HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10. E
Rev. 00
GHASHA CONCESSION
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ANNEXURE 10 PROJECT EXECUTION REQUIREMENTS
ANNEXURE 10E QUALITY MANAGEMENT REQUIREMENTS
REV
DATE
REASON FOR ISSUE
BY
CHKD
APPROVED
EPC ITT PM
PEM
00 B2 B1 A1
Issued for Tender
05-Oct-22 12-Sep-22 Re-Issued for Approval 26-Aug-22 10-Aug-22
Issued for Approval Issued for Review
RT RT RT RT
BS BS BS BS
VR VR VR VR
MM/LR MM/LR MM/LR MM/LR
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Contents
1
GENERAL … 5
1.1
PURPOSE … 5
1.2
SCOPE … 5
1.3
DEFINED TERMS AND ABBREVIATIONS … 5
2
3
4
5
6
7
REFERENCE DOCUMENTS … 8
QUALITY MANAGEMENT SYSTEM REQUIREMENTS … 10
COMPANY QUALITY POLICY STATEMENT … 11
PROJECT QUALITY PLAN … 11
KEY PERFORMANCE INDICATORS (KPI) AND PROCESS IMPROVEMENT … 13
CONTRACTOR’S QA/QC RESOURCES AND ORGANIZATION … 13
7.1
PERSONNEL COMPETENCE, TRAINING AND AWARENESS … 14
8
9
10
11
DOCUMENT MANAGEMENT. … 14
MANAGEMENT OF CHANGE … 15
MANAGEMENT REVIEW … 15
QUALITY AUDITS … 15
11.1
INTERNAL AUDITS … 16
11.2 EXTERNAL AUDITS … 16
12
13
14
CONTROL OF NON-CONFORMANCE … 17
PRE-CONTRACT AWARD REQUIREMENTS… 18
POST CONTRACT AWARD / PLANNING STAGE … 19
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
15
16
DETAILED ENGINEERING QUALITY REQUIREMENTS … 19
PROCUREMENT AND SUBCONTRACTING QUALITY REQUIREMENTS … 21
16.1 GENERAL … 21
16.2 PLANNING AND PROCESS CONTROL … 23
16.3 PROCUREMENT / SUBCONTRACT REQUISITIONING … 23
16.4 VENDOR / SUPPLIER / SUBCONTRACTOR SELECTION … 24
16.5 REVIEW OF PURCHASE DOCUMENTS … 25
16.6 VENDORS / MANUFACTURERS / SUBCONTRACTORS PRE-AWARD QUALITY
AUDIT 25
16.7
TECHNICAL BID EVALUATION (TBE) … 26
16.8 KICK-OFF MEETING (KOM) … 27
16.9 PRE-INSPECTION MEETING (PIM) … 27
16.10
INSPECTION AND SURVEILLANCE CHECKS … 28
16.11 APPOINTMENT OF INDEPENDENT THIRD-PARTY INSPECTION AGENCIES
(TPIA) 30
16.12 PRESERVATION, PACKING AND STORAGE … 31
16.13 VENDOR / SUPPLIER MANUFACTURING RECORDS BOOK (MRB) … 31
16.14 CERTIFICATION OF CONFORMITY – COC … 32
17
CONSTRUCTION QUALITY REQUIREMENTS … 33
17.1 GENERAL REQUIREMENTS … 33
17.2
INSPECTION AND TEST ACTIVITIES … 35
18
19
MECHANICAL COMPLETION AND PRE-COMMISSIONING … 39
QUALITY REPORTING … 40
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20
APPENDICES … 42
20.1 APPENDIX (A): TYPICAL PROJECT QUALITY PLAN (PQP) CONTENTS … 43
20.2 APPENDIX (B): CONTRACTOR PROJECT ORGANIZATION REQUIREMENTS 45
20.3 APPENDIX (C): QUALITY DOCUMENTS CATEGORIZATION … 47
20.4 APPENDIX (D): INSPECTION AND CERTIFICATION LEVELS … 48
20.5 APPENDIX (E): KEY PERSONNEL COMPETENCE, TRAINING AND AWARENESS
49
20.6 APPENDIX (F): NOT USED … 51
20.7 APPENDIX (G): CONTROL OF NON-CONFORMANCES … 52
20.8 APPENDIX (H): PRE-INSPECTION MEETING (PIM) REQUIREMENTS … 53
20.9 APPENDIX (I): PROJECT KEY PERFORMANCE INDICATORS (KPIS) … 55
20.10 APPENDIX (J): CONTRACTOR AND LOWER TIER SUBCONTRACTORS,
VENDORS QUALITY PERSONNEL REQUIREMENTS … 58
20.11 APPENDIX (K): TYPICAL INSPECTION AND TEST PLAN … 69
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HAIL AND GHASHA DEVELOPMENT PROJECT
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ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
1 GENERAL
1.1 PURPOSE
The ANNEXURE along with its APPENDICES is provides the mandatory minimum Quality Assurance and Quality Control requirements which shall be adopted for implementation by CONTRACTORs and its CONSULTANTs, SUB-CONTRACTORs, VENDORs, SUPPLIERs and MANUFACTURERS performing WORK on the PROJECT to provide assurance that WORK contracted by COMPANY is in full compliance with COMPANY Quality standards and PROJECT requirements.
CONTRACTOR and his lower tier SUBCONTRACTORs, SUPPLIERs and VENDORs shall comply with latest ANDOC Quality policy statement.
1.2
SCOPE
This ANNEXURE is intended to specify the minimum basic PROJECT Requirements for CONTRACTORs Quality Management System and shall not relieve the CONTRACTOR of any contractual obligations. Any deviation from this Annexure shall be identified by CONTRACTOR and shall require a written approval from COMPANY.
This Annexure is mandatory and applicable for implementation in the each stage of the PROJECT execution until final handover.
In this ANNEXURE, the term CONTRACTOR includes CONTRACTOR and its lower tier SUB- CONTRACTOR’S, SUPPLIERS, VENDORS, CONSULTANT’S, or any entity who is responsible for delivering some or all parts of the contract scope of WORK.
1.3 DEFINED TERMS AND ABBREVIATIONS
ADNOC
Abu Dhabi National Oil Company
AH
Asset Holder
ALARP
As Low As Reasonably Practicable
AO
ASNT
AUT
AVL
CAPA
CAR
Asset Owner
American Society for Non-Destructive Testing.
Automatic Ultrasonic Testing.
Approved VENDORs List
Corrective Action Preventive Action
Corrective action request
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HAIL AND GHASHA DEVELOPMENT PROJECT
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ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
COC
COW
CPMT
CSWIP
DFO
EDMS
EPC
FAC
FAT
FEED
HAZID
Certificate of Conformity
Carry Over Work
CONTRACTOR’s PROJECT Management Team
Certification Scheme For Welding Inspection Personnel
Documentation for Operation
Electronic Document Management System
Engineering, Procurement And Construction.
Final Acceptance Certificate
Factory Acceptance Test.
Front End Engineering Design
Hazards Identification
HAZOP
Hazards and Operability
HSE
HSEIA
IA
IVB
ICP
IDC
IM
Health, Safety & Environment
Health, Safety and Environmental Impact Assessment
Integrity Authority
Independent Verification Body
Independent competent person
Interdisciplinary Checking.
Integrity Management
IRN /IRC
Inspection Release Note / Inspection Release Certificate
ISO
ITB
ITP
ITT
JV
International Organization for Standardization
Invitation to Bid
Inspection &Test Plan
Invitation to Tender
Joint Venture
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QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
KPIs
MOC
MRB
MTC
NCR
NDT
OWL
P&ID
PAC
Key Performance Indicators
Management of Change
Material/Manufacturer Record Book
Material Test Certificate
Non Conformance Report
Non Destructive Testing
Outstanding Work List
Process & Instrumentation Diagram
Provisional Acceptance Certificate
PAUT
Phased Array Ultrasonic Testing.
PCN
PEP
Personnel Certification In Non-Destructive Testing As Per BS EN ISO 9712 Requirements.
PROJECT Execution Plan issue by CONTRACTOR
PHSER
PROJECT Health, Safety And Environmental Review.
PIM
PMI
PMT
PO
PQD
PQMS
PQP
PQSR
QA
QC
QM
Pre-Inspection Meeting
Positive Material Identification
PROJECT Management Team
Purchased Order
PROJECT Quality Department
PROJECT Quality Management System
PROJECT Quality Plan
PROJECTs Quality System Requirements
Quality Assurance
Quality control
Quality Manger
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HAIL AND GHASHA DEVELOPMENT PROJECT
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QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
QMS
QPR
QRA
RFI
SAT
SOW
TA
TBE
TD
Quality Management System
Quarterly Performance Review
Quantitative Risk Assessment
Request for Inspection
Site Acceptance Test
Scope of Work
Technical Authority
Technical Bid Evaluation
Technical Deviation.
TOFD
Time of Flight Diffraction (Ultrasonic Testing)
TOR
TPIA
TPI
Terms of Reference
Third Party Inspection Agency
Third Party Inspection
2 REFERENCE DOCUMENTS
The following codes, standards and specifications shall form part of this specification. When an edition date is not indicated for a code or a standard, the latest edition in force at the time of contract award shall apply.
It shall be the CONTRACTOR’s responsibility to obtain and be familiar with all codes and standards so referenced.
Order of Precedence shall be as stipulated in the AGREEMENT.
CONTRATOR shall at all times assure the highest safety, integrity, lowest risk / hazard and highest Quality levels.
CONTRACTOR shall design, engineer, Construct, Install, Commission and Handover the facilities in accordance with all applicable LAWS, regulations, standards and specifications as per order of precedence:
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QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Title
Number ADNOC Group Engineering Standards AGES-GL-13-001 AGES-GL-13-002 AGES-SP-13-001
AGES-SP-13-002
AGES-SP-13-003 ADNOC Offshore Standards A0-Q-PQ-STR-001 A0-Q-PQ-CP-001 A0-Q-PQ-GDL-001 A0-Q-PQ-PRO-001 A0-Q-PQ-SP-001 A0-Q-PQ-GDL-002 A0-Q-PQ-PRO-002 A0-Q-PQ-SP-002 A0-Q-PQ-SP-003 SHELL DEPs DEP 82.00.10.10-Gen
DEP 91.00.00.10-Gen
CONTRACTOR QA/QC Requirements Positive Material Identification of Equipment and Piping Criticality Rating Specification Procurement Inspection and Certification Requirements on the Project Traceability of Shop and Field Piping Materials
Project Quality Control Framework Code of Practice for Project Procurement Inspection Guideline for Project Quality Plan Procedure for Project Non-conformity Management EPC Contractor Quality Personnel Requirements Guideline for Developing Company Project Quality Plan Procedure for Prevention and Control of Counterfeit Material Specification for Requirements for Projects Contractor Quality System Specification for Quality Assurance and Quality Control Requirements for Construction Works Project Quality Assurance (Latest Revision) Sector-Specific Quality Management Systems- Requirements for Product and Service Supply (Endorsement of ISO/TS 29001)
DEP 82.00.10.30-Gen
Engineering information specification (EIS)
DEP 00.00.05.05-Gen ISO STANDARDANNEXURES ISO 9000 ISO 9001 ISO 9004 ISO 10005 ISO 10006 ISO 14001 ISO / IEC 17025
ISO 19011
ISO / TS 29001
ISO 45001
ISO / IEC 17020
Index to DEP publications
Quality Management Systems-Fundamentals and Vocabulary Quality Management Systems-Requirements Quality Management – Quality of an Organization – Guidance to Achieve Sustained Success Quality Management Systems-Guidelines for Quality Plans Quality Management Systems-Quality Management in Projects Environmental Management Systems - Requirements The Competence of Testing and Calibration Laboratories Guidelines for auditing management systems Petroleum, Petrochemical and Natural Gas Industries-Sector- specific quality management systems – Requirements for product and service supply organizations.
Occupational Health and Safety Management Systems - Requirements Conformity Assessment – Requirements for operation of various types of bodies performing Inspection
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Number
ISO / IEC 17065
API SPECIFICATION
API Spec. Q1
API Spec. Q2
Title Conformity Assessment – Requirements for bodies certifying products, processes and services
Specification for Quality Management System Requirements for Manufacturing Organizations for the Petroleum and Natural Gas Industry Specification for Quality Management System Requirements for Service Supply Organizations for the Petroleum and Natural Gas Industries
3 QUALITY MANAGEMENT SYSTEM REQUIREMENTS
CONTRACTOR shall establish a PROJECT Quality Management Systems in compliance with ISO 9001:2015 and API Specification Q1 (Specification for Quality Management System Requirements for Manufacturing Organizations for the Petroleum and Natural Gas Industry) or API Q2 (Specification for Quality)ISO 29001 (Petroleum, petrochemical, and natural gas industries —Sector-specific quality management systems —Requirements for product and service supply organizations).
The CONTRACTOR shall adopt a Process Approach while developing, establishing implementing, and improving the PQMS, considering ISO and the latest edition of International Standard.
The PQMS structure shall consist of quality planning, control, assurance, and continuous improvement processes in addition implementing the concept of risk-based thinking addressing risks and opportunities for maximizing the effectiveness of the quality management system, achieving improved results and preventing negative effects.
CONTRACTOR shall apply the Deming PDCA cycle- as minimum to all PROJECT processes and to the PQMS with an overall focus on risk-based thinking.
