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2082-PM-CQP-7011 Rev.0 - Constructin Quality Plan
2082-PM-CQP-7011 Rev.0 - Constructin Quality Plan
This document is property of M/s. ICON INDUSTRIAL ENGINEERING SERVICES PVT. LTD. The information in this document to be used only for the purpose provided for and shall not be
disclosed to third parties nor reproduced in part or in whole without prior written permission of M/s. ICON INDUSTRIAL ENGINEERING SERVICES PVT. LTD.
TABLE OF CONTENTS
1. INTRODUCTION...............................................................................................................3
2. REFERENCES..................................................................................................................3
3. ABBREVIATIONS AND DEFINITIONS.............................................................................3
4. QUALITY PLAN................................................................................................................4
5. FIELD DESIGN CHANGES..............................................................................................4
6. DEVELOPMENT OF INSPECTION AND TEST PLANS (ITP).........................................4
7. DEVELOPMENT OF PROCEDURES AND FORMATS FOR INSPECTION & TESTING5
8. INSPECTION & TESTING PHILOSOPHY........................................................................6
9. REQUIREMENTS FOR THE INSPECTION TEAM..........................................................6
10. SUPPORT DURING INSPECTION...............................................................................7
11 SHOP INSPECTION AND TESTING............................................................................7
12 FIELD INSPECTION AND TESTING............................................................................7
13 DOCUMENT AND DATA CONTROL..........................................................................16
14 FINAL QUALITY DOSSIER.........................................................................................16
15 CONSTRUCTION PHASE QUALITY PERSONNEL REQUIREMENTS.....................17
16 LIST OF INSPECTION & TEST PLANS FOR THE CONSTRUCTION PHASE.........18
1. INTRODUCTION
1.1 SCOPE
This procedure outlines the minimum requirements for inspection and testing of materials,
components, equipment, and permanent installations that shall be conducted during the
procurement (PQP) during construction and construction works (CQP) of the project and
recorded in a systematic manner to meet project quality requirements.
1.2 PURPOSE
1.2.1 To ensure that approved practices, procedures, inspection and test plans and Audit program
are in place and are being utilized, as they apply, throughout Site construction phases of the
project
1.2.2 To provide for early and prompt detection of deficiencies and for timely and effective
corrective action
1.2.3 Provides an outline of the organization structure, coordination activities and responsibilities
during inspection and testing. These shall be used by the CONTRACTOR for incorporating
into its detailed processes to meet project requirements.
1.2.4 To serve as a basis for Quality Audits.
1.2.5 Define responsibilities of Site key personnel
2. REFERENCES
Construction Execution Plan
Procurement ITPs
Construction ITPs
3. ABBREVIATIONS AND DEFINITIONS
1.3 ABBREVIATIONS
ITP : Inspection and Test Plan
RFI : Request for Inspection
1.4 DEFINITIONS
The definitions that are more common for Inspection & Testing are provided below:
1.4.1 Company/Owner: TASNEE
1.4.3 Hold Point – Inspection point defined as "Testing or execution of work must not proceed
unless identified inspectors are present to witness as per approved ITP
1.4.4 Inspection: An activity such as measuring, examining, testing, or gauging one or more
characteristics of an entity and comparing the results with specified requirements in order to
establish whether conformity is achieved for each characteristic
1.4.5 Inspection & Test Plan (ITP) - It is the sequence of Inspections & Tests that need to be
conducted on each equipment / installation as it progresses through the different stages of
manufacturing / installation as applicable. It also references the documents needed for
conducting, recording each inspection / test and the responsibilities of all involved agencies
1.4.6 Project Focal Point: Person nominated by TASNEE as overall responsible for coordination and
1.4.7 Project Specification: Document specific to the project and defines the specific requirements
to be implemented in design, procurement, inspection, and testing.
