Master Project Quality Plan J80-1501

Bright East Steel Factory
CONT#.: 6510728588 No. : BESCO-MS-J80-1501-1
Project Quality Plan Rev. : 00

JOB #.: J80-1501
Issued Date : 27-July-2015
BI-10-01610
INSTALL HYDROCRACKER GAS SCRUBBER

PROJECT
(RAS TANURA)
SUPPLYING, FABRICATION, GALVANIZING &

DELIVERY OF STEEL STRUCTURE
EFFECTIVE DATE: JUNE-09-2015

NEXT PLANNED UPDATE: FEBRUARY-2016
BESCO General Use Only 1

PROJECT QUALITY PLAN
J80 1501 Install Hydrocracker Gas Scrubber
REMARKS:

Approval Sheet
This project quality plan was reviewed and accepted for

implementation for Install Hydro Cracker Gas Scrubber
Project.
Recommended By: Besco
M. ARFAN Project Quality

Manager
Name Role Signature Date
Approved By: ARAMCO
Name Role Signature Date
Revision History Sheet

A First Draft PQM PM 08/26/2015

Rev. Description Recommended Approved Effective
By By Date
List of Acronyms
BI Budget Item
CAR Corrective Action Report
TOD Terminal Operations Department
EDR Equipment Deficiency Report
ERA Expenditure Request Approval
GI General Instruction

ID Inspection Department
IFP Invitation For Proposal
ITP Inspection and Test Plan
LSTK Lump Sum Turn-Key
MPQP Master Project Quality Plan
NCR Non-Conformance Report
MSAE Mandatory Saudi Aramco Engineering
R
NMR Requirements
Non-Material Requirements
PID Project Inspection Division
PM Project Manager
PP Project Proposal
NAPD Northern Area Projects Department
PQI Project Quality Performance Indices
PQM Project Quality Manager
PQP Project Quality Plan
QA Quality Assurance
QC Quality Control
QMIS Quality Management Information System
SAEP Saudi Aramco Engineering Procedure
SAES Saudi Aramco Engineering Standards
SAIR Saudi Aramco Inspection Representative
SAMSS Saudi Aramco Materials Specification
SAPMT Standards
Saudi Aramco Project Management Team
VID Vendors Inspection Division
Table of Content
DESCRIPTION PAGE
REMARKS: II
APPROVAL SHEET II
REVISION HISTORY SHEET III
LIST OF ACRONYMS IV
TABLE OF CONTENT V
QUALITY POLICY STATEMENT VI
QUALITY OBJECTIVE VII
1 SCOPE 17
1.1 GENERAL...................................................................................................................... 17

1.2 DESIGN BASIS................................................................................................................. 17

1.3 PROJECT SCOPE.............................................................................................................. 17
1.4 APPLICATION................................................................................................................. 17
2.1 SAUDI ARAMCO STANDARD CONTRACTS SCHEDULES..................................................................18
2.2 SAUDI ARAMCO GENERAL INSTRUCTION MANUAL.....................................................................18
2.3 SAUDI ARAMCO ENGINEERING STANDARDS.............................................................................18
2.4 SAUDI ARAMCO INSPECTION PROCEDURES..............................................................................18
2.5 INTERNATIONAL STANDARDS............................................................................................... 18
3 TERMS AND DEFINITIONS 18
3.1 GENERAL...................................................................................................................... 18
4 QUALITY MANAGEMENT SYSTEM 18
4.1 GENERAL REQUIREMENTS.................................................................................................. 18
4.2 DOCUMENTATION REQUIREMENTS.......................................................................................18
5 MANAGEMENT RESPONSIBILITY 19
5.1 MANAGEMENT COMMITMENT............................................................................................ 19
5.2 CUSTOMER FOCUS........................................................................................................... 19
5.3 QUALITY POLICY............................................................................................................. 19
5.4 PLANNING..................................................................................................................... 19
5.5 RESPONSIBILITIES, AUTHORITY AND COMMUNICATION................................................................20
5.6 MANAGEMENT REVIEW..................................................................................................... 24
6 RESOURCE MANAGEMENT 25
6.1 PROVISION OF RESOURCES................................................................................................. 25
6.2 HUMAN RESOURCES........................................................................................................ 25
6.3 INFRASTRUCTURE............................................................................................................ 25
6.4 WORK ENVIRONMENT...................................................................................................... 25
7 PRODUCT REALIZATION 25
7.1 PLANNING OF PRODUCT REALIZATION...................................................................................25
7.2 CUSTOMER-RELATED PROCESSES.......................................................................................... 26
7.3 DESIGN AND DEVELOPMENT............................................................................................... 26
7.4 PURCHASING.................................................................................................................. 27
7.5 PRODUCTION AND SERVICE PROVISION..................................................................................28
8 MEASUREMENT, ANALYSIS AND IMPROVEMENT 29
8.1 GENERAL...................................................................................................................... 29
8.2 MONITORING AND MEASUREMENT.......................................................................................29
8.3 CONTROL ON NON-CONFORMING PRODUCT...........................................................................31
8.4 ANALYSIS OF DATA.......................................................................................................... 31
8.5 Improvement.............................................................................................................. 32
Quality Policy Statement
‫بسم الله الرحمن الرحيم‬
QUALITY POLICY ‫سياسة الجودة‬

Achieving customers’ satisfaction during ‫إحراز رضاء العمالء خالل‬

Fabrication of Steel Structures as per their ‫طبقا لما ورد في‬..………
specifications & requirements. ‫امواصفات و المتطلبات‬.
Continual improve the whole system to exceed ‫التحسين) المستمر للنظام حتى‬
customers’ expectations through measurement/ ‫تجاوز توقعات العمالء عن‬
‫طريق القياس و المقارنة و‬
comparison and taking necessary corrective
)‫اتخاذ االجراءات) التصحيحية‬
activities accordingly. ‫المناسبة والضرورية‬
Precise implementation of the ISO 9001: 2008 ‫تنفيذ نظام ادارة الجودة ايزو‬
Quality Management System. ‫ بدقة‬2008:9001
Encouraging training and learning culture ‫تعزيز) ثقافة التدريب و المعرفة‬

throughout the Company. ‫على مستوى كل المؤسسة‬
Improving welfare & safety of the employees. ‫تحسين مستوى راحة و سالمة‬
‫الموظفين‬
Quality Objective
‫بسم الله الرحمن الرحيم‬
QUALITY OBJECTIVES ‫أهــداف الجــــودة‬

