1 - PQP, - LNG - JETTY A

PLDSJ MF Doc.
No:MF/AFC/PLD/PRO/18
PROJECT QUALITY PLAN

DAHEJ STAND BY JETTY PROJECT UNDERTAKING(DJPU)
Rev: R2
Date: 15/07/2011.
TABLE OF CONTENTS:
Section No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Introduction Scope
Title
Page 3 3 3-4 4-9 10 12 12-24 24-28 29 29-31 32-33
Terms, Definition and Abbreviation Quality Management System Management Responsibility Resource Management Project Execution Measurements and Improvements Organization Chart List of Corporate QMS Procedures / Site Procedures / Method Statements List of ITPs / Quality Formats / Check List Quality Assurance Plan Attachments
PLDSJ MF Doc.No:MF/AFC/PLD/PRO/18

Rev: R2
Date: 15/07/2011.
1.0 INTRODUCTION The Project Quality Plan has been issued as a project management summary and provides interpretation / description of contract and Owner requirements related to the Quality Assurance activities. PQP defines DJPU activities, practices, resources and the sequence for the effective implementation of the project quality Management system. PQP shall meet the requirements of ISO 9001:2008, ISO:9004:2009 and Quality Management Systems Requirements of M/s DJPU and Contract Specifications of PROJECT: Marine Facilities For Standby Jetty Project at Dahej LNG Terminal PQP will be revised, whenever necessary as per mutual agreement between Owner PLNG Limited and DJPU. The overall project schedule with dates will be available as per the Doc no MF/AFC/PLD/PRO/11 Rev-0 2.0 SCOPE The Quality Assurance System as outlined in this Project Quality Plan shall be applicable to the PROJECT: Marine Facilities For Standby Jetty Project at Dahej LNG Terminal The quality assurance process as explained in PQP shall cover the following and is applicable to DJPU Employees and its sub contractors associated to this Project. Engineering Construction planning Procurement of Services, Materials and Equipments Project Execution and Field Installation Inspection and Testing Control of Non conforming Product Progress Reporting Control of Documents and Records 3.0 TERMS, DEFINITION AND ABBREVIATION OWNER : PETRONET LNG, limited, Delhi. CONTRACTOR : DJPU Infrastructure Limited, Mumbai. IL : Independent Laboratory. PM/EIC : Project Manager/Engineer In charge HO : Head Office (Corporate Office - DJPU House, Mumbai). ITP : Inspection and Test Plan. SOP : Standard Operating Procedure. CPE : Construction Plant & Equipment. QAP : Quality Assurance Plan PQP : Project Quality Plan MTC : Manufacturers Test certificate IMT : Inspection Material testing IRN : Item receipt note ISO CELL : International Standard Organization
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NCR PO QA QAP QC QMS
: Non Confirmation report : Purchase Order : Quality Assurance : Quality Assurance Plan : Quality Control : Quality Management Systems
NOTE: QMS related terms in this PQP shall have the meanings as defined in ISO 9000:2005, "Quality Management Systems -Fundamentals and Vocabulary. 4.0 QUALITY MANAGEMENT SYSTEM DJPU has established and documented a Quality Management System Manual, which aims at Continual Improvement in accordance with the contractual requirements stipulated in Exhibit H Section B and Annexure HI Project Quality Management System as defined in this Project Quality Plan shall be applicable to all the Major construction activities performed by DJPU Additional Quality System requirements as advised by Owner from time to time shall also be complied with.
4.1 QMS DOCUMENTATION DJPU and Project Quality Management System documentation shall be as structured hereunder,
ISO 9001 REQUIREMENTS CONTRACTS REQUIREMENTS
QUALITY MANAGEMENT SYSTEM MANUAL
QUALITY MANAGEMENT SYSTEM PROCEDURES
CORPORATE DEPARTMENTAL PROCEDURES
METHOD STATEMENTS
RECORDS
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As a part of the Quality System Programme, DJPU Project shall document the system in the form of Works Procedures, Quality Assurance Plan (QAPs)/ Inspection &Testing Plan. The Quality Management System documentation includes the following: A) DJPU Quality Management System Documentation: i. Quality Policy statement and Quality Objectives, ii. Quality Manual outlining the various processes, iii. Quality Management Systems Procedures B) Project Quality Management Systems Documentation: i. Project Quality Plan ii. Works Procedures / Method Statement iii. Inspection & Test Plan / QAPs iv. DJPU QMS documents as applicable to the Project
Corporate Level
Project Level
4.2 CONTROL OF DOCUMENTS All documents, which constitute part of contract, will be codified as per project numbering system and dealt with in a controlled manner. List of documents / deliverables to be developed by DJPU and its suppliers shall be maintained. Review and approval of Project documents shall be as indicated in procedure for document Control. Owners mail review registers will be maintained to control all incoming and outgoing mail. Drawing registers will be maintained for receipts & Issue of drawings with the status of drawings and sketches and to record their issue. When drawings are received from Consultants/Architect will be updated in Drawing Receipt Register. The appropriate versions of all relevant documents shall be made available at the location where quality activities are performed. Measures are established to ensure the superseded documents are destroyed or suitably identified to prevent inadvertent use. One copy-superseded drawing is to be maintained for reference. Reference: Document control Procedure MF/AFC/PLD /PRO/01
4.3 CONTROL OF RECORDS All the records pertaining to the Quality Management System shall be identified through the codification number. Records can be maintained as filed hard copies and /or on electronic media as per the Owner requirement.
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For records that are maintained in electronic media, the user department shall take precautions against the unauthorized use of the records. The user department shall prepare the Master List of Records maintained at the department in the prescribed format for this purpose and shall paste a copy of the same at point of use. 4.3.1 Compilation of quality Records Project Quality Records shall be compiled from start of project till the project completion and will be filed in such a manner as they are easily retrieved. Project records will also be stored on computerized data storage and transfer system accessible by DJPU Project team. All quality records are to be kept till the project completion at site office by site document controller. All records will be maintained as per the ISO procedure. On Project completion, quality records both in hard and soft copies will be handed over to Owner in accordance with requirements of contract 4.3.2 Site Document Control Construction Records including sub contractor inspection and test records will be maintained to demonstrate achievement of required quality and the effective implementation of the construction quality programme during the execution of LNG Jetty. Reference Control of Quality Records Procedure PR 9901 02 & MF/AFC/PLD /PRO/01 4.4 RESPONSIBILITY & AUTHORITY Top Management of DJPU has defined and communicated the responsibilities and authorities of the personnel within the organization. The responsibilities of various department heads at site are as follows: I. PROJECT MANAGER PM shall be responsible for implementation of an effective quality assurance system at site. Apart from his other responsibilities, the Project manager shall be responsible for the following. Establishment, implementation & maintenance of the QA system at site, with the assistance of site QA group of DJPU.
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Taking necessary actions to see that quality policy of the organization is understood & implemented at all levels of the site organization. Keeping the top management at HO informed about the performance of QA&QC system, thus enabling quality improvement with management information system (MIS), as an effective tool. Conducting regular meetings with the Dept. heads & site QA group to assess the progress made in achieving the documented QA system. Co-ordination with head office quality assurance department, through the corporate MR in all quality related matters, at regular intervals.
II. QA / QC MANAGER The QA/QC manager shall be responsible for Establishing & implementing the documented quality system. Identifying & defining the quality procedures & quality assurance plans. Conducting quality inspection for all the works at site. Statistical analysis of test results. Interaction on all quality matters with the Project manager and with corporate QAQC Manager as required. Interaction with Owner for approval of bought-out items. Inspection & testing of all construction materials like cement, sand, aggregate & other miscellaneous items. Submission of documents to Owner for source /vendor approval. Calibration of laboratory & other IMT equipment and maintaining of calibration records. Detecting non-conformances and disposal of the same during & after the construction operation. Field-testing as per approved QAP/ITP & procedures. Maintenance of documents of all test conducted at laboratory & field. Evaluation & acceptance of test results (After conducting test, test results to be submitted to Owner for approval). Maintenance of documents of Inspection. Implementing Preventive /corrective action for non-conformity. Maintenance of schedule of tests to be carried out monthly and quarterly detailing out the agency (external/internal) for carrying out the tests. Reconciliation of cement, aggregates, sand and admixtures.

