STANDARDS PUBLICATION
KOC STANDARD FOR
PROJECT QA / QC GENERAL
REQUIREMENTS
DOC. NO. KOC-Q-014
(Rev. 2)
STANDARDS TEAM
DOC. NO. KOC-Q-014
Page 1 of 100
REV. 2
STANDARDS PUBLICATION
KOC STANDARD FOR
PROJECT QA / QC GENERAL
REQUIREMENTS
DOC. NO. KOC-Q-014
(REV. 2)
STANDARDS TEAM
DOC. NO. KOC-Q-014
Page 2 of 100
II
II
REV. 2
KOC STANDARD FOR
PROJECT QA I QC GENERAL
REQUIREMENTS
DOC. NO. KOC-Q-014
(REV. 2)
ISSUING AUTHORITY:
STANDARDS TEAM
2
08/03/2017
1
24/04/2008
Rev.
Date
Issued as
Task Force
KOC Standard
(TF-QC/03)
Issued as
Task Force
KOC Standard
(TF-QC/02)
Description
Prepared by
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G. S. Kumar
B. Srinivasan
halid B. AI-Shammari
Mohd. Emam
S. Kumar
Faisal Mirza
TF-Leader
Snr. Engr. Standards
Team Leader Standards
Tel. No. 65218
Tel. No. 63234
Tel. 61896
DOC. NO. KOC-Q-014
Page 3 of 100
REV. 2
TABLE OF CONTENTS
Page No.
FOREWORD
5
1.0
SCOPE
6
2.0
APPLICATION
6
3.0
TERMINOLOGY
3.1 Definitions
3.2 Special Definitions
3.3 Abbreviations
7
7
12
12
4.0
REFERENCE STANDARDS, CODES AND SPECIFICATIONS
4.1 Conflicts
4.2 List of Standards, Codes and Specifications
14
14
14
5.0
CONTRACTOR’S QUALITY MANAGEMENT SYSTEM FOR THE
PROJECT
19
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
19
19
19
20
22
23
25
26
26
26
27
ISO 9001 Accreditation
Project Quality Documents
Required Quality Management Documents
Project Quality Manual (PQM)
Project Quality Plans (PQP)
Contractor’s and Subcontractor’s Resources and Personnel
Contractor’s Management Review
Contractor’s Internal and External Audits
Auditing of KOC Approved Manufacturer
Internal Audits
Audit Report
6.0
CONTRACTOR’S QUALITY CONTROL REQUIREMENTS
6.1
Project Pre-Inspection Meetings (PPIM)
6.2
Construction Pre-Inspection Meeting (CPIM)
6.3
Inspection Schedule
6.4
Conceptual Design and Detailed Design Phase
6.5
Procurement Phase
6.6
On-Site Construction Phase
6.7
Pre-Commissioning Phase
27
27
28
28
28
29
40
44
7.0
MATERIAL MANAGEMENT
44
8.0
LABORATORY QUALIFICATION
46
9.0
QUALIFICATION OF BODIES PERFORMING INSPECTION
46
10.0 QUALIFICATION OF BODIES PERFORMING PRODUCT
CERTIFICATION
47
DOC. NO. KOC-Q-014
Page 4 of 100
REV. 2
11.0 OBJECT CONFORMITY AND CERTIFICATION
47
12.0 BASELINE DATA COLLECTION
47
13.0 MATERIALS FROM STOCKIST / DISTRIBUTORS
48
14.0 COUNTERFEIT, FRAUD AND BOGUS REPORTS PREVENTION
PLAN
48
15.0 NON-DESTRUCTIVE EXAMINATION (NDE) AND THIRD PARTY
INSPECTION BODIES
49
16.0
50
APPENDICES
APPENDIX-A
CONTRACTOR QA / QC PERSONNEL QUALIFICATIONS
51
APPENDIX-B
THE CONTROL OF NON-CONFORMANCES
55
APPENDIX-C
PROJECT PRE-INSPECTION MEETING (PPIM)
58
APPENDIX-D
VENDOR PRE-INSPECTION MEETINGS (VPIM)
62
APPENDIX-E
CONSTRUCTION PRE-INSPECTION MEETING (CPIM)
68
APPENDIX-F
MANUFACTURING RECORD BOOK (MRB) AND
CERTIFICATION REQUIREMENTS
72
TYPICAL QA PROCEDURES TO BE PROVIDED
BY THE CONTRACTOR
83
TYPICAL QC PROCEDURES TO BE PROVIDED
BY THE CONTRACTOR
85
APPENDIX-I
PROCUREMENT FROM STOCKIST
87
APPENDIX-J
BASELINE DATA THICKNESS MEASUREMENTS
90
APPENDIX-K
INSPECTION AND TEST PLAN (ITP) TEMPLATE
96
APPENDIX-G
APPENDIX-H
ACKNOWLEDGEMENT
100
DOC. NO. KOC-Q-014
Page 5 of 100
REV. 2
FOREWORD
This document “KOC Standard for Project QA / QC General Requirements” (KOC-Q-014,
Rev. 2) is intended to provide the general requirements for Quality Assurance and Quality
Control work to be adopted for use in all KOC Projects. The earlier document (KOC-Q-014,
Rev. 1) issued in April 2008, has been revised for incorporation of latest requirements.
This KOC Standard (Rev. 2) has been approved by the Standards Team in consultation with
the Standards Technical Committee (STC) for consistent use throughout the Engineering and
Operational Functions of Kuwait Oil Company (K.S.C).
This Standard is essentially based on API Q1 and API Q2 and the ISO family of Standards
and ISO 9000, 9001, 9004 and 17025 in addition to the other ISO standards related to
“conformity assessment” i.e. ISO / IEC 17000 family. It is necessary that organizations
executing projects for Kuwait Oil Company (KOC) and bodies performing conformity
assessments on behalf of those organizations or KOC should be aware of the various
changes in the ISO Standards and Guides that are associated with this KOC Standard.
This Standard sets out to achieve the following objectives:
a) To provide the basic guidance for establishing effective QA / QC Requirements and
conforming to KOC requirements.
b) To harmonize current practices by rationalisation, standardisation and internal control of
acceptable existing practices.
c) To maintain KOC requirements of safety, protection to plant, personnel and environment
established by KOC.
Feedback as well as any comments or suggestions derived from the application of this
Standard at any stage of design, construction, maintenance and field experiences are invited
and should be directed to:
Team Leader Standards
(Chairman, Standards Technical Committee)
Projects Support Services Group, K. O. C.
P.O. Box- 9758, Ahmadi-61008
State of Kuwait
DOC. NO. KOC-Q-014
Page 6 of 100
REV. 2
1.0
SCOPE
1.1
This Standard defines KOC general requirements for Quality Assurance and
Quality Control work to be adopted for use in all KOC Projects. These
requirements are also applicable for the work of Contactors, Manufacturers,
Suppliers, Vendors, Sub-Vendors, Service Providers for all the work associated
with Conceptual Design, FEED, Detailed Design, Procurements, Site Construction,
Pre-commissioning and Commissioning. Parts of this Standard are applicable to
KOC direct purchasing of materials and equipment intended primarily for KOC
stores.
1.2
Quality system elements to be implemented shall be in accordance with KOC
Contract Specifications, KOC Standards, and applicable International Codes and
Standards.
1.3
This Standard is an addition to the latest ISO 9000 family, ISO / IEC 17000 family,
API Q1 and API Q2 which form basis of this Standard.
1.4
KOC requires the Contractor to properly implement those quality elements into its
Quality Management System, in order to provide confidence to KOC that the
intended quality will be achieved in the delivered products, equipment or goods
and services provided, and that the new facilities are constructed in compliance
with the Contract and applicable KOC and International / Industry Engineering
Codes, Standards and Specifications.
2.0
APPLICATION
2.1
Quality requirements shall be implemented in all the following phases of the
project.
a)
Conceptual Design Phase by KOC/Contractor.
b)
Design and Front End Engineering Design (FEED) Phase by KOC /
Contractor.
c)
Detailed Engineering Phase by the Contractor after Contract award.
d)
Procurement Phase by the Contractor, Manufacturer and Service
Provider.
e)
Construction Phase by the Contractor and Service Provider.
f)
Pre-commissioning and Commissioning Phase by the Contractor.
DOC. NO. KOC-Q-014
3.0
TERMINOLOGY
3.1
Definitions
Page 7 of 100
REV. 2
For the purposes of this Standard, the terms and definitions given in ISO 9000, ISO
9001, API Q1, API Q2, ISO 29001 and the following definitions apply. Other
definitions in KOC-QAMS-001 document may also be considered as appropriate.
3.1.1
Assessment
The technical term is used when conformity assessment to a standard specification or
regulation is applied:
a)
First-Party Assessment
First Party Assessment to a standard, specification or regulation is carried out
by the supplier organization. In other words, it is self-assessment.
b)
Second-Party Assessment
Second Party Assessment is carried out by a customer of the supplier
organization. For example, the supplier invites a potential customer to verify
that the products goods and services which it is offering conform to relevant
ISO product goods and services standards.
c)
Third-Party Assessment
In this case, the conformity assessment is performed by a body that is
independent of both supplier and customer organizations. An example is ISO
9001 certification where an organization’s quality management system is
assessed by an independent “certification” or “registration” body against the
requirements of ISO 9001 standard. If the system conforms to the
requirements, the certification / registration body issues the organization with
ISO 9001 certificate.
3.1.2
Authorized Inspector (AI)
An inspector regularly employed by an ASME accredited Authorized Inspection
Agency (AIA) or the National Board of Boilers and Pressure Vessel Inspectors in
accordance with the requirements in the latest edition of ASME QAI-1.
3.1.3
Authentic Material Good
Material good produced under the control of the legitimate manufacturer, originator of
the good or holder of intellectual property rights.
3.1.4
Authentication
Act of establishing whether a material good is genuine or not.
3.1.5
Authentication Element
Tangible object, visual feature or information associated with a material good or its
packaging that is used as part of an authentication solution.
3.1.6
Calibration
A set of operations that establish, under specified conditions, the relationship between
the values of quantities indicated by measuring instrument or measuring system and
the corresponding values realized by standards.
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3.1.7
Calibration Laboratory
Laboratory that performs calibration.
3.1.8
Certification
Certification program or scheme is the procedure by which written assurance is given
that a product, goods or services conform to a standard or specification.
3.1.9
Conformity Assessment
Activity that provides demonstration that specified requirements relating to a product,
process, system, person or body are fulfilled (ISO 17000).
3.1.10
Contractor
Party which was awarded an agreement with KOC to carry out all or part of the
design, engineering, procurement, construction and commissioning for a project or
operation of a facility.
3.1.11
Contract Documents
Documents that comprise a contract, e.g., in a construction contract, the ownercontractor agreement, conditions of the contract (general, supplementary, and other
conditions), plans and / or drawings, specifications, all addenda, modifications, and
changes thereto, together with any other items stipulated as being specifically
included.
3.1.12
Counterfeit, (Verb)
To simulate, reproduce or modify a material good or its packaging without
authorization.
3.1.13
Counterfeit Good
Material good imitating or copying an authentic material good.
3.1.14
Documented Information
This term replaces the term “Documents / Records” in ISO-9001-2008. The term
“Documented Information” is now used by ISO-9001-2015.
3.1.15
First Article
Representative sample of a product, component, or output from a process used to
verify that prescribed activities have satisfied the requirements as specified by KOC.
NOTE: Samples can include trial purchases and prototypes.
3.1.16
Fraud
A willful act of deception that creates human or economic harm. Examples are
a)
product related such as counterfeiting, illicit diversion, alteration, intellectual
property infringement.
b)
Identity fraud such as identity theft (imposter fraud, disguise, credential
alteration).
c)
document fraud such as certificate fraud.
3.1.17
Inspection
Conformity evaluation by observation and judgment accompanied as appropriate by
measurement, testing, gauging or otherwise comparing the product with the
applicable requirements.
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3.1.18
Inspection Data Sheet / Source Inspection Plan
Document prepared by the Contractor and normally attached with the Engineering
Requisition (ER) or Purchase Order (PO) to indicate the required inspection, testing,
certification, documentation and involvement of both the Contractor and KOC in the
inspection activities at vendors, manufacturers and suppliers. Inspection requirements
shall be collected from various KOC documents (contract, data sheets, technical
specifications, standards, drawings, addendums, etc.).
3.1.19
Inspection Level (IL)
The specified amount of inspection coverage (at a specific vendor and / or subvendors) that is necessary to ensure that a product, goods or services conform to the
requirements.
3.1.20
Inspection and Test Plan (ITP)
The working document, which identifies the specific inspections and tests to be carried
out for the equipment, material, site works or services required by the Contract. The
document shall be prepared by Contractor, subcontractor, Vendor, Manufacturer or
Supplier (as applicable) to show the systematic chronological activities along with
responsibilities of undertaking (Refer also Appendix-K of this Standard).
3.1.21
Inspection Release Note
Inspection Release note is a formal notification to vendor/sub-vendor of that the item
supplied are released for dispatch or shipment. It should state clearly the items found
acceptable including the material part number, unique traceability and other details.
3.1.22
Laboratory
Body that calibrates and / or tests
(Note: In case where a laboratory forms part of an organization that carries out
other activities besides calibration and testing, the term “Laboratory” refers only to
those parts of the organization that are involved in the calibration and testing
process”. The term “Laboratory” refers to a body that carries out calibration or
testing at or from a permanent location, at or from a temporary facility or in or from
a mobile facility).
3.1.23
Manufacturer
Any manufacturer marking equipment or materials in conformance with the marking
requirements of an API standard and other codes/standards e.g. ASME, ASTM, ISO
etc.
3.1.24
Mechanical Completion Certificate (MCC)
Certificate issued by KOC to the Contractor when the total facility (or portion thereof
for a ‘partial’ MCC) defined in the Contract has been installed and tested in
accordance with the Contract and is available for Commissioning and start-up.
3.1.25
NDE
Non Destructive Examination. Used synonymous to NDT (Non-Destructive Testing)
The development and application of technical methods to examine materials and / or
components in ways that do not impair future usefulness and serviceability in order to
detect, locate, measure, interpret, and evaluate flaws (Ref: ASME V).
DOC. NO. KOC-Q-014
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REV. 2
3.1.26
Pre-Commissioning
Testing of system components for completion, continuity, operability and in the case of
process plants, their ability to withstand operating conditions prior to the introduction of
fluids (hydrocarbons or other fluids) into the facility.
3.1.27
Product
The result of a set of interrelated or interacting activities which transforms inputs into
outputs. A product could be one or all of four categories (services, hardware, software,
processed material).
3.1.28
Products and Services
This term “products and services” used in ISO-9001-2015 replaces the term
“Products” used in ISO 9001-2008.
3.1.29
Project
Unique process, consisting of a set of coordinated and controlled activities with start
and finish dates, undertaken to achieve an objective conforming to specific
requirements, including the constraints of time, cost and resources.
3.1.30
Project Close Out
The final inspection, submission of necessary documentation, acceptance, and
concluding payment on a construction project, as required by the contract documents.
3.1.31
Project Quality Program
A document prepared by KOC, Contractor or Consultant on behalf of KOC, defining
general requirements for quality matters related to a particular Contract or order.
Where Project Quality Program is not provided by KOC, the Contractor shall prepare
and submit the same for KOC review and approval.
3.1.32
Quality
Degree to which a set of inherent characteristics fulfills requirements (need or
expectation that is stated, generally implied or obligatory). Inherent characteristics are
defined as the physical (e.g. mechanical, electrical, chemical or biological
characteristics); the sensory (e.g. related to smell, touch, taste, sight, hearing); the
behavioral (e.g. courtesy, honesty, veracity); the temporal (e.g. punctuality, reliability,
availability); the ergonomic (e.g. physiological characteristic, or related to human
safety); and the functional (e.g. maximum speed of a machine).
3.1.33
Quality Assurance (QA)
Part of Quality Management (coordinated activities to direct and control an
organization with regard to quality) focused on providing confidence that quality
requirements will be fulfilled.
3.1.34
Quality Assurance Program
The overall Program or Management System established to assign responsibilities
and authorities, define policies and requirements, and provide for the performance
and assessment or work.
3.1.35
Quality Control (QC)
The physical verification that the product conforms to these planned arrangements by
inspection, measurement, etc.
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3.1.36
Quality Management
Coordinated activities to direct and control an organization with regard to quality.
Note: Direction and control with regard to quality generally includes establishment of
the Quality Policy and Quality Objectives, Quality Planning, Quality Control, Quality
Assurance and Quality Improvement.
3.1.37
Quality Management System
Set of interrelated or interacting elements to establish policy and objectives and to
achieve those objectives which direct and control an organization with regard to
quality.
3.1.38
Quality Manual (QM)
A document consisting of the recorded quality management system of the
organization which includes policies, procedures, specifications, standards, drawings,
reports and practices intended for the overall planning and administration of activities
which impact on the quality within an organization.
3.1.39
Quality Plan (QP)
A document prepared by the Contractor or supplier, setting out in chronological order
the specific quality practice, procedures, organization, resources, timing and activities
relevant to a particular Contract, sub-Contract or Purchase order. It defines the direct
control functions and procedures which inspects, measure, test, record and control
procurement, fabrication construction, site installation, pre-commissioning and / or
mechanical activities through establishment process, specifications and standards for
all matters and disciplines involved. Normally developed in line with ISO 10005 series
of standards. The Quality Plan has to be tailored to reflect special details and
requirements of the KOC Contract.
3.1.40
Service
Performance of an activity by one function or organization for another.
3.1.41
Service Quality Plan
Document that establishes procedures, resources, processes, and any required
sequence of activities identifying and controlling the quality requirements.
3.1.42
Service-Related Product
Materials, equipment, and software used in the execution of a service.
3.1.43
Sub-Contractor
Any party with which the Contractor enters into an agreement to supply services or
materials for the Work, and including the sub-Contractor’s suppliers, vendors and / or
manufacturers.
3.1.44
Supplier
Organization (group of people and facilities with an arrangement of responsibilities,
authorities and relationships) or person that provides a product (result of a process,
services, hardware, software, processed materials) (Refer ISO 9000 definitions).
DOC. NO. KOC-Q-014
3.1.45
Page 12 of 100
REV. 2
Test
A technical operation that consists of the determination of one or more characteristics
or performance of a given product, material, equipment, organism, physical
phenomenon, process or service according to a specified procedure.
(Note: The result of a test is normally recorded in a document sometimes called a test
report or test certificate).
3.1.46
Testing laboratory
Laboratory that performs tests.
3.1.47
Third Party Inspectorate (TPI)
An organization independent of the Contractor, Vendor or Manufacturer and
possessing the necessary competence to verify that any or all of the design,
manufacture, construction and installation satisfy the specification and purchase order
requirements. TPI could be utilized by KOC and/or the Contractor as a representative
for carrying out inspection at vendors, suppliers and manufacturers.
3.1.48
Vendor
Any firm, organization or company that manufacture, produce, sells goods or services.
3.1.49
Work Phases
Work phases in this Standard are meant to be the conceptual design, FEED, detailed
design, procurement, site construction, pre-commissioning and commissioning.
3.2
Special Definitions
The following definitions are provided to indicate KOC meaning of those terms within
the text of this Standard:
3.2.1
Shall
Is used to indicate that a provision or requirement is mandatory.
3.2.2
Should
Is used to indicate that a provision is not mandatory, but recommended as good
practice.
3.2.3
May
Is used to indicate that a provision is permitted.
3.2.4
Can
Is used to indicate possibility and capability.
3.3
Abbreviations
AI
Authorized Inspector (ASME / National Board Inspector)
CAB
Conformity Assessment Body
CR
Concession Request
CRA
Corrosion Resistant Alloy
DOC. NO. KOC-Q-014
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REV. 2
CRB
Construction Record Book
CPIM
Construction Pre-Inspection Meeting
CQAP
Construction Quality Assurance Plan
CSWIP
Certification Scheme for Welding and Inspection Personnel
CWI
Certified Welding Inspector
ECP
Engineering Change Proposal
ERB
Engineering Record Book
FEED
Front End Engineering Design
ITP
Inspection & Test Plan
KOC
Kuwait Oil Company (K.S.C.)
MOM
Minutes of Meeting
MRB
Manufacturing Record Book
MT
Magnetic Testing
NB
National Board
NCR
Non-Conformance Report
NDE / NDT
Non Destructive Examination
(Synonym to NDT – Non Destructive Testing)
OMM
Operations and Maintenance Manual
PCA
Project Controlling Authority (This could be the PMC)
PMC
Project Management Consultant
PMI
Positive Material identification
PO
Purchase Order
PPIM
Project Pre-Inspection Meeting
PQM
Project Quality Manual
PQP
Project Quality Plan
PQR
Project Quality Record
PQR(W)
Procedure Qualification Record (Welding)
PRB
Project Record Book
PT
Penetrant Testing
DOC. NO. KOC-Q-014
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PWHT
Post Weld Heat Treatment
QA
Quality Assurance
QC
Quality Control
QM
Quality Manual
QP
Quality Plan
RFC
Request for Concession
RFD
Request for Deviation
RFW
Request for Waiver
RT
Radiographic Testing
TPI
Third Party Inspectorate
UT
Ultrasonic Testing
VPIM
Vendor Pre-Inspection Meeting
VT
Visual Testing
WI
Work Instructions
WPS
Welding Procedure Specification
4.0
REFERENCE STANDARDS, CODES AND SPECIFICATIONS
4.1
Conflicts
REV. 2
In the event of conflict between this Standard and the latest edition of standards /
codes referred herein, or other purchase or contractual requirements, the most
stringent requirement shall apply.