1.4.8 Quality System: Is the organizational structure, procedures, processes, and resources
needed to implement quality management
1.4.9 Review Point: An activity undertaken to completely determine the suitability, adequacy, and
effectiveness in the documents for an activity or inspection to achieve established
objectives. This may take the form of documentary or visual inspection to determine the
extent to which planned activities are realized and planned results achieved to meet
specified requirements.
1.4.10 Spot Witness: A step at which the WORK must be randomly inspected in the presence of
designated representatives. The CONTRACTOR / supplier is obligated to always notify the
designated inspector(s) at a reasonable time in advance. However, the CONTRACTOR shall
proceed if the COMPANY’s representative is unavailable.
1.4.11 Surveillance Point – A specifically defined routine step in construction where witness of the
COMPANY is waived due to highly repetitive nature of activity. However, COMPANY shall be
notified whenever such an activity is being carried out
1.4.12 Witness Point: WORK must be inspected in the presence of identified entity’s
(Owner/Contractor/ vendor) representatives. May proceed with the work past a Witness
Point provided that the designated inspection representative agrees and normally a
subsequent similar operation is witnessed at the earliest opportunity.
4. QUALITY PLAN
1.5 The principles and their partial embodiment within the Quality Policy follow.
• Customer Focused
• Leadership
• Process approach
• System approach of Management
• Continual Improvement
1.6 Quality Plan shall describe:
• Project Scope
• Governing document of the quality management system.
• Site Quality Procedures, including specific procedures for the given Project,
developed by Contractor/Sub-Contractor, and approved by COMPANY
• Inspection Test Plans (ITP)
5. FIELD DESIGN CHANGES
1.7 Design Modification Procedure (2082-PM-SMP-7010) is established as system to control site
change designs, the construction technical queries, both relative reporting and approval.
Inspection shall be carried out on such works only if RFI is enclosed with the approved change.
6. DEVELOPMENT OF INSPECTION AND TEST PLANS (ITP)
1.8 Project Focal Point shall coordinate with the CONTRACTOR and Owner Quality team to develop
project specific Quality Plan, ITPs for each type of equipment and installation. If ITPs are
developed by Sub contractors and Vendors, CONTRACTOR shall review them for fulfilment of
Project Requirements prior to submission for COMPANY’s approval.
1.9 The shop Inspections and Tests Plans shall incorporate the requirements Inspection Levels for
the Procurement Stage with minimum inspections as per procurement ITPs-2082-PM-ITP-7009.
1.10 For field Inspections and Tests, the Inspection & Test Plans for the Construction Stage listed in
2082-PM-ITP-7013 Rev.0_SITE ITP shall be utilized.
1.11 The above are minimum requirements for shop and field inspections and shall be developed
further by the CONTRACTOR for the approval of COMPANY to cover the full scope of equipment
and construction. Other inspections and test requirements as described in the Project
Specifications, COMPANY Engineering Standards, Applicable Codes and drawings shall also be
incorporated into the Inspection requirements. If any other tests or inspections are required in
suppliers’ opinion, supplier shall propose them.
1.12 In case of conflict between the inspection & test items in this section including appendices and
those specified in the referenced specification, the more stringent requirements shall govern
unless approved in writing by COMPANY.
7. DEVELOPMENT OF PROCEDURES AND FORMATS FOR INSPECTION & TESTING
1.13 Project Focal Point shall ensure CONTRACTOR prepares Inspection and Testing procedures,
method statements are prepared and shall incorporate requirements and acceptance, or
rejection criteria contained in applicable specifications, standards, and other design documents.
1.14 Quality Verifying Documents (Inspection Formats) shall also be developed with:
• Project Title.
• CONTRACTOR’s/Sub-contractor’s/Vendor’s Name.
• Inspection location.
• Type of work/Equipment.
• Personnel attending the inspection.
• Type of inspection and test.
• Inspection procedure.
• Inspection date and time.
• Reference Specifications
• The inspector/tester.
• Details of test and inspection.
• Acceptance criteria.
• Inspection and test results.
• Approval Status / Disposition; and
• Signatures of authorized personnel witnessed / reviewed.
