Nisoc: Quality Contorol Plan (QCP)

‫نگهداشت و افزایش تولید میدان نفتی بینک‬
‫سطح االرض و ابنیه تحت االرض‬
NISOC ‫عمومی و مشترک‬

:‫شماره پیمان‬ Quality Contorol Plan (QCP)
‫پروژه‬ ‫بسته کاری‬ ‫صادرکننده‬ ‫تسهیالت‬ ‫رشته‬ ‫نوع مدرک‬ ‫سریال‬ ‫نسخه‬ 25 ‫ از‬1 : ‫شماره صفحه‬
053 - 073 – 9184
BK GNRAL PEDCO 000 QC PR 0002 D00
‫ مخزن‬27 ‫طرح نگهداشت و افزایش تولید‬
Quality Contorol Plan (QCP)
D00 Oct. 2021 IFC P.Imani M.Fakharian M.MEHRSHAD

Rev. Date Purpose of Issue/Status Prepared by: Checked by: Approved by: COMPANY Approval
Class: 2 Company Doc. Number:
Status:
IDC: Inter-Discipline Check
IFC: Issued For Comment
IFA: Issued For Approval
AFD: Approved For Design
AFC: Approved For Construction
AFP: Approved For Purchase
AFQ: Approved For Quotation
IFI: Issued For Information
AB-R: As-Built for COMPANY Review
AB-A: As-Built –Approved
‫‪NISOC‬‬ ‫عمومی و مشترک‬

‫شماره پیمان‪:‬‬ ‫)‪Quality Contorol Plan (QCP‬‬
‫پروژه‬ ‫بسته کاری‬ ‫صادرکننده‬ ‫تسهیالت‬ ‫رشته‬ ‫نوع مدرک‬ ‫سریال‬ ‫نسخه‬ ‫شماره صفحه ‪ 2 :‬از ‪25‬‬
‫‪053 - 073 – 9184‬‬
‫‪BK‬‬ ‫‪GNRAL‬‬ ‫‪PEDCO‬‬ ‫‪000‬‬ ‫‪QC‬‬ ‫‪PR‬‬ ‫‪0002‬‬ ‫‪D00‬‬
‫‪REVISION RECORD SHEET‬‬
‫‪PAGE‬‬ ‫‪D00‬‬ ‫‪D01‬‬ ‫‪D02‬‬ ‫‪D03‬‬ ‫‪D04‬‬ ‫‪PAGE‬‬ ‫‪D00‬‬ ‫‪D01‬‬ ‫‪D02‬‬ ‫‪D03‬‬ ‫‪D04‬‬
‫‪1‬‬ ‫‪X‬‬ ‫‪66‬‬
‫‪2‬‬ ‫‪X‬‬ ‫‪67‬‬
‫‪3‬‬ ‫‪X‬‬ ‫‪68‬‬
‫‪4‬‬ ‫‪X‬‬ ‫‪69‬‬
‫‪5‬‬ ‫‪X‬‬ ‫‪70‬‬
‫‪6‬‬ ‫‪X‬‬ ‫‪71‬‬
‫‪7‬‬ ‫‪X‬‬ ‫‪72‬‬
‫‪8‬‬ ‫‪X‬‬ ‫‪73‬‬
‫‪9‬‬ ‫‪X‬‬ ‫‪74‬‬
‫‪10‬‬ ‫‪X‬‬ ‫‪75‬‬
‫‪11‬‬ ‫‪X‬‬ ‫‪76‬‬
‫‪12‬‬ ‫‪X‬‬ ‫‪77‬‬
‫‪13‬‬ ‫‪X‬‬ ‫‪78‬‬
‫‪14‬‬ ‫‪X‬‬ ‫‪79‬‬
‫‪15‬‬ ‫‪X‬‬ ‫‪80‬‬
‫‪16‬‬ ‫‪X‬‬ ‫‪81‬‬
‫‪17‬‬ ‫‪X‬‬ ‫‪82‬‬
‫‪18‬‬ ‫‪X‬‬ ‫‪83‬‬
‫‪19‬‬ ‫‪X‬‬ ‫‪84‬‬
‫‪20‬‬ ‫‪X‬‬ ‫‪85‬‬
‫‪21‬‬ ‫‪X‬‬ ‫‪86‬‬
‫‪22‬‬ ‫‪X‬‬ ‫‪87‬‬
‫‪23‬‬ ‫‪X‬‬ ‫‪88‬‬
‫‪24‬‬ ‫‪X‬‬ ‫‪89‬‬
‫‪25‬‬ ‫‪X‬‬ ‫‪90‬‬
‫‪26‬‬ ‫‪91‬‬
‫‪27‬‬ ‫‪92‬‬
‫‪28‬‬ ‫‪93‬‬
‫‪29‬‬ ‫‪94‬‬
‫‪30‬‬ ‫‪95‬‬
‫‪31‬‬ ‫‪96‬‬
‫‪32‬‬ ‫‪97‬‬
‫‪33‬‬ ‫‪98‬‬
‫‪34‬‬ ‫‪99‬‬
‫‪35‬‬ ‫‪100‬‬
‫‪36‬‬ ‫‪101‬‬
‫‪37‬‬ ‫‪102‬‬
‫‪38‬‬ ‫‪103‬‬
‫‪39‬‬ ‫‪104‬‬
‫‪40‬‬ ‫‪105‬‬
‫‪41‬‬ ‫‪106‬‬
‫‪42‬‬ ‫‪107‬‬
‫‪43‬‬ ‫‪108‬‬
‫‪44‬‬ ‫‪109‬‬
‫‪45‬‬ ‫‪110‬‬
‫‪46‬‬ ‫‪111‬‬
‫‪47‬‬ ‫‪112‬‬
‫‪48‬‬ ‫‪113‬‬
‫‪49‬‬ ‫‪114‬‬
‫‪50‬‬ ‫‪115‬‬
‫‪51‬‬ ‫‪116‬‬
‫‪52‬‬ ‫‪117‬‬
‫‪53‬‬ ‫‪118‬‬
‫‪54‬‬ ‫‪119‬‬
‫‪55‬‬ ‫‪120‬‬
‫‪56‬‬ ‫‪121‬‬
‫‪57‬‬ ‫‪122‬‬
‫‪58‬‬ ‫‪123‬‬
‫‪59‬‬ ‫‪124‬‬
‫‪60‬‬ ‫‪125‬‬
‫‪61‬‬ ‫‪126‬‬
‫‪62‬‬ ‫‪127‬‬
‫‪63‬‬ ‫‪128‬‬
‫‪64‬‬ ‫‪129‬‬
‫‪65‬‬ ‫‪130‬‬

