Tuesday, March 31, 2009

Quality Assurance Plan 3 of 6

7. PROCUREMENT CONTROL

The section covers the procedure to ensure that purchased products and services conform to specified requirements.

7.2. Control of Procurement Document
7.2.1. Preparation of Requisition.
Design Engineer shall prepare the requisition on the basis of the OWNER’S basic Engineering data, including the following, as deemed necessary:
- Scope of Supply
- Delivery Date and Location
- Applicable Project Codes, standards, OWNER’S specifications and CONTRACTOR’S design and QA/QC documents.
- Requirements for personnel qualification, inspection and test, and shipping preparation and reporting.
- QA/QC requirements, such as the establishment of QA Program, non-conformance control, inspection requirement, the extension of QA/QC requirements to the lower tiers, etc.
- Documents to be supplied to Vendor - Vendor’s documents required, such as; Fabrication procedure, Welding Procedure Specification & Procedure Qualification Record, Qualified Personnel List, Inspection and Test Procedure, QA/QC Plan, Inspection and Test Records, Special Process Records Technical Documents, etc.
- Right to access and Guarantee Description .

7.2.2. Review of Requisition.
A review of requisition and changes thereto shall be made to assure the adequacy of specified requirement. Review and approval shall be conducted in the same way as described in para.5.3.3. Procurement Manager shall check the requisition and attach the necessary documents for the inquiry or for the Purchase Order. Project Managed shall give the final approval.

7.3. Selection of Vendor.
7.3.1. CONTRACTOR shall select potential Vendors in principle among “Vendor List” which will be establish between OWNER and CONTRACTOR.

7.3.2. Procurement Manager shall issue Request for Quotation to potential Vendors.

7.3.3. Upon request of Project Manager, QA/QC Manager shall perform QA/QC surveillance to Vendors in accordance with the QA levels of products and services to be made. The result shall be reported to Project Manager.

7.3.4. The selection of Vendor, and the extend of control shall be dependent upon the type of products and services, Vendor’s demonstrated capacity and past performance of the similar work, the evaluation of Vendor’s quotation, QA evaluation, and the capability on schedule and cost.

7.3.5. The final Vendor List shall be submitted to OWNER for approval.

7.4. Evaluation and Verification of Vendor’s Performance.
After the Purchase Order, CONTRACTOR exerts the following control.

7.4.1. Review and Approval of Vendor’s Documents Vendor’s documents shall be reviewed by Design Engineer or Inspection Coordinator and approved by engineering Manager for their compliance to the requisition. Where it deems necessary, design Engineer shall send them to the relevant engineers for Inter- Design Check.

 7.4.2. Control and Verification of Vendor/ subcontractor Performance.

7.4.2.1. A kick-off meeting and pre-inspection meeting will be held between CONTRACTOR and Vendor for coordination and mutual understanding. At the monthly coordination meeting, the status of progress, schedule of inspection and major problems are reported, discussed and confirmed.

 7.4.2.2. CONTRACTOR or his representative shall be afforded the right to access Vendor’s facilities for communication and inspection.

7.4.2.3. Procurement Manager shall keep abreast of the current status and expedite Vendor’s manufacturing and delivery schedule of products, and shall report to Project Manager.

7.4.2.4. Inspection shall be performed to verify and confirm the compliance of products to the specification.

7.4.2.5. Audit shall be performed on QA activities of Vendor, as necessary, taking the performance status into account.

7.5. Control Sub-vendor.
At the Pre-inspection meeting CONTRACTOR and Vendor, Inspection Coordinator shall check the quality requirements of Vendor to his Sub-vendor.

This section covers the identification procedure of products to assure the correctness of products, maintenance of traceability, and the prevention of inadvertent use of incorrect products including Field activities.

8.2. Identification Procedure.
8.2.1. Physical Identification Physical Identification using low stress die stamping shall be used to the maximum extent possible. Where physical identification on the item is impractical, physical separation procedure control such as by tags, labels and records shall be employed.

8.2.2. In-Process Identification.
- A transfer of marking shall be controlled.
- Identification during storage shall be controlled (separation, tag, etc).
- Non-conforming items shall be identified and separated.
- Inspection status (accepted, rejected, not yet inspected) shall be identified.

8.2.3. Marking shall be applied in a manner and at a location that would not leave detrimental effects on the items.

8.3. Records.
The record shall be traceable to the item and shall be checked by Inspector. Where required, vendor shall submit “As-built Sketch of Material Allocation” in which the marking location including weld-line numbers are shown to CONTRACTOR.

