Document Number

Kamoa Copper SA KCSA-PROC-QMS-001

Rev. No. Rev. Date
Quality Management System
00 24/06/2022
Page Number
QMS Procedure 1 of 7

CONTRACTOR QMS READINESS

PROCEDURE

© Copyright - All Rights Reserved - This documentation is considered the intellectual property of KCSA. Unauthorized reproduction or distribution of
this documentation or any portion of it may result in severe civil and criminal penalties, and violators will be prosecuted to the maximum extent
possible under law.

1
1. Objective
To ensure the Contractor Quality Management System is in place and in conformance with the KCSA
Construction Quality Management System, Project Specifications, international codes & standards prior to,
during and at the close out of a project.

2. Abbreviations, Terms and Definitions

Abbreviation/Term Definition
AIA Authorised Inspection Authority
ASME American Society of Mechanical Engineers
AWS American Welding Society
Employer or Purchaser, which also means Kamoa Copper SA as defined in the
Client
Contract.
CM Construction Manager
The organization or company whose tender has been accepted, including
Contractor
Contractor’s personnel, representatives and Suppliers.
DC Document Controller
DRA DRA Projects
EPCM Engineering, Procurement and Construction management
The responsible Project engineer or authorized client representative as stated in the
Engineer
Contract.
HOC Head of Construction
ISO International Organisation for Standardization
ISO 9001: 2015 International Quality Management Standard
IMTE Inspection, Measuring & Testing Equipment
LMI Lifting Machinery Inspector
MS Method Statement
MSS Mechanical Site Supervisor
NCR Non-Conformance Report
Project project is a series of tasks that need to be completed to reach a specific outcome
PM Project Manager
Project Construction Manager The Project Construction Manager appointed for the Kamoa-Kakula Project.
Project Manager The Project Manager appointed for the Kamoa-Kakula Project.
Phased inspections at completion of a section of Works to identify any deviations by
Punch Listing
the Contractor from his Contract in terms of scope, Drawings and Specifications.
P1 Punch Phase 1 of the inspections to be done internally by contractor team
P2 Punch Phase 2 of the inspections between contractor team and KCSA Supervisor
P3 Punch Phase 3 of the inspections between contractor team and KCSA team
C1 Certificate Construction Completion Certificate
QA Quality Assurance
QC Quality Control
QCI Quality Control Inspector
QCP Quality Control Plan
QMS Quality Management System
SANS South African National Standards
SHEQ Safety, Health, Environmental & Quality
SCM Senior Construction Manager
SMPP Structural, Mechanical, Platework, Piping
SOW Scope of Work
SVI Site Variation Instruction
TQN Technical Query Note

3. Lessons Learnt
Although most of the management and supervisory personnel from KCSA, EPCM (DRA; ENFI) and contractors
attended the KCSA QMS induction sessions, an unacceptable high number of NCR’s was raised during the
construction period of the Kakula Copper Mine Phases 1 & 2 in terms of non-conformance to specifications.
It was derived from the Lessons Learnt sessions that contractors ignored the requirements of the KCSA
Construction Quality Management System, the applicable project specifications as well as the relevant
international construction codes and standards. The associated cost and time spent on corrective action / rework
of the non-conformances caused unacceptable delays in the project schedules.
All contractors shall contribute to the Lessons Learnt during the specific project and going forward, all NCR’s will
be included in the Lessons Learnt section.
4. KCSA QMS requirements – Prior to mobilizing to site:
Upon award of the tender, the contractor shall submit to the KCSA Construction QMS Manager the following:
4.1 QMS Onboarding File with the following information:
• Project Quality Plan
• Site Quality Control Procedure
• Construction Completion Procedure.
• Document Control Procedure
• Material Control Procedure in place. (Material receiving inspection, OSD reports, Material Certificates)
• Control of Non-Conformance Procedure.
• Copy of contract describing the Scope of Work.
• Company Organizational Chart.
• Responsibility Matrix - RACI
• Name list of management, QC Inspector/s, supervision and artisans.
• CV’s of management, QC Inspectors, supervision and artisans with certified copies of qualifications.

4.2 Mock / Sample Data Book with the following information to be reviewed by KCSA Construction QMS Manager.
• Data Book Index per discipline
• Applicable Method Statements.
• Quality Control Plans per discipline.
• Applicable checklists as per QCP’s.

