WAHA OIL COMPANY
(PART A: TECHNICAL)
SECTION 7:
QUALITY ASSURANCE AND QUALITY CONTROLS
TENDER DOCUMENT
ENGINEERING, PROCUREMENT, CONSTRUCTION,
INSTALLATION AND COMMISSIONING OF 6K
PRODUCTION FLOWLINES AND EXPORT PIPELINES
Prepared by
Major Projects Department
November 2024
Page 1 of 12
SECTION 7
QUALITY ASSURANCE & QUALITY CONTROL
CONTENTS
1.0 INTRODUCTION 3
2.0 QUALITY ASSURANCE STANDARDS 3
3.0 IMPLEMENTATION OF QUALITY ASSURANCE 3
4.0 QUALITY PLAN 4
5.0 PROCEDURES AND WORK INSTRUCTIONS 8
6.0 REFERENCES 12
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SECTION 7 – QUALITY ASSURANCE & QUALITY CONTROL
1.0 INTRODUCTION
This document provides requirements on the implementation of Quality
Assurance.
2.0 QUALITY ASSURANCE STANDARDS
CONTRACTOR shall apply a system based on ISO 9000/2015
Standard for Quality Assurance for CONTRACTOR activities and shall
ensure the same standards are applied to Subcontractors and
Suppliers.
30 IMPLEMENTATION OF QUALITY ASSURANCE
3.1 Activities
CONTRACTOR shall organise himself in such a way that the technical,
administrative and human factors affecting the quality work, protection
of the environment and welfare of CONTRACTOR and WAHA
personnel are under control. All such control should be oriented
towards safety and the reduction, elimination and, most importantly,
prevention of quality deficiencies.
The management system is documented in the Project Quality Plan,
addressing critical activities, such as:
- Determination of customer needs;
- Definition of the methods to be employed to achieve them;
- Assessment of the criticality of activities and products;
- Allocation of responsibility and definition of controls;
- Generation and maintenance of quality records;
- QA audit and review;
- Quality improvement.
3.2 Staff
As with safety, quality is the responsibility of line management and of
each and every individual working on the project. The staff shall be
backed up by dedicated or corporate QA staff, Who must retain a high
degree of independence and objectivity, reporting directly to Senior
Management and with a functional link to the corporate quality
organisation. Typically, QA staff will be responsible for:
- Coordinating the preparation of the Project Quality Plan;
- Assessment of potential Suppliers' and subcontractor quality
systems and quality plans;
- Monitoring:
- The implementation of the project quality system;
- Activities of Contractors and Suppliers in implementation of their
quality plans;
- The gaining of regulatory permits for the project;
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- The execution of audits and reviews and the follow-up of any
actions arising from them.
3.3 Documentation
CONTRACTOR QA activities shall be fully documented. Critical
activities shall be performed according to written procedures or work
instructions based on proven techniques, and evidence of compliance
recorded. It is accordingly essential that CONTRACTOR exercises
proper judgement in deciding which and activities are critical.
4.0 QUALITY PLAN
CONTRACTOR shall prepare a Quality Plan for WAHA approval. The
Project Quality Plan is a documented description of the project
management system and must be approved by Senior CONTRACTOR
management to demonstrate commitment to quality
Project Quality Plan:
The Quality plan shall cover the following issues:
a) Project Objectives
- Objectives to be achieved
- Criteria requiring to be satisfied, including Health, Safety
and Environmental Performance targets
- Governing regulations and standards
b) Description of measures to achieve the objectives, i.e. the
Quality System
- Project quality policy and purpose/scope of the Quality
Plan
- Organisation, responsibilities, resources, skills, training
- Contractors, suppliers, equipment, facilities
- Procedures, controls (matched to Critical Activities)
c) Description of the responsibilities and schedule for audits and
reviews.
The management system as documented in the Quality Plan shall be
designed to eliminate problems by ensuring management pre-
commitment, to the provision of well documented records, which give
an audit trail. It shall also ensure that records and handover
documentation are properly planned and completed during the work.
CONTRACTOR shall prepare a schedule of audits of a selection of
CONTRACTOR procedures. Copies of resultant Audit Reports and
any resultant action close-outs will be issued to WAHA.
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The Project quality plan shall include the following:
Construction Schedule
- Milestones where quality-related construction activities,
inspection and tests occur.
- Hold-points for witness and approval, e.g. for critical
interfaces, weights, hydro testing.
Management responsibilities
The plan should identify those key individuals within the organisation
responsible for:
- Ensuring that the activities required by the quality system or
Project Specification are planned, implemented and controlled
and their progress monitored;
- Communicating requirements peculiar to the specific product,
project or contract to all affected departments, Contractors,
Suppliers and customers, and resolving problems that arise at
the interfaces between such groups;
- Reviewing the results of any audits conducted;
- Addressing how concession requests relating to required
quality system elements are to be dealt with;
- Implementing corrective actions.
Contract review
The plan should indicate when, how and by whom the requirements
specified for the project are to be reviewed. The plan should also
indicate how the results of this review are to be documented and how
conflicting or ambiguous requirements are to be resolved.
