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SAEP-1154 - Guideline For Contractor's Quality Plan
SAEP-1154 - Guideline For Contractor's Quality Plan
1 Scope............................................................. 2
2 Applicable Documents................................... 2
3 Definitions...................................................... 2
4 Instructions..................................................... 3
5 Contents of the Quality Plan.......................... 5
6 Responsibilities............................................ 23
1 Scope
1.1 This Saudi Aramco Engineering Procedure (SAEP) provides guidelines to assist
Contractors in the preparation, review, acceptance and revision of Quality Plan
covering as applicable, design, procurement, and construction and pre-
commissioning activities.
1.3 A Quality Plan may also be used where a documented Quality System does not
exist, in which case procedures may need to be developed to support the Quality
Plan.
1.4 Depending on the scope of the plan, a Qualifier may be used such as "Quality
Assurance Plan".
2 Applicable Documents
3 Definitions
For the purpose of the procedure, the definitions given in ISO 9000:2000 together with
the following definitions apply. Terms which are repeated here for clarity but have
been defined in other International Standards are identified by placing the number of the
standard after the definition.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Quality Plan: Document specifying which procedures and associated resources shall
be applied by whom and when to a specific project, product, process or contract. [ISO
9000]
Type Test: Test or series of tests directed towards approval of a design conducted to
determine that is capable of meeting the requirements of the product specifications.
Hold Point: Inspection or Test may not proceed without the QA/QC organization
representative in attendance.
Witness Point: It defines a point that provides QA/QC organization with the
opportunity to attend the Inspection or Test, at their option.
Shall: "Shall" expresses a provision that is binding between two or more parties.
4 Instructions
4.1 Preparation
4.1.2 When preparing a Quality Plan, the processes applicable to the contract
shall be defined and documented. These should originate from each
discipline or department within the Contractor's organization and
combined to form the Quality Management System with a scope to
match the scope of the project.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
4.1.4 When the Contractor intends to subcontract portion(s) of the work, the
sub-contractor(s)' Quality Plan(s) should be made part of the contractor's
Quality Plan as the project evolves. The Contractor must ensure that the
Sub-Contractor(s)' Quality Plan(s) is not in conflict with ISO 9001 and
Schedule Q of the Contract. It is therefore often necessary for the
Contractor to develop additional procedure(s) describing the Contractor's
control over the Sub-Contractor.
4.1.6 As a minimum cover sheet of the Quality Plan shall state the Contractor
Name and Logo, Document Title, Project Title, WBS number or BI/JO
number, and the Contract Number.
4.1.7 List of the "Quality Plan" controlled copy holders shall be identified.
4.2.1 The Quality Plan should be reviewed for adequacy and formally
accepted by an authorized function, i.e., Quality Manager, Management
Representative, Project Director, etc.
4.2.3 The Quality Plan shall be submitted no later than 30 calendar days after
the effective date of the Contract. Where the project is conducted in
phases, the Contractor shall submit the Quality Plan for each project
phase no later than 30 days prior to the start of that phase as agreed on
the overall Quality Procedures of the project during the project proposal.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
4.2.4 Procedures referenced in the Quality Plan and work instructions are an
integral part of the plan and must be submitted to Saudi Aramco with the
Quality Plan.
4.3 Revision
4.3.1 The Contractor should revise his Quality Plan as appropriate to reflect
changes on the project or quality practices. (Re-issue of organization
charts should be stand-alone documents to minimize need for updates of
the quality plan.)
4.3.2 All changes should be reviewed for impact and adequacy by the same
authorized function which conducted the review of the original quality
plan.
Structure:
• Developing a Quality Plan to the ISO 9001:2000 edition shifts the focus from
procedures to the processes. Whereas the ISO 9001:1994 emphasized the necessity
of procedures, ISO 9001:2000 places reliance on a network of processes. It also
requires greater top management involvement in assuring that an effective Quality
Management System was developed. In accordance with Schedule Q, the contents
of the Contractor's Quality Plan shall address the ISO-9001:2000 requirements.