053 - 073 – 9184
CONTENTS
1. INTRODUCTION ............................................................................................................................................. 4
2. GENERAL DEFINATION …………………………………….……….……………………………………………..5
3. PURPOSE ....................................................................................................................................................... 5
4. SCOPE ............................................................................................................................................................ 6
5. DEFINITIONS & ABBREVIATION .................................................................................................................. 7
6. QUALITY OBJECTIVES ................................................................................................................................. 8
7. ROLES, RESPONSIBILITY, AUTHORITY AND COMMUNICATION ............................................................ 9
ROLES, RESPONSIBILITIES .............................................................................................................................................. 9
7.1 PROJECT ROLES AND JOB PROFILE ................................................................................................................ 9
7.2 RESPONSIBILITY AND AUTHORITY .................................................................................................................... 9
8. CONTROL OF DOCUMENTED INFORMATIONS ....................................................................................... 11
8.1 CONTROL OF DOCUMENTS ............................................................................................................................ 11
8.2 CONTROL OF RECORDS ................................................................................................................................ 11
8.3 DOCUMENTATIONS FOR QUALITY CONTROL ................................................................................................... 12
9. PREPARATION AND QUALIFICATION OF WELDING PROCEDURES………...………………………….12
9.1 QUALIFICATION OF WELDERS………………………………………………………………………………….12
9.2 FILED QUALITY CONTOROL ……………………………………………………………………………………13
9.3 RADIOGRAPHY AND OTHER NON-DESTRUCTIVE METHODS ………………………………..…………14
10. INSPECTION AND TEST PLANS................................................................................................................. 15
11. QUALITY CONTROL PROCEDURES AND STANDARD PRACTICES………………………………...…….16
12 QC SUPPLEMENTARY DOCUMENTS…………………………………………………………………..………18
12.1 TEST AND INSPECTION DOCUMENTATION……………………………………………………………………..…..…18
12.2 RECORD FILE OF QC DOCUMENTATION…………………………………………………………………………..…18
12.3 HAND OVER OF AS-BUILT DOCUMENTS………………………………………………………………………19
13. CONTROL OF MONITORING AND MEASURING DEVICES ................................................................................... 19
14. EXTERNALLY PROVIDED PROCESSES, PRODUCTS AND SERVICES ................................................. 20
15. PRODUCTION AND SERVICE PROVISION ................................................................................................ 20
16. PURCHASING ............................................................................................................................................... 20
17. PURCHASING PROCESS ................................................................................................................................ 22
17.1 PURCHASING INFORMATION .......................................................................................................................... 22
17.2 VERIFICATION OF PURCHASED PRODUCT ....................................................................................................... 22
17.3 CONTROL OF PRODUCTION, FABRICATION, CONSTRUCTION, COMMISSIONING AND SERVICE PROVISION .......... 23
18. IDENTIFICATION AND TRACEABILITY………………………………………………………………...………23
19. OPERATION.................................................................................................................................................. 24
19.1 PLANNING AND CONTROL .............................................................................................................................. 24
19.2 MONITORING AND MEASUREMENT OF PROCESSES ........................................................................................ 24

053 - 073 – 9184
1. INTRODUCTION
Binak oilfield in Bushehr province is a part of the southern oilfields of Iran, is located 20 km
northwest of Genaveh city.
With the aim of increasing production of oil from Binak oilfield, an EPC/EPD Project has
been defined by NIOC/NISOC and awarded to Petro Iran Development Company
(PEDCO). Also PEDCO (as General Contractor) has assigned the EPC-packages of
the Project to "Hirgan Energy - Design and Inspection" JV.
2. GENERAL DEFINITION
The following terms shall be used in this document.
COMPANY: National Iranian South Oilfields Company (NISOC)

PROJECT: Binak Oilfield Development – General Facilities
EPD/EPC CONTRACTOR: Petro Iran Development Company (PEDCO)
EPC CONTRACTOR: Joint Venture of : Hirgan Energy – Design &
Inspection(D&I) Companies
SUB-CONTRACTOR A subcontractor is a natural or legal person who
specializes in performing executive work and the
contractor enters into a contract with her to perform
part of the operations subject to the contract
VENDOR: The firm or person who will fabricate the equipment or
material.
EXECUTOR: Executor is the party which carries out all or part of
construction and/or commissioning for the project.
THIRD PARTY INSPECTOR (TPI): The firm appointed by EPC CONTRACTOR and
approved by GC & COMPANY (in writing) for the
inspection of goods.
SHALL: Is used where a provision is mandatory.
SHOULD: Is used where a provision is advisory only.
WILL: Is normally used in connection with the action by
COMPANY rather than by an EPC/EPD
CONTRACTOR, supplier or VENDOR.
MAY: Is used where a provision is completely discretionary.

053 - 073 – 9184
3. PURPOSE
“Hirgan Energy - Design and Inspection “has implemented a Quality Management System to
satisfy the needs of Client and to improve management of the project as per project contractual
requirements. This Project Quality Plan shows the structure of the Quality Management System
and describes how it works and introduces the policy and procedures or references used by
Contractor to ensure conformance to the necessary requirements of international standards: ISO
9001 and additional contractual requirements of Integrated Management Systems (IMS). It also
delineates authorities, interrelationships and responsibilities of the personnel responsible for
performing within the system. This Project Quality Plan is used internally to guide the
Contractor's employees through the various requirements of the ISO 9001 standard which will be
met and maintained in order to ensure customer satisfaction obligation and policy, continuous
improvement of the processes and provide the necessary instructions that create an empowered
workforce.
This Project Quality Plan is used externally to introduce our Quality Management System to our
relevant interested parties and other external organizations. The Project Quality Plan is used to
familiarize them within the implemented controls at the project, to assure them that the integrity
of the Quality Management System is maintained, focused on customer satisfaction and
continuous improvement.
One of the main priorities of “Hirgan Energy - Design and Inspection “is to maintain high quality
of the works and to improve continuously the Quality System. The present manual covers all
construction quality assurance and quality control procedures, practices and documentation, as
follows:
 Preparation and updating of Construction QA/QC plan including:
 Description of procedures and standard practices,


