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LNG EPC
Code Description
A Proceed - No comment
B Proceed - With comment
C Do Not Proceed - Revise &Resubmit
D Cancelled
E Received as information
Signature:
2017.01.0 2017.01.06
6 13:02:39
09:35:23 Shunji Takeuchi +07'00'
+07'00'
B01 Approved for Use Sri Adi W 5-Jan-17 N. Seniawan 5-Jan-17 S. Takeuchi 5-Jan-17
A04 Re-Issued for Approval Sri Adi W 27-Dec-16 M. Sugai N. Seniawan 27-Dec-16 S. Takeuchi 27-Dec-16
A03 Issue for Approval Sri Adi W 27-Nov-16 M. Sugai N. Seniawan 27-Nov-16 S.Takeuchi 27-Nov-16
A02 Re-Issued for Review Sri Adi W 8-Nov-16 M. Sugai N. Seniawan 8-Nov-16 S.Takeuchi 8-Nov-16
A01 Issue for Review Sri Adi W 5-Oct-16 N. Seniawan Ninomiya.K 5-Oct-16 S.Takeuchi 5-Oct-16
Rev Reason for Issue Author Date Checked Date Approver Date
! This document is copyright and shall Document Number CONTRACTOR Doc Number
not be reproduced without the
permission of BP
TEP-930-PLA-QA-BP4-0007 870310-PTS-930-QUA-PLA-00802
Document Class
© BP p.l.c.
Security Classification:
BP Internal 2
Tangguh Expansion Project – LNG EPC
Project Quality Plan For Site Construction
Table of Contents
1 Introduction ................................................................................................. 6
1.1 Project Overview ...................................................................................................6
1.2 Purpose & Scope ...................................................................................................6
1.3 Symbols, Abbreviations and Definitions .................................................................7
2 CONTRACTOR’s SITE Organization ............................................................... 9
2.1.1 On SITE Project Organization ....................................................................................... 9
2.1.2 On SITE Project QC Organization ................................................................................. 9
3 Responsibility............................................................................................... 9
3.1.1 SITE Manager and Responsibilities ............................................................................... 9
3.1.2 Field QC Manager and Responsibilities........................................................................10
3.1.3 Site QC Engineer and Responsibilities .........................................................................10
3.1.4 Site QC Inspector and Responsibilities ........................................................................11
3.1.5 NDE Coordinator and Responsibilities .........................................................................12
3.1.6 Welding Quality Engineer and Responsibilities ............................................................12
3.1.7 PCOS Administration and Responsibilities ...................................................................12
3.1.8 Delegation and Authority (DOA)...................................................................................13
6 Attachments .............................................................................................. 36
6.1 Attachment # 1 – General Document/Procedures ................................................36
6.2 Attachment # 2 – RFI Work Flow .........................................................................36
6.3 Attachment # 3 – QCP Work Flow .......................................................................36
Revision History
Amendment Revision Amender Name Amendment
Date Number
5-Oct-16 A01 Sri Adi W Issue for Review
7-Nov-16 A02 Sri Adi W Issue for Re-review
27-Nov-16 A03 Sri Adi W Issue for Approval
27-Dec-16 A04 Sri Adi W Re-Issued for Approval
5-Jan-17 B01 Sri Adi W Approved for Use
OMS references
OMS section ref OMS section title Relevant section of this
document
Related documents
Document number Document name Description of
Content
TEP-930-PLA-QA-BP4-0003 Project Quality Plan for EPC
Stakeholders
Name Date Reviewed
1 Introduction
1.1 Project Overview
BP Berau Ltd., hereafter known as COMPANY, is the operator of Tangguh LNG, a two train natural
gas (NG) liquefaction facility in Bintuni Bay, Papua, Indonesia. The facility includes associated onshore
infrastructure, two offshore platforms, pipelines and twelve wells. These facilities are the Trains 1 and
2 development at Tangguh.
COMPANY has initiated the Tangguh Expansion Project to commercialise the incremental resource
into high margin gas markets based on a single LNG (liquefied natural gas) train expansion (Train 3).
