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DISCLAIMER
All information contained within this document must only be used for the purpose for which it was created. As such the information
should not be used as a basis for any fabrication, construction, installation and/or operation other than as already agreed in writing by
F2 without further engineering studies to validate its application. F2 cannot be held liable for the consequences of any use or misuse of
the information contained within this report which exceeds its original and stated purpose. Where a particular valid Non-Disclosure
Agreement exists in relation to the information contained within this document it is to be treated as strictly confidential and not to be
shared with a third party without the express permission of F2.
List of
Updated/Modified
Rev Purpose sections
HOLDS LIST
List of holds
Section Description
Contents
1 Introduction ....................................................................................................................... 9
Contractor’s Scope of Work ................................................................................................ 9
SUPPLIER’s Scope of Work ................................................................................................ 10
2 Document Scope ............................................................................................................... 10
3 General References ........................................................................................................... 10
Codes, Standards and Guidelines...................................................................................... 10
EMPLOYER Documents ..................................................................................................... 11
CONTRACTOR Documents ................................................................................................ 11
JDN Project Documents .................................................................................................... 11
SUPPLIER Project Documents ........................................................................................... 12
SUPPLIER Corporate Reference ........................................................................................ 13
4 Terms and definitions ....................................................................................................... 13
Abbreviations .................................................................................................................... 13
Project Definitions ............................................................................................................ 14
5 PROJECT QUALITY MANAGEMENT SYSTEM ........................................................................ 15
Quality Management System Hierarchy ........................................................................... 16
Management Commitment .............................................................................................. 17
Project Organisation and Responsibilities ........................................................................ 17
6 PROJECT QUALITY POLICY AND KEY PERFORMANCE INDICATOR ......................................... 21
Project Quality Policy ........................................................................................................ 21
Key Performance Indicators (KPI’s) ................................................................................... 21
7 RESOURCES MANAGEMENT .............................................................................................. 23
Provision of the Resources................................................................................................ 23
Infrastructure and Work Environment ............................................................................. 23
Quality Induction and Awareness ..................................................................................... 23
8 DOCUMENT AND DATA MANAGEMENT ............................................................................. 24
sUPPLIER Document Register (SDR) .................................................................................. 24
Deliverables Preparation, Verification and Approval Process .......................................... 24
8.2.1 Single Discipline Documents: verification and Approval ................................... 24
8.2.2 Multi-Discipline Documents: Verification and Approval ................................... 24
Management of Project Document .................................................................................. 25
Control of Project Records ................................................................................................ 25
Final Documentation......................................................................................................... 25
Customer Property............................................................................................................ 26
9 MANAGEMENT OF CHANGE .............................................................................................. 26
Technical Queries/Field design change/deviation and concession request ..................... 27
List of figures
Figure 1-1: Location of Formosa 2 OWF .................................................................................................. 9
Figure 5-1 Project Quality Management System .................................................................................. 16
Figure 11-1: Location AFD structure...................................................................................................... 34
Figure 16-1 Lessons Learned Work Process .......................................................................................... 49
List of tables
Table 1-1 Table of Revision Change Details............................................................................................. 4
Table 1-2 Table of Holds .......................................................................................................................... 4
Table 4-1: Table of Abbreviations.......................................................................................................... 14
Table 4-2: Table of Project Definitions .................................................................................................. 15
1 INTRODUCTION
The Formosa 2 OWF is a Taiwanese OWF located in the straits between mainland China and Taiwan,
off the coast of Zhunan & Houlong in the Miaoli County.
The Formosa 2 OWF is on the seaward side of the Formosa 1 project and consists of two (2) licensed
areas awarded by the Taiwanese Bureau of Energy (BoE). The size of the combined area is
approximately 68.8 km2 with a maximum installed capacity of 378MW and is shown in Figure 1-1. The
combined area has water depths ranging between 35 m and 55 m and distance from shore on the
closest boundaries ranges from 3.8 to 9.5km.
The Environmental Impact Assessment (“EIA”) was successfully approved for the Project in May 2018.
The EIA permits a range of WTGs from 6 to 9.5MW, giving a maximum of 54 WTGs. The Wind Turbine
Generator type will be 47x Siemens SWT167-8.0MW.
The foundation type is a four-legged pre-piled jacket structure. Due to the Sites’ proximity to shore,
there is no offshore sub-station envisaged to be delivered as a part of the Project. Instead there will be
up to four (4) 66kV subsea export cables from collector WTG positions running to shore and being
jointed with the land export cables in a transition joint bay. The cables will be terminated at a dedicated
onshore sub-station (to be situated approximately 1km inland) before being connected to the grid at
Taipower’s 161kV Ying-Pan Substation.
The Project programme is targeting achievement of the Commercial Operation Date (“COD”) by
December 2021.
2 DOCUMENT SCOPE
The purpose of this document is to detail all the contractual requirements to ensure quality of the work
carried out for the Project at PTSI - Karimun site.
It details how the Quality Management System shall be implemented and maintained for the contract
and performance of the work. Discreet elements for quality will be implemented by each process
owner in accordance with SUPPLIER/CONTRACTOR requirements and international standard for
quality management system (ISO 9001 requirements).
The objectives of this Project Quality Plan (PQP) are:
• To establish a communication on Quality Management System requirements;
• To define the responsibilities, activities and controls necessary to achieve the quality objectives;
• To manage the project processes and resources in a planned, efficient and controlled manner;
• To ensure that the Project works are carried out to the required level of quality;
• To demonstrate through quality records that project activities have been carried out efficiently
and effectively;
• To provide a mechanism to demonstrate and promote continual performance improvement.
The scope outlined in this Project Quality Plan shall be applicable to the project activities to be carried
out by SUPPLIER at PTSI Karimun Yard.
