2342-Aa00-Jsm-501 - 0 - Quality Management Requirement For Epc Contractors
2342-Aa00-Jsm-501 - 0 - Quality Management Requirement For Epc Contractors
Page
DOCUMENT REVISIONS
INDEX
1. SCOPE 3
2. DEFINITION 3
3. QUALITY MANAGEMENT SYSTEM REQUIREMENTS 3
3.1. REFERENCE STANDARDS AND DOCUMENTS 5
3.2. LAW, CODE AND STANDARD 5
6. COMPANY PROPERTY 9
6.1. COMPANY INFORMATION/DOCUMENT 9
6.2. COMPANY MATERIAL/EQUIPMENT 10
7. DESIGN 10
7.1. DESIGN OPERATING PROCEDURE 10
7.2. DESIGN QUALITY CONTROL 10
7.3. DESIGN INTEGRITY 10
8. PROCUREMENT 11
9. CONSTRUCTION 12
10. CONTRACTOR QUALITY AUDITING 12
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
1. SCOPE
This specification defines the minimum quality management requirements to be fulfilled by
the EPC CONTRACTOR (here after referred as “CONTRACTOR) during the implementation
of the EPC Project.
CONTRACTOR shall comply with COMPANY requirements set forth in all CONTRACT
specifications and documents tailoring its own specific Quality Management System (QMS)
as described in the Quality Manual and Procedures applicable to the scope of work.
CONTRACTOR shall be totally responsible for the quality of work required by the
CONTRACT.
2. DEFINITION
COMPANY SCOP – State Company for Oil Project
Contract The contract between COMPANY and CONTRACTOR
CONTRACTOR The party which carries out all work of design, engineering,
procurement, construction, commissioning and/or
management of the Project
KPI Key Performance Indicators
Project Karbala Refinery Project
PQM Project Quality Manager
PQP Project Quality Plan
QMS Quality Management System
Subcontractor/Vendor The party which manufactures and/or supplies equipment,
technical documents/drawings and services to perform the
duties specified by COMPANY/CONTRACTOR
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
OVERALL
PROJECT
QUALITY PLAN
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
COMMON PROCEDURES
Until the resolution is officially made by COMPANY, regardless of the above precedence, the
most stringent shall govern.
- Document control
- Records
- Needs and Expectation of COMPANY
- Quality Policy with related Project KPI and Targets
- Project Senior Management Review
- Resource Control (i.e. Personnel, Offices, Hardware, Software, Logistic, Work
Equipment, Telecommunication, Financial Resource) and Resource Mobilization Plan
- Engineering and Design Control (design review input, design output definition, design
development plan and schedule, design verification, design review, design validation,
design changes control to ensure technical integrity of the Plant)
- Purchasing Control (Compliance with Vendor/Subcontractor List)
- Shop Inspection Manufacturing and Shop Fabrication Surveillance, Testing and
Certification of Equipment and Materials
- Independent third Party inspection
- Positive Material Identification
- Preservation and Packing Instruction
- Long Term Storage Instruction
- Erection, Installation, Operating and Maintenance Instructions
- Selection of additional Vendors/Subcontractors
- Subcontractor Quality Management arrangements
- Manufacturer’s Data Report
- Construction Supervision Control
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
5. RESOURCES MANAGEMENT
The CONTRACTOR shall provide resources to implement the QMS as set forth in the
CONTRACT, in terms of personnel, hardware, software and other facilities.
5.1. Personnel
The CONTRACTOR shall assign, to perform the work described in the CONTRACT,
personnel who are skilled and experienced in similar nature of projects; these personnel
shall have adequate knowledge and ability to read, interpret and implement COMPANY
project requirements as specified in the CONTRACT documentation.
The CONTRACTOR shall identify the minimum skill required by the Project activity
implementation, and shall ensure that the necessary training activities are planned, carried
out and documented and its effectiveness evaluated.
The key personnel assigned to Project activities shall be the prime responsible for the
familiarizations with CONTRACT documentation and with Project documents (including the
Project procedures and plans) to be utilized during the Project phases.
CONTRACTOR shall submit to COMPANY within thirty (30) calendar days from the effective
date of the CONTRACT a list, sorted by discipline for each work phase, of proposed Key-
Role Personnel to be approved by COMPANY.
He shall be qualified Auditor as stated in ISO 19011:2002 - Guidelines for Quality and/or
Environmental Management System Auditing, be familiar with QMS Standards and be able
to exercise judgment against the criteria of standards.
He shall have a university degree or equivalent with a minimum five (5) years related to the
Oil and Gas Project Quality Management.
