TRANSWATER Engineers of integrated Solution w [PROVISION To SUPPLY AND INSTALL MULTIPHASE FLOW METER | JFOR PETRONAS CARIGAL! SON GHD-PENINSULAR MALAYSIA loperaTions PETRONAS OS ‘DOCUMENT TORAWING TRANSUITTAL Tans Wo PCSB-TWAPCSE-T PUCOODE [arsed 87 HANO/POSTICOURIERIE-WAT [bate onzr0T7 Otrematon Hse document are ewe U0 [fo: PROJECT MANAGER From: Ack Bn Mosian Petronas Caria Sdn Bh, Prject Engineer ‘operas Semenanjung Malays, Kompleks Operasi Pevonas, Transwoler API Sn Bhd 24300 Kerth, Terengganu Glenmare Operation () No25, Jalan Pernt U2, Kawasan Peredustien Temasya, Seksyen UI JATIN: MRMOHO KHAIRUDDIN SAID ‘Bandar Glenmare, 40150 Shak Alem, PROJECT MANAGER Selangor Der Enson, Maioysa Tesoed or Retssved or evew Aopioval Faieatearan Project Engineer rae (reco Rotated pproved Retest Approves) {for Detailed Engineering’ Cy {or construction Onion Cosson roa Others please speci) D067 wm No 027 rT ove. casey | sue _[Nooteomy | rena AGP OOtGE SP. PROJECT QUALITY PLAN ~ |e] 7 Iran occiment css Asa Forrovew ermaon sandy Recomea By # Name: Date feeoteses eu scrcvesp by song nd mney sree tara |PCSO comment code [J rowomaeven [resort For approve [Tovrea van comment [restore Sign By Date[AAGPOO095-PIM-PR-3004 Rev.B0 PROJECT QUALITY PLAN COVER PAGE PETRONAS ® PROVISION TO SUPPLY AND INSTALL MULTIPHASE FLOW METER FOR PETRONAS CARIGALI SDN BHD-PENINSULAR MALAYSIA OPERATIONS. PROJECT QUALITY PLAN TRANSWATER Engineers of Integrated Solution rev} DATE STATUS PREPARED| QA REVIEW) CHECKED| APPROVED BY BY By By NAMES | NAMES | NAMES | NAMES sicn | sign | sion | _ sign OWNER'S COMMENT Bo | onze Tesued For Aporoval woof mo mul 9 (Cl APproveomeviewen (approve with COMMENT [L_ RESUBWIT FOR APPROVAL [O_RESUBWIT FOR REVIEW NAME SIGN [me [oare@rasnaree | ‘AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN ‘TABLE OF CONTENT 4.0 INTRODUCTION 20. QUALITY PLAN 3.0 PROJECT ORGANISATION AND RESPONSIBLITIES 40. PROJECT QUALITY PROGRAM 50 DESIGN & ENGINEERING CONTROL 60 DOCUMENT & DATA CONTROL 7.0 PROCUREMENT 80 CONSTRUCTION 90 FACTORY ACCEPTANCE TEST & SITE ACCEPTANCE TEST/COMMISSIONING 10.0 TRACEABILITY 11.0 QUALITY CONTROL 120 QUALITY RECORDS 13.0 NON-CONFORMANCE AND CORRECTIVE ACTION 44.0 INTERNAL QUALITY AUDIT Transwater Aol Son. 1 Revo10 20 ‘AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN Cree Introduction This document comprises the PROVISION TO SUPPLY AND INSTALL MULTIPHASE FLOW METER FOR PETRONAS CARIGALI SON BHD-PENINSULAR MALAYSIA OPERATIONS. Project Quality Plan and its attachments. This shall be the model implemented during all phases ‘of work carried out by the project team and Contractor. Quality Pian 24 QAIQC Definition and Expectations Quality as ‘the grade of performance that meets or exceeds the client's expectations’. To determine if quality has been achieved, itis first necessary to define the expectations for the client 2.2 Objective The objectives of the Quality Plan are to establish methods by which the project management team is able to: + Ensure installed facilities meet the requirements defined in the design basis memorandum, supporting design, and construction specifications + Ensure all non-conformances are identified and reported to an appropriate level, resolution plans are developed and implemented, and appropriate follow-up actions are taken to confirm acceptable results + Provide timely identification that project processes are not operating satisfactorily or that hardware non-conformances exist, thus minimizing consequent rework costs and schedule impacts + Provide documentation that confirms compliance to project requirements and subsequently meets production operations documentation requirements for operating and maintaining Transwater Api Sdn. Bh, ia Revo3.0 © TRANWATER ‘AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN Lnsedretetr bi Project Organization and Responsibilities 3.4 Project Organization Chart Refer to document number AKGP00095-PM-VD-3002 for the Project Organization Chart 3.2. Project Manager Overal: General management of the work on the entire project, to ensure that itis cartied out on-time, in {ull conformance with contract requirements, and within, budget. Detailed responsibilities: ‘+ Managing contract review ‘+ Establishing project schedule + Agreeing project policies for the sub-contracting wor + Reviewing the department's allocation to projects of personnel, materials, equipment and services, against approved budgets and programs + Reviewing the progress with regard to quality, time and cost, and approving corrective actions where these are required ‘+ Liaison with regutatory authorities and clients, as necessary 3.3 Project Enginoor Overall: Responsible to the Project Manager. Supply of an engineering and design service that meets the combined requirements of the project to the required quality, and to agreed budget levels, Detailed responsibilities: + Provide leadership and guidance to team on executing their roles and responsibilities especially in Mechanical, Electrical & Instrument and System, + Oversee total project execution to ensure project in accordance with design, budget and schedule. Includes interfacing with client representatives, + Oversee project production efforts to assure projects are completed satisfactorily, on time and within budget ‘+ Supervise preparation of deliverable materials required to meet project specifications. Transwater Ap! Sdn. Bhd 3 Revo| an ong ese eras oa ensue ‘+ Evaluate performance and provide feedback for improvements and conduct technical discussion with the teams and customer to share project information ‘+ Ensure that the team as a whole provides adequate coverage in all the product and Identity training needs for individuals and ensure that there is a plan to bridge the training gaps + Manage resource utilization and balance workload across the team and provide technical support, «Escalate / delegate issues raised by the team — act as the focal point of contact between your team and customer. 