19225 Project Quality Plan Rev 2[1]

CUSTOMER GASCO PLANT LOCATION RUWAIS ABU DHABI GAS INDUSTRIES LTD. (GASCO)

PROJECT No. 5248

PROJECT RUWAIS 4th NGL TRAIN

Agreement No. 13524801 Rev. 2

Doc. No. 5248-00-AA-4181

PROJECT QUALITY PLAN

DOC. TYPE : A 09 DOC. CLASS : 2 2

21 Jul 10

45

Re-issued for Construction (Complete document revised)

RB1

SS

KR

1

4 Dec 09

47

Issued for Construction

HGF

TY

KR

0

25 Nov 09

47

Issued for Company Approval

HGF

TY

KR

B

30 Oct 09

48

Issued for Company Review

HGF

TY

KR

A

29 Sept 09

48

Issued for Internal Review

N.R

THY

K. R

Rev.

Date

Page

Description

Prepared

Checked

Approved

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

TABLE OF CONTENTS 0.0

INTRODUCTION - CONTROL OF PROJECT QUALITY PLAN (PQP) ...................... 5

0.1

DISTRIBUTION .......................................................................................................... 5

0.2

AMENDMENTS AND REVISIONS ............................................................................. 5

1.0

SCOPE OF WORK AND RELATED RESPONSIBILITIES ......................................... 5

2.0

APPLICABILITY OF PROJECT QUALITY PLAN ...................................................... 7

3.0

REFERENCES ........................................................................................................... 7

4.0

DEFINITIONS AND ABBREVIATIONS ...................................................................... 8

5.0

QUALITY MANAGEMENT FRAME WORK................................................................ 9 5.1 Business Processes ........................................................................................ 10 5.2 Project QMS .................................................................................................... 11 5.3 Development & Control of the Project QMS ..................................................... 12 5.4 Quality Management System DocumentsThe Quality Management System (QMS) documentation structure applicable to this project is given below: ........................................................................... 12 5.5 Document and Data Control............................................................................. 13 5.6 Storage of Records .......................................................................................... 14

6.0

MANAGEMENT RESPONSIBILITY ......................................................................... 14 6.1 Management Commitment ............................................................................... 14 6.2 Project Quality Policy Statement ...................................................................... 16 6.3 Client Focus..................................................................................................... 17 6.4 Quality Management Reporting ....................................................................... 17 6.5 Project Quality Objectives ................................................................................ 18 6.6 Responsibility, Authority and Communication .................................................. 18 6.6.1 Responsibility and Authority.................................................................... 18 6.6.2 Communication....................................................................................... 19

7.0

RESOURCE MANAGEMENT ................................................................................... 19 7.1 Provision of Resources .................................................................................... 19 7.2 Human Resources ........................................................................................... 20 7.3 Training, Awareness and Competence ............................................................ 20 7.3.1 Contractor’s Staff .................................................................................... 20 7.3.2 Training / Awareness of Subcontractor Staff ........................................... 21 7.4 Infrastructure ................................................................................................... 21 7.5 Work Environment ........................................................................................... 21

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

PROJECT IMPLEMENTATION ................................................................................ 21 8.1 Planning For Project Implementation ............................................................... 23 8.1.1 Interface Management ............................................................................ 23 8.1.2 Change Management Process ............................................................... 24 8.1.3 Planning for Quality ................................................................................ 24 8.2 Company Related Processes........................................................................... 24 8.2.1 Determination and Review of Company's Requirements ......................................................................................... 24 8.2.2 Company Communication....................................................................... 24 8.3 Design Control ................................................................................................. 25 8.3.1 Design and Development Planning ......................................................... 26 8.3.2 Design Inputs.......................................................................................... 26 8.3.3 Design Outputs ....................................................................................... 27 8.3.4 Design Review........................................................................................ 27 8.3.5 Design Verification .................................................................................. 27 8.3.6 Design Validation .................................................................................... 28 8.3.7 Software and Spreadsheet Validation ..................................................... 28 8.3.8 Control of Design Changes ..................................................................... 28 8.4 Procurement / Subcontracting Control ............................................................. 28 8.4.1 Purchasing process ................................................................................ 29 8.4.2 Vendor Selection .................................................................................... 29 8.4.3 Purchasing Information ........................................................................... 30 8.4.4 Verification of Purchased Products and Services.................................................................................................. 30 8.4.5 Expediting and Shipping ......................................................................... 31 8.4.6 Sub-contracting ...................................................................................... 31 8.5 Production / Construction and Service Provision.............................................. 33 8.5.1 Control of Production / Construction and Service Provision .................................................................................... 33 8.5.2 Vendor Inspection Management Philosophy ........................................... 34 8.5.2.1 Inspection Classification ......................................................................... 34 8.5.2.2 Contractor’s Own Resources .................................................................. 34 8.5.2.3 Second Party Inspection Services .......................................................... 34 8.5.2.4 Consistency in Inspections ..................................................................... 34 8.5.2.5 Equipment/Material Release ................................................................... 35 8.5.3 Site QC Enhancement ............................................................................ 35 8.5.4 Material & Equipment Management at Construction Site .................................................................................... 36 8.5.5 Validation of Processes for Production and Service Provision .................................................................................... 36 8.5.6 Identification and Traceability ................................................................. 36 8.5.7 Company's Property ............................................................................... 37

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8.6 8.7

9.

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

8.5.8 Preservation of Product .......................................................................... 37 Control of Monitoring and Measuring Devices .................................................. 38 Mechanical Completion, Commissioning and Start-Up..................................... 39 8.7.1 Mechanical Completion, which includes PreCommissioning ....................................................................................... 39 8.7.2 Commissioning and Start-up................................................................... 39 8.7.3 Completion and Handover ...................................................................... 39

MEASUREMENT, ANALYSIS AND IMPROVEMENT .............................................. 40 9.1 Planning for Measurement, Analysis and Improvement. .................................. 40 9.2 Monitoring and Measurement .......................................................................... 42 9.2.1 Company's Satisfaction .......................................................................... 42 9.2.2 Audits ..................................................................................................... 42 9.2.3 Monitoring and Measurement of Processes ............................................ 43 9.2.4 Monitoring and Measurement of Product ................................................ 43 9.3 Control of Non Conforming Product ..................................................................... 43 9.4 Analysis of Data................................................................................................... 44 9.5 Improvement.................................................................................................... 44 9.5.1 Continual Improvement........................................................................... 44 9.5.2 Lessons Learned and Knowledge Sharing .............................................. 44 9.5.3 Corrective Action .................................................................................... 45 9.5.4 Preventive Action .................................................................................... 45

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0.0

PROJECT QUALITY PLAN

Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

INTRODUCTION - CONTROL OF PROJECT QUALITY PLAN (PQP)

This Project Quality Plan has been prepared in accordance with the Contractor’s Management System Requirements and Company Contract requirements. The Project Quality Manager is responsible for maintaining and updating this PQP. 0.1

DISTRIBUTION

The PQP shall be controlled through out the Project and the users are responsible for referring to the latest version available in Contractor’s Intranet or as controlled Hard Copy. 0.2

AMENDMENTS AND REVISIONS

The PQP shall be a live document throughout the life cycle of the Project. Consequently, revisions to PQP shall be introduced as and when necessary. CONTRACTOR shall pay particular attention to any impact of ISO 9001:2008 to this document. The revisions shall be identified in the Revision Status box on the front cover and marked up in the relevant sections (i.e., vertical line on either side of a page). For a complete revision/ rewrite the revision marking will be avoided. All revisions are subject to the same controls applicable to the initial development of the plan. 1.0

SCOPE OF WORK AND RELATED RESPONSIBILITIES

The scope of work for the Contract Ruwais 4th NGL Train, involves Design, Engineering, Procurement, Construction, Pre-Commissioning and Commissioning of Process Units and Utilities and Offsites pertaining to the scope of work. Figure below shows Ruwais 4th NGL Train project locations. As a minimum, EPC for the Ruwais 4th NGL Train project scope of work includes multidiscipline works of the following units :

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

Process Units • •

• •

Fractionation Unit 41 • Fractionation • Refrigeration • Mole Sieves Treating • Deo Treating • Propane Treating Unit 45 • Sulphur Recovery Unit Unit 06 • Storage (Excluding Tanks)

Utilities And Offsites • Unit 07 • Potable Water • Distilled Water • Fresh Cooling Water • Steam & Condensate • Dm Water • Fuel Gas • Air (Instrument Air, Plant Air) • Nitrogen • Sulphuric Acid And Caustic Storage And Distribution • Diesel System • Sour Water Stripper • Waste Water Treatment • Flare System

•

Unit 08 • Sea Water Plant

The detailed plan and split of scope among Subcontractors will be according to the project procedure 5248-00-FA-4240 Sub Contracting Plan. Procurement activities for this Project are managed and monitored from Contractor’s office in Seoul & Abu Dhabi with support from Contractor’s other international offices in UK, Europe, Asia and US. Engineering activities are carried out from Contractor’s Seoul office, under control of the Engineering Manager.

