PROJECT QUALITY PLAN

D1 9th Nov. 2008 Draft J.Banks

Rev. No Date Status Originator Reviewed Approved

PROJECT QUALITY PLAN

 REVISION HISTORY

D1 Draft
Rev. No Status Revision Description Approved

PROJECT QUALITY PLAN

 COMPANY QUALITY POLICY STATEMENT

It is the policy of the BJN.JV to provide products and services that satisfy the customer’s needs,
meets specified quality requirements and is in accordance with contractual, specification, code
plus regulatory requirements and executed within the specified time scale.

To ensure that this is accomplished, the Project Quality Plan has been developed to comply with
the requirements of the BS EN ISO 9001/2000 International Organization for Standardization.

These objectives are as follows:-

 Personnel shall achieve and sustain the required quality level of products and services as
to continually meet the customer’s needs.
 Personnel shall provide confidence to the B/JN.JV management that the intended quality
is being achieved and sustained.
 Personnel shall provide confidence to the customer that the intended quality is being
achieved and sustained.
 Personnel shall provide confidence to the customer that the intended quality is being, or
will be, achieved in the delivered product or service.

The quality assurance personnel performing activities affecting quality shall have sufficient
authority, access to work areas, and organizational freedom to prevent and identify quality
problem. They shall also initiate, recommend and provide solution to quality problem through
designated channels, and verify implementation of corrective action.

The Project Manager has the authority and responsibility for overall management. The Site
Manager has the overall responsibility to implement the quality assurance system and other
personnel shall be responsible for performing activities as described in this Quality Assurance
Manual. The Site Manager has the responsibility for the overall management of the quality
assurance system.

The authority to verify the implementation of the Project Quality Plan related to field work is
delegated to the QA/QC Manager. The QA/QC Manager is responsible for assuring that the
requirements established in this Manual are adhered to, he is also responsible for reporting the
implementation status directly to the Site Manager.

The Site Manager shall resolve any conflict that cannot be resolved between the QA/QC Team
and other organizations. All resolutions shall be within contractual documents, applicable codes
and standards and this Project Quality Plan.

Signed: -------------------------------------------------

Managing Direcector

PROJECT QUALITY PLAN

 TABLE OF CONTENTS

ITEM PAGE No

TOP SHEET 1

REVISION HISTORY 2

B/JN.JV QUALITY POLICY STATEMENT 3

TABLE OF CONTENTS 4

1. EXECUTIVE INTRODUCTION 8

2. TERMS and DEFINITIONS 10

3. ORGANIZATION 11

 Scope
 Responsibilities and Authority
Project Manager
Site Manager
Contract Manager
QA/QC Manager
QA/QC Team
Material Control Manager
Safety Manager
Administration/Accounts Manager
 Project Organisation Chart (Function)

4. QUALITY ASSURANCE SYSTEM 13

 Application of the Quality Assurance Manual

 Control of the Quality Assurance Manual
 Distribution Control
 On-going Evaluationof the Quality Assurance Manual Systems
 Revision Control
 Attachments (APPENDIX 1)

5. DOCUMENT CONTROL 15

 Scope
 Responsibilities
Site Manager
Construction Manager

PROJECT QUALITY PLAN

ITEM PAGE No

QA/QC Manager
 Attachments (APPENDIX 1)

6. PROCUREMENT CONTROL 17

 Scope
 Responsibilities
Project Manager
Materials Manager
Contract Manager
 Material Requisition
Procurement Details
 Receiving Inspection
 Attachments (APPENDIX 1)

7. MATERIAL CONTROL 19

 Scope
 Responsibilities
Materials Manager
Construction Manager
QA/QC Manager
 General
 Attachments (APPENDIX 1)

8. WORK PROGRESS CONTROL 21

 Work Process Controls

 Special Work Controls (Welding)
Qualification of Weld Procedures
Qualification of Welders and Weld Machine Operators
Non-destructive Examination
 Attachments (APPENDIX 1)

9. INSPECTION AND TEST CONTROLS 24

 Purpose
 Scope
 Definition of Terms
 Responsibilities
QA/QC Manager
Materials Manager
 Procedure for Material Receipt
Receiving Inspection
Preparation of Inspection and Test Plan
 Work Process Control and In-house Inspection

ITEM PAGE No

 Final Inspection
 Control of Inspection Measuring and Test Equipment
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  Attachments (APPENDIX 1)

10. SITE NON-CONFORMANCE CONTROL 28

 Purpose
 Scope
 Responsibilities
QA/QC Manager
ResponsibleDiscipline Team Leader
 Definition of Terms
Non-conformance
Corrective Action
 General
 Site NCR Numbering System
 Attachments (APPENDIX 1)

11. CORRECTIVE/PREVENTIVE ACTION 30

 Scope
 Resposibilities
QA/QC Manager
Responsible Team Leader
 General
 Attachments (APPENDIX 1)

12. TRAINING 32

 Scope
 Responsibilities
Project Manager
QA/QC Manager
Site Supervisos
 General

13. QUALITY ASSURANCE RECORDS 33

 Scope
 Responsibilities
QA/QC Manager
Contract Manager
 General

14. QUALITY AUDITS 34

 Scope

ITEM PAGE No

 Responsibilities
QA/QC Manager
Contract Manager
 General
 Audit NCR Numbering System
 Attachments (APPENDIX 1)

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15. APPENDIX 1 36

PROJECT QUALITY PLAN

 B/JN.JV QUALITY ASSURANCE MANUAL

1. EXECUTIVE INTRODUCTION

This Project Specific Quality Assurance Plan has been developed to ensure that each member of
the Project Team and any relevant lower tier sub-contractors are aware of the project quality
objective and has been developed to fully address the scope of work, responsibilities, applicable
procedures and work execution methods with reference to:
BS EN ISO 9002 2000 Quality Assurance in Design, Development, Production, Installation
and Servicing.
ISO 10005 : 1995 (E) Quality Management - Guidelines for Quality Plans.
The Project Manager will be responsible for all compliance activities throughout the duration of the
project. These will include ensuring successful implementation of Management System
Procedures in administrative, and construction operations and auditing anagement systems
implementation for construction and installation.
Conducting quality compliance awareness in administrative offices and construction offices to
include engineering, construction supervision and inspection personnel.
Effective follow up and close out of non compliance or other necessary actions as a result of
design reviews and hazard studies.
Establish and maintain a master action register for non-compliance or areas of concern.

A Project QA/QC Manager will be appointed for this construction scope of work. A suitably
qualified QC Supervisor will be appointed to ensure operations are performed in accordance with
the contract requirements, specifications and international codes

The Quality Assurance Plan system implementation shall be evaluated by scheduled compliance
audits on Project Management, Document Control, Quality Control, Engineering Disciplines,
HAZOPS, Technical and Construction operations to ensure that the project’s quality objectives
are being achieved at the relevant locations on site. The compliance audit programme will be
reviewed for effectiveness during the scheduled project management review meetings. Where
necessary follow-up audits will be conducted to satisfy any areas of concern that may arise.

In addition to these audits, the project manager will conduct awareness seminars at the site
construction offices to reinforce procedural understanding and project objective compliance.
These will be planned for timely orientation of the work force, shortly following project mobilization
and at the onset of constuctional works.

Low tier sub-contractors and vendors will be selected upon their proven ability to perform within
the requirements of ISO 9001 2000, selection may be by certification to ISO 9001, appraisal or
client nomination.

Low tier sub-contractor and vendor control will be determined by review of specified requirements,
bid evaluation, and activity monitoring based on a criticality rating index assignment. Based on the
scope of supply, the criticality-rating index assigned will be fundamental in defining the verification
activities, including material traceability.

Sub-contractors and/or vendors will be required to identify their inspection and testing activities by
means of an Inspection and Test Plan (ITP). The ITP shall be submitted to the Project Manager
for review for inclusion of any intervention points required by the project management or a
designated third party. In addition to the ITP, the subcontractors/vendors shall provide a schedule
identifying activity duration and key inspection activities. Design/ Fabrication kick-off meetings will

PROJECT QUALITY PLAN

be scheduled, to include sub-vendors, pre-inspection meetings with fabrication sub-contractors,
monitor progress and plan any product audits/inspection.

