PQP Rev. 001
PQP Rev. 001
PQP Rev. 001
0 7-16-2016 IST Submission for review & approval of PQP Project Manager
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TABLE OF CONTENTS
S/No Ref. No. Description Page
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1 Purpose & Scope 5
1.1 Purpose 5
1.2 Scope 5
2 Normative References 6
3 Terms & Definitions 7
3.1 Distribution List 10
4 Quality Management System 11
4.1 General Requirements 11
4.1.1 Interaction and Application of Processes 12
4.2 Documentation Requirements 13
4.2.1 General 13
4.2.2 Quality Plan 13
Level 1 – Quality Management System Documents 14
4.2.2.1
Level 2 – Quality Procedures 14
4.2.2.2
Level 3 – Inspection & Test Plans 14
4.2.2.3
Level 4 – Reporting Formats 14
4.2.2.4
4.2.3 Control of Documents 14
4.2.4 Control of Records 17
5 Management Responsibility 18
5.1 Management Commitment 18
5.2 Customer Focus 19
5.3 Quality Policy 20
5.4 Planning 21
5.4.1 Quality Objectives 21
5.4.2 Quality Management Planning 23
5.5 Responsibility, Authority and Communication 24
5.5.1 Responsibility & Authority 24
5.5.2 QA/QC Organization Chart 24
6 Resource Management 29
6.1 Provision of Resources 29
6.2 Human Resources & Competence 30
6,2.1 General 30
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6.2.2 Competence Awareness & Training 31
6.3 Infrastructure & Equipment Integrity 32
TABLE OF CONTENTS
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6.4 Work Environment 32
7 Project Execution (Product Realization) 33
7.1 Planning of Project Execution 33
7.2 Customer Related Processes 35
7.2.1 Determining Project Requirements 35
7.2.2 Reviewing Project Requirements 36
7.2.3 Customer Communication 37
7.3 Design and Development 38
7.3.1 Design & Development Planning 38
7.3.2 Design & Development Inputs 38
7.3.3 Design & Development Outputs 38
7.3.4 Design & Development Review 39
7.3.5 Design & Development Verification 39
7.3.6 Design & Development Validation 39
7.3.7 Design & Development Changes 39
7.4 Procurement and Purchasing 40
7.4.1 Procurement & Purchasing Process 40
7.4.2 Procurement & Purchase Information 41
7.4.3 Verification of Purchased Products 42
7.4.4 Control of Procured/ Purchased Products 43
7.5 Control of Production and Service Provision 45
7.6 Control of Monitoring and Measuring Devices 47
8 Measurement, Analysis and Improvement 48
8.1 General 48
8.2 Monitoring and Measurement 49
8.2.1 Customer Satisfaction 49
8.2.2 Internal Quality Audit 49
8.2.3 Monitoring & Measurement of Processes 49
8.2.4 Monitoring & Measurement of the Product/ Work 50
8.2.5 Independent Testing Laboratory, NDT Agency 51
8.2.6 Field Inspection Coordination Procedure 54
8.3 Control and Reporting of Non-conforming Product/ Activities 55
8.4 Analysis of Data 57
8.41 Monthly Quality Management Report 57
8.5 Improvements 59
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8.5.1 Continual Improvement 59
Cont’n.
TABLE OF CONTENTS
S/No. Ref. No. Description Page
8.5.2 Corrective Action
8.5.3 Preventive Action
Attachments/ Appendices
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The purpose of this Project Quality Plan (PQP) is to describe and set out quality policies,
procedures and practices of GTPP to maintain an effective Project Quality Management System
(PQMS). It is a management tool to keep employees of GTPP aware of the commitment and
cooperation required to achieve the quality objectives and customer satisfaction. It is also a
suitable training document to reduce the learning curve.
Quality Management is a key ingredient in maintaining the continuing success of GTPP. The
principles of Quality Management will be passed on to the sub-contractors and vendors who are
participating in this project to ensure their full participation in the success of the project. Sub
-contractors and vendors will also be taken on board our definition of quality and establish,
document and maintain effective and economical Quality Systems to ensure and demonstrate
that products i.e. Results of activities or processes conform to specified Saudi Aramco Schedule
“Q” requirements. This PQP and the Quality System Documents outlined herein describe how
GTPP Quality Management System is designed to ensure that quality requirements are
recognized and that consistent and uniform control of these requirements is adequately
maintained. The PQP defines how effective control is established by use of formal written
procedures. The PQMS includes provisions for prompt detection of discrepancies and for timely
effective corrective action.
1.2 Scope:
The principle of this Project Quality Plan is to set out the strategy and techniques to be employed
to manage the Sub-contract works including the establishment of a management quality policy
statement and quality objectives for execution of the contract works.
This plan is established in accordance with the requirements of GTPP Quality Manual and in
accordance with Saudi Aramco requirements. The Plan shall also set out the basic structure and
interaction of the management documentation, the management processes to be controlled by
which the control referred shall be achieved.
The intent of this Quality Plan is to construct Flare Gas and its associated works in Qatif that
meets with Saudi Aramco Engineering Standards, Procedures and all applicable regulatory
requirements. Furthermore this plan aims to enhance Saudi Aramco satisfaction through the
effective application of the system, including processes for continual improvement of the system.
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This Project Quality plan is intended to be used as required for the Sub Contract activities
involved in the contract as per following scope of work.
Under this package, the following Sub Contract works will be performed:
4) Demolition work of Existing Utilities and Facilities that are affected by the Proposed
Construction.
5) Reinstatement Work.
This is the overall Project Quality Plan of GTPP to define the project quality requirements and
implementation plan for the completion of the project as defined in the detailed Scope of Works.
2. Normative References:
Other Documents:
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Schedule “Q”: Quality Assurance & Control, Inspection and Testing
ISO References:
For the purpose of this Quality plan, the following terms and definitions in addition to terms and
definitions given in ISO 9000:2005, Schedule “Q” and SAEP-1154 shall apply and have the meaning
indicated in this section. No attempt is made to define ordinary words which are used in accordance
with their established dictionary meaning.
For the purpose of the procedure, the definitions given in ISO 9000:2005 together with the following
definitions apply. Terms which are repeated here for clarity but have been defined in other
International Standards are identified by placing the number of the standard after the definition.