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

APPLICABILITY OF PROJECT QUALITY PLAN

This Project Quality Plan is applicable for all phases of the project activities associated with NGL 4 Project. The Subcontractors are required to follow their own Project Quality Plans, approved by Contractor and Company.

3.0

REFERENCES

ISO 9000: 2005 ISO 9001: 2008 ISO 9004:2009 ISO 19011: 2002

- Quality Management Systems – Fundamentals and Vocabulary. - Quality Management Systems – Requirements. -Managing for the sustained success of an organization – A Quality Management Approach - Guidelines for Quality and/or Environmental Management System Auditing.

13524801-B.10

- Quality Management Requirements.

Contractor:

- 5248-00-AA-4001 Project Execution Plan. - Project Specific Procedures.

Company

- ITB (or ITT) Package for Index,Invitation to Tender, Instruction to Tenderers, Signature Agreement and Aricles of Agreement

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

DEFINITIONS AND ABBREVIATIONS Company Contractor Subcontractor

Vendor / Supplier

Process Owner Audit

AFC GRE KPI Project CAR HO HSSE IDC IT ISO ITP ITR MTO MOM NGL KPI PQP QA QC QCP QMS SITS

Abu Dhabi Gas Industries Ltd (GASCO). Petrofac and G.S Engineering & Construction - Joint venture. Any entity that has entered into an agreement with Contractor for the execution of a defined scope of work under a legally binding agreement. The person, firm or entity to whom the Purchase Order is issued to provide goods and shall include its representatives, successors, assigns and employees. Functional Discipline or Department with principle interest in the efficiency and effectiveness of a core business process. Systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to determine the extent to which audit criteria are fulfilled. Approved for Construction. Glass Fibre Reinforced Epoxy Key Performance Indicator Ruwais 4th NGL Train Project at Abu Dhabi, Ruwais, UAE. Corrective Action Request. Home Office Health Safety, Security & Environment Inter Discipline Check Information Technology International Organization for Standardization Inspection and Test Plan Inspection and Test Record Material Take off Minutes of Meeting Natural Gas Liquefaction Key Performance Indicator Project Quality Plan Quality assurance Quality Control Quality Control Procedure Quality Management System Schedule Information Tracking System

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TDR TPI TPMS VDR VDRL WPS PQP Petro-PCS UAE

PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

Technical Document Register Third Party Inspection Total Project Management System Vendor Document Register Vendor Documents Required List Welding Procedure Specification Project Quality Plan Petrofac - Project Completion and Certification System United Arab Emirates

Definitions of quality assurance and quality management terminology shall be as given by ISO 9000:2005 standard.

5.0

QUALITY MANAGEMENT FRAME WORK The basic framework for establishing, integrating and continually improving the way CONTRACTOR executes the project is shown below and is based on the tried and tested model: “Plan-Do-Check-Act”. P o lic ie s

O b je c t iv e s

P la n

O r g a n is a tio n

B u s in e s s P r o c e s s e s

D o

C heck

S tra te g y

R is k A s s e s s m e n t s

L e s s o n s L e a rn e d

A ct

K e y P e rfo rm a n c e I n d ic a t o r s

A u d it s

A c tio n T ra c k in g

S y s te m Im p ro v e m e n t

S te e rin g G ro u p R e v ie w s

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GASCO

PROJECT QUALITY PLAN

ABU DHABI GAS INDUSTRIES LTD.

5.1

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

BUSINESS PROCESSES

Contractor’s key business processes for the project are as below

Project Management Project Management Core Process

Support Process HSSE Quality

Engineering

Human Resources Administration Finance

Procurement

Construction Management

Information Technology Document Control

Commissioning

Contracts & Commercial

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5.2

PROJECT QUALITY PLAN

Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

PROJECT QMS The project QMS is described in this Quality Plan. Project procedures are created when necessary to cover the scope of work as identified in the Contract.

Contract Quality Requirements

Project Execution Plan

Contractor’s

Project Quality Policy and

Project Quality

Project

Other

Plan

HSSE

Plans

Objectives

Selected Corporate

Project

Procedures

Procedures

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PROJECT QUALITY PLAN

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5.3

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

DEVELOPMENT & CONTROL OF THE PROJECT QMS Within a short time of the Effective Date, the quality management system shall be fully functional and integrated into the project management system. The Subcontractors shall perform their work according to their quality management system approved by CONTRACTOR & COMPANY. Refer 5248-00-AA-4184:Quality Requirements for Subcontractors ,used for conveying the project quality requirements to Subcontractors. CONTRACTOR shall assist Subcontractors to develop an acceptable Quality System, if necessary. Depending on the subcontract scope of activities, either Contractor’s or the Subcontractor’s qualified personnel shall carry out site QA/QC activities. The Contractor shall assign qualified staff for QA/QC tasks and shall review and approve the Subcontractor’s key personnel to be appointed for QA/QC tasks. Curriculum vitae and certifications of key QC personnel with the Contractor and Subcontractors shall be reviewed.The number of QC personnel shall be adequate to cover the workscope as per the approved inspection and test plans.

5.4

QUALITY MANAGEMENT SYSTEM DOCUMENTSTHE QUALITY MANAGEMENT SYSTEM (QMS) DOCUMENTATION STRUCTURE APPLICABLE TO THIS PROJECT IS GIVEN BELOW: P olicie s

O b je ctiv e s

O rgan isa tion

Strate gy

- O rga n isa tio n C h a rts - A u th o rity M a trice s - J ob D e scrip tio n s

- M a n u a ls - P ro g ra m m e s - Pla n s

B u sin e ss P ro ce sse s

P roce du re s

G u id e s

W ork In stru ctio n s

F o rm s/ C h e cklists

In sp e ctio n & T e st P la n s

In te rn a l Stan d a rd s

V a lid a te d Sp re ad sh e e ts

R e co rd s (u nco ntro lle d )

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5.5

Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

DOCUMENT AND DATA CONTROL Documents and Data pertaining to this project are controlled in accordance with the procedure 5248-00-AA-4004 ‘Document Control Procedure’. Complete list of project deliverables are contained in Contractor’s Technical Document Registers. Contractors electronic systems SITS and TPMS shall be used for this purpose. The main elements of the Document Control Records is as follows: PROJECT DOCUMENTS (DRAWINGS, SPECIFICATIONS, DATA SHEETS, CONSTRUCTION PROCEDURES ETC.) CONSTRUCTION TECHNICAL

VENDOR DOCUMENT

DOCUMENT

DOCUMENT

REGISTER

REGISTER

DOCUMENT DISTRIBUTION MATRIX

A transmittal method shall be used to exchange engineering documents between the organisations involved. The distribution of documents shall be as per the Document Distribution Matrix established for the Project. Dedicated Document Controllers are assigned for Central Document Control, Subcontractor Document Control, Vendor Document Control and Site document Control. The Central Document Controller acts as the single focal point for implementation of Contractor’s Document Control System, The main elements of document control are as below: (a) (b) (c) (d)

(h)

Registration and electronic filing of documents. TPMS & SITS system shall be utilised. Maintaining original signed prints of documents (hard copy filing). Preparation and issue of transmittals for issue of documents. Maintaining transmittal log of the documents issued to Company, Subcontractors, Vendors etc. Distribution of documents per the applicable distribution matrix. Maintaining TPMS & SITS with the latest revisions of documents issued. Maintaining Technical Document Register / Vendor Document Register / Construction Document Register as updated with the details of the current revisions and issue details. Generating exception reports for follow up with originators and reviewers of documents.

(i)

Tracking of Technical deliverable list shall be done utilising the SITS electronic system.

(e) (f) (g)

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Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

Refer 5248-00-AA-4003: Project Numbering Procedure and 5248-00-AA-4010: Contractor IT Support & Services to Company in HO for more details.

