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Construction Quality Management System Booklet

For
Cross Country Pipeline Project

Job Number
4003/4004

Document No
2

Revision Number
G

RELIANCE
ENGINEERING ASSOCIATES (P) LIMITED

AA

Date

23/07/02

Prepared By

S.N.
Samaddar

Department/Division

Quality Management

Reviewed
By

Location:

Jamnagar

Approved
By

Hard copy of this procedure shall be treated as uncontrolled if not signed by approver

Total pages - 10

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED

CONTENTS
1.

INTRODUCTION

2.

PURPOSE

3.

SCOPE

4.

REFERENCE DOCUMENT

5.

ABBREVIATIONS & DEFINITIONS

6.

APPROACH
6.1

CONCEPT

6.2

ORGANIZATION STRUCTURE, RESPONSIBILITY AND AUTHORITY FOR


QUALITY MANAGEMENT

6.3
6.4
6.5

MDR FLOW CHART


FOR FLOW CHART
SER FLOW CHART

7. ANNEXURES
I.

INSPECTION AND TEST PLANS

II.

REPORTING FORMATS

Construction Quality Management System for CCPL


Doc. No.:2QM00QMSGE002, Date 23/07/02

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Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED

1. INTRODUCTION
Work for cross-country pipeline has to start in the following routes.
a) Jamnagar Bhopal Pipeline via. Ahmedabad and Indore
b) Goa-Hydrabad Pipeline via Kolhapur and Sholapur
The project is expected to move at war footing with all challenges to achieve world record in
Quality and progress. Quality Management System therefore has been designed in a manner
that following objectives are achieved.
To ensure that only job with no non-conformities are accepted and allowed for precommissioning.
To control rework by defined management system approach thus directly contributing to the
progress.

2. PURPOSE
Purpose of this document is to provide Quality Management approach for this project with detailed
responsibility and authority at each level of Management including the concerned discipline
engineers, which are responsible for carrying out the quality control/ inspection activities at site.

3. SCOPE
The scope of Quality Management approach as covered in this document is limited to construction
phase of Cross Country Pipeline activities including the pump station activities. This document will
be submitted to President (REAL) for his approval and the same shall be applicable for all
construction work of the project after his approval.

4. REFERENCE DOCUMENTS
10000QAMGE001 Apex Quality Manual REAL

5. ABBREVIATIONS & DEFINITIONS


FOR

Field observation report

HO

Head Office

HOD

Head of Department.

ITP

Inspection and Test Plan

Construction Quality Management System for CCPL


Doc. No.:2QM00QMSGE002, Date 23/07/02

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Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED


MDR

Material discrepancy Report

NCR

Nonconformance Report

QMD

Quality Management Department

RO

Retail Outlets

SER

Site Engineering Request

WPS

Welding Procedure Specification

6. APPROACH
6.1

CONCEPT
The approach for managing construction quality is through quality control/ inspection and
improvement mode and covers mainly,
i.
ii.

Verification of Incoming Material


Verification of Construction activities in process

iii.
iv.

Final Inspection
System Dossier

v.

Monitoring and measurement of quality through Audit during all above phases of
construction.
Improvement based on the various findings.

vi.

The Panoramic view of approach for managing quality of above activities is given in the
following matrix.

Construction Quality Management System for CCPL


Doc. No.:2QM00QMSGE002, Date 23/07/02

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Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED


PANORAMIC VIEW OF MANAGING CONSTRUCTION QUALITY
SL
No

Stages

Scope of work

Inspection of incoming
Material (Free issue items)
1.

Incoming Material

Methodology
At REAL
Ware House

By review of material test certificates and verification of material.


(Contractor shall verify the material for its correctness before accepting from
stores.)

At Site

Random verification of material received shall be carried out.