Improving the level of agreed services

‫الرفع من كمية و جودة‬.
Products.
Improving the variety of Services/Products. ‫الرفع من قدر تنوع المنتج‬.
Continually improve customer satisfaction ‫التحسين المتواصل لمؤشر رضاء‬

Index. ‫العمالء‬
‫التحسين) المتواصل لكفاءة و‬

Continually improve staff skills and satisfaction. ‫رضاء الموظفين‬
‫التخفيض المتواصل لمستوى‬

Continually reduce the wastage level. ‫اإلستهالك‬
‫يساهم كل الموظفين في تحقيق‬

All staff shall contribute towards achieving ‫هذه األهداف) و ذلك بتجميع‬
these objectives by systematic data collection, ‫ اتخاذ) القرارات‬،‫منهجي للبيانات‬
timely decisions and finally enforcing agreed ‫في الوقت المناسب وتنفيذ‬
corrective/preventive actions truly and timely. ‫ الوقائية‬/ )‫االجراءات) التصحيحية‬
‫المتفق عليها في الحين و باخالص‬
BESCO is awarded by Saudi ARAMCO to construct

(PIPE RACK) and fulfill Saudi Aramco’s commitment in
a reliable and cost-effective manner.
To achieve the above objective and satisfy the

Proponent`s expectations, BESCO is committed to
establish, measure, and maintain measurable quality
objectives and to develop and implement a Project

Quality Plan based on the requirements of the Saudi

Aramco Engineering Procedure (SAEP-1154)
Each project team (Inspection Department,

Proponent, and Contractors) participant is personally
responsible for his work and to initiate actions to
ensure implementation of quality measures and
continuous quality improvement.

1 Scope
This Quality Plan is to establish the scope to be perform by BESCO pursuant to the
CONTRACT and describes or references the applicable drawings, standards and
specifications, as well as the administrative, procedural and technical requirements that
BESCO shall satisfy or adhere to in the performance of the work.
1.1 General
BESCO shall, in accordance with and subject to the terms & conditions of the Contract,
perform all operations, works, services and other related activities required and
necessary for the timely and satisfactory completion of supplying, Fabricating,
Galvanizing and delivering of the Steel Structure to Site.
1.2 Design basis
The new Pipe Rack has been design for Hydrocracker Gas Scrubber in critical
combinations and locations.
1.3 Project Scope

Contractor shall:
a. Draw shop drawings ready for fabrication (i.e. Erection Schemes).
b. Procure all materials required for the steel structure.
c. Supply, fabricate and galvanize all steel structures according to SAES-H-001.
d. Perform all required test and inspection as per 12-SAMSS-008 and 12-
SAMSS-007.
e. Transport and deliver all materials at project location “Hydrocacker Unit
(J80) at Ras Tanura refinery”.
f. Carry out the work with due diligence, skills and efficiency in accordance with
sound principles prevailing within the industry and acceptable to SAUDI
ARAMCO.
g. Notify SAUDI ARAMCO in advance and in timely manner for any inspection
to take place in order for SAUDI ARAMCO to arrange with all interested
parties to inspect work.
h. Prior to start of work (fabrication of structure), submit method statement
and/or all applicable procedures of fabrication, Galvanizing and shipping for
the work for SAUDI ARAMCO’s review and approval. Such approval shall in
no way relieve BESCO of any of its obligations under the contract.
i. Field verification of any fabrication errors.
j. Delivery of missing bolts/members/drawings.
k. Updating of any BESCO drawings.
l. Coating touchup of any re-works.
1.4 Application
This quality plan applies to all Works and personnel directly related to the Project.

2. References
2.1 Saudi Aramco Standard Contracts Schedules

 Schedule Q “Quality Assurance and Control, Inspection and Testing”
2.2 Saudi Aramco General Instruction Manual
 SAEP-1154 Engineering Procedure
2.3 Saudi Aramco Engineering Standards

 12-SAMS-008 Erection of Structural and
 12-SAMS-007 Fabrication of Structural and Miscellaneous Steel
 SAES-H-001 “Coating Selection and Applicable requirements for
Industrial Plants & Equipment.
 SAES-H-101V “Saudi Aramco approve data sheets- Paints & Coatings”
 PIP STF05501 “Fixed Ladders and Cages”
 PIP STF05520 “Details for Pipe Railing for Walking and Working Surfaces”
 SAES-B-006 “Fireproofing for Plants”
 AD-03671-001 “Concrete Fireproffing for structural Members”
2.4 Saudi Aramco Inspection Procedures

 SA Form-175 “Inspection & Testing Requirements”
2.5 International Standards

 ISO 9001-2008 “Quality Management System Requirements”
3 Terms and Definitions
3.1General
3.1.1 For the purpose of this quality plan, the general quality terms and
definitions given in the international standards ISO 9000 apply.
3.1.2 List of acronyms used in this document is given in the preceding pages of the
Quality Plan.
4 Quality Management System
4.1 General Requirements

4.1.1 This Project Quality Plan (PQP) describes the structure, procedures,
elements and processes to implement quality management system for J80 1501. It
also defines the roles and responsibilities of BESCO Inspection Department (ID) for
the Quality of the facilities being provided to SAUDI ARAMCO under the scope of the
project.