 QA/QC responsibility matrices and document flow,
 Inspection report forms,
 PREPARATION AND QUALIFICATION OF WELDING PROCEDURES.
 QUALIFICATION OF WELDERS.
 Field quality control, including:
- Traceability during fabrication and erection works,

- Control of compliance with relevant procedures,
- Visual inspection,
- Radiographic inspection,

053 - 073 – 9184
- Ultrasonic inspection,
- Magnetic particle inspection,
- Liquid penetrant inspection,
- Preparation of welding books and welding inspection reports,
- Supervision of pipeline/flow line pigging and gauging,
- Supervision of hydrostatic testing,
- Completion of the documentation,
4. SCOPE
The quality plan is applicable to all of quality management actions in the process of project
management, design, procurement, construction, pre-commissioning, commissioning, handover
and startup.
PROJECT DETAILS
 In the surface part of this project and according to the policies made, the National
Iranian South Oilfields Company intends a set of gas pressure density, including the
construction of two rows with a row of reciprocating electric compressor tow with a
total capacity of 15 MFMR Build the firm using new technologies and advanced
control system. According to the technical, economic and environmental studies and
also the review of available options, it has been decided to build a Binak gas pressure
compression complex near the existing gas facilities.
 Also, in the surface part of this project and due to the increase in the oil flow of Binak
field, the construction of 8-inch underground gas transmission pipelines and 4-inch
aboveground gas transmission pipelines is on the agenda of the National Iranian
South Oil Fields Company.
 In the underground part of this project, construction of location and access road to
wells of 6 newly constructed wells (2 of which need power supply and other related
facilities for in-well pump use) and modifications to 4 existing wells (Along with
electricity supply for pump use in wells and other required facilities) is on the agenda
of the National Iranian South Oil Fields Company. In addition, the construction of 6
new flow pipelines from the aforementioned development wells to the Booster-Cluster
Binak complex and the development of the existing multi-way Booster-Cluster Binak
are among the job descriptions of this project.

053 - 073 – 9184
5. DEFINITIONS & ABBREVIATION
For the purposes of this document, the following terms and definitions apply:
 Quality: Degree to which a set of inherent characteristics fulfils requirements.

 Quality Management: Coordinated & Control & checking activities to
direct and control an organization with regard to quality.
 Interested party: person or organization that can affect, be affected by, or
perceive itself to be affected by a decision or activity of the project.
 Customer Satisfaction: Customer’s perception of the degree to which
the customer’s requirements have been fulfilled.
 Requirement: Need or expectation that is stated, generally implied or obligatory.
 Audit: Systematic, independent and documented process for obtaining
audit evidence and evaluating it objectively to determine the extent to
which audit criteria are fulfilled.
 Auditor: Person with the demonstrated personal attributes and
competence to conduct an audit.
 Conformity: Fulfillment of a requirement.
 Objective evidence: Data supporting the existence or verity of something.
 Continual Improvement: Recurring activity to increase the
ability to fulfill requirements.
 Correction: Action to eliminate a detected nonconformity.
 Corrective action: Action to eliminate the cause of a detected
nonconformity or other undesirable situation.
 Preventive action: Action to eliminate the cause of a potential
nonconformity or other undesirable potential situation.
 Effectiveness: Extent to which planned activities are realized and
planned results achieved.
 Efficiency: Relationship between the result achieved and the resources used.
 Infrastructure: System of facilities, equipment and services needed for
the operation of an organization.
 Defect: Non-fulfillment of a requirement related to an intended or specified use.
 Capability: Ability of an organization, system or process to realize a
product that will fulfill the requirements for that product.
 TPI: Third Party Inspector which will carry out independent inspection and
certification according to the scope of work that will be defined by
CONTRACTOR.
 ITP: Inspection and Test Plan, a document which identifies all Quality
Control activities (inspection, examination, tests and etc.) to be performed
during operation, fabrication, construction and execution of works.

053 - 073 – 9184
 AGREEMENT: The agreement between CONTRACTOR & interested

parties such as COMPANY.
 SITE: Project site
 IMS: Integrated Management Systems
 Competence/Competent: Combination of skills, experience, knowledge and capability.
 JQAR: Job, Quality, Authority & Responsibility (relating to Job Profile of personnel)
 OSDR: Overage, Shortage, Damage & Repair (relating to material and QC inspections)
6. QUALITY OBJECTIVES
Contractor's Project Manager ensures that Project Quality Objectives are established at relevant
functions and levels. The objectives are measurable and consistent with the quality policy. Our
Project Quality Objectives are:
- Reduce non-conformities in execution operation to the acceptable and logical

level according to the risks and opportunities of the PROJECT. This objective
will be achieved through the use of work instruction, standards and codes by
qualified employees who will be monitored by QC inspectors. Nonconformity
will be recorded and will be analyzed in a team work activity to find
nonconformity causes. Then the suitable corrective action will be planned and
followed up by responsible people who will be defined in corrective action
plan.
- To Reduce repair and rework items at Site, as an objective, this will be
achieved through the record, analysis and find the causes of repairs and
reworks in a team work activity. Then the suitable corrective/preventive action
will be planned and followed up by responsible people who will be defined in
corrective/preventive action plan. In this regard, achieving safety performance
will be another aspect of the objective. This objective will be achieved through
the use of this Project Quality Plan by qualified employees and will be
monitored by QA/QC personnel at site and head office. NCRs and TQs will be
recorded and analyzed in a team work activity to fined event causes. Then the
suitable corrective actions will be planned and followed up by responsible
people who will be defined in action plans. The effectiveness of the action and
after action review can be requested in the CARs to ensure the quality
assurance implementation at site.
- To meet Project schedule in engineering, procurement and construction as an
objective, this will be achieved through the planned Project activities and
provide suitable resources and qualified employees which will be monitored by
Project Manager according weekly and monthly Project reports. Deviation

053 - 073 – 9184
from Project schedule will be analyzed to find deviation causes. Then the
suitable compensation plan will be provided and followed up by responsible
specialists which will be defined by Project Manager.
7. ROLES, RESPONSIBILITY, AUTHORITY AND COMMUNICATION
ROLES, RESPONSIBILITIES
This is the responsibility of QA/QC manager to performance this document (PQP) as the template
and guideline for Project Quality Plan requirement of contractor.
7.1 PROJECT ROLES AND JOB PROFILE

