ABSTRACT
QA/QC SERVICES IN EPC COMPANY EACH SEGMENT
HAS BEEN EVALUVATED AND DISCUSSED
Rajendran, Gobikumar
SAP NO:500127080
ASSIGNMENT-1
Evaluation of Product/Service Value Adding Process
INTRODUCTION
DESIGN AND DETAILED ENGINEERING
The EPC contractor can start detail engineering and design once all scope parameters—such as
equipment choice, schedule, location, and budget—have been determined and approved by all parties.
To determine and create the best design for project success, all departments and disciplines collaborate.
They ought to put out effort into creating a plan that balances affordability and effectiveness. Following
the design phase, a set of meticulous drawings are produced by the contractor's engineering team and
will be utilized in the construction process.
About EPC business is responsible for overseeing all project phases under a single contract, the EPC
technique frequently enables speedier project delivery. For this reason, a lot of project owners decide to
collaborate with EPC contractors while completing extremely time-sensitive projects. Because traditional
techniques like design-bid-build are no longer transactional, work can frequently be finished faster. From
front-end planning to construction, a single team may perform the work in a coherent manner, which
enables EPC contractors to overlap project stages and optimize the project's overall sequencing.
ABBREVIATION DESCRIPTION
BCM Booster Compression Module
CAT Category
CPF Central Processing Facility
CTR Cost Time Resource
EFAT Extended Factory Acceptance Test
EPC Engineering, Procurement, Construction
FAB Fabrication
FAT Factory Acceptance Test
FEED Front End Engineering Design
FS Functional Safety
HAZID Hazard Identification Studies
HSES Health, Safety, Environment, & Security
IC Interim Certificate
IRC Inspection Release Certificate
ITP Inspection and Test Plan
IVB Independent Verification Body
KPI Key Performance Indicator
MDR McDermott Australia Pty Ltd
MOC Management of Change
MRB Manufacturer Record Book
MRR Material Receipt Report
NCR Non-conformance Report
NDT Non-Destructive Testing
OFI Opportunity for Improvement
PIM Pre-Inspection Meeting
PIMS Punch List Management System
PMT Project Management Team
PO Purchase Order
POQR Purchase Order Quality Requirement
PPM Pre-Production Meeting
PQMP Project Quality Management Plan
PQMS Project Quality Management System
PROM Project Risk and Opportunity Management
QA/QC Quality Assurance/Quality Control
QHSES Quality, Health, Safety, Environment and Security
QMS Quality Management System
OOT Out of Tolerance
OS&D Overage, Shortage & Damage
RFQ Request for Quotation
SCM Supply Chain Management/Manager
TBE Technical Bid Evaluation
TPIA Third Party Inspection Agency
TQ Technical Query
TQD Technical Query and Deviations
VEM Vendor Equipment Manual
WVS Written Verification Scheme
ENGINEERING DELIVERABLES
Detail Engineering and Design Deliverables
Scope of Work
Project Schedule (Level 3)
Overall Constructability Review
Total Installed Cost (TIC) Estimate
Process Flow Diagrams (PFDs)
Process Drawing List
Process
Pressure Safety Valve (PSV) Study
Piping and Instrumentation Diagram (P&ID)
Plot Plan
Equipment Arrangement Plan
3D Model
Line List
Tie-In List
Piping Layout/Plans and Sections
Piping Stress Analysis
Equipment Trim Drawing
Specialty Item List
Mechanical/Piping
Related Piping Standards
Equipment Reference Drawings
Fabrication Isometrics with Bill of Materials (BOM)
Equipment Process Data Sheets
Equipment List
Certified Equipment Drawings
Equipment Calculations
Vendor Data Sheets
Equipment Installation Operating Manual (IOM)
Detail Engineering and Design Deliverables
Foundation Location Plan
Foundation Drawings
Structural Design and Analysis/Sketches
Building Plans and Elevation
Civil/Structural
Concrete Details
Steel Details
Calculation Package
Single-Line Diagrams (SLDs)
Instrument Index
Electrical Classification Plan
Instrumentation and Electrical
Controls Logic
Specification Sheets
QUALITY ASSURANCE AND QUALITY CONTROL
QA/QC is a key Addon service in EPC companies, Project Quality Management Plan details the Quality
Management System (QMS) requirements to be employed for the Engineering, Procurement and
Construction (EPC) including In-Yard Pre-Commissioning & Commissioning activities of the Project.
