5A QA PL 01Rev00 Project Quality Manual

DOCUMENT NO:

PETRONAS CARIGALI WHITE NILE (5B) LTD

QA-PL-001

OGP TECHNICAL SERVICES SDN BHD SUDAPET LTD

Sudapet Ltd.

THAR JATH DEVELOPMENT PROJECT

PROJECT QUALITY MANUAL

REVISION RECORD REV NO. 00

REVISION DESCRIPTION

DATE OF ISSUE

ISSUED FOR PMC’S IMPLEMENTATION

5/1/2005

Approval

OWNER

CONSULTANT

REV NO

Origin.

Engineering

Procurement

Construc- Commisstion ioning

Contract

QA

HSE

Project Control

00

CHECKED BY

DATE:

APPROVED BY

DATE:

PROJECT MANAGER

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TABLE OF CONTENTS

RECORD OF CHANGE AMENDDATE OF MENT AMENDMENT NO. OR RE-ISSUE

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PAGE NUMBER REPLACED

REV. NO.

REASON FOR CHANGE

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TABLE OF CONTENTS 1.0PURPOSE AND SCOPE............................................................... ........................5 2.0OBJECTIVES...................................................................................... ..................5 3.0REFERENCE................................................................................................... ......5 4.0QUALITY MANAGEMENT SYSTEMS......................................... .........................5

4.1Project QMS Documentation................................................................................7 4.2Control of Document and Records........................................................................7 5.0MANAGEMENT RESPONSIBILITY................................................. .....................8

5.1Project Quality Policy...........................................................................................8 5.2Project Objectives.................................................................................................8 5.3Organization Structure..........................................................................................8 5.4Quality Planning....................................................................................................8 5.5Management Review.............................................................................................8 5.6Internal Communication........................................................................................8 6.0RESOURCE MANAGEMENT......................................................................... .....10

6.1Human Resources................................................................................................10 6.2Project Infrastructure...........................................................................................10 6.3Health, Safety and Environmental (HSE)...........................................................10 7.0PRODUCT REALIZATION PROCESS...................................... ..........................11

7.1Proposal and Contract Management....................................................................11 7.1.1Determination of OWNER’s Requirement...................................................11 7.1.2Review of OWNER’s Requirement..............................................................11 7.1.3Communication with OWNER.....................................................................11 7.2Design and Engineering Management................................................................12 7.3Procurement Management...................................................................................12 7.4Construction Management..................................................................................13 7.5Commissioning Management..............................................................................13 7.6General Requirement for Product Realization Process.......................................14 7.6.1Identification & Traceability........................................................................14 7.6.2Customer Property........................................................................................16 7.6.3Preservation of Project Materials.................................................................16 7.6.4Control of Monitoring and Measuring Devices...........................................16 7.6.5Liaison with Local Authority and Regulatory Bodies..................................16 8.0MEASUREMENT, ANALYSIS & IMPROVEMENT...................................... .........16

8.1Customer Satisfaction.........................................................................................16 8.2Quality Audits.....................................................................................................17 8.2.1Internal Audits..............................................................................................17 8.2.2External Audits.............................................................................................17 8.3Monitoring and Measuring of Product and Processes.........................................17 8.3.1Quality Control Surveillance........................................................................17 8.3.2Work Processes Monitoring and Measuring................................................18 8.4Non - Conformance Control ...............................................................................18 8.4.1SUPPLIER’s and CONTRACTOR’s Non-Conformance............................18 8.4.2CONSULTANT’s Non-Conformance .........................................................18 8.5Analysis of Data..................................................................................................19

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TABLE OF CONTENTS

8.6Improvement.......................................................................................................19 8.6.1Continual Improvement................................................................................19 8.6.2Corrective Action ........................................................................................19 8.7Preventive Action................................................................................................19

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PURPOSE AND SCOPE The purpose of this manual is to specify the requirement of Quality Management System (QMS) abide by the CONSULTANT that consists of OGP and SUDAPET in Thar Jath Development Project to address OWNER’s satisfaction and to comply with OWNER’s requirement, applicable regulatory and the ISO 9001:2000 requirement.