CONTRACTOR has established an integrated system for human resource management
through the organization and its projects shall prepare their own JQARs as per the project roles
based on the mentioned Job descriptions and Profiles.
JQARs are the requirement of ISO 9001 standard and essential for clarification the detail of the
jobs, roles, qualifications, responsibilities and authorities. Utilizing the JQAR documents, the
Project Manager controls the competencies of the project team member and manages the
project resources to ensure the job is done according to the project objectives.
7.2 RESPONSIBILITY AND AUTHORITY

A project organization chart illustrates the interrelation of personnel in the project.
Responsibilities and authorities of each position based on the organizational chart have been
defined in Project Job, Qualifications, Authorities, Responsibilities "JQAR” document.
Attachment.3 (Organization Chart)
Summarized key IMS responsibilities and authorities in project typically are:
 Project Manager:
Project manager is responsible to manage the PROJECT scope, time, cost according
to the contract and also ensure all rules, regulations and standards are met to satisfy
the relevant interested parties of the PROJECT with acceptable level of risk and use of
all possible opportunities.
The Project Manager is responsible for overall Project's Quality requirements and
ensures its implementation. He shall provide all necessary resources (budget,
manpower and technical affairs, etc.) to fulfil the Project quality and schedule. He will
fully support the team of quality, auditors and inspectors.

053 - 073 – 9184
Project Manager is also owner and responsible against the Project Quality Plan and
ensure all its requirements are met during the execution of the project.
 The Project QA/QC Manager is responsible to manage for Quality of project work
performance and accomplishments. All technical documents required to be reviewed
shall be according to quality requirements. The Project QA/QC Manager works directly
and closely with Project Manager.
 The Project Engineering Manager is responsible for Project technical issues
including, design review, verification and validation issues in activities such as
preparation, review, approval, distribution and maintaining up to date project technical
documents and technical communications.
 The Project HSE Manager is responsible for ensuring the health, safety and welfare of
all personnel involved in the performance and/or inspection of the work, and also
responsible for the risk management issues from the beginning of the PROJECT. This
person will act according to the requirements of the “Risk Management Procedure” and
will follow-up the risks and opportunities of the project.
 The Project Planning and Control Manager is responsible for planning, scheduling,
progress measurement, and reporting, invoicing, and cost control to all phase of the
work. It is possible to exclude cost controlling to independent discipline according to the
scale and scope of the PROJECT and the project structure to cover the strategy and
objectives of the COMPANY.
 The Project Procurement Representative is responsible for all Procurement activities
of project. The inspection and quality measures shall be fully communicated among
both procurement and quality teams to assure the quality policy.
 The Site Manager is responsible for Quality of Site work performance and
accomplishments. All technical documents required to be reviewed shall be according
to quality requirements. The Site Manager works directly and closely with QA/QC
manager to ensure the effective quality level and minimize the project quality risk of work
to the acceptable risk level with the appropriate risk strategy defined in risk assessment
table.
 Project Employees - All employees are responsible for the quality of their work and
implementation of the Quality Policy, IMS requirements and procedures applicable to
processes they perform. Employees are motivated and empowered to identify and
report any known or potential problems and issues then recommend related
solutions through internal audits and/or the continual improvement, risk/opportunity and
corrective action processes.
 Responsibility Assignment Matrix: Responsibilities of project team against different
tasks have been defined in the Responsibility Assignment Matrix. (Attachment)

053 - 073 – 9184
8. CONTROL OF DOCUMENTED INFORMATIONS
To satisfy the COMPANY requirement, Project DCC or documentation responsible persons are
to review the addition requirements and also numbering, filing, coding and document control
procedures and apply them with reference to “Project Coordination Procedure (BK-GNRAL-HD-
000-PM-PR-0001)”.
8.1 CONTROL OF DOCUMENTS

Major categories of documents are recognized as follows:
 Contract specification and drawings
 Applicable industry codes and standards
 Applicable state and local regulations
 Equipment supplier recommendations for handling, storage, preventive maintenance
and installation
 Project Correspondence
All Documents will be identified by a unique code which is describes in “Project Coordination
Procedure”. DCC provides a list of latest version of Project documents and status of every
document. This list is available for all employees through computer network sharing facilities.
The documents are hyperlinked to this list.
Distribution of documents will be done through transmittal forms according to the above
mentioned procedures. Also our computer base systems will able us to define access, control
and distribute documents appropriately.
All QC procedures and ITPs shall be reviewed by QA/QC Manager and engineering
department and approved by Project Manager. According to Contract, relevant procedure shall
be submitted to TPI and COMPANY for approval, comment or information.
Other Project procedure according the scope of procedure will be reviewed by related
Managers and approved by Project Manager and will be controlled by QA/QC Manager.
COMPANY has right to review and comment the PROJECT related procedures according to
contract and its scope.
“Project final documents” will be provided according to the Contractual requirements.
8.2 CONTROL OF RECORDS

Quality records are maintained to provide evidence of conformity to requirements. Control of
Records requirements has been discussed and approved by project different parties to define
the controls needed for identification, collection, indexing, access, filing, storage, maintenance
and disposition of Project Quality records. The Project Quality records are legible and store in a
way that they are readily retrievable, in facilities that provide a suitable environment to prevent
damage, deterioration or loss.

053 - 073 – 9184
8.3 DOCUMENTATIONS FOR QUALITY CONTROL

EPC Contractor shall prepare appropriate quality procedures relevant to all activities and works
identified in this plan including the General ITPs (if practical).
Any further Quality Control Plan from Vendors or Sub-contractors shall be subject to
presentation, discussion and clarification with EPC Contractor and EPD/EPC Contractor prior
to incorporation into contract documents, and prior to award of purchase orders or contracts.
The report forms are included in MDL, divided into 5 topics:
- Welding, NDT, Hydrotest.
- Pipeline / Flowing / In-Plant.

