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CONTENTS
1. GENERAL
1.1 Introduction
1.2 Scope
1.3 Purpose
1.4 Quality Policy
1.5 References
1.6 Definitions
1.7 Revisions
2. PROJECT ORGANIZATION AND RESPONSIBILITIES
3. MANAGEMENT REVIEW
4. PROJECT APPROACH
5. CONTRACT REVIEW
6. COORDINATION PROCEDURE
7. PROJECT CONTROL PROCEDURE
8. MATERIAL CONTROL
9. DOCUMENT AND DATA CONTROL
10. DESIGN CONTROL
11. CONCESSION REQUESTS AND TECHNICAL QUERIES
12. PROCUREMENT
13. PRE-COMMISSIOINING & COMMISSIONING ASSISTANCE
14. INSPECTION AND TESTING
15. NON-CONFORMING PRODUCT, CORRECTIVE AND PREVENTIVE ACTION
16. PERFORMANCE IMPROVEMENT AND KEY PERFORMANCE INDICATORS
17. CONTROL OF QUALITY RECORDS
18. QUALITY AUDITS
19. TRAINING
20. STATISTICAL TECHNIQUES
21. REPORTING
22. ATTACHMENTS
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
1. GENERAL
1.1 INTRODUCTION
This quality control plan is the principal quality document for the project. It plans
and summarizes the quality system and the resources and controls for its
implementation on the project. It defines and establishes the principle and
structure of the quality system as it is applied to the “Hook-Up, Pre-
Commissioning and commissioning assistance Project”, Kashagan Field
Development Experimental Program Project, Kuryk, Republic of Kazakhstan.
1.2 SCOPE
This Quality Plan is applicable to the hook-up, pre-commissioning and commissioning
assistance of the following areas of the OFFSHORE facility:
• Train 2 Pipe-racks and Modules
• Riser Island Pipe racks and Flare
• Island –A (Optional)
The detailed scope of work is as per the COMPANY document ‘Schedule-D Scope of
Work for Contract No. 2009-0363’. The matrix of responsibility for CC EPC scope is as
per the Attachment -1.
This plan covers the CC EPC scope of onshore & offshore management, project
engineering, fabrication, construction and maritime personnel, plant, materials, temporary
facilities, facilities and equipment.
The main work areas pertaining to CC EPC scope of work are,
1.3 PURPOSE
The purpose of this quality plan is to ensure that:
• The requirements of the ISO9001:2008 standard and the CONTRACTOR quality
system are met.
• The COMPANY quality requirements understood and met.
• The Quality management system is planned, documented, communicated and
understood by project personnel, implemented and audited and that the process
conforms to the specified requirements of the contract objectives and policy.
Signature: pp.
Date: Signature:
Date:
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
1.5 REFERENCES
1.5.1 ISO 10005:2005 Quality Management – Guidelines for Quality Plans
1.5.2 ISO 9001:2008 Quality Management Systems – Requirements
1.5.3 ISO 9000:2005 QMS – Fundamentals and Vocabulary
1.5.4 Schedule –D Scope of Work Contract No. 2009-0363
1.6 DEFINITIONS
1.7 REVISIONS
• This Project Quality Plan shall be revised to ‘APPROVED’ Status and issued prior to
commencement of main construction activities.
• This project Quality Plan shall be revised and reissued in accordance with the project
procedure, ‘KE01-B0-000-KD-Z-ST-5002-000, Hook-up and commissioning
contractor document requirement schedule CDRS’. The PRELIMINARY ISSUE
shall be revision P01. The ‘APPROVED FOR CONSTRUCTION’ issue shall be with
‘C01’ revision. Subsequent revisions shall be ‘C02’, ‘C04’, etc.
• The CS& QM department shall be copied on all revised issues of this Project Quality
Plan.
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
• Revisions shall be the responsibility of the QA/QC Manager or his designee, and
shall be made so as to constantly reflect the current project quality system, contract,
and statutory as well as regulatory requirements.
2.2 RESPONSIBILITY
2.2.1 The Project Manager is ultimately responsible for the quality of the finished
works. He also delegates responsibility to the Managers and Supervisors to
ensure the quality of the work or services performed by their workforce.
2.2.2 The appointed QA/QC Manager or his designees are the quality management
representatives within the terms of ISO 9001:2008 standard clause 5.5.2.