4.2
List of Standards, Codes and Specifications
The current issues and amendments of the applicable codes and standards,
including but not limited to the following:
4.2.1
American Petroleum Institute (API)
API SPEC Q1
Specification for Quality Management System Requirements for
Manufacturing Organizations for the Petroleum and Natural Gas
Industry
API SPEC Q2
Specification for Quality Management System Requirements for
Service Supply Organizations for the Petroleum and Natural Gas
Industries
DOC. NO. KOC-Q-014
4.2.2
4.2.3
Page 15 of 100
REV. 2
API RP 5 SI
Recommended Practice for Purchaser
Surveillance and / or Inspection at the Supplier
Representative
API RP 578
Material Verification Program for New and Existing Alloy Piping
Systems
API STD 650
Welded Tanks for Oil Storage
API STD 653
Tank Inspection, Repair, Alteration, and Reconstruction
API STD 1104
Welding of Pipelines and Related Facilities
American Society of Mechanical Engineers (ASME)
ASME B 31.3
Process Piping
ASME B 31.4
Pipeline Transportation Systems for Liquids and Slurries
ASME B 31.8
Gas Transmission and Distribution Piping Systems
ASME QAI-1
Qualifications for Authorized Inspection
ASTM International (American Society for Testing and Materials)
ASTM E 329
Standard Specification for Agencies Engaged in Construction
Inspection, Testing, or Special Inspection
ASTM E 543
Standard Specification for Agencies Performing Nondestructive
Testing
ASTM E 1212
Standard Practice for Quality Management Systems for
Nondestructive Testing Agencies
ASTM E 1359
Standard Guide for Evaluating Capabilities of Nondestructive
Testing Agencies
ASTM F1448
Standard Guide for Selection of Security Technology for
Protection Against Counterfeiting, Alteration, Diversion,
Duplication, Simulation, and Substitution (CADDSS) of Products
or Documents
ASNT-CP-105
Standard Topical Outlines for Qualification of NDT Personnel
ASNT CP 189
ASNT Standard for Qualification
Nondestructive Testing Personnel
ASNT SNT TC 1A
Personnel Qualification and Certification in Nondestructive
Testing, and ASNT-CP-105: Standard Topical Outlines for
Qualification of Nondestructive Testing Personnel
AWS D1.1 / D1.1M Structural Welding Code
and
Certification
of
DOC. NO. KOC-Q-014
4.2.4
4.2.5
Page 16 of 100
REV. 2
British Standards (BS)
BS 10501
Guide to Implementing Procurement Fraud Controls
BS EN 10168
Steel Products Inspection Documents List of Information and
Description
BS EN 10204
Metallic Products Types of Inspection Documents
BS EN 62198
Managing Risk in Projects — Application Guidelines
BS ISO 37001
Anti-bribery Management Systems — Requirements with
Guidance for Use
International Organization for Standardization (ISO)
ISO 2859
(Part 1,3,4,5,10)
Sampling Procedures for Inspection by Attributes:
Part 1: Sampling Schemes Indexed by Acceptance Quality Limit
(AQL) for Lot-by-Lot Inspection
Part 3: Skip-lot Sampling Procedures
Part 4: Procedures for Assessment of Declared Quality Levels
Part 5: System of Sequential Sampling Plans Indexed by
Acceptance Quality Limit (AQL) for Lot-by-Lot Inspection
Part 10: Introduction to the ISO 2859 Series of Standards for
Sampling for Inspection by Attributes
ISO 9000
Quality Management Systems — Fundamentals and Vocabulary
ISO 9001
Quality Management Systems — Requirements
ISO 9004
Managing for the Sustained Success of an Organization — A
Quality Management Approach
ISO 9712
Non-Destructive Testing - Qualification and Certification of NDT
Personnel
ISO 10005
Quality Management Systems - Guidelines for Quality Plans
ISO 10006
Quality Management Systems
Management in Projects
ISO 10007
Quality Management Systems Guidelines for Configuration
Management
ISO 10012
Measurement Management Systems - Requirements for
Measurement Processes and Measuring Equipment
ISO 11484
Steel Products — Employer's Qualification System for NonDestructive Testing (NDT) Personnel
ISO 12931
Performance Criteria for Authentication Solutions Used to
Combat Counterfeiting of Material Goods
-
Guidelines
for
Quality
DOC. NO. KOC-Q-014
Page 17 of 100
REV. 2
ISO 13879
Petroleum and Natural Gas Industries - Content and Drafting of a
Functional Specification
ISO 13880
Petroleum and Natural Gas Industries - Content and Drafting of a
Technical Specification
ISO 19011
Guidelines for Auditing Management Systems
ISO 28001
Security Management Systems for the Supply Chain — Best
Practices for Implementing Supply Chain Security, Assessments
and Plans — Requirements and Guidance
ISO 20807
Non-Destructive Testing Qualification of Personnel for Limited
Applications of Non-Destructive Testing
ISO 31000
Risk Management - Principles and Guidelines
ISO DIS 34001.4
Security and Resilience - Security Management System for
Organizations Assuring Authenticity, Integrity and Trust for
Products and Documents
ISO / IEC
Directives (Part 1)
ISO / IEC Directives, Part 1 - Procedures for the Technical Work
ISO / IEC
Guide 68
Arrangements for the Recognition and Acceptance of Conformity
Assessment Results
ISO / IEC 17000
Conformity Assessment Vocabulary and General Principles
ISO / IEC 17011
Conformity Assessment - General Requirements for
Accreditation Bodies Accrediting Conformity Assessment Bodies
ISO / IEC 17020
Conformity Assessment - Requirements for the Operation of
Various Types of Bodies Performing Inspection
ISO / IEC 17021
Conformity Assessment -- Requirements for Bodies Providing
Audit and Certification of Management Systems
ISO / IEC 17025
General Requirements for the Competence of Testing and
Calibration Laboratories
ISO / IEC 17040
Conformity Assessment General Requirements for Peer
Assessment of Conformity Assessment Bodies and Accreditation
Bodies
ISO / IEC 17065
Conformity Assessment - Requirements for Bodies Certifying
Products, Processes and Services
ISO / TR 10013
Guidelines for Quality Management System Documentation
DOC. NO. KOC-Q-014
ISO / TS 29001
4.2.6
4.2.7
4.2.9
REV. 2
Petroleum, Petrochemical and Natural Gas Industries — SectorSpecific Quality Management Systems — Requirements for
Product and Service Supply Organizations
NACE Standards
NACE MR0103 /
ISO 17495
Petroleum, Petrochemical and Natural Gas Industries - Metallic
Materials Resistant to Sulphide Stress Cracking in Corrosive
Petroleum Refining Environments
NACE MR0175 /
ISO 15156
Petroleum, Petrochemical and Natural Gas Industries - Materials
for Use in H2S-Containing Environments in Oil and Gas
Production
NACE TM0177
Laboratory Testing of Metals for Resistance to Sulfide Stress
Cracking and Stress Corrosion Cracking in H2S Environments
NACE TM0187
Evaluating Elastomeric Materials in Sour Gas Environments
NACE TM0284
Evaluation of Pipeline and Pressure Vessel Steels for
Resistance to Hydrogen-Induced Cracking
NACE TM0296
Evaluating Elastomeric Materials in Sour Liquid Environments
Pipe Fabrication Institute (PFI)
PFI ES-42
4.2.8
Page 18 of 100
Standard for Positive Material Identification of Piping
Components Using Portable X-Ray Emission Type Test
Equipment
KOC Standards and Specifications
KOC-Q-015
KOC Standard for Positive Material Identification (PMI)
KOC-QAMS-001
Procedures for Quality Assurance Management System for
Projects
Project Specifications & Other KOC Documents
In addition to the Standards and Recommended Practices referenced herein, the
Controlling Teams in KOC shall designate other relevant Project Specifications as
required for the project.
DOC. NO. KOC-Q-014
Page 19 of 100
REV. 2
5.0
CONTRACTOR’S QUALITY MANAGEMENT SYSTEM FOR THE PROJECT
5.1
ISO 9001 Accreditation
The Contractor shall have been certified to the latest ISO-9001 standard.
Accreditation to ISO-9001:2008 is acceptable until August 2018. Starting Sep.
2018, certification to ISO 9001:2015 shall be mandatory.
5.2
Project Quality Documents
The Contractor is required to prepare various Project Quality Management
documents and shall submit those document for KOC review and approval as per
the indicated times specified in this Standard.
5.3
Required Quality Management Documents
List of the required Quality documents (applicable to all Project stages-Refer
Clause 2 of this Standard) is provided in Table (1) below. Time of submission may
be changed by the KOC Controlling Team.
Table (1) Quality Documents to be Prepared by Contractor for
KOC Review and Approval
Sr.
Quality
Document
Preparation
Time of
submission
to KOC
With the
bidding
document
Remarks
1
Project Quality
Manual
Based on ISO-9000, ISO9001 and other ISO family
and ISO/TS-29001.
2
Project Quality
Plans
This is the contractor’s
Overall project quality plan.
Based on ISO 10005.
60 days after
award
To be also
discussed
during PPIM
This overall ITP is to be
prepared by contractor to
include all activities by
Contractor.
60 days after
award
To be also
discussed
during PPIM
Vendor Quality
Manual
To be prepared by each
vendor based on ISO-9001,
API-Q1 and API-Q2 Specs.
Min. 30-days
before VPIM
To be also
discussed
during VPIM
5
Vendor Quality
Plans and ITP
To be prepared by each
vendor. Based on API Q1,
ISO 10005 and contract
requirements.
Min. 30-days
before VPIM
To be also
discussed
during VPIM
6
Service
Organization
Quality Manual
and ITP
To be prepared as per APIQ2 (2011).
Min. 30-days
before VPIM
To be also
discussed
during VPIM
3
4
Project ITP
To be also
discussed
during PPIM
DOC. NO. KOC-Q-014
Page 20 of 100
REV. 2
7
MRB,
manufacturing
record books
To be provided for all purchase
orders, fabrications and
construction.
Upon
completion of
the purchase
order
8
Project Closeout
report
Procedure and Report contents
to be proposed by contractor for
KOC review and approval. Final
report after commissioning.
After
commissionin
g stage
9
Subcontractors and
sub vendors
Quality Document
Each sub vendor or
subcontractor shall submit its
Quality Manual, Quality Plan,
and ITP to the contractor then
to KOC for review and
approval. MRBs are similar to
item 7 in this Table.
Min. 30-days
before sub
vendor or
subcontractor’
s start of
activities.
10
Project Record
Book (PRB)
including Operation
& Maintenance
Manual (OMM),
Engineering record
Book (ERB),
Construction
Record Book
(CRB).
To be completed and submitted
to KOC before handing over of
the facility.
Min. 60 days
prior to
construction
completion
MRB index to be
agreed with
Contractor and
KOC.
5.4
Project Quality Manual (PQM)
5.4.1
The Contractor shall submit its own PQM as well as the PQM of the main subcontractor(s) for review by KOC at the time of bid submission. A review of the
bidder’s PQM and QA / QC commitments under the Contract shall form part of the
bid technical evaluation / acceptance.
5.4.2
The PQM shall be prepared in accordance with latest references in Clause 3.0 of
this Standard including all the requirements of API Q1(2013) / API Q2 (2011) /
ISO / TS 29001 (2010). It shall address how the Contractor intends to maintain
sufficient QA / QC staff and resources specifically assigned to the Contract and
shall ensure their ability to perform their duties in accordance with the Contract
requirements during all phases of the Contract.
5.4.3
The PQM shall document the Contractor’s Corporate Management policy and
objectives for, and commitment to, quality and quality planning and risk
assessment and management. The PQM shall describe how this policy is
understood, implemented and maintained at all levels of the Contractor’s
organization.
DOC. NO. KOC-Q-014
5.4.4
Page 21 of 100
REV. 2
The PQM shall contain an organization chart showing the Contractor’s corporate
and project organization responsible for managing, performing and verifying the
Work. It shall clearly show the assignments of personnel responsible for the
Contractor’s PQP for all of the Contract Phases.
The organization chart shall be supported with a description of each key position
reporting and functional responsibility and authority. The corporate QA/QC head /
manager shall report to the organization Senior Management. Site construction
QA/QC manager shall report functionally to the corporate QA/QC head/manager
and not to the site construction manager.
5.4.5
The Contractor shall define a system to be implemented to incorporate levels of
inspection’ coverage as outlined in Clause 6.5.4 of this Standard.
5.4.6
The PQM shall be organized to fulfil ISO / TS 29001, API Q1 and API Q2
requirements including but not limited to the following topics:
a)
Quality Management System:
This will include the general requirements, outsourced processes and / or
services, documentation requirements, quality manual, control of
documents, and control of records.
b)
Management Responsibility:
This shall include management commitment, customer focus, quality policy,
planning, quality objectives, quality management system planning,
responsibility, authority and communication, management representative,
internal communication, management review, review input and output.
c)
Resource Management:
To include provision of resources, human resources, competence, training
and awareness, infrastructure and work environment.
d)
Product Realization:
This part of the project quality manual shall comprise the following items
i. Planning of product realization.
ii. Customer related processes.
iii. Design and development.
iv. Purchasing.
v. Production and Service Provision.
vi. Control of monitoring and measuring equipment.
e)
Measurement, analysis and improvement
This part shall include monitoring and measurements for customer
satisfaction, internal audits, monitoring and measurements of processes and
products, control of non-conforming products analysis of data,
improvements and corrective actions.
DOC. NO. KOC-Q-014
Page 22 of 100
REV. 2
5.5
Project Quality Plans (PQP)
5.5.1
The Contractor shall establish and submit to KOC its Project Quality Plans as per
the following:
5.5.2
a)
Project procedures and general responsibilities for the quality assurance
and quality control (QA / QC) program.
b)
Protocols to ensure that the Engineering Work, Procurements and Facility
Site Work Construction (FSWC) and Processes Equipment Installation will
be executed in accordance with the relevant portions of the Contract.
The Contractor shall be responsible for preparing and submitting for KOC approval
the quality plans for all the phases of the project / Contract. In preparing quality
plans, the guidance of the latest API Q1 / Q2 / ISO 10005 shall be followed. Quality
plans related to the following phases shall be submitted to KOC for review and
approval. Quality plans shall be prepared and submitted to KOC at least sixty (60)
calendar days before starting the activity. For fast track projects or when so
directed by KOC, the quality plans may be submitted at less than sixty (60) days
before starting the activity. The following Quality Plans shall be submitted by the
Contractor
a)
b)
c)
d)
e)
f)
Overall project quality plan;
Engineering quality plan;
Procurement quality plan;
Site construction and installation quality plan;
Pre-commissioning and commissioning quality plan;
Individual vendors, suppliers, service providers and sub-contractors quality
plans. API-Q1 / API-Q2 shall be strictly adhered to.
5.5.3
The Quality Plan (QP) shall include functional Quality Control (QC) instructions and
work procedures for the applicable work phases and work elements described in
the Contract documents and this Standard.
5.5.4
The QP shall reference procedures that describe in detail who, how and when the
Contractor, subcontractor or Vendor will test and inspect the characteristics of any
given product, in all phases of the Work.
5.5.5
“As-Built” documentation and the Manufacturing Record Book (MRB) shall contain
original signed off QP’s and all relevant document, which will provide the factual
evidence concerning compliance with the Contract requirements.
5.5.6
The Contractor shall provide a QP for review and approval by KOC for each work
phase. QP’s shall be provided a minimum of sixty (60) calendar days (or less as
per Clause 5.5.2) prior to the scheduled start date for the specific work phase. In
addition to the requirements of API Q1 / Q2 / ISO 10005, the QP shall address the
following areas as applicable.
a)
b)
c)
d)
e)
Engineering and Design qualification, evaluation and validation.
Materials or facilities, or portions therefore, to be inspected and tested.
Materials receiving and handling.
Witnessing / Hold points.
Frequency and location for inspection and testing.
DOC. NO. KOC-Q-014
f)
g)
h)
i)
j)
k)
l)
m)
Page 23 of 100
REV. 2
Inspection and test method(s) and procedures.
Inspection and Test Plans (ITP).
Acceptance criteria.
Records of inspection or tests.
Contractor’s procedures for the qualification and certification of Services,
such as but not limited to RTRP Pipe and Fitting Joining Procedures,
Non-destructive Examination (NDE) personnel, crucial coatings personnel,
positive material verifications and all other special processes applicable for
planned work activities.
Third Party Inspection Companies intended to be utilized by the Contractor
and the services they will provide. API Q2 standard shall be followed.
Contractor Inspection personnel listing by discipline and name per Work
Phase. (To be included as an appendix to the QP and is to be updated as
personnel change and submitted to KOC). Resumes shall be provided to
KOC for review. At KOC option to better determine technical competence to
perform in the position requested, the Contractor’s candidates shall have
follow-up interviews and / or tests administered by KOC. If a candidate has
a past history of negative performance with KOC, he may be rejected.
Levels of inspection coverage to be provided as defined in Clause 6.5.4 and
Table (2) and (3) of this Standard.
5.5.7
The latest revision of the QP shall be available at the Contractors’ and subContractor’s design offices, procurement, fabrication and installation/construction
locations.
5.5.8
The QP shall contain an organization chart, which shall show reporting
relationships from the inspector level up to and including corporate, and senior
project management, internal and external lines of communication, as well as the
interface between the Contractor, sub-Contractors, vendors, manufacturers,
suppliers and KOC.
5.6
Contractor’s and Subcontractor’s Resources and Personnel
5.6.1
The Contractor shall submit the names and resumes of its designated Quality
Assurance (QA) Manager / Quality Control (QC) Manager, QC Engineers /
Supervisors, inspectors and Procurement QC Engineers / Supervisors, welding
Engineers, etc. with the bid documentation addressing the Contractor’s proposed
QA / QC program.
5.6.2
Prior to the Contract kick-off meeting, the Contractor and each main SubContractor, as a minimum, shall appoint a qualified QA / QC Manager designated
to the project quality efforts. The primary functions of the QA / QC Manager shall
include but not be limited to the following:
a)
Establishing QA / QC policy with his senior management.
b)
Preparing and maintaining a Project Quality Assurance Manual (QAM)
incorporating the agreed policy and setting out a Quality System for the
conduct of the project and the control of quality within its engineering
support, its Contractors, suppliers and consultants in regard to design,
procurement, construction, pre-commissioning and commissioning.
DOC. NO. KOC-Q-014
Page 24 of 100
REV. 2
c)
To develop, coordinate, issue and obtain approval of the QAM, (with
changes as required subsequent to bid submittal and Contract award) and
the PQP.
d)
To review, evaluate, monitor and audit the effectiveness of the Quality
System and to verify compliance of Work output with, or identify areas of
non-conformance to specifications, standards and conditions specified in
the Contract.
e)
To co-ordinate the QC activities at the vendor (supplier) works and on site
and liaise with the third party Inspectorate as necessary.
f)
To bring about the establishment of procedures for the systematic
collection, collation, indexing and retrieval of project documentation
including but not limited to drawings and certificates either within the project
or the Contractor’s organization.
g)
To have a special responsibility for review of material requisitions, purchase
orders and suppliers technical bide evaluation in conjunction with design
engineers.
h)
To initiate and participate in Quality Audits of its own organization,
Contractors, sub-Contractors, vendors, sub-vendors and suppliers.
i)
To liaise with KOC on all matters related to certification and handover of
documentation at completion of the project.
5.6.3
The QA / QC Manager and QA / QC staff shall not be directly or indirectly
responsible for performing other than the Quality functions. The QA / QC Manager
shall be at a level of authority at least equal to that of the line Manager directly
responsible for the Work. The QA / QC Manager shall functionally report to the
Contractor’s corporate QA / QC Senior Manager or President. Personnel
performing quality functions shall have sufficient and well-defined responsibility,
qualifications, authority, and organizational freedom to identify quality problems
and areas of non-conformance and to initiate, recommend and substantiate
corrective actions.
5.6.4
The procurement, construction inspectors, QC Engineers, Welding Engineers and
pre-commissioning QC Engineers / Supervisors shall report to the Contractor’s QA
/ QC Manager and shall be supported by qualified personnel to effectively
accomplish their functions which include, but are not limited to:
a)
review of engineering/material requisitions, purchase orders and technical
bids evaluation for compliance with the Contract and applicable codes,
standards and specifications,
b)
review of vendors and suppliers quality plans and ITPs,
c)
review of vendors, suppliers and sub-contractors documents on quality,
testing, conformity and certification,
DOC. NO. KOC-Q-014
Page 25 of 100
REV. 2
d)
organizing and establishing the sub-Contractors, vendors and suppliers preinspection meetings (VPIM),
e)
issuance and coordination of source inspection assignments,
f)
issuing site inspection requests related to all types of work (mechanical,
civil, electrical, instrument, etc.),
g)
witness before and in presence of KOC representatives all site construction
testing and inspection activities as per the requirements of the relevant
ITPs,
h)
preparing welders qualifications and welding procedures qualifications,
i)
monitoring welding quality, welders performance and NDE activities and
records,
j)
performing mechanical completion
preparing required documents,
k)
establishing pressure testing packages, coordination with KOC for review
and witnessing and preparing relative documents,
l)
arranging instrument calibration, safety and safety relief valve management
system, testing and all related vendors and site testing records,
m)
other contract requirements that are not mentioned in above Clauses 5.6.4
(a) to (l) inclusive.
checks, database activities
and
5.6.5
The Contractor may sub-contract with qualified agencies per ISO / IEC 17020 and
API Q2 to provide QC services subject to KOC approval. Details of such
agreements shall be submitted to KOC for review and approval.
5.6.6
The Contractor shall ensure that QA/QC personnel assigned to the work are in
compliance with the requirements of this Standard and the Contract.
5.6.7
The Contractor agreements with all Sub-Contractors shall ensure that SubContractors will strictly adhere to the requirements of this Standard.
5.7
Contractor’s Management Review
5.7.1
The Contractor’s senior management shall review the quality system on a regular
basis to ensure that the system is suitable and effective. Changes to a quality
system previously submitted to KOC for concurrence which result from
management reviews may be incorporated in the QP, with the concurrence of
KOC. The management review audit shall be scheduled events included in the
agreed project audit program schedule.
5.7.2
Results and recommended actions of the management review shall be submitted
to KOC within three (3) weeks after the scheduled review date.
DOC. NO. KOC-Q-014
Page 26 of 100
REV. 2
5.8
Contractor’s Internal and External Audits
5.8.1
The Contractor shall develop and implement an internal and external audit
program and schedule covering all work phases. This shall include audits of the
Contractor’s quality function and responsibilities per this document. Auditing
program shall include also sub-contractors and vendors. Guides for auditing as per
ISO 19011 shall be followed.
5.8.2
Auditors and auditing leaders shall have appropriate competence levels in terms of
personal attributes, education, work experience, training and experience as further
provided in ISO 19011. The Contractor shall submit to KOC for review and
approval, all the “CV” of internal and external auditors before starting any auditing
activity.
5.8.3
The Contractor shall submit a Quality Audit schedule to KOC for review and
concurrence within 60 days of Contract award. As a minimum, audits shall be
carried out at the 25% and 75% completion stage for each work phase or as may
be deemed necessary as instructed by KOC.
5.9
Auditing of KOC Approved Manufacturer
KOC approved manufacturer are generally qualified, based on documents rather
than actual auditing visits. It is extremely necessary that Contractor should carry
out its own assessments, auditing and other technical evaluation before signing
any contractual agreements or purchase orders with any of them. Auditing reports
for all vendors / suppliers shall be submitted for KOC review and information.
Accordingly, KOC shall have the right to reject purchasing proposals from vendors
or suppliers that are in the process of removal from the KOC approved list.
Contractor shall submit to KOC the list of proposed audited vendors prior to raising
any PO.
5.10
Internal Audits
5.10.1
Audits shall be performed in accordance with pre-established written procedures or
checklists and conducted by trained personnel not having direct project
responsibilities in the areas being audited.
5.10.2
During the procurement phase, the Contractor QC personnel and processes shall
be audited to ensure QC effectiveness, e.g. that the vendor is in compliance with
applicable KOC and Industry engineering standards.