4.2 Documentation Requirements
4.2.1 General
4.2.1.1 This PQP complies, as applicable, with the requirements of ISO-9001-2008
“Quality Management Systems - Requirements” and SAEP-1154 “Guidelines for
Contractor’s Quality Plan”.
4.2.2 Quality Manual

4.2.2.1 QMS-BESF-01.
4.2.3 Control of Documents

4.2.3.1 This PQP is a controlled document, and Project Quality Manager (PQM) and the
Project Manager (PM) shall approve revisions. This PQP will be revised and
updated as a minimum at thirty percent (30%) completion of the design phase
and at forty percent (40%) completion of the Fabrication phase. PQM will update,
control and distribute all revisions and minor amendments to the concerned
stakeholders and maintain a log of all controlled copy.
4.2.4 Control of Records

4.2.4.1 PQM will establish and maintain records to provide evidence of effective
implementation of quality plan, to verify the progress towards achieving the plan
objectives, and to document the continuous improvement of the quality
measures.
4.2.4.2 All records will be maintained readily identifiable and retrievable.
5 Management Responsibility
5.1 Management Commitment

5.1.1 This PQP documents the agreement on, and commitment to, the project scope of
work requirements, all SAUDI ARAMCO standards and specifications, mandatory
standard drawings, COMPANY adopted national or international codes and
standards and project specifications by the Saudi Aramco Project Management
Team (SAPMT) and Inspection Department (ID). This is accomplished through
careful evaluation of the project objectives during Project Proposal preparation to
ensure the optimum results.
5.1.2 This PQP demonstrates the project team commitment to establish and maintain
quality objectives and outline the steps required to achieve and maintain these
objectives.
5.1.3 This PQP also demonstrates the project team commitment to communicate the
importance of meeting the stakeholders’ expectations and the commitment to
ensure the adequacy and availability of resources.
5.2 Customer Focus

5.2.1 Not Applicable.

5.3 Quality Policy

5.3.1 BESCO Quality Policy Statement is given in the forward pages of this quality plan.
This policy statement is fully adopted for this project.
5.4 Planning
5.4.1 Quality Objectives

5.4.1.1 This PQP establishes the basis for the Project Quality Performance Indices
and is the benchmark from which all subsequently considered Quality changes are
measured.
 Project Quality Performance Index (PQI): ≥ 88%
 Equipment Deficiency Report (EDR): Zero
 Weld Rejection Rate (on joint basis): ≤ 5%
 RFI acceptance Rate: ≥ 95%
 RTFI Assessment Disagreement: ≤ 5%
 NCR Ratio (Company: Contractor): 1:10
 SA Worksheet: Zero
 Response time by Construction agency to QMIS entries: ≤ 48 hrs
 Repeated Violations for total violations reported: ≤ 5%
5.4.2 Quality Management System Planning

5.4.2.1 The planning of quality management system involves establishing and
maintaining an integrated system that is based on the following strategies:
 Recognize and eliminate the cause of potential non-conformities to prevent
their occurrence.
 Careful review of quality procedures and inspection and test plan prior to
granting approval.
 Perform early review and evaluation of quality procedures for practicality
and level of implementation and initiate timely process improvement
measures.
 Share previous Projects Lessons Learned with Clients.
 Emphasize the importance of quality personnel qualifications and ensure
that only competent personnel are accepted for the project.
 Conduct planned technical focused quality assessment of special processes,
in addition to the scheduled assessment by the CONTRACTOR and Inspection
Department Assessment Group.
 Measure the total Quality Performance through monthly scheduled PQI
evaluation and review with SAPMT and Contractor.
5.5 Responsibilities, Authority and Communication
5.5.1 Responsibility and Authority

5.5.1.1 This Master Project Quality Plan is the tool used by the BESCO Mnagement
to ensure that the responsibilities and authorities of key project team members are
identified and communicated within the project team.
5.5.1.2 Organization charts for the project with interfaces are illustrated in
Attachment I.

5.5.1.3 Responsibilities of BESCO Project Management Department Manager and

the Inspection Department Manager.
5.5.1.4 Project Manager Responsibilities

5.5.1.4.1 Has the overall quality responsibility during all phases of the project.
5.5.1.4.2 Ensure, along with the PQM that the Contractor, subcontractors, and
vendors possess and implement quality management systems per the
requirement of Schedule “Q”.
5.5.1.4.3 Provide follow up on the project objectives and ensure that performance
targets are met during the life of the project.
5.5.1.4.4 Ensure that the project has the required resources to accomplish various
activities of the project.
5.5.1.4.5 Resolve ID/Project Management conflicts, if any.
5.5.1.4.6 Promote and build awareness of the project quality requirements.
5.5.1.4.7Ensure effective communication among all project stakeholders.
5.5.1.5 Project Quality Manager Responsibilities:

5.5.1.5.1 The PQM will review all new potential Quality Systems to ensure that bidder
has and maintains quality system in accordance with the requirements of
Schedule “Q”.
5.5.1.5.2 The PQM shall ensure that Contractor develops, implements, and maintains
a Quality Plan according to Schedule “Q”.
5.5.1.5.3 Prepare, update, control and distribute the Master Quality Plan.
5.5.1.5.4 Initially determine the ID manning level and Mobilization Plan for the
various phases of the project.
5.5.1.5.5 Finalize Inspection level for equipment and material, and the minimum
contractor inspection manning levels to be included in Schedule “Q” of the
Contract.
5.5.1.5.6 Coordinate all inspection activities for the project throughout all the project
phases.
5.5.1.5.7 Assign Inspection Representative(s) to attend the Job-Explanation meeting
as well as the Kick-off meeting to present Schedule “Q” to the potential &
successful bidders.
5.5.1.5.8 Ensure preparation of NCRs for issuance by Project Management.
5.5.1.5.9 Resolve ID/Project Management conflicts, if any.
5.5.1.5.11 Initiate focused assessments of specific work elements (Construction Phase)
to ensure that the project quality activities and processes are effective.
5.5.1.5.12 Maintain Project Performance Quality Index (PQI) per established system.
5.5.1.5.13 Discuss PQI with the Contractor and the Project Manager.
5.5.1.6 Project Engineer quality responsibilities will include but not limited to:
5.5.1.6.1 Implementation of the PQP.