3.4 Mechanical Engineer Overall: Responsible to the Project Manager. Supply of an engineering and design service that meets the combined requirements of the project to the required quality, and to agreed budget levels. Detailed responsiblties: + Managing and design for mechanical piping or related task ‘+ Engineering and design services for mechanical + Design verification + Design reviews + Design change monitoring ‘© Sub-contract design monitoring ‘+ Technical evaluation ‘+ Reviewing designs and documentation + Design services to construction + Preparation of operating and maintenance manuals + Commissioning projects + Structural requirement Transwater Api Soh. Bho! 4 Rov60‘AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN ee TRanswarer 36 Overall: Electrical and Instrument Engin« Responsible to the Project Manager. Supply of an engineering and design service that meets the combined requirements of the project to the required quality, and to agreed budget levels. Detailed responsibilities: Managing the instrument and electrical work: Planning and scheduling instrument and electrical activities; Preparing and verifying instrument and electrical documents; Controling, distribution and retaining instrument and electrical documents ; Evaluating the suppliers and sub-contractors; Processing customs documentation, and obtaining clearance Perform detailed calculations to compute and establish manufacturing, construction, ‘and installation standards and specifications Prepare specifications datasheets of materials and equipment Prepare specttications for purchase of materials and equipment. Plan layout of electric and Instrument drawing for the project. Direct and coordinate manufacturing, construction, installation, maintenance, support documentation, and testing activities to ensure compliance with specifications, codes, and customer requirements, Design, implement, maintain, and improve electrical instruments, equipment, facilies, ‘components, products, and systems for commercial, industrial, and domestic purposes. Transwater Api Sch. Bh 5 Rev.60ARGPOO095-PM.SP -3004 PROJECT QUALITY PLAN & TRANSWATER 26 Procurement Overa Responsible to the Project Manager. Management of purchasing activities on the project in ‘accordance with the requirements of the Clients. Detailed responsibilities: ‘Managing all aspects of the project procurement process with supplier and vendor 8 of Planning, organizing and controling it's department to meet the quality objec the company and in line with company quality policy Responsible to managing and monitor purchasing coordinator, expediting coordinator and logistic coordinator to unsure all itervequipment deliver on time. To prepare procurement progress report on weekly and monthly basis. Product quality management, interface with Purchasing and Engineering team to resolve suppliers’ issues, Liaising with the Project Manager to ensure project procurement decisions are managed strategically Ensuring purchasing policies and procedures followed To work with purchasing officer to establish approved vendor list and conduct vendor/subcontractor review Maintain records of goods ordered and received. Locate vendors of materials, equipment or supplies, and interview them in order to determine product availability and terms of sales. Prepare and process requisitions and purchase orders for supplies and equipment. Control purchasing department budgets. Review purchase order claims and contracts for conformance to company policy. Resolve vendor or contractor grievances, and claims against suppliers, Represent companies in negotiating contracts and formulating policies with suppliers Direct and coordinate activities of personnel engaged in buying, selling, and distributing materials, equipment, machinery, and supplies. Transwater Api Sdn. Bh 6 Revo‘AAGPO0095-PM-SP -3004 PROJECT QUALITY PLAN ens ] 3.7 Project Control Overall Responsible to the Project Manager. Arranging the necessary resources with the department heads, and the necessary planning. Controlling and reporting project progress, and arranging corrective action where necessary to maintain project schedule and the specified quality Detailed responsibi ‘= Managing contract review with all affected parties; © Planning, scheduling, controlling and reporting of activities on the ) project; ies: # Arranging for corrective action as necessary for maintaining schedule + Identifying and controlling interfaces between all functional groups; ‘+ Project change control; ‘* Reviewing and coordinating third party quality control; ‘= Arranging with departments for corrective action as necessary for quality; ‘© Arranging for the maintenance, retention and turn-over of project records; © Project administration; ‘© Environmental protection and mitigation measures. 