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Formosa 2 Offshore Wind Farm Project

PROJECT QUALITY PLAN

DOCUMENT NUMBER : F2-FOU-CON-SAI-PL-QA-00002

Author: Checked: Approved by:


Name: Rajnish Dixit Name: Tamal K Dhar Name: Dominique HUDAULT

Job Title: Job Title: Job Title:


QA Engineer Project Quality Manager Project Manager
Signature: Signature: Signature:

JDN: Signature: Reviewed by JDN, no


Name: Charlotta Noren further comments
p.p. Pieter Poelsma

0 28.01.2020 Approved for Construction DRA TDH DHU PPIE


A 15.07.2019 Issued for review PPA PRR DHU PPIE
Rev No Date Status Issued by Checked by Approved by JDN Review

STRICTLY CONFIDENTIAL
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.

REVISION RECORD SHEET

List of
Updated/Modified
Rev Purpose sections

A Issued for review First Issue

0 Approved for Construction Sixth Issue

HOLDS LIST

HOLD number Description of HOLD Sections

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Document title:

PROJECT QUALITY PLAN


Project:

FORMOSA 2 OFFSHORE WIND FARM


Subproject:

FOUNDATIONS & CABLES SUPPLY AGREEMENT (FCSA)


Employer:

SUPPLIER Document no : N.A


Contractor Document no.: JDN3973.PQM.SAI.02.02
Employer Document no.: F2-FOU-CON-SAI-PL-QA-00002
Prepared by: Saipem S.A.

00 28.01.2020 APPROVED FOR CONSTRUCTION Rajnish Dixit Tamal K Dhar Dominique H


A4 08.01.2020 RE-ISSUE FOR REVIEW Rajnish Dixit Tamal K Dhar Dominique H
A3 06.12.2019 RE-ISSUE FOR REVIEW Rajnish Dixit Paul Prabir Dominique H
A2 16.11.2019 RE-ISSUE FOR REVIEW Rajnish Dixit Paul Prabir Dominique H
A1 22.08.2019 RE-ISSUE FOR REVIEW Pradeep P Paul Prabir Dominique H
A0 15.07.2019 ISSUE FOR REVIEW Pradeep P Paul Prabir Dominique H
Rev. Date Description of revision Prepared Checked Approved
SUPPLIER

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Project Quality Plan Revision 00

Document distribution and access


The latest approved revision of this document is accessible to all members of the Project Management
Team on the network server.

Revision change details


Revision Location Brief description of change
A0 n/a New document
A1 n/a Revised as per CONTRACTOR’S CRN
A2 n/a Revised as per CONTRACTOR’S CRN with additional comments
A3 n/a Revised as per CONTRACTOR’S CRN with additional comments
A4 n/a Revised as per CONTRACTOR’S CRN with additional comments
00 n/a No Comments added
Table 1-1 Table of Revision Change Details

List of holds

Section Description

Table 1-2 Table of Holds

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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

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10 PROCUREMENT QUALITY MANAGEMENT .......................................................................... 27


Vendor and Sub-Supplier Qualification Process ............................................................... 27
Quality Requirements for Vendor and Sub-supplier......................................................... 28
Pre-Production Meeting ................................................................................................... 29
Surveillance and Inspection Plan ...................................................................................... 29
Vendor and Sub-suppliers Dossier .................................................................................... 30
11 FABRICATION .................................................................................................................... 30
Quality Management Requirements ................................................................................ 30
Inspection and test plan.................................................................................................... 31
Sub-suppliers and Vendors PQP and ITP........................................................................... 31
Field Receiving Inspection................................................................................................. 31
Inspection and Surveillance Activities............................................................................... 32
11.5.1 Initial inspection ................................................................................................ 32
11.5.2 In process Inspection ......................................................................................... 33
11.5.3 Final Inspection.................................................................................................. 33
Assurance Flow Diagram (AFD) ......................................................................................... 34
Control of Mechanical Completion ................................................................................... 34
PUNCH LIST MANAGEMENT ............................................................................................. 35
Quality Control Records .................................................................................................... 36
Project Final As-Built Documentation ............................................................................... 36
Process Control During Project Execution ........................................................................ 37
Weld Repair and Rejection Rates...................................................................................... 37
12 INTERFACE MANAGEMENT ................................................................................................ 38
13 COMMISIONING, TESTING, HANDOVER AND LOADOUT ..................................................... 38
14 MATERIAL CONTROL IDENTIFICATION AND TRACEABILITY.................................................. 39
Material Control Certification, Identification and Traceability ......................................... 39
Handling, Storage and Preservation ................................................................................. 40
15 PROCESS CONTROL ........................................................................................................... 40
Process Control for Vendor & Sub-supplier ...................................................................... 40
Welding ............................................................................................................................. 41
NON-DESTRUCTIVE testing (NDT) ..................................................................................... 41
Coating Application ........................................................................................................... 42
Inspection and testing....................................................................................................... 42
Regulatory Requirements ................................................................................................. 42
Control of Monitoring and Measuring Devices................................................................. 43
16 MONITORING AND MEASUREMENT OF PROCESS ............................................................... 43
Quality Audit Program ...................................................................................................... 43
16.1.1 Internal Audit..................................................................................................... 44
16.1.2 External Audit .................................................................................................... 44

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16.1.3 Audit Report ...................................................................................................... 45


Management of Non-Conformance Reports (NCR) - Audit .............................................. 45
Management of NON-CONFORMANCE Reports (NCR) - Product ..................................... 45
Contract Document Review .............................................................................................. 46
Management Review ........................................................................................................ 46
Customer Complaint / Satisfaction ................................................................................... 47
Analysis of Data................................................................................................................. 47
Risk management.............................................................................................................. 48
Coordination Meetings ..................................................................................................... 48
Reporting .......................................................................................................................... 48
16.10.1 Quality Reporting .............................................................................................. 48
Lesson Learned ................................................................................................................. 49
APPENDIX A – PROJECT QUALITY POLICY ............................................................................................ 50
APPENDIX B – ORGANIZATION CHART ......................................................................................... 51
APPENDIX C – PROJECT QUALITY AUDIT SCHEDULE ..................................................................... 52

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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

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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.

Figure 1-1: Location of Formosa 2 OWF

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.

CONTRACTOR’S SCOPE OF WORK


Jan De Nul will execute the engineering, procurement, construction and installation of both the
foundations and subsea cable scope for a wind farm layout 47x 8MW turbines on jacket foundations,
called the Foundations and Cables Supply Agreement (“FCSA”).

