1.1
Control of monitoring and
measuring devices
The Project QA/QC personal shall determine the minimum
monitoring and measurement to be undertaken and the monitoring and measuring
devices needed to provide evidence of conformity of product (e.g. packages,
systems, equipment, materials, etc) to determined requirements (see Section 7.2.1 – Determination of requirements
related to the product).
The Project QA/QC personal shall established processes
to ensure that monitoring and measurement can be carried out in a manner that
is consistent with the monitoring and
measurement requirements.
Where necessary to ensure valid results, measuring equipment shall:
a)
be calibrated or verified at
specified intervals, or prior to use,
against measurement standards
traceable to international or national measurement
standards; where no such standards
exist, the basis used for calibration or verification are recorded;
b) be adjusted or re-adjusted as necessary;
c) be identified to enable the calibration status to be determined;
d) be safeguarded from adjustments that would
invalidate the measurement result;
e) be protected from
damage and deterioration during handling,
maintenance and storage.
In addition, the project QA/QC personal shall assess and
record the validity of the previous measuring results when the equipment is
found not conforming to requirements. The Project shall take appropriate action
on the equipment and any product affected. Records of the results of
calibration and verification shall be maintained (see section 4.5 – Control of records).
When used in the monitoring and measurement of specified
requirements, the ability of computer software to satisfy the intended
application shall be confirmed. This is undertaken prior to initial use and
reconfirmed as necessary.
The project QA/QC personal during Vendors fabrication,
shall establish the level of inspections as
per the criticality rating of the equipment, material or package. Inspection
Matrices included in the POs specify the minimum inspection and testing
requirements expected from the vendors.
Moreover Vendors Inspection and Test Plans (ITPs) specifically tailored
for the Project scope, in compliance with the above mentioned Inspection
matrices, shall be formally approved previous to the commencement of the fabrication activities.
Vendors will be required to ensure that appropriate
measuring devices are procured, controlled, calibrated and maintained as per
the requirements (manufacturer recommendation as per type, unique
identification, location, frequency of checks, check method, environmental
condition and acceptance criteria). Vendor Inspection Team (Third Party Agency
coordinated by the Engineering Contractor) shall verify vendors’ compliance
with this requirement.
Inspection and Testing activities planned could be
adapted according to the vendors’ performance during fabrication.
Construction and installation activities will require
minimum monitoring and measurement requirements established by project
specification and details. Project specific ITPs will be required to Construction Contractors for Cairn formal
approval prior to the commencement of
the construction activities.
Contractors will also be required to ensure that
appropriate measuring devices are procured, controlled, calibrated and
maintained as per the requirements. Cairn Quality Team in Construction shall
verify the contractors’ compliance with this requirement.
Contractors QA/QC Coordinator shall maintain the log of
“Quality related measuring and test equipment” and monitor their calibration
status.
The measurement capability of equipments shall be
consistent with the measurement requirements specified in the contract and the engineering
documents.
The Project QA/QC Superintendent –at site- shall ensure
implementation of the calibration and control
processes.
1.2
Pre-Commissioning,
Commissioning QAP
Procedure DECO-RX-OP-PRO-0001 “Handover Procedure &
Protocol” describes the Project processes associated with the handover of
systems (sub-systems) from Construction to Commissioning and from Commissioning
to Operations.
The objectives of the Pre-Commissioning and Commissioning phases
are:
-
To demonstrate that the Mangala
Process Terminal Plant (MPT) and associated equipment, pipelines, control
system and facilities function together as a whole and meet the design and functional parameters of the contract specification.
-
To ensure that all the systems and
procedures used to achieve this objective result in the commissioning work
being carried out safely.
-
To ensure that all inspection,
testing and checking is managed efficiently to protect the overall Project Schedule and ensure the
earliest Project completion.
1.2.1 Pre-Commissioning
The pre-commissioning includes all actions necessary
activities to enable a System to reach Mechanical Completion (MC) and the ready
for commissioning (RFC) condition.
The Construction Team shall conduct pre-commissioning activities
but the Commissioning Team is required to verify in order to ascertain as much
confidence as possible. These activities will be tracked and controlled by the
use of Hand-Over Dossiers previously developed by the Certification Team with
the input of the commissioning team. These activities shall be carried out according to the prepared schedule of activities built
into the overall project schedule
thereby allowing integration with the Construction schedule.