Tangguh Expansion Project will consist of new offshore facilities, including wellhead platforms and
pipelines, and onshore development on the existing Tangguh brownfield site. The new onshore
facilities will include one additional natural gas liquefaction train of a similar design and capacity to the
existing trains, an onshore receiving facility (ORF), new LNG and condensate loading berth, additional
boil off gas (BOG) recovery, condensate storage tank, utilities, flares and the infrastructure to support
logistics and the associated increase in the temporary and permanent workforce.
commissioning and start up activities carried out for the Tangguh Expansion Project are performed in
compliance with the Project requirements and in line with TEP-930-PLA-QA-BP4-0003 Project Quality
Plan for EPC. It shall not cover all TEMPORARY WORK activities.
The quality plan measures as presented herein include quality control organization; methods of
performing, documenting, and enforcing quality control operations of both the CONTRACTOR and
SUBCONTRACTORS (including inspection and testing); inspections to be performed; and protocol
describing corrective actions.
This Project Quality Plan for Site Construction shall apply to project scope of the PERMANENT WORK
which is applicable for
ITP (Inspection and test Plan), Specific Section(s) of QCP that identify and
define Inspection sequences. It is prepared in accordance with the
corresponding ITP(s) of QCP and with all the applicable contractual,
PT Penetrant Testing
UT Ultrasonic Testing
RT Radiography Testing
SITE General Designation to define the various locations of the Project facilities
MECHANICAL The point at which a plant system or the entire plant has been physically
COMPLETION
completed , inspected, cleaned and documented to be in accordance with
drawings, specifications, code, applicable laws and regulation and is ready
for safe Dynamic Commissioning.
CONTRACTOR’s SITE Organization Team shall be responsible for all aspects of the management and
execution of the Site WORK, including but not limited to planning, control, reporting, supervision,
administration, management of SUBCONTRACTORS, quality management, expediting, HSSE
management, local content management and obtaining all necessary APPROVALs, clearances and
permits, all in accordance with the SPECIFICATION.
Refer to below procedure for details organization chart:
- TEP-930-ORG-PM-BP4-0001 Project Organization Chart
- TEP-930-ORG-CU-BP4-0001 Project Field Office Organization Chart
In case of any rotation, Field QC Manager/his deputy shall responsible to manage all site QC
resources’ scheduled under his supervision efficiently and delegates the task to other person who is
capable of and is willing to undertake the assignment
3 Responsibility
3.1.1 SITE Manager and Responsibilities
SITE Manager reports directly to the Project Director and he has the responsibility and authority
delegate by the Project Director as below:
• SITE Manager shall be responsible to manage, plan and supervise all CONTRACTOR and
SUBCONTRACTORs activities at the SITE.
• SITE Manager shall be responsible for all SITE-related Quality programmes, PERSONNEL
management which includes preparation, MOBILISATION, SITE activities and demobilisation of
PERSONNEL and to deliver the WORKS in accordance with the CONTRACT.
• Establishment and maintenance of inspection and test plans on their functions based on the
Inspection and Testing Plan;
• Coordinate the inspection program, testing and do review of the inspection reports; including
coordination with the third party inspection as applicable.
• Review of corrective actions to be taken for nonconforming items of equipment and material for
construction work
• assessing and approving quality control personnel of the organizations in charge of works;
• prepare and review quality control plans within remit;
• checking work procedures, including those relating to special processes;
• checking that material and equipment are correctly received, stored, preserved and handled;
• checking that materials are correctly identified and traceable;
• checking, insofar as within remit, the “test packages” provided for the final checks;
• checking the documents certifying the tests, controls and inspections carried out and ensuring
their orderly collection and management;
• checking procedures and equipment to be used in tests, controls and inspections and agreeing on
the applicable operating procedures with the organization in charge of the works;
• attending the tests, controls and inspections carried out by the CONTRACTORs, checking
conformity with the Site Quality Control Plan and obtaining the relevant documentation;
• helping with the systematic collection of lessons learned on the individual site;
• ensuring the preparation of the QA/QC discipline dossier for final handover to the COMPANY;
• Providing specialist support to the FQCM in relations with the COMPANY and the responsible
Authorities and reporting problems that cannot be directly resolved.