1.15 Testing shall be performed in accordance with approved inspection and testing procedure in
conjunction with the latest PROJECT SPECIFICATION.
• Calibrated instrumentation
• Appropriate equipment
1.17 The forms shall be supplemented, reformatted, or modified as needed to be compatible with
CONTRACTOR’s and COMPANY’s quality system, but applicable verifications of these forms shall
be retained as a minimum.
8. INSPECTION & TESTING PHILOSOPHY
1.18 Project Focal point shall be responsible for coordinating the sequence of the WORK to
accommodate all required tests and inspections and coordinate timely inspections.
1.1 Project Focal Point shall monitor CONTRACTOR’s quality activities at any stage and coordinates
with Company Quality representatives who have the right to issue a surveillance report,
inspection report and/or nonconformity reports if any activity is found to be not as per PROJECT
SPECIFICATION, drawings. Etc. Furthermore, when COMPANY rejects any
equipment/material/installation that is found to be unacceptable or fails to comply fully with
the requirements of the PROJECT SPECIFICATIONS, Project Focal Point shall ensure that
CONTRACTOR takes up corrective action shall notify COMPANY for re-inspection as required.
1.2 COMPANY/COMPANY’s REPRESENTATIVES reserve the right to demand for test or special
examination of any material to determine compliance with the Project Specifications. Any
material proven defective as a result of such test will be rejected. CONTRACTOR shall perform
such tests and examinations, even though not specified herein, when directed to do so by
COMPANY/COMPANY’s REPRESENTATIVES.
1.3 CONTRACTOR shall furnish samples of materials to be tested at no extra cost to COMPANY. In
such cases, test samples will be selected by the testing laboratory or the Inspector and not by
CONTRACTOR. Whenever requested, CONTRACTOR shall deliver samples of any material
proposed to be used in the WORK, free of charge, to a place directed by COMPANY.
1.4 COMPANY reserves the right to witness CONTRACTOR’s inspections and tests at any stage which
may be in addition to identified inspection steps. Such inspection shall not in any way relieve
CONTRACTOR of responsibility to comply with PROJECT requirements and to furnish material,
equipment and services required as per the CONTRACT.
1.5 COMPANY reserves the right to assume the inspection functions if CONTRACTOR inspection
performance is not satisfactory. In such cases the cost of inspection shall be back charged to the
CONTRACTOR.
9. REQUIREMENTS FOR THE INSPECTION TEAM
1.6 OWNER shall assign a team consisting of qualified and enough personnel together with systems
and facilities to manage and coordinate the inspection and Testing activities during procurement
and construction. This team shall also be responsible for managing coordination with COMPANY
and Vendors/Manufacturers/Sub contractors, handling the notification for inspection, reports,
action correspondence and messages, release/rejection notices and any other quality issues. In
addition, the team shall maintain the master inspection files for the project and process the
necessary correspondence, communications, and reports.
1.7 Inspection personnel shall not report directly to immediate supervisors responsible for Work
being inspected. Inspection personnel shall be free from the pressures of cost, schedule, and
production. Furthermore, they shall have the authority and independence to perform their roles
in efficient and effective manner.
1.8 Project Focal Point thru Owner Inspection Team shall ensure the CONTRACTOR/Vendors
/Manufacturers /Subcontractors Inspection Personnel are adequate, qualified, and competent
to perform them inspections and monitoring of the activities.
10. SUPPORT DURING INSPECTION
Project Focal Point shall ensure that:
1.9 COMPANY representatives are in place and facilitated by CONTRACTOR during inspection
activities.
1.10 COMPANY representatives shall have access to WORK specifications, drawings, procedures,
standards, and any other documents which will allow them to monitor, verify and report the
inspection and testing activities.
1.11 CONTRACTOR to schedule and accompany, as required, COMPANY representatives on any site
visits when requested, work closely with COMPANY representatives to ensure effective Quality
Control.
1.12 Arrange and facilitate the meetings on Quality Control and Inspection issues as required by
COMPANY representatives. CONTRACTOR shall provide such auxiliary services as requested.
