Specification for Quality Assurance Requirements for Product ...

Page 1 Specification for Quality Assurance Requirements for Product and Service Printed 03/05/09

The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.

Petroleum Development Oman L.L.C.

Specification for Quality Assurance

Requirements for Product and Service

User Note:

The requirements of this document are mandatory. Non-compliance shall only be

authorised by the Document Owner or his Delegate through STEP-OUT approval.

A controlled copy of the current version of this document is on PDO's EDMS. Before

making reference to this document, it is the user's responsibility to ensure that any hard

copy, or electronic copy, is current. For assistance, contact the Document Custodian or

the Document Controller.

Users are encouraged to participate in the ongoing improvement of this document by providing

constructive feedback.

RESTRICTED Document ID: SP-1171 May-09 Filing Key: Business Control

Petroleum Development Oman LLC

Revision: Approved Effective: Dec-07

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i Document Authorisation



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ii Revision History

The following table lists the four most recent revisions to this document. Details of all revisions prior to these are

held on file by the issuing department.

Version No. Date Author Checked Scope / Remarks

Version 1.0 24/04/2000 OTT/151 OTT/15 Revision and re-formatting of ERD 84-

02 (September 1995 issue).

Version 2.0 17/12/2007 UEC/111 UEC/11 Revised following Shell Philosophy

iii Related Business Processes

Code Business Process (EPBM 4.0)

iv Related Corporate Management Frame Work (CMF) Documents

The related CMF Documents can be retrieved from the Corporate Business Control Documentation Register TAXI.

Doc. ID Document Title

CP-117 Project Engineering Code of Practice

SP-1122 Specification for Project Quality Plan

DEP 82.00.10.10 Project Quality Assurance

DEP 91.00.00.10 Sector-specific quality management systems - requirements for product

and service supply organizations (Endorsement of ISO/TS 29001)



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Contents

Part 1

1. Introduction 6

1.1 Purpose…………………………………………………………………………………………….. 6

1.2 Changes to the Specification………………………………………………………………………. 6

1.3 Specification Owner's Responsibility……………………………………………………..………. 6

1.4 Effective Period …………………………………………………………………………………… 6

1.5 Review and Improvement…………………………………………………………………………. 6

2. Specification Requirements…………………………………………………………………………. 7

2.1 Scope …………………………………………………………………………………………….. 7

2.2 Quality Management System……………………………………………………………………… 7

Part 2 Additional requirements to ISO/TS 29001

Amendments/Supplements to ISO/TS 29001 8

4.1.1 Quality Management during the Contract Execution ……………………………………………… 8

4.2.2.2 Contract Quality Plan……………………………………………………………………………… 8

4.2.2.3 Inspection and Test Plans…………………………………………………………………………. 8

4.2.3.3 Contract Documentation …………………………………………………………………………. 8

5.5.1.1 Company's Inspector Roles & Responsibilities…………………………………………………… 9

5.6.4 Contract Quality Management Review…………………………………………………………… 10

6.2.1 General…………………………………………………………………………………………… 10

6.2.2.2 Competency of Verification Personnel…………………………………………………………… 10

6.2.2.3 Quality Verification Personnel ………………………………………………………………….. 10

Corporate Quality Assurance Manager ………………………………………………….. 11

Welding Enigineer……………………………………………………………………….. 11

NDT Engineer……………………………………………………………………………. 12

QA/QC Engineer …………………………………………………………………………. 12

Quality Control Inspector ………………………………………………………………… 13

QC Inspectors - Civil and Structural……………………………………………………… 13

QC Inspector - Instrumentation…………………………………………………………… 14

QC Inspector - Electrical…………………………………………………………………. 14

7.3.8 Approval of Design Deliverables ……………………………………………………………….. 14

7.4.1.2 Criteria for Vendor Selection, Evaluation and Re-evaluation ………………………………….. 15

7.4.3.1 Verification of Purchased Product ………………………………………………………………. 15

7.5.1.2 Process Controls…………………………………………………………………………………. 16

7.5.1.3 Contract Monthly Reports……………………………………………………………………….. 16

7.5.3.1 Identification and Traceability…………………………………………………………………… 17

7.5.5.2 Periodic Assessment of Stock…………………………………………………………………… 17

7.6.1 Control of Monitoring and Measuring Devices…………………………………………………. 17

8.2.2.1 Internal Audit …………………………………………………………………………………. 17

8.2.2.2 Submission of Action Plans……………………………………………………………………. 18

8.3.2 Release or acceptance of Non-conforming Product under concession ……………………….. 18

8.4.1 Analysis of Data ……………………………………………………………………….. 18

8.5.2.2 Corrective Action response times ……………………………………………………….. ……. 19

8.5.3.1 Preventive Action ……..……………………………………………………………………….. 19

Appendix A - Glossary of Definitions, Terms and Abbreviations ………………………………….. 20

Appendix B – References……………………………………………………………………………….. 22

Appendix C - Contract Quality Plan Guidelines …………………………………………………….. 23

Contract Quality Plan Index (Typical Example)………………………………………… 24

Appendix D - Quality Control Plan (Inspection and Test Plan) - Typical Format…………………….. 25