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SUPPLIER’S SCOPE OF WORK


SAIPEM, called the Foundation Supplier (FOU), will execute the procurement, construction and
Loadout of 32 jacket foundations.
Reference document :
• Foundation Fabrication Plan, F2-FOU-CON-SAI-PL-PM-00001

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

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(7) Petroleum and Natural Gas Industries – Specific


Requirements for Offshore Structures – Part 2: Seismic
Design Procedures and Criteria ISO 19901-2:2004
(8) Petroleum and Natural Gas Industries Fixed Steel Structures ISO 19902:2007
(9) Environmental Management System ISO 14001:2015
(10) Paints and Varnishes – Evaluation of Degradation of
Coatings – Designation of Quantity and Size of Defects,
and of Intensity of Uniform Changes in Appearance ISO 4628
(11) Non-Destructive Testing DNVGL-CG-0051
(12) Surface Preparation and Protective Coating NORSOK M-501:2012
(13) Project certification of wind farms according to IEC 61400-22 DNVGL-SE-0073
(14) Cathodic Protection Design DNV-RP-B401
(15) Corrosion Protection for Wind Turbines DNVGL-RP-0416
(16) Wind Turbine Installation Units DNV-OS-J301
(17) Wind Turbines IEC 61400
(18) Support Structures for Wind Turbines DNVGL-ST-0126
(19) Fabrication and Testing of Offshore Structures DNV-OS-C401
(20) Construction Specification for Fixed Offshore Structures EEMUA 158
(21) In the North Sea Quality requirements for fusion welding of
metallic materials Part 2: Comprehensive quality requirements ISO 3834
(22) Types of inspection documents EN 10204_2004

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

JDN PROJECT DOCUMENTS


(27) N/A Project Health Safety Plan F2-FOU-CON-JDN-PL-HS-000001
(28) Quality Plan F2-FOU-CON-JDN-PL-QA-00001
(29) Project Charter JDN3973.PQF.01.01
(30) Environmental Management Plan F2-FOU-CON-JDN-PL-HS-00002
(31) Offshore Management of Change Procedure F2-FOU-CON-JDN-PR-PM-00001
(32) SCHEDULE -8 Project Procedure
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(33) SCHEDULE 9 – 05 Interface Management


(34) SCHEDULE 9 – 09 Quality Management System Requirements
(35) SCHEDULE 9 – 10 Interface Management Matrix
(36) SCHEDULE 9 – 11 Project Control Manual
(37) SCHEDULE 9 – 12 Consent Regulatory Compliance
(38) SCHEDULE 9 – 14 Transfer of care Custody
(39) SCHEDULE 9 – 15 Key personnel
(40) SCHEDULE 9 – 16 Project Certification Requirements
(41) SCHEDULE 9 – 18 QHSE
(42) SCHEDULE 10 – 02 FOU Codes and Standards
(43) SCHEDULE 10 – 03 FOU Design and Manufacturing
Requirements.
(44) SCHEDULE 10 – 04 FOU Testing and Verification Requirements
(45) SCHEDULE 10 – 14 Mock-up Test
(46) SCHEDULE 10 – 15 Delivery
(47) SCHEDULE 10 – 16 Fabrication Document Requirements
(48) SCHEDULE 10 – 33 E&I Interface Matrix

SUPPLIER PROJECT DOCUMENTS


(49) Fabrication Execution Plan F2-FOU-CON-SAI-PL-PM-00001
(50) Inspection, Monitoring and Test Equipment
Control Procedure F2-FOU-CON-SAI-PR-QA-00010
(51) Project Non-conformance Management Procedure F2-FOU-CON-SAI-PR-QA-00004
(52) Project Quality Audit Program & Schedule F2-FOU-CON-SAI-SC-QA-00001
(53) Material Management and control procedure F2-FOU-CON-SAI-PR-QA-00017
(54) Visual Inspection Procedure F2-FOU-CON-SAI-PR-QA-00007
(55) Weld Repair Procedure F2-FOU-CON-SAI-PR-CN-00004
(56) Dimension Control Procedure F2-FOU-CON-SAI-PR-QA-00008
(57) NDT Control Procedure F2-FOU-CON-SAI-PR-QA-00009
(58) Technical Deviation and Concession Procedure F2-FOU-CON-SAI-PR-QA-00005
(59) Procurement Execution Plan F2-FOU-CON-SAI-PL-PC-00001
(60) Progress Measurement Procedure F2-FOU-CON-SAI-PR-PN-00002
(61) Project Reporting Procedure F2-FOU-CON-SAI-PR-PM-00002
(62) QA/QC Requirement for Supplier of Material F2-FOU-CON-SAI-PR-PC-00004

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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

SUPPLIER CORPORATE REFERENCE


(75) Management System Guideline Quality MSGGR-GROUP-QUA-001-E
(76) Quality Management System Methodologies STD_GR-GROUP-QUA-001-E
(77) Management of Non-Conformities CR_OF-SCTOF-QUA-004-E
(78) Quality in Project OPR-COR-QUAL-001-E
(79) Quality Reporting OPR-COR-QUA-022-E
(80) REX & LL Management CR_OF-SCTOF-QUA-007-E
(81) Customer Satisfaction Questionnaire CR-COR-QUAL-001-E
(82) COMPANY Induction and Awareness WI-PTSI-HR-005-E
(83) Recruitment and Personnel Selection WI-PTSI-HR-010-E

4 TERMS AND DEFINITIONS


ABBREVIATIONS

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

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ITP Inspection Testing Plan


IVP Independent Verification Party
IMTE Inspection, Monitoring and Test Equipment
KPI Key Performance Indicators
LDE Lead Discipline Engineer
MoC Management of Change
NCR Nonconformance Report
PD Project Director
PM Project Manager
PMO Project Management Office
PMT Project Management Team
PQE Project Quality Engineer
PQM Project Quality Manager
PQP Project Quality Plan
PQE Project Quality Engineer/ QA Engineer
PPM Project Procurement Manager
PSL Project Supplier List
QA Quality Assurance
QC Quality Control
QMS Quality Management System
OSD Overage, Shortage and Damage
SOW Scope of Work
STP Specific Technical Practice
TC Technical Concession
TD Technical Deviation
TM Technical Manager
TQ Technical Query
MDR Manufacturer Data Record
OWF Offshore wind Farm
Rev Revision
JDN Jan De Nul n.v. Taiwan Branch
SDR Supplier Document Register
Table 4-1: Table of Abbreviations

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.

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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

5 PROJECT QUALITY MANAGEMENT SYSTEM


The Quality Management System to be utilized on Formosa II Project is designed to meet the
requirement of ISO 9001. The intention of this quality management system is to ensure that products
and services supplied to the SUPPLIER are in full compliance with the contract requirements, statutory
and regulatory requirements; this is achieved through the implementation of planned and systematic
ways of performing the work.

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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.

QUALITY MANAGEMENT SYSTEM HIERARCHY


The SUPPLIER Project Quality Management System consists of a hierarchy of documents, summarized
as follows;

Figure 5-1 Project Quality Management System

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

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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.