5.1 Scope
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.4.1.1 Objectives
a) Develop the project Quality Management System
1) Identify the processes of the QMS.
2) Describe the Quality Management Processes.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.4.2.1 General
a) Develop documents to implement the project Quality
System.
b) Develop documents that reflect what the Contractors'
organization does.
c) Ensure all referenced documentations are available for
Saudi Armco's use at the Contractor's design,
procurement, fabrication and construction locations.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
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5.5.4 Planning
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.5.6.1 General
a) Evaluate the performance of the Quality System.
b) Evaluate whether the quality system should be improved.
c) Review the project Quality System every six months to
ensure the system is adequate and suitable.
d) Maintain records of all the reviews.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.6.2.1 General
a) Ensure personnel have the right experience.
b) Provide manpower forecast schedule on a monthly basis.
c) Ensure that planned staffing levels meet the Contract
requirements.
d) Develop a system notifying Saudi Aramco of sudden
manpower changes due to sickness or any other reason.
e) Ensure that resumes of all the proposed QA/QC personnel
are being submitted for Saudi Aramco review and
approval.
f) Ensure personnel have the right education.
g) Ensure personnel have the right training.
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Document Responsibility: Inspection Department SAEP-1154
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Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.6.3 Infrastructure
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5.7.4 Purchasing
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Issue Date: 31 March, 2004
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f) Record calibrations
g) Provide calibration certificate
5.8.1 General
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Issue Date: 31 March, 2004
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5.8.5 Improvements
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
6 Responsibilities
6.2 Saudi Aramco will review and approve the CONTRACTOR's Quality Plan and
Inspection and Test Plans in accordance with Schedule Q and will monitor and
asses the implementation of the plan.
Revision Summary
31 March, 2004 New Saudi Aramco Engineering Procedure.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.1 Scope
Example: The intent of this Quality plan is to construct (Identify the Project) in
accordance with Saudi Aramco Engineering Standards, Procedures and all applicable
regulatory requirements. (Clearly define the product that this Quality Plan is to be
applied to and indicate the phase, Procurement, Design, Construction or Pre-
Commissioning that this Quality plan is to be applied to)
Example: For the purpose of this Quality Plan the following terms and definitions in
addition to terms and definitions given in ISO 9000:2000, Schedule Q and SAEP-1154
shall apply and have the meaning indicated in this section. No attempt is made to
define ordinary words which are used in accordance with their established dictionary
meaning. (List all the terms and definitions not identified in ISO 9000:2000, Schedule
Q and SAEP-1154 which would be used in the Quality Plan. It is recommended to
repeat for clarity some of the terms from ISO 9000:2000 and Schedule Q)
Example: In order to implement the QMS, the (contractor) has developed the following
matrix that identifies: the process needed to ensure effective operation and control of
the processes; availability of information necessary to support the effective operation
and monitoring of these processes; methods of measurement, monitoring, and analysis
needed in order to implement those actions that will achieve planned results and
continual improvement.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
(The matrix is a suggested way of addressing these issues. Other ways of addressing
these issues are acceptable provided all processes listed in Attachment I appropriate to
the project are addressed.
An alternative way to identify quality processes and objectives is the use of a detailed
schedule which identifies tasks and objectives. However, Process risk, controls to
mitigate the risks, and measurements needs to be added.
The contractor generally has developed a quality manual and implements control
procedures to describe its standard operating practices (processes) that apply on
various projects. Standard procedures would address topics such as shown in
Attachment I of this procedure.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
When parts of the work are subcontracted, the subcontractor's portion of the work
needs to be reflected in the quality plan or be referenced to a stand-alone subcontractor
quality plan. When a stand-alone subcontractor quality plan is applied, the prime
contractor needs to develop a detailed procedure how he intends to control the
subcontractor's activities.
On this project the subcontractors shall be performing work under this Quality Plan.
(Title) shall incorporate the scope of the services performed by the subcontractors into
the requirements of this quality plan. The conformance of the subcontractor to this
Quality Plan is subject to periodic internal audits in accordance with paragraph 5.8.2.2
of this quality plan. (Title) will perform such internal audits 15% and 60 % completion
of each project phase. Areas for noncompliance shall be resolved to the satisfaction of
the (contractor and Saudi Aramco) and records maintained.