5.6

STORAGE OF RECORDS The objective for establishing and maintaining the records is to provide evidence of the conformity to requirements and of the effective operation of the Project QMS. Quality records shall be handled in accordance with the Contractors procedure for Document Control: 5248-00-AA-4004. All process owners are responsible to ensure the collection, registration and systematic maintenance of the Quality records within the scope of their work. All quality records pertaining to the Quality Management System and the Project, as applicable, generated by the Contractor, Subcontractors and Vendors are stored either as computer database (SITS,TPMS & Petro-PCS) under defined system names and /or saved as hard copy in office / site locations. Site QC inspectors shall collect the ongoing testing, inspection and welding records daily and all these ITRs will form a part of the completion cheksheets established by the Petro-PCS System .

6.0

MANAGEMENT RESPONSIBILITY

6.1

MANAGEMENT COMMITMENT The commitment of the Contractor's top Management is driven by the Project Quality Policy Statement. QMS and its effectiveness are demonstrated by the following means: • • •

Communicating the importance of meeting Company's requirements and Statutory and Regulatory requirements. Establishing and Quantifying the Project Quality objectives in line with the Project Quality Policy. Supplying the resources for the project activities.

In order or achieve the Project Quality Objectives the Project Management shall review above commitment in Formal Project Management Reviews as per ISO 9001:2008 requirements.

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

The Project Director is responsibile for all Project activities. Project has assigned Deputy Project Directors , who shall be responsible for managing the Project Services, Procurement, Subcontracts and Pre/post order Coordination management, and ensuring the overall effectiveness of the management systems, both technically and commercially. The Deputy Project Directors, Procurement Manager, Construction Director, Project Engineering Manager, Commissioning Manager and Project HSE Manager will report directly to the Project Director. Contractor has competent and qualified engineering staff, including Process, Mechanical, Piping, Electrical, Telecom, Loss Prevention and Instrumentation engineers, designers, and draftsmen, who shall report through Engineering Discipline Leaders. The Engineering Discipline Leaders shall report to the Project Engineering Manager. At Construction site, Construction Director, Site Quality Manager, Construction Managers and Construction Superintendents, along with Project team shall implement the Project Quality Plan and monitor the process performances against the Project Quality Objectives and communicate the results to Management. Construction Director monitors and reports the implementation of Quality Management Systems by the Contractor and Subcontractors through Internal and External Audits as per procedure “Project Audit Plan 5248-00-AA-4183 and regular Surveillance Inspections during Construction, Pre-commissioning and Commissioning Phases.

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6.2

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

PROJECT QUALITY POLICY STATEMENT

NGL 4 PROJECT QUALITY POLICY STATEMENT The Project Sponsors have the ultimate responsibility for the quality of products and services provided to Company, including compliance with standards and legislation and fulfillment of contractual quality requirements to Company’s satisfaction. The nature of CONTRACTOR activities places particular emphasis upon experience, expertise, capability, reliability and quality. The prime objective of the CONTRACTOR Management is to provide the necessary expertise and to carry out and complete the Contract Scope of Work in a timely manner, to the specified quality, safety, and statutory requirements, within the agreed Contract value. In addition CONTRACTOR Management is committed to providing the required level of quality throughout the entire life of the Project. In order to achieve these objectives, CONTRACTOR will implement and maintain an effective Project Quality System designed and developed specifically for the Project with Corporate support from the CONTRACTOR Partners, where required. The elements of the system are defined and outlined in the Project Quality Plan and will be supported by a comprehensive suite of Project specific procedures and plans. The Project Quality System shall be based on ISO 9001 : 2008 and be designed to ensure all Contract, quality, safety and regulatory requirements are recognised and that a consistent and uniform management control system is prepared, implemented and maintained to meet these requirements. Compliance with the Project Quality Plan shall be verified by monitoring and auditing the system in accordance with the Project Quality Audit Schedule. The schedule shall be revised and developed to reflect the requirements of the Project. All personnel engaged on the Project shall be suitably qualified, experienced and trained, issued with instructions to their responsibilities and provided with all the necessary work methods. CONTRACTOR accepts the responsibility for the quality of the work performed and /or managed by CONTRACTOR. CONTRACTOR shall ensure this policy is understood, implemented and maintained at all levels on the Project. Suggestions for quality improvements are welcomed at any time from employees, Subcontractors, Vendors and Company. Signed : Kurt Reeves NGL4 Project Director.

Date:

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6.3

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

CLIENT FOCUS The implementation of the Contractual requirements is carried out under the responsibility of the Project Director. The Project Director shall be responsible for compilation of the Customer feedback based upon the feedback from Customers throughout the life of the Project and self-assessment. Ensuring Company requirements are understood during pre-bid and post award stages through various reviews and the actions arising are implemented. Contractor conducts regular Meetings with Company to understand the perceptions during Project execution. Customer feedback received by Contractor shall be handled in accordance with the procedure 5248-00-AA-4187: ‘Customer Feedback’. Customer comments received by Contractor Project Personnel in the course of Project execution shall be resolved by taking appropriate corrective actions as soon as possible by the applicable personnel. In addition to this, during the Construction, Pre-Commissioning and Commissioning Phases, the Company’s concerns and perceptions are received by the Construction Director, Construction Managers and Commissioning Manager from the Company’s Site Representative and resolved by initiating remedial measures on priority basis and communicated to the Project Director.

6.4

QUALITY MANAGEMENT REPORTING The Contractor shall report as a minimum the following Quality matters in the monthly project report: • Summary of the Project Quality Plan Development, procedures, work instructions and Quality Control Plan development and respective review, approval and issue status, inclusive of Subcontractors • Summary of all internal and external audits carried out • Listing of CARs from audits, the close-out status and planned dates for follow-up • Listing of Nonconformance Reports, the close-out status and planned dates for follow-up • Major areas of concern or weaknesses identified in QMS and details of any investigations to prevent the recurrence of failures • Summary of inspection and tests carried out • Plan for pre-inspection meeting of critical equipment and the inspection look-ahead for the following month.

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Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

• Any changes in key QA/QC staff • Weld defect rates for construction work 6.5

PROJECT QUALITY OBJECTIVES Contractor shall enforce quality management and systems, enabling achievement of Project objectives set forth in the Contract. In this context the following shall be implemented:

6.6

•

Project Quality Organisation with sufficient authority and appropriate resources to support delivery of the Contractor’s quality visions.

•

An environment in which ‘best practice’ is developed and shared.

•

Project deliverables that satisfy contractual specifications, relevant standards, and prevailing legislation.

•

Alignment of CONTRACTOR systems and behaviour with Client’s quality requirements.

•

To enhance customer satisfaction by being responsive to their needs and establishing good effective and professional relationships with all parties involved in Project

•

Meaningful quality performance indicators based on accurate data and used in decision making

•

A Strong Project Quality Audit and Review programme assuring compliance with systems and processes, effectiveness of which is reviewed and acted on by Project Management

•

Provide continual improvement of project through continuous updating from lessons learned and implementation of necessary actions.

•

An environment in which every individual takes personal responsibility to keep up the quality of their work. RESPONSIBILITY, AUTHORITY AND COMMUNICATION

6.6.1 Responsibility and Authority The Overall Project Management Organisation Chart and the Quality Organisation Chart are included in Attachment- 1. Refer ‘Project Execution Plan’ for the organisation charts of all the project functions and the project key personnel list. Since the organisation charts are dynamic in nature and bound to change during the project development, the current revisions shall be communicated independently. Any change in key QC personnel during the project execution shall be communicated to Company for approval. CONTRACTOR has nominated the Project Quality Manager as the Management representative for Quality.

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

6.6.2 Communication All communications between the Contractor and the Company shall be carried out through Project Director or his deputy in accordance with the procedure 5248-00-AA-4000: ‘Co ordination Procedure for Company Communication is carried out by means of letters, transmittal forms,meetings and reports. The use of e-mails shall be limited to non-formal communication. Unless otherwise specified by Company, Contractor shall prepare the minutes of all scheduled meetings with Company. All MOMs shall be numbered consecutively and shall be issued within three working days of the completion of a meeting, for mutual agreement and signatures. Approved MOMs shall be formally distributed as a record for all parties to proceed with their work on agreed points. 7.0

RESOURCE MANAGEMENT

7.1

PROVISION OF RESOURCES In order to achieve effective resources management, the Contractor Project Management shall be closely co-ordinated regarding supply of qualified personnel, material and equipment. Qualified and suitable resources are supplied from:

• • • •

Within CONTRACTOR’s organisations, New recruitment, Local suppliers, Subcontractors.

