RECORD OF CHANGE Rev.
TABLE OF CONTENT
1.0 INTRODUCTION 5
1.1 Description 5
1.2 Purpose 5
1.3 Scope 5
2.0 PROJECT ORGANIZATION AND RESPONSIBILITIES 5
3.0 PROJECT QUALITY MANAGEMENT SYSTEM (QMS) 6
3.1 Project QMS Documentation Hierarchy 6
3.2 Control of Documents 6
3.3 Control of Records 7
3.4 Identification and Traceability 7
3.5 Customer Property 7
3.6 Preservations of Product 7
3.7 Control of Non Conformance Product 8
3.8 Change Control 8
3.9 Training and Competency 8
4.0 PLANNING & CONTROL OF ENGINEERING, PROCUREMENT,
CONSTRUCTION AND COMMISSIONING (EPCC) 9
4.1 Planning of EPCC 9
4.2 Project Control 9
5.0 CONSTRUCTION 9
6.0 COMMISSIONING 10
7.0 INTERFACE WITH CLIENT AND SUBCONTRACTORS 10
8.0 INSPECTION AND TESTING 10
8.1 Inspection and Testing Programs 10
8.3 Inspection and Test Status ` 11
9.0 MEASUREMENT, ANALYSIS AND IMPROVEMENT 12
9.1 General 12
9.2 Customer satisfaction 12
9.3 Internal Audit 12
9.4 Measurement and Monitoring Processes 13 9.5 Measurement and Monitoring Project Deliverables & Performance 13 9.6 Control of Non Conformance Product 13
9.7 Analysis of Data 13
9.8 Continual Improvement 14
9.9 Corrective Action 14
9.10 Preventive Action 14
10.0 APPENDIX 15
1.0 INTRODUCTION 1.1 Description
This document describes the quality management (QM) principles, techniques and requirements to be applied during the execution of Protank projects.
1.2 Purpose
To define the Quality Management System Pre-Fabrication, Construction and Commissioning of the Protank projects
To ensure that quality objectives are achieved at all levels within the PROJECT.
To ensure that the application of Quality Management is standardized in Protank projects.
1.3 Scope
This Project Quality Plan (PQP) has been developed in accordance with Corporate Quality Management System and to the project’s expectations. As the project progresses, this PQP will be revised as and when necessary to maintain compliance with those requirements.
This PQP applies to all project materials, equipment, engineering, construction, commissioning and services incorporated into, performed on or that are directly applicable to the permanent works as defined in the CONTRACT, where PROTANK is having authority, responsibility and accountability of the affected WORKS. The quality requirements defined by the CONTRACT and within this document are to be applied by all, including SUBCONTRACTORS.
2.0 PROJECT ORGANIZATION AND RESPONSIBILITIES
2.1 The Project Management Organization Chart is depicted in Appendix 1.
2.2 Vice President Project Division (Managing Director of Protank Gas) which is responsible report to CEO having activities, responsibilities and authorities of :
2.2.1 To establish system and method for the activities of : Project Planning and Control
Quality Assurance
Safety Management System
Project Material Control Management Human Resources Development Management Information System
2.2.2 To recruit, maintain and develop all employee skill & knowledge.
2.2.3 To Assign functional responsibilities of the respective discipline Listed in 2.2.1 to support project activities.
2.3 Head of Project Management report to the Managing Director and having activities, responsibilities and authorities of :
2.3.1 To manage all project construction type and site fabrication.
2.3.2 To establish production plan yearly and expected production plan for at least 3 (three) years in advance for construction and fabrication activities.
2.3.3 To establish, maintain and improve construction productivity standard for each category of work.
2.3.4 To establish strategy to improve performance capability to achieve Company Targets in sales, productivity, and profitability and to meet Client Expectations in quality, safety and delivery/schedule that to be supported by RSD.
2.2 The overall quality of a completed project is achieved by team effort. Every individual is responsible for the quality of his/her work. Each project member must ensure that the input provided (data) is adequate, the work is completed in accordance with project quality management system documentation, and the completed work (output) is checked/verified before passing on to Client/Customer.
2.3 The Head of Project Management has overall responsibility for quality assurance (QA) and its implemented stage of the all project. He is in-charge of the operations for overall project and reports to Managing Director.