These auxiliary services may include but are not necessarily limited to providing access facilities
and labour necessary for duties to be performed by Testing laboratory and/or COMPANY,
including furnishing ladders, hoist, power, lighting, water supply, securing and protecting of
samples and test equipment at the jobsite, taking samples or assisting with taking samples, and
like services, materials, and equipment.
1.13 Where required, Project Focal Point shall ensure that Licensor personnel participate in agreed
inspection activities at Vendor works as well as at site to ensure the quality control activities are
completed and recorded to Licensor satisfaction. Licensor personnel shall be required to
endorse inspection reports to demonstrate their participation in inspections throughout the
fabrication, inspection and installation process and their agreement to the items supplied.
3.1.1 Before start of Site WORK, CONTRACTOR shall arrange an Inspection Coordination Meeting
with COMPANY to establish a complete understanding of the inspection requirements and
procedures for the WORK.
3.1.2 CONTRACTOR shall prepare and submit to COMPANY for its review a quality control
execution plan which shall include all field inspection and testing plans.
3.1.3 The quality control execution plan shall provide continuous quality control of materials,
equipment, fabrication, and the erection work, from the time that materials and equipment
arrive at the WORK Site until Mechanical Completion Date. They shall also describe plans for
inspection, testing, and utilization of other controls such as checklists, reports, records, etc.
3.1.4 The quality control execution plan shall cover but not limited to:
• Site Quality Organization
• Review and approval of quality documents
• Inspection and Test requirements
• Preparation of Inspection and Test Plans, review, and approval
• Roles and responsibilities of independent Inspection & Testing Agencies
• Control of Field Works
• Review and approval of quality documents
• Inspections Schedule
• Coordination and requests for Inspections
• Inspection by CONTRACTOR
• Inspection reporting system
• CONTRACTOR’s interfaces with COMPANY’s inspection representatives
• Handling of COMPANY observations during inspections.
3.2 QUALITY ORGANIZATION
3.2.1 Both COMPANY/CONTRACTOR shall ensure that adequate field inspection and managerial
staff are assigned as per Appendix 4 ‘Construction Phase Quality Personnel Requirements’ as
a minimum.
3.2.2 Ensure Inspection Personnel are adequate, qualified, and competent to perform their
inspections and monitoring of the construction work.
3.2.3 Inspectors shall be capable to analyse all relevant quality requirements and tailor Inspection
and Test Plans and checklists and perform their duties for their disciplines.
3.2.4 Inspectors shall be available full time at all locations during the WORK and at any sub-
contracted WORK.
3.2.5 All inspection personnel of the CONTRACTOR and construction sub-contractors will be
subject to approval by the COMPANY.
Assistance for the coordination with design and engineering offices on clarification.
Where required, propose alternate solutions to problems.
Assist in the development of detailed pre-commissioning planning and progress
Audits quality performance at the job site.
Making sure that personnel have the necessary information in their posts concerning
audit for the prefect development of their function
Coordinate all the in-site contractor and sub-contractor quality inspectors and
supervisors
Design Review (if applicable) for ITP's, Procedures material test supports, calibration,
record, Record of in process inspection, NCR report quality report, waivers, quality
management
Assures necessary corrective actions to quality related problems and coordinates
inclusion of OWNER-unique quality control requirements- in the quality system
3.2.7 SITE QUALITY CONTROL SUPERVISOR
Site QC Supervisors report in day to day "operational to Construction Team Leads and
functionally to Site Quality System Manager
Verify that Contractor issue Quality Plan, procedures, and ITPs in its works.
Implement the Project Quality Control Procedures, requirements for specific areas of
responsibility and monitor the quality of work performed
Other Functions:
Monitoring Quality implementation and performance of Inspection Tests Plans (ITP's)
Report Non-Conformance (NCR), Quality Observations (QOR)
Maintain inspection record files. Verify the documents for completeness and initiate
corrective actions
Provide assistance to discipline superintendents and supervisors on interpretation of
quality requirements.