Handover
The plan should indicate how CONTRACTOR will ensure that WAHA
is provided with information and back-up after handover such as:
- Provision of Supplier documentation and manuals;
- Documentation recording the technical and operational
concepts underlying the plant design.
Non-conformance and variation
The plan should address how and under what circumstances the
CONTRACTOR would request WAHA approval to vary from the
contract requirements or to obtain a concession for an item, which
does not meet specified requirements. In doing so the plan should
indicate:
- Who would have the responsibility to request such
concessions;
- How such a request would be made;
- What information is to be provided and in what form;
- Who has been identified as having the responsibility and
authority to accept or reject such concessions.
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The plan should indicate how non-conforming products are identified or
segregated to prevent misuse until properly disposed of.
Design control
The plan should indicate when, how and by whom validation and
verification of design output conformity to design inputs is to be carried
out, controlled and documented. Where applicable, the plan should
indicate the extent to which the customer is to be involved in design
activities, such as participation in design reviews and design
verification tests. The plan should reference applicable codes,
standards and specifications.
Document control
The plan should indicate:
- What documents are to be provided and controlled;
- How documents will be identified so that their relationship to
the plan can be readily determined;
- How, and by whom, access to such documents can be
obtained;
- How, and by whom, changes to documents are reviewed and
approved.
Purchasing
The plan should indicate:
- Important products that are to be purchased from Suppliers,
from whom they are to be purchased, and the relevant quality
assurance requirements that is to be applied;
- The methods to be used to select, appraise, evaluate and
control Suppliers;
- Requirements for, and reference to, Supplier quality plans,
where appropriate;
- The methods to be used to satisfy regulatory requirements
which apply to purchased products.
Materials identification and trace-ability
The plan should define the scope and extent of trace-ability
requirements, including how affected products are to be identified. The
plan should indicate:
- How contractual and regulatory authority trace-ability
requirements are identified and incorporated into working
documents;
- What records relating to such trace-ability requirements are to
be generated and how they are to be controlled and
distributed.
Handling, storage, packaging and delivery
The plan should indicate:
- How the requirements for handling, storage, packaging and
delivery are to be specified and met;
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- How materials and equipment will be delivered to the site in a
manner that will ensure that they will not be damaged;
- How materials and equipment will be stored at site prior to
installation.
Installation
Where equipment is to be installed the plan should indicate how the
requirements are to be specified, and the work subsequently tested.
Inspection and testing
The plan should indicate:
- How the project team or their Contractors will verify Supplier's
product conformance to specified requirements;
- Where each inspection and test point is located in the process
sequence;
- Specific requirements for the identification of inspection and
test status;
- What characteristics are to be inspected and tested at each
joint, the procedures and acceptance criteria to be used, and
any special tools, techniques or personnel qualifications
required;
- Where the customer has established points for its witness or
verification of selected characteristics of a product or process;
- Where inspections or tests are required to be witnessed or
performed by regulatory authorities;
- Where, when and how the Supplier intends, or is required by
the customer or regulatory authorities, to use third parties to
perform:
- Type tests;
- Witness testing (including on-site acceptance);
- Product verification;
- Material, product, process or personnel certification.
Inspection, measuring and test equipment
The plan should indicate the control system to be used for inspection,
measuring and test equipment specifically intended for use for the
project or contract, including:
- Identification of such equipment;
- Required accuracy of the equipment;
- Method of calibration;
- Method of indicating and recording calibration status;
- What records of usage of such equipment are to be
maintained so that the validity of previous results can be
determined when such equipment is found to be out of
calibration.
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Quality audits
The plan should indicate the nature and extent of quality audits to be
undertaken and how the results are to be used to correct, and prevent
recurrence of deficiencies which affect the project or contract. Such
audits may include:
- Internal audits by CONTRACTOR
- Third party or regulatory authority audits, including those
carried out for certification purposes.
Quality records
The plan should indicate how key records specific to the contract are to
be controlled, including:
- What records are to be kept
- What the legal or regulatory authority requirements are and
how they are to be satisfied;
- What form the records will take (such as paper, microfilm,
tape, disc or other medium);
- How legibility, storage, irretrievability, disposition and
confidentiality requirements will be defined and satisfied;
- What methods will be used to ensure that records are
available when required;
- Checks to ensure all records will be provided in the English
language
Requirements for Procedures
The quality plan shall list those procedures required to control the work
and shall include those procedures listed below as a minimum.
5.0 PROCEDURES AND WORK INSTRUCTIONS
Procedures must be prepared for critical activities where inter-
departmental interfaces are involved.
Procedures should be framed as briefly as possible and incorporate
activity flow charts where possible. Emphasis should be given to proper
definition/agreement on the following elements:
- CONTRACTOR interface with WAHA
- Input/output
- Review points and resulting actions
- Interfaces between departments and functions etc.
- Design verification
- Definition of responsibilities and authorities, including
competency requirements.