5.10.3
When necessary, the contractor shall initiate corrective actions. Implementation of
corrective actions shall be verified through re-audit of the activity.
5.10.4
The Contractor shall submit to KOC two hard copies and one electronic copy of all
audit reports within two (2) weeks of completion of the schedule audit.
DOC. NO. KOC-Q-014
Page 27 of 100
REV. 2
5.11
Audit Report
5.11.1
As a minimum, the audit reports shall follow the format as below:
a)
Cover sheet
b)
Audit report text
c)
Attendance Register
d)
Audit notification
e)
Non-Conformance Reports (NCRs), Worksheets (copies
Corrective Action Requests
f)
Any Appendices useful to the report
only)
and
5.11.2
The audit report text shall include the following:
a)
Summary
b)
Introduction
c)
Audit objective
d)
Opening meeting
e)
Basis of audit (i.e. listing of documents in preparing the audit, including
references to prior audits)
f)
Details of audits / results (i.e. references to NCR’s / Worksheets (WS’s),
audits observation and outstanding waiver actions)
g)
Agreed corrective actions
h)
Conclusions
i)
Recommendations
5.11.3
The Company representatives and / or its nominated agency shall be invited to
participate in the internal and external audits.
6.0
CONTRACTOR’S QUALITY CONTROL REQUIREMENTS
6.1
Project Pre-Inspection Meetings (PPIM)
6.1.1
Having approved by KOC of the Project Quality Documents (Project Quality
Manual and Project Quality Plans) as per Clauses 5.4 & 5.5 of this Standard, the
Contractor shall arrange for the Project Pre-inspection Meeting (PPIM) to discuss
and clarify the entire aspects of Quality Assurance, Quality Control, Conformity
Assessments, Inspection and Certification and other quality issues. The meeting
shall be held at the head office of the Contractor. The meeting shall be attended by
KOC Engineering Project representatives and the Inspection & Corrosion
(Projects) Team representatives. Refer to Project Pre-inspection Meeting in
Appendix C of this Standard.
6.1.2
The PPIM minutes of meeting (MOM) and related documents shall be considered
as Contractual documents and shall be revised as and when necessary subject to
agreements of both KOC and the Contractor.
DOC. NO. KOC-Q-014
Page 28 of 100
REV. 2
6.2
Construction Pre-Inspection Meeting (CPIM)
6.2.1
At least ninety (90) calendar days before starting the site construction, the
Contractor shall submit for KOC review and approval it’s Site Construction Quality
Plans (SCQP). The plans shall be based on ISO 10005 and shall include other
plans prepared by sub-Contractors. The main Contractor shall have reviewed its
sub-Contractor’s quality plans prior to inserting in the SCQP dossiers.
6.2.2
Upon approval of the SCQP, the Contractor shall arrange for the CPIM to be held
at its site offices or at KOC offices. The agenda of the CPIM shall be as per
Appendix E of this Standard. Other items may be added as necessary. The CPIM
should be held not less than thirty (30) days prior to the start of Site activities.
6.2.3
Urgent Site activities such as surveying, slit trenching, fluid and soil sampling,
emergency tie-in connections and other activities tied to existing facility shut downs
may start before the CPIM as would be agreed with the KOC Controlling Team.
6.3
Inspection Schedule
The Contractor shall submit to KOC a quality control Inspection schedule that
covers the current week, provides a two-weeks look ahead for the procurement,
construction and pre-commissioning work phases, and a one-month look ahead for
the design work phase.
6.4
Conceptual Design and Detailed Design Phase
6.4.1
Conceptual Design and Design Phase Quality Objectives
The QP shall define the Conceptual Design or Design Phase, procedures and
responsibilities to assure that the engineering and design tasks are performed in
accordance with contract requirements and KOC Standards, and applicable
international engineering codes, standards and specifications.
6.4.2
Conceptual Design and Design Phase Planning
Prior to the start of Conceptual Design or Design Phase, the Contractor shall make
a detailed review of the contract requirements to identify and define engineering
and design work in order to develop a plan for achievement of the project design.
The responsibility for each Design Phase activity shall be identified and shall be
updated as the design progresses.
6.4.3
Organizational and Technical Interfaces
The Contractor shall establish and clearly identify organizational design interfaces.
The design control procedures shall describe how different design disciplines;
sub-Contractors, vendors and / or manufacturers are to be used in executing
project design responsibility. These interfaces and procedures shall be regularly
evaluated by the Contractor’s management per the agreed audit schedule to
ensure that design / work is proceeding under controlled conditions.
DOC. NO. KOC-Q-014
6.4.4
Page 29 of 100
REV. 2
Engineering and Design Documents and Drawings
The Contractor shall implement a design verification procedure. The Engineering
and Design Documents and Drawings shall be audited at different stages by the
Contractor’s QA / QC Team. Each of the individual discipline design packages
(process, mechanical, electrical, civil, etc.) shall be audited. A QC back-check
shall be carried out by each discipline prior to issuing to KOC of Engineering
Documents including the “Approved for Construction” work drawings. The design
drawings shall be checked by competent individuals other than those performing
the original work. The completed design Documents and Drawings shall indicate
the evidence of the Contractor’s design supervision and management approval.
6.4.5
Design Changes and Non-Conformance
All design changes shall be identified and controlled per the agreed procedure
included in the QP. The evaluation, preparation, checking, issuing and controlling
of design changes shall be similar to the original document issue. Logs shall be
maintained to show current revision status. Log of outstanding deficiencies or nonconformances shall be maintained in the format included in the QP. A file
documenting any corrective actions taken, or procedures implemented, to prevent
a recurrence of any deficiency or items of non-conformance shall be maintained for
each log entry.
6.4.6
Document Control
Measures shall be established by the Contractor to control the issuance, retrieval
and revision of documents (e.g. drawings, procedures and instructions) including
changes to such documents. Participating organizations shall have in their
possession procedures for control and revision of such documents to preclude the
possibility of using outdated or inappropriate documents in the work.
6.5
Procurement Phase
6.5.1
Evaluation and Auditing of Vendors, Suppliers, Manufacturers, Sub-Contractors
The Contractor shall audit and evaluate all vendors, suppliers, manufacturers and
sub-contractors before signing any agreements or raising purchase orders with
them. It is to be noted that vendors on KOC approved list have not been site visited
or audited by KOC. The Contractor shall define the procurement QA/QC activities,
including the identification of critical materials that will require specific Inspection
and Testing Plans (ITP’s) and Pre-Inspection Meetings (PIM) in its QP to assure
that procurement and vendor performance are properly monitored by qualified
personnel. Activities and methods used to assure that procured equipment,
materials and services conform to the Contract requirements shall also be defined.
DOC. NO. KOC-Q-014
6.5.2
Page 30 of 100
REV. 2
Engineering Requisitions by Contractor or Sub-Contractor
The Contractor’s or Sub-Contractor’s procurement activities shall start with
analysis of the engineering requisition packages to ensure that the requirements of
the Contract and this Standard are in place and acceptable at the engineering
requisitions and quotation stage. Inspection data sheets / source inspection plans
shall be attached with all requisitions and purchase orders in order for the vendors
/ suppliers to be fully aware of the Contract quality requirements. Appropriately
prepared inspection data sheets help vendors in providing proper ITPs. This
standard KOC-Q-014 shall be attached to all engineering requisitions and
purchase orders.
6.5.3
6.5.4
Inspection and Testing at Vendors, Suppliers and Manufacturers
a)
An Inspection and Testing Plan (ITP) that details all “Hold” (H), “Witness”
(W), “Review” (R) “Approval” (A), Surveillance (SU) points found by
combining all the associated requirements of the specifications and the
Contract shall be included in the engineering requisitions and purchase
orders and shall be reviewed and approved by KOC before placement of the
order and prior to start of the manufacturing or production work. The ITP
shall be finally verified and marked at the vendor pre-inspection meeting for
all identified purchase orders and sub-Contracts. Adopting of inspection
levels (IL) for any product or service as per Tables 2 and 3 of this Standard
requires prior KOC approval.
b)
The ITP shall be structured to show the systematic chronological activities
along with responsibilities of undertaking, reference controlling document /
procedure / standard, the acceptance criteria, the role of each involved party
(Vendor, Contractor, Sub-Contractor and KOC). Appendix-K provides a
typical ITP format that shall be used, otherwise more advanced vendor ITP
could be utilized instead.
c)
On bi-weekly basis, the Contractor shall submit to the Company a
manufacturing / testing status report for the main equipment and materials
(compressors, pumps, pressure vessels, valves, line pipe, and other items
that require Class 1 and Class 2 inspections).
Inspection Levels (Classes)
a)
The following system of coding the levels of planned inspection shall be
used to define inspection requirements. Key factors such as complexity,
special materials, unusual processes, safety, reliability, quality history of
vendor, ease of replacement, site location, etc. shall be considered. Tables
2 and 3 of this Standard provide the four levels of inspection that shall be
adopted by the Contractor.
DOC. NO. KOC-Q-014
Page 31 of 100
REV. 2
b)
The Inspection Levels (Classes) as per Table (2) represent the minimum
KOC requirements that shall be applied by the Contractor. The assigned
level of inspection may change, increasing or decreasing, during the course
of the work as a result of the vendor performance. Any such changes shall
be approved in advance by KOC, however at the full responsibility of the
Contractor.
c)
The Contractor shall provide and document QA/QC activities in the
procurement of equipment and material to be used or installed during the
construction and installation of the facilities in accordance with the
requirements of the contract schedules.
d)
The Contractor shall expand Table (3) given below to include all equipment
and materials required as per the contract. The new tabulation shall be part
of the PQP.
e)
As per KOC Project Admin and Coordination Procedure, the following
Inspection Levels (Classes) shall be adopted by the Contractor,
Subcontractors, Vendors and Sub-Vendors. The Contractor is responsible
for including these requirements in all agreements, engineering requisitions
and purchase orders.
DOC. NO. KOC-Q-014
Page 32 of 100
REV. 2
Table (2) Inspection Levels (Classes)
Class (1)
VPIM required
Class (2)
VPIM required
Class (3)
VPIM may be
required
Class (4)
This is a full stage inspection carried out progressively from
commencement of manufacturing to final acceptance. This does not
necessarily mean full-time witnessed in-line inspection during product
manufacturing except for “Metallic Line Pipe” at pipe mills and site
erected storage tanks.
This class shall include the following:
(1) Review and scrutinizing of source materials chemical and
physical properties (Original Materials Test Certificates).
(2) Comparing materials marking and heat numbers against
materials test certificates.
(3) Witness PMI (positive material identification)
(4) Witness all qualification tests (manufacturing, welding, coatings,
etc.)
(5) Witness NDE calibrations before production/testing.
(6) Scrutinizing the implementation of approved manufacturer’s
quality control systems including ITP (Inspection & Test Plans).
(7) Witness of all pressure and performance tests, followed by
inspection of disassembled equipment as applicable.
(8) Witness of manufacture repairs after KOC approval.
(9) Monitor approved manufacturer’s assembly, erection and all
prescribed tests as per ITP and applicable standards.
(10) Review the equipment and products certificates and the MRB
(Manufacturing Record Book)
(11) Perform visual and dimensional inspection of equipment and
materials including marking and traceability.
(12) Inspect for proper drying and sealing of equipment and products
before packaging.
(13) Verify packing and marking identification.
(14) Sign all relevant certificates.
Limited Stage Inspection of equipment and materials. In progress
surveillance inspections shall be made on regular basis (daily, weekly,
etc.) as specified by key factors. It shall include inspection meetings,
review document and certificates, attendance to all (H) and (W)
inspection points. Perform final inspection and release for shipment.
Perform goods receiving inspection when equipment/materials are
received at site.
Same as Class (2) except that in-progress surveillance visits shall be
limited to one or more visits.
Review documents and certificates. Perform final inspection before
shipping. Perform goods receiving inspection when quipment /
materials are received at site.
DOC. NO. KOC-Q-014
Sr.
1.0
1.1
1.2
1.3
1.4
2.0
Page 33 of 100
REV. 2
Table (3) Inspection Levels (Classes) of Equipment / Material
Inspection Level (Classes)
Equipment / Material
1
2
3
4
PRESSURE VESSELS
Separator, Desalters, Scrubbers, Knock-Out Drums,
Absorbers, Cladded Vessels, Deaerator, CRA Vessels,
Clarifier, High Pressure Filter Vessels
Low Pressure Filter Vessels, Utility Vessels, Pipeline
Scrapper Traps (Launchers / Receivers), Drip Barrels,
Drain Vessels
Air Filters, Air Cylinders, etc.
Chiller Units
x
x
x
x
2.4
2.5
2.6
STORAGE TANKS
Site Erected Wet or Dry Crude Tanks and Brackish /
Treated Water Tanks
Shop Fabricated Tanks
Chemical Tanks, Diesel Storage Tanks, Fire Fighting
Foam Concentrate Tanks
Potable Water Tanks (steel or non-metallic)
Tank Mixers
Pressure Vacuum Valves and Vent Valves
3.0
3.1
3.2
3.3
COMPRESSORS, TURBINES & PUMPS
Gas Compressors and Turbines
All Types of Pumps Except Metering and Diaphragm
Metering and Diaphragm Pumps and Air Blowers
4.0
4.1
4.2
4.3
4.4
4.5
HEATERS
Direct Fired Heaters
Indirect Bath Heaters (water, glycol or oil bath)
Salt Bath Heaters
Electric Heaters for Fuel and other services
Incinerators
5.0
5.1
HEAT EXCHANGE EQUIPMENT
Shell & Tube, Air Cooled and Plate Type
x
6.0
Metering Skids
x
7.0
7.1
7.2
LIFTING APPLIANCES
Overhead Cranes (Site Test Each Item)
Chain Blocks and Davits
8.0
8.1
8.2
8.3
8.4
8.5
8.6
8.7
ELECTRICAL
Switchgear, 11 kV, 3.3 kV and 440 v/415 v Panels
Transformers – Medium 11/440, 3.3/440, 11/3.3
Transformers – Low Voltage
Motors – 120kW and above
Motors – below 120kW
Alternator / Generator Sets 1MW and above
Alternator / Generator Sets below 1MW
2.1
2.2
2.3
x
x
X
x
X
X
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
DOC. NO. KOC-Q-014
Sr.
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
8.18
8.19
8.20
8.21
8.22
8.23
8.24
8.25
9.0
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
Page 34 of 100
Table (3) Inspection Levels (Classes) of Equipment / Material
Inspection Level (Classes)
Equipment / Material
1
2
3
4
9.15
9.16
9.17
9.18
10.0
10.1
PIPING AND VALVES
Steel Line Pipe for Pipelines (API 5SI, Level C)
10.2
Carbon Steel Plant Process and Utility Piping (API 5SI,
Level B)
10.3
10.4
x
Cables, Power & Control
Control Relay Panel
Explosion / Flameproof – Fixtures, Boxes, Power
Sockets
General Lighting and Electrical Fixtures, Small Power
Sockets, Switches
UPS Systems, Batteries and Chargers
Variable Speed Drive Units
Data Acquisition Panels/Systems
Interface Relay Panels
Marshalling Cabinets
MOV Actuators
Solar Power System
DC Power Supply Units
Distribution Boards
Junction Boxes
Earthing & Bonding System
Annunciator Panels
Local Control Stations (pushbutton stations), Power
Isolators
Solar Power Systems
INSTRUMENTS & CONTROLS
DCS, ESD, SCADA, F& G
General Local Control Panels
Vendor Panels for Packaged Equipment
Venturis, Orifices and Metering Tubes
Control Valves and Actuators
Pressure or Vacuum Relief Valves
ESD Valve and Actuators
Motor Operated Valves
Local Controllers, Transmitters, I/P Converters
Analyzers for Dew point, Oil in Water etc.
Gauges for Pressure, Level, Temperature
Switches for Pressure, Level, Temperature, Flow
Instrument Cables
Fire Alarm System, Detectors (Fire, Smoke, Heat,
Toxic, Gas, etc.), Sounders & Flashing Beacons
Fire Alarm System for Building
Cable Trays and Junction Boxes
Condition Monitoring
Pig Signallers
9.14
REV. 2
Corrosion Resistant Alloys (CRA) Pipe, Fittings &
Flanges
Valves for Pipeline, Plant Process and Utility
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
DOC. NO. KOC-Q-014
10.6
10.7
10.8
10.9
11.0
x
Carbon Steel Fittings & Flanges for Pipelines and
Process Piping, Flange Bolting & Gaskets, Flange
Insulation Kits, Blinds, Spacers, Spring Hangers,
Barred Tees, etc.
RTRP Pipe & Fittings
RTP Pipes
Thermoplastics (HDPE, PVC, uPVC, etc.)
Induction Bends
11.2
11.3
11.4
11.5
11.6
CATHODIC PROTECTION AND COATING
Anodes, Transformers, Rectifiers, Junction Boxes,
Cables, Reference Electrodes
Pipeline Coating and Lining (API 5SI, Level C)
Girth Weld Coating
In-Situ Lining for Pipelines
Storage Tank Coating and Lining
Pressure Vessels Coating/Lining
12.0
HVAC
13.0
TELECOM EQUIPMENT
14.0
CALM BUOY SYSTEMS AND ACCESSORIES
(Nb.: Classification society may have different
inspection level-classes (to be discussed during PPIM)
15.0
15.1
15.2
15.3
15.4
STEAM BOILER STATIONS
Drums (Steam & Mud)
Steam Turbines
Air Heaters
Tubing
16.0
16.1
16.2
HDPE LINING OF STEEL PIPELINES
HDPE Pipe Manufacturing
HDPE Installation
17.0
17.1
17.2
17.3
17.4
17.5
17.6
17.7
PACKAGES
Chemical Injection Package
Nitrogen Generation Package
Gas and Liquid Dehydration Packages
Refrigeration Package
Instrument & Plant Air Packages
Flare Package
Solar Power Systems
11.1
REV. 2
Table (3) Inspection Levels (Classes) of Equipment / Material
Inspection Level (Classes)
Equipment / Material
1
2
3
4
Sr.
10.5
Page 35 of 100
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
X
x
x
x
18.0 FIRE PROTECTION
x
18.1 Deluge System
x
18.2 Fire Fighting System
Note to Table (3): Depending on project size (Major, Medium, Minor); the applicable parts only shall be
applied. Contractors should expand or reduce Table (3) to meet the specific contract / project
requirements.
DOC. NO. KOC-Q-014
6.5.5
Page 36 of 100
REV. 2
Audit and evaluation of vendors / suppliers and sub-Contractors before signing any
agreements or raising Purchase Orders (POs).
The Contractor shall evaluate vendors’ and suppliers’ capabilities to meet the
requirements of the API Q1 / API Q2 and ISO 17000 series as well as any KOC
related contract conditions and international standards and specifications prior to
award of the work. Reliance solely on vendor’s certification to ISO Quality Systems
or listing in KOC’s approved manufacturer list is not secure approach. Contractor’s
evaluations and audits made to vendors / suppliers / sub-Contractors shall be
submitted to KOC prior to purchasing or contracting.
6.5.6
Procurement Data
a)
The Contractor’s purchase orders/agreements with vendors, suppliers and
sub-contractors shall include, but not limited to the following:i.
KOC project specifications, data sheets and drawings shall be
referenced to in the material and equipment engineering and
procurement requisitions. Where a sub-vendor will be involved, the
Contractor shall require the vendor to distribute these requirements
also to the sub-vendor as part of the order.
ii.
All quality, inspection and testing requirements shall be as per this
KOC Standard.
iii.
KOC and Contractors requirements related to instructions, procedures,
drawings, specifications, vendor inspection plans, inspection and test
records, manufacturing record books (MRB), etc.
iv.
Requirements of vendor QA/QC records and completed dossiers to be
prepared, submitted, or made available for Contractor’s and KOC’s
review and approval. (e.g. welding procedures, welding, repairs, heat
treatment procedures, welder qualifications, hydrotesting, coating and
Non-destructive examination, NDE procedures, etc.).
v.
List of inspection and witness points that must be applied on the subvendors by the vendor and / or Contractor or KOC.
vi.
Identification of records that shall be retained, controlled, maintained,
or delivered to the Contractor prior to installation or use of the procured
item. Also advising that all documents shall be submitted in electronic
file formats on CD / DVD.
vii.
Provision for KOC and Contractor’s right of access to the Vendors’
facility and work documents for inspection and audit.
viii.
Contractor supplemental technical specifications.
DOC. NO. KOC-Q-014
b)
c)
Page 37 of 100
REV. 2
The following documents shall be submitted to KOC for review and approval
before placement of any purchase order. Before submitting to KOC, those
documents shall have been reviewed by the Contractor’s QA / QC Team to
ensure that all Contract requirements are fulfilled.
i.
Contractor engineering requisitions;
ii.
Data sheets;
iii.
Technical bid analysis for at least three bids;
iv.
Un-priced purchase orders
Subcontractor’s Purchase Orders
The Contractor shall review its sub-Contractor’s purchase orders and its
supplier’s sub-orders to ensure that relevant KOC requirements are passed
on to sub-suppliers.
d)
Contractor’s and KOC Inspection at Vendors
The Contractor shall add to his purchasing document the following
statement: “Contractor and KOC inspection is required during manufacturing
and prior to shipment from your plant. The Contractor, KOC and / or its
representatives (Third Party Inspection Agency) shall have free access to all
manufacturing facilities, all purchase orders and inspection report files.
Advance notification is required to be submitted to the Contractor so that it
can arrange with KOC, the Contractor’s and KOC’s inspectorate to attend
the VPIM and the other manufacturing/production activities. The unpriced
purchase order and other relative technical documents shall be sent to KOC
Representative Inspectorate by the Contractor”.
e)
Submittal of Inspection Documents to KOC Inspectors (TPI)
The Contractor shall compile and forward to KOC inspectorate, at least two
(2) weeks prior to the pre-inspection meeting and start of any production,
fabrication or manufacture, either at the prime vendor or a major subvendor, one (1) set of the Contractor’s Inspection Assignment Package.
The package shall include:
i.
A complete copy of the Contractor’s un-priced purchase order / Subcontract including engineering requisitions, drawings, technical
attachments or appendices.
ii.
Copies of sub-supplier’s purchase orders.
iii.
Inspection requirements per this Standard including ITPs.
iv.
Inspection assignment sheets specifying the QC person or agency that
will perform the QC function on behalf of the Contractor.
DOC. NO. KOC-Q-014
f)
Page 38 of 100
REV. 2
v.
The level of Contractor inspection (See 6.5.4).
vi.
Address of work, contact person information, etc.
vii.
Agenda for each vendor pre-inspection meeting (VPIM) shall be
submitted to KOC Representative with the Inspection Assignment
Package (Refer also Appendix-D of this Standard).