The responsibility for compliance to product specification will be placed with the suppliers’ in-
house quality control services. However, the project management are ultimately responsible for
compliance and will monitor QC activity by means of product audits or third party verification. For
items of equipment purchased in Nigeria, the project management will provide for QC activities
locally.

Quality system reporting will be routed via the project compliance representative to prove overall
acceptable quality to the project status. Monthly reports will be prepared to include the status of
audits planned, audits performed, corrective actions raised and outstanding, together with the
progress of selection and monitoring of the low tier sub-contractors and vendors engaged on the
project if applicable.

< O >

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2. TERMS and DEFINITIONS

For the purpose of this Project Quality Assurance Manual and supporting procedures the following
terms/definitions shall apply.

Quality System Organisational structure, procedures, processes and

resources needed to implement quality management.

Quality Assurance All those planned and systematic actions necessary to provide
adequate confidence that a product or service will satisfy given
requirements for quality.

Quality Control The operational techniques and activities that are used to fulfil
requirements for quality.

Quality Plan A document setting out the specific quality practices,

resources and sequence of activities relevant to a particular
product or project.
Quality Audit A systematic and independent examination to determine
whether quality activities and related results comply with
planned arrangements and whether these arrangements are
implemented effectively and are suitable to achieve objectives.

Project Unique process consisting of a set of co-ordinated and

controlled activities with start and finish dates, undertaken to
achieve an objective conforming to specific requirements,
including constraints of time, cost and resources.

Other definitions will be as given in ISO 8402: Quality Management and Quality Assurance -
Vocabulary.

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3. ORGANISATION

 Scope

To describe the responsibilities and authority of the personnel responsible for and organising the
quality activities for successfully executing the project to the required standards.

 Responsibilities and Authority

Project Manager

The Project Manager has the authority and responsibility for overall management including but not
limited to; approval of the Quality Assurance Manual, approval of material requisition.

Site Manager

Implementation of this Project Quality Plan.

Has the overall responsibility for construction activities including the quality thereof.
Review of the Project Quality Plan.
Review of the work procedure for work method statements and their implementation and
execution.
To direct all of the work and coordinate the constructional execution throughout all phases of the
works.
Review and approval of construction Technical Queries.
Contract administration.
Control of the incoming & outgoing documents.

Construction Manager

Establishment and execution of construction schedules.

Preparation of material requisitions.
Implementation of work procedure and techniques for method statements.
Preparation of Construction Technical Queries (CTQ).
Preparation of Field Change Request (FCR).
Reporting on the construction progress and problems (if any) to the Site Manager
Planning & scheduling, issuing of progress report.
Requisition for calibration of inspection, measuring and test equipment.
Preparation of as-built drawings.

Quality Assurance/ Quality Control Manager

He shall be responsible for the establishment and evaluation of quality assurance systems and
shall verify implementation thereof.
To establishment and prepare for approval the Quality Assurance Manual and Quality Control
Procedures and Systems.
Control distribution and status control of the Quality Assurance Manual.
Evaluation of the Quality Assurance Manual for system effectiveness and reporting such to the
Project Manager.
Quality audits.
Review of procedural documentation.
Review and approval of inspection & Test Plans (ITP).
Performance of receiving, in-process and final inspection.
Issue of Nonconformance Reports (NCR)and Corrective Action Requests (CAR).
Reporting quality problems and quality control status to the Project Manager.
To check and confirm whether the latest revision documents are implemented on site.
Implementation of work procedures for work methods and techniques.
Control and logging of calibration of inspection, measuring and test equipment.
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Control of all construction documents received from the contractor.

Quality Assurance/Quality Control Team

To perform quality assurance and quality control activities, shall have sufficient authority, access
to work areas and organizational freedom to prevent and identify problems. They shall also
initiate, recommend and provide solutions to quality problems through designated channels and
verify implementation of solutions.

Materials Manager

Material control, logging, inspection, storing, quarantine, rotation issue and preventative
maintenance.

Safety Manager

Responsible for HSE at the construction site reporting to the Project Manager. The Safety
Manager has a functional reporting line to the QA/QC Team, thus ensuring any NCR/area of
concern may be identifed and placed on the action register for follow up and close out.

Administration/Accounts Manager

General site company affairs and administration.

Labour organisation and rotation.
Site Finance and accounting.

 Project Organisation Chart (Function)

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4. QUALITY ASSURANCE SYSTEM

 Application of the Quality Assurance Manual

The Quality Assurance Manual (QAM hereafter) applies to construction work performed by
B/JN.JV.
The detailed administrative procedures to implement this QAM are described in the Quality
Control Procedures.
The organization and team performing activities affecting quality shall perform the activities
according to the procedure, instruction and drawing prepared to implement this QAM.

 Control of the QAM

This QAM shall be prepared by the QA/QC Manager and approved by the Project Manager.

 Distribution Control

All copies of this QAM are classified into controlled and uncontrolled copies.
The QA/QC Team Manager shall distribute controlled copies of the QAM to management and the
client.
Personnel who possess the controlled copy shall receive new revisions automatically. Personnel
who possess uncontrolled copies shall not receive the revised copy.
The QAM shall be distributed in accordance with the Distribution Sheet.
Personnel who receive the controlled QAM shall sign on the distribution sheet of the QAM and the
signed distribution sheet shall be returned to Document Control. The distribution sheet for the
QAM shall be controlled and maintained by the QA/QC Manager.

The QA/QC Manager shall record the distribution and receipt date of the controlled copies on
revision and update the Document Distribution Control Register.

 Ongoing Evaluation and Implementation of the Quality Assurance Systems

The QAM is a live document; quality audits and quality assessment shall be regularly executed in
order to evaluate the effective of the quality assurance system and to verify whether the quality is
according to the QAM and related procedures. Deviations shall be reported to the Project
Manager for QAM revision.

 Revision Control

Upon revision of the QAM, the related paragraph, reason/description for revision, revision number
and revision date shall be recorded on the revision history sheeted of the QAM.
The revised part shall be marked with vertical line in the margin to the right of the revised section,
procedure or paragraph.
The distribution of the revised QAM shall be controlled in the same manner as original. The
personnel in possession of revised controlled copies of the QAM shall ensure the return of the
previous copy to Document Control, clearly marked as superceded.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 27 EGTL-B/N.JV-FORM-027 Document Distribution Register

Item 33 EGTL-B/N.JV-FORM-033 Project Quality Plan Revision Status Register

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5. DOCUMENT CONTOL

 Scope

To describe the requirements for the change control preparation, review, approval and distribution
of the documents affecting quality such as drawing, specification, instruction and procedure to be
used in order to execute the quality assurance requirements of this QAM.
All quality documents to be maintained according to this QAM requirements shall be prepared,
reviewed, approved, distributed, controlled and maintained in accordance to Quality Control
Procedure (QCP) by the responsible Team Manager and also in accordance with contractual
documents.

Documents to be controlled by this QAM are as follows:

The documents and specifications provided by the client.

This QAM and the QCP.
Work procedures required to fabricate, install, inspect and test.
Non-conformance Reports (NCR), Corrective Action Requests (CAR), quality audit records.
Design documents; drawings, DCN, CTQ.
Procurement documents, procurement details, material requisition.
Inspection & Test Plans (ITP)

All documents shall be prepared according to applicable procedures which meet the requirements
of contractual documents and applicable codes and standards.
The prepared documents shall be approved by the responsible Team Manager and reviewed by
personnel in the responsible team for suitability, completeness and accuracy. The prepared
documents shall be reviewed and approved by the QA/QC Manager
The personnel in charge of preparation,review and approval shall sign the relevant documents.
Team Managers responsible for distribution of documents shall assign distribution and number of
copies after discussion with the related team.
Documents shall be identified with “controlled”, “for review”, “for reference”, “for approval”, or “for
construction” in accordance with this procedure.
The Site Manager in charge of issue and receipt of drawings, DCN and CTQ shall record and
maintain the status of DCN and CTQ issued as design against each drawing in the control log.
The change to documents shall be controlled and distributed in the same manner as original
documents

Obsolete documents shall be identified with ”Superceded” by the Site Manager. The latest
drawings and documents shall be utilised at all the required locations to facilitate the effective
functioning of the quality system.