PROJECT ORGANISATION AND RESPONSIBILITIES


The Project Management Team (PMT) is represented in the Project Organization Chart illustrates the
main lines of authority, responsibilities, communication and reporting channels.
Besides, a specific Project Quality Organization Chart shall illustrates the responsibilities, coverage and
the reporting channels covering fabrication yard.
It shall be the responsibility of all members of the Project Team to be aware and comply with the
Project Quality requirements and principles stated in this Plan.
Project Director (PD)
The PD is the main responsible for the Project as main representative to CONTRACTOR, and supported
by Project Manager (PM), Project Quality Manager and Discipline Managers.
The PD main responsibilities are as follow but not limited to:
• Represent and commit on behalf of the SUPPLIER;
• Establish a positive working relationship with CONTRACTOR;
• Establish, together with CONTRACTOR, Project vision, goals, and success criteria, and
implement these together with a clear understanding of scope of work, schedule, and
deliverables throughout the organization;
• Develop and adjust the Project organization to the needs at each Project phase;
• Ensure clear lines of responsibility in the organization, split of scope of work and
communication of decisions throughout the organization;
• Develop strategies for the achievement of excellent Project performance.
• Ensure all personnel are provided with the procedures required to effectively perform their
assigned tasks;

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• 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;

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• 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

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• 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

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• 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

6 PROJECT QUALITY POLICY AND KEY PERFORMANCE


INDICATOR
PROJECT QUALITY POLICY
The Project Management Team is fully committed in providing products and services that fulfill
CONTRATOR expectations.
In accordance to SUPPLIER Quality Policy, the SUPPLIER Project Director wishes to establish, implement
and maintain an effective Project Quality Program for the duration of the Project as described in this
Project Quality Plan and to achieve the Project Quality Objectives.
The SUPPLIER establishes Project Quality Policy duly endorsed by Project Director. The Project Quality
Policy (see Appendix A) applies to the overall Project. The Quality Policy shall be widely communicated,
assimilated and applied by all the Project Team members during Project and Quality Induction.
The Project Team is responsible for the direction and effectiveness of the efforts to ensure delivery of
Quality Management requirements within their scope of their assigned responsibilities. The Project
Team line organizations and disciplines are responsible for planning and performing their Work under
controlled conditions and achieving the Quality Objectives pertaining to their respective departments
Scope of Work
Sub-Suppliers and Vendors are committed to ensure Quality in every aspect of its operations. It is sub-
supplier policy to conduct its business in a manner that assures the services provided meet specified
requirements.

KEY PERFORMANCE INDICATORS (KPI’S)


The Project Objectives and Targets with KPI’s shall form an integral part of the Project’s Quality
Management System, and such Project Key Performance Indicators shall be measurable and consistent
with the Project Quality Policy including the commitment to continual improvement.
The Project Objectives and Targets developed with KPI’s shall be taking into consideration of practical
targets and added value to the Project. The Key Performance Indicators (KPI’s) shall also be updated
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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 KEY PERFORMANCE INDICATORS


No. DESCRIPTION INDICATOR TARGET EVALUATION PERIOD REMARKS
1 Conducting Internal & Actual Vs Planned 90% Quarterly Cut off Date:
External Quality Audits as
25th day of last
per Actual Audit Plan
month of the
2 Issuance of Quality Audits Audits conducted Vs 10 Working Days Quarterly previous quarter
Reports after conducting Reports issued to 24th day of
Quality Audits last month of
current quarter.
3 Submission of Disposition NCRs 7 Working Days Quarterly
(Correction/ Corrective received/Submission Reporting Date:
Action) for the Non- of disposition action Latest by 7th day
Conformances received of 1st month of
from CONTRACTOR/ next quarter
EMPLOYER.
4 Weld Repair Rate % of Weld Repair 2% Monthly Cut off Date:
(length wise) (Total length of non- from 25th day of
acceptable defects previous month
divided by tested to 24th day of
weld length current month.
multiplied by 100%) Reporting Date:
Latest by 7th day
5 Material Receiving Receiving of MRIR 7 Working Days Monthly
of next month
Inspection after receiving from warehouse Vs
complete set of supporting Inspection & release
documents.
6 OSD (Overages, shortages Packages with OSD 7 Working Days Monthly
and damage) Receiving
Inspection report

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.

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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

INFRASTRUCTURE AND WORK ENVIRONMENT


SUPPLIER will provide and maintain, secured office space and working station for performance of the
Project activities throughout the entire phase.
Work environment are provided in accordance and in compliance with Indonesian laws and regulation
of work place.
The SUPPLIER aims to maintain a high profile on the employee safety and health aspect, going beyond
the dictates of the law and always with a view to continues improvement. The SUPPLIER is in fact
committed to supplying its personnel with working environments and instruments increasingly safer
and more optimal for the psychophysical wellbeing of the human resources.

QUALITY INDUCTION AND AWARENESS


Project Quality Department shall coordinate the Project Quality Induction and Awareness to Project
Team through schedule arrangement and venue for the Induction and Awareness at beginning stage
of the Project and as well when new employees joined the Project. Project Quality Department will
collaborate and deliver the Project Induction to the Project team. A register shall be maintained for
the Project Team whom attending the Project Quality Induction and Awareness as a record as well.

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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.

8 DOCUMENT AND DATA MANAGEMENT


SUPPLIER DOCUMENT REGISTER (SDR)
Supplier Document Register (SDR) shall be developed and maintained as a live document, identifying,
recording and tracking of all controlled documents in the Project. The SDR shall be kept updated with
document status and submitted in electronic file format to CONTRACTOR on a monthly basis.
Reference Document:
▪ Supplier Document Register

DELIVERABLES PREPARATION, VERIFICATION AND APPROVAL


PROCESS
SUPPLIER shall develop deliverables for the Project with Project documentation requirements, which
include to Identify, track and record all controlled Project documents.

8.2.1 SINGLE DISCIPLINE DOCUMENTS: VERIFICATION AND APPROVAL


The documents of technical and non-technical are prepared by the personnel of respective discipline
assigned to the project.
The document shall be verified by a person with appropriate expertise appointed by Project Discipline
Leader (PDL). The verification carried out shall be documented using specialist checklists (if available)
defined by SUPPLIER internal procedures. Once correctness of the executed work process and
compliance with project constrains/requirements are ensured, the PDL approves the document.
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).
Single discipline documents from Engineering are approved by PDL whereas non-technical documents
shall be by the Discipline Manager.

8.2.2 MULTI-DISCIPLINE DOCUMENTS: VERIFICATION AND APPROVAL


The preparation of multi-discipline documents shall be coordinated by PDL responsible for the
document, who shall issue and send it by mail to the other disciplines/functions, requesting them to
compile specific part of the document or to provide missing data to the document for their field of
expertise.
PDL responsible for the document collects and integrates the information and data received from other
disciplines/functions.
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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.