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III. PLANNING, MONITORING & QS The Planning manger shall be responsible for Planning of various resources Viz. manpower / machinery / material. Updating the planning networks and site organization chart on a regular basis during the actual execution, for monitoring and control. Submission of daily /weekly/monthly report to Owner and head office on progress of works. Co-ordination between various site groups. Reconciliation of steel. Preparation of method statement for all the works components. Subcontractors evaluation & selection after getting due approval of the Owner. Drawing control. Identification of critical path and analysis IV. CONSTRUCTION, PLANT & EQUIPMENT / WORKS (CPE) The manager shall be responsible for Utilization of all plant & equipment, its safe operation & maintenance. Supervision of repairs Preparing & implementing plant maintenance schedules. Requisitioning of spares, consumable & part stock items. Mechanical Electrical adjustments & maintenance of equipment plants. Maintenance of plant records & compilation of equipment reports as part of MIS. Inspection & Testing of incoming spares & partly fabricated assemblies, etc. Statutory compliances Safety responsibility to be identified V. PURCHASE & STORE The Purchase & Store manager shall be responsible for Preparations of purchase order, giving all details of the indented item. Inviting inquires from vendors in case of new purchase. Techno-commercial comparison, in consultation with the technical group. Regular follow-up with the party / vendor to expedite the supply / delivery Vendor selection & evaluation as per procedure. Maintaining the required inventory Receiving of incoming item & its inspection in consultation with the indenter & the QC group. Segregating items on the basis of their inspection status. Proper product identification. Preparation of IRN, inspection report & updating records in computers. Preparation of monthly stock report. Issue of material to site & arranging proper transportation.
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Storage of material shall be as per relevant codes/Owner specifications. Maintaining records of MTCs and submitting a copy of the same for records to QA&QC manager. Reference Quality Control Procedure for Procurement PR 9901 02 & MF/AFC/PLD /PRO/06
VI. SAFETY The Safety manager shall be responsible for Preparation & implementation of safety procedures in consultation with the corporate safety manager. Accident prevention program implementation. Procurement of all safety equipment & appliances needed for the work. Reporting & analysis of all incident, near-miss, accidents and unusual occurrences Conducting safety educational / motivational training. Inculcating safety culture at site. Co-coordinating with Owners safety department. Job Safety Analysis or Risk Analysis will be prepared before the start of activity and communicate to all level of employees Every day conducting tool box meeting Fulfill all the statutory requirement (state and central government) related to environment matters. VII. CONSTRUCTION MANAGER The Works manager shall be responsible for Implementation of approved methods of construction, meeting the pre-planned targets for all works envisaged under the contract. Safe deployment of all labour including that of subcontractors. Utilization of all plant & equipment, its safe operation & Maintenance jointly with the construction plant equipment group. To ensure that the best & safest methods are adopted to carry out works of the best quality possible. Due regards for all property, public services & the public land adjoining the work or crossing the works (as the case may be). Maintenance of site records pertaining to various site activities. Optimum utilization of resources like manpower, machinery etc.

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VIII. ADMINISTRATION MANAGER The administration manger shall be responsible for Recruitment of local employees , statutory compliance and maintaining coordination with the employees Maintenance of attendance register, time cards, Over time registers etc Maintaining industrial relations, grievances handling, liaisoning Preparation of work order and agreements Safe deployment of all labour and employees Staff welfare, vehicle management and take care of all RTO matters Maintaining Wages register Manpower transport arrangement Workman compassion, Insurance and covered under third party insurance
5.0 MANAGEMENT RESPONSIBILITY 5.1 Management Commitment The DJPU Project Manager is responsible for the establishment, implementation and evaluation of the quality management system at project and will periodically review its effectiveness. This will be achieved by: a) Implementing measures that satisfy statutory, regulatory and OWNERS requirements , b) Ensuring the dissemination of the project quality policy, establishment of quality objectives consistent with quality policy and establishment of an implementation plan to achieve quality objectives, c) Ensuring the continual improvement of processes, obtaining the necessary management resources for the scopes of the work and ensuring its effective operation. 5.2 Customer Focus The DJPU Project Manager in conjunction with DJPU Project Management Team shall ensure that work processes are identified at an appropriate time to meet contract requirements including statutory and regulatory requirements regarding deliverables, equipments, materials and services to be provided by the DJPU.
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5.3 QUALITY POLICY: QUALITY POLICY
Dahej Stand By Jetty Project Undertaking(DJPU) is committed to achieve and sustain excellence in its construction business through an established Quality Management System. We aim to achieve Customer Satisfaction by providing Goods and Services as per contractual, statutory and regulatory requirements and in the process improving companys competencies and competitiveness. We shall achieve this through continual improvement of our business processes, organizational drive on innovation and productivity and effective human resource management. We value training and sharing of information at all levels within the organization.
QUALITY OBJECTIVES
1 Enhancement of Customer Satisfaction. 2 Timely completion of Projects. 3 Effective Planning and Monitoring System. 4 Effective Human Resource Management. 5 Continual Improvement in Productivity of our Resources. 6 Reduction in wastage of Major Construction Materials.
K.Subrahmanian Managing Director
Dated : 18.08.2008
Revision : 03
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6.0 RESOURCE MANAGEMENT 6.1 Provision of Resource a) DJPU shall identify, determine and initiate mobilization of appropriate resources to execute services as described in scope documents, in a timely manner. b) The mobilization resources shall be ensure that implementation, maintenance of quality management system and continual improvement of its effectiveness. c) Detailed project manpower plans are produced by DJPU and are maintained and continuously reviewed throughout the project duration. 7.0 PROJECT EXECUTION DJPU shall establish appropriate project execution processes for design, procurement, construction and progress monitoring. As part of the overall planning and scheduling processes DJPU will develop project management tools to establish clear, complete and consistent definitions of the following, a. Contractual project work scope and its requirements b. Project objectives and its priorities c. Performance targets d. Manpower mobilization plan e. Project Progress control f. Design, procurement, subcontracting and construction plan g. Project health, safety and environment plan h. Quality records needed to provide evidence that realization process and resultant products meets requirements i. Control over outsourced process Reference: Project Execution Plan MF/AFC/PLD/PRO/12 Construction plan -- MF/AFC/PLD/PRO/13
7.1 DESIGN & ENGINEERING

