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QA / QC

IN OIL & GAS projects


ENJEUX & OUTILS
ORIGIN OF NON QUALITY
ORGANISATION
LOGISTICS
PROCUREMENT
BREAKDOWN RATE
DEFAULTS
PLANNING

OPERATOR
POOR ATTENTION
LACK OF TRAINING

70 80 % 20 30 %
Quality Basis

EQUIPEMENTS
OPERATORS
CONTROL
by paying attention to
their qualifications
by a periodic and
systematic approch
by looking to their
performances

QA/QC WHY ?

The objective of implementing a quality assurance approach
for work done by suppliers / contractors / vendors is to:
ensure that the equipment or service supplied complies with
specification or contract requirements.
reinforce the Contractor's awareness to his responsibility for
the work
minimise Company's involvement and hence Company's
costs
minimise delays to schedule caused by the use of excessive
Hold points
produce evidence of compliance (the 'audit trail') and
measure Contractor/Supplier performance.

Purpose

The purpose of this procedure is to
specify the Company's minimum
requirements for Quality
Assurance/Quality control during
design, procurement and
construction phase of HelM
facilities.

Scope

This procedure presents the Sarost's minimum
requirements for QA/QC in all Contracts and
Purchase Orders with their nominated Suppliers
(Consultants, Contractors and Vendors).


The requirements are based on the use of the I SO
9000 Series of Quality Management and Quality
Assurance Standards.

Scope

This procedure forms a part of the Contract or
Purchase Orders.
Contract Quality Plan and Quality Control Plan
Guidelines, offers Suppliers (Consultants,
Contractors and Vendors) guidelines on the
contents and development of a Contract Quality
Plan and Quality Control Plan that will meet the
requirements of this procedure.

A system or equipment item will be critical if it
safeguards the integrity of the facility or impacts
upon its ability to meet performance objectives.

An activity can be critical by reason of its
importance to the success of the project or through
risks associated with it.

QA/QC for Critical activities / Equipments

Quality Assurance of Design


List of all the types of deliverable produced by the design
contractor.


Identify which deliverables requires Sarost review /
approval to ensure the technical integrity of the design.

Design QA Plan

Project Engineer shall
prepare and approve
authorisation matrix
defining the required
technical authorisation
(TA) level for each type of
project documents for
review and approval.

The Design Deliverables Matrix
The matrix specifies the
discipline TA approval required
for each deliverable depending
on the criticality level.

A default criticality has been
assigned to each deliverables.

DELIVERABLE REVIEW LEVELS
Technical Autorisation Levels
Level 1 Corporate Functional Discipline Head. Sets the boundaries wherein the
discipline operates.

Level 2 Experienced Professional. Can handle himself without outside support in
almost all discipline situations.

Level 3 Engineer with specialised but yet incomplete skills in one or more areas of the
discipline.

Design QA Plan
The design contractor produces and verifies the deliverables according to
its own ISO 9001 approved QA system before issuing to the Sarost
engineer.

The deliverable(s) is then issued to the Sarost engineer who is responsible
for obtaining the correct level of review and approval in accordance with
the approved design QA plan.

Once the necessary approvals have been obtained the Sarost engineer
returns the deliverable(s) back to the design contractor.

Process flowchart for design deliverables is shown in Appendix 3.




Process flowchart for design deliverables
(Same as PQP)
Deliverable Criticality Rating



Quality System
The Supplier (Consultant, Contractor, Manufacturer and Vendor)
shall implement and use a Quality System that complies with the
appropriate Standard from the ISO 9000 Series, (latest edition), as
listed below, and the requirements of this procedure.
I SO 9001: Quality Systems - Model for quality assurance in
design development, production, installation and servicing.
or
I SO 9002 : Quality Systems - Model for quality assurance in
production, installation and servicing.
The Standard shall be selected to cover all work activities
(consultancy, project management, procurement, construction,
and provision of goods, products or services), associated with the
Contract or Purchase Order.

Where the Contract includes design work, ISO 9001 shall
be used.


