Sajithkumar 03-Dec-2018

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PROJECT QUALITY PLAN

DOCUMENT NUMBER : EBS/STD/PQP - 001
PROJECT NUMBER : ------
PROJECT TITLE : Warehouse & Workshop for Salalah LPG project
EPC CONTRACTOR : PETROFAC INTERNATIONAL
CONTRACTOR. : STEEL BUILDINGS LLC
PROJECT DOCUMENT : N/A
NO.

Reviewed and
Prepared by Approved by
Rev Date Description Approved by
(EBS) (CLIENT)

Resubmitted for Review &

1 2/10/2018 RAGHURAM FIRAAS
Approval

Submitted for Review & Approval RAGHURAM FIRAAS

0 3-Sep -2018

Document Title : Project Quality Plan, Rev:1 Project Document No : EBS-STD-PQP-001

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INDEX
1.0 SCOPE

2.0 PURPOSE

3.0 REFERENCES

4.0 QUALITY MANAGEMENT SYSTEM

4.1 ISO Certification
4.2 Quality Management System
4.3 Project Quality Mnagement
4.4 Quality Control

5.0 PROJECT MANAGEMENT/PROJECT CONTROL

6.0 CONTROL OF THE PROJECT QUALITY PLAN

7.0 GENERAL
7.1 Objectives Statement
7.2 Scope of Work – Material Description and specifications summary
7.3 Quality System Manual and Operating Procedures Reference
7.4 Document Control, Receipt and Issuing Procedures
7.5 Work Activities
7.6 International code & Standards

8.0 ORGANISATION
8.1 Organisation Chart
8.2 Reporting Responsibilities

9.0 RECORDS / FORMS

10.0 PROJECT SPECIFIC QUALITY CONTROL PLANS

10.1 Quality Control Plan

11.0 Key Personnel Listing & Designation

12.0 FABRICATION AND ERECTION METHOD STATEMENT

APPENDIX-A: Organisation Chart – EBS

APPENDIX-B: Organisation Chart – For Project

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1.0 SCOPE

Establishes the Project Quality plan, required to achieve the Quality requirements as per
Project requirements with in scope of work applicable to all structural steel works
undertaken for Warehouse & workshop for Salalah LPG project .

2.0 PURPOSE

To ensure that Quality Assurence and Quality Control activities are Planned and
established to meet the requirements of the company’s Quality Policy,Quality objectives
and Customer/Project requirements and to verify that the project team is performing its
task in accordance with a) Contract scope of work b) regulatory requirements(if
applicable ) and codes of practice c) Specific project procedures/Specification

3.0 REFERENCES

Annexure - A ----- List of Operating Quality Control plan & Procedures of EBS
Annexure –B ----- List of Project Specification for Structural Steel work

4.0 QUALITY MANAGEMENT SYSTEM

4.1 ISO Certification

EBS’s Quality Management System was audited and originally certified in 2001 by Viscount
Quality certifications, to comply with the quality assurance requirements of ISO 9001: 2015

The scope of EBS’s accreditation covers:

‘For Design, Manufacturing of pre-Engineered Metal Buildings,High Rise Buildings,Steel
Structures and Accessories.

4.2 Quality Mnagement System

EBS’s Quality System is developed around a Quality Assurance Manual is based on ISO
9001:2015, which addresses the relevant elements of ISO 9002. This Quality Assurance Manual
is supported by detailed Deprtemental Quality System Procedures are intended to comply with
all the prescriptions of ISO 9001:2015.
In turn these Quality System Procedures are supported by Operating Quality Procedures required
for different activities in the process control.

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EBS has developed Operating Quality Procedures for all essential activities involved in
Fabrication, welding ,Painting and testing works and these operating procedures will be
modified, if and as required, to meet the specification requirements of particular projects.

