BUSINESS UNIT: Flint Infrastructure Services Limited TITLE: Construction Quality Plan DOCUMENT ID: FIS-330820001-PM-QP- ??? OWNER: Senior Project Manager EFFECTIVE AS OF: May 17, 2010 REVISION: 001 Page 1 of 41 CONSTRUCTION QUALITY PLAN DOC. NO. FIS-330820001-PM-QP REV. DATE PREPARED BY TECHNICAL SERVICES LEAD (Print Name & Sign,) REVIEWED & APPROVED BY DIVISIONAL QUALITY MANAGER (Print Name & Sign,) REVIEWED & APPROVED BY PROJECT DIRECTOR/ SENIOR PROJECT MANAGER (Print Name & Sign,) REVIEWED & APPROVED BY CLIENT REPRESENTATIVE (Print Name & Sign,) 001 May 17, 2010 Gord Galvin Joe Hall Jay Gupta
Transcript
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 1 of 41
CONSTRUCTION QUALITY PLAN DOC. NO. FIS-330820001-PM-QP
REV. DATE
PREPARED BY TECHNICAL
SERVICES LEAD (Print Name & Sign,)
REVIEWED & APPROVED BY
DIVISIONAL QUALITY MANAGER
(Print Name & Sign,)
REVIEWED & APPROVED BY PROJECT DIRECTOR/
SENIOR PROJECT MANAGER
(Print Name & Sign,)
REVIEWED & APPROVED BY CLIENT
REPRESENTATIVE (Print Name & Sign,)
001 May 17, 2010
Gord Galvin
Joe Hall
Jay Gupta
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 2 of 41
Table of Contents
CONSTRUCTION QUALITY PLAN ................................................................................... 1
A: Revision History ............................................................................................................. 4
1.0 GENERAL ................................................................................................................. 5 1.1 Scope and Objectives .................................................................................................................... 5 1.2 Modifications and Additions ........................................................................................................... 6 1.3 Reference Documents.................................................................................................................... 7
4.0 PROJECT ORGANIZATION, ROLES AND RESPONSIBILITIES ............................. 9 4.1 Program Director .......................................................................................................................... 11 4.2 Senior Project Manager................................................................................................................ 11 4.3 Sr. Construction Manager ............................................................................................................ 12 4.4 General Manager Quality (Reporting to VP Construction Operation) .......................................... 13 4.5 Technical Services Team Lead (Reports to SPM) ....................................................................... 14 4.6 QA/QC Lead (Reports to Technical Services Lead) .................................................................... 15 4.7 Quality Assurance Coordinator (Reporting to QA / QC Lead)...................................................... 17 4.8 Discipline Q.C. Coordinators (Reporting to QA/QC Lead) ........................................................... 19 4.9 Discipline Q. C. Inspectors (Reporting to QC Coordinators/Lead) ............................................... 20 4.10 Discipline Field Specialists (Reporting to Technical Services Lead) ........................................... 21 4.11 Turnover Coordinator (Reports to Technical Services Lead) ....................................................... 22 4.12 Technical Assistant (Reports to Technical Services Lead) .......................................................... 23 4.13 NDE/Weld Mapping Technician (Reports to QC Welding Coordinator ) ...................................... 24 4.14 Document Control Lead / Coordinator (Reports to Technical Services Lead) ............................. 25
5.0 QUALITY ASSURANCE ACTIVITIES ..................................................................... 25 5.1 Review of EWP and CWP (Workface Planning) .......................................................................... 25 5.2 Document Management Control .................................................................................................. 27 5.3 Purchasing and Sub-contracting .................................................................................................. 30 5.4 Quality and Technical Audits (Should we mention the Attest program?) ..................................... 31 5.5 Control of Non-conformances ...................................................................................................... 33 5.6 Material Management .................................................................................................................. 34 5.7 Inspection, Inspection and Test Plans (ITP) ................................................................................ 37 5.8 Training ........................................................................................................................................ 38 5.9 Change Management ................................................................................................................... 38 5.11 Corrective and Preventive Action ...................................................... Error! Bookmark not defined. 5.12 Control of Records ............................................................................ Error! Bookmark not defined. 5.13 Identification and Traceability ............................................................ Error! Bookmark not defined. 5.14 CWP Turnover ................................................................................... Error! Bookmark not defined. 5.15 Continuous Improvement System ..................................................... Error! Bookmark not defined. 5.16 Forms and Exhibits ............................................................................ Error! Bookmark not defined.
6.0 QUALITY CONTROL ACTIVITIES ............................ Error! Bookmark not defined. 6.1 Control of Monitoring and Measuring Devices .................................. Error! Bookmark not defined. 6.2 Quality Surveillance Reports / Inspection (QSR ............................... Error! Bookmark not defined. 6.4 Structural Steel Works....................................................................... Error! Bookmark not defined. 6.5 Buildings ............................................................................................ Error! Bookmark not defined. 6.6 Piping and Equipment ....................................................................... Error! Bookmark not defined.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 3 of 41
6.7 Welding ............................................................................................. Error! Bookmark not defined. 6.8 Electrical and Instrumentation ........................................................... Error! Bookmark not defined. 6.9 Protective Coatings/ Linings/ Insulation ............................................ Error! Bookmark not defined. 6.10 Heat Tracing ...................................................................................... Error! Bookmark not defined. 6.11 Building .............................................................................................. Error! Bookmark not defined.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 4 of 41
A: Revision History
Sl. No.
CQP
Section no.
Sheet no.
Rev. no.
Date of Amendment
Amendments made
Need for amendment
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 5 of 41
1.0 GENERAL
This Construction Quality Plan (CQP) is an integral part of the Quality Management System of Flint Infrastructure Services Ltd. and is prepared for each project to meet the customer’s requirements. This is a system of prevention, detection and correction. Both quality assurance and quality control activities are included in this plan. Quality Assurance is defined as a set of activities oriented to demonstrate that an entity (the project in this case) meets all quality requirements. Quality Assurance activities are carried out in order to inspire the confidence of both customer and project stake holders that all quality requirements are being met. Quality Control is defined as a set of activities or techniques whose purpose is to ensure that all quality requirements are being met. In order to achieve this purpose, processes are monitored and performance problems are solved.
1.1 Scope and Objectives (to be reviewed & revised) Within the scope of the project, FISL has the direct responsibilities for: Rough grading of work areas and construction roads (Earthworks) with a granular
working surface for later construction operations (activity to be subcontracted).
Undergrounds and piling: Underground piping includes HDPE firewater, RCP sewers,
CHD system and all buried electrical systems (activity to be subcontracted) Foundations: All foundations including equipment foundations, granular tank bases,
dikes and foundations in the tank farm. Structural Steel: Erection of pre-fabricated structural steel at the site and at the HJB
modularization yard. Modularization: Assembling, installation, connection and test of approx. 170 modules
Mechanical and Piping: Prefabrication, installation and erection of all mechanical
equipment and piping systems except those included within the scope of EPC Contractors.