MANAGEMENT OF PROJECT DOCUMENT


The flow of documents to and from CONTRACTOR for review and approval is controlled and managed
by the Document Control Leader. Document control will extract the documents and send to
CONTRACTOR Document Management System through ACONEX tool.
The flow of document for internal comment is control by the Document Control Leader.
All controlled Project documents shall be traceable for its development, approval, issue, revision,
distribution, maintenance, use, storage, security, obsolescence or disposal within the SDR. Major Sub
supplier documents are also included.
Documents will be numbered in accordance with contractual specification requirements. Project
Document Controller is in charge of maintaining and keeping up to date the Project SDR in accordance
to Document Control Procedure

CONTROL OF PROJECT RECORDS


Records are established and maintained to provide evidence of conformity to requirements and of
effectiveness of the SUPPLIER.
Records are identified through their process code and numbered in progressive order. Records form a
part of Project document management system.
Once the records have been completed, checked, signed by all required parties and distributed to all
concerned, they shall be filed in order to facilitate traceability. Each respective Process Owner shall be
responsible to maintain the records.
Records shall be stored in an appropriate location and in a manner permitting security, prevention of
deterioration. Document Control will address identification, legibility, retrieving, filing, indexing,
numbering, distribution, and the reproduction quality of Quality Records. All records are required to
be submitted to CONTRACTOR storage in Aconex.

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.

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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

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TECHNICAL QUERIES/FIELD DESIGN CHANGE/DEVIATION AND


CONCESSION REQUEST
SUPPLIER shall record Engineering Technical Queries or Field design change (FDC) to ensure
management, control, tracking and response of SUPPLIER initiated Technical Queries or Field design
change. The Management of Change procedure covers a formal question and response route between
sub supplier, SUPPLIER and CONTRACTOR team for all queries on technical issues. The procedure shall
define the processes of receipt, logging, distribution, tracking and timely response and resolution of
TQs and FDC.
A TQ/FDC Register shall be established and maintained with status of all TQ/FDC reported to
CONTRACTOR on a regular basis through Document Controller.
Sub-Supplier and Vendors shall affix their signature prior to submission for SUPPLIER review. SUPPLIER
shall review and approve Sub-supplier/ vendor’s Deviation and Concession prior to submission to
CONTRACTOR. However, when any of the Sub-supplier/ vendor’s Deviation and Concession is not
accepted by SUPPLIER, such Deviation and Concession from Sub-supplier/ vendor’s will not be
forwarded to CONTRACTOR. SUPPLIER approved Deviation and Concession will be forward to
CONTRACTOR for approval.
SUPPLIER, Sub-supplier/ vendors shall not proceed with work until the CONTRACTOR approves the
Deviation and Concession Request submitted. CONTRACTOR’S format no. F2-ENG-CON-F2-FO-IN-
00001 shall be used to address the same. In-case of urgency, Contractor will respond as early possible
for Supplier's TQ/Deviation etc.. If case of delay, Contractor may give clearance through email to
proceed further. Formal close-out of the TQ/Deviation etc. might be done later inline with email
response.
Reference Document:
Management of Technical Change Procedure, F2-FOU-CON-SAI-PR-CN-00022

10 PROCUREMENT QUALITY MANAGEMENT


Project Procurement Manager is responsible for the procurement of equipment, materials & services
for the project in accordance with specified requirements, and the evaluation and selection of
Vendor/sub supplier for equipment, materials & services.
The Project Procurement Manager shall ensure that Purchase Order and Contract drawn up is formally
correct and that their contents, clauses and annex clearly indicate the supply scope and conditions.
Any modification made and considered appropriate, then the Purchase Order is printed and authorized
if the total Purchase Order amount falls within its Attorney Limits.
If that is not the case, the Project Procurement Manager shall sign-off the Purchase Order, then
forward the Purchase Order to the hierarchical position authorized for its approval.
Reference Document:
▪ Procurement Execution Plan, F2-FOU-CON-SAI-PL-PC-00001
▪ Expediting Procedure, F2-FOU-CON-SAI-PR-PC-00003

VENDOR AND SUB-SUPPLIER QUALIFICATION PROCESS


Sub-supplier/ Vendor shall be selected and evaluated on the basis of their ability to meet Project
requirements including HSE and Quality Assurance System requirements.
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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 VENDOR AND SUB-SUPPLIER


The Project Quality requirements shall be clearly identified and to be communicated to potential Sub
suppliers for compliance.
Quality Specifications are implemented in order to define Sub-suppliers’ obligations regarding the
Quality Management System requirements to be followed. The purpose is to assure and document
that purchased supply or subcontracted work by Sub-suppliers meets the required level of Project and
CONTRACTOR Quality requirements.
The PQM shall review these Specifications and implemented plans, in order to meet CONTRACTOR and
Project specific requirements.
The Vendor/ Sub-suppliers shall maintain Key Performance Indicators for their project QMS
implementation that includes quality improvements and training where required. If necessary,
Vendor/ Sub-suppliers project Quality KPIs to be reviewed and approved by SUPPLIER to ascertain
project performance.
The Vendor/ Sub-suppliers shall implement an internal control procedure for managing Non-
Conformances. This procedure shall address disposition as per SUPPLIER specification “Non-
Conformance Management Procedure”.
The Sub-suppliers shall comply with SUPPLIER’s Quality Requirement to assure that the level of quality
specified for services, equipment and materials to be supplied is achieved throughout the execution of
the work relevant to the Purchase Order and Contract, and shall be read in conjunction with Quality
Assurance and Quality Control Requirements for Suppliers of Material and Equipment and Project

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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.

SURVEILLANCE AND INSPECTION PLAN


The general scheduling of Surveillance and Inspection activities (Pre-Production Meeting (PPM),
intermediate inspection, punch list, final inspection) and related documentation (notification, reports)
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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

VENDOR AND SUB-SUPPLIERS DOSSIER


At the time of submitting IRN, the Vendor/ Sub-suppliers is requested to provide and issue all the
technical documentation stamped by the Inspector (material certificate, NDE reports, testing reports,
etc.) related to Material & Equipment in electronic format “pdf” to SUPPLIER.
This batch of documentation, called “Dispatch Dossier” or “Manufacturing Record Book” (MRB), shall
be upload in a dedicated folder of the Project Document Control System or shared disk, and shall have
accessible for excess from the Site.
The content of the MRB shall be vary and depending on the type, size and complexity of
equipment/packages but it shall contain all documentation referenced in the ITP and all records of
inspection, testing as required by PO or item Requisition.
Vendor/ Sub-suppliers shall establish the content of MRB as a minimum but not limited to, all
certificates, declarations, test reports and any other document as required in the applicable approved
ITP and Supplier Document Register List (SDRL).
The MRB shall be compiled in such a way that it follows the fabrication history sequence of the referred
item. The MRB shall provide sufficient information to demonstrate the integrity and the Quality of the
Supply and conformity to the purchase order requirements.

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

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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.