Acknowledgement, Receipt: A letter of transmittal, print order and transmittal (POT) or electronic
return receipt that is used to confirm the recipient received the documents transmitted.
Appraisal: Assessment of a supplier’s capability of controlling quality carried out before placing
orders.
Authorization: The sign-off on a document, of the individual who confirms that internal review
and approval of the document was completed and all comments were resolved.
Client satisfaction: Client’s perception of the degree to which the client’s requirements have
been fulfilled.
Code: The code(s) or national/ industry standard(s) specified in the customer documents, for
design, fabrication and installation.
Compliance: All indication or judgment that the product or service meets the requirement of the
relevant specification or regulation; also the state of meeting the requirements.
Construction: The organization that performs fabrication and/ or installation, located at the field
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site.
Design Process: The verification that design criteria comply with specified requirements that
design data and methods are valid for the range of applications; and that the completed
design satisfies the design criteria.
Document: Hard copy or electronic record such as manuals, procedures, process control
documents and reports.
Hold Point (H): Inspection or Test may not proceed without the QA/QC organization
representative in attendance.
Improvement: Actions taken to increase the effectiveness and efficiency of activities and
processes in order to provide added benefits.
Inspection and Test Plan (ITP): Document which defines or identifies in a tabulated form the
inspection, test methods, procedures and acceptance criteria to be used during
construction and commissioning.
Inspection Assignment Package: A set of documents that include details of purchased material/
equipment and their quality requirements needed to perform full inspection at the vendor/
sub-vendor facility.
Materials and Items: All inclusive generic items used to describe the constituents that are
procured, fabricated and assembled to complete the facilities.
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Pre-Commissioning: Testing of system components for continuity, operability and in the case of
the process plants, their ability to withstand operating pressure prior to the introduction of
feedstock or other final products into the facility.
Quality Assurance: All the planned and systematic activities implemented within GTPP quality
system, and demonstrated as needed, to provide adequate confidence that an entity will
fulfill requirements for quality.
Quality Audit: A systematic and independent examination to determine whether quality activities
and related results comply with planned arrangements and whether these arrangements are
implemented effectively and are suitable to achieve objectives.( Project duration is 10
months and needs Internal Audit at 15 % 60% Procurement and 15% 60% Design &
Construction Audit , that will be under the responsibility of the Main Contractor.
Quality Control: GTPP employs operational techniques and activities that are used so that its
operations and services conform to the quality requirements as per Saudi Aramco.
Quality Management: All activities of the overall management function that determines the
quality policy, objectives and responsibilities, and implements them by means of quality
planning, quality control, quality assurance and quality improvement with GTPP Quality
System.
Quality Plan: Document specifying which procedures and associated resources shall be applied
by whom and when to a specific product, process or contract. (ISO 9000)
Quality Policy: The overall intentions and direction of an organization with regard to quality, as
formally expressed by top management.
Record: A document in hard copy or electronic form used to record permanent information
needed for procurement.
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Specification: A written document describing the general requirements of materials inspection
and/ or process including acceptance standards.
Standard: A document approved by a generally recognized body which results from the process
of formulating and applying rules for an orderly approach to a specific activity.
Supplier: A company supplying goods or services who were included in the RVL or Regulated
Vendor Lists
Traceability: The ability to verify the history, location or application of an item by means of
recorded identification.
Witness Point (W): Inspection or Test may proceed as scheduled if QA/QC organization
representative is not present.
Waiver: Written authorization to use or release a product or work that does not conform to the
specified requirements.
After approval by Arabian BEMCO / Saudi ARAMCO, a controlled copy of the Project Quality
Plan shall be issued to key personnel on the project as per the Distribution List. The
distribution shall be controlled and recorded by the QA Manager ( BEMCO)and recorded.
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GTPP Document Controller Copy 6 006
GTPP Planning Engineer Copy 7 007
The Project Quality Plan, is the property of GTPP and shall not be copied or distributed
Without the prior approval, authority and consent of the Company.
GTPP will establish, document, implement and maintain a Quality Management System
(as depicted by this Quality Plan) for the Project, Closed Relief System and Flare Gas
Recovery System in Qatif Producing Facility, which meets contract requirements more
specifically Schedule “Q”.
Project Quality Plan is developed and implemented to ensure all “activities” are controlled
and documented records are maintained to ensure compliance with the Contract
Requirements, BEMCO/ Saudi Aramco requirements, statutory, regulatory and industry
requirements.
The processes/ procedures identified for Quality Management System and applicable
throughout the Organization are designed to result in continually improving effectiveness
of operations in our ability to satisfy BEMCO/ Saudi Aramco requirements.
GTPP has developed project Quality Management system in line with ISO 9001: 2008
requirements and Project Specification Requirements that includes Processes,
Procedures, Forms and various Quality Management System Reports.
GTPP has established, documented and implements an effective QMS as a means of ensuring that
its construction of the project conforms to specified requirements, to foster an environment of
continual improvement, and to identify its position as a leading construction organization.
The GTPP QMS is comprised of the Processes (refer to 4.11 below) that take opportunities and
converts them into value added outputs to satisfy our customers’ needs and expectations.
The sequence and interaction of the Processes are described in Item 4.11 below.
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The criteria and methods required to ensure the effective operation and control of these processes
are defined and documented.
The entire QMS documentation and other key information necessary to support the operation and
monitoring of the processes are available to all personnel, and other parties requiring access.
Appropriate levels and types of monitoring and measurement of processes have been determined
and are documented in relevant procedures.
The QMS includes policies and procedures for implementation of actions required to achieve
planned results, and for continual improvement of the processes.
Appraisal/Approval
of Sub supplier/ Materials/ Equipment
Sub contractor Traceability
Custome
Project
Control
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Each procedure and process has a process owner who has the prime responsibility for
ensuring that the process:
4.2.1 General
GTPP is following Schedule “Q” clause 3 and has established the following
documentation for its quality management system:
Quality policy and quality objectives (refer to Appendix XII)
- Work Instructions.
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GTPP established and maintains a Quality Plan. The Quality Plan identifies
the scope of the Quality Management System, and any exclusion to the
requirements of ISO 9001:2008 and Schedule “Q”. It includes procedures and
documents covering work activities. It includes a description of sequences and
interactions of processes that fall under the scope of the quality management
system. Where a process or procedure differs from the requirement of the
contract, the contractual requirement shall prevail and the process or
procedure shall be applied.