The purpose of this document is to provide the project team with requirements as to the responsibilities
and resources within the project organization of CONTRACTOR, to identify critical quality related
activities and to define controls required to ensure that the project quality objectives are met.
The EPC Project Quality Management Plan is a “live” document and as such will be subject to periodic
reviews / changes (min once a year) in line with identified and agreed amendments and improvements to
the Project Quality Management System during the project Where applicable, references are made to
CONTRACTORs internal procedures and relevant sections.
If there are any contradictions between this document and the Contract documents, the latter shall
prevail.
1) Engineering Management Plan
2) Information Management Plan
3) Project Subcontracts and Procurement Plan
4) Turbo Machinery Management Plan
5) Construction Management Plan
6) Risk & Opportunity Management Plan
7) Interface Management Plan
8) Engineering Document Deliverables Register
9) HSES Management Plan
10) EEHA Management Plan
11) Project Quality Audit Schedule
12) Project Controls Plan
13) Project ICAPS Management Procedure
14) Material Receipt Inspection Procedure
15) Functional Safety Management Plan
16) Construction Quality Management Plan
17) Project Set-up Procedure
18) Project Close-Out
19) Audit Procedure
20) Criticality Assessment for Procured Equipment and Materials
21) Management of Change
22) Global Source Inspection
23) Organization Chart
24) Management of Non-Conformance
CODES AND STANDRADS
Quality management systems – Fundamentals and Vocabulary - ISO 9000
Quality Management Systems ISO 9001
Petroleum, petrochemical and natural gas
industries – Sector -specific quality
management systems - Requirements for ISO/TS 29001
product and service supply organizations
Quality management systems – Guidelines for quality plans ISO 10005
Environmental management systems –Requirements with guidance for use ISO 14001
Occupational health and safety management systems – Requirements OHSAS 18001
QUALITY MANAGEMENT SYSTEM
STRUCTURE OF QUALITY MANAGEMENT SYSTEM
CONTRACTOR’s quality management system is fully certified to ISO 9001 and ISO/TS 29001 [App. C].
The Quality Management System (QMS) applies to all activities within CONTRACTOR’s Scope of Work
involving all related resources, Sub-contractors, Suppliers, and facilities employed on the Project. All
Subcontractors and Suppliers (and their sub suppliers) involved in the Project will use their own certified
Quality Management Systems as long as they meet the Contract’s provisions. The effective
implementation of these QMS’s will be measured and monitored through CONTRACTOR’s Quality
surveillance and audit process.
The Project Quality Manager is responsible for the preparation and maintenance of this PQMP. The
Project Manager is responsible for the authorization and its issue.
The QMS is organized in accordance with Figure QMS Hierarchy. The Contractor Management System
processes and documentation are consolidated and managed within “Unifi” as presented below:
How It’s Done – Is Contractor’s Global Operating Model that visualizes the philosophy of the way
we do business. It underpins how Contractor works, as an organization, and includes all phases
of a Project, regardless of size or complexity (Figure 4.1-2)
Unifi Governance – This include Management System Manual and well as outlines the process
for creating new processes or documents within the management system.
Project Execution and Delivery – Include all Contractor Regional and Global common
operational procedures for execution and delivery of projects.
Quality, Health, Safety, Environment and Security – Include all Regional and Global common
procedures and Guidelines for QHSES management.
Commercial; Legal, Compliance & Risk; Human Resources; Communications, Marketing &
Administration; Finance; and Information Technology - Include all Regional and Global common
procedures and Guidelines for functional processes management.
