B11 Living Quarters Quality Plan Procedures

QUALITY MANAGEMENT
SYSTEM DOCUMENT
QUALITY DETAIL PROCEDURE
DOC. NO : EJ/SSB/B11LQ/1.4.2/08
DATE
: 13/04/10
REV. NO
: 0
SAMPLE
PROJECT QUALITY PLAN PROCEDURES
PROVISION OF HOOK-UP AND COMMISSIONING SERVICES FOR B11 LIVING

QUARTERS MODULE AND HELIDECK
THIS DOCUMENT PRESCRIBES COMPANY PRACTICE AND IS FOR INTERNAL USE ONLY.
IT SHALL NOT BE REPRODUCED IN WHOLE OR IN PARTS OR RELEASED TO A THIRD PARTY WITHOUT
PRIOR CONSENT FROM THE HEAD OF RESPONSIBLE DEPARTMENT.
PREPARED BY
COMMISSIONING ENGINEER
CONTROLLED COPY
REVIEWED BY
MANAGER, COMMISSIONING
NO. :
APPROVED BY
PROJECT MANAGER
UNCONTROLLED
COPY
RESPONSIBLE DEPARTMENT: HOOK-UP & COMMISSIONING
C : B11 LQ /Sec.1.4.2 Project Quality Plan Procedure
Page 1 OF 24
QUALITY MANAGEMENT
SYSTEM DOCUMENT
QUALITY DETAIL PROCEDURE
DOC. NO : EJ/SSB/B11LQ/1.4.2/08
DATE
: 13/04/10
REV. NO
: 0
REVISION
PURPOSE OF ISSUE
DATE ISSUE
ISSUED BY
A
B
0
Issued for review

Re-issued for approval
Issued for Construction
02/04/2008
06/06/2008
07/06/2008
Hook-up and Commissioning

Hook-Up and Commissioning
Hook-Up and Commissioning
AGREED BY SSB AUTHORISED REPRESENTATIVE
...................................................................
(SIGNATURE)
...................................
(DATE)
NOTE : Please return approved copy to :
BROOKE DOCKYARD ENGINEERING & WORKS CORPORATION

HOOK-UP AND COMMISSIONING DEPARTMENT
ENGINEERING DIVISION
SEJINGKAT, JALAN BAKO
93050 KUCHING, SARAWAK
Page 2 OF 24
B11 LIVING QUARTERS

MODULE AND HELIDECK
TABLE OF CONTENTS
SECTION
DESCRIPTION
PAGE
1.0
PURPOSE
4 OF 24
2.0
SCOPE
4 OF 24
3.0
REFERENCES
4 OF 24
4.0
PROJECT QUALITY ORGANIZATION
4 OF 24
5.0
DUTIES AND RESPONSIBILITIES

5.1
Project Team Leader
5.2
Lead Commissioning Engineer
5.3
Technical / Document Clerk
5.4
Planning Engineer
5.5
Cost Engineer / Estimator
5.6
HSE Engineer
5.7
Material Planner/ Coordinator
5.8
Designer / Draftsman
5.9
QA / QC Engineer
5-9 OF 24
6.0
PQP REVIEW
10 OF 24
7.0
APPLICABLE QUALITY MANAGEMENT SYSTEM (QMS)

ELEMENTS
7.1
Project Contract Review
7.2
Document Control
10-12 OF 24
8.0
PRODUCT IDENTIFICATION AND TRACEABILITY

8.1
Process Control
8.2
Interfacing Controls
8.3
Procedures and Work Instructions
8.4
Variance Order Controls
8.5
Special Process Control
8.6
Commissioning
8.7
Inspection and Testing
8.8
Control of Inspection and Testing Equipment
8.9
8.10
Control of Non-conforming Products Corrective Action
8.11
Handling, Storage, Packaging, Preservation and Delivery
8.12
Quality Records
8.13
Quality Assurance Audits and Quality Awareness Program
8.14
Training
8.15
Project Statistical Data
13-22 OF 24
Page 3 OF 24
1.0
PURPOSE
This Project Quality Plan (PQP) intends to provide the control methods in all the work
processes involved in the engineering, offshore fabrication, installation, pre-commissioning and
commissioning phases of B11LQ Modules and Helideck.
2.0
SCOPE
This PQP shall be applied during the entire duration of this project and shall be complied
by EJ Joint Venture Sdn Bhd (EJJV) to perform works or services and to supply
consumables materials for the project.
3.0
REFERENCES
QUALITY ASSURANCE MANUAL
QUALITY ASSURANCE AND CONTROL PROCEDURES MANUAL
COMPANY PROJECT MANAGEMENT GUIDE AND PRACTICE
COMPANY PROJECT DEVELOPMENT GUIDELINE
PETRONAS TECHNICAL SPECIFICATION
ASME/ANSI B31.3
AWS Dl.1
API 1104
4.0
PROJECT QUALITY ORGANIZATION