Sub-Supplier and vendors that shall be utilized within the project framework shall carry out their
activities in accordance with the contents and guideline of this plan.
3 GENERAL REFERENCES
CODES, STANDARDS AND GUIDELINES
(1) Quality Management Systems Requirements ISO 9001: 2015
(2) Quality Management Systems: General requirements for
the competence of testing and calibration laboratories. ISO 17025 : 2017
(3) Quality Management Systems – Fundamentals & Vocabulary ISO 9000 : 2015
(4) Quality Management Systems – Guidelines for Quality Plans ISO 10005 : 2018
(5) Quality Management Systems – Guidelines for Quality
Management in Projects ISO 10006 : 2017
(6) Paint and Varnishes - Corrosion protection of steel
structures by protective paint systems ISO 12944-4
EMPLOYER DOCUMENTS
N/A
CONTRACTOR DOCUMENTS
(23) Policy statement Jan De Nul Group (QHSSE) JDN.QF.01.01
(24) Leadership Matrix JDN.SF.01.08
(25) Project Management Manual JDN.PQM.01.01
(26) Management of Change – Working On Offshore Projects JDN.QP.09.18
And Equipment
(63) Risk & Opportunity Management Procedure F2-FOU-CON-SAI-PR-PM-00003
(64) HSE Plan Jacket Fabrication F2-FOU-CON-SAI-PL-HS-00006
(65) Environmental Management Plan F2-FOU-CON-SAI-PL-HS-00007
(66) Management of Technical Change Procedure F2-FOU-CON-SAI-PR-CN-00022
(67) ITP for Jacket Fabrication F2-FOU-CON-SAI-PL-QA-00020
(68) ITP for J-Tube F2-FOU-CON-SAI-PL-QA-00014
(69) ITP for coating corrosion protection F2-FOU-CON-SAI-PL-QA-00015
(70) ITP for electrical & instrumentation F2-FOU-CON-SAI-PL-QA-00016
(71) ITP for load out and sea fastening F2-FOU-CON-SAI-PL-QA-00017
(72) ITP for dimensional control F2-FOU-CON-SAI-PL-QA-00018
(73) ITP for switch gear equipment installation F2-FOU-CON-SAI-PL-QA-00019
(74) Interface Management Procedure F2-FOU-CON-SAI-PR-IN-00001
Abbreviation Meaning
DC Document Controller
DCR Deviation Concession Request
EM Engineering Manager
ETP Engineering Technical Practice
IRN Inspection Release Note
ISO International Organization for Standardization
PROJECT DEFINITIONS
Terms Definition
EMPLOYER Formosa 2 Wind Power Co. Ltd.
CONTRACTOR Jan De Nul n.v Taiwan branch
SUPPLIER Saipem S.A.
PROJECT Formosa 2 Offshore Wind Farm
Project Management Team All personnel’s of JDN or SAIPEM assigned to a management function in
the project organization as defined in the “Organization Chart”
Sub-Supplier Means any company or person to whom SUPPLIER has subcontracted
directly or indirectly at any level the performance of any part of the
Work.
Terms Definition
Concession Request A concession is a request seeking permission by completing the
Concession Request (Form) to use or release a product that does not
confirm to specified requirements. A concession is requested when the
SUPPLIER or their Sub-Supplier / Vendor has produced non-conforming
product which they want CONTRACTOR to accept for use or to use as it
is.
Deviation Request A deviation is a request seeking permission by completing the Deviation
Request (Form) to deviate from the originally specified CONTRACTOR
requirements such as Functional Design spec, and other Engineering
Standards as well to Non-Engineering Documents prior to realization. A
deviation is requested when the SUPPLIER or their Sub-Supplier / vendor
identifies that they will not meet CONTRACTOR Project specified
requirements.
Non-Conformance A non-conformance is the nonfulfillment of a requirement
Vendor means party supplying materials, equipment and goods to SUPPLIER
Technical Query A request from SUPPLIER to CONTRACTOR for clarification on the
interpretation of a Specification or requirement
Document Management System An electronic document management system chosen by the Contractor
which shall be used to control and manage the agreed deliverables and
any other documents issued in accordance with the Works. The
Contractor may change the chosen DMS.
Final As-Built Documentation The final as-built report to be submitted in accordance with these
Contractor’s Requirements.
Inspection and Test Plan Records within one (1) document all inspection and testing
requirements relevant to a specific process (i.e., a process within the
construction, installation or commissioning phases of the Project).
Interface Management The system which details the requirements, processes and tools by
which interfaces are managed.
Manufacturing Record Book To be developed by the Supplier as part of the Final As-Built Report in
line with section 3.3 of Schedule 10-16.
Punch List Refers to the process for recording Site or factory-based snags and
defects (i.e., it formally records (typically via a register) snags and
Defects identified during Site or factory inspections, reviews, or more
formal snagging reviews).
Quality Assurance Flow Diagram Designed to provide a step-by-step quality sign-off as a series of sign-off
boxes that confirm via agreed documentation that a Milestone is both
physically complete and can be demonstrated to have met agreed
technical, legal, regulatory and performance requirements.
Table 4-2: Table of Project Definitions
This Project Quality Management System governs all activities during all phases of the Work. Project
documentation requirements are identified and included within the Project SDR, where quality system
documents will be supplemented by Project specific procedures and plans as necessary. The project
SDR will include a schedule for document development; this will ensure that all required
documentation is developed, checked, reviewed and approved in a timely manner in line with Project
requirements.
All Project documents are retained in a dedicated Project area within the network, where read-only
access to the latest revision of the Project documents is granted to the Project team.
The Project Director is ultimately responsible for the correct implementation of Project Quality
Management Plan and to cooperate with all functions particularly with the Project QA/QC Manager,
to ensure the relevant Project Coordination requirements are met and satisfied both from the practical
and formal point of view.
