3513-M3GE-0-25-0001-A[1]

COMMENTS RESOLUTION SHEET[ CRS ]

CONTRACT NUMBER

GC12105200

CONTRACT TITLE

EPIC FOR UPGRADATION OF AC UPS UNITS IN NGL3, MESAIEED

QP EXTERNAL TRANSMITTAL REFERENCE

EDM/GC12105200/EXT/TN/0034

DATE

25‐02‐2013

DOCUMENT NUMBER

3513‐M3GE‐ 0‐25‐0001

DOCUMENT REVISION

2

DOCUMENT TITLE

PROJECT QUALITY PLAN

No. 01.

QP COMMENTS No comments

QP PROJECT NUMBER

3513

CONTRACTOR RESPONSE Pre‐startup audit identified under sec 13.2 with tentative schedule 90‐95% (as per planning package) of project of  project completion and audit schedule revised accordingly. Discussed and agreed with QAC 24

Page 1 of  1

PROJECT QUALITY PLAN

TABLE OF CONTENTS CROSS REFERENCE TO ISO 9001:2008 Clause No

Project Quality Plan

1.0

Introduc tion

2.0

Clause No

ISO 9001:2008 Quality management system

Scope

4.0 4.0

3.0

References

4.0

Quality management system

4.0

Abbreviations And Definitions

4.0

Quality management system

5.0

Project Quality System

4.0

Quality management system

5.1

Quality Objective Projec t Quality plan Revision and Approval

5.2

Quality management system

5.4.1

Quality Objec tives

4.2.3

C ontrol of Documents

5.3

Quality Policy

5.3

5.4

Organization

5.5

5.5

Respo nsibility

5.5

Quality Policy Responsibility, Authority and Communication Responsibility, Authority and Communication

PROJECT QUALITY PLAN

1.0

INTRODUCTION  This Projec t Quality Plan states the quality requirements to b e followed in QP Contract GC12105200 EPIC for Upgradation of AC UPS Units in NGL3, Mesaieed  The Proposed Projec t Q uality Plan will be utilized as a tool to control q uality and to verify and d emonstrate the projec t quality achieved.  The persons performing the task will plac e emphasis on doing it right the first time, with clear, concise definition of requirements by the originator of the work requested, followed by the confirmation and paraphrasing of assignment. Subsequently the person performing the task will reconfirm the requirements and work plan during the early phases, and pre-agreed milestones througho ut the e xec ution of the work. All activities will be planned, documented, organized, managed and effectively discharged in a controlled manner such that the work carried out by DOPET is of a quality commensurate with the requirements of the contract.  This quality system to be adhered to on this projec t ba sed on DO PET's quality system C ertified to the requirements of quality system standard ISO 9001: 2008.

PROJECT QUALITY PLAN QP-STD-Q-003 Rev 1-C orpo rate Stand ard proc urements of ma terials and equipment

for Quality requirements for

And other All QP specifications referred in the contract are applicable to this project

4.0

ABBREVIATIONS AND DEFINITIONS

4.1

Abbreviations

4.2

QP

Qatar Petroleum

DOPET

Doha Petroleum C onstruction C o. Ltd.

PQP

Projec t Quality Plan

QC P

Quality C ontrol Plan

ITP

Inspe ction and Test Plan

QA/ QC

Quality Assurance and Quality C ontrol

C AR

C orrec tive Ac tion Request

SPIR

Spare Parts Interchangeability Rec ords

DEFINITIONS

PROJECT QUALITY PLAN the Projec t Doc ument C ontroller and Projec t Doc ument C ontroller shall issue the latest copies to a ll cop yholders as per the List. Italic may be used to highlight part of the text or to indicate the changes that have occurred since a documents last revision. A bold vertical bar shall be placed in the left margin of an engineering document, to indicate the area of change that has occurred since its previous revision.

Distribution List

QA / QC Ma nager

Master C opy

Projec t Ma nger

1

Proc urement Ma nager

2

Engineering C oordinator

3

C ommissioning Enginee r

4

HSE Manager

5

PROJECT QUALITY PLAN

5.3

Quality Policy

PROJECT QUALITY PLAN

5.4

Organization  The Projec t Orga nization C hart (Attachment-1) illustrates the Projec t Organization structure, relating functional reporting relationships and interfaces with QP. CV’s of proposed staff and qualification of the proposed QC inspection personnel used for the project shall be submitted to QP before using them in the project.

