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EPC Contractor:
PT. PP (Persero)
Tbk.
O&U/TRI/AE/PQP/001
Purpose:
ISSUED FOR APPROVAL
Document Type:
QA/QC
Issued for
0 18-04-17
Approval
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Re
Description Date Prepared Checked Approved
v.
DISTRIBUTION LIST
PP
Project Manager
Project Control Manager
Procurement Manager
Construction Manager
QC & Commissioning Manager
Admin & Finance Manager
Engineering Manager
Project Engineer
Mechanical Lead Engineer
Piping Lead Engineer
Process Lead Engineer
Civil Lead Engineer
Electrical Lead Engineer
Instrument Lead Engineer
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TABLE OF CONTENT
I. General4
II. Scope 4
III. Purposes 4
IV. Reference 4
V. Terms and Definition 5
VI. Project Quality Policy and Quality Objectives. 5
VII. Organization and Key Responsibilities 8
VIII. Resources Management10
IX. Product Realization 11
X. Corrective and Preventive Action 25
XI. Quality Control 27
XII. Quality Records 28
XIII. Quality Audit 28
XIV. Attachment 28
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I. General
This Project Quality Plan (PQP) is created as minimum guidance for the implementation of
Quality Management System (QMS) ISO 9001:2008 on offsite & utilities for RMDP project.
This PQP is briefly general guidance to be executed and effectively in order to assure the safe
and reliable quality in all project activities for Project Management, Construction, Site
Engineering (if any), Quality Control, Material handling & Control, Safety, Pre-Commissioning,
Commissioning, and Project Hand Over.
II. Scope
This Project Quality Plan (PQP) is applied to project Offsite & Utilities (O&U) for RMDP project
in Balikpapan in order to comply with client requirements stipulated in the contract
documents. This PQP will be applied with revision or adjustment depends on the nature of
project and client requirement. If this PQP has conflict with the contract document, the latest
revision of the contract document shall take precedence.
III. Purposes
This document describes the proposed QMS to be utilized by PT.PP Persero (Tbk) EPC division
for project and will be described in more detail with Project Plan and related disciplines
execution plans, project procedure which relevant with design manuals / work breakdown
structure.
IV. Reference
The following words and phrases shall have the meanings hereby assigned to
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Quality Policy is established which include a commitment to comply with requirement and
continually improve the effectiveness of the QMS and provides a frame work for establishing
and reviewing quality objective. The quality objectives including those required to be met the
requirements of the project are established at relevant functions and levels within the
Project and the quality objectives shall be measurable and consistent with the PP - EPC
management system policy and clients objective. All levels within the organization have
committed in business cycle to provide the excellent services of our scopes as per contract
document to our clients which have added value for all stakeholders.
Excellent services are focused to maintaining and continually improving quality and
productivity that trigger of competitive price, on time schedule/delivery, safe, secure, health
work environment, and profitable value. Beside, excellent services are achieved through
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maintaining and developing people for multi-tasking who have competency, multi-skill, and
effective mentality for implementing, maintaining and continually improving work methods,
technology, quality management system and good client relations in running business cycle.
Other monitoring related QA/QC performance will be included on QSHE Project Assessment
Score Card System that will be conducted quarterly.
Quality policy shall be socialized to all employee in any means of communication method such
meeting, toolbox meeting etc.
To ensure the responsibilities and the authorities are defined and communicated to all
employees, brief outlines of the key personnel responsibilities associated with the project is
describe on below description for all positions / functions level is defined in this document.
The project organization had been structured to accommodate all phases of the project.
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1. Ensure that the Project Quality Management System is implemented and maintained.
2. He shall report to client, end user and Board of Director on the performance of the
Project Quality Management System, any need for improvements and for the provision
of all necessary and appropriate action to ensure fulfillment of customer satisfaction
and compliance to the quality standard requirements.
1. The overall site management and project co-ordination with the Client.
2. Ensure that all the aspect of the job which are under the companys scope of work are
carried out in accordance with the approved design and specification to achieved
quality standard that is complied with clients requirement.
3. Ensure that the quality commitments described in the PQP are implemented by
various sections that are involved in the project according to their respective field of
work.
1. the overall design and engineering management and for leading and supervising a
team of engineers as they develop, test, modify, and create solutions to technical
problems.
2. Supervise and lead engineers, scientists and technicians who design machinery, plan
and develop civil projects, and oversee production and quality control.
4. Oversee the research and development of new products and procedures. Hire, train,
and mentor other engineers and supporting staff.
5. Write performance reviews and solve internal issues and make detailed plans to
accomplish goals.
1. Establish, implement, coordinate and maintain the Quality System as per this PQP
dully approved by the appropriate authority.