Where the Contract is purely for production, construction,
installation, commissioning and hand over, then ISO 9002
shall be used.
Quality System

Elements of a Quality Management System

Processes
Data
Management
Methods
Responsibilities
Product Quality
Continuous
Improvement
Customer
Satisfaction
Resources
Organizational
Structure


The term Process Control in ISO 9000, shall be
considered to embrace all work activities from
Tendering and Contract Award to Completion of the
Contract.



Activities such as; Contract Management, Cost
Control, Planning and Scheduling, Progress
Measurement, Reporting, 'As Built' Documentation
etc. shall have properly documented Procedures or
Work Instructions.

Quality System

Quality System

Suppliers in selected Work Categories may be required
to attain Third Party Registration of their Quality
System.

Work Categories required to attain registration will be
informed by the project Manager.



Quality System
Where Suppliers are not required to attain Third
Party Registration, they shall demonstrate that
they have a Quality System that complies with
ISO 9001 or 9002, as appropriate for the contract
or purchase order scope.
Quality Management during
tender process
Documents to be Submitted

Quality system documentation
QA/QC
Procedure
Organisational Structure
Corporate
Organization
Contract Organization
Sub - Contractors organizations
QA/QC
Inspection &
Verification personnel
*Welding
*Coating
*NDE
*Structural
*Instrumentation
copies of their qualifications, including
any training courses attended.
Photocopies of qualifications must be
attested.
Subject to
Approval by
Company and
Sarost


Office
based
Site
based
Full or
part time ?


Mobilisation
Dates ?


defining and controlling
inspection, measuring
and test equipment
validating processes

product identification
and traceability at all
stages of production
controlling and defining
production and process

controlling
documentation
controlling purchasing

personnel training and
qualification
controlling the product
design
P D
C A
quality system shall embody for design, production and distribution

records;
servicing;


statistical techniques


labeling and packaging
controls;
handling, storage,
distribution and installation



product acceptance;
controlling nonconforming
product;
instituting corrective and
preventive action when
errors occur
P D
C A
quality system shall embody for design, production and distribution
copy of ISO 9001 or 9002
Certificate shall be submitted.
Copy of Quality System and
Compliance Audit Reports
prepared for previous Contracts.
Quality System Audit
Gap analysis vs Audit Report
shall be submitted
Documents to be Submitted
with the tender

If not available
Documents to be Submitted
Within 14 Days of Contract Award
Quality Policy statement.
Brief description of the Suppliers
company and the business activities.
Quality objectives and scope of the
Quality System.
Description of the Quality System documentation
Quality Manual, Quality Procedures, Work
Procedures, Work Instructions, Contract Quality
Plans etc ...and how it is controlled
Organisation Chart, highlighting the
Quality Assurance, Quality Control,
Inspection and Verification personnel.
Onsite Organisation Chart, showing the
relationship to the Corporate Organisation
Job Descriptions showing the
Responsibilities and Authority of all
personnel whose work has a quality
function.
Quality
Manual
Contract Quality Plan (CQP)
Corporate
quality
Manual
CQP
*Outline of how the Suppliers corporate
Quality System shall be applied and
implemented on the contract.

*Identify all main work activities and
sub-activities to be controlled by the PQP.
*Identify which activities will be carried out by
Sub-Contractors and how it will be monitored and
controlled by the Supplier.
DO
Check
&
Review
Plan
Control Quality Plan
3.Identify all work activities and sub-activities,
including those performed by Sub-Contractors, to
be controlled by the CQP.

4.Detailed methodology how quality system and
work performed by Sub-Contractor shall be
monitored and controlled by the Supplier.

5. Details of how Quality Planning shall be
undertaken and controlled.

Construction Checks






Method Statements

Check that Method Statements for initial
activities have been finalised and approved.

Check that Method Statements have been
included in the Project Document Control
procedures and issued in accordance with the
Distribution Matrix

Check that a schedule for development of
remaining Method Statements has been
prepared
























Materials Control
Has an MMS program been set up to
monitor the procurement of permanent
materials?

