45956a SP-1171 - Specification For Quality Assurance Requirements For P 1
45956a SP-1171 - Specification For Quality Assurance Requirements For P 1
45956a SP-1171 - Specification For Quality Assurance Requirements For P 1
SP-1171
Document Type
Specification
Security
Unrestricted
Discipline
Owner
Issue Date
Version
Quality Management
CFDH Quality
th
24 June 2012
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
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Document Authorisation
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ii Revision History
The following table lists the most recent revisions to this document. Details of all revisions prior
to these are held on file by the issuing department.
Version No.
Date
Author
Checked
Scope / Remarks
Version 1.0
24/04/2000
OTT/151
OTT/15
Version 2.0
17/12/2007
UEC/111
UEC/11
Version 3.0
24/06/2012
UEQ/11
UEQ
Business Process
QIPS
Document Title
CP-117
CP-190
CP-131
SP-1122
SP-2061
SP-2065
PR-1247
PR-1964
PR-1984
PR-1866
GU-364
DEP 82.00.10.10
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TABLE OF CONTENTS
i
ii
iii
iv
Introduction............................................................................................................... 7
1.1
Purpose .................................................................................................................... 7
1.2
Scope ....................................................................................................................... 7
1.3
1.4
1.5
1.6
2.1
2.2
2.3
Quality Control Plan (QCP) / Inspection and Test Plan (ITP) .................................. 9
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
ISO/TS 29001 - 7.4.1.2 Criteria for Vendor Selection, Evaluation and Re-Evaluation
- Supplemental ....................................................................................................... 17
3.9
3.10
3.11
3.12
3.13
ISO/TS 29001 - 7.6.1 Control of Monitoring and Measuring Equipment Supplemental ......................................................................................................... 20
3.14
3.15
3.16
3.17
3.18
Appendix 1
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Introduction
1.1
Purpose
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1.2
Scope
This document specifies the Company's minimum requirements for
Management System in all Contracts and Purchase Orders with the Suppliers.
Quality
1.3
1.4
1.5
Effective period
The requirements of this specification shall remain in force indefinitely unless
superseded by an authorised revision.
1.6
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Specification Requirements
2.1
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2.2
Quality Plan
Where stated specifically in a contract or a Purchase Order, a specific Contract Quality
Plan (CQP) or a Project Quality Plan (PQP) shall be prepared at the beginning of
Contract / Order. The CQP / PQP shall describe the organizations corporate quality
management system elements applied to the project and additional measures in order
to comply with the requirements of this specification and any other contract specific
quality requirements. The CQP / PQP shall be submitted within stipulated time as per
the Contract. The Contractor shall not commence any work until the CQP / PQP is
approved.
Subcontractors shall comply with main Contractor CQP. In case the CQP of the main
Contractor does not adequately cover sub-contracted scope of work, the main
Contractor shall ensure that the Sub-contractor submits a separate CQP for the
applicable scope of work to Company for approval complying with this specification.
The need for a CQP / PQP for procured products will be determined based on its
criticality. Generally Quality Plan (PQP / CQP) is not required for packaged products
(e.g. skids mounted manifolds, pressure vessels, cyclones, heat exchangers, surface &
sub-surface equipment of Electrical Submersible Pump Systems) and Bulk Products (e.
g. pipes, fittings, flanges, valves).
CQP / PQP should be prepared using the Suppliers standard templates / formats and
taking appropriate guidance from ISO 10005: Quality Management Systems Guidelines for quality plans, CP-190 and DEP 82.00.10.10. Gen. as applicable. Example
content of a Contractors CQP and Vendors PQP is included in Appendix 3.
CQP / PQP shall address inter-related systems which are applicable to the scope of
work such as Discipline Controls and Assurance Framework (DCAF), Operations
Readiness and Assurance, Technical Integrity Verification (TIV) and Flawless Project
Delivery (FPD) etc.
The Tender issue of Contract Quality Plan (normally Revision 0), is a preliminary issue
addressing all requirements of this specification in general terms in such a way that it
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2.3
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3.1
3.2
Approval Authority
QCPs / ITPs
Site related
Procedures
Deviations from
specifications
10
Deviation
from
Company
approved
Manufacturers, Suppliers,
Stockists &
Vendors
Method
statements
Contract
&
Functional TA-2.
technical
Functional TA-1.