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Engineering & Design control is implemented to ensure that the design is performed in compliance with applicable Indian laws, regulations, codes, standards and Owners requirement and that design basis are properly incorporated into design documents. Engineering & Design activities will be performed as per stages outlined hereunder, 7.1.1 DESIGN AND DEVELOPMENT PLANNING The Process of design and development shall include: a. Design and development stages b. The process of review, verification, and validation, where appropriate c. Assigning responsibilities for all stages of design and development 7.1.2 DESIGN AND DEVELOPMENT INPUTS Prior to commencement of engineering work, following requirements will be reviewed and determined. a. Scope of work b. Applicable Owner Dahej Marine facilities Project specification c. Statutory and regulatory requirements d. Applicable codes and standards e. Verification of existing facility by Engineering survey f. Other requirements added by the DJPU
It shall be determined and reviewed for adequacy and completeness. DJPU Project Manager shall notify the owner of any/all queries arising from review of design requirements. At the conclusion of the review, the required documents shall be prepared and issued by DJPU. 7.1.3 DESIGN AND DEVELOPMENT OUTPUTS Design output shall be expressed and be documented to verify and validate in comparison with design input .Design outputs shall: a. Meet the design input requirements
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b. Contain or reference to acceptance criteria c. Conform to appropriate statutory and regulatory requirements, if required d. Specify the characteristics of the product that are essential for its safe and proper use. e. Engineering discipline managers shall approve the Design outputs. A comprehensive checking/verification/authorization is established for all design activities on the project. Direction is provided on the necessary levels of authorization for deliverables to ensure a consistent approach to the verification activity.
7.1.4 DESIGN AND DEVELOPMENT REVIEW, VERIFICATION AND VALIDATION The design and development review, verification and validation, shall be carried out during the design development phase of the project. Details of the planned design reviews are contained in the design plan, with the planned dates for implementation shown on the project schedule. At suitable stages systematic reviews of design shall be performed in accordance with planned arrangements. Participants in such reviews shall include representatives of function concerned with the design stage being reviewed. Records of the reviews and any necessary action shall be maintained.
7.1.5 CONTROL OF DESIGN AND DEVELOPMENT CHANGES The design and development changes shall be identified, reviewed, verified and validated as appropriate and shall be approved before implementation Reference: Engineering Plan MF/AFC/PLD/PRO/03 List of drawing and Documents MF/AFC/PLD/PRO/04
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7.1.6 FIELD ENGINEERING The DJPU Field engineering team shall be mobilized to support engineering activities at the project during the construction period. Field design request /notice is raised to the owners for their approval in the field during the construction period and form for the field design change is maintained in the field. These engineering activities shall be executed in accordance with documented procedures to address the following: a) Follow-up detailed engineering, and residual engineering at site b) Technical services for construction activities, c) Preparation of us-built drawings, d) Revision of engineering drawings, as required e) Initiate request for quotations for OWNER
7.1.6 QUALITY STAFF SUPPORT TO ENGINEERING DJPU project staff shall conduct surveillance reviews of engineering requisitions to ensure that inspection and certification requirements are being met and the appropriate quality requirements are being included.
7.1.7 Interface Control DJPU shall determine the interface between its own discipline and others. Project Manger shall manage such interface with the engineering managers when conflict occurs and such conflicts cannot be resolved with the engineering mangers. The major scheduled interface shall be shown in the Interface control procedure
MF/AFC/PLD/PRO/10.
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7.2 PROCUREMENT PROCESS As per contract approved suppliers/sub-contractors shall be maintained by site and head office for the products or service procured through site. All purchased product shall be verified or inspected, by a pertinent authority designated by Project Manager, in accordance with the purchased specification to ensure that the purchased product meets the requirements. Verification of sub-contractor shall be done by Execution Department to ensure that contractual specifications are fulfilled.
The selection, evaluation and re-evaluation of the suppliers and sub contractors for products and services that affect the Quality of the product shall be done on Quality and delivery parameters in accordance with Project requirements. All suppliers and sub-contractors shall be evaluated once in six months at site for the products or services procured through site.
For other materials like aggregate, sand, admixture, bentonite etc. shall be procured by DJPU after obtaining approval from OWNER as per approved vendor list. 7.2.1 PURCHASING INFORMATION The Purchase Order (PO) shall bear the specific purchase requirements as per approved quality plans including delivery details. Purchase Order shall be reviewed for adequacy of purchase information and approved prior to release to the supplier by the PM of DJPU. The Purchase Order shall contain the following information: a. A description of the product to be procured with all needed specification, wherever applicable, b. Applicable type, class, grade or other precise identification
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c. Requirements for approval of product, d. Inspection Instructions e. Title number and edition of the quality management system standard to be applied. f. Requirements specific to the product, e.g. Shelf life in case of materials where the same has an impact on the quality of the materials, g. Quality Records In case of any amendment to the Purchase Order, the amendment shall be reviewed and approved by the Project Manager in consultation with the indenter prior to release of the amendment. 7.2.2 VERIFICATION OF PURCHASED PRODUCT Purchased equipment, materials and/or services shall be verified for conformance to the applicable requirements specified in procurement documents. Verification activities shall be based on the nature and criticality of the items or service purchased, and shall include reviews, inspections (at predetermined points and time) , testing , and testwitnessing, as appropriate. The extent of verification shall be specified in the procurement documents for each Purchase Order and Contract Enquiry and agreed the Purchaser, the Contractor and Supplier / Subcontractor, or between the DJPU and Supplier / Subcontractor. Purchase Orders and Contracts for all significant items or services contain stipulation for the provision of Quality Plans / Inspection & Test Plans as a means of documenting the quality control and documentation requirements. Vendors and Subcontractors shall submit for Purchaser review, comment and approval special procedures for which the results cannot be fully verified by subsequent inspection and testing of the product.
Reference: Corporate Procedure for Selection & Evaluation of vendor PR 9925 06