- Mechanical.
- Civil.
- Instrumentation.
The forms were prepared on the grounds of the recommendations given by related codes and
standards, and in compliance with the good field practice.
9. PREPARATION AND QUALIFICATION OF WELDING PROCEDURES
The preparation and qualification of the welding procedures is carried out by Welding /NDE
(Non-Destructive Evaluation) Group (see fig.1) in accordance with the requirements of ASME
IX, API Standard 1104, ANSI/ASME B31.3, B31.4, B31.8, AWS D1.1, etc.
There are many welding procedures covering most of the pipeline and in-plant piping
construction activities. These procedures are prepared by EPC Contractor engineers and
qualified under the supervision of EPD/EPC Contractor , They are included in MDL .
Any further qualification of a procedure that may appear necessary for a job will be prepared by
experienced welding engineers and submitted to the Client for approval. After being approved
by the Client, the procedure will be carried out in the fabrication yard by experienced welders
under the supervision of welding inspectors from EPC Contractor QA/QC Department, Certified
materials and consumables shall be used. The mechanical testing will take place in authorized
laboratory, approved by the EPD/EPC Contractor.
9.1 QUALIFICATION OF WELDERS
The welder’s testing and qualification is carried out by the Welding/ NDE Group (see fig.1).
The qualification of welders under the qualified welding procedures is carried out according to

053 - 073 – 9184
the requirements of ASME IX API Standard 1104, ANSI/ASME B31.3, B31.4, B31.8, AWS
D1.1, etc The testing takes place in the fabrication yard under the supervision of welding
inspectors from EPC Contractor QA/QC Department . Certified materials and consumables are
used. Welder’s Performance Test Record is prepared and signed for the successful welders.
The welders are provided with ID cards for the duration of the works.
9.2 FIELD QUALITY CONTROL
The field quality control is carried out by the Field Inspection Group (see fig.1). The following
activities take place:
 Preparation and updating of welding maps.
 Tracing prefabrication, blasting, priming, and painting.

 Visual inspection of welding, blasting, priming, and painting.
 Checking paint thickness.
 Monitoring work compliance with the relevant procedures.
 Checking skid assembly.
 Checking vessels.
 Checking rotating equipment.
 Checking earthworks.
 Concrete pour checking.
 Grouting checking.
 Checking instrument installation.
 Preparation of mechanical, civil, electrical and instrumentation checklists.
The following documents are related to the field quality control:
 Visual Inspection Report
 Workshop/Erection Welding Report

 Trench Inspection Report
 Joint Insulation Inspection Report
 Lowering and Backfilling Report
 In-plant Piping Coating Report


053 - 073 – 9184
 Skid Assembly Report

 Vessel Inspection and Closing Report
 Rotating Equipment Report
 Mechanical Equipment Checklist
 Mechanical Completion Checklist
 Earthwork checklist
 Backfilling checklist
 Concrete Pour Checklist
 Instrument Installation Record
9.3 RADIOGRAPHY AND OTHER NON-DESTRUCTIVE METHODS
The non-destructive testing is carried out by NDT Group .
Appropriate NDT equipment and materials are provided:
 Gamma-ray sources,
 Films and chemicals,

 Image quality indicators,
 Viewers and pentameters,
 Photo-laboratory equipment,
 MOI equipment,
 Ultrasonic equipment,
 Dye penetration testing chemicals,
 Field hardness testing equipment (if necessary).
The evaluation of the results is performed by Welding/NDE Group .The staff is properly qualified.
The minimum qualification required is Level II.
The following documents are related to the NDT/NDE:

 Liquid Penetration test Report
 Radiographic Examination Report

053 - 073 – 9184
 Magnetic Particle Test Record

 Ultrasonic Test Record
9.4 PREPARATION OF WELDING BOOKS AND WELDING INSPECTION REPORTS
The welding book for the pipelines, and the welding inspection report for the in plant piping, are final
documents summarizing all welding and NDT carried out. They contain welding history and reference to
all reports related to the welding of a pipeline or in-plant piping element. The preparation of these
documents is a continuous processes during the execution the words. The completion of such document
takes place after the line or spool obtains status of “NDT clear”. The welding book/welding inspection
report, together with all related inspection reports, form the Test Package, which is to be completed
before the hydrostatic testing.
Examples are :
- Test package example

- Hydrotesting documentation example
- Welding book
10. INSPECTION AND TEST PLANS
Inspection and Test Plans shall define the efforts of EPC Contractor and EPD/EPC
Contractor and Vendors and Subcontractors with regard to Quality Assurance and Quality
Control associated with execution of specific Work. EPC Contractor shall ensure that
Inspection and Test Plans provided by Vendors and Subcontractors comply with the
Contract documents.
Some of key Quality Control documents and requirements based on the project scope and
needs are listed as below:
 Revisions to Project's Technical Specifications:

EPC Contractor shall ensure all revisions to the Technical specifications and drawing
are completed and approved prior to the start of any construction work on Site.
 Inspection and reporting Procedure:

EPC Contractor shall issue a Inspection and Reporting Procedure that will conclude the
reports to be issued to EPD/EPC CONTRACTOR as per contract requirements.
 Procurement Procedures:
EPC Contractor shall issue a Procurement Procedure to be issued to COMPANY as
per contract requirements
 Construction Procedures

053 - 073 – 9184
Based on the Project Technical Requirements, CONTRACTOR is responsible to

develop the following Project Construction Procedures and documentation in place
(Also the procedure shall be approved prior to start of any work):
 Welding Procedures
Welding Procedures Specifications (WPS), Procedure Qualification Records (PQR) and
Welder's qualification Certificates are normally required and shall be submitted to the
EPC Contractor for review / approval prior to the start of any welding works at plant.
 NDT Procedures
Non Destructive Testing Procedures are required and it May be submitted to the EPC
Contractor / TPI for review or approval. The contractual requirements will be defined in
relevant Inspection and Test Plan.
 Concrete Mix Design and Performance Procedures

 Painting Procedures
 QC Inspection & Test Plans
Prior to commencement of fabrication and construction activities, EPC Contractor is

responsible to submit Inspection and Testing Plans for EPD/EPC Contractor approval.
Also no work shall be started without EPD/EPC contractor approved ITP.
 Preventative Maintenance Schedule

EPC Contractor shall ensure all critical equipment that will have long lead times prior to
installation are identified, scheduled and reviewed for the Preventative Maintenance.
11. QUALITY CONTROL PROCEDURES AND STANDARD PRACTICES
In order to provide the assurance of the quality, the following procedures and standard practices
are applied:
- Standard practice for visual examination,

- Standard practice for radiography,
- Standard practice for liquid penetration examination,
- Standard practice for magnetic particle inspection,
- Standard practice for ultrasonic testing,
- Hydrotesting procedure,
- Standard practice for surface preparation and painting inspection
- Standard practice for tank and vessel cleaning;
- Standard practice for lowering pipe into trench, trench padding and backfilling,
- Standard practice for tank construction & erection
- Welding procedures,
All these documents are based on the applicable codes and standards, such as ASME Section V,
ASME Section VIII, ASME Section IX, ANSI/ASME B31.3, B31.4, B31.8, API Standard 1104, etc.,
as well as on the schedules and specifications of Client.