This Project Quality Management System hierarchy is the result of the various inputs consisting of
SUPPLIER requirements, SUPPLIER Quality Management System, applicable Codes and Standards,
Statutory and Regulatory, and other requirements
MANAGEMENT COMMITMENT
The Project Management team is committed for successful implementation of this PQP and ensuring
the Project Quality Policy and CONTRACTOR’s Objective are understood at all levels and maintained
during execution of the Project.
The Project Management demonstrates their commitment with the following activities:
• Communicate Project contractual aspects and applicable regulation requirements to the
project functions;
• Establishing the Project Quality Policy;
• Establishing the Project Key Performance Indicator (KPI’s) and monitor their implementation
and achievement status throughout the execution of the Project;
• Ensure the new facilities of development within the existing plan and any interfaces;
• Ensuring the active participation of our Sub-Suppliers and vendors in achieving Quality
performance and addressing CONTRACTOR expectations.
• Assign adequate resource to the Project in term of competence and qualifications.
The needs and expectations of the CONTRACTOR are identified and satisfied by means of compliance
with contractual requirements, periodic review of the processes during project execution and
appropriate measures and assessment by conducting periodic audits.
• Assign responsibilities for the planning, coordination and control of activities affecting the
performance of Project activities;
• Monitor those activities deemed critical to the success of the Project;
• Advice the Project Team on QA/QC related customer complaints and taking necessary actions;
• Review and approve audit reports and corresponding actions;
• Control non-conformities and corrective actions as well as preventive actions;
• Ensure all personnel are competent for the assigned roles;
• Facilitate training to ensure that each member of the Project Team is competent to implement
this Project Quality Plan.
Project Manager (PM)
• Ensure the definition and preparation of the Project Execution Plan including Quality
Management addressing in particular how to manage potential risks in all critical areas of
design, procurement of project materials and subcontracting services, fabrication,
construction, installation, commissioning and supervise the definition / preparation of the
Project Execution Schedule.
• Represent Saipem towards Clients, Licensors, Partners and Subcontractors managing
contractual aspects
• Behave in accordance with the Saipem leadership Model and make sure the full Project
Management Team does the same
• Ensure the implementation of methodologies related to risk/opportunity, knowledge
management, lessons learned, cost of non-quality and the respect of Saipem Golden Rules and
Silver Guide Lines
• Ensure the implementation of the project strategies and the project activities planning (Project
Execution Plan, Quality Plan, Procurement Plan, HSE Plan, Fabrication Plan, Installation Plan,
etc.)
• Supervise all project activities with regards to Quality, HSE and Sustainability topics supported
by the other project organization roles
• Stay abreast of the evolution of and implement the project management tools and
methodologies
• Ensure the issue and the implementation of all required home office and site procedures
• Approve and supervise planning and control activities supported by the other project
organization roles, implementing the corrective actions needed to achieve the established
project objectives and ensure the issue of project reports
• Supervise site/yard activities supported by the other project organization roles
• Ensure the issue of project reports to the Client
Project Quality Manager (PQM)
PQM coordinates the application of the SUPPLIER Quality Management System to the project. His
duties include:
• Perform the role of Project Quality Management Representative;
• Assure the implementation and maintenance of the Project Quality Management System;
• Ensure the development of this Project Quality Plan is in line with the requirements of
CONTRACTOR;
• Ensure the implementation of this Project Quality Plan;
• Support the respective Project Manager and the Project Procurement Manager in the
development of the technical assessment exercise and quality program whenever applicable;
• Identify and provide resources for verification activities to ensure quality standards are
implemented and maintained;
• Ensuring the Project Director and Project Team that all quality premises and guidelines defined
in Project Quality Plan are correctly implemented at any activity stage by means of monitoring
and auditing the Work performances in respect to the established quality objectives;
• Ensure quality requirements are in compliance with all current statutory and legislative
obligations;
• Analyst and monitor the established Project Quality Objectives and Targets;
• Plan and conduct quality audits;
• Participate in CONTRACTOR and/or Third Party audits;
• Follow-up and close-out of non-conformities, corrective actions and preventive actions;
• Organize and conduct Project Management Review at predetermined intervals;
• Report the status of corrective and preventive actions and overall effectiveness of the Project
Quality Plan.
• QAQC resources and deployment of personnel as per Project requirements.