Designating site surveillance team after coordination with Construction Manager and Field QC
Manager;
Reviewing site surveillance report and corrective action respond.
• Ensuring all inspections are held correctly and proven with an inspection report;
• Initiating NCR for any discrepancy that fails to meet the project requirement or acceptance
criteria;
• Any other activities required for achieving the desired level of quality
• Coordination with SUBCONTRACTORs and the Third Party NDE Inspection Company;
• Coordinating all welding procedure specification and procedures qualification reports with
SUBCONTRACTOR;
This activity includes the verification in advance of the Certification/Degree Level required for the
single Quality Inspector, and eventual planning of further Training, in order to reduce the duplication of
site functions (e.g. Civil Inspector, if properly qualified, can also be HVAC Inspector).
Refer to Project QA/QC Organization for the resources required Document No: TEP-930-ORG-QA-
BP4-0001
• assessment and approval of quality control personnel (also supported by the Project
Quality Manager)
• preparation and/or verification/approval of Site Quality Control Plans (also supported by the
Project Quality Manager)
• definition and Implementation of Quality section of test packages for piping system
inspections
• scheduling QC meetings
Field Quality Control Manager, with the support of (Discipline) QC Engineer ensures that the timely
presence of QC Inspectors for the planned inspections.
Construction Manager, with the support of Discipline Superintendent, ensures the coordination for
effective planning and implementation of inspections, for construction and pre-commissioning
activities
All activities under quality Control shall be clearly defined in procedure or method statements,
detailing: scope of work, how and where it will be performed, work execution and verification
responsibilities and relevant quality records.
All stages of Construction shall be inspected using the applicable Project QCPs, detailing the quality
Inspections to be performed by the Construction SUBCONTRACTOR with allowance for
CONTRACTOR, COMPANY and Migas/TPI surveillance/witness/hold point interventions
- Typical QCPs list provided in the TEP-930-SPE-QA-BP4-0003 Quality Requirements for Site
Subcontractor.
- TEP-930-EM-BP4-0003 EPC Master Document Register for actual QCPs issued for this
project
The Inspection Test Plan (ITP) defined in the Quality Control Plan (QCP) are loaded in PCOS and
represent a set of test codes, each one identifying a specific inspection or test to be performed during
the execution of the works Once the certification is completed, the scanned copies of the certificates
are digitally stored in the system for future reference and use
Testing shall be performed in accordance with written test procedures defined in QCP. Such test
procedures shall incorporate or reference the requirements as contained in the contract technical
specifications, codes, and industry standards. SUBCONTRACTOR shall submit the test procedures to
the CONTRACTOR and COMPANY for review and acceptance prior to their implementation.
For any additional inspection required which is not covered by QCP provided by CONTRACTOR, the
SUBCONTRACTOR shall prepare new QCP/ITP for CONTRACTOR approval. The new
QCP/ITP/Inspection Forms shall be made in the same format with CONTRACTOR’s QCP, and shall, as
a minimum, contain the required scope of inspections to satisfy all contractual, engineering and
Suppliers applicable documentations, specifications, standards and codes pertinent to the specific
parts an or items of the Works
Construction SUBCONTRACTOR shall submit to CONTRACTOR for approval all new “Inspection
Form” prior to include them in QCP/ITP(s) for site implementation.