A copy of Red Line As Built P&ID’s shall be required
to Construction Group once they finish the pre-commissioning activities.
Drawings shall be included on
handover dossiers through
Certification Team for Commissioning consultant purposes during the
handover process.
1.2.2 Mechanical Completion
The Ready For Commissioning (RFC) applies to the stage
when all necessary pre-commissioning activities are complete, Punch-lists and
exceptions are identified and agreed, and the system becomes ready for
commissioning activities.
All Pre-commissioning Inspection and Test Records (ITRs)
must be furnished to the Certification Team. Dispensation can only be given by
agreement of both commissioning and quality teams. They must be explicitly stated
on the RFC certificate. Responsibility for closure of items given dispensation
still remains with construction team.
1.2.3 Commissioning
Encompasses all those activities, required to enable the Start Up of
a unit and/or system.
Completion of the commissioning phase is achieved when
all reworks and repairs identified during that phase have been concluded; all
required function test reports have been satisfactorily completed and reviewed by the Certification
Team and all “A” and “B” items from the punch list have been closed.
A copy of Red Line As Built P&ID’s shall be required
to Commissioning Group once they finish the Commissioning activities. Drawings
shall be included on handover dossiers through Certification Team for Operations
consultant purposes during the handover process.
1.2.4 Start-up
Encompasses all those operational activities after
commissioning that relate to the performance
and operational testing of the units/systems/scopes of work. Upon
satisfactory completion of the performance verification the systems will be in
a condition of completion and a Handover Certificate is issued.
2 MEASUREMENT, ANALYSIS AND IMPROVEMENT
2.1
General
The Project shall plan and implement the monitoring, measurement,
analysis and improvement processes needed:
a)
to demonstrate
conformity of the product (see
section 8.2 – Monitoring
and measurement),
b)
to ensure
conformity of the quality management system, and
c)
to continually
improve the effectiveness of the quality management system.
This shall include determination of applicable methods, including
statistical techniques, and the extent of their use.
In order to ensure the compliance with the above-mentioned
requirements, the following activities
are planned:
-
Design Verification (see section 7.3.5),
-
Vendor’s Fabrication Inspection and Testing (see
section 7.4.4),
-
Construction Inspection and Testing (see sections
7.6, 7.7 and 8.2.4),
-
Quality Audits on Project QMS,
including Contractor’s, Subcontractor’s, Vendor’s, Sub- Vendor’s Project QMS,
as required (see section 8.2.2),
-
Management Review (see section 5.6).
2.2
Monitoring and measurement
2.2.1 Customer satisfaction
As one of the measurements of the performance of the
quality management system, the Project shall monitor information relating to
customer perception as to whether the organization has met customer
requirements.
As explained in
‘customer focus’ (section 5.2) project customers’ requirements have to
be constantly revised in order to verify
conformance and to address any new requirement within project processes. Communication and interfaces
between Project and Corporate departments
is fundamental for achieving this purpose.
Early involvement of Cairn Field Operations personnel on
Project Engineering and Design activities ensures a continuous client input and
feedback on project results and progress. Complaints, comments and suggestions
prepared by field operations shall be evaluated by the correspondent project
discipline including the Project Engineering Manager and shall be
implemented once agreed by the Project Manager.
Project auditing and reviews shall be specifically
scheduled as part of the Project Audit Programme for monitoring and measuring
customer requirements compliance (i.e:
Indian regulations compliance and corporate audits to the project).
2.2.2 Quality Auditing
The Project QA Manager shall conduct internal audits at
planned intervals to determine whether the quality management system:
a)
conforms to the planned arrangements
(see 7.1), to the requirements of this International Standard and to the
quality management system requirements established by the organization, and
b)
is effectively implemented and maintained.
An audit program is planned on a project basis, taking
into consideration the status and importance
of the processes and areas of the
project to be audited, as well as the results of previous audits. The audit criteria, scope, frequency and
methods are defined. Selection of auditors and conduct of audits shall ensure
objectivity and impartiality of the audit process. Auditors shall not audit
their own work.