A staffing plan is established by the Project Director/Deputy Project Director in the beginning and the progress reports will indicate the manning level against this plan. The materials and equipment shall be managed under the responsibility of the Deputy Project Directors in coordination with the Procurement Manager. The other resources, such as computer, office furniture and personnel protective equipment, shall also be supplied under the responsibility of the Deputy Project Directors/ Project Engineers.

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7.2

PROJECT QUALITY PLAN

Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

HUMAN RESOURCES Personnel are assigned to Departments as required by the approved staffing plan. Care is taken to ensure these assignments are given to persons with appropriate qualifications and experience. Curriculum vitae records are maintained in the CONTRACTOR Personnel Department, together with records of academic qualifications. Job Descriptions are maintained by Personnel Department for all Personnel . Each Department Manager and Project Director shall ensure personnel performing quality related activities under their responsibility are adequately trained and qualified. Training needs shall be identified and training provided to ensure personnel can conduct their duties as required by the Company in line with the Project Quality Objectives. Effectiveness of training is to be evaluated. Training records shall be maintained, and annual performance evaluations are performed and recorded. Human and physical factors of the work environment needed to achieve conformity of product is monitored. This includes Safety Training and availability of Personnel Protective Equipment in order to cope with the work environment.

7.3

TRAINING, AWARENESS AND COMPETENCE 7.3.1 Contractor’s Staff It is the policy of the Contractor to appoint competent personnel for the Project. Upon mobilisation, all persons shall undergo following induction programmes: •

Project induction which is provided by the Project Director or his nominee , induction on HSSE is provided by HSSE Manager or his nominee and Induction on Quality is provided by Project Quality Manager or his nominated representative.

•

Additional training shall be given to the project team members to adopt and implement any new tools and techniques required for the Project.

•

The Project Discipline Managers/Leads shall consider Company's requirements and applicable standards or specifications requirements during evaluation of personnel and for the organisation of additional training programmes necessary to implement any new tools and techniques required for the Project.

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Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

7.3.2 Training / Awareness of Subcontractor Staff Subcontractor staff shall be provided with training and/or awareness on handling special processes and material involved in the Project. Examples for these areas are Petro-PCS, Welding of Corrosion Resistant Alloys, Positive Material Identification etc. This shall be achieved through various Construction Preparedness Workshops conducted at Site before start of each new critical activity and construction phase of the Project. It is the responsibility of the Construction Discipline Managers to provide support to the Construction Site Quality Manager in identifying and implementing the activity based Construction Preparedness Workshops. The Discipline Managers shall ensure the relevant staff (including those of Subcontractors) attend these workshops. 7.4

INFRASTRUCTURE Infrastructure for efficient execution of the project shall be implemented under control of the Project Director /Deputy Project Directors. This shall include: •

Workspace, offices, camps, warehouse, storage yards, workshops, industrial area, and associated facilities.

•

Equipment, hardware and software.

•

Suitable maintenance of construction and test materials and equipment etc.

7.5

WORK ENVIRONMENT The work environment necessary to achieve conformity of project activities shall be identified and managed by the Project Director. These measures shall include: • • • •

8.0

Working methods specified in procedures and processes applicable to the project. Professional ethics ensured by the Contractor's Management Physical factors and working conditions. Human factors like creative work methodology, ergonomics, safety measures, etc. PROJECT IMPLEMENTATION

The processes required for performing, monitoring and measuring all significant activities and their sequence and interaction are determined for this project in order to achieve error/defect free deliverables and facilities. The main activities involved in project management and their interrelationships are as per the following chart.

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PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

Start

1.Project Sponsor Nominate key Project Management Personnel

2.Project Director Finalise Project Organisation Charts.

3.Project Task Force Project Contract review

. 4.Project Task Force Develop Contract Execution Plan & Project Co ordination

5.Project Task Force Develop Project Schedule, Project Quality Plan & Design Basis

6.Project Task Force Project Execution

7. Project Management Team Co ordinate team members & external agencies

8. Project Management Team Monitor, Report & Control Project Execution

Project Complete

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8.1

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

PLANNING FOR PROJECT IMPLEMENTATION The planning programme is established and monitored by the Project Control Manager and controlled by the Senior Planning Engineer. Contractor shall develop project schedules at three different levels as described below. Level 1 : Project Master Schedule Level 2 : Project Control Schedule Level 3 : Detailed Project schedule The schedules shall be developed in a manner that can be rolled-up from the lowest level up to the highest level. Subsequent to the mobilization at site, Subcontractors shall prepare detailed schedules, and the same shall be used for updating the level 2 schedule. The planning programme and details regarding realisation of planning programme are included in the monthly reports issued to the Company. The implementation, supervision and verification of these processes, as well as the provision of the resources and documentation required, shall be carried out under control of the Project Director /Deputy Project Director assisted by the Projects, Quality, Design and Construction Departments. The methodology for raising invoices and receiving payment from Company shall be established in the beginning of the Project. Refer following procedures for further details: 5248-00-AA-4066 : Planning & Scheduling. 5248-00-AA-4065: Progress Measurement Procedure. 5248-00-AA-4062: Invoicing Procedure. 8.1.1 Interface Management The Interface Management System shall include the following functional areas of responsibilities spanning from Design to Commissioning: • • • • •

Identification of Interfaces Planning & Registering Interfaces Implementation & Resolution of Interfaces. Recording of all Interfaces Prompt and up-to-date reporting of interfaces

The Interface Manager is responsible for setting up and maintaining Contractor Interface Management System Register. Refer 5248-00-AA-4090: Interface Plan.

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Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

8.1.2 Change Management Process The main objective of a change management process is establishing a system for controlling the budget variations and to issue/modify control budget for variation cost codes on the changes during the course of project. Changes could be due to scope changes, deviations and others as per Company requirement or Company authorised/nominated agencies e.g. Project Management Consultants, Engineering Consultants and others. Refer the following procedures for further details: 5248-00-AA-4061 : Design Deviation/ Concession Request Authorisation Procedure 5248-00-AA-4066 : Planning and Scheduling Procedure

8.1.3 Planning for Quality Contractor’s PQP is the main document for overall planning of quality and will be supported by various Procedures and ITPs generated for the project processes by Contractor, Subcontractors and Vendors. Contractor will approve the quality plans of Subcontractors/Vendors to ensure integrity of the Project QMS. ITPs for equipment/materials and construction ITPs will be submitted to Company for review and identification of inspection intervention points. 8.2

COMPANY RELATED PROCESSES 8.2.1 Determination and Review of Company's Requirements The proposal team reviews Company’s requirements specified in tender documents at the tender stage. Further contract review will be conducted after contract award by the project team. After review and approval of the Contract documents, the amendments/variations, if any, shall be prepared and followed by Project Director during execution phase (see 8.1.2 above). 8.2.2 Company Communication All information and documents received from or issued to Company shall be handled, distributed, filed, reviewed and followed-up by the Project Management with the aim of meeting Company's requirements. In addition, Contractor will strive to gather adequate Company feed back on the quality of services provided. Document comments sheets will be the primary source of receiving Company feedback. 5248-00-AA-4000 : Coordination Procedure for Company

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8.3

Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

DESIGN CONTROL Design and engineering activities are carried out in Contractor's Seoul office, with support under control of the Engineering Manager. Refer 5248-00-AA-4120: ‘Engineering Procedure’ 5248-00-AA-4004: ‘Document Control Procedure The following Process Flow chart provides major steps in Design and Engineering. D e s ig n P r o c e s s S ta rt P r o p o s a ls D ir e c t o r P r o je c t D ir e c t o r

D is c ip lin e E n g in e e r E n g in e e r in g M a n a g e r P r o je c t D ir e c t o r

T e c h n ic a l D ocum ent R e g is t e r

C o n tra c t R e v ie w

R e c o rd s

C o l l a t e D e s ig n In p u ts a n d R e v ie w

D e s ig n

P ro c u re m e n t R e g is t e r

P la n n in g L . D is c ip lin e E n g in e e r E n g in e e r in g . M a n a g e r P r o je c t D ir e c t o r D is c ip lin e E n g i n e e r L e a d D is c ip lin e E n g in e e r I P & I D R e v , P lo t P la n R e v , S k i d F ab R ev, H A Z O P , S IL S tu d y e tc .