2.0

OBJECTIVES To specify the requirement for quality management system where OGP and SUDAPET as the CONSULTANT shall:

3.0

4.0

•

Demonstrates its ability to provide consistent product that meets customer and applicable regulatory requirements, and

•

Addresses OWNER’s satisfaction through the effective application of the system, including processes for continual improvement and prevention of non-conformity.

REFERENCE Project Execution & Quality Plan

QA-PL-002

Quality Management Systems- Requirement

MS ISO 9001:2000

QUALITY MANAGEMENT SYSTEMS OGP/SUDAPET (CONSULTANT) as the Project Management CONSULTANT of the Thar Jath Development Project is committed to implement the ISO 9001:2000 Quality Management System in all aspect of CONSULTANT’s SCOPE OF WORKS, as stated in Project Management Consultancy Agreement. This commitment shall be displayed in CONSULTANT’s roles and responsibilities in MANAGEMENT RESPONSIBILITY, RESOURCE MANAGEMENT, PRODUCT REALIZATION PROCESSES, and MEASUREMENT, ANALYSIS & IMPROVEMENT programs. In order to achieve that target, CONSULTANT has identified the overall project work processes and determines the sequence and interactions of these work processes for successful execution of the project. The operational procedures and means of controlling these processes have been established in documented procedures and standing work instructions. These procedures and instructions shall be continually measured, monitored and analyzed to ensure the planned results are achieved and CONSULTANT’s performance in satisfying OWNER’s expectation is continually improved. Figure 1 depicted the general CONSULTANT’s work processes.

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THAR JATH PROJECT PROCESSES CORE PROCESSES Key Responsible Personnel 1. Proposal Mgr

1. Project Mgr

Contract Finalized

Formation of Project Team

1. Eng. Mgr

Commence Basic Engineering

1. Eng. Mgr.

Manage / Execute Detail Engineering

1. Project Mgr 2. Proc. Mgr.

1. Project Mgr 2. Contr. Mgr

Manage Procurement Activities: Selection/Eval. of Suppliers Issuance of PO’s to Suppliers Buying/Expediting/Inspection/Wa rehousing of Materials

ITB Preparation For Sub-Contractors: Selection/Eval. of subcons Award of Subcons

1. Project Mgr 2. Const. Mgr

1. Project Mgr 2. Comm. Mgr

1. Project Mgr 2. QA/QC Mgr 3. Proj. Cont. Mgr

Monitoring & Verification WORKS on Construction by Contractor

ISO9001:2 000 Management 1. Quality System 2. Management Responsibility 3. Resource Management 4. Product Realization

SUPPORT PROCESSES

OGP/SUDAPET HOME SUPPORTS: Project Management Business Development Contracts Procurement Engineering QA/HSE Human Resource Mgmt Finance Information Technology

Monitoring & Verification WORKS on Commissioning by Contractor

Monitoring & Verification WORKS on Final Handover WORKS by Contractor

FIGURE 1

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Project QMS Documentation The categories of document included in QMS are as follows:

4.2



Project Execution & Quality Plan. This quality plan, QA-PL-002 shall represent the quality manual for the project.



Statement of Quality Policy. OGP Quality Policy is included in this quality policy.



Project Functional Objectives. The plan, QA-PL-002 shall state in detail functional objectives and the measurable targets.



Contract between WNPOC and OGP/SUDAPET for the Provision of Project Management Consultancy Services. This document provides OWNER's requirements to be fulfilled by CONSULTANT in the execution of the Project.



Project Implementation Manual (PIM). This document contains the overall project quality management system documented plans and procedures, including this Project Quality Manual. CONSULTANT's project management methods and requirement, and execution strategies shall be specified in this document. The complete list of plans and procedures in PIM is in Appendix A and the structure of the document is in Appendix B.



Special Work Procedures. This document will only be generated by CONSULTANT, whenever, is required by OWNER and CONTRACTOR unable to provide such document. The types of document that fall under this category are Commissioning Procedures, Training Manual, Welding Procedures Qualification, etc.



OWNER Supplied Document. OWNER supplied document shall comprise of drawings, specifications, regulatory handbooks, etc. of external origin that are relevant to the project.



Project Records. All records produced during CONSULTANT’s execution of PMC scope of works specified in the PMC contract. This shall cover all works in engineering, procurement, construction, commissioning and warranty. Control of Document and Records.