 Responsibilities

Site Manager

Control of incoming and outgoing correspondence.

Document control.
Receipt of drawings, Design Change Notice (DCN) received from the client and the related team
review. Approval of Construction Technical Queries (CTQ) prepared by the construction team.
Control of drawing and design change documents (CTQ, DCN).
Control of Quality Assurance records.

Construction Manager

Issuing of costruction/erection procedures for site fabrication and installation.

Preparation of As-built Drawings.
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QA/QC Manager

Preparation and distribution of the Quality Control Procedure (QCP) to site, other organizations
and the client.
Preparation of work procedures.
Preparation and approval of Inspection &Test Plans (ITP).
Review of procurement documents.
Issue and control of Nonconformance Reports (NCR) and Corrective Action Requests (CAR).
Preparation and control of quality audit report findings.
Ensure suitable capability of document control funtions.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 27 EGTL-B/N.JV-FORM-027 Document Distribution Register

Item 28 EGTL-B/N.JV-FORM-028 Master Drawing and Revision Status Register
Item 29 EGTL-B/N.JV-FORM-029 Master Document and Revision Status Register
Item 30 EGTL-B/N.JV-FORM-030 Master Control Form and Revision Status Register
Item 31 EGTL-B/N.JV-FORM-031 Master Inspection Report and Revision Status
Register
Item 33 EGTL-B/N.JV-FORM-033 Quality Assurance Manual Revision Status Register

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6. PROCUREMENT CONTROL

 Scope

To describe the requirements for procurement of materials used in construction.

 Responsibilities

Project Manager

Approval of material requisition.

Materials Manager

Requisition for contractor supplied materials to the contractor.

Procurement schedule control.
Request receiving inspection for B/JN.JV supplied materials to the QA/QC Team.

Construction Manager

Preparation & approval of procurement details.

Preparation of material requisition.

QA/QC Team Manager

Review of procurement documents for materials.

Vendor Inspection.
Receiving inspection.

 Material Requisition

Procurement Details

The Construction Team shall prepare as required the procurement details for materials in
accordance with this procedure.
The procurement details shall include the following items:
General terms.
Scope of Supply (Work).
Technical requirement – applicable code, standard and detail drawing.
Inspection and testing requirements.
Documentation requirements.

Procurement details shall be reviewed by the Construction Manager and QA/QC Team personnel
to ensure that the specified requirements are met.
The Construction Team shall hand over the approved procurement details with material
requisition to the Procurement Office for purchasing through the Project Control Team.
The Materials department personnel on the basis of the approved materials requisition shall
perform the procurement activities.
Changes to procurement documents shall be maintained and controlled in the same manner as
original.

 Receiving Inspection

B/JN.JV supplied materials:

PROJECT QUALITY PLAN

When materials are received from vendor to site, the shipping documents shall be sent to the
QA/QC Team for receiving inspection.
The receiving inspection shall be performed and reported by the QA/QC Team in accordance with
Receiving Inspection Procedure as follows:
Visual
Identification
Packing
Painting
Dimension
Quantity
Welding
Document review
The results of receiving inspection shall be distributed to the related teams by the QA/QC Team.

Contractor supplied materials:

When materials are received from the contractor, the Materials department shall perform receiving
inspection.
The non-conforming items shall be controlled in accordance with the requirement of applicable
Quality Control Procedure.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 04 EGTL-B/N.JV-FORM-004 Master Storage Control Register

Item 21 EGTL-B/N.JV-FORM-021 Material Receipt/Issue Control Register

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7. MATERIAL CONTROL

 Scope

Todescribes the requirements for transportation, handling, storage,segregation, preservation,

fabrication and installation, issue, rotation, identification and traceability control of materials,
components and equipment (“materials” hereafter) used in construction work.

 Responsibilities

Materials Manager

Transportation, handling, storage and preservation control of materials, components & equipment.
Identification control from receipt to issue for materials, components and equipment.

Construction Manager

Identification and traceability control of receipt, fabrication, assembly, installation and

commissioning for materials, components and equipment.

QA/QC Manager

Monitoring and surveillance of implementation for this QAM and the related procedures.

 General

Transportation, identification, handling, storage, issue and preservation control of the materials
affecting quality shall be in accordance with related procedures.
The related procedures are prepared and approved so as to meet the requirement of contractual
document and technical specification, and the following items shall be included in the related
procedures.
Verification and marking method for identification of the received materials, components and
equipment.
Handling, storage, preservation method and warning notice for material, components and
equipment.
Storage area, warehouse control and preservation area shall be controlled in accordance with the
related procedures and character of materials. American National Standards Institute materials
protection and storage requirements shall be the basis for conducting ware housing methods.
All materials used in construction shall be monitored at appropriate intervals so as to prevent
damage, deterioration and loss.
Identification markings are applied using material and methods which provide a clear and legible
identification and do not detrimentally affect quality or function of the product.
Physical identification shall be used to the maximum extent possible. Where physical identification
on the materials is either impractical or insufficient, physical separation, procedural control or
other appropriate means shall be employed.
When material is subdivided, the original identification marking shall be transferred to all pieces
prior to cutting.

Identification marking/tagging shall be monitored and traced by the QA/QC Team through all
process. Tractability record sheet for piping system shall be compiled by the QA/QC Team to
identify required tractability information.
When materials are required the special control condition including the specified
humidity/temperature, these materials shall be controlled in accordance with the storage manual
provided by vendor.
Non-conforming items shall be controlled in accordance with the requirements of Section 9 of this
QAM.

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Any such materials that is lost, damaged or is otherwise unsuitable for use shall be recorded and
reported as per Section 10.
Materials not conforming to contractual requirements shall be quarantined.
The Project Control Team shall maintain control log for receipt, storage and issue of materials.
The contractor supplied materials shall be verified, stored and maintained as per materials
purchased by B/JN.JV.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 04 EGTL-B/N.JV-FORM-004 Master Storage Control Register

Item 05 EGTL-B/N.JV-FORM-005 “Hold-Construction” (Label)
Item 06 EGTL-B/N.JV-FORM-006 “Hold-Material” (Quarantine Label)
Item 14 EGTL-B/N.JV-FORM-014 Site Non-conformance Report
Item 21 EGTL-B/N.JV-FORM-021 Material Receipt/Issue Control Register
Item 24 EGTL-B/N.JV-FORM-024 Over Short Damage Report
Item 26 EGTL-B/N.JV-FORM-026 Site Non-conformance Report Register

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8. WORK PROCESS CONTROL

 Scope

Todescribes the requirements of job control for fabrication, installation inspection and test process
of the items relating to quality, and control methods of personnel and procedures relative to
executing these operations.

 Responsibilities

Construction Manager

Implementation of work procedures.

Inspection requests for the nominated inspection points.
Preparation for weld procedure qualifications, welders and welding machine operators
qualification tests.

QA/QC Manager

Review of work procedures.

Preparation, approval and nomination of inspection points of ITPs.
Performance / witness of inspection / test points nominated on ITPs.
Welders and welding machine operator’s qualification tests.
Maintenance and control WPS/welder performance qualification test records.
Maintenance of Non-Destructive Examination (NDE) records.
Maintenance of traceability records.
Approval of WPS.

 General

The fabrication/installation activities of the items affecting quality shall be controlled by procedure,
drawing, checklist and ITPs.
Special processes such as welding and NDE are those processes to be controlled specially.
These special processes shall be performed by qualified personnel and procedures in accordance
with specified requirements.
The equipment used in special processes shall meet the requirements of technical specifications,
applicable codes and standards.
The records for the personnel and equipment qualified shall be maintained, and available for
review by the client.
Procedure, drawings, checklist and ITPs established for special processes shall be distributed to
the related organization in accordance with section 5 of this QAM.

 Work Process Controls

The QA/QC Team shall prepare the ITP based on techinal specifications, drawings, applicable
codes and standards.
Work procedures for fabrication / installation of items based on technical specification, drawing,
applicable codes & standards shall be prepared by the Construction Team, reviewed by the
QA/QC Team and approved by the Project Manager.