Refer to Appendix 1 for the various proposed Organization Charts respectively. There are three
major engineering services to be utilized for the project namely:
-
Project Workpack and Cost Control

Fabrication and Commissioning
Quality Assurance
The scope of work and responsibilities of each group is mentioned in the Project Execution
Plan.
Page 4 OF 24
5.0
DUTIES AND RESPONSIBILITIES

5.1
Project Team Leader

5.1.1 Reporting directly to client Project Manager for the development of the
commissioning workpack.
5.1.1.1
Development of pre-commissioning / commissioning testing plans and

priorities, that will be applied for onshore and offshore works.
5.1.1.2
Manage and coordinate testing pre-commissioning and commissioning

interfaces with construction, design engineering, procurement and
vendor services.
5.1.1.3
Development of testing and pre-commissioning & commissioning

procedures in accordance with the specification, drawing, codes and
standards and vendor recommendations and coordinate endorsement
by operation. He has to liaise with client Operations Department and
personnel in establishing commissioning procedures.
5.1.1.4
To coordinate and update client in respect to the preparation and

progress of the commissioning workpack and development.
5.1.1.5
During the workpack and project implementation offshore he shall

be responsible to client operation the following
a)
b)
c)
d)
e)
f)
g)
h)
Implementation of safety program for offshore testing and

commissioning.
Timely completion of testing and commissioning activities.
Offshore testing and commissioning requirements i.e testing
consumables, equipments, manpower and support services
from other parties.
Preparation of MTO, commissioning spares, testing
equipment, shiploose list for the Hook up and Commissioning
phase and coordinate timely deliveries.
Vendor assistance requirement and mobilization as and when
required.
Testing and Commissioning progress control and reporting.
Coordinate with Operation on system priorities, and sub-system
ready for witnessing and handover.
Compilation of Testing and Commissioning documentations,
redline as-built drawings, equipment dossiers, etc.
Page 5 OF 24
5.2
Lead Commissioning Engineer

5.2.1
Prepare system overview and Commissioning Testing Plan (CTP).
5.2.2
Review and finalize testing

procedure and checksheets.
5.2.3
Able to determine vendor assistance requirement and mobilization, to be able

to incorporate in the workpack.
5.2.4
Leads the team in preparing procedure for testing and commissioning of

subsystem / system in accordance with the procedure and schedule of
priorities. Ensure testing and commissioning procedure meets design criteria
and intent purpose. He shall be supported by Electrical and Instrument
Engineers and Mechanical / Rotary Commissioning Engineers.
5.2.5
Preparation of the definition of Mechanical completion.
5.2.6
During the workpack and project implementation offshore, he has to undertake

the overall coordination of the commissioning activities with client Operation
supervision.
5.2.7
Advise operation personnel commissioning on sub-system / system ready for

testing.
5.2.8
Identifying need of third party inspectors and vendors.
5.2.9
Ensuring timely development compilation of the Commissioning Workpack

and preparation of final documentation.
5.2.10
Clarifying inquiries on operations and maintenance of the system and/or

equipment.
5.2.11
Preparing the relevant documentation for requisition of test equipment and

tools.
5.2.12
Liaise with QA/QC for compliance to requirements prior

Commissioning and Testing (i.e weld test, NCR clearance, etc.).
5.2.13
Monitoring, control, documentation and compilation of site changes and

variation orders.
5.2.14
Monitoring, Control Documentation and Compilation of site changes and

variation orders.
and
pre-commissioning/commissioning
to
Pre-
Page 6 OF 24
5.3
5.4
5.5
Technical Writer / Document Clerk

