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Attachment 12 - Quality Control Template
Attachment 12 - Quality Control Template
TA’AZ CONSTRUCTION
Quality Control
1. PURPOSE 3
2. SCOPE 3
3. RESPONSIBILITIES 3
4. PROCEDURE 3
These procedures show the steps and the guidelines to be followed by the construction
contractor to ensure that performed service adheres to a defined set of quality criteria or
meets the requirements of the client or customer.
2. SCOPE
COMPANY develops and manages production of the Majnoon Oilfield on behalf of the Basra
Oil Company (BOC). The Development Production Service Contract (DPSC) is the contractual
basis between BOC and COMPANY. The first phase is the First Commercial Production (FCP)
of the Majnoon Field which is now complete, with a production capacity of 220,000 barrels
of oil per day.
The Growth Well Pads Preparation project is initiated to support the COMPANY drilling
programme at various Well Pad locations; the scope for this contract includes Greenfield
well pads and Brownfield well pads.
The WORK shall include, but not be limited to, access roads to well pads, site (well pad)
development, internal roads, in-situ and pre-cast concrete works for well cellars, rig slabs,
flow line culverts and pipe & cable tray sleepers, piling works for manifold foundations,
French drains, cable trenches, fencing and HDPE membrane lined pits for drill cuttings.
3. RESPONSIBILITIES
QA/QC Manager is responsible for roll out and awareness of the procedure within the
Project Team. Review queries and potential resolutions
QA/QC Inspector is responsible to make sure that these procedures are to be followed and
implemented on site in a proper manner
4. PROCEDURE
EPSC Discipline Engineer and Engineering Lead Complete Part 2 and 3. It is the responsibility
of the Discipline Engineer to review, develop a proposed resolution to the query, and gain
support from Engineering Lead. The Discipline Engineer may have to in some circumstances
consult with Company and initiate a study or design change if required. The Engineering
Lead is responsible to review and endorse the proposed resolution by Discipline Engineer.
Originator and COMPANY Site Representative Complete Part 5. It is the responsibility of the
Originator to track, monitor, expedite the closure of the work and notify COMPANY
representative to inspect / verify that the work has been completed.
Example shown below of completed Part 5.
COMPANY Representative and TQ Administrator Complete Part 6. It is the responsibility of
the COMPANY Representative to verify, sign and notify TQ Administrator that TQ can be
closed out. TQ Administrator receives signs and updates TQ Register once closed out by
COMPANY Representative. Site Document Control scans and distributes closed out TQ to
the relevant parties.
Example shown below of completed Part 6.
TQ Transmittal Flow Chart
All deviations shall be raised using the Project TDR Form (Appendix A). TDR Administrator of
sufficient competence shall be nominated to ensure that deviation requests are given the
appropriate priority and a realistic required response time. The form should include
sufficient information for TDR Administrator to act upon and identify prime disciplines
involved; any relevant supplementary information and/or documents should be attached to
the form. The TDR Administrator should also be in a position to review priorities of
outstanding deviations on behalf of the Project team, especially where delays to their
resolution may occur.
Any TD that has an impact on cost and / or schedule may require having a Variation initiation,
if the TD is approved.
Suitable Subjects for Technical Deviation Requests
Acceptable examples of technical deviation requests may include:
Request For deviations to Basis for Design (BFD) and Project Specifications.
Material changes from approved design.
Change to an appropriate code or standard.
Contractual Matters
Material Purchase Requests
Organisational Changes
Planning Matters
Management of plant & process change to plant which has already been commissioned
and handed over
A Technical Deviation Request (TDR) will be made if the Project Team or Contractor is unable
to comply with the Codes, Standards or Project Technical Specifications.
Medium: Failure to resolve could have medium term implications with respect to
project schedules, or HSE performance; requires a response from Engineering
Contractor within 5 working days.
Low: Has little impact on project schedules or HSE performance, but may provide
an improvement in operating efficiency; requires a response from
Engineering Contractor within 6 working days.
Registration
TDR’s are registered in the Technical Deviation database, which is maintained by TDR
Administrator.
Deviation description
Reference number of Procedure, Specification or standard applicable to proposed
deviation.
Status of Deviation (permanent or temporary).
Plant and Unit of Equipment
Information on initiator (Name, Position)
Details of Deviation Request (proposal, justification)
Risk assessment (mitigation and control measures).
All the relevant associated documents must be attached to the TDR prior to submission.
Each TDR shall be given a unique number by TDR administrator.
TDR’s shall be categorised as priority rating mentioned in 7.1.2
SDC forwards the completed form to EPSC focal point for input to the review and approval
or rejection. In all instances of a TDR being assessed, care should be taken to ensure that it
does not compromise, health, safety and/or the environment.
Once the TDR is considered valid, the TDR must be forwarded to the appropriate COMPANY
Technical Authority, who shall review all comments, decide on their acceptability, and
recommend approval, or rejection of the TDR.