3.8 System Engineer Overall: Responsible to the Engineering Manager. Final testing and commissioning of project facilities, In accordance with individual project requirements and system development. Detai 3 responstbilties: ‘© Arranging with department heads for the organizational structure, authority and responsibilities of those involved in system development and commissioning activites. + Organizational interfaces with project coordinators, engineering, procurement and construction ‘+ Develop the system interface and programming for the project + Responsible on the system integration and testing + Planning, scheduling and controling commissioning activities + Pro-commissioning activities and test + Site safety during commissioning + Arranging for the maintenance, retention and turn-over of commissioning records Transwater Api Sn. Bh 1 Rev.60‘TRANSWATER ‘AAGPO0095-PM-SP -3004 PROJECT QUALITY PLAN Ss 39 QAQC Engineer Overal: Ensuring that the departments establish, implement, and maintain a quality system across all projects. Auditing the system and advising of non-compliance, requesting corrective action, and reporting to management Detailed responsibil Assisting departments to establish and maintain procedures for allertical activities Specifying quality assurance requirements for purchase and subcontract work in agreement with the Engineering Manager Verifying the system for reporting and disposing of non-conformance Internal audits of activities in engineering, procurement, construction and commissioning External audits of suppliers and sub-contractors, as required by the Procurement Manager Indoctrination and training in quality awareness and responsibilities 4.0 Project Quality Program 44 42 43 44 45 46 ‘The Quality Program applied to this PROVISION TO SUPPLY AND INSTALL MULTIPHASE FLOW METER FOR PETRONAS CARIGALI SDN BHD-PENINSULAR MALAYSIA OPERATIONS project consists of the Project Quali Plan, Inspection Test Plan and Procedures which addresses the specific quality requirements of each phases of work ‘This Project Quality Plan has been created for this project to provide the project team with essential information on the applicable Project Specific Procedures, the Major work process controls, key staff responsibilities and others. ‘The Project Quality Plan also summarizes both in text and through a reference matrix the actions to be taken to implement the Quality System in Engineering, Procurement, Construction and Commissioning activities & quality responsibilties, ‘The Quality Engineer is responsible to the Project Manager for the preparation and for any revision to the Quality Plan. The Project Manager is responsible for the approval of the Quality Plan and overall Project Quaity. All activities are carried out in accordance with the Project Procedures. All procedure shall be kept in both hard copy and soft copy. Transwater Api Son Be. 8 Revo5.0 ‘AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN Cle Design and Engineering Control 5.1. Design and Engineering Planning Design activities will be planned in accordance to project requirement, Design plan identifies ‘activities to be carried out in design stages including review, verification and validation activities, allocates responsibilities and highlights qualified personnel equipped with adequate resources. Design plan which will be updated as designiproject progresses, is the combination of the project schedule (design is part of project activity), quality plan and document submission schedule, 1 different groups involved in design and r assignment of responsiblity. The organization manages the interfaces betw development to ensure effective communications and cle 5.2 Design and Engineering Input Design and engineering input will be the system performance criteria and will be contained in the customer's functional specifications. The relevant functional group shall review all design input including previous similar design, regulatory & statutory requirement where deemed appropriate. Any unclear/vague/ambiguous items in the input willbe clarified with the customer. 5.3 Design and Engineering Output Design and engineering output shall meet input requirement, be documented and expressed in the way that enable other process such as procurement, fabrication or service to begin. The design output shall be reviewed for adequacy by the relevant functional group before release, Design output shall state or make reference to project acceptance criteria and specify the project essential safety precaution, 5.4 Design and Engineoring Review Design and engineering review shall be conducted at appropriate stages of design process by relevant functional group. The review activities will help to establish the practicality of design encounter any problems found during design and engineering and ensure functional suitability of design output It also helps to establish the suitability of the design output. Review records shall be maintained Transwater Aoi Sdn. Be, 0 Revo60 ‘AAGPO0095-PM-SP -3004 PROJECT QUALITY PLAN pee 8.8 Design and Engineering Verification During the configuration and implementation of the project, design outputs are verified by the relevant functional group relative to the design input. Design verification will hep to identify any incomplete, ambiguous or conflicting requirements in the Design Input. 