2.2.3 The responsibility of all personnel who manage, perform and verify work
affecting quality is defined and documented in the following documents:
• Quality Management Procedures
• Quality Control Procedures
• Inspection & Test Plans
• Method Statements
2.2.4 Within the quality system all department and discipline Managers are responsible
for:
• Implementing and maintaining the project quality management system
and ensuring that the project quality policy and objectives are understood
and achieved by all personnel within their department or section.
• Identifying and evaluating actual or potential problems that may affect
quality.
• Maintaining and revising where necessary the quality management
procedure relevant to their department or section.
• Quality of work produced by all personnel within their section.
• Ensuring staff awareness and understanding of the project quality
management system and the requirements of the applicable quality
management procedures and have ready and unlimited access to them.
• Ensuring that staffs are adequately qualified and experienced in their
relevant discipline to perform the duties of their position in a satisfactory
manner.
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
3. MANAGEMENT REVIEW
3.1 The Quality Management System is reviewed regularly to ensure its continuing
suitability, adequacy and effectiveness. Reviews are conducted by the project team in
Management Review Meetings (In accordance with the requirements of KE01-B0-000-
CC-A-PR-0004-000, with the present of the required disciplines and functions, to address
whether the quality system is being properly implemented and followed.
3.2 The management reviews shall be documented and used as part of quality records and
consist of structured and comprehensive evaluation of performance.
3.3 The management review meetings shall be scheduled at regular intervals (once in every
four months) from the effective date of the contract.
4. PROJECT APPROACH
4.1 GENERAL
5. CONTRACT REVIEW
5.1 The Estimation Department has performed an initial review of the CONTRACT
documents prior to award. The minutes of the “tender review board meeting” constitute
the record of “contract review” prior to award of CONTRACT.
5.2 Codes and standards to be applied to the project shall be identified during the contract
document review (COMPANY Doc: KE01-00-000-KD-Q-LS-0001-000 - Codes and
standards document register). Any unfamiliar codes and standards will be highlighted on
its respective procedure.
5.3 Country laws and regulations applicable to the project have been identified during the
contract document review, and these laws shall also be imposed on the vendors and
subcontractors for the project.
5.4 On award of contract CONTRACTOR shall conclude review of the contract, including
applicable standards and procedures, and initiate the further development of the necessary
execution plans, schedules and procedures to implement the CONTRACT.
5.5 CONTRACT review shall include all kick-off meetings and familiarization activities such
as distribution of copies of the relevant parts of the contract documents within the project
organization. CONTRACT amendments-if any, shall be in the form of change orders or
approved technical variances and shall be reviewed by appropriate project management
personnel and put into effect. Records of CONTRACT review shall be separated and
maintained.
5.6 Any amendments to the contract shall be approved by the CONTRACTOR and
COMPANY before proceeding.
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
6. COORDINATION PROCEDURE
6.1 Internal coordination of management decisions, information, documents, etc., within the
organization on site and CC EPC’s Area Office and COMPANY project teams is covered
by the various sections of this PQP and associated documents.
6.2 Coordination of CONTRACTOR and COMPANY shall be agreed during mobilization
and specified in a procedure covering details such as: protocol for standard addressees for
documents, standard form of transmittal, format, number and addressees of standard
copies of documents and data, authority for approval, COMPANY access to computer
network etc.
6.3 Coordination with subcontractors shall be agreed before award of subcontract and shall
cover details such as: addresses for documents, standard form of transmittal, format and
number and addressees of copies of documents / data, authority for approval, etc.
6.4 Coordination with local and national authorities shall be detailed at the mobilization stage
in full consultation with COMPANY and the applicable section of CONTRACT.
7.1 CONTRACT and Final planning and scheduling documents shall be transmitted to the
site at mobilization stage. The planning shall also incorporate the winter season inactivity
of installation and hook-up work and provision of permit, authorizations, certifications,
transit and customs documentation. The Construction Controls Manager shall be
responsible for ensuring that this transmission takes place and that all relevant documents
are included.
7.2 The Construction Controls Manager is responsible for preparing and updating schedules
in accordance with contract requirements.
7.3 In agreement with the Site Construction Manager and the prior to commencing the work,
the Construction Controls Manager shall issue a progress monitoring procedure.
7.4 Construction Controls Manager shall transmit planning and scheduling data to the Site
Construction Manager who is then responsible for ensuring that the materials, documents
and other input resources are available at the job site before each item of work begins.