4.3 Legal Compliance Data File

A Legal Compliance Data File shall be established to ensure all legal liability requirements in your scope are
met and captured as per project requirements.
The following must be included:
• Electrical COC Certificates for compliant installations.
• Pressure Test Certificates for pressure vessels.(air receivers, boilers etc.)
• Pressure Test Certificates for high pressure piping.
• LMI load test certificates.

5. KCSA QMS requirements for site establishment

5.1 Employ the following certified, competent and experienced personnel:
• Earthworks / Civil Supervisors, Structural, Mechanical, Piping, Welding Supervisors.
• Experienced Surveyor/s.
• Experienced Material Controller.
• Trained & experienced Bricklayers.
• Trained & experienced Painters.
• Experienced QC Inspectors for each construction discipline.
• Trained & experienced Document Controller.
• Welding administrator.
• Welders and coded Welders.
• NDT Technicians.
• SAIW / CSWIP Level 1 Welding Inspectors.
• Mechanical Fitters.
• Pipe Fitters, Pipe Fabricators.
• Certified HDPE Plasticians.

5.2 Offices, workshops, toilets, storage facilities, tools and plant equipment
• Ensure office staff have suitable office facilities to manage the required QMS documentation.
• To have dedicated and safe and covered working areas for welding and fabrication activities.
• To ensure all vehicles, lifting equipment, cranes, telehandlers are approved by KCSA.
• To ensure adequate number of inspected and approved mobile generators, lighting generators and water
pumps are on site.
• Controlled, dry, ventilated store rooms for welding equipment.(to be stored separately from others tools and
equipment)
• Have safe and of the correct quantity welding equipment available. (see attached Welding equipment list)
• Ensure all Inspection, Measuring Tools and Equipment (IMTE) are in good form, calibrated and calibration
frequency adhered to.
• Approved PPE for all disciplines.
 • Only approved full face flip up welding helmets shall be issued to welders and used on site.(no hand held)
• To have the required piping fabrication tools and equipment in place.
• Pipe welding shall be done in enclosed facilities (cocooning)
• Adequate design and number of pipe trestles.
• To ensure all HDPE fusion welding equipment are in good condition and calibrated.
• To ensure the correct mechanical hand tools are available for artisans.
• Have approved electrical grinders, pencil grinders and cutting machines of adequate quantity.
• No self-made spanners or tools are allowed in workshops or on site.
• Calibrated welding machines for coded welding.
• Calibrated welding electrode baking ovens.
• Calibrated welding electrode holding ovens.
• Calibrated welding electrode hot boxes.
• Adequate welding screens and welding bays.
• Controlled, dry and ventilated storage facility for welding electrodes.
• Controlled, dry and ventilated storage facility for gas cylinders.
• Approved pickling and passivation baths for stainless steel pipe spools.
• Approved storage facility for chemicals.
• Approved storage facility for NDT materials and equipment.

5.3 Responsibilities of contractors in terms Welder Qualifications and Welding Procedure Specifications:
The following is an extract from ASME BPVC Code XI Qualification of Welders:
“Each employer (contractor) is responsible for all welding done by his employees; accordingly, B31.9
requires that the contractor provide his welders with a "welding procedure specification (WPS)," which is a
"recipe" for making a weld.
• The WPS describes the base metals that may be welded, the welding process, the electrode or filler metal,
the groove design to be used, the preheat temperature and post-weld heat treatment that is required and
other welding conditions.
Contractors must qualify the welding procedures they intend to use by welding and testing test pieces
following each WPS that their welders will follow.
• Contractors must also qualify the welders that they employ by having them demonstrate that they can
produce sound welds following the Contractor’s WPS’s.
• Each qualified welder shall be issued with a Qualification ID badge to be in his / her possession at all times
whilst performing welding duties on site.” (see example below)

5.4 Welding Data File (see attached Welding Data File Index if welding is in your SOW)
• Approved Welding Procedure Specifications for the relevant welding processes in the SOW.
• Welder Qualification Records (WQR) for each Welder are in place.
• Welders shall be tested and certified according to the required ASME XI and AWS D1.1 Standards.
• Welders shall have identity cards with them at all times while on site. (see example further down)
• Have approved NDT procedures for each type of testing in place.
• Company profile and contact details of the approved 3rd party NDT company assigned to perform RT
(Radiographic Testing)
• Company profile and contact details for the AIA (Authorized Inspection Authority)

The Welder ID badge will reflect the following information:

• Recent clear photo of the welder
• Name and surname
• Employer name (contractor)
• Employee number
• Welder Stamp Number
• Welding Process/s qualified
• Date of qualification
• Expire date

5.5 Ensure attendance of the KCSA Quality Management System Induction for the following personnel:
• Management, supervisors and QC Inspectors
• Artisans for their respective construction disciplines.
• Semi-skilled workers.
 6. KCSA QMS requirements for contractors – during construction phase.
• Ensure you have the latest revision QMS documentation, drawings and procedures in place.
• Ensure effective weekly QMS reporting.(Weekly Data Book Status Tracker, QC Inspector Inspection reports)
• Have an approved skill transfer plan in place for local workers.
• Have copies of the required Project Specifications on file and have a good understanding thereof.
• To have copies of the required international codes and standards on file and have a good understanding
thereof.
• The responsibility is with the contractor to ensure conformance and compliance with the latest revisions and
editions of the applicable regulations as well as international codes and standards.
• If NDT is in your scope and done in house, only competent and certified NDT Technicians shall be
employed. (approved by KCSA)
• Load testing of lifting equipment to be done by an approved LMI.
• Pressure testing of vessels and piping to be installed by qualified and certified artisans and pressure testing
witnessed and certified by an approved 3rd party AIA.
• Contractor Supervisors, Foremen and QC Inspectors must wear identifiable Hi-Vi vests with name tags on
site. (approved by KCSA)
• Bag & Tag as well as a Flange management system to be implemented with piping installations.
• EPCM & Contractors to do monthly QMS self-audits and submit to the KCSA QMS manager on a monthly
basis.
• QC Inspectors to be empowered to stop a job not conforming. (Written authority, ID badge etc.)

7. Applicable international codes and standards

Contractors shall familiarize themselves and ensure conformance to the below international construction codes
and standards as applicable.
Code / Standard abbreviation Description
ASME BPVC Section IX Welding, Brazing, and Fusing Qualifications for welders
ASME BPVC Section V Non-destructive Examination
AWS D.1.1 Structural Welding Code for steel.
ASME VIII BPVC Section VIII Rules for Construction of Pressure Vessels Division 1
ASME B31.1 Power Piping
ASME B31.2 Fuel Gas Piping
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
ASME B31.5 Refrigeration Piping and Heat Transfer Components
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME B31.8S Managing System Integrity of Gas Pipelines
ASME B31.9 Building Services Piping
ASME B31.11 Slurry Transportation Piping Systems
API Standard 650/620 Design and Construction of Large, Welded, Low-Pressure Storage
ISO 12944:2018 Corrosion Protection Standard
SANS South African National Standards as applicable
SANS 347 Categorisation and Conformity Assessment Criteria for all Pressure Equipment
SANS10142-1 Code of Practice for the Wiring of Premises, Part 1: Low Voltage Installations

8.
The following are brief descriptions of the above Construction Codes and Standards that are relevant to
KCSA projects mentioned in brackets.
• ASME BPVC Section IX - Welding, Brazing, and Fusing Qualifications (Smelter, Kamoa 1, other areas as per SOW)
This Section contains rules relating to the qualification of welding, brazing, and fusing procedures as required by other BPVC
Sections for component manufacture. It also covers rules relating to the qualification and requalification of welders, brazers,
and welding, brazing and fusing machine operators in order that they may perform welding, brazing, or plastic fusing as
required by other BPVC Sections in the manufacture of components. Welding, brazing, and fusing data cover essential and
nonessential variables specific to the joining process used.
Careful application of this Section will help users to comply with applicable regulations within their jurisdictions, while achieving
the operational, cost and safety benefits to be gained from the many industry best-practices detailed within these volumes.
Intended for manufacturers, users, constructors, designers and others concerned with the design, fabrication, assembly,
erection, examination, inspection and testing of pressure vessels, plus all potential governing entities.
• ASME BPVC Section V – Non-destructive Examination (Smelter, Kamoa 1, other areas as per SOW)
This Section contains requirements and methods for non-destructive examination which are referenced and required by other
BPVC Sections. It also includes manufacturer's examination responsibilities, duties of authorised inspectors and requirements
for qualification of personnel, inspection and examination. Examination methods are intended to detect surface and internal
discontinuities in materials, welds, and fabricated parts and components. A glossary of related terms is included.
Careful application of this Section will help users to comply with applicable regulations within their jurisdictions, while achieving
the operational, cost and safety benefits to be gained from the many industry best-practices detailed within these volumes.
 Intended for manufacturers, users, constructors, designers and others concerned with the design, fabrication, assembly,
erection, examination, inspection and testing of pressure vessels, plus all potential governing entities.

