Purpose
purpose of this procedure is to describe the Project Quality Management System
requirements that will be applicable for SUPPLIERS on TORTUE FPSO Project
Definition and abbreviations
SHALL BP requirement used in BP applicable documents ‐
Mandatory
SHOULD specific recommendation where conformance is not
mandatory
MAY Permissive statement. Option that is neither mandatory
nor specifically recommended
ITP Inspection and Test Plan
MRB Manufacturing Record Book
PIM Pre‐Inspection meeting
PQP Project Quality Plan
PO Purchase Order
QA Quality Assurance
QC Quality Control
QMS Quality Management System
Order of Precedence
In case of conflict between requirements specified herein and the requirements
of any other
referenced document, the order of precedence shall be:
1. International and local statutory regulations
2. Project data sheets
3. Project specifications
4. Referenced Company documents, including GPs and GISs
5. Referenced national and international codes and standards.
Quality Management System
SUPPLIER shall have established, documented and maintains a Quality
Management System
(hereafter “QMS”) that complies with the latest version of either American
Petroleum
Institute (API) Specification Q1, API Specification Q2 or International Organization
for
Standardization (ISO) 9001.
The QMS shall be certified by a recognized accredited body. The certificate must
be current,
valid and applicable to the scope of work.
Project resources management and training
SUPPLIER shall ensure that all personnel assigned to execute the PO are
competent and have
the necessary qualifications, experience and training for their designated
functions
An adequate level of resources (at the location where the equipment and/or
material object of
this Purchase Order shall be executed) shall be described and demonstrated by
SUPPLIER in
terms of personnel (mobilization, qualification) and for machines (design
software, specific
production and control equipment, etc...).
Quality Resources and Competencies
The Quality Resources shall be selected on their experience and skills, and based
on the
relevant Job Descriptions.
It is under responsibility of SUPPLIER’s Quality management to provide and
ensure and
demonstrate that Quality resources have the requisite experience and
competency to support
the Project or Scope of Work.
Indeed, SUPPLIER shall provide evidence of personnel competence, for personnel
performing
or verifying the WORK, particularly but not be limited to:
Quality training
A register of certified/qualified inspectors working on the project (welding/NDT/
Painting/Dimensional Control/Fittings/Ex / Flange management…) shall be issued
and
maintained by the SUPPLIER to ensure that Qualifications of workers are still
valid.
All Qualification training and competency records shall be maintained during the
project and
available for review to CONTRACTOR/COMPANY and/or other parties.
When necessary, the Quality resources could be supplemented using a
nominated third party
inspection service company for QC of procured equipment or for inspection
activities at yard.
This third party shall be managed by the SUPPLIER accordingly.
SUPPLIER shall prepare a PO‐specific Inspection and Test Plan (ITP) which
identifies in
chronological order the major steps of the manufacturing programme from initial
design work
through manufacturing & assembly to final inspection, testing and release.
The ITP shall indicate at least:
‐ a detailed breakdown of WORK activities;
‐ acceptance criteria, specifications, codes and standards;
‐ control procedures to be used to complete those specific activities;
‐ record(s) produced to demonstrate compliance;
‐ SUPPLIER’s own intervention points in individual columns using the H, W, R, S
points for
both in‐house activity and at their SUB‐SUPPLIERs, together with Company and
any
required Third Party involvement as necessary to meet Project and Code
requirements
etc. Provision should be made for the individual surveillance points to be ‘signed
off’ by
Supplier/Company/Third Party, as required.
The following definitions are applicable:
‐ reference to any SUBCONTRACTOR Scope of WORK, where applicable
SUPPLIER shall give a minimum notice of 5 working days to CONTRACTOR prior
to the
respective Hold and Witness activity taking place. Any changes to the
notification period may
be discussed and agreed at the Pre‐Inspection Meeting.
The agreed notification period and means of notification shall be detailed in
SUPPLIER
Project Quality Plan.
all materials and equipment shall be subject to final inspection and release as
identified within
the applicable PO, Criticality Rating and Inspection and Test plan requirements.