5.5.1.6.2 Ensure along with the Inspection Representative(s) that the Contractor(s),
sub-contractors and vendors implement project quality requirements in
accordance with the Contract.
5.5.1.6.3 Ensure the review and approval of the QA/QC personnel by the Inspection
Representative(s).
5.5.1.6.4 Ensure that a Project Management member acknowledges all QMIS latest
Version shall be used to record Project Quality Issues, PM Member provides
response to QMIS entries in the system in timely manner
5.5.1.6.5 Resolve all deviations identified by Inspection Representatives with the VID
and address all open issues in regular Project Management/Contractor
meetings.
5.5.1.6.6 Control of design review and changes.
5.5.1.6.7 Control of all technical information received from, and issued to, other
departments, contractor(s), sub-contractors and vendors
5.5.1.6.8 Shall have SAP role to process tasks for NCR/WS if any.
5.5.1.6.9 Shall attend weekly Quality meeting along with Inspection.
5.5.1.6.10 Track status of all issued Non-conformance Reports/Worksheets.
5.5.1.6.11 Obtain Inspection Representative’s concurrence prior to the NCR closeout.
5.5.1.6.12 Initiate Lesson Learned Implementation workshop at the early stage of
project.
5.5.1.6.13 Shall take lead to clarify any conflicts if any, raised against the requirements
of ID during project execution with CSD and as per SAEP-302.
5.5.1.6.14 Shall utilize SAP for Quality Transmittals to Inspection Department which
require Inspection review & approval in order to reduce hard copy transmittal.
5.5.1.7 Project Engineer responsibilities will include but not limited to:
5.5.1.7.2 Control of design review and changes.
5.5.1.7.3 Control of all technical information received from, and issued to, other
departments, contractors or vendors.
5.5.1.7.4 Inspect construction work and initial with dates all QMIS entries. (Response
time shall be 24 hours.)
5.5.1.7.5 Ensure technical compliance.
5.5.1.7.6 Maintain contact with other organizations within the Company for technical
issues related to the project.
5.5.1.7.7 Review material specifications, purchase requisitions and purchase orders.
5.5.1.7.8 Provide alternatives/suggestion to improve project quality, schedule and
cost.
5.5.1.8 Saudi Aramco Inspection Representative (SAIR):

5.5.1.8.1 The SAIR is the representative of the PQM during the design and
procurement phases and normally he is the focal point for all quality matters on
the project during these phases. His responsibilities are detailed in SAEP-1150
and VID-M-016 and the following list contains the main ones.


5.5.1.8.3 Participate in the Bid Explanation Meeting and the Kick-off meetings for
various project phases.
5.5.1.8.4 Review the contractor quality plans and make sure that they meet the
minimum requirements per Schedule “Q” of the Contract.
5.5.1.8.5 Review the purchase documents and verify the qualifications of selected
suppliers.
5.5.1.8.6 Participate or arrange for the Company participation in the pre-inspection
meetings for purchase orders and verify the qualifications of the proposed
QA/QC personnel.
5.5.1.8.7 Arrange for the Company source inspection at vendor site according to the
approved ITP of purchase orders.
5.5.1.8.8 Ensure with the project engineers that the required fabrication and
manufacturing special processes are available and approved by the approval
authorities per the contract requirements.
5.5.1.8.9 Review inspection reports received from Contractor’s inspectors as well as
the Company inspectors and communicate findings to SAPMT.
5.5.1.8.10 Prepare NCR for SAPMT approval and issuance to Contractor for the
unresolved quality violation and concerns.
5.5.1.8.11 Arrange for company quality assessments and participate in the Contractor’s
quality audits.
5.5.1.8.12 Track and maintain quality records
related to the project.
5.5.1.9 Project Inspection Representative:

5.5.1.9.1 The Project Inspection Representative is the representative of the PQM
during the construction phase and normally he is the focal point for all quality
matters on the project during this phase. His responsibilities are detailed in
SAEP-1150 and the following list contains the main ones:
5.5.1.9.3 Participate in the preconstruction
meeting.
5.5.1.9.4 Review the Contractor quality plan, quality procedures, and the inspection
and test plan.
5.5.1.9.5 Verify the QA/QC personnel qualifications and the level of coverage from
the Contractor side.
5.5.1.9.6 Perform continuous quality monitoring on all construction activities and
arrange for special assessment sessions on various quality control aspects of the
project.
5.5.1.9.7 Arrange and coordinate the Company inspection activities and ensure that
adequate resources are available to meet the inspection and testing
requirements.
5.5.1.9.8 Maintain QMIS latest version and highlight potential and occurred violations
to SAPMT
5.5.1.9.9 Concur Weekly Quality Meeting Minutes.

5.5.1.9.10 Provide awareness / training required for utilizing SAP workflow to PMT for
Quality Transmittals. The advantages of utilizing SAP are
 Standardize & control Submittals Process
 Maintain permanent record in SAP
 Easy tracking / retrievable / utilizing
 Utilizing workflow system
 Easy to monitor quality status
 Globally accessible
 Reduce paperwork
5.5.1.9.11 Prepare NCR for issuance by SAPMT.
5.5.1.9.13 Arrange for focused assessments of specific work elements to ensure that
the project quality activities and processes are effective.
5.5.1.9.14 Participate in the mechanical acceptance activities per the guidelines of GI-
2.710.
5.5.1.9.15 Track and maintain quality records related to the project.
5.5.1.10 Contractor Responsibilities:

5.5.1.10.1 The Contractor’s and Sub-Contractor’s Management Responsibilities for the
Project quality shall be described in their Quality Plan and in accordance with
Schedule “Q” requirements.
5.5.2 Management Representative