All document and record shall be properly, controlled and maintained for usage, filing, storage, archiving, and distribution purpose. The procedure, Document Control, QA-PR-001 shall specify the resources and practices in managing of project documents. The list of controlled document shall be in the Deliverable List. The lists of records are available in the procedure Control of Project Records, QA-PR-003. For QMS Procedures, beside the mandatory procedures, a procedure shall be produced only when required. The QA Engineer shall assess this requirement.

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MANAGEMENT RESPONSIBILITY

5.1

Project Quality Policy

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The project quality policy is shown in Figure 2. The project management is committed to ensure that the communication of this policy and other requirement of the project regarding the project QMS shall reach all personnel and understood by them. Continual checking on its effectiveness shall be conducted by one or more of these ways of auditing, internal departmental meetings, quality campaign, management reviews etc. 5.2

Project Objectives For list of Project Objectives, refer to document Project Execution & Quality Plan, QA-PL-002.

5.3

Organization Structure The project organization, and specific responsibilities and authorities for key project personnel shall be as specified in the Project Execution and Quality Plan. This document shall include the functional objectives defining functional group interfaces and responsibilities for key project activities. The responsibility for maintenance of the current organization charts and ensuring that the defined responsibilities and authorities of the key personnel reflect the current project organization, rests with the Project Director. The Project Director shall have the prime responsibility in implementation of QMS in the project. He shall be supported by the Project Managers and QA/QC Manager who shall have the organizational freedom and authority within the CONSULTANT’s team to identify quality problems, recommend corrective action and verify that implementation of necessary corrective actions are being taken. The other Managers shall be responsible to implement and control quality within their own department.

5.4

Quality Planning Refer to document Project Execution & Quality Plan, QA-PL-002.

5.5

Management Review A periodic quality system performance review shall be performed and documented by project management. The purpose of this review shall be to analyze overall effectiveness of the project quality system, and identify any necessary improvements. The results of each review shall be documented and approved by the Project Director in accordance with the above referenced procedure.

5.6

Internal Communication CONSULTANT shall ensure that all communication regarding the effectiveness of QMS is done effectively among all project team members. The procedure Communication and Correspondence Control, PM-PR-004 shall generally define the rules and methods the internal communication shall be performed.

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OGP QUALITY POLICY OGP Technical Services Sdn. Bhd. is committed to providing services that conform to the requirements and expectations of its clients in the oil, gas and petrochemical industry. OGP shall strive to consistently meet the agreed requirements for safety, quality, timeliness, appropriate technology, reliability, cost effectiveness and operability in realizing the vision to be "A Multinational Service Provider of Choice". To fulfill this goal, OGP's quality management system is based on the ISO 9001:2000 quality management standards and guided by the Five Quality Principles. This will ensure a planned, systematic and proactive approach to quality as a work culture. All employees share the responsibility of the quality management system and the role they play in instilling the culture of continual improvement and learning.

HJ MOHD RADZI B SALLEH Chief Executive Officer OGP TECHNICAL SERVICES SDN BHD

1st October 2003

FIVE QUALITY PRINCIPLES Conformance to Requirements Prevention Right Things Right Everytime Price of Nonconformance Proactive Leadership at all Levels

FIGURE 2 – QUALITY POLICY

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RESOURCE MANAGEMENT Project Services Manager shall be responsible to ensure all resources are sufficient to support execution of the project. He shall be supported by OGP/Sudapet Human Resource function in Kuala Lumpur and Khartoum ensuring all staffs’ requirements is complied.

6.1

Human Resources Prior to joining the project team, personnel shall be screened by CONSULTANT’s Project Manager. This is to ensure personnel shall have adequate qualifications, trainings and experiences. Project Services Manager shall keep all personnel resumes. Appropriate Personnel Performance Appraisals (PPA) shall be conducted yearly by each joint venture company to monitor the personnel’s competencies.

6.2

Project Infrastructure All facilities required such as communication equipment, emails, furniture, stationeries, pantries, computers, etc. shall be provided in the site office. The Office Administrator is responsible to ensure sufficient infrastructure is available at site. An appropriate maintenance plan shall be established to ensure all facilities are in good condition for works.