CONTRACTOR shall develop, implement and maintain a documented PROJECT Quality Management System in the form of a PROJECT Quality , Quality Policy, Procedures, work Instructions, Check sheets and Forms
The overall PROJECT Quality Management Systems (PQMS) shall provide the methods and the processes for coordinated management of the PROJECT.
Each PROJECT process shall have designated owner who will be either a function manger, discipline lead or delegate on the PROJECT. The process owner’s prime responsibility to ensure its process complies and achieves its objectives, they shall be responsible for documenting, approving, implementing, and assessing their processes to comply with PROJECT requirements.
Where CONTRACTOR is composed of joint venture with various Joint venture partners, CONTRACTOR shall establish an integrated Quality Management system and shall submit an integrated Project Quality Plan which shall include responsibility assignment matrix (RACI)
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QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
clearly defining roles and responsibilities of JV lead and/or each JV Partner in completing QMS activity, task or deliverable.
The purpose of the responsibility assignment matrix is to
a) Ensure that JV leadership takes the responsibility of all the project activities and assures controls for PROJECT activities performed by all JV Partners in accordance with approved PROJECT requirements.
b) Set clear responsibilities/accountabilities in the form of a Responsible, Accountable,
Consulted, and Informed (“RACI”) matrix.
c) Ensure clear understanding of the activities to be performed, in line with the QMS
requirements and process owner identification.
d)
Identify relevant stakeholder
4 COMPANY QUALITY POLICY STATEMENT
The COMPANY is committed to conduct all activities in accordance with its established company quality policy statement and to act positively to achieve its objectives
It is equally essential that all CONTRACTOR implement a comprehensive Project Quality Management in line with COMPANY Quality Policy Statement.
5 PROJECT QUALITY PLAN
CONTRACTOR shall prepare the specific PROJECT Quality Plan and submit it to the COMPANY for review no later than thirty (30) calendar days after the EFFECTIVE DATE of this AGREEMENT.
The PROJECT Quality Plan shall be in accordance with the latest elements of ISO 9000 series applicable to the Contract and this document, which shall include, but not limited to the following:
• PROJECT Context.
• Statuary and Regulatory requirements
• Leadership and commitment
• PROJECT quality Policy and Quality objectives
• Corporate Quality and PROJECT quality Organization chart.
•
Interface responsibilities.
• Responsibility Matrix.
• Communication and coordination procedure.
• Planning.
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PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
• Design and development
• Design review and verification.
• Design validation.
•
Inter Disciplinary check (Routine and Milestone)
• Process Procurement and subcontracting quality requirements.
• Control of external providers, products and services
• Manufacturing control.
• Construction control.
• Quality records and documentation Control.
• PROJECT construction certification system covering progress and Quality milestones
and deliverables.
• Control of performance and performance matrices (Internal & External KPIs).
• List of approved SUPPLIERs and VENDORs to be used for the PROJECT.
• List of special services and their providers.
• List of approved Sub-Contractor’s.
• Others.
CONTRACTOR PROJECT Quality Plan shall be in line with the requirements of Appendix (A) of this ANNEXURE. The CONTRACTOR shall prepare an overall PQP for the PROJECT.
The plan shall include narrative details of how the CONTRACTOR interprets and shall implement the individual element (requirement) of ISO 9001:2015 for application to this PROJECT WORK including the input, output, controls, and verifications for each process to be put in place to assure quality during each stage of the design, procurement, construction, COMMISSIONING, start-up, test-run and final-acceptance. The quality plan shall clearly identify the PROJECT quality objective and quality policy.
The contractor shall detail in a matrix format how the CONTRACTOR’s quality system addresses all the elements of ISO 9001:2015, reference responsible PARTIES within the CONTRACTOR’s organization for the implementation / control of each area, the applicable procedures used to control/assure each area and the verifying records produced for each type of control and the frequency of quality assurance check for each activity
The PQP shall contain organization charts that show reporting relationships from the inspector through the level above the CONTRACTOR’s PROJECT manager for this AGREEMENT, internal and external lines of communication, as well as the interfaces between the CONTRACTOR and its SUBCONTRACTOR’s and VENDORs/SUPPLIERs, and between CONTRACTOR and COMPANY.
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Rev. 00
CONRACTOR shall submit SUBCONTRACTORS/VENDORS/SUPPLIERS’ PROJECT Quality Plan for COMPANY approval and shall ensure that it conforms the PROJECT requirements and the PROJECT Quality Plan.
6 KEY PERFORMANCE INDICATORS (KPI) AND PROCESS IMPROVEMENT
Contractor shall continuously monitor, measure, analyze and evaluate the PROJECT quality management system for continual improvement.
CONTRACTOR shall establish KPI (Key Performance Indicators) to measure the quality performance. The KPI shall be established to cover all discipline activities & covering all process (Engineering, Procurement, Construction, and Pre-commissioning) in line with the established PROJECT quality policy and objectives as per Appendix (I) of this ANNEXURE.
KPIs shall be reported on weekly and monthly basis to COMPANY. Trend analysis shall be submitted to COMPANY for KPIs along with corrective actions for KPIs which do not meet the targets.
A system for tracking and reporting the status and performance of the inspection and testing activities shall be established and implemented. Records of all tests and inspections shall be maintained and should contain the necessary signatures of endorsement and acceptance where required.
CONTRACTOR shall submit a Lessons Learnt verification and implantation procedure in accordance with the requirements of ANNEXURE 3B, Section 13 and shall develop a system to capture PROJECT lessons learnt during execution. Captured lessons learnt shall be part of the PROJECT close out report.
7 CONTRACTOR’S QA/QC RESOURCES AND ORGANIZATION
The CONTRACTOR Quality organization shall be fully independent and reporting directly to CONTRACTOR’s senior management and having the necessary authority for ensuring that the PROJECT Quality requirements are implemented and maintained.
CONTRACTOR’s production & construction management shall have no influence on quality organization in any form or under any conditions, other than operational liaising.
The CONTRACTOR’s QA/QC Managers shall have organizational authority at least equal to that of the line manager directly responsible for execution of the WORK. The designated QA/QC Manager shall be available during all phases of WORK until final handover of the PROJECT. CONTRACTOR’s QA/QC personnel shall have sufficient and well-defined responsibility, qualifications, authority and organizational freedom to identify quality problems and areas of non- conformance and initiate, recommend and substantiate actions.
COMPANY shall interview the CONTRACTOR / Sub-Contractor’s proposed QA/QC candidates and may disqualify any individual or agency on technical grounds or unsatisfactory performance.
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Rev. 00
CONTRACTOR/SUB-CONTRACTOR’s, VENDORS QAQC & PROJECT personnel qualification and certification requirements shall conform to the requirements of Appendix (B), (E) and (J) of this ANNEXURE, and the numbers of QA/QC personnel of each discipline. In addition, the key Quality personnel will be subject to assessment and face-to-face interviews by COMPANY as well as on-job probation period before final approval.
CONTRACTOR shall nominate the PROJECT Quality Manager for this Contract within seven (7) calendar days of the effective date of this AGREEMENT. The QA/QC Manager shall be mobilized on the PROJECT through the completion of final acceptance activities
CONTRACTOR shall nominate the Procurement QC Lead for this AGREEMENT within seven (7) calendar days of the effective date. The Procurement QC Lead shall report to PROJECT Quality Manager and shall be mobilized for the full PROJECT duration until the completion of all procurement activities and final handling over of all related documents.
CONTRACTOR shall designate the Construction QC Manager minimum two months prior to the start of any construction activity.
CONTRACTOR shall provide any QA/QC personnel replacement as required, due to vacations, illness, temporary assignments, emergency leave, resignations or other reasons, as necessary, to maintain required QA/QC coverage. CONTRACTOR shall advise the COMPANY of such personnel and QA/QC coverage at least thirty (30) calendar days in advance of scheduled absences or changes. However, approved KEY PERSONNEL shall not be replaced until PROJECT completion, unless the CONTRACTOR has submitted justification for the replacement and has obtained COMPANY approval.
7.1 PERSONNEL COMPETENCE, TRAINING AND AWARENESS
CONTRACTOR shall maintain a competency and technical authority matrix for personnel involved in the PROJECT activities. In case of skill gaps, training matrix shall be established to close such gaps which shall include training schedule. The matrix shall include the name of personnel, discipline tentative week for training and core competencies or area identified for training. Training matrix shall be updated every month.
CONTRACTOR shall maintain all the records related to personnel qualification, training and competency and made available for COMPANY review and audit.
8 DOCUMENT MANAGEMENT.
CONTRACTOR shall be responsible that all PROJECT documentation is controlled by means of PROJECT document control, distribution, filing and numbering systems to identify the document status such as approval issue status, revision, etc. in accordance with requirements of ANNEXURE 10G.
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Rev. 00
CONTRACTOR shall submit a Document management procedure no later than Seven (7) calendar days after the EFFECTIVE DATE of this AGREEMENT or prior to any deliverable to submitted to COMPANY.
9 MANAGEMENT OF CHANGE
CONTRACTOR shall not authorize any changes to the approved PROJECT Quality Management system, plans, procedures, methods, and PROJECT requirements without authorization from COMPANY. CONTRACTOR shall submit a PROJECT Management of change control procedure. that document shall address as a minimum Identification, planning, evaluation, controlling, reviewing the impact, and recording of the proposed changes. Management of Change procedure shall be prepared in compliance with requirements of Annexure 10B4 and 10B5.
10 MANAGEMENT REVIEW
CONTRACTOR’s senior management shall review the PROJECT specific Quality system on a regular basis In accordance with ISO 9001:2015 requirements to ensure that the system is suitable and effective.
CONTRACTOR shall report the results and recommended actions of such reviews to the COMPANY Representative during the monthly progress review meeting. Changes to the Quality system that result from CONTRACTOR’s senior management reviews shall be incorporated in the PROJECT Quality plans with the approval of the COMPANY representative.
11 QUALITY AUDITS
CONTRACTOR shall submit detailed integrated audit procedure and audit schedule for company review and approval. Issuance of audit schedule shall be aligned with PQP issuance.
COMPANY shall be invited to participate in all audits and reviews performed by the CONTRACTOR. Audit notifications and agenda shall be submitted to the COMPANY at least seven (7) calendar days in advance for audits being performed within UAE and fourteen (14) calendar days in advance for audits planned outside UAE.
CONTRACTOR shall submit to the COMPANY, a copy of each AUDIT REPORT, along with details of audit findings, within fourteen (14) calendar days of its completion including the action plan to remedy the audit findings.
Corrective Actions Requests (CAR) raised during audits shall be submitted to company for information. CONTRACTOR shall investigate root causes and initiate corrective actions for nonconformities identified in each audit within two weeks from audit completion date. CONTRACTOR shall verify implementation and effectiveness of the corrective actions before submitting to COMPANY.
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11.1 INTERNAL AUDITS
As a minimum CONTRACTOR shall conduct the internal audits at 30%, 60%, and 90% of each location/phase/function/discipline/package VENDORs for its Engineering, Procurement, and Construction. CONTRACTOR shall submit its detailed audit schedule and checklists to COMPANY including audits of Sub- Contractor’s / VENDORs. Any rescheduling of the audits can be done only with formal approval of the COMPANY representative. Follow up audits shall be conducted at regular intervals on key areas in accordance with the CONTRACTOR audit program duly approved by the COMPANY.
The internal auditor shall have enough experience in auditing and certified by an international auditors certification authority (e.g. IRCA or Equivalent). Internal Audit program shall include all phases of the PROJECT until handover and shall also include (but not limited to) mechanical completion audit, RT Film digitization audit and completeness of hand over of document audit. Periodic audit of the VENDOR / SUB-CONTRACTOR as per the EPC Contract requirements will be carried out and reported to COMPANY.
11.2 EXTERNAL AUDITS
POST MOBILIZATION AUDITS
COMPANY shall conduct a post mobilization quality audit after (1-3 months) from the contract award date in order to ensure contractor’s readiness in terms of resources and team mobilization and to highlight any short falls at early stage of the PROJECT.
INTERIM QUALITY AUDITS
In order to have confidence in the performance of CONTRACTOR’s PROJECT Quality Management System, COMPANY will perform quality system compliance audit on the EPC phases for Engineering, Procurement, and Construction activities at least 2 times.
COMPANY also May conduct a follow up external audit after mechanical completion (after pre- commissioning but before commissioning) to ensure all the findings of the previous audits are closed before commissioning and handover to operation.
UNPLANNED / AD-HOC QUALITY AUDITS
COMPANY may also perform unplanned Quality and Technical compliance audits or Focused Assessment on critical functions and current negative trends of performance for reported the CONTRACTOR and Sub-CONTRACTOR’s activity. disciplines or processes on CONTRACTOR shall provide assistance and access to their systems and VENDOR /SUB- Contractor systems as required.
CONTRACTOR should initiate corrective actions for the findings identified in each audit. CONTRACTOR shall verify implementation of corrective actions prior to finding close out.
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CONTRACTOR to ensure and shall submit to the COMPANY a copy of each audit report and the close out plan for all findings irrespective of the category they are classified as per the CONTRACTOR non-conformance management system within 14 calendar days of its completion.
The COMPANY Representative or its nominee shall be invited to participate in all audits and reviews. Audit and review notifications along with checklist shall be submitted to the COMPANY Representative fourteen calendar days in advance.
CONTRACTOR PROJECT Quality Manager shall be responsible for all Quality audits during each phase of the PROJECT.