Level 3 documents are Inspection and Test Plans for the subject
Project consolidated list of ITP’s (SATIP’s) for the project which
includes BEMCO ITP’s and referred in Appendix III.
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Other relevant applicable vendor ITP’s, as required in the contract
shall be submitted by BEMCO , to Saudi Aramco for approval and
PQP shall be amended accordingly.
The Quality Plan referenced procedures and Inspection & Test Plans are controlled
documents. The Quality Assurance Manager of BEMCO, is responsible to ensure the
initial issue and subsequent changes are acknowledged by those authorized to receive
the Quality Plan.
A documented procedure has been established to control documents required for the
Quality Management System. Project documents shall be maintained at the site field
office.
Access to these files shall be limited to the Project Manager, Quality Assurance
Manager, Quality Control Manager and Quality Document Controller ( BEMCO)
The Quality Plan, referenced procedures and Inspection & Test Plans are
controlled documents. The QA Manager of ( BEMCO)
is responsible to ensure the initial issue and subsequent changes are
acknowledged by those authorized people to receive the Quality Plan.
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Only the latest authorized issue of project documents shall be available for use by
the BEMCO personnel. Documents not authorized for use, voided documents or
superseded documents (Red-Stamped Superseded) shall be marked, placed in a
different file at a different location as a means to prevent use.
GTPP shall use approved Transmittal Form (using the document numbering
scheme given by BEMCO/ SAPMT Document Controller) for the
correspondences recommended by Saudi Aramco.
All documents transmitted to Saudi Aramco for review shall use a transmittal form
which identifies the item transmitted and the action to be taken by Saudi Aramco.
The Project Manager is responsible for reviewing the contract and identifying
submittals and deliverables to be transmitted to BEMCO/ Saudi Aramco as per
project management procedure included in this plan.
A copy of the approved Quality Plan, Procedures, and Inspection & Test Plans for
Saudi Aramco use shall be available at all locations where work is undertaken for
this project.
All Quality Procedures document shall be reviewed and approved for release/
distribution by the responsible authorized discipline engineer/ party.
GTPP shall make the applicable issues of such documents based on the
contractual freeze date available at all function areas and inspection and test
points where they apply so they are readily accessible to the personnel
concerned.
The issue, control and recall of all engineering documents are under the
jurisdiction of the Technical Manager. He will be assisted by the Document
Controller at project site. Inspection & Test Plans and other related instruction
shall be issued by the Quality assurance Department. Test Reports shall be
prepared and issued by discipline and Quality Control.
The system of documentation and data control shall ensure that essential
drawings, technical requirements, contract change information, inspection
instructions, specifications or any other document required by Quality
Management System, are available at the time and place of operation.
Approved Quality Procedures of the latest issue, shall be distributed by the Quality
Control Manager to all locations where required for the effective functioning of the
Quality Program.
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GTPP shall destroy or put superseded stamp on document/ drawing (if required
for future reference) from all points of issue and activity locations.
GTPP shall ensure that Request for Information is raised and submitted to Saudi
Aramco when required.
GTPP shall ensure applicable documents from external sources (Saudi Aramco &
national/ international standards) are monitored for its integrity, use and
distribution by the assigned project personnel. GTPP internal violations shall be
reported through approved project Corrective Action Request (CAR). Details of
who, what, how, and when are defined in written procedures and other reference
of GTPP documents.
Note: Procedure for Document and Data control includes the provision of control of software
for suppliers’ systems supplied by supplier/ manufacturer.
All documents transmitted to Saudi Aramco shall identify the action taken by the engineer.
The document status shall be updated based on the response.
Methods shall be used to track the status of transmittals that require action by the
recipient. Documents issued for construction will be approved by qualified and
authorized individuals as required by the contract. As-built documents shall be
maintained by Document Controller at the field office. An index of as-built documents
shall be maintained as part of the file. As-built conditions shall be recorded on project
documents by blue line. All documents shall be verified for accuracy by the Project
Manager and shall be transmitted to BEMCO/Saudi Aramco at the end of the project.
Only the latest authorized issue of project documents shall be available for use by the
contractor personnel. Documents not authorized for use, voided documents or
superseded documents shall be marked and stamped “superseded” and placed in a
different file at a different location as a means to prevent use.
An index of project records shall be part of the file. Responsibility for the accuracy and
completeness of the records is assigned to the ( BEMCO)QA Manager. Access to
records shall be under the control of the ( BEMCO) Project Manager, QA Manager
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together with the Document Controller. Removal of records to a location other than the
immediate area where the file is located shall be restricted to the Document Controller.
Measures to identify removed files and their location will be maintained.
c) Concessions request.
These quality records on project are filed based on guidelines of SAEP-127: Security
and Control of Saudi Aramco Engineering Data outside of Saudi Aramco.
An index of project records shall be part of the file. Responsibility for the accuracy and
completeness of the records is assigned to the Document controller. Access to records
shall be under the control of Document Controller.
hand over dossier/ construction dossier is compiled based on the Master Index (to be
submitted later) approved by the Saudi Aramco Representative (SAPMT).
GTPP copy will be retained till receipt of the Final Acceptance Certificate. All original
drawing diskettes/ electronic form of sepias are stored in the KICL corporate office.
5 Management Responsibility
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Procedure GTPP -OP-01, Management Review
- Ensuring that the activities required for the quality management system
or contract are planned, implemented and controlled and their progress
monitored.
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Taking the corrective actions for Saudi Aramco NCR within seven (7) days from
the issuance period.
- Report this NCR to BEMCO thru Saudi Aramco PMT & PID.
GTPP project quality plan and the system included therein, by describing how
the quality assurance program of GTPP is designed to ensure that all quality
requirements are recognized and that a consistent and uniform control of these
requirements are adequately maintained.
Reference Documents: Appendix XIV (Minutes of Meeting Log; MQMR; NCR closure,
Project & QC personnel CV Submittal Log, Verification of control point’s survey)
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GTPP is committed to ensuring that all construction-related services meet the needs
and expectations of our clients’ and other interested parties. Our primary objective is
to maintain a high quality standard while keeping to the client’s budget and
completion time, and ensuring that all construction-related services comply with the
contractual and applicable statutory requirements, including safety and
environmental requirements. Please see the attached GTPP Policy Statement at
Appendix XII for further reference. To achieve this goal we strive to:
Ensure that GTPP top Management shall review the Quality Management
System on a regular basis (every 6 months) for continuing suitability.