On this project the subcontractors shall perform work under their own QMS System.
(Title) shall review the subcontractor QMS Manual for conformance to the ISO 9001
standard as it applies to the assigned scope of work. (Title) shall perform an evaluation
of the subcontractor's implementation of their QMS Manual on an (identify interval)
basis. Reports of such evaluations shall be maintained by (title) for the duration of the
project. Any noncompliance shall be resolved to the satisfaction of (contractor) and
records maintained.
Example: The (contractor) has established the following documentation for its quality
management system:
• Quality policy and quality objectives
• This Quality Plan
• Documented procedures as shown in Table (number) (Procedure references
should be listed in a convenient table and the actual procedures to be submitted
with this Quality Plan)
• Planning, operation, and process control documentation such as:
o Inspection & Test Plans (ITP)
o Work instructions
o Records of internal reviews
o Inspection and test reports
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Example: The (contractor) established and maintains a Quality Plan. The Quality Plan
identifies the scope of the Quality Management System, and any exclusion to the
requirements of ISO 9001:2000 and Schedule Q. It includes procedures and documents
covering work activities. It includes a description of sequences and interactions of
processes that fall under the scope of the quality management system. (Authorized
exclusions are identified in this procedure and shall be clearly stated in the quality
plan.)
5.4.2.3 Control of Documents:
Example: The Quality Plan, referenced procedures and Inspection & Test Plans are
controlled documents. (Title) is responsible to ensure the initial issue and subsequent
changes are acknowledged by those authorized to receive the Quality Plan.
A documented procedure has been established to control documents required for the
Quality Management System. Project documents shall be maintained at the following
locations (identify home office, field, etc.). Access to these files shall be limited to
(titles).
(Title) is responsible to review all project documents for conformance to the contract
prior to submitting to Saudi Aramco. This review shall be indicated on each item by
(indicate method, for example, stamp, signature, statement, etc. When responsibilities
for review of various project documents rests with different persons [engineers, quality
manager, project manager etc.], it is advisable to reflect such responsibilities in a
matrix form). All documents transmitted to Saudi Aramco shall identify the action
taken by the engineer. The document status shall be updated based on the response.
Methods shall be used to track the status of transmittals that require action by the
recipient. (Describe the methods to be used. Incorporate any specific contract
requirements such as Waiver Requests and design changes).
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Only the latest authorized issue of project documents shall be available for use by
contractor personnel. Documents not authorized for use, voided documents or
superseded documents shall (identify how they shall be kept from use) for example, be
marked, place in a different file at a different location as a means to prevent use.
(Title) is responsible to review all documentation for conformance to the contract prior
to transmitting to Saudi Aramco. This review shall be indicated on each document by
(indicate method, for example stamp, signature, statement, etc.).
All documents transmitted to Saudi Aramco for review shall use a transmittal form
which identifies the item transmitted and the action to be taken by Saudi Aramco. The
document status shall be updated based on transmittal information.
(Title) is responsible for reviewing the contract and identifying submittals and
deliverables to be transmitted to Saudi Aramco. (Describe how this activity is
controlled [for example, status list, marked contract, submittal log, drawing log, etc.).
Controls shall be established to track the status of any item on the list that requires
authorization or approval. These items shall not be released until approved or
authorized. (Describe the methods to be used. Incorporate specific items in Schedule Q
requiring Saudi Aramco approval).
A copy of the approved quality plan, procedures and Inspection & Test Plans for Saudi
Aramco use shall be available at all locations where work is undertaken for this project.
5.4.2.4 Control of Records:
An index of project records shall be part of the file. Responsibility for the accuracy and
completeness of the records is assigned to (title). Access to records shall be under the
control of (title). Removal of records to a location other than the immediate are where
the file is located shall be restricted to authorized persons (who?). Measures to identify
removed files and their current location shall be maintained.
(Title) shall identify those records to be transmitted to Saudi Aramco upon completion
of the project and transmit the appropriate records.