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Corporate Procedure for Selection & evaluation of vendor - PR 994 02 Procurement Plan MF/AFC/PLD/PRO/05 Quality control Procedure for Procurement MF/AFC/PLD/PRO/06 7.3 PRODUCTION AND SERVICE PROVISION
7.3.1 CONTROL OF PRODUCTION AND SERVICE PROVISION The construction and installation process at site shall be planned in such a way that the processes are carried out in controlled conditions. The controlled conditions shall include the following: a. Approved procedures / instructions defining the sequence of performing an activity. b. Deployment of suitable equipment and machinery to complete the activity in stipulated time. c. Compliance with documented procedures / instructions, QAPs / ITPs, contract requirements, standards / codes. d. e. Trained and qualified personnel for performing the job. Maintenance of working environment in neat, clean and tidy condition by good house keeping. The sub contactors data provided by construction department shall be evaluated concerning departments. QA department shall evaluate finally and register pre qualified subcontractor in vendors data system. Sub contractors shall be selected from the pre qualified subcontractor based on their evaluated ability and in accordance with the requisition requirements. The processes shall be monitored continuously to ensure that the process is carried out as per documented procedures / instructions.
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Identification of the appropriate monitoring and measurement devices to measure and monitor these processes shall made available at point of use including maintenance and calibration wherever necessary. The release / handover of product, delivery and post delivery activities shall be controlled to meet the product requirements. References : Project Execution Plan MF/AFC/PLD/PRO/12 Construction Plan - MF/AFC/PLD/PRO/13 7.3.2 VALIDATION PROVISION OF PROCESSES FOR PRODUCTION AND SERVICE
The Project Manager shall be responsible for qualifying the special process, equipment, and personnel. Such requirements shall be specified and approved. DJPU site Management shall establish arrangements for these processes including, as applicable: Establishments of acceptance criteria for review and approval of the processes a. Approval of Equipment and qualification for personnel b. Approval of specific methods and procedures and its application c. Requirements for quality records d. Revalidation when conditions and requirements are changed.
7.3.3
IDENTIFICATION AND TRACEABILITY
The process of identification and traceability shall be maintained to identify a. The status of product in all stages of construction b. Hazardous / Non Hazardous/Flammable/Inflammable materials.
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All the materials / components / items, including partly fabricated assemblies / process items shall be identified with proper numbering / marking labels / tags etc. Store at site shall ensure that the identification is maintained either on the item or its record traceable throughout the storage, fabrication, processing and installation stages. For the items received at Stores, the stores personnel under the guidance of Store In charge shall be responsible for identification (tagging, documenting status in register) in consultation with concerned inspecting (authorized) personnel. For construction items, Site QA/QC Manager shall be responsible for maintaining test results / reports, test certificates, which shall indicate the item details (such as batch no., lot no, date of receipt) and also the inspection status i.e. Under Inspection, Inspected- Found OK and Inspected - Rejected. In case of other items, indenting personnel (authorized) shall be responsible for conducting the required inspection. In case of field activities, site personnel / staff, under the guidance of Section In charge shall be responsible for proper identification of process / constructed structures. 7.3.4 CUSTOMER PROPERTY The property of customer, if any, including any intellectual property, provided for use or incorporation in the product like data, drawings, equipments or materials shall be identified, verified, protected and safeguarded. If any customer property is lost, damaged or otherwise found to be unsuitable for use, shall be reported immediately and records of identified conditions shall be maintained. Further process shall follow contract requirements.
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7.3.5 PRESERVATION OF PRODUCT All the incoming, in process products shall be identified for a particular category of product Viz. flammable/inflammable, Hazardous/Non hazardous and shall be handled manually or mechanically, stored, as per manufactures
recommendations and owners requirements, in the designated area and shall be protected to prevent damage to the product. All non-conforming materials shall identified and kept separately from the conforming materials with proper tags and shall be sent back to supplier with prior intimation. Hazardous materials shall be identified and stored separately from other materials. Storage for various items shall be done as per IS:4082,IS4081,other relevant IS codes and as follows:I) CEMENT: Cement shall be stored in weatherproof covered storage and shall be protected from moisture. FIRST IN -FIRST OUT rotation system shall be followed for its use. Cement stored for more than 60 days in the stores of the DJPU shall be tested for setting time and compressive strength.
II) REINCEFORCEMENT STEEL: Rebars shall be stacked near cutting and bending yards diameter wise on either wooden planks or masonry platforms.
III) STURCTURAL STEEL: These shall be stacked section wise on either wooden planks or masonry platforms. IV) WELDING CONSUMABLES: These shall be stored inside under controlled conditions as manufacture specifications
V) EXPLOSIVES: These shall be stored safe and secured conditions or as guided by manufacturer guidelines or statutory requirement. These will be issued only to certified blaster.
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7.4
CONTROL OF MONITORING AND MEASUREMENT DEVICES All the monitoring and measuring devices shall be numbered and a comprehensive list shall be available with the user department. The Calibration Status of the monitoring and measuring devices shall be identified through a tag attached to the device. All the monitoring and measuring devices shall be calibrated or verified at specified intervals as mentioned in the calibration plan, prior to use. Calibration of monitoring and measuring devices shall be traceable to National / International Standards and where no such standard exists, the basis used for calibration or verification shall be documented. The calibration frequency may be reviewed if the device is found to be out of calibration within the validity period. All the monitoring and measuring devices shall be safeguarded against any
unauthorized adjustments and protected from damage and deterioration during handling, maintenance. Providing suppliers documentation and manuals for the equipments for training and reference. When equipment is found to be defective or Out of Calibration, a `NonConformance report shall be prepared. The results of previous inspections shall be assessed; documented and appropriate action shall be taken. The calibration records of all the monitoring and measuring devices shall be maintained as Quality Records throughout the period the device is in use at site. Reference : Corporate Procedure for Calibration of Instruments PR 8522 01
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7.5 PROJECT ADMINISTRATION The construction and installation process at site shall be planned in such a way that the processes are carried out in controlled conditions. The controlled conditions shall include the following: f. g. h. i. j. Approved procedures / Method statements/ instructions defining the sequence of performing an activity. Deployment of suitable equipment and machinery to complete the activity in stipulated time. Compliance with documented procedures / instructions, QAPs / ITPs, contract requirements, standards / codes. Trained and qualified personnel for performing the job. Maintenance of working environment in neat, clean and tidy condition by good house keeping.
The processes shall be monitored continuously to ensure that the process is carried out as per documented procedures / instructions. Identification of the appropriate monitoring and measurement devices to measure and monitor these processes shall be made available at point of use including maintenance and calibration wherever necessary. The release / handover of product, delivery and post delivery activities shall be controlled to meet the product requirements. 7.6 PROGRESS REPORTING The Project shall submit Bar chart for monitoring progress of works, Daily work program (Including Laboratory Test & Survey checks.), Weekly and Monthly Progress Report including Photograph with dates imprinted to Owner LNG.
Interface points will discuss in the monthly interface meeting along with the owner and other contractors. 7.7 TRAINING Training will be conducted by trained qualified personals for performing the job and in safety for new staff as well as for existing staff or revised roles.
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7.8 HAND OVER DJPU project team shall ensure that the operators are provided with proper information by giving training in the use of new equipments with the help of qualified trainers along with the equipment suppliers documents and manuals.
8.0 MEASUREMENTS AND IMPROVEMENTS 8.1 INSPECTION AND TEST STATUS For those items of construction that require inspection and test, complete inspection check sheet or other appropriate record forms will be maintained to demonstrate that all the required activities have been performed, and that the results are satisfactory. 8.2 QUALITY AUDITS
8.2.1 INTERNAL QUALITY AUDITS The Quality Management Cell/ISO CELL from DJPU HO is responsible for Quality Audits of the system to monitor its performance. For the duration of Dahej Project, every four months Quality audits will be conducted until completion and project audit plan shall be supplied to owner for review. The results of the audit will be reviewed in order to correct and prevent recurrence of deficiencies which affects the project The audit will cover a. Project planning & Monitoring activities b. Sub contracting activities c. Procurement activities d. Stores activities e. Construction activities f. Document control system g. Data Analysis and Improvements h. Workshop activities i. Engineering j. Interface Management k. Ongoing job monitoring by approved quality plan
Reference: Corporate Procedure for Internal Audit PR 9001 03

