Monday, August 10, 2009

Quality Assurance Plan 2 of 6

2.1. CONTRACTOR Quality assurance policy shall be formulated to achieve the product and services, which are defined as on time schedule, competitive project cost, safely execution and operation, are compliance with the OWNER requirements. As apart of quality assurance is to satisfy the OWNER at all stage of project, from design until commissioning.

2.2. CONTRACTOR’S executive management shall be required to confirm their commitments to implement this plan by signing the QA policy statement.

2.3. PM and each relevant Manager are responsible for assuring that all phases of the program for which he is responsible are operating strictly in accordance with the QA program.

2.4. QA/QC Manager and his delegates have organizational freedom from disciplines, being directly responsible for performing the work, and have the authorities to conduct audit, identify quality problem and to guide solutions.

This section covers the organization and its authority and responsibility in the performance of activities affecting quality related to the project.

3.1. Organizational Chart
See Attachment -1

3.2. Authority and Responsibility

Project Manager has overall authority and responsibility for the execution of the project regarding the contractual condition, the establishment of the project organization and coordination, the implementation and maintenance of QA Plan, monitoring the job quality, the effective cost and schedule control, and the entire project management.

Engineering Manager is responsible to report to PM for all engineering aspects of the project and for assuring that the design is made in compliance with the applicable specifications. He shall coordinate overall engineering activities.

3.2.3. Lead Project Planning and Control
Lead Project Planning Control is responsible to report to PM for the control of cost, schedule, documents, material and loss prevention control on the planning and execution.

Construction Manager is to assist PM to handling the construction activities and ensure that the activities are in accordance with the requirements of this plan.

Procurement Manager is responsible for all aspects of the procurement of equipment, material and services, including purchasing, expediting and shipping. He shall establish the procurement policy including the activities specified by the QA Plan.

In order to ensure the implementation of the QA Plan, QM will be assigned in the project organization. He will report directly to the PM. QM will have sufficient authorities, organization freedom, and direct access to all managers to perform his duties.

Safety, Health and Environment Manager shall assist the PM in conducting the safety, health and environment programs under the direction of PM. The HES Manager shall check the concept of each work plan or procedure and report his conclusion to the PM.

Material and Logistic Manager shall be responsible to the PM for overall control of materials, including receiving, checking, inspection, storing, issuance, handling over and disposal of material.

Commissioning Manager is to assist PM by offering a testing and commissioning requirement related to project specification.

3.3. Delegation of Authority
Each manager has the responsibility for the functions assigned to him. The manager may delegate his tasks to the designated personnel. However, this does not relieve him of his responsibility.

At the award of the contract as applicable, CONTRACTOR shall arrange and conduct a preliminary review of the contract package to ensure that:
4.1. Project requirements are adequately defined and documented
4.2. Any requirements are in compliance with any applicable codes and standards.
4.3. When incomplete, ambiguous or conflicting input are found in the course of the contract review, CONTRACTOR’S Project Manager will discuss with OWNER to draw up the requirements and the result shall be recorded for confirmation.

5.1. General
This section covers the design and engineering control procedure to ensure that CONTRACTOR’S design is performed in strict compliance with OWNER’S requirements, applicable laws and regulation, codes and standards, and that the quality requirements for equipment and materials are properly attained.

5.2. Establishment of Design Interface
5.2.1. Design Interface between OWNER and CONTRACTOR
Engineering Manager shall control design interfaces by identifying design and engineering responsibilities and establishing the ‘COORDINATION Meeting”
The design information transmitted across the interface between OWNER and CONTRACTOR shall be incorporated in such documents as P&ID, Plot Plan, Data sheet, etc, for proper control.

5.2.2. Design Interface within CONTRACTOR
Engineering Manager shall plot design activities, identify design inputs and outputs, etc. The internal screening meeting shall be held to resolve interface problems by cross check and collation between relevant design groups in a timely manner. Physical design interface are identified by internal coordination meeting of design groups within the design division.

5.2.3. Design Interface between CONTRACTOR and Vendor
In accordance with Vendor print handling procedure, etc, communication lines, key personnel, documents to be submitted, witnessing, and other information transmitted across the interfaces shall be identified in the purchase specification. Where necessary, the meeting for engineering coordination shall be held between Vendor and CONTRACTOR.

5.3. Design Process Control
5.3.1. Review of Design Input from OWNER Engineering Manager shall conduct a preliminary review of the contract package to ensure that the requirements are adequately defined and documented and that any requirements differing from those in the tender documents are resolved. Engineering Manager shall identify the design requirements such as OWNER’S basic design data, regulatory requirements, applicable codes and standards, etc to provide the consistent basic for succeeding design work. Design input shall be coordinated by Engineering Manager, considering the past experiences of the similar plants, the feed back data, etc. When incomplete, ambiguous or conflicting inputs are found in the course of engineering review, Engineering Manager shall discuss with OWNER for drawing up the requirements.

5.3.2. Document Preparation On the basis of design inputs, Design Engineer shall prepare design and engineering documents, such as data sheets, specifications, instructions, drawings, procedures, etc. The documents shall meet design-input requirements, contain or reference product and/or acceptance criteria, and conform to applicable statutory requirements.

5.3.3. Review and Approval Authorization with Design Group
Documents prepared by Design Engineer shall be reviewed and approved by his lead Engineer. As to the Vendors/ Subcontractors design documents. Inter-Discipline Check
The Design Engineer and his Lead Engineer shall initiate Inter-Discipline Checks, when the contents of a design document require review by the other pertinent discipline(s). Comments generated during Inter-Discipline Check shall be reflected in the design documents. For the documents to be submitted to OWNER, section 6 of this Plan shall be referred to.