INSPECTION AND TEST PLAN


The Project Quality Manager, in accordance with the contractual terms and specifications, shall ensure
to issue the above listed project-specific Inspection and Test plans in section 3.5 Supplier Project
Documents. The Inspection and Test Plans shall include the minimum inspections and tests required,
assuring the quality of the work performed, together with the relevant interventions and
responsibilities of all involved organizations.
Applicable Quality Records (Inspection & Test Records) to be collated and included in the Final As-Built
Dossier are referenced in each Inspection and Test Plan.
The Inspection and Test Plans shall be submitted to the CONTRACTOR for review / approval after the
Project Manager’s approval. The CONTRACTOR shall state his own intervention points and approve the
Inspection and Test Plans. Once approved, the Inspection and Test Plans shall be distributed to the
involved parties/organizations. The Sub-suppliers and Vendors shall issue their own Inspection and
Test Plans to cover the assigned Scope of Work in accordance with the applicable contractual terms
and specifications.
The Project Quality Manager shall ensure to review the Sub-suppliers and Vendors Inspection and Test
Plans shall indicate SUPPLIER inspection intervention points and shall obtain the CONTRACTOR’s
approval and his relevant intervention points as required.
The specific Inspection and Test Plan (ITPs) will be developed by SUPPLIER prior to perform the Works
and to ensure that the ITPs produced by Sub-suppliers and Vendors are aligned with the defined
Inspection and Test Plan.
At all stages of fabrication, inspections shall be carried out as per the Project ITPs, detailing the quality
Inspections to be performed by SUPPLIER, CONTRACTOR and Authority surveillance/witness with
designated intervention points.

SUB-SUPPLIERS AND VENDORS PQP AND ITP


PQP and ITP as applicable for Sub-suppliers and Vendor scope of work will be approved and endorsed
by SUPPLIER and forward to CONTRACTOR for approval.
The Sub-suppliers and Vendor will issue their procedures, plans and other project documents to cover
the assigned scope of work and/or purchase order in accordance with specified requirements of the
CONTRACT.

FIELD RECEIVING INSPECTION


Field receiving inspection will be performed as part of the acceptance process for receipt of
materials/equipment in site complies with project requirements.
SUPPLIER receiving inspection personnel will perform the initial visual inspection of the materials,
verify receiving documentation by item, material certifications, quantity and description and check for
obvious shipping damage. If found any shipping damage, an Overage, Shortage and Damage (OS&D)
Report is initiated in accordance with the SUPPLIER Inspection Receiving Practices.
The inspector will prepare a Receiving Inspection Record for each item with the attributes to be
inspected or verified and Initiate a Non-conformance Report if the material/equipment is found to be
nonconforming.
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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

INSPECTION AND SURVEILLANCE ACTIVITIES


In order to ensure that work activities comply with project design and fabrication requirements
SUPPLIER will performs Inspection and Surveillance during different phase of fabrication.
QC Inspector performs inspections at storage areas as well in accordance with the requirements and
any discrepancies noted during inspections will be recorded.
The result of inspection and surveillance will be recorded and report into relate form to provide
sufficient evidence for current and future review and that project requirements have been performed
in respect to the code, standards, specifications and quality requirements.
SUPPLIER shall ensure all works, necessary for the preparation and performance of inspections,
examinations and tests, including equipment, tools (i.e.: pressure gauges, temperature measuring
equipment, NDE equipment, measuring device, etc.), scaffolding and protection to enable
CONTRACTOR representatives conduct and witness all the activities in safe manner.

11.5.1 INITIAL INSPECTION


Prior to the commencement of work and any activities, the following verifications shall be performed:
• Applicable documentation such as drawings specifications, standards codes etc., to be used
for fabrication shall be listed, available and controlled;
• Special process procedures and procedures qualifications shall be available in reviewed and/or
approved status and they shall be adequate to ensure that work is performed under controlled
conditions, with all parameters identified and monitored in accordance with applicable
standards and specifications;
• All personnel performing inspection activity (special process and fabrication activity requiring
experience and qualification) shall be identified and qualified. Such qualification shall be kept
updated and recorded;
• All testing and measuring equipment shall be suitable to perform the required quality control
activities. Testing and measuring equipment shall be identified and instruction for their use,
calibration and storage shall be available;
• Calibration and setting shall be performed by SUPPLIER in accordance with the approved
procedure;
• Certification forms shall be approved and available prior to perform related inspection
activities;

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• Detailed receiving inspection on materials and equipment’s arriving on site is required and
must include inspection for shipping damage.

11.5.2 IN PROCESS INSPECTION


SUPPLIER shall ensure that the work is carried-out in accordance with the latest approved fabrication
drawings, specifications, standards, codes and or statutory requirements as applicable, and shall
perform all in-process inspections and examinations necessary to verify quality and to obtain from
SUPPLIER authorization to proceed prior to the covering up, burying and insulating any item, part, area
or system of the Works.
During fabrication the following verifications shall be performed:
• Materials used for fabrication are always identified and properly preserved;
• Personnel performing special processes are qualified and identified;
• Latest approved fabrication documents are used;
• Inspection are performed as planned;
• Special process equipment used are identified and correctly calibrated;
• Measurement and testing equipment are certified, identified and calibrated as per procedure;
• Approved work procedures and plans are followed;
• Environmental condition are satisfactory, otherwise measures shall be implemented to protect
the work;
• Defects occurring systematically on the work performed by sub-supplier are identified and
adequate corrective actions are implemented;
• All inspection examinations and tests to be performed are orderly and correctly scheduled to
meet project requirement.

11.5.3 FINAL INSPECTION


Upon completion of each work, SUPPLIER shall ensure that the required inspections and testing have
been performed as per relevant SOW ITPs and the results confirm that all specifications, standards and
Code requirements are met.
On completion of fabrication of any SOW either partly, area or system of the Works, the following
verification shall be performed:
• Final inspections and test as specified in applicable Project ITPs;
• All required quality records and summary according to Project ITPs have been issued and
approved;
• Applicable documentation has been reviewed, red marked and issued as site revision (as built);
• Check to ensure that all NCR’s have been closed out satisfactorily and all documentation have
been completed;
• Review final documentation and traceability of quality records of system, part or area of the
Works to ensure satisfactory mechanical completion prior to submit the same to SUPPLIER.