User Comment Form……………………………………………………………………………………….. 26



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PART 1: 1 Introduction

1.1 Purpose

This specification revises SP 1171, version 1.0, April 2000. The purpose of this Specification is to

specify the Company's minimum requirements for Quality Management Systems in all Contracts and

Purchase Orders with their nominated Suppliers. This specification is intended to set Company Quality

Assurance Standards during design, procurement, construction and maintenance phases of facilities

1.2 Changes to the Specification

This specification shall not be changed without approval from the Custodian, the Materials and Corrosion

Functional Discipline Head (CFDH), UER (UEC/1), who owns this specification. Any user of this

specification, who encounters an inaccuracy or ambiguity, is requested to notify UEC/11, using the User

Comment Form provided at the end of this specification and send the copy with comments and personal

details to DCS.

1.3 Specification Owner's Responsibility

The owner of this specification, UEC/1, as CFDH Materials and Corrosion, is responsible for authorising

all proposed deviations or amendments to the specification and for the instigation of periodic reviews and

updates in accordance with Clauses 1.2 and 1.5.

1.4 Effective period

The requirements of this specification shall remain in force indefinitely unless superseded by an

authorised revision.

1.5 Review and Improvement

This specification will be reviewed and updated once every three years. The review authority will be

UER (UEC/1, CFDH Materials and Corrosion). Any revision and updates before three years period, is at

the discretion of the reviewing authority, UER (UEC/1).



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2. Specification Requirements

2.1 Scope

This specification specifies the Company's minimum requirements for Quality Management System in all

Contracts and Purchase Orders with the Suppliers This specification is based on International Technical

specification ISO/TS 29001 Petroleum, petrochemical and natural gas industries – Sector-specific

quality management systems --- Requirements for product and service supply organizations which is

adopted by the Company with additional requirements as specified in this document.

This Specification is not applicable to ex-stock items.

The body of this specification is the Quality Management System Specification and forms part of the

Contract or Purchase Order. Definitions, terms and abbreviations used are defined in Appendix A and

referenced standards are listed in Appendix B.

Appendix C, Contract Quality Plan Guidelines, offers Suppliers guidelines on the contents and

development of a Contract Quality Plan that will meet the requirements of this specification.

Appendix D, Inspection and Test Plan (ITP) Guidelines, offers Suppliers guidelines on the contents and

development of a Quality Control Plan that will meet the requirements of this specification.

2.2 Quality Management System

The Supplier (Consultant, Contractor, Manufacturer and Vendor) shall implement and use Quality

Management System that complies with ISO/TS 29001, and additional requirements of this specification.

ISO/TS 29001: Petroleum petrochemical and natural gas industries – Sector specific quality

management systems --- Requirements for product and services supply organizations

Suppliers shall attain Third Party Registration of their Quality Management System. Certification to ISO

9001 is acceptable. The registration shall be from an Accredited Certifying Body (for example, BSI, BV,

DNV, and LRQA etc), who are themselves accredited by a National Accreditation Authority to assess

Quality Management Systems.

Where Suppliers are not yet certified to ISO 9001, they shall demonstrate that they have a Quality

Management System that complies with ISO/TS 29001 until they are certified as above.

If any part of the Contract is Sub-Contracted, the Supplier shall ensure that the Sub-Contractor maintains

a Quality Management System that meets the requirements of this specification for the sub-contracted

work. The Supplier shall remain ultimately responsible for the quality of the Sub-Contractor's work.



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PART 2 - Additional requirements to ISO/TS 29001 are given below:

Amendments/Supplements to ISO/TS 29001

Add the following clauses

4.1.1 Quality Management during the Contract Execution

For Contract Activities (Oman):

Quality management System as described in the CQP shall be implemented for EPC projects, Engineering Service

Contracts like EMC, ODC etc, and no work shall start unless the Company approves CQP. ITPs and verification

personnel appropriate to work being executed shall be approved by the Company. This shall also apply to sub-

contractor activities.

For Packaged Products ( e.g. skids mounted manifolds, pressure vessels, cyclones, heat exchangers, surface &

sub-surface equipment of ESP Systems and Bulk Products like line pipe, fittings, flanges, valves)

Fabrication activities may start at supplier or sub-contractor workshops that are certified to ISO 9001 for the given

scope of work and shall implement quality management system on all activities related to the contract to ensure all

technical requirements as specified in the company technical specifications are met.

Add the following clause:

4.2.2.2 Contract Quality Plan

The requirements specified in Appendix C shall be fulfilled. The Supplier shall have a nominated Management

Representative (MR), who shall have defined responsibility for the Corporate Quality System, in accordance with

Clause 5.5.2 of ISO/TS 29001. The roles and applicable responsibilities of the MR shall be stated in the CQP.

