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Quality Assurance and Quality Control

Requirements

Approved: NAME _____________________

(Project Manager) Signature

Approved: NAME _____________________

(Head of department) Signature

Approved: NAME _____________________

(Client) Signature

Date Issued: 22 October 2009

Configuration Management
Document Number: DRAMS-QA-PR-200 Date issued : 22 October 2009
Author: A.Hill Status: Issued
Quality Assurance and Quality
File Name: Revision: 0
Control Requirements

TABLE OF CONTENTS
TABLE OF CONTENTS.................................................................................................................................2
1. REVISION RECORD SHEET.........................................................................................................3
2. PURPOSE..........................................................................................................................................4
3. REFERENCES..................................................................................................................................4
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4. DEFINITIONS...................................................................................................................................4
5. QUALITY MANAGEMENT SYSTEM..........................................................................................5
6. SUPPLIER / CONTRACTOR SELECTION.................................................................................5
6.1 PRE-AWARD ASSESSMENT..............................................................................................5
6.2 SUPPLIER / CONTRACTOR QUALITY PLANS..................................................................5
6.3 DOCUMENT SUBMISSIONS...............................................................................................5
7. SUPPLIER / CONTRACTOR QUALITY ASSURANCE............................................................5
7.1 GENERAL REQUIREMENTS..............................................................................................6
7.2 CRITICALITY RATINGS.......................................................................................................6
7.2.1 Critical...................................................................................................................................6
7.2.2 Major.....................................................................................................................................6
7.2.3 All Other................................................................................................................................6
8. SUPPLIER / CONTRACTOR SURVEILLANCE.........................................................................6
9. NON CONFORMANCE...................................................................................................................7
10. CONCESSION REQUESTS............................................................................................................8
11. FINAL INSPECTION RELEASE...................................................................................................8
11.1 FINAL INSPECTION............................................................................................................8
12. QUALITY DATA BOOK (REFER TO THE CONTRACT REQUIREMENTS)......................8
12.1 FRONT SHEET....................................................................................................................9
12.2 SPINE MARKINGS...............................................................................................................9
12.3 OPERATING AND MAINTENANCE MANUALS (MECHANICAL EQUIPMENT).................9
13. CHANGE REQUEST CONTROL..................................................................................................9
13.1 CHANGES WITH CONTRACTUAL IMPLICATIONS.........................................................10
13.2 COMMUNICATION OF CHANGE REQUEST...................................................................10
14. QUALITY SPECIFICATIONS.....................................................................................................10
14.1 GENERAL..........................................................................................................................10
14.2 SHOP DETAILING.............................................................................................................10
14.3 WELDING...........................................................................................................................10
14.4 CORROSION PROTECTION.............................................................................................10
14.4.1 Fabrication / Steelwork / Plate work / Piping......................................................................10
14.4.2 Mechanical/Electrical Equipment (Capital).........................................................................11
14.5 HOT DIP GALVANISING...................................................................................................11
14.6 RUBBER LINING AND OTHER LININGS..........................................................................11
14.7 INSPECTIONS...................................................................................................................11
15. QUALITY RECORDS....................................................................................................................11
16. DOCUMENTATION AND RECORDS Retention......................................................................11

Document Number: DRAMS-QA-PR-200 Page 2 of 12

File Name: Quality Assurance and Quality Control Requirements
Revision and Issue Date: Rev 0 – 22.10.2010
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1. REVISION RECORD SHEET

Page Revision Description Date

Document Number: DRAMS-QA-PR-200 Page 3 of 12

File Name: Quality Assurance and Quality Control Requirements
Revision and Issue Date: Rev 0 – 22.10.2010
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2. PURPOSE
This document is intended to instruct the Supplier / Contractor as to the minimum
Quality Assurance and Control requirements for the supply of goods and / or
services in terms of the contract placed on them, and to ensure that the
communication between the Supplier / Contractor and DRA is clearly defined.

3. REFERENCES
The following latest editions shall apply:
 ISO 9001:2008: Quality Management Systems Requirements
 ISO 9000:2005: Quality Management Systems – Fundamentals and
Vocabulary
 The DRA Contract / Order
 DRAMS-QA-PR-300 Non Conformance Procedure
 DRAMS-QA-PR-400 Concession Request Procedure
The Suppliers / Contractors are required to request specific documentation which
may be required from DRA. This is not limited to the documentation listed in this
document.