5.4. Design Verification
5.4.1. Design verification shall be conducted to verify, confirm, and substantiate the design, taking the importance to safety, complexity, degree of standardization, the state of art, and the similarity to previously proven design, the assumption, etc into account.

5.4.2. The design verification shall be conducted by means of the following measures such as:
- Undertaking demonstration or qualification test(s)
- Carrying out alternative calculations
- Scrutinizing by comparing the design with the similar proven design, if applicable.

5.5. Control of Design Changes
5.5.1. Changes to design documents such as specifications, procedures, drawings, etc shall be reviewed and approved, in principle, by the same manner as applied to the original.

5.5.2. In the event that inconsistency or inadequacy is found, the finder shall request the originating design group to change the document, using Engineering Revisions Request and Engineering Revision Instruction sheet.

5.5.3. The proposed change shall be evaluated for correctness and the effectiveness including the impact on fabrication, schedule, cost, etc.

5.5.4. The changed parts shall be marked for easy identification, and the revision date, revision number, and the reason of the change shall be noted on the document.

5.5.5. The changed document shall be submitted to OWNER for approval. The original copy of approved documents, including “As built” drawings, shall be submitted to OWNER.

5.5.6. Obsolete documents shall be destroyed or withdraw for disposition.

5.5.7. Files containing copies of the latest revision of documents shall be maintained and be easily accessible for use.

5.6. Engineering Hold
Design Engineer shall identify the engineering hold, when the design is uncertainties. The relevant work involved in such engineering hold shall not be proceeding without the clear solution given by responsible Design Engineer.

5.7. Deviation and/or Alternative
If it is by Design Engineer that any alternations to, or deviation from the contract package or engineering documents supplied by OWNER are necessary, the proposed deviation and/or alternatives shall be submitted to OWNER through Lead Engineer and Engineering Manager for approval with the explanatory data.

6.1. General
This section covers the procedure to control all documents affecting quality to assure that documents are processed properly, and that the latest applicable documents are available to the personnel or organization concerned on schedule.

6.2. General Control Measures
6.2.1. Responsibility Prior to commencement of the work, Engineering Manager shall list up all the engineering documents to be prepared for the work, such as procedures, instructions, drawings, checklist, including Vendor’s/ subcontractor’s. He also shall identify the categories of documents (for approval, for comment, for information). Controlling staff is responsible for the document control. He directs Document Controller to collect, distribute and totally control documents.

6.2.2. Identification and Control of Documents. Numbering of documents
Each documents prepared by the relevant discipline shall be assigned a unique number in accordance with the Document Numbering System establish for the Project. Listing of Documents
Document Controller shall list up the documents to be submitted to OWNER. It shall be updated for issuance, receipt, and approval to identify the current document status. Filling of Documents
Document Controller shall establish a filling system of project documents to facilitate the availability and retrieval of documents and to keep the documents updated. Distribution of Documents
Document Controller shall enter into the document list and the specified numbers of copies are sent with a document transmittal sheet to the proper location.
The receipt acknowledgment signature shall be obtained on the Transmittal sheet. Special care shall be taken on the revised documents.

6.3. Control of OWNER Supplied Documents
6.3.1. Documents furnished by OWNER shall be clearly identified and maintained by Document Controller separately from other documents. Engineering Manager is responsible for the maintenance and distribution of OWNER supplied design documents.

6.3.2. Review and Change
Where any discrepancies are found through the design checking or review, a responsible Design Engineer for the document shall notify and propose the change request and submit it to OWNER through Engineering Manager and Project Manager for approval. In an urgent case, notification by oral communication may be made followed by written notes. The Internal procedure for the preparation, revision and distribution will be the same as per 5.3 and 5.5 of this procedure.

6.4. Control of Documents Prepared by Vendor
Document Controller shall control all receiving, recording, distributing and filling vendor’s documents. The document control system is basically the same as the general process described above, except inspection records which Inspection Coordination is responsible.
Manufacturing work specified in Vendor’s design documents shall proceed only after obtaining CONTRACTOR’S approval.

6.5. Control of Outdated Documents
The obsolete document copies shall be destroyed by the responsible person in accordance with the instruction contained in the document transmittal sheet, after the substitution with the latest version. Document Controller shall check the receiver acknowledgment to confirm that the latest approved documents are used at proper locations.

6.6. Design Document Control at the Construction Site
6.6.1. Design documents required for field construction will be prepared by CONTRACTOR’S home office and distributed to the site by Engineering Manager.

6.6.2. Field document controller designated by Construction Manager is responsible for the document control at site. He shall establish Site Document Control System on the basis of home office system, taking into consideration the site special situation.

6.6.3. Field Document Controller shall identify the document transmitted from home office and control the distribution using the site Document List.

6.6.4. If it becomes necessary to change the design, Chief Field Engineer shall contact home office through Construction Manager to obtain the direction. When a design changes a deliverable that has already been released to OWNER, Chief Field Engineer shall obtain OWNER’S review and release of the revised deliverable before proceeding with the change. Where a design change does not change a document or drawing that OWNER review as a deliverable and it is practicable to change at the site, he makes the change and, after approval at the site, where necessary. However, he shall report the changes to home office for the change and record.

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