Ensure that all employees understand the needs and expectations of our client
in an effort to achieving customer satisfaction.
Implement the requirements of Quality Manual, Project Quality Plan and other
documented plans/ procedures so that works are carried out in a consistent and
efficient manner.
Monitor performance to ensure corporate objectives are met through regular
contract review, internal audits and site inspections.
Our overall quality goals are to achieve our quality policy, maintain the integrity
and continually improve our QMS compliant with ISO 9001:2008 and Schedule
“Q”.
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It is GTPP policy that construction activities are performed with the utmost attention
to quality, safety and respect to the environment. Quality, Health and Safety as well
as the maintaining a good working and living environment are our prime concerns.
5.4 Planning
5.4.1 Quality Objectives
The top management of GTPP has identified the following quality objectives for the
project. The main quality objective of this contract is Quality of all its services,
workmanship and materials rendered to Saudi Aramco, will conform to all
contractual requirements and give value to its Customer with full satisfaction to
complete this project in time as per contract. GTPP considers attainment of these
objectives will be a continuous process of quality management system
improvement, and reputation of GTPP in the market. GTPP will strive to maximum
to achieve these objectives with full compliance to contractual requirements, proper
allocation of manpower with skilled work force, cost control, schedule control, etc.
GTPP will also seek continuous improvement in quality assurance procedures and
quality control with the ultimate aim of providing zero defects.
The objectives are controlled by measuring project quality indices which GTPP will
make use as part of continual improvement by analyzing each area as performance
objectives/ key performance indicators in order to enhance efficiency of the quality
system. These indicators will be discussed in the quality tool box meeting as well
as Quality Performance meeting.
The overall project quality objectives mentioned below will be monitored and
measured as follows:
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Repeated Violations for total violations reported : ≤ 5%
Acceptance of proposed QC Candidates : > 90%
Document Review Rejection from ID : 5% per month
Non-Conformity Ratio (LBE/NCR/WS) Company: Contractor : 1: 10
Closing LBE/NCR/WS within Agreed Completion Date (ACD): 100%
NCR approval : within three (3) business days
To ensure that safety of the personnel, facilities and environment have been
carefully considered and that appropriate measures have been implemented.
The elements that comprise the quality planning process for implementation and
development are this Quality Plan, Inspection & Test Plans (SATIP’s, SAIC’s &
SATR’s provided by Saudi Aramco), project organization charts that prescribe
personnel allocations and mobilizations, titles of individuals, sub-contractors
necessary to complete the Work. The integration of quality improvement initiatives
are described in paragraph 5.6, Management Review, in 8.2 Monitoring and
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Measurement, and 8.5 Improvements.
Increase and enhance Contractor work quality and job site awareness
through the Quality Tool Box Talk.
When conditions require change, the process is controlled and the integrity of the
quality management system is maintained.
Changes to the quality system are controlled. It is the responsibility of the Quality
Assurance Manager and the Project Manager that when conditions require change,
the process is controlled and the integrity of the quality management system is
maintained.
GTPP top management shall ensure that responsibilities and authorities are defined
and communicated within the organization. The Project Manager and QA Manager
(BEMCO) are responsible to create/ update the project organization chart and the
Quality Organization Chart.
GTPP quality personnel are endorsed to ( BEMCO) Saudi Aramco Units for interview/
approval prior to work as per Schedule “Q”.
GTPP quality personnel shall be dedicated to perform quality function as described in
Schedule “Q”. Paragraph 5.9. GTPP shall make personnel changes required due to
vacations, illness, temporary assignments, emergency leave, resignations or other
reasons as necessary to maintain required Quality coverage at least thirty (30)
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calendar days in advance of scheduled absences or changes and as soon as possible
for other changes.
Only one (1) QA/QC Inspector assigned to the project, Quality Inspector shall be
dedicated to the work in the Project as required by the Main Contractor ( BEMCO),
and perform no other function on this project. In providing effective Inspection as per
Quality requirements, GTPP assures optimum use of manpower, technological and
financial resources utilizing expertise is developed around highly competent, technical
and managerial personnel experienced in engineering and construction techniques.
CV Submissions:
GTPP shall make sure all CV’s be submitted to BEMCO, for review and approval prior
to the mobilization of the project quality personnel.
GTPP shall make necessary arrangements of qualified personnel for the backup for
the following reason but not limited to:
Illness
Temporary assignments
Emergency Leave
To this end, GTPP has an obligation to ensure that the final product, i.e. result of
activities or processes meets its fitness for purpose and has been carried out in
accordance with the Job Specification and is consistent with design requirements.
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1) Project Manager
2) Site Superintendent
3) QA/QC Inspector
4) Safety Engineer
5) Work Permit Receiver
6) Project Administrator Coordinator
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GTPP has assigned Site Superintendent as the overall Site
supervision representative for Civil, Mechanical and Electrical
activities on this project. He shall ensure that all jobs or works
executed were all as per approved Drawings, Specifications and
per approved submittals.
a) Responsible for the implementation of the Project as per
approved Work Schedule and also coordinates with QA/ QC
Inspector prior to execution of any activities to avoid NCR or
Non conformance issues.
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service by implementing process controls, data analysis and
measurement device.
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d) Ensuring all permits are available for works on site and all safety
precautions are taken.
m) Carrying out HSE inspections/ audits on site and reporting status and
effectiveness of the system.
Ensures that all controlled Quality Documents related to the Project are
maintained to the latest issue, and that these documents are made
available at all locations where operations essential to the effective
functioning of the Quality System are performed.
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“Superseded” if retained for record purposes.
6. Resource Management{
The overall organization for the project shall be in accordance with the
organization charts included as an attachment to this Project Quality Plan (Please see
Appendix V for reference).
GTPP will ensure that all resources required for the successful execution of the project are
provided within the stipulated time frame. These resources include manpower, equipment,
temporary site facilities for GTPP, site facilities for Saudi Aramco, soft ware, computers, lifting
equipment, lifting tools & tackles, storage space / area, survey instruments, testing equipment,
machineries, personal protective equipment (PPE), etc.