4. DEFINITIONS

DRA DRA Mineral Projects (Pty) Ltd

Client All references to Purchaser, or Employer.
Critical Equipment See 7.2.1
Major Equipment See 7.2.2.
Quality The Quality Management System will include all of the
Management activities as defined in the Scope of Work.
System The system shall be maintained during the supply period
and any guarantee period as stipulated in the Scope of
Work.
The Supplier / Contractors’ quality system will be based
on ISO 9001:2008. Alternative models may be
considered for approval by the Project Quality Manager
and / or the Client.
Quality Control A document setting out the specific practices, resources
Plan and sequences of activities required to ensure that a
particular product, component or piece of equipment
achieves its specification
Data Books A Data Book of records, capable of demonstrating the
(Quality Dossiers) achievement of quality, shall be prepared by the Supplier

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/ Contractor.

5. QUALITY MANAGEMENT SYSTEM

Project Quality Management shall be implemented based on the requirements of
ISO 9001:2008, the DRA Project Quality Plan – DRAMS-QA-PR-100 and Quality
Control Plans supplied by Suppliers / Contractors.

6. SUPPLIER / CONTRACTOR SELECTION

6.1 PRE-AWARD ASSESSMENT

Suppliers / Contractors may be subject to assessment to evaluate their capability

and capacity to perform the work package in relation to quality, technical
requirements and time schedules and any other project specific criteria identified
by the Engineer or Client. Assessment may be based on historical performance.

6.2 SUPPLIER / CONTRACTOR QUALITY PLANS

Suppliers / Contractors of critical and major equipment will be required to

produce a detailed Quality Plan that defines their quality actions during
manufacture and installation.
These plans will specify or refer to the essential technical, quality and contractual
requirements of the Supplier’s / Contractor’s scope of work. They will include the
activities and processes as well as the key controls necessary to ensure that
contract requirements are achieved.
Key controls will include test and inspection documents as well as Client
Intervention, Hold, Witness and Surveillance points clearly indicated on the
Supplier’s / Contractor’s detailed Quality Plan. This must be approved by the
Responsible Engineer.
Suppliers / Contractors shall be required to attend a contract kick off meeting
after the award of the contract, but prior to manufacture.
See DRAMS-QA-FO-010 for the QCP Check List

6.3 DOCUMENT SUBMISSIONS

All relevant quality documents shall be submitted, where applicable, as

‘Packages’ (Dossiers).
Following a DRA review of these documents together with drawings and
calculations, the Quality Plan will be submitted to the Client for review, should
this be required.

7. SUPPLIER / CONTRACTOR QUALITY ASSURANCE

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The Project Manager / Engineer will prepare the “Critical” and “Major” equipment
schedule.

7.1 GENERAL REQUIREMENTS

The Project Engineer in conjunction with the Project Manager is responsible for
the control and monitoring of all Supplier / Contractors.
Quality Control (QC) on specific packages will be the responsibility of the
Package Engineer, with the assistance of a quality inspector, where required.
Supplier / Contractors will be required to demonstrate compliance to the relevant
parts of ISO 9001:2008.

7.2 CRITICALITY RATINGS

Ratings, critical, major and other, as below, are defined to allow / enable
inspectors and / or expeditors to understand the importance of that piece of
equipment.
7.2.1 Critical
A component or permanent assembly is critical if;
 Its failure is likely to result in hazardous or unsafe conditions for individuals
using, maintaining or depending upon the equipment or structure of which it
is a part: and / or
 If the failure of which is likely to significantly affect the performance of
important equipment or the structure of which it is part: and / or
 If it requires 24 hours or more to replace, assuming immediate availability of
spares.
7.2.2 Major
A component or permanent assembly is major, if the failure thereof is likely to
materially reduce the ability to use the equipment or structure of which it is a part.
7.2.3 All Other
Equipment termed “minor” i.e. not affecting human safety, not likely to have an
influence on the functioning of the product shall be controlled via the Quality
Control System.
In the event of disagreement between the Engineer and the Supplier / Contractor,
the DRA Project Engineer’s decision on classification of parts and sub-
assemblies shall be final.
Criticality must be specified on the relevant QCPs

8. SUPPLIER / CONTRACTOR SURVEILLANCE

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Surveillance will be carried out by DRA discipline Engineers, Quality

Representative or specialist QC Consultants and will primarily ensure adherence
to the Approved Quality Plan and Client specifications.
Surveillance will ensure and monitor that:
 All activities including inspection and testing during manufacture and
assembly are being conducted in accordance with documented procedures,
instructions and the sub-Supplier / Contractors approved Quality Plan.
 Records of these activities have been generated where applicable.
 The specified and approved manufacturing procedures have been adhered
to.
 The product is acceptable at that status of manufacture or assembly.
 All inspection measuring and test equipment utilised is calibrated where
practicable.
 In the event of a non-conformance, corrective action procedures are
adhered to.
 Surveillance reports will be issued for all Visits and Inspections for
Mechanical equipment, and Steelwork.
 Detailed Inspection Reports will be generated for all QCP intervention
points.
 Detailed Dimensional Reports as required
 Compliance and adherence with approved certified drawings.