The following items shall be included in these work procedures:

Scope of work.
Reference documents.
Applicable specifications.
Equipment list and warning notice.
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Work performance procedure.
Inspection / test procedure and acceptance criteria.
Attachments: ITP, checklist, record form, etc.

The ITP established in accordance with setion 8 of this QAM shall include the item list for work
process needed to fabricate and install the items including inspection and tests required.
The QA/QC Team shall appoint the inspection point (review, witness, hold, random inspection
point) in order to decide whether the witness of inspection is required or not when the ITP is
reviewed. ITP shall be approved by the client before commencing.
The Construction Team shall perform the fabrication and installation work according to the ITP
and procedure reviewed and approved by the QA/QC Team.
The major items to be used for fabrication and installation work shall be traced and controlled with
identification number from the initial receipt up to fabrication and installation of the items
according to the requirements of section of this QAM.
Non-conforming item shall be controlled in accordance with the requirements of chapter 9 of this
QAM.
The completed ITP/related quality records produced during fabrication and installation work shall
be controlled according to the requirement of section 13 of this QAM.

 Special Work Controls (Welding)

Qualification of Weld Procedures

The Construction Team shall arrange the qualification tests for WPS in accordance with
contractual documents and standards and shall request the witness for the qualification test for
WPS to the Contractor. The Construction Team shall give a minimum formal notice of 24 hours
prior to commencing Welding Procedure Qualification. The Construction Team shall hard-stamp
test coupon in the presence of contractor. Test results shall indicate unique number stamped on
coupon.
The WPS shall be approved by the result of welding of test coupons, the testing of specimens in
accordance with the requirements of contract and applicable codes & standards, and approved by
the record of the welding data and test results in the Welding Procedure Qualification
Specification (PQR).
The welding data to be recorded in the PQR shall include the essential variables, and the actual
variables used in the welding of the test coupons shall be recorded.
The WPS shall list the essential variables, the supplementary essential variables (if required,)
non-essential variables and identification number of the certified PQR in accordance with the
requirements of contract and applicable code and standard
The PQR shall be certified by the QA/QC Team and by the independent third party as approved
by the contractor.
The Construction Team shall submit test results of Welding Procedure Qualification together with
PQR for contractor’s acceptance prior to conducting welder qualification test.
The Construction Team shall prepare and maintain an Index of all Welding Procedures in
accordance with contractor form.
All W.P.S shall be reviewed by the client prior to use.

Qualification of Welder and Welding Machine Operators

The Construction Team shall prepare a plan of welder qualification test.

The Construction Team shall implement the WPS to be used in welder qualification test and
request the witness for qualification test to the QA/QC Team..
The QA/QC Team shall give a minimum formal notice of 24 hours to the client prior to
commencing Welder and Welding Machine Operator Qualification test.
All Welders and Water Operator Qualification Tests shall be documented based on client forms.
Welder shall be qualified by the welding of test coupon, the testing of specimens and the test
results in accordance with the requirements of contract, applicable code and standard, and the

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shall be recorded on Welder Qualification Test (WQT).or Welding Machine Operator Test
(WOQT).
The qualified welder shall be allocated unique identification numbers by the QA/QC Team in
accordance with Quality Control Procedure and contractual requirements.
The actual variables, test results and qualified range used in welding of test coupon shall include
in the WQT record and certificate.
The QA/QC Team shall prepare and maintain a qualified welder list, based on the certified record
of WQT. These details will be recorded on the welder’s ID card which will be shown on demand
by the welder in question at any time during welding operations on site.

Non-destructive Examination (NDE)

NDE shall be performed by approved companies in accordance with the approved specifications,
standards and procedures.
NDE technique procedures shall be prepared by the NDE company in accordance with technical
specifications and applicable codes & standards and must be approved by the company prior to
work commencement.
Personnel performing non-destructive examination shall be qualified / certified in accordance with
the requirements of applicable standards and the contract.

NDE records shall be maintained as Quality Assurance records by the QA/QC team as per
Section13.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 15 EGTL-B/N.JV-FORM-015 Weld Procedure Specification (WPS)

Item 16 EGTL-B/N.JV-FORM-016 Procedure Qualification Record (PQR)
Item 17 EGTL-B/N.JV-FORM-017 Welder Performance Qualification (WPQ)
Item 18 EGTL-B/N.JV-FORM-018 Welding Operator Performance Qualification (WPQ)
Item 28 EGTL-B/N.JV-FORM-028 Master Drawing and Revision Status Register
Item 29 EGTL-B/N.JV-FORM-029 Master Document and Revision Status Register
Item 30 EGTL-B/N.JV-FORM-030 Master Control Form and Revision Status Register
Item 31 EGTL-B/N.JV-FORM-031 Master Inspection Report and Revision Status
Register

PROJECT QUALITY PLAN

9. INSPECTION AND TEST CONTROLS

 Purpose

To describe the methodology of how to obtain and maintain the level of quality required by the
customer by performing inspection/test requirements, as required by the applicable specifications,
codes and standards.

 Scope

To describe the method for the preparation and control of Inspection and Test Plans (ITP), work
process control and the performance of inspection / tests performed at site.

 Definition of Terms

Inspection and Test Plan (ITP)

The Inspection and Test Plan notes the inspection points (Witness Point, Hold Point, Monitor
Point Review Point) required by the personnel performing inspection in order to verify whether the
work affecting quality is performed according to the specified requirements of procedures,
instructions, specifications, codes and standards, and drawings.

Hold Point (H)

This point shall be witnessed by the designated inspection personnel at a pre-arranged time.
Work shall not proceed to the next activity until inspection or witness has been completed.

Witness Point (W)

This point necessitates witness by the designated inspection personnel, however if any inspection
personnel do not attend at the designated time, the work may continue uninterupted.

Monitor Point (M)

Random inspection of on-going works without prior arrangement.

Review Point (R)

This point relates to review of documents or records whether during or upon completion of the
works.

 Responsibility

Construction Manager

Preparation of the ITP with the consultation of the QA/QC Manager.

Witness of inspection / test points as assigned.
Registration of measuring and test equipment with the QA/QC Manager.
Requisition for calibration of measuring and test equipments.

QA/QC Manager

Review and approval of the ITP.

Performing the inspection / test inspection points as assigned.
Review of the relevant inspection reports.
Maintenance and control of calibration status of measuring and test equipment.
PROJECT QUALITY PLAN
Materials Manager

To organise with the QA/QC team for inspection of material and goods received.

 Procedure for Material Receipt

Receiving Inspection

For the equipment and materials received, the person in charge of the Project Control Team shall
request the QA/QC Team Manager for receiving inspection relating to the following; shipping
documents, receiving date and location, order number, package number. Confirmation of material
quantity and vendor inspection documents if applicable.
Temporary materials used as aids to construction are excluded.
The QA/QC Team shall perform the appropiate type of receiving inspection, the report based on
shipping documents and vendor quality assurance reports with reference to:

Vendor quality control documents.

Quality
Quantity
Dimensions
Identification
Packing
If all NCRs (if any) issued during source inspection are closed out.
OSD report

If inspection results identify non-compliance with the specified requirements, the QA/QC Team
Manager shall isolate the nonconforming materials with “WITHHOLD” tag.
When the receiving inspection have been completed, the QA/QC team Manager shall notify the
results of inspection and copy the receiving inspection documents/Inspection Report to the Project
Control Team in order to amend or dispose of the nonconforming materials.
Claim Report for the non-conforming materials shall be prepared by the Project Manager in
accordance with company instructions.

Preparation of the ITP

The Construction Manager shall review the applicable discipline specifications, codes and
standards and shall select the items in order of criticality for inclusion in the ITP by consultation
with the QA/QC Team Manager and the customer.
The following minmum items shall be included in all ITPs according to discipline:

Unique ITP No.

Description of item(s) to be inspected and tested.
Applicable procedures, codes or standards citing the relevant clauses
Controling inspection reports by report document number.
Inspection points (H, W, M, R).
Welding records.
Authorised signatorees.