5.6 Design and Engineering Changes Design and engineering changes, modifications or revisions shall be identified, documented, reviewed and verified as appropriate and approved by the relevant functional group before implementation. The review of design and engineering changes shall include evaluation of the effect of the changes to the project execution schedule/cosvquality. Design and engineering changes and any necessary follow-up actions are recorded and maintained. Document and Data Control Documented procedures shall be established to control all documents and data that relate to the requirements of the quality system including, documents of external origin, where applicable. Document numbering, revision method, electronic copy control including CD-ROM, document distribution control including third party documents shall be discussed during internal kick-off meeting 6.1. Document and Data Approval and Issue Documents shail be reviewed and approved by authorized person before issuance. A master list of current documents and their revisions is maintained to preclude the use of obsolete documents. Documents essential to the effective operation of a process shall be made available at the location of the process. All obsolete documents shall be removed. When itis essential to retain an obsolete document; it shall be identified with the word “OBSOLETE” 6.2 Document and Data Changes Changes to document and date shall be reviewed and approved by the same function that performed the original review and approval. The issuing authority has access to and takes rrotice of the relevant information when undertaking @ review and approval of document changes. Where practical, the nature of the change shall be identified in the document or appropriate attachments Transwater Api Sch. Bh 10 Rov.8070 & TRANSWATER AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN ee 6.3 Document Distributed in Electronic Media Documents may be distributed in electronic media. Electronic distribution of documents shall ‘meet the following conditions: ‘+ The chosen electronic media is accessible to work stations affected by the documented process. * Users of the document have read access only. + Only the individuals charged with the task of maintaining the document have wrte access. ‘+ Amaster copy bearing the signature of the approving authority supports the document. ‘+ Users of the document are notified via separate mall or memo when the document is amended. Procurement 7.4 Purchasing Process The purchasing items shail be identified and the delivery schedule shall be documented in Bill of Materials (BOM). Purchase requisition package shall be prepared by the respective discipline Engineer based on design document. ‘Supplier schedule plan shall be reviewed periodically and suitable action shall be taken if any deviation in schedule plans. Inspectioné. test shall be conducted / witnessed at the suppliers place and test records shall be reviewed in accordance with Inspection test plan. Inspection test activities shall be notified to third party in accordance with Inspection test plan, ‘The purchasing system shall be organized to ensure that purchased products and the selected ‘supplier conform to the specified requirements. 7.2 Evaluation of Suppliors The evaluation and selection of the suppliers are based on their ability to supply product in ‘accordance with Clients requirements. Criteria for selection, evaluation shall be established. An ‘approved Vendor List (AVL) or approved Supplier List (ASL) on the basis of defined criteria related to supplier's ability to meet requirements for quality, cost and delivery are established Evaluations/assessments are carried out periodically and records of the results of evaluations/assessment and any necessary actions arising from the evaluation shall be maintained. Transwater Ap! Sdn Bd, " Rov.808.0 ‘AAGP00085-PM-SP -3004 PROJECT QUALITY PLAN & TRANSWATER 7.3 Purchasing Information Purchasing documents shall contain data clearly describing the product ordered, including where applicable, Type, class, style, grade or other positive Identification; specifications, drawings, process requirements, inspection instructions and other relevant technical data; approval or qualification requirements; other special requirements such as, but not limited to, certificate of analysis or compliance, inspection reports. Purchase order shall be reviewed for adequacy on specific requirements and approved by the authorized personnel before release to suppliers, Changes to purchase orders shall be processed according fo established procedures. 7.4 Verification of Purchased Product ‘A receiving method, which includes required inspection, has been established and implemented to ensure that purchased products meet specified purchase requirements. Where required, purchase products shall be verified at supplier's premises when deemed necessary and Verification arrangements and method of products released shall be specified in purchasing documents. Construction Construction process can be separated into two (2) which include construction at yard and construction at site, Both processes require specific procedure and quality control. For detailed elaboration on construction plan, refer to Project Execution Plan AAGPO0095-PM-SP-3005. Welding Procedure Specification (WPS), Procedure Qualification Record (PQR) and Welder Qualification Test (WOT) must be conducted before fabrication process will start 81 Construction at Yard Most of the pipe spools will be fabricated at yard thus it is crucial for fabricator to do exact, ‘measurement at site and to follow