Project QA/ Quality Engineer (PQA/PQE)
• Provide the necessary back-up to the Project Quality Manager (PQM) regarding quality
contractual issues both during tender and project execution phase
• Support the PQM for the following activities:
• Ensure the definition and implementation of the PQM S and the identification, preparation
and distribution of needed Project
• Quality Plans and procedures in accordance with the Company Quality Management System
(QMS)
• Ensure that the correct implementation of the PQMS is checked and monitored through the
planning of quality audits
• Ensure, within the project organization, the planning of activities aimed at promoting the
applicable Contractual Quality Requirements
• Participates to Project Management meetings, to ensure coordination between Quality
activities and Project Management activities
• Ensure the issue of quality requirements to be incorporated, in the contractual documents,
with Vendors and
• Subcontractors and organizations in charge of works
• Ensure that the integrity of the Company QMS is maintained when changes are made to the
system for the project
• Ensure the correct implementation of planned quality audits, taking in account all project
processes, including the issue of relevant audit reports
• Conduct external audit to Vendors and Subcontractors QMS
• Ensure management of nonconformities
• Promote appropriate actions in order to prevent or eliminate potential non-conformities and
their causes
• Ensure the management of Cost of Non Quality process
• Ensure knowledge and awareness of Quality requirements within the Project Team, also
performing Quality Training activities
• Collect and analyse project quality data in order to organize and lead the Project Quality
Management Review
• Ensure the management of lessons learned process
• Ensure Customer satisfaction process implementation
• Report Project information and data to Company's Quality Manager by means of Corporate
methodologies and tools
QC Coordinator(s)
• Support the PQM in defining the Project Quality Control System and in identifying needed
project quality control plans and QC procedures in accordance with the Company Quality
Management System
• Support the PQM / QCM in planning and allocating Q C Supervisor functions to the various area
of the project, ensuring coordination of assigned personnel
• Review Quality Control Plans, verify that tests, controls and inspections are carried out
according to Quality Control Plans/Inspection Test Plans and that personnel has access to all
required project documentation
• Check procedures and equipment to be used in tests, controls and inspections and agrees on
the applicable operating
• procedures with the organization in charge of the works
• Review applicable QC procedures, including those relating to special processes
• Check that material and equipment are correctly received, stored, identified, traceable
preserved and handled (if needed)
• Verify the implementation of the inspection, control and test notification process
• Check documents certifying tests, controls and inspections carried out and their orderly
collection and management, mechanical completion included
• Verify that tests, controls and inspections are carried out by contractors
• Verify the correct implementation and application of Quality Tools
• Provide specialist support to the PQM / QCM in interfacing with the Client and third parties
• Verify the correct application and, whenever necessary, the update of site Quality Control
Plans/procedures
• Ensure training of Site Personnel on QC topics
• Verify proper Non Conformity detection and recording, as well as relevant corrective actions
implementation
• Verify the preparation of the Quality section of the final dossier. In case of subcontracted
activities, verify the QC section of the dossier is properly collected
• Verify that inspection/control/test reports are verified, recorded, filed and traceable
• Collect and analyse project QC data to be provided to PQM / QCM, also in view of the Project
Quality Management Review preparation
• Support PQM / QCM in the management of lesson learned process
• Report Project QC information and data to PQM / QCM by means of Corporate methodologies
and tools
following a periodic review in order to reflect the achievements in reference to the agreed
measurement criterion. The Key Performance Indicators (KPI’s) shall be subjected to CONTRACTOR
approval prior to implementation.
SUPPLIER shall measure and monitor these targets through Key Performance Indicator (KPI) as required
by CONTRACTOR. This objective and targets shall be communicated to all relevant PERSONNEL
involved in the Project team with the aim to ensure a proper understanding on how they shall
contribute to the achievement of Project KPI. The objectives and the targets shall be periodically
monitored in order to evaluate their achievements.
Sub-Contractor’s KPIs will be inline with Supplier’s KPIs and same shall be evaluated and reported
along with Supplier’s KPI analysis (Planned Vs Achieved).
Following Project specific Key Performance Indicators (KPIs) covering the major areas shall be adopted
and monitored accordingly.
Project Manager shall ensure the application of the monitoring in collaboration with the Project Quality
Manager and relevant Project Discipline Heads for successful achievement of the objective and the
KPI’s. Key Performance Indicators.
7 RESOURCES MANAGEMENT
PROVISION OF THE RESOURCES
SUPPLIER ensures and monitor that adequate skills and infrastructure are provided to meet the
requirements of the Project.
SUPPLIER’s Human Resources Department, having the Work Instruction process for the recruitment
and selection of personnel, meeting the qualitative and quantitative employment needs of resources,
ensuring they have met all the requirements and are specifically motivated in relation to the
CONTRACTOR’s activities and Project requirements. Personnel assigned on the Project are selected
based on Project requirements and their skill and competence level. The responsibility of assigning
adequate resources to the project is with the department managers of the SUPPLIER.
Selection of personnel for the Project, including selection of independent specialized personnel, is
made based on Human Resources and Projects requirements. Personnel are required to verify their
experiences with regards to the job function during recruitment. An annual performance evaluation
will also be carried out to identify the needs for further training.
As per Supplier’s doc. ‘Company Induction And Awareness’, all the personnel are provided overall
induction about company’s policies, rules & regulations, etc. In addition to that ‘Project Specific’
induction programs are also conducted for personnel deployed for a particular project. As all the
personnel are recruited based on the project specific requirements. Their qualification, experience,
training/ certifications etc. are tested/examined during interview/recruitment process. However,
attendance records for project specific induction are maintained for all project personnel.
Reference Document:
▪ SUPPLIER’s Organization Chart (Appendix -B)
▪ Recruitment and personnel Selection, WI-PTSI-HR-010-E
▪ Company Induction And Awareness, WI-PTSI-HR-005-E
The Project Team will be familiarized with the Project Requirements in several ways. During the initial
stages of the Project, a Project Kick-off Meeting will be held, where the scope of work, the Project
organization and the areas of responsibility will be disseminated to the Project Management team and
CONTRACTOR. Process owners from the respective departments will also be required to attend this
meeting and deliver the presentation on respective departments on plan, readiness, deliverables etc.
PDL responsible for the document shall analyze the comments and data received from the other
disciplines and shall verify the relevant correctness and acceptability, resolving any inconsistencies and
including them in the document master copy.
The document shall be verified by the PDL or by a person with appropriate expertise appointed by PDL.
The document will then send out for internal document review for interdisciplinary input via Doc
Controller and any comments will be forwarded to the Originator to integrate the comments as
applicable and relevant.
The document is then further reviewed by the Lead Discipline Engineer (LDE) or his Deputy another
Discipline Specialist (Verification) followed by the Engineering Manager (Approver).
The Approver is responsible for the checking and assurance of the deliverables before issuing formally
the Document to the Document Control to issue to CONTRACTOR. The document Approver shall ensure
that the document is coherent with the Project requirements, satisfies objectives of the Project and is
respecting the latest Design requirements.
FINAL DOCUMENTATION
Project records provide evidence of the quality that the product is in compliance with contractual
requirements. Project records pertaining to the work shall contain the necessary signatures of
acceptance or endorsement where required by the parties concerned.