The inspection points shall be classified into “H”, “W”, “M”, “R”.
H: Hold point.
W: Witness point
M Monitor
R: Review point

 Work Process Control and In-house Inspection

PROJECT QUALITY PLAN

The works affecting quality shall be performed in accordance with applicable technical
specification, procedure, instruction, code & standard and the ITP.
Welding shall be performed by the welder qualified in accordance with WPS described in the
drawing or welding book.
The QA/QC Team Manager shall attend the welder qualification tests.
The qualified welder status shall be recorded on the Qualified Welder List.
The special processes such as NDE, PWHT shall be performed according to approved
procedures.
ITP items shall be witnessed by personnel independent of those having direct responsibility for
the activities.
The QA/QC Team Manager shall receive the inspection application from the Construction Team
Manager points assigned to the ITP.
After each inspection/test is completed, the responsible personnel shall prepare the
inspection/test report or checklist according to the applicable procedure, instruction and standard.
The number of inspection results, report/checklist/certificate and NCR that occurred by
inspection/test shall be as described on then ITP.
The results of welding inspection shall be inscribed on the welding records of the ITP.

 Final Inspection

All completed items shall be inspected for identification, traceability, calibration control, protection
from loss, preventative maintenance and other characteristics as requested, plus the suitability
and completeness of the related quality assurance records.

 Control of Inspection, Measuring and Test Equipment.

Basic equipment for keeping accuracy such as rulers, tape measures need not be calibrated.
Frequently used measuring and test equipment for keeping accuracy shall be visually checked for
damage prior to use.
Equipment suspected of being inaccurate shll be re-calibrated.
Damaged, non-calibrated or non-functional equipment shall be isolated.
Calibration activities are performed at site, the calibration procedure for the equipment shall be
prepared and the calibration activities are performed by the qualified personnel.
The measuring and test equipment calibration shall be performed within the specified time
frequency by qualified personnel in accordance with recognised international standards unless
specified otherwise.

All calibrated measuring and test equipment shall be clearly tagged showing test and renewal
dates.
Team leaders shall shall check the condition of calibration validity proir to use.
The QA/QC Team Manager shall prepare, maintain and control the Calibration Record Register to
include but not limited to the following:

Description.
Make.
Type/Model.
Identification/Serial number.
Calibration Frequency.
Range.
Accuracy.
Allowable Error.
Calibration Report Number.
Results of Calibration.
Date.

Item Equipment Validity Period

PROJECT QUALITY PLAN
 1 Temperature Recording Devices 1 Year
2 Multi-testers 1 Year
3 Electrical Characteristic Testers 1 Year
4 Tong Testers 1 Year
5 Pressure Gauges 20 cycles
6 Torque Wrenches 6 Months
7 Surveying Equipment 2 Years
8 DFT Coating Gauges On use
9 Surface Profile Gauges On use
10 Radiation Monitoring Equipment By NDE Co.
11 Electrode Ovens 1 year
12 Electrode Quivers Monthly
13 Vacuum Box (see 5) 20 cycles
14 Other -
15 Other -

 Relevant Attachments (APPENDIX 1- Page 36)

Item 23 EGTL-B/N.JV-FORM-023 Receiving Tank Material Report

Item 24 EGTL-B/N.JV-FORM-024 Over Short Damage Report (OSD)

PROJECT QUALITY PLAN

10. SITE NON-CONFORMANCE CONTROL

 Purpose

To establish and implement the system for identification, documentation and disposition of non-
conforming items, which do not comply with the specified requirements.

 Scope

This chapter applies to the system for identification, documentation and disposition of non-
conforming materials, components, equipment and methods adverse to quality utilised in
construction the works.

 Responsibility

QA/QC Manager

To issue Non-conformance Report (NCR).

Approval of NCR corrective action and subsequent verification by follow-up followed by close-out.
Up-dating of Non-conformance Log.
(Non-conformities regarding the quality system as identified by internal quality assurance audits are
formally recorded on Audit Findings Reports).

Responsible Discipline Team Manager

Acceptance of NCR actions.

Implementation of corrective action.
Investigation of the cause of conditions adverse to quality and establishment of counter measures
to prevent re-occurrence.

 Definition of Terms

Non-Conformance

Materials/conditions/methods/documents/omittance adverse to quality by not complying with

specified requirements.
Items that suffer damage/functional problems during fabrication or installation although they
complied with applicable code and standard previously.

Corrective Action

An action taken to eliminate the causes of an existing nonconformity, defect or other undesirable
situation in order to prevent recurrence.

 Genaral

Personnel involved with supply/construction/inspection/testing activities observing any non-

conformance during shall notify the QA/QC Team.
The QA/QC Manager shall issue the NCR describing the non-conformance and the proposed
corrective action in accordance with the requirements of the contract document, applicable codes
and standards.
The QA/QC Team shall record the status of the prepared NCR on the Site NCR Status Log and
distribute the NCR to the related teams responsible for corrective action.
Upon completion of corrective action verified by follow-up, the NCR shall be “closed out” and the
Site NCR Log updated accordingly.

PROJECT QUALITY PLAN

Non-conforming items, if possible shall be segregated/quarantined from conforming items and
identified by a “HOLD” tag.

 Site NCR Numbering System

EGTL-B/JN.JV-NCR-SITE-XXX

XXX Consequetive Serial Number

NCRs issued during audits shall not be recorded on the Site NCR Status Log as they are inclusive
to the Audit Report.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 05 EGTL-B/N.JV-FORM-005 “Hold-Construction” (Label)

Item 06 EGTL-B/N.JV-FORM-006 “Hold-Material” (Quarantine Label)
Item 12 EGTL-B/N.JV-FORM-012 Corrective Action Request (CAR)
Item 14 EGTL-B/N.JV-FORM-014 Site Non-conformance Report
Item 25 EGTL-B/N.JV-FORM-025 Corrective Action Request Register
Item 26 EGTL-B/N.JV-FORM-026 Site Non-conformance Report Register

PROJECT QUALITY PLAN

11. CORRECTIVE/PREVENTIVE ACTIONS

 Scope
To describe the requirements for corrective and preventive action to assure that the conditions
adverse to quality are identified promptly and corrected, the cause of the condition is investigated
and corrective and preventive action taken to preclude recurrence.

 Responsibilities

QA/QC Manager

Identify or be informed of conditions adverse to quality.

Produce CAR for use by the relevant responsible team to implement.
Verify whether corrective action is performed successfully; follow-up.
Control of Corrective Action Request (CAR) status central register.
The QA/QC Manager shall have the authority to stop works and report to the Site Manager should
any major quality problem be identified which adversely affects quality.
Establish the means for non-reoccurance.

Responsible Team Leader

To ensure implementation of CAR requirements before further adverse actions are performed.

 General

The QA/QC Team is responsible for identifying and addressing conditions adverse to quality. The
conditions adverse to quality are discovered through review of all processes and work operations
which affect product quality, inspection and test records, defect records, surveillance audits,
employee’s observation and reports, and nonconformance reports.
The QA/QC Team shall issue Corrective Action Request (CAR) against the conditions/actions
adverse to quality for use by the responsible team for effective action.

The following items shall be included in the CAR:

The conditions/actions which adversely effect quality.

Corrective action required including time limit for implementation.
Actions to prevent for reoccurrence.
Follow-up on whether corrective action is taken or not.

The responsible team leader in charge of corrective action shall implement the described remedial
action within the specified time limit required. The status of CAR shall be controlled and
maintained by the QA/QC Team.
The QA/QC Team Manager in charge of CAR issue shall verify whether corrective action
successfully achieved.
The QA/QC Team in charge of issue of CAR, if the content of corrective action is satisfactory,
shall document his acceptance on the CAR.
The analysis result of CAR and relevant information on actions taken which may necessitate
changes to procedures are reported to the Site Manager for management review.

 Relevant Attachments (APPENDIX 1- Page 36)

Item 11 EGTL-B/N.JV-FORM-011 Internal Audit Schedule

Item 12 EGTL-B/N.JV-FORM-012 Corrective Action Request (CAR)
Item 25 EGTL-B/N.JV-FORM-025 Corrective Action Request Register

PROJECT QUALITY PLAN

12. TRAINING

 Scope

To describe the requirements for vocational training of site personnel.

 Responsibilities

Project Manager

Approval of training plans and verification of training execution for site personnel of various
disciplines.