D e ta ile d D e s ig n

D e s ig n R e v ie w

ID IT b y D is c i p li n e s

R e c o rd s

L e a d D is c ip lin e E n g in e e r s E n g in e e r in g M a n a g e r

L e a d D is c ip lin e E n g in e e r

D e s ig n V e r ific a tio n

ID C

C lie n t

B y D is c ip lin e s

L e a d D is c ip lin e E n g in e e r E n g in e e r in g M a n a g e r P r o j e c t D ir e c t o r C om pany

L e a d D is c . E n g in e e r E n g in e e r in g M a n a g e r P ro je c t M a n a g e r C om pany

P r e - c o m m is s io n in g M anager P r o je c t D ir e c t o r E n g in e e r in g M a n a g e r C om pany

D e s ig n C hanges

D e s ig n O u tp u t

D e s ig n V a l id a t i o n

End

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Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

8.3.1 Design and Development Planning The Project Team shall maintain Technical Document Register and Procurement Register for planning and monitoring of engineering deliverables. SITS & TPMS electronic systems will be utlised for this purpose. The Project Director controls the design and development interfaces with the Company and with the Subcontractors/Vendors. Project Engineering Manager is responsible for the design control activities particularly: • The organisation of engineering activities. • Subcontracting and supervision of relevant design works. • Distribution of tasks and allocation of areas of responsibilities. • Design data input control. • Supervision of the review, verification and validation of design activities and documents. • Design output control, particularly the approval of the deliverables. • Design change control. Project Control Engineer and Senior Project Engineer assist Project Director and the Project Engineering Manager for planning, co-ordination, document control and interface control during the design phase. 8.3.2 Design Inputs The design requirements to be met are defined and recorded in various specifications included in the Contract documents, which include: • functional and performance requirements. • applicable statutory & regulatory requirements. • Other requirements such as environmental impact, safety for operation of facilities. Contractor’s experience gained from the execution of previous projects of a similar nature (Lessons Learned) shall also be used as a design input. The input requirements shall be reviewed for adequacy and resolution of incomplete, ambiguous or conflicting requirements by the Engineering Department and the results shall be communicated to Company if any deviation is identified. A project specific “Technical Query” form is used to address technical queries and a “Deviation Request” form is used for addressing the deviations from the specifications. Technical Queries and the Deviation Requests shall be logged in control registers and monitored by Project Engineer. Refer 5248-00-AA-4005: Lesson Learned Management Procedure Refer 5248-00-FA-4015: Site Technical Query Procedure Refer 5248-00-AA-4061: Design Deviation/Concession Request Authorisation

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Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

8.3.3 Design Outputs The outputs of the design and development process are recorded in drawings and documents suitable for verification against the design and engineering inputs. These are prepared, reviewed, approved and submitted to Company as required by the co-ordination procedure included in the Contract. The Group Leads / Engineering Discipline Leaders shall ensure latest status of relevant engineering discipline deliverables are accurately entered in the SITS dbased which is viewable to the project team members”. Refer 5248-00-AA-4120: Engineering Procedure Refer 5248-00-AA-4061: Design Deviation/Concession Request Authorisation Refer 5248-00-AA-4005: Lesson Learned Management Procedure 8.3.4 Design Review Design reviews shall include: • • • •

Evaluating results to ensure contractual requirements are fulfilled Identifying problems, if any, Determining solutions and Follow up actions.

A schedule for Design Reviews shall be established by the Engineering Manager to perform the reviews at defined stages. The Constructability Reviews shall be led and coordinated by the Construction Manager / Construction Support Engineer during the execution phase of the Project. Company shall be notified prior to these reviews for giving an opportunity for participation as per the procedure . 8.3.5 Design Verification The design verification is carried out on all design deliverables to ensure they: • • • •

meet the design input requirements specified in the contractual documents. contain or make reference to acceptance criteria, for the relevant products. define the characteristics of products that are essential to their safe and proper use. provide information for purchasing, testing and construction activities.

Qualified Engineers nominated by the Engineering Discipline Leader perform this verification. The Engineering Discipline Leader decides the need for independent design verification for a revised engineering deliverable based on the evaluation of the extent of technical changes and their impact on the overall design.

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Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

8.3.6 Design Validation The validation of the design is performed during the Pre-com/Commissioning phase and submitted for Company's approval as required in the Contract, relevant specifications, procedures and processes. The results are recorded in test reports and relevant actions are followed-up by the Commissioning Coordinator and the Quality Department. 8.3.7 Software and Spreadsheet Validation Software and Spreadsheet Validation in the Engineering is to be established to meet the following requirements: •

Accuracy and reliability of software and spreadsheets to ensure reliability of results for the intended purpose.

•

Clarity of inputs, assumptions and methodology so that outputs can be checked or repeated by others.

•

Adequacy of verification procedures, in keeping with the criticality of the calculation or analysis for which the software or spreadsheet is used.

The effectiveness of this shall be observed during the internal audits. Refer 5248-00-AA-4010 : Contractor IT Support & Services to Company in HO. 8.3.8 Control of Design Changes Design changes or modifications shall be identified by the Discipline Engineer and approved by the Engineering Manager and the Project Director in accordance with the procedure 524800-AA-4061: Design Deviation/Concession Request Authorisation Procedure The Project Director shall obtain Company’s approval before implementation, where changes to project scope are involved. The Design Changes shall be logged in control register and shall be monitored by the Senior Project Engineer in accordance with the procedure.

8.4

PROCUREMENT / SUBCONTRACTING CONTROL Procurement activities are carried out at Contractor's Seoul & Abu Dhabi office (with support from Contractor’s other offices as required, in co-ordination with the Engineering for permanent products. All information and documents received from and issued to Vendors shall be handled,

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PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

distributed, filed, reviewed and followed-up by the Project Procurement Manager in coordination with the Senior Project Engineer and Project Engineering Manager. Refer the procedure 5248-00-EA-4000 ‘Procurement Procedure’ for further details. 8.4.1 Purchasing process The Procurement Manager is responsible for organising the procurement activities and requesting, selecting Vendors and obtaining Company's approval for potential Vendors. The Project Quality Manager is responsible for ensuring QA/QC participation in: • • • •

Evaluation of Vendors Verifying Vendor quality requirements specified in purchase orders Reviewing the Vendors quality submission Verifying products as per relevant ITPs.

The Lead Procurement Engineer/Buyer: • Ensures the purchase packages are defined • Establishes selection and evaluation criteria • Selects qualified Vendors and holds an “approved Vendors list” • Maintains evaluation records. The Project Discipline Engineer • Prepares technical documents and ensure their review before distribution to Vendor • Evaluates the technical offer. • Reviews Vendor documents. 8.4.2 Vendor Selection Vendors shall be selected from the Company Approved Vendor List as well as from Contractor pre-qualified Vendors (subject to Company approval). Contractor will obtain Company approval at an early stage of the procurement cycle for any additional Vendors. Alternative sources shall be selected as per the Procedure 5248-00-EA-4001 Pre Qualification of additional Vendors The evaluation of Vendors shall be dependent upon the type of product, the Vendor's ability, and the impact of product on the final installation. It is Company policy that all Vendors shall hold ISO 9001:2008 certification relevant to the scope of supply. However, case by case acceptance can be given for Vendors supplying non critical items. If any Vendor is not certified to ISO 9001:2008, their

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Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

quality system shall be assessed / reviewed and necessary approval from Company shall be obtained to use them. Sourcing from stockists, when unavoidable, shall done after obtaining written authorization from Company on a case by case basis.

8.4.3 Purchasing Information The Procurement Manager ensures the purchase packages define the relevant requirements and shall establish a close working relationship and feedback system with each Vendor. COMPANY’s technical and quality requirements shall fully incorporated in these documents, based on the nature of the product/item. When necessary, project specific requisition check lists are developed by engineering disciplines which will aid the following: • • • • •

Compile a requisition covering various contractual scope elements Check the requisition in a systematic manner Uniformity in preparation and checking within disciplines and across the disciplines Reduce the need for change orders Reduce Vendor conflicts during execution

Prior to release, all purchasing data and documents shall be reviewed and approved by the Contractor. The purchase order or relevant documents shall include the Inspection Classes and “Vendor Quality Requirements” based on criticality ratings of items to be purchased. Refer project document 5248-00-EA-4002: Vendor Shop/Source Inspection Procedure. The purchasing documents shall indicate Company shall be given the right to verify at source the product or service related activities.

8.4.4 Verification of Purchased Products and Services The ITPs prepared by Vendors shall reviewed and approved by Contractor QA/QC Engineers considering criticality rating of each item. The following actions shall ensure the compliance with the purchasing documents: • • • •

Review of Vendor documents by Engineering Discipline Leader and QA/QC Engineer (Quality Plans, Procedures and Inspection and Test Plans). No manufacturing activity shall start before approval of relevant ITP by Contractor Planned inspection and surveillance at Vendors' premises considering the importance of the product. Follow-up by the Project Procurement Manager

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•

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

Receiving inspection at site by Material Controller/QC Team.