Is a trained MMS operator available?

Is the interface between the Drafting,
Procurement and MMS established to
ensure information flow is maintained?

Organise and participate in a six-monthly
stock-take, sign stock-take sheets, reconcile
perpetual inventory records value to
Balance Sheet value. Write offs (lost or
obsolescent stock) to be approved by
Division Manager.


























Welding Control
Welding Procedure Qualifications

*Check that the Welding Engineer or
Inspector is completing a Welding
Procedure Qualification (WPQ) form.
*Check that Welding Inspectors are
recording all welding parameters on a
Procedure Running Sheet (PRS) during
qualification of the WPQ.
*Check that the Welding Engineer is
reviewing and approving all WPSs from
Subcontractors and Vendors prior to
commencement of fabrication.
*Check that Inspection and Testing
requirements for Subcontractor and Vendor
welding is being included in their
Inspections and Test Plans


























Pressure Testing
Check that the Project Manager has appointed a Pressure Testing
Coordinator & that the Test Coordinator has prepared a Test Pack for
each test and has marked the limits of each test on the P&IDs

Check that the Test Packs are being numbered in accordance with
the procedure and registered with Document Control & that Test
Packs initially issued for use are set at Revision 0

Check that the Test Coordinator has established a Pressure Test
Register to track testing progress and that this is being maintained up
to date

Check that required Pressure Testing equipment has been obtained
and calibrated (see Plant & Equipment Checklist also) & that
Pressure Testing records reference testing equipment by description,
model and serial number to ensure traceability of the test to the
equipment used
























Fabrication
Check that the Fabrication Supervisor is reviewing Fabrication
Requests, endorsing and returning a signed copy to the Project
Engineer

Check that Fabrication measuring and testing equipment has been
obtained and calibrated (see Plant & Equipment Checklist also)

Check that the Fabrication Supervisor is marking Fabrication
Drawings as Master, as per the procedure

Check that the Welding and Materials Traceability Records are being
used to enable Traceability of Fabrication and materials

Check that the Welding Engineer is reviewing and approving all
WPSpecifications s from Subcontractors and Vendors prior to
commencement of fabrication.
Check that Welders are only working on Materials marked with
Green Inspection Status Identification & that items are being
sprayed with Yellow paint or tagged with Yellow ribbon when
Welding has been inspected and passed as Visually Acceptable












Construction Checks

Quality Control Plan (Test and Inspection Plan) - Typical Format
Quality Control Plan - Typical Example for Hydro Testing

Service Contract Work Orders


Indicate how the Contract Quality Plan and
specific Quality Assurance requirements
will be applied to individual Work Orders
issued under a Service Contract. This may
be in the form of a Project Quality Plan,
developed from the Contract Quality Plan.

Service Contract Extra Work Orders

Contract Quality Plan
Specific Quality Assurance
requirements
Service Contract
SOW
Extra-Work Orders
Subject to
Company & Sarosts
Approval before work
starts
DO
Check
&
Review
Plan
DO
Check
&
Review
Plan
Corporate Quality System Procedures
.Corporate Work Procedures and Work Instructions.

Contract Specific Procedures and Work Instructions.
List of procedures and work instructions that shall
be used on the Contract by Sub-Contractor(s) for
assigned work activities.
Applicable Procedures, Work Instruction &
Checklists

QUALITY CONTROL
What is Quality Control ?

Quality Control is a process to measure and
analyze project results from specific
operational activities using specialized
operational monitoring and verification tools
and techniques to determine if the results in
compliance to established quality standards
or requirement.

This process shall also include identification
and elimination of nonconforming products
and identifying ways to eliminate the causes
of non-conformances.