2.4 The Project Manager has responsibility to see that the quality related requirements are adhered to and that competent resources are available, in time and to assist in achieving delivery project. They are in the best position to do so since their management role oversees the whole job and all the technical work and allows co-ordination of the different quality requirements and reports to Head Project Management and Managing Director.
2.5 A Project Quality Coordinator shall be appointed to be responsible for establishing, monitoring and maintaining up-to-date the Project Quality Management System. The Project Quality Coordinator shall be responsible for all Quality Assurance activities for all phases of the project and for all sites. The Project Quality Coordinator shall be supported by an adequately trained and resourced Quality Assurance and Inspector.
2.6 The PROJECT specific responsibilities of key personnel shall be in accordance with the contract requirements. Job Description of each key personnel can be referred to Individual Job Descriptions
2.7 A Quality Control Inspector(s) shall be appointed to control the total scope of inspection activities for the CONTRACT. Adequately trained Quality Control Staff shall support the Quality Control Inspector(s).
3.0 PROJECT QUALITY MANAGEMENT SYSTEM (QMS).
PROTANK shall also ensure that all SUBCONTRACTORS (including Suppliers) engaged for this CONTRACT will operate a Quality Management System that complies with the requirements of ISO 9001: 2000 or equivalent and applicable to the scope of their WORK.
SUBCONTRACTOR’s Project Quality Plan shall include set Quality Management Objectives, policies and procedures to demonstrate compliance with the CONTRACT.
3.1 PROJECT QMS Documentation Hierarchy.
The PROJECT Documentation Hierarchy for this PROJECT as follows:
Level Project Documents Reference Document
I Manual, Policy, Plan
Corporate Quality Manual, Corporate Quality Policy and TNB Quality Policy
II Procedures As per Master Document Register III Working Instruction, Work Method
Statement, Engineering Calculations, etc
As per Master Document Register and Drawing List
IV Forms, Reports. As per Master Document Register
3.2 Control of Documents
All documents, internal and external origin, which are related to the implementation of this PROJECT shall be properly controlled by respective disciplines or/and site office. The details are specified in Document Control Procedure to define the following controls:
Approval of documents for adequacy prior to issue; The review, revision and re-approval of documents; Identification of the current revision status of documents;
Ensuring that documents remain legible, readily identifiable and retrievable; Ensuring that documents of external origin are identified and their distribution
controlled; and
Prevention of intended use of obsolete documents, and to apply suitable identification to them if they are retained for any purpose.
3.3 Control of Records
All records that are required for the QMS are controlled by the Control of Records Procedure. Records are maintained to provide evidence of conformance to requirement and of effective operation of this PQP. The procedure shall address the identification, storage, retrieval, protection, retention time and disposition of records.
3.4 Identification and Traceability
In order to prevent the misuse or misapplication and to maintain identity of purchased material and completed product, PROTANK shall establish a system to ensure product identification and traceability throughout the duration of service to customer.
Traceability of products is possible through the following:
Service/Project Code and Name Document Numbering
Equipment/ Material Part Number, Batch Number, etc.
Purchased products are stored at designated yard/s or in identified containers, shelves and racks in the store. The nonconforming products during stages of incoming, in-process and final inspection shall be identified through relevant markings to ensure easy segregation.
During project execution, the nonconforming item shall be identified for possible repair or rectification.
3.5 Customer Property
PROTANK will exercise appropriate care with customer property while it is under the organization’s control or being used by PROTANK. Customer property is identified, verified, protected and if any customer property is lost, damaged or otherwise found to be unsuitable for use, this be reported to the customer and records maintained (see 4.3).
Customer property may also be an intellectual property such as product design and technical drawing which are provided by the customer to PROTANK to use for project execution.
3.6 Preservation of Product
PROTANK shall preserve the conformity of product during internal processing and delivery to the intended destination. This preservation shall include identification, handling, packaging, storage and protection. Preservation shall also apply to the constituent parts of a product.
3.7 Control of Monitoring and Measuring Device
All measuring devices that require accuracy, precision and that will affect the quality of the final product shall be calibrated or/and verified at defined interval. The Quality Control Inspector shall coordinate the activity on identification equipment for calibration.