Assist the Project Focal Point in day-to-day quality control and assurance matters.
Assist the pre-commissioning engineer in the definition of the pre-commissioning systems
and the preparation of detailed component lists for each system.
Assist the field scheduling engineers in the preparation of pre-commissioning schedules
and the follow up on progress in pre-commissioning.
Maintain up-to-date status on tests and inspections performed.
3.2.8 QC DOCUMENT CONTROLLER
3.3.1 One month before the start of each new type of construction activity, CONTRACTOR shall
submit its complete set of project specific Inspection & Test Plan, method statement,
inspection / record formats (quality verifying documents) etc for COMPANY approval.
CONTRACTOR shall also submit Procedure Qualification records, Personnel Qualification
Records etc as applicable.
3.3.2 Where field testing is required, CONTRACTOR shall develop system test plans. A pre/post-
test checklist containing test control prerequisites shall be developed and used to ensure
that systems are properly prepared for tests and test media and testing equipment are
removed after the tests are completed.
3.4 INSPECTION COORDINATION, EXECUTION AND REPORTING
3.4.1 Inspection Schedule
“Monthly/Weekly Inspection and Testing Schedule” to be planned in order for COMPANY
inspection team to arrange and prepare in advance for the inspections. This shall focus on
the new types of construction works that will start in the future so that the required types of
inspection personnel and procedures can be arranged in advance.
at pre-fabrication yard. CONTRACTOR shall also ensure that records of all pre-fabrication
material/equipment are satisfactory and completed in a timely manner and accompany the
prefabricated material/equipment to site.
3.4.3.6 If any part of the WORK or the Facilities is closed or covered before the required inspection
or witnessing has been performed, or performed without agreement by COMPANY, if
required by COMPANY, this part of the WORK or the Facilities shall be opened or
uncovered for inspection or witnessing on CONTRACTOR's expense.
3.4.4 Inspection & Test Reports
3.4.4.1 CONTRACTOR is responsible to maintain and update the inspection and test records. This
responsibility shall not be delegated to sub-contractors without prior approval of
COMPANY. In any case, status of each inspection and test shall be maintained directly by
the CONTRACTOR.
3.4.4.2 Daily entry is required for all the inspection and test records. Details shall be provided to
COMPANY upon request. CONTRACTOR shall provide a weekly status report to
demonstrate that entry has been maintained and is up to date.
3.4.4.3 CONTRACTOR shall establish a proper system for tracking of comments raised by
CONTRACTOR and COMPANY during inspections and tests. Re inspections shall be
arranged timely to close out all comments.
3.4.4.4 These records shall be maintained and submitted to COMPANY as part of Turnover and
shall comply with the PEIs requirements.
3.4.5.1 CONTRACTOR shall maintain statistical analysis of the inspection records. After each
inspection / test, CONTRACTOR shall fill up the records on the same day and classify each
record as follows:
• Accepted – Meaning the Inspection / Test meets all requirements
• Accepted with Comments – Some minor requirements have not been met which need
correction. However next activities can proceed
• Rescheduled – CONTRACTOR’s inspector informed COMPANY’s inspector at-least one
hour before the scheduled time for inspection / test that the work is not ready.
• Hold – Inspection / Test was conducted but inspection / test report is awaited from
third party inspection / testing agency
• Rejected – Work did not meet requirements and needs repair / rework.
3.4.5.2 CONTRACTOR shall conduct statistical analysis of the percentage of inspections / tests that
are rejected or rescheduled per discipline. The maximum percentage for rejections per
discipline shall be ten percent and for rescheduled shall be 15% per discipline. If these
figures are exceeded, CONTRACTOR’s Field Quality Manager shall conduct detailed analysis
to identify the root causes so that necessary remedial action can be undertaken.
All NDT and Laboratory Testing shall be conducted by independent third-party testing
agencies approved by COMPANY.