5.3.1
To assist in contract document compilation i.e. final document workpack etc.
5.3.2
To assist engineers in preparing the "Workpack" such as data encoding of

jobcards using in-house jobcard system, typing the scope of work, summaries,
work scoping / site visit report etc. for both Onshore and Offshore preparation
job.
5.3.3
To keep proper filling for all contract documents / final documentation and
workpack.
5.3.4
Involve directly with Engineering Department, Safety QA/QC, Procurement and

Safety Department to provide clerical support such updating status report.
Planning Engineer
5.4.1
Develop planning bar chart, CPN, manpower histogram and S-Curve for the
project.
5.4.2
Develop progress monitoring package and updating for reporting
5.4.3
Prepare daily and weekly progress report.
5.4.4
Preparing progress reports, analyses and areas of concern.
Cost Engineer / Estimator

5.5.1
Developing the Cost Control Strategy
5.5.2
Estimation of the required resources
5.5.3
Monitoring of cost and resources
5.5.4
Coordination and follow-up of the required resources
5.5.5
Coordinating of contractual issues
5.5.6
To prepare and estimate cost for additional works and up-date the status
5.5.7
Coordination of punchlist line items and follow up / up-date the status
Page 7 OF 24
5.6
5.7
5.8
5.9
HSE Engineer
5.6.1
To prepare safety jobcard analysis in every task Mechanical, Electrical and

Instrument, pre-commissioning and commissioning
5.6.2
To liaise and coordinate with client representative on matters pertaining to

safety.
5.6.3
To establish and coordinate safe working method.
Material Planner/Coordinator
5.7.1
Performs receipt inspection of incoming materials. Coordinate client inspection.
5.7.2
Document materials inspection by using the Materials Receipt Inspection

Report. Filing of reports and material mill/test certificates.
5.7.3
Updating of the Material Status Report.
Designer/Draftsman
5.8.1
To check the completeness of the issue drawings based on the quantity and
number of copies against the list in the drawing transmittal from client.
5.8.2
To update Drawing Control List which indicate the drawing and revision
number.
5.8.3
To issue a relevant copy of the drawings to the workpack team, which consist
of Discipline Engineers, Material Planner and QA/QC Engineer for workpack
preparation.
QA/QC Engineer
5.9.1
Responsible for the implementation and documentation of the project quality

procedures.
5.9.2
To ensure that inspection and testing are performed and documented in

accordance with the inspection and test plans.
5.9.3
Performs periodic audit on fabrication, installation, testing and commissioning

activities. Monitoring and implementation of corrective actions.
5.9.4
To develop specific quality control procedures when needed.
Page 8 OF 24
5.10
5.9.5
To ensure that the documentation of all inspection records is properly done

by the discipline engineers and inspectors.
5.9.6
To perform inspection when the need arises
5.9.7
Coordination with the client's inspector on inspection and testing activities.
5.9.8
Perform welder evaluation on a weekly basis.
5.9.9
To provide direction to inspectors on a daily basis to clarify assignments and

activities to be met and performed.
5.9.10
Responsible for the final documentation of the project.
Commissioning Engineers
5.10.1
Develop specific commissioning procedures.
5.10.2
Implement and document commissioning activities.
5.10.3
Ensure that client is informed on the tests that required client's presence.
Coordinate by sending notice of inspection.
5.10.4
He shall complete the required checksheets prior to submission to the client for
approval.
5.10.5
Preparation and compilation of inspection records, drawings and commissioning

checksheets into a System Handover Document for client approval.
5.10.6
Initiate "red-line" marking on drawings and diagrams with regards to actual

changes from the construction drawings.
5.10.7
Provide updates of activities to the Planning Engineer to be included in the

daily progress reporting.
Page 9 OF 24
6.0
7.0
PQP REVIEW
6.1
This Project Quality Plan shall be reviewed monthly to determine its effectiveness in
the implementation of the Company quality objectives for the project.
6.2
The review is to be performed based on audits and feedbacks by the client and the
Company's Quality Management Team. The review shall be documented and copied to
the client.
APPLICABLE QUALITY MANAGEMENT SYSTEM (QMS) ELEMENTS