CONTRACTOR shall maintain a matrix of all CAPAs’, Observations identified during the above stated Audit programs. CONTRACTOR shall monitor closure and submit to COMPANY the updated matrix on a Monthly basis.
THIRD PARTY Audit (compliance audit)
COMPANY may appoint Third Party to perform Quality and Technical Compliance audits on CONTRACTOR as and when required against ISO 9001 and PROJECT contractual, requirements of this AGREEMENT and the approved PROJECT procedures/specification. CONTRACTOR shall provide assistance and access to their systems and to their SUB- CONTRACTOR/VENDOR systems as required. CONTRACTOR shall address findings of these audits within (TWO) 2 weeks of the date of audit completion.
12 CONTROL OF NON-CONFORMANCE
• Non-conformances shall be identified, reported, and resolved as per Appendix (G) of this
ANNEXURE.
• The CONTRACTOR shall establish and maintain an effective system for controlling non- conforming material, including procedure for the identification, segregation, presentation and disposition for rework or repair.
• All non-conforming supplies shall be identified to prevent use, shipping, or mixture with
conforming supplies. Holding / quarantine areas shall be allocated for segregation. Either at fabrication or construction sites.
• Critical NCRs issued by the CONTRACTOR, SUBCONTRACTORs, VENDORs,
Manufacturers and SUPPLIERs shall be copied to COMPANY and its representatives for disposition approval. Critical NCRs are the ones which involve substantial rework and / or delay in delivery of the product by 3 weeks or above.
• CONTRACTOR & COMPANY Issued NCRs shall be registered by CONTRACTOR single
NCR Log Register
• CONTRACTOR shall maintain NCRs log sheet, which shall be updated regularly and
presented to COMPANY in the regular quality meetings.
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• All NCRs shall be dully endorsing by discipline Engineering concurrence & their
deposition shall be verified and actions are rectified were dully inspected and reports are signed by respective QA/QC.
• The CONTRACTOR shall investigate the causes of non-conforming items and initiate corrective actions to prevent reoccurrence. Repair and reworked item shall be re- inspected in accordance with the applicable ITPs without any cost impact to COMPANY.
13 PRE-CONTRACT AWARD REQUIREMENTS
During the technical bid evaluation stage and pre-contract award, CONTRACTOR shall provide in his bid a “Quality assurance execution Plan” that explains in detail how he will implement the Quality assurance requirements in all phases of the Contract scope.
CONTRACTOR shall ensure similar evaluation of their proposed subcontractors, prior to Subcontract award, and assure himself that subcontractors shall deliver on quality as per PROJECT quality Requirements.
The following documentation shall be submitted by the bidder along with the QA execution plan:
• Quality Management System Certificates of compliance with ISO 9000 provided by
accredited independent body covering the intended SOW and the specific locations of the CONTRACTOR / Consultant that are going to be utilized during the PROJECT execution.
• The list of general management procedures applicable to the contract with outline of
objective and filed application.
• PROJECT documentation and records control procedure.
•
Internal audit procedure with the list of qualified auditors.
• Corporate Quality Organization.
• Audit schedule for previous 36 months (three years) showing planned and completed
audits.
• Quality Audit report from past PROJECTs duly signed by Client.
• Statistic report for audits (External / Internal) findings for previous three years.
• FEED verification and endorsement report.
• Preliminary PROJECT Quality Plan specific to the PROJECT and demonstrating
CONTRACTOR understanding of all PROJECT particularities and shall satisfy the following:
• Compliance to PROJECT SOW.
• Detailed proposed Inspection Agencies intended to be used by Contactor for Quality
Control or surveillance approved by COMPANY.
•
Include Quality organization chart compliant with Section 7 and Appendix (J) of this
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ANNEXURE for each phase of the Contract and details interfaces with Tenderer’s corporate Quality organization. Include resumes of Quality personnel assigned to the PROJECT at each phase of the Contract.
• Refer Appendix (C) for quality documents and their categorization, CONTRACTOR shall
prepare quality document list related to the PROJECT along with his submission.
14 POST CONTRACT AWARD / PLANNING STAGE
CONTRACTOR shall establish a PROJECT Quality policy and PROJECT Quality objectives along with Key Performance Indicators (KPIs). PROJECT KPIs shall be prepared as per criteria of Appendix (I) of this ANNEXURE as a minimum and shall be aligned with overall PROJECT Quality Objectives.
The PROJECT kick-off meeting shall be held at the first instance after Contract award to Contractor. The objective of the meeting is to clarify and confirm the CONTRACTOR understanding of the requirements to ensure total compliance with applicable specifications and PROJECT requirements. Within one month of Contract award, CONTRACTOR shall submit to COMPANY a detailed and dedicated PROJECT Quality Plan, which describes the specific practices, procedures and resources, which shall be implemented for all PROJECT activities and phases.
Appendix (A) of this ANNEXURE gives the “least contents” for any “PROJECT Quality Plan” which shall be in line with “SOW” and “PROJECT Execution Plan”.
A schedule for development of applicable procedures may be supplied progressively (as applicable) where the scope dictates. Refer Appendix (C) for sample of quality documents and their categorization, CONTRACTOR shall prepare a comprehensive quality document list related to the PROJECT and send for COMPANY approval.
15 DETAILED ENGINEERING QUALITY REQUIREMENTS
During the design stage and subsequent PROJECT phases, CONTRACTOR shall submit for each discipline a specific Engineering Discipline Quality Plan.
As a minimum CONTRACTOR shall establish and submit the following design procedural controls:
• Design Development and Control Procedure
• Design Change Control Procedure
• Technical Queries Procedure
•
Inter Discipline checking Procedure
• Design Review Procedure
• Design Verification Procedure
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• Design Validation Procedure
• Change Management Procedure.
• Technical authority systems procedure.
• Competency Management Procedure
•
Identification and Traceability procedure.
• Calibration and inspection of measuring and test equipment procedure
• Subcontractor management procedure
• Vendor management procedure
• Softwares and Spreadsheet Control and Validation Procedure
• Engineering deliverables minimum reviews, checks and approvals.
• Design Assurance reviews plan and procedures (HAZOP, QRA, PHSER,
Constructability, Maintainability, Operability…etc.) as applicable
•
Identification of long lead items
• Planning at Level 1-4 as appropriate
• WORK breakdown structure (WBS) as required
• Use of units and symbols
• Coordination procedure with Company, Subcontractors, VENDORs, TPIA and IVB; etc.
• Discipline and inter-discipline check
• Design reviews and verifications, including milestone verification and validation reports
to Company
• Use of computer software and hardware product licenses, as applicable
• Basis of design documentation
• Calculations and alternative calculations, and validations
• Technical library including specifications, standards, codes, VENDOR data etc.
• Technical appraisal and change management and control
• Production of specifications including amendments
• Production of drawings and material take-offs (MTO’s) including revisions
• Safe Operations assessments (SAFOPS)
• Operability assessment including 3D multidiscipline model reviews
• Constructability assessment
• Maintainability and Life Cycle Cost assessment
• Process simplification Procedure
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• Value Engineering procedure
• Value Improvement Practices
• Continues improvement Plan and procedure
• Spare’s philosophy including preparation of operation/maintenance manuals
• Criticality rating procedure
• Compilation of Manufacturer Data Books (including asset registration and data sheets)
and as Built Record; etc.
•
Identification of PROJECT documentation for quality records
• The unique characteristics of individual plant item and their specific requirements
• Packaging, handling, storage, and preservation maintenance per equipment
• Communications and document control
• Production of technical and commercial reports
The above list is not exhaustive, and any other activity deemed necessary by Contractor or Company shall be included for appropriate procedural control.
CONTRACTOR shall perform all design and engineering services in accordance with the PROJECT engineering procedures and the requirements of PROJECT SOW, appropriate National, International and industry codes and standards, good engineering, and construction practices, etc., as required to produce a design that is inherently safe, demonstrates design integrity, and meets performance requirements specified in the AGREEMENT.
During the design stage, CONTRACTOR shall provide a criticality Rating to each PROJECT item included in the SOW. This level shall be directly related to the required inspection and certification levels for each applicable plant item. Based on the criticality level the inspection and test plans and the involvement of the Third Parties inspection / certification shall be established by Manufacturer and CONTRACTOR for each item. Refer to applicable PROJECT specifications under Section 2 (References). CONTRACTOR shall submit criticality rating procedure for company review and approval.
16 PROCUREMENT AND SUBCONTRACTING QUALITY REQUIREMENTS
16.1 GENERAL
CONTRACTOR is responsible for ensuring that all supplies and services are resourced from VENDORs, SUPPLIERs, and SUB-CONTRACTORs listed in COMPANY approved VENDOR’s list (AVL) as enclosed in the Contract documents.
CONTRACTOR shall submit Subcontractor management procedure and Vendor management procedure for company review and approval.
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All SUBCONTRACTOR and VENDOR deliverables shall be reviewed, commented, and approved by CONTRACTOR prior to submission to company. SUBCONTRACTOR and VEDOR deliverables, if rejected by CONTRACTOR, shall not be submitted to COMPANY.
CONTRACTOR shall be responsible for the quality of all procurement of all equipment and material for the completion of the PROJECT WORK in accordance with contractual procurement SOW, including, Pre-Commissioning, and commissioning spare parts.
New materials shall be ordered, specified, designed, and manufactured for COMPANY in specific as per the applicable technical norms and Quality requirements.
CONTRACTOR shall be responsible of implementation of quality assurance and quality control measures to prevent introduction of counterfeit or defective material to the PROJECT.
Ex-stock, surplus or leftover materials are NOT permitted to be used in COMPANY PROJECTs under any conditions, unless approved by COMPANY for special circumstances based on a strong justification from the CONTRACTOR.
CONTRACTOR shall procure all consumables and other materials required to execute the PROJECT, including materials used for fit-ups, transportation, temporary supports …etc. in full compliance to the applicable requirements.
For materials requiring certificates type 3.2 according to EN 10204, the CONTRACTOR shall ensure that all 3.2 type certificates issued by the Manufacturer and endorsed by a recognized international TPI organization within the COMPANY Approved VENDORs List, certification body shall be hired by the purchaser and is independent and not representing VENDOR or CONTRACTOR.
CONTRACTOR’s Quality system shall ensure the following, as a minimum
• Criticality rating, inspection level, Identification and traceability requirements are clearly identified in the Purchase documents and material requisition as well as in Subcontract documents.
• Purchase orders and Subcontracts contain all the applicable, approved, accurate, complete technical data, tests, inspections, and documentation requirements.
• A formal system operates for verification and acceptance activities (e.g., audit,
inspection, surveillance …etc.) shall be established and to be performed by suitably qualified personnel at appropriate stages by CONTRACTOR in order to ensure conformance to specified requirements.
• Non-conformance and changes from the specified requirements are detected and reported to the CONTRACTOR’s concerned authority then shall be escalated to COMPANY by relevant Quality documents such as Non-Conformity Report (NCR) and/or Technical Deviation (TD) respectively as deemed applicable.
• Terms and conditions in POs and Subcontracts shall contain the following statement “No
technical deviation shall be accepted post award”.
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• Provisions for performance evaluation of vendors and subcontractors
16.2 PLANNING AND PROCESS CONTROL
• CONTRACTOR shall prepare and submit quality control procedure for company review
and approval. Where these procedures are issued by VENDORs / SUBCONTRACTS, the same shall be reviewed and at least approved with comments, by CONTRACTOR before submission to COMPANY.
• Planning for procurement activities, shall be done for the overall PROJECT schedule,
particularly to ensure the availability of materials required and critical material / equipment, which may affect the PROJECT schedule.
• CONTRACTOR shall prepare schedule for complete scope, which will include the
planned and actual dates at least and not limited to the following:
▪
Inquiry
▪ Purchase Order
▪ Expected Time of Material / Equipment Delivery (ETD)
▪ Expected Time of Material / Equipment Arrival at site (ETA)
▪ Construction, Pre-commissioning and Commissioning
▪ Production Schedules and Status Reports
▪ Prior to the initiation of the WORK, the SUPPLIER/CONTRACTOR shall produce
and submit to COMPANY a realistic production schedule.
▪ Throughout the duration of the execution, the Manufacturer / VENDOR /
S U B C O N T R A C T O R shall prepare and submit weekly status reports and
schedule updates.
▪ KPI shall be developed by CONTRACTOR and shall be submitted for
COMPANY approval & its performance data shall submitted in the weekly
reports to COMPANY.
16.3 PROCUREMENT / SUBCONTRACT REQUISITIONING
Requisition shall be prepared by the CONTRACTOR’s Design and Engineering department and shall consider the following:
• TBE shall be a logic gate for preparation of material requisition.
• Design data.
• Applicable Codes, Standards, Specifications, and other special PROJECT requirements.
• Materials of constructions to be used, including clearly specified requirements on material
testing, certification, and acceptance criteria,
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•
Inspection and testing activities to be carried out detailing scope, extent, interventions, and acceptance criteria as indicated in the “Inspection and Test Plan” for part(s) and / or equipment.
• The unique characteristics of individual plant item and their specific requirements
concerning packaging, preservation, storage, and handling.
• Data and drawing requirements for SUBCONTRACTORs including the requirements for
the content and compilation of Final Dossiers.
• Manufacturer’s Record Book (MRB) / Construction Dossiers Index shall be submitted for COMPANY Approval, & is in line with PROJECT Documentation, content is required for any sourced manufacturing item.