Records Identifications
The Contractor shall maintain an effective system for continuity of order
identification to ensure that drawings, specifications, and inspection
requirements are properly transmitted to vendors at all tiers of order
placement.
g)
Vendors and Manufacturer’s Quality
The contractor shall ensure that all vendors and manufacturers have and
maintain acceptable QA/QC programs in accordance with the relevant ISO9000 series standards or equivalent. The Contractor shall perform quality
audits and maintain reports for this purpose.
h)
Product Identification and Traceability
In all its purchase orders, the Contractor has to specify that Manufacturers,
Vendors, sub-Vendors and sub-Contractors shall perform and identify
products and materials during manufacturing, production and site
construction particularly for Corrosion Resistant Alloys (CRA), alloy steels,
non-ferrous and specialty materials. This shall be performed through
positive material identification (PMI) per KOC-Q-015, API RP 578, the
applicable standards, specifications and drawings as well as where agreed
upon during VPIM and progressive inspection at Vendors and
Manufacturers. PMI shall also be made for components manufactured at
foundries, sub-Vendors and suppliers. The Contractor shall perform PMI at
Site for any equipment and material when requested by KOC. All such PMI
tests shall be at the time and cost of the Contractor.
i)
Additional Inspection and Testing
KOC and / or its nominated inspectorate shall have the right to require that
additional inspection, testing and PMI be made at the Contractor’s cost and
time in the event that:
i.
Material to be used in the project cannot be identified.
ii.
Reasonable doubt exists about the authenticity of its identity.
DOC. NO. KOC-Q-014
j)
k)
l)
Page 39 of 100
REV. 2
Process Control During Procurement
i.
Vendors and sub-Contractors shall submit for the Contractor and KOC
review, and approval, all special process procedures (such as, but not
limited to, welding, welding repair, NDE, heat treatment, plating, critical
coatings, tank lining, gunite lining, alloy verification, etc.) for which the
results cannot be fully verified by subsequent inspection and testing of
the product.
ii.
The Contractor, sub-Contractor and Vendor procedures shall be
submitted to KOC for review and approval prior to the start of the work.
iii.
Vendors and sub-Contractors shall qualify their personnel for NDE,
critical coating and welding. Vendors shall also qualify the welding and
repair procedures non-metallic piping joining & cable splices as
specified by KOC Standards, applicable international standards,
specifications and approved QP. The Contractor shall review and
approve such qualifications before submitting them to KOC and prior to
the start of the work.
Inspection and Testing
i.
The Contractor shall schedule and perform source inspection at
vendors and major sub vendors in accordance with the Contract
requirements. After being compiled in accordance with Clauses 6.3
and 6.5, the Contractor’s inspection schedules and inspection
assignment packages for each specific purchase orders or subContract shall be submitted to KOC at least three (3) weeks before the
VPIM. Minutes of the VPIM shall be forwarded to KOC within two (2)
days of the meeting.
ii.
Where a Vendor plant attendance is not required or is waived by KOC,
the Contractor shall collect and compile the Vendor’s data to meet the
requirements of Appendix-F of this Standard on MRB. Such
documents shall be reviewed by the Contractor to ensure that all
Contract requirements have been met, before submitting to KOC.
Procurement Inspection and Test Records
The Contractor shall require its sub-Contractors / Vendors to submit
manufacturing and test reports which provide sufficient information to
establish that the equipment or item has passed all the tests and
inspections against specified contract criteria. The Contractor shall review
these records prior to issuing the inspection and / or shipping release. A
copy shall be provided to KOC for concurrent review and acceptance.
m)
Control of Non-conforming Products
Non-conformances shall be identified, reported and resolved per AppendixB to this Standard.
DOC. NO. KOC-Q-014
n)
Page 40 of 100
REV. 2
Quality Records and MRB
Quality Records and manufacturing record books (MRB) shall be in
accordance with Appendix-F to this Standard. Details of the MRB for each
purchase order shall be submitted to KOC for review.
o)
Inspection Reports
Periodical Vendor Inspection Reports shall be submitted to KOC for review.
Upon acceptance of material or equipment, a final inspection report shall be
issued and a copy submitted to KOC. This report shall provide details of
QA / QC activities performed during manufacturing and fabrication of the
equipment or material. Evidence of review and acceptance by the
Contractor shall be provided. The report shall provide the following as a
minimum:
i.
ii.
iii.
iv.
v.
Copies of KOC approved waiver(s) to Contract requirements.
All approved and signed off ITP’s.
Copies of all certification points contained within the purchase order.
Copies of all NCR’s with final dispositions and resolutions.
In cases where the vendor is responsible for export packing, the final
inspection report shall be prepared after export packing has been
inspected and accepted by the Contractor.
6.6
On-Site Construction Phase
6.6.1
Construction Phase Quality Objectives
a)
On-site quality control activities shall be the prime responsibility of the
Contractor. The presence of KOC quality control staff shall not relieve the
Contractor of that prime responsibility. The on-site quality control work shall
be based on the Quality Plan submitted to KOC as per Clauses 5.4 and 5.5
of this Standard.
b)
The Contractor shall plan, perform and manage all quality related work
activities and ascertain that all fabrication and construction are performed in
accordance with the Contract requirements. All construction and installation
activities shall be made in accordance with KOC approved procedures to be
submitted by the Contractor. Appendices G and H of this Standard provide
lists of QA / QC Site procedures that the Contractor should provide for KOC
review and approval. The list is not conclusive and the Contractor should
add further procedures to fulfill the Contract requirements.
c)
All the drawings, specifications, procedures and other documents required
for conducting the on-site inspection work shall show approval / release
from KOC. Such documents shall be made available to KOC inspection
representative upon request.
d)
The Contractor’s QC personnel, as a minimum, shall meet the qualifications
requirements of Appendix-A to this Standard.
DOC. NO. KOC-Q-014
e)
6.6.2
Page 41 of 100
REV. 2
The Contractor shall provide KOC with an organization chart defining
responsibilities and authorities within the Contractor’s quality group. The
Contractor shall consider the following:
i.
The chart shall be revised and resubmitted in advance of any significant
changes found necessary as the project progresses through the various
phases.
ii.
In the case of temporary absences due to leaves, business trips or
training, KOC shall be advised well in advance and in writing of
delegated authorities or other alternative arrangements made for key
personnel. For extended cases of sickness KOC shall also be notified
in writing of alternative arrangements including replacement.
iii.
Responsibilities of key personnel shall be fully described, including
those for auditing and monitoring the effectiveness of Quality Systems
including those of sub-Contractors and Vendors.
iv.
Contractor shall submit the CVs of all inspection personnel including
subcontractors for KOC review and approval. KOC reserves the right to
interview Contractor’s QA / QC group personnel in order to assess their
levels of qualification, experience, competence and to insist at any time
on the removal from work site if not comply / adhere to the KOC /
Contract requirements and procedures.
Inspection and Testing Plans (ITP)
a)
The Contractor shall develop a plan showing in detail the methods and
timing for examinations, measurements or tests to assure compliance with
Contract requirements. The Contractor shall be responsible for all required
inspection, tests, and material examination at the work sites. This shall
include receiving, in-process and final inspections.
b)
Specific inspection points shall be indicated in the QP (which includes
inspection and testing plans) and related procedures where the Contractor
inspection is mandatory. KOC approvals to the QP and ITP shall be
obtained before starting inspection work at work site.
c)
Inspection and Test Plans and related procedures shall include provisions
for ensuring and recording that prerequisites for any given test have been
met, that adequate and calibrated instrumentation is available and used,
and that the necessary inspection is performed.
d)
Site construction and installations shall be inspected by both the Contractor
and KOC. Inspection Notification (IN) system shall be established by the
Contractor for application throughout all site construction phases for all work
discipline (civil, mechanical, electrical, instruments, HVAC, etc.). In advance
inspection notification of at least 48 hours shall be issued to KOC.
DOC. NO. KOC-Q-014
6.6.3
6.6.4
6.6.5
Page 42 of 100
REV. 2
Control of Sub-Contractors and Service Supply Organizations
a)
The requirements of Clause 5.0 of this Standard on Quality Management
System shall apply.
b)
The Contractor shall ensure that the Quality Management System of the
Service Supply Providers are in accordance with API-Q2.
Material Identification and Traceability
a)
The Contractor shall generate and maintain an identification procedure for
all materials, parts and components, including partially fabricated
assemblies. Traceability shall be maintained on equipment, materials, parts
and components, as required by the standards and specifications.
Identification of an item shall be addressed either by using tags, stamps,
colour coding, stencils or labels or by records traceable to an item
throughout fabrication, erection, installation, repair, modification and use of
the item.
b)
The location and the method of identification shall not affect the function or
quality of the item being identified. The procedure shall require that
verification of correct identification of material, parts and components be
made and documented prior to installation.
c)
Equipment or materials not in compliance with the Contract requirements
shall be rejected, segregated and then physically removed from the work
site within two (2) days of being rejected. Written confirmation that the
material has been removed to identified quarantine area shall be issued by
the Contractor to KOC at the time the material is removed.
Control of KOC Supplied Material and Equipment
The Contractor shall implement a documented control system for all KOC supplied
material or equipment. The written procedure shall provide for verification, proper
storage, security and maintenance of such material and equipment. This
procedure shall also have provisions for dealing with losses, damage or other
problems discovered with such material and equipment.
6.6.6
Process Control
a)
The Contractor shall develop and implement effective procedures for
controlling all fabrication and construction processes, which will be, clearly
identified with key parameters / variables affecting quality as specified in the
appropriate Contract specifications or instructions.
b)
The Contractor shall verify all fabrication and construction processes initially
and regularly monitors all process parameters thereafter. Such procedures
shall provide for witness points to independently verify critical dimensions
such as module interface, anchor bolt locations, pipe bends, etc. before
proceeding with the work.
DOC. NO. KOC-Q-014
6.6.7
6.6.8
Page 43 of 100
REV. 2
Special Processes
a)
The Contractor shall establish and qualify procedures to ensure that special
processes such as RTRP Pipe and Fittings Joining procedures, coating
application, welding, cable splicing / termination, heat treating, concrete
batching, cable / conduit seals, cleaning, non-destructive testing /
examination, alloy verification and the certification of Intrinsically Safe (IS)
safety systems (where utilized), etc., are accomplished under controlled
conditions in accordance with all applicable standards and specifications.
All process parameters shall be identified, with acceptance criteria specified
and monitored.
b)
Applicable procedures / instructions for special processes shall be
submitted with the QP. All special process procedures shall be reviewed
and approved by KOC prior to the start of fabrication or construction.
c)
Provisions shall be made by the Contractor for protecting new installations
before the pre-commissioning. This shall include but not limited to
temporary cathodic protection, properly removing test liquid from the
pipelines and piping when pre-commissioning is expected to be delayed,
preservation of equipment and pipelines and piping using nitrogen or other
approved mothballing process, etc. Equipment made of CRA materials shall
be properly dried, and preserved to avoid cracking and galvanic corrosion.
Provision and Calibration of Inspection, Measuring and Test Equipment
a)
The Contractor shall provide at site all materials, equipment and other
facilities required for inspection and testing of the new installations as
required by the Contract drawings, specifications, design codes or
standards, approved procedures or good engineering practice.
b)
The Contractor shall develop and implement procedures for the control of
inspection, measuring and testing equipment. Specific tools and equipment
shall be identified to make and perform tests in the field with instructions for
their use, calibration, and storage. The Contractor shall identify, maintain,
control, adjust, and calibrate tools, gauges, instruments and other
measuring and testing devices used for activities controlling quality.
Calibration shall be performed at established periods, not to exceed six (6)
months against certified equipment or references, or valid national or
international standards.
c)
Calibration records shall be latest and valid at the time of inspection or
testing. The calibration records shall be easily traceable to the measuring
and test instrument and shall be maintained at the work Site. The
Contractor shall periodically verify the serial numbers on the records against
those on the equipment. Devices should be tagged indicating the date of
last calibration. Provisions for correcting measurement and test equipment
found out of calibration shall be identified. Specific attention shall be given
to NDE equipment, theodolites (transits) and lasers, welding machines, weld
rod and flux ovens, and pressure gauges.
DOC. NO. KOC-Q-014
d)
6.6.9
Page 44 of 100
REV. 2
The Contractor shall audit and document the validity of previous inspection
and test results when inspection, measuring and test equipment is found to
be out of calibration.
Inspection and Test Work Status
The Contractor shall establish measures to identify inspection and test progress.
Such measures shall provide means for ensuring that required inspection and tests
are performed and the required resources are available to meet the Contract
schedule and that the status of the inspection and test work is known throughout
execution of the Contract duration.
6.6.10
Material Handling, Storage and Preservation
The Contractor shall establish procedures to control handling, storage, and
preservation of material in accordance with all applicable Contract specifications,
manufacturer recommendations and KOC Standards. The procedure shall list all
Contract and inspection requirements for maintaining the quality of the material or
equipment as well as provide for documentation that the required activities have
been performed. Special handling, storage and preservation shall be accomplished
by qualified individuals with predetermined work and inspection instructions.
6.6.11
Fabrication and Construction Reports
The Contractor shall maintain at Contractor’s fabrication yard(s) and Work Site
office(s), a copy of all documentation in reference to or referred in the drawings,
specifications and procedures for the inspection of equipment and materials used
in the fabrication and construction of the facilities.
6.7
Pre-Commissioning Phase
The QA/QC requirements shall be as per the Contract mechanical completion, precommissioning, and start up requirements.
7.0
MATERIAL MANAGEMENT
7.1
It is the responsibility of the Contractor to ensure proper material management
function as follows:a)
To ensure proper transportation and handling equipment during loading,
offloading and handling of equipment and materials.
b)
To consider preservation of materials during site handling, transportation
and storage.
c)
To consider timely use of material with limited life.
d)
To ensure material inspection and identification on receipt.
e)
To ensure accurate identification of material on issue.
DOC. NO. KOC-Q-014
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REV. 2
f)
All incoming materials to site shall be checked by the Contractor to confirm
that they are of the required quantities, and that they are appropriately
identified, certified and free from damage.
g)
Non-conforming and undefined materials shall be held in quarantine area
until they are rectified, replaced or accepted by concession.
7.2
The Contractor shall submit for approval, samples of architectural items, civil
materials, electrical components and all such items specified in the Contract.
7.3
As a minimum, the following inspections shall be made by the Contractor
periodically (for stored materials and equipment) and when any new equipment or
materials are received at the Contractor’s local stores or work site:
a)
Examination upon receipt, consistent with practicability, to detect damage in
transit.
b)
Inspection for completeness and proper type as per the Contract
requirements and approved purchase order specifications.
c)
Periodic inspection and precautions to assure adequate storage conditions
and to guard against damage from handling and deterioration during
storage.
d)
Functional testing, either prior to or after installation, or both, as required by
Contract to determine satisfactory operation.
e)
Identification and protection from improper use or disposition; and
f)
Verification of quantity.
7.4
Materials and Equipment in Sour Service
7.4.1
All materials and equipment in sour service shall be manufactured, tested and
certified in accordance with the related KOC/International standards and the
following NACE standards as applicable:
a)
ANSI / NACE MR0175 / ISO 15156;
b)
NACE MR0103;
c)
NACE TM0284;
d)
NACE TM0175.
7.4.2
Elastomeric materials shall be tested and certified to NACE TM0187 and NACE
TM0296 as applicable.
7.4.3
Manufacturing reports, test results and complete inspection dossiers shall be
regularly submitted to KOC for review and approval and shall also be included in
the final Manufacturing Record Book (MRB) of the equipment or materials.
DOC. NO. KOC-Q-014
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REV. 2
8.0
LABORATORY QUALIFICATION
8.1
All testing and calibration laboratories that are utilized by the Contractor, subContractors, vendors, sub-vendors or suppliers shall be competent and accredited
in accordance with the requirements of ISO / IEC17025 standard. This requirement
is applicable to all organizations performing tests and / or calibrations. These
include, first, second and third-party laboratories, and laboratories where testing
and / or calibration forms part of inspection and product certification.
8.2
Accreditation is applicable to all laboratories regardless of the number of personnel
or the extent of the scope of testing and/or calibration activities. All laboratories
shall have been accredited and certified from a KOC approved laboratory
accreditation agency. When a laboratory does not undertake one or more of the
activities covered by ISO / IEC17025, such as sampling and the
design/development of new methods, the requirements of those Clauses do not
apply.
8.3
Laboratories operating within production / manufacturing organizations shall also
be accredited to ISO / IEC17025 standard.
Important Note
Conformity of the quality management system within which the laboratory
operates to the requirements of ISO 9001 does not of itself demonstrate the
competence of the laboratory to produce technically valid data and results. Nor
does demonstrated conformity to ISO / IEC17025 standard imply conformity of the
quality management system within which the laboratory operates to all the
requirements of ISO 9001.
9.0
QUALIFICATION OF BODIES PERFORMING INSPECTION
9.1
All Inspection Bodies that are utilized by the Contractor, sub-Contractors, vendors,
sub vendors or suppliers shall be competent and accredited in accordance with the
requirements of ISO / IEC17020 standard;
9.2
Accreditation of an inspection body shall demonstrate that:
9.3
a)
It is competent to perform specific inspections or specific types of
inspections;
b)
Its quality system is documented, fully operational and addresses and
conforms to all elements of ISO / IEC17020 and API-Q2;
c)
It is operating in accordance with its quality system; and
d)
It conforms to any additional requirements or specific fields or programs
necessary to meet particular user needs.
Authorized Inspection Agencies (AIA) and Authorized Inspectors (AI) and
supervisors shall be accredited and certified in accordance with ASME QAI-1.
DOC. NO. KOC-Q-014
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REV. 2
10.0
QUALIFICATION OF BODIES PERFORMING PRODUCT CERTIFICATION
10.1
All Product Certification Bodies that are utilized by the Contractor, sub-Contractors,
vendors, sub-vendors or suppliers shall be competent and accredited in
accordance with the requirements of ISO / IEC 17065.
10.2
Accreditation of Bodies performing Product Certification shall demonstrate that:
a)
It is competent to perform specific product certifications or specific types of
product certifications;
b)
Its quality systems is documented, fully operational and addresses and
conforms to all elements of ISO/IEC 17065 and API-Q2;
c)
It is operating in accordance with its quality system; and
d)
It conforms to any additional requirements or specific fields or programs
necessary to meet particular user needs.
11.0
OBJECT CONFORMITY AND CERTIFICATION
11.1
The field of conformity assessment includes activities defined in the International
Standard ISO 17000, such as testing, inspection and certification, as well as the
accreditation of conformity assessment bodies.
11.2
The expression “object of conformity assessment” or “object” is used in this
Standard and in the International Standard ISO 17000, to encompass any
particular material, product, installation, process, system, person or body to which
conformity assessment is applied. A service is covered by the definition of a
product.
11.3
Products that are not inspected as per Tables (2) and (3) of this Standard and
which are considered as commercial-off-the shelf items shall be tested, inspected
and certified by a Conformity Assessment Body (CAB) to determine if it complies
or performs in accordance with the specified requirements.
12.0
BASELINE DATA COLLECTION
12.1
The Contractor shall arrange for and undertake all baseline data activities including
providing isometric drawings of the fabricated and installed piping network. The
baseline data shall provide as a minimum the following information;
a)
the equipment and piping materials of construction;
b)
the joining / welding type, NDE and pressure testing made;
c)
the actual measured wall thickness of all pipe spools, fittings, connections
and static equipment;
d)
static equipment and line specifications, design and operating data and
reference to P&IDs;
DOC. NO. KOC-Q-014
e)
Page 48 of 100
REV. 2
painting or coating type and the dry film thickness and reference
specification / standard used.
12.2
The Contractor shall submit for KOC review and approval its “Baseline Data
Preparation Procedure” well in advance of the start of the work, and preferably at
the time of submitting the Project Quality Plan (PQP).
12.3
Completed baseline data records shall be submitted to KOC in stages
commensurate with the progress of work. The records shall be provided in MS
Office Excel sheets so that it could be integrated with the existing Risk Based
Inspection (RBI) KOC records and software under the control of Inspection &
Corrosion (Projects)Teams.
12.4
Equipment to be included in the baseline data are those newly installed ones by
the Contractor within the Scope of the project / Contract. These equipment include
the stationary pressure vessels, heat exchange equipment, storage tanks (shop
fabricated or site erected), scraper traps, and heaters, flare stacks, flare tips, slug
catchers, etc. All drawings for equipment and piping isometrics shall be submitted
in soft copy in both AutoCAD and PDF formats.
12.5
Measurements of wall thickness shall be made as per Appendix-J of this Standard.
13.0
MATERIALS FROM STOCKIST / DISTRIBUTORS
13.1
Procurement of materials from Stockist / Distributors shall be restricted to the
minimum possible limits. Prior KOC approval is required. It is not permitted to
divide any purchase order or quantity into smaller orders or quantities to entail
procurement from Stockist.
13.2
Stockist may be qualified for supplying of materials if they can meet the
qualification criteria in Appendix-I of this Standard. The Contractor shall ensure
that proper auditing is carried out before application for KOC approval.
13.3
Material Test Certificates (MTC) to be submitted by stockist shall be certified and
traceable to original MTC. All materials from Stockist shall be new, unused and
free from any visual defects, damages and corrosion. All items shall be visually
inspected by the Contractor’s inspector before shipping to the work site or stores at
KOC premises.
14.0
COUNTERFEIT, FRAUD AND BOGUS REPORTS PREVENTION PLAN
14.1
The Contractor shall establish, maintain and operate a Fraud and Counterfeit
Avoidance, Detection, Mitigation, and Disposition program to be followed for KOC
project. The Contractor shall also establish work instructions to be attached with all
engineering requisitions, purchase orders and subcontract agreements.
ISO DIS 34001.4 may be used to prepare the program.
14.2
Counterfeit, Fraud and Bogus actions by vendors, manufacturers and suppliers
shall be avoided at all phases of the project. It is the contractor’s responsibilities to
ensure prevention also during fabrications, site welding, coating, lining, NDE, etc.
at fabrication shops and at work site where the project is executed in Kuwait.
DOC. NO. KOC-Q-014
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REV. 2
14.3
The Contractor shall establish, maintain and operate a performance criteria for
authentication solutions to be used to combat counterfeiting of material goods. The
guidelines provided in ISO 12931 may be used. Log books containing all cases of
counterfeit, fraud and bogus reports shall be established by the Contractor and
shall be made available to KOC review on periodical basis.
15.0
NON-DESTRUCTIVE EXAMINATION (NDE) AND THIRD PARTY INSPECTION
BODIES
15.1
The Contractor shall be responsible for qualifying and selecting the NDE service
providers and Third Party Inspection organizations in line with ISO / IEC 17020,
ISO 11484, ISO 20807, ASTM E329, ASTM E543, ASTM E1212 and ASTM E1359
as applicable.
15.2
The contractor shall ensure that its quality management system and its third party
quality system satisfy the requirements of ISO 17020 and shall provide for KOC
review and approval, the documents that prove compliance. The Contractor shall
ensure that requirements for the competence of bodies performing inspection and
for the impartiality and consistency of their inspection activities are fulfilled.