7.1
Project Contract Review

7.1.1
Review of the contract shall be performed prior to the award of the work to
define and clear the scope of work in terms of its various requirements.
7.1.2
Ambiguities and exceptions shall be notified and cleared with the client
through a clarification meeting. Deviations shall be documented and discussed
with CLIENT for approval.
7.1.3
During the execution of work, site changes shall be documented and

forwarded to CLIENT for approval. Variation orders are to be controlled in
accordance with the applicable procedure and guideline provided by CLIENT.
7.1.4
All contract reviews, technical clarifications/queries, tender clarifications,

minutes of meetings and other contract documents shall be retained in the
Company's Document Control Section for retrieval.
Reference Procedures:
EJJV.QP.CN.001, REV. 0 : Contract Review EJJV.QP.CN.002,
REV. 0 : Change Order Control
7.2
Document Control
7.2.1
Project Filing System

7.2.1.1
All communication, correspondence and data in hard copy shall be

filed in accordance with the Project Files List. This does NOT
apply to manuals, procedures, and drawings (technical
documents) which are covered below.
Page 10 OF 24
7.2.2
7.2.1.2
Technical documents received from the client, consultants,

subcontractors and suppliers and documents produced by EJJV
shall be controlled in accordance with EJJV.QP.QA.001,
"Document Control Procedure".
7.2.1.3
Documents shall be distributed by the Project Document Controller in

accordance with the matrix prepared by the Project Team Leader in
concurrence with the Project Document Controller and the
Quality Assurance Manager. This matrix shall be held in the
Document Control Section.
Project Documents
Procedures, codes and specifications are to be controlled by the Quality
Assurance Engineer/Inspector. These documents are to be kept and
maintained at EJJV facilities. This includes the following
7.2.3
7.2.2.1
Company Standard QA/QC Procedures
7.2.2.2
Project Specific Procedures
7.2.2.3
Commissioning Procedures
7.2.2.4
Project Work Instructions
7.2.2.5
Welding Procedure Specifications
7.2.2.6
Procedure Qualification. Records
7.2.2.7
CLIENT General Specifications
7.2.2.8
Codes and Standards, i.e. ASME IX, ANSI B31.3, API 1104
Document Review, Approval and Issuance

7.2.3.1
Project specific procedures are to be reviewed and approved by the

Project Team Leader. Procedures are controlled as defined in the
Document Control Procedure.
7.2.3.2
Only the latest revision is to be used. Obsolete drawings, procedures

or specifications shall be identified, segregated and shall not be used
in the project.
Page 11 OF 24
7.2.3.3
7.2.4
Document transmittals shall be filed by the Document Controller.

There shall be a Project Document Register which is updated
whenever a document is developed, revised and distributed.
Project Revisable Technical Documents

All project revisable documentation shall be controlled by the Company
Document Controller in accordance with the Document Control Procedure. The
project Document Controller shall revise the project Document Register
periodically and forward the markup to the Company Document Controller
office in KL for updating of the Master Document Register and issue of
reports.
7.2.5
Standards and Codes

The Project Team Leader shall obtain the required standards and codes
for the project
7.2.6
Drawing Control
7.2.6.1
AFC drawings shall be distributed in accordance with the

Drawing Distribution Matrix prepared by the Project Team Leader
in conjunction with the Document Controller and the Quality
Assurance Engineer.
7.2.6.2
Use Document Transmittals whenever drawings are to be

furnished. Ensure that, transmittal copies are forwarded by the
recipients to the Document Controller to acknowledge receipt.
7.2.6.3
A Project Drawing Register is to be drawn up by the project

Document Controller. It is to be updated whenever new revisions
are received.
Page 12 OF 24
8.0
PRODUCT IDENTIFICATION AND TRACEABILITY

-
Upon acceptance receipt inspection, project materials, i.e. pipes, plates, flanges,
valves, fittings, etc, and all load-bearing structural components as well as
pressure-containing parts, shall be identified by color coding which denotes a specific
type of material. These color codes are as per CLIENT's specification for each type of
material.
Each type of material shall be stored or stacked separately into racks. Materials such as
duplex stainless steel shall be protected from any contamination caused by mixing with
other type of steels.
Mill Certificates shall be denotes with the Material Receiving Inspection Report number
for an efficient retrieval of information.
When required by the contract, the project materials shall be identified with the
specific area or location to which these are intended for construction or erection. Forms
of identification, i.e. color code, tagging, marking, etc., are in accordance with the
applicable client specification.
Prior to cutting of plates or pipes, an inspection shall be conducted to verify the