To Prevent the installation of incorrect materials of construction for low chrome and alloy materials in process or pressure containing duty, CONTRACTOR shall attach “Alloy Verification Procedure” to the Purchase order for the relevant Vendors and Subcontractor, in which the requirements or examination methods, the qualification of inspectors, sampling methods, acceptance criteria, identification marks, record, etc, are defined.
The Vendor’s/ Subcontractor’s procedure shall be reviewed and approved by CONTRACTOR.

This section covers the procedures for controlling work procedures and special processes, which are common in fabrication and installation stages to ensure that the processes are performed under controlled conditions.

9.2. General Control of Fabrication and Installation.
9.2.1. Environmental Control
9.2.1.1. Vendor/ Subcontractor shall establish the control measures to keep working area clean and under suitably controlled conditions to prevent products from mixing-in of foreign materials and not to cause detrimental effects on products.

9.2.1.2. CONTRACTOR shall check the controlled status of working area at witness inspection or by patrolling, as appropriate, and give recommendation for correction, if any.
9.2.2. Fabrication and Installation Planning.
9.2.2.1. Design engineer and Inspection Coordinator shall identify applicable regulations, codes, and standards for fabrication and installation, inspection and monitoring points, acceptance criteria, etc, as appropriate, in the procurement documents.

9.2.2.2. For major products, design Engineer shall request Vendor/ Subcontractor to submit procedures in which process sequence, inspection and/ or monitoring items and the methods are made clear.

9.2.2.3. CONTRACTOR/Vendor/ Subcontractor are requested to prepare travelers, check lists, records, etc. to monitor and confirm the compliance of work and products with the requirements.

 9.2.2.4. Where qualification is required for specific work, the qualification procedures and the records shall be maintained.
9.2.3. Controls during Fabrication and Installation.
9.2.3.1. Prior to the commencement of significant work, PM/CM will hold a kick-off meeting between CONTRACTOR and Vendor/ Subcontractor for manual understanding and confirmation.

 9.2.3.2. CONTRACTOR shall perform the continuous monitoring of processes to ensure that the specified requirements are met.
9.2.3.3. When it becomes necessary to change procedures in the course of fabrication and/ or installation, CONTRACTOR and Vendor/ Subcontractor shall get into communication with each other to make proper change or take corrective actions.

9.3. Special Process Control.
9.3.1. Welding Process Control.
9.3.1.1. Welding shall be controlled in accordance with the regulation, codes and standards, etc. design Engineer of Engineering group shall specify the requirements:
- Detailed drawing of welding configuration.
- Welding Procedure Specification.
- Welding Procedure Qualification Test Report.
- Qualified Welder List.

9.3.1.2. In the requirements, acceptance criteria in accordance with the applicable codes and standards and the use and maintenance of proper equipment shall be included.

9.3.1.3.The relevant design engineer shall review and approve Welding Procedure Specification and Procedure Qualification Record. Inspection Coordinator will confirm them and specify inspection items, witnessing, required records, etc. in the inspection and test program.

9.3.1.4. CONTRACTOR/ Vendor/ Subcontractor shall establish control measures to identify qualified welders, kinds of qualification and terms of validity. Superintendent shall monitor maintenance of welder performance by checking welding reports and/or through daily supervising, and recommend the retaining, etc. of the degraded welder, if necessary.

9.3.1.5.Welding materials, especially coated electrodes and filler materials shall be controlled of the identification, storage, delivery, backing, and holding, and the use.

9.3.1.6. Welding especially on the pressure retaining parts shall be recorded of the items specified in the Welding Procedure Specification including pre and/or post-heat treatment. Inspector or Superintendent will check welding records and evaluate the control status of welding.
9.3.2. Control of Other Special Processes.
9.3.2.1. Other special processes such as heat treatment, non-destructive examination, cleaning, special leak test, etc. shall be performed by the procedures, equipments specified by relevant Design Engineer.

9.3.2.2. CONTRACTOR/ Vendor/ Subcontractor shall submit the procedure for approval, as required. After obtaining the approval, they shall perform special process in accordance with the approved procedure by qualified or adequately proficient personnel, using calibrated equipment and proper materials. They also shall perform adequate monitoring during the process and generate the work record.

9.3.2.3. CONTRACTOR’S Inspector shall check and confirm the work and the results through the work records.

9.4. Training.
9.4.1. In the event that qualifications are required for special processes and/or personnel performing specified work, CONTRACTOR shall specify the qualification in the purchase specification, as appropriate.

9.4.2. CONTRACTOR/Vendor/ Subcontractor shall establish and perform necessary training to obtain the qualification and to maintain the required skill.

9.4.3. Identification methods for the qualified procedures and/or personnel shall be established, and the appropriate records shall be established and maintained.

9.4.4. CONTRACTOR shall confirm the qualification and monitor the performance, and when any degradation is found, require Vendor/ Subcontractor to do retraining.

10. INSPECTION AND TEST PLAN.
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