These activities shall be conducted in accordance with procedure 5248-00-EA-4002: Vendor Shop/Source Inspection Procedure Monthly inspection look ahead plans shall be submitted to Company in addition to notifying relevant inspections within the contractual notice period.

8.4.5 Expediting and Shipping The Procurement Manager controls expediting and Shipping activities from Seoul & AbuDhabi office in accordance with the following procedures: 5248-00-EA-4015 Expediting” 5248-00-EA-4014 Freight Management and Transportation Plan The later activities, such as customs clearance, inland transportation and the logistics shall be controlled by the Inland Logistics Manager. Refer Procedure : 5248-00-EA-4006: Customs Clearance 5248-00-EA-4014: Freight Management & Transportation Plan

8.4.6 Sub-contracting The sub-contract management activities are given in the following process flowchart.

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Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

S U B C O N T R A C T P R O C E S S F L O W

Rev. 2

C H A R T

M o b iliz a t io n

S U B C O N T R A C T S IT E M A N A G E R C O N S T R U C T IO N D IR E C T O R P R O J E C T D IR E C T O R

S e le c t io n o f Su b co n tra cto rs

D e v e lo p m e n t o f S u b co n tra cto r Q P la n s & P ro ce d u re s

SU B C O N T R A C T O R

M o d if y , in c o rp o r a te A p p ro v a l

A

N o

P R O J E C T D IR E C T O R Q U A L IT Y E N G IN E E R

C lie n t A p p r o v a l

N o

C O M P A N Y

M o d if y , in c o rp o r a te co m m e n ts

B

SU B C O N T R A C T O R

Y e s C o n s t ru c t io n b y su b -co n tra cto rs

C o n tro l

A

SU B C O N T R A C T O R

Y e s

B

co m m e n ts

A u d it & s u r v e illa n c e

C O N S T R U C T IO N T E A M

Q U A L IT Y E N G IN E E R

C P R O J E C T D IR E C T O R Q U A L IT Y E N G IN E E R C O M P A N Y

A p p ro v a l

Y e s

R e co rd s

N o

C o r r e c tiv e A c t io n

C

S U B C O N T R A C T O R

SU B C O N T R A C T O R P R O J E C T Q U A L IT Y M A N A G E R

C o m p le t io n

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Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

Construction Director in conjunction with the Project Director and Deputy Project Directors shall be responsible for: • • • • • • •

Identifying activities to be sub-contracted, Pre-qualifying potential sub-contractors, Issuing enquiries, Carrying out technical and commercial evaluations, Proposing the selected sub-contractor, Preparing sub-contract agreements and obtaining signatures, Maintaining Sub-contract Schedule, monitoring and controlling these activities.

These activities shall be conducted in accordance with the Project Subcontract Management Procedure. The potential Subcontractors shall be pre-qualified by Contractor. Pre-qualification documentation for potential Subcontractors not within the registration process with Company (to be advised by Company) shall be submitted to Company for approval. The Construction Director/Construction Managers shall monitor the scope of supply of subcontracted works at site. The Construction Director shall monitor implementation of all quality requirements identified through review of subcontractor quality submissions, audits, surveillance and inspections as per approved Inspection and Test Plans. REFER 5248-00-AA-4241: Subcontracting Procedure. 8.5

PRODUCTION / CONSTRUCTION AND SERVICE PROVISION 8.5.1 Control of Production / Construction and Service Provision The Contractor's Project Team under the responsibility of the Project Director shall plan and control the construction, inspection and testing activities ensuring the following: • • • • • •

Availability of specifications, plans, drawings, procedures, processes and work instructions that define the characteristics of the construction, inspection and testing. Availability, use and maintenance of suitable construction, installation, inspection and testing equipment. Availability and use of suitable measuring and monitoring equipment. Availability of work force with proper qualification. Operators /Technicians shall be qualified to internationally recognised standards and or to the satisfaction of Company. Implementation of suitable monitoring and measurement activities. Implementation of processes for release ,delivery and/or installation of product and/or service including applicable post-delivery activities.

Further details shall be provided in the following: 5248-00-FA-4005 5248-00-FA-4004 5248-00-FA-4000

Construction Inspection Procedure Construction Co ordination Procedure Construction Execution Plan.

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Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

8.5.2 Vendor Inspection Management Philosophy The following philosophy shall be applied for inspection and certification of equipment and materials. 8.5.2.1 Inspection Classification The level of QA/QC applied to procured items shall be determined with reference to the item criticality. The criticality assessment establishes the importance of an item with respect to design, procurement, manufacturing & operation and the consequences of its failure. The inspection classes will be determined based on the criticality rating and will be shown in the Purchase Requisitions for various project equipment and materials. 8.5.2.2 Contractor’s Own Resources Contractor shall review the Criticality Rating of the equipment and materials and decide whether to use own resources or utilise a 2nd party for inspection, including deployment of Resident Inspectors at manufacturing facilities. A program for the inspection shall be developed by the Contractor during the procurement phase of the Project. Refer 5248-00EA-4002: P Vendor Shop/Source Inspection Procedure. 8.5.2.3 Second Party Inspection Services Since the procurement shall be done from different countries it is not practical for the Contractor to employ it’s own resources everywhere. Hence Second Party Inspection services will be used for carrying out inspection of certain equipment and bulk materials. The requirement for Second Party Inspection shall be clearly defined in the Purchase Orders issued to the Vendors. 8.5.2.4 Consistency in Inspections As stated above, Contractor shall be deploying a large number of Inspectors at various Vendor locations, from own resources and from inspection agencies. In order to bring consistency in inspections, the Contractor shall ensure applicable ITPs and QCPs provide the inspection and testing requirements in sufficient details. Contractor’s QC Engineers, during the review/approval of ITPs and QCPs, shall also consider inputs from the Lessons Learned (from previous projects) and the known flaws for equipment/materials to establish the intervention points. Contractor shall provide copies of unpriced Purchase Orders, ITPs and vendor details to Company as required.

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Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

8.5.2.5 Equipment/Material Release Irrespective of the usage of direct resources or hired resources for inspection, the Contractor will establish an inspection release system which identifies all documents are approved and there are no outstanding technical queries, nonconformances or concessions not fully closed-out. To ensure this, the Inspection Relese Note will be issued by Project Inspection Manager only once the final inspection status is reported as acceptable. The Inspection Release Note is used as a trigger to initiate the Shipping Release process. Contractor shall advise Company of status of Inspection Release Notes on a regular basis.

8.5.3 Site QC Enhancement The Site Quality Manager shall be delegated the clear power and immediate access to Contractor’s senior management to stop any works that are nonconforming. Weekly Quality Team Meetings shall be held at site, Company Quality Representatives shall be invited, in order Company and Contractor personnel are updated about all QC matters and nonconformances. Inspection and surveillance during the Construction phase shall be enhanced by assigning qualified and specialised QC Inspectors in different disciplines and by taking the following measures:

•

•

• • •

•

The inspection and testing requirements shall be detailed in the Inspection and Test Plans for each process, indicating which record/verification document is produced for each stage. Contractor’s intervention points shall be marked against each activity/stage in the Inspection and Test Plans during the document approval stage to establish the QC involvement. Detailed QC procedures shall be developed for all critical processes, also considering the Lessons Learned from previous projects. Subcontractor staff shall be provided with training and/or awareness on handling special material and processes involved in the Project. All QC activities and their history/records shall be compiled on a database referencing the ITP/QC Procedure/Certification so that the status can be generated at any time. Primary control of this function will be Petro-PCS All critical processes shall be continuosly monitored until the process performance is satisfactory to achieve project quality objectives.

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PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

8.5.4 Material & Equipment Management at Construction Site Site Material & Equipment Control System shall be established for Material Control, Storage, Issue, Preservation and Traceability at construction site to cover all disciplines: Piping, Mechanical (Static & Rotating), Civil/Structural, Electrical, Instrumentation and Telecom. The process starts from MTO phase where materials are allocated with tag numbers,material codes etc. on construction drawings, which in turn are stamped/stencilled and colour coded as per contract requirements. The Construction Director, Construction Manager, Material Control Manager, QC Inspector and subcontractor teams in full co-ordination shall manage the Material Control and Traceability at field. The efficient implementation of Site Material & Equipment Control methods shall enhance construction management to meet project schedules. Refer work procedures 5248-00-FA-4013: Material Traceability Procedure and 5248-00-FA-4012: Material Handling Procedure. 8.5.5 Validation of Processes for Production and Service Provision All those processes, where the resulting output cannot be verified by subsequent monitoring or measurement, such as welding, concrete mixing etc. shall be validated and Company approval obtained prior to their use. The validation measures include the following actions: • • • • •

Identification, preparation and approval of the procedure specifications (e.g. WPS); Verification and acceptance of materials (the same type of material will be used for production); Process qualification using approved equipment and qualified personnel; All qualification records (e.g. visual, destructive and non destructive testing) generated, approved and maintained; Revalidation when any essential variable is changed.