Material Specification, Heat Number and Size of the material. Result of the inspection
shall be recorded into the Material Verification Report. The Material Specification and
the Heat Number of the material shall be transferred prior to cutting.
A weld summary shall be developed to indicate the history of each joint throughout
the stages of fabrication. The summary shall contain the report numbers of
inspection performed during material verification, fit-up, visual, NDT, PWHT,
hydrostatic testing and painting. The QC Inspector shall update the summary
whenever an inspection is performed.
Welding Visual Inspection Reports shall indicate the welding process, the joint number,
drawing number, WPS number, and the welder number.
Each inspection point/joint shall be marked with joint number, line number welder
number and the applicable NDT performed. Color coding using GREEN is to indicate
the acceptance of the applicable NDT. This is to facilitate a faster verification especially
when a succeeding test, such as hydrotest, is to be performed.
The Lot Number or Heat Number of all welding electrodes, filter wires, or fluxes, shall
be recorded into the Welding Consumable Register which is maintained by the QC
Section.
-
Scrap or surplus materials shall be identified by the color code for each type of
material, with the material specification and the heat number clearly stamped.
Page 13 OF 24
As required by the contract, a Positive Material Identification shall be performed of

specific incoming materials, and weldments. The process shall be in accordance with
GS 18-10-1 and the reference procedure below. All materials or joints inspected by PMI
shall be identified by color code as provided by the GS mentioned above
EJJV.QP.MT.001, REV. 0 : Material Control
EJJV.QP.MT.002, REV. 0 : Control of Customer Supplied Materials
EJJV.QP.MT.003, REV. 0 : Positive Material Identification.
8.1
Process Controls
8.1.1
8.2
Planning and Scheduling

8.1.1.1
Level 1, Level 2 and Level 3 planning packages shall be developed

and submitted for approval by the client.
8.1.1.2
The Project Plan and Schedule should be able to monitor the

actual progress against planned targets.
8.1.1.3
The planning package shall specifically mention and capture

manpower and equipment loading and schedules.
8.1.1.4
Progress reporting shall be made on the daily basis using the

report format provided by the contract. The Project Team shall
formulate corrective actions in order to maintain the achievement of
planned targets.
Interfacing Controls
8.2.1
Resources for each discipline shall be determined and prepared on hand prior
to the start of the project. Manpower and equipment are sourced, hired or
purchased.
8.2.2
Weekly meeting with CLIENTS shall be conducted to discuss and monitor

performance, progress and compliance to the requirements of this PQP.
8.2.3
Internal coordination meetings shall be conducted to the discuss inter-phases

activities between various disciplines. It shall be encouraged to hold informal
brainstorming sessions to seek clarifications and agreements.
Page 14 OF 24
8.3
Procedures and Work Instructions

8.3.1
Procedures and Work Instructions shall be developed to cover the various

fabrication stages as follows:
8.3.1.1
8.3.1.2
8.3.1.3
8.3.1.4
8.3.1.5
8.3.1.6
8.3.1.7
8.3.1.8
8.3.1.9
8.4
8.5
Material Cutting
Fit-up
Welding
Repair of Duplex Steel
Painting
Erection
Pre-commissioning
Commissioning
8.3.2
Each discipline engineer i.e. QC, Mechanical, Electrical and Instrument shall be
responsible in the development of procedures and work instructions.
8.3.3
Flowcharts shall be used to supplement work instructions and procedures to

establish a user-friendly approach.
8.3.4
Translation to Bahasa Malaysia of procedures and instructions are done as

some of the company workers may not be conversant with the English
language.
Variance Order Controls

8.4.1
Change orders shall either be client or EJJV generated. Each site change may
be initiated by CLIENT through a site instruction or by EJJV issuing a
change order notice.
8.4.2
Variance orders are to be documented by relevant drawings and diagrams

when submitting to the client for approval.
8.4.3
EJJV-issued Variance Order Notice shall be signed by the Project Team Leader
prior to being sent to CLIENT for approval.
Special Process Control