Project records shall constitute the final document deliverables required in accordance with
contractual requirements.
Requirements for the identification and transfer of Project final documentation to CONTRACTOR upon
the completion of the work will be identified and indicate archival and electronic medium requirement.
Reference Document :
As Built Document Dossier F2-FOU-CON-SAI-DO-CN-00001
Fabrication Document Requirement, Schedule 10 – 16
CUSTOMER PROPERTY
SUPPLIER will maintain CONTRACTOR supplied products/information by such product that is lost,
damaged or is otherwise unsuitable for use is recorded and reported to the CONTRACTOR.
Customer property includes following but not limited such as material, equipment, documents and
software, intellectual property right belongs to customer (including the customer assigned licenser)
and personal information.
9 MANAGEMENT OF CHANGE
Management of Change (MoC) is the process of initiating, reviewing, authorizing and actioning
changes in a timely manner in order that project objectives are met.
SUPPLIER will provide MoC System including Processes, Procedures, software and PERSONNEL to
identify, evaluate, justify, document, action, and close-out all approved Changes that occur within
the WORK in order to manage the impacts.
Change will be proactively managed by SUPPLIER throughout all phases to support the progression
and execution of the WORK.
SUPPLIER through the use of MoC system and processes will ensure:
▪ All technical changes are captured, filed, reviewed and evaluated;
▪ All technical changes are subject to an approval process before being implemented;
▪ Any potential impacts on cost or schedule are considered as part of the assessment and
approval process;
▪ Quality and HSE issues associated with change are assessed and considered;
▪ Changes can be monitored and tracked through the identification, assessment, approval
and implementation stages; and
▪ All Technical Changes with cost, schedule or other contractual impact are processed as
Contractual Changes as required under the CONTRACT.
SUPPLIER’s Change Register and associated Change Forms and attachments will be provided to
CONTRACTOR as part of the Monthly Progress Report.
Reference Document:
Management of Technical Change Procedure, F2-FOU-CON-SAI-PR-CN-00022
The evaluation of Sub supplier for equipment including service shall be performed by Disciplines
(Engineering, Procurement, Quality, HSE team) in accordance with Vendor / Sub-supplier Qualification
Process.
The detailed procedure and methods for the selection and order of suppliers for products including
service shall through the following phases:
• Issue the pre-qualification questionnaire to Sub-supplier/ Vendor to assess the Technical,
Quality, HSE, Commercial and Facility capacity aspects.
• Evaluate the Pre-Qualification Document from Sub-supplier/ Vendor.
• Sub-supplier/ Vendor Qualification Assessment visit for specific work packages where they can
demonstrate successful assessment Result.
• All Sub-supplier/ Vendor Qualification Assessment packages shall be issued formally to
CONTRACTOR for approval prior to award of the associated Subcontract or Purchase Order.
In the event that SUPPLIER wishes to let a Major Sub-contract to an organisation not listed at Schedule
04-02, this shall only be possible with the written agreement of CONTRACTOR. CONTRACTOR shall
respond within thirty (30) days. Approval from CONTRACTOR shall not be unreasonably withheld
Reference Document:
• Sub-Contractor/Sub-Supplier Management Plan F2-FOU-CON-SAI-PL-PC-00004
• Procurement Execution Plan, F2-FOU-CON-SAI-PL-PC-00001
• Request for Quotation – Bid Management – Tabulation, WI-PTSI-PRO-002-E
• Approved Sub Supplier / Vendor, Schedule 04-02.
Quality Requirements for Services. A list detailing the Quality documentation requested to Sub-
suppliers is included in the procedure.
Reference Document :
• QA & QC Requirement for Supplier of Material and Equipment, F2-FOU-CON-SAI-PR-PC-00004
• Packing and Marking Procedure, F2-FOU-CON-SAI-PR-PC-00005
PRE-PRODUCTION MEETING
The pre-production meeting with Sub-suppliers and Vendors will be performed during and/or after
post order award at Vendor premises or SUPPLIER office.
The pre-production meeting will be organized for Sub-suppliers and Vendors which categorized Highly
Critical Purchase Order and/or Subcontract and the meeting shall be organized by the Project Order
and/or Procurement Inspection Lead. The proposed date of the pre-production meeting shall be 14
days before purchase order or fabrication commenced. The following items shall be reviewed during
pre-production inspection meeting:
• Purchase Order, specific inspection and quality control requirements;
• Specification “Manufacturing surveillance and inspection requirements”;
• Certification requirements;
• Review of exceptions/deviations to technical specification of the PO;
• Checking of the contractual supplier document requirements list (SDRL);
• Review of Design & Engineering activities;
• Review of the Sub-suppliers document schedule, checking of revision index of SDRL;
• Review of sub-orders requirements for inspection at sub-supplier’s plants;
• Review and finalization of Sub-suppliers Inspection and Test Plan (ITP);
• Traceability and material certification;
• Welding procedures;
• Painting procedures;
• Qualification / Certification of personnel (Welders, Non-Destructive Examination operators,
Painting operators & Inspectors, etc…);
• Testing instrument calibration and certification;
• Procedure for Deviation Request / Concession Request;
• Non-Conformity Report procedure.
The above-mentioned pre-production meeting shall be minutes and signed by Vendor and Sub-
suppliers representatives.
shall be planned, updated, in an Inspection register. Updating shall be made on weekly and monthly
basis.
Accurate scheduling of inspection activities planned in next four weeks shall be updated on weekly
basis with “Two months look ahead schedule” and “Four Weeks Look Ahead Inspection Schedule” and
made available for Project Management and CONTRACTOR’s information.
Supplier shall issue ‘Request for Inspection (RFI)’ for W-Witness & H-Hold points to
Contractor/TPI/Employer (as applicable as per approved ITP) one day before commencement of
particular inspection stages.