15.3
Qualification and certification of NDE personnel shall meet the requirements of ISO
9712, ISO 11484, ISO 20807 or ASNT SNT-TC-1A / ASNT-CP-189. Qualification
and certification documents shall be submitted to KOC for review and approval.
15.4
The Contractor quality system and organization shall include NDE qualified and
certified personnel capable of managing all NDE activities at vendors, suppliers,
sub-contractors and at site. The NDE section(s) shall include level III personnel
who shall be qualified in all the NDE methods used by the NDE service provider.
This may require more than one nominated Level III person.
15.5
The Contractor quality personnel shall supervise all site NDE activities and shall
review all inspection and test reports carried out by the third party organizations
and the NDE service providers before submitting to KOC.
15.6
The Contractor shall establish procedures to describe and maintain all NDE
management activities and shall submit these documents for KOC review and
approval.
15.7
Contractor’s proposed third party inspection organizations and NDE service
providers shall be submitted for KOC review and approval. Details of the
qualifications and evaluations by Contractor shall be included among the
submittals. Unpriced copies of the agreements shall also be submitted for KOC
review. No work shall be started before KOC approval.
DOC. NO. KOC-Q-014
16.0
Page 50 of 100
REV. 2
APPENDICES
Appendix-A:
Contractor QA/QC Personnel Qualifications
Appendix-B:
The control of Non-Conformances
Appendix-C:
Project Pre-Inspection Meeting (PPIM)
Appendix-D:
Vendors Pre-Inspection Meeting (VPIM)
Appendix-E:
Construction Pre-Inspection Meeting (CPIM)
Appendix-F:
Manufacturing
Record
Book
(MRB)
and
Certification
Requirements
Appendix-G:
Typical QA Procedures to be Provided by the Contractor
Appendix-H:
Typical QC Procedures to be Provided by the Contractor
Appendix-I:
Procurement from Stockist
Appendix-J:
Baseline Data Thickness Measurements
Appendix-K:
Inspection & Test Plan (ITP) Template
DOC. NO. KOC-Q-014
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APPENDIX-A : CONTRACTOR QA / QC PERSONNEL QUALIFICATIONS
A.1
Quality personnel shall be college or university graduates in engineering (degree)
or diploma, need to have a minimum of 6 / 10 years industrial experience
respectively, including at least 4 years inspection experience in a given inspection
specialty; and shall be fully conversant with industry standards and specifications;
and can perform a variety of complex inspection functions with minimal
supervision.
A.2
The “Inspector” shall be able to review and comment on revisions to industry
standards and specifications; be able to perform in-depth design reviews to verify
conformance to the Contract and international standards and specifications on
projects in the design and construction stage.
A.3
Additional requirements shall apply for specific disciplines as follows:
A. 3.1
Welding Inspector:
Welding inspector shall be a diploma holder in the respective discipline with
minimum six (6) years of experience in the relevant field or a graduate engineering
with minimum four (4) years of experience. Welding inspector shall be certified as
an American Welding Society CWI, CSWIP Certified Welding Inspector, or KOC
approved equivalent. Inspector shall have a demonstrated background and
thorough knowledge of codes such as ASME-B31.3, B31.4, B31.8, AWS-D1.1, API
650, API 653, API-1104, ASME Section V & IX, etc. Where Non-destructive
Examination (NDE) forms part of the work, and the Inspector is required to review,
audit or ensure NDE programs and results, he shall have been previously qualified
and certified to a minimum ASNT Level II in the relevant method/s. If performing
Non-destructive Examination in VT, MT, PT, RT or UT, or affecting the results of
Non-destructive Examination, he shall be certified in the specific method/s. When
performing, reviewing, ensuring or auditing Radiographic Testing Film
Interpretation (RTFI), the Inspector shall be certified in RTFI in accordance with
ASNT-RI, CSWIP 3.1 or equivalent standards.
A.3.2
Civil Inspector:
Degree or Diploma in civil engineering with minimum six (6) years of experience in
the relevant field. Civil inspector shall demonstrate a thorough working knowledge
of recognized building codes such as the Uniform Building Code (UBC) or
equivalent standards.
A.3.3
Coating Inspector:
Coating inspector shall be a diploma holder in the respective discipline with
minimum six (6) years of experience in the relevant field or a graduate engineering
with minimum four (4) years of experience. Shall have a thorough knowledge and
proven ability of all phases and types of critical coating applications and methods
and recognized industry standards and qualified to NACE CIP level II – certified or
level III.
DOC. NO. KOC-Q-014
A.3.4
Page 52 of 100
REV. 2
Plumbing and HVAC Inspector:
Shall satisfy the qualification requirements of a journeyman plumber, or equivalent;
and shall demonstrate a thorough knowledge of codes such as the Uniform
Plumbing Code and the Sheet Metal and Air Conditioning Contractors National
Association (SMACNA) codes and/or equivalent standards.
A.3.5
Crane Inspector:
Shall demonstrate a thorough working knowledge of codes, such as: ASME /
ANSI-A 17.1 (Safety Code for Elevators and Escalators), ASME / ANSI A17.2,
(Guide for Inspection of Elevators, Escalators, and Moving Walks), ANSI-B30.1
through B30.16 (Lifting Devices and Ancillary Items), or equivalent standards.
A.3.6
Electrical Inspector:
Shall satisfy the qualification requirements of a journeyman electrician, or
equivalent; and shall demonstrate a thorough working knowledge of codes such as
NFPA 70 (The National Electric Code), or equivalent standards.
A.3.7
Communication Inspector:
Shall demonstrate a thorough working knowledge of telecommunications, be
familiar with: North American or International Telecommunications Standards;
Building Industry Consulting Services International – Telecommunications
Distribution Methods Manual (BICSI-TDMM); National Electrical Codes; and
National Electrical Safety Codes, or their equivalents.
A.3.8
Instrument Engineer / Technician / Inspector:
Shall satisfy the requirements of a fully qualified Instrument Technician / Engineer
meeting the requirements laid out by the Instrument Society of America or the
Institute of Measurement & Control, with a minimum of a diploma in Technology or
equivalent and 8 years field experience in construction and pre-commissioning
both plant and equipment.
A.3.9
Non-destructive Testing (NDE) Personnel:
a)
All Contractor and sub-Contractor NDE disciplines & certification levels shall
hold current certification attesting to NDE qualifications.
b)
NDE Level III – shall have certification issued by ASNT (or equivalent as
approved by KOC) in the required NDE method(s) specified by KOC and
shall be required to fulfill the full scope of a practicing level III including, but
not limited to: method application, interpretation of results, interpretation of
codes and standards, preparation of procedures, and training of Level I and
Level II personnel.
DOC. NO. KOC-Q-014
A.3.10
Page 53 of 100
REV. 2
c)
Radiographic Examination and Radiograph Film Interpretation Technicians
– shall be qualified to perform X and Gamma Ray radiographic examination.
When performing, reviewing, ensuring or auditing Radiographic Testing Film
Interpretation (RTFI), the inspector shall be certified in RTFI in accordance
with ASNT-RI, CSWIP 3.1 or equivalent standards.
d)
Ultrasonic Examination Technician – shall be qualified to perform
longitudinal and shear wave ultrasonic examination of welds utilizing A-Scan
ultrasonic flaw detection equipment. Phased array and Time of Flight
Diffraction (TOFD) inspector shall be qualified to ASNT SNT-TC-1A / ASNTCP-189.
e)
Liquid Penetrant Examination Technician – shall be qualified to perform
visible and fluorescent Liquid Penetrant examination.
f)
Magnetic Particle Examination Technician – shall be qualified to perform
wet and dry visible and wet fluorescent magnetic particle examination.
Quality Assurance Manager:
Shall have demonstrated knowledge and training in the ISO-9001 standard, or
equivalent; a university degree in engineering, with a minimum of ten (10) years of
direct experience in quality assurance system activities in the oil, gas and
petrochemical industries. Shall have minimum four (4) years of experience in the
capacity of Quality Assurance Manager.
A.3.11
Site Quality Assurance/Quality Control Manager:
Shall have a demonstrated knowledge and training in the IS0-9001,or equivalent; a
university Engineering Degree in particular discipline (demands specific to the
type of Project). Have minimum 10 yrs. experience in Oil, Gas or Petrochemical
Industry, shall be fully conversant with International codes and standards and have
6 yrs. of direct inspection experience in site construction.
A.3.12
Procurement Quality Supervisor:
Shall have demonstrated knowledge and training in the use of measuring and test
equipment routinely used in conducting inspections, have a university degree in
engineering with a minimum of ten (10) years experience directly relating to
supervision of vendor inspection activities in the oil, gas and petrochemical
industries as well as site construction inspection. He shall have a minimum of four
(4) years experience in the capacity of Quality Control Manager or Procurement
Quality Supervisor.
DOC. NO. KOC-Q-014
A.3.13
Page 54 of 100
REV. 2
Vendor Inspector:
As a minimum, must be knowledgeable of national codes and fabrication methods;
and shall be qualified to perform specialized inspection and testing of oil and gas
processing materials, plant surveys as required to verify vendor compliance with
purchase order and KOC and / or international standards. Where Non-destructive
Examination (NDE) forms part of the work, and the inspector is required to review,
audit or ensure NDE programs and results, he shall have been previously qualified
and certified in accordance with a certification program to a minimum ASNT Level
II or level III in the relevant method/s. If performing Non-destructive Examination in
VT, MT, PT, RT or UT, or affecting the results of Non-destructive Examination, he
shall be certified to a minimum ASNT Level II in the relevant method/s. When
performing, reviewing, ensuring or auditing Radiographic Examination Film
Interpretation (RTFI), the inspector shall be certified in RTFI in accordance with
ASNT-RI, CSWIP 3.1 or equivalent standards.
A.3.14
Quality System Auditors:
Auditors shall be qualified to ISO-19011 and competent in the discipline being
audited, familiar with quality system standards and be able to exercise judgment
against the criteria of the standards. Auditors must be able to communicate clearly
in writing and orally. Auditors shall have satisfactorily completed a training course
and passed the course examination. Auditors shall have participated in a minimum
of four (4) audits for a total of at least 20 days including documentation review,
actual audit activities and audit reporting.
A.3.15
Welding Engineer:
Shall have Engineering Degree in mechanical/metallurgy with 10 yrs. experience in
Oil,Gas or Petroleum industries and six year directly involved in welding
management and inspection. He shall have extensive knowledge in ASME IX,
ASME V, API 1104, ISO 3834 and ISO 14731 codes and standards and shall have
a welding certification from an industry recognized institute.
A.3.16
Cathodic Protection (CP) Inspector
The CP inspectors and technicians shall be employed by a company in the KOC
CP approved list. The inspectors and technicians shall be a Cathodic Protection
Specialist Engineer (NACE certified as CP – Technicians or equivalent) and shall
have a minimum of 4 years experience in CP systems installation in the Oil & Gas
industry. He shall also have experience in CP testing, inspection and
commissioning during construction of pipelines, storage tanks and facilities.
A.3.17
CP Designer:
The designer shall be employed by a company in the KOC CP approved list and
shall be a Cathodic Protection Specialist Engineer (NACE certified as CP Specialist or equivalent). Shall have a minimum of 8 years experience for degree
holder and 12 years for diploma holder in design of CP systems in the Oil & Gas
industry. Shall have experience in CP testing, inspection and commissioning
during construction of pipelines, storage tanks and facilities.
DOC. NO. KOC-Q-014
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REV. 2
APPENDIX-B: THE CONTROL OF NON-CONFORMANCES
B.1
Non-Conformance Report (NCR)
NCR is a report issued when a product, process or procedure does not comply
with the set standards for a product, process or procedure under inspection.
B.2
Purpose of Controlling and Documenting Non-Conformance
a)
The non-conformance is identified and actions are taken accordingly.
b)
Decisions on the disposition of non-conforming components are properly
taken and documented.
c)
Non-Conformance Reports (NCR) are processed according to an
established system.
d)
Investigations and analyses of non-conforming materials are made to
assess failure modes, mechanisms and effects, and that subsequent
corrective action is devised and implemented.
e)
The frequency and history of non-conformances are reviewed systematically
and, when necessary, corrective action is initiated.
f)
Any action to correct a non-conformance and to prevent its recurrence is
carried through to its conclusion.
g)
Components not conforming to the requirements of the applicable
specifications or other requirements are identified as such, segregated and
held for review.
B.3
The Contractor shall establish and maintain an effective and positive system for
controlling non-conforming material, including procedures for the identification,
segregation, presentation and disposition of reworked or repaired supplies. Repair
of non-conforming supplies shall be in accordance with documented procedures
approved by KOC. Nonconformance and Corrective Action procedure shall be
established by the contractor for KOC review and approval.
B.4
Procedures shall be maintained to prevent inadvertent use of design documents,
materials, parts, components, services, or workmanship not conforming to
requirements of the Contract, codes and specifications. Procedures shall include
closed-loop control for the identification and documentation of non-conformances,
corrective actions and waivers of Contract requirements.
B.5
The acceptance of non-conforming supplies is the prerogative of and shall be as
prescribed by KOC. All non-conforming supplies shall be positively identified to
prevent use, shipment and mixture with conforming supplies. Holding areas,
mutually agreeable to the Contractor and KOC, shall be provided by the
Contractor.
DOC. NO. KOC-Q-014
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REV. 2
B.6
NCRs issued by the Contractor, sub-Contractors, vendors, manufacturers and
suppliers shall be copied to KOC and its TPI representative to document specific
Contract scope, standards and specification violations being observed.
B.7
The Contractor shall investigate the causes of non-conforming items, and initiate
corrective actions to prevent reoccurrence of non-conformities.
B.8
Repair and rework items shall be re-inspected in accordance with applicable
procedures. Controls to restrict further processing or installation of a nonconforming or defective item(s), pending a decision on its disposition, shall be
established and maintained.
B.9
All NCRs shall be documented on a Non-conformance Report Log, which is to be
submitted by the Contractor at the regular progress meeting.
B.10
Concession (Waiver) of Inspection Requirements
Inspection requirements as identified in the QP Contractor’s inspection, testing or
examination during the various work phases may only be waived with KOC written
approval.
B.11
Concession (Waiver) of KOC Standards or Specifications
Waiver of KOC Standards and project specifications during all work phases
requires the written approval of KOC.
B.12
Classification of Non-Conformances
All non-conformances are classified according to their severity as either minor or
major. Any departure of a characteristic from the specified requirements which can
be remedied by a corrective action and does not contravene the applicable KOC /
Project documentation is deemed to be a minor non-conformance. All other
deviations are deemed major non-conformances.
B.13
Non-Conformance Report (NCR)
Any Non-Conformance observed / raised shall be addressed through NCR, a
Typical NCR Format provided herein.
DOC. NO. KOC-Q-014
Project No.
Contract No.
Project Title:
Contractor Name:
Page 57 of 100
Kuwait Oil Company (KOC)
Typical NCR
Format
REV. 2
NCR No.
Date:
Added to NCR Log:
Component Category:
Section (A): Identification
1. Originator Name:
5. Part Description:
2. Contractor/Vendor:
6. Drawing No.
3. PO No.
7. Quantity:
4. Date NC noticed:
8. Action taken to prevent misuse:
Non-conformance found during which activity:
□ In-process inspection at vendor
□ Final inspection at vendor
□ Incoming goods receiving inspection at site
□ During site testing
□ Other:
Section (B): Description of Non-Conformance (NC) {use continuation page if necessary}
1.
Observed Non-Conformance (NC)
2.
Reasons for the NC
□ Use as it is
□ Repair
□ Rework
Section (C): Contractor and /or Vendor Proposed Disposition
□ Return to supplier
Responsible Manager/Engineer
□ Reject
Name:
Date:
Justification for proposed disposition:
Section (D): Corrective Actions
Description of proposed actions:
Approval of corrective actions
Name:
Title
Signature
Date
Section (E): KOC approval of Disposition & Corrective actions
Approval of KOC Disposition & Corrective actions:
Name
Title
Signature
Date
Section (F): Closing the Non-Conformance (NC)
Planned disposition has been completed and corrective action has been initiated
Name
Title
Signature
Date
Issued for KOC on:
DOC. NO. KOC-Q-014
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APPENDIX-C: PROJECT PRE-INSPECTION MEETING (PPIM)
C.1
A meeting shall be scheduled between KOC and the Contractor to discuss and
clarify the entire aspects of Quality Assurance, Inspection and Certification. Other
concerned parties may be invited to attend by either KOC or Contractor. The
meeting shall be held as early as possible, but after receiving and reviewing by
KOC of the project Quality Manual and Quality Plan and other documents
highlighted in this Appendix. This meeting shall be chaired by KOC concerned
Inspection & Corrosion (Projects) Team representatives.
C.2
Documents covering the PPIM topics shall be prepared by the Contractor for
discussion and shall be attached to the minutes of meeting. The Minutes of
Meeting (MOM) and attached supporting documents shall be contractual and shall
be used as a reference for other project phases. Hard and soft copies of the MOM
and all attachments shall be submitted to KOC and all attendees for retention.
C.3
The meeting shall be held at the contractor head offices where all disciplines
(specialties) are available for successful undertaking of the meeting. The main
agenda items shall be as follows:-
C.3.1
Discussing the Quality Manual, Programs and Plan and any comments or
reservations made by KOC and / or the Contractor.
(Contractor to make ready all latest documents for discussions. Discussion
comments shall be incorporated as applicable and the Quality Manual, Programs
and Plans shall be revised and attached to the MOM).
C.3.2
KOC’s responsible Teams and agencies for the quality and inspection
activities.
(KOC to explain and provide the list of Inspectorate selected for its inspection
involvement at vendors and site. KOC shall provide a flow chart showing Teams
and parties involved).
C.3.3
Co-ordination and routing of quality documents within KOC’s Teams.
(Contractor to explain and provide relative documents transmittals e.g. routing
procedure, flow charts, responsibilities, authorization, names and signatory, etc.).
C.3.4
The Contractor approach and resources for undertaking the quality
assurance and quality control during the entire phases of the project
(Conceptual design, design, procurement, construction and pre-commissioning.)
The contractor shall explain how QA is applied for each phase of the project, e.g.
in design work, drawings and calculations submittals and how Engineering QA /
QC manager ensures that all activities have been based on the contract
requirements, relevant standards and KOC Specifications / Standards. Contractor
shall explain how consistency is maintained throughout all project phases.
Contractor shall explain also how QC will be managed at vendors and at site.
Which inspection agencies (provide details) will be employed at various
manufacturing vendors, e.g. for rotating equipment, pressure vessels, NDE,
Laboratories, etc. Contractor shall submit to KOC the unpriced agreements with all
such organizations employed for QA/QC work at venders and at site.
DOC. NO. KOC-Q-014
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C.3.5
Organization charts and qualifications of the QA/QC team that will be
involved in the work.
The charts shall provide details of each person and the category of work he is
involved (civil, mechanical, electrical, instruments, piping, rotating, pipelines,
tankage, etc.). Subordinates shall also be shown on the organization charts with
qualifications and training / certifications obtained, etc. the CVs, qualifications and
certifications shall be provided for each key personnel in all disciplines.
C.3.6
The Contractor proposed agencies or sub-Contractors that will be involved
in the QA/QC work, vendor and site inspection, testing and calibrations of
materials and equipment or any other related activities.
Before the meeting, the Contractor should have discussed the details of QA / QC
to be carried out by subcontractors and service providers e.g. NDE, labs, coating /
lining, welding, pressure testing, pipeline cleaning and drying, caliper pigging, etc.
Contractor shall also provide lists of Third Party Inspectors employed at site and
vendors. Item C.4.4 and C.4.6 may be amalgamated. Contractor’s prepared
documents shall be presented to the meeting and shall be attached to the MOM.
C.3.7
Review and discuss the current status of design and procedural documents
required of the Contractor.
Documents status of design work by the Contractor, subcontractors and main
vendors, e.g. rotating equipment, heat exchangers, pressure vessels, boilers, etc.
shall be provided along with plans to satisfy the contract schedule.
C.3.8
Review and discuss the list and status of Contractor’s quality procedures to
be used at vendors and site.
Contractor shall present the list of all quality procedures intended to control the
work at vendors, site and head office. Completed Quality procedures shall be
provided for discussion. List of incomplete procedures shall be submitted along
with anticipated dates of submission shall be provided.
C.3.9
Discuss the list of selected vendors, contact names, addresses,
manufacturing, testing and assembly locations, status of engineering
requisitions, purchase orders and proposed inspectorate at each.
Before attending the meeting, Contractor should have decided on selected vendors
for each equipment and material. Engineering requisitions shall be presented to
the attendees for review. All engineering requisitions should have been submitted
to KOC Controlling Team for review/approval as per contract. The contractor shall
explain how the requirements as per the contract including but not limited to data
sheets, KOC standards, project specifications, supplementary letters and this KOC
Standard (KOC-Q-014) have been addressed adequately in the material requisition
and purchase orders.
C.3.10
Contractor’s plans and methods for auditing (internally, vendors and subContractors).
Contractor should have prepared relevant documents related to auditing including
procedures, auditees, timing, locations, engineering auditing, procurement,
vendors auditing, contractors and sub-contractors auditing, etc. Documents shall
be attached to MOM.
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C.3.11
Divisions of responsibility and authority between Contractor’s home office
and site based QA/QC personnel in respect of vetting of procurement
documents, auditing, vetting of procedures for site applications, vendor
inspection coordination, vetting of inspection reports and certification of
materials and equipment, documentation of non-conformance and
concession requests (waivers).
Responsibilities and authorities flow charts shall be presented and explained.
Documents shall be attached to MOM.
C.3.12
Establish ITPs, vendor pre-inspection meeting requirements, attendees and
agenda.
KOC and Contractor shall discuss the project specific inspection levels category of
equipment and materials as specified in Table (3) of this Standard and agree on
the vendors that require holding pre-inspection meetings. Contractor shall call for
vendor pre-inspection meetings only when certain documents have been received
by KOC, approved code A or B. Guidance is provided also in Appendix-D of this
KOC Standard. PPIM agenda shall be discussed and agreed upon and if additional
items are found necessary, it shall be added to the agenda provided in Appendix-D
to this Standard.
C.3.13
Discuss the proposed approval route for Quality Plans and Vendor
Certification Dossiers.
Quality plans shall be discussed from the viewpoint of routing by the Contractor to
KOC and back to the Contractor then to vendors or sub-contractors. Also the
submission and contents of Certification Dossiers shall be explained and
documented by the Contractor taking into consideration Appendix-F of this
Standard.
C.3.14
Establish methodology for provision of purchase orders and related
documents to KOC Third Party Inspectorate(s).