Responsibility
Performer
Approval by
Ware House
Supervisor
Discipline
Engineer

State
Construction
manager

Site Discipline
Engineer

Spread Control
manager

Site Discipline
Engineer

Spread Control
manager

Site Discipline
Engineer

Spread Control
manager

Field QMD
Engineers

Spread QMD lead

Site Discipline
Engineer

Spread Control
manager

Site Discipline
Engineer

Spread Control
manager

Spread QMD lead

Overall
Coordinator
(QMD)/ Overallin-charge QMD

Inspection of Material
Supplied by Construction
Contractor

Site Inspection other than


Welding, NDT and
Testing

2.
Construction in process

3.

Welding, NDT and


Pressure Testing

4.

Final Inspection

Site Inspection
(Quality Records
compilation, Review and
approval)

5.

System dossiers

Final Documentation

REAL discipline engineer shall review test certificates (TC) and correlate the
TCs with mill identification marks on the material prior to its acceptance.
At site
Wherever discrepancy was noticed during identification, REAL discipline
engineer shall raise MDR. Use the MDR flow chart given in Clause 6.3 of
this document for resolve the issue.
Verify the receipt of Statutory approvals & ensure that copy is available with contractor sitein-charge. Ensure specified conditions are complied with.
Stage Inspection will be carried out and quality reports are to be prepared as per approved
Inspection and test plan.
Wherever discrepancy was noticed FOR / SER (as applicable) will be raised and resolution is
obtained as per flow charts given in this document.
Stage Inspection will be carried out and quality reports are to be prepared as per approved
Inspection and test plan.
Wherever discrepancy was noticed FOR / SER (as applicable) will be raised and resolution is
obtained as per flow charts given in this document.
All relevant Quality records will be prepared as per the requirement of the approved ITP for
the activity. Formats for construction quality activities are planned in clause 6.6 of this
document.
All approved Quality records will be compiled based on ITP relevant to activity and
discipline. (Integration by Horizontal / discipline basis)
All quality records compiled based on discipline will further compiled into system Dossier per
Spread. (Integration by Vertical / all disciplines involved)

Monitoring the job quality and overall compilation of inspection records by regular

6.

Internal Audit During


all above phases of
construction

Overall Monitoring by
Audit/ Surveillance

Construction Quality Management System for CCPL


Doc No.-2QM00QMSGE002, Date 23/07/02

surveillance visit.
Following up for the corrective actions of the audit findings.
Compiling overall re-work status and reporting to Spread Construction Manager and Overall
Coordinator QMD.
Planing over all audits and conducting as per the schedule. (Frequency of audit once in 30
days)
Reporting the overall status of quality and audit findings for the project.

Page 5 of 10

Overall
Coordinator
QMD

Overall in-charge
QMD

Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED


Sr.
No.

Stages

Scope of Work

7.

Improvement in the
working system

Corrective and preventive


action against the
observations.

Construction Quality Management System for CCPL


Doc. No.-2QM00QMSGE002, Date :23/07/02

Methodology
Analysis of data from FOR, NCR, CAR
Defining the responsibility for corrective and preventive action

Page 6 of 10

Performer

Approved by

Spread Control
manager

Construction In
Charge

Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED


6.2

ORGANIZATION STRUCTURE, RESPONSIBILITY & AUTHORITY


Controlling the quality of jobs being executed at site, is the responsibility of all concerned discipline engineers. (Responsibility Matrix of
discipline engineers in respect to job quality) and the functional responsibility of monitoring the approach of managing construction quality shall
be as per the following Organization structure of QMD.
Responsibilities
Conceptualizing of Quality Management System and

Overall In-charge
Quality Management

Overall In-charge
Cross Country
Pipeline Project

translating it into working system

Providing necessary training to all executives


Planing over all audit schedule, conducting with audit
team. (Frequency of audit once in 45 days)
Reporting the overall status of quality and audit
findings for the project.

Spread
Construction
Managers

Overall
Coordinator - QM

Monitoring of site by regular surveillance visit and


reporting to State chief.