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8.2.2 EXTERNAL QUALITY AUDITS External Audit be those performed by DJPU on any critical vendors and subcontractors. Audits of the DJPU quality management system on site by third parties such as Bureau Veritas Certification India Ltd are classed as Management System Appraisals. The frequency of audit is once in six months 8.2.3 MONITORING AND MESUREMENT OF PROCESSES The Project Manager shall apply suitable methods for monitoring and, where applicable, measurement of the work processes and performance of the project. Monitoring and measuring on quality related processes should be carried out in accordance with the established implementation plan to achieve the project objectives and to ensure conformity of the products, When the results of monitoring and measuring activities of processes are unsatisfactory, responsible individuals are required to take timely corrective action under the direction of Project Manager to ensure conformity of the product. Project Manager shall verify the results of monitoring and measurement of processes and suitability and its effectiveness of actions taken to mitigate unsatisfactory results. 8.2.4 MONITORING AND MEASURMENT OF PRODUCT Inspection and test required to ensure that specified requirements for the product are met shall be controlled by written procedures including inspection and test plans. The required inspection and test and the records to be produced shall be in accordance with applicable inspection level and class and certification requirements of the Contract and shall be described in project procedures and inspection and test plans. All required notifications of inspections are sent to the OWNER and PMC according to contract requirement to allow their participation therein, when applicable. 8.2.4.1 INSPECTION AND TEST PLAN (ITP) The Project Manager shall develop project specific construction ITPs with the assistance of Head Office and under the supervision of the project quality assurance manager. ITPs shall cover project inspection and test requirements for the constructed facility. 8.2.4.2 RECEIVING INSPECTION Project receiving inspection procedure by the DJPU or its contractors at the Dahej site shall ensure that incoming equipment and materials procured shall not be used or
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processed until it has been successfully inspected or otherwise verified as conforming to specified requirements. Verification of the specified requirements shall be in accordance with the inspection and test plans and/or documented procedures. Records of receiving inspection shall be maintained. In determining the amount and nature of receiving inspection, consideration shall be given to the amount of control exercised at the vendors premises and the recorded evidence of conformance provided. When an incoming product is released for urgent use prior to verification, it shall be positively identified and recorded in order to permit immediate recall and replacement in the event of nonconformity to specified requirements.
8.2.4.3 IN PROCESS INSPECTION AND TEST When in-process inspection and test for the construction items is required the procedures shall require hold-points i.e holding of the items further processing until the required inspection and tests have been completed or necessary reports have been received and verified. 8.2.4.4 FINAL INSPECTION AND TEST When final inspection carried out in accordance with a prepared ITP and/or documented procedure to complete evidence of conformance of the finished product(s) to specified requirements. Inspection and test plans and/or documented procedures for final inspection and testing shall require that all specified inspection and tests, including those specified either on receipt of product or in-process, have been carried our and that the results meet specified requirements. No product shall be released or used until specified in the ITP and/or documented procedure has been satisfactorily completed and the associated data and documentation are available and authorized. 8.3 CONTROL OF NONCONFORMING PRODUCT a) The project organization shall establish and implement documented procedures to ensure that equipment; materials & deliverables that do not conform to specified requirements are controlled to prevent unintended use. b) This control shall provide identification, documentation, evaluation, segregation when practical, disposition of nonconforming items, and for notification to personnel
26

Rev: R2
Date: 15/07/2011.
is responsible for rectification. OWNER shall be notified in a formal manner, as applicable c) Records of the nature of nonconformity and subsequent actions taken to prevent reoccurrence including concession rework and repair shall be maintained. d) When nonconforming item is corrected, it shall be subject to re-verification to demonstrate conformity to the requirements. DJPU shall ensure that any product which does not conform to product requirement is identified and controlled in order to prevent its unintended use unless it is specifically authorized. The procedure of nonconforming product shall follow by taking action to eliminate the detected nonconformity. DJPU shall report to the customer the identified non-conformance product and shall propose the disposition process to be followed to get the customers approval if necessary. Rectified non conforming product shall be subject to re verification to demonstrate conformity to the requirements. QA manger shall take action to eliminate the cause of the non conformity in order to prevent recurrence. Corrective action shall be appropriate to the level of the effects of the non conformity encountered. DJPU shall ensure corrective action is taken in this project activity.
8.4 ANALYSIS OF DATA Project Manager shall determine, collect and analyze appropriate data to demonstrate a suitability and effectiveness of the project quality management system and to evaluate whether continual improvement of effectiveness of the project quality management system is achieved. Following Data to be analyzed by using statistical techniques includes, but is not limited to a. Achievement level of quality objectives b. Results of periodical validation on project quality management system c. Results of monitoring and measurement of processes and items d. Status of NCRs and their disposition e. Results of project audits f. Results of corrective and preventive actions g. Quality performance of suppliers and subcontractors h. Project schedule and its progress i. Other corporate quality objectives
27

Rev: R2
Date: 15/07/2011.
8.5 IMPROVEMENT 8.5.1 CONTINUAL IMPROVEMENT a) The project manager shall review at planned intervals and use the results of data analysis to continually improve the effectiveness of quality management system and the applicable project work. b) Continual improvement shall be revised accordance with quality plan. When necessary, the plan shall be revised according to the overall level of achievement. c) The Project Manager shall continually monitor and report status of scheduled activities during the project period. If progress and effectiveness is unsatisfactory, the plan shall be revised and countermeasures established and implemented to assure improvement and/or change to the project performance.
8.5.2 CORRECTIVE AND PREVENTIVE ACTION Appropriate corrective and preventive action shall be taken to correct any nonconformity. Steps shall be taken to eliminate the root cause of the identified or potential nonconformity to prevent occurrence or recurrence. Deviation from approved designs and /or approved quality system procedures noted during quality audits or quality surveillance shall be documented using Audit Report, Corrective Action or Preventive Action report forms. In addition, as part of preventive action, DJPU project management team shall review the available lessons for the applicability to the project and incorporate into activities where improvements in project quality, safety, cost and/or schedule can be achieved. Reference: Site procedure for control of Non Conforming Product.
28

Rev: R2
Date: 15/07/2011.
9. ORGANISATION CHART
Project Manager
Manager Safety
Manager Planning/QS
Manager - CPE
Construction Manager
Manager QAQC
Safety Officer Day / Night
Engineers QAQC
Manager Admin
Manager Procurement/Store
Civil Works (On-shore)
Piling Engineer
Civil Works (Off-shore)
Camp Boss
Assistant
Surveyors
10. LIST OF CORPORATE QMS PROCEDURES:

SR.NO. 1 2 3 4 5 6 7 DOCUMENT NO. DESCRIPTION REMARKS
PR 9001 01 PR 9001 02 PR 9001 03 PR 9001 04 PR 9001 05 PR 9001 06 PR 9001 07
Document Issue and Control Control of Quality Records Internal Audit Procedure for Management Review Procedure for Drawing, Receipt, Issue and Control Procedure for Corrective and Preventive Action Procedure for Customer Satisfaction and Communication with customer
29

Rev: R2
Date: 15/07/2011.
8 9 10
PR 8522 01 GL 9001 01
PR 9954 02
Calibration of Instruments Guidelines for Codification Procedure for Training and Development
LIST OF SITE PROCEDURES

SR.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 DOCUMENT NO. DESCRIPTION REMARKS
MF/AFC/PLD/PRO/1 MF/AFC/PLD/PRO/2 MF/AFC/PLD/PRO/3 MF/AFC/PLD/PRO/4 MF/AFC/PLD/PRO/5 MF/AFC/PLD/PRO/6 MF/AFC/PLD/PRO/7 MF/AFC/PLD/PRO/8 MF/AFC/PLD/PRO/9 MF/AFC/PLD/PRO/10 MF/AFC/PLD/PRO/11 MF/AFC/PLD/PRO/12 MF/AFC/PLD/PRO/13 MF/AFC/PLD/PRO/14 MF/AFC/PLD/PRO/15 MF/AFC/PLD/PRO/16 MF/AFC/PLD/PRO/17 MF/AFC/PLD/PRO/18 MF/AFC/PLD/PRO/19
Document Control Procedure Correspondence Procedure Engineering Plan List of Drawing and Documents Procurement Plan Quality Control Procedure for Procurement Schedule Control Procedure Interface Information Interface Control Procedure Overall Project Schedule Project Execution Plan Construction Plan Work Breakdown Structure Progress Measurement Procedure Invoicing Procedure Invoicing Schedule HSE Plan Quality Plan Control of Non conforming product
LIST OF METHOD STATEMENT SR.NO. DOCUMENT NO.