QA/QC Manager

Establishment of training plan and execution of training on quality assurance systems for QA/QC
personnel.
Execution of training for quality assurance systems as requested from other teams of other
disciplines.

Site Supervisors

Establishment of training plan and execution of training for site personnel.

 General

Each team Manager performing activities affecting quality shall establish training plan and
execute training according to training plan.
QA/QC Team shall execute training for quality assurance system according to the request from
each Team Manager.
Scope of training shall include, but not limited to the following.

Quality Assurance Manual (QAM) and Quality Control Procedures (QCP)

Technical items.
Qualification items
Specific vocational training

Training results shall be documented and maintained.

PROJECT QUALITY PLAN

13. QUALITY ASSURANCE RECORDS

 Scope

To describe the requirements to identify, collect, index, access, file, store, maintain and dispose of
(if necessary) the quality assurance records which provided objective evidence of activities and
items affecting the quality of the project. All Quality Assurance records shall be filed and
controlled in such a manner that they are easily traceable and shall be stored in the suitable
storage area to protect them from damage, deterioration and loss. The Quality Assurance records
to be transferred to the company shall be transferred with their index list after review by the
QA/QC Team Manager.

 Responsibilities

QA/QC Manager

Responsible for preparation and issue of Quality Assurance Record Control Procedure, to include;
collection, identification, colation, review, indexing maintenance, storage and disposition/,transfer
of all quality assurance records compiled.

Construction Manager

Control and maintenance of quality assurance records occurred during construction.

Sending quality assurance records/including as-built drawings to the QA/QC Team after
completion of construction work. Documents shall be transfered as per contract requirements.
Retention time of all Quality Assurance records (hard-copy type or electronic media) shall be as
per contract requirements. The Construction Team in possession of Quality Assurance records
accrued during construction shall transfer same to the QA/QC Team.

 General

Quality Assurance Records are documents providing complete objective evidence of the activities
and items affecting quality during the project.

Quality Assurance Records are to include, but not limited to:

Quality Assurance Manual (QAM)

Quality Control Procedure (QCP)
Work Procedures and ITPs.
WPS WQT history.
All inspection and test reports.
Procedures and Instruction provided by vendors, if applicable.
Material certificate, test certificates including consumables.
As-built drawing, technical specification and procurement documents.

PROJECT QUALITY PLAN

14. QUALITY AUDITS

 Scope

To describe the requirements for quality audits in order to verify the effectiveness and
implementation of the quality assurance system

 Responsibility

QA/QC Manager

Establishment of quality audit schedule.

Assignment of auditors and approval of audit plan.
Approval of audit report.
Coordination with audit team during audit period
Verification of corrective action result for audit finding items.
Reporting audit report to the management.
Notifying the company of resulting report.
Implementation of corrective action against audit finding items during audit

 General

The audit schedule shall be established according to work progress to verify quality activities
throughout the project according to various disciplines. The audit shall be performed at least once
annually.
The leader of audit team shall notify audit scope, schedule and audit team to the audited
organization at least 10 working days before schedule audit. The leader of audit team shall notify
company to observe if they so wish.
Audit team shall perform audit by use of audit check-list after pre-audit conference and audit result
shall be reported on the audit format.
At the conclusion of the audit, team shall conduct post-audit conference with appropriate
personnel of the audited organization in order to inform audit results and corrective action if any.
Audit report shall include audit scope, name of auditors and audited personnel, audit result
summary and audit finding items.
Audit report shall be agreed by the QA/QC Manager and copied to the site Manager.
Audit team shall review corrective action contents against audit finding items and shall perform
additional audit to verify satisfactory response by follow-up. Audit team shall close-out audit
finding report after verification that corrective action is completed. Audit team shall request new
corrective action if the original corrective action is workable.

Audit records shall be controlled as quality assurance records in accordance with the
requirements section 12.

 Audit NCR Numbering System

EGTL-B/JN.JV-AUD-XXX-YYY

XXX Audit Number

YYY Consequetive NCR Serial Number

 Relevant Attachments (APPENDIX 1- Page 36)

Item 11 EGTL-B/N.JV-FORM-011 Internal Audit Schedule

PROJECT QUALITY PLAN

Item 13 EGTL-B/N.JV-FORM-013 Notification of Audit
Item 09 EGTL-B/N.JV-FORM-009 Pre-audit Attendance List
Item 19 EGTL-B/N.JV-FORM-019 Audit Checklist
Item 07 EGTL-B/N.JV-FORM-007 Quality Assurance Audit Report
Item 08 EGTL-B/N.JV-FORM-008 Audit Non-conformance Report
Item 10 EGTL-B/N.JV-FORM-010 Post-audit Attendance List
Item 20 EGTL-B/N.JV-FORM-020 Audit Non-conformance Report Register

PROJECT QUALITY PLAN

 15. APPENDIX 1

Item Form No Description

01 EGTL1-BNS-VES-QAS-QF-000001 Controlled Document Transmittal Form
02 EGTL1-BNS-VES-QAS-QF-000002 Non-controlled Document Transmittal Form
03 EGTL1-BNS-VES-QAS-QF-000003 Correspondance Transmittal Form
04 EGTL1-BNS-VES-QAS-QF-000004 Material Storage Control Register
05 EGTL1-BNS-VES-QAS-QF-000005 “Hold-Construction” (Label)
06 EGTL1-BNS-VES-QAS-QF-000006 “Hold-Material” (Quarantine Label)
07 EGTL1-BNS-VES-QAS-QF-000007 Quality Assurance Audit Report
08 EGTL1-BNS-VES-QAS-QF-000008 Audit Non-conformance Report (NCR)
09 EGTL1-BNS-VES-QAS-QF-000009 Pre-audit Attendance List
10 EGTL1-BNS-VES-QAS-QF-000010 Post-audit Attendance List
11 EGTL1-BNS-VES-QAS-QF-000011 Internal Audit Schedule
12 EGTL1-BNS-VES-QAS-QF-000012 Corrective Action Request (CAR)
13 EGTL1-BNS-VES-QAS-QF-000013 Notification of Audit
14 EGTL1-BNS-VES-QAS-QF-000014 Site Non-conformance Report
15 EGTL1-BNS-VES-QAS-QF-000015 Weld Procedure Specification (WPS)
16 EGTL1-BNS-VES-QAS-QF-000016 Procedure Qualification Records (PQR)
17 EGTL1-BNS-VES-QAS-QF-000017 Welder Performance Qualification (WPQ)
18 EGTL1-BNS-VES-QAS-QF-000018 Welding Operator Performance Qualification (WOPQ)
19 EGTL1-BNS-VES-QAS-QF-000019 Audit Checklist
20 EGTL1-BNS-VES-QAS-QF-000020 Audit Non-conformance Report Register
21 EGTL1-BNS-VES-QAS-QF-000021 Material Receipt/Issue Control Register
22 EGTL1-BNS-VES-QAS-QF-000022 Qualified Welders Register
23 EGTL1-BNS-VES-QAS-QF-000023 Receiving Tank Material Inspection Report
24 EGTL1-BNS-VES-QAS-QF-000024 Over Short Damage Report (OSD)
25 EGTL1-BNS-VES-QAS-QF-000025 Corrective Action Request Register
26 EGTL1-BNS-VES-QAS-QF-000026 Site Non-conformance Report Register
27 EGTL1-BNS-VES-QAS-QF-000027 Document Distribution Register
28 EGTL1-BNS-VES-QAS-QF-000028 Master Drawing and Revision Status Register
29 EGTL1-BNS-VES-QAS-QF-000029 Master Document and Revision Status Register
30 EGTL1-BNS-VES-QAS-QF-000030 Master Control Form and Revision Status Register
31 EGTL1-BNS-VES-QAS-QF-000031 Master Inspection Report and Revision Status Register
32 EGTL1-BNS-VES-QAS-QF-000032 Equipment Calibration Register
33 EGTL1-BNS-VES-QAS-QF-000033 Quality Assurance Manual Revision Status Register
34 EGTL1-BNS-VES-QAS-QF-000034 Daily Erection Activity Report
35 EGTL1-BNS-VES-QAS-QF-000035 Daily Weld Inspection Report
36 EGTL1-BNS-VES-QAS-QF-000036 Welder Qualification ID Badges
37 EGTL1-BNS-VES-QAS-QF-000037 Matertials Status Daily Site Report
38 EGTL1-BNS-VES-QAS-QF-000038 -
39 EGTL1-BNS-VES-QAS-QF-000039 -
40 EGTL1-BNS-VES-QAS-QF-000040 -