4.3 Project Quality Management

The QA/QC Manager is the functional head of QA/QC Department. He has overall
responsibility for:
 co-ordinating and harmonising quality efforts between operating entities.
 representing the company regarding quality matters.
 participating in Quality Management Steering Committee activities.
 verifying that the quality system is applied to work performed and that personnel are
trained in its use.
Inspections, audits, checks and testing is handled by the Project QA/QC Manager \QC
Supervisor. He has the responsibility on the project level to:
 Aid in the development of systems that:
 Identify and record quality problems
 Control further processing, delivery, or installation of non-conforming product until
the deficiency or unsatisfactory condition has been corrected.
 Initiate, recommend, or provide solutions through designated channels.
 Verify the implementation of solutions.
 Take action, as deemed appropriate, in the event of serious deviations from specified
quality requirements.
The assurance and control of essential activities are carried out by EBS’s QA/QC Manager or
QC supervisor with the assistance of QC Inspector(s) from either EBS or their subcontractors,
depending on project scope of work.
4.4 Quality Control
EBS’s approach to quality control is summarised as follows:

- Acceptable levels of quality are to be clearly established Through ITP before the start
of Fabrication and are to be consistently applied throughout the project.

- Project Management and Production department will fully support the principles of
quality control and will ensure that quality levels are maintained.

- Fabrication supervision will understand and accept the philosophy and techniques of
quality control and will be dedicated to achieve the quality levels established for the
Project.

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The quality of work at the work shop will be measured through inspection and testing.
Inspection and testing will be based on approved Inspection and Test Plan and poject
specification as applicable.

Quality control will not be restricted to supervision and monitoring of the Fabrication and
performance only. As consumable materials are received in EBS ware house prior to Fabrication
,receiving inspection will be conducted to ensure that the items received conform to
specification, Delivery Note and Purchase Order requirements. Any discrepancies discovered in
the inspection will be referred back to the Procurement dept., personnel for follow-up and
resolution with the sub vendor.

The Production(Work Shop management ) and project team management will bear primary
responsibility for ensuring that quality control is maintained during Fabrication of the Project.
They will be responsible for receiving, handling and interpreting all of the engineering drawings,
specifications and for monitoring all Fabrication work for compliance to the intent. Work Shop
and Project’s entire team will share this responsibility during the daily monitoring of the work
under each individual’s direction, through visual inspection to ensure quality workmanship and
through observation and confirmation that work forces are applying appropriate Fabrication
methods.

5.0 PROJECT MANAGEMENT / PROJECT CONTROL

5.1 The concept for project control is a planned, controlled and disciplined approach, which
emphasizes and requires the following actions:

- Early and timely decisions on specific project requirements

- Critical path planning and schedules based on plan of construction and equipment
and materials availability.
- Early and continuous fabrication\construction involvement.
- All equipment and materials needed by Fabrication plan are identified, scheduled and
controlled.
- Firm control of changes
- Prompt and effective reporting on all aspects of the Project for management analysis
of performance and the initiation of action where required.

5.2 Schedule Planning and Control

a) Major Objectives

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The objective of the schedule planning and control will be to meet the contractual
time limits and to move the Project as rapidly as possible. Namely, the major
objectives of the schedule control function will be to:

- Establish and maintain the Project Master Schedule, highlighting the key project
milestones and project parameters necessary to attain the overall project schedule
objectives.
- Ensure that the Project Master Schedule and other control scheduled are
effectively communicated throughout project organization in a timely manner.
- Identify and predict adverse schedule situations as far in advance of the
occurrence as possible to allow corrective action to be taken.
- Provide a basis for sound project management decisions, which will enable timely
execution of the Project and maintain it continuously with fabrication and
construction requirements.

b) Basic Philosophy

Schedule control will be developed in a step wise manner, parallel with the
development of the project scope definition. The schedule control approach will be
broken down into the following three distinct phases:

- Overall Planning
- Detailed planning
- Monitoring, reporting and control.

The objective of overall planning phase will be to establish an overall time schedule,
which clearly establishes project key milestones (hard and soft) as specified by and
agreed to with the Company.