6.3

Health, Safety and Environmental (HSE) The project acknowledges the need of conducive working environment and protection against accidents and mishaps to be implemented and maintained. It will be the roles of all project team members to ensure this requirement is met. For the specific HSE matters, the responsibility for ensuring the necessary commitments are made, implemented and maintained to protect the health and safety of employees and other persons working on the project shall be with the HSE Manager. A specific HSE plan for managing Heath, Safety And Environmental Management System (HSEMS) is established for the project, refer to procedure SF-PL-001. This HSE plan shall be used as the major guideline in managing HSE in the project. The HSEMS covers the requirement of implementation, measurement, analysis and improvement program of health, safety and environment for the project and it is an obligation for members in the project to conformance to the stated requirement.

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PRODUCT REALIZATION PROCESS

7.1

Proposal and Contract Management 7.1.1

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Determination of OWNER’s Requirement The determination of OWNER’s requirement shall be managed during the Proposal Stage by OGP’s and Sudapet’s Business Development Division (BDD) and supported by other divisions and department. OWNER’s requirement is normally stated in Letter of Intent, Request for Proposal, Invitation to Bid, or others.

7.1.2

Review of OWNER’s Requirement Formal reviews and clarification shall be conducted against OWNER’s requirement. A Proposal Team is formed to conduct these reviews. The Proposal Manager shall obtain inputs from the team and consolidate them into a Proposal. The Proposal shall be reviewed by OGP’s/Sudapet’s Proposal Council prior to delivery to OWNER. Upon acceptance of this proposal, the proposal requirement shall be considered contractual between OGP and OWNER. The end product of this process is the PMC proposal document between OGP/Sudapet and OWNER.

7.1.3

Communication with OWNER CONSULTANT is committed to provide an effective customer communication program with OWNER on CONSULTANT’s deliverables in the project. The type of communication identified applicable for the execution of the project can be categorized into:

•

Daily verbal communication e.g. meetings and discussions

•

Interchange of correspondence e.g. transmittals, letters, etc.

•

Issuance of reports on progress or other project highlights e.g. Monthly progress reports, etc.

All verbal communication must be supported by documented evidence in order for them to become valid as project’s information or data. In order to facilitate written communication with OWNER, the procedure Communication and Correspondence Control, PM-PR-004 is established.

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Design and Engineering Management CONSULTANT shall be responsible for all engineering deliverables in basic engineering works. The Engineering Manager shall have the responsibility for ensuring that the all-basic engineering designs meet all contract, code, and regulatory requirements for safety, reliability and operability. In detail engineering, however, the direct responsibility for design and engineering shall be with CONTRACTORs and PMC Engineering Manager is responsible to monitor and verify that all detail engineering deliverables by CONTRACTORs conform to all contract, code, and regulatory requirements for safety, reliability and operability. Section 8.1 of the Project Execution & Quality Plan, QA-PL-002 is established to define scope of engineering works by PMC and is supported by the procedure in Monitoring and Verification of Engineering by OTHERS (EN-PR-001) for the specific program in managing CONTRACTORs engineering works. The following elements will be the focus of PMC’s design and engineering management:

7.3

•

Design input and output

•

Design verification

•

Design review

•

Management of changes

Procurement Management The responsibility for the procurement of contractually specified materials and equipment, which comply with the specification, delivery, and budget requirements, and implementation of the approved project procurement plan, rests with the CONTRACTORs for all facilities. PMC’s Contract & Procurement Manager shall have the responsibility to ensure that the procurement activities of CONTRACTORs are carried out in accordance to the contractual requirement. The section 8.2 of the Project Execution & Quality Plan, QA-PL-002 defines the resources and practices of CONSULTANT’s procurement planning and supported by the procedure in Monitoring and Verification of Procurement by OTHERS (PO-PR-001). The following elements will be the focus of the procurement works:

•

Qualification of personnel

•

Purchasing process

•

Purchasing information

•

Verification of purchased product

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Quality Management System requirement