The quality control activities shall include the
following:

Conduct general surveillance on
engineering deliverables
Conduct required inspection at
SUPPLIERs manufacturing/fabrication
facilities

Lead specific data analysis works for
quality improvement
Conduct third party inspection verification
Conduct general surveillance on
construction and commissioning activities
Witness and approve Welding Procedure /
Welder qualification
Witness and approve validation other
special construction and commissioning work
processes
Monitor construction process traceability
Monitor punch list program
Conduct verification on mechanical
completion and commissioning
completion readiness
Lead specific data analysis works for
quality improvement
Final Documentation
Quality Control Plan shall include
*Specified Acceptance / Rejection Criteria

*List of Activities and Sub-Activities requiring
Quality Control and or stage inspection.


*Hold, Witness, Surveillance, Monitoring and
Review points
*When Third Party Inspection (TPI) is a Contract
requirement, the QCP(s) and Quality document(s)
shall also be reviewed and endorsed by the
nominated TPI Agency.
*Sub-Contractor(s) QCP(s) and quality document(s)
shall be reviewed and endorsed by Contractor, before
submitting for Company approval.
*Inspection &Test Plans
QC Inspectors (Location Site Office)
The QC inspector shall operate independent of the personnel performing
the work and report to the QA/QC Engineer for the Contract. He shall be
responsible for:
Surveillance of all specified construction activities as per inspection
plan, specifications and codes.
Witnessing all checks/ tests, as per ITP and interpretation of results.
Reporting of non-conformance to QA/QC Engineer.
Preparation of inspection reports and compilation of test packs.
2.7 Qualifications and Duties of The Suppliers Quality
Assurance,
Inspection (Quality Control) and Verification Personnel.
2.7.1 Corporate Quality Assurance Manager
2.7.2 Quality Assurance Engineer
2.7.3 Quality Control Inspector - Multi-Discipline
(Welding, Painting, NDE)
2.7.4 QC Inspectors - Civil and Structural
2.7.5 Q C Inspectors Instrumentation

2.8 Quality Assurance Auditing
2.9 Purchasing
2.10 Inspection, Measuring and Test Equipment
2.11 Third Party Certification

2.12 Pressure Vessels
2.12.1 Vessels Manufactured Outside Tunisia
2.12.2 Vessels Manufactured in Tunisia
2.13 Static Equipment
2.14 Quality System Certification
2.15 Legal Authorizations


Acceptance / Rejection Criteria
The following Statistical Indicators are controlled:

- Improvement Indicator:

I (ii) = Non Conformities closed at Target date > 1
Non Conformities that should have been closed at Target date

- Percentage of welding repair

I (wr) = (Measured in Inches) repaired welds < 0.3 %
(Total inches) welds

- Percentage of steel rework

I (cr) = (Measured in Kg) reworked/defected steel < 0.1 %
(Total in Kg) installed steel structure


Quality Records

Verifying
Documents that
shall be issued
to Sarsot as
Quality Records
shall be
identified and
given a
reference
number.
Records to be
kept for use by
the Supplier
only
Records to be
reviewed by
Sarost during
the Contract
Define the
content and
format of Test
Packs, per
discipline that
shall be agreed
with Sarosts
Representative
in advance.
Records to be
handed to Sarost
Records
requiring
Approval / Hold
& Witness by
Sarost
Internal Audit Schedule
preliminary
External Audit
Schedule of Sub-
Contractors.
preliminary
Internal
Audit
Schedule
Audit Team
Members
Audit Schedule
INTERNAL AUDITS
Internal Audits the Supplier will conduct on the Quality System throughout the Contract.
Supplier shall provide a copy of their internal and external audit notification to Sarost at least
five working days in advance of the planned audit date.
Company reserves the right to join the audit as an observer.
A Compliance Audit shall be carried out at least once per month on all work activities that have
recently commenced.
EXTERNAL AUDITS

External Audits the Supplier will carry out on Sub-Contractors and Vendors.

External audits shall be carried out by a third party certification Authority.
PROCEDURE

Include a detailed Audit Schedule for the Contract.
Supplier shall provide Sarost copies of all internal and external audit reports
along with audit check list used during audits.
Third Party Certification


Where Third Party Certification is required
in the Scope of Work, include details of the
Third Party Certification Authority.Include
details of the services they will provide to
the Supplier, in the form of a draft Sub-
Contractors Quality Plan.Provide details of
the personnel they will employ on the
Contract.