053 - 073 – 9184
The procedures and standard practices are included in MDL of the Project .
The following quality control procedures have to be developed for control of activities in Project's
different stages. The decision of preparing these documents is by the QC department according to
the contract and the scope of the PROJECT. All QC Procedures shall be prepared and submitted
to Contractor by subcontractors/ vendors/ suppliers or manufactures according to contract spilt of
work.
a) Mechanical QC Procedures
 Protection, Preservation. & Maintenance of Equipment
 Fabrication, Installation & Pressure Testing of Piping & Vessels
 Installation of Mechanical Equipment
 Preparation of Rotating Equipment for Operation
 NDT Procedure / Welding Procedure
 Heat Treatment Procedure
b) Civil and Steel Structure QC Procedures
 Steel Structure Fabrication & Installation
 Earth Work Procedure
 Concrete Work Procedure (Form Work, Concrete Pouring, Curing, Grouting and
Repair)
 Building Construction (Masonry Wall, Precast, Roof Construction, etc.)
c) Electrical QC Procedures
 General Electrical Works Procedure (Including cabling, Conduit Installation, Cathodic
Protection System- C.P. Data sheet, Grounding System Installation, UPS, Junction Box
installation, Switchgears, lighting system, Control Panel, Termination & Splicing, HV
Cables, etc.)
 Electric Motor Installation
 Generator Installation
d) Instrumentation QC Procedures
 Instrument Installation (Calibration, Hook up, loop check, etc.)
 Pressure Testing of Instrument Piping
e) Painting and Insulation Procedures
 Painting and Insulation Procedure (including Surface Preparation)
 Concrete Fire Proofing (if any)
 Coating Procedure
f) Storage Tanks Procedures
 Storage Tanks Fabrication Procedures
 Storage Tanks Installation Procedures
 Storage Tanks Pressure Test Procedures
 NDT/Welding Procedures

053 - 073 – 9184
12. QC SUPPLEMENTARY DOCUMENTS
Personnel performing quality control activities will be informed by DCC department of the
latest approved documents and procedure which are necessary for the execution of the
work. The submitting of Project documents to COMPANY is in according to Agreement.
The following technical documents to be used for the construction of the PROJECT will be
made available to the Quality Control Staff at the work Site:
 Construction drawings
 P&ID diagrams
 COMPANY specifications
 Technical specifications (detail engineering)
 Codes and standards
 Project working procedures and / or instructions
 Vendors inspection and testing certificates
 Vendors requirements and instructions
 Other applicable documents
12.1 TEST AND INSPECTION DOCUMENTATION

The final reports and certificates of tests and inspections of the works will be collected
Checking and issued by the QA/QC Manager to the EPC Contractor in accordance with
the relevant Final Documentation procedures or specifications.
The documentation will include the following information (as minimum):
 Item and place being tested

 Time and date performed test
 Type of check, test and inspection and it's results
 Person performing
 Instrument identification No (when applicable)
 Reference documents for requirements (when applicable)
12.2 RECORD FILE OF QC DOCUMENTATION

The QC Manager EPC Contractor is responsible to ensure the implementation of
procedure for the filing of all documents relevant to inspections and test in each working
Site.
Retained records will include:
 Results of reviews, tests, inspections and material analysis

 Monitoring report of work performance

053 - 073 – 9184
 Qualification record of personnel, procedures and equipment

 Drawings, specifications if necessary
 Calibration reports
 Non-conformance reports and corrective actions
 Vendor's instructions, requirements and recommendations, if required
 Vendor's latest approved drawings
 Material and documents status reports
 Vendor's inspection and testing certificates, if necessary
 As built drawings
12.3 HAND OVER OF AS-BUILT DOCUMENTS

All related as built Project document will be handed over to EPC Contractor according to
“Completion & Handover Procedure (BK-GNRAL-PEDCO-000-PM-PR-0006) " and "Project
Coordination Procedure". This shall be included but not limited to following items:
 QA/QC Documentation
 QA/QC Documentation Retention
EPC Contractor will submit to the EPD/EPC Contractor the Copies of Project Quality
Control and Quality Assurance documentations for archival. CONTRACTOR will retain
his own copy for a minimum period of two years or project duration, any period is
longer. Project manager is responsible to control and permit files deletion and
document retention and disposition as per project documentation control procedure.
 Punch Listed Items

Prior to completion of a Project Milestone, all punch listed items shall be identified,
coordinated and cleared with COMPANY for each working disciplines.
The following weekly status report of punch listed items will be reported to the
Construction Manager:
 New Punch listed Items Raised
 Punch listed Items Closed
 Total Outstanding Punch listed Items
Final outstanding Punch items which cannot be cleared for any reason shall be agreed
with the COMPANY and to be recorded in punch exception list prior to final handover.
 Warranty Claims
In such cases where there is a failure of the product, the QA/QC Handover Dossiers
will be able to identify whether there is a product manufacturing, installation,
construction defect or if it was an operational failure.
13. CONTROL OF MONITORING AND MEASURING DEVICES
Any electrical/ electronic instrument and measuring devices used to determine the acceptability
of an item will be calibrated and monitored for its state of accuracy.