Construction Management The responsibility for the fabrication, installation, inspection and test of the procured project materials and equipment shall rests with the CONTRACTORs. This shall include the required documentation such as special procedures or work instruction that are required for execution of construction activities and the identification and usage of suitable monitoring and measuring devices used in construction. CONSULTANT’s Site Manager shall be responsible for monitoring and verification of construction works done by CONTRACTOR. This shall include quality surveillance of the CONTRACTOR's construction activities to ensure conformance to the contractual requirement. The section 8.3 of Project Execution & Quality Plan, QA-PL-002 defines the scope of PMC’s roles in Construction Management and activities in Monitoring and Verification of Construction by OTHERS (CO-PR-001). The following are the main elements that will the focus of CONSULTANT’s construction program:

7.5

•

Site Notification

•

Construction Strategies, Sequence and Progress

•

Construction tools and equipment

•

Manpower

•

CONTRACTOR’s Quality Management System Documentation

•

Monitoring and Measurement Devices

•

CONTRACTOR’s Work Instruction

•

Quality Surveillance

•

Construction Records

•

Mechanical Completion Status

•

Punch-listing and Punch Clearing

Commissioning Management

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The responsibility for conducting testing and commissioning activities on the constructed facilities shall rests with the CONTRACTORs. This shall include the required documentation such as special procedures or work instruction that are required for execution of commissioning activities and the identification and usage of suitable monitoring and measuring devices used in commissioning. CONSULTANT’s Commissioning Manager shall be responsible for monitoring and verification of commissioning works done by CONTRACTOR. This shall include quality surveillance of the CONTRACTOR's commissioning activities to ensure conformance to the contractual requirement. The section 8.4 of Project Execution & Quality Plan, QA-PL-002 defines the scope of CONSULTANT’s role in Monitoring and Verification of Commissioning by OTHERS (CM-PR-001) and CONSULTANT’s management strategies to manage commissioning. The following are the main elements that will be the focus in commissioning management:

7.6

•

Commissioning Strategies, Sequence and Progress

•

Punch-listing and punch-clearing

•

Manpower

•

CONTRACTOR’s Quality Management System Documentation

•

Special tools and equipment for commissioning

•

Quality Surveillance

•

Commissioning Records

•

Mechanical Completion Status

•

Safety

General Requirement for Product Realization Process The following sections are the requirement that is common to all activities in product realization. The individual responsibility and authority will fall automatically to the lead personnel of a department or group where the activities occurred. 7.6.1

Identification & Traceability

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All project’s documentation, materials and equipment shall be remained identifiable and traceable through all phases of the product realization. The unique identification by the originator shall be assigned to the documented procedures, records, construction or purchased materials or equipment. Product status are critical information, wherever, appropriate product traceability system shall be developed to control and record with unique identification of product.

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Customer Property CONSULTANT shall exercise care with customer property while it is under the CONSULTANT’s control or being used by CONSULTANT. CONSULTANT shall identify, verify, protect and safeguard all customer property. Any incident of loss and damage or otherwise found to be unsuitable, OWNER shall be notified timely.

7.6.3

Preservation of Project Materials This responsibility shall be directly under SUPPLIERs and CONTRACTORs supervision. A system should be developed to handle materials identification, handling, packaging, storage and protection in a proper manner. CONSULTANT’s field personnel shall be responsible to monitor and verify this activities on behalf of CONSULTANT.

7.6.4

Control of Monitoring and Measuring Devices Softwares used by CONSULTANT during basic engineering shall be required for verified and confirm for its ability to satisfy the intended application prior to initial use and reconfirmed as necessary. For other monitoring and measuring devices used in procurement, construction and commissioning, the responsibility shall rest with the SUPPLIERs and CONTRACTORs. CONSULTANT shall monitor and verify the activities conducted and review the records for compliance.

7.6.5

Liaison with Local Authority and Regulatory Bodies CONSULTANT’s commitments to ensure all statutory and regulatory requirements, are adhered to by all parties involved in the project. For approvals, which are directly under the supervision of CONSULTANT, the Logistic /Liaison Officer shall be responsible for the overall coordination of the regulatory approval process, and to act as the project contact person with regulatory authorities. For other approval process directly under CONTRACTOR’s supervision, CONSULTANT’s responsibility is to monitor CONTRACTOR’s activities and verify the status of each approval. Support from other departments or group within CONSULTANT’s organization will be obtained as necessary.