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Document Responsibility: Inspection Department SAEP-1154
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Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
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Document Responsibility: Inspection Department SAEP-1154
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Example: The (contractor) has the following policy regarding the quality of the goods
and services we offer to our customers.
(State the quality policy here)
Example: The elements that comprise the quality planning process are this Quality
plan, Inspection & Test Plans, project organization charts that prescribe personnel
allocations and mobilizations, titles of individuals, subcontractors necessary to complete
the Work, and the integration of quality improvement initiatives described in paragraph
5.5.6 Management Review and 5.8 Measurement and Monitoring.
When conditions require change, the process is controlled and the integrity of the
quality management system is maintained. (Describe how changes to the quality
system are controlled, i.e., allocation of resources, changes in work scope, internal
procedures or work instruction modification.)
5.5.5 Responsibility, Authority, and Communication
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
The (title) shall have organizational authority at least to that of the line managers
responsible for the execution of the work. All QC personnel shall functionally report to
the (select as appropriate Quality Manager, Quality Assurance Manager, Quality
Control Manager, Quality Control Supervisor or similar position).
While assigned to the project, quality personnel shall be dedicated to the work
described in Schedule Q, Attachment I and perform no other function on this project.
The (contractor) has assigned responsibilities and authority in the following manner.
(Use functional titles instead of names to reduce the number of quality plan revisions.
Focus description of activities on prevention of nonconforming conditions, problem
identification, problem solution, verification of corrective action and follow up to
ensure problem resolution. Correlate with the organization chart. Describe how this
information is communicated to personnel).
5.5.5.2 Appointing a Quality Manager/Management Representative:
Example: The (contractor) has assigned (title: Quality Manager, Project Quality
Manager, Quality Assurance Manager, etc.) as the management representative for
quality on this project. He shall ensure the quality system is established, maintained
and implemented and shall report to top management on an (identify interval) and make
recommendations for quality system improvements. Reports shall be issued in writing
to top management and maintained in an open status until the resolution of outstanding
items. The management representative for quality shall assure that the project team is
aware of customer requirements regarding the project. (When Schedule Q does not
require appointment of a quality manager, this role reverts back to the Corporate
Management Representative).
5.5.5.3 Internal Communication:
5.5.6.1 General:
Example: The (contractor) top management shall review the Quality Management
System at least once every six months to ensure its suitability, adequacy, and
effectiveness. The QMS, quality policy, and quality objectives will be evaluated for
any needed change. Records of these reviews shall be maintained.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.6.2.1 General:
Example: The (Contractor) shall assign personnel to the project in accordance with
Schedule Q, Attachment VI that is competent on the basis of applicable education,
training, skills, and experience. All personnel assigned to this project shall meet the
minimum qualification and experience levels specified in Schedule Q, Attachment I.
(Title) is responsible to review the contract to determine any customer requirement for
competency level of personnel assigned to the project and ensure that assignment of
personnel including subcontractors meet the requirements. Resumes of all quality
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
(Contractor) planned staffing levels shall comply with the Saudi Aramco approved
quality plan. Reduction from required level of quality personnel specified in Schedule
Q shall require Saudi Aramco written approval.
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Document Responsibility: Inspection Department SAEP-1154
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Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
5.6.3 Infrastructure:
Example: The (Contractor) provides a work environment suitable for it to achieve its
business objective and satisfy project requirements. (Address in general terms
workplace and associated facilities, equipment, hardware, software, and support
administrative services. Consider work space, work environment, accessibility to
computers, appropriate software, and other tools necessary to assure acceptable Work).
5.6.4 Work Environment
Example: The (Contractor) shall plan and document the project execution process. The
documentation for project execution is stated in paragraph 5.3.2 of this quality plan.
The quality objectives for the (design, procurement, construction activities, etc.) are
identified in (consider the contract, internal quality objectives, etc.).
Verification and validation are incorporated into the planning process as follows:
(describe how verification and validation activities are incorporated. Consider design
review, acceptance testing, planned inspections, approval, etc. The resource loaded
schedule may be used to identify verification and validation activities.)