Functional
Product
Group
Service Codes
Custodian
(PGSC list)
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Issue Inspection Release Note of Product/ Sign test packs (QA/QC dossier).
To ensure close out of NCRs with suitable corrective and preventive actions.
The signature of the Companys Inspection personnel (QA/QC Inspector/TPI) shall not
absolve the suppliers responsibilities to supply the product that meets contractual
requirements.
3.3
3.4
Initial review within 6 (six) months from effective date of the contract focussing
mainly on ensuring that all contract enablers such as resources, plans,
procedures, tools, systems etc. are in place.
Thereafter the review frequency may be changed to once a year unless system
deficiencies impacting project delivery requires more frequent reviews.
Within one month prior to the demobilisation of the key project team members,
a final contract quality management review shall be performed focussing mainly
on contract results and capturing lessons learned.
The Suppliers Contract Quality Manager shall participate in the review meeting.
The minutes of meetings of the review shall be maintained and shall be made available
to Company on request. It shall contain areas of concern and weakness identified in the
Quality Management System and actions recommended for mitigation.
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3.6
Duties
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Duties
4. Shall
have
experience
in
quality
management in projects covering design /
engineering, procurement, construction,
inspection/testing and commissioning
phases.
of
inspection and exposed to multi discipline
works of oil and gas construction field.
Quality
Control
Plans
9. Overall
control,
supervision
and
implementation of Contract quality and
technical requirements; resolution of
quality
problems;
preparation
and
maintenance of Contract quality records.
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Duties
Same as the duties of Lead / Senior
Engineer except that it is done under
supervision.
3. Shall
4. Shall
Auditors
Quality Manager and Lead / Senior Quality Engineer who meets the above requirements
are automatically qualified to lead and/or participate in quality audits.
Other Auditors (team members, not lead) shall be graduates with at least five years Oil
and gas experience in the same field being audited and shall have conducted minimum
10 relevant audits. They shall be trained to carry out audits as follows:
For External Audits 5 day course registered with IRCA, RABQSA or equivalent
acceptable to Company.
For Internal Audits - 2 day course registered with IRCA, RABQSA or equivalent
acceptable to Company.
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Company reserves the right to independently test and assess inspection personnel
competence levels. Personnel who fail to meet company minimum requirements shall
be removed and replaced at contractor cost.
Quality Control Inspector - (Welding/ Painting/ NDT/GRE/PE)
Qualifications
1. HND/Diploma
in
Mechanical
/
Metallurgical Engineering or equivalent
with minimum 4 years of inspection
experience in construction industries out
of which 2 years shall be gained in oil and
gas facility construction.
Duties
Duties
engineering.
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work
documents
such
as
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Q C Inspectors Instrumentation
Qualifications
Duties
1. Implement
Instrumentation engineering.
3. Shall
QC Inspectors Electrical
Qualifications
1. Shall
be HND/Diploma in Electrical
engineering and Compex certified.
Duties
1. Implement
4.
5.
Note:
For information on qualification and experience of various jobs not described in this
document, contact the relevant Corporate Function Discipline Head.
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3.8
3.9
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The participants of Quality Alignment / PIM may include representatives from the
Company or the authorised representative, Suppliers Third-Party Inspection Authority
(TPIA) if specified, Supplier and Sub-suppliers involved in the supply chain.
Refer Appendix 4 for further details.
Specific Verification and Test Requirements.
The Supplier shall ensure that the material test certificates conform to Contract
requirements.
Where Third Party Certification is specified in the Suppliers Scope of Work in the
Contract, the Supplier shall use a Third Party Inspection Agency that is approved by the
Company or recognized by European Union member states**. The Supplier shall ensure
that the TPI agency is suitable for the scope of work and personnel deployed to certify
are competent.
** Inspection agencies outside European Union that are directly under technical control
of a TPI agency recognized by European Union member states are acceptable.
The Suppliers Third Party Inspection Agency shall carry out the following activities as a
minimum:
Ensure the Supplier personnel including QA/QC personnel are suitably qualified
and competent, where specified.
Ensure proper test & inspection equipment is used, calibrated and certified.
Witness Packing for shipping, based on Shipping Release Note from the
Purchaser or the Customer.