5.5.2.1 The Management Representative for Quality is the Project Quality Manager as
per GI-400.001.
5.5.2.2 The PQM or his designated representative shall ensure that the Contractor
ensures that all vendors, suppliers, sub-suppliers and manufacturers has and
maintains quality system as per Schedule “Q”.
5.5.2.3 During all phases, PQM or his representative(s) will review and approve
Contractor quality plans, QA/QC procedures and Inspection and Test Plans
(ITP’s) prepared by contractors in accordance with Schedule “Q” to determine if
the Contractors’ commitment, organization, quality system, personnel and
processes are adequate to achieve contractual and project requirements.
5.5.3 Internal Communication

5.5.3.1 General
5.5.3.1.1 The Project Manager is responsible for ensuring the implementation of this
Project Quality Plan and overall project activities.
5.5.3.1.2 Project Manager shall ensure that quality objectives are established and met
at all levels within the organization.
5.5.3.1.3 The efforts of all stakeholders shall be taken to complement each other as
one Saudi Aramco project team.
5.5.3.1.4 The Organization Chart for the Project with interfaces is illustrated in
Attachment I.
5.5.3.1.5 The roles, responsibilities and interface between the Project Management
and the Inspection Department (ID) are prescribed in GI-400.001 “Quality

Management Roles and Responsibilities”. In addition, Inspection Department
responsibilities during design, procurement, construction and pre-
commissioning phases are detailed in Saudi Aramco Engineering Procedure
SAEP-1150 “Inspection Coverage on Projects”.
5.5.3.1.6 Project Quality Manager (PQM) will work closely with PMT to interface with
Project Management on all inspection matters from the Project Proposal Phase
through Mechanical Completion and ensure that the project quality
requirements are met.
5.6 Management Review
5.6.1 General
5.6.1.1 Formal management review for Install Hydrocracker Gas Scrubber project will be
scheduled and conducted during Design and Procurement Phase.
5.6.1.2 PM will maintain the schedule and the records from the management reviews.
5.6.1.3 Within three weeks before the review due date, PM will call for the
management review and finalize the exact date of the review.
5.6.1.4 Management review participants shall include the following management
personnel or their delegates:
 SAPD Manager
 Inspection Department Manager
 PID Superintendent
 VID Superintendent
 SAPMT Project Manager
 Proponent Representative
 Sr. Project Engineer
 Project Quality Manager
 SAIR
 Contractor and main subcontractor project managers
 Contractor and subcontractor QA/QC managers
5.6.2 Review Input

5.6.2.1 The input to the management review will include information on:
 Project status,
 Results of audits and status of identified corrective actions,
 Results and recommendations of the Contractor’s management review,
 Project performance indices,
 Follow-up action from previous management reviews,
 Concerns that might affect the quality management system.
5.6.3 Review output

5.6.3.1 The output of the management review would include any decisions and actions
related to:
 Improvement of the effectiveness of the project quality management
system and its processes,
 Resources needs.

6 Resource Management
6.1Provision of Resources
6.1.1 PM will determine and arrange for the resources needed for the effective
execution of the project.
6.1.2 PQM will determine and arrange for inspection resources to ensure the
effectiveness of the project quality management system and its processes.
6.2 Human Resources

6.2.1 General
6.2.1.1 PM with the help of the PQM will ensure that personnel affecting the project
quality are competent on the basis of appropriate education, training, skills, and
experience.
6.2.1.2 All contractors’ quality personnel will be evaluated and qualified per the
requirements of Schedule “Q”.
6.2.2 Competence, Awareness, and Training

6.2.2.1 This quality plan, project proposal package, and the contract schedule are base
documents from which the awareness of the project requirements shall start.
6.2.2.2 PM will promote and build awareness of the project requirements within all
Saudi Aramco personnel assigned to the project.
6.2.2.3 PQM ensure that all Quality personnel are aware of the project requirements.
6.3 Infrastructure
6.3.1 Project Management will determine, provide, and maintain the
infrastructure needed during the execution of the project for all personnel fully
assigned to the project including Inspection Department personnel.
6.3.2 Infrastructure includes workspace and associated utilities, work equipment
and tools such as computers, copy machines, fax machines and stationeries, and
supporting services such as communications.
6.4 Work Environment

6.4.1 PM with the help of PQM and other leaders of project stakeholders will
build and maintain teamwork relationships among all individuals assigned to the
project and will ensure a healthy work environment during the project life.
6.4.2 PM will arrange Special Access if any required for work site for all personnel
fully assigned to this project including Inspection Department Personnel.
7 Product Realization
7.1 Planning of Product Realization

7.1.1 Planning of product realization for this project will follow the established
Saudi Aramco procedures. Project proposal stage is considered the stage where all
requirements of the project are identified.

7.1.2 This quality plan identifies the quality objectives of the project. (refer to
section 5.4.1)
7.1.3 Specific required verification, validation, monitoring, inspection, and test
activities would be developed by the Contractor and reviewed by the project team
against the various Saudi Aramco requirements as parts of the Contractor’s quality
management system.
7.2Customer-related Processes
7.2.1 Not applicable.
7.3Design and Development
7.3.1 Design and Development Planning

7.3.1.1 Project Management Team will identify the design and development stages
and will determine the review, verification, and validation that are appropriate to
each design and development stage.
7.3.1.2 PM and PQM will ensure that the design contractor is implementing
a written procedure for the design control and that procedure is in compliance
with the project requirements.
7.3.2 Design and Development Inputs
7.3.2.1 Project DBSP and the project proposal package constitute the determined
design and development inputs.
7.3.2.2 All the project stakeholders, in accordance with the requirements SAEP-14
and SAEP-303, will review these design inputs during the project proposal stage.
7.3.3 Design and Development Outputs

7.3.3.1 PM will ensure that the outputs of design and development are provided in
a form that enables verification against the development and design inputs.
7.3.3.2 PM will make available, control, and maintain a copy of all project
documents such as specification and drawings and data available at work place
for use by project stakeholders.
7.3.4 Design and Development Review

7.3.4.1 PM will ensure that systematic reviews of design are performed in
accordance with the requirements of SAEP-303.
7.3.4.2 PM will ensure that records of review comments along with the comment
resolution status are maintained.
7.3.4.3 PM and PQM will ensure that the design contractor is implementing a
written procedure for internal design review prior to issuing the design
documents for Saudi Aramco review.
7.3.5 Design and Development Verification

7.3.5.1 PM will ensure that design verification is performed in accordance with
planned arrangements to ensure that the design and development outputs met
the input requirements.