“Inspection Form” shall be filled up with all information required to record the details of the
Inspection activity performed and will become “Certificate” once signed by the parties involved in the
inspection. For this purpose, the Inspection Form shall be compiled with all information indicated in
the template title blocks, as well as traceability and numbering information and data relevant to the
inspection performed such as but not limited to:
- inspection checklist;
- applicable parameters;
- tolerances;
- explanatory notes if necessary (e.g. reference to previous records in the case of unsuccessful
previous tests);
- test date;
• ITPs;
• Technical Quality documentation of the materials supplied at site not subject to control
by the Vendor Inspection;
In the event that QCPs have to be prepared at Site, the Field Quality Control Manager
ensures:
b. Field Quality Control Manager verifies the planning of operations by the organizations involved
in the inspections
c. Field Quality Control Manager ensures distribution of the QCPs to the (Discipline) QC Engineer
functions to check the conformity of quality control documents issued for prefabrication/Site
Construction works.
d. (Discipline) QC Engineer checks, within his area of responsibility, the conformity of the
SUBCONTRACTOR QCP/ITPs and documents concerning quality control activities with respect
to the quality requirements specified for the project.
e. Field Quality Control Manager involves Site Engineering Manager in the checking process when
any of the following occur:
• requirements concerning quality control for which a request for exemption or deviation
has been requested
• complex assemblies for which the SUBCONTRACTOR has already expressed or must
express specific control requirements, instructions and recommendations for assembly
activities
• Whenever verification of the technical accuracy of the QCP/ITPs and the quality control
documents is considered necessary.
f. Field Engineering Manager ensures the checks indicated in the previous item, with the
assistance of the Discipline superintendent and Discipline Engineer functions and/or involving
Project home office when necessary for further checking by the Engineering Disciplines of the
Engineering Department.
For the high critical SUBCONTRACTORs, some activities will be carried out as follows;
- CONTRACTOR will perform the assessment at their pre-fabrication shop or site, the Field
QC Manager or his delegation shall perform readiness assessments to evaluate the
SUBCONTRACTOR’s planning and preparedness for the commencement of prefabrication or
construction activities. The objective is to proactively identify any potential deficiencies or
omissions early, thereby allowing time for any corrective actions to be implemented prior to
commencement of the discipline activity.
- CONTRACTOR will also perform audit which respect to the progress activities which detail
program explained on the Project Audit Schedule
- Perform Construction Surveillance Activities which will be detail by the by the specific
program and also consider the maturity of the project QMS implementation at site
An area shall be provided for non-destructive testing. The area shall be located at a safe distance
from the working area to conduct radiographic inspection without interrupting the prefabrication. The
area shall comply with all statutory and safety requirements.
The surface preparation and painting of prefabricated items shall be done in a separate are and
adequate undercover workshop facilities shall be provided.
CONTRACTOR purchased materials which are received at Site Warehouse are verified by Project
Store personnel for quantity, overage, shortage & damage as per P.O. & delivery notes and prepare
MRIR to complete only the material receiving part and pass it to Material Inspector for quality
inspection part. If any discrepancies noted related to overage, shortage & damage then OSD Report
(with Photos If necessary) shall be raised immediately and pass it to Material Controller for necessary
action.
Material Inspector will verify the documents such copies of MRIR, P.O.’s, delivery notes/packing list,
MTC,MSDS, drawings etc., and perform physical verification on heat number, quantity, supplier,
country of origin etc., against above mentioned documents and complete the remaining part of MRIR
for quality inspection. If any discrepancies noted, NCR shall be raised immediately and pass it to
Material Controller for necessary action.
Similarly, project supplied materials which are received at Prefabrication Shop the above process will
be followed however if any discrepancy related to OSD or NCR will be passed to project site
representative for necessary action.
Similarly, for COMPANY free issued items, if OSD/NCR is raised shall be communicated to
COMPANY site representative for necessary action.
Finally material traceability table will be prepared after fabrication of each module by Material
Inspector.
Any material received without all the required material/test certification or other specified
documentation will be segregated and quarantined "On Hold" pending receipt of the missing
documentation.
If specified in the Project Specification or stated in the Purchase Order Documentation, during
material receiving inspection, PMI (Positive Material Identification) test shall be carried out to verify
the nominal chemical composition of an alloy material.
completion and handover to commissioning. This procedure is based on the contractual requirements
and manufacturer recommendation.