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The Company reserves the right to inspect products or services purchased by the
Suppliers from Sub-suppliers. Such inspection shall take place at the source, in the
Supplier's premises, on site or at the Sub-supplier's premises. Verification or Inspection
by the Company is not a substitute for verification or Inspection by the Supplier nor
absolve the Supplier of its contractual obligations. Hold, Review and Witness Points
shall be identified in the Inspection and Test Plans for Suppliers, Sub- suppliers, Third
Party Inspector / Authorised inspector and Company. Company shall be given at least
10 working days notice to attend such verifications/Inspections.
Where the Company employs a Third Party Inspection Agency, they shall have the
same access to the Suppliers Quality System documentation and reports as the
Company.
3.10
3.11
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3.12
with
manufacturers
3.13
3.14
For projects less than six months duration one audit covering all activities (after
completion of 50% project progress, but after start of the construction scope of work if
applicable) may be sufficient.
An Audit Schedule shall be included in the Contract Quality Plan, which shall be
approved by the Company. The Audit Schedule shall include External Audits carried out
by the Supplier on Sub-suppliers.
Audit schedule shall be reviewed at the time of the contract quality management review
and updated as required. The updated audit schedule shall be issued to Company for
information.
ISO 19011 shall be used for guidance on auditing quality management system.
Contractor shall notify Company Quality Management function and Project
representative to participate in internal audits, external audits on sub-suppliers and third
party certification audits as an observer. The audit notification shall be delivered to the
Company at least five working days in advance of the audit date.
Any NCR identified during the audit, shall be classified based on the risk severity as
Serious, High, Medium and Low as per PR-1866.
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The audit reports shall be issued to the Company within 2 weeks after the audit close
out. The audit opinion shall be derived on a four point scale based on PR-1866 as
GOOD, FAIR, UNSATISFACTORY and UNACCEPTABLE.
The Company reserves the right to carry out scheduled or unscheduled audits, reviews
and surveillance of the Supplier and Sub-suppliers.
The Supplier shall maintain a tracking system of all Corrective Action Requests raised
during Internal and External Audits and Third party certification audits including audits
carried out by the Supplier on sub-suppliers. The audit tracking system shall be updated
monthly and a copy is issued to the Company on monthly basis.
3.15
3.16
3.17
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Summary of Internal and External Audits carried out and reported against the
Audit Schedule.
Up-dated audit tracking system listing corrective Actions for each Audit, the
current status and the planned dates for follow up and closeout.
Summary of Tests and Inspections carried out on site and off site including
those on Sub-Contracted activities.
SP-1171 - Specification for Quality Management System
Requirements for Product and Service
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Statistics that indicate quality trend from the start of contract for the following as
a minimum:
a) Number of Customer Complaints/Site Inspection Reports.
b) Variances raised.
c) Product NCRs.
d) Welder performance and repair rates based on radiography.
e) Status of deployment of QA and QC resources against the resource
plan
f)
g) Recurring nonconformities.
h) Concerns on Preservation of items and equipments
3.18
i)
j)
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Definitions
Company
Contractor
The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a
project, or operation or maintenance of a facility
Ex-stock
Manufacturer
Supplier
Sub-supplier
Shall
Should
User
Vendor
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Abbreviations
API
ASME
ASNT
AWS
CAR
CCMS
CFDH
AWS
CP
CQP
CRA
CSWIP
CV
Curriculum Vitae
DCAF
DEP
DSS
EMC
EP
EPC
GRE
GU
Guidelines
HDPE
IRCA
ISO
ITP
MESC
MT
NACE
NCR
NDE
Page 24
Code of Practice
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ODC
PCN
Personnel
Certification
Non-Destructive Testing
Product Group
Service in
Category
PE
PGSC
Polyethylene
PT
Penetrant Testing
PGSC
PMI
PWHT
QA
Quality Assurance
QC
Quality Control
QCP
RABQSA
RABQSA
A
personnel
and training
certification
body body
created
merging
RABQSA
is a personnel
and training
certification
created
in 2004Registrar
merging
Accreditation
Board (RAB)
with(RAB)
Quality
Society
ofSociety
Australasia
(QSA). (QSA).
Registrar Accreditation
Board
with
Quality
of Australasia
RT
Radiographic Testing
SP
Specification
SS
Stainless Steel
TA
Technical Authority
TPI
UT
Ultrasonic Testing
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Appendix 2- References
In this specification, reference is made to the following publications. Unless specifically
designated by date, the latest edition of each publication shall be used together with any
amendments.
