QUALITY CONTROL PLAN

CONTENTS
1 INTRODUCTION ................................................................................................................ 1

1.1 Overview ............................................................................................................................. 1

1.2 Purpose of this Plan ............................................................................................................ 1

1.3 Reference Documents ........................................................................................................ 1

1.4 Terms and Definitions ......................................................................................................... 2

1.5 Abbreviations and Acronyms .............................................................................................. 2

2 OVERVIEW OF THE PROJECT QUALITY CONTROL ..................................................... 4

2.1 ISO 9001:2008 Requirements ............................................................................................ 4

2.2 Quality Control Objectives .................................................................................................. 4

2.3 Quality Control Policy.......................................................................................................... 4

3 QUALITY CONTROL ORGANIZATION STRUCTURE ...................................................... 6

4 ROLES AND RESPONSIBILITIES ..................................................................................... 7

4.1 Project Director ................................................................................................................... 7

4.2 Project Management Quality Assurance Manager (PM QAM) ........................................... 7

4.3 Work Group (WKG) Construction Manager (WKG CM) ..................................................... 8

4.4 Work Group (WKG) Quality Managers (WKG QM) ............................................................ 9

4.5 Work Group Site Quality Inspector ................................................................................... 10

5 QUALITY CONTROL PLAN PROGRAMME .................................................................... 12

5.1 Responsibility .................................................................................................................... 12

6 DOCUMENTATION AND DATA CONTROL .................................................................... 13

6.1 Quality Control of Documents (ISO 9001:2008 Clause 4.2.3) .......................................... 13

6.2 Quality Control Records (ISO 9001:2008 Clause 4.2.4)................................................... 15

6.3 Inspection of Site Documents ........................................................................................... 16

7 INSPECTION AND TEST PLAN ....................................................................................... 17

7.1 Definitions ......................................................................................................................... 17

7.2 Preparation of ITP ............................................................................................................. 18

7.3 Procedure for ITP.............................................................................................................. 19

7.4 Request for Inspection (RFI) ............................................................................................. 19

7.5 Final Inspection ................................................................................................................. 19

7.6 Responsibilities ................................................................................................................. 19

7.7 Flow Chart of ITP Procedures .......................................................................................... 20

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8 MATERIALS AND EQUIPMENT MANAGEMENT CONTROL ......................................... 21

8.1 Material Test on site and on Manufacturers laboratory .................................................... 21

8.2 Material and Equipment Certified by Manufacturer .......................................................... 21

8.3 Material and Equipment Inspected by Third Party............................................................ 21

8.4 External Material Test Flow Chart .................................................................................... 21

9 CALIBRATION, MONITORING AND MEASURING EQUIPMENT .................................. 23

9.1 Site Testing ....................................................................................................................... 23

9.2 External Calibration........................................................................................................... 23

9.3 Internal Calibration ............................................................................................................ 23

9.4 Calibration Workflow: ........................................................................................................ 25

10 CONSTRUCTION QUALITY CONTROL .......................................................................... 26

10.1 Introduction ....................................................................................................................... 26

10.2 Inspection Checks............................................................................................................. 26

10.3 Site Works Inspections Flow Chart ................................................................................... 28

11 TRACKS WORKS CONTROL .......................................................................................... 30

11.1 Introduction ....................................................................................................................... 30

11.2 Inspection Checks............................................................................................................. 30

12 TUNNEL WORKS CONTROL .......................................................................................... 32

12.1 Introduction ....................................................................................................................... 32

12.2 Inspection Checks............................................................................................................. 32

13 EWG SYSTEM TESTING MANAGEMENT ...................................................................... 34

13.1 Test Planning Documents ................................................................................................. 34

14 GUIDE LINES ................................................................................................................... 39

14.1 Sub-system Test Plan (SSTP) .......................................................................................... 39

14.2 Type Test .......................................................................................................................... 39

14.3 Factory Acceptance Test .................................................................................................. 39

14.4 On Site Test ...................................................................................................................... 39

14.5 Trial Run Test ................................................................................................................... 44

14.6 Inspection Checks for subsystems ................................................................................... 46

15 NON-CONFORMANCE REPORT (NCR) ......................................................................... 48

15.1 Raising a Non-Conformance Report................................................................................. 48

15.2 Non-Conformance Register and Referencing .................................................................. 49

15.3 Action to be taken on receipt of NCR ............................................................................... 49

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15.4 Root Cause to NCR .......................................................................................................... 50

15.5 Corrective action to NCR .................................................................................................. 51

15.6 Preventive action to NCR ................................................................................................. 53

15.7 NCR Tracking Report........................................................................................................ 54

16 QUALITY SYSTEM AUDIT PROCEDURE ....................................................................... 56

16.1 References ........................................................................................................................ 56

16.2 Definitions ......................................................................................................................... 56

16.3 Audit Process .................................................................................................................... 56

16.4 Quality Audit Schedule...................................................................................................... 59

17 PROCEDURES AND METHOD STATEMENTS .............................................................. 61

17.1 Working Methods .............................................................................................................. 61

17.2 Method Statements ........................................................................................................... 61

Appendix

A – INSPECTION TEST PLAN FORMS

B – NON-CONFORMANCE REPORT (NCR) FORMS

C – NCR REGISTER

D – AUDIT NOTIFICATION FORM

E – LIST OF PROJECT FORMS & CHECKLIST

F – REQUEST FOR INSPECTION

G - QUALITY SURVEILLANCE REPORT

H – METHOD STATEMENT TEMPLATE

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