053 - 073 – 9184
Rule to follow is: if the measuring device determines the conformity of the item it calibrated or
validated before use, then it will be calibrated.
Items included in this are:
 Transit levels
 Electrical measuring devices
 Frequency meters
 Precision levels
 Mechanical measuring instruments
 Pumps to measure flow capability
 Pete tubes
 Pressure gauges
 Relief valves
 Revolutions per minute (RPM) measuring instruments
 Other devices which use to determine conformity of an item
14. EXTERNALLY PROVIDED PROCESSES, PRODUCTS AND SERVICES
Project manager shall ensure that externally provided processes, products and services conform
to requirements and control measures are provided and fully executed. Any required inspection
or measurement and monitoring shall be provided to meet the determined results with no
unacceptable risk.
15. PRODUCTION AND SERVICE PROVISION
Production and service provision activities which are describe as following, will be done by
Subcontractors. Site Manager supervises construction activities. Also QA/QC department will
monitor these activities during audits, KPIs and Project control reports to ensure all ISO 9001
and contractual requirements will be fulfilled.
16. PURCHASING
Following procedures define the procurement phase quality activities to ensure that QC/QA
Manager properly monitor procurement activities and supplier performance:
 Procurement plan and procedure

 General Inspection and test plan for procurement
 Vendors Pre-Qualification procedure
 Supplier Performance Evaluation procedure
 Inspection procedure
 supplire Quality Control requirements

053 - 073 – 9184
Definition of critical characteristics for purchased products that affect the quality of the
PROJECT outcome and the method of communication these characteristics to supplier to
enable adequate control of purchased product throughout the PROJECT will be done as
describe in " supplire Quality Control Requirements".
Purchase of materials and equipment and associated quality documentation will be done in
according to Project schedule which will be monitored by QA/QC Manager to ensure of quality.
Based on the criticality and complexity of the equipment, inspection level will be defined.
There are 4 inspection levels for equipment and materials is according to “Procurement
procedure ICE-EID-MI-SP01-Rev.01
Level I:
Inspection Level I is defined as a full stage inspection carried out progressively from
commencement of manufacturing to final acceptance. This does not normally mean full-time
witnessed in-line inspection during product manufacturing; however, this may be required on
occasions where work program demands regular attendance.
Level II:
Inspection Level II is defined as specific stage inspection of equipment and final
inspection of equipment prior to shipment. Stages of inspection shall be agreed upon during a
pre-inspection meeting to be held with the VENDORS after purchase award.
Level III:
Inspection Level III is defined as final condition or as built examination(s) and test(s). Inspection
may be on one or more pieces of equipment or on a random batch selection.
Level IV:
Inspection Level IV is defined as the review and acceptance/endorsement of
manufacturer's attestation, including any data book requirements to approved ITP.
As described in above mentioned procedures and this Quality Plan:
Sub Contractor shall arrange a kick-off meeting and pre-inspection meeting between EPC
Contractor and EPD/EPC Contractor representatives at supplier shop, for all key equipment
packages, prior to start of manufacturing activities by Supplier.
EPC Contractor will carry out inspection of all procured equipment or other items during design,
fabrication, manufacturing and testing according to requirements defined in the contract
technical specifications, codes, and standards which will be reviewed in design process.
Hold, witness, review, monitoring, reviewed and approved and surveillance points will be
identified in the ITP for Contractor, Supplier, Third-Party Inspector or authorized Inspector, and
EPD/EPC Contractor and COMPANY.
Supplier appraisals, Quality assurance audits of Suppliers, Quality surveillance and inspection
of Supplier's activities are describe in purchase procedure (BK-GNRAL-PEDCO-000-PM-PR-
0005) and ICE-EID-MI-SP01-Rev.01

053 - 073 – 9184
17. PURCHASING PROCESS
CONTRACTOR has established purchasing processes to ensure purchased product or service

conforms to requirements, therefore:
a) Evaluates and selects its suppliers based on their ability to supply product or service in
accordance with requirements;
b) Defines the type and extent of control to be exercised depending upon the type of product or
service, the impact of purchased product or service on the quality of final service/product,
and previously demonstrated capability and performance of Vendors.
The results of evaluations and necessary actions will be maintained.
The method and purchase process is in accordance with the purchase procedure (BK-GNRAL-
PEDCO-000-PM-PR-0005).
17.1 PURCHASING INFORMATION

The purchase process and Inspection is according to the company procedure ICE-EID-MI-
SP01-Rev.01 & EPC Contractor purchase procedure (BK-GNRAL-PEDCO-000-PM-PR-0005).
Purchase Orders and other documents contain information describing the product to be
purchased, including where appropriate:
a) Requirements for approval of product, procedures, processes, equipment, and personnel

b) Quality management system requirements.
Procurement Manager ensures the adequacy of specified requirements contained in the

purchasing documents prior to their release.
17.2 VERIFICATION OF PURCHASED PRODUCT

EPC Contractor identifies and implements plans and the activities necessary for verification of
purchased product. These activities may include according to the company procedure ICE-EID-
MI-SP01-Rev.01 :
a) Obtaining objective evidence of the product quality,

b) Inspection and audit at supplier’s premises,
c) Review of the required documentation,
d) Inspection of products upon receipt, and
e) Delegation of verification to the supplier, or supplier certification.
EPC Contractor does not use any product until it has been verified as conforming to
requirements.
Purchased product shall be inspected for acceptance at the Suppliers shop or the construction

053 - 073 – 9184
Site by involved parties as per approved ITP.
When verification performs at supplier premises, EPC Contractor states the intended verification
arrangements and the method of product release on the Purchase Order.
17.3 CONTROL OF PRODUCTION, FABRICATION, CONSTRUCTION, COMMISSIONING

AND SERVICE PROVISION
Any Subcontractor or vendor addresses its plan to carry out production, Fabrication,
Construction, Commissioning and service provision under controlled conditions. Consideration
will be given to the following when Subcontractor describes its controlled conditions:
 Contract specifications and drawings, including applicable existing as-built drawings

 Applicable industry codes and standards
 Procedures including equipment manufacturer recommendations of storage and
installation
Any Subcontractor will establish the necessary controls to assure that equipment serial/tag/part
numbers and material spec/grade/heat/lot markings are maintained and traceable. Warehouse
controls will be established to assure that only the correct materials/items are released for
installation/use.
Any Subcontractor provides for the availability, calibration and use of appropriate equipment
and measuring and test equipment.
Any Subcontractor establishes and implements an inspection/surveillance system to monitor
fabrication and installation activities, The contractor and the third party inspector oversee the
above processes.
18. IDENTIFICATION AND TRACEABILITY
Any Subcontractor applies Document coding schemes to drawings and specifications to

typically identify the Subcontractor's product sufficient for conformity to this clause.
The IMS of Subcontractors will address the following:
 Material (Spec, grade and heat/lot number),
 Equipment/ component (tag/serial/part number),
 Inspection/ test status of fabrication/installation activities Methods may include:
 Tags (hold, accept, reject),
 Markings on item (care required to assure that marking method is non-detrimental),
 Location (bonded area for reject items),
 Documentation traceable to the item (inspection reports, notation on drawings and so
on),
 Entries in computer databases