Third Party Certification

Internal audit
cycle
External
Audit
cycle
Third
party
audit cycle
*Monitoring, surveillance, inspection, witnessing
and acceptance testing to be carried out by
the Third Party Certification Authority.

*Include Curriculum Vitae of all personnel for
approval by Sarost.





GENERAL QUALITY ASSURANCE PROVISIONS
Scope
Applicable Documents
Order of Precedence
Contractor Requirements
Inspection Provisions
In-Process Control
Quality Conformance Inspection
Nonconforming Material
Manufacturing Processes
Inspection Records
Certifications
Identification and Traceability
Protective Finishes and Coatings
Latent Material Defect
Inspection Methods
Inspection and Test Equipment
Test Methods
Corrosion Prevention and Control
Screw Threads
GENERAL QUALITY ASSURANCE PROVISIONS

Welding Torque
Fit Testing of Covers and Cases
Soldering & Brazing
Electrical Tests for Electrical / Electronic Assemblies
Tensile Test
Charpy Impact Test
Macro-Etch Examination
Hardness Test
Case Hardness Depth
Staking
Riveting
Packaging Inspection
Marking Inspection
Nondestructive Testing
Magnetic Particle Inspection
Radiographic Sample Plan
First Article Requirements
Special Process Procedure



Quality Management during the Contract
Details of any investigations into non-conformance and action to prevent recurrence of any Quality System failures.
Summary of Tests and Inspections carried out on site and off site and on Sub-Contractors.
Summary of Procedure development and approvals.
handover from construction to commissioning approach
Weekly report showing the % of completion split by system
Areas of concern or weakness identified in the Quality System :
Glass transition temperature of the joints is not checked
Sample selection criteria and acceptance criteria are not established.
Pre-qualified pressure not provided and unable to confirm whether it is considered while calculating the Hydrostatic
pressure testing
Document control procedure (drawing register)
Material certificate from vendors and retrievability from isometric number
Modifications and repairs , MSDS
Clibration certificate of pressure gauge and its accuracy ( accaptance criteria of ISO 14692-2 SECTION 8.2)
Job description communicated
Stress analysis
Procedure for the control of the records
Timeline plan of close- out actions
Quality Management during the Contract
Details of any investigations into non-conformance and action to prevent recurrence of any
Quality System failures.

Summary of Tests and Inspections carried out on site and off site and on Sub-Contractors.
Number of Complaints raised during the preceding period and the cumulative total, action
taken to address complaints and close out.

Number and nature of variance raised, cumulative numbers, approval status, implementation
and documentation of the variance.

Supplier NCRs raised, corrective and preventive action and close out.

Welder performance and repair rates based on radiography.

Work performance and repair rates based on control reports.

Status of deployment of QA and QC resources and their Company approval status.

Quality Assurance, Inspection
(Quality Control) and Verification Personnel

Notes:
The above numbers exclude any personnel employed either by the Supplier or Company
from a Third Party Certification Authority.

Numbers specified in the above Table do not include Corporate QA Personnel.
Qualifications and Duties of the Suppliers Quality
Assurance, Inspection (Quality Control) and
Verification Personnel

Supplier's all QA, Inspection (Quality
Control) and Verification personnel shall be
subject to Company approval prior to
mobilisation on Contract and to site.
The duties of the Quality Assurance,
Inspection and Verification personnel shall
include, but not be limited to the following
activities:

Corporate Quality Assurance Manager

Note:
For Design Consultancy contracts, the candidate shall have appropriate technical qualifications
on above lines and possess same number of years of relevant experience as per serial 3 above in
the design organisation involved in oil and gas offshore facility design.
QUALITY & RISK
QUALITE

Impose une dmarche globale
Regroupe autour des
CINQ ZERO OLYMPIQUES




Le ZERO DEFAUT
Le ZERO DELAI
Le ZERO STOCK
Le ZERO PAPIER
Le ZERO PANNE
La Rgle 20 / 80
milestones
Retards de plus de 15 jours
80 %
20 %
EXERCICE
LISTER LES 20 % des MILESTONES
QUI SELON VOUZ SONT A
LORIGINE DES 80% Des RETARDS
SUR LE PLANNING.