1 2 3 4 5 6 7 8
DESCRIPTION
General Method StatementOnshore soil Investigation works General Method StatementEarth Filling works
REMAR KS
2264-PLNG-MS-001 2264-PLNG-MS-002 2264-PLNG-MS-003 2264-PLNG-MS-004 2264-PLNG-MS-005 2264-PLNG-MS-006 2264-PLNG-MS-007 2264-PLNG-MS-008
30

Rev: R2
Date: 15/07/2011.
11.0 LIST OF ITPS/QUALITY ASSURANCE PLAN SR.NO. DOCUMENT NO. DESCRIPTION REMARKS
PART- A: CIVIL WORK 1 MF/AFC/PLD/ITP/01 Cement Slag 2 MF/AFC/PLD/ITP/02 Coarse Aggregate 3 MF/AFC/PLD/ITP/03 Fine Aggregate 4 MF/AFC/PLD/ITP/04 Water 5 MF/AFC/PLD/ITP/05 Admixture 6 MF/AFC/PLD/ITP/06 Reinforcement 7 MF/AFC/PLD/ITP/07 GGBS 8 MF/AFC/PLD/ITP/08 Mix Design. 9 MF/AFC/PLD/ITP/09 RCC Work 10 MF/AFC/PLD/ITP/10 Piling 11 MF/AFC/PLD/ITP/11 Transport, Placing, Compaction & Curing. 12 MF/AFC/PLD/ITP/12 Grouting 13 MF/AFC/PLD/ITP/13 Cement OPC 53 Grades. 14 MF/AFC/PLD/ITP/14 Cement PPC. 15 MF/AFC/PLD/ITP/16 Cement OPC 43 Grades PART B: STRUCTURAL AND PILE FABRICATION 1 MF/AFC/PLD/ITP/15 Pile Fabrication & Splicing 2 MF/AFC/PLD/ITP/17 Pile Painting 3 MF/AFC/PLD/ITP/18 Steel Structure Fabrication 4 MF/AFC/PLD/ITP/19 Steel Structure Painting PART C: MECHANICAL WORK PART D: ELECTRICAL AND INSTRUMENTATION
LIST OF QUALITY FORMATS: SR.NO.

1 2 3 4 5 6 7 8 9 10 11 12
DOCUMENT NO.
MF/AFC/PLD/QF/01 MF/AFC/PLD/QF/02 MF/AFC/PLD/QF/03 MF/AFC/PLD/QF/04 MF/AFC/PLD/QF/05 MF/AFC/PLD/QF/06 MF/AFC/PLD/QF/07 MF/AFC/PLD/QF/08 MF/AFC/PLD/QF/09 MF/AFC/PLD/QF/10 MF/AFC/PLD/QF/11 MF/AFC/PLD/QF/12
DESCRIPTION
Fineness of Cement Consistency & Initial & Final setting of cement Soundness of cement Sp. Gravity & water Absorption Of Coarse Agg. Sp. Gravity & Water Absorption of Fine Agg. Flakiness & Elongation Index of Aggregate. Aggregate Impact Value Moisture Content Determination. Sieve Analysis of Sand. Sieve Analysis of Coarse Agg. 10mm Sieve Analysis of Coarse Agg. 20mm Sieve Analysis of Combined Aggregate
REMARKS
31

Rev: R2
Date: 15/07/2011.
13 14 15 16 17 18 19 20 21
MF/AFC/PLD/QF/13 MF/AFC/PLD/QF/14 MF/AFC/PLD/QF/15 MF/AFC/PLD/QF/16 MF/AFC/PLD/QF/17 MF/AFC/PLD/QF/18 MF/AFC/PLD/QF/19 MF/AFC/PLD/QF/20
Checklist Of pour card. Pile Installation & pre Pore Check List. B/Plant Calibration. Concrete Comp Strength. Bentonite Testing. Bar Bending schedule. Atterberg limits. Maximum Dry Density & Optimum Moist. Content. MF/AFC/PLD/QF/21 Field Density Test.
LIST OF CHECK LIST

SR.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DOCUMENT NO. DESCRIPTION REMARKS
MF/AFC/PLD/QC/01 Survey Report MF/AFC/PLD/QC/02 Pile Driving Report. MF/AFC/PLD/QC/03 Pre excavation report. MF/AFC/PLD/QC/04 Excavation & Backfilling Report. MF/AFC/PLD/QC/05 Concrete Blinding & inspection Report. MF/AFC/PLD/QC/06 Rebar, Formwork & Embedded Records. MF/AFC/PLD/QC/07 Pre Pour inspection for concrete. MF/AFC/PLD/QC/08 Concrete receive Inspection. MF/AFC/PLD/QC/09 Concrete pour Card. MF/AFC/PLD/QC/10 Concrete Placing, Finishing & Curing inspection. MF/AFC/PLD/QC/11 Earthwork pre filling Checklist. MF/AFC/PLD/QC/12 Inspection of Grouting. MF/AFC/PLD/QC/13 Routine B/Plant Inspection. MF/AFC/PLD/QC/14 Inspection of Protective coating. MF/AFC/PLD/QC/15 Sheet pile driving Checklist. MF/AFC/PLD/QC/16 Precast Placing Checklist.
32
PLDSJ MF
Doc.No:MF/AFC/PLD/PRO/18
DAHEJ STANDBY JETTY PROJECT UNDERTAKING (DJPU)
Rev: R2
Date: 15.07.2011.
12.0 QUALITY ASSURANCE PLAN