The objective of the second phase will be to develop the detailed work plan, which
will be adequate for controlling and tracking the progress of the Project. This will
also match the release of drawings and delivery of materials to the required path of
construction.
Once the planning work has been completed, control will be maintained by
monitoring and comparing actual accomplishment against the plan, making
adjustments and forecasts. It will be vital to successful completion of the Project to
identify potential problem areas as early as possible by close monitoring so that
corrective action can be taken before a problem becomes serious.

c) Organization

The schedule planning and control function will be under the control of the Project
Manager who will be staff to the DGM operation. Regarding this function, the
Project Manager will:

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- Prepare the schedule control plan and schedules
- Provide day-to-day monitoring\ reporting and coordination among disciplines.
- Coordinate with Company on schedule and progress matters through the DGM-
operations.
- Track and report the status of problem areas until they have been resolved.
- Provide Company and DGM-operations with accurate and timely report.

Monitoring, Reporting and Control:--

As soon as the detailed schedule planning is completed, the schedule control

operation will switch to the monitoring, reporting and control phase. This phase will
extend from the completion of the detailed planning until the completion of the
Project. The objective of this phase will be to monitor, track and control the progress
of the Project using a variety of schedule and progress related documents that will
identify adverse trends or schedule exceptions.

To obtain current project status of fabrication, project review meetings will be

conducted along with Plant Managers so that problems can be identified and resolved
as early as possible.If the problem can not be resolved at Project level, it will be
brought to the attention of DGM -Operations.

d) Progress Measurement and Control

In order to evaluate current project status and forecast future trends, the progress of
each phase of the Project will be measured and reviewed by making a comparison
between actual progress and planned progress.

6.0 CONTROL OF PROJECT QUALITY PLAN

The QA/QC Manager or QA/QC supervisor develops project quality plan.

Plant/CSD/Project Manager reviews the project quality plan (PQP) and submits to client
for approval. QA/QC Manager in conjunction with Plant/Project Manager shall identify
and distribute to Concernd operational personnel required to receive the PQP as per
section 11 of this document.

Master lists will be updated by QA/QC Supervisor or Manager giving Date, Revision,
Title, Recipient Name, Date Approved as shown in section 7.4 of this PQP.

It is the responsibility of all department heads to ensure:

a. That each Project Quality Plan retained in their department is immediately updated
with the latest Revision.

b. That the QA/QC Department is notified of any recommendations to modifications of

controlled plans.

c. To recommend any changes that will improve quality efficiency control within their
Department.
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The QA/QC Manager or Supervisor shall be responsible for the control, revision and
distribution of PQP.

Documents relevant to control of Project Quality Plan as per ref. Of QMS document #
EBS/QMS/007 E -------Control of Document

7.0 GENERAL

7.1 OBJECTIVES STATEMENT

7.1.1 General Statement on Quality Objectives.

The assurance of Quality is fundamental to all work undertaken by the Emirates Building
System (EBS) and is practised by all personnel in their daily activities.

Quality is enhanced by working in a systematic method to formalised procedures

designed to eliminate the occurrence of deficiencies.

It is the responsibility of the Management to ensure that these procedures shall be

compiled by persons with adequate qualifications, and integrated into the requirements of
the regular working methods, which shall be clearly defined and documented.

EBS Operating Quality System Procedures shall be used as guidelines in the control of
project specific areas such as procurement, I.M.T. (Inspection, Measurement & Testing),
Nonconformances, Training, Document Control, Inspection & Testing, Quality Records,
etc.

The Management of the Emirates Building systemes LLC shall review, at a minimum
interval of twelve months, the quality management system to ensure its continuing
suitability and effectiveness.

It shall be the responsibility of the QA/QC Manager to monitor through audit the quality
management system in order to verify the ongoing application of the necessary systems
and procedures.

7.1.2 Overall Statement on Quality Objectives

Management of the Emirates Building systems LLC establishes the Quality Objectives in
support of the Quality Policy. These objectives are reviewed during the annual
Management Review committee meetings and ratified or modified to answer the
requirements of the Company as well as of the Customer.