9. NON CONFORMANCE
A Non Conformance Report (NCR) - DRAMS-QA-FO-006 - may be issued during
the course of fabrication or manufacture, where the Supplier / Contractor fail to
meet the agreed specification due to (but not limited to) any of the following
causes:
 Any finished dimension outside tolerance.
 Mechanical properties outside specification.
 Identification or traceability is lost.
 Non destructive examination has revealed indications outside specification.
 The non-conformance affects safety, performance, maintainability, life or
interchange ability of the unit.
 Failure of the Supplier / Contractor’s quality system has occurred.
The DRA QC Inspector shall raise a non-conformance report on the Supplier /
Contractor.

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Non conformance reports will be registered and recorded by the DRA Project
Lead Quality Representative and issued to the DRA Discipline / Package
Engineer for his action. Copies of all “Closed Out” non-conformance reports shall
be included in the data book.
DRA will not be required to accept the non conforming materials or condition/s
involved unless rectified to the satisfaction of the Discipline / Package Engineer.
All costs incurred in rectifying \ the non-conformance to specification, shall be for
the Supplier / Contractor’s account.
Refer to DRAMS-QA-PR-300 Non-Conformance Procedure.

10. CONCESSION REQUESTS

Should the Supplier / Contractor become aware of a condition or situation, during
the execution of his Contract, which may materially or financially affect the
agreed contractual specification contained in the Contract, he shall apply to DRA
for a concession to use alternative means or materials to fulfil his Contract. The
concession request document is the medium to be used for this process.
DRA will not accept any non-conforming critical or major items of equipment
unless formally accepted by the relevant Engineer.
Concession requests must be submitted to the DRA Discipline / Package
Engineer for approval prior to the acceptance of any rework if any defects or
deviations from the agreed specification.

11. FINAL INSPECTION RELEASE

All “major” and “critical” items of equipment and fabrication will be subjected to a
final inspection prior to dispatch from the works. No despatch of such equipment
or fabricated items will be permitted or accepted at site unless the appointed
DRA Responsible Engineer or his Designated Representative has issued a
written final acceptance and release note, a copy of which shall be attached to
the Supplier / Contractor’s delivery documentation.
Notification of such an inspection, the time and venue, will be communicated to
the appointed Client’s representative should involvement be stipulated/required.

11.1 FINAL INSPECTION

The final inspection will include, but not be limited to:

 Checking of conformance to order details i.e. equipment tag number, paint
colour and thickness, guarding, motor voltage, drive alignment, tightness of
assembly bolts;

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 Ensuring that the correct revision of drawings have been used for
Manufacture / Fabrication
 Dimensional checks to approved drawings
 Witness of trial running, if possible, and recording of free running
clearances, motor power draw, bearing temperatures, etc.;
 Final shipping release documentation checked for correctness and delivery
address;
 Confirmation of Completion of the Data Dossier.
 Status of Operating and Maintenance Manuals.
 Packing Requirements as stated in the contract.

12. QUALITY DATA BOOK (REFER TO THE CONTRACT

REQUIREMENTS)
A Data Book will be compiled for all “critical” and “major” items of equipment.
The generation and supply of the data dossier will form part of the contract. The
content of the dossier shall be according to the approved content index (DRAMS-
QA-FO-008).
The Data Book contents shall be contained within hard back folders and each
Data Book shall be identified as follows:

12.1 FRONT SHEET

The front sheet shall contain the following:

 Equipment Description
 Manufacturer
 Manufacturer’s Reference Number
 Client
 Contract Number
 Project Description
 Item Number
 Inspection Authority Reference Number (If applicable)
 Compiler
 Checker and Approver.

12.2 SPINE MARKINGS

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 Manufacturer
 Project
 Project Number
 Description
 Client
 Equipment number/s

12.3 OPERATING AND MAINTENANCE MANUALS (MECHANICAL EQUIPMENT)

Suppliers of Proprietary Equipment shall ensure they provide the necessary

Operational and Maintenance Manuals for the equipment they supply.
Refer to the Contract Requirements for quantities required.