Normally the contractor’s inspection agency gets various documents including the
purchase orders, engineering requisitions, ITP, contract specifications and other
documents needed for his daily involvements at vendor. Contractor shall explain
how those documents are also provided to KOC third party inspectorates
appointed by KOC well in advance of the VPIM and start of manufacture at
vendors / suppliers or subcontractors.
C.3.15
Discuss routing of vendor inspection notifications, waivers, release notes,
non-conformance or non-acceptance notes etc.
Contractor shall prepare flow chart documents and the formats to be used for
Inspection Notifications (IN), non-conformance, waiver requests, release notes
(inspection and shipping) and other formats not mentioned here. Contractor shall
ensure that such documents have its logo, date, project number and title, contract
number and engineering requisition and purchase order numbers. Formats shall
show also full details and address of the vendor as well as parties receiving
copies of the documents.
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C.3.16
Discuss the MRB and certification requirements and dossiers including the
electronic formats.
Contractor shall explain its procedure for preparation and submittal of MRBs
required from vendors, sub-vendors, sub-contractors, site construction, etc.
Contractor shall also explain the contents of each MRB and electronic formats that
must be searchable and subdivided into easy finding chapters and titles.
C.3.17
Discuss the implementation of KOC-Q-014 Standard.
Contractor to ensure that KOC Standard for Project QA / QC General
Requirements “KOC-Q-014” is attached to every engineering requisition and
purchase order and every sub-vendor and subcontractor agreement.
C.3.18
Discuss the accreditation of testing laboratories as per KOC-Q-014 and ISO
17025.
C.3.19
Discuss the intended welding management and processes of piping and
pipelines including manual, automatic, mechanized, etc. as well as the source
of machines and qualifications. Explain where each process will be used and the
substitute action when a process has failed to guarantee welding quality. Explain
the actions for welding procedure qualifications and welders/operators
qualifications.
C.3.20
Discuss the NDE methods to be applied for piping and pipelines welding, source
of machines, training of operators, etc.
C.3.21
Discuss how Contractor will prevent of FRAUD by the contractor, subcontractors,
vendors, sub-vendors, suppliers, stockist, etc. Contractor shall provide a document
/ procedure that should be attached to every engineering requisition, purchase
order, sub-contract, NDE contracts, third party inspection, etc.
C.3.22
Discuss how Contractor will manage the use, inspection and identification of
“fasteners” to be used by vendors, sub-contractors. Contractor document in this
regard shall be prepared for KOC review. KOC approved document on “fasteners”
shall be attached to all engineering requisitions, purchase orders and subcontracts.
C.3.23
Discuss in detail the “Inspection release note” and “shipping release note”.
Inspection and shipping release shall be made only at the manufacturing facilities
or fabrication shops. No shipping shall be made unless inspection release is
granted by KOC. No inspection release will be given after the materials have
arrived at site work.
C.3.24
Inspection requirements must be addressed in detail along with each
engineering requisition and PO. Engineering requisitions and purchase orders
shall be submitted for KOC review and approval. There shall be no conflict in data,
quantities or specifications between the engineering requisition and purchase
order.
C.3.25
Contractor personnel attending the PPIM and VPIM must be fully aware of the
contract, engineering requisition and purchase order including this KOC Standard
KOC-Q-014.
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APPENDIX-D: VENDOR PRE-INSPECTION MEETINGS (VPIM)
D.1
With reference to Table (2) and (3) of this KOC Standard, items in Class (level) 1
and 2 shall have VPIM arrangement by the Contractor. Where necessary, selected
items in Class (level) 3 may require VPIM.
D.2
The purpose of this meeting is to ensure that everyone at the Supplier/Vendor who
will be involved in manufacturing, fabrication and monitoring the quality of the
Equipment / Materials fully understands specific requirements and details of the
job, especially those requirements that may be non-routine or different relative to
normal Supplier / Vendor quality surveillance. Advance preparation by the Vendor,
Contractor and KOC inspectors is important for the pre-inspection meeting to
ensure the meeting covers all necessary issues requirements as specified in the
contractual agreements, KOC datasheets, KOC Standards including this Standard
KOC-Q-014.
D.3
During the PPIM, vendors/suppliers requiring VPIM are defined and agreed upon
with KOC. Upon the request of KOC and / or the Contractor, the list may be
modified when mutually agreed upon between the two parties. Before calling for
VPIM, the Contractor shall ensure that certain documents have been submitted to
KOC and accepted as code “A” or “B”. Refer to Table D.1.
D.4
VPIM shall be held at the manufacturing or production facility only. In case of
major equipment (e.g. compressors) and packages where main sub-Vendor is
involved, the meeting may be extended to be held at the main sub-Vendor facility
as well; however all such meetings shall be made during only one visit. VPIM shall
normally take two days while for major equipment similar to compressors, three
days shall be required.
D.5
KOC Engineers and / or its Third Party Inspectorates will attend the VPIM. The
Contractor inspectors appointed to perform the inspection at the Supplier/Vendor
shall also attend the VPIM. If the Contractor intends to appoint a third party
inspection agency for performing the inspection work, then KOC approval of that
TPI shall be needed. Furthermore Contractors’ third party inspectors shall also
attend the VPIM. KOC Project Inspection Engineer shall always be the chairperson
of the VPIM. When KOC Project Inspection Engineer is not present, the KOC TPI
engineer shall be the chairperson of the meeting.
D.6
Upon completion of the meeting, the Contractor shall provide KOC with both a hard
copy and electronic copy of the meeting including all attachments. The documents
shall be submitted to KOC not later than two (2) days.
D.7
Prerequisite for the VPIM
The Contractor or Supplier/Vendor shall not call for VPIM when the manufacturing
facility is idle for renovations or holidays. Calling for the VPIM shall not be started
unless the following have been satisfied:
a) That the engineering work related to the equipment or material is substantially
completed and manufacturing could be started.
DOC. NO. KOC-Q-014
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REV. 2
b) That relevant drawings specially GA drawings, Cross-sections, material lists,
NDE and weld maps, etc. have been submitted and approved by KOC as code
“A” or “B”.
c)
That comments raised by KOC on the engineering, design and quality have
been resolved.
d) That the Engineering Requisitions (ER) and un-priced Purchase Orders (PO)
have been received, reviewed and approved by KOC as code “A” or “B”.
e) That all relevant quality and applicable production procedures (welding
procedures, NDE procedures, coating and lining, etc.) have been received and
approved by KOC as code “A” or “B”.
f)
That all quality plans and ITP’s including those related to main sub-Vendors
have been received, reviewed and provisionally approved by KOC as code “A”
or “B”.
g) Invitation have been sent to KOC and other parties at least 14 calendar days
in advance of the day of proposed meeting along with the VPIM check list as
per Table D.1
h) Manufacturing shall not start unless the VPIM has been held successfully.
i)
That contractor has managed the VPIM to avoid requesting more than one
meeting on the same day or at more than one place / country.
j)
That contractor’s authorized and qualified personnel shall attend the VPIM in
order to resolve or respond to queries or conflicts in technical and/or
contractual matters. Attendance shall be on full-time basis not part time basis.
D.8
In accordance with the Contract co-ordination procedure, the Contractor shall
officially advise KOC on the proposed date and place of the meetings at least 21
calendar days in advance.
D.9
The following is a typical KOC VPIM agenda that should be followed by all parties.
VPIM chairperson has the right to change the sequence of agenda. For new
vendors, the mill tour may better be the starting of agenda:
D.9.1
Equipment or materials involved.
A list of equipment or materials shall be presented to show the main feature of
each item, its specification, special requirements, quantity, etc. the list shall be
either inserted in the MOM or attached to the MOM.
D.9.2
Review of Engineering Requisition (ER) and Purchase Order (PO) status and
appendices to verify completeness and confirmation to Contract specifications,
procedures, drawings, etc.
Vendor shall present copies of the latest ERs and POs for review by attendees. It
should be discussed and clarified that the latest revisions of ER or PO have no
unapproved changes to design, materials, testing, completion, delivery, etc.
DOC. NO. KOC-Q-014
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REV. 2
D.9.3
Review of exceptions or deviations to ER or PO.
Vendor shall present any KOC approved deviations/changes to the ER or PO.
Deviation serial numbers, dates and contents shall be presented for discussions as
necessary. In-process deviations that have been sent for KOC approval, shall also
be presented and attached to MOM. It is necessary that all inspectors be fully
aware of all deviations/changes to avoid conflicts during the manufacturing and
inspection activities.
D.9.4
Status of design and approval.
This item is related to equipment involving design work at the vendor or
subcontracted to other organizations. Vendor shall prepare the design status brief
summary for attendees discussion.
D.9.5
Vendor furnished documents status.
Vendor has to present the status of submittals including procedures, specifications,
calculations, method statements, etc. vendor shall present a list containing all
project documents highlighting those completed and others in hand or not yet
started. Chronological submittals should be considered.
D.9.6
Raw materials status, sub vendors and manufacturing / testing locations.
Vendor to present a tabulation/document to show sources of materials suppliers,
their location and country, inspection at sub vendors, type of testing made at sub
vendors, who is witnessing tests and how inspection release is managed. Material
status and delivery to production/fabrication shop to be explained.
D.9.7
Sub-suppliers and their Quality Requirements.
Vendor to provide the list of sub-suppliers (as applicable), their location and
country, how quality requirements are incorporated in the purchase orders and
how inspection is managed and witnessed by the supplier and the vendor. Vendor
is requested to provide an evidence of such control on the item(s) handled for
current KOC project.
D.9.8
Critical Path and Long-Lead Equipment / Materials.
Vendor to explain status of long lead equipment or materials and their impact on
production and completion. Vendor may request for KOC assistance if applicable.
Vendor to explain also how its inspection is arranged at such sub vendors and
whether expeditors are employed.
D.9.9
Review of vendor Quality Plan.
Copies of latest quality plan shall be presented to attendees. Vendor shall explain
in chronological order, the specific quality practice, procedures, resources, timing
and activities relevant to the PO.
D.9.10
Review and Marking of Inspection & Test Plan(s) (ITP).
Vendor shall present the latest version of ITP(s) for review and marking by the
Contractor and KOC. ITP may be amended based on actual production or
manufacturing arrangements which were not foreseen during review in Kuwait.
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D.9.11
Vendor project organization.
The vendor project organization shall be explained and attached to the MOM. The
organization chart shall also indicate job title, responsibilities, subordinates,
reporting to senior management and relation with production managers. Link and
communication with sub vendors (e.g. NDE, PWHT, painting, shipping agents,
etc.) should be shown on the chart.
D.9.12
Review of manufacturing procedure, specification and qualification (if applicable).
Manufacturing procedure shall be discussed only if applicable. The procedure
should have been submitted before to KOC review/approval. Where welding is
involved, the WPS, PQR and welders/operators qualification shall also be
discussed. If these documents have been approved previously by KOC, it will be
required to list the procedures numbers and welders numbers as an attachment to
the MOM.
D.9.13
Fabrication / Manufacturing / Production schedule and inspection program.
Vendor shall provide a preliminary program showing the fabrication, manufacturing
or production times/weeks for each item or group of items. The program shall show
also the dates/weeks for inspection and testing of each item. The program shall be
updated frequently and sent to the contractor, the buyer, KOC and the third party
inspectors appointed by contractor and KOC.
D.9.14
Traceability and certification.
Discussion on this part shall include the vendor procedure for “traceability and
certification” and how the heat numbers and part numbers will be provided on
products/items. Certification as required in this Standard (Refer App. F)
D.9.15
Special Requirements on Inspection and testing.
Vendor shall discuss and explain its process and procedure for special
requirements such as “performance testing” or “functional testing” that may be
required for certain equipment e.g. compressors, pumps, metering facilities, etc.
D.9.16
Third Party Inspection (TPI) and Authorized Inspector (AI)
Vendor shall explain and discuss with Contractor and KOC, the presence of AI
and whether AI is involved in the project equipment e.g. pressure vessels.
Contractor and KOC will explain the nature and inspection responsibilities of TPI.
D.9.17
Quality records.
Model inspection and test records forms shall be presented by Vendor. Vendor
shall explain how MTC, test reports, chemical testing (e.g. HIC, SSC) and other
testing records are organized, offered for AI and TPI then filed in MRB.
D.9.18
Inspection release and shipping release.
Inspection release and shipping release shall be discussed and explained by all
parties in line with contract requirements. These documents are required to be
submitted to KOC controlling Team and also KOC Inspection & Corrosion
(Projects) Team. KOC payment to Contractor will not be started unless inspection
and shipping release are received by KOC.
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D.9.19
Vendor concession request procedure.
When the vendor would like to submit a concession, certain format should be used.
Vendor may have its own procedure that should then be provided for discussion by
the attendees.
D.9.20
Non-Conformance Report (NCR) procedure.
The vendor NCR procedure shall be presented for discussion and possible
amendment. There should be a log-book for listing the details of each concession.
The route of submitting a concession shall be discussed.
D.9.21
Points of contact.
Attendees from KOC shall provide the details of contact persons from the
Controlling Team and Inspection & Corrosion (Projects) Team. Vendor and
contractor shall also provide their contact persons. These details shall be provided
correctly to ensure proper communications
D.9.22
Inspection notifications
Vendor shall explain its proposal for notifying all parties including inspectors to
attend the witness and hold point activities. KOC shall also clarify its preference for
notification for this particular project.
D.9.23
Manufacturing Record Book (MRB) requirements.
The content and index of MRB shall be discussed. The proposed parts and content
of the MRB shall be explained. Appendix-F shows the requirements.
D.9.24
Offices and communications means at vendor shop for KOC representatives.
D.9.25
Inspection Visit Arrangement.
D.9.26
Areas of concern.
D.9.27
Any other business.
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Table D.1: Checklist to be prepared and submitted by Contractor before calling for VPIM
Project Title
Vendor Name
Country and Address
of Vendor Shop
Equipment
Contract No.
Contractor
Prepared by / Title
Date
Proposed VPIM Date
Sr.
Item
1
General Arrangement Drawing
with Necessary Details
2
Detailed Drawing and Weld /
NDE Maps
3
Vendor and Main Sub
Vendor’s ITP’s
4
Welding Procedures (WPS)
and Qualifications (PQR)
5
Hydrotest & NDE Procedures
(RT,UT,MT,PT etc.)
6
Vendor and Main Sub Vendor
Quality Plans, Programs etc.
7
Manufacturing Procedures and
Qualifications (as applicable)
8
Lining, Coating & Painting
Procedures
9
Other Main Procedures (as per
Contract)
10
Engineering Requisition and
Unpriced PO and Attachments
11
Vendor Data Sheet (if
applicable)
12
Sub vendor List
Rev.
Yes
Submitted
No
NA
Approval
Status
Comments
Notes
1. This checklist shall be completed by the Contractor and verified by KOC before calling for VPIM. The
contractor shall attach the list along with VPIM notification. Documents shall be code (A- approved) or (code B approved with comments).
2. Definition of Terms used in the Checklist
NA: Not Applicable
ITP: Inspection & Test Plan
WPS: Welding Procedure Specification
PQR: Procedure Qualification Record
RT: Radiographic Examination
UT: Ultrasonic Examination
MT: Magnetic Particle Examination
PT: Penetrant Examination
PO: Purchase Order
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APPENDIX-E: CONSTRUCTION PRE-INSPECTION MEETING (CPIM)
E.1
General
Construction Pre-Inspection meeting (CPIM) is intended to discuss the
implementation of the Construction Quality Assurance Plan (CQAP).
The objectives of the CQAP are:
E.2
a)
Explain the quality program and organization to be carried out so that the
project is constructed in accordance with the Contract requirements, KOC
Standards and international standards;
b)
Describe procedures for inspection and documentation of construction
activities;
c)
Provide assurance that the finished site work and installations will meet the
requirements of the construction documents, approved drawings, standards
and specifications; and
d)
Describe how any unforeseen variations or conditions that could affect the
construction quality will be identified, documented, and dealt with during
construction.
Elements of a Typical CQAP
A typical CQAP is anticipated to contain the following parts:
a)
An introduction to describe the project requirements and the CQAP
overview.
b)
The project QA / QC organization and the key personnel involved in the site
construction, their role and responsibilities, their authorities, qualifications
and relations with other site management personnel.
c)
Procedures for handling documents and submittals.
d)
Inspection types, procedures and verification including the role of KOC
supervisors and inspection personnel.
e)
Construction non-conformance, variations, deficiencies and rectifications in
addition to corrective actions.
f)
Site changes handling and approval.
g)
Performance monitoring, auditing, and improvement.
h)
Management of documentation (issuing, routing, approving, storing,
retrieving, securing, updating control, computerized system, etc.).
i)
As-built documents, final dossiers, close out reports, lessons learned, etc.
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E.3
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REV. 2
Typical Agenda for CPIM
The following items represent a typical agenda for the construction pre-inspection
meeting. The agenda could be amended to add additional items or exclude others
depending on the complexity of the projects.
a)
Introduction.
b)
Co-ordination, Communication, Offices, Beverage, PCs, Internet, Filling
Cabins, and Film Viewing rooms, etc.
c)
Overall project construction organization (KOC, Contractor, Project
management Contractor, Sub-Contractors, etc.). QA / QC Function
organization for all.
d)
Organization Charts for site personnel (KOC, Contractor, Sub-Contractors).
e)
QA/QC Control at Sub-Contractor shops (Fabrications shops, painting
shops, galvanizing etc.)
f)
Personnel knowledge and Experience (CV’s, Training, etc.).
g)
Availability of and access to required documents (Contract, drawing,
procedures, etc.).
h)
Mechanism to ensure that latest revisions are included.
i)
Discuss the main Construction Quality Assurance Plan (CQAP) and any
Sub-plans (refer E.2)
j)
Review the list of Site relevant procedures. Discuss completeness, status
and availability at site for all involved personnel.
k)
Site Inspection & Test Plans (ITP’s) and approval status for various activities.
l)
Site Instruction. Authorities to stop the work.
m)
Responsibilities / Role (Construction & QC) for the following disciplines:
i.
Mechanical
ii.
Equipment erection (rotating and static)
iii.
Piping
iv.
Pipelines
v.
Tanks
vi.
Coatings and Paintings
vii.
Welding and NDE Review
DOC. NO. KOC-Q-014
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viii.
Civil
ix.
Steel Structure
x.
Electrical and Instruments
xi.
Building
xii.
HVAC
xiii.
Others
REV. 2
n)
The Contractor Inspection Requests (Inspection Notification 48 hours in
advance) and consolidated daily inspection activities.
o)
Methods and Routing of Inspection Notification (IN) (e-mail, fax, etc.).
p)
Documents including Inspection Forms.
q)
Pre-commissioning activities. Hydrotest package to be submitted only after
ensuring complete installations as per P&ID and other drawings.
r)
Piping wall thickness measurements for marking on test packages (baseline
data).
s)
Test and Inspection Reports managements and filling.
t)
Laboratories / Testing Facilities to be used by the Contractor and SubContractors including civil labs.
u)
Testing Facilities for safety, safety relief valves and other instruments, etc.
v)
Valve refurbishment program, procedures, locations, etc.
w)
Welders performance testing and qualifications.
x)
Welding Procedure Specifications (WPS) Qualifications.
y)
Emergency Procedures to deal with hydrocarbon release, damages, etc.
during the site work, tie-ins, etc.
z)
Non-conformance control and concession requests.
aa)
Locally procured materials inspection, testing, management, etc.
bb)
Site and Shop Fabrication QA / QC Control by Contractor and KOC.
cc)
Site changes, approval, and responsibilities. Approval of site changes made
to previously approved drawings, procedures, plan, etc.
DOC. NO. KOC-Q-014
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REV. 2
dd)
Control of Inspection Activities to ensure consistency (notification receiving,
logging, reviewing, distribution, action, disposition of non-conformance,
acceptance/rejection, filing, advising results, etc.).
ee)
KOC authorized parties to approve site documents, concessions, repairs,
release, rejections, etc.
ff)
Material management issues (acceptance of goods receiving, inspection of
goods, check materials protection and storage arrangements, markings,
marking transfer, loading and transportation, etc.).
gg)
Positive Materials Identifications.
hh)
Documents generated by Site Construction Team. Records of Construction
activities and inspection logs.
ii)
Weekly Construction and QA/QC meetings with the Contractor/subContractors.
jj)
Sub-Contractors awareness of the Contract requirements.
kk)
Personnel training and qualifications.
ll)
Non readiness of inspection after receiving Inspection Notifications (IN).
mm) Control of “Fraud” in radiography work and other works.
nn)
Work performed / covered without KOC knowledge or approval / agreement.
oo)
Construction Dossiers / Manuals (responsibilities, contents, compiling,
approval authority, design/shape, soft formats, preparation plan, when to
start and complete, etc.).
pp)
Inspection of Equipment and Items manufactured locally.
qq)
Auditing of Contractor and sub-Contractors.
rr)
Lessons learned reports and close out reports.
DOC. NO. KOC-Q-014
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REV. 2
APPENDIX-F: MANUFACTURING RECORD BOOK (MRB) AND CERTIFICATION
REQUIREMENTS
F.1
Manufacturing Record Books (MRB)
F.1.1
The Contractor shall instruct all suppliers, vendors and manufacturers to prepare
Manufacturing Record Book (MRB) during the course of the manufacturing
program. The MRB shall represent the product in the as – built condition and shall
be submitted to the Contractor and KOC for review and approval upon completion
of all manufacturing and testing activities. The purpose of the MRB is to provide
KOC with a certification dossier and record of compliance to the Contract with
sufficient and necessary data for future reference.
F.1.2
Within four (4) weeks of purchase order award, the Vendor shall submit to the
Contractor and KOC a proposed “MRB Index”. The minimum certification
requirements shall be as outlined in the following Clauses of this Appendix. The
content and presentation of the MRB shall be discussed and agreed upon at the
Project Pre-Inspection Meeting and the Vendor Pre-Inspection Meeting.
F.1.3
The draft / review copy of the MRB shall be issued by the Contractor for Company
review not later than twenty-one (21) calendar days after shipping release. If not
issued during this period, then the equipment/goods shall be placed in quarantine,
with all delays/costs borne by the Contractor.
F1.4
MRB shall be structured in three parts as follows:
Part 1 – Purchase Order Data: Shall include but not be limited to the following:
a)
b)
c)
d)
e)
Un-priced copy of the original purchase order;
Un-priced copies of all change orders;
Engineering queries;
Approved deviation and concession requests;
Minutes of meetings including approved ITP.
Part 2 – Manufacturing Data: Shall include but not be limited to the following:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Material Test Certification (MTC) and Test Reports;
Inspection and Test Reports;
Sub-vendor manufacturing records;
Quality plans;
Manufacturing Procedures including welding and coating;
Manufacturing Qualification certificates;
Non-conformance / corrective action reports;
Inspection release notes;
General Assembly. drawings and detailed as-built drawings;
Design calculations;
As-built data sheets.