2. Assist the site management through regular state of inspection of field production
activities in accordance with the Inspection and Test Plan (ITP) appendix in the PQP to
ensure that work is carried out in conformance with relevant specification and
drawings.
1. Overall planning and control of schedule, progress, resources, and cash flow,
productivity, efficiency, additional work and profitability.
3. Check all of documents such as PO/RO, invoices, Sub-Contract Order, payroll, etc.
1. Actual performance of work assigned to them and has direct control of labor working
under them.
3. Ensure that the drawings being used for the execution of the work are latest revision.
1. Purchasing material, tool and consumable needed in the project. He also responsible
for equipment for material handling.
A. Staffing
PP EPC will provide adequate numbers and qualified personnel, to ensure that
personnel work affecting conformity to product and service requirement is fulfilled
base on contract document. Ensure that all personnel are aware of their activities to
the achievement of project objective. PP EPC also shall appoint an adequate number
of competent QA and QC to ensure an adequate Quality Management in the
execution of the contract.
B. Information Technology
Computer software that consist of applications that is build and developed by in-
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C. Infrastructure
PP - EPC will provide and maintain working space, office equipment and other
supporting services as required. Include For the purpose of liaison and making client
approval, intends to have a small team resident in Contractors home office(s)
supported time to time by specialist on short visit & required: office space, secretary,
filling cabinet & general stationary equipment, line telephones, internet access, fax &
photocopier, parking.
1. Design Planning
The Engineering plan, which defines the client and/or consortium and PP - EPC
requirements to the Engineering team, shall be provided. The above plans are
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5. Design Validation
B. Procurement
All materials, equipments and or services shall be procured from the appropriate
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and reliable sources / vendor comply with project specification and deliver in good
condition and in a timely manner.
Appropriate and reliable sources shall be considered with vendor quality
management procedure and customer specification shall be clearly stated on the
purchase order with full detailing of the product and or service required. Continuous
monitoring of the vendor and or sub contractor performance shall be undertaken by
means of quality surveillance and expediting. Appropriate and reliable sources shall
be considered with vendor quality management procedure and customer
specification shall be clearly stated on the purchase order with full detailing of the
product and or service required.
Continuous monitoring of the vendor and or sub contractor performance shall be
undertaken by means of quality surveillance and expediting.
The activities include preparation of procurement documents, the assessment and
selection of vendors, tendering and evaluation of bids, requisitioning, control for
quality and schedule, and control of certification documentation. Control of
purchasing materials and services shall be initiated with a kick off meeting as
required in the relevant quality programs with vendors in order to reach a thorough
understanding of the purchase order conditions and requirements.
1. Selection of Vendor
PP - EPC will select potential vendors in principle follow to the vendor list and PP -
EPC may add vendors additional to those agreed only with the express approval of
client. Procurement Manager will issue request for quotation to potential vendor,
upon request of Project Manager, QA/QC Manager shall perform QA/QC surveillance
to vendor in accordance with the QA levels of product and services to be made. The
result shall be reported to Project Manager.
2. Vendor Qualification
Quality Management or evaluation shall take consideration, but not limited to the
following:
4. Material Delivery
After materials and equipments have been verified and ready to delivered, traffic
department will arrange and controlling the materials and equipments delivered till
destination safely and accordance to the project schedule. PP - EPC shall comply with
all the requirements of Government of Indonesia's UU 10 /1995 (Customs
inspection of foreign goods by the appointed surveyor), as it applies to the project.
The efficient and proper handling and storing are vital to successful of the project.
Proper material storage system must be designed to accommodate the loads of the
materials to be stored, the sensitive environmental needs for different materials, the
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functional, efficiency, safety and the protection of the materials from fire, water and
local disturbance. Prior to material arrive at site, method of handling and storage
area has to well prepare to avoid any impact from bad handling and storing,
including Material Damage, Loss Material and Safety Issue.
PT PP Divisi EPC should be able to implement the best practice of handling and
storing of material and methods for eliminating the occurrences of such accidents.
All products supplied by Client are handled in a controlled manner and Subject to
inspection on receipt to verify conformance to the specified requirements and
conditions. All products that are received in a damaged state or without the relevant
documentation shall be segregated and the cause recorded and reported to the
Client.
C. Construction
"PP - EPC commits to construct a safe and quality product, within schedule and
budget, to fully meet clients requirements".
Detailed planning shall be made prior to start with any work, to ensure safety,
quality and its target progress. Evaluations during performing the works shall be
conducted periodically to maintain the project objectives.
Any sub contractor shall be pre qualified prior to be included in the bidder list of any
project to ensure their capabilities to deliver quality products to fully meet the
projects and customers requirements. Subcontractor performance during project
execution shall be monitored and evaluated thoroughly to assess their qualification
for any future relationship.