Cairn Procedure DECO-RX-PM-PRO-0102 “Audit Procedure and
Programme” together with document DECO-RX-PM-SCH-0100 “Audit and Review
Schedule” outlines the method for carrying out Quality and technical audits.
Cairn India, as a Project Governance Organization,
requires that all Contractors used
for the Project Development shall prepare and identify
within their own Project Quality Plan an audit schedule which shall take into
account a detailed work time schedule and shall include Subcontractor’s /
Vendor’s auditing activities.
All Contractors shall invite Cairn Quality
Representatives – through the Project Quality Manager - to attend all audits
conducted, including those on Subcontractors/Vendors.
Copies of Contractors audit reports, corrective action
requests and close-out reports shall be provided to the Project Quality Manager.
The Project Quality Manager / QA Superintendent(site)
will reserve the right to issue audit notifications to Contractors and perform
QA audits of Contractor’s, Subcontractor’s and Vendor’s project quality
management systems. Cairn Project Quality Manager and/or its authorised Project
representatives shall be afforded access at all reasonable times for the
purpose of audit, review and
surveillance of aspects that are subcontracted.
The Project QA Superintendent shall
liaise with contractors to ensure that any arising corrective actions are
satisfactorily carried-out and closed-out within a mutually agreed timescale.
Follow-up activities shall include the verification of
the actions taken and the reporting of verification results (see section
8.5.2).
2.2.3 Monitoring and measurement of processes
The Project Quality Manager shall apply suitable methods
for monitoring and, where applicable, measurement of the QMS processes. These
methods shall demonstrate the ability of the processes to achieve
planned results. When planned
results are not achieved, correction and corrective action shall be taken, as appropriate, to
ensure conformity of the product.
Document DECO-RX-Q-PLN-0101 “Key Activities Matrix”
defines the key quality activities, procedures, responsibilities etc., for the
PQP implementation and project processes control and monitoring. The matrix
lists in a logical sequence the key activities from all the project process
required to be monitored. It
identifies individual activities, controlling procedures/ standards,
verifying documentation and method by which compliance is assured.
In Project day to day activities, the process owners
(those project functions responsible for process outputs) shall monitor the
performance and results obtained compared with was expected. If necessary, the Project
Quality Function will be always available for providing support on process
analysis (interfaces with other processes, responsibilities, resources,
methods, etc.) in order to achieve the process improvement.
The Project Manager shall organise the periodic meetings
in order to monitor process outputs, interfaces and progress: Engineering
meetings, Procurement meetings, Project Management Meetings, including both
Cairn personnel and Contractors Personnel.
Cairn Discipline Engineers shall continuously monitor
and having an update status of the activities developed by their particular
disciplines, their outcomes and progress. When deviations on planned results
are obtained (i.e.: progress and/or quality of the outcomes), actions shall be taken
as appropriate. The evaluation of one specific process, sub-process or
interface shall involve the Project QA
Manager support.
Document DECO-RX-Q-SP-2000 “Vendor Quality Assurance
Requirements” details the minimum QA
requirements that vendors are required to comply with.
Document DECO-RX-Q-SP-0001 “Quality Assurance
Requirements Contractors” details the minimum QA requirements that contractors
are required to comply with.
2.2.4 Monitoring and measurement of product
At appropriate
stages of the project and in accordance with the planned arrangements (see
section
7.1
- Planning of product realization),
the Project Manager shall monitor and measure the project performance to verify
that project requirements have been met.
According to the pre-established verification plan, document
DECO-RX-Q-PLN-0101 “Key Activities Matrix”, the Project Quality department will
inspect product along its different development stages:
-
During the design (Deliverables verification as per
section 7.3.5),
-
At the supplier facilities during its manufacturing, and/or at delivery
(as per section 7.4.4),
-
During the installation or construction,
-
At final stages of construction and/or during commissioning.
The evidence of conformity with the acceptance criteria
shall be maintained in Quality Records indicating the person(s) authorizing
release of product (see section 4.5 – Control of records).
The product release and service delivery shall not proceed until the
planned arrangements (section
7.1 - Planning of product realization) have been
satisfactorily completed, unless otherwise
approved by a relevant Project authority and, where applicable by Cairn
Operations (acting as the Project Client).