8.0

MEASUREMENT, ANALYSIS & IMPROVEMENT

8.1

Customer Satisfaction Customer complaints or feedbacks shall be noted from CONSULTANT’s interfacing with OWNER in official meetings, correspondences, and also in nonofficial daily interfaces. Any CONSULTANT personnel can report any customer complaints or feedback to the QA/QC Engineer. QA Engineer will evaluate and verify the complaints and check the validity of the complaint with customer. If valid, the Customer Complaint Notice (CCN) shall be raised and forwarded to the Project Manager for corrective and preventive actions.

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Customer satisfaction survey shall also be conducted to measure customer satisfaction on CONSULTANT’s performance during the specified intervals. Results from the survey shall be analyzed and corrective/preventive actions, if any, shall be identified and implemented. 8.2

Quality Audits 8.2.1

Internal Audits The responsibility for coordination of internal quality audits on the activities of the project team rests with the QA Department. Audits performed on the activities of the QA Department shall be performed by a team from one of the functional groups, preferably the engineering group and coordinated by the Project Manager. All quality audits shall be performed in accordance CONSULTANT's procedure, Project Audits, QA-PR-005

with

A program identifying the nature and timing of internal quality audits shall be prepared jointly by the QA and functional departments, and approved by the Project Manager at the commencement of project activities. This program shall be updated by the QA Department monthly. 8.2.2

External Audits CONSULTANT is committed to ensure all parties in the project shall adhere to the contractual requirement. CONSULTANT shall conduct external audit on SUPPLIERs, CONTRACTORs and SUBCONTRACTORs involve in the project to measure the performance of other parties. The audit shall be based on the SUPPLIERs’ and CONTRACTORs’ quality management system processes. The CONSULTANT’s procedure Project Audits, QA-PR-005 shall be applicable.

8.3

Monitoring and Measuring of Product and Processes. 8.3.1

Quality Control Surveillance All required quality control inspection and test shall be identified and documented in Inspection and Test Plan (ITP). This ITP shall be reviewed and approved by CONSULTANT. In general, the responsibility of conducting the inspection and test shall rest with the CONTRACTOR and for the CONSULTANT, unless specified otherwise; the responsibility is to witness or review records. For critical product features, CONSULTANT may require a HOLD POINT to inspect the product.

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Work Processes Monitoring and Measuring Beside inspection and test on products, monitoring and measuring of processes shall also be conducted by CONTRACTOR to ensure acceptable final product is achieved consistently. Regular surveillance on critical work parameters or variables by CONTRACTOR’s personnel at work site can ensure this consistency. CONSULTANT shall also assign its personnel to monitor and verify CONTRACTOR’s surveillance activities.

8.4

Non - Conformance Control 8.4.1

SUPPLIER’s and CONTRACTOR’s Non-Conformance CONTRACTOR and SUPPLIER shall be responsible for identifying, documenting, investigating, and resolving all nonconformities in accordance with applicable approved quality plans. The responsibility for the review of CONTRACTOR or VENDOR activities in addressing non-conformities, ensuring compliance with approved quality plans and procedures, and providing recommendations as to any necessary actions by the applicable VENDOR, CONTRACTOR, or CONSULTANT, shall rest with the QA Department. Reviews of VENDOR or CONTRACTOR non-conformance documentation shall be performed monthly, and summarized on a report to be evaluated by the Project Management Team. The responsibility rests with CONSULTANT to ensure that the CONTRACTOR or VENDOR fulfils responsibilities related to nonconformance control in each of the functional areas. Where it is necessary for CONSULTANT to identify non-conformances, they shall be identified, documented, investigated, and resolved in accordance with the procedure, Control of Contractor’s NonConformance, QA-PR-007.

8.4.2

CONSULTANT’s Non-Conformance CONSULTANT shall be responsible for identifying all deviations or nonconformities on the requirements of engineering design and project management. For those situations when an event is identified or when a method, an approach or an action by CONSULTANT, if allowed to proceed are likely to result into non-conformities, a Quality Alert is to be used to document and resolve the situation.

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For those situations when a non-conformity is actually observed and confirmed, a Non-Conformance Report (NCR) shall be raised against the doer of the non-conformity. Correction action must be taken immediately to prevent further unintended use or delivery to the downstream processes. All non-conformance incidents must be thoroughly investigated to identify appropriate corrective action (refer section 8.6.2) in order to prevent recurrence. The management of the NCR shall be in accordance with the procedure Control of CONSULTANT’s Non-Conformances, QA-PR006.