5.5

Responsibility

5.5.1

All personnel assigned by DOPET (including subcontractor personnel) to the project are responsible for the quality of their own work  The responsibility of senior personnel is specified below, although a ll personnel will be working as a team. 1) Project Manager - Responsible for overall project, progress, cost control etc. Main contact person between DOPET - QP, DOPET – DOPET’s Subc ontractors. Tota l responsibility for the timely executions of the Projec t. Based at hea d o ffice a nd reporting to the Dope t management. 2) HSE Manager - Responsible for implementation and monitoring the HSE

PROJECT QUALITY PLAN 8)  Q A / Q C En g i n e e r - Fre q u e n t v i si ts t o si te m a y b e c a rri e d o u t t o a sse s a l l ongoing activities. Other responsibilities are stip ulated in the relevant se c t io n o f t h is d o c u m e n t . Re p o r ti n g t o t h e Q A / Q C En g i n e e r .

9) Safety Officer- Respo nsible for implementation of the safety prac tices and implements safety policy at site in accordance with the project req uirements. Rep orting to the HSE Manager 10) Project Control Manager: Monitor the work against the planned schedules. Analyze deviations, change of contract scope or delay and if required reschedule to meet the target dates. Prepare weekly/monthly progress report as per contract requirements and submit to QP for review and approval. Reporting to the Dop et management 11) QA/ QC Inspector - The no minated Quality Representative for this projec t and responsible for monitoring the implementation and execution of the plan and reporting findings to the project management and QC Engineer. He may request quality assurance reviews and audits where determined necessary and responsible for monitoring nonconformance until they are satisfactorily resolved or correc ted. Other responsibilities include coo rdination with C lient’s representatives. Rep orting to the Q A/ QC Engineer 12) Site Superintendent- Responsible for all construction and installation

PROJECT QUALITY PLAN attachment to this PQP. The d isciplines to be audited will be determined as the projec t progresses.

d)  The QA/ QC Ma nager or QA/ QC Engineer is responsible for preparing the audit plan, co-ordination of the audit and ensures that personal performing audits are independent of those having a direct responsibility of the activity.

e)  The audits are planned to assess whether a ctivities are being performed according to the Projec t Quality Plan and p roc edures.

f)  The

respective Discipline Ma nager/ Engineer or Subc ontractor representative is responsible for taking timely corrective action on deficiencies found during the audit

g)  Trained members of the compa ny’s own staff may undertake audit or hired auditors with experience and qualification appropriate to the area to be e xamined.

h) Should a serious non-confo rmity arise within the quality system; the Q A/ QC Manager or QA/Qc Engineer may initiate an urgent unscheduled audit. Such audit shall be performed and reported in accordance with this procedure. Unscheduled audits shall be identified respectively in the internal audit report log.

PROJECT QUALITY PLAN 5.7.1

General Non-compliance observed either during the audit, site surveillance, or other activity shall be reported and recorded as soon as practicable and shall be subjec t to c lose control such that: 1. Non-c onforming items are clea rly identified in an unambiguous manner 2.  Their unauthorized or inadvertent use and progress or mixing with conforming items is prevented. 3.  The approved disposition is implemented by authorized personnel. Reinspection shall be carried out to original requirements if reinstatement within the work is conside red . 4. Rec ords are ma intained which readily and p ositively identify and trace the non-conforming item, service or activity and the nature and extent of the non-conformance. 5. Corrective and preventive action shall be promptly implemented in order to minimize non-c onformanc es and prec lude their repetition 6. Non-conformances and corrective/preventive action accordance with ISO 9000 quality system requirements.

shall

be

in

PROJECT QUALITY PLAN 5) C orrec tive action shall include an evaluation of the following

C ommercial Issues  Tec hnical C onsiderations Schedule impact Raising of site o r tec hnical queries and change control issues 6) C AR(S) shall be c losed o ut with in max two weeks from C AR(S) Issuanc e

date. 5.7.3

Repea ted Follow-up Where a follow-up verifies the satisfactory corrective/preventive action(s) have not been completed, then the QA/QC Manager or QA/QC Engineer shall direc tly liaise with the c onc erned department head to find a solution.