In case of Consortium or Joint Venture, Directorate Quality Manager shall be defined as well
as PQM for each Partner and/or Location of Contractor.
Directorate Quality Manager shall report to CONTRACTOR Representative and shall comply
as minimum with same requirements of above for PQM.
Quality Auditors
He shall have five (5) years QMS experience in auditing activities oil, gas and petrochemical
projects he/she is worked in.
Auditors shall be qualified as stated in ISO 19011:2002 and competent in the discipline being
audited, familiar with QMS Standards and be able to exercise judgment against the criteria
of standards.
Auditors shall have satisfactorily completed a training course and passed the course
examination.
He shall be able to read, write and speak English Language and shall be fully conversant
with applicable Industry Standards and Specifications.
Auditors shall have participated in a minimum of four (4) audits for a total of at least 20 days
including documentation review, actual audit activities and audit reporting during the past
three (3) years.
Procurement Quality Control Coordinator
He shall have a university degree or equivalent and five (5) years inspection experience with
a minimum of three (3) years directly relating to supervision of vendor inspection activities in
the Contract Scope of Work (oil, gas and petrochemical projects, infrastructure,
communication, etc.).
Shop Inspector
As a minimum, he/she shall be a High School graduate, or equivalent.
He shall be able to read, write and speak the English Language.
He shall have five (5) years inspection experience in manufacturing plants, including two (2)
years of this inspection experience in the specific commodity and processes to be inspected.
He shall be fully conversant with applicable Industry Standards, Specifications, and
Fabrication Methods and shall perform a variety of inspection functions with minimal
supervision as required to verify Vendor compliance with the purchase order requirements.
He shall be able to read the Engineering Drawings.
He shall have to knowledge and understanding of ISO 9001:2008 Quality Management
requirements and implementation.
He shall meet an additional minimum requirements for each specific inspection discipline
(welding, NDT, Heat Treatment, Mechanical, PMI, etc).
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
6. COMPANY PROPERTY
6.1. COMPANY information/document
All information, written or oral, drawings and documentation including any information therein
contained, and any business information, delivered by COMPANY or Licensors to
CONTRACTOR, directly or indirectly, shall be considered proprietary information by
CONTRACTOR and shall not be used by CONTRACTOR for purposes other than those
connected with the CONTRACT, nor be disclosed to any third party except when such
information or knowledge:
- is know to the public or becomes part of the public domain through no fault of
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
CONTRACTOR
- is in the possession of CONTRACTOR prior to disclosure by COMPANY as appears.
If, in the course of performing the Project, CONTRACTOR is required to disclose any portion
of COMPANY's or Licensor’s proprietary and/or confidential information to any third party
including the Subcontractors, CONTRACTOR shall secure COMPANY's written approval to
disclose such information, identifying such third party.
Upon such approval, CONTRACTOR shall, prior to disclosure of such information, drawings
and documentation including any information therein contained to any party, enter in to a
secrecy and non-use agreement with such third party.
CONTRACTOR shall provide an explanation with a copy of his standard procedures for
protecting proprietary and confidential technology and information of COMPANY and any
Licensor.
CONTRACTOR shall describe the plan to implement COMPANY security procedures to
protect drawings and other documents. Specifically address:
- Electronic Media Data
7. DESIGN
7.1. Design Operating Procedure
Process Design and Engineering shall be executed under procedural controls and measures
that address validity and accuracy of the input to design and verify that the output of the
design satisfies COMPANY requirements (refer to Vol.3 and Vol.5 of the ITB).
CONTRACTOR shall detail all applicable procedures and checks to be utilized to ensure the
quality of the end product and the processes used to develop it, including all in house and
licensed software, and other engineering and design tools and methods.
CONTRACTOR design output shall comply with Statutory and Regulatory requirements,
Contractual Codes and Standards and Licensor's Design Packages.
CONTRACTOR shall detail all applicable Quality Control procedures and check lists to be
utilized to ensure the quality of the technical deliverables issued on Project.
The Quality Control procedure shall:
- check that engineering output (each deliverable) is correct, complete and consistent
before issue;
- ascertain that CONTRACTOR and/or Project rules, standards and templates have been
applied;
- identify and highlight any design irregularities, together with the appropriate corrective
action.
system shall be established to ensure that each deviation is traceable that all approved
changes are verified as complete.
CONTRACTOR shall submit those design changes to COMPANY for review/approval prior
the work start.
CONTRACTOR shall make sure that no change (or deviation) from specification will be
implemented without previous approval of “Request for Deviation" (DR) by COMPANY (refer
to procedure 2342 AA00 JSM 102 – Project Coordination between COMPANY and
CONTRACTOR).