Procedures shall be developed as indicated below as a minimum.
5.1 Design Procedures
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The Plan needs to contain only an Index to the detailed procedures;
they must be readily available for reference but need not form part of
the document itself.
In the event that a Design Subcontractor is appointed by
CONTRACTOR a satisfactory Quality Plan from sub-contractor shall
be obtained by CONTRACTOR to address all the items in the list
below which are relevant to the scope of work. CONTRACTOR shall
provide WAHA with a copy of such Quality Plans.
1. DESCRIPTION OF THE ORGANISATION AND
PROJECT
- Brief description of scope of work, references the Basis of
Design.
- Positions of staff responsible for design and support functions,
including filing and document control.
- Person responsible for monitoring QA system effectiveness.
2. IDENTIFICATION OF CRITICAL SYSTEMS
- Systems and sub-systems, which are critical for safety,
reliability or requiring external certification or approval (e.g.
Lloyd's, Stoomwezen).
- Codes, standards and procedures which will be used.
3. INDEX OF RELEVANT PROCEDURES
- Tender and Contract Review.
- Approval Interfaces and requirements with WAHA
- Control of the preparation of design briefs and engineering
specifications.
- Control of documents, including requisition, transmittal, review,
approval, revision and distribution.
- Control of interfaces between engineering disciplines,
Contractors, systems, structures.
- Control of computer software.
- Control of specialist Sub-contractors, e.g. process consultants,
architects.
- Review and approval of original design work and of proposed
changes to approved baseline.
- Concessions and deviations.
- Review of overall design by experienced personnel.
- Qualitative or quantitative assessment of reliability.
- Assessment of maintainability and operability.
- Assessment HAZOP.
- Control of Engineering Dossier content, status, storage and
retrieval.
4. QA ACTIVITIES
- Index of activities for the QA group, derived from the
procedures identified above.
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- Formal audit of design control, follow-up of corrective actions.
- Cost, Time, Resource Sheets and plan for Quality activities,
linked to project network.
5.2 Procurement Procedures
CONTRACTOR procedures should address all the items in
the checklist below:
Production Schedule
- Where quality-related processes, tests and inspection occur.
- Proposed hold-points for witness and approval.
Index of Procedures
- Approval requirements and interfaces with WAHA
- Preparation of requisitions.
- The quality of sub-supplier products.
- Qualification of work, inspection and test procedures.
- Qualification and identification of operators.
- The quality and identification of incoming material.
- Calibration and maintenance of inspection and test equipment.
- Packing, shipping, protection and preservation of finished
products.
- Preparation and supply of finished documentation.
5.3 Construction
CONTRACTOR procedures should address all the items in
the checklist below:
- Review of contract requirements.
- Preparation and circulation of fabrication drawings,
specifications and work procedures.
- Specification of conditions under which work can be
performed.
- Specification of criteria for workmanship and inspection.
- Selection and control of Sub-contractors and Suppliers.
- Control of engineering documents, their supply, transmittal,
review, approval and distribution.
- Control of the Engineering Dossier.
- Control of incomplete work punch-lists.
- Control of activities required for certification by Government
departments, or their agencies.
- Control of weight and Centre of Gravity locations, including
weighing procedures.
- Control of interfaces between disciplines, structures and
systems.
- Formal review and submission of proposed changes to
approved contract drawings or specifications, including minor
changes.
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5.4 Materials Control Procedures
CONTRACTOR procedures should address all the items in the
checklist below:
- Control of purchased goods and services.
- Control of the quality and identity of incoming materials.
- Protection, preservation, handling and storage of material.
- Rejection of non-conforming material.
- Control of material documentation.
5.5 QC Procedures
- Qualification of work processes, e.g. welding, non-destructive
testing.
- Surveillance and control of work procedures, e.g. welding.
- Final inspection of completed items.
- Indication of inspection status.
- Effective communication between QC personnel and those
involved in construction and materials control concerning
concessions and corrective actions.
- Qualification and identification of operators.
- Control, calibration and maintenance of inspection and test
equipment.
- Recording the results of inspections and tests.
- Review of commissioning plans, requirements and resources.
5.6 Commissioning Procedures
- Preparation and distribution of commissioning plans and
procedures.
- Specification of special conditions for commissioning tests.
- Recording the results of commissioning tests and running
trials.
- Recording and displaying the status of commissioned items.
- Control and completion of punch-lists of incomplete work.
- Pre-Start-up Audits.
5.7 QA Activities
- Index of activities for the QA group, derived from the
procedures identified above.
- Cost, Time, Resource Sheets and Plan, linked to project
network.
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6.0 REFERENCES
INTERNATIONAL STANDARDS
Quality Management and Systems- Fundamentals and Vocabulary -
ISO 9000 – 2015.
Quality Management Systems – Requirements – ISO 9001 – 2015.
Quality Management Systems – Guidelines for Performance
Improvement -ISO 9004 – 2018.
Guidelines for Quality and / or Environmental Management Systems
Auditing – ISO 19011 – 2018.
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