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Part 3 – Operating & Maintenance Data / Manuals: Shall include but not limited
to the following:
a)
b)
c)
d)
Maintenance data / manual
Operating data / manual
Operating spare parts data
As-built drawings
F.1.5
All documents contained within the MRB, which are subject to KOC and the
Contractor approval shall include evidence of that approval by means of stamp, or
transmittal. Part 2 of the MRB shall be reviewed by KOC and the Contractor
inspector(s) prior to submittal for KOC approval. The document should be
substantially complete before the equipment or materials are released. (All
necessary documentation shall be reviewed with satisfactory results and the TPI
shall verify and confirm the status prior to release of equipment / materials).
F.1.6
The Contractor shall perform review by its Engineering and QA Teams prior to
submitting the MRB to KOC. No corrections to the MRB will be made during this
review; however, additional information may be considered necessary. In this case
the Contractor shall provide an addendum to the MRB.
F.1.7
Where modifications or revisions arise after the submission of the MRB, the
Vendor shall update all copies in possession of the Contractor with adequate
replacements of revised documentation.
F.1.8
The MRB shall be supplied in hardback bound documents furnished in A4 size and
bound with round head screwed brass paper fasteners. All drawings shall be
reduced to A4 or A3 size if still legible. Prints not adaptable to A4 or A3 size shall
be reduced as much as practicable and shall be folded with the title visible and
placed in A4 or A3 size clear plastic wallets. In addition to the hard copies, all the
MRB’s shall be also provided on CD ROM’s in MS Word Text. Drawings shall be
provided in Acrobat PDF Formats. AutoCAD drawings shall be converted to
Acrobat format as well. Soft copy of documents shall be in searchable format with
hyperlinks.
F.2
General Requirements For The Certification Dossiers
F.2.1
Certification Dossiers shall be compiled on an ongoing basis during manufacture.
F.2.2
Duplication of documents within a dossier shall be avoided.
F.2.3
All pages within the Dossier must be clearly marked with (i) Contractor Requisition
Number (ii) item or Tag Number (iii) Page Number (iv) Volume Number (if
applicable).
F.2.4
All documents shall be in the English language or be provided with an English
translation. For critical or complex documents such as hazardous area or fire safe
certification, any translation should be certified correct by a component body.
F.2.5
All documents subject to Contractor’s approval must include evidence of that
approval by stamp, transmittal or fax copy.
DOC. NO. KOC-Q-014
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F.2.6
Certification Dossiers must be substantially complete before the goods are
released. All items of certification must have been reviewed with satisfactory
results and the inspector(s) should confirm that no required document approvals
are outstanding.
F.2.7
Certification Dossiers shall be reviewed by the inspector(s) prior to formal submittal
for approval. The Contractor shall perform checks by both discipline engineering
and QA functions prior to submission to KOC. No corrections may be made by the
Contractor but additions may be made from their own files as considered
appropriate subject to such additions being clearly attributable to the Contractor.
F.2.8
Few single copies only shall be submitted for KOC approval. The final copies shall
be made only after final approval.
F.2.9
Final acceptance of dossiers will be by KOC as the end user.
F.2.10
One copy of each dossier shall be designated as the “User’s Master Copy” and
any other copies shall be indicated as verified true copies of this master and the
date of the copy indicated. The master copy shall contain the main vendor’s
certificate of conformance with an original signature. It shall also contain original
certificates for materials except where these are from the Vendor’s stock, obtained
from Stockist or procures by sub-Vendors.
F.3
Records & Reports of Inspection, Tests & Calibrations
F.3.1
When specifying documents to be included in certification dossiers, particular
attention shall be paid to the distinction between certificates, reports and records.
Reports and records typically include useful data and definitive statements
whereas Certificates can consist of vague unsupported statements certifying that
tests, inspections or calibrations have been carried out with satisfactory results.
Such statements from vendors or sub-Contractors have no value to KOC after
expiry of the guarantee.
F.3.2
Records and reports shall always directly reference the subject materials or
equipment by item number, serial number or tag number as appropriate.
F.3.3
When testing is performed on a sample basis, this shall be made clear and the
items represented by the sample shall be indicated.
F.3.4
When inspections or tests are performed against a written procedure, this shall be
referenced.
F.3.5
Acceptance criteria shall always be referenced. Whenever possible, criteria
contained in standards referenced in purchase order documentation shall be
stated.
F.3.6
Both the performance date and the report date shall be indicated.
F.3.7
When reports consist of more than one sheet, all sheets shall indicate the report
number, and the first page shall indicate the number of pages and attachments.
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F.3.8
Any corrections, alterations or additions made to reports after endorsement by
inspectors shall be clearly attributable and dated.
F.4
Materials Test Certificates (MTC)
F.4.1
When original certificates are required to be put in the certification dossier, verified
true copies will also be acceptable if verified by the authority who issued the
original certificate. Verified copies must bear the original signature of the person
making the verification.
F.4.2
Certificates for wrought butt weld fittings shall be supported by certification for the
parent plate or pipe. Such supporting certification need not be original whether or
not this requirement applies to the fittings certification.
F.4.3
Corrections to certificates will not be acceptable in any circumstances. When
errors are found in certificates they should be reissued at source or the material
rejected.
F.4.4
When supplementary heat treatment or tests have been performed by other than
the material supplier, these shall be reported on separate sheets attributable to the
performing authority and not on the original certificates.
F.4.5
Transcribed data will normally only be acceptable on material certificates in the
following circumstances:a)
b)
Heat analyses for wrought materials
Certificates issued by stockist for bolting materials or screwed and socket
weld fittings, which contain data and test results taken from Manufacturer’s
certification and certified as having been accurately transcribed.
F.4.6
When material is required to satisfy a carbon equivalent limit as determined by the
long formula
(C + Mn/6 + Cr+ Mo + V/5 + Ni + Cu/15) then all the component
elements of this formula shall be determined and reported. It will not be acceptable
to assume zero content for an unreported element.
F.4.7
For non-ferrous alloys, where the standard gives a minimum value for the
predominant element, it is not acceptable for this element to be certified as
“remainder” as this does not take into account the levels of impurities, which may
be present.
F.5
Heat Treatment Records & Charts
F.5.1
When heat treatment of materials is performed solely to satisfy the requirements of
a material specification, it will be sufficient for the Manufacturer to declare the heat
treatment on his material certificate. Normalizing temperatures need not be
declared, but tempering and simulated PWHT temperatures should be stated.
F.5.2
When heat treatments are performed on materials to meet NACE MR0175/ISO
15156 requirements, sufficient details shall be reported to enable conformance to
be verified. Hardness testing on the treated components must be made and
recorded in this case.
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REV. 2
F.5.3
When heat treatments are performed on fabrications, charts or records shall be
provided.
F.5.4
For heat treatments performed in Kuwait, originals of heat treatment charts shall be
provided. Other heat treatment charts and records may be verified true copies.
Verified copies must bear the original signature of the person making the
verification.
F.5.5
Records and reports should always directly reference the subject materials or
equipment by item number, serial number or tag number as appropriate.
F.5.6
The scales and units of temperature/time recorder charts shall be clearly marked
on the chart together with a clear indication of the direction of time progression.
F.5.7
The location and identification of thermocouples shall be indicated in a sketch
directly on the chart or on a referenced attachment.
F.5.8
When heat treatments are performed against a written procedure, this should be
referenced.
F.5.9
Both the performance date and the report date shall be clearly indicated.
F.5.10
When records consist of more than one sheet, all sheets should indicate the report
number, and the first page should indicate the number of pages and attachments.
F.5.11
When records are allowed in lieu of recorder charts, actual holding temperatures
and times shall be reported. For post weld or stress relieving treatments, maximum
actual heating and cooling rates shall be also be recorded.
F.6
NDE Reports
F.6.1
For non-destructive examinations performed in Kuwait, original reports shall be
provided.
F.6.2
Reports should always directly reference the subject materials or welds by item
number, serial number, tag number, line number, weld number etc. as appropriate.
F.6.3
The person who interpreted the examination shall endorse the report. The level of
interpreter qualification shall be indicated on each report.
F.6.4
Details of the examination technique, equipment, consumables and extent shall be
reported. When technique sheets have been separately approved, reports need
only reference these sheets. In the case of radiography, the responsible person
who performed the examination shall attest to the reported examination technique.
F.6.5
Both the performance date and the report date shall be clearly indicated.
F.6.6
Reports consisting of more than one sheet shall indicate on all sheets, the report
number, and the first page should indicate the number of pages and attachments.
DOC. NO. KOC-Q-014
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REV. 2
F.6.7
When heat treatment or forming has or will be performed, NDE reports shall
indicate whether examination was before or after these operations.
F.6.8
When codes are used to report types of indications or the status of repair or reexamination, these shall be defined.
F.6.9
Minimum achieved sensitivity levels or calibration standards shall be reported
together with acceptance criteria.
F.7
Mechanical Items (Pressure Vessels, Exchangers, Pumps, Valves, Relief
Valves, Pipes, Bends, Flanges, Vendor Fabrication Pipe Work, Site
Fabricated Piping & Pipelines)
F.7.1
Components that require “Material Certification”
a)
b)
c)
d)
e)
f)
All components comprising the pressure envelope;
All nozzle compensation pads;
Lifting / tailing attachments;
Components attached to the shell by welding;
Weld consumables including consumables for overlay cladding;
All materials requiring impact testing.
F.7.2
Certification dossiers shall be complied for each item or group of similar items that
are to be destined for the same location. For piping materials, certification shall be
provided to BS EN 10204 3.1 level except that certificates of conformity issued by
the Vendor (rather than the Manufacturer), and giving adequate details of both the
materials covered and of the Standards with which the materials comply, may be
provided for bolting and gaskets.
F.7.3
Contents of “Certification Dossiers” shall be as follows (as applicable):
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Index of the dossier
Code Data Form or Certificate of Conformity
Third party Final Report or Certificate of Inspection
Inspection & Test Plans (ITP) signed by all inspection authorities
List of materials or layout sketch, showing the position of the component
cross-referenced to page numbers of material certificates and any
supplementary reports
Material test certificates including hardness testing as required
Material repair records
Weld key map / seam identification sketch. (When the Manufacturer opts to
maintain a written record of the work performed by each coded welder in lieu
of stamping the welders identification against his welds, this record shall be
included in the certification dossier. This record need not extent beyond
“Code” welds.)
Welding procedures and qualification records
Production test records
NDE reports & records. When repairs have been carried out, reports of the
original examinations shall be included
DOC. NO. KOC-Q-014
l)
m)
n)
o)
p)
q)
r)
s)
t)
u)
v)
w)
x)
y)
z)
Page 78 of 100
REV. 2
Reports of any required special tests (SSC, HIC etc.)
Heat treatment charts / records
Pressure and leak test reports
Coating or lining application records and examination reports
Nameplate rubbing (facsimile)
As-built General Arrangements Drawing and isometric drawings for piping.
Records of critical dimensions
All design calculations (including relief valves supplied with packaged
vessels.)
Function test records shall be provided for actuated valves
Valve pressure / temperature ratings
Special certificates (fire safe, etc.)
Bend manufacturing procedures and qualification tests
Pump Performance test records, vibration records and function test records
for instruments and controls
Pipeline welds traceability, pressure testing charts, gauging, cleaning and
drying records
Dimensional records
F.8
Mechanical Items (Storage Tanks, Shop Fabricated or Field Erected)
F.8.1
Material certification shall be provided to the 3.1 level of EN 10204 for the following
components:
a)
b)
c)
d)
e)
F.8.2
Plates for shell, roof, bottom and mill fabricated fittings
Wind girders and compression rings
Anchorage and other load bearing attachments
Primary supporting sections of roof trusses
Sealing components and proprietary drain system for floating roof type tanks.
Contents of “Certification Dossier” shall be as follows (as applicable). Statement of
conformity shall also be in line with ISO / IEC 17030 and 17050.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
Master and volume index
Certificate of Conformity to the applicable construction code together with
“as-built” data sheet
Inspection & Test Plans (ITP) signed by all inspection authorities
Cross reference to vendor certification dossiers containing item certification
for appurtenances etc.
Material certificates cross-referenced to location records
Material repair records
Weld key plan(s), WPS’s & PQR’s
Summary sheet of qualifications of utilized welders
Production weld records to include WPS and welder traceability and crossreferences to NDE reports and heat treatment records if applicable
NDE reports & records and heat treatment charts / records
Pre-erection foundation level survey record, dimensional and settlement
records
Hydrostatic and leak test reports
Coating application records including qualification tests made for special
lining systems
DOC. NO. KOC-Q-014
n)
o)
p)
q)
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REV. 2
Tank calibration record
General arrangement drawing and cathodic protection drawings (sacrificial
and impressed currents)
Nameplate facsimile
All relevant design calculations including but not limited to derivation of
allowable stresses, design pressure and maximum design pressure for tanks
subject to small internal pressure, required compression area at the roof to
shell, shell thickness, venting and emergency relief, overflow capacity,
anchorage, cathodic protection calculations, test pressure for fixed roofs,
drainage capability for floating roofs, overturning, sliding, wind loadings and
wind induced vibration, wind girder height and sections, roof buoyancy,
floating roof stress analysis, fixed roof support, shell opening reinforcements
(including significant piping loads at nozzles.
F.9
Compressors, Diesel Generating Packages and Solar Power Systems
F.9.1
Manufacturer’s certification shall state the standard or specification to which it has
been constructed and tested. This shall include components that have been
constructed to other standards and specifications.
F.9.2
For mechanical components of compressors and auxiliaries, the Manufacturer
shall certify that all materials are in compliance with drawings, data sheets and
specification requirements and to make actual certificates available to inspectors
for review during the shop inspection stage.
F.9.3
Function test and calibration records shall be provided for instruments and controls
whether tested with the compressor package or at the Manufacturers’ works.
F.9.4
Pressure and leak test reports shall be provided as appropriate for all piping
components and systems, and items of pressurized or fluid containing equipment.
F.9.5
Certification dossiers shall be suitably indexed and cross-referenced with major
equipment items in separate sections. Dossiers shall be complied for each set and
include the following:a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
Completed data sheet certified, “as-built” by the Vendor
ITP signed by all inspection authorities
Main general arrangement drawings
Material certificates and material repair records
Inspection reports of the different components
WPS and PQR, Heat treatment and NDE reports
Compliance to NACE MR0175 / ISO 15156 as applicable including hardness
test records
Pressure and leak test records
Mechanical run test, function test records and strip examination report
Electrical test records
Calibration records, electrical and instrument tests
Safety or safety relief valve data sheets
Function test and calibration records shall be provided for instruments and
controls whether tested with the packages or at the manufacturers’ works.
DOC. NO. KOC-Q-014
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REV. 2
F.10
Electrical Equipment
F.10.1
Untagged, bulk and component type items (glands, plugs, etc.) need only be
entered once for each type.
F.10.2
Both the hazardous area certification and the inventory schedule shall also be
included in the certification dossier for the equipment. When the equipment is
installed in a packaged unit by a vendor, certificates of compliance to any
conditions applicable to installation, modification or interconnections shall also be
provided.
F.10.3
When equipment will be installed at Site, the Contractor will be responsible for
providing certification relating to installation.
F.10.4
On completion of all installation, the Contractor shall collate all area classification
drawings, equipment certification and inventories into one dossier.
F.10.5
For power transformers certification dossiers shall include Manufacturer’s
certification for windings, tap changers, oil, current transformers, level indicators,
relief valves, relays etc. as applicable. Records shall be provided to demonstrate
compliance in respect of all specified tests and inspections whether in-house or
witnessed.
F.10.6
For switch gears, the completed data sheets shall include type test certificate,
component certificates, routine test records, records of insulation resistance
measurements, etc. All required test and calibration reports shall include actual
measured values.
F.10.7
Relevant KOC Standards for electrical equipment and Recommended Practices for
installation and testing of electrical equipment / selection, installation and
maintenance of electrical equipment in hazardous areas provides other details
which shall also be adhered to. For electrical equipment to be used in potentially
hazardous areas, Vendors shall be required to provide details at the time of
tendering, of all electrical instruments and equipment together with the appropriate
certification. A register shall also be provided, listing the following information:a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Equipment tag number
Brief description
Manufacturer
Model/Type number
Certifying authority (e.g. BASEEFA)
Certificate number
License expiry date
Type of protection (e.g. Ex d)
Apparatus (gas) group (e.g. IIB)
Temperature class (e.g. T4)
IP rating – if available (e.g. IP54).
DOC. NO. KOC-Q-014
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REV. 2
F.11
Instrumentation
F.11.1
Material certification shall be provided for all components comprising the pressure
envelope. Certification dossiers shall include reports for any required NDE or
pressure tests.
F.11.2
For materials with hardness limitations, hardness values shall be reported. It shall
be made clear whether these values have been taken from actual finished
components or from raw material certification with or without supplementary heat
treatment.
F.11.3
Function test records shall be provided which demonstrate compliance in respect
of all specified features.
F.11.4
Calibration records shall be provided for all supplied instruments for which
calibration tolerances are specified. Calibration records need not be provided for
the vendor’s test instrumentation, but these should be made available for checking
by the inspector(s).
F.11.5
For Bulk Instrument Fittings, Tubing, Manifolds, Seal Pots etc., pressure test
reports shall be provided for all items subject to such testing. Material certification
shall be provided for all components comprising the pressure envelope of seal
pots. Detailed drawings of seal pots shall be included in the certification dossier.
For other items it will normally be sufficient for the manufacturer to provide
certificates giving item description and material designations and stating
compliance to purchase order or to catalogue description if these are used.
F.11.6
For Bulk Cable and Fittings, abbreviated certification packages shall be included
with release documentation with each shipment and in the case of cable; these
shall clearly reference the drum identification. On completion of the order, a
comprehensive and fully indexed certification dossier shall be provided with
minimum document duplication and incorporating the following:
a)
Manufacturer’s certificates of conformity. These shall fully describe the
certified material and any special features, and shall refer construction and
test codes. It will not be sufficient to describe material only by reference to
manufacturer or purchaser’s coding
b)
Where suitability for exposure to prolonged direct sunlight is required, this
shall be declared on the certificate of conformity
c)
Type test approval certificate or reports
d)
Records of routine electrical tests
e)
Dimensional control records.
DOC. NO. KOC-Q-014
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REV. 2
F.12
Lifting Appliances (Overhead Traveling Cranes)
F.12.1
Manufacturer’s certification shall declare the standards to which the equipment or
component has been constructed and tested.
F.12.2
Load test certificates and certificates of examination shall be provided for lifting
equipment (hooks, shackles etc.).
F.12.3
Certification dossiers should be suitably indexed and cross-referenced. Dossiers
should be complied for each unit and include the following:a)
b)
c)
d)
e)
f)
F.12.4
Material certificates for runway beams, major loaded structural members of
bridges and hoist rope
NDE reports and records
Electrical test records
Function test records
Load test records
As built dimensional record.
After installation at the work site, certificate of satisfactory installation and test
issued by a certifying agency approved by KOC (e.g. Lloyds Register, Det. Norske
Veritas, Bureau Veritas, American Bureau of shipping, Germanischer Lloyd, etc.)
shall be obtained. The original of this certificate together with records of site
inspections and tests shall be appended to the certification dossier in a separate
section.
DOC. NO. KOC-Q-014
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REV. 2
APPENDIX-G: TYPICAL QA PROCEDURES TO BE PROVIDED BY THE CONTRACTOR
Category
1. Management Responsibility
2. Project Risk Management
3. Quality System
4. Contract Review
5. Design Control
6. Document & Data Control
7. Purchasing
8. Control of Customers
Supplied Product
Typical Procedures
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(a)
(a)
(a)
(b)
(c)
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
(a)
(b)
(c)
(d)
(e)
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(a)
(b)
Work Rules & Regulations
Project Administrative Directives
Project Organization & Responsibilities
Invoicing
Planning & Scheduling
Progress Measurements
Monthly Progress Report
Work Breakdown
Internal Audits
Procurement QA/QC Management Coordination
Const. QA/QC Management Coordination
Contractors Vehicle Sticker Request
Office Security
Contractors ID Processing
Confidential Information Plan
In line with BS IEC 62198
Contractor QA Manual and Plans
Confirmation of Verbal Instructions
Change Orders
Subcontracting
Design Basis
Design Change Control
Site Change Control
Interface Coordination
Calculations
Design Coordination, Reviewing & Approval
Vendor Drawing Control
Engineering Requirements
Computer Aided Design/Engineering
Material Take-Off Lists
Plant Tie-in and Rerouting/Relocations
Safety Engineering
As-Built Drawings
Engineering Controls
Standardization of Material
Constructability Program
Correspondence and Communication
Minutes, Conference and Telephone Notes, and Trip Reports
Document Numbering and Identification
Document Distribution & Control
Project Files
Material / Engineering Requisition
Control of Vendor Documents
Technical Evaluation of Bids
Procurement Plan
Purchasing
Expediting
Traffic & Logistics
Material substitution
Spare Parts Procurement
Parent Equipment, P.O. and Spare Parts Data Control Log
Material Receipt and Storage
QA/QC Review of Purchase Requisitions
Assessment of Selected Vendors Quality Systems
Subcontracting
Spare Parts Procurements
Preventive Maintenance
DOC. NO. KOC-Q-014
9. Product Identification &
Traceability
10. Process Control
11. Inspection & Testing
12. Inspection, Measuring &
Test Equipment
13. Inspection & Test Status
14. Non Destructive
Examination (NDE)
15. Control of Non-conforming
Product
16. Corrective & Preventative
Action
17. Handling, Storage,
Packaging and Delivery
18. Quality Records
19. Internal Quality Audits
20. Training
21. Servicing
22. Statistical Techniques
Page 84 of 100
REV. 2
(a)
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(a)
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
Vendor Drawing Control and Material Requirements
Engineering Requirements
Material Take-Off Lists
Control of Special Processes
Review of Welding Procedures
Painting, Cathodic Protection, Chemical Injection, etc.