Refer below procedure for receiving, handling, storage and preservation of materials for details
Doc.No. TEP-900-PLA-MM-BP4-0001- Material Management Plan and TEP-900-PLA-OP-BP4-0002
Preservation Management Plan
Field Quality Control Manager, within his area of responsibility and with the assistance of (Discipline)
QC Engineer, checks that the following requirements have been met:
an adequate system for the identification of materials, components and partially erected
structures using tags, stamps, colours, adhesive labels, or via traceability records, managed
and updated during manufacture, assembly, installation, repairs, modifications and use of
materials and equipment has been set up
A proper materials traceability system (where complete traceability is requested) is in accordance with
Project requirements, together with unequivocal records and the manufacturers’ certificates capable
of assuring the traceability of materials from receipt through to every phase of manufacturing,
assembly, installation, repairs, modifications and usage
In the event that early work in relation to TEMPORARY WORK, Construction Manager, within his area
of responsibility and supported by the Discipline Superintendent ensures conformity of the
SUBCONTRACTOR ITPs with regards to the quality control requirements defined in contract,
engineering and supplier documents (specifications, drawings, standards, etc.). If specified in the
SUBCONTRACTOR ITPs, CONTRACTOR QC shall perform field inspection as required.
In case of early works which part of the PERMANENT WORK such as Site Preparation Work (i.e.,
Train 3 Area, etc.), Access Road Construction Work, Bridge Construction Work, etc., Field QC
Manager/Engineer shall ensure all inspections as provided in paragraph 5.2 and or 5.3.
SUBCONTRACTOR shall submit each week to the CONTRACTOR Representative a two-week look
ahead schedule of all planned QA/QC activities.
Sufficient planning is required in order to perform the required tasks with minimal interference with
other activities. However, SUBCONTRACTOR must allow sufficient time for all
inspections/surveillance required to satisfy all Project requirements
• Detailed receiving inspection on materials and equipment arriving on site is required and
must include inspection for shipping damage.
Wherever inspection & test plan mentioned Hold or Witness point, relevant SUBCONTRACTOR QC
inspector shall inform to COMPANY representative through Quality Control of CONTRACTOR.
RFI will be sent to CONTRACTOR and COMPANY at least 48 hours in advance during week days,
weekends and public holidays. (Attachment- 3)
In-process inspection is divided into the following categories (but not limited to)
Reports of all inspection and test records will be filed and maintained for CONTRACTOR / COMPANY
verification and approval.
Once the Inspection Report is completed, the scanned copies of the certificates/test records are
digitally stored in the PCOS system for future reference.
• Final inspections and test as specified in applicable Project QCP/ITPs have been carried out;
• All required quality records and summary according to Project QCP/ITPs have been approved
and uploaded into PCOS;
• Applicable documentation has been reviewed, red marked and issued as prefabrication
revision (as built);
• Check to ensure that all Repairs, Open Punch list items and NCR’s have been closed out
satisfactorily and all documentation have been completed;
• Review final documentation and traceability of quality records of system, part or area of the
Works to ensure satisfactory mechanical completion;
• To ensure proper packing method implemented in order to avoid damage during
transportation.
• Check to ensure that all NCR’s have been closed out satisfactorily
• Final inspections and test as specified in applicable Project ITPs have been carried out;
• Ensure that preparatory inspections include a review of contract requirements;
• Ensure that all materials and /or equipment have been tested and approved;
• Ensure that provisions have been made to provide required testing;
• Examine work area to ascertain that all preliminary work has been completed;
• Examine materials, equipment, and samples to ensure that they conform to approved shop
drawings or submittal data, that all materials and/or equipment are on hand, and that all
monitoring and measuring equipment is properly calibrated and in proper working condition;
• Subsequent to the preparatory inspection and prior to commencement of work, the
SUBCONTRACTOR shall instruct each applicable worker on the level of workmanship
required to meet contract specifications.
The initial phase inspection is the time to discuss and agree on the required level of quality
associated with a given work activity. Any discrepancies relative to work quality should be addressed
at this time.
Surveillance Point (S): Involvement for monitoring a phase of work activities. A written
notification (RFI/IN) is not requested by the Construction SUBCONTRACTOR
Review (R): Review of documentation/reports. A written notification (RFI/IN) is not
requested by the Construction SUBCONTRACTOR.