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Example: The (Contractor) will review the (contract agreement) to determine customer
requirements. (Title) will evaluate these requirements and determine any additional
requirements including regulatory and legal ones, which may not have been identified
by the Saudi Aramco, and need to be implemented to support the delivery of the Work.
Example: The (Contractor) has assigned the responsibility to review the contract to
(title). The (title) shall ensure that the requirements are understood, and that we have
the capability of performing the work. The contract shall be reviewed by (title) to
ensure any agreed-to changes have been incorporated. The review shall be documented
in the following manner and records maintained.
(Describe the methodology)
Changes shall be documented and issued to all staff responsible for execution of the
original contract by (title).
5.7.2.3 Customer Communication:
Example: (Title) is responsible to establish and maintain communication with the Saudi
Aramco Representative regarding engineering, procurement inspection, or construction/
precommissioning activities. (Describe methods of communication with Saudi Aramco.
Consider weekly communication meetings, formal written communication, etc.)
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Example: The (Contractor) shall plan and control the design and address staging,
review, verification, and validation activities; personnel responsibilities and authorities,
interfaces between discipline; and any update in this plan during the project. (Describe
your methods of executing this planning process. Consider reference to the resource
loaded schedule, reference to the project organizational chart and description of
personnel duties and responsibilities, coordination with subcontractors, inspection,
testing labs, interdisciplinary review, coordination of construction crafts, etc.).
5.7.3.2 Design and Development Inputs:
Example: (Title) shall be responsible to develop (how) and transmit (how) written
design criteria to the (design staff). (This can be done by supplying the design staff
with a list of design criteria for example, codes, standards, specifications, drawings,
technical information, etc.)
(Title) is responsible to evaluate all design inputs for adequacy and assure any
ambiguous or conflicting requirements are resolved.
5.7.3.3 Design and Development Outputs:
Example: Outputs of the design process are documented in a manner that enables
verification against design inputs.
Outputs are those deliverables required by the Saudi Aramco in accordance with the
contract and include but are not limited to studies, reports, analysis, scope development,
designs, and specifications.
All calculations shall be signed and dated by the originator and checked prior to
finalization by an engineer competent in the discipline but without direct responsibility
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Document Responsibility: Inspection Department SAEP-1154
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Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
for performing the calculation. A system to validate the programs or algorithms for
computer-forming calculations is employed. (It's recommended to describe the
calculation program in detail, including the forms or format used, the method of
affixing signatures and dates, the numbering and tracking system used, etc, or reference
a procedure that covers the details of the calculation process and include the procedure
in the procedure section of the Quality Plan).
Schedules and estimates shall be reviewed by (title) prior to their issue to Saudi
Aramco.
5.7.3.4 Design and Development Review:
Example: (Contractor) shall perform periodic formal design reviews and shall notify
Saudi Aramco two weeks prior to start of any Design Review. Design documents are
circulated for internal review and coordination of disciplines. Review may include E-
review at design stages specified in SAEP-303. The process shall be documented
(Specify how. Common practice is collection of comments by discipline in tabular form
and recording corrective action for each problem area). A CADD system is developed
and controls (what are they) have been established to safeguard the integrity of the
drawings. (A procedure describing the development of drawing and specifications in
detail needs to be referenced and the procedure submitted with the quality plan.)
The review process shall address the ability of the design to fulfill requirements and
identify problem areas and proposed corrective actions.
All design reviews shall be completed prior to the schedule Design Reviews stated in
Schedule "B". Saudi Aramco comments and any internal comments shall be addressed
in written form and records of resolution kept until completion of the project. (A
procedure shall detail the methods employed, who shall resolve the comments, and what
form shall the documentation take.)
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Example: (Title) is responsible to assure the output meets the design inputs. (Describe
the methods of performing this activity such as checking function, sealing of design
drawings, etc.)
A constructability review (shall or shall not) be performed as part of this contract. (If
performed, describe the methods to be employed or reference a procedure, and include
the procedure in the quality plan).