The Testing Agencies shall prepare project specific test procedures based on applicable
project specifications and job requirements. These shall be approved by the CONTRACTOR
before submitting to COMPANY for review and approval.
The Testing Personnel employed by the third-party testing agencies shall be competent in
their specific area based on education, skills, experience, and performance to the
satisfaction of CONTRACTOR and COMPANY. NDT personnel shall be qualified and certified
in accordance with applicable requirements.
The inspection and testing laboratory shall have adequate resources and facilities for
inspection and testing. They shall be calibrated and be able to meet the inspection and test
requirements.
3.6 MATERIAL AND EQUIPMENT PROTECTION
3.6.1 General
3.6.1.1 The CONTRACTOR shall be responsible for the protection of material and equipment until
the Facility is accepted by OWNER.
3.6.1.2 Equipment and material shall be delivered to the Site preserved in accordance with the
Project Specifications and instructions from Suppliers/manufacturers. Equipment
protection procedures shall be applied by the CONTRACTOR as needed to maintain
protection in accordance with Project Specifications and instructions from
Suppliers/manufacturers.
3.6.1.3 Specific lubrication and field preservation for equipment shall be in accordance with
requirements identified in the applicable Specifications or manufacturers
recommendation.
3.6.1.4 The manufacturer’s recommended practices for the application of each preservative shall
be strictly followed. Special consideration should be given to the preservative’s
temperature, surface cleanliness, method of application and quality of preservatives.
3.6.1.5 As a general rule, the manufacturer’s packaging and preservation measures will not be
disturbed unless required for the installation or the checkout of equipment / material.
Exceptions to this rule will be those items which will require preventative maintenance
during storage.
3.6.1.6 Surfaces shall be clean and free of water, grease, oil, metal particles, dirt, and debris prior
to application of preservatives. Highly finished, exposed precision surfaces shall be
cleaned, and fingerprints neutralized immediately prior to application of preservatives.
3.6.1.7 Petroleum base preservatives shall not be applied to the following:
a) Items fabricated from textiles, plastics, mica, rubber, cork, paper, leather,
and leather products.
b) Electrical and electronic parts and equipment such as condensers, electrical
connectors, distributor rotors, circuit breakers, fuses, switches, resistors, and
rectifiers.
c) Items which would suffer damage to mechanism or structure or where
malfunction or unsafe operational conditions would result due to application
or removal of the preservative compound.
3.6.1.8 Exterior surfaces of materials shall be checked for corrosion, chipping, or scarring. Paint
shall be reapplied where necessary to prevent rust.
3.6.1.9 Austenitic stainless-steel surfaces of pipe, pipe fittings, and flanges shall be protected from
exposure to salt air and contact with galvanized steel or groundwater, other contaminating
materials.
3.6.1.10 Each manufacturer’s recommendations for preserving its particular piece of material must
be reviewed and implemented. Whenever the manufacturer’s approved recommendations
conflict with the requirements of Project Specifications, the more stringent
recommendations shall prevail.
3.6.1.11 All fabricated spools or straight pipe runs shall be delivered to Site with flange/end covers
and with the insides cleaned and dry.
3.6.2 Protection Activities
3.6.2.1 CONTRACTOR shall submit, for OWNER review and comment, procedures describing
preservation operations required during the Works. Preservation Operations are defined as
those activities that are performed periodically to deter corrosion and deterioration of
equipment and materials during storage or while sitting on foundations. Preservation
activities shall include, but are not limited to:
a) Lubrication: Manufacturer’s recommendations may require draining of old
lubricants and the application of new lubricants on a periodic basis. Grease
lubricated bearings frequently present problems, especially if moisture has
condensed in the bearing housing, and the lubricant is hygroscopic (moisture
absorbing and retaining). If this occurs remedial action requires disassembly
before relubricating and all old grease must be purged from reservoir and
fittings.
b) Application of Corrosion Inhibitors
o Oil and grease used for corrosion resistance (inhibited oil or grease) shall be of
the type specified in the Supplier’s instructions.