The Project Manager is responsible for assessing organizational and project needs including
oversight functions and develops resource requirements in order to assure resources necessary
to implement and improve the process of the QMS and address Saudi Aramco satisfaction
issues are provided in a timely manner.
Key staff shall be assigned to the project as described in the Manpower Requirement
Program. As a general principle, only suitably skilled, trained, experienced and qualified
personnel shall be assigned to the work.
All personnel, whose activities have a direct bearing on the quality of the work, shall be made
available for interview by Saudi Aramco, if required, before they are assigned to the project.
All QA/QC personnel qualifications shall be reviewed interviewed and accepted by KICL before
submitting their CV’s to Saudi Aramco for review. All QA/QC personnel assigned to the project
shall meet the minimum qualification and experience requirements stipulated in the Schedule
“Q”. This includes any replacements that may become necessary due to vacations,
illness, emergency leaves, etc. Saudi Aramco shall be notified at the earliest possible time of
any such changes in the QA/QC personnel.
The GTPP Job Interview Form is included in the Lists of Applicable Forms at Appendix - XIII for
reference.
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6.2.1 General
GTPP shall assign Key Staff and personnel to the project in accordance with the
requirements of Schedule “Q”, Attachment VI that is competent on the basis of
applicable degree or education, training, skills and experience. All personnel assigned
to the project shall meet the minimum qualification and experience levels specified in
Schedule “Q”, Attachment I. The QA Manager is responsible to review the contract to
determine the customer requirement for competency level of personnel assigned to the
project and ensure that assignment of personnel including sub-contractors meet the
requirements. Resumes of all quality personnel including sub-contractor quality
personnel shall be submitted to Saudi Aramco for review and approval at least two
weeks prior to the start of work. All procedures and personnel qualifications for special
processes shall be submitted thirty (30) days prior to start of work.
GTPP will provide on a monthly basis a list of approved personnel forecast to mobilize
on the next 60 days as well as for those scheduled to be demobilized in the next 60
days. Attached (Appendix – X) is the project manpower histogram indicating the number
of QC personnel for mobilization and demobilization.
GTPP planned staffing level shall comply with the Saudi Aramco approved quality plan.
Reduction of quality personnel from the required level as stated in Schedule “Q” shall
require Saudi Aramco written approval.
Regular training sessions following the induction training shall be conducted on the
project to keep the personnel continuously aware of the requirements. all quality
requirements are explained and that HSE precautions are in place.
GTPP employees and sub-contractor shall be made aware of the quality requirements
of the project and how their work activities shall contribute to the achievement of quality
objectives.
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basis to explain the company’s expectations of the output of the work to be done, the
use of the approved method statements to avoid rework and non-conformances and the
proper use of tools and equipment in conformance to HS&E requirements. The project
team shall support the monitoring and assisting in all required aspects for the internal
site trainers. Some of the core areas where toolbox training is required are explained
below.
Site quality training for coal tar epoxy coating application foreman and works.
Site quality training for waterproofing sheet membrane installation foreman and
works.
Site quality training for ready mixed concrete pouring/ shrinkage crack
prevention foreman and works.
Site quality training for materials handling and storage of epoxy coated steel
reinforcing bars.
Site quality training for cable tray installation foreman and works.
.
6.3 Infrastructure & Equipment Integrity
All equipment deployed on the project shall be fit for use on the project site. Authority, Legal,
Saudi Aramco requirements for vehicles, lifting equipment and tackles will be complied with
during the use and installations on the project.
GTPP shall provide a work environment suitable to achieve its business objective and satisfy
project requirements. Workplace and associated facilities, equipment, hardware, software and
support administrative services shall be provided as required for the project. Accessibility to
computers, appropriate software and other tools shall be issued to authorized personnel.
Proper infrastructure, safety tools and tackle, necessary rest/ ablution facilities and other
requirement to provide a safe conducive work environment will be provided. This will help to
ensure provision of construction services in conformity to Saudi Aramco requirements.
Necessary house procedures and relevant contract requirements will be posted at pertinent
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locations.
The project will be executed strictly in accordance with the specifications and
drawings, approved procedures, programs, and shall comply with the following
requirements of Project Execution Phase:
Quality Objectives:
- Saudi Aramco approval rate with code A &B (% first pass) for material
submittal.
- Customer satisfaction.
The whole processes of project/ construction operations can be split into the
following phases:
Design Control – Detail design computations, drawings and shop drawings (if
applicable) shall be submitted to Saudi Aramco for review and approval. KICL
shall perform design review at appropriate and agreed stages during the design
phase.
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Pre-commissioning Control – Prior to the completion of work, KICL shall perform
the inspection required as per Schedule “B” to complete the pre-commissioning
activities and documents.
Closing-out of all snag lists (punch list items) and non-conformances (raised by
Saudi Aramco or internal by KICL).
All the above processes, forming the project/ construction operations are covered by
design/ engineering specification and project specific procedures. Records required
to demonstrate compliance are indicated in each of the relevant documents, plans,
procedures and Inspection and Test Plan.
Method Statements for critical activities on site will be submitted to ensure proper
planning of the detailed construction activities including specification requirements,
equipment, and risk assessments of possible hazards and control measures which
need to be addressed and in place for a safe operation.
Acceptance criteria for the work will be developed where appropriate. Records
attesting to conformity of processes and resulting work shall be maintained. Records
shall include but not limited to the following:
Disposition reports.
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Project management review records
GTPP will review the contract agreement to determine the customer requirements in
The Sub-Contract work.. The Project Manager will evaluate these requirements and
determine any additional requirements including regulatory and legal ones, which may
not have been identified by BEMCO/ Saudi Aramco and need to be implemented to
support the delivery of the work.
Any future requirement that differs from those of the contract are resolved and
documented,
The contract review carried out prior to the final acceptance by GTPP, if any future
changes required to do with the approval of BEMCO/ Saudi Aramco, perhaps to the
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scope of work, or the original contractual milestone, in that case a review shall take
place with BEMCO/ Saudi Aramco and GTPP prior to final acceptance.
GTPP has assigned the responsibility to review the contract to the Project Manager.