• AWS D.1.1 Structural Welding Code for steel.

This code is widely used both internationally and locally for managing welding quality in structural steel constructions and
buildings, bridges, draglines, oil production platforms, mining headgear, shaft steelwork, earthmoving and mining equipment,
as well as power station structures.
This code contains the requirements for fabricating and erecting welded steel structures. When this code is stipulated in
contract documents, conformance with all provisions of the code shall be required.

• ASME VIII BPVC Section VIII - Rules for Construction of Pressure Vessels Division 1 (Smelter & Kamoa 1)
This Division of Section VIII provides requirements applicable to the design, fabrication, inspection, testing, and certification of
pressure vessels operating at either internal or external pressures exceeding 15 psig. Such pressure vessels may be fired or
unfired. Specific requirements apply to several classes of material used in pressure vessel construction, and also to
fabrication methods such as welding, forging and brazing. It contains mandatory and nonmandatory appendices detailing
supplementary design criteria, non-destructive examination and inspection acceptance standards. Rules pertaining to the use
of the U, UM and UV ASME Product Certification Marks are also included.
Careful application of this Section will help users to comply with applicable regulations within their jurisdictions, while achieving
the operational, cost and safety benefits to be gained from the many industry best-practices detailed within these volumes.
Intended for manufacturers, users, constructors, designers and others concerned with the design, fabrication, assembly,
erection, examination, inspection and testing of pressure vessels, plus all potential governing entities.

• ASME B31.1 - Power Piping (Smelter)

Applications: electric generation stations, industrial institutional plants, central and district heating plants, power boilers and
high temperature(exceeding 250 degrees F), high-pressure(more than 15 PSIG of water pressure, 106PSIG steam pressure)
water boilers. Code Prescription: Designing, Material selection, erection, Testing, and inspections for the piping system.

• ASME B31.2 – Fuel Gas Piping (Smelter)

Application Sectors: Gas Transmission and Distribution Piping System
Applications: Gas piping systems
Code Prescriptions: Design, Fabrication, Installation, and Testing of piping systems.

• ASME B31.3 - Process Piping (Smelter, Kamoa 1, other areas as per SOW)
Application Sectors: chemical, petroleum plants
Applications: Petroleum refineries; chemical, pharmaceutical, textile, paper, semiconductor, and cryogenic plants; and related
processing plants and terminals.
Code Prescription: Material selection, Designing, assembly, erection, Testing, and inspections for the piping system.

• ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids. (Smelter)
Application Sectors: Natural gas processing plants, refineries, stations, Ammonia plants, terminals (marine, rail, and truck).
Applications: Primary and associated auxiliary liquid petroleum and liquid anhydrous ammonia piping at pipeline terminals
(marine, rail, and truck), tank farms, pump stations, pressure reducing stations and metering stations, including scraper traps,
strainers, and proper loops; Storage and working tanks including pipe-type storage fabricated from pipe and fittings, and piping
interconnecting these facilities, Liquid petroleum and liquid anhydrous ammonia piping located on the property which has been
set aside for such piping within petroleum refinery, natural gasoline, gas processing, ammonia, and bulk plants.
Code Prescription: Material selection, Designing, assembly, erection, Testing, and inspections for the piping system.

• ASME B31.5 - Refrigeration Piping and Heat Transfer Components. (Smelter)

Application Sectors: Refrigeration Piping and Heat Transfer Components
Applications: Refrigerant inspection, heat transfer components, and secondary coolant piping for temperatures as low as -320
°F (-196 °C), whether erected on the premises or factory assembled
Code Prescription: Material selection, Designing, assembly, erection, testing, and inspections for the piping system.