Note: Guidance is given in ISO 10005: 2005 Quality Management Systems- Guidelines for quality plans may be

used instead of requirements given in Appendix C.


4.2.2.3 Inspection and Test Plans

For Package and bulk products, ITPs shall be approved by the Company. The requirements specified in Appendix D

shall be fulfilled.

The Company has the right to identify in the ITP the review, surveillance, witness and hold points.


4.2.3.3 Contract Documentation

All documentation related to the Quality Management System shall be available at the location where work is being

carried out.

The Supplier shall maintain the latest revision of the relevant Contract Documents, Drawings, Contract Technical

Specifications , International Standards , CQP, ITPs, Procedures and Work Instructions, etc. at the location where

work is being carried out.



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The following documents shall be approved by the Company authorities as stated below:

Table-1

Sl No: Document Description Approval Authority

1 CQP, ITPs & NDT Procedures QA TA-2

2 CVs of NDT Engineer, Welding Engineer, QA Engineer

and QA Manager

UEC/11 Section QA TA-2

3 CVs of other Quality Verification personnel QA TA-2

4 WPS/PQRs & Welding related procedures Welding TA-2

5 Method statements (Site related) & Procedures Relevant discipline TA-2

6 Engineering Drawings & Deliverables As per SP-1122

7 Non-standard MESCs Static equipment CFDH

8 Deviations from Contract technical specifications Relevant CFDH

9 Material selection reports Material TA 2

10 Design Basis As per SP-1122

11 Project material specifications Material TA 2

12 Deviation from Company approved Manufacturers,

Suppliers, Stockists & Vendors

Relevant Product Group Service

Code’s Custodian (PGSC list)


5.5.1.1 Company’s Inspector Roles & Responsibilities.

Inspector (QA/QC Inspector & TPI) roles and responsibilities shall be as follows but not limited to:

• Verify the product conformance to contractual requirements at various stages of the

fabrication/manufacturing as stated in Company approved ITP and applicable technical specifications.

• Review quality documentation to verify product conformance to contractual requirements.

• Carry out surveillance inspections to verify processes and procedures compliance.

• Issue Release Note of Product/ Sign test packs (QA/QC dossier).

• The role of the company’s Inspector/TPI shall be limited to surveillance role, unless stated otherwise in the

Company approved ITP.

• To monitor manufacturers/contractors’ activities with respect to quality performance.

The signature of the Company’s (QA/QC Inspector/TPI) shall be taken as he/she verified and accepted the

details in the document reviewed. The signature of the Company’s (QA/QC Inspector/TPI) shall not absolve

the supplier’s responsibilities to supply the product that meets contractual requirements.



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5.6.4 Contract Quality Management Review

Supplier shall ensure that the site Quality Management System is reviewed at frequency of not more than three

months till the end of the contract. The Corporate Quality Manager shall participate in the review meeting. Areas of

concern or weakness are to be identified in the Quality Management System and actions recommended to be

recorded in minutes of meeting.

6.2.1 General

Add at the end para. 6.2.1:

The verification personnel should have previously worked on similar Contracts in similar capacities and shall have

formal qualifications (e.g. CSWIP, AWS, and British Gas or equivalent which is acceptable to UEC/11 section) as

appropriate.


6.2.2.2 Competency of verification personnel

The Supplier shall establish control features (technical authority system) for ensuring verification personnel are

competent. Verification personnel working for the supplier at Company’s construction sites shall be approved by the

company as stated in Table-1.

Records shall be established and maintained to demonstrate that all verification personnel are competent


6.2.2.3 Quality Verification Personnel

The Supplier shall assign and deploy competent Verification Personnel for the Contract to ensure that the Quality

Management System and Quality Control are effectively established, implemented and maintained throughout the

Contract. There shall be sufficient verification personnel to cover all disciplines work and activities, all Sub-

Contractor's work at the site and off site facilities. This shall be clearly documented along with their responsibilities

and authorities in the CQP. They shall be independent of the work being performed and shall have no other duties or

responsibilities.

The Supplier shall assign at least one dedicated QA/QC Engineer for each contract and located at work site. The

QA/QC Engineer shall functionally report to the Supplier’s Corporate QA Manager on all Quality and technical

matters and report to the Site Manager on day to day activities.

The actual staffing levels will depend on the work load, complexity of the work, number of disciplines working on

the Contract at any one time, number of Sub-Contractors, the number of locations where work is being carried out

on site/off site and the quality performance of the contractor.

The Supplier shall prepare a QA/QC personnel resource plan on a monthly basis to cover all verification activities as

required by ITP. The adequacy of the QA/QC resources shall be reviewed by the Company representatives at sites

during progress review meetings.

When the Supplier has its own internal qualification scheme (e.g. Welding Inspector, Painting Inspector), the

qualification scheme shall be approved by the Company.