In case of welding, the welder/operator and welding procedure specification may be simultaneously qualified. Welding procedure, performance qualification tests and field joint procedure qualification tests shall be considered as Company witness points and coordinated accordingly with Company. 8.5.6 Identification and Traceability The identification and traceability system shall be applied for the following: • • • •

Pipes, valves, fittings, GRE and accessories, welding consumables. Welded joints and welders Other permanent items / equipment incorporated in the construction Inspection, test and quality verification status

Products and construction activities shall be identified during all phases of product realisation by means of legible and durable markings maintained from initial receipt to final destination

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PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

and/or by using relevant follow-up documentation. The identification of items of equipment and certified materials, ITP and all test records shall be maintained by the project. Material certificates, construction welding book and inspection reports are supporting elements for identification and traceability of products. Responsibilities for identification and traceability are as follows: • • • •

Engineering Discipline Lead specifies identification requirements in purchase documents. Material Controller verifies the required identification during material receipt. Site QC establishes and ensures appropriate system for identification and traceability. Construction team implements measures for identification and traceability.

8.5.7 Company's Property Company's property shall be identified, verified, stored, protected and maintained by the Contractor, while under the Contractor’s responsibility. Products supplied by the Company shall be inspected and accepted prior to acceptance into the stores by the Material Controller where it will be identified and stored in a manner avoiding damage and deterioration. Company supplied products that are lost, damaged or unsuitable for use, shall be recorded, and reported to the Company in order to find required solutions. 8.5.8 Preservation of Product Products are protected from deterioration or damage during identification, handling, packaging, storage, construction and up to delivery of the installations to the Company in accordance with the procedure 5248-00-FA-4035: Equipment Maintenance and Inspection Procedure. The Construction Director/Construction Managers/Construction Superintendent shall ensure appropriate facilities are made available for handling, packaging, storage and preservation of products. The Material Controller shall be responsible for carrying out handling, packaging and storage activities. Handling All incoming materials and provided items shall be handled with care by suitable means to prevent any damage to the products. For this, depending upon the nature of the item to be handled, different devices such as cranes fitted with spreader bars, slings or hooks with soft protection, as required, are employed. Safe working practices and Vendors' special handling instructions shall also be implemented.

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GASCO ABU DHABI GAS INDUSTRIES LTD.

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

Packaging Packaging and marking of all materials to be sent to the site shall be controlled by the Procurement Manager to ensure compliance with specified requirements and proper identification. Storage Secure storage areas shall be identified for storage purpose, with suitable access routes to them, including covered and uncovered areas and the type of materials to be stored in each location. The storage areas on site shall be suitably protected to prevent entry of unauthorised persons. Storage of pipes shall be done considering the size, safety aspects and safe preserving methods. Stainless steel, Alloy steel and Carbon steel pipes shall be segregated. Vendors' recommendations with regard to storage and preservation of the equipment shall be strictly adhered to. Goods, which fall under statutory regulations for dangerous goods, shall be packed, marked, and stored separately in accordance with the relevant regulations. Protection Protection of the items during storage or handling shall be done as per instructions obtained from the Vendors. Delivery The delivery of completed facilities with associated documentation and their acceptance shall be organised by the Project Director in co-ordination with the Company. 8.6

CONTROL OF MONITORING AND MEASURING DEVICES Each Construction Superintendent/Supervisor in co-ordination with the Construction Manager shall identify the measurements to be made and the monitoring and measuring devices required. The Construction Superintendents shall ensure appropriate measuring devices are procured and they are calibrated as per the requirement. The Site Material Controller shall maintain the Log of Quality related measuring and test equipment and monitor their calibration status. The Test equipment user shall ensure appropriate test equipment is employed and within calibration dates.

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Petrofac GS CONTRACTOR

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RUWAIS 4 NGL TRAIN

GASCO ABU DHABI GAS INDUSTRIES LTD.

8.7

PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

MECHANICAL COMPLETION, COMMISSIONING AND START-UP 8.7.1 Mechanical Completion, which includes Pre-Commissioning Notification for mechanical completion will be issued to Company after ensuring all QC checks have been completed and signed off. Accordingly all inspection and test records and relevant documentation shall be available to Company for review. Documentation will be compiled and submitted in the as-built mark up condition. Construction Manager shall ensure the complete execution of the following activities: • • •

Completion of construction and pre commissioning ITR’s. Completion of system punch and completion of Category A items Acceptance of above documents by Company.

•

System walkdown carried out jointly with CompanyThe Inspection and Test Records and Procedures for Pre-commissioning shall include those individual elements of the systems, which shall be progressively incorporated into subsystems and complete systems.Refer 5248-00-FA-4204: Acceptance and Hand Over Procedure.

8.7.2 Commissioning and Start-up Commissioning shll be carried out by Contractor. Contractor shall supply trained and qualified personnel. When the plant and its supporting facilities are ready for operation, Company shall start-up the plant and commence initial operation with the objective of achieving onstream operation. Once a unit or equipment has achieved onstream operation, performance testing is carried out by agreement between Company and Contractor. Performance testing comprises of a series of tests performed by Company and the Contractor shall provide commissioning expertise in support of the Company throughout each test run. Succesful completion of all unit and equipment performance tests shall lead to the issue of the Certificate of Completion. Refer 5248-00-FA-4202: Pre Commissioning and Commissioning Execution Plan Refer 5248-00-FA-4201: Pre Commissioning and Commissioning Procedure Refer 5248-00-FA-4203: Test Run Procedure Refer 5248-00-FA-4205: Right First Time Start Up Initiative Implementation Plan 8.7.3 Completion and Handover Contractor shall assure quality, consistency and completeness of Construction, Precommissioning and Commissioning by utilising the Petro-PCS software system. This system facilitates tracking of Systems and Sub-systems of the Project, compiling and assigning engineering data to System and Subsystems and assigning the applicable construction, precommissioning and commissioning checksheets to the components. Using Petro-PCS as the electronic completions and certification system, the Commissioning team will manage the verification and testing scope of work from construction through pre-commissioning and commissioning. Petro-PCS also functions as a tool for management of punch items.

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Petrofac GS CONTRACTOR

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RUWAIS 4 NGL TRAIN

GASCO ABU DHABI GAS INDUSTRIES LTD.

PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

Contractor shall compile documentation pertaining to the construction and pre-commisioning completion checks in dossiers arranged by System/Subsystem. These dossiers shall contain all information required to demonstrate the system has reached the stage ready for commissioning. As the construction, commissioning and operations team use the same database, then Systems and Sub-systems can be verified for functional performance and during handover the requisite documentation and acceptance certification can be generated. Refer 5248-00-FA-4204: Acceptance and Hand Over Procedure. Refer 5248-00-FA-4206: Petro-PCS Input and Change Procedure.

9. 9.1

MEASUREMENT, ANALYSIS AND IMPROVEMENT PLANNING FOR MEASUREMENT, ANALYSIS AND IMPROVEMENT.

The process of Measurement, Analysis and Improvement is shown below. M e a s u re m e n t

A n a ly s is

Im p r o v e m e n t

N o I n t e r n a l a u d it in n n

N o n c o n f o r m it y

C o m p lia n c e

Yes

N e g a tiv e P e rfo rm a n c e in d ic a t o r s

C o r r e c t iv e a c tio n

T re n d s

P o s it iv e

F u tu re w o rk Feedback

P re v e n tiv e a c tio n

A c tio n

C lo s e o u t

C u s to m e r s a t if a c t io n

C r it iq u e

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Petrofac GS CONTRACTOR

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RUWAIS 4 NGL TRAIN

GASCO

PROJECT QUALITY PLAN

ABU DHABI GAS INDUSTRIES LTD.

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

Following shall be planned and implemented: Project compliance with the contract requirements of the Project QMS compliance with the international standards and contract requirements Continual improvement of the effectiveness of the QMS.