• Provision of COMPANY and CONTRACTOR’s right of access to VENDOR /
SUBCONTRACTOR facility and WORK related documents for inspection and audit.
16.4 VENDOR / SUPPLIER / SUBCONTRACTOR SELECTION
• CONTRACTOR shall place orders and sub-orders only with SUPPLIERs &
Manufacturers included in the COMPANY Approved VENDORs List (AVL) for procurement and manufacture of all equipment, parts, and materials including bulk and all special materials. Similarly, SUBCONTRACTS shall be placed only with approved SUBCONTRACTORs.
• VENDORs / SUPPLIERs / SUBCONTRACTORs shall possess a valid ISO accreditation (ISO 9001, 14001, 18001, & ,17065, 17020, 17025 “for laboratories”) and technical accreditation from SHELL, ASME, API …etc. according to their scope of work and applied specifications requirements.
• Only ISO/IEC 17025:2017 ‘’General requirements for the competence of testing and calibration laboratories’’ accredited laboratories shall be utilized for testing of any procured Item/material/Equipment and the calibration of testing equipment
• Product certification bodies shall be accredited to ISO/IEC 17065 Conformity assessment
— Requirements for bodies certifying products, processes, and services
• Third Party Agencies and inspection bodies shall be accredited to ISO/IEC 17020
Conformity assessment — Requirements for the operation of various types of bodies performing inspection
• CONTRACTOR shall assess / audit VENDOR / SUPPLIER or Sub-CONTRACTOR’s Quality system and technical capabilities to ensure that it is suitable and satisfies the requirement for the procured supply or service before production commencement, as the reliance solely on VENDOR’s certification to ISO quality system or being listed in COMPANY AVL is deemed to be the minimum requirements.
• CONTRACTOR shall ascertain that VENDORs / Suppliers / SUBCONTRACTORs bids
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are evaluated and checked with respect to the following:
a) Compliance with the PROJECT applicable codes, standards, specifications,
and other special requirements.
b) Conformance of bids with the conditions and requirements of the bid invitation.
c)
Deviations / exceptions stated by bidders to the bid invitation.
d) Quality program of VENDORs / SUPPLIERs / SUBCONTRACTORs.
e)
Evaluation of control measures established by VENDORs / SUPPLIERs /
SUBCONTRACTORs to monitor their Quality system and activities.
f)
Procurement system and use of required raw materials of construction and their
g)
h)
i)
appropriate certification and control.
Program for “Prevention of Counterfeit Materials”.
In-house inspection capabilities.
Compliance with stipulated fabrication, testing, inspection, and acceptance requirements.
j)
Preliminary inspection and test planning, including specifying the extent of
involvement of COMPANY, CONTRACTOR, VENDORs / SUPPLIERs, and
Third-Party Inspection (TPI) agencies at appropriate stages of fabrication /
assembly.
k)
Identification of essential documents as specified in the PROJECT Contract including as built.
l)
Past experiences and performance of the VENDORs / SUPPLIERs /
SUBCONTRACTORS on PROJECTs of similar nature and scope.
m) The foregoing activities, checks, evaluations, & reviews shall be documented
and readily available for auditing purposes at the discretion of COMPANY.
n)
Location of manufacturing and transportation to the port especially for
packages and large size items.
16.5 REVIEW OF PURCHASE DOCUMENTS
CONTRACTOR shall submit to COMPANY purchase requisitions, Data Sheets, and other
similar documents to verify application of the appropriate COMPANY Standards and
Inspection Requirements.
16.6 VENDORS / MANUFACTURERS / SUBCONTRACTORS PRE-AWARD QUALITY AUDIT
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Pre-award quality audits / shop audits are undertaken based on any needs identified as a
result of
the
reviews conducted on proposed VENDORs
/ SUPPLIER’s
/
SUBCONTRACTORS Quality management system and technical evaluation results prior to
PO award.
COMPANY may also request these audits in the following circumstances:
• When VENDOR / SUPPLIER / SUBCONTRACTORs had a history of inadequate capability, poor Quality or failures with COMPANY or other operating companies.
• When VENDOR / SUPPLIER / SUBCONTRACTOR has not supplied material to
COMPANY before.
• When there is major doubts to the VENDOR’s / SUPPLIER’s / SUBCONTRACTOR’s /
Manufacturer’s systems and controls, Sufficient experience, facilities, and resources such as machines, manning, and procedures to provide the materials / equipment / items according to the technical, Quality, commercial, and schedule requirements.
Contractors audit team consisting of appropriate Quality members shall conduct this along
with discipline engineers (as applicable) and COMPANY shall be invited to witness the audit
activities. This audit results shall identify any further actions or precautions required by the
COMPANY PROJECT team to ensure that PO / Subcontract requirements are fully met and
develop all failure barriers for the product conformity and acceptance.
Pre award audits are normally undertaken on equipment and materials with criticality rating
(1) and (2) or others when deemed necessary by COMPANY.
16.7 TECHNICAL BID EVALUATION (TBE)
• CONTRACTOR shall conduct Technical Bid Evaluations on all requisitions for selecting VENDORs / SUBCONTRACTORs. VENDOR / SUBCONTRACTOR bid document reviews shall be conducted to verify compliance to PROJECT requirements.
• CONTRACTOR shall generate detailed Technical Bid Evaluation (TBE) Reports showing, as minimum, compliance to each requirement of data sheets, specifications, material requisitions, etc. The TBE Report template shall be agreed with COMPANY during the early stage of detailed engineering phase. There shall be at least (3) bids per requisition.
• Technical Bid Evaluation template shall be presented to COMPANY for approval.
• COMPANY shall approve technical Bid Evaluation documents before PO / Subcontract
placement, unless otherwise specified.
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16.8 KICK-OFF MEETING (KOM)
CONTRACTOR shall conduct a Kick-off Meeting (KOM) with any awarded VENDOR /
SUPPLIER / SUBCONTRACTOR after PO / Subcontract placement with the presences of
COMPANY representatives.
• List of necessary Document’s list shall be in place with respective to specific VENDOR,
Manufacturers, SUBCONTRACTORs or SUB-SUPPLIERs if any.
• The objective of the KOM is to clarify and confirm VENDOR’s / SUBCONTRACTOR’s
understanding of the requirements and to agree on the following:
▪ Engineering documents, drawings, datasheets, and specifications included in Material
Requisition
▪ Quality Requirements
▪ Communication channels
▪ VENDOR documents submission and return protocol
▪ Focal points
▪ Manufacturing and Delivery schedule, where applicable
▪ Documents Requirements
▪ PIM dates and PIM Pre-requisites
▪ Any other business
16.9 PRE-INSPECTION MEETING (PIM)
Pre-Inspection Meeting (PIM) shall be conducted with any hired SUPPLIER / Principals, for
Criticality Ratings one (1), (2) and 3. For all main Construction SUBCONTRACTS, PIM shall
be conducted. Pre-inspection meeting is held at the stage when VENDOR / Manufacturers /
SUBCONTRACTORs have received following documents as a minimum approved with
comments:
▪ Execution Schedule
▪
Inspection and Test Plan (s)
▪ Manufacturing Procedure Specification (MPS)
▪ Welding Procedures
▪ NDE Procedures
▪ NDE Personnel approvals
▪ General Assembly Drawings, as applicable
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▪ Sub VENDOR schedule / List of external service providers
▪ Prevention of Counterfeit and defective Material Plan.
▪ Material Test Certificates – at least for the first lot to be used for starting fabrication E.g., plate cutting, piping pre-fabrication etc. MTC reviews and approvals may be done later but must be performed before starting fabrication.
• Pre-Inspection Meeting (PIM) shall be held with any hired SUPPLIER /
SUBCONTRACTOR in principle to address critical control activities and related areas of concern.
• PIM shall be held at VENDOR’s / SUBCONTRACTOR’s production facility in presence of,
all concerned parties / stakeholders (Manufacturer, CONTRACTOR, SUBCONTRACTORs, TPI, and COMPANY Reps…. etc.) and shall be conducted before any WORK commencement to ensure full understanding on the execution SOW, quality requirements and the level of required control on the construction activities. PIM Minutes of Meetings shall be drafted and signed by all attendees at the time of the meeting and officially submitted to company as per the specific PROJECT coordination and communication procedure.
• For Criticality 1 & 2 packages / equipment, PIM shall be conducted at VENDOR’s
production facilities. For others, PIM may be held through remote meetings (MS Teams etc.) subject to written COMPANY approval. For Construction, PIM shall be conducted at Construction SITE.
• PIM package shall be submitted for COMPANY final review and approval at least two (2)
weeks prior PIM commencement.
• Detailed PIM requirements are shown in Appendix-(H) of this ANNEXURE and in
PROJECT specifications listed in Section 2 (Reference Documents).
16.10
INSPECTION AND SURVEILLANCE CHECKS
• CONTRACTOR shall be responsible for carrying out inspection / witness testing, for all
manufacturing / construction activities at SUPPLIERs / Sub-SUPPLIERs / SUBCONTRACTOR’s premises as specified in relevant ITPs.
• The scope of inspection shall be identified in the inspection and testing plans (ITP), which
shall be prepared as per the minimum requirements stated below:
▪ Process description.
▪ QC requirements.
▪ Responsibilities.
▪ Applicable procedures.
▪ Acceptance criteria.
▪ Percentage of tests to be done (including increased inspection levels when
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performance requirements are not met).
▪ Verifying documents (Inspection Records Forms).
▪ Release form records between disciplines.
▪
Inspection intervention level (review, surveillance, witness and hold).
• All ITPs shall be presented on predefined template as presented on Appendix (K) and shall include the requirements of individual codes and standard, Purchase Orders, requisitions, COMPANY developed standards and Specifications, National Standards etc., as applicable.
• CONTRACTOR shall be responsible for ensuring that all necessary inspections and / or tasks were carried out by competent inspectors from its own organization or from a contracted Inspection Agency approved by COMPANY AVL. (No organization involved in manufacturing or expediting for the PROJECT shall be employed for inspection purposes).
• COMPANY has the right at any time to inspect the WORK in manufacturer’s / SUBCOTRACTOR’s premises; CONTRACTOR’s Representative shall always accompany COMPANY Representative on visits to SUPPLIERs / manufacturers premises.
• CONTRACTORS, SUB-CONTRACTORS, VENDORS / MANUFACTURERS …etc. shall
provide all necessary information, cooperation, and access of facilities and documentation to the COMPANY representative in a prompt and timely manner.
• For VENDORS / MANUFACTURERS, CONTRACTOR shall ensure that timely notice is obtained from manufacturer of availability for inspection with at least two (2) weeks for source inspections outside UAE and one (1) week for source inspections inside UAE. CONTRACTOR shall notify company for PIM and FAT/IFAT/YAT tests (4) weeks in advance of the planned date.
• CONTRACTOR shall assign Inspection Coordinators who co-ordinate all PROJECT
Procurement inspection activities.
•
Inspection Notification Format and content shall be agreed and approved by COMPANY.
• CONTRACTOR shall receive and distribute as necessary all Inspection Test reports maintaining an Inspection Report Register, and Inspection files by Purchase Order containing a copy of all inspection related matters including that of the “Inspecting Authority” where issued.
• CONTRACTOR shall keep strict control of all Material Test Certificates and ensure that deviations have been accepted by COMPANY in writing, prior to conveying acceptance of any such deviations.
• CONTRACTOR has to specify that manufacturers, VENDORs, sub-VENDORs and SUBCONTRACTORs shall perform and identify products and materials during manufacturing, production and site construction particularly for corrosion resistant alloys
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(CRA), alloy steel, non-ferrous and special materials, this shall be performed through positive material identification (PMI) as per applicable PROJECT specification, PMI shall also be made for component manufactured at foundries, sub-VENDORs and SUPPLIERs. The CONTRACTOR shall perform PMI at site for any equipment and material when requested by COMPANY.
• COMPANY or its nominated inspector shall have the right to require that additional inspections testing, and PMI be made at CONTRACTORs cost in the event that:
▪ Material to be used in the PROJECT cannot be identified.
▪ A reasonable doubt exists about the authenticity of its identity.
• The CONTRACTOR shall generate and maintain an identification and traceability procedure for all materials, parts and component including partially fabricated assemblies.
• CONTRACTOR shall ensure that the inspection release note, issued by the authorized
inspector, confirms that:
▪ All inspection and tests have been complete and successful as per approved
inspection & test plan at VENDOR as well as Sub-VENDOR facilities
▪ COW, if any, has been listed and approved by relevant authorities as per approved
OWL procedure
▪ Red line marked-up as-built drawings, where applicable, reflect the actual
manufactured product
▪ No outstanding NCRs from VENDOR, CONTRACTOR, and COMPANY, unless
specifically approved and listed in OWL.
• All Inspection Release Notes shall be reviewed for correctness and completeness and
endorsed by CONTRACTOR Inspection Coordinator, before further issuance to COMPANY and VENDOR authorizing delivery preparations such as preservation, protection & packing.
• CONTRACTOR shall ensure that the Shipping Release Note, issued by the authorized inspector, confirms that Preservation, Protection & Packing has been completed as per approved procedures.
16.11 APPOINTMENT OF INDEPENDENT THIRD-PARTY INSPECTION AGENCIES (TPIA)
CONTRACTOR shall engage the services of an independent Third-Party Inspection agency
(TPIA) for material certification and comply with following:
• CONTRACTOR always remains fully responsible for the inspection performed by these
Third-Party inspection agencies.