7.5 Progress shall be reported weekly and monthly in accordance with contract requirements.
8. MATERIAL CONTROL
8.1 A material identification procedure shall be implemented to ensure that all materials,
parts and components, including fabricated assemblies are suitably identified. Sufficient
data shall be recorded on a software database (TALISMAN) to provide the degree of
traceability applicable to the material concerned.
8.2 The location and method of identification (marking) shall not adversely affect the
function or quality of the item concerned.
8.3 Prior to the final installation of material, parts and components, a check shall be made to
confirm that a valid identification has been applied.
8.4 CONTRACTOR shall establish the storage facilities both in the Onshore Support Base
and also at Island D on the areas allocated by the COMPANY
8.5 Material, equipment and fabricated assemblies provided by CONTRACTOR shall be
subject to the requirements of KE01-B0-000-CC-J-QM-0001-000 “Material Management
& Control” and Section-17 of Schedule ” D” Contract No. 2009-0363.
8.6 Material Handling, Storage and Preservation
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
• All materials shall be handled, transported, and stored in such a way that potential for
deterioration or damage is prevented. Received materials and components shall be
stored in the original packing until such time as it is needed. Preservation activities
shall be performed as per the COMPANY’s approved system and checklists with due
attention to the guidelines/requirements of the vendors, before, during and after
installation.
• The local laws and international regulations shall be adhered for storing the classified
and hazardous materials. The personnel shall be trained in the handling and storage of
hazardous materials.
• Preservation of material at Offshore Facility will be done by other Contractors.
12. PROCUREMENT
12.1 PROCUREMENT PLAN
12.1.1 The requirements of this section follow ISO 9001:2008 standard, clause 7.4.
12.1.2 CC EPC shall prepare a procurement plan for materials and consumables required
for the hook-up and pre-commissioning scope of the project.
12.1.3 Vendor list of prospective Suppliers shall be prepared after taking into
consideration their Quality Systems, product standards, documented experiences
or by carrying out Supplier evaluations.
12.1.4 Quality requirements shall be clearly specified in all purchase orders or
subcontract agreements.
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
12.1.5 Purchasing of all permanent works materials will be carried out in accordance
with KE01-B0-000-CC-B-PR-0001-000 and all subcontracts will be issued as per
KE01-B0-000-CC-A-PR-0006-000.
12.1.6 The “Outsourcing process” according to the requirement of ISO 9001:2008
standard, Section 4.1, is detailed in KE01-B0-000-CC-A-PR-0006-000.
concerned parties. A copy of the audit report shall also be sent to the COMPANY
within 15 days of the completion of each audit.
19.1.8 The QA/QC Manager or his designee shall maintain a log of Corrective Action
Notices (CANs).
19.1.9 A preliminary audit schedule is annexed to this procedure (Attachment -5) which
will be developed during the course of the project.
20. TRAINING
20.1 TRAINING POLICY
20.1.1 The standard CC EPC policy is to employ project personnel who have previous
demonstrated experience in working with the standards and codes applicable to
the project. Any requirements for additional training shall be addressed as per
project specific quality management procedure KE01-B0-000-CC-Q-QM-0004-
000 “Training and Personnel Qualification”. Project personnel shall be qualified
for their function. Additional specific operator training will be provided if
required.
20.1.2 Training needs shall be the subject of discussion at management review meetings.
20.1.3 All personnel in the project who may have an effect on project quality and who
will stay on the project for more than two months shall have a quality induction.
Records showing this induction shall be maintained.
20.1.4 The QA/QC Manager shall ensure that managers, site senior staff and quality
related personnel are familiarized with:
• The essentials of the ISO 9000 series of standards.
• The project quality system as set out by this project quality plan.
• The quality management procedure applicable to each manager’s work and duties
• Implementation of detailed procedures such as QCP’s, ITP’s.
21. REPORTING
21.1 A Monthly QA/QC Report shall be prepared to demonstrate the effective
implementation of the quality management system. As a minimum, the following shall be
included:
• Listing of Non-Conformance Reports Issued, Closed and Pending.
• Listing of Quality System Audits
• Listing of all defective or rejected material received on site.
• Welding rejection rate together with a chart showing the history of the welding
rate.
• Listing and status of engineering waivers
22. ATTACHMENTS
Attachment – 1 : Matrix of Responsibilities for the contractor
Attachment – 2 : List of Quality Management Procedures
Attachment – 3 : List of Applicable QCPs & ITPs
Attachment – 4 : Project Quality System Matrix
Attachment – 5 : Indicative Quality System Audit Schedule
Attachment – 6 : Project Organization Chart (4 Sheets)
DOC No.