Final Inspection shall be performed in accordance with ITP on completion of the manufacturing and
testing of Material and Equipment as well before they are packed. On conclusion and acceptance of
Final Inspection, the Inspection Release Note (IRN) will be issued by SUPPLIER.
Reference document :
• Request for Inspection Procedure, F2-FOU-CON-SAI-PR-QA-00020
11 FABRICATION
QUALITY MANAGEMENT REQUIREMENTS
The Project Quality Manager shall assign different role & responsibilities to different QC Coordinators
like QC Coordinator, QC Coordinator (Dimensional Control), QC Coordinator NDT (Level III), QC
Coordinator (Corrosion Protection) and QC E&I Supervisor to control overall fabrication activities.
The QC Coordinators are responsible to monitor fabrication and quality activities to the extent
necessary to provide Project with adequate confidence that appropriate measures are being taken to
control and achieve quality.
The Project Quality/QA Engineer will be responsible monitor the fabrication quality surveillance,
inspection, testing, and documentation activities. He is also responsible to provide quality performance
indicator data to the Quality Lead / Coordinator who will provide quality statistics to the PQM from
time to time when required and on weekly and monthly basis.
Similarly, for CONTRACTOR free issued items inspection will be carried out as per PO, Delivery notes ,
approved drawings, if OS&D / NDR is raised it shall be communicated to CONTRACTOR site
representative for necessary action.
Any material received without all the required material/test certification or other specified
documentation from vendors will be segregated and quarantined “On Hold” pending receipt of the
missing documentation.
Reference document :
• Material Management and Control Procedure, F2-FOU-CON-SAI-PR-QA-00017
• Project Non Conformance Management Procedure, F2-FOU-CON-SAI-PR-QA-00004
• Detailed receiving inspection on materials and equipment’s arriving on site is required and
must include inspection for shipping damage.
• SUPPLIER takes responsibility for assuring their work, with sign-off only being provided once
documentation is complete
• The system is ready for handover and all assurance documentation is provided.
The final AFD shall form part of SUPPLIER’s handover documentation at completion.
An example of an AFD structure is shown below:
• Supplier sign-off
1. Component / Phase 1 • Contractor sign-off
• Employer sign-off
• Supplier sign-off
2. Component / Phase 2 • Contractor sign-off
• Employer sign-off
• Supplier sign-off
3. Component / Phase 3 • Contractor sign-off
• Employer sign-off
Reference Doc :
Schedule 09 – 09 QMS Requirements – FOU Fabrication
When inspection indicates defects in a welded joint that requires repair, the repair shall be carried out
in compliance with the applicable code and standard requirement and in accordance to a weld repair
procedure (F2-FOU-CON-SAI-PR-CN-00004) which shall be approved prior to the performance of the
repair.
In the event that a weld is required to be repaired more than once, the Contactor shall be informed
before repair welding. Sharp defects of any size shall be rejected.
Removal of defective weld metal shall be done by Air arc gouging, machining, grinding or any other
method, which produces a clean, uncontaminated surface for re-welding. Oxy-acetylene gouging is not
acceptable. All arc-air gouges shall be ground to bright metal to remove residual carbon. The defect
shall be removed by grinding or arc-air gouging.
Weld repair record and rejection rates to be maintained throughout the fabrication programme.
Structural repair rates would be on linear basis and Piping repair rates would be on basis of number of
joints. Weld repair rate will be reported on weekly basis and analysis would be conducted on monthly
basis and submitted to the Contractor. In case rejection rates are found exceeding the KPI limit,
Supplier would assess the cause of rejection and identity when there is the need to implement
corrective actions.
12 INTERFACE MANAGEMENT
Interface Management aims at providing a consistent method by which interfaces can be identified
and managed during any of the Project phases: engineering, procurement, fabrication, mechanical
completion and pre-commissioning.
Supplier shall clearly identify all the interfaces between the work and the work of other Sub-Suppliers
at an early stage of the Project and shall co-operate with Contractors and any other related third
parties to achieve continuity of systems forming part of the Project.
The Interface Management Procedure shall be developed and put into operation to coordinate the
activities within the Supplier’s complete control and those activities which interface and/or impinge
upon the Work.
Supplier shall be responsible for all interfaces of the Work with other parties’ work and shall assign an
Interface responsibility include resolving and coordinating project technical interfaces between
multiple work packages / Sub Contractors, engineering and ensure compliance with schedule, overall
design consistency and integrity.
• Storage, preservation and issue of materials from stores and stockyards to production or to
others operated by sub-supplier and vendors.
• Identify, verify, protect and safeguard CONTRACTOR supplied materials and equipment for use
or incorporation into the product or process.
Reference Document:
• Materials Management and Control Procedure, F2-FOU-CON-SAI-PR-QA-00017
15 PROCESS CONTROL
PROCESS CONTROL FOR VENDOR & SUB-SUPPLIER
Process Control shall cover all activities which included Engineering, Procurement and fabrication
activities. SUPPLIER will ensure that adequate process control procedures and work instructions are
developed, documented and subject to review and approval by CONTRACTOR or CONTRACTOR’s
Representative to ensure the following:
• All sections and requirements of this PQP are addressed where and when applicable to the
fabrication, task or work being performed;
• When absence of written procedures would adversely affect the Quality and/or Safety or task
being undertaken;
• Responsibility for performing any verification activities during process;
• Criteria for acceptance and approval of work and workmanship;
• Where acceptance criteria have not been specified, criteria for acceptance shall be developed
on a fit for purpose basis and clearly justified and documented;
• Where practical, attributes, visual standards or examples of workmanship shall be provided;
• Details of tools and equipment and, where applicable, provisions for their method of
calibration.
SUPPLIER shall identify all special processes during Project execution based on the scope of work, and
such special processes shall be performed by competent Personnel in accordance with specifications,
standards, plans and procedures governing.