PROTANK and its SUBCONTRACTOR shall establish and maintain a system to ensure sound control of measuring and monitoring devices. This would include the establishing of a documented procedure to control the usage and the calibration of such devices. The procedure could be developed by PROTANK or/and by its SUBCONTRACTORS/suppliers of the manufacturer of the device themselves.
All calibrated equipment shall be handled and stored appropriately to ensure that they are not damaged and adjusted in order to maintain their accuracy and precision.
3.8 Change Control
Any technical changes that will affect the quality, cost and schedule of the PROJECT shall be reported and controlled in accordance with PROTANK’s Corporate Change Control Procedure, MGM-PR-002.
SUBCONTRACTOR’s shall manage such change in accordance to their internal procedure. The changes shall not be implemented without PROTANK’s and CLIENT’s approval.
3.9 Training and Competency
PROTANK and it’s SUBCONTRACTORS will indoctrinate and familiarize their personnel within their respective organization in the requirements of this Quality Plan and applicable implementing procedures. A training plan shall be developed to ensure the following where applicable:
a) Project Manager uses this Quality Plan as an aid understanding how it will fulfill the Quality requirements of the PROJECT.
b) Emphasis shall be placed on the identification of actual or potential Quality problems and the initiation of preventive or remedial measures.
c) Training requirements shall be established to all personnel that are to be employed for this PROJECT and the training requirements such as fire fighting, specialist skills training, internal management and coordination, etc.
d) Quality awareness activities shall be performed regularly to improve the quality awareness of the personnel involved with the PROJECT.
e) To identify key personnel for critical processes, such painting and blasting for certification by CLIENT or third party.
4.0 PLANNING AND CONTROL OF ENGINEERING, PROCUREMENT, CONSTRUCTION & COMMISSIONING.
4.1 Planning of EPCC
4.1.1 PROTANK shall plan and develop the processes needed for EPCC realization to ensure all deliverables from project execution are consistent with Client requirements.
Quality objectives and requirements for the Project
The need to establish processes, documents, and provide resources specific to the Project.
The required verification, validation monitoring, inspection and test activities specific to the product and criteria for acceptance as per approved ITP.
Any records necessary to provide confidence of conformity of the processes and resulting product.
Determination of application related requirement if not provided by Client Determination of relevant standards or regulatory requirement if any.
4.2 Project Control
4.2.1 The project execution shall be monitored against planned budget, schedule and quality requirement. The SUBCONTRACTOR performances shall be monitored and measured during daily/weekly meeting and progress meeting with Client
4.2.2 Each SUBCONTRACTOR shall have their own planning and control personnel to measure their performance and report to PROTANK and CLIENT. PROTANK’s Project Control Manager shall have overall responsibility to monitor and verify SUBCONTRACTOR’s performance, as well as the performance of PROTANK. Project Master Schedule shall be updated and communicated with Client during Progress Meeting.
5.0 CONSTRUCTION.
PROTANK and it’s SUBCONTRACTORS shall prepare procedures for the CLIENT’s review and approval to cover pre-fabrication, construction and installation, pre-commissioning, commissioning and start up of the facility. During the development of the procedures the following shall be addressed:
a) Performing constructability reviews during detailed design and procedure development b) Providing input to the overall Project Master Schedule(s).
c) Defining field required dates for materials and equipment and ensuring appropriate priorities are assigned to critical items such that the Project Master Schedule is maintained.
d) Establishing efficient and safe working procedures, including the methodology for the transportation and erection of plates:
Receiving product on site and segregating products awaiting for inspection and making all necessary arrangements for storage and preservation.
Performing and documenting receiving inspection, activities, including the prompt reporting of non conforming product.
Consideration and proposal of methodology or techniques or to modify or deviate from the contract that would the schedule, efficiency, safety, maintainability, or operability of the facility
Develop a training or indoctrination plan to ensure that personnel are familiarized with the quality requirements of the contract.
Criteria for inspection and acceptance of safety or quality critical equipment.