8.5

Analysis of Data Methods for analysis of data shall be identified in accordance to the suitability of the methods to project execution and OWNER’s requirement. Specific meetings shall be conducted, whenever necessary, to analyze any non-conformances or potential non-conformances, characteristics and trends of processes. The overall project performance shall be documented in Project Close-Out Report.

8.6

Improvement 8.6.1

Continual Improvement CONSULTANT is committed to continually improve the effectiveness of the quality management system through the use of quality policy, project objectives, audit results, analysis of data, corrective and preventive actions and management reviews.

8.6.2

Corrective Action Using appropriate investigation and analysis of data technique, CONSULTANT shall attempt to identify the root cause of a nonconformance incident. This is applicable to both internal and external parties’ non-conformities. CONSULTANT’s procedure, Control of CONSULTANT’s Non-Conformances, QA-PR-006 and Control of CONTRACTOR’s Non-Conformances, QA-PR-007 is established to define the process of identifying corrective action and the documentation associated to it.

8.7

Preventive Action All potential non-conformances are recorded in Quality Alert Report (QAR). Similar to NCR, QAR is issued to individual or department where the potential non-conformities are anticipated. QAR must be validated by QA Department prior to issuance. Action taken by the QAR recipient shall be recorded in QA/QC. CONSULTANT procedure, Control of Potential Non-conformance, QA-PR-004 is established to define management of QAR.

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APPENDIX A LIST OF PLANS AND PROCEDURES

FUNCTIONAL DESCRIPTION

DOCUMENT NO

DOCUMENT DESCRIPTION

PM-PR-001

Project Document Filing System

PM-PR-002

Document Numbering System

PM-PR-003

Invoicing Procedures

PM-PR-004

Communication & Correspondence Control

QA-PL-001

Project Quality Manual

QA-PL-002

Project Execution & Quality Plan

QA-PR-001

Document Control

QA-PR-003

Control of Project Records

QA-PR-004

Control of Potential Non-Conformance

QA-PR-005

Project Audits

QA-PR-006

Control of CONSULTANT’s Non-Conformances

QA-PR-007

Control of CONTRACTOR’s Non-Conformances

PC-PR-001

Contract Change Management

Project Controls

PC-PR-00

Trending Monitoring Procedure

Engineering

EN-PR-001

Monitoring & Verification of Engineering by OTHERS

Procurement

PO-PR-001

Procedure for Monitoring & Verification of Procurement by OTHERS

Construction

CO-PR-001

Monitoring of Verification of Construction by OTHERS

Commissioning

CM-PR-001

Monitoring and Verification of Commissioning by OTHERS

HSE

SF-PL-001

Project Safety Plan

Project Management

Quality Assurance

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APPENDIX B PIM DOCUMENT STRUCTURE FOR THAR JATH DEVELOPMENT PROJECT PCC AND EPCC STAGE

PROJECT IMPLEMENTATION MANUAL

PROJECT EXECUTION & QUALITY PLAN (QA-PL-002)

PROJECT QUALITY MANUAL (QA-PL-001)

PROJECT

QA

ENGINEERING

PROCUREMENT

CONSTRUCTION

COMMISSIONING

Project Document Filing System (PM-PR-001)

Document Control (QA-PR-001)

Monitoring & Verification Of Engineering WORKS by Others (EN-PR-001)

Monitoring & Verification Of Procurement WORKS by Others (PO-PR-001)

Monitoring & Verification Of Construction WORKS by Others (CO-PR-001)

Monitoring & Verification Of Commissioning WORKS by Others (CM-PR-001)

Document Numbering System (PM-PR-002) Invoicing Procedures (PM-PR-003) Communication & Correspondence Control (PM-PR-004) Contract Change Management (PC-PR-001)

Requirement for Preparation of Project Document (QA-PR-002) Control of Proj. Records (QA-PR-003) Control of Potential NC (QA-PR-004) Project Audit (QA-PR-005) Control of CONSULTANT’s NonConformances (QA-PR-006) Control of Contractor’s Non-Conformances (QA-PR-007)