The Project Manager shall ensure that the requirements are understood, that we have
the capability of performing the work. The contract shall be reviewed by the Project
Manager to ensure any agreed to changes have been incorporated. The contract review
shall be documented in the following manner and records maintained. Much of the
information in the contract will be relevant to the Project Quality Plan.
For Vendors & Sub-contractors not approved by Saudi Aramco, GTPP shall
submit a minimum of three (3) sub-contractors/ vendors with the following:
Financial Status
Reference List
Technical data
GTPP shall keep open the opportunity to submit 4th and 5th vendors if Saudi
Aramco rejects one or more of the first three.
Scope of Work.
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Saudi Aramco supplied products/ services/ informing of any type. e.g.
Standard Drawings or details, Standard Specifications.
Saudi Aramco review and approval of Submittals shall not relieve GTPP of the
responsibility of any deviations from the requirements of the contract documents
unless contractor has advised in writing the Owner on any such deviation at the
time of submission and BEMCO/ Saudi Aramco has accepted that specific
deviation. In addition to, any acceptances by Saudi Aramco shall not relieve
GTPP from the responsibility for errors or omissions in Compliance Submittals
or from the requirements under this contract.
Any deviation from the Project Technical Specification Documents and Contract
Scope of Works shall be subject to BEMCO/Saudi Aramco review/ approval.
Changes shall be documented and issued by the Project Manager to all staff
responsible for the execution of the original contract.
Communications means between BEMCO/ Saudi Aramco and GTPP includes but not
limited to, documents provided by BEMCO/Saudi Aramco, letters, emails, faxes,
submittals of deliverables by GTPP, weekly quality meetings and other meetings
whenever necessary.
Project Manager is responsible to establish and maintain communication with BEMCO/
Saudi Aramco representative regarding or construction activities. Project Manager is
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responsible for evaluation of the BEMCO/Saudi Aramco feedback/ complaints and
responding to them.
By Main Contractor;
There shall be audit at 15% & 60% stages and audit report shall be submitted to Saudi
Aramco.
All the applicable Saudi Aramco, international codes and standards, regulations
required for this project shall be maintained and specified (with their cut-off dates) by
our outsourced design sub-contractor in their Project Quality Plan.
All the correct versions of applicable Saudi Aramco, International Codes and Standards,
Regulations used in delivering the design and development outputs shall be specified
(with the standards cut-off date of September 2014) by our outsourced design sub-
contractor in all the applicable deliverables.
All calculations, design and development outputs shall be signed and dated by the
originator, checked and approved prior to finalization by an authorized engineer
competent in the discipline but without direct responsibility for performing the
calculations. A system to validate the programs or algorithms for computer forming
calculations too shall be employed.
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Outsourced design sub-contractor shall ensure that the design and development
outputs/ deliverables referred above shall control the project quality, complies stake
holder requirements and enhance the client satisfaction.
The Project Manager of GTPP is responsible to assure the output meets the design
inputs. Records of verification activities shall be maintained by Engineering Document
Controller of outsourced design subcontractor and shall be maintained by the project
Document Controller for GTPP.
In coordination with the outsourced design sub-contractor, GTPP shall plan and
carryout periodic meeting for design and development verification to ascertain that the
outputs meets the inputs by carrying out the reviews, performing alternate calculations,
review of design output documents.
Constructability review is required to be performed as part of this contract.
Design validation verifies that user’s needs are met. These shall be performed in
accordance with planned arrangements mentioned in 7.3.1 Design and Development
Planning, to ensure that the resulting product shall meet the specified requirements.
This will be achieved by ensuring completed works are checked, tested, commissioned,
and Saudi Aramco user departments/ authorities/ proponents have accepted the works.
For the nature of the construction industry, the design validation documents will be final
inspection reports, snag lists if any, testing and commissioning reports and the
provisional and final acceptance certificates.
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All requests for design changes as a result of design review, verification, validation,
BEMCO/ Saudi Aramco instructions, changes in law/ regulations, etc. will be recorded
in Design Change or Saudi Aramco approved formats. Affected changes shall be
documented, reviewed and approved.
The Project Manager is responsible to provide the interface with BEMCO/ Saudi
Aramco representative during the execution of the contract. Supplements or addenda
developed during this period shall receive the same level of review as the original
document and will be reviewed by BEMCO Engineering Manager/ Coordinator and/ or
Project Manager prior to issue.
Revision to project design documents shall be controlled. Revisions are reviewed to the
same level as the original document as stated. .
Only the document controller/ authorized personnel shall be allowed to distribute the
drawings to GTPP and its sub-contractors for project use.
Only IFC drawings shall be used for the construction of works on site.
As-built shall be developed per contract requirements and to verify the implementation
of the changes. As-built shall be independently reviewed internally to ensure field-
marked prints and other sources of as-built information have been correctly translated
onto the original document.
Supply of raw materials, fabrications, services and finished items shall be processed
from Saudi Aramco approved vendors or as per approved VENDOR mentioned in RVL
lists.
To the extent practical, GTPP shall procure its materials from Saudi Aramco approved
sources. Other sources for material selected by Purchasing shall be evaluated and
approved by GTPP QA/QC Department, Procurement and BEMCO/ Saudi Aramco
engineering prior to placing them on the acceptable Vendor’s list.
The extent of control over purchasing includes quality surveys and monitoring at the
supplier’s premises as required.
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A current list of approved vendors for parts and processes shall be maintained and
distributed by the Purchasing Department.
Contract/ purchase orders shall be spot checked by the QA/QC department to the
extent required to ensure that all pertinent drawings, specifications and complete
information relative to the item(s) procured are listed and that the sources of supply
have all the data required to supply Materials of an acceptable quality.
QA/QC Department shall evaluate all purchase items where any of the following
conditions apply:
In accordance with the Schedule ’G” of the contract, purchase orders with Supplier’s
and Sub-contractor shall be defined services and/ or product requirements. All
requisitions shall be reviewed by GTPP for technical and quality requirements prior to
submitting to BEMCO /Saudi Aramco for review.
Submittal references
Description
Quantity
The quality documents, if any, requested from the suppliers shall be specified on the
purchase order:
Quality Plan
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Delivery Schedule
Contractual Requirements
Contractual requirements
Schedule
Quality requirements
Detailed Inspection & Test Plans for all equipment and material shall be prepared by
suppliers and submitted to Saudi Aramco with the Inspection Assignment Package
(IAP) three weeks prior to start of fabrication.