6.0 COMMISSIONING
PROTANK shall provide a system for verifying that installation and erection activities are conducted in accordance with the requirements of the contract. Mechanical completion activities shall be performer and acceptance criteria are me and to verify the satisfactory completion of systems in preparation for pre-commissioning
Pre-commissioning and commissioning activities include all forms of static, dynamic, and performance testing. The effective implementation of pre-commissioning and commissioning activities serve to confirm the Quality of Design, manufacture, fabrication, and construction by demonstrating that functional and performance requirement have been met.
7.0 INTERFACE WITH CLIENT AND SUBCONTRACTORS.
PROTANK is committed to provide an effective customer communication program with CLIENT and its SUBCONTRACTORS in this PROJECT. The type of the communication identified applicable for the execution of this PROJECT can be categorized into:
Daily verbal communication e.g. meetings and discussion Interchange of correspondence e.g. transmittals, letters, etc.
Issuance of reports on progress or other PROJECT highlights e.g. Monthly Report.
8.0 INSPECTION AND TESTING 8.1 Inspection and Testing Programs
Inspection and test plans and quality control plans shall be developed by PROTANK and its SUBCONTRACTORS and Vendors to ensure that all stages of the WORKS are subjected to the minimum inspection and test requirement a as detailed in the CONTRACT standards and specifications. Methods of inspection and testing shall be clearly defined in applicable inspection and test procedures in order to ensure the following is provided:
A description of the activity taking place
A description of the process activity to be controlled Quality characteristic to be verify
Criteria for acceptable
Applicable control procedures to be applied
Responsibilities for the inspection, testing and verification activities
Verifying documents or quality records produced to confirm compliances with acceptances criteria
Identification of activities subject to audit by client.
Inspection are performed by authorized and competent personnel
8.2 Inspection, Measuring and Test Equipment
Procedures for control of inspection, measuring and test equipment shall be implemented to ensure the following:
All items of inspection, measuring and test equipment shall be of the correct type, grade and capacity for their intended purpose
Where necessary, training shall be given in the correct use of inspection measuring and test equipment and method of calibration such that the test equipment is operated by competent personnel.
All items of inspection measuring and test equipment are identified by serial number, tag number, internal plant number or other suitable means of identification. All items of inspection measuring and test equipment are maintained in accordance
with PROTANK and its SUBCONTRACTORS approved calibration schedules and procedure or manufacturer’s recommendations.
Current and valid calibration certificates are available for all items of Inspection, measuring and test equipment.
A register of all calibrated items indicating their calibration validity and due date shall be maintained.
Procedures shall be put in place of identified any withdraw any item of inspection, measuring and test equipment that is not calibrated or shows signs of damage or deterioration that may affect verification of quality characteristic, including methods of identification and retest of work if applicable.
Where in house calibration procedures are used, references standards shall be clearly traceable to national or international standards.
Responsibility for calibration maintenance and preservation of inspection, measuring and test equipment.
8.3 Inspection and Test Status
The inspection and test status of all work during all stages of the project shall be known and PROTANK and SUBCONTRACTORS shall ensure that adequate control procedures and inspection and test plans are put in place to ensure the following:
Inspection and test logs are maintained detailing the dates of production, inspection and test method, test status, name or identity of the inspector and verification records such as NDT Report, Pressure Test Report etc.
9.0 MEASUREMENT, ANALYSIS AND IMPROVEMENT 9.1 General
Measurement data are important for making fact-based decisions. The Management Representative ensures effective and efficient measurement collection and validation of data to ensure PROTANK's performance and the satisfaction of its customers.
PROTANK shall plan and implement the monitoring, measurement, analysis and improvement processes needed:
To demonstrate conformity of the product;
To ensure conformity of the quality management system, and
To continually improve the effectiveness of the quality management system.
9.2. Customer Satisfaction
PROTANK shall establish a system to measure the extent of customer satisfaction and also the effectiveness of the QMS to meet the customer requirement.
The Business Development Division shall be responsible to identify a suitable system and conduct the customer’s satisfaction at appropriate interval (such as every 2 years, etc). Data obtained shall be analyzed to measure the extent of customer satisfaction and also identified areas for improvements. The results of this review will be included as input during management review meeting.