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The Quality Policy of the Emirates Building systems LLC is supported by the following
quality objectives :

a) To ensure Customer satisfaction through quality of its products and services

b) To develop people through training and modern technologies

In order to familiarise all EBS employees in accordance with the system.the EBS
quality Policy is prominently displayed at all locations where activities are ongoing.

All EBS employees are expected to perform in accordance with this system and are
encouraged to identify and suggest ways to improve this system.

7.2 SCOPE OF WORK

Scope of work includes supply, Fabrication, welding, painting and delivery of structural
steel to site, Oman.

7.3 QUALITY SYSTEM MANUAL & OPERATING QUALITY PROCEDURE

REFERENCE

The following documents have been used in formulating this Project Quality Plan as
mentioned in section 7.1.1 of this project quality plan.

a) EBS General Operating Quality Procedure ------ As per Annexure - A

7.4 DOCUMENT CONTROL,RECEIPT AND ISSUING PROCEDURE

All Quality documents (PQP, QCP(ITP) & Quality Procedures) relating to this contract
will be retained in the custody of the QA/QC Manager/Supervisor .

A distribution matrix for project all specific quality documents will be maintained by
QA/QC Manager/Supervisor.

7.5 WORK ACTIVITIES

Work activities covered and controlled by this Project Quality Plan are:
A) Mechanical work
1) Welding Procedure & Welder Qualification
2) Fabrication and welding
3) Non Destructive Testing (In-house)
4) Painting
5) Packing
6) Shipping
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7.6 INTERNATIONAL CODE & STANADARDS

The following list of International Codes & standards shall be used in conjunction with
the EBS’s Quality System Manual, Project Quality inspection test Plan and Operating
Quality Procedures. Client’s/Project specifications shall be used as a basis for the system.
All other standards and procedures shall be used as and when required.

The belwo documents are maintained by EBS Corporate QA/QC Department and copies
are distributed to concerns as and when required.
International Codes and Standards & Company documents:

Title Document No.

Structural welding code -steel - AWS D1.1:2015
Specification and approval of Welding Procedures for - BS EN 288 -3/BS EN
Metallic Materials 15614-1
Specification and approval of Welding Procedures for - BS EN 15613:2004
Metallic Materials-Qualification based on Pre-Production
welding test
Specification and approval of Welder Qualification - BS EN 287-1
Hot Rolled Products of Structural Steels - BS EN 10025-2:2004
Structural use of steel work in building - BS 5950-2:2001
Recommended Pracice of ASNT - SNT-TC-1A:2011
Mechanical test for steel products - ASTM A 370
Surface preparation of Steel - BS EN ISO 8501-1
Steel Structures Painting Council - Volume 1& 2
Welding Coordination –Tasks and responsibilities - BS EN ISO 14731:2006
Tolerance on dimensions ,shape and mass for hot rolled stell - BS 10029:1991
plates 3mm thick or above
Quality requirements for fusion welding of metallic materials - BS EN ISO 3834-1,2 &3
Specification for Hot Rolled sections - BS 4-1:2005
Delivery requirements for surface condition of hot rolled - BS EN 10163 -1 :1991
steel plates ,wide plates and sections.

8.0 ORGANIZATION
The project will be carried out by EBS. Whereas EBS will have Plant (off-site) and on-
site allocation of staff and management for their works (fabrication & supply),
EBS will have own staff, labor and adequate management allocated and distributed to the
Project for their respective works organized in hierarchical order. Allocation and
organization of personnel may be subject to changes to Suit project requirements.

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8.1 ORGANIZATION CHART

Organisation Chart for EBS - SEE APPENDIX-A
Organisation Chart for Project – will be submitted as separate Submittal)

8.2 REPORTING RESPONSIBILITIES

8.2.1 DGM-Operations

He shall be the authorised representative of the Contractor. They shall have overall
responsibility for all aspects of the work from start to finish, including construction,
safety, quality and planning. The DGM-Operations shall report directly to the General
Manager.