Value engineering (shall or shall not) be performed as part of this contract. (If
performed, describe the methods to be employed or reference a procedure, and include
the procedure in the quality plan).
Example: The (contractor) has developed a system to assess if the design was
constructible and met Saudi Aramco requirements (if computer simulation is used,
provide details).
(Title) performs this analysis. The results are recorded and used as part of our
corrective and preventive action program. (Describe the methods of accomplishing this
activity).
5.7.3.7 Control of Design and Development Changes:
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Example: Where subcontractors and suppliers are engaged to work on this project, their
capability to perform the assigned scope of work is evaluated by (title) in accordance
with Schedule Q, Attachment III. Physical surveys, when needed shall be performed by
a qualified auditor and supported by a technical specialist for the equipment under
consideration. Except as provided in Schedule Q, Attachment III, paragraph 1.3.6,
evidence of qualification of subcontractors and suppliers shall be provided to Saudi
Aramco.
Example: In accordance with Schedule "G" of the Contract, purchase orders with
subcontractors and suppliers will define service or product requirements, Quality
management system requirements, applicable procedures, and processes, equipment,
and personnel qualifications in sufficient detail to ensure the work performed meets the
purchase order requirements. All requisitions shall be reviewed by (title) for technical
and quality requirements prior to submitting to Saudi Aramco for review. (Describe
how this is done in a procedure and attach to the quality plan).
5.7.4.3 Verification of Purchased Products:
Example: In accordance with Saudi Aramco Form SA-175, work preformed by the
suppliers and sub-suppliers shall be reviewed for conformance to contract requirement
and accepted by (title) and documented by (describe how work of subcontractors is
accepted).
(Title) is responsible to ensure that the equipment and materials ordered for this project
under this contract meet contract requirements and are delivered on time. The
following steps shall be taken to ensure that the suppliers are capable of providing
appropriate items:
Supplier suborders shall be reviewed for conformance to the original purchase order
requirement and document.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Detailed Inspection and Test Plans for all equipment and material with Inspection
Levels 2, 3, or 4 per "SAER-1972" shall be prepared by Suppliers and submitted to
Saudi Aramco with the Inspection Assignment Package three weeks prior to start of
fabrication.
Applicable supplier process control procedures (i.e., welding, heat treatment, NDT,
refractory installation, PMI) shall be reviewed by (title) and submitted to Saudi Aramco
as required.
Equipment/material delivered for use on the project shall be inspected by (title) at the
supplier/sub-supplier facilities in accordance with SAER 1972. Rejected material shall
not be allowed to ship. When no Form SA-175 exists, material shall be inspected upon
receipt at site. Non-conforming material shall be returned to originator or marked in a
manner that shall prevent its use.
Inspection Disposition Reports shall be prepared within two weeks following release to
ship material and submitted to Saudi Aramco.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
• The work environment is safe and conforms to health and safety requirements in
the contract.
• Methods are employed to monitor resource expenditure against expected results.
• Procedures, work instructions, and/or installation instructions are available to
the workforce.
• Codes, standards and other references, including portions of the contract are
available to the workforce.
• Standards of workmanship are implemented.
• Where required, licensed or certified personnel are assigned to the project to
perform activities requiring such license or certification.
• A program to monitor the effectiveness of these process controls is in place and
implemented.
• Criteria for release, approval, and acceptance are established.
(Identify the controls implemented on the contract and identify the title(s) of those
responsible to see that commitments made in the plan are implemented and
documented).
5.7.5.2 Validation of Processes for Production and Service:
Example: The validation of the design is the constructed project that satisfies the Saudi
Aramco requirements.
The validation of certain construction processes can only be ascertained when load is
applied or operation is initiated. For the project, these processes include (select
appropriate ones, add others as necessary. This is not a complete list. Refer to
Schedule Q, Attachment IV, and paragraph 2.1):
• Welding
• Heat Treatment
• Nondestructive testing (NDT)
• Positive Material Identification (PMI)
• Structural concrete placement
• Paving and asphalting
• Coating
• Bolt tensioning
• High voltage cable splicing/termination
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
The (contractor) assures these processes can achieve planned results through (include
all that apply. Add others as necessary):
• Process qualification
• Equipment and personnel qualification
• Defined methods and procedures
• Records shall be maintained and revalidation performed as necessary.