7.3.5.2 PM will ensure that the Contractor is maintaining records of the verification
results.
7.3.6 Design and Development Validation

7.3.6.1 PM will ensure that design validation is performed in accordance with
planned arrangements to ensure that resulting products is capable of meeting
the specified application or the intended use.
7.3.6.2 Wherever applicable, validation process for purchased equipment will be
done at the manufacture site prior to shipping the equipment to the project site.
7.3.6.3 PM will ensure that the contractor is maintaining records of the validation
results.
7.3.7 Control of Design and Development Changes

7.3.7.1 PM with the help of PQM will ensure that the Contractor is implementing
and maintaining written procedures to control the design and development
changes at all stages of the project.
7.3.7.2 PM and PQM will ensure that all changes to the design and development are
documented and maintained in a location reachable by all project stakeholders.
7.3.7.3 PM and PQM will ensure that current revisions of design outputs are the
working copies and all obsolete or old revision are withdrawn and destroyed
according to a written procedures.
7.4 Purchasing
7.4.1 Purchasing Process

7.4.1.1 The PM or representative will ensure the Contractor define Procurement
QA/QC activities including the identification of critical products with Inspection and
Test Plans (ITPs) inclusive of Pre-Inspection meetings.
7.4.1.2 The PQM or representative will ensure requisition Packages reviewed and
meet project requirements which include SAES, SAMSS and SAEP-1151 associated
SA-175 forms and standard drawings and project procedure are in place and
acceptable at requisition development stage.
7.4.1.3 PM will ensure the resolution of review comments and incorporation of
comments is taking place prior to the PO placement.
7.4.2 Purchasing Information

7.4.2.1 PM and PQM will ensure that the purchase orders include the applicable
SAMSS, SAES, project specifications, standard drawings and applicable inspection
and testing requirements (SA-175 forms).
7.4.2.2 PM and PQM will ensure that the purchase orders include listing of required
Non-Material Requirements (NMR) referencing SA-7900 series form requirements
such as instructions, procedures, drawings, specification, vendor inspection plans,
inspection and test records.

7.4.3 Verification of Purchased Product

7.4.3.1 The PM or representative shall compile and forward to the PQM or
Representative, per the requirements of schedule Q, two (2) sets of the Contractor’s
Inspection Assignment Package. This shall include:
 A complete copy of the un-priced purchase order/Subcontract and list of
attachments.
 Copies of sub-supplier’s purchase orders.
 Inspection requirements per SAEP-1151 and associated form SA-175/s.
 An inspection assignment sheet specifying the QC person or agency that will
perform the QC function.
 The level of BESCO inspection.
7.4.3.2 Agendas for each pre-inspection meeting shall be submitted to the PM or
PQM COMPANY Representative with the Inspection Assignment Package.
7.4.3.3 BESCO shall maintain an effective system for continuity of order
identification that ensures that drawings, specifications, and inspection
requirements are properly transmitted to vendors at all tiers of order placement.
7.4.3.4 BESCO shall ensure that all vendors and manufacturers have and maintain
acceptable QA/QC programs in accordance with the relevant ISO-9000 Series
standards or equivalent. The CONTRACTOR shall perform quality audits and
maintain reports for this purpose.
7.5 Production and Service Provision
7.5.1 Control of Production and Service Provision

7.5.1.1 Project Manager or his designated representative and PQM shall ensure that
the Contractor handles, stores, preserves and delivers all project materials as
specified in all applicable specifications, manufacturer recommendations and SAUDI
ARAMCO standards.
7.5.1.2 Contractor’s Material Receiving Inspection Procedure shall be reviewed and
approved by the PQM. Project Inspection Team shall participate in the receiving
inspection activities. All inspectable material shall not be released for installation
until the receiving inspection is complete. PQM or his representative shall ensure
that the Contractor maintains records or receiving inspection findings.
7.5.2 Validation of Processes for Production and Service Provision

7.5.2.1 PQM or his representative shall ensure that the controls manufacturing
processes during procurement phase in accordance with Attachment III to Schedule
“Q”.
7.5.2.2 PQM or his representative shall ensure that the controls manufacturing
processes during construction phase in accordance with Attachment IV to Schedule
“Q”.
7.5.2.3 PQM or his representative shall ensure that the Contractor prepares
controls and operates procedures and systems to provide satisfactory control of all
processes. These processes and procedures shall be reviewed and approved by the
PQM or his representative.

7.5.2.4 PQM or his representative shall ensure that the Contractor provides
continuous monitoring of those processes that require such needs and their
compliance with documented procedures.
7.5.2.5 PQM or his representative shall ensure that the Contractor and its Sub-
Contractors implement suitable Preventive Maintenance of fabrication/installation
equipment.
7.5.2.6 PQM or his representative shall ensure that all special processes are
performed by qualified personnel using approved written procedures and controlled
equipment. All process parameters shall be identified with acceptance criteria
specified and monitored.
7.5.3 Identification and Traceability

7.5.3.1 Project Manager or representative(s) shall ensure and maintains a
quarantined area to control and track all non-conforming, suspect or rejected
material. Project Manager shall maintain Testing and Mechanical measurement
tools within calibration date during the life of project.
7.5.3.2 PQM or his representative shall ensure that controls of the material
identification and traceability in accordance with the Contract requirements.
7.5.3.3 PQM or his representative shall ensure that the controls non-conforming
materials is in accordance with Schedule “Q”.
7.5.3.4 Saudi Aramco supplied materials shall be identified and tracked as per
COMPANY procedures.
7.5.4 Customer Property

7.5.4.1 Not applicable.
7.5.5 Preservation of Products

7.5.5.1 PM and PQM will ensure that all project equipment and facilities are
maintained and preserved in accordance with the equipment manufacture
requirements and the requirements of the applicable standards and procedures.
7.5.6 Control of Monitoring and Measuring Devices

7.5.6.1 PM and PQM will ensure that the Contractor is implementing and
maintaining a written procedure for the control of monitoring and measuring
devices.
7.5.6.2 PQM will arrange periodic inspection and quality reviews to ensure the
effectiveness of the contractor quality procedure pertaining to the calibration and
control of measuring devices.
7.5.6.3 PQM will verify that all acceptance measurements are carried out using
calibrated equipment.