• The Third-Party inspection agency shall operate as an independent body and shall not
act as or representing of CONTRACTOR.
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• The scope of inspection services by the independent Third-Party Inspection agency shall be governed by, and not limited to, the verification of requirements as stipulated in the purchase order and its attachments and / or the requirements as detailed in the PROJECT Quality plan and ITPs.
• COMPANY may review / audit the CONTRACTOR inspection arrangements and systems
taking into account the requirements noted above.
16.12 PRESERVATION, PACKING AND STORAGE
The CONTRACTORs shall prepare procedures and systems that describes the appropriate
implementation and control of preservation and packing requirements in order to safeguard
materials and equipment against corrosion and damage during transit and storage and
protection of all markings used for identification purposes are protected.
The CONTRACTOR shall prepare short- and long-term storage control measures and
procedures for safeguarding materials and equipment (including spare parts) from damage;
particularly, in the period between manufacturing and Ready for Installation / Start-up at the
construction site.
The following provisions should be addressed in CONTRACTOR’s procedure:
• The unique characteristics of individual plant item and their specific requirements for
packaging, preservation, storage, and handling.
• Handling and preservation during sea freight including loading and unloading.
• Outside storage and handling at remote desert locations.
•
Internal storage and handling at warehouse locations.
• Lifting operations at remote locations.
• Use of suitable materials for packaging and preservation.
• Marking and identification.
• Schedule of inspections of long term stored items including preservation.
16.13 VENDOR / SUPPLIER MANUFACTURING RECORDS BOOK (MRB)
Within two (2) weeks of purchase order award, the VENDOR shall submit through
CONTRACTOR a proposed “MRB Index”. Showing the contents which discussed and agreed
upon at the Pre- Inspection Meeting.
The MRB shall contain at least, and not limited to, the following items:
• Purchase requisition including data sheets.
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• Purchase order “PO” (un-priced)
• As-built drawings and shall be provided with review, validate, and approval provisions.
• Design calculations provided with review, validate, and approval provisions.
•
Inspection and test plans (ITPs).
• Manufacturing procedure specifications (MPS).
• Welding logs and weld maps.
• Welding procedure specifications (WPS’s) and procedure qualifications records (PQR’s).
• Non-destructive test (NDT) procedures / records.
• Hydrostatic / pressure test procedure / records.
• Leak tightening / pneumatic, fugitive emission tests …etc., procedures (as applicable)
• Heat treatment procedure / records
• Painting / coating records and test certificates.
• Cathodic protection system, as-built documents, and all related testing and
commissioning records (as applicable)
• Material test summary and traceability supported with Material Test Certificates (MTC).
• Testing procedures.
• FAT/IFAT/YAT/ SAT (Factory / Site Acceptance Tests) procedures and certificates.
• Sub-orders index and orders.
•
Inspection release notes (IRN).
• Master log / register of NCR’s and analysis of NCRs.
• Technical deviations (TDs).
• Packing, preservation, & handling procedure.
• Final product certificates such as “Certificate of Conformity”.
Close out report including all Quality concerns and all lessons Learned covering both positive
and negative aspects.
Within three (3) weeks of issuing final IRN, the VENDOR shall submit through CONTRACTOR
the final MRB as per the approved index.
16.14 CERTIFICATION OF CONFORMITY – COC
CONTRACTOR shall ensure that VENDORS furnishes a CERTIFICATE OF COMPALIANCE
(COC) for materials, equipment, and packages to CONTRACTOR. CONTRACTOR/TPI shall
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endorse the COC and submit to COMPANY in accordance with PROJECT documentation
requirements.
The content of the certificate include as a minimum:
▪ Compliance statement to purchase order requirements.
▪ Narrative details of Quality activities performed during manufacturing and fabrication
of the equipment or material.
▪ Details of COMPANY approved changes to COMPANY’s requirements.
▪ All ITPs witnessed inspection activities.
▪ Details of quality records as specified in Purchase Order.
▪ Non-conformities if any.
17 CONSTRUCTION QUALITY REQUIREMENTS
17.1 GENERAL REQUIREMENTS
CONTRACTOR Quality Management system shall assure control of construction activities
including all activities associated with Fabrication, Erection, Assembly, Pre-commissioning,
and Commissioning assistance and start-up of the PROJECT.
CONTRACTOR shall implement control of all process in accordance with PROJECT
specification, PQP, specific activity quality control procedures, method statements and
approved ITP’s.
Quality Control Procedures shall clearly state methods for the qualification, process control,
QC verification and documentation of construction activities to meet the specified technical
and quality requirements. This shall include specific procedures/method statements, detailing
how an activity will be performed and the detailing the methods of quality checks, together
with the responsible persons and the verifying document/check sheets to be produced.
CONTRACTOR shall inspect all PROJECT Material and equipment received at site at SITE
in accordance with PROJECT requirements. CONTRACTOR shall establish a dedicated
inspection & test plan for material receiving inspections at SITE, covering each type of
equipment and materials as per PROJECT requirements. Inspection & test plan shall be
reviewed and approved by COMPANY.
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Construction activities procedures and method statements shall detail the technical / actual
scope, how and where activities will be performed, who is responsible for the actual activity,
who is responsible to verifying the activity, acceptance criteria and which record / verification
document shall be produced
Critical activities, such as welding, non-destructive examinations, and performance/proof
testing will be given special consideration.
CONTRACTOR shall demonstrate that control of operation involving welding conforms as
minimum to ISO 3834-1 ‘’ quality requirements of fusion welding of metallic material’’ to the
level of detailed Comprehensive Quality Requirements in ISO 3834-2 latest editions.
All welding procedure qualification tests and welder performance qualification tests shall be
subject to witnessing and approval by COMPANY.
CONTRACTOR shall identify before start of construction activity all welding procedures in the
PROJECT and shall submit Preliminary Welding Procedures Specification (PWPS) for
approval. PWPS shall include all required qualification tests with reference to applicable codes
and specification and tests acceptance criteria. CONTRACTOR shall not run the qualification
unless the PWPS is approved by COMPANY. PWPS format shall be agreed and endorsed
by COMPANY.
Prequalified welding procedure shall not be accepted, CONTRACTOR shall perform all
welding procedures qualifications on PROJECT material for PROJECT scope.
All welding procedure qualification tests and welder qualification tests shall be supervised and
witnessed by a dedicated quality personnel and CONTRACTOR’S welding engineer, and shall
be witnessed, endorsed and attested by Independent Third Party. All associated costs shall
be borne by CONTRACTOR.
At COMPANY discretion, COMPANY may select a sample welded joint(s) from production
welding to validate the mechanical, chemical, metallurgical and corrosion properties are
consistently achieved during production. Testing and reworks activities shall be borne by
CONTRACTOR cost. All hydrostatic test headers and lifting gears / equipment / ancillaries
shall be tested and certified by a Third Party, and certificates shall be submitted to COMPANY
before commencement of any WORK, prior to proceeding next process.
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All Quality activities including status & records lists shall be compiled as per scope of WORK
and CONTRACTOR shall implement an electronic database (Electronic Data Base
Management System “EDMS”) referencing the appropriate ITP, procedure, and certification
so that the Quality status can be continually monitored as the WORK progresses. COMPANY
shall approve the proposed data base management system.
The CONTRACTOR shall provide COMPANY with a weekly update of all Quality issues on
site together with a regular and brief description of all non-conformances issued.
As part of the CONTRACTOR’s Quality system, CONTRACTOR shall consider that
COMPANY will operate their non-conformance reporting system within the PROJECT. Thus,
on receipt of COMPANY non-conformance reports (NCRs), CONTRACTOR shall prepare
correction and corrective / preventive actions plan within 3 working days. Where such non-
conformances are identified as major, the affected product shall be isolated, related operation
shall be suspended, and immediate course of actions (i.e., containment, root cause analysis,
correction, and corrective / preventive actions) shall be carried out to maintain both the
PROJECT progress and Quality up to PROJECT norms.
The CONTRACTOR’s Quality system shall include documented controls for the following
construction activities:
• All activities connected with ISO 9000 series and this specification herein.
• Receipt, storage, handling and issuance of material and equipment (CONTRACTOR procured and / or COMPANY free issued material and equipment to be included).
•
Identification and traceability of all materials in accordance with Contract documents.
• Measuring and testing equipment including calibration and certification.
• Construction / engineering changes and processing of site queries.
• Control of non-conformities and all related correction, corrective, and preventive
actions.
• Repair rates, failure cases, and rework percentages.
• Generation and compilation of inspection and test records.
17.2 INSPECTION AND TEST ACTIVITIES
• The inspection and test plan (ITP) from the CONTRACTORs and their SUPPLIERs & Sub- CONTRACTORs, shall detail all the manufacturing, fabrication, construction, installation, and commissioning aspects / stages in a logical sequence in a progressive manner related to activity.
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• Provisions shall be made on the ITP, which allows individual activities to be endorsed
(signed off) by the concerned parties as described formerly. ITP shall be prepared as per the minimum requirements of Appendix (K).
• CONTRACTOR shall provide all necessary supervision and inspection during the
execution of the PROJECT activities.
• CONTRACTOR shall provide, and have continuously available, the equipment required
for inspection of all or part of the WORK. The equipment including (dimensional, metrological, NDT…etc.) shall be suitable for examining, measuring, and testing efficiently and accurately.
• All inspection equipment shall be attested, calibrated, and certified by independent,
recognized, & accredited testing laboratory as per their manufacturer recommendations and / or COMPANY request whenever necessary, and shall be in good condition and properly maintained.
• All NDT procedures shall be prepared by qualified and certified ASNT ACCP NDT Level
III or equivalent certification approved by COMPANY.
• All Painting & Coating procedures shall be prepared by qualified and certified NACE
Level III or equivalent certification approved by COMPANY.
• The CONTRACTOR shall submit to the COMPANY a written NDT procedure specific to
the job for prior approval, after which the techniques (contained in the procedure) shall be qualified by demonstrating satisfactory evidence of compliance with that procedure.
• When there is a requirement for NDT examination in percentage wise of the total number
of welds the following requirements shall apply:
▪ Welds shall be randomly and independently selected throughout the fabrication /
construction period and fully examined.
▪ The random selection shall be equally distributed overall the welders, all type of
welds, all welding procedures, all pipe sizes / thicknesses, and all welding position.
▪ Where reduced percentage of examination is permitted and the resulting test shows defects, then two additional samples of the same kind welded by the same welder shall be given the same type of examination.
▪
If any of the items found defective, then two further samples of the same kind shall be examined for each defective item found by that sampling.
▪ This shall continue until fully examined and repaired or replaced as necessary to
meet the specification requirements.
• CONTRACTOR shall establish an RT Films Digitization System as per ASME V Article II capable to Display, process, quantify, store, and retrieve conventional radiographic films into digital images, to achieve the following objectives:
▪ Enable digital archiving of radiographic films without loss of quality.
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▪ Reduce storage space and costs.
▪
Improve accessibility of data.
▪ Streamline and semi-automate report generation.
▪ Eliminate accidental damage of films due to handling.
▪ Extend archive life.
• Advance NDT Techniques: PAUT, AUT, TOFD etc.:
▪ Where radiography is not practical to use at site, advanced NDT techniques such as
Phased Array (PAUT) or AUT may be allowed in lieu of radiography subject to procedure qualification and approval of COMPANY.
▪ Technicians for advanced NDT techniques such as PAUT or AUT or TOFD shall be tested on a dummy test piece with hidden defects and test report shall be confirmed against actual defects. Such tests shall be witnessed by CONTRACTOR and COMPANY. Technician’s demonstration report shall be approved by CONTRACTOR and COMPANY.
▪ The test results shall be interpreted and finally reported by the CONTRACTOR / Sub-
CONTRACTOR’s certified ASNT ACCP level III, or CSWIP / PCN level II.
• RT backlog percentage (or another agreed advanced method of comprehensive testing) for any system shall not exceed 2 days’ of production for pipelines and 3 days for piping works; otherwise, welding activities shall be suspended until safe clearance of that backlog.
• The required minimum qualifications of any RT / UT interpreter shall be:
▪ ASNT ACCP NDT Level III, or
▪ PCN Level II in RT, PAUT, AUT, or
▪ CSWIP Level II in RT, or
▪ ASNT ACCP Level II along with RTFI (Radiographic Film Interpretation) certification
▪ Minimum (7) years of experience after certification date with suitable experience in
the Oil & Gas.
In addition to the above, the pre-selected candidate will be subjected to assessment and face- to-face interview by COMPANY as well as on-job probation period.
• The CONTRACTOR or Manufacturer in charge, shall meet the required standard
specification, and practice for Quality management systems set by COMPANY to control the independent or in-house organizations performing non-destructive testing (NDT).
• NDT testing organization / Sub-CONTRACTOR shall be subject to systematic verification
/ audits and assessment process to verify their compliance with COMPANY requirements.
• CONTRACTOR / Sub-CONTRACTOR shall assist COMPANY’s representatives in the
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execution of inspections and tests by providing personnel, inspection, and test equipment as required.
• Material traceability and Positive Material Inspection (PMI) shall be in accordance with approved procedures and as per COMPANY reference standards, any PMI check for welding joint shall be 3 readings: Base metal 1, Weld joint, Base metal 2.
• CONTRACTOR shall review and track PROJECT errors & failures such as welding &
welder repair rates on a daily basis. Weld repair rates and on-spot welders’ performance shall be evaluated on a weekly basis.