5.7.4

Management Review  The Q A/ QC Ma nager or QA/ QC Engineer shall monitor the results of a udits in order to identify serious deficiencies in the Quality System and any adverse trends. He shall prepare and submit the following in the management review meeting:-

PROJECT QUALITY PLAN 1) All documents related to the projec t qua lity shall be classified as controlled documents. 2)  The Projec t Ma nager is responsible for the control of projec t da ta/ documentation including that provided b y Sub-c ontrac tors and Q P. 3) All existing and new deliverables are identified in the list of deliverables and controlled by revision number when revisions are made. 4) Projec t Document/Drawings shall be numbered in accorda nce with ES-D-10 sec tion 6.1. Unique numbering system shall be followe d for numbering documents. 5) A list of applicable national and international standards with the year of revision shall be maintained 6) Document transmittals shall be controlled by using unique numbered document transmittal Forms. 7) Internal document distribution shall be controlled by using internal document distribution lists form or distribution ma trix. 8) Separate document transmittal register shall be maintained for QP and ea ch Sub-contractor.

PROJECT QUALITY PLAN correspondence, purchase orders, change orders and expediting and inspec tion rep orts. 5) Procurement manager coordinates with project Engineer & QA/ QC Ma nager where necessary.

manager,

QA/QC

6) Procurement Manager shall develop and maintain a electronically procurement status register, capable of registering, planning, tracking, monitoring, expediting and reporting on the Requisitions and Purchase Orders. Status of procurement documents is recorded and updated throughout the purchasing cycle to record and check ongoing activities. Pre-award review of bids with vendors and check that the bids meet with the project requirements. 7) Equipment shall be selec ted as per QP a pproved Vend or list

8.2

Requisitioning

8.2.1

Purcha se req uisitions (Spe cifications) for materials, parts, equipment and units shall be prepared by the e ngineering c onsultant c onsidering the following: 



Basic design da ta General and particular information on materials and equipment and provisions for materi l sub titution if found t a later date.

PROJECT QUALITY PLAN documentation prepared by engineering consultant shall be reviewed by the Project engineer/Project Manager and submitted to QP for comments and approval. All equipment datasheets and specification together with purchase requisition document shall be approved by QP prior to p urchase. Procurement department can take advance action before QP approval, with the permission of projec t mana ger. All equipment material shall require app rova l by QP prior to purchase. Advance purchase action can be initiated by procurement department with the permission of projec t mana ger.

8.3

Qualification Vendors (Subcontractors)

8.3.1 Vendors shall be selected from the preferred vendors list as detailed in the contract. Permission shall be obtained from QP before using any vendor other than from the preferred vendor list. Applications to make use of an alternate vendor shall be submitted to QP and written justification for deviation with evidence 8.3.2 Subcontractors selected shall be assessed to ensure that they are currently capable of manufacturing the equipment, parts and materials to the

PROJECT QUALITY PLAN purchased/ordered/fabricated is sufficient to ensure that it will be acceptable and suitable for its intended use. Following salient fea tures shall be c onsidered. 











8.3.4

Size, type and number/qua ntity of e quipment and materials. Knowledge and working experience with projects specifications and ap plicab le C ode/ Standa rds Organizational availability

and

manpower

qualifications,

experience

and

Resources for meeting project quality requirements, describing any external assistance required by the subcontractor in the field of fabrication, inspection and testing and/or additional manpower requirements.  The type of management of the subc ontractor, their operations, verifica tion and doc umentation systems, proc ed ure structure, organization and auditing system. Housekeeping, material storage and ha ndling

DOPET project management shall be fully responsible for the completion, checking, implementation and approval of sub-contractors documentation including reports, essential project documents and quality plans etc

PROJECT QUALITY PLAN 







8.5

In-house inspection capabilities, including knowledge experienc e of dealing with Third Party Inspec tion agencies.

and

Preliminary inspection and test planning including, specifying the extent of involvement of QP, DOPET, Stockiest and Sub-contractors  TPI (where ap plicable) at appropriate stages of fabrication/assembly. Identifica tion of essential documents including As Built. Past experienc e of the sub-c ontractor on projec ts of a similar nature and scope

Quality Control At Contractors & Sub-Contractors Works 1) Sub-c ontrac tors are req uired to submit with their bid, or within 30 days of contract award, a d etailed description of the Quality C ontrol Organization, Indicating the number, background and function of each individual, the lines of mode of reporting and communication interface with personnel assigned to engineering tasks. 2) Quality C ontrol Plan or Inspec tion and Test Plan shall include Subcontractor/DOPET/QP inspection points from all stages of manufacturing of ordered items.