8 Measurement, Analysis and Improvement
8.1General
8.1.1 Project team will plan and implement monitoring and measurement processes to
demonstrate conformity of the project, ensure the implementation of this quality
plan, and to continually improve the effectiveness of the project quality system. This
will include the quality audits and continuous monitoring of the project indices and
objective measures.
8.1.2 PM and PQM will ensure in maintaining a program for measurement, analysis, and
improvement of his own quality system.
8.2 Monitoring and Measurement
8.2.1 Customer Satisfaction
8.2.1.1 Not applicable.
8.2.2 Internal Audit
8.2.2.1 The Inspection Department/Inspection Assessment Group [IAG] shall

conduct internal assessments of overall project quality per 00-SAIP-013 to ensure
the effectiveness of this Project Quality Plan and compliance with the Contract. As
a minimum, internal assessments shall be carried out at fifty percent [50%] of
completion stage for the Procurement and Construction WORK Phase.
8.2.2.2 PQM or his designated SAIR shall ensure that the Contractor develops and
implements an internal audit program covering all WORK Phases in accordance
with Schedule “Q”.
8.2.2.3 PQM shall ensure that all corrective action requests generated during the
assessments are controlled, tracked and corrected. Also, he shall ensure that
preventive measures are established to prevent re-occurrence of non-conformities.
8.2.2.4 During Procurement Phase, the SAIR will review Contractor’s internal and
vendor assessments and monitor results on an on-going basis. The SAIR may
observe the Contractor’s assessments, or if necessary, conduct his own
independent assessment. Findings, including CARs will be forwarded to SAPMT for
resolution with the Contractor.
8.2.2.5 During Fabrication Phase, the PQM will review internal assessment and
monitor results on an on-going basis. The PQM or his designated representative
may observe the assessments.
8.2.2.6 The PQM shall initiate focused assessment of specific work elements to
ensure that the project quality activities and processes are effective, e.g. welding
verification. All findings, including CARs shall be forwarded Saudi Aramco ID.
8.2.3 Monitoring and Measurement Of Processes

8.2.3.1 BESCO Inspection Team led by the PQM shall inspect the facilities during all
phases as per SAEP-1150 and GI 2.710.

8.2.3.2 PQM or his representatives shall inspect purchased materials/equipment

and closely implement in-process inspection and final inspection in accordance
with SAEP-1150, VID-M-16, SAEP-1151, SA 175 Forms and the approved Inspection
& Test Plan (I&TP).
8.2.3.3 PQM shall ensure that controls the inspection and testing during
procurement phase in accordance with Attachment III to Schedule “Q”.
8.2.3.4 PQM shall ensure that the Contractor controls the inspection and testing
during construction phase in accordance with Attachment IV to Schedule “Q”.
8.2.3.5 Contractor’s Material Receiving Inspection Procedure shall be reviewed and
approved by the PQM. Project Inspection Team shall participate in the receiving
inspection activities. All inspectable material shall not be released for installation
until the receiving inspection is complete. PQM shall ensure that the Contractor
maintains records of receiving inspection findings.
8.2.3.6 PQM shall ensure that the Contractor keeps the inspection status reports
current and available for SAUDI ARAMCO’s review at all times.
8.2.4 Monitoring and Measurement of Product

8.2.4.1 PQM shall established and maintain documented procedure for the control
of quality records in accordance with Schedule “Q” requirements.
8.2.4.2 PQM shall ensure that no fabrication starts prior to approval of special
processes procedures.
8.2.4.3 PQM shall conduct pre inspection meetings (as required) prior to start
manufacturing.
8.2.4.4 PQM shall ensure that all inspection points and requirements were
successfully completed prior to shipment.
8.2.4.5 PQM shall ensure to document and agree on outstanding inspection issues
that will be rectified.
8.2.4.6 Project Manager ensure that the Project Records is in accordance with the
Schedule “B” and SAEP-122.
8.2.4.7 PQM shall ensure and maintain Inspection Disposition Report in accordance
with Attachment III to Schedule “Q”.
8.2.4.8 The quality records control system of the Vendor Inspection Representatives
(SAIR) shall be standardized as per VID-M-016 “Procedures for SAIR” requirements
and this Master Project Quality Plan.
8.2.4.9 PQM shall use the standard filing system of Project Inspection Division (PID) to
control the construction quality records.
8.2.4.10 The Project Inspection Team members shall ensure that all quality records
identify the inspected item, the applicable requirements, the inspections
performed, the date of inspection, the inspector name, the result obtained and
the feedback on corrective and preventive actions.
8.3 Control on Non-Conforming Product