• Welds and welder repair rates / percentages for piping, pipelines, steel structures,
pressure vessels, storage tanks, plate work …etc. shall be closely monitored by the CONTRACTOR and reported to COMPANY on weekly and monthly basis in statistical analysis manner.
• Repair rate / percentage shall be calculated based on the number of tested joints by RT, UT, MT or DPT (as applicable), for pipelines & piping, while to be calculated by metric length of tested joints for storage tanks, pressure vessels, steel structures and other plate work considering the following:
▪ Repair rate / percentage shall not exceed 3% of the total number of welded joints or
0.5% of the total welded length in a week as detailed above.
▪
In case the weekly repair rate / percentage exceeds above limit, a full detailed investigation shall be carried out by the CONTRACTOR to detect the root cause of the defect, eliminate it, and implement corrective measures to prevent recurrence and reduce the repair rate / percentage to within maximum limit.
▪ When weekly repair rate / percentage exceeds 5% of the total number of welded
joints or 1% of the total welded length, CONTRACTOR shall be officially warned by COMPANY and WORK shall be suspended until satisfactory completion of the investigation and root cause analysis associated with the courses of rectification, corrective, and preventive actions which shall be accepted and approved by COMPANY.
▪ Weekly as well as overall cumulative weld repair rate / percentage shall be reported on weekly basis through the periodic Quality reports. Monthly reports shall include overall cumulative weld repair rate.
▪ CONTRACTOR shall be proactive with regards to monitoring the weld /welder repair rates and elimination of the potential causes that might lead to the critical limits.
▪ Welders’ repair rate / percentage shall be monitored on a weekly basis and shall not
exceed 3% of the total welders’ weekly production.
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18 MECHANICAL COMPLETION AND PRE-COMMISSIONING
CONTRACTOR shall complete Mechanical Completion, Pre-Commissioning on subsystem basis, and turnover the entire PROJECT and successfully complete all checks and tests to the stage when the system (or part-thereof) is ready for Commissioning.
CONTRACTOR shall develop separately and submit for COMPANY approval Prior to the first Mechanical Completion date, for any section of the PROJECT, the following Plans:
• Mechanical Completion Plan.
• Pre-commissioning Plan.
• Commissioning Plan.
Each plan shall include, but not be limited to the following as a minimum:
• The approved battery limits: sections / sub-systems / system, Mechanical completion, pre-
commissioning, Commissioning, and shutdown activities.
• List of Tag numbers.
• List of Inspection Test Report for each system per Tag.
• CONTRACTOR’s Organization chart for each plan, including CVs of key staff.
• List of VENDORs involved in each plan, including schedule, duration, and CV of each.
• VENDOR representative (VENDOR Mobilization plan including their involvement during
Commissioning).
• Sub-contracting plan in case of special services like intelligent pigging and other Services.
• Detailed execution method, philosophy, plan and procedure including schedules,
• Methodologies for each plan Sequence of Start-Up and Commissioning.
•
•
Identification Commissioning spares and their list.
Interfaces with existing operating or new facilities and developing co-ordination Procedure.
• Pre-commissioning for Tie-ins and identification of Tie-in schedule.
• Schedule for Mechanical Completion and Ready for Commissioning for each Section / sub-
system of the PROJECT.
•
Identification and list of activities, which involve COMPANY inspection and tests.
CONTRACTOR shall utilize a Construction Commissioning Management System / PROJECT Completion System (Software). The software package shall ensure the following:
• The PROJECT is mechanically complete, commissioned and certified ready for safe
Operation.
• The PROJECT documentation is complete for use during the life of the Asset.
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• Trainings shall be provided by the VENDOR for COMPANY employees.
•
•
It shall be a proven software package used in the oil & gas industry. The number of user Licenses shall be unlimited for the whole of the PROJECT and for unlimited time.
It shall be populated by CONTRACTOR with a full set of engineering data for each discipline containing all relevant equipment information (e.g., DWGs, P&IDs, data sheets, etc.). In addition, it shall have data registers that hold all references (PROJECT coding, systems, areas - etc.), Documentation, procedures, tests, scanned images, pictures and so on.
• The software package shall incorporate the tests and procedures for the total scope of WORK and schedule. It shall be capable of holding O&M Manuals, specifications,
• Calculations, VENDOR information, etc. The system shall be capable of generating all kinds of reports and checklists from the data information centre. The reports shall be schedule based and supply alerts of activity points to be completed. All generated information shall be stored in a historical database.
CONTRACTOR shall employ PROJECT and commissioning software package specialists experienced in setting up (descriptions and codes) the database. The specialists shall produce, control and close- out all documents and activities to complete closure of the PROJECT.
CONTRACTOR shall ensure that all systems and subsystems are tested as specified and all the major punch list items are closed before releasing for the commissioning activities.
the CONTRACTOR shall carry out Commissioning Process activities as per “Commissioning Plan”, which must be developed, updated, and finalized during the design phases of the package of the Contract.
The “Commissioning Plan” shall be supported by the “Commissioning Procedures” which will take into account issues noted below and the precise terms and conditions of the Contract including applicable specifications.
19 QUALITY REPORTING
Quality reports shall be issued by CONTRACTOR in weekly, biweekly and monthly basis, or as deemed appropriate by the COMPANY Quality team with regards to the PROJECT size / phase and nature of activity.
As a minimum, the PROJECT Quality Report shall cover the following areas:
- Engineering
• Areas of concern with recommenced corrective actions.
• Log for Technical Deviations (TD/DCAs) and Technical Queries (TQ), with status.
• Engineering KPIs.
- Procurement
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• Procurement status (TBEs, KOM, PIM, FAT and expected delivery date) with the
monthly inspection calendar for the procured items, and 3-months look-ahead Plan especially for PIM & FAT.
• Log for local and worldwide RFIs (Requests for Inspection).
• Three months Look ahead consolidated inspection schedule Package Fabrication
status and quality reporting.
- Construction
• Weekly and cumulative weld & welder repair rates with weld defects analysis for
piping, pipelines …etc. separately.
• Site QA / QC Activities in progress during the period.
• Material and equipment receiving inspection status during the period.
• NDT backlog.
• Log for l Construction RFIs (Requests for Inspection).
• Weekly and accumulative weld & welder repair rates with weld defects analysis for
piping, pipelines …etc. separately.
•
In weekly basis, reporting the actual number of all cut-out & re-welded joints and the reason (s) for cutting (e.g., site modification, new revision, repairs …etc.).
- Quality Assurance
• Summary of developed PROJECT Quality Plan (PQP), procedures, work
instructions, and Quality control plans, with respective reviews, approvals, and issue status (including Sub-CONTRACTOR / VENDOR documents).
• QA / QC Organization status (plan for allocation /demobilization of Quality
personnel, and any approved changes).
• Summary of all internal and external audits carried out, reported against the audit
schedule.
• Major areas of concern or weakness identified in the Quality system and details of
any investigations to prevent the recurrence of failures.
• Log for PROJECT NCRs (internal & external) with corrective action reports, status,
and the planned dates for follow up & close-out.
• Log for audit CARs (Corrective Action Requests) with summary of all internal and
external audits carried out & reported against the audit schedule.
• Quality KPIs statistics and analysis.
• Historical Lessons Learned statistics
• Lessons Learned captured during execution
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Quality review meetings shall be held between CONTRACTOR quality heads and their counter parts from COMPANY to discuss the above-mentioned points in a weekly, Bi-weekly or monthly basis, or when deemed necessary by COMPANY.
20 APPENDICES
Appendix A: Typical PROJECT Quality Plan (PQP) Contents
Appendix B: CONTRACTOR PROJECT Organization Requirements
Appendix C: Quality Documents Categorization
Appendix D: Inspection and Certification Levels
Appendix E: Key Personnel Competence, Training and Awareness
Appendix F: Not Used
Appendix G: Control of Non-Conformances
Appendix H: Pre-Inspection Meeting Requirements
Appendix I: PROJECT Key Performance Indicators
Appendix J: CONTRACTOR and Lower Tier Sub-CONTRACTOR / VENDOR Quality Personnel Requirements
Appendix K: Typical Inspection & Test Plan
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20.1 APPENDIX (A): TYPICAL PROJECT QUALITY PLAN (PQP) CONTENTS
The following aspects shall be covered in the CONTRACTOR’s PROJECT Quality Plan (s) in addition to the ISO 9000 & 10005 requirements:
- Cover Sheet and Revision History
a. Document purpose
b. Policy statement
- INTRODUCTION
a. PROJECT scope and background
b. PROJECT constraints
c. QA standards
d. PROJECT specifications
- Execution Strategy
a. PROJECT risks
b. Critical activities
c. Control strategy
d. PROJECT schedule
e. PROJECT Quality Objectives and KPIs
f. Commissioning & handover
- Organization, Responsibilities, & Interfaces
a. PROJECT general organization chart with nominations
b. PROJECT QA/QC detailed organization chart with nominations
c. PROJECT Interfaces (internal & external)
d. Definition of specific roles and responsibilities
- PROJECT documentation control and traceability system
a. Main CONTRACTOR documentation /records control system
b. Control of Sub-CONTRACTORs and VENDORs documents /records
c. PROJECT documentation handover and retention policy
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- Integration of CONTRACTORs & SUPPLIERs
a. Define CONTRACTOR interfaces
b. CONTRACTOR and SUPPLIER Quality system
- Audits and Reviews
• Schedules and details for:
a. Technical audits.
b. QA audits (internal & external)
c. Procurement reviews
d. Lessons Learnt review (previous PROJECTs)
e. Safety reviews (PHSER, HSEIA, HAZOP, QRA, HAZID, PSSR, SIL, etc.)
- Quality Process Improvement
a. Lessons Learnt methodology of collection and compilation.
b. PROJECT close-out
The following shall be referred in PQP as applicable.
I. SOW / TOR
II. All applicable procedures
III. HSE manual
IV.
Job description
V. Approved VENDORs & CONTRACTORs lists
VI. Review matrices
VII. Coordination procedure
VIII. Environmental guidelines and risk assessment
IX. Construction guidelines
X. Standards & specifications
XI. Control terms & coordination
XII. Other QA/QC plans
XIII. Other HSE plans
XIV. Execution statement requirements
XV. Tender evaluation criteria
XVI. Deliverable’s list
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Page 44 of 69
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.2 APPENDIX (B): CONTRACTOR PROJECT ORGANIZATION REQUIREMENTS
GENERAL
• PROJECT Specific organization is the only acceptable organization to COMPANY with fully dedicated team members to the PROJECT. CONTRACTOR shall not share its personnel with any other PROJECT or single business activity related to CONTRACTOR or COMPANY sides.
• CONTRACTOR shall formalize the acceptance of the personnel to be appointed for the
PROJECT key positions and shall seek the approval of COMPANY before confirming their assignments, which will be subject to review of CVs and face-to-face interviews.
• Approved key personnel shall not be replaced or demobilized until PROJECT completion, unless the CONTRACTOR has submitted very strong reasons and justifications for the replacement / demobilization, which shall be subject to COMPANY approval prior to any release from the PROJECT.
• CONTRACTOR quality resources deployment plan shall be part of quality monthly report.
• Key personnel are defined as any CONTRACTOR PROJECT person holding a managerial, team leading or supervisory role (I.e. Directors, mangers, team leaders, superintended or senior engineers)
• The CONTRACTOR PROJECT organization shall include a detailed description of
CONTRACTOR’s organization relevant to the PROJECT SOW which should include:
- An organization chart of the CONTRACTOR’s PROJECT Management Team,
Interfaces with COMPANY, Sub-Contractor’s, Third Parties …etc.
- The proposed Key staff that will be involved in the PROJECT supported with their CV’s
showing: qualifications, valid certificates & licenses, training, and experience relevant
to the proposed position.
- CONTRACTOR shall formalize the acceptance of the personnel to be appointed
specifically for QA/QC tasks and shall seek the approval of COMPANY before
confirming their assignments.
-
All qualification certificates shall be valid, and shall be presented with each CV.
-
Previous ADNOC acceptance will be considered but cannot guarantee approval or
acceptance for the new PROJECT.
GROWTH / REDUCTION OF QA ORGANIZATION
CONTRACTOR shall obtain approval from COMPANY about the schedule and mobilization / de- mobilization of the initially assigned QA / QC personnel in order to ensure adequate schedule of resources. Top management is accountable for the Quality and every individual working within the
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
organization is responsible to deliver Quality on the PROJECT, backed up by the dedicated and specific quality personnel with a functional reporting to the organizational quality responsible.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.3 APPENDIX (C): QUALITY DOCUMENTS CATEGORIZATION
The below list showing a sample of quality documents and their categorization, CONTRACTOR shall prepare a comprehensive quality document list related to the PROJECT and send for COMPANY approval as per ANNEXURE 10G, PROJECT documentation requirements
SN
Description
Class
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PROJECT Quality Plan (PQP)
Inspection and Test Plans (ITP)
Manufacturing Procedures
Material Identification and Traceability Procedure
NDT/ Heat Treatment Procedures and Test Plan
PROJECT Quality Audit schedule and Procedure
List of selected Welding Consumables
Construction – Quality documents - QCP’s
List of Testing Equipment / Calibration
NCR’s (Issued by COMPANY and (CONTRACTOR, Sub-Contractor, VENDORs etc.)