o Silica gel may be used for moisture protection inside equipment. Type,
quantity, and manufacturer as specified in the Supplier’s instructions shall be
used.
c) Inert Gas Charges: Inert gas may have been used to prevent oxidation of the
interior of vessels, heat exchangers, etc. As a rule, the material will have been
charged to specified pressure at the factory. Materials so treated, are usually
equipped with a factory installed pressure gauge. As long as the gauge registers
a positive pressure it is not necessary to recharge unless extreme temperature
difference is encountered or contemplated. CONTRACTOR shall follow the
instructions issued by the manufacturer.
Visual inspections are those normal activities which are performed periodically to
verify that initial preservation and periodic preservation operations are being
performed. Visual inspection activities shall include:
a) Inspection of Desiccant
The interior of some materials is provided with moisture absorbers to prevent
atmospheric corrosion. These inhibitors shall be maintained for the life of the
equipment storage.
CONTRACTOR shall perform periodic inspection to assure the desiccant has
performed the required function.
b) Adequacy of Storage Conditions: CONTRACTOR shall verify that the storage of
materials is adequate to maintain the conditions described in the detailed
material protection requirements set forth herein.
c) Inspection for Damage: Although the materials have been checked when
received, they are still subject to damage. CONTRACTOR shall perform periodic
inspections after material has been received to ensure that stored material is
still in good condition and that there is no damage due to the accidental, partial,
or total crushing of the material to the extent that it requires repairs in order to
render it adequate for its intended use.
d) Inspection for Corrosion: The material protection program requires application
of corrosion inhibiting films and lubricating oils. CONTRACTOR shall perform
periodic inspections and remove any corrosion and reapply inhibitors or oils as
required.
e) Inspection for Deterioration: Many materials will deteriorate due to oxidation
or decomposition over extended periods in storage. Examples of this are:
hardening of bagged cement and exceeding the shelf life of paint. CONTRACTOR
shall perform visual inspection and remove all deteriorated material and ensure
that this material shall not be used for the Works.
3.6.4 Protection from Construction Activities
In addition to visual inspection for damage, some material requires positive protection
measures, to prevent construction damage. (Protecting anchor bolt threads with
guards after setting in concrete is an example of this activity). CONTRACTOR shall
establish procedures which address the protection of installed material
3.7 WELDING CONTROL
3.7.1 Welder Qualification Test
3.7.2 Weld Repair Rates
3.7.2.1 CONTRACTOR shall review and track project and Welder repair rates daily. COMPANY will
monitor and evaluate production weld repair rates and welder performance weekly.
3.7.2.2 For piping, the weld repair rate shall be calculated on number of joints basis. Maximum
project repair rate shall not exceed 4%. The repair rate for individual welders must not
exceed 5% weekly.
3.7.2.3 For field fabricated tanks and pressure vessels, the weld repair rate shall be calculated on a
linear basis and repair rate shall not exceed 1.5%. The repair rate for individual welders
must not exceed 2%.
k) Provides a completion progress report that will give the incremental and cumulative
completion profile of welding against pre-established actual quantities for field and
shop welds. Unit basis shall be available in either weld joints or diameter inches.
l) Validates heat numbers from both adjacent components being joined which are
recorded on daily welding reports during field or shop inspection against a material
certificate database, to determine if the heat number exists, and that the correct
material has been used in the location reported.
3.7.3.2 Trend analysis shall be performed on individual welder performance to ensure
unsatisfactory personnel are removed or re-trained to ensure consistent quality levels are
maintained. CONTRACTOR shall update the information in its approved database system,
on a daily basis from a daily welding report form in an agreed format.
3.8.1 CONTRACTOR shall identify the critical valves (criticality rating 2) during the engineering
stage using the criteria in appendix 5 of this PEI.
3.8.2 CONTRACTOR shall prepare a list of all critical valves and submit to COMPANY for review.
3.8.3 In addition to shop inspections, all critical valves and pressure relief valves shall be retested
in the field before installation for body leakage and passing according to the applicable
standards.