Electrical: Installation of all temporary and permanent electrical services in Froth
Treatment area. Instrumentation and Controls: Installation, wiring and connection of instruments and
controls except those included within the scope of EPC Contractors.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 6 of 41
This Construction Quality Plan has been prepared for the execution of the above mentioned scope of work. The main objective of this plan is to provide key personnel in the project organization with a framework in which they have the responsibility and authority to execute the work in the most efficient way, without jeopardizing the quality of work as required by Client complying with all the established quality requirements indicated in specifications, drawings, applicable codes, standards and any other applicable contractual document. To achieve this, we have established the following additional objectives: Guarantee the consistency in quality standards to be applied in different construction
activities. Document all the inspections and tests performed through inspection & Test Plans (ITP) Ensure that all inspection and test records are maintained in such a way that they are
updated and can be audited internally and externally by the Client. Ensure Progressive Turnover Documentation. Establish Quality trends. Provide Project and Construction Management with the tools to verify quality trends Establish an alert mechanism when quality performance is declining and implement
corrective action before we reach unacceptable quality levels. Design feedback system to prevent recurrence of non-conformances. Establish Quality Assurance activities on Sub-contractors.
1.2 Modifications and Additions This Quality Plan is a controlled document and should be kept updated. Any modification and/or addition to this plan should be reviewed and approved by FISL QA/QC Manager, Sr. Project Manager and the Client (Client). Approval and revision history is shown below in the table.
Rev.
Section/ ID No.
Revision History
Author/ issued by:
QA/QC Manager
Reviewed & approved by
QA/QC Manager
Reviewed & approved by Sr. Project Manager
Reviewed & approved by
Client (Client)
001
Joe Hall
Jay Gupta
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 7 of 41
Rev.
Section/ ID No.
Revision History
Author/ issued by:
QA/QC Manager
Reviewed & approved by
QA/QC Manager
Reviewed & approved by Sr. Project Manager
Reviewed & approved by
Client (Client)
1.3 Reference Documents This Construction Quality Plan (CQP) has been developed based on the following reference documents: International Quality Standards ISO 9001:2000, Quality management systems-requirements
ISO 9004:2000, Quality management systems-Guidelines for performance
improvements
ISO 10005:1995, Quality management-Guidelines for quality plans
ISO 10006: 2003 (E), Quality management systems-Guidelines for quality management in projects
Husky Oil Reference Documents: Client Quality Plan - SNRS-01-99-CT-FP-00001-1, RFP – Schedule F. All Project specific Client standards and Specifications Project baseline procedures FISL Reference Documents Quality Management System Manual (FIS-000-GN-QM-001)
2.0 QUALITY MANAGEMENT APPROACH To achieve the quality goals established for the project (section 3.2) and the objective of this construction quality plan successfully, the Project and Construction Management Team will apply 8 quality management principles:
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 8 of 41
Customer focus: The Construction Management Team (CMT) and the Project Management Team (PMT) will be customer focused. They understand current needs and will strive to understand future needs of our Client (Husky Oil) to meet their requirements and exceed their expectations.
Leadership: Every member of the management team will take leadership in his or her
role in fulfilling the needs of the Client (Husky Oil) and to meet and exceed their expectations.
Involvement of people: In the construction and project management, people at all levels
shall be involved and their abilities will be utilized for the organization’s benefits.
Process approach: All activities and related resources shall be managed as a process
Continual improvement: Continual improvement of our overall performance is a permanent objective and we will achieve this through Plan-Do-Check-Act cycle.
Factual approach to decision making: All our decisions will be based on the analysis of
data and information.
Mutually beneficial supplier relationship: We will be subcontracting many processes within the scope of the project. We think that our organization and our subcontractors are interdependent. Therefore, we will establish mutually beneficial relationship with our subcontractors to enhance the ability of both to create value.
Additionally we have prepared this Quality Plan and identified two major processes to validate that the major deliverables are completed with an acceptable level of quality. The two major processes are:
2.1 Quality Assurance Processes: Refer to section 5.0
2.2 Quality Control Processes: Refer to section 6.0
3.0 QUALITY POLICY & OBJECTIVES
3.1 Policy Flint Infrastructure Services Ltd. (FISL) at the divisional level has declared its quality policy as follows:
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 9 of 41
“Our principal objective is to meet or exceed the requirements of our clients by providing them with quality professional services that fully satisfy their requirements, applicable codes, and Safety Codes Act & Regulations for the province of Alberta; and by delivering services on time and within budget. Our fundamental goal is to achieve sustained profitable growth. This growth shall be based on long- term relationship with our clients, by providing a service that consistently meets or exceeds their needs and expectations. Only training and involving all employees to be responsible for the quality of their work can achieve this growth. Flint Infrastructure Services Ltd. (FISL) management will review and issue quality objectives of FISL. All the activities of the quality management system should be directed to meet the quality objectives. All personnel should contribute in meeting the targets set in the quality objectives. FISL management is committed to continually improve the quality management system and to the successful implementation and maintenance of the quality management system All employees shall support this “Quality Policy.”
3.2 Quality Objectives (Project) The ultimate quality goal is to achieve 100% customer’s satisfaction. To achieve this The FISL Management Team has established the following quality objectives: 100% compliance to Client’s specifications 100% compliance with this quality plan
Application of lessons learned in the previous projects and in this project in an ongoing
basis
Achieve weld rejection rate less than 3%
Ensure all work is correct and complete
Complete project on or ahead of schedule
Complete project on or below budget
4.0 PROJECT ORGANIZATION, ROLES AND RESPONSIBILITIES
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 10 of 41
The project organizational structure has been established in accordance with the requirements and policies of FISL, Client and the conditions particular to this project. The previous project experience has been considered for the selection of the most appropriate organizational structure (See attachment 1). This project organizational structure has been designed to encourage effective and efficient communication and cooperation between all participants in the project. The Sr. Project Manager, Sr. Construction Manager, Construction Managers, Project Manager, Functional Team Lead and Functional Management team have ensured that the project organizational structure is appropriate to the project scope, the size of the project, local conditions and the processes employed. This project organizational structure shall be reviewed periodically to determine whether it continues to be suitable and adequate. Job or role descriptions, including assignments of responsibility and authority as per this organizational structure has been prepared and documented to meet the requirements of the international quality management standard ISO 9001:2000. The followings are the job descriptions of some of the team members of the project.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 11 of 41
4.1 Program Director The Program Director shall be responsible in developing and maintaining a strong working relationship with owner’s Project Management Team (PMT), Construction Management Team (CMT), Engineering Team, and Flint Functional Management Team. The Program Director has the following key responsibilities: Supports constructability assessments for new programs by working closely with the
client’s Project Management Team (PMT), and Engineering Team assigned to the program.
Sets expectations with engineering firm and client at all levels of organization.
Agrees on gate process that will be used for the project.
Provides the “GO NO/GO” recommendation to the Flint Infrastructure Leadership Team
(FISLT) based on the business goals for the opportunity.
At the appropriate time in the planning phase begins developing the PMO by identifying the key positions of the PMO. Once the PMO positions are agreed with the Vice President, the PD hires the Senior Project Manager (s) (SPM) and other key positions that will support the planning phase of the program.
Works jointly with Vice President in the development of the Program/Project contract.