Activity Item No. QUALITY MANAGEMENT Establish project quality plan for use as the project management system using DJPU corporate management procedures and PETRONET project specific requirements. CUSTOMER RELATED PROCESSES (CONTRACT REVIEW) Petronet review of scope of work. Compare scope with tender documents. Confirm / request clarification of contract documentation. Confirm ability to meet stipulated project / contract requirements for the engineering services with regards to quality. ISO Reference Procedure Reference Originator / Responsibl e Person Project Quality Manager Proposal Manager Project Manager Project Engg. Manager Project Manager Project Engg. Manager Project Manager Project Engg. Manager Project Manager Lead Discipline Manager Approved Project Programme / Schedule Document /Record/ Ref DJPU PLL/PMC
01
MF/AFC/PLD/PR O/18
02
7.2
PR 9950 01 PR 9950 02 PR 9950 03
03
04
05
PRODUCT REALISATION (PLANNING) Review SOW, communicate design / engineering requirements for engineering services / project to designated personnel & establish engineering, design HSE Plans / PQP plans, audit plans & engineering schedules for the engineering services on the project. Ensure that risk scenarios are identified & included within the process through risk & reviews. RESOURCE MANAGEMENT Review and confirmation of key & core competences within the consortium capable of supporting the services required. Establish that sufficient engineering, QHSE & project & construction resources are available to execute the work in line with the schedule to assure all activities. DESIGN INPUT Review inputs to design / engineering development. Compare data received from project from feed study with development data to assure compatibility and compliance to HSE philosophies and requirements and record analysis of design input, discrepancies noted and responses provided to PETRONET.
7.1 / 7.3.1
Engineering Plan
I/R
6. 7.3.1
PR 9940 01 PR 9949 01 Engineering Plan
Project Approved Plan / Schedule
I/R
7.3.2
Engineering Plan
QF 9948 01 QF 9948 02 QF 9948 04
I/R
34
PLDSJ MF
Rev: R2
Date: 15.07.2011.
06
07
08
DESIGN CHECKING Originator self-checking is performed against set criteria to measure the accuracy of the work and assure that calculations and assumptions are correct. Discipline checking is performed to review the correctness, completeness and freedom from ambiguity of self checked work, and to ensure that changes have been properly addressed and fully acted upon. Inter-discipline checking is performed to assure that the documents are compatible with related documents produced by other discipline including OHSE & HSE Engineering inputs received from PETRONET. INTERNAL AUDIT Plan, execute and report on the performance of internal quality and technical audits on the PETRONET project based upon the DJPU scope of work to be performed IMPROVEMENT Monitor ongoing performance of activities and the progress of any improvement initiates, recommendations or corrective actions to be applied to the project or corporate management system process. SAFETY STUDIES & ASSESMENTS Performance of specific safety studies and assessments required within the project scope and requirements to achieve required compliance levels: Quantitative Risk Assessment (QRA) (Review & update) Health, Safety & environment Impact Assessment (HSEIA Phase II) (Review & update) Hazardous Areas Classification (Review & confirmation) Hazardous Operations (HAZOP) session (Review & update) Fire and Explosion Modeling Analysis (DJPU impact confirmation of EIL / PETRONET review / update) Environmental Impact Identification (ENVID) (Review & confirmation) Safety Integrity Levels (SIL) (Review & Confirmation)Plant Fire Fighting System (Review & confirmation) Fire & Gas Detection Systems ( Tanks) ( Review & confirmation) Environmental Impact Spill Containment ( Non-containment tanks only) Personnel Health & Safety Equipment ( Review & confirmation) SIMOPS (Simultaneous Operations) Session (input)
7.3.5 / 7.3.7
Engineering Plan
Project Manager Lead Discipline Manager
QF 9948 01 QF 9948 02 QF 9948 04
I/R
R/M
8.2.2
PR 9001 03
Project Quality Manager Project Manager Project Quality Manager.
QF 9001 05 QF 9001 08 QF 9001 09 QF 9001 10
I/R
R/M
8.5.1
PR 9001 08
I/R
R/M
09
7.3.2 / 7.3.3 / 7.3.4
HSE Plan
HSE Manager
R/M I/R W/R
35
PLDSJ MF
Rev: R2
Date: 15.07.2011.
10
DESIGN REVIEW Format review of the design or results against the original input criteria has been performed with input from QHSE & HSE Engineering and recorded. DESIGN VALIDATION Formal approval of the data and / or software to assure that the intended results are attainable on a consistent basis and are free from inherent error and that consideration of plant and process safety, ergonomics, constructability and environmental controls is included in accordance with the defined scope of work for the Project. DESIGN VERIFICATION Approval of verification stage / agreement on how designs released. Agree who approves before release. Agree systems of design verification records/Agreed procedure are all performed in accordance with DJPU corporate systems and PETRONET project requirements. SOFTWARE VALIDATION & CONTROL Agreed software tools /agreed software validation checks performed /agreed records/review records/agreed procedure.
7.3.4
Engineering Plan
Engineerin g Manager
I/R
R/M
11
7.3.6
Engineering Plan
Engineerin g Manager
I/R
R/M
12
7.3.5
Engineering Plan
Engineerin g Manager Project Control Manager Project Manager Project Control Manager Project Manager
I/R
R/M
13
7.3.6
Engineering Plan
I/R
R/M
14
CHANGE CONTROL Implement and maintain robust change system to ensure that the current status of all data is accurate at all times.
7.3.7
Engineering Plan
I/R
R/M
15
CONTROL OF DOCUMENTS Established document management system or practices are implemented upon the project utilizing DJPU corporate organization procedures supplemented by the specified project requirements to provide accurate and timely control of all technical and organizational documents required to fulfill the contract / project scope of work. Submittal, receipt and transmittal routines are established and maintained.
4.2.3
MF/AFC/PLD/PRO/01 PR 9001 01
Project Control Manager Project Manager
QF 9001 01 QF 9001 02 QF 9001 03
I/R
R/M
36
PLDSJ MF
Rev: R2
Date: 15.07.2011.
16
PROCUREMENT Implement the consortium procurement practices based upon the corporate systems. Plan the procurement & delivery of all items based upon site construction programme. Assure that the selection of suitable vendors and subcontractors.
MF/AFC/PLD/PRO/05 MF/AFC/PLD/PRO/06
7.4
PR 9925 01 PR 9925 02 PR 9925 03 PR 9925 04 PR 9925 05 PR 9925 06 MF/AFC/PLD/PRO/05 MF/AFC/PLD/PRO/06 PR 9925 01 PR 9925 02 PR 9925 03 PR 9925 04 PR 9925 05 PR 9925 06
Project Procureme nt Manager
QF 9925 01 QF 9925 02 QF 9925 09 QF 9925 07 QF 9925 08 QF 9925 27
I/R
17 PURCHASING Utilizing the technical purchasing specifications generated from the engineering deliverables, assure the technical and qualitative selection of vendors and subcontractors to provide equipment and services to meet technical requirements fit for services.
7.4
Project Procureme nt Manager Project Purchasing Manager Project Procureme nt Manager Project Quality Manager Quality Engineers Project Manager Project Constructi on Manager Project Quality Manager
QF 9925 01 QF 9925 02 QF 9925 09 QF 9925 07 QF 9925 08 QF 9925 27
R/M
18
VENDOR MANAGEMENT Coordination of vendor supply, technical data interfaces, clarifications & queries, inspection, certification, release, logistics and shipping performed through the DJPU organizations, including any vendor support, spare parts and warranty issues.
MF/AFC/PLD/PRO/05
7.4
PR 9925 06
QF 9925 09 QF 9925 07 QF 9925 08 QF 9925 27
R/M
19
SUBCONTRACTOR CONTROL Coordination of contractors / sub-contractors; scope of works, deliverables, technical data interfaces, clarifications & queries, inspection requirements, HSE requirements, logistics and shipping of items sub-assemblies, on-site interfaces and supervision, work package release, supervisory management performed by .
7.4
PR 9940 02
QF 9940 01 QF 9940 01A QF 9940 01B QF 9940 01C QF 9940 02 QF 9940 03 QF 9940 04 QF 9940 05A QF 9940 05B QF 9940 06
R/M
37
PLDSJ MF
Rev: R2
Project Manager Project Site Manager Project Control Manager Project Site Manager Site QAQC Manager Project Constructi on Manager Project Manager Project Site Manager Site QAQC Manager Project Control Manager Project Site Manager Project Constructi on
Date: 15.07.2011.
20
MOBILISATION & SITE ESTABLISHMENT The planning and provision of adequate and appropriate resources to manage and execute the work on site including manpower, facilities, equipment, utilities and power. The implementation of the DJPU site organization and management systems on site to support the on-site activities.
7.1
PR 8571 CP 03
I/R
21
CONSTRUCTION & ERECTION Employment of construction methods and techniques utilizing correct construction, erection, and assembly and jointing technologies to safety erect the Project and supporting infrastructures and building. 7.5.1
PR 9940 01
I /R
22
PROCESS CONTROL Control over the complete construction process by the use of management systems, planning tools, experience supervision and the measurement of quality, health & safety and progress performance against set performance criteria. Control over the acceptance of non-conforming products or activities and resolution of corrective actions to meet specified requirements.
7.5.2 8.2.3 8.3
Site procedure for Control of Nonconforming Product
I/R
23
INSPECTION & TESTING The systematic examination of all components based upon pre-determined criticality of items, components, sub-assemblies, assemblies and packaged equipment at interfaces by specified inspection methods and techniques including: visual, dimensional, non-destructive and destructive testing, painting, coating and insulation testing, mechanical, and electrical and
7.5.3
W /R
38
PLDSJ MF
Rev: R2
Manager Project QAQC Manager Project Commissi oning Manager Site QAQC Manager Project Commissi oning Manager Client Commissi oning Manager Project Control Manager Site QAQC Manager
Date: 15.07.2011.
24
25
26
pressure testing. The compilation of test inspection records and visual identification or test status to permit verification of the successful completion of test activities and release for mechanical completion and precommissioning activities. MEHANICAL COMLETION & PRE-COMMISSIONING Assurance of the mechanical completion of all systems prior to the precommissioning / commissioning of the plant on a system-by-system basis. Management of the pre-commissioning activities in cooperation with client to assure the readiness of the plant for commissioning. Obtain mechanical completion certificate for facilities and pre-commissioning handover completion certificates from Client. COMMISSONING The completion of commissioning of the project facilities including interfaces with the tanks and marine facilities and assist Client to achieve start-up of the facilities including cool-down and stabilization of product. Provide of plant operatives and maintenance personnel, handover of commissioning and operations & maintenance manuals; spare parts and operational spares systems to client. Obtain commissioning handover completion certificates from Client for Re-Gas facilities. QUALITY RECORDS Coordinate and correlate the vendor / subcontractor manufacturing record dossiers and site construction record dossiers between all DJPU members to provide a complete and definitive set of project records for handover to PETRONET in a controlled and sequential manner in line with agreed project milestones.
Legend: I-Inspection, R-Review, M-Monitoring, H-Hold point, W-Witness
H/W
H /W
4.4
PR 9001 02
QF 9001 04
R/H
39
PROJECT : EPCC Marine Facilities For Standby Jetty Project at Dahej LNG Terminal. ACTIVITY: Inspection and Test Plan for Pile Fabrication CLIENT: Petronet LNG Limited CONTRACTOR: Dahej Stand By Jetty Project Undertaking(DJPU)
Sr No ACTIVITY DESCRIPTION Reference SPEC./STANDARD CONTRACTOR EXECUTION CONTRACTOR QUALITY PLL/PMC ACCEPTANCE Frequency of Activity
DOCUMENT NO MF/AFC/PLD/ITP/15 REVISION R2 DATE OF Rev. 15.07.2011