Rejected material shall not be allowed to ship. When no form SA-175 exists. Material
shall not be inspected upon receipt at site. Non-conforming material shall be returned to
originator or marked in a manner that shall prevent its use.
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GTPP shall submit each week a two-week look-a-head schedule of all planned vendor
inspections electronically in a format acceptable to BEMCO/Saudi Aramco.
All procured/ purchased materials are correctly identified and stored as per vendor/
supplier recommendations. On receipt of the expiry dates will be checked, where
available on the item, and the First IN – First Out (FIFO) principle is used for issue.
Special care is taken for materials that need to be stored outside for need of space.
Materials such as reinforcing bars and metallic pipes, waterproofing materials, cable
tiles, galvanized items will be supported on timber skids/ pallets covered by
polyethylene sheet to protect such materials from dampness, corrosion and weather/
elements.
Most of the construction materials are identifiable by means of labels and packaging by
the vendor/ supplier. Where not available, materials will be suitably identified by using
colored markers and/ or tags. Vendor/ supplier will be consulted for storage
arrangements requiring special conditions of temperature and environment
Inflammable materials are stored in well ventilated areas, with suitable segregation of
areas for different kind of materials, e.g. Oil, Diesel, Gas cylinders, etc. are kept in
separate areas
GTPP understands the critical operation involved during the project execution works. As such,
coordination, use of dated and approved drawings and strict compliance to HSE requirements
and approved method statements will be ensured. GTPP understand that Work Permit System
for the individual areas and will comply with the Saudi Aramco requirements.
The GTPP Project Manager together with the Site Superintendent , QA/QC Inspector
and the project team will ensure that the work is executed in line with the relevant
procedures/ method statements, suitable equipment used and the work is monitored at
various stages as required by the specifications and as identified in the relevant
operating procedures.
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Inspection shall be done using calibrated instruments at pre-defined inspection times as
per the Inspection & Test Plans.
All sub-contract arrangements for executing works reflect the maintenance clause so as
to ensure servicing/ product warranty is guaranteed for Saudi Aramco. Records of
correspondence with relevant sub-contractors during this stage are maintained and
retained in the GTPP office.
All Operational/ Maintenance Manuals and Spare Parts Lists and Spares as applicable
for the project shall be submitted to Saudi Aramco for approval sufficiently in advance of
completion and handover stage. Saudi Aramco comments shall be incorporated and all
submissions will be done accordingly in compliance to SAEP-122, Project Records and
SAEP-329, Project Close-out Report.
The Project Manager ensures that the process description is to outline the planning and
progress monitoring of project.
The work environment is safe and conforms to health and safety requirement in
the contract.
Codes, standards and other references, including portions of the contract are
available to the workforce.
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All above activities are defined under project procedures mentioned in this quality plan.
The validation of the design is the constructed project that satisfies Saudi Aramco
requirements.
The validation of certain construction processes can only be ascertained when load is
applied or operation is initiated. For the project, these processes include as necessary.
Application of load and operations would only be allowed if the mentioned processes
have been applied/completed successfully, which will be proved before operations by
suitable approved testing’s.
Coating
GTPP assures these processes can achieve planned results through following
documented procedures, Inspection Checklist and Inspection and Test Plans
referenced in this document.
Process qualification
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GTPP will develop, implement and maintain a system to identify, design or report
documents so they remain traceable to their originator and contain Saudi Aramco
identification. Saudi Aramco plant, equipment tagging system will be complied with.
Incoming materials are correctly identified and stored. Most of the construction
materials are identified by means of labels and packaging by the manufacturer/
supplier. Where not available, materials will be suitably identified by using markers or
tags. All materials coming out of store shall be traceable by marking/ label, store
records, test certificates, etc.
will be maintained on equipment, materials, parts and components as specified in Saudi
Aramco standards and manufacturer’s specifications. Unless otherwise specified in
SAEP-1160: Tracking and reporting of Welding, NDT and Pressure testing for Capital
Projects.
GTPP will include a documented system for tracking pipe welding rejection including
that of sub-contractors, detailing reporting of repair rates, and accounting for required
tracer (penalty) radiography. Documents and records will enable an item to be traced
throughout fabrication, erection, installation, repair, modification and use of item.
Details of who, what, how and when are defined in written procedures and other
referenced GTPP documents.
As applicable, GTPP shall maintain a system to receive, log and maintain Saudi
Aramco supplied documents, data, material or equipment. .
As applicable, all Saudi Aramco supplied material shall be inspected against the
shipping documents for accuracy and damage by the Project Controls Manager and
stored in such a way to prevent damage or deterioration.
A system shall be maintained for the handling, storage and shipping, including
cleaning, packing and preservation of all items through the entire manufacturing,
receipts, construction process till the commissioning phase is completed and handed
over to Saudi Aramco. All precautions shall be taken to protect material from abuse,
misuse, damage, deterioration and unauthorized use.
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Restricted storage areas shall be made available for the isolation and protection of
accepted raw material, semi-finished parts and finished parts pending use or shipment.
GTPP and subcontractor shall establish, maintain, and implement a written program to identify,
control, and calibrate measurement and monitoring devices used to assure conformity of work
as required by the contract. The program shall contain the following elements:
- A program of corrective actions to repair or replace items that do not meet acceptance
criteria.
- A program to ensure measuring and monitoring devices are protected from damage
deterioration and unauthorized alterations of settings.
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Copies of the Calibration Certificates will be available at the GTPP office and original at
site. Same copies shall be submitted to Saudi Aramco for information.
The instrument and measuring equipment are stored in such a way as to avoid damage and
alter the calibrated status. Users of all instruments and equipment are responsible to check that
the measuring devices they are using are calibrated and accurate. Initial checks are generally
done to ensure accuracy. Instruments/ equipment used by sub-contractors on site will be
subjected to the same control.
Calibration checks/ accuracy checks will be done before actual measurement of any
characteristic. Any instrument showing errors will be subject to calibration. Any measurement
done with such instrument will be validated once again using calibrated instrument.
All inspection, measuring and test equipment and devices used to determine conformance to
Saudi Aramco specification, including that used for welding, non-destructive testing,
dimensional control, pressure testing, coating thickness, shall be controlled, calibrated and
maintained with an established written calibration and maintenance schedule.