WELDING
The Welding procedures will be developed prior to the welding activities started at fabrication site,
this welding procedure have to be approved by SUPPLIER, CONTRACTOR and third party, Welding
inspectors will be in attendance at SUPPLIER premises for fabrication site as required in attendance for
the inspection in accordance with Inspection and Test Plan.
Welding activities shall be carried out in a planned and controlled manner to ensure that all Welding
activities are accomplished in accordance with the approved procedures, the referenced International
Code/Standards and the applicable CONTRACTOR Specifications for all the activities to be undertaken
by SUPPLIER.
The Project Quality Manager, in conjunction with the Welding Department, shall review the Project
specifications and identify the requirements to control Welding activities. These requirements will be
documented in the “Welding Control Procedure” and subsequently monitored in the respective
Inspection and Test Plan and ITP’s.
The Welding Control Procedure shall address the following as a minimum:
• Applicable Codes and Standards;
• Applicable SUPPLIER Welding procedures;
• Responsibilities of relevant personnel;
• Welding Inspection documentation to be generated.
• The Inspection and Test Plan, Ref: shall address the following as a minimum:
• Process Description Activity
• Responsible Person
• Process Control Reference
• Acceptance Criteria Reference
• Verifying Document
• Intervention Points for SUPPLIER/CONTRACTOR/Third Parties
The Project Quality Manager shall review the Project specifications and identify the requirements to
control NDT activities. These requirements will be documented in the “NDT Control Procedure” and
subsequently monitored in the respective Project Inspection and Test Plan.
The NDT Control Procedure” shall address the following as a minimum:
• Applicable Codes and Standards;
• Applicable SUPPLIER NDT procedures;
• NDT operator qualification requirements.
Reference Procedure:
NDT Control Procedure, F2-FOU-CON-SAI-PR-QA-00009
COATING APPLICATION
Coating activities shall be performed as part of the Project quality planning activity under
approved dedicated Project Inspection and Test Plan. These activities shall be carried out in
planned and controlled procedures to ensure that all Coating activities are accomplished in
accordance with the approved procedures, reference International Code/Standards and
applicable CONTRACTOR Specifications for the activities to be undertaken by SUPPLIER.
Blasting and painting procedures shall be qualified to confirm compliance with the Project
specifications. The results of the Procedure Qualification Test (PQT) shall be recorded in the
specific qualification report formats and shall be using the same methods, equipment and
consumables as detailed in the procedures. Blasting and painting procedure and report formats
shall be submitted to CONTRACTOR for review and approval.
REGULATORY REQUIREMENTS
SUPPLIER shall to facilitate and coordinate the execution of the Permits Plan in order to have the
relevant Permits in a timely manner to meet project’s requirements such are:
• Identify project’s permit requirements.
• Develop a master Permits and License Register which shall provide information of all Permits
and Licenses required for the project, complete with the dates for planned, submittal,
expected completion, and application/approval status and or others.
• Organize and hold a periodic coordination meeting between CONTRACTOR and SUPPLIER to
ensure the alignment of specified regulatory requirements and obligations.
The audit schedules shall be updated as required to reflect auditing progress, CONTRACTOR or
CONTRACTOR’s Representative may participate in any phase of quality audit. The audit schedules
specific to the Project will require the following:
• The audit schedules shall cover all the aspects of the Project including the effectiveness of the
systems, processes conformity, quality objectives and documents;
• SUPPLIER will perform the audits which respect to process sequence approach as well as
Project progress, Risk Based and cover for each stage of the Project;
• The audit shall be performed for each phase to ensure the entire Project activities are captured
by the audit schedule;
• The Project Audit Schedule is considered as a live version of the Project execution which will
be updated based on actual progress. The audit schedules shall be prepared by Project Quality
Engineer, reviewed by PQM and approved by PD and issue for information to CONTRACTOR;
• Performance of routine surveillance in addition to the scheduled Project Internal & External
Quality Audits;
• A system of controlling and closing out deficiencies by way of a log that shall be established
and maintained by the PQE with the support of the PQM.
Reference Document:
• Project Quality Audit Procedure (F2-FOU-CON-SAI-PR-QA-00001)
• Project Quality Management System Audit Program & Schedule (F2-FOU-CON-SAI-SC-QA-
00001)
• Appendix C – Project Quality Audit Schedule (An Appendix of Project Quality Management
System Audit Program & Schedule)
MANAGEMENT REVIEW
The PQM together with PD and other project team members shall review and evaluate the Project
Quality Management Plan periodically during the project execution, in order to ensure continuing
suitability, adequate, effectiveness, efficient and maintain continual improvement of the PQP.
SUPPLIER shall plan to conduct the Management Review once in a year as overall and cumulative
review of the performances of Project Management System.
All the Management Review inputs are presented, described and summarized from the above
meetings and the input of Management Review shall consist the following:-
• Project Quality plan conformance including key performance indicator;
• Quality Audit result and status of corrective and preventive action ;
• Process performance and product conformity and NCR trends;
• Customer feedback/complaints and customer satisfaction from CONTRACTOR;
• Change that could affect the Project QMS;
• Recommendation for improvement and Lessons Learnt;
• Effectiveness of action to address risk and opportunities.
ANALYSIS OF DATA
Project team will determine, collect and analyze appropriate data to demonstrate the suitability and
effectiveness of the QMS and to evaluate where continual improvement of the effectiveness of the
QMS can be implemented.
Data collection and analysis shall be performed with appropriate procedure, method, time and cycle
established based on the process characteristic. This shall include the data generated from the
following processes, where appropriate.
Data gathered from the following areas are analyzed to examine SUPPLIER Quality Management
System and implement activities for continual improvement:
• Key Performance Indicator
• Internal audit, process monitoring and measurement, inspection and test, control of non-
conformance, corrective and preventive action;
• Processes needed to analyze data in the procurement, fabrication, etc.