8.3.1 The Inspection Representative shall keep the Project Management representative
informed of all potential NCR’s.

8.3.2 The Inspection Representative shall document any violation to the Contract
requirements, with a copy to the PQM. He shall initiate NCR’s as required and
forward them to the Project Management Representative for issuance to the
contractor in accordance with GI400.001, SAEP-352, 12-SAMSS-007, 12-SAMSS-008,
SAES-H-001 and SAEP-1150.
8.3.3 When the Inspection Representative has generated a valid and agreed NCR that
was not issued by Project Management to the contractor as per SAEP-381 the
Project Quality Manager shall issue a Work Sheet to the Project Management
Representative.
8.3.4 Project Manager or his representative shall ensure that all non-confirming
materials are quarantined and not used for the project until one of the following
acceptable resolution is achieved:
 The non-conformance is waived as per SAEP-302.
 The non-conformance is corrected to meet COMPANY requirements.
 The non-conformance is scraped and replaced with new materials that meet
COMPANY requirements.
8.3.5 PQM or his representative(s) shall ensure that the Contractor’s quality plan
procedure and implementation for the control of non-conformance are in
accordance with Schedule “Q”.
8.4 Analysis of Data

8.4.1 The PQM will maintain Project Quality Index (PQI) as per the ID established system
to track and evaluate the Contractor.
8.4.2 The PQM shall maintain records of Project Quality Performance Indicators [e.g.
ratio of BESCO NCR’s versus Saudi Aramco, welder reject rate, repair, etc. ….) to
track and evaluate the projects quality status. The minimum frequencies of reviews
are shown on table below.
Measurement Frequency
Performance Index (PQI): Monthly
EDRs Monthly
NCRs Weekly & Monthly
Weld Rejection Rate Weekly
Repeat Violations Weekly & Monthly
Final Inspection Acceptance Rate Monthly
Response to E-log entries Weekly
RTFI disagreement Weekly
NDT backlog Weekly
8.4.3 BESCO shall prepare and submit a monthly quality management report in a format
acceptable to Saudi Aramco to demonstrate effective implementation of the
Quality System. BESCO monthly quality management report shall include all items
specified in Paragraph 7.7 of Schedule “Q” with a summary of findings.
8.4.4 The Inspection Representative shall provide Quality Status Reports to the Project
Management Representative and PQM. These reports shall highlight deviations
from the contract, MSAERs, Project Specifications or BESCO Quality Plans. The
PQM through the ID Manager will also report specific areas of concern to
Proponent, Project Management and ES Executive Management in accordance with
SAEP-1150.

8.5 Improvement
8.5.1 Continued Improvement

8.5.1.1 PQM or his designated SAIR shall promote and disseminate the preventive
measures through the Project Team to recognize and consequently eliminate
potential non-conformities.
8.5.1.2 The project and Team shall achieve established objective and continually set
challenging targets on potential improvement and/or weaknesses areas.
8.5.2 Corrective Action

8.5.2.1 Project Manager or his representative shall address and resolve all issued
NCR’s and Worksheets on a timely manner and ensure that the responsible
contractor carries out corrective actions.
8.5.2.2 Project Manager or his representative shall track status of all Contractor and
Company issued NCR’s and obtain the Inspection Representative’s concurrence prior
to closeout of any NCR.
8.5.3 Preventive Action

8.5.3.1 BESCO or his designated Inspector shall promote and disseminate the
preventive measures to the Project Team to recognize and consequently eliminate
potential non-conformities within the company Quality system.
8.5.3.2 BESCO Project management team shall prepare and provide project
information addressing all Project Phases in accordance with SAEP-329 to help other
teams in planning and executing future projects.
8.5.3.3 PQM or his designated SAIR shall ensure that the Contractor’s quality plan
and procedures for corrective and preventive action of non-confirming product or
activity are in accordance with Schedule “Q” requirements.

Master Project Quality Plan J80-1501

Uploaded by

Copyright:

Available Formats

Master Project Quality Plan J80-1501

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Master Project Quality Plan J80-1501

Uploaded by

Copyright:

Available Formats

What is the project scope?

What is the project scope?

What quality standards are referenced?

What quality standards are referenced?

Bright East Steel Factory

CONT#.: 6510728588 No. : BESCO-MS-J80-1501-1

Project Quality Plan Rev. : 00

INSTALL HYDROCRACKER GAS SCRUBBER

SUPPLYING, FABRICATION, GALVANIZING &

EFFECTIVE DATE: JUNE-09-2015

BESCO General Use Only 1

BESCO General Use Only 2

This project quality plan was reviewed and accepted for

Recommended By: Besco

M. ARFAN Project Quality

Approved By: ARAMCO

Name Role Signature Date

Revision History Sheet

BESCO General Use Only 8

A First Draft PQM PM 08/26/2015

BESCO General Use Only 8

BESCO General Use Only 8

1.2 DESIGN BASIS................................................................................................................. 17

Quality Policy Statement

‫بسم الله الرحمن الرحيم‬

QUALITY POLICY ‫سياسة الجودة‬

BESCO General Use Only 8

Achieving customers’ satisfaction during ‫إحراز رضاء العمالء خالل‬

Encouraging training and learning culture ‫تعزيز) ثقافة التدريب و المعرفة‬

‫بسم الله الرحمن الرحيم‬

QUALITY OBJECTIVES ‫أهــداف الجــــودة‬

BESCO General Use Only 8

Improving the level of agreed services

Improving the variety of Services/Products. ‫الرفع من قدر تنوع المنتج‬.

Continually improve customer satisfaction ‫التحسين المتواصل لمؤشر رضاء‬

‫التحسين) المتواصل لكفاءة و‬

‫التخفيض المتواصل لمستوى‬

‫يساهم كل الموظفين في تحقيق‬

BESCO is awarded by Saudi ARAMCO to construct

To achieve the above objective and satisfy the

BESCO General Use Only 8

Quality Plan based on the requirements of the Saudi

Each project team (Inspection Department,

BESCO General Use Only 8

1.2 Design basis

1.3 Project Scope

BESCO General Use Only 25

2.1 Saudi Aramco Standard Contracts Schedules

2.3 Saudi Aramco Engineering Standards

2.4 Saudi Aramco Inspection Procedures

2.5 International Standards

3 Terms and Definitions

4 Quality Management System

4.1 General Requirements

BESCO General Use Only 25

4.2 Documentation Requirements

4.2.2 Quality Manual

4.2.3 Control of Documents

4.2.4 Control of Records

5.1 Management Commitment