8.5.1
EJJV shall generate procedures to verify the accuracy and quality of

product or process which is termed as a special process. The procedures
is also able to rectify on the usage of the special equipment to be used
for inspection.
Page 15 OF 24
8.6
8.5.2
Equipment to used shall be reliable by having a valid calibration and traceable

to a calibration standard.
8.5.2
Operators or skilled technicians to perform the verification are to be

selected by virtue of qualification and experience.
Commissioning
8.6.1
As EJJV will commission systems the following shall be considered in the

commissioning plans:
8.6.1.1
8.6.1.2
8.6.1.3
8.6.1.4
8.6.1.5
8.6.1.6
commissioning responsibilities of EJJV

scope of commissioning activities
interfaces with hook-up group
resources required
preparation of checksheets and procedures
criteria for handover
8.6.2
CLIENT shall be consulted and presented with the plans for review and
approval prior to the start of the commissioning activities.
8.6.3
Make use of the construction group's resources. Tie up with the

construction activities in order to minimise the time of handover.
8.6.4
If required, the planning shall include the order and timetables of

deliveries for commissioning spares like lubricating oils, filters, greases,
chemicals, packing materials, etc.
8.6.5
List down the commissioning spares for one year and two years.
8.6.6
Set up system of checksheets, ensure that results of tests are recorded in the
checksheets and signed by CLIENT upon completion.
8.6.7
Ensure that commissioning resources are present, such as:

8.6.7.1
8.6.7.2
8.6.7.3
Supervision personnel
Client engineers to witness the tests
Vendor's representatives
Page 16 OF 24
8.6.8
Check the availability of commissioning documentation which include:

8.6.8.1
8.6.8.2
8.6.8.3
8.6.8.4
8.6.9
Equipment inventory
Equipment record cards
System
and
equipment
manuals
Procedures
Commissioning activities will be monitored by the Q.C. Engineer or

Inspector to ensure that procedures and work instructions are implemented.
EJJV.O.P.09-0, REV. 0
EJJV.QP.QC.001, REV. 0
EJJV.O.P.04-0, REV. 0
EJJV.O.G.06-1, REV. 0
EJJV.QG.02-3, REV. 0
EJJV.QP.QC.01 1, REV. 0
EJJV.QP.PJ.001, REV. 0
8.7
Change Order Control

Welding and Fabrication
Qualification and Evaluation Of Welders
Control of Welding Consumables
Surface Preparation and Coating
Pressure Testing
Repair of Valves
Valves Leak Test
Post Weld Heat Treatment
Hardness Testing
Insulation
Project Management Monitoring and
Control
Planning and Scheduling
Piping and Mechanical Pre-Commissioning
Electrical
and
Instrument
PreCommissioning

8.7.1
Inspection and testing are to be conducted in accordance with clientapproved Inspection and Test Plan (ITP). See attached Inspection and Test
Plan for Piping, mechanical, electrical and instrument works.
8.7.2
The inspection activities are performed during the following stages: material
receiving, in-process and final inspection. Each of these stages are to have
distinct ITP's to be adhered to during the fabrication.
8.7.3
In-process inspection utilizes checksheets or checklists. It is to be ensured

that the preceding inspection activity is completed prior to conducting the
next step of fabrication.
Page 17 OF 24
8.7.4
Final inspection and testing is performing line checking and system check to
verify that the system is not having outstanding non-conformances or
incomplete inspection/test.
8.7.5
When all tests and works. have been completed, a System Handover is
carried out. The System Handover Package is composed of the test records,
drawings and diagrams for the whole system. This shall be forwarded upon
the discipline engineer's approval, to the client for acceptance.
8.7.6
All inspection records and certificates are to be maintained by the QC

Department. However, each discipline is responsible for the updating and
filing of their records. These records shall form the Final Project
Documentation.
8.7.7
The Final Documentation Index is to be submitted to the client for approval

upon award of the contract.
EJJV.QP.02-0, REV. 0 : Inspection and Test Status
8.8

8.8.1
The QC Department is to maintain and update an Equipment Register to

indicate the calibration status of all the test equipment to be used.
8.8.2
Equipment requiring calibration shall be calibrated by an authorized third party.