(Contractor) shall develop and maintain a system to identify construction materials and
equipment to the extent required by the contract or applicable codes and standards.
Nonconforming material shall be identified or removed to prevent inadvertent use.
(Describe the system to be employed to identify equipment and material on the project.
Consider, tagging, marking, color coding as appropriate.)
Example: The (contractor) shall develop and maintain a system to receive, log, and
maintain Saudi Aramco – supplied documents, data, material, or equipment. (Title) is
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
responsible for this function and shall advise the Saudi Aramco Representative of any
items that are unsuitable for use, lost, or damaged.
All Saudi Aramco supplied material shall be inspected against the shipping documents
for accuracy and damage by (title) and stored in such a way to prevent damage or
deterioration.
(Title) is responsible for the final disposition of supplied items at the conclusion of the
project in accordance with contract requirements. Note: (If no data, equipment, or
materials are provided by Saudi Aramco this section does not apply and a statement to
that effect should be include in the Quality Plan.
5.7.5.5 Preservation of Material and Equipment:
Example: During the development of the plans and specifications, the (contractor) shall
evaluate construction material and equipment and include in the plans and
specifications any requirements for handling, storage, packaging, preservation, and
delivery necessary to ensure requirements are met. (Title) is responsible for this
activity. Equipment suppliers shall be requested to provide storage and preservation
procedures for purchased equipment.
(Title) shall review the construction contract and ascertain through the inspection
process that requirements for handling, storage, packaging, preservation, and delivery
necessary to ensure requirements are being implemented by the contractor,
subcontractor, and suppliers. Nonconforming conditions shall be documented.
(Contractor) shall establish, maintain and implement a program for handling, storage,
and preservation of equipment and material for this project.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
(Describe the specific program for this project or include the contractor's generic
program and indicate those portions that apply to this project.
Contractors with design responsibilities should consider addressing this paragraph for
computer programs used to assure design or report data are correct. They may also
need to address this paragraph if specific monitoring and measuring methods are
specified in the plans and specifications for the contractor to implement prior to
acceptance of the work.)
Example: The (contractor) has defined, planned and implemented the following
measurement, monitoring, analysis and improvement activities to assure conformity and
achieve improvement. (Identify your methodology. The following should be
considered. Add to or delete as appropriate to the contract scope of work.)
• Customer satisfaction surveys
• Internal audits
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
• In-process reviews/inspections/tests
• Control of nonconformities
• Data analysis
• Corrective, preventive, and improvement activities
5.8.2 Monitoring and Measuring
Example: The (contractor) has developed the following methods to obtain data and
monitor customer satisfaction and/or dissatisfaction. (Identify the methods used.
Consider weekly meeting minutes, correspondence, surveys, etc.)
5.8.2.2 Internal Audit:
Example: The (contractor) has established, and will maintain, and implement an
internal quality audit program to verify that quality activities and related results comply
with planned contractual arrangements and to determine the effectiveness of the quality
program and associated procedures. The internal quality program has the following
attributes:
• Internal procedures govern these activities
• Internal audits shall be scheduled based on requirements in Schedule Q. The
schedule shall be transmitted to the Saudi Aramco Representative within 30
days of the effective date of the contract.
• Personnel conducting internal audits are capable of objectivity and impartiality
in conducting audits. They will not audit their own area.
• Reports of internal audit results shall be generated and issued to affected
departments. Company management and Saudi Aramco shall receive copies of
report within two weeks of audit completion.
• Corrective action shall be monitored and brought to a close.
• Follow-up internal audits shall be conducted as appropriate, to ensure
implementation of corrective action, and the results reported to Company
management and Saudi Aramco.
• The activities of subcontractors working under this quality management system
will be included in the audit program.
• The activities of subcontractors working under their own quality management
system will be audited. As a minimum such subcontractor quality audits will be
conducted every six months.