QUALITY

60
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LE MORAL
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Good
ONE in THREE CHANCES to SUCCEED !!!
Source : PMI
RISK MANAGEMENT STANDARD
It is assumed that the reader is fully acquainted with the
contents of the Risk Management Principles that support
the Standard. The start of Risk Management for a project
should be done in conjunction with the production of the
Project Statement as part of the Definition Phase of the
Systems Development Life Cycle (SDLC). Project risks
should be recorded in the Risks, Assumptions and
Constraints paragraph of the Project Statement.
There are two stages in the process of Project Risk
Management. They are:
Risk Assessment; and
Risk Control.


RISK ASSESSMENT

There are three steps to be performed in the completion of
Risk Assessment.
1. Identify Review all the project plans and identify areas
of uncertainty 2. Analyze Define how the identified areas
of uncertainty could affect the performance and success of
the project in terms of scope, quality, duration and cost.
3. Prioritize Prioritize each risk to determine the amount
of action or effort required.



RISK ASSESSMENT
The proposed Ship Recycle Plan adopts the
following processes across the various recycle
stages:

Identify Assess Mitigate Manage




Analyze
Risk Analysis is performed by categorizing all the identified risks according to
the likelihood of their occurrence and the impact that they will have on the
project. Use the matrix below to assist in the Risk Analysis. This will also
assist with the Prioritization of the Risks.
Analyze
LI KELOOD OF OCCURENCE
The High or Low likelihood of a risk occurring is to be determined by the
Vendor Project Manager and appropriate project team members and rated
accordingly. Record this determination and provide a comment describing the
rating Likelihood of Occurrence.

PROJ ECT I MPACT
Rate each risk High or Low according to the impact that it will have on the
project. Record the overall Impact Rating and provide a comment to
further describe this rating to the project. Also record (as appropriate)
additional Impact Rating comments in terms of scope, quality, time and/or
budget.
Update the Risk Definition Form with the appropriate ratings and comment(s)
relating to the Analysis performed

Prioritize
Each risk must be Prioritized for action by
the project team as follows:


RISK CONTROL
CONCEPT DEVELOPMENT SELECTION
CONCEPT DEVELOPMENT SELECTION
Assessing the risks three categories

Management Check-list
Environmental Risks
Sub Sea bad surprises !!
Main actors in oil drilling and
shipping processes

Procurement
Procurement Strategies Development and
Implementation
Call for Tenders launch and follow-up
Bid evaluation
Negotiation of contracts
Expediting
Contract Management
Contractual Strategy Definition and
Implementation
Claims preparation (EOT, Variations and
Disruption)
Subcontract Administration
Quantity Surveying
Subcontracts Close-out
Cost Control
Identification, Recording, Tracking and
Allocation of all expenses according to Cost
Breakdown Structure (CBS)
Cost Control Procedures Implementation
Budget Preparation and Follow-up
Cash Flow Forecasting
Change Orders Management

Planning

Breakdown Structures set-up (WBS, OBS,
RBS and CBS)
Resource Management
Scheduling (CPM, PERT,...)
Physical progress follow-up
Shutdown Planning
Reporting
Cost Estimating
Analogous Cost Estimating (Top-Down)
Parametric modeling (Capacity-Factored,
Equipment-Factored,...)
Detailled Cost Estimating (Bottom-up)
Capitalization
Quality Management
Project Quality Plan set-up
Quality Assurance
Quality Control
Inspection
Document Control
Establish and Maintain Document Control
procedures
Risk Mangement
Risk Management Plan set-up
Risk Identification, Assesment and
Mitigation