Calibration is to be traceable to standard practices. Records of calibration
are to be maintained by the QC Department for retrieval and verification
purposes.
8.8.3
Inspection and test equipment are to be maintained by competent

technicians and stored in controlled conditions to maintain the accuracy
of measurements when in use.
8.8.4
Each equipment shall be assigned a unique Identification Tag Number for

traceability purpose.
Reference Procedure:
EJJV.QP.05-2, REV. 0 : Control
Measuring and Testing Equipment
of
Page 18 OF 24
8.9

8.9.1
Materials received from CLIENT are inspected by the Material

Coordinator/QC Inspector shall be tagged to classify whether they are:
8.9.1.1
8.9.1.2
8.9.1.3
8.9.1.4
Awaiting Inspection
Rejected
Accepted
On hold
8.9.2
Rejected materials shall be segregated and identified to ensure that these are
not used for whatever purposes.
8.9.3
The inspection shall be conducted in accordance with the relevant

specifications and standards. The Material Coordinator/QC Inspector shall
indicate the status and date of inspection on the items inspected.
8.9.4
Inspection conducted during offshore fabrication shall be recorded and

documented using the standard Company formats contained in the applicable
procedures. Results of inspection are to be indicated on the inspected items
by using tag, permanent marker, label or color code.
8.9.5
Items which have undergone final inspection shall be tagged to facilitate

an identification for future processing or opening, i.e. opening of flanges,
vessels, etc. after the final inspection.
EJJV.QP.08-0, REV. 0 : Material Handling, Storage Packaging & Delivery
Page 19 OF 24
8.10
Control of Non-conforming Products and Corrective Action

8.10.1
Non-conforming products shall be segregated and identified. The nature of

non-conformance will be recorded in the Non-conformance Report. When
necessary, drawings or illustration shall be attached to provide the details
and extent of the non-conformity.
8.10.2
The Non-conformance report shall be forwarded to the Project team Leader

and copied to the client for approval of the proposed repair or disposition.
The discipline engineer is to provide the necessary corrective action to be
taken and the corresponding preventive measure.
8.10.3
The implementation of the proposed corrective action shall be monitored by

the QA/QC Department in order to subject the item to the applicable
inspection and testing. Only when the outcome of the test is satisfactory
that the Hold tag on the item is removed and the item is released for use.
8.10.4
A Non-conformance Log shall be maintained by the QA/QC Department. The

trend of non-conformities shall be recorded and monitored in order to
develop preventive action to minimize the recurrence of a non-conformity.
8.10.5
For issues where a formal NCR is unnecessary, a punchlist shall be compiled

and resolved progressively.
8.10.6
For non-conformance reports from the client, the NCR shall be registered
first and then copied to the Project Quality Assurance Engineer and Project
Lead Commissioning Engineers to determine the necessary corrective action.
8.10.7
Corrective and preventive action arising from the Company's audits shall be
registered as project Corrective Action Requests, implemented and followedup to verify effectiveness.
EJJV.QP.07-0, REV. 0 : Control of Non-conforming Products EJJV.QP.03-0,
REV. 0 : Corrective and Preventive Action EJJV.QP.04-0, REV. 0 : Corrective
and Preventive Action
Page 20 OF 24
8.11
Handling, Storage, Packaging, Preservation and Delivery

8.11.1 Project Materials shall be stored, released and used in a controlled manner.
Appropriate preservation methods and practice shall be used to maintain the
integrity of the materials.
8.11.2 Materials shall be identified with the methods provided by the client
specifications. Storage is carried out on racks and bins separating the
materials b y location numbers and material color coding.
8.11.3 Accepted and issued materials shall be updated in the Material Inventory
List. The Material Coordinator shall provide a copy of the list on a weekly
basis.
8.11.4 Different types of materials are stored and preserved according to the
Company relevant procedure. Special type of materials and products are to be
separated and protected from the rest to avoid contamination, i.e. duplex
steels.
8.11.5
The handling personnel and end-users shall be briefed with the

appropriate methods of handling and use of certain type of materials thru
Tool Box Meetings and Mobilization Briefing.
8.11.6
Fabricated pipe spools are to be protected by ends caps (plywood or rubber)

prior to shipment at site. Duplex pipes shall be and covered with plastic
sheets.
EJJV.QP.08-0, REV. 0 : Material Handling, Storage Preservation and Delivery
Page 21 OF 24
8.12
Quality Records
8.12.1
Project quality records comprise essential documentation that each

department of the project team is maintaining. This includes but not limited
to the following:
8.12.1.1
Contract documents, including contract review minutes of meeting,