All Criticality
1 and 2 equipment and selected Criticality 3 equipment, shall also be subject to
CONTRACTOR approval prior to release.
Criticality 4 equipment and materials shall also undergo final inspection release
(to be agreed
case by case)
For more details, please refer to MS002‐MP‐PRO‐012‐00007 ‐ QCS requirements
for
SUPPLIER (HOLD) [Ref 3]
The SUPPLIER is responsible for all activities and work completed by their Sub- Suppliers. The
review, checking
and acceptance of Sub-Suppliers documentation shall be carried out by SUPPLIER before being
submitted to
CONTRACTOR/COMPANY . The SUPPLIER shall conduct necessary design reviews, inspection,
testing and
acceptance of materials from their Sub-Supplier before the CONTRACTOR/COMPANY is invited to
witness
inspection, testing or accept the items or activity.
The SUPPLIER shall give a minimum notice of 14 calendar days followed by 48 hours re confirmation
by e mail to each identified party for any “HOLD” & ‘Witness’ Point (per agreed ITP).
The designated contact detail for all involved parties shall be agreed during PIM. Any changes to the
notification period may be discussed and agreed at the PIM, (e.g. a revision may be considered if
required parties are resident in the SUPPLIER works).
ITP and Inspection Notification format /Template are included as Appendix – 1 & 4.
Compliance, Regulatory legislation, class and verification
SUPPLIER shall be responsible to ensure that his equipment, systems, materials
and
components is compliant to Regulatory legislation, class notification and
verification.
Refer to MS002‐PM‐SPE‐012‐00003–instructions for SUPPLIERs with regards to
Classification
/ Verification [Ref. 8]
Project Codes and standards
There is an established Project code and standards procedure that list and
reference all
Project Codes & Standards, Technical Specifications, Classification and
Certification
requirements for the Project.
Requests for concessions or deviations from Codes & Standards, Project
Specifications, Data
Sheets, Drawings and Specified Construction Material shall be raised using
CONTRACTOR’s
Technical Deviation Procedure processes.
In the event of conflict, actual or implied, among documents, the order of
precedence is
stated in the defined Project Codes and Standards.
All codes, standards and regulations shall be at their latest available edition
unless otherwise.
Refer to MS002‐PM‐LST‐012‐00003 ‐ Project List of Applicable Codes And
Standards (HOLD)
[Ref.11]
Purchase Order execution
11.1 Meeting with SUPPLIER
Pre-Inspection Meeting
When required by criticality rating and POQR, a Pre‐Inspection Meeting (PIM)
shall be
arranged by the SUPPLIER at an appropriate time in the execution cycle and
include all
appropriate attendees (such as representatives from COMPANY or its agents,
CONTRACTOR,
Third Party Inspection Agency …)
The objective of this meeting is to review implementation of the ITP and agree
and finalize
the principal Quality Assurance and Control, Inspection, Testing, Class and
Certification
requirements prior to commencement of manufacture or construction.
For more details, please refer to MS002‐MP‐PRO‐012‐00007 ‐ QCS requirements
for
SUPPLIER (HOLD) [Ref.3]
Progress report are requested to be issued by supplier monthly basis and
composed by:
‐ Highlights of any issue and its relevant area of concern;
‐ Highlights of any topic related with contractual delivery date fulfilment;
‐ Engineering progress and status;
‐ Procurement progress and status;
‐ Fabrication progress and status.
‐ Quality Status
Fabrication activities
Ccommencement of fabrication can only be launched when design and
manufacturing
documents are at a minimum code 2 approval status
Material management and traceability
SUPPLIER’s quality system shall provide assurance that required appropriate
identification
and traceability of primary equipment and materials is maintained throughout
the execution
of the purchase order. The three traceability levels defined in Table here below
should be used
to identify and specify traceability requirements.
Certification
The requirements and definitions regarding equipment certification are given in
Table here
below and shall be in accordance with EN 10204.
Note: If Code 3.2 certification (as defined in Table) is required, “material product
testing” shall
be performed in the presence of a CONTRACTOR/COMPANY nominated
representative or
the inspector designated by the official regulations
Handling, storage and Preservation
All Materials and Equipment shall be protected against deterioration and the
SUPPLIER shall
provide all necessary recommendations, temperature and humidity control
preservation to
ensure and guarantee the initial preservation.