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ASSURANCE FLOW DIAGRAM (AFD)


Assurance Flow Diagram (AFD) is designed to provide a step-by-step quality sign-off as a
series of sign-off boxes that confirm via agreed documentation that a quality
Milestone/quality-related work is both physically complete and can be demonstrated to have
met quality and performance requirements. Supporting documentation including quality
control documentation shall be listed within an associated register. The AFD shall be jointly
agreed between CONTRACTOR and SUPPLIER and shall reflect the SUPPLIER’s actual work
sequence. The applicable assurance documents that sit below each element sign-off shall also
be agreed between CONTRACTOR and SUPPLIER.
The intent of the AFD is to ensure:

• SUPPLIER provides the necessary assurance documentation for the progresses

• 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

Figure 11-1: Location AFD structure

Reference Doc :
Schedule 09 – 09 QMS Requirements – FOU Fabrication

CONTROL OF MECHANICAL COMPLETION


Supplier shall ensure the Mechanical Completion facilitates the handover of the system from the
fabrication authority to the Pre-Commissioning authority.
During the mechanical completion, the following item need to be clarified before Mechanical
Completion certificate to be signed by fabrication authority;
• Report on all non-conformities identified and correction action taken.
• Fabrication records, including all test results.
• Manage Punch List. Refer Punch list Management Procedure F2-FOU-CON-SAI-PR-ME-00001
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• Manage any kind of resource like hours, key people or tools


• Manage parts for maintenance
• Manage instrumentation recertification or test.
• Manage as-built drawing
• Manage hazardous material (asbestos, chlorinated fluorocarbons, poly-chlorinated biphenyls,
lead or chromate based paints, isocyanate-cured materials.
• Manage the documentation
• Operation and maintenance documentation, including all applicable product information
required to operate and maintain the system.
• Manage the interfacing management and coordination.
• Manage any training required for sub supplier.

PUNCH LIST MANAGEMENT


During Construction & Pre-Commissioning any discrepancy, defect or missing
item found will be recorded as punch item. For the completion purpose, these punch items are
classified into three types according to the priority to be closed:
1) Punch List “A” (PL-A)
Punch List category A is classified to the non-conformity item which blocking the
commencement of Hydro test Activity/safely energized for commissioning. The nonconformities
are such as; wrong installation of welded support piping system, missing main
structures, wrong piping material install, missing hot work etc.
PL-A category punch list blocks the issuance of Mechanical Completion Certificate (MC1).
2) Punch List “B” (PL-B)
Punch List category B is classified to the item that can be repaired, completed, corrected at
later date. This punch list will allow equipment to be commissioned without implications for
safety of plant and personnel.
Closing of this PL-B is prerequisite issuance of System Handover (SH-1) Certificate.
3) Punch List “C” (PL-C)
Punch List category C is classified as minor punch item.
PL-C is recorded may be closed post of Issuance of the System Handover (SH-1).
All punch items gathered during official inspection with company will be registered and managed by
completion management system (CMS).
Reference Doc :
Punch list Management Procedure F2-FOU-CON-SAI-PR-ME-00001 questionnaire completion

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QUALITY CONTROL RECORDS


SUPPLIER shall issue all reports for the inspections executed. Unless otherwise agreed, the reports shall
be compiled by using SUPPLIER “Inspection Form” provided along with ITP(s).
“Inspection Form” shall be filled up with all information required to record the details of the Inspection
activity performed and will become “Certificate” once signed by the parties involved in the inspection.
For this purpose, the Inspection Form shall be compiled with all information indicated in the template
title blocks, as well as traceability and numbering information and data relevant to the inspection
performed such as but not limited to:
• Inspection checklist;
• Test details and condition;
• Applicable parameters;
• Reference acceptance criteria;
• Tolerances;
• Test results and/or evaluation;
• Explanatory notes if necessary (e.g. reference to previous records in the case of unsuccessful
previous tests);
• Test date;
• Latest drawing details
• Monitoring and Measuring Equipment use
The reports, issued from each type of “Inspection Form” compiled, shall be univocally coded by
reporting the QC Code complete and adding a progressive numbering.
SUPPLIER shall scan the reports on a daily basis, just after the last signature, and send them immediately
to quality team by means agreed at site for the electronic filing.
Unless otherwise instructed by SUPPLIER, the original signed copy of each Quality records shall be
delivered for filing.
All reports are numbered with corresponding date and shall be registered in a SUPPLIER electronic
Database as for record. Sub-supplier and VENDOR shall provide Data entry operators to be trained by
SUPPLIER as required.

PROJECT FINAL AS-BUILT DOCUMENTATION


SUPPLIER shall provide to CONTRACTOR the Project final documentation in the end of Project execution
phase. The Project final documentation will be issued to CONTRACTOR in accordance with the
requirements of the Contract. The coverage areas of Project final As-Built Documentation are all
documents related to the entire scope of work in the contract that identify all aspects of the final
manufacturing and fabrication work.
Manufacturing Record Book (MRB) as part of Final As Built Documentation will be compiled as the work
progress, following the approved by CONTRACTOR and EMPLOYER As built index. A separate file will be
created for each Jacket and submitted as soon as all inspections/tests have been satisfactorily executed.
Doc Reference :
Schedule 10 – 16, Fabrication Document Requirements
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PROCESS CONTROL DURING PROJECT EXECUTION


The Project Execution Plan shall apply to engineering, procurement and fabrication activities required
in completing the scope of work.
SUPPLIER shall ensure that adequate process control procedures are developed, documented and
subject to review and approval by CONTRACTOR to ensure the following:
• All sections and requirements of this Project Quality Plan, Project Inspection and Test Plans
and Project Procedures are addressed where and when applicable to the fabrication task or
Work being performed;
• Responsibility for performing the inspection and testing and any verification activities during
the process;
• Criteria for acceptance and approval of work and workmanship;
• Where acceptance criteria has 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;
• Where contractually required, SUPPLIER shall gain CONTRACTOR and Independent Verification
Party approval of the following process qualifications.

WELD REPAIR AND REJECTION RATES


If NDT examination of weld appears to indicate a defect, then such weld shall be repaired and re-
examined by means of same NDT method. Welds shall also be examined for inadequate penetration,
incomplete fusion, burned-through areas, slag inclusions, gas pockets, under cutting and improper
weld geometry. If these or any other defects are discovered which, exceed the limits of this
specification and referenced codes, then all such welds shall be repaired or replaced. To pass the visual
examination and magnetic particle test or liquid penetrant test, all welds shall present a uniform
appearance.

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,

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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.

An interface matrix shall address the following:

• Planning and identifying where interfaces exist;


• Integration of activities with all other parties working on the Project;
• Roles and responsibilities in relation to interfaces;
• Lines of communication;

Reference Document No.:


F2-FOU-CON-SAI-PR-IN-00001, Interface Management Procedure
Schedule 09 – 05, Interface Management
Schedule 09 – 10, Interface Management Matrix
Schedule 10 – 33, E&I Interface Matrix

13 COMMISIONING, TESTING, HANDOVER AND LOADOUT


SUPPLIER Commissioning Team will mobilize Commissioning core personnel in advance of the project
in order to perform detailed engineering activities. During execution phase, SUPPLIER Commissioning
team will be mobilized for the following purposes:
• Follow up, monitor and check the status of Commissioning’s needs post arrival (Consumable,
tools, temporary equipment and spare parts);
• Early set-up for office spaces, internet network, printers and telephones for Commissioning
personnel;
• Witness the MC activities as per Inspection and Test Plans (Ref. [Inspection and Test Plans])
• Follow up the MC progress;
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• Commissioning execution at fabrication yard.