PROJECT QUALITY PLAN

 ATTACHMENT 1

CONTROLLED DOCUMENT TRANSMITTAL FORM (CDTF)

No DATE

To

From B/JN.JV

Subject

No Document No Description Rev Qty

1
2
3
4
5
6
7
8
9
10

ALL PREVIOUS REVISIONS TO BE DESTROYED OR CLEARLY MARKED AS ”SUPERCEDED”

Remarks

Sent Name Position Signed Date

Received Name Position Signed Date

Form No EGTL1-BNS-VES-QAS-QF-000001 2 Copies

PROJECT QUALITY PLAN

 ATTACHMENT 2

NON-CONTROLLED DOCUMENT TRANSMITTAL FORM (DTF)

No DATE

To

From B/JN.JV

Subject

No Document No Description Rev Qty

1
2
3
4
5
6
7
8
9
10

ALL PREVIOUS REVISIONS TO BE DESTROYED OR CLEARLY MARKED AS ”SUPERCEDED”

Remarks

Sent Name Position Signed Date

Received Name Position Signed Date

Form No EGTL1-BNS-VES-QAS-QF-000002 2 Copies

PROJECT QUALITY PLAN

ATTACHMENT 3

CORRESPONDANCE TRANSMITTAL FORM (CTF)

No DATE

To

From B/JN.JV

Subject

No Correspondance No Description Rev Qty

1
2
3
4
5
6
7
8
9
10

Remarks

Sent Name Position Signed Date

Received Name Position Signed Date

Form No EGTL1-BNS-VES-QAS-QF-000003 2 Copies

PROJECT QUALITY PLAN

ATTACHMENT 4

MATERIAL STORAGE CONTROL REGISTER (MSCL)

No DATE

ITEM

LOCATION INDOOR OUTDOOR

Non-
Accept Remarks
accept

Storage Facilities

1) Accessibility
2) Cleanliness
3) Fire protection
4) Temperature control
5) Humidity control
6) Security

Storage Method

1) Accessibilty
2) Arrangement
3) Stacking/Racking
4) Segregation-Contamination
5) Segregation-Hazardous
6) Packaging

Control Condition

1) Identification
2) Tagging
2) Protective Cover
3) Preservation Materials
4) Preventive Maintenance
5) Cleaning.

4. Others

Form No EGTL1-BNS-VES-QAS-QF-000004

PROJECT QUALITY PLAN

ATTACHMENT 5

HOLD
(CONSTRUCTION)
SITE NCR NO ________________________

Form No EGTL1-BNS-VES-QAS-QF-000005

Form No EGTL1-BNS-VES-QAS-QF-000005

PROJECT QUALITY PLAN

ATTACHMENT 6

QUARANTINE

HOLD
MATERIALS
SITE NCR No ______________________

Form No EGTL1-BNS-VES-QAS-QF-000006

Form No EGTL1-BNS-VES-QAS-QF-000006

PROJECT QUALITY PLAN

ATTACHMENT 7

QUALITY ASSURANCE AUDIT REPORT

AUDIT REPORT NO EGTL-B/JN.JV-AUD-XXX TYPE OF AUDIT

REPORT PAGES Internal ( ) External ( )

ORGANISATION

AUDIT SCOPE AUDIT DATE(S)

REFERENCE DOCUMENTS
1. ISO 9001-2000-Quality Management Systems
2. Sub-contract No 63727-ON-K007
3.
AUDITEES
1.
2.
3.

(A) Audit Summary

(B) NCR Summary

Continued

PROJECT QUALITY PLAN

(C) Observations

(E) Recommendations

(F) Audit Overview

Audit Team Lead Auditor Audit Team Member

Name Name
Sign Sign

Approved by Received by
Name Name
Designation Designation
Sign Sign

Distribution Attachments
1. 1. Pre Audit Attendance Sheet
2. 2. Audit Check List (+Results)
3. 3. NCR’s
4. 4. Post Audit Attendance Sheet

Form No EGTL1-BNS-VES-QAS-QF-000007

PROJECT QUALITY PLAN

ATTACHMENT 8

AUDIT NON-CONFORMANCE REPORT (NCR)

AUDIT REF EGTL-B/JN.JV-AUD-XXX NCR NO EGTL-B/JN.JV-AUD-XXX-YYY

LEVEL OF CONCERN Major ( )

DATE
Minor ( )

ORGANISATION

ISSUED TO DESIGNATION

REFERENCE DOCUMENTS
1. ISO 9001-2000-Quality Management Systems
2. Contract Documents
3.
AFFECTED ITEM PROCEDURE/METHOD/MATERIALS/DOCUMENTS/RECORDS
1.
2.
3.

Description of Non-conformance

Issued by Acknowledged by
Name Name
Designation Designation
Sign Sign

Date Date
Continued

PROJECT QUALITY PLAN

Proposed Corrective Actions/Comments

Proposed Completion Date

Proposed Actions/Comments Agreed by

Name
Designation
Sign

Date

Corrective Actions Verified And NCR Closed Out by

Name
Designation
Sign

Date

Form No EGTL1-BNS-VES-QAS-QF-000008

PROJECT QUALITY PLAN

ATTACHMENT 9

PRE-AUDIT ATTENDANCE SHEET

AUDIT NO EGTL-B/JN.JV-AUD-XXX AUDIT DATE

ORGANISATION

AUDIT TEAM

Company Name Designation Sign

1.
2.
3.
4.
5.

AUDITEES

Company Name Designation Sign

1.
2.
3.
4.
5.

OBSERVERS

Company Name Designation Sign

1.
2.
3.

Form No EGTL1-BNS-VES-QAS-QF-000009

PROJECT QUALITY PLAN

ATTACHMENT 10

POST-AUDIT ATTENDANCE SHEET

AUDIT NO EGTL-B/JN.JV-AUD-XXX AUDIT DATE

ORGANISATION

AUDIT TEAM

Company Name Designation Sign

1.
2.
3.
4.
5.

AUDITEES

Company Name Designation Sign

1.
2.
3.
4.
5.

OBSERVERS

Company Name Designation Sign

1.
2.
3.

Form No EGTL1-BNS-VES-QAS-QF-000010

PROJECT QUALITY PLAN

ATTACHMENT 11

INTERNAL AUDIT SCHEDULE

YEAR 2009 2010

Audit Schedule
No Activities to be Audited (3 monthly-dependant Comments
on site activities)
1. Doc Control (QA/QC) TBA
2. Doc Control (General) TBA
3. Material Control TBA
4. Erection TBA
5. Welding TBA
6. Welding Consumables TBA
7. NDE TBA
8. Painting TBA
9. Hydrotest TBA
10. Survey TBA
11.
12.

Prepared by Approved by
Name Name
Designation Designation
Sign Sign

Date Date

Form No EGTL1-BNS-VES-QAS-QF-000011

PROJECT QUALITY PLAN

ATTACHMENT 12

CORRECTIVE ACTION REQUEST (CAR)

Response
CAR No Issued Date
Date
Organisation Contact

Related
Document(s)

CAR
Description

Remarks

Prepared by Acknowledged by

Name Name
Designation Designation
Sign Sign

Date Date

Follow-up Result Closed-out

Satifactory ( ) Name
Unsatisfactory ( )* Designation
Sign
*Further Follow-up ( )
*Issue Site NCR ( )
Date

Form No EGTL1-BNS-VES-QAS-QF-000012

PROJECT QUALITY PLAN

ATTACHMENT 13

NOTIFICATION OF AUDIT

ORGANISATION

Audit Reference No

Proposed Date

Scope and Activities to be

Audited
Checklist and Applicable
Documents to be Provided

Auditor’s Team List

Auditee’s Team List

Audit Facilities Required

Auditee’s Alternative Date

Reason

Issued by Acknowledged by
Name Name
Designation Designation
Sign Sign

Date Date

Form No EGTL1-BNS-VES-QAS-QF-000013

PROJECT QUALITY PLAN

ATTACHMENT 14

SITE NON-CONFORMANCE REPORT

NCR NO EGTL-B/JN.JV-NCR-SITE-XXX AREA/TANK

LEVEL OF CONCERN Major ( )

DATE
Minor ( )

ORGANISATION

ISSUED TO DESIGNATION

REFERENCE DOCUMENTS
1.
2.
3.
AFFECTED ITEM PROCEDURE/METHOD/MATERIALS/DOCUMENTS/RECORDS
1.
2.
3.