D. Commissioning
PP - EPC commits to perform commissioning, start up, performance test and also
maintain a safe and quality product during warranty period to full meet project
requirement. The detailed requirements for mechanical acceptance shall be agreed
between PP - EPC and client.
E. Project Coordination
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To achieve the project's objectives, coordination during the execution of the project
shall be managed with primary concern on safety, quality, schedule and cost. The
coordination procedure between client, PP - EPC and Subcontractor shall be
established, in which each scope of work, line of communications, information
transmissions routes, etc. are defined. All procedures shall be subject to agreement
and approval of client in so far as such procedures related to client's rights and
responsibilities under the contract. The procedure shall be issued to all relevant
parties. Information of project status; Inquiries; contras or order handling, and
feedback, shall be communicated and treated effectively. Project document shall be
prepared, issued and updated in timely manner. The project scope and requirements
shall be clearly defined and communicated to the project team member and that the
execution is consistent.
1. Project Control
Project control system is establish and implement to provide guidance for the
execution of the project and to anticipate and minimize project cost, potentials cost
trouble and schedule delay.
Activities within project shall be monitored, schedule and the actual progress is
controlled against the current plan, an early warning shall be provided as well as the
corrective action in case of any deviation from the plan. Appropriate alternative
solution shall be introduced to minimize schedule impact. These schedules shall be
updated in accordance with project developments, and issued to client monthly
intervals.
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3. Project Report
The Project status shall be periodically reported in order to give clear picture for all
relevant parties on the ongoing progress and fore casting all projects area of
concern. The project report shall contain adequate project status and list significant
information of the project work activities. Fixed Assets and Cost Report are also
prepared and as necessary will be submitted to client for their accounting record. PP
- EPC shall highlight which activities are behind schedule and demonstrate in detail
by reference to individual networks or bar line schedules how such delays impact on
the final completion of the project, at the same time outlining steps being taken to
correct such delays.
4. Material Control
All material, which designed, purchased, delivered and installed shall have controlled
and systematic identification and traceability for ensuring that correct materials of
right quality are used in the product and that the individual items and the final
products are in full compliance to the specified quality requirements and are
provided with relevant material certification as necessary.
The plan should address but not limited to the following Subject:
Definitive estimate.
Fabrication status.
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A system to monitor the material status will also be develop and frequently updated
to provide current information and early warning in case of potential delivery
schedule delay and over-shortage material is observed. Traceability requirements
the materials/products shall remain identified throughout the work execution for
ensuring and maintaining accuracy and correctness during application and
installation of these at the designated places and that the materials/products and
their elements are traceable to their respective quality records. The degree and or
stringency of traceability are determined according to the quality classification of the
product and project requirements.
All documents affecting quality whether its come from client, vendors, and
subcontractor and internally located at site shall be suitably controlled to ensure that
sufficient and correct information is available at all times, and any obsolete
documents are removed from use.
Quality records are the documented evidences that processes are executed
according to the quality systems plan and requirements, such as inspection results,
audit results, calibration data, data sheets, technical specifications, engineering
changes, corrective action request, etc. In the ISO Standard, Quality records are kept
to demonstrate conformance to specified requirements and to the effective
operation of the Quality Management System. PP - EPC shall maintain complete
records of all materials and documents received, and appropriate filling and storage
system. In addition to the above, this policy is intended to structure, standardize and
control all contractors level of information that directly impacts the quality of
product. All incoming and outgoing document are handled in a systematic and
controlled manner to ensure that appropriate edition of the pertinent documents
are available at all relevant locations for the personnel concerned and obsolete
documents are removed from all points of use. The Document Management System
provides registers to identify documents and, where applicable, showing status of
the document such as revision, purpose of the issue, preparation schedule / actual
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a) Document changes
Ensure that all changes to documents and data are reviewed and approved by the
same function / organization and authorized personnel that performed the original
issue. Where revisions have been undertaken, the new revision number shall be
stated and the previous revision shall be clearly stamped as superseded. Certain
copies of preceding issues may be retained for reference purposes but these shall be
stamped as superseded, as noted above.
b) Revision status
All documents subject to revisions may whenever possible, have the relevant
sections marked to indicate the revision, and the relevant control sheet completed
stating the revision.
c) Document issuance
d) Contract Management
Prior to and during the execution of the project, contract with the partner and or
client shall be reviewed in depth in order to avoid any dispute and to ensure that the
scope of work stipulate in the contract is within PP - EPC competencies, when
incomplete, ambiguous or conflicting inputs are found in course of the contract
review, contractors project manager will discuss with client to draw up
requirements, and result shall recorded for confirmation.
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Contract
Contractors Proposal
This shall also be applied to contract with vendor and sub-contractor engages in the
project. Contract