engineering design in order for a smooth construction at site. QA/{QC Engineer is responsible to monitor the fabrication process at yard starting from the ‘material arrival until the pipe spools are to be delivered at site. List of records and inspections need to be done throughout the fabrication process. The records comprise of, but not limited to Transwater Api Sah. hd 2 Rov6010.0 Transwater Api Sdn. Bhd 13 AAGPO00S 004 PROJECT QUALITY PLAN es © Welder list ‘+ Material Inspection Record + Fit-up Report * Visual Inspection Record ‘© Weldment Summary Report + NDT Report + Hydrotest Report ‘+ Blasting and Painting Report If inspection by client is needed at any time during this process, Request for Inspection (RFI) shall be sent to cient for their further perusal. Refer to Inspection Test Plan (ITP) — ‘AAGP00085-Q-SP-1001 for the list of inspection required during this process. Factory Acceptance Test and Site Accoptance Test / Commissioning Factory Acceptance Test and Site Acceptance Test work shall follow the Procedure — AAGPO0095-INS-PR-1026 and AAGPO009S-INS-PR-1027 - Traceability Procedures and methods shall be established to identify materials, products during all stages of the production, delivery and storage and installation. Where appropriate, or required by contract, the product shall be identified with a unique serial ‘number (on an individual basis or batches) to enable traceability. Traceabilty records shall be maintained. Quality Controt All the inspection& test activities shall be identified and documented in Inspection & Test Plan (ITP), ITP includes quality documents required for approval, inspection & test activities, records required, specification reference, inspection’ hold! witness/ review points and third party scope.& TRANSWATER ‘AAGPO00095-PM-SP -3004 PROJECT QUALITY PLAN 12.0 Quality Records Quality records shall be generated and maintained to substantiate control of quality related activities. These records serve to demonstrate the achievement of the required quality and the effective of quality management system. It also provides a basis for measurement and feedback essential for continual improvement, Such records comprise, but are not limited to: ‘+ Inspection records © Calibration recordsiresutts + Supplier assessmentievaluation reports + Corrective action reports ‘+ Management review meeting minutes + Design review records + Contract review records * Design validation records + Design and development change records ‘+ FAT pre-SAT and SAT sign-off records/sheets + Manufacture data record Records shall be understandable and identifiable to the materials or products involved and stored in a manner, which is readily retrievable, and in facilities that provide a suitable environment to minimize their deterioration, damage or loss. Where agreed contractually, Quality records shall be made available for evaluation by the customer or his representative. 13.0 Non-conformance and Corrective Action All non-conforming material or product shall be controlled to avoid unintended use or installation. Controls include the provision for identification, documentation, evaluation, segregation (when practical), disposition of non-conforming product, and notification of the functions concerned. The responsibilty for review and authority for the disposition of nonconforming product shall be in accordance with documented procedures, Transwater Api Sdn. Bh “4 Rev 80& TRANSWaTER AAGP00095-PM-SP -3004 PROJECT QUALITY PLAN ae 140 Non-conforming product may be disposed of as follows: ‘+ Reworked or sorted to meet specified requirement + Used with approval from authorized party (engineering or customer acceptance) + Rejected or scrapped + Re-grade for alternate applications Planned and documented program for corrective and preventive actions shall be established to ensure conditions adversely affecting quality are promptly identified, causes of discrepancies are determined, and positive steps taken to prevent recurrence. Corrective actions shall address the following: + Analyze processes, work operations, records, documented procedures and work instructions to identity the root cause. ‘+ Implement actions to prevent recurrence. ‘+ Ensure actions implemented are effective. + Document the changes arising from the corrective actions ‘+ Effective handling of customer complaints Internal Quality Audit A strategic program of planned and periodic internal quality audits shall be implemented to verify compliance and effectiveness of the Quality Management System. All activities related to quality management system shall be audited at least once in each calendar year or more frequently when required, including project execution or outsourced fabrication activities. Audits shall be planned and carried out by trained personnel, independent of those having irect responsibilty for the activity being audited. The aucit shall examine the processes, procedures and systems by following a writen procedure, plan or checklist. Audit shall be executed through review of records, interviews and observation of the activity The results of the audit shall be documented and brought to the attention of the personnel having direct responsibilty in the area audited. Department managers shall be responsible for implementing corrective actions for any deficiencies detected ‘A follow-up audit shall be performed to verify effectiveness of the actions, Transwator Aol Sdn. Bhd, 6 Revo