Once the TDR is approved and commented by appropriate TA and any other required
parties i.e. Safety, Project Engineer, and Project Manager. It shall be endorsed or rejected
and issued for implementation.
The RFC process starts after contract award with the KOM. The Contract Holder, Area
HSE Lead, HSE RFC Engineer and the contractor agree a date for screening the RFC
requirements against the contract scope. This occurs during a Clarification/
Expectation meeting. Within 7 days from the KOM the contractor shall develop and
submit project specific contract pre-mobilization documentation.
Within 28 days from the KOM, the Pre-mobilization documents are to be submitted by
the contractor through Document Management System (ASSAI) for COMPANY review.
When submitted contract documentation is approved in code-1 or code-2, the RFC
Report shall be prepared by RFC HSE Engineers and endorsed by Contract Holder,
Contract Owner and Area HSE Lead. This provides approval for the contractor to start
mobilizing activities.
RFC Checklist elements are given a “green” or “amber” status, which indicates whether
the elements are fully in place, or need further work before allowing an activity to take
place. The RFC shall be signed by CH, CO, Area HSE Lead, RFC Engineer and Contractor
PM. An RFC Verification Audit will take place after 30 days of issuing the RFC and will
evaluate the effectiveness and the implementation of the approved documents,
arrangement and agreements listed into
the RFC Matrix. Additionally, pending items of the signed RFC Checklist will be tracked to
completion.
Review of the HSSE & SP and QA/QC Documentation will be against COMPANY procedures
and standards that include CSSS and 7 Pillars coaching.
RFC HSE Engineer shall issue weekly updates to Contract Holder and HSSE&SP Lead until the
process is completed.
Preparation
Road Transportation and Journey Management
Medical Emergency Response
Training and HSSE Resources
(Toxic) SIMOPS & H2S (brownfield only)
PPE
Environmental Management
Camp facility and infrastructure
Worksite Hazard Management
HSE Management System
Each of the above elements is further divided into sub-elements specific to the area of
focus. Some of the elements do not need to be fully in place at the time of completing the
RFC e.g. ongoing training programs.
The RFC Checklist is issued with a Rev. Number for tracking purposes.
The assigned RFC Team shall review and assign review Code into ASSAI within 2 weeks of
receiving the document. It is recommended to carry our regular meetings with the
contractor to close any gaps and achieve conformance.
The assessment criteria for the RFC Audit is based on the attached RFC Matrix Document
provided in Appendix 1. All elements are applicable to the project unless excluded during
the expectation meeting.
RFC HSE Engineer will fill the RFC Matrix and assign the colour code according to the
reviewed document code.
If a particular element is not relevant to the scope of services, it can be excluded from the
RFC during the clarification meeting.
If the assessment results in Red, contractor shall not be permitted to commence the works,
Contract Holder shall start corrective actions as per contract.
All mandatory requirements have to be either Green of Amber for the contract to proceed.
Under certain circumstances, contractor mobilization to site may proceed while other
documentation is still being prepared. Derogation shall apply in these circumstances. E.g.
Mobilization of site facilities may proceed while SIMOPS procedure is still being prepared.
4.4 RFI procedure
Requirements for COMPANY to inspect the contractor’s works shall be defined in the
contractors ITP when submitted for approval. Those items nominated by COMPANY as
either Witness or Hold points shall require the contractor to raise and submit a RFI.
RFI shall be submitted to COMPANY as defined in this procedure and must be received in
COMPANY DC a minimum of 24 hours prior to contractor planned inspection time,
exceptions to be discussed and approved by COMPANY Field Quality Team.
When work is complete the contractor construction supervisor shall raise the RFI, sign
and date and pass manually to the relevant COMPANY construction representative for
verification of readiness to inspect. COMPANY construction representative shall sign and
date the RFI.
Contractors QC inspector and COMPANY inspector shall jointly agree the readiness for
inspection to proceed and sign and date the RFI form.
Contractor shall then submit the RFI complete with all relevant design drawings and
documents through contractors document control function to COMPANY DC.
COMPANY DC will forward the RFI package by email in a timely manner to the assigned
COMPANY discipline inspector so he can plan his inspection and coordinate with the
contractor’s inspector.
In most cases the COMPANY and contractors’ inspector will carry out a joint inspection,
but there may be occasions when inspections are completed separately.
A Witness point is not a mandatory inspection point. However; if the COMPANY inspector
does not attend the inspection within a one-hour period after the time on the RFI then
the contractor may continue the work.
A Hold point is mandatory and cannot be passed before the COMPANY inspector and
contractor’s inspector have accepted the work in alignment with Clause 7.2.
The work being inspected shall be either accepted or rejected.
For accepted work the contractors’ QC inspector and COMPANY QC inspector shall sign
and date the RFI form to verify their acceptance.
Contractor shall retain the original accepted RFI package for inclusion in the final
construction handover dossier.
For work rejected the contractor QC inspector and COMPANY QC inspector shall agree
the disposition and annotate the RFI form accordingly clearly stating the reason(s) for
cancellation/rejection/not ready for inspection.