PROJECT QUALITY PLAN 1) Inspection and testing shall be performed at predetermined stages in construction operations as per approved ITP in order to ensure continuous control and progressive verification of compliance with quality criteria and to assist in the early detection of non-conformances and ensure full compliance with project specifications, manufacturing practices etc. 2)  The Inspections shall be carried out by a ppropriately trained and qualified personnel other than those who perform the subject work activity. 3) C V and q ualifica tions of Inspection personnel shall be forwarded to QP for approva l before utilizing them in the projec t. 4) Where spec ial expertise is req uired during inspec tion activities spec ialist discipline engineers will either assist the Inspector or exec ute the inspec tion. 5) Inspection personnel shall be mad e thoroughly familiar with special projec t requirements and proc edures. 6) Inspection and testing shall be performed in accordance with project specific Quality Control Plan or Inspec tion & Test Plans which shall be prepa red upo n award of the contract.

7) All equipment inspection and testing requirements shall be as per approved QP specification and da ta sheet

PROJECT QUALITY PLAN transit and storage and that all marking used for identification purpose are protected. 10.2

Short and Long Term Storage 1) Short and long term storage control measures shall be established for safeguarding materials and equipment from damage, particularly, in the period b etween manufac turing a nd ready for installation a t the job site 2) Following issues concerning packaging and preservation and storage shall be taken into account for the materials/equipment. Where necessary procedures or instructions shall be prepared addressing the following issues and issued in a timely manner in order to safeguard materials and equipment against corrosion and da mag e d uring transit and storage. 

 The unique charac teristics of individual plant item and their specific requirements concerning packaging preservation storage and handling.



Handling a nd preservation during loa ding and unloading.



Outside storage and ha ndling a t remote desert locations.



Internal storage and ha ndling a t warehouse loc ations.

PROJECT QUALITY PLAN 3) DOPET shall execute pre-commissioning activities to demonstrate that each pa rt of the fa cilities is mec hanically completed and rea dy for commissioning.  This shall be demonstrated at job sites throughout the Shutdown phase covering receipt of materials and equipment to final inspe ction and inspection data repo rts in accorda nce with project quality requirements by assembly of quality rec ords supp orting the Q uality C ontrol Plan for the following: 









Inspec tion test plan shall referenc e Proc edures, Work instructions, Acceptance criteria in compliance with QP-STD-Q-004 Lifting of equipments and parts shall be carried out by qualified personnel and certified lifting equipment in accordance with applicable project specification Notification for in process and final inspection between QP shall be planned in ac cordanc e with projec t specification requirements Final documentations with material certificates, signed inspection documentation, as-built documentation data shall be available to ensure mecha nical completion Mechanical commissioning shall be in accordance with the completion req uirements supp orted by outstand ing punch list items etc .

PROJECT QUALITY PLAN 1) For equipments Vendor data reports shall be in accordance with the requirements as stipulated in the contract purchase order containing materials used , manufacturing history co ntaining following minimum. 

General da ta like drawing/ da ta sheets with identification tag number.



Surfac e p reparation a nd p ainting repo rts



Quality Control Plan and Inspection control sheets.



Design c alculations



Agreed deviations



As-Built drawings



Release certificate







Certificate of compliance to applicable code issued and signed by app ropriate authority Calibration certificates for the used instruments( chart recorder, gauges etc)  Test certificate and manufactures da ta of safety relief devices

PROJECT QUALITY PLAN f) As-built marked up AFC drawings g) Quality C ontrol rep orts h) Supp liers and vendo rs do cumentation needed for commissioning. i)

11.5

Rea dy for commissioning certifica te

C ommissioning 1) Commissioning shall be carried out in accordance with specified req uirements of the contract. Commissioning activities shall be c arried out as per QP approved plans, schedules and procedures by experienced, qualified commissioning team. 2) New installation shall be fully commissioned after pre-c ommissioning, in order to demonstrate the reliability, integrity and performance of relevant eq uipment in actual running condition. This shall be achieved b y DOPET and vendors and suppliers representative.