13. CHANGE REQUEST CONTROL

Any change requests made to Supplier / Contractors must be approved by the
Discipline / Package Engineer or Construction Manager, documented and
communicated to all parties who will be affected by the change.
Changes must be done in accordance with the DRA Change Management
Procedure DRAMS-PM-PR-400.

13.1 CHANGES WITH CONTRACTUAL IMPLICATIONS

Changes that have contractual and / or financial implications must be

communicated in writing or by means of an order amendment, as described and
within the time provided for in the Contract.

13.2 COMMUNICATION OF CHANGE REQUEST

Changes made that could affect the design and / or other disciplines involved in
the project. It is therefore imperative that they be rapidly communicated to the
Project Manager / Engineer and others concerned to ensure timeous inclusion of
the details, thereby minimizing the time and cost impact on the project.

14. QUALITY SPECIFICATIONS

It is the Supplier / Contractors responsibility to ensure that they conform to
documents required to fulfil the DRA Contract / Order specific requirements.

14.1 GENERAL

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All fabrication of components and structures, as well as proprietary equipment, is

controlled by DRA in accordance with the contractual specifications and
Approved Drawings (Supplier / Contractors to request these, when necessary).

14.2 SHOP DETAILING

Refer to DRAMS-DO-PR-400 – Procedure for Shop Detailing of Structural Steel.

Interfaces will be approved by DRA prior to commencement of fabrication as
directed by the DRA Project Engineer.

14.3 WELDING

Sub-Suppliers / Contractors / fabricators must submit welding procedure

specifications to the DRA Discipline / Package Engineer for acceptance prior to
welding. A summary of Welders and Procedure Qualification Records to be
utilized shall also be submitted.
All welders employed on this contract will be qualified in accordance with the
relevant approved welding specifications (codes). The qualification shall be
current / valid according to the qualification specification and each welding
process.

14.4 CORROSION PROTECTION

14.4.1 Fabrication / Steelwork / Plate work / Piping

Corrosion Protection shall be performed in accordance with the Contract / Order
requirements. This to be requested / confirmed from the Discipline / Package
Engineer.
Ensure correct colours are used.
14.4.2 Mechanical/Electrical Equipment (Capital)
Corrosion Protection of Capital Equipment shall be in accordance with the
Equipment Supplier / Contractors Painting System, unless otherwise stated /
requested. (Ensure correct colours are used)

14.5 HOT DIP GALVANISING

Hot dip galvanising shall be performed in accordance with DRA Procedure:

DRAMS-MEC-SPEC-400 – Hot Dip Galvanising Procedure.

14.6 RUBBER LINING AND OTHER LININGS

Rubber lining shall be performed in accordance with DRA Procedure: DRAMS-

MEC-SPEC-300 – Rubber Lining Procedure.
Other linings such as Steel linings and Ceramics shall be in accordance with the
Contract / Drawing / Specification requirements.

14.7 INSPECTIONS

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Refer to DRAMS-QA-FO-007 QCP for Fabrication of Steelwork, Plate work and

Lining which formulates inspection and hold points. This is a generic Quality
Plan and is intended for guidance to Supplier / Contractors (for reference only).
In the event of incompatibility, ambiguity or lack of information in specifications,
drawings or other documentation during manufacture, the DRA Engineer
responsible will impose a ruling, which shall be final on the interpretation and
requirements.
All structural components shall be identified in accordance with the shop detailing
numbering system. All plate work items will be identified according to the
corresponding numbers as stated on fabrication drawings. The minimum shall be
hard marking/stamping or etching/labelling.

15. QUALITY RECORDS

An index of quality record requirements as shown in DRAMS-QA-FO-008.

16. DOCUMENTATION AND RECORDS RETENTION

Retained By Minimum
No. Document/Record Document Number
/ At Retention
Fabrication of Steelwork, DRAMS-QA-FO-007 Quality Dept 3 Years
1 Platework and Lining (Generic
Quality Plan)
2 Quality Dossier Index DRAMS-QA-FO-008 Quality Dept 3 Years
Operating and Maintenance DRAMS-QA-FO-009 Quality Dept 3 Years
3
Manual Index
4 QCP Check List DRAMS-QA-FO-010 Quality Dept 3 Years
Contractors’ Certificate of DRAMS-QA-FO-011 Quality Dept 3 Years
5
Compliance
DRAMS-MEC-SPEC- Piping 3 Years
6 Piping Specification
100
Specification for Erection and In progress Mechanical 3 Years
7
Installation of SMP Equipment
Minutes and Reports DRAMS-QA-FO-001 Quality Dept 3 Years
8
DRAMS-QA-FO-003

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