Management of Change – MOC process is intended to ensure that hazards and risk created by
change are identified, properly assessed, understood and that the controls and governance are in
place to mitigate them at any stage of the work.
QMS Hierarchy
PROJECT QUALITY PLANNING, QUALITY ASSURANCE AND CONTROL
The project quality planning chart, Figure 4.4-1, illustrates the compilation and integration of the
Project Quality Systems of CONTRACTOR and its prime Sub-contractors. Typically, the EPC
Project Quality
Management Plan is modularized to reflect the phasing of the project as it develops (shown left to
right)
and to communicate the plan in more manageable doses.
The chart is split in two separate parts. The first being QA (Quality Assurance) or the prevention
methodology / logic and the other is the QC (Quality Control) or verification activities required to
determine
product conformity.
This Project Quality Management Plan shall consider the list of corporate procedures from
CONTRACTOR. These corporate procedures form the basis of CONTRACTOR’s standard
operating
procedures.
Typical Project Quality Planning Chart (for illustration purposes only)
QUALITY OBJECTIVES AND PERFORMANCE INDICATORS
The Quality objectives for this project shall be as follows:
Ensure that the analysis, calculations, and design meet the following conditions:
Properly planned, performed, and completed as per COMPANY specifications, applicable
procedures, codes, standards, and statutory and regulatory requirements.
Organizational and technical interfaces between different disciplines which input into the
design process shall be defined and the necessary information documented, transmitted and
regularly reviewed.
Design output shall be documented and expressed in terms that can be verified and validated
against Design Input requirements.
At appropriate stages of the design, formal documented reviews of the designs results shall
be planned and conducted.
At appropriate stages of design, design verification shall be performed to ensure that the
design stage output meets the design-stage input requirements.
Design validation shall be performed to ensure that product conforms to defined COMPANY
requirements.
All design changes and modifications shall be identified, documented, reviewed and approved
by authorised personnel before their implementation.
Responsible for an overall project QA/QC activity;
Review of Contract specifications, identify the project specific requirements, produce and
administer this Project Quality Management Plan as well as other project quality deliverables;
Ensure that all material procured, inspected, tested, and delivered with acceptable quality level
according to Contract and Project Specifications.
Ensure that during construction, all items are fabricated, inspected, tested, and handed over with
acceptable quality level as per project Contract and Project Specifications.
Ensure that Inspection and Test Activities and Inspection Notifications are managed effectively
with relevant parties during procurement, construction and In-Yard Pre-commissioning and
Commissioning stages of Project.
To minimize deviation from Project standards, Specifications and Processes and use Technical
Queries where appropriate.
Ensure that Non-conformance reports managed efficiently throughout the various stages of the
project and critical issues to be addressed with corrective action plans.
Ensure that previous projects lesson learnt are adopted and repeated non-conformances are
minimized.
Ensure that Monthly KPI aligned with project objectives and analyzed throughout the project.
Ensure that all project activities carried out to highest standard and all technical documents /
deliverables undergo a comprehensive check and review process to ensure they meet all
requirements prior issuance to COMPANY.
Ensure that Product Integrity is maintained and verified throughout all phases of the project by
ensuring the compliance with Contract quality requirements and to National and International
Codes, Standards and Statutory Regulations.
The Project shall be executed in line with the requirements of the Contract and CONTRACTOR
Quality policy, standards, guidelines and procedures at all phases. The project document control
centre will maintain a controlled copy of key references and standards which shall be available to
all Project team members.
CONCLUSION
Organizations should take a comprehensive approach that seamlessly incorporates QA and QC in order
to guarantee quality throughout the product development and delivery process. Achieving high-quality
products, customer satisfaction, and business success all depend on ensuring quality in product
development and delivery. By putting in place strong quality control procedures, organizations can
enhance product quality, save costs, boost productivity, adhere to regulations, decrease customer
complaints, and promote a continuous improvement culture. Including quality assurance and QC from the
beginning of the product development process will surely lead to long-term success, competitive
advantage, and client loyalty.