Description of Non-conformance

Issued by Acknowledged by
Name Name
Designation Designation
Sign Sign

Date Date
Page 1 of 2

PROJECT QUALITY PLAN

 Proposed Corrective Actions/Comments

Proposed Completion Date

Proposed Actions/Comments Agreed by

Name
Designation
Sign

Date

Corrective Actions Verified And NCR Closed Out by

Name
Designation
Sign

Date
Page 2 of 2

Form No EGTL1-BNS-VES-QAS-QF-000014

PROJECT QUALITY PLAN

ATTACHMENT 15

WELD PROCEDURE SPECIFICATIONS (WPS) As per ASME IX. Appendix B

Continued

PROJECT QUALITY PLAN

Form No EGTL1-BNS-VES-QAS-QF-000015

PROJECT QUALITY PLAN

ATTACHMENT 16

PROCEDURE QUALIFICATION RECORDS (PQR) As per ASME IX. Appendix B

Continued

PROJECT QUALITY PLAN

Form No EGTL1-BNS-VES-QAS-QF-000016

PROJECT QUALITY PLAN

ATTACHMENT 17

WELDER PERFORMANCE QUALIFICATIONS (WPQ) As per ASME IX. Appendix B

Form No EGTL1-BNS-VES-QAS-QF-000017

PROJECT QUALITY PLAN

ATTACHMENT 18
WELDING OPERATOR PERFORMANCE QUALIFICATIONS (WOPQ)
As per ASME IX. Appendix B

Form No EGTL1-BNS-VES-QAS-QF-000018

PROJECT QUALITY PLAN

 ATTACHMENT 19

AUDIT CHECK LIST

AUDIT No EGTL-B/JN.JV-AUD-XXX AUDIT TYPE Internal ( ) External ( ) PAGE XX of YY

Prepared by Approved by
Organisation
Designation Designation

CLAUSES
S/N ITEM/DESCRIPTION RESULT COMMENTS
ISO 9001
1.
2.
3.
4.
5.
6.
7.
8.
Continued

9.
10.
-
-

Result: S.: Satisfactory U : Unsatisfactory A : Acceptable with Concern and Reported as Observation N/V; Not Verified

PROJECT QUALITY PLAN

Form No EGTL1-BNS-VES-QAS-QF-000019

PROJECT QUALITY PLAN

 ATTACHMENT 20

AUDIT NON-CONFORMANCE REPORT REGISTER

Proposed Actual
Issued
No AUDIT NCR No Organisation Description of Nonconformance Close-out Close-out
Date
Date Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000020

PROJECT QUALITY PLAN

ATTACHMENT 21

MATERIAL RECEIPT/ISSUE CONTROL REGISTER

Received Issued Stock Comments

No Item Unit
Date Quantity Received by Date Quantity Issued by Date Quantity

1.

Received Issued Stock Comments

No Item Unit
Date Quantity Received by Date Quantity Issued by Date Quantity

2.

Received Issued Stock Comments

No Item Unit
Date Quantity Received by Date Quantity Issued by Date Quantity

3.

Form No EGTL1-BNS-VES-QAS-QF-000021

PROJECT QUALITY PLAN

ATTACHMENT 22

QUALIFIED WELDER’S REGISTER

No Welders ID No First Name Family Name

1. Pipe Plate Fillet

Date WPS No Process
Diameter Thickness Thickness Thickness
Positions Positions Positions
Range Range Range Range
A
B
-
Comments

No Welders ID No First Name Family Name

2. Pipe Plate Fillet

o
Date WPS N Process
Diameter Thickness Thickness Thickness
Positions Positions Positions
Range Range Range Range
A
Continued
B
-
Comments

No Welders ID No First Name Family Name

3.

PROJECT QUALITY PLAN

 Pipe Plate Fillet
Date WPS No Process
Diameter Thickness Thickness Thickness
Positions Positions Positions
Range Range Range Range
A
B
-
Comments

Form No EGTL1-BNS-VES-QAS-QF-000022

PROJECT QUALITY PLAN

ATTACHMENT 23

RECEIVING TANK MATERIAL INSPECTION REPORT

Report No Date Supplier Tank No Tank Name Packing List

Yes ( ) No ( )

Order No Packaging No PackageType General Description

Over Short Damage

No Item Quantity Accept Remarks
(O) (S) (D)
1.
2.
3.
4.
5.
Continued
6.
7.
8.
9.
10.

PROJECT QUALITY PLAN

 -

Inspected By Storage Area OSD Report No

Form No EGTL1-BNS-VES-QAS-QF-000023

PROJECT QUALITY PLAN

ATTACHMENT 24

OVER SHORT DAMAGE REPORT (OSD)

Report No Date Supplier Tank No Tank Name Packing List

Yes ( ) No ( )

Order No Packaging No PackageType General Description

OVER (O)
Quantity Quantity Quantity
No Item Remarks
Ordered Received Over
1.
2.
3.
4.
5.
-
Continued

SHORT (S)
Quantity Quantity Quantity
No Item Remarks
Ordered Received Short
1.
2.

PROJECT QUALITY PLAN

3.
4.
5.
-
DAMAGE (D)
o
N Item Damage Quantity Remarks/Quarantine
1.
2.
3.
4.
5.
-

Form No EGTL1-BNS-VES-QAS-QF-000024

PROJECT QUALITY PLAN

 ATTACHMENT 25

CORRECTIVE ACTION REQUEST REGISTER

Proposed Actual
Issued
CAR No Organisation Description of Corrective Action Requested Close-out Close-out
Date
Date Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000025

PROJECT QUALITY PLAN

 ATTACHMENT 26

SITE NON-CONFORMANCE REPORT REGISTER

Proposed Actual
Issued
No SITE NCR No Organisation Description of Nonconformance Close-out Close-out
Date
Date Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000026

PROJECT QUALITY PLAN

ATTACHMENT 27

DOCUMENT DISTRIBUTION REGISTER

Revision No & Controlled

No Document Title Document No Distributed To: Remarks
Date Non-controlled
1.
2.
1. 3.
4.
5.
1.
2.
2. 3.
4.
5.
1.
2.
3. 3.
4.
5.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000027

PROJECT QUALITY PLAN

 ATTACHMENT 28

MASTER DRAWING AND REVISION STATUS REGISTER

No Drawing No Title Rev Date Status Rev Date Status Rev Date Status
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000028

PROJECT QUALITY PLAN

 ATTACHMENT 29

MASTER DOCUMENT AND REVISION STATUS REGISTER

No Document No Title Rev Date Status Rev Date Status Rev Date Status
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000029

PROJECT QUALITY PLAN

 ATTACHMENT 30

MASTER CONTROL FORM AND REVISION STATUS REGISTER

No Form No Title Rev Date Status Rev Date Status Rev Date Status
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000030

PROJECT QUALITY PLAN

ATTACHMENT 31

MASTER INSPECTION REPORT AND REVISION STATUS REGISTER

No Inspection Report No Title Rev Date Status Rev Date Status Rev Date Status
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000031

PROJECT QUALITY PLAN

ATTACHMENT 32

EQUIPMENT CALIBRATION REGISTER

Calibration Calibration Calibration

No Description Make Model Serial No Remarks
Date Expiry Date Report No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
-
-

Form No EGTL1-BNS-VES-QAS-QF-000032

PROJECT QUALITY PLAN

ATTACHMENT 33

PROJECT QUALITY PLAN REVISION STATUS REGISTER

No Revision No Date Status Revision Description

1.

2.

3.

4.

5.

Form No EGTL1-BNS-VES-QAS-QF-000033

PROJECT QUALITY PLAN