Responsible for Business Decision Point (BDP) preparation, declaration, passage, and resolution of “Out of Bounds” conditions
Oversees the development of the Functional Plans and schedule BDP’s with the FILT
based on the Divisional Operating Model
4.2 Senior Project Manager The Senior Project Manager shall ensure that all personnel are capable of performing work up to the standards as outlined in this Quality Management System Manual. The Senior Project Manager shall have overall responsibility to maintain a quality product, and for implementation of contract work and subcontract work. The Senior Project Manager has the responsibility to: Develop and maintain a strong working relationship with the Owner’s Project
Management Team, Construction Management Team, Engineering Team, and Flint’s Functional Management Team.
Provide and agree on all candidates for hire in project positions
Provide day- to- day direction to project team members
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 12 of 41
Develop and execute the Construction Execution Plan
Engage Functional Managers when functional performances are not to the functional plan
Responsible for the Front End Services Plan development and coordinate engagement
of all functional representation for the project
Responsible for the project budget (direct and indirect) and profitability as it pertains to the functional group and the project budget
4.3 Sr. Construction Manager The Sr. Construction Manager is the principal responsible for construction activities in accordance with engineering design. He is also responsible for the implementation of this Construction Quality Plan. A team of construction managers, supervisors and foremen supports the Sr. Construction Manager. He will support the QA/QC Leads with information required to show evidence of compliance with the required quality standard. Technical Service Lead and QA/QC Leads will support the Sr. Construction Manager regarding the requirements and analysis of situations, which will allow him to take corrective and preventive actions with the purpose of ensuring the construction quality. The Sr. Construction Manager shall stop the work when the TS Lead or QA/QC Leads advise him to do so in quality related aspects, in order to resolve problems raised during construction.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 13 of 41
4.4 General Manager Quality (Reporting to VP Construction Operation)
Primary Function The Divisional Quality Manager will develop the Divisional Quality Management System
(QMS) including the model for the Facility and Construction Organizations, the guardian of the Quality Programs (Manuals, Processes, and Procedures, Work Instructions), and the applications to support the programs.
The Divisional Quality Manager is responsible for: Developing and maintaining a strong working relationship with the Quality Manager in
fabrication facility, Technical Services Team Lead in site construction and owner’s Quality Representative.
Developing Employee Development Plan for Career Planning & Succession Planning,
Resource Management Plan within the Infrastructure Division.
Measuring and reporting Key Performance Indicators (KPI) Key Responsibility Areas Ensures Quality Management Plans for each project follows Flint’s programs and, meet
the Client specifications.
Improve and develop new processes and procedures in support of continuous improvement.
Maintain and improve quality functional protocol, develop and communicate the QMS
model to the Divisional PMO Directors, SPM and the Functional Managers.
Approve all Quality Management Plans, recruitment, developing strategies for training & development of all Program Quality Team Leads and other Quality personnel for the facility & projects.
Develops program necessary to progress through the various Quality roles within Flint.
Aligns with workforce growth initiatives.
Provides direction and support towards development and implementation of new or improved welding technologies, method and process. Approves feasibilities and over sees the trial in HJB, followed by the implementation and rollout in all fabrication and construction sites.
Carryout PMP for all program Technical Services Team Leads and facility Quality
Manager.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 14 of 41
Manages an overall staffing plan that identifies all quality department employees, their
location, their level, and their potential next assignment.
Close gaps in the development of a single Quality Manual for the Facility (HJB), and improving the existing Field Construction Quality Manual, Process, and Procedures.
Develop an appropriate internal and external audit and attest schedule for both facility
(HJB) and Construction programs.
4.5 Technical Services Team Lead (Reports to SPM) Primary Function The Technical Services Team Lead is responsible for the successful planning of the
technical services requirements for the project construction quality functions, document control function and maintaining surveillance of the project quality performance.
Execute overall control, direction and management of contracted deliverables with
respect to technical services being directly responsible to Sr. Project Manager.
Responsible for the development of the project specific quality plan, Inspection & Test Plans for all disciplines, review quality manual to incorporate the client specific requirements.
Responsible to provide direction in preparation of the project specific Construction
Quality Plan (CQP) sections dealing with quality management, field engineering, continuous improvement, commissioning, turnover, document control and lessons learned.
Ensure that personnel within the Technical Services Team receive proper orientation
and training.
Carryout PMPs for Quality Leads directly and responsible for PMP of other staff within the department.
Assists in the recruitment process in conjunction with the SPM, FISL-HR, and Divisional
Quality Manager. Key Responsibility Areas The Technical Services Team Lead is directly responsible to the Sr. Project Manager for
the performance of the quality management system and accountable to the Divisional Quality Manager for alignment of project deliverables with corporate quality standards.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 15 of 41
Developing and maintaining a strong working relationship with the Owner’s quality representatives, engineering house, construction team and HJB’s quality team.
Developing, tracking of all quality manual changes, lead the development of Project
Specific Quality Protocols with project teams, identify, comprehend, validate and develop client’s quality deliverables into project quality documentation. Maintains and controls quality management system manuals including managing of QA/QC document revisions.
Communicates to the Project Managers of the project quality deliverables, standards
and project specific requirements. Reviews EWPs – CWPS to develop project quality plan, kick off the project with an
understanding of all quality requirements, welding requirements, quality plan. Inspection and Test Plans (ITPs)
Attests / Audit all project quality management system to verified quality project protocols,
submit flash reports on attest, audits, responsible for quality metrics reporting and quality KPIs.
Assists project controls in capturing and documenting project lessons learned and
maintains log of lessons learned. Responsible for employee training & development, career planning & succession
planning within the infrastructure Technical Services Department and prioritize key resources for timing of project deliverables.
Supporting the hiring of Program Technical Services Team members and providing
proper induction program. Ensures required quality audits of FISL construction team and sub-contractors are
carried out, documented and reported to the Divisional Quality Manager/SPM complete with recommendations for continuous improvement.
Provides E and HS as well as risk and change management support to the project team
4.6 QA/QC Lead (Reports to Technical Services Lead) Primary Function The Project QA/QC Lead coordinates all the Quality Control and Quality Assurance
activities with QA Coordinator and respective discipline QC coordinators, inspectors, other specialist support assigned to QA/QC group.
Ensures project quality control group meets the FISL and client expectations with
respect to all contracted quality control deliverables including all as required construction
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 16 of 41
execution quality control plan, field quality inspections and supply documentations to QA group.
Provides feed back if required any changes to quality plan, ITPs and ensures its full
implementation of discipline specific quality management plan. Ensures all in process field inspection of welding, hydro tests preparation,
reinstatements’ are done in timely manner Ensures required quality audits of FISL construction teams and sub-contractors are
carried out, documented and reported to the TS Lead / Divisional Quality Manager / SPM / Program Directors complete with recommendations for continuous improvement.
