Basis of the engineering data received from Contractor applicable documents following as
deemed necessary:

12.1 Scope of work, delivery date, location, applicable project code, and standard,
specification, and design and QA/QC document.

12.2 Requirement for personnel qualification, inspection and test and shipping preparation
and reporting.

12.3 QA/QC Requirements, such as the establishment of QA Program, Non Conformance

Control, Inspection Requirements, the extension of QA/QC Requirements.

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12.4 Vendor document required, such as Inspection Test Records (Mill and Test
Certificate), QA/QC Plan, Special Process Records Technical Documents, MSDS etc.

XIII. MATERIAL CONTROL

Material Control identification procedure of products to assure the correctness of product,

traceability and the prevention of inadvertent use of incorrect product including field activities.

XIV. IDENTIFY PROCEDURE

For identification control, documents controller provides vendor as mill certificate and test
certificate of goods and specification for mayor items, marking for packing and shipping
instruction, in which the marking method, marking location, marking items and colour coding
are specified.

.14.1 PHYSICAL IDENTIFICATION

Where physical identification on the item is impractical, physical separation procedure control
such as by tags, labels, and records shall be employed.

14.2 IN-PROCESS IDENTIFICATION

A transfer of marking shall be controlled and identification during storage shall be controlled,
separated, and labelled by tags etc.

Non-conforming items shall be identified and separated based on inspection status (accepted,
rejected, not yet inspected) shall be identify.

Marking shall be applied in a manner and at a location that would leave detrimental effect on
the items.

For material from vendor there must be stamp from fabricator of like material spec, logo
fabricator, tugs number, etc.

XV. RECORD

The record shall be traceability to the items and shall be checked by Inspector.

Inspector shall submit document inspection “as built sketch of material” allocation in
which the marking location including weld number.

XVI INSPECTION AND TESTING PLAN

Inspection and testing to verify the conformance of products and service to the specified
requirements of the contract, applicable codes and standard for the procurements phase.

Sub contractor will follow Contractors ITP with related inspection format.

16.1 INSPECTOR

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Inspector Coordinator select inspector on the basis of prior experiences and qualification. The
nominated inspection classification:

*Adequate current experiences

*Skilled and / or qualified inspector can be available where requested.

*Suitable network service at any location where products are fabricated.

16.2 INSPECTION AND TEST EXECUTION CONTROL

*Pre-inspection meeting will be held for mayor items or when deemed necessary by inspector
coordinator with contractor for mutual understanding prior to the fabricating.

*Witnesses’ inspection will be conducted at shop or field by inspection Representative for the
Hold Point items.

*Final inspection shall include a record review of the result and resolution of non-
conformances identified by prior inspections. Inspector coordinator shall check the inspection
record and when the record is found to meet purchase order requirements.

XVII LOGISTIC

17.1 PLANNING, CONTROLLING GENERAL

All materials will identify on handling, storage, and shipping on the basis of legal restrictions,
and specification on the procurements documents.

17.2 HANDLING AND STORAGE

*The methods and means of handling that the prevent damages or deterioration.

*All material handling shall be clearly identified by marking, tags, labels, location, etc to
prevent abuse, misuse and loss.

*Handling of heavy components specials handling by operator and lifting equipment, the
equipment checked periodically at appropriate intervals.

XVIII. QUALITY RECORDS

17.1 Record shall be classification into the following categories:

1. General document : QA Document, Project Document

2. Engineering document : Design Document, Vendor Document

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3. Procurement document : Requisition, Purchasing Order, Delivery

Order

4. Shop quality document : Manufacturing Record, Inspection & Test

record

5. Construction record : Site Construction & Installation Record

17.2 QAQC manager / QAQC engineer have to obey the filling system and prepare quality
record index to identify all the records to be collected and filled with the cooperation of
relevant design engineering.

17.3 The size of record, format of record, contents of file shall also be defined.

17.4 Record shall be legible with approved signs and the identification

17.5 Record shall be made available with subcontractor and submit to contractor upon
request within the retention period.

XIX. AUDIT

18.1 QA/QC Officer establish audit plant for internal and external, consideration to the
importance of items and service for which the received orders and to their past performance.

18.2 Audit is performed in accordance with the appropriate procedure, Scheduling and
check list by auditor.

18.3 Audit is performed in accordance with the predetermined schedule, which includes
audits for the site work at appropriate stages.

18.4 In the event that QA/QC Officer deems necessary through routine monitoring of
QA/QC activities as required by the contact, additional internal audits are to be selected.

18.5 Audit will be performed by QA/QC Officer or personnel designated by him on the
particular areas.

Audit result shall be recorder in audit check list and reported to Construction Manager
together with audit summary report. These shall be reviewed by Construction Manager and
sent to the Project Manager, with recommended for the corrective actions.

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