SUPPLIER shall implement project specific requirements related to Preservation
and shall
include a dedicated inspection control point in the ITP.
SUPPLIER shall take measures to avoid carbon steel / ferrite cross contamination
of stainless
steel and other exotic materials
SUPPLIER shall be compliance to MS002‐CG‐PRO‐012‐00004 Project Vendors
Initial
Preservation Specification [Ref.5]
Control of measuring and Test Equipment
The SUPPLIER shall ensure that:
‐ All necessary Inspection, measuring and monitoring equipment are controlled,
calibrated
and preserved in a satisfactory condition.
‐ Procedures are established for the control of Inspection, measuring and
monitoring
equipment, such equipment are registered
‐ Measuring equipment are calibrated or verified at specified intervals, adjusted
or
readjusted as necessary, have known calibration status, safeguarded from
adjustments
and protected from damage
‐ SUPPLIER procedures, equipment, calibration records and certificates are made
available
to CONTRACTOR/COMPANY.
Mechanical completion
Containment failures on high risk processing facilities can result in significant
incident. Key
contributors to high risk leaks are poorly or inappropriately made‐up flanges and
clamped
connectors, where the potential to leak and its consequence are significant.
SUPPLIER shall be responsible to have a traceable system to document all bolted
flange
connections tightening by means of manual torque wrenches or hydraulic
tightening. The
flange connections shall be marked on a suitable document, e.g. a mark‐up
isometric drawing
or by using an electronically tracking system for flange tightening. Information
shall include,
but not be limited to the following information:
‐ piping class;
‐ tension/torque;
‐ nominal flange size, pressure class, bolt size and length;
‐ type of tool and hydraulic pump pressure;
‐ date and signature by the operator
All packages should be delivered tested. The test pressure shall unless otherwise
specified be
in accordance with ASME B31.3. Pressure test recorder shall be kept as evidence.
Hydrostatic
testing shall be used wherever it is possible and in preference to any other
testing method.
Hydrostatic testing shall be performed using water as the testing medium. Any
other fluid will
follow recommendation of ASME B31.3. In addition, SUPPLIER shall be
responsible to ensure
cleanliness of pipe prior to shipment to verify that no internal debris/moisture is
present.
For more details, please refer to
‐ GPO‐CM‐GLN‐00005: Build it Tight Flange Management Guide
‐ GPO‐CM‐GLN‐00004: Build it Clean Guide
‐ GPO‐CG‐PRO‐00001: GPO Commissioning Practice
As part of Mechanical completion review, SUPPLIER shall fill in MC checksheets as
per
MS002‐CG‐PRO‐012‐00001: Vendor Completion requirement. [Ref. 6]
Release of Equipment and Materials
The testing and inspection activities to be performed at the SUPPLIER
manufacturing
facilities to verify the equipment’s performance functionality (FAT), shall be
included in the
ITP and SUPPLIER shall define and include all tests, inspections, controls,
acceptance criteria
and documentation required. Inspection and testing requirements for each item
of equipment
and material type are defined in the codes, standards, specifications and data
sheets specific
to that item.
SUPPLIER shall be responsible for ensuring that the following items, including any
items from
SUB‐SUPPLIERs, are completed and in place before calling for a Final Release
Inspection.
‐ All Supplier documentation submittals in accordance with the SDRL complete
‐ All ITP and POQR requirements verified as being complete
‐ All Deviation Requests (DRs) closed and approved by CONTRACTOR
‐ All Concession Requests (CRs) closed and approved by CONTRACTOR
‐ Where raised, any Punch List items are closed out and any work transfer to site
agreed by
CONTRACTOR
‐ Where applicable, all certified EX‐Equipment has been allocated Project tag
Number and
subjected to full ‘Detailed’ inspection by SUPPLIER and verification by
CONTRACTOR.