In the Construction and Installation
Phase the “product” will be conformed by all the technical deliverables
formalizing the design intent, the materials and equipment supplied by vendors
and manufacturers and all the ”in process” constitutive parts of the Mangala
Surface Facilities being
installed (skids, vessels), fabricated (piping spools),
poured (concrete), laid (pipelines, cables), built (structures), connected
(instruments), etc., until becoming the process and utility systems required.
Based on the nature of equipment to be inspected, the receiving
inspection shall be performed by a qualified Quality Inspector.
Materials, equipment and sub-contracted work shall not
be accepted for incorporation in the construction process unless accompanied by
the relevant certification material, dossier or package, suitably endorsed and
accepted by Cairn Quality Inspector and / or by the contractor’s Quality
Inspector as appropriate. Any package, equipment or material arriving on the
worksite without the correct documentation (as requested in the purchasing
information) shall be quarantined
until receipt of the correct and
approved documentation.
The Quality Inspectors in liaison with the Construction
Supervisors will carry out the required in- process inspections and
surveillances for every single construction and installation activity as
established in the approved Inspection and Test Plans (ITPs).
Where there are specific characteristics for required
materials (raw materials and/or components), the specifications or standards to
which the materials have to conform shall be stated in the ITP (see ITP template in attachment 7).
Project Quality Inspectors representing Cairn India,
will be entitled to “certify and release” construction activities conform to
design, as per the acceptance criteria included in the pre- elaborated
Inspection and Test Records (ITRs).
Contractors shall have their own Quality Inspectors who
shall be composed of sufficient numbers of suitably qualified personnel to
ensure that all inspection, testing, dimensional control and
certification is conducted in accordance with the contract requirements.
Inspections by Cairn shall not absolve
Contractors from their responsibility to carry out such inspection and testing
as shall ensure that the requirements of the contract are satisfied.
Every final inspection and testing shall be subject to
acceptance by Cairn Quality Inspector, as applicable.
Test procedures will be based on applicable design
specifications, codes and standards. Moreover, contractors’ Inspection and Test
procedures will require approval from Cairn Project Quality
Manager prior to the commencement of such activities.
8.3
Control of nonconforming product
The Project shall ensure that products, in any of their
development phases (deliverables, equipment, materials and facilities), which
do not conform to requirements shall be identified and controlled to prevent its unintended use, incorporation to the construction process or delivery.
Identified products which do not conform to requirements
shall be handled by means of one or
more of the following ways:
a)
by taking action to
eliminate the detected nonconformity;
b)
by authorizing its use, release or acceptance under a documented concession by a relevant
authority and, where
applicable, by the customer (see
section 5.2);
c)
by taking action to
preclude its original intended use or
application.
These type of actions are focused on the adequate
treatment of non-conforming product (correction of the non-conforming situation)
but could be insufficient to prevent their recurrence. Independently of the nature of the non-conformity (a common
and repetitive deviation or a particular and isolated case) a corrective action
in order to eliminate the root-cause of the non-conformity (instead of only
acting on the consequence) shall also be taken as per section 8.5.2.
The controls and related responsibilities and authorities for dealing with a nonconforming product are
defined in the procedure DECO-RX-Q-PRO-0101 “Management of Project Non-conformities”.
Records of the nature of nonconformities and subsequent
corrective and preventive actions taken, including concessions obtained (if
any), shall be maintained (see section 4.5 – Control of records).
When a nonconforming product is corrected it is subject
to re-verification to demonstrate conformity to the requirements.
When a nonconforming product is detected after delivery
or its use, the Project Manager will take appropriate corrective action in
consultation of Project Manager to the effects, or potential effects, of the nonconformity.
8.4
Analysis of data
The Project Quality Manager or his designee shall determine, collect and analyse appropriate
data to demonstrate the suitability and
effectiveness of the QMS and to evaluate where continual improvement can be
made. This shall include data generated as a result of monitoring and
measurement and from other relevant sources.
The analysis of data shall provide information relating to
a)
customer satisfaction (see 8.2.1),
b) conformity to project and product
requirements (see 7.2.1),
c)
characteristics and trends of projects, processes and products including opportunities for preventive
actions, and
d) suppliers/contractors performance.