053 - 073 – 9184
19. OPERATION
19.1 PLANNING AND CONTROL

EPC CONTRACTOR has planned and developed the processes for Project with the goal of
meeting Project requirements, interested parties’ satisfaction and continually improving the IMS.
In planning these processes, EPC CONTRACTOR has determined the following:
 Quality objectives,
 The need to establish processes, documentation, provide resources, risk, opportunities
and facilities. Specific requirements to the PROJECT such as test laboratories,
radiography, subcontractors, etc. will be considered in different levels of the processes
and activities.
 Review, Verification and Validation activities and criteria for acceptability which are
identified procedures such as QC Procedures and “Project Inspection and Test Plans”.
 The necessary records to provide evidence for the processes.
 Project schedule include construction, pre-commissioning, commissioning and start-up
activities
 Responsibilities
 Infrastructure
19.2 MONITORING AND MEASUREMENT OF PROCESSES

QA/QC team applies suitable methods for monitoring and where applicable measurement of the
quality management system processes. These methods demonstrate the ability of the
processes to achieve planned results. When planned results are not achieved, corrective action
is taken as appropriate to ensure conformity of the process.
QA/QC team monitor the ability and performance of processes according the key performance
indicators defined for each process.
The method of monitoring these indicators includes:
 Define key performance indicator
 Define data gathering needs
 Suggest the provision forms and data logs to record data
 Suggest the provision data and provide reports (use of statistical histograms where
need)
 Survey of data according to key performance indicators
 Take corrective action where the result of survey is not satisfactory
In addition:
 Performance of process outputs will be checked during QA/QC activities such as
inspection, test and quality audits. The record of these activities include
nonconformities, Corrective action report, repair, reworks and so on, will be analyzed
through statistical methods like histogram to show the ability of process and eventual

053 - 073 – 9184
weakness points and improvement opportunities.

 Use of
 Suitable Equipment & devices
 Suitable Method and procedures
 Qualified and competent man power and
 Heed of safety rules
 Performance of processes according to Project schedule will be monitored through
Project control reports and progress measurement procedure and execution plan of the
PROJECT.
Monitoring of processes for system/procedure conformity generally will be accomplished by
performing surveillance, audits or document reviews. Such assessments evaluate the following:
 Purchasing practices and control
 Document control
 Material identification, traceability, and control
 Material/equipment storage and preservation
 Welding, including welder qualification, and filler material control
 Heat treatment
 Painting
 Non-destructive examination

Nisoc: Quality Contorol Plan (QCP)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Nisoc: Quality Contorol Plan (QCP)

Uploaded by

Copyright:

Available Formats

‫نگهداشت و افزایش تولید میدان نفتی بینک‬

‫سطح االرض و ابنیه تحت االرض‬

NISOC ‫عمومی و مشترک‬

‫ مخزن‬27 ‫طرح نگهداشت و افزایش تولید‬

Quality Contorol Plan (QCP)

‫نگهداشت و افزایش تولید میدان نفتی بینک‬

D00 Oct. 2021 IFC P.Imani M.Fakharian M.MEHRSHAD

‫‪NISOC‬‬ ‫عمومی و مشترک‬

‫‪REVISION RECORD SHEET‬‬

NISOC ‫عمومی و مشترک‬

NISOC ‫عمومی و مشترک‬

The following terms shall be used in this document.

COMPANY: National Iranian South Oilfields Company (NISOC)

NISOC ‫عمومی و مشترک‬

 Preparation and updating of Construction QA/QC plan including:

 Description of procedures and standard practices,

 PREPARATION AND QUALIFICATION OF WELDING PROCEDURES.

 Field quality control, including:

- Traceability during fabrication and erection works,

NISOC ‫عمومی و مشترک‬

NISOC ‫عمومی و مشترک‬

5. DEFINITIONS & ABBREVIATION

 Quality: Degree to which a set of inherent characteristics fulfils requirements.

NISOC ‫عمومی و مشترک‬

 AGREEMENT: The agreement between CONTRACTOR & interested

- Reduce non-conformities in execution operation to the acceptable and logical

NISOC ‫عمومی و مشترک‬

7. ROLES, RESPONSIBILITY, AUTHORITY AND COMMUNICATION

7.1 PROJECT ROLES AND JOB PROFILE

7.2 RESPONSIBILITY AND AUTHORITY

NISOC ‫عمومی و مشترک‬

NISOC ‫عمومی و مشترک‬

8. CONTROL OF DOCUMENTED INFORMATIONS

8.1 CONTROL OF DOCUMENTS

8.2 CONTROL OF RECORDS

NISOC ‫عمومی و مشترک‬

8.3 DOCUMENTATIONS FOR QUALITY CONTROL

- Pipeline / Flowing / In-Plant.

9. PREPARATION AND QUALIFICATION OF WELDING PROCEDURES

9.1 QUALIFICATION OF WELDERS

NISOC ‫عمومی و مشترک‬

9.2 FIELD QUALITY CONTROL

 Preparation and updating of welding maps.

 Tracing prefabrication, blasting, priming, and painting.

The following documents are related to the field quality control:

 Visual Inspection Report

 Workshop/Erection Welding Report

NISOC ‫عمومی و مشترک‬

 Skid Assembly Report

9.3 RADIOGRAPHY AND OTHER NON-DESTRUCTIVE METHODS

The non-destructive testing is carried out by NDT Group .

Appropriate NDT equipment and materials are provided:

 Films and chemicals,

The following documents are related to the NDT/NDE:

NISOC ‫عمومی و مشترک‬

 Magnetic Particle Test Record

9.4 PREPARATION OF WELDING BOOKS AND WELDING INSPECTION REPORTS

- Test package example

10. INSPECTION AND TEST PLANS

 Revisions to Project's Technical Specifications:

 Inspection and reporting Procedure:

NISOC ‫عمومی و مشترک‬

Based on the Project Technical Requirements, CONTRACTOR is responsible to