• ASME B31.8 - Gas Transmission and Distribution Piping Systems. (Smelter)

Application Sectors: Gas Transportation
Applications: Pipeline Facilities used for the transportation of gas.
Code Prescription: Designing, Material selection, installation, testing, and inspections for the piping system.
• ASME B31.8S - Managing System Integrity of Gas Pipelines. (Smelter)
Applications: Pipeline Facilities used for the transportation of gas. This means all parts of physical facilities through which gas
is transported, including pipe, valves, appurtenances attached to the pipe, compressor units, metering stations, regulator
stations, delivery stations, holders, and fabricated assemblies.
The principles and processes are applicable to all pipeline systems. This Standard is specifically designed to provide the
operator (as defined in section 13) with the information necessary to develop and implement an effective integrity management
program utilizing proven industry practices and processes. The processes and approaches within this Standard are applicable
to the entire pipeline system.
Code Prescription: Designing, material selection, installation, testing, and inspections for the piping system.
• ASME B31.9 - Building Services Piping. (Smelter, Kamoa 1, other areas as per SOW)
Application Sectors: industrial, institutional, commercial, and public buildings, and multi-unit residences.
Applications: Pipeline facilities used in the industrial, institutional, commercial, and public buildings, and multi-unit residences,
which does not require a range of sizes, pressures, and temperatures covered in ASME B31.1.
Code Prescription: Designing, Material Selection, installation, testing, and inspections for the piping system.

• ASME B31.11 - Slurry Transportation Piping Systems. (Smelter, Kamoa 1, other areas as per SOW)
Application Sectors: Plants and terminals, pumping and regulating stations which transport Slurry.
Applications: Piping transporting aqueous slurries of non-hazardous materials, such as coal, mineral ores, concentrates, and
other solid materials.
Code Prescription: Designing, Material Selection, installation, testing, and inspections for the piping system.

• API Standard 650/620 - Construction of Large, Welded, Low-Pressure Storage Tanks (Smelter & Kamoa 1)
This standard establishes minimum requirements for material, design, fabrication, erection, and inspection for vertical,
cylindrical, aboveground, closed- and open-top, welded storage tanks in various sizes and
The design rules given in this Standard is minimum requirements. More stringent design rules specified by the Purchaser or
furnished by the Manufacturer are acceptable when mutually agreed upon by the Purchaser and the Manufacturer.

• ISO 12944:2018 - Corrosion Protection Standard (All KCSA areas)

ISO 12944 is a globally recognised standard that lays out the rules and guidelines for the protection of assets from corrosion
by use of coating systems and paint. The standard covers paint and coatings for steel structures in atmospheric, immersed,
and buried environments. It does not cover coatings for concrete, non-metallic substrates, high-temperature surfaces,
chemical immersion, and other uses.

• SANS 1200 - South African National Standards for all earthworks and civil works.

9. QMS conformance at the closing out stage of the project

Applicable regulations as listed but not limited to the table below.
Regulation Description
Occupational Health and Safety Act 85 of 1993 of the Republic
Pressure Equipment Regulations (PER)
of South Africa.
Mines Health and Safety Act 1996 (Act No. 29 of 1996) of the Protection of the health and safety of employees and other
Republic of South Africa. persons at mines
“Categorisation and Conformity Assessment Criteria for all
SANS 347
Pressure Equipment”.
Code of Practice for the Wiring of Premises, Part 1: Low
SANS10142-1
Voltage Installations

The contractor shall ensure that all the Data Books for his SOW shall be at 100 percent completed status with all of the
following points below in place:
• The intervention points in the approved Quality Control Plan/s shall be signed of and the referenced documentation
attached.
• Required construction and installation checklists completed and signed off as referenced by the approved QCP.
• NDT requirements fulfilled as per project specifications, regulations as well as international codes and standards.
• The required NDT documentation shall be included in the respective Data File/s.
• Pressure testing requirements as per project specifications and regulations fulfilled with traceable documentation.
• Load testing requirements fulfilled and certified by an approved LMI with traceable documentation.
• The “Legal Register” file shall be up to date and handed over to the client.
• All Technical Query Notes are closed out to the satisfaction of the Engineer.
• All Concession Requests are closed out to the satisfaction of the Project Manager.
• Redlined drawings completed and forwarded to the design Engineer to issue “As Built” drawings.
• Ensure all weld maps are captured, detailed and traceable to the welder stamp number.
• Ensure “As Built” drawings are received back from the design Engineer and filed in the Data Book.
• All Non-Conformance Reports are closed out and corrective and preventative actions applied.
• Lessons Learnt from the project captured and forwarded to the Project Manager.
• Ensure the Data Book is approved by the client QMS Manager.
• The required electronic copies are made and handed over together with the approved Data Book.
• Ensure all OEM manuals are handed over to the KCSA Document Controller.
• Ensure effective and on time handover of Data Books to the KCSA QMS department.

End of procedure.