Assists in preparation of group staffing plan based on the estimates, recruitment, training
and development, and overall staff supervision within the group. Reviews scope of work, ensure the CWP, ITP matches the scope and identify inspection
and test requirements and quality documentation requirements. Key Responsibility Areas Responsible for the timely and satisfactory execution of project construction quality
control activities as per the plan and signed off ITPs by all parties. Leads in the development of the quality control protocols for the group, Program
Technical Services Team members as a whole and ensures it is implemented. Assists in support and ensure participation in FISL’s safety program including attending
toolbox talks, workface THA’s, weekly safety meetings and the BBO Program. Identifies, and implements client quality control deliverables into the as per site specific
quality plan and ITPs. Supports the hiring of quality control team members and providing day-to-day direction
to these employees. Provides technical expertise and mentoring to quality control team members and
develops training plans & ensures its implementation. Conducts PMP reviews of the direct reports.
Timely compiling of all required quality documents for turnover packages to meet the
client specified schedule and provides quality control documentation to Shared QA group.
Supports in to implement on the corrective action reports, as well as the NCR process
and ensures that the required activity is carried out on site and has the agreement of client inspector and signed off.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 17 of 41
Ensures the project quality inspection and test plan are delivered to the team, that every
one comprehends and implements the ITPs. Involved in the NCR and the rework reporting system, work trend analysis, Processing of
and compiling responses to client and internal NCRs, CAR and CSR. Provides input to improvements to System and Processes and participates in lessons
learned process and drive proposed changes that will enhance project success. Carryout PMPs for Quality Leads directly and responsible for PMP of other staff within
the department. Assists in the recruitment process in conjunction with the SPM, FISL-HR, and Divisional
Quality Manager. Reviews EWPs – CWPS to develop project quality plans, kick off the project with an
understanding of all quality requirements, welding requirements, quality plan. Inspection and Test Plans (ITPs).
Attests / Audits all project quality management system to verified quality project
protocols, submit flash reports on attest, audits, responsible for quality metrics reporting and quality KPIs.
Assists project controls in capturing and documenting project lessons learned.
Maintains log of lessons learned. Responsible for employee training & development, career planning & succession
planning within the infrastructure Technical Services Department and prioritize key resources for timing of project deliverables.
Supports the hiring of Project Technical Services Team members and providing proper
induction program.
4.7 Quality Assurance Coordinator (Reporting to QA / QC Lead)
Primary Function The Quality Assurance Coordinator works with QA Team and construction planning
team to identify project scope, requirements, and deliverables of the project, reporting to QA/QC Lead.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 18 of 41
Conducts Quality Audits of all the sub contractors and FISL construction teams to ensure all activities confirm to FISL QMS, project specific Quality Plan, Client Project Specifications, Procedures and Work Instructions.
Coordinates with all discipline construction groups and quality groups to meet the FISL
and client expectations with respect to all contracted quality deliverables including turnover requirements.
Ensures the Piping ISO’s are stamped with the proper welding information before the
commencement of the work Co-ordinates with discipline lead’s to ensure all NDE requirements, Weld mapping, As-
built / redlines Drawings are up to date with RFI/NCR/DCN information. Co-ordinate preservation activities as per project requirements
Key Responsibility Areas Provides QA input during the Engineering Work Package, reviews work scope, EWP,
CWP. Responsible for the timely and satisfactory preparation of ITPs in line with scope of work. Identifies inspection and test plan requirements, quality documentation requirements,
and ensures the ITPs match the CWP scope of work. Assists and support FISL safety program, workface THA’s, weekly safety meetings and
the BBO Program. Identifies, and develops a strong understanding of the clients engineering specifications
and quality deliverables in order to contribute to a coordinated and efficient construction plan.
Assists team in pre-population of information for inspection test requirements in the work packages. Verifies the information in the hydro test packages with respect to quality fulfilling the
client specifications. Ensures that new employees are provided project specific training and understands
FISL, Project specific procedures, requirements, and deliverables. Participates in lessons learned process and drive proposed changes that will enhance
project success. Takes ownership and follows up for status / actions of all RFI, NCR, PAR, CAR, QSR
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 19 of 41
4.8 Discipline Q.C. Coordinators (Reporting to QA/QC Lead)
Primary Function Discipline Quality Coordinators manage all Quality Control inspection activities within
their specific discipline in a timely manner. Ensure discipline quality group meet FISL and client expectations with respect to all
contracted deliverables including all required construction documentation from mechanical completion, turnover packages, construction completion and transfer of care custody and control.
Assist in CQP development, ensures its implementation, also full implementation of
discipline specific quality management plan and client interface. Assist in preparation of group staffing plan, recruitment, training and development, and
overall staff supervision within the specified discipline. Key Responsibility Areas Responsible for the timely and satisfactory execution of project construction quality
control activities within the specific discipline. Assist in the development of the quality control protocol for the discipline quality team
members and ensures it is implemented. Assist in support and ensure participation in FISL’s safety program including attending
toolbox talks, workface THA’s, weekly safety meetings and the BBO Program. Identify, and implement client quality deliverables into the discipline quality execution. Support the hiring of quality control team members and providing day-to-day direction to
these employees. Mentor to discipline quality control direct report team members and assists QC Lead to
develop training plans & ensure its implementation. Conducts PMP reviews of direct reports.
Timely compiling of all required quality documents for turnover packages to meet the
client specified schedule. Support in to implement on the corrective action reports, as well as the NCR process
and ensures that the required activity is carried out on site and has the agreement of client inspector.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 20 of 41
Ensure the project quality inspection and test plan are delivered to the quality team, that every one comprehends and implements the ITPs.
Involve in the NCR and the rework reporting system, work trend analysis, Processing of
and compiling responses to client and internal NCRs, CAR and CSR. Participate in lessons learned process and drive proposed changes that will enhance
project success.
4.9 Discipline Q. C. Inspectors (Reporting to QC Coordinators/Lead)
Primary Function Responsible for the timely and satisfactory execution of project construction quality
control activities within the specific discipline. Ensure discipline quality group meets the FISL and client expectations with respect to all
contracted deliverables including all required construction, and quality control program. Assist QA/QC Leads to prepare internal audit schedule and conduct audits for the
discipline group. Key Responsibility Areas Assists in the development of the quality control protocol for the discipline quality team
members and ensures it is implemented. Assist in support and ensure participation in FISL’s safety program including attending
toolbox talks, workface THA’s, weekly safety meetings and the BBO Program. Identify, and execute client quality deliverables into the discipline quality execution. Mentor to discipline quality control activities and assists QC Lead to develop training
plans & ensure its implementation and signed off all exhibits by himself & client representative.
Timely compiling of all required quality documents for turnover packages to meet the
coordinator/lead schedule. Support to implement corrective action reports, as well as the NCR process and ensures
that the required activity is carried out on site and has the agreement of client inspector. Ensure the project quality inspection and test plan are followed to the requirements,
signed off by himself and client representative where ever required.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 21 of 41
Involve in the NCR and the rework reporting system, work trend analysis, Processing of
and compiling responses to client and internal NCRs, CAR and CSR. Participate in lessons learned process and drive proposed changes that will enhance
project success. Perform and document inspection in reception. Responsible for carrying out the coordination of system walk downs, inspection of
completed construction within his discipline to ensure compliances to the specification, standards, P & Ids, and IFC drawings.