‐ Preservation requirements are complete and inspected
When all of the above points have been complied with and inspection activities
have been
satisfactorily completed an Inspection Release Note (IRN) will be prepared by
CONTRACTOR,
reviewed and approved by COMPANY and issued by CONTRACTOR Inspector
during Final
inspection activities.
IRN will not be prepared if the Non‐Conformance / SUPPLIER Punch List have not
been
closed, unless otherwise authorized by the Project. In such case, the IRN will
record Project
instruction.
Manufacturing Record Book
SUPPLIER shall prepare a Manufacturing Record Book (MRB) which contains all
the respective
certificates and manufacturing documentation relating to the PO.
Compilation of the Manufacturing Record Book shall be made on an on‐going
basis by
SUPPLIER and presented to CONTRACTOR inspection representative for
acceptance to
provide visibility of any potential problems with materials and equipment
compliance to the
stated requirements.
SUPPLIER shall review and endorse all contents of the Manufacturing Record
Book prior to
submission to CONTRACTOR
Any required endorsement by Third Party to meet material, code or type
approval
requirements acceptance shall be coordinated by SUPPLIER during the ongoing
compilation
of the MRB to ensure that it is complete prior to final inspection of the material
and
equipment.
Sub–Supplier certification and documentation content shall be compiled and
incorporated
into the Manufacturing Record Book in a coherent manner that is easily
identifiable and
traceable.
For more information, please refer to MS002‐PM‐PRO‐012‐00018 : Final
documentation for
SUPPLIERs [Ref.4]
CONTRACTOR/COMPANY Right of Access
CONTRACTOR/COMPANY shall be granted electronic and hard copy access to all quality plans,
procedures, documentation, and other quality records relating to the work including data extracts.
Such access to view includes the right (subject to provisions with regard to proprietary information) to
photocopy, photograph or otherwise record data necessary to verify that requirements have been met.
CONTRACTOR/COMPANY and their appointed representative shall at all times have access to the
workshops and testing facilities, including workshops of sub-suppliers engaged in supplying material
or in fabricating the equipment for the purpose of inspecting the purchased equipment.
Measurement, Analysis and Improvement
By SUPPLIER
The Supplier shall develop and maintain an audit program as required by their
own QMS. This
includes internal Quality audits of their management systems, specific interface
processes
that relate to the PO, and Sub‐Suppliers audits.
When requested by Company, the Supplier shall provide copies of their internal
and Sub‐
Supplier audit reports for review
COMPANY, Third Party Authority and/or CONTRACTOR shall have access at all
reasonable
times on prior notice to the facilities, equipment, materials, personnel and
records of the
SUPPLIER, strictly for the purpose of auditing their respective QMS.
COMPANY, Third Party Authority and/or CONTRACTOR will ensure that adequate
notification is given to allow participation. (Minimum ten (10) working Days);
Control of non-conformance
Non‐Conformance detection may be internal to SUPPLIER’s & Sub‐SUPPLIER’s
Organizations, or by CONTRACTOR, COMPANY, and/or Third Party Authority
SUPPLIER non‐conformity management system must comply with ISO9001: 2015
and be
aligned with COMPANY’s Non‐Conformance and Corrective Action requirements.
Quality Reporting
A dedicated section for the Quality Management System shall be addressed by
the SUPPLIER
in the MONTHLY REPORT indicated:
‐ The status of the quality control inspections, related to the activities listed in
the ITP.
‐ The status of the non‐conformances, as observed by CONTRACTOR, COMPANY
and/or Third Party
‐ The status of the corrective actions resulting to the non‐conformances, or
issued
further to a review/audit by CONTRACTOR,
‐ The status of Deviation/Concessions Requests and identified risks,
‐ The status of Quality indicators versus objectives
HAZARDOUS AREA ATEX CERTIFIED EQUIPMENT
SUPPLIER'S shall provide product certification issued by an EU Notified Body for all Hazardous area
electrical
equipment. SUPPLIER self-certification is acceptable for Mechanical equipment but not acceptable for
electrical
equipment.