clarifications, change orders
8.12.1.2
Specifications
8.12.1.3 Company and Project quality procedures
8.12.1.4
Constructions, installation and commissioning procedures
8.12.1.5
Work instructions
8.12.1.6
Standards and codes
8.12.1.7
Field inspection reports
8.12.1.8
Equipment calibration reports
8.12.1.9
Human resources personnel records
8.12.1.10 Drawings (AFC & As-built)
8.12.1.11 Vendor's catalogues and data
8.12.1.12 Checksheets and handover records
8.12.1.13 Work package
8.12.2
Project records shall be retained and stored in the project files. They shall be
archived in accordance with the procedures.
8.12.3
The Project Document Controller shall assign a unique index file code for each
department to correspond with the type and names of records to be
maintained, filed and updated.
8.12.4
Records shall be in A4 size sheet but those larger, as in drawings and

catalogues may be reproduced or just filed as they are, provided the filing
space is not restricted.
8.12.5
Audits shall be performed to verify the timely updating and completeness of

records as mentioned above.
8.12.6
Upon the completion of the project, the QA/QC Department shall initiate
the compilation and classification of project documents to be included in
the final documentation. An index of the Final Documentation is to be
submitted to the client for approval.
8.12.7
Back-up copies of electronic data shall be taken once a week and stored at
the project document room for safekeeping. Latest anti-virus software shall
be utilized.
Page 22 OF 24
8.12.8
Mechanical binders for final documentation shall comply with the client's
specification. The number of copies to be forwarded to the client is
dictated by the contract.
EJJV.QP.09-0, REV.O :
8.13
Control of Quality Records
Quality Assurance Audits and Quality Awareness Program

8.13.1
Audits shall be conducted during the project duration to verify compliance

to this PQP. Auditing is to, be carried out as per the audit schedule which is
submitted to the client at the start of the project.
8.13.2
Notice of audits shall be sent to the auditees and CLIENT shall be

informed of the planned audit. The client may join the audit as observer.
See attached Audit Schedule.
8.13.3
Non-conformance reports and Corrective Action Requests are compiled with

the audit reports. Trends analysis of non-conformities shall be established
and the QA/QC Department shall conduct follow-up audits to verify the
implementation of corrective and preventive actions.
8.13.4
Tool box meetings, briefings, Quality suggestion scheme, and Quality slogan
contests shall be initiated by the management.
EJJV.QP.10-0, REV.0 : Quality Assurance Auditing
8.14
Training
8.14.1
Tool box meetings shall be conducted daily to explain and impart quality
requirements to engineers and workforce. Topics of meetings are planned
ahead and forwarded to CLIENT for information.
8.14.2
Attendance during tool box meetings is to be recorded. Action items and

discussions shall be minuted and copied to CLIENT.
8.14.3
The Project Team Leader is responsible for the identification of all training and
ensuring that appropriate training is made available.
Page 23 OF 24
8.14.4
During the site phase of work, all personnel shall be inducted to safety and
general project requirements. The Project Team Leader shall retain the
following records relating to above:
8.14.4.1 A list of staff who have been inducted into the operation of the
above procedures.
8.14.4.2 A list of all site personnel inducted into the site/vessel.
EJJV.QP.HR.001, REV.O : Training and Personnel Develop
8.15
Project Statistical Data

8.15.1
The QA/QC Department shall submit the following reports to CLIENT on a

weekly basis:
Welder Repair Rate
Welder's Repair Rate
Non-conformance Breakdown Report
Non-conformance Trend Analysis Report
8.15.2
Welding Repair rate for piping is calculated on "as per weld basis", which
is the number of weld joints repaired divided by the total joints tested. For
structural welding, the repair rate is the length of repair divided by the
total length of weld tested
8.15.3
The maximum allowable repair rate for welders shall be 3%. Welders who
exceed shall be sent a first warning. Failure to improve after one week shall
require the welder to re-qualify.
Page 24 OF 24

B11 Living Quarters Quality Plan Procedures

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QUALITY MANAGEMENT

PROVISION OF HOOK-UP AND COMMISSIONING SERVICES FOR B11 LIVING

RESPONSIBLE DEPARTMENT: HOOK-UP & COMMISSIONING

C : B11 LQ /Sec.1.4.2 Project Quality Plan Procedure

Issued for review

Hook-up and Commissioning

AGREED BY SSB AUTHORISED REPRESENTATIVE

NOTE : Please return approved copy to :

BROOKE DOCKYARD ENGINEERING & WORKS CORPORATION

C : B11 LQ /Sec.1.4.2 Project Quality Plan Procedure