8. PROCUREMENT
CONTRACTOR shall select its Vendors based on their ability to meet specified requirements
in accordance with specification 2342 AA00 JSM 602 - Criteria for Selection of Vendors.
The request by purchasing documents of all necessary commercial and technical
requirements and data shall be in accordance with Specification 2342 AA00 JSM 601 –
Procurement Guidelines and Requirements.
CONTRACTOR shall carry out the verification of purchased equipment, material, and
services by expediting inspection, surveillance, and surveillance audit. The methods shall
provide for interfaces necessary to coordinate with the COMPANY, certification agency, or
COMPANY's designated inspection monitor/third party as required.
CONTRACTOR and/or its Subcontractors shall prepare detailed Inspection and Test Plans
(ITP) for each type of equipment and materials; each ITP shall identify the inspection level
and detail all witness, hold and certification review points.
As a minimum, each ITP shall contain the process description, the Quality Control
requirements, the notification requirements for Vendor inspection witness and hold points
(minimum five (5) calendar days), the responsibility for inspection test, the applicable
procedures, the acceptance criteria, the inspection points (hold, witness, surveillance,
review).
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
Inspection, test and material certifications shall be documented and the relative records shall
submit to COMPANY within forty eight (48) hours of the visit.
About Special Processes, such as welding, non destructive examination, etc..,
CONTRACTOR shall submit to COMPANY for approval the work procedures, personnel
qualifications and/or personnel qualification procedures, at least thirty (30) calendar days
prior to start of manufacturing.
The qualification records shall be available to the COMPANY Representative on request.
COMPANY reserves the right to reject CONTRACTOR Inspection Personnel before works
starts or during the course of work; CONTRACTOR shall permit COMPANY to interview all
proposed inspectors prior the start of the work.
CONTRACTOR shall establish the procedure for the control, the storage, and the
maintenance of material or equipment supplied by COMPANY, if applicable.
9. CONSTRUCTION
CONTRACTOR shall establish a Quality Control team within its field organization that shall
be familiar with applicable National and International Codes and Standards, Iraq Statutory
requirements and Project specification and standards.
CONTRACTOR shall issue for COMPANY review and approval, one (1) months before the
start of applicable work, the Construction Quality Control Plans for each construction work
category.
Each Construction Quality Control Plan shall cover all work categories and shall detail all
review, witness, surveillance and hold points for COMPANY, CONTRACTOR, and
Subcontractors; it shall also include the methods, the applicable procedures, the acceptance
criteria, the extent and timing for examinations, the measurements or tests.
The Notification requirements for Request For Inspection (RFI) shall be minimum twenty four
(24) hours for site works, forty-eight (48) hours for weekend.
Construction Quality Control Plans and related procedures shall include provisions to ensure
that test prerequisites have been meet, that adequate calibrated instrumentation is available
and used, and that necessary inspection is performed.
The Special Processes, such as welding, non destructive examination, etc…, require the
COMPANY approval of work procedures, personnel qualifications and/or personnel
qualification procedures.
CONTRACTOR shall ensure that these special processes are accomplished under
controlled conditions as specified in all applicable standards and specifications.
All process parameters shall be identified with acceptance criteria specified and monitored.
All Procedures and Personnel Qualification shall be submitted for review at least ten (10)
days prior to the start of the work.
CONTRACTOR shall include an identification procedure for all materials, parts and
components, including partially fabricated assemblies; this procedure shall require that
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
Each audit shall be documented in a written report, which shall be made available within ten
(10) working days since the last day of the audit.
A copy of all audits reports and relative recommended actions (corrective and/or preventive)
shall be submitted to COMPANY, for information.
All quality audits performed by CONTRACTOR, both internal and external, shall be executed
by qualified (in accordance with par. 5.1.1) auditors not directly responsible for the area
being audited.
COMPANY may participate to CONTRACTOR Quality Audit (internal/external) whenever
deemed necessary.
CONTRACTOR shall respond to all Non Conformity Reports issued by COMPANY in writing
within 48 hours of receiving notification of non conformity, including proposed corrective
action.
CONTRACTOR shall investigate the root causes of non conformity items, and initiate
corrective actions to prevent recurrence of non conformities.
CONTRACTOR shall segregate all non conforming design output, materials and assemblies
to a clearly designated rejection site. CONTRACTOR shall track and control all non
conforming equipment or materials until is reused, exported, or otherwise disposed of.
CONTRACTOR shall notify the COMPANY Representative of the disposition of all rejected
materials on a monthly basis.
The Project (Quality) Objective/Targets shall be documented in the PQP and its monitoring
shall be submitted monthly to COMPANY.