Perform final walk down with client representative including identification of turnover
exceptions within the discipline. Verify completion of punch list and RFI items. Carryout field verification of all modifications, changes executed by the construction due to
RFIs and NCRs or through any other deviation notices and make sure that they are done as per the specifications and standards & also have client’s approval.
4.10 Discipline Field Specialists (Reporting to Technical Services Lead)
Primary Function Address and provide engineering solution to on-going construction technical issues
raised through RFIs, NCR, FCNs and “Point & Do” (P&Do) within the discipline and advice to the construction execution team.
Ensure compliances to specifications, standards, P & IDs, IFCs drawings as applicable
for FCRs, FCNs, DCNs, FDCNs, EDNs, RFIs, P&Dos and RFCAs. Key Responsibility Areas Ensure on going construction technical problems within the discipline are addressed
properly and propose engineering solutions and advice to the construction execution teams.
Performs all field checks and gathers all information required to raise RFI and NCR. Maintains the NCR/RFI hard copies and Logs in the FDMS system. Reviews all Engineering and Vendor drawings and develop ITP’s for each CWP.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 22 of 41
Supports construction and QC in interpreting drawings, specifications, standards and
Code requirements, Assists in developing Test Packages and Stored Energy Calculations for Pneumatic
Testing Responsible for carrying out the coordination of system walk downs, inspection of
completed construction within his discipline to ensure compliances to the specification, standards, P & Ids, and IFC drawings.
Participates in final walk down with client representative including identification of
turnover exceptions within the discipline. Review scope definitions and boundary limits prior to notification of the turnover
coordinators. Work with respective discipline superintendents to identify remaining work when the
system is nearing completion including work go list. Verify completion of punch list and RFI items. Carryout field verification of all modifications, changes executed by the construction due
to RFIs and NCRs or through any other deviation notices and make sure that they are done as per the specifications and standards & also have client’s approval.
Coordinates the work within the discipline QC inspectors, including hydro test
coordinator in case of mechanical discipline. Assist in support and ensure participation in FISL’s safety program including attending
toolbox talks, workface THA’s, weekly safety meetings and the BBO Program. Participate in lessons learned process and drive proposed changes that will enhance
project success.
4.11 Turnover Coordinator (Reports to Technical Services Lead)
Primary Function Co-ordinates the activities of the turnover group Ensures that the turnover processes as required by Client are followed and contract
deliverables are supplied on schedule and client interface.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 23 of 41
Assists in preparation of group staffing plan, recruitment, training and development, and overall staff supervision within the specified discipline.
Key Responsibility Areas Receives & files all QA/QC documents by Construction Work packages (CWP) Ensures that there is an efficient system in place for exchange of turnover information
between the quality control, quality assurance leads, discipline coordinators, field engineers or technical coordinators, QC inspectors, data input, and document control.
Liaison with Leads, Construction Managers & Project Managers for development of
systems and procedures as required. Ensures that the turnover and document control processes are used on the project will
facilitate a smooth transaction of engineering/construction documents into the project and construction generated turnover documents back out to the client.
Follows up with the QA and QC team to get all required documents required to assemble
the turnover packages. Understand well the turnover procedure lay out by client & Flint Technical Services Team
Plans and maintain group staffing, manages the overall administration of staff and
responsible to complete staff PMP’s. Prepares and documents turnover plan from construction, testing, system integration,
and turnover.
4.12 Technical Assistant (Reports to Technical Services Lead) Primary Function Receives & files all QA/QC documents by Construction Work packages (CWP) Assists Turnover Coordinator to ensures that the turnover processes as required by
Client are followed and contract deliverables are supplied on schedule and client interface.
Key Responsibility Areas Works in close cooperation with Document Control team and QC team to assemble the
turnover packages. Assists all positions as directed to ensure an efficient exchange of turnover information
between the quality control, quality assurance leads, discipline coordinators, field specialists, QC inspectors, and document control.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 24 of 41
Works directly with various disciplines of the technical services group to assist in domain specific tasks
Helps facilitate a smooth transaction of engineering/construction documents into the
project and construction generated turnover documents back out to the Client. Manages and populates all requisite project logs Whatever clerical functions are required in support of quality objectives
4.13 NDE/Weld Mapping Technician (Reports to QC Welding Coordinator )
Primary Function The NDE/Weld Mapping Technician is responsible to ensure the information on NDE activities and weld mapping is well documented and acceptable for completion of turn-over packages. Key Responsibility Areas The NDE/Weld Map Technician is: Responsible for maintaining a copy of reports and a log of all reports associated with the
NDE activities on all systems, equipment and vessels. Responsible for maintaining a log of all welds performed on the systems, equipment and
vessels with the weld map coordinating the locations of the welds performed Responsible to ensure all the NDE and welds reports and logs are appropriately filed for
the corresponding systems and compiled for the applicable turn-over of system. Interfaces with the Discipline Coordinators and the Field Engineering staff to obtain all
the relevant information to be transferred onto drawings and documentation to reflect the installed condition.
Demonstrates a professional work ethic and actively participates as a member of the
field Technical Service Team. Interfaces with the discipline coordinators to understand the schedule for completion of
NDE/Weld Mapping. Assess the impact of inefficiencies on the successful delivery of completed information
updates.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 25 of 41
4.14 Document Control Lead / Coordinator (Reports to Technical Services Lead)
Primary Function Supervise and oversee that all functions of the Technical Document Control management within the program/project and manage the group to its maximum efficiency. To train and educate staff in FDMS to manage technical documents and ensures its control. Key Responsibility Areas
Liaise with engineering house for, delivery of EWPs, receipt of CWPs, storing in FDMS (flint Document Management System), and distribution to Workface Planning Team.
Follow up with Engineering house, workface planning group within the project for the project document deliverables.
Trains staff on Technical Document Management System and specifically how to use FDMS to its maximum efficiency.
Liaise with functional Leads/Managers, Sr. Project Managers, and Program Director to ensure information flow and document storage/distribution is as per project document control protocol and in line with divisional document management plan.
To prepare & review staff PMP’s.
Oversee procedures & processes, distribution, control and process improvements.
Review roles and responsibilities with team members.
Set up Document Control management system within the project/program.
Generate final drafts for Document Control generated documents.
Standardize Document Control Forms and Exhibits.
Assist turnover group to prepare in process turnover of the project during the life cycle of the project.