During preassembly, onshore commissioning, testing, Handover and load out, SUPPLIER shall ensure
that all parties shall witness and verified the installed safety critical equipment’s and their
performance as well ensuring they are functioning well.
SUPPLIER shall ensure the scope for contract has been delivered as per the contract requirements
and stipulated. Project requirements.
Reference Document:
Mechanical Completion Plan, F2-FOU-CON-SAI-PR-CN-00016

14 MATERIAL CONTROL IDENTIFICATION AND


TRACEABILITY
MATERIAL CONTROL CERTIFICATION, IDENTIFICATION AND
TRACEABILITY
SUPPLIER shall address the needs of controlling procedures for material control, certification,
identification and traceability in accordance to CONTRACTOR Specification.
SUPPLIER shall address the need for controlling procedures, and Inspection and Test Plans for material
control, certification, identification and traceability, which shall ensure but not be limited to the
following requirements:
• All materials or equipment from whatever supply source and which are intended to be
incorporated into the Project works, shall be subject to material control, certification,
identification and traceability requirements;
• All purchase requisitions and subcontracts, where applicable clearly identify the requirements
for material control, certification, identification and traceability from raw product through to
final installation;
• A system of material receiving inspection and marking or tagging of items that maintains
traceability through normal manufacturing processes without loss or deterioration;
• Methods of maintaining identification and transfer of traceability to parts, equipment and
materials that are separated from a batch lot or obtained/cut from a larger source;
• Plans for verification activities at Sub-supplier and Vendor premises, where the traceability of
items, parts, equipment or materials to inspection, test or composition of materials is
considered critical and safe.
• Methods of recording items, parts, equipment or materials on applicable drawings during
engineering design, procurement activities;
• Where internal material identification systems are used, cross reference tables or other
suitable means of traceability shall be provided;
• Methods of checking material identification including material composition and properties, if
necessary, whether at source location or site;
• Adequate provision of suitably trained and qualified staff for the purposes of material control,
identification and verification activities;

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• 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

HANDLING, STORAGE AND PRESERVATION


SUPPLIER will define the requirements for controlling of handling, storage and preservation of products
at job site. Handling, storage and preservation will comply, at minimum, with the following
specifications.
All equipment that requires special treatment to prevent damage, packing & transportation method,
the requirement will be specified in the purchasing document.
SUPPLIER will develop procedure to prevent the improper handling or storage of materials or equipment
could have the potential to create an impact on the quality of the item. The procedures will include:
• Handling and storage methods to prevent damage or deterioration of quality of the product.
• Use of designated storage areas or stock rooms to prevent damage of deterioration.
• Methods for authorizing receipt and dispatch products to and from the storage areas.
• The preservation work is undertaken safely and that any used material are correctly disposed
of.
• That the preservation work is completed in accordance of the agreed schedule.
• That the preservation is effective so there is no reduction in equipment performance from
Material Delivery (from vendor premises) till Load Out (at supplier premises).
Quality personnel shall monitor, at appropriate intervals, handling and storage activities for compliance
with procedures and detection of deterioration of products in all storage facilities.

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;

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• 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

NON-DESTRUCTIVE TESTING (NDT)


NDT activities shall be carried out in a planned and controlled manner to ensure that all NDT activities
are accomplished in accordance with the approved procedures, the referenced International Code /
Standards and the applicable CONTRACTOR Specifications for the activities to be undertaken by
SUPPLIER.
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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.

INSPECTION AND TESTING


SUPPLIER shall provide for planned and systematic control of all quality related activities performed
during the fabrication inspection and testing of the PO scope of supply.
The VENDOR and Sub-supplier shall submit ITPs to SUPPLIER for review and CONTRACTOR approval.
SUPPLIER will attend to witness various stages of production and CONTRACTOR will also be invited.
Any inspection or test requirements for purchased items will be identified in the Purchase Order and
confirmed as acceptable upon goods receipt.

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.

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CONTROL OF MONITORING AND MEASURING DEVICES


SUPPLIER established Inspection, Monitoring and Test Equipment Control Procedure, which details a
system for the calibration of inspection, test and monitoring equipment used by SUPPLIER and Sub-
supplier at fabrication yard for which calibration and precision are considered essential to the quality
of the work.
SUPPLIER selects appropriate measuring and test equipment in complying the specified accuracy and
capacity to the specified requirements, whereas equipment, gases, jigs, or other related devices to be
verify the acceptability of products, controlled, calibrated and/or adjusted at specified intervals to
maintain the accuracy and precession within the required limits by establishing the control procedures.
The control of measuring equipment shall include the records, control logs, the identification of validity
to show the calibration status, the handling and storing to prevent damage and deterioration.
All verified and/or calibrated equipment shall be issued with respective certificates and will be
provided with a tag or sticker indicating calibration status, the control procedure shall be defined in
the Inspection and Test Plan.
SUPPLIER ensures the master standard/gauge of measuring and testing equipment shall be calibrated
by an organization accredited to ISO 17025. The Certificate of ISO 17025 for calibration organization
will be submitted to SUPPLIER from Vendors/Sub-supplier for validation.
Records concerning the accuracy and validity of the inspection, measuring and test equipment shall be
maintained and traceable to national and international standards. All inspection, measuring and test
equipment shall be stored and safeguarded to avoid unauthorized adjustments or damage, which
would invalidate the calibration setting.
Laboratory Accreditation applies to all Non-destructive testing, Mechanical testing and the laboratory
shall be certified to ISO/IEC 17025:2017.
Inspection, Monitoring and Test Equipment Control Procedure”, F2-FOU-CON-SAI-PR-QA-00010 shall
address the following as a minimum:
• Requirements for Calibration and Maintenance of IMTE;
• Identification / documentation for calibrated IMTE;
• Requirements for Vendors and Sub-supplier;
Reference Document:
Inspection, Monitoring and Test Equipment Control Procedure, F2-FOU-CON-SAI-PR-QA-00010

16 MONITORING AND MEASUREMENT OF PROCESS


QUALITY AUDIT PROGRAM
The Readiness Assessment will be performed in early of project to ensure the all activities have been
performed by all discipline align with Project requirements.
The audit schedules shall have sufficient audit scope to ensure all elements of this PQP and those of
the contract are implemented effectively and in a timely manner. The audit schedules cover for both
Internal and External in the Project Quality Management System Audit Program and Schedule.

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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)

16.1.1 INTERNAL AUDIT


The Project Internal Audit Schedule develops based on process activities, progress approach by each
discipline and function within the SUPPLIER organization, associated risk which identified during
Project Risk Assessment. The overall Internal Audit schedule will cover Engineering, Project Control,
Procurement, Pose Order (Including Logistic and Material) and Fabrication. The audit objective is to
verify the Project QMS implementation;
• In compliance with the applicable requirements of ISO 9001:2015 Standard;
• In compliance with the applicable statutory and regulatory requirements, CONTRACTOR
requirement and Project requirements;
• Effectively and adequately implemented and updated to achieve continual improvement.