International Standards
Specification for quality programs for the petroleum, petrochemical
and natural gas industry
API Spec Q1
ISO/TS 29001
ISO 3834
ISO 3834-1
ISO 3834-2
ISO 19011
ISO/IEC 17025
ISO 10005
ISO/TR 10013
ISO 9001
ISO 9712
Company Specifications
Project Engineering Code of Practice
CP-117
CP-190
SP-1122
SP-2061
SP-2065
SP-2069
PR-1247
PR-1964
PR-1984
PR-1866
GU-364
Shell Specifications
Project Quality Assurance
DEP 82.00.10.10
DEP 70.70.70.11
DEP 31.10.00.10
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Information Management
1. Document Control
2. Quality Records Management and Certification
3. Control of Software
J.
K. Management of Change
L. Continuous Improvement
1. Audits
2. Health Checks
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Design Planning
II.
Engineering Deliverables
III.
Design Reviews
IV.
Technical Assurance
a) Design Verification
b) Design and Novel Technology Validation
V.
Technical Deviations
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J.
L. Prepare project team contact list for all key personnel on the organization chart, including
street mail address, e-mail address, office/mobile/home phone numbers, and pager
numbers
M. Review in detail the proposed Project Schedule
N. Contractor submit schedule for all work
O. Review the proposed Document Register
P. Agree on Document Distribution Matrix and ensure recipient electronic and office address
details are accurate
Q. Agree to review period for Company review and comment of project documents
R. Discuss reporting requirements and frequency
S. Customize final documentation
T. Discuss Inspection and Non-conformance Notification Procedures including distribution
lists, inspection waiver procedures, notification timelines, and approval process.
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Reconfirm and agree on the scope of work. Review Workscope breakdown between
Supplier and sub-suppliers. Confirm location of all sub-suppliers.
J.
Confirm / Clarify Inspection visit arrangements. Confirm arrangement for office and
communication facilities for Company /TPI.
K. Confirm / Clarify Factory acceptance testing / Final inspection and Release authorisation.
L. Confirm / Clarify packing, packaging, protection and preservation requirements.
M. Confirm / Clarify handling and transportation requirements.
N. Confirm / Clarify requirement for progressive compilation of manufacturing data book and
labelling / index of manufacturing data book.
O. Review purchase order status status of document approval, material status,
P. Review status of Inspection and Test Plan, clarify sign off authority of ITP and re-confirm
quality intervention points.
Q. Review the plan for ITP execution.
R.
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Monitor Point (M): A critical step in fabrication and testing where it is optional that the
Company inspect the component/equipment or witness an activity. The Company shall be
notified at a duration specified in the contract in advance of the first occurrence of the activity
at each worksite. No further notification for like activities at each worksite shall be required.
The activity may proceed with or without the Companys attendance.
Approval Point (A): A critical step in design, procurement, and or fabrication and testing
where it is mandatory that the Company approve a document/qualification/ equipment/or
activity. The Company shall be notified at a duration specified in the contract in advance of
the first occurrence of the activity or provided the document in a period of time specified by
the contract. The activity may not proceed without the Companys approval.
Review Point (R): A critical step in design, procurement, and or fabrication and testing where
it is desirable that the Company review the document/qualification/ equipment/or activity. A
separate notification is not needed unless otherwise specifically requested; the Company may
perform this along with any of the other intervention types.
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Contract/PO No.:
Seq.
No
Description /
Activity
Controlling
Procedure
Product / Service:
Organization:
ITP No:
Location:
Specification
Acceptance
Criteria
Reference
Suppliers
Verification
Personnel
Form to
record
results of
compliance
Subsupplier
rd
Company
Comments/Remarks
Other
Example Only
*Inspection and test mark-up legend: I = Inspect/Test, M = Monitor, W = Witness, H = Hold Point, R = Document Review, A= Document Approval
Sub-Supplier
Supplier
rd
3 Party
Company
Other
Signature:
Print Name:
Date:
Page 35
SP-1171 - Specification for Quality Management System Requirements for Product and Service
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Appendix 6
Name:
Ref ID
Page Ref:
To:
Date:
CFDH Quality
Document Authority:
Page 36
Date:
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