11.6

Handover and Hando ver Dossier 1) DOPETshall handover fully operable system. Any defec t in design, materials

PROJECT QUALITY PLAN Where applicable, training shall be provided by involving equipment manufacturer representatives during pre-commissioning / commissioning pha se to provide nec essary training to Q P for this contract scop e supply.

13.0

Attachments 13.1

Projec t Orga nization C hart

13.2

Projec t Audit Sched ule

 Project Organogram

DOPET Management

 A.K. Gan guly Procurement Manager 

NARENDERAN C.K HSE Manager 

RAJASEKHAR QA/QC Manager 

V.GOPI Project Control Manager 

 K.RAJMOHAN Project Manager 

QP PROJECT REPRESENTATIVE

 ALFREDO L. L O Planning & Cost Eng.

RAMESH GANESAN Project Engineer

QP QA Dept.

BENZEER Sr. QA/QC Engineer 

Expeditor / Material Controller  RAJESH R GAJERA QA/QC Engineer 

Office Base

DOPET IN HOUSE ENGINEERING Supplier Miscellaneous MURALITHAR R.MARI Engineering Co-Ordinator 

CELSO Sr.ElectricalEngineer 

QA/QC Inspector 

SAFETY OFFICER

Rajan Puthiyeduth

E&I TBA

Sub- Contractors

CIVIL (sub Contractor)--TBA

1). AC/DC UPS ---- TBA 2). 415V MCC Modification --- TBA 3). F&G Modification --- ICS 4). DCS Modification --- ABB . I --6) Building Constrcution --- TBA 7) Geotechnical investigation --- TBA 8) Topograhical --- TBA 9) HVAC --- TBA 10) TPI (FAT/SAT) --- TBA

CONST. SUPERINTENDENT John Samuel

SYED SAUD AHMED Civil/Structural Design Engineer 

JACKSON VICTOR InstrumentEngineer 

CIVIL ENGINEER (CONST.) TBA

Pre - Commissioning/ Commissioning Team

Site Base

CIVIL/ELECTRICAL/INSTRUMENT CREW

 Contractor:

Doha Petroleum Constructi on Company Ltd. P.O. Box 1744 - Doha - Qatar 

Rev.A

 ATTACHMENT 1

roec

e:

 Contract No.

EPIC FOR UPGRADATION OF AC UPS UNITS IN NGL-3,MESAIEED

GC12105200

CHETAN KUMAR N.PATEL Sr. Loss Prevention Engineer 

en :

a ar

e ro eum

Dopet Ref: J-24555

Doha Petroleum Construction Co. Ltd. Post Box 1744 - Doha - Qatar - Tel: 44600350 - Fax: 44601066

PROJECT AUDIT SCHEDULE GC 12105200 -PAS-01;Rev A Date: 05/03/2013

 AUDIT SCOPE Project management Organization and Resources Planning Project Co-ordination Document Control  Approval and Distribution, Transmittal Contract documents and Approved Deviations Filing Purchasing Supplier selection Purchase requisition /Purchase Order Approval and issue Expediting Inspection and testing Packing, Handling, storage and preservation Construction (including sub-contractor) Functional Disciplines Organization & Mobilization Process control/ procedure approval Qualification of personnel Inspection and testing and Test reports Non-conformance reporting Handling and storage during construction Pre-Start up Audit Mechanical Completion records Punch Lists Function testing Pre-commissioning and commissioning  As-Built Documentations System acceptance certificates Project Dossiers Sections changed in the latest revision shall be identified by text highl ighted in bold italic ty pe

Page 1 of 1

AUDITEES

TENTATIVE SCHEDULE

Project Manager Project Engineer Planning Engineer Document Controller Procurement Manager

25% completion

Project Manager Project Engineer Site Superintendent QA/QC Representative Commissioning Engineer

Document controller Project Manager Project Engineer QA/QC Representative

50% completion

90-95% com pletio n

3513-M3GE-0-25-0001-ATTACHMENT 2