SUPPLIERS shall remain responsible for compliance with requirements of International Standard IEC
60079
and Directive 2014/34/EU as applicable to the scope of supply / work. Particular attention shall be
paid to
requirements of IEC 60079-14 (Electrical installations in hazardous areas) and IEC60079-17
(Electrical
installations inspections and maintenance).
LIFTING EQUIPMENT AND TACKLE
TYPE APPROVAL CERTIFICATES
Corrosion Protection, Colour Coating, Marking and Fireproofing
Coating, painting, fireproofing works shall be performed after the completion of welding works.
In case planned welding is required after coating, painting or fireproofing works, 50 mm strip or the manufacture
recommended dimension which is greater on both sides of the weld shall be kept uncoated and touched up after
the welding work.
In case un-planned welding work occurs, any coating, painting or fireproofing shall be completely removed and
the surface shall be prepared, re-coated and painted or fireproofed in accordance with approved touch-up
procedures.
3. RIGHTS AND RESPONSIBILITIES
3.1. CONTRACTOR's Rights
(1) CONTRACTOR reserves the right to witness, monitor or audit Vendors’ and Module Fabricators’ and their
Lower tier Vendors’ and Module Fabricators’ inspection and testing activities at Vendors’ and Module
Fabricators’ or their lower tier Vendors’ shops and Module Fabricators’ yards at all times.
Note: CONTRACTOR will send their capable qualified and experienced staff to Vendors Shop and Module
Fabrication Yards to carry out technical audit to confirm material’s and module’s compliance with
technical requirement of the contract. The timing of these audits may coincide with pre-inspection
meetings and QC surveillance visits for in-process inspections.
(2) CONTRACTOR reserves the right to increase the extent and frequency of its inspection and monitoring
regardless of the scope specified in the relevant requisition and ITP (Inspection and Test Plan).
(3) CONTRACTOR reserves the right to reject any part of Materials and/or Fabrications that is found to be of
unacceptable quality or workmanship, or fails to comply with the requirements of Purchase Order/Contract. A
nonconformance report (hereinafter called NCR), which states the basis of rejection, will be prepared and
issued to Vendors and Module Fabricators.
(4) CONTRACTOR reserves the right to disqualify Vendors’ and Module Fabricators’ or their lower tier Vendors’
and Module Fabricators’ quality control (hereinafter called QC) personnel and QC inspectors from working for
shop inspection of Materials and/or Fabrications, if their competence, performance, workmanship or
qualification is detected unsatisfactory by CONTRACTOR.
3.2. Vendors’ and Module Fabricators’ Responsibilities
(1) Vendors and Module Fabricators shall carry out all inspections and tests in a controlled and systematic
manner in order to ensure that Materials and/or Fabrications are in full compliance with all requirements of
Purchase Order/Contract and all required inspections and tests are successfully conducted and documented.
(2) Vendors and Module Fabricators shall permit CONTRACTOR, LNGC or their representative free access at
any time to Vendors’ and Module Fabricators’ or its lower tier Vendors’ shop and Module Fabricators’ yards
where Materials are being manufactured as well as access to inspection and test records.
(3) When inspection is carried out by the Vendors or Module Fabricators, or witness inspection is required by
CONTRACTOR, Vendors and Module Fabricators shall provide the following at Vendors’ and Module
Fabricators’ own cost:
(a) All inspection and test equipment and facilities required for inspection or test.
(b) Sufficient personnel to execute inspection or test.
(c) Latest manufacturing documents and drawings related to witness inspection and test, which shall have
CONTRACTOR’s approved signature.
(4) Inspection, witnessing and monitoring activities by CONTRACTOR shall not relieve Vendors and Module
Fabricators of their contractual obligations and responsibilities to provide Materials and/or Fabrications in
conformance with requirements of Purchase Order/Contract.
5.4.1. For Vendors
(1) Vendors shall submit to CONTRACTOR a monthly inspection schedule for Materials or any part thereof.
Monthly inspection schedule for the following two (2) months shall be submitted by 20th of every month.
(2) Monthly inspection schedule is not necessary for bulk materials for instruments, electrical and piping.
5.4.2. For Module Fabricators
To be discussed at Module Fabrication Yard among all parties.