Perform/Submit (P): Perform works and when requested by W/H for other parties
prepare inspection and submit RFI/IN.
CONTRACTOR shall fill and issue the RFI/IN to COMPANY when its involvement type indicated in
the ITP is either W (Witness) or H (Hold), for each Inspection, according to Contract requirement.
CONTRACTOR shall coordinate with COMPANY the daily inspection, examination and test in
accordance with the RFI/IN issued.
CONTRACTOR will provide the access for the TPI at the jobsite and documentation to ensure that
proper inspections or examinations can be perform
The CONTRACTOR and COMPANY perform a completion inspection of the work to verify if the
structure, outfitting, pipe work etc. have been installed inspected and tested as per ITP, in order to
demonstrate the compliance with all project specification. In addition, complete records of inspection
and tests will be compiled as evidence that the work has been carried out in accordance with project
requirements.
The Punch List helps to define which actions must be done to achieve the Construction Completion
related to completion stage.
This scope of work will be under CONTRACTOR Commissioning Team, Site QC function will assist
commissioning team upon request. At the end of the commissioning, the final release, including all
test results and reports, will be issued.
The PCOS will be set-up and managed during engineering stage, and then be used on all worksites
throughout all stages of the work.
Mechanical completion of all systems will be verified by commissioning team on handover from
construction team to confirm that construction work scopes have been completed, all relevant items
recorded on the project punch lists, as built drawings updated and all associated handover certification
completed.
5.8.1 QC Certification
The QC certification of inspection results is be documented as indicated in the QCP/ITP of
SUBCONTRACTOR and according to the methods agreed with the COMPANY.
(Discipline) QC Engineer/Inspectors are responsible, within the competence of their discipline, for the
correct compilation of inspection forms used during inspection.
As a rule, immediately after an inspection is carried out, the Inspection Form is to be compiled and
signed by the functions called to witness the test.
The involvement codes are those defined on ITPs included on the Project QCP
Field Quality Control manager is responsible for monitoring the complete status of inspections
All verified and/or calibrated equipment will be issued with respective certificates and will be provided
with a tag or sticker indicating calibration status. Also calibrated equipment’s will be stored in
appropriate location after its use. Equipment’s which require special care regarding temperature or
humidity for storage shall be kept such a place after its use.
Equipment’s which require calibration or expired will be kept in separate storage location with proper
identification marking for unintended use.
Welding machines are standardized every six months internally, identified with sticker and monitored
its validity every six months.
The QC department will maintain a calibration Log, listing identification details of calibrated equipment
as well as reference to calibration certificates and expiry dates. SUBCONTRACTOR’s instruments will
also be included in the calibration log.
The calibration frequency will be in accordance with relevant calibration procedure requirements.
Refer below Project procedure for Control of Inspection Tool and Test Equipment Doc Number. TEP-
930-PRC-QA-BP4-0008. TEP-930-PRC-QA-BP4-0011
The system is expected ton provide reporting on the status of piping prefabrication regarding the
productivity of welders, NDTs run on welds, backlog of NDT requests, and the test pack welding
summary. It also releases the spools from prefabrication to installation
WPS/ PQR which is identified as obsolete are segregated and removed from the work area for further
disposition
Upon qualification test, welder certificate shall be approved by Ditjen MIGAS as appropriate. Also list
of welders register and Welder ID card will be prepared and maintained.
Prior to production welding, welding superintendent and welding inspector will verify the welder ID
against qualified WPS for correctness.
Unqualified welders are identified separately and trained again for requalification. Welder qualification
registered will be established, updated and maintained for entire duration of project.
Welding consumable will be handled carefully, in order to avoid damage to the packing. When packing
of basic electrodes is damaged (Aluminium foil no more under vacuum or heat shrink polythene
broken) a physical verification and checking shall be performed to the electrode. When no physical
damage on the electrode is found then it shall be re-dried before using in the shop.