9.3 Internal Audit
Project Management Team is committed to ensure that the QMS is in compliance to the designated business processes, documented procedures and to the ISO 9001:2000 requirements and the system is effectively being implemented and maintained. The Procedure, PT-PR-QA-004 is written to accomplish this objective, PROTANK’s Corporate Quality Manager is given the responsibility for planning, conducting and maintaining Quality Audit Program as per procedure. Internal audit is to be conducted in accordance with Audit Schedule to:
Conforms to the planned arrangements to the requirements of the ISO9001:2000 International Standard and to the QMS requirements established by PROTANK.
Is effectively implemented and maintained.
The auditors must be trained as an internal auditor and they cannot conduct an audit for their own division.
All audit findings and results shall be documented and brought to the attention of the person with managerial responsibility in that area. That person shall be responsible to identify and implement the corrective action as per documented procedure.
The project team shall identify the key performance indicator for core processes or divisional basis. The indicators shall be monitored, analyzed and review during the management review meeting or at any progress meeting.
9.5 Monitoring and Measurement of Project Deliverables and Performance
Monitoring and measurement activities are a requirement at appropriate stages of the projects or services to ensure all requirements are met. Project Manager is given the responsibility to install appropriate management tools to monitor and measure the projects/services performance in terms of cost, schedule, quality and HSE. Reports on each measured project/service element shall be produced and submitted to PROTANK Top Management and CLIENT (upon request). Feedback or complaint from CLIENT and Top Management due to non-conformances against such project/service shall be attended as per PROTANK relevant procedures. All activities involved in the process of monitoring and measurement of PROJECT deliverables and performance shall be documented in project document, such as Project Execution Plan or Project Control.
9.6 Control of Nonconforming Product
PROTANK shall ensure that product that does not conform to requirement is identified and controlled to prevent further defect or deterioration to the product and services provided by PROTANK. The control and related responsibilities and authorities for dealing with non-conforming products are defined in PT-PR-QA-003, Handling and Control of Non-Conformance Procedure.
PROTANK deals with nonconformance services by one of the following way: By taking action to eliminate the detected nonconformity
By authorizing its use, release or acceptance under concession by the relevant authority or customer.
By taking action to preclude its original intended use or application.
Record of the nature of non-conformities and any subsequent actions taken including concessions shall be maintained.
When non-conforming service detected after delivery/ completed project or use has started, PROTANK shall take action appropriate to the effects, or potential effects, of the non-conformity.
9.7 Analysis of Data
PROTANK shall establish a system to demonstrate suitability and effectiveness of the QMS and evaluate to conclude whether continual improvement to the QMS could be made. The method that is use in conducting is not fixed and shall be defined by the process owner owned determination to select based on the suitability and the accuracy required for each analysis to be carried out. The analysis of data shall be performed in order PROTANK to obtain the status of the following essential business and project quality indicators:
Customer Satisfaction.
Characteristics and trends of process and products or services. Performance of Contractors and Suppliers
Effectiveness of implementation Corrective and Preventive Actions.
9.8 Continual Improvement
PROTANK is plans and manages the processes necessary for the continual improvement of the effectiveness of the QMS.
PROTANK is committed and facilitates the continual improvement of the effectiveness of the QMS through the use of the quality policy, objectives, audit results, analysis of data, corrective and preventive action and management review.
9.9 Corrective Action
PROTANK shall establish a system for handling, identifying and implementing corrective actions detected during the processes and products or/and services life cycle in order to eliminate the cause of non-conformities and prevent the recurrence of the non-conformities. The procedure, Corrective, Preventive Action and Customer Complaint Procedure was established to define requirements for:
Reviewing non conformities (including customer complaints) Determining the causes of non conformities
Evaluating the need for action to ensure that non conformities do not recur Determining and implementing actions needed
Records of the results of action, and Reviewing corrective action taken
9.10 Preventive Action
PROTANK shall establish a system to determine action to eliminate the cause of potential non-conformities in order to prevent their recurrence. The Corrective Preventive Action and Customer Complaint Procedure was established to define requirements for:
Documenting potential non conformities and their causes
Evaluating the need for action to prevent occurrence non conformities Determining and implementing action needed
Records of results of action taken, and Reviewing preventive action taken.
The data or source from the following activities or records can be used as the input, as minimum to identify and analyze appropriate preventive actions as stipulated in above procedure.
9.0 APPENDIX