Rejected work shall be subject to a new RFI.
Rejected RFI forms shall be retained by contractor alongside the final accepted RFI form
for the work and included in the final construction handover dossier.
Contractor shall send copies of completed RFI forms for both accepted and rejected work
through COMPANY DC for company records.
COMPANY inspectors shall make sure the records of all inspections are retained for ready
reference during contract duration.
COMPANY DC will pass a copy of the completed accepted/rejected RFI forms to the
discipline COMPANY inspector and QC clerk to allow traceability records to be maintained.
4.5 RLMU Red Line Mark Up procedure
The scope of the procedure covers the drawings/documents that are used by
Construction Contractor and is limited to the list of drawings/documents type enclosed as
per Appendix A – that defines which document/drawing types are to be Redline marked-
up, produced As-Built, then used for 3D model update (where applicable) and finally
returned to COMPANY as approved As-Built drawings.
Document types are also referenced to the Tier number from “The Production Standard
Critical Documents and Drawings (OE)”. Tier 1 documents shall always be maintained
in 2 hard copies (master and slave).
It is the responsibility of the Engineering Manager to make sure all these documents are
undergone the RLMU and, where necessary, As-Built.
Project manager is accountable for ensuring that this process is carried out in a
controlled manner prior to FAC (Facility Acceptance Certificate) is issued.
The drawing/document list shall be maintained and matured throughout the project
execution. The As-built Package (DCAF ID 435) requires a QA check of the following
elements on the list:
completeness of as-built drawings, records and specifications;
availability of vendor documentation for all equipment; and
operating and maintenance procedures against experience gained during
commissioning.
As an example, such list for FCP Gas is referenced to as “List of Critical Documents for
FCP Gas (Sweet)”, document number TGRS-GEN-SIP-JA-6611-0001.
This procedure supports RLMU preparations for Start-Up from Mechanical Completions
through Commissioning and As-building of the selected drawings/documents after Start-up
until Transfer of Ownership to the Asset, as illustrated in Figure1 Handover Flow Diagram
This procedure covers the process steps of completing the work on site through closing the
RFI and getting the final acceptance from the client
The first step of this procedure starts with the QC inspector on site, who is observing the
progress of all the activities on site on daily basis, once an activity is completed 100% the
inspector checks the work thoroughly to make sure that the work has been done according
the required specification, in case there are some remarks, the QC inspector informs the site
engineer to fix it, after getting the work completed 100%, the QC inspector fills a check list
record on site and then hand over this list to the QC department manager to attach this list
with the RFI (request for inspection) and submit to the client’s document control officially
for the external final inspection
Check list records are attached
2 Inspection of setting out/ grid reference/ bench mark and steel/wood pegs
indicating various elevations
3 Inspection of clearing backfilling area from construction debris
4 Inspection of soft spots if any
5 Verification of fill material test reports
6 Inspection of excavation area setting out and mark up
7 Inspection of formation level
8 Inspection of impermeable membrane if any
9 Inspection of concrete protective system
10 Verification of protective coating thickness report if applicable
11 Verification of compaction test reports
12 Inspection of finish level
Remarks:
Record Acceptance
Contractor QC COMPANY QC
Name
Signature
Date
ITR No: C-0302X
INSPECTION AND TEST PLAN Project document no:
CONCRETE WORKS P4A-GEN-TAZ-QA-5733-
0001
BOC-1694
INSPECTION TEST RECORD Rev.: 001
REINFORCED CONCRETE PRE-POUR Contract no: BOC-1694
Drawing no: Rev.:
RFI no: Record: Date:
Structure/member:
Area:
Sl Description of Inspection Activity Result
no:
1 Formation level inspection (visual)
5 All setting out verified by Surveyor including anchor bolts and blinding concreting
level and all dimensions checked and correct within tolerances (Survey Report
attached as necessary)
6 Form surface cleanliness verified
7 Reinforcement number, size, spacing and binding inspection. Binding wire shall be
tucked inside.
8 Reinforcement is free of loose rust, grease, oil, paint or any other deleterious
material
9 Reinforcement cover shall be in accordance with IFC drawing
11 Form work cleaned to remove dust and binding wire cut pieces. Form work
cleaning pocket closed
12 Fresh concrete sampling and testing inspection
Remarks:
Remarks:
6 Cast concrete surface is covered with polythene sheet and wet hessian after
surface finishing
7 Wet hessian is kept continuously wet by spraying water post concrete set
Remarks:
Name:
Signature:
Date:
MAJNOON OIL FIELD ITR No: C-403R
SOUTHERN IRAQ Project Doc No:
P4A-GEN-TAZ-QA-5733-0003
INSPECTION AND TEST PLAN FOR ROAD Rev. : 001
WORKS & ASPHALT WORKS
Project No: 1694
Road Works Inspection Record
Page : 18
Record Acceptance
TAAZ QC COMPANY QC
Name
Signature
Date