All welding materials will be collected from the store using the electrode issuing log. Welding
supervisor / welding foreman to ensure the correct flow of the welding consumable during the
prefabrication or site construction. At the end of shift the electrodes will be put in holding oven/quiver.
All welding consumables found damaged or without identification will be removed from production
area and, if no more reusable, will be scrapped.
Candidates working as welding inspector shall have qualification either in AWS CWI or CSWIP 3.1 or
Equivalent and painting & coating Inspectors in NACE coating inspector level 2 or equivalent.
Similarly candidates working as NDT operator shall have ASNT level 2 or equivalent national standard
compliance with ISO 9712 requirements. The use of level 1 NDT Operators is not permitted.
All Level 3 NDT personnel shall be qualified in accordance with ISO 9712. ASNT Level III personnel
will be acceptable only if examined and certified directly by ASNT. Level III NDT personnel certified by
another ASNT Level III are not acceptable
Welding Inspector and NDE qualification registered will be established, updated and maintained for
entire duration of project.
All QA/QC personal assigns for this project shall be assessed and register on TEP-930-LST-QA-BP4-
0002 QA/QC Competency Assessment Register
SUBCONTRACTOR QC will ensure that heat treatment furnace and accessories including
temperature recorder are in good working condition prior to load the joints or components.
Temperature recorder will be calibrated by recognized third party laboratory traceable to national or
international standard. The frequency of calibration shall be generally not longer 12 months for the
recorder and thermocouples. Record of certification shall be maintained for verification.
Heat treatment will be performed as per approved procedure. Record of post weld heat treatment will
be available for CONTRACTOR/ COMPANY verification.
In case inspection Forms are not available, SUBCONTRACTOR shall prepare new forms and submit to
CONTRACTOR for approval all new “Inspection Form” prior to include them in QCP/ITP(s) for
prefabrication or site construction implementation.
“Inspection Form” shall be filled up with all information required to record the details of the
Inspection activity performed and will become “Certificate” once signed by the parties involved in the
inspection. For this purpose, the Inspection form shall be compiled with all information and data
relevant to the inspection performed such as but not limited to:
• Inspection checklist;
• Applicable parameters;
• Tolerances;
SUBCONTRACTOR may distribute copies of Certificate to all signatory including PCOS Administration
and provide for an orderly collection, filing and distribution of all Certificates and prepare quality
records for final documentation hand over.
Any certificate produced after inspections shall be colour scanned at the minimum resolution of 200
dpi, producing a PDF file.
The surveillances shall provide the mechanisms for detecting any potential deficiencies activities or
observation which covers from pre-fabrication, construction, installation until completion in order to
prevent major construction defects thoroughly:
- Pre-pouring concrete for heavy equipment and / or field erected tank foundation;
- Pre-pressure testing activities;
- Pre-insulation for pipe heat tracing;
• Surveillance based on verification activities;
Construction verification activities shall take place at any time throughout the construction cycle to
verify compliance with project requirements and the implementation of SUSU mitigation plan as
required by SUSU Team. The frequency of these assessments shall be evaluated by the Field QC
Manager on an on-going basis, but the recommended minimum assessment frequency shall initially
be set at once a month on the selected of subcontractor and it’s recommended that identified
negative / positive trends are taken into consideration for altering frequencies.
Discrepancies, deficiencies and observations noted while implementing the Construction Surveillance
Program shall be brought to the attention of the Subcontractor for corrective action.
The Assigned CONTRACTOR QC Inspector shall prepare the Non Conformance Report and attach the
relevant inspection reports detailing the nonconformity found and possible solution.
The CONTRACTOR NCR register will be submitted a weekly basis as part of the Quality Management
Report. , noting the following details:
• The date and time of implementing the disposition and remedial action;
CONTRACTOR shall track and control all non-conforming until it is reused, exported, or otherwise
disposed of.
5.10.4 Audit
For Construction, audit should be started from Pre-fabrication activities throughout the construction
completion. The audit should also covers element of SUSU implementation plan for Focus Area
construction. The detail of audit program describes in TEP-930-SCH-QA-BP4-0001 Project Quality
Audit Schedule.