/ or Critical NCRs
issued by
WPS, PQRs and Welders Qualifications
EPC CONTRACTOR Rep. / TPI Rep. CV’s
MTC’s
Testing procedures
Construction – Quality reports
Pre-Inspection Meeting Package
1
1
3
2
2
1
2
2
2
1
1
1
2
2
2
2
Category 1: Documents, which require formal approval of COMPANY
Category 2: Documents to be issued for comments only, without requiring formal approval from COMPANY
Category 3: Document to be issued for Information only
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.4 APPENDIX (D): INSPECTION AND CERTIFICATION LEVELS
Procurement Inspection and certification levels shall be as per PROJECT specification R-CA0000- 54-SPE-0015: PROJECT minimum Inspection and certification requirements and AGES-SP-13-002.
Requirements described in above document are the minimum requirements. Additional requirements indicated in material requisition (Material / Equipment specifications & data sheets) shall be fully adhered to.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.5 APPENDIX (E): KEY PERSONNEL COMPETENCE, TRAINING AND AWARENESS
CONTRACTOR shall ensure the competency and qualification of all personnel and their
experience in their respective areas.
The PQP shall reference competency plan for managing and assuring the competence of those
responsible for executing and controlling the quality. All persons responsible for executing and
controlling the WORK should be competent, properly qualified, certified and are skilled and
experienced in accordance with the PROJECT requirements. As minimum but not limited to the
plan will specify the COMPTENCY of Personnel responsible of the following:
• Material Receiving and Preservation of Critical equipment and material
• Lifting inspectors
• CRA welding inspectors
• Personnel responsible of inspection of electrical equipment in hazardous and explosion
areas.
• Advanced NDT Inspectors
• Leak testing.
•
Inspection of Fiscal Metering Equipment
•
Inspector performing remote inspection
Training needs should be identified and provided when a gap in competency is identified as
needed. All qualification, training and competency records shall be maintained. All records shall
be made available to the COMPANY for verification as and when required by the COMPANY.
CONTRACTOR shall submit training matrix for discipline and personnel involved in the
PROJECT activities. The matrix shall include the name of personnel, discipline tentative week
for training and core competencies or area identified for training. The matrix shall be
continuously updated throughout the PROJECT life.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
All personnel involved in the PROJECT shall be made aware of the PROJECT Quality
Management System requirements, processes and procedure as part of their on-boarding
process. CONTRACTOR shall retain evidence of such inductions.
Awareness Training programs shall be conducted to those persons who are responsible for
controlling the quality of the work to ensure that they are aware of the Quality Management
System requirements and be updated with COMPANY Quality Policy and Objectives as part of
PROJECT Induction Training/Awareness. This Training should not only include Quality staff but
also other staff in the PROJECT affecting the Quality of work being executed.
CONTRACTOR Quality Manager or his delegate shall conduct quality toolbox meeting on a
weekly basis to CONTRACTOR/SUBCONTRACTOR quality inspectors and to maintain records
as evidence.
Before starting any construction activity toolbox meeting addressing the specific quality
requirements shall be conducted for the craftsman involved in the WORK.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.6 APPENDIX (F): NOT USED
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.7 APPENDIX (G): CONTROL OF NON-CONFORMANCES
• The CONTRACTOR shall establish and maintain an effective system for controlling non-
conforming material, including procedure for the identification, segregation, presentation and disposition for rework or repair.
• All non-conforming supplies shall be identified to prevent use, shipping, or mixture with
conforming supplies. Holding / quarantine areas shall be allocated for segregation. Either at fabrication or construction sites.
• Critical NCRs issued by the CONTRACTOR, sub-CONTRACTORs, VENDORs,
Manufacturers and SUPPLIERs shall be copied to COMPANY and its representatives for disposition approval.
• CONTRACTOR shall maintain NCRs log sheet, which shall be updated regularly and
presented to COMPANY in the regular quality meetings.
• The CONTRACTOR shall investigate the causes of non-conforming items, and initiate
corrective actions to prevent reoccurrence. Repair and reworked item shall be re-inspected In accordance with the applicable ITPs.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.8 APPENDIX (H): PRE-INSPECTION MEETING (PIM) REQUIREMENTS
• CONTRACTOR shall prepare a list of VENDORs at which PIM will be undertaken, followed by three (3) months look ahead PIM plan shall be prepared and sent to COPMANY in a regular basis, in order to allow enough time for COMPANY to plan its representatives / TPI mobilization.
• PIM package shall be submitted for COMPANY final review and approval at least two (2)
weeks prior PIM commencement.
• CONTRACTOR shall confirm PIM date by issuing notification to COMPANY at least three (4)
weeks before commencement date.
• PIM minutes of meeting (MOM) shall be officially submitted to COMPANY within two working
days post PIM commencement.
• PIM meeting shall be arranged by the VENDOR when the following requirements are met:
▪ The engineering work related to the equipment or material is substantially completed
and manufacturing could be started.
▪ The COMPANY comments on the engineering, design and quality have been
resolved.
▪ That the Material Requisition and un-priced purchase orders have been received,
reviewed and accepted by COMPANY.
▪ That all relevant procedure has been received and accepted by COPMANY.
▪ That all quality plans and ITPs including those related to sub-VENDORs have been.
Received, reviewed and at least approved with comments.
• The following is a typical PIM package contents which should be prepared by
CONTRACTOR:
▪ Pre-inspection meeting agenda.
▪ Final approved purchase order (un-priced).
▪ The approved material requisition.
▪ Production schedule.
▪ Approved drawings.
▪ The final approved specifications as a part of PO.
▪ The approved manufacturing procedures.
▪ The approved inspection and test plans (ITPs).
▪ NDT procedures and NDT operator’s qualifications.
▪
Inspection and testing procedures.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
▪ Manufacturer / VENDOR approved CV’s (for key personnel) with the organization
chart.
▪ Technical clarifications / deviations (if any) as authorized / approved by COMPANY.
▪ Notification of the appointed Third-Party Inspection Agency (TPIA) and the approved
CVs for assigned TPI personnel.
▪ Welding book (as applicable) including: WPSs / PQRs, Base Material Certificates, etc
• The following is a typical PIM agenda that should be followed by all parties involved:
▪
Introduction and objectives.
▪ Equipment or material involved.
▪ Review of purchase order and appendices to verify completeness and confirmation to
contract specifications, procedure, drawings, etc.
▪ Review of exceptions or deviations to purchase order (If any).
▪ Raw materials, sub VENDORs and manufacturing/testing locations.
▪ Review of VENDOR QMS.
▪ Verify the calibration certificates related to measurement and testing instruments.
▪ Review of VENDOR PROJECT organization.
▪ Status of VENDOR procedures.
▪ Review of manufacturing procedures, specification, and qualification.
▪ Production schedule and inspection program.
▪ Traceability and certification.
▪
Inspection and testing.
▪ Third party inspection.
▪ Quality records.
▪ Review and final marking of the manufacturing quality plan (ITP).
▪
Inspection release and shipping release.
▪ Non-conformances procedure.
▪ Point of contacts and communication channels.
▪
Inspection notifications.
▪ Manufacturing record book (MRB) requirements.
▪ Areas of concerns.
▪ Any other business.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
▪ Mill/shop tour.
20.9 APPENDIX (I): PROJECT KEY PERFORMANCE INDICATORS (KPIS)
CONTRACTOR shall establish a PROJECT KPIs as per the below table as minimum,
COMPANY and CONTRACTOR shall agree on any additional KPIs deemed necessary to
measure the monitor and measure the performance of the PROJECT quality management
system . CONTRACTOR shall measure; monitor and report PROJECT Key Performance
Indicators on monthly/weekly basis as applicable. Reports shall be provided to COMPANY
detailing any improvement actions taking place if the KPI’s are not meeting the targets.
Contractor may revise the KPIs or the measuring frequencies in agreement with the COMPANY
to fit to PROJECT requirements and nature.
Activities
HAZOP actions outstanding
Holds outstanding
No. Design Changes and/or Deviations resulting in changes to design basis
Design deliverables
Key Performance Indicators(KPI)
No. outstanding / (No. raised) Highlight by type (e.g., HAZOP / HAZID)
Key Focus Area/Quality Objective
Engineering / Design
t i n U
%
Freq.
Target Performance
Monthly
<5%
No. design issues/queries closed in month / (Total number raised)
Engineering / Design
No. design changes and/or deviations resulting in changes to design basis
Engineering / Design
No. of document delivered late / No. required by schedule
Engineering / Design
%
Monthly
<5%
Nos Monthly
NA
%
Monthly
<5%
Audits and Reviews Performed/Planned
Quality
%
Quarterly
90%
Quality audit Findings
No. of cleared in the month/ ( No, required due in the month)
Organizational Resources
No. Resources /( No. Planned)
Quality
%
Quarterly
90%
Quality
%
Monthly
90%
NCRs
No. open/total No. raised
Quality
%
Monthly
<5%
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1
2
3
4
5
6
7
8
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Activities
Key Performance Indicators(KPI)
Key Focus Area/Quality Objective
t i n U
Freq.
Target Performance
Repeat NCRs
No. Repeated NCRs in month/ Total No. NCRs
Quality
%
Monthly
<5%
9
10
11
12
13
Quality Observations (near- miss/ defect prevention) Weld repair rate For 100% NDE specifically to RT (or PAUT) Weld Repair Rate for Structural / Tanks / Vessels, relevant to volumetric NDT
NDT Backlog /Pipeline(RT or PAUT)
No. Quality Observations (near- miss/defect prevention) in month
No. of welds repaired in week × 100/(Total No of Radiographed week)
Length Repaired x 100 / (Total length NDT’d)
Quality
Nos Monthly
NA
Quality
%
Weekly
<3%
Quality
%
Weekly
<0.5%
No of joints back logged
Quality
Nos Weekly
14
NDT Backlog /Piping(RT,MT,PT)
No of joints back logged
Quality
Nos
weekly
15
Back Log PWHT
Backlog of 5 joints per day Quality
Nos Monthly
16
17
Coating Rejection Rate
Painting Rejection Rate
Coating Repair Rate<1% Quality
%
Monthly
Painting Repair Rate<1% Quality
%
Monthly
18
No of POs issued
Number of PO’s issued vs planned
Procurement
%
Monthly
90%
19
Pre-Inspection Meeting (PIM)
20
Closure of NCRs
PIM meetings conducted prior to start of fabrication/supply
No. closed in month / No. req. by due date*
Procurement
%
Monthly
100%
Procurement
%
Monthly
90%
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No more than 2 consecutive days of Welding Production No more than 3 consecutive days of welding production Backlog <5 Nos joints Per day
Coating Repair Rate <1%
Painting Repair Rate <1%
#
Activities
VENDOR TQs outstanding
VENDOR ITP witness and hold points
VENDOR Quality Records & Data outstanding
21
22
23
24
25
26
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Key Performance Indicators(KPI)
No. interface issues/queries closed in month / Total No. outstanding No. of witness & hold points missed / No. of witness & hold points scheduled No. of documents delivered late × 100 / No required by schedule
Key Focus Area/Quality Objective
t i n U
Freq.
Target Performance
Procurement
%
Monthly
90%
Procurement
%
Monthly
<5%
Procurement
%
Monthly
<5%
RFC documentation Hand-over
No. of documents delivered /(No required
Documentatio n
Nos Monthly
95%
Construction ITP witness and hold points
Contractor/ Subcontractor Inspection resourcing
No. of witness & hold points missed / No. of witness & hold points scheduled
Inspectors available /planned (by discipline)
Construction
%
Monthly
<5%
Construction
%
Monthly
90%
27
Site Queries
No. cleared in month / Total No. outstanding
Construction
%
Monthly
90%
28
29
Construction Inspection
No. of rejected RFIs
Construction
Nos Monthly
<3
Construction Inspection
No. of Open RFIs against closed RFIs
Construction
%
Monthly
95%
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
20.10 APPENDIX (J): CONTRACTOR AND LOWER TIER SUBCONTRACTORS, VENDORS
QUALITY PERSONNEL REQUIREMENTS
The objective of this appendix is to define CONTRACTOR’s Quality Control, Quality Assurance
and
Inspection personnel head count, competency requirements and
their roles &
responsibilities.
This Appendix covers Quality Personnel for MAIN CONTRACTORS, SUB- CONTRACTORS
VENDORS, SUB VENDORS, covering all phases from Engineering through Procurement,
Construction until Commissioning and Handing over to Company.
This Specification is not applicable to quality personnel whom representing ADNOC and their
operating Companies.
MINIMUM REQUIREMENTS FOR NUMBER OF QUALITY PERSONNEL
Tables-1, 2 and 3 defines the minimum requirement of Contractor’s Quality personnel in terms
of the required quality disciplines and head count. However, COMPANY reserves the right to
request the headcount of CONTRACTOR’s Quality personnel considering the workload and
performance.
PROJECT Value in USD (EPC Value)
Requirements
Overall PROJECT Quality Manager ( PQM)
Full time PQM to manage all PROJECT phases QA/QC
Construction Quality Manager (CQM)
Full time CQM to manage all construction Site QA/QC
Sr. QC Engineer
Sr. QA Engineer
Lead Procurement QC Eng.
Procurement QC Coordinator
Full time Sr. QC Eng. per each discipline as applicable E&I, CIVIL, Material Mechanical; etc.
One full time to manage all PROJECT phases QA activities and Audits.
One Full time Lead Procurement QC Eng, to manage Procured equipment / Materials QC.
One or more full time to coordinate all Procurement QC activities.