SUBMITTAL REPORT FOR INFORMATION
REMARKS
FABRICATION & Splicing

A) Receipt of materials and storage / stacking B) Receipt of electrodes, filler wire & verification A) Welder's Procedure Specification (WPS) & 2 Procedure Qualification Record (PQR) B)Welder Qualification Test WQT Tender Specification & Drawings Tender Specification & As per Approved WPS I/W R/W API 5L/BID SPEC. 100% MTC/Report
I/W
AWS D1.1/IS 814:1991
100%
MTC/Report
Tender Specification & AWS D1.1 Tender Specification , AWS D1.1 Tender Specification, Manufacturers recommendation&AWS D1.1
W/R
AWS D1.1
100%
Report
W/R
AWS D1.1 AWS D1.1/Manufacturers Recommendations
100%
Report/ID Card
Storage& Baking Of Electrodes
100%
Reports
A) Cutting & Edge preparation 4 B) Fitup & Dimensional Check C) Botton shoe to be prepared
Tender Specification/WPS
RW
WPS
100%
Tender Specification Tender Specification
H W
W W
w S Lamination to be checked-DPT
100% 100%
Report Report
WELDING
5 A) Welding As Per Approved Procedure/WPS B) Visual Inspection Of Completed weld Tender Specification/WPS Tender specification/AWS D1.1 H H H H R/W R/W WPS AWS D1.1 100% 100% Report
NDT
A)Radiography Testing (RT) 6 H H AWS D1.1 100% Report
B) Dye penetrant testing(DPT)
RW
AWS D1.1
100%
Report As perJob Requirement/ Report
C) Ultrasonic testing(UT)
RW
AWS D1.1
100%
FINAL INSPECTION
7 A) Straightness B) Dimensions Tender specification,Drawings& AWS D1.1 H H H H H W RW R/W R/W Total length > 15 mtrs=15mm, API RP 2A 100% 100% 100% Report
c)Ovality A: Approval S:Surveillance
R: Review Doc.
Rw:Random Witness Page 1 of 1
W: Witness
H: Holdpoint

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PROJECT QUALITY PLAN

Section No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Introduction Scope

Page 3 3 3-4 4-9 10 12 12-24 24-28 29 29-31 32-33

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

NCR PO QA QAP QC QMS

QUALITY MANAGEMENT SYSTEM MANUAL

PROJECT QUALITY PLAN

QUALITY MANAGEMENT SYSTEM PROCEDURES

CORPORATE DEPARTMENTAL PROCEDURES

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

5.3 QUALITY POLICY: QUALITY POLICY

PROJECT QUALITY PLAN

7.1 DESIGN & ENGINEERING

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

Reference: Corporate Procedure for Selection & Evaluation of vendor PR 9925 06

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

IDENTIFICATION AND TRACEABILITY

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

Reference: Corporate Procedure for Internal Audit PR 9001 03

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

PROJECT QUALITY PLAN

Safety Officer Day / Night

Civil Works (On-shore)

Civil Works (Off-shore)

10. LIST OF CORPORATE QMS PROCEDURES:

PR 9001 01 PR 9001 02 PR 9001 03 PR 9001 04 PR 9001 05 PR 9001 06 PR 9001 07

PROJECT QUALITY PLAN

LIST OF SITE PROCEDURES

LIST OF METHOD STATEMENT SR.NO. DOCUMENT NO.

2264-PLNG-MS-001 2264-PLNG-MS-002 2264-PLNG-MS-003 2264-PLNG-MS-004 2264-PLNG-MS-005 2264-PLNG-MS-006 2264-PLNG-MS-007 2264-PLNG-MS-008

PROJECT QUALITY PLAN

LIST OF QUALITY FORMATS: SR.NO.

PROJECT QUALITY PLAN

MF/AFC/PLD/QF/13 MF/AFC/PLD/QF/14 MF/AFC/PLD/QF/15 MF/AFC/PLD/QF/16 MF/AFC/PLD/QF/17 MF/AFC/PLD/QF/18 MF/AFC/PLD/QF/19 MF/AFC/PLD/QF/20

LIST OF CHECK LIST

PROJECT QUALITY PLAN

12.0 QUALITY ASSURANCE PLAN

PR 9950 01 PR 9950 02 PR 9950 03

PR 9940 01 PR 9949 01 Engineering Plan

Project Approved Plan / Schedule

QF 9948 01 QF 9948 02 QF 9948 04

PROJECT QUALITY PLAN