The implementation of audit program shall be lead by Project QA lead supported by Field QC manager
and/or his deputy. The audit execution should be in accordance with TEP-930-PRC-QA-BP4-0006
Quality Audit Procedure. Project QA Lead will also be responsible to follow up audit finding until the
close-out.
Reference;
The implemented corrective action shall be proportional to extent of actual non-conformity and the
risks involved. This is performed after a root cause analysis of nonconformity.
Corrective actions may require changes in methods, procedures and organization applicable to the
current Project. These changes may need to be addressed immediately. All parties involved will agree
upon corrective action.
Corrective actions may be a concern for future Projects where action may be taken accordingly. In
this case, the corrective action can lead to establishment of a preventive action.
Quality function assigns a dedicated engineer as FAP-08 Testing Leader to follow up the mitigation
risk identified. Quality will bring the concern about SUSU program which highlighted by SUSU
Coordinator during audit and accommodate his input into audit input/checklist, as well as assessment
apply for SUBCONTRACTOR during execution.
The detail plan of CONTRACTOR’s SUSU Program can refer to CONTRACTOR’s document no TEP-
900-PRC-CU-BP4-0002 Start up, Stay up Delivery Program (SDP), Strategy and Plan.
5.10.7 Meeting
CONTRACTOR participates to QA/QC meetings as directed by COMPANY. Meetings, in general, shall
be held weekly and/or otherwise agreed at site or as specified in the Coordination Procedure.
Scope and agenda of the meeting shall be agreed by participants according to the quality issues
arising during construction work. As a minimum quality meeting agenda shall include the following
topics:
Field Quality Control Manager (FQCM) ensures the recording and filing of the following documents:
The original records of inspections carried out at site are systematically collected, kept and registered
in a data system under the responsibility of the Field Quality Control Manager, which assures, by daily
checking, the implementation of this collection and recording.
FQCM regularly informs the PQM of the status of recording and Filing.
Actions
a) Field Quality Control Manager ensures the collection and orderly filing of quality documents
for the preparation of the QA/QC Dossier in accordance to a Project procedure issued in
accordance to contract requirements when defined and/or the methods concurred with the
parties involved.
b) Field Quality Control Manager, by NDT QC Coordinator/Engineer, ensures the collection, filing
and correct conservation of documents and films related to non-destructive tests on welded
joints, of technological tests and diagrams of heat treatment after welding.
c) Upon completion of the works, Field Quality Control Manager shall collect the records and
quality documents and, after approval by Site Project manager, transmit them to Project
document control for delivery to the COMPANY, in accordance with contractual requirements
and according to the methods defined by Project Management.
Unless otherwise agreed with COMPANY, the QA/QC dossier index is prepared by numbering
Volume progressively, whereby sections and folders are numbered in accordance with QC-
Coding system as shown in the following examples:
6 Attachments
6.1 Attachment # 1 – General Document/Procedures
Volume Index
Quality Procedures
NCR Log
NCR
VOL-01 SEC. GEN-1.5 List monitoring and measuring devices and calibration certificates
Concession request
CERTIFICATES
VOL-02 CIVIL SEC.1 PIL -SOIL IMPROVEMENT (PILES)
…..other
…..other
…..other
…..other
…..other
…..other
…..other
VOL-05……..
The filing system is by folder and separate File for each “QC Code”, starting from the first report
issued.
The “CERTIFICATES” are filed on separate volume also by the relevant discipline (CIVIL, PIPING,
ELECTRICAL, INSTRUMENTATION, MECHANICAL, ETC…),
CONTRACTOR/COMP
SUBCONTRACTOR NOTES
ANY/ TPI
PREPARATION
OF RFI
UPDATING RFI
INSPECTION
INSPECTION
WITNESS
WITNESS
Negative Positive
REPORT ISSUING
SIGNING OFF
REPORT
REPORT
REPORT LOG
COPY
UPDATING
PREPARATION
QA/QC DOSSIER
Preparation and
Approval of QCPs
Issuance of QCPs
Project ITPs
Implementation