Project performance indicators with regards to the
Project QMS implementation shall be established, monitored and analysed. The
results shall be presented during the
Management Review (see 5.6.1) for determination of the suitability, effectiveness and adequacy
of the QMS.
Main indicators derived from project quality objectives (see 5.4.1)
are the following:
-
No. of NCR related to the QMS implementation.
-
No. of NCR related to applicable
standards and contractual and regulatory requirements compliance.
-
No. of project deliverables
re-issued after having reached the approved for design status / total of
project deliverables having reached the approved for design status.
-
No. of project deliverables
re-issued after having reached the approved for construction / total of project deliverables having reached
the approved for construction status.
-
No. of project
deliverables re-issued after having reached
the approved for purchase status
/ total of project deliverables having reached the approved for
purchase status.
-
No. of QA Audits conducted / No. of QA audits planned.
-
No. of Vendors QA audited / No. of QA audits planned
to Vendors.
-
No. of Contractors QA audited / No. of QA audits
planned to Contractors.
-
No. of team building activities executed / No. of
team building activities planned.
-
No. of NCRs per Vendor (and status: raised, open, closed).
-
No. of NCRs per contractor (and status: raised,
open, closed).
8.4.1 Analysis Tools & Techniques
The Project QA
Manager is responsible for selecting the
appropriate tools and techniques to
use for the analysis of data and/or
displaying the results of the analyses. Tools and techniques could include:
-
The use of software (e.g., Microsoft Excel, other
similar software);
-
Deployment of charts (e.g., bar charts, pie charts,
other similar techniques);
-
Simple comparison techniques;
-
Other methods suitable to the task.
8.5
Improvement
8.5.1 Continual improvement
The Project QA Manager shall continually review the
effectiveness of the quality management
system through the use of the quality policy, quality objectives, audit
results, analysis of data, corrective and preventive actions and management
review in order to discuss the results with the Project Management Team and
take the appropriate improvement actions.
All work associated with the Project shall be undertaken
within an environment of continuous performance improvement.
All project personnel shall be responsible for reporting
quality deficiencies and suggested improvements.
Ad-hoc improvement teams/groups shall be established, as
required, to tackle particular problem areas and to identify/facilitate
solutions for improvement.
The Records Management System will be the vehicle for
registering and monitoring of formal recommendations for improvement.
8.5.2 Corrective action
The Project Management Team in all shall take Corrective Actions to
minimize or eliminate the cause of
non-conformities identified in order to prevent their recurrence.
The following
actions shall be performed by the Project Team:
-
Review of non conformities,
including Cairn Corporate complaints for all
processes executed.
-
Determination of the causes of
non-conformities and the appropriate
corrective actions by the Process Owners
-
Implementation of the corrective action needed and
recording of the results.
-
Review by the Project QA Manager or
designee the corrective actions taken, evaluating their effectiveness.
The impact or importance of the problem encountered shall be
considered during the evaluation of the corrective actions needed.
Procedure DECO-RX-Q-PRO-0101 “Management of Project
Non-Conformities” defines the requirements for the developing the
above-mentioned actions.
8.5.3 Preventive action
The Project Management Team shall also determine
necessary actions to eliminate the causes of
potential nonconformity in order to prevent their occurrence.
Preventive actions are appropriate to the effects of the potential problems.
The project quality management has established the
following activities for preventing the
occurrence of potential non conformists:
a)
determining potential
nonconformists in Project processes and products
and their causes,
b)
evaluating the need for action to prevent occurrence of nonconformists,
c)
determining and implementing action needed,
d)
records of results of action taken (see section 4.5
– Control of records),
and
e)
reviewing preventive action taken.
In addition
to the requirements specified above, preventive actions are documented through:
-
Preventive Maintenance
activities as defined in Section 6.3, Infrastructure.
-
Calibration
activities performed in accordance with Section 7.6
- Control of monitoring and measuring devices.
-
Contract review meetings, see Section 7.1 – Product realization.
-
Design development and planning; see Section 7.3 - Design and development.
-
Preproduction and/or production
meetings, including documented meeting minutes.
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