5.0 QUALITY ASSURANCE ACTIVITIES
5.1 Review of EWP and CWP (Workface Planning) Workface Planning is an Initiative that will be used by FISL on this project to increase productivity and cost savings in the fabrication shops, assembly yards and site. The entire idea is to place required resources and materials at the workplace before construction work is commenced. Resources include manpower equipment, and necessary information, i.e. engineering info, Quality Control, and Safety. So, Workface planning is the process of organizing and delivering all the elements necessary before construction work is started to enable craft person quality work in a safe, effective and efficient manner. This will contribute to higher project performance. FISL has also established a “Workface Planning Process” (FIS-000-GN-PC-009) within its Quality Management System at the divisional level.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 26 of 41
FISL Workface Planning Team will receive issued for construction drawings (IFC) from Flint Document Control and review the scope of work, and establish the strategy, man-hour estimates, materials estimates, equipment estimates, subcontract estimates and small tools and consumables estimates and submit all of the foregoing to Client Construction Management Team. The development of the Construction Work Package (CWP) as per Client Procedure ??? will be the team effort between Client Construction Management and FISL Workface Planning Team. The Workface Planning Team will have filled out Client Construction Work Package (CWP) Form with the required information. This will be the proposed CWP and is the “How” of the IFC information, standard, specification and procedure. All the necessary information to conduct work within a specific discipline for a design area is indicated in this package. The Workface Planning Team will be supported by different discipline leaders, QA/QC leads. The Discipline Leaders belonging to the Workface Planning Team shall review the content of the IFC information in order to assure the constructible design with the best methods of construction before utilizing these drawings and information on the construction site. The review should be carried out with the purpose of verifying if the drawings have all the details for construction Drawings related to every discipline shall be reviewed by utilizing checklists according to system and equipments selected from Work Break down Structure (WBS). Check lists, all documents and drawings properly signed (by who reviewed with) with the respective date are considered as quality records for traceability. Multi-disciplinary reviews shall be performed to verify consistency between drawings, specifications of different disciplines with vision to have safe, operational, reliable and sustainable design. This process consists in: Detail review of construction drawings and specifications Detailed project scope review The evidence of these reviews will remain in drawing history, minutes and notes of the applicable meetings. If any modifications, additions need to be done in the drawings, a request for information (RFI) or a Point & Do (P&Do) is issued to the Client. Once all the concerns are resolved, Workface Planning Team shall complete and release Construction Work Package (CWP). This CWP will contain the following information, but not limited to: Materials Tools
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 27 of 41
Equipment Trades/specialists Detailed Inspection and Test Plan Drawings Vendor information Safety requirements Supervisory review Once approved by the owner, the CWP form (Proposed CWP) will then act as the official Work Authorization for the relevant CWP. The Technical Documentation Control shall put all the drawings and specifications in FDMS database. Only the updated version of drawings and specifications will be in FDMS database and are ready to be used for construction activities. The Project Construction/Fabrication Management Team shall use the drawings from FDMS along with the information received from the Client through RFI. The CWP will be sent to the site before the related job is started.
5.2 Document Management Control FISL will utilize a Document Control System to report and control the distribution and administration of the project documentation as per the Client Procedure SNRS-01-99-G-ST-00001-1. Document Control System is being set up at a program level and Sunrise Oil Sands Project will be a part of this. For more information please refer to FISL Document Management Plan (FISL-PM-DMP-100) and Document Control Procedure (FIS-000-GN-PR-001). All the project related documents (specifications, drawings, request for information, design change notice, field change notice, design change request, inspection and test records, nonconformance reports, audit reports etc.) are controlled as per above mentioned Corporate plan and procedures. If required a site specific Document Control procedure will be developed and implemented. The objective of this process is to maintain a centralized document control system which includes all engineered documents for construction (supplied by Client),
5.2.1 Distribution and Identification All the updated drawings and specifications shall be in the FISL Corporate FDMS database. The documents to be controlled on the construction site include but not limited to the followings: IFC drawings Project standards and specifications
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 28 of 41
Instrument data sheet Design change notice (DCN) Field change notice (FCN) Field change request (FCR) Request for information (RFI) Non Conformance Report (NCR) Management of changes on Procedures Trends Construction Work Authorization (CWA) The Construction Site Document Control Coordinator shall have access to FDMS as a user. Whenever drawings and specifications are required for construction activities, The Document Control Coordinator on site can make a print out. All the print out drawings and specifications shall be maintained in the document control room by the Document Control Lead / Coordinator. All these documents are registered in accordance with Project Document Control Work Instruction (FIS-000-DC-WI-001) referenced in FISL Quality Management System. This work instruction describes the actions to be taken when documents are received and dispatched. No drawings, specifications or other documents can be removed from the document control room. Interested parties can consult drawings and other documents in the room. The Document Control Coordinator shall make copies of the drawings printed out from FDMS and distribute to the concerned parties with the transmittal. The transmittal shall be signed off by the recipient. All the transmittals shall be filed and maintained by the Document Control Coordinator on site. A filing system shall be established to ensure that all necessary controlled documents and information are easily retrievable and are delivered to the proper location and personnel responsible for executing the work. A Master List of all received documents shall be developed and maintained by Document Control Leads on the site. This master List will provide the following details for each document: Document reference Document number and Title Document revision no. Date of approval (if required)
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 29 of 41
Transmittal no. The Document Control Coordinator shall log the distribution of these documents in the Document Distribution Matrix All the controlled documents generated by FISL for this project shall be sent with a transmittal (FIS-000-DC-FF-002) and shall be acknowledged as received by signature of the recipient. Obsolete/superseded documents shall be identified as such. The Document Control / Technical Service department shall maintain a log for the following documents: Request for information (RFI)
Filed change notice (FCN)
Design Change Notice (DCN)
Technical Deviation Notice (TDN)
Management of changes in Procedures
The Log shall indicate the following information: Contractor’s name
Document number
Brief description
Tag number
CWP no.
Date of issue/closure
5.2.2 Filing and Archiving All the documents shall be maintained to the up-to date revisions using a filing and archiving system so that they are readily available to personnel performing work.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 30 of 41
5.3 Purchasing and Sub-contracting
5.3.1 Purchasing All the bulk materials /equipment are acquired by Client. FISL shall coordinate with the Client for effective and on time reception of these materials and equipments meeting the priorities for construction. FISL must have information from Client about shipping and delivery date of materials and equipments. If the deliveries of materials and equipment are going to cause costly construction delays, the FISL will advise Client to review their procurement plan and strategy. Client shall endeavor to pursue the timely delivery of materials and equipments so that FISL progress is not hindered. Purchasing on site is limited to those articles which are required for the fabrication and erection activities on site, i.e. welding consumables etc. All purchasing by FISL will be done in compliance with the purchasing procedure (FIS-000-GN-PC-003).
5.3.2 Sub-contracting FISL will need to subcontract the following services but not limited to: Work areas and construction roads (earth works) Piling & underground piping (including HDPE firewater, RCP sewers, CHD system and
buried electrical systems). Transportation of modules fabricated at HJB module yard. Painting and coating Concrete pumping We shall use FISL and Husky Oil Sunrise approved suppliers for these services wherever possible using their Approved Vendor List. If a specific supplier is not in their Approved Vendor List, the same will be pre-selected from FISL Approved Suppliers List. The subcontractors and suppliers will be pre-selected/evaluated under the following criteria: Project reference/previous satisfactory experience Supplier with a certified quality management system Satisfactory assessment conducted by company personnel Ability to deliver materials or services on time
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 31 of 41
Price and credit terms For all work to be sub-contracted a scope will be developed with anticipated schedules and then tender price from qualified suppliers will be solicited. Any subcontractor not specified in Client Approved Vendor List and pre-selected by FISL shall be subjected to Client approval. FISL will have the direct responsibility for all works sub-contracted. QA/QC Leads assigned to the project will work with sub-contractors evaluating their performance and progress. Sub-contractors providing critical services on site shall be asked to provide a Safety Plan and a Quality Program. The purchasing process (FIS-000-GN-PC-003) documented in the FISL Quality Management System describes the criteria for selection of vendors, supplier quality problem and performance evaluation and all the forms to be used to keep records. All services and products will be subcontracted as per FISL corporate subcontracting processes. For detail, please refer to the following processes: Subcontracting Process (FISL-SCM-SCON-PRPC-001) Requisition for Subcontract (FISL-SCM9a-SCON-PRPC-001) Subcontract Solicitation and Award (FISL-SCM9b-SCON-PRPC-001) Subcontract Agreement (FISL-SCM9c-SCON-PRPC-001) Subcontract PO Creation (FISL-SCM9d-SCON-PRPC-001) Subcontract Receiving (FISL-SCM9e-SCON-PRPC-001) Subcontractor Close-out (FISL-SCM9g-SCON-PRPC-001)
5.4 Quality and Technical Audits (Should we mention the Attest
program?)