16.1.2 EXTERNAL AUDIT


Project External Quality Audit will be carried out to select Sub-supplier or Vendor which considered as
high critical Sub-supplier or Vendor. The audit will be performed during period at 30% and 70%
achieved progress to verify following item:
• Scope of supply/service of Vendor/Sub-supplier is in line with Contract requirements;

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• Quality Management System (QMS) of Vendor/ Sub-supplier complies with contractual


agreements, International standards, and applicable Statutory and Regulatory requirements;
• QMS of Vendor/ Sub-supplier is effectively and adequately

16.1.3 AUDIT REPORT


Upon completion of the closing meeting audit then the audit completion a report of the audit shall be
prepared by the Lead Auditor and issued within ten working days.
The report shall identify the objectives and methodology of the audit and summarize any findings. The
report shall detail positive and/or negative findings, Non-Conformance Report, Observations and may
offer recommendations, including follow up action.
The Audit Report shall be reviewed and approved by PQM prior to its issuance to Auditee and
CONTRACTOR for information. A record of all audits report shall be maintained by PQM.
SUPPLIER audit procedure and schedules which detail described in SUPPLIER's specific document.

MANAGEMENT OF NON-CONFORMANCE REPORTS (NCR) - AUDIT


The provision of issuing Non-Conformance Reports have the scope of correcting the deficiency through
an by immediate action/ detailed correction and corrective actions, if any.
As a minimum define how the following actions taken are achieved:
• Investigation and analysis of the root cause of deficiency or non-conformance and follow by
correction & corrective action to prevent its reoccurrence in the future;
• Use deficiencies root cause to analyses potential deficiency and follow by preventive action to
prevent re-occurrence;
• Analysis of recurrent problems in order to ascertain the root cause or identification of trends;
• Review of technical queries and concession requests for trends or recurrent problems specific
to the Project;
• Review and where appropriate revision of procedures, including monitor the implementation
of the changes;
• Record the results of investigation and analysis, as well as recommendations;
• Follow up and close out of correction & corrective action and verify the efficiency of actions
taken.
Detailed procedure of the NCR is described in SUPPLIER's document
Reference Document:
Project Non-conformance Management Procedure (F2-FOU-CON-SAI-PR-QA-00004)

MANAGEMENT OF NON-CONFORMANCE REPORTS (NCR) - PRODUCT


Products that fail to meet the specified requirements shall be identified and controlled to prevent its
unintended use or delivery. This event shall be documented by the use of non-conformance reports.
During procurement and fabrication any conditions that do not meet contract requirements and that
cannot be corrected by the end of the workday shall be rejected and documented.
The NCR shall be issued but not limited to condition to the following circumstance:
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• Nonproven process that implement to manufacture/fabrication;


• Nonconforming products to project requirement;
• Non-fulfillment of applicable code and standards;
Where non-conforming product or processes have been identified, they shall be notified to
CONTRACTOR verbally the same day and in writing (NC report) within two (2) days, and NC report
re-submitted again after subsequent corrective actions are identified and implemented. Non-
conformity report shall as a minimum contain: detailed description of non-conformity including
photographic evidence (where applicable), Root cause analysis, corrective / remedial action taken
including testing / re-analysis / disposition where applicable, plan with time and deadline for
closure, evidence of completion.
And NCR will not be issued to:
• “Normal” defects and “faults”/” breakdowns” during fabrication, fabrication that cannot
compromise regular production activities and can be fixed locally in line with normal practices
and with approved procedure (e.g.: welding defects); these defects are normally recorded
through inspection and test reports;
• Over (excess), Shortage and Damage of material listed in the packing list or in the Purchase
Order, where OSDR procedures apply;
SUPPLIER Project Quality Engineer to collate that above information in order to transform the data
into quantitative statistics. The data will be analyzed to find if any trend using Pareto Quality Engineer
to raise NCR to records the issues follow by propose corrective actions.
SUPPLIER shall establish and maintain procedures of Nonconformance report. The procedure
describes how to requests for an immediate action and preventing its occurrence in the future, by
eliminating the causes of potential deficiencies in order to prevent their reoccurrence.
Evidences of the remedial action and corrective action implementation shall be recorded and
maintained to substantiate that repaired; reworked or corrected items have been re-inspected and/or
re-tested according to the applicable procedures.
Reference Document :
• Project Non-conformance Management Procedure (F2-FOU-CON-SAI-PR-QA-00004)

CONTRACT DOCUMENT REVIEW


The Contract Document Review is carried out to provide the Project Team with an overall
understanding of the Contract Documents and Contract requirements. The review allows each
discipline in the Project Team to identify critical contractual requirements affecting their area of work,
and to implement actions required to monitor and resolve them. Special attention shall be given to
the review of the Contract Terms and Conditions and the Technical Specifications. Errors,
discrepancies, unclear requirements and new additions must be highlighted and disseminated
amongst the Project Team. Clarifications shall be made with CONTRACTOR if required. Reference shall
be made to the Contract documents received from CONTRACTOR.

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.

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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.

CUSTOMER COMPLAINT / SATISFACTION


SUPPLIER shall perform customer satisfaction monitoring during execution of the Project. SUPPLIER
has methodology to asses CONTRACTOR perception as to the level to which the SUPPLIER has satisfied
their requirements in the Project execution phase.
The Customer satisfaction will be implemented through
• Sponsor meeting which is attended by SUPPLIER Steering Committee;
• Customer satisfaction questionnaire survey and;
• Analysis of CONTRACTOR complaints (as applicable)

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.

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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”.

16.10.1 QUALITY REPORTING


SUPPLIER shall issue quality reports on monthly and weekly (if required by CONTRACTOR) basis which
shall include the following minimum information for each reporting period:
• Quality issues;
• Quality performance indicators;
• Nonconformance status;
• Upcoming quality activities;

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• Quality Audit status.


• Analysis of Key Performance Indicators (as per KPIs evaluation cycle) will be included in
Monthly Quality Reports.
Quality records shall be identified and maintained to demonstrate achievement of the required Quality
as described in SUPPLIER requirements. Quality Records shall include all as built and final document
deliverables required in accordance with contractual requirements.

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.

Figure 16-1 Lessons Learned Work Process

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APPENDIX A – PROJECT QUALITY POLICY

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APPENDIX B – ORGANIZATION CHART

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APPENDIX C TO PROJECT QUALITY PLAN

PROJECT QUALITY AUDIT SCHEDULE Date 26/11/2019

Rev. 00

FORMOSA 2 OFFSHORE WIND FARM PROJECT - FCSA Sheet 1 of 1

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

Planned Postponed Completed Predated


Legenda
P X C Y
Notes: This is the template for tentative schedule for the Internal & External audits. This will be a live document and to be updated whenever there will be any change(s) and conveyed to CONTRACTOR.

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