3.9 INSPECTION OF FIELD CHANGES.
3.9.1 Before backfilling buried services, CONTRACTOR should prepare ‘As Built’ drawing and
obtain COMPANY approval.
3.9.2 All approved field engineering changes shall be inspected, and the drawings shall be marked
accordingly. These shall be tracked and updated in a register. A soft copy of the register
should be submitted for the COMPANY every month. At the end of the project, COMPANY
shall use the register to confirm that all field changes have been incorporated.
4 DOCUMENT AND DATA CONTROL
4.1 The Control of the documentation in Site will be carried out according to the 'Site Document
Control Procedure' (2082-PMSDC-7016) which describes the distribution, identification and file
of the documents and generated registrations of quality of the units and work services.
4.2 To control the authorized signatures at Site for documents, protocols etc., during the phase of
Construction, the Sheet of Confirmation of signatures will be used. This Sheet will be updated in
while incorporating personal. The Site Manager will have the record of these signatures picked
up in the previous document.
4.3 QA/QC Matrix with the approval and distribution personnel of Quality procedures for the site
should be implemented in this project.
5 FINAL QUALITY DOSSIER
5.1 Final Quality Dossier will be prepared by CONTRACTOR will include, at least, but not limited to:
a. Cover page
b. Index
c. Manufacturing Certificate
d. Material certificates.
e. Material Receiving inspection
f. Approved Quality Control Plan
g. Welding/ NDE, approved WPS, welding materials and consumable, welders list with
cumulative welding rejection/ repair rate,
h. Approved painting, blasting and abrasives material certificate inspection reports
i. Materials with a full identification of the item where they have been used with
traceability and material certificates.
j. Non-Conformity Reports and Repairs reports with final disposition and resolutions.
k. Discipline wise works documentation
l. Final Technical Drawings.
MAIN CONTRACTOR
Construction Discipline Sub-contractor Inspectors
Inspectors
Inspection Discipline: Civil
One inspector per twenty-five (25) One inspector for each three (3)
Earthwork earthwork machines or one inspector Subcontractor inspectors (minimum
per fifty (50) laborers one inspector)
One inspector for each three (3)
One inspector per fifty (50) carpenters +
Form work Subcontractor inspectors (minimum
Iron workers
one inspector)
Batch Plant
One Inspector per Batch plant One Inspector for all
(Concrete & Asphalt)
One inspector for each three (3)
Structural Steel One inspector per fifty (50) installers Subcontractor inspectors (minimum
one inspector)
One inspector for each three (3)
U/G Piping One inspector per fifty (50) installers Subcontractor inspectors (minimum
one inspector)
One inspector for each three (3)
HVAC One inspector per fifty (50) installers Subcontractor inspectors (minimum
one inspector)
MAIN CONTRACTOR
Construction Discipline Sub-contractor Inspectors
Inspectors
Inspection Discipline: Mechanical
One inspector for each three (3)
One inspector for each five (5)
Rotating equipment Subcontractor inspectors (minimum
machinery installation crews
one inspector)
One inspector for each fifty (50) One inspector for each three (3)
Piping including
workers (welders, fabricators, bolt Subcontractor inspectors (minimum
welding
tightening personnel etc.) one inspector)
One inspector for each three (3)
Static Equipment One inspector for each fifty (50)
Subcontractor inspectors (minimum
including welding workers
one inspector)
One inspector for each three (3)
One inspector for each fifty (50)
Insulations Subcontractor inspectors (minimum
workers
one inspector)
One inspector for each three (3)
One inspector for each forty (40)
Coating Subcontractor inspectors (minimum
workers
one inspector)
Electrical / Instrumentation
One inspector for each three (3)
Electrical One Inspector per forty (40) workers subcontractor inspectors (minimum one
inspector)
One inspector for each three (3)
Instrumentation One Inspector per forty (40) workers Subcontractor inspectors (minimum one
inspector)