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
(A procedure that addresses the responsibilities and requirements for planning and
conducting internal audits and for reporting results and monitoring records is required
and must be included in this quality plan.)
Example: The project execution processes described in Section 5.7 of this Quality plan
necessary to achieve Saudi Aramco requirements are measured and monitored as
follows: (Describe the measuring and monitoring methods to assure your processes are
acceptable. Consider internal audit results, error and omission punch lists, number
and types of Log book entries, nonconformance reports, etc.)
These methods shall confirm the continuing ability of each process to satisfy its
intended purpose. When planned results are not achieved, corrective preventive actions
shall be taken to assure conformity.
5.8.2.4 Monitoring and Measuring of the Work:
The measurement, monitoring, and acceptance of the design are addressed in the design
and development section.
(Title) shall ensure that incoming equipment and materials are inspected and accepted
for project use prior to incorporation into construction. When material is received
without Inspection Release, the (title) shall perform inspection against the purchase
order requirements and verify that the equipment and material meets the specified
standards. The process shall be documented (Specify what methods will be used to
document the process, Material Acceptance Report, signed delivery ticket, signed
invoice or bill of lading, etc.)
During construction (title) shall inspect the quality of the construction effort through
regular inspections of the work in progress, as agreed to in the respective Inspection and
Test Plans, approved by Saudi Aramco. Activities shall be recorded via inspection and
test reports attached to relevant procedures and work instructions and acceptance
verified against written acceptance criteria obtained from applicable contract documents
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
or referenced codes and standards. (Title) shall notify Saudi Aramco by initiating
Requests for Inspection (RFI) for all inspection points coded as Witness or Hold.
All test results shall be documented on forms appropriate for the tests, and dated and
signed by the test personnel. Results shall be issued as required by the contract.
(Describe the NCR program for this project in a documented procedure. Address
elimination of the nonconformity, requirements for product release or acceptance under
concession, actions to preclude recurrence, reverification after correction, and
program to mitigate the effects of installing or using defective product. Where sub-
contractors use their own NCR procedure, specify how this procedure fits into the prime
contractors' NCR program).
During procurement and construction any conditions that do not meet contract
requirements and that cannot be corrected by the end of the workday shall rejected and
documented.
(Title) shall track the condition (how) until restoration to the designed conditions.
Example: (Title) shall track the condition (how) until restoration to the designed
conditions or until the "as-installed" condition is accepted by Saudi Aramco. All
violations of Saudi Aramco standards and specifications that result in "as-installed" or
"use-as-is" recommendations shall be documented as Waiver in accordance with SAEP-
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
Example: The (contractor) collects and analyzes appropriate data to determine the
suitability and effectiveness of its quality management system and to identify where
improvements can be made in the quality management system.
The following data are gathered and analyzed, (title) is responsible for the effort and to
ensure closure where QMS improvements are warranted.
Identify the data and analysis methods that will be used, consider:
• Customer satisfaction/dissatisfaction
• Conformity of products to requirements
• Measuring and monitoring data
• Trends of both positive and negative compliance
• Internal quality audit data
• Others as applicable
5.8.5 Improvements:
(Identify what you use to facilitate continual improvement of the QMS. Consider
quality policy changes, goal/objective changes, implementation of the results of
management review, audit findings, analysis of nonconformities, corrective action and
preventive actions implemented.)
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Document Responsibility: Inspection Department SAEP-1154
Issue Date: 31 March, 2004
Next Planned Update: 1 April, 2005 Guidelines for Contractor's Quality Plan
(Contractor) shall establish measurements system and track performance for any Saudi
Aramco specified improvement initiatives in accordance with Schedule Q, Attachment
VI.
Example: The (contractor) has established a corrective action program to eliminate the
causes of the nonconformity and prevent its recurrence.
A documented procedure for corrective action has been established and is included in
this Quality Plan.
Example: The (contractor) has a program of preventive action, which anticipates the
potential causes of nonconformities and works to reduce or eliminate these potential
causes.
A documented procedure for preventive action has been established and is included in
this Quality Plan.
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