All measuring and test equipment and devices having an effect on quality shall bear a tag,
sticker or other suitable marking, indicating calibration status. The validity of previous
inspection and test results when measuring and test equipment are found be out of calibration
shall be assessed and documented.
Equipment and devices used for measuring, testing and inspection shall require an initial
inspection for accuracy, or shall be proven prior to release for use on production.
The program shall provide for a pre-planned calibration frequency chart showing all applicable
test and inspection equipment, calibration frequency and status.
8.1 General
GTPP will plan and implement the monitoring, measurement, analysis and
improvement processes to demonstrate with the conformity to contract requirements,
process performance objectives, conformity of the planned quality management
system, and for the continuous improvement of the quality management system.
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3) Internal & external non-conformities
4) Repeated violations
5) Process performance measures
6) Analysis of data
7) Management review
The improvement process includes:
1) Corrective action
2) Preventive action
3) Continuous improvement
The above processes are discussed in detail below.
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The project execution processes described in Section 7 of this Quality Plan
necessary to achieve Saudi Aramco requirements are measured and
monitored as follows:
- Analysis of data,
- Customer satisfaction,
8.2.4 Monitoring and Measurement of the Product/ Work (Inspection & Testing)
GTPP will establish, maintain and implement a program stated in 7.3 Design
Development to control the development, review and release of designs that are
in conformance with Saudi Aramco requirements. The program shall be
controlled by written procedures, instructions, or checklist as appropriate
.Results shall be recorded, authenticated and distributed..
GTPP shall establish, maintain and implement a program as per 7.4,
Procurement and Purchasing to control procurement, inspection and acceptance
of equipment, material and construction activities performed by GTPP own work
forces or its sub-contractors. Records shall be maintained.
GTPP Procurement QC Inspector shall ensure that incoming equipment and
materials are inspected and accepted for project use prior to incorporation into
construction. When material is received without inspection release,the
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BEMCO Project’s Quality Personnel shall inspect the quality of the
construction effort through regular inspection of the work in progress as
agreed to in the respective Inspection and Test Plan during construction.
Activities shall be recorded via inspection and test reports attached to relevant
procedures and work instructions and acceptance verified against written
acceptance criteria obtained from applicable contract documents or
referenced code and standards.QA/QC Inspector shall notify BEMCO/ Saudi
Aramco by initiating Requests for Inspections (RFI) for all inspection points
coded as Witness or Hold or any works prior to proceed further with following
activity.
Each of these Inspection and Test Plans indicates the various testing
activity for production and installation, the relevant specification/
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acceptance criteria and the QC Checklist (verifying document)
required for the inspection documentation.
The QC Inspector will raise the request for inspection and test for
Hold and Witness activities. Additionally, it is understood that
BEMCO/Saudi Aramco has the right to witness at any moment the on-
going construction activities, as per contract agreement.
Definition of Symbols
All the controls and tests that involve BEMCO/ Saudi Aramco are
intended to be performed jointly with GTPP QA/QC organization. Any
test/ inspection report which will be reviewed by GTPP and reviewed
by BEMCO/Saudi Aramco as applicable.
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RFI’s shall be raised only through the QMIS (Quality Management
Information System) as per SAEP-1150 par. 9.5. This can be initiated
by the RFI Initiator, and all mandatory steps shall be adhered as per
QMIS User Manual.
RFI’s in QMIS has five (5) categories. The selection of the appropriate
category by PID Inspector is based on RFI inspection result of the
issued RFI. These Categories are as follows:
2) Job Not Ready: BEMCO or PID Inspector shall reject the issued
RFI if the activity is not ready for inspection. The RFI will be in
open rejected disposition status in QMIS and will be closed when
the final inspection is completed and accepted.
4) On Hold: BEMCO or PID Inspector may place the issued RFI “On
Hold” status if there deficiency is minor and can be rectified within
few hours.
Weekdays:
At least 24 hours prior to the time required for inspection.
Weekends/Holidays:
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At least 48 hours prior to the time required for inspection.
The Project Manager along with the QA/QC Inspector and ( BEMCO
Quality Inspection Division) will ensure all final inspection and testing
are carried out as outlined in the Inspection & Test Plans. The punch
Lists will be generated and closed out as applicable. Testing, Pre-
Commissioning & Commissioning Completion will be followed upon
successful completion of final inspection, close out of snag points
which will not directly affect the Pre-Commissioning & Commissioning
activities.
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The data package shall be issued for the following: ( Scope of Main
Contractor)
All agreed “Yes” items on the MCC Exception Item List shall have been
completed and approved by the Acceptance Committee members or
their representatives.
All Operation and Maintenance (O&M) manuals will have been submitted
to the Proponent for review four (4) weeks prior to MC.
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Once the corrective and preventive actions are agreed and coordinated with
GTPP Project Manager , they will be implemented at site. GTPP will forward to
BEMCO/Saudi Aramco records of all NCR’s within forty eight (48) hours of
issue. Corrective actions shall investigate the root cause of non-conformities
and initiate corrective actions to prevent recurrence of non-conformities seven
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(7) days of the issue date unless otherwise justified ( Non-conformance issued
by BEMCO/ Saudi Aramco)
On review and approval by BEMCO/ Saudi Aramco, the corrective actions will
be completed and offered for re-inspection and then closed as applicable. The
non-conforming work shall be put on Hold until the corrective action as
accepted by BEMCO/ Saudi Aramco.
All NCR’s will be registered in the NCR log/ register. GTPP Internal NCR Log,
C. Non-conformance Identified during Quality Audit
General Items
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1) Listing of quality audits completed (internal and sub-contractor), in
progress, and planned the next month.
4) Listing of supplier inspections performed and those planned for the next
month.
This section describe GTPP and sub-contractor activities during the month to
continually improve its processes, correct and eliminate non-conformities,
prevent potential problems and improve schedules, etc. It will include trend
analysis for processes identified above.
The following data are gathered and analyzed, the QA/QC Inspector is
responsible for the effort and to ensure closure where Quality system
Improvements are warranted.
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5) Others as applicable
8.5 Improvements
The project QA/QC Inspector will ensure all agreed corrective actions have
been completed and related non-conformance reports closed out.
LISTS OF ATTACHMENTS;
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1) Scope of Works
2) Project Organizational Chart
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