Both quality and technical audits shall be conducted at 15%, 50% and 80% of project completion as per FISL Quality Audits Procedure (FIS-000-GN-PR-003) and Client Construction Audit procedure (SNRS-01-99-CT-FP-00001-1, 15.3,19, 15.4, 2, e). Qualified personnel independent of those having direct responsibility of the areas being audited shall carry out the audit. The purpose of these audits shall be to verify
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 32 of 41
compliance and/or non-conformances to the Construction Quality Plan and Inspection and Test Plans (ITPs). For each audit, an Internal Quality Audit Plan (FIS-000-QA-FF-002) shall be developed. QA/QC leads are responsible for developing this internal quality audit plan. The leaders of each discipline accompanied by QA/QC leads shall audit technical aspects of the project activities. QA/QC leads are responsible for planning and coordination of these audits. The Internal Audit Plan should include the following points:
The specific activities and areas to be audited Date/time of the audit
Name of the auditors
Name of person responsible for the areas to be audited or their nominated
representatives. The audits shall cover but not limited to such aspects like: Receiving inspection
Control of inspection records
Calibration of measuring devices
Control of special processes
Project document control
ITP audit
NCR/RFI process
Project turnover documents
Statutory/regulatory requirements
Audit findings are recorded in Quality Audit Report Form (QA-FF-004 / FIS-000-GN-QA-004). Originals of all audit reports are kept on file for the duration of the project for turnover with project documentation. For each audit, a Quality Audit Summary Report (QA-FF-005 / FIS-000-QA-FF-005) will be prepared by QA/QC Leads and handed over to the Construction Manager, Sr. Project Manager and the QA/QC Manager.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 33 of 41
Any non-conformance resulting from these audits is to be answered within reasonable time to the Sr. Project Manager and divisional QA/QC Manager of Flint Infrastructure Services Ltd. describing corrective action planned and taken.
5.5 Control of Non-conformances
Non-conformance can exist both in processes and products like: errors in workmanship, errors in carrying out procedure, material deficiencies, unapproved practices, not in compliance with specified codes and/or standard. Non-conformance can be detected from different sources like internal/external quality audit, management review, inspection etc. All non-conformances shall be managed as per Client (SNRS-01-99-CT-FP-00001-1, 15.3, 9, 28, 15.4, 10) A Non-conformance Report (NCR), form FIS-000-QC-FF-001 shall be used to treat any deviations in construction quality with respect to project requirements, drawings, and codes. Construction Activities The Construction Manager is responsible to communicate the non-conformance to the person responsible for the particular construction activity and complete the NCR providing disposition and the date of completion. Flint submits NCR with proposed disposition to Client QA for review and approval. As soon as the NCR disposition is received by Flint, this NCR is distributed to the responsible party/Supervisor, Construction & Project Management for action. The Construction Manager or the designate will proceed to coordinate the necessary activities for correcting the non-conformance. After the disposition is completed the Construction Manager will inform QA/QC Leads to verify the disposition The QA/QC Leads will coordinate with QC inspectors for verification. Upon verification, the QC Inspector(s) will sign off the NCR accepting or rejecting the disposition and will forward it to the QA/QC Leads. NCR is then returned to Client QA for close out. QA/QC Leads shall analyze the recurrence trends for similar non-conformance with the purpose of determining corrective action. QA/QC group shall maintain a NCR Log Index with the following content: NCR number
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 34 of 41
Activity or process where nonconformance was detected Area or discipline Description of nonconformance Serial number Warehouse If the products (consumables, materials, equipments and components etc.) received in the warehouse do not comply with the receiving inspection criteria, the receiving inspection Inspector will issue a Quality Surveillance Report (QSR) and forward it to the QA/QC Leads along with the receiving inspection report. The QA/QC Leads will review the QSR and issue it to the client QA for disposition this may involve the client issuing their own NCR in the case of client supplied materials or in the case of Flint procured we may go straight to the NCR process. The QC Inspector will follow up the Implementation of the corrective action. Once the problem is solved, The Inspector will complete the NCR and forward it to the Client for disposition verification and close out.
5.6 Material Management Material Management (This needs a complete
rewrite and we should get Toyo’s procurement procedures to feed into this)
All project materials, components and equipments shall be received, handled, stored and issued in a controlled and professional manner as per Client Procedure SNRS-01-99-M-SP-00030-1 and FISL document “Material Management Process” (FIS-000-GN-PC-004).
5.6.1 Inspection in Reception
It is the understanding that all the equipment supplied by Client has undergone all necessary tests at the Vender’s facility and that Client has checked all the certificates of tests at the time of release. The Receiving Inspector shall limit only to check the certificates of tests done on the equipment and not proceed to perform the tests. If certificates of tests or any other document is missing, a QSR, form QC-FF-003 shall be issued to Client and the equipment will be quarantined.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 35 of 41
Non Tagged Items: The materials group shall inspect all incoming material for visual damage prior to off-loading. Discrepancies and or damage will be noted on the freight bill and signed by the receiving person and the carrier’s representative. A Material Receiving Report (MRR), form MM-FF-001, will be generated and all discrepancies will be noted on the Notice of Acceptance and custody Transfer form (00-080). Over Short & Damage Report (OS&D) to be completed and submitted to CLIENT/ Site Material Lead within one day of receiving the material. In case of any non-conformance, the QC Inspector will be informed and a QSR (QC-FF-003) shall be initiated. Tagged Items: Material group to notify QA/QC Lead on the receiving date for each Tagged item in advance. QA/QC shall inspect each Tagged item for visual damage prior to unloading. Any damages must be noted as exceptions in the Transfer of Care and Custody form (00-080) and the freight bill. Flint will produce and forward a Material Receiving Report (MRR), MM-FF-001 to CLIENT/ Site Material Lead within one day of receiving the material. In case of any non-conformance, the QC Inspector will initiate a QSR (QC-FF-003) immediately. Flint Material Coordinator shall maintain a Material Receiving Report Log (MM-FF-004). In case of any missing documents, the Materials group will identify the material, equipment and/or component as “Under Observation” for release and segregate it in a designated area in the warehouse or in the field (in case of equipment) and expedited appropriately.