8.2.2 EBS Project Manager

Project Manager shall be directly responsible to the DGM-Operations for all aspects of
Planning ,Procurement & Fabrication Coordination. He is the focal point for field liaison
with the project Representatives.

8.2.3 EBS Plant Manager

The Plant Manager is directly responsible to the Fabrication for overall project through
his Managers & Supervisors. He has direct control of all work shop personnel, equipment
and material movements. He shall coordinate with QA/QC Manager or supervisor to
implement the quality requirements of the project. The Plant Manager shall directly
report to DGM-Operations.

8.2.4 EBS QA/QC Manager /Engineer

Responsible for compilation and maintenance of QCP's as well as revision and

distribution of the project quality plan. Additional responsibilities include the calibration
control of equipment/instruments, NCR's, verification and availability of procedures,
ITP, etc. He shall supervise the QC Inspectors and ensure that the work is carried out in
accordance with Project requirements or relevant international standard as
applicable.EBS QA/QC Manager shall advise Plant Manager on quality matters and
report the findings to EBS Project Manager.

8.2.5 QC Inspectors

Responsibilities include the inspection and documentation of all activities associated

with their respective disciplines (mechanical works such as Fabrication,welding, painting
and NDT etc.) They will ensure that the quality requirements are met as per client’s
specification.
NDT carried out by EBS NDT Technicians shall report directly to the QA/QC
Supervisor. They shall ensure that the work is carried out in accordance with
specifications and procedures.

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8.2.6 Material Controller

Material Controller shall be responsible for receipt and issue of materials and goods
ensuring that correct identification, registration, storage and preservation takes place. He
shall be responsible for all material files and records.

9.0 RECORDS / FORMS

9.1 Each format shall have a unique document number .All Report Formats will be attached
along with relevant Operating Quality Procedures.

9.2 Whenever a new format is required, the QA/QC Supervisor will develop the format in
consultation with the concerned personnel and subsequently submitted to the QA/QC
Manager for review and approval. The contents and formats of the following reports will
be submitted to client review for approval. Dependent on client requirements and project
specifications, these reports will be submitted in the final package, as a minimum:

Mechanical
 Packing/delivery note
 Fabrication Inspection Reports
 Weld visual and dimensional inspection report
 NDT Reports
 Blasting and painting inspection report

10.0 PROJECT SPECIFIC QUALITY CONTROL PLAN

10.1 Quality Control Plans

QA/QC Engineer/Supervisor shall monitor the performance of all tests undertaken to

establish conformance with Quality Control Plan requirements, duly assisted by
Inspector(s) responsible for relative activities.

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Revision: A
Date : 18- June-2018

11. KEY PERSONNEL LISTING & DESIGNATION

S/ NO. NAME TITLE

01 Samir Akra General Manager
Dy.General.Manager
02 Jamil Fayad
(Sales and Marketing)
03 Sameer Ahmad Sales Manager - UAE
04 Joseph Chidiac DGM -Operations
05 Firass Project Manager
06 Mittri Matta DGM-Technical
07 Martin Paul Plant Manager
08 Pandian IT Manager
09 Raghuram QA/QC Manager
10 Rudy QA/QC Supervisor

12.0 FABRICATION METHOD STATEMENT /PROCEDURE

(Ref. Project Docuemnt # EBS-STD-SFP-004)
This method statement/procedure gives a brief description of the steps taken prior to and during
the Fabrication phase of the project. The operating Quality procedures and quality control plans
incorporated in the project quality plan gives detailed description of the methods used to achieve
compliance to the Project specifications and relevant interanational standard requirements.
Activities are involved as follows:
a) Preparing cutting sheet
b) Material requisation
c) Cutting materials
d) Fit up and fabrication
e) Welding
f) Blasting and painting
g) Paint touch up at EBS
h) Final inspection and release of structure for shipping & Packing and shipping

Document Title : Project Quality Plan, Rev:1 Project Document No : EBS-STD-PQP-001