• • •

The Project Director shall ensure the Process Owners establish Performance Indicators, monitor their performance, and take appropriate actions for improvement. The following table lists Performance Indicators per Process and their review frequency. Target

Review Frequency

Responsibility

100%

Weekly

Director

0

Quarterly

1. IFC Revisions Vs No. of IFC Drawings

10%

Monthly

2. Average Vendor Document Review Cycle

10 Working Days

Monthly

3. Issued for Company Review (ICR) Code 1 Documents

7%

Monthly

4. Issued for Approval (IFA) Code 1 Documents

3%

Monthly

KPI Project Management

Project

1. Actual Progress Vs Planned 2. Number of Repeat CARs Engineering

Engineering Manager

Procurement 1. Actual Enquiries Vs Planned (cumulative figure)

100%

Weekly

Project

2. Actual Award Vs Planned (cumulative figure)

100%

Weekly

Procurement

site 1% Overall Note (1)

Monthly

3.

Damage of Materials/Equipment (cumulative figure)

on

arrival

at

4. No. of Post Delivery NCRs on Equipment / Materials

0

Quarterly

Construction Management

Construction

1. Max. Weld Rejection (overall)

5% (Note 1& Monthly 2)

2 Max Site Nonconformities

10/ Month

3. Number of Repeat Site Nonconformities 4. No. of Welds NDEs Vs No. of Welds Completed

Director/ Manager

Monthly Monthly

100%

Monthly

1. Adherence to Audit Schedule

100%

Quarterly

2. Timely Close-out of CARs (Internal Audits)

100%

Quarterly

Quality

3. No Missed Inspections (Procurement Stage)

100%

Monthly

Manager

Quality Management Project

Note: 1) Damage of Material/Equipment on Arrival at site = (No. of Damage Reports in a Month x 100)/ (No of Shipping Release Notes in that Month). Note 2) Structural 5% by total length of deposited weld Note 3) Piping 5% of total number of RT films taken

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9.2

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

MONITORING AND MEASUREMENT 9.2.1 Company's Satisfaction During the execution of Project, Company’s comments regarding project activities shall be analysed and relevant improvement actions shall be taken in order to improve any problem areas. Company feedback shall be gathered during the various meetings, reviews, correspondences, joint inspections and day-to-day interactions. Negative feedback / concerns raised by Company requiring resolution shall be reported to the Project Director for initiating satisfactory close out actions by concerned process owners. During project execution and post-delivery phases, any feedback by Company requiring action shall be subject to immediate and satisfactory resolution by the appropriate level of the Contractor’s Management. Project Management shall be responsible for compilation and analysis of the Company feedback throughout the life of the Project and self-assessment. The Project Director shall inform the process owners about any major problems raised by Company during the execution and shall follow up actions. The process owners shall be responsible for handling these complaints. 9.2.2 Audits The Project Quality Manager shall plan and implement internal audits and external (Vendor/Subcontractor) audits using trained and qualified auditors. Audits are performed in accordance with the procedure 5248-00-AA-4183 “Project Audit Plan and ISO 19011: 2002 Guidelines for Quality and/or Environmental Management Systems Auditing. The audit process shall be implemented in a planned manner and based on the status and importance of the processes and activities, and the results of the previous audits. The audit schedule shall cover all activities carried out by Contractor, Subcontractors and Vendors. The Project Quality Manager shall maintain the Audit Schedule. The Project Quality Audit Schedule shall be submitted to Company for information. Other than the planned audits, the need for surveillance audits will be decided by the Project Quality Manager / Site Quality Manager based on the completed audit results and the surveillance inputs. The Project Quality Manager shall notify the Company minimum seven (14) days in advance of the performance of external audits for the opportunity to attend the audits as Observer. One copy of the audit report shall be forwarded to the Company within fourteen (14) days of the conclusion of the audit.

Page 42 of 45

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RUWAIS 4 NGL TRAIN

GASCO ABU DHABI GAS INDUSTRIES LTD.

PROJECT QUALITY PLAN

Petrofac GS CONTRACTOR Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

The Process Owners shall perform the corrective/preventive actions relating to audits results. The Project QA Manager with the support of Site QC Manager shall maintain the Audit Status Log and Corrective Actions Status Log for tracking all relevant actions until close-out. 9.2.3 Monitoring and Measurement of Processes All processes are monitored as defined in the applicable ITPs and recorded in relevant quality formats. The process performance is measured by the KPIs identified. 9.2.4 Monitoring and Measurement of Product Depending on the nature of the product, monitoring and measurement are carried out: • Upon receipt of products from Vendors; • In process; • At final stages of construction. Before starting the receiving inspection, the Material Controller shall ensure appropriate documents such as the purchase order, approved data sheets and drawings, material certificates, and vendor recommendations, if required, are available. The receiving inspection shall be performed by Material Controller, assisted by a qualified Quality Inspector or Supervisor when requested. Test Procedures shall be developed and implemented by the Sub-contractor. Products shall only be released when the appropriate inspections and tests are completed. The Quality Inspectors in liaison with the Construction Superintendents shall carry out the required in-process inspections and surveillances. Quality Engineer shall issue Request for Inspection to Company when completed work is subjected to inspection in accordance with ITPs.

9.3

CONTROL OF NON CONFORMING PRODUCT Identification, recording and seggregation of Nonconforming Product is exercised throughout the Project by Contractor’s Personnel and by hired Inspectors in accordance with procedure ref. 5248-00-FA-4040 ‘Control of Nonconforming Product. The Subcontractors are required to submit their nonconformance procedures to Contractor for approval prior to start of work. The proposed use by concession or repair of a nonconforming product shall be reported to the Company for agreement.

Page 43 of 45

Petrofac GS CONTRACTOR

th

RUWAIS 4 NGL TRAIN

GASCO ABU DHABI GAS INDUSTRIES LTD.

PROJECT QUALITY PLAN

Agreement No. 13524801

Doc. No. . 5248-00-AA-4181

Rev. 2

Any rejected products shall be removed from construction site utilisation points (quarantined). The description of the nonconformity or details of any repair done shall be recorded for future reference. All repaired and reworked products shall be re-inspected. When a non-conformity is detected after installation, the consequences for future construction shall be reviewed and the necessary actions carried out by the Site Construction Manager.

9.4

ANALYSIS OF DATA The following data generated by the Project Management, Engineering, Procurement and Construction Departments shall be subject to analysis on monthly/quarterly basis by the relevant process owners: • • • • • •

Results of internal and external audits Records of Client's satisfaction or dissatisfaction Compliance with the product requirements Characteristics and development of processes and products, including opportunity for preventive actions. Records regarding Vendors Performance Indicators

The review results shall form input to Contractor’s Management Review for determination of the suitability, effectiveness and adequacy of the QMS.

9.5

IMPROVEMENT 9.5.1 Continual Improvement The Project Quality Manager shall review and analyse the following elements for improvement of the effectiveness of the QMS. • • • • •

Project quality objectives Internal and external audit results Data analysis reports Corrective and preventive actions Management review reports

9.5.2 Lessons Learned and Knowledge Sharing Lessons learned from the previous Projects are logged by the Contractor.

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GASCO ABU DHABI GAS INDUSTRIES LTD.

PROJECT QUALITY PLAN Doc. No. . 5248-00-AA-4181

Petrofac GS CONTRACTOR Agreement No. 13524801

Rev. 2

The Lessons Learned information can become input to the following areas identified in this Project Quality Plan:

• • • •

Design input Vendor inspection management philosophy Training / awareness and competence Site QC enhancement

9.5.3 Corrective Action Corrective actions shall be implemented to reduce or eliminate the causes of identified nonconformity in order to prevent recurrence in the following manner: • • • •

Review of non conformities, including Company’s complaints for all processes executed. (by the process owners). Determination of the causes of non-conformities and the appropriate corrective actions. (by the process owners). Implementation of the corrective action needed and recording of the results. (by the Process Owners). Review/verification of the corrective action taken. (by the Quality Engineer).

The impact or importance of the problem encountered shall be considered during the evaluation of the corrective actions needed.

9.5.4 Preventive Action The following steps are implemented for preventive actions to eliminate the causes of potential non-conformities and to prevent occurrence. • • • •

Determination of potential non conformities and of their causes (by the Process Owners). Evaluation and determination of preventive actions to be undertaken in order to avoid the occurrence (by the Process Owners). Implementation of preventive actions (by the Process Owners). Review of the preventive action undertaken (by Project Quality Manager).

The impact or importance of the potential problem shall be considered during the determination of the preventive action needed.

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