Agip Kazakhstan North Caspian Operating
KE01-B0-000-CC-Q-QC-0001-
Company N.V 000
Hook-up, Pre-commissioning & Commissioning
Assistance
Attachment-1 - Matrix of Responsibilities for the CONTRACTOR (refer the latest issue)
ENGINEERING
CONTRACTOR CONTRACTOR
Erection & maintenance of scaffolding
COMPANY +
n.a. (2)
Lifting using floating crane CONTRACTOR
Lifting using mobile cranes on the cofferdams and other
CONTRACTOR n.a.
means on the ground
Handling of construction wastes, scrap and surplus and
loading on transport vessels at Offshore Sites CONTRACTOR CONTRACTOR
Performed by an Other
Transport and disposal of scrap and wastes COMPANY n.a. Contractor
Mechanical ITPs
ITP-1035-117 Piping Erection KE01-B0-000-CC-Q-QP-0001-000
Electrical ITPs
ITP-1035-301 Installation of cables KE01-B0-000-CC-Q-QP-0008-000
Instrumentation ITPs
ITP-1035-409 Instrument Calibration KE01-B0-000-CC-Q-QP-0015-000
DY PROJECT
MAN AGER
Const. Control Site Cons. Project Com. QA/QC Manager HSE & S Manager PMV Manager
Manager Manager Isl-D Manager
Material Office Engr IT Engineer Doc Engr Sr. Planning Subcon Head of Translator/In Sr. Envir Training Doctor Security Sr. HSE
Engineer ISL-D
ISL-D Engineer Coordinator Admin terpretation officer officer officer officer
Clerk
DOC No.
KE01-B0-000-CC-Q-QC-0001-000
Agip Kazakhstan North Caspian Operating Company N.V
Hook-up, Pre-commissioning & Commissioning Assistance
PROJECT
MANAGER
Attachment -6 Page 2 of 5
SECRETARY
ORGANIZATION CHART (BASE CASE) ISLAND-D
DY PROJECT
MAN AGER
Const. Control Proj. Comm. Site Cons. QA/QC Manager HSE & S Manager PMV Manager
Manager Manager Manager Island-
Refer Page 1 Refer Page 1 Refer Page 3 Refer Page 1 Refer Page 3
Forman
DOC No.
KE01-B0-000-CC-Q-QC-0001-000
Agip Kazakhstan North Caspian Operating Company N.V
Hook-up, Pre-commissioning & Commissioning Assistance
PROJECT
MANAGER
Attachment -6 Page 3 of 5
ORGANIZATION CHART (BASE CASE) ISLAND-D SECRETARY
DY PROJECT
MAN AGER
Const. Control Site Cons. QA/QC Manager Proj Comm PMV Manager HSE Manager
Manager Manager Island- Manager
Plant
Piping Inspector Computer
storekeeper
Inspector Instrumentat operator
Steel Plant
Inspector foreman
Technician
Clerk
DOC No.
KE01-B0-000-CC-Q-QC-0001-000
Agip Kazakhstan North Caspian Operating Company N.V
Hook-up, Pre-commissioning & Commissioning Assistance
PROJECT
MANAGER
SECRETARY
Attachment -6 Page 4 of 5
Administrator Sr. Training HSE training Project comm PMV (Plant) Interface
Atyrau Supervisor officer Manager Manager coordinator
Atyrau
Training
Transport Supervisor Permits/licen Chief
Coordinator ce services accountant
Discipline Plant
Camp supervisor transport offr
Head of Payroll /
coordinator
translation cashier
Clerk Plant
Travel Visa purchaser
coordinator Translator
interpreter
Personnel
Local
officer
authorities
Translators /
Ecologist
interpreters
IT support
Ecologist
Engineer
DOC No.
KE01-B0-000-CC-Q-QC-0001-000
Agip Kazakhstan North Caspian Operating Company N.V
Hook-up, Pre-commissioning & Commissioning Assistance
PROJECT
MANAGER
Attachment-6 Page 5 of 5
ORGANIZATION CHART (BASE CASE) KURYK SECRETARY
DY PROJECT
MANAGER
Material Plant
Comm. Clerk
Coordinator Storekeeper
Infra. Engr
Technician
Local Material
Purchaser Checker
Translator/in Expeditor
terpreter