• Customer complaints, Customer appreciation, Cost of Non-Quality, Lesson learn and
satisfaction level
The data obtained will be converted to statistical graph to simplifier in analysis. The result of analysis
will be input for Management Review.
RISK MANAGEMENT
Upon Contract Award, the Project Director and Risk Engineer shall establish a Risk and Opportunity
Management Plan. Risk and Opportunity Review and Assessment meetings will be held periodically to
update the status of the identified risks and their cost and time impacts. In addition, Risk Review
Meetings will be held regularly with the Project Director and the Risk Owners to update on the
effectiveness of the mitigation measures for these identified risks.
Reference Document: Risk and Opportunity Management Procedure
COORDINATION MEETINGS
Coordination Meeting shall be planned and held at intervals which are agreed with CONTRACTOR,
throughout the duration of the Project. Coordination meeting can be classified into three (3) types:
• SUPPLIER Internal Coordination Meeting;
• SUPPLIER and CONTRACTOR Coordination Meeting;
• SUPPLIER and Sub-supplier Coordination Meeting.
Prior to production and subcontract Work, SUPPLIER shall organize Kick-Off Meetings with Vendors
and Sub-suppliers to ensure all parties are clear on the requirements for reporting, interfacing, decision
making etc.
The Project Quality Manager shall participate in any coordination/progress meetings which may
involve QA/QC activities including those held by the Project Disciplines, Vendors or Sub-suppliers.
Coordination/Progress meetings will be held during engineering, procurement and fabrication phases
of the Project.
SUPPLIER may notify CONTRACTOR in advance and may arrange CONTRACTOR to participate in the
meetings.
Outputs from the Coordination Meetings shall be recorded using Minutes of Meeting.
REPORTING
SUPPLIER will issue weekly and monthly Project progress reports for SUPPLIER Project team internal
reference use by the SUPPLIER Project team and for CONTRACTOR information on the status of the
Work. These reports shall address the progress details of all activities including Engineering,
Procurement and fabrication during the preceding period. SUPPLIER’s Discipline Managers shall
prepare for their responsible scope and submit to the Planner for compilation. Details of the reporting
can be found in “Project Reporting Procedure”.
LESSON LEARNED
Lessons learned process is employed to ensure the systematic collection of the positive and negative
lessons learned, render the individual lessons learned an asset of the CONTRACTOR and to avoid
repeating the errors committed in the past.
The work process is divided into the following phases:
• Identification and evaluation of experience gained as a potential lesson learned or finding;
• Processing of the lessons learned;
• Capitalization and distribution of the lesson learned;
• Implementation of applicable actions;
• Review of the experience gained from the whole lessons learned process;
• Distribution (for information purposes) of the findings to the appropriate location of work in
progress.
During the initial phase of the Project, the Project Director ensures the systematic application of the
SUPPLIER’s past lessons learned from previous Projects through a sharing session for the Project
Management Team. Applicable lessons learned from past experience shall be identified and
disseminated across the Project Management Team to increase awareness and to improve fabrication
processes.
During the execution phase of the Project, lesson learned sessions shall be conducted if any potential
lesson learned situation is identified during the Work.
The Project Quality Manager supports the Project Director in the organization and implementation of
the initial meeting and for follow-up on the application of the selected lessons learned during the life
of the Project.
Rev. 00
SUPPLIER: SAIPEM INDONESIA KARIMUN YARD CONTRACTOR : JAN DE NUL n.v EMPLOYER : SWANCOR RENEWABLE ENERGY COMPANY
Prepared by: Project Quality Engineer Reviewed by: Project Quality Manager Approved by: Project Manager
YEAR : 2020
Audit Months/Weeks
Sl No. Process/Organization to be audited Location
Status Jan. Feb. Mar. Apr. May Jun Jul. Aug. Sept. Oct. Nov. Dec.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Planned P
1 Readiness Review Audit SIKB YARD Postponed
Completed
Planned P
Document Control, Drawings and
2 SIKB YARD Postponed
Submission of Procedures
Completed
Planned P
Project Management & Construction
3 SIKB YARD Postponed
Engineering
Completed
Planned P
4 Procurement / Purchasing Process SIKB YARD Postponed
Completed
Planned P
5 Material Management SIKB YARD Postponed
Completed
Planned P
Welding Consumable Management and
6 SIKB YARD Postponed
Control
Completed
Planned P
7 Dimensional Control SIKB YARD Postponed
Completed
Planned P
Structural Fabrication, Erection and
8 SIKB YARD Postponed
Process Control
Completed
Planned P
9 Welding Control SIKB YARD Postponed
Completed
Planned P
10 Non-Destructive Testing SIKB YARD Postponed
Completed
Planned P
Inspection and Test Control / Inspection
11 SIKB YARD Postponed
Records
Completed
Planned P
Equipment Preservation & Installation -
12 SIKB YARD Postponed
Mechanical
Completed
Planned P
13 Calibration & Control SIKB YARD Postponed
Completed
Planned P
14 Painting & Coating SIKB YARD Postponed
Completed
Planned P
15 Electrical and Instrumentation Activities SIKB YARD Postponed
Completed
Planned P
16 Mechanical Completion Management SIKB YARD Postponed
Completed
Planned P
17 Work Packs Flow/ Handover Records SIKB YARD Postponed
Completed
Planned P
18 Final Document Dossier SIKB YARD Postponed
Completed
Planned P
19 Sub-Contractor 1 TBA Postponed
Completed
Planned P
20 Sub-Contractor 2 TBA Postponed
Completed
Planned P
21 Sub-Contractor 3 TBA Postponed
Completed
Planned P
22 Sub-Contractor 4 TBA Postponed
Completed