Quality Assurance

The premise of any quality system is that when projects are properly executed, human errors can be controlled through
the organization of the work, competence of persons performing the work, verification of the design, appropriate
inspection (quality control), and quality assurance during all phases.

Operators may operate in compliance with a quality system that meets the requirements of ISO
9001 or an accepted equivalent. To ensure that all activities will result in products, processes and services
that meet the stated quality requirements, the quality systems consider the following:

o safety performance targets are a quality characteristic and safety performance is included in the sco
pe of quality activities
o requirements of the quality systems for organizations delivering products, processes and services
o requirements to verify the quality surveillance of contractors, manufacturers and fabricators
o requirements for compliance verification at appropriate project stages (milestones) to en- sure that
effective interface control between activities is achieved
o requirements to ensure that operations are performed within the design parameters
o adequate actions are taken regarding incidents and findings from inspection and monitoring
o repair and intervention work meets specified requirements and that safety is maintained at all times

Quality surveillance of the manufacturing, fabricating, and installation activities is done by the
Project Quality Team or by an inspector contracted to perform the work on their behalf.
The level of quality surveillance should be sufficient to verify that the project specifications are met,
procedures followed and that the specified quality level is maintained.
Quality surveillance is performed in accordance with established the Project Quality Plan.

Quality systems should achieve a balance between the technology, risk level and complexity of
the facility during design, manufacture, fabrication, installation, operation and maintenance. Some the
important elements of a successful project quality system are listed below:

o quality professionals are involved early in the design process to ensure conformance with
project specifications
o recognition that tight schedules create quality issues
o development of detailed quality plans very early in the project
o effective tracking of subcontractors performance, particularly of critical components and services
o implementation of a proactive quality management program including design, procurement,
construction, installation, commissioning and turnover
o enforcement of adherence to contractual requirements
o mitigation of schedule and cost risks
o proactive Project Quality Program training of all project participants
o implementation of a comprehensive surveillance and audit program

Project Quality Plan

The project quality plan should cover all project phases from concept development to facility
turnover. Most manufacturers, fabricators and contractors approved by major operators have a
documented and implemented quality system that should meet most project requirements. The Project
Quality plan should include all contractors responsibilities for design and include by reference the
contractors own documented and implemented quality system (assuming it meets project requirements).
The quality plan should give special consideration to the following activities:
 o audit implementation of the contractors quality systems
o proper reporting and recording of audit findings
o review of design input and information given in the design basis
o documentation and verification of all applied software
o verification of design output including fulfillment of regulatory and project requirements
o highlighting of all characteristics of the design that are crucial to the safety and proper
functioning of the facilities

Manufacturers, fabricators and contractors have welding as part of their production process
generally have documented and implemented the requirements needed for quality control and assurance.
Their internal procedures will often comply with most contractual and regulatory requirements,
but theyshould be reviewed before fabrication begins to ensure they meet all project requirements.

Manufacturers, fabricators and contractors are normally expected to inspect and monitor their
own activities. The Project Quality Team should ensure that all of the contractors' monitoring, inspection,
and preventative and corrective action activities are documented and the records will be available for
review as needed.

Repeated non compliance with quality requirements that indicate systematic deviations from
procedures and/or inadequate workmanship should initiate the following actions:

o investigation into the causes of the deviations

o reassessment of the quality system
o corrective action to establish acceptability of products
o preventative action to exclude reoccurrence of similar deviations

Products not meeting the requirements of specifications and procedures must be removed or
have waivers approved by project management.
If repair or use of the product is proposed, the operator's approval should be required.
The documentation and justification for acceptance of deviations should be available for review.