Inspection Coordination
Inspections and Testing at Vendors and at Site
Site Inspection Coordination
Inspections at Vendors Facilities
Inspection at Site
Inspection at Vendors Facilities
Radiographic Examination (RT)
Computed Radiography
Ultrasonic Examination (UT)
Magnetic Particle Examination (MT)
Hardness Testing (HT)
Leak Detection
Positive Material Identification (PMI)
Liquid Penetrant Examination (PT)
Time of Flight Diffraction (TOFD)
Visual Inspection (VT)
In Line Inspection (ILI)
Pipeline Video Camera Inspection
Acoustic Emission Examination (AE)
(a)
Non-conformance Reports
(a)
(b)
(c)
(d)
(e)
(a)
(b)
(a)
(b)
(c)
(a)
(b)
(a)
(b)
Audits
Stop Work Directives
Inspection at Vendors Facilities
Non-Conformance Reports
Surveillances
Traffic & Logistics
Material Receipt & Storage
Project Files
Project Record Books
Mechanical Completion Procedures and Documentation
Audits
Surveillances
Training
Qualification & Certification of Inspection & Audit Personnel /
Agencies
Servicing Program
Statistical Report of NDE and Welding Quality
(a)
(a)
DOC. NO. KOC-Q-014
Page 85 of 100
REV. 2
APPENDIX H: TYPICAL QC PROCEDURES TO BE PROVIDED BY THE CONTRACTOR
1. Mechanical QC
Procedures
2. Civil Structural
QC Procedures
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
(q)
(r)
(s)
(t)
(u)
(v)
(w)
(x)
(y)
(z)
(aa)
(bb)
(cc)
(dd)
(ee)
(ff)
(gg)
(hh)
(ii)
(jj)
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
(q)
(r)
(s)
(t)
(u)
(v)
(w)
(x)
(y)
(z)
(aa)
(bb)
(cc)
(dd)
Selection, Accreditation and Approval of Laboratories
Protection, Preservation & Maintenance of Equipment
Bolting and Sealing
Cold-Cutting & Preparation For Hot Work
Scaffolding
Car-Sealing of Valves
Rigging
Hydrocarbons Release and Control Procedure
Site Handling & Identification of Piping Material
Piping Demolition
Piping Fabrication
Piping Installation
Pressure Testing of Piping
Non Destructive Examination
Positive Material Identification
Preservation of Special Equipment (e.g. Rotors)
Hot-Tapping
Tie-Ins
Flushing of Hydraulic Oil Control System
Spacer Inserts Socket Welds
Site Handling & Identification
Pre-Installation of Mechanical Equipment
Installation of Mechanical Equipment
Rotating Equipment Alignment
Preparation of Rotating Equipment for Operation
Tube Rolling Procedure
Control of Site Welding
WPS and PQR Qualification
Preheat and Interpass Heating
Heat Treatment
Post Weld Treatment (Under and Above Ground Piping)
Demolition of Electrical Equipment
Conduit Installation
Micro tunneling, Sleeving and Road Crossing
Pipelines and Piping Cleaning, Gauging, Flushing and Dewatering.
Pipelines and Piping Pressure Testing, Dewatering, Water Disposal and Drying.
Site Handling & Identification of Structural Materials
Structural Demolition
Structural Fabrication
Structural Installation
Site Handling and Identification of Civil Materials
Surveying
Site Preparation
Civil Demolition
Disposal of Waste Materials
Excavation
Dewatering
Backfilling
Formwork
Concrete Reinforcement
Concrete Pouring
Concrete Curing
Grouting
Concrete Repair
Asphalting
Concrete Floor Construction
Building Masonry Wall Construction
Dry Wall Construction
Building Roof Construction
Building Ceiling Construction
Doors and Windows Installation
Building Insulation
Waterproofing
Wall And Floor Finishes
Raised Flooring Installation
Pre Cast Building Construction
DOC. NO. KOC-Q-014
3. Electrical QC
Procedures
4. Instrumentation
QC Procedures
5. Fiber Optic
Communication
Systems
6. Cathodic
Protection
7. Coating QC
Procedures
Page 86 of 100
REV. 2
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
(q)
(r)
(s)
(t)
(u)
(v)
(w)
(x)
(y)
(z)
(aa)
(bb)
(cc)
(dd)
(ee)
(ff)
(gg)
(hh)
(ii)
Demolition of Electrical Equipment
Storage, Handling & Identification of Electrical Materials
Conduit Installation
Cable Pulling
Grounding System Installation
Duct Bank Installation
Electric Motor Installation
Generator Installation
Switchgear Installation
Transformer Installation
Battery UPS System Installation
Junction Box Installation
Motor Control Installation
Lighting System Installation
Control Panel Installation
Relay Installation
Breaker Installation
Cable Testing
Grounding System Testing
Motor Testing
Switchgear Testing
Transformer Testing
Battery Testing
Conduit Seal Pouring
Multi Way Switch Installation
Termination & Splicing HV Cables
UPS Testing
Variable Drive System Installation and Testing
Interface Panels Installations and Testing
Marshalling Panels Installation and Testing
Building Fire Alarm System Installation and Testing
E-SCADA (Data Acquisition) System Installation and Testing
Lighting System Illumination Measurements
Solar Power Systems Installation and Testing
Capacitor banks, local control stations, isolators, annunciator panels, etc.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
Site Handling & Identification of Instrumentation
Demolition of Instrument
Instrument Pre-installation Calibration
Instrument Installation Transmitter Transducers
Instrument Installation Control Valves
Instrument Installation Switches
Testing and Installation of Safety and Safety Relief Valves
Instrument Installation of Analyzers
Instrument Installation of Indicators
Miscellaneous Instrument Installation
Field Pressure Testing Of Instrument Piping
Instrument Loop Check
(a)
In-Plant Communication System Installation
(a)
(b)
Cathodic Protection Design, Impressed current and Sacrificial Anodes
Cathodic Protection Systems Installation
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
Site Selection, Handling & Identification of Coating Materials
Coating Qualification, Testing and Approval
Qualification of Coating and Painting Applicators
Surface Preparation for Painting and Coating
Coating and Painting Repairs
Field Girth Welds and Other weld Coating
Surface Preparation for Insulation
Cladding
Concrete Fire proofing
Quality Control of Coating, Painting and Insulation Activities
DOC. NO. KOC-Q-014
Page 87 of 100
REV. 2
APPENDIX-I: PROCUREMENT FROM STOCKIST
I.1
General:
a) Procurement from Stockist shall be limited to piping materials and off-the shelf
items that are provided with conformity assessment reports / certificates.
Where pipe lengths justify mill runs; the purchasing shall be direct from only
the KOC approved pipe manufacturers.
b) Contractor shall not be allowed to divide process pipe lengths into smaller
portions to have KOC permit for purchasing from Stockist rather than having
pipe mill run.
c)
Materials approved to be procured from Stockist shall be secured from Stockist
who have been evaluated and have the capability to satisfy the contractual
quality requirements. The Contractor shall place purchase orders with only the
evaluated Stockist that have satisfied the QA process as per this Appendix and
other applicable parts of this Standard.
d) All materials procured from Stockist shall have been manufactured by Vendors
on KOC approved list.
e) It is KOC policy to exclusively purchase materials, components and
assemblies that have not previously been used either in whole or in part within
a prior application.
I.2
Testing of Stock Materials
In addition to submission of MTCs, the following tests and examinations shall be
undertaken by the Stockist at their own cost and time.
a) For sour service, pipes and fittings shall be tested for HIC as per NACE
TM0284 and results shall satisfy the requirements specified in ANSI / NACE
MR 0175 / ISO 15156 criteria. Hardness measurements shall be made on
piping and accessible wetted parts of valves, to check conformity with NACE
Standards. Stockist shall provide the SSC test reports from the manufacturer in
accordance with NACE TM0177.
b) PMI as per KOC Standard KOC-Q-015 shall be made for any Corrosion
Resistance Alloy (CRA) Piping (valves, components, etc.) Test results shall
satisfy the original standard of the material.
c)
Non-Destructive Examination shall be complied with purchase order, contracts
specifications, KOC Standards, Material Specifications.
d) Stockist shall arrange to carry out random check testing for pipes & fittings
(one sample per heat / lot) of the material including but not limited to chemical
analysis, mechanical testing, hardness testing, HIC testing, etc. at their own
cost. The testing shall be made at approved laboratories accredited to ISO
17025. Such testing shall be witnessed by the contractor and KOC
representatives.
DOC. NO. KOC-Q-014
Page 88 of 100
REV. 2
e) Tests and data required by related KOC standards and / or international
standards shall be carried out by the Stockist in case such test are not
included in the MTC. These tests shall also be made at approved and
accredited to ISO 17025 laboratories and witnessed by the contractor and
KOC.
I.3
Documents from Stockist
a) All quality records, data, or correspondence to Contractor / KOC such as
Inspection Reports, Record of Test Data, Certificate of Conformity and
Release Certificates are required for KOC review and approval. All such
documents shall be in the English language.
b) Material Test Certificates (MTC) to be submitted by stockist shall be certified
and traceable to original MTC.
c)
I.4
Materials from Stockist shall meet KOC Contract requirements, KOC
Standards and International standards as applicable. For instance, it is not
acceptable to supply materials for sour service on the basis of testing an
available stock material. It is necessary that materials have been manufactured
originally to be suitable for sour service. Any additional testing as part of the
purchase process will be considered as part of “quality verification” only.
Qualifications of Stockist
a) The Stockist must hold appropriate ISO 9001 Certification and approval. Any
change to this approval shall be kept in file for KOC review.
b) The Stockist shall have an established quality system / program adequate to
assure a quality product or service that complies with applicable KOC
Standards, specifications and applicable Contract requirements. The quality
program, including procedures and operations, shall be described in detail in a
quality manual or other appropriate document. The document shall include, but
shall not be limited to, a detailed description of the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
Organization showing quality department relation with
management
Duties responsibilities and reporting relationship of the inspectors
Record keeping system
Auditing and approval of sub-Vendors / sub-Contractors
Personnel training
Control of rejected items
Shelf life control program (as applicable)
Receiving Inspection Procedures
Tools and test equipment list and calibration programs
Store Keeping and Control facilities
Environmental Control and preservations
Internal Audit program
Discrepancy control, corrective actions, root cause analysis.
senior
DOC. NO. KOC-Q-014
c)
Page 89 of 100
REV. 2
The Stockist quality manual shall be kept current and shall be readily available
to KOC or Contractor QA audit team.
d) When requested, the Stockist shall provide a Quality Plan which satisfies the
requirements of this Standard. The Quality Plan shall be formally accepted by
Contractor and KOC prior to any formal document issue.
e) Any sub-contracting by the Stockist (e.g. galvanizing, coating, etc.) shall be
with the prior approval of KOC. Detailed procedures, quality plans and other
required documents shall be provided prior to commencement of the job for
KOC approval.
f)
Concessions will only be granted in exceptional circumstances. Concessions
shall require written authorization from KOC prior to incorporation into the
delivery standard of the item. Stockist may submit concession applications for
consideration by KOC using their own documentation if agreed by the
Contractor / KOC.
DOC. NO. KOC-Q-014
Page 90 of 100
REV. 2
APPENDIX-J: BASELINE DATA THICKNESS MEASUREMENTS
J.1
General
During the field construction stage, the Contractor shall undertake wall thickness
measurements for Static Equipment and Piping as per the following KOC
requirements: Measurements shall be made on all carbon steels and CRA
materials. Proper measuring instruments shall be used by the Contractor and
type(s) of such instruments shall be indicated in the “Thickness Measurement
Procedure” to be submitted by Contractor for KOC review and approval.
J.2
Measurements Techniques and Requirements
a) Measurements of thickness shall be made in accordance with ISO 16809,
SE-797, ASTM-435, ASTM-578 using the pulse-echo method.
b) The object to be measured shall allow for ultrasonic-wave propagation. There
shall be free access to each individual area to be measured. The surface of the
area to be measured shall be free of all dirt, grease, lint, scale, welding flux
and spatter, oil or other extraneous matter that could interfere with the
examination. If the surface is coated, the coating shall have good adhesion to
the material. Otherwise it shall be removed.
c)
Ultrasonic thickness testing shall be performed by qualified and capable
personnel. certified in accordance with ISO 9712 or equivalent.
d) For static equipment, thickness shall be recorded on the general arrangement
drawing that shows all parts.
e) For Piping, the thickness measurements shall be recorded on the ISOMETRIC
drawings that are prepared and used by Contractor for shop and field work.
f)
The contractor shall mark up the location of the thickness spots in the soft copy
of isometrics also. AUTOCAD shall be the software to be used for developing
isometric drawings.
g) The marked-up piping isometrics shall form part of the Ultrasonic Thickness
Measurement Reports. Both soft and hard copies of the documents shall be
submitted to the Company.
h) The thickness data shall be in the form of a spreadsheet given against the
unique number assigned for each Piping Line Number. This shall be in the
form of an EXCEL sheet and both soft and hard copies shall be submitted to
the Company. The spread sheet shall contain the information listed in J.3.
i)
Thickness measurements shall be carried out prior to painting of the piping
spools unless the ultrasonic instrument is capable of reading the steel
thickness underneath the paint.
DOC. NO. KOC-Q-014
J.3
Page 91 of 100
REV. 2
Ultrasonic Thickness Test Report
Thickness Test Report shall include but not be limited to the following data:
operator’s name;
operator’s qualification details;
operator’s company details;
dates of first and last measurement in this report;
location/site details;
instrument type and serial number;
probe type description (including element size/frequency) and serial number;
reference block details, if applicable;
couplant type;
equipment measuring method/mode;
material type;
instrument setting details, i.e. method;
general description of plant/structure/parts under inspection including definition
of surface conditions, e.g. Coated/insulated/rough/smooth/shot-blasted;
n) details of company/agency requiring and purpose of survey;
o) reference to applied standard or specifications;
p) operator’s name and signature.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
J.4
Static Equipment Thickness shall be made as per Table J.1
Table J.1: Static Equipment Measurements
Location
Number of test points
Remarks
Shell courses
4 spots each at 90° apart at two Total 8 spots at
locations on the shell 150 mm away Vessel Orientation
from the circumferential weld joint
Lines
Dished Head
4 spots each at 90° apart at Vessel
Orientation Lines at the knuckle radius
Total 5 spots
portion and one Spot at the center of
crown portion
Conical end
4 spots each at 90° apart at two Total 8 spots at
locations on the shell 150 mm away Vessel Orientation
from the circumferential weld joint
Lines
Nozzles
2 spots each at nozzle / manhole neck
Total 8 spots
at two diametrically opposite points.
Note: For cladded vessels, thickness measurement shall be carried out based
on the calibration verification done on a specimen of same thickness and
similar cladding material.
DOC. NO. KOC-Q-014
J.5
Page 92 of 100
REV. 2
Pipe Thickness Measurements
a) Thickness measurement locations shall be made as per Figure J.1.
Measurements shall be taken at the ends and middle portion of the pipe.
b) Thickness readings shall be made for all piping above 2” nominal size. Pipes
having 2” nominal size and below shall have two (2) thickness readings at
each spot.
J.6
Fittings Thickness Measurements
Thickness measurements for fittings (elbows, tees and reducers) shall be made as
per figures J.2, J.3, and J.4. of Weldolet, Sockolet, Threadolet, Nippolet, Swaged
Nipple and similar reinforced fittings are not required to be thickness measured.
J.7
Report to be Attached With Isometric Drawing and Static Equipment Report
The report shall contains but not be limited to the following information:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
J.8
Name of the Contractor;
Contract No.;
Plant / Facility No.;
Report No. and Date;
P&ID No.;
Isometric Sketch No.;
Piping Line Number;
Line Start & End (From xx to xx);
Line Surface Condition (Bare/ Painted);
Procedure No.;
Piping Component, Size;
Observed Thickness at UTM Spot:, Min. Thickness:, Nominal Thickness;
Inspected By: Technician Name / Sign & Date;
Reviewed By: Name / Sign & Date;
Approved By: Name / Sign & Date.
Thickness Measurements for Storage Tanks
a) Thickness measurements of storage tank components shall be made during
the tank construction work and shall be recorded on proper drawings as per
the procedure to be submitted by the Contractor.
b) Thickness of bottom plates shall be made at five (5) locations, four at the
periphery (N, S, W, E) and one at the center. At the periphery, the annular
plates and sketch plates shall be measured.
DOC. NO. KOC-Q-014
Page 93 of 100
REV. 2
Figure J.1: Thickness measurement locations on Straight Pipe
Figure J.2: Thickness measurement locations on Elbow
DOC. NO. KOC-Q-014
Page 94 of 100
REV. 2
Figure J.3: Thickness measurement locations on Reducer
Figure J.4: Thickness measurement locations on Tee
DOC. NO. KOC-Q-014
Page 95 of 100
REV. 2
Date :
Table J.2: Base Line Thickness Data Report - Piping
Project
Name:
Project
No.:
Contract
No.:
Contractor
Name:
Plant
No.:
Surface Condition :
Report
No.:
P&ID
No.:
Service :
Line No.:
Line
From:
Line
To:
Procedure
No.:
UT Eqpt.
Model
and
Number
Probe Size/
Type /
Frequency
Thickness
Measurement
Location
(TML No.)
Component
1
TEE
Size
Observed
Wall Thick.
at
Clockwise
Direction
Material Specification :
Measured Thickness
Readings
1
2
Calibration:
Avg.
Thk.
Minimum
Thk.
Nominal
Thk.
Remarks
3
a.
b.
c.
a.
2
PIPE
b.
c.
d.
a.
b.
c.
d.
3
ELBOW
e.
f.
g.
h.
i.
4
Reducer
a.
b.
c.
d.
Thickness
Measured By
(Contractor)
Name
Designation
Signature
Date
Reviewed By
(Contractor)
Witnessed By
Reviewed By
(KOC)
Remarks
DOC. NO. KOC-Q-014
Page 96 of 100
APPENDIX-K: INSPECTION AND TEST PLAN (ITP) TEMPLATE
REV. 2
DOC. NO. KOC-Q-014
Page 97 of 100
REV. 2
APPENDIX (K): Continued / Notes on Inspection and Test Plan (ITP) Template:
1.
Column 1 –
Indicate the task number Tasks shall be numbered chronologically taking
into consideration design, procurement, production, fabrication, construction,
packing, transportation and installation/commissioning, as appropriate.
2.
Column 2 and 4 –
The task and associated quality control activity, or activities, to be carried
out shall be described. Vendor is responsible for determining ITP QC
activities particular to the scope of work. However, KOC/Contractor may
insert any additional activities that may be considered necessary. Stages of
each Task shall be further detailed by the Vendor under subtitles, e.g. 1.1,
1.2 and 2.1, 2.2 etc.
3.
Column 3 –
Indicate, by the use of “I” or “S”, whether the task or activity is to be carried
out in-house (I) by the Vendor or alternatively utilizing a Subcontractor (S).
4.
Column 5 –
Give procedure title and reference.
5.
Column 6 –
The acceptance criteria pertaining to each activity is to be stated.
6.
Column 7 –
The verifying documents are to be stated e.g., “Pump Testing Procedure
No. XXX Rev. xx dated xx/xx/xxxx”.
7.
Column 8 –
The Vendor must place a ‘W’ (Witness), ‘H’ (Hold), ‘R’ (Review),
‘SU’ (Surveillance) as applicable, for every Quality Control Activity, since
such activities are required to be witnessed, reviewed or monitored by the
Vendor’s QC / Inspection organization. When all activities are undertaken by
the Vendor alone, all activities shall be marked “H”. KOC shall have the right
to amend the intervention for any activity to be undertaken by the Vendor.
8.
Column 9 –
Will be completed by Contractor (or Buyer) and will indicate those activities
to be subject to Witness (W), Hold (H), Review (R) or Surveillance (SU)
Inspection by the Contractor (or Buyer).
9.
Column 10 –
Will be used to indicate intervention activity required by the appointed
Verifying Body or Authorized Inspector e.g. pressure vessels to ASME VIII-1
and ASME VIII-2. This section shall be completed prior to final approval by
KOC.
DOC. NO. KOC-Q-014
Page 98 of 100
REV. 2
APPENDIX (K): Continued / 10.
Column 11 –
Shall be entered by KOC after marking of columns 8, 9 and 10 by all other
parties.
11.
Column 12 –
Shall be signed by the Vendor’s representative responsible for
undertaking the task, to indicate that it has been satisfactorily completed in
accordance with contract requirements.
12.
Columns 8, 9, 10 & 11 –
Shall be signed off progressively by the respective parties to indicate
acceptance of the activity.
13.
Terminology Used in Inspection Test Plans (ITP’s)
The following definitions shall apply to the preparation and use of Vendor’s
Inspection and Test Plans.
a)
Inspection & Test Point –
A location or stage in the manufacturing cycle where inspection and/or
testing are performed by personnel whose responsibility is to determine
the acceptability of products or services and to record inspection and
test data.
b)
Hold Point (H) –
An inspection point in the manufacturing cycle beyond which work shall
not proceed without the specified activity, work or function being
witnessed unless KOC has notified the Contractor / Buyer / Vendor in
writing that he may proceed. Hold points require formal notification to
the Contractor / Buyer / KOC including all Third Party Inspector (TPI)
representatives. When KOC cannot attend, the inspection and test
results shall be delivered as soon as possible.
c)
Witness Point (W) –
An inspection point in the manufacturing cycle which will be witnessed
or verified. If the witnessing representative is unable to attend after
being provided with the required notice, then Vendor may proceed.
Witness points require formal notification to the Contractor / Buyer /
KOC including all Third Party Inspector (TPI) representatives. When
KOC cannot attend, the inspection and test results shall be delivered
as soon as possible.
At least fifteen (15) calendar days prior to reaching any ITP activity
which has been designated as a “Hold” or “Witness” Point, the Vendor /
Contractor shall notify KOC and all involved third party inspectors (TPI)
specifying the date, time and location at which the activity is to be
carried out.
Notification shall be by facsimile or other agreed
procedure.
DOC. NO. KOC-Q-014
Page 99 of 100
REV. 2
APPENDIX-K: Continued / d)
Surveillance (SU) –
The continuing evaluation of the status of procedures, methods, etc.,
and analysis of records to assure that quality requirements will be met.
No formal notification is required.
e)
Review (R) –
The process of verifying by examination of documentary evidence that
nominated inspections and/or tests have been satisfactorily conducted.
Review points are not notifiable points.
f)
In-House (I) –
Applies to production at a facility under the direct control of the Vendor.
g)
Sub-Supplier (S) –
Applies to production at a facility under the control of a sub-supplier to
the Vendor.
DOC. NO. KOC-Q-014
Page 100 of 100
REV. 2
ACKNOWLEDGEMENT
The Draft of this Standard (Rev. 2) had been circulated to the KOC User Teams for review and
responses were received from the following Teams:
PROJECTS SUPPORT SVCS. GROUP
Team Leader PMC Management
PROCESS SAFETY MGMT. GROUP
Team Leader Insp. & Corr. (S&EK)
Team Leader Insp. & Corr. (N&WK)
Team Leader Insp. & Corr. (Projects)
FIRE GROUP
Team Leader Fire – Support Services
AHMADI PROJECT GROUP
Team Leader HSE (CSD)
OPERATIONS SUPPORT GROUP (S&EK)
Team Leader HSE (S&EK)
SUPPORT SERVICES GROUP (WK)
Team Leader Project Management I (WK)
HEALTH, SAFETY & ENV. GROUP
Team Leader Safety
OPERATIONS GROUP (EK)
Team Leader Maintenance (EK-II)
PRDN. & PROJECTS (GAS) GROUP
Team Leader Jurassic Projects Mgmt.
CONTRACTS GROUP
Team Leader Contracts I
PURCHASING & MAT. MGMT. GROUP
Team Leader Inventory Control
Team Leader Receiving & Quality Insp.