5.6.2 Storage All the materials, equipment and/or components are procured by Client. For equipment storage and preservation follow Client Procedure (SNRS-01-99-M-SP-OOO30-1). The implementation of this program is required from receipt of equipment, for both short term (less than 3 months) and long term (more than 3 months) durations. Preservation is of special importance when equipment is idle for more than three months in a humid or dusty climate and when manufacturer preservation requirements are necessary to preserve warranties. Check that out side storage has a free draining area, pallets, cribbing, waterproof covering with ventilation to retard moisture accumulation, dust protection, stockpiling to avoid damage, ventilated area, temporary supports and space heaters. Check that the warehouse, for inside storage, is well ventilated and warm dry. FISL Preservation Inspectors shall ensure all the preservation requirements are followed as per the Client Procedures in the Specification and provide documentation per Attachment A: Machinery Receiving and Inspection Checklist and Attachment B: Preservation Inspection Activities. In addition any required rust preventatives should be as per Attachment C: Recommended Commercial Rust Preventatives Page.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 36 of 41
.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 37 of 41
5.7 Inspection, Inspection and Test Plans (ITP)
The ITP template shall be based on Client Quality Management – Sample Form Typical Inspection and Test Plan Format and be used to develop ITP’s as per Client Procedure (SNRS-01-99-CT-FP-00001-1, 15.6.2, 1, B, V). Inspection and Test Plans (ITP) shall be developed for each CWP Scope of work and submitted to Client for approval. These plans demonstrate a planned and systematic series of controlled inspections throughout the course of construction. Once approved, the plans will be made available to QC Inspectors, Discipline Supervisors for implementation. Upon commencement of work the ITP shall be made available at site to be continuously used (throughout the progress of work) by those responsible for construction. QA/QC Leads shall coordinate with QC Inspectors, the performance of progressive inspections (surveillance inspection) as well as final inspections. All the inspections shall be performed using Inspection and Test Plans (ITP) which identifies the acceptance criteria. Originals of surveillance reports shall be signed by the QC Inspectors and endorsed by the QA/QC Leads after verification of documents. The QA/QC Leads shall forward a copy of this report to the Discipline Supervisor and to Client Quality Group / Discipline Field Engineer for review. In case of any non-conformance, a NCR shall be generated. Corrective and/or preventive actions shall be taken as per Corrective and Preventive Action procedure included in this plan. FISL QC inspectors shall perform final inspection prior to notifying Client of Construction completion. All the deficiencies shall be corrected following NCR and Corrective/Preventive Action procedures. Upon notification of Construction completion, Client Quality / Engineering shall conduct final walk-down of systems/subsystems. On an on going basis each activity as referenced in the ITP will be signed off by FISL and Client Representatives and filed in the respective CWP binders in QC office. Each FISL Discipline Leader shall issue a 24 Hr Notice to Client Quality Group Discipline Field Engineer of all referenced activities classified as “Witness” (W) or “Hold” (H) and obtain signatures accordingly. All ITPs are signed off and submitted to Client Turnover Coordinator for each subsystem (Copies) by FISL Site Turnover Coordinator. The Turnover Coordinator shall maintain all the original signed off ITP’s during the project life cycle.
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 38 of 41
5.7.1 New Inspection & Test Plans
It is possible that due to changing work requirements, new Inspection & Test Plans are prepared. These plans will be re-submitted to Client for approval. When approved by Client, QA/QC Leads, Project Manager and Construction Manager are responsible for implementing such plans.
5.8 Training
FISL Project, Construction, QA/QC, Health, Safety & Environmental and HR Management have taken all the necessary steps to ensure that the project team members and construction personnel are competent based on experience, qualification and training to perform their jobs effectively and efficiently during recruitment process. All the training needs of personnel are managed as per FISL Recruitment and Training Process (FIS-000-GN-PC-001), and Site Orientation Work Instruction (FIS-000-HR-WI-001). Site Orientation Work Instruction focuses on training related to the following areas of construction quality: Requirements specific to site Procedures Specifications Understanding of construction quality plan, inspection and test plans, standard work
instructions etc. Material, equipment and/or components storage, handling, preservation Storage of materials off the ground Control of non-conforming products Control and care of welding consumables
5.9 Change Management
Changes are inevitable in a project. Change management is all about identifying, evaluating, authorizing, documenting, implementing and controlling changes. We shall implement the following procedure to manage any change in the project:
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 39 of 41
A Change Request Form (FIS-000-GN-FF-007 can’t find in FISL forms ) shall be issued for any change proposed and forwarded to the Discipline Specific Field Specialist. The Field Specialist, upon receipt of the change request form shall note the proposed change in the Change Request Log (PM-FF-007) and forward it to the Project Manager. The Change Log shall contain: FCR Number
Description of the change
Originator
Issue date
Impact assessment by (not on form above)
Approval by (not on form above)
Approved: Yes/No (not on form above)
Date approved (not on form above)
Date authorized (not on form above)
Comments
The Project Manager with the support of the project team and the construction team shall assess the impact of the change on the project and any interdependent project. If within the Project Manager’s authority, the change proposal shall be accepted or rejected. If it is outside the Project Manager’s authority, the decision shall be referred (with a recommendation) to the appropriate level for a review and decision. The change proposal may be: Accepted for immediate implementation
Accepted, subject to certain conditions being met
Accepted, but implementation is deferred to a later date
Rejected
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 40 of 41
Once the decision has been made, the Project Manager may need to obtain further financial authorization if necessary. All the outcomes of process shall be recorded in the Change Log If accepted: Change should be implemented.
Project documentation should be updated.
Concerned parties shall be informed about the change.
The originator of the change request shall be informed of the outcome and if the change is rejected, reasons for the decision should be given. Under the scope of change management, we shall implement already adopted forms like Request for Information (RFI), Field Change Notice (FCN), and Field Change Request (FCR) as well as the Point & Do process. In all these circumstances, the Project Manager shall assess the impact of change.
5.9.1 Field Change Notice (FCN)
If any work or service requires special instructions, a field change notice will be received from Client. (Contractor to provide Document per Sch F, 2.12? no forms found in FISL files) FISL Document Control will maintain a running Filed Change log (PM-FF-007) to indicate status and progress. All FCN shall be copied to Cost Control. The approved FCN shall exhibit the subsystem number and noted on each affected document. FISL Construction Discipline Supervisor shall upon completion of the work sign and date the FCN, return the original to FISL Document Control who will then issue to Client Quality Group Discipline Supervisor. FISL Document Control shall maintain a log indicating: Flint or Flint Sub-Contractor’s name (Originator)
FCN number;
Brief description
Tag number
Subsystem number
BUSINESS UNIT:
Flint Infrastructure Services Limited
TITLE:
Construction Quality Plan
DOCUMENT ID:
FIS-330820001-PM-QP- ???
OWNER:
Senior Project Manager
EFFECTIVE AS OF:
May 17, 2010
REVISION:
001
Page 41 of 41
Date of issue/closure
The FCN will not be closed out until FISL Project Controls Group assigns a cost to the FCN.