Monitoring overall compilation of inspection records.


Following up for the corrective actions of the audit
findings.
Reporting to overall coordinator for the status of
corrective action.
Compiling overall re-work status.

Inspection and testing as per Inspection and test plan.


Preparation and compilation of inspection records.
Reporting re-work.
Taking corrective and preventive actions for the audit
observations.
Reviewing/forwarding contractors procedures and
Quality Plans.
Monitoring manpower suitability provided by
contractors.
Ensuring availability of latest drawings and
specifications.

Construction Quality Management System for CCPL


Doc. No.: 2QM00QMSGE002, Date 23/07/02

Spread Lead - QM
1- Each Spread

Field QMD Engineers

Site Discipline
Engineers

(Welding, NDT, Testing)

Other Activities
Functional
Administrative
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Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED


6.3

MATERIAL DISCREPANCY REPORT (MDR)


Whenever material discrepancy is noticed the following flow chart (for Material
Discrepancy Report) shall be used to resolve the issue

Need for MDR is identification


at Field and warehouse
Applicable document
(Specification,
procedures etc.

Project execution group

Area Discipline Engineer /


Warehouse supervisor raises

Filled MDR format

Numbering of MDR by the


warehouse supervisor.

Numbered MDR

MDR is then sent to State


Material Coordinator / Spread
Construction Manager .

Material Control
department

Review and resolution of MDR by


Spread level Material Coordinator /
Spread Construction Manager.

Spread Construction manager gives the


MDR to the originator for necessary
action and a copy to Spread QMD lead
and Material coordinator for
information.

No

Project execution group

Is the material
acceptable?

Copy of MDR with necessary


attachments is sent to
Procurement for necessary
action with rework data.

Yes
The material is used and the
originator closes the MDR

Construction Quality Management System for CCPL


Doc. No.-2QM00QMSGE002, Date 23/07/02

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Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED

6.4

FIELD OBSERVATION REPORT (FOR)


Whenever discrepancy is noticed during construction of Cross Country Pipeline execution
the following flow chart (for Field Observation Report) shall be used to resolve the issue

Need for FOR is identification at


Field
Applicable document
(Specification,
procedures etc.

Project execution group

Area Discipline Engineer raises


FOR

Numbering of FOR by the


discipline engineer.

Filled FOR format

Numbered FOR

FOR is then sent to Spread


Construction Manager .

Review and resolution of


FOR by Spread
Construction Manager

Not resolved

Send to Engineering
/ consultant for
resolution

Resolved

Spread Construction Manager forward


the FOR to the originator for necessary
action and a copy to Spread QMD lead
for information.

Originator to verify the


corrective action taken and
close the FOR

Construction Quality Management System for CCPL


Doc. No.-2QM00QMSGE002, Date 23/07/02

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Quality Management
Jamnagar

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED


6.5 SITE ENGINEERING REQUEST (SER)
Whenever any change or deviation is required for specified requirement during construction
of Cross Country Pipeline Project, the following flow chart (forSite Engineering Request )
shall be used to resolve the issue.

Identification of Information /
Request

Applicable documents
Specification,
procedures etc.

Area Discipline engineer raises SER


after consulting spread construction
manager.

Numbering of SER by Discipline


Engineer.

Filled SER format

Numbered SER

Project execution group


SER is then sent to
Engineering/consultant Manager
through Spread Construction Manager

Review of proposed resolution /


request / information required as per
SER by Engineering Manager /
Consultant

Engineering department
/Consultant

Engineering Manager / Consultant


provide necessary resolution and sends
the SER to spread Construction Manager

Spread Construction Manager gives the


SER to the originator for necessary action

Project execution group

Originator writes the rework qty,


if any, certified by SCM and hand
over the copy to Planning/QMD
for monitoring Rework

Construction Quality Management System for CCPL


Doc. No.-2QM00QMSGE002, Date :-23/07/02

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Quality Management
Jamnagar