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Table-2 Shop /Construction site QC Inspectors requirements for Onshore PROJECTs.
Discipline
Contractor
Sub-Contractor
CIVIL/STRUCTURAL/GRE
Earth Works & Paving
1 per 5 Sub-Contractor Inspectors
1 per 50 Workmen
Concrete Foundation
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
Buildings
1 per 5 Sub-Contractor Inspectors
1 per 50 Workmen
Steel structural(site or shop)
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
GRE Works*
1 per 5 Sub-Contractor Inspectors
1 Per 10 Workmen
HVAC & MEP
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
Refractory & Fire proofing
Mechanical/ Piping
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
Receiving Inspector
1 at each Site Warehouse
1 at each Site Warehouse
Rotating & Mechanical Inspector
1 per 5 Sub-Contractor Inspectors
1 per 15 Workmen
Piping
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
Valve testing
1 per Valve testing Location
NA
Coating and Insulation
1 per 8 Sub-Contractor Inspectors
1 per 3 crews per Site
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Table-2 Shop /Construction site QC Inspectors requirements for Onshore PROJECTs.
Discipline
Contractor
Sub-Contractor
Test Pack Coordinator
As per Requirements. (Minimum One)
Minimum One
Welding
Receiving Inspector
1 at each Site Warehouse
1 at each Site Warehouse
Field and shop Welding
1 per 5 Sub-Contractor Inspectors
1 per 15 Workmen
NDT & PMI & PWHT / Hardness Coordinators
As per Requirement (Minimum One)
RT film interpreters. More are
and based on NDE volume and
required depends upon
locations, more are required.
volume of NDE and
Minimum One in addition to
spreads/locations
Welding Engineer*
1 dedicated to PROJECT
1 per Work Site
NDT Level III Engineer
PIPELINE WOKS
1 dedicated to PROJECT
1 per Work Site
Receiving Inspector
1 at each Site
1 at each Site Warehouse
Stringing & Bending
1 per PROJECT
2 per PROJECT.
Field & Repair Welding
1 per each Crew(Onshore)
2 per Crew mainline & Tie ins.
I per Repair Crew
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Table-2 Shop /Construction site QC Inspectors requirements for Onshore PROJECTs.
Discipline
Contractor
Sub-Contractor
NDT
1 Per each Crew – At Site for AUT.
Rest – At Site office – As required.
For RT, separate film interpreters are
required.
1 Per each Crew – At Site for AUT
Rest – At Site office – As
required. For RT, separate
coordinator
and
film
interpreters are required
Backfilling (onshore only)
1 for each Crew
1 for each Crew
Coating Inspector
1 for each Crew
1 for each Crew
Hydro test Coordination & Document Review
1 Quality Engineer
1 per Test Crew
Cathodic Protection
1 Per PROJECT
1 Per PROJECT
ELECTRICAL / INSTRUMENTATION
Electrical and instruments material Receiving Inspector
Electrical / Cathodic Protection
1 at each Site Warehouse
1 at each Site Warehouse
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
Instrumentation
1 per 5 Sub-Contractor Inspectors
1 per 25 Workmen
Calibration of Valves
1 per Crew
Telecom
1 per Site
1 per Crew
1 per Site
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
Table-2 Shop /Construction site QC Inspectors requirements for Onshore PROJECTs.
Discipline
Contractor
Sub-Contractor
- All site GRE installation and testing shall be witnessed, supervised by manufacturer technical
representative on full time basis. All inspection records to be endorsed for good workmanship.
- For every 5 Contractor Inspectors or more per discipline, there shall be one QC engineer and
QC supervisor in that discipline. Similarly for every 5 Sub-Contractor Inspectors or more per
discipline, there shall be one QC engineer and one QC supervisor in that discipline
- A minimum of one (1) QC engineer and one (1) QC Inspector will be assigned by
Contractor/Subcontractors for each position above if the number of workers / labors/ welders /
technicians and QC Inspectors performing the activities is below the specified ratio.
The Above personnel requirements will apply to Contractor if no Subcontractor is involved.
Table-3 QC Inspectors Requirement On Vessels For Offshore PROJECTs Only.
Discipline
Required inspectors
Pipelines
Welding Inspectors Multi disciplines Inspectors [Coating, AUT& Mechanical]
1 Per Vessel for each shift
1 Per Vessel for each shift
Pigging/Tie-in/Flushing & Dewatering/Sampling:
Multi disciplines Inspectors
1 Per Vessel
Deck, Jacket and other Installations:
Multi disciplines Inspectors
1 Per Vessel
Deck, Jacket and other Installations:
Multi disciplines Inspectors
1 Per Vessel
Hook-up:
Multi disciplines Inspectors
Multi disciplines Inspectors
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HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 1 – OFFSHORE FACILITIES
ADNOC Project No PXXX
QUALITY MANAGEMENT REQUIREMENTS ADNOC Doc. No. PK1-10.E
Rev. 00
QUALIFICATION REQUIREMENTS
PROJECT Quality Manager
• Bachelor of mechanical or metallurgical engineering, or other relevant engineering
degree.
• Certified ISO 9001 Lead Auditor.
• Having a total experience of min. 20 years with specific experience as a QA / QC manager
for min. 10 years in the Oil & Gas PROJECTs.
• Good command in PROJECT Quality auditing.
• Strong personality and leadership skills.
• Fluent English lingual skills.
Construction Quality Manager:
• Bachelor of mechanical or metallurgical engineering, or other relevant engineering
degree.
• Certified ISO 9001 Lead Auditor.
• Having a total experience of min. 20 years with specific experience as a QA / QC
manager for min. 10 years in the Oil & Gas PROJECTs.
• Relevant background in welding, NDT, and coating / painting.
• Strong personality and leadership skills.
• Fluent English lingual skills.
PROJECT Quality Assurance Manager:
• Bachelor of mechanical or metallurgical engineering, or other relevant engineering
degree.
• Certified ISO 9001 Lead Auditor.
• Having a total experience of min. 20 years with specific experience as a QA manager
for min. 5 years in the Oil & Gas PROJECTs.
• Good command in PROJECT Quality auditing.
• Strong personality and leadership skills.
• Fluent English lingual skills.
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QC Senior Engineer
• Bachelor of mechanical or metallurgical engineering, or other relevant engineering
degree.
• ISO 9001 Lead Auditor.
• ASNT Level II in RT, UT, MT, and PT.
• CSWIP 3.2 or AWS-CWI or another acceptable equivalent (approved by COMPANY).
• Having a total experience of min. 15 years in the Oil & Gas PROJECTs.
• Strong experience in welding, NDT, and coating / painting.
• Strong supervisory, coordination, and reporting skills.
• Fluent English lingual skills.
QC Engineer
• Bachelor of mechanical or metallurgical engineering, or other relevant engineering
degree.
• ISO 9001 Internal Auditor.
• ASNT Level II in RT, UT, MT, and PT.
• CSWIP 3.1 or AWS-CWI or another acceptable equivalent (approved by COMPANY).
• Having a total experience of min. 8 years as QC Engineer in the Oil & Gas PROJECTs.
• Hands on experience in welding, NDT, and coating / painting.
• Good command in PROJECT Quality auditing.
• Strong coordination and reporting skills.
• Fluent English lingual skills.
Sr. QA Engineer / QA Engineer
• Bachelor of engineering in a relevant discipline.
• Certified and registered IRCA Lead Auditor in ISO 9001
• Having a total experience of min. 12 years as QA Engineer with strong background of
the Oil & Gas PROJECTs environment.
• Strong knowledge and experience in leading PROJECT Quality audits.
• Strong coordination and reporting skills.
• Fluent English lingual skills.
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Welding Engineer
• Bachelor of mechanical or metallurgical engineering with Masters’ Degree in welding.
• Alternatively, Bachelor of mechanical or metallurgical engineering with Professional
certification in welding engineering (IWE, CWE, or another acceptable equivalent
(approved by COMPANY)).
• ASNT Level II in RT, UT, MT, and PT.
• Having a total experience of min. 12 years in welding related activities within the Oil &
Gas PROJECT environment.
• Fluent English lingual skills.
Welding Inspector
• Having a total experience of min. 5 years in the Oil & Gas industry (construction and
source inspection).
• Engineering Diploma in a relevant discipline.
• CSWIP 3.1 or AWS-CWI or another acceptable equivalent (approved by COMPANY).
• Good English lingual skills.
Sr. Coating / Painting Inspector
• Having a total experience of min. 10 years in the Oil & Gas industry (construction and
source inspection).
• Engineering Diploma in a relevant discipline.
• NACE Level II or CSWIP / BGAS Grade 2, or another acceptable equivalent (approved
by COMPANY).
• Good English lingual skills.
Electrical Inspector
• Shall be at least diploma in Electrical discipline and minimum 6 years of Electrical
Construction QC experience involving Oil & Gas / Petrochemical PROJECTs.
• Inspectors shall preferably be certified to COMPEX or equivalent requirements.
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Rev. 00
Instrumentation Inspector
• Shall be at least diploma in Instrumentation discipline and minimum 6 years of
Instrumentation Construction QC experience involving Oil & Gas / Petrochemical
PROJECTs.
Coating / Painting Inspector
• Having a total experience of min. 5 years in the Oil & Gas industry (construction and
source inspection).
• Engineering Diploma in a relevant discipline.
• NACE Level I / II or CSWIP / BGAS Grade 1 / 2, or another acceptable equivalent
(approved by COMPANY).
• Good English lingual skills.
VENDOR Inspectors
• Having a total relevant experience of min. 5 years in the Oil & Gas industry (VENDOR /
source inspection).
• Engineering Diploma in a relevant discipline.
• Familiar with Shell DEP’s and international codes & standards.
• Professional qualification / certification in the relevant discipline (welding, coating,
painting, NDT, …etc.).
• QA/QC Inspectors (GRE /GRP, Piping, Pressure Vessels, Tanks, Civil, Electrical /
Instrumentation, Cathodic protection … etc.) Having a total experience of min. 5 years in
the Oil & Gas industry (construction and source inspection).
• Engineering Diploma in a relevant discipline.
• Certified to the related discipline in Quality.
• Good English lingual skills.
NDT Technicians
• Radiographer shall be certified to ASNT or CSWIP / PCN level II with 3 years’
experience after certification, relevant to Oil & Gas PROJECTs.
• RT film interpreter shall be certified to ASNT ACCP level III, or CSWIP / PCN level II in
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Rev. 00
RT with 5 years’ experience after certification, relevant to Oil & Gas PROJECTs.
• Ultrasonic testing technician shall be certified to CSWIP / PCN level II certification with 5
years’ experience after certification, relevant to Oil & Gas PROJECTs.
• Other technicians shall have ASNT or CSWIP / PCN level II certification with min.
5years of relevant experience in Oil & Gas industry
• Alternative equivalent qualifications may also be acceptable, subject to COMPANY
approval.
Advanced NDT Inspector - AUT/PAUT/TOFD
• Hold a Degree/Diploma in Engineering or an approved equivalent.
• Shall be qualified in accordance with TWI CWSIP ISO 9712 Level-II for AUT Inspector.
• Shall be qualified in accordance with BINDT/PCN ISO 9712 Level-II for PAUT / TOFD
Inspector.
• Shall have prior experience in the relevant method and shall have worked in 3 prior
PROJECTs in similar capacity.
Underwater Inspector
Qualified in accordance with CSWIP 3.1U or an approved equivalent with Minimum 5 years
(2 years related to Upstream or downstream Oil and Gas Industry) in the 3.1 U abilities and
in addition be able to apply underwater magnetic particle inspection techniques and A scan
techniques using compression wave probes visual inspection of underwater structures, use
of camera both still film and CCTV, measurement of cathodic potentials and the use of
ultrasonic digital thickness meters.
ROV Inspector:
This inspector is an above water member of the inspection team Qualified to CSWIP 3.3U
or approved equivalent Minimum 5 years’ experience (3 years related to oil or
petrochemical industry) in the techniques included in the (CSWIP 3.1U) requirements,
recording and processing data, use of communications systems, have a knowledge of QA
relevant to underwater inspection and of remotely applied inspection system.
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Rev. 00
Under Water Inspection Controller
Qualified to CSWIP 3.4U or an approved equivalent Minimum 5 years’ experience (3 years related to Oil or petrochemical industry) in all aspects of the 3.3U ROV in addition to the techniques included in 3.2U requirements. Also have acknowledge of diving systems, capabilities and limitations of ROV’s and an understanding of inspection planning and briefing.
PERSONNEL APPROVAL
• All contractors’ quality personnel shall be approved by ADNOC prior to any engagement
in ADNOC PROJECTs.
• Contractor quality personnel shall have adequate experience and qualification to carry
out the required tasks professionally. It is the responsibility of the Contractor to verify
and validate their competencies/qualifications prior submitting their CVs for ADNOC
review and approval.
• Assessment/ interview records by the contractor for the proposed candidates shall be
submitted to ADNOC along with the CV and qualifications certificates.
• COMPANY has the right to interview any of the Contractor personnel either via
telephone or face-to-face or both and to conduct written test, to verify their competency.
ADNOC has the right to reject any proposed personnel without the need for indicating
the reasons, in which case the Contractor shall propose another candidate for review
and approval by ADNOC in a timely manner without affecting the PROJECT schedule.
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20.11 APPENDIX (K): TYPICAL INSPECTION AND TEST PLAN
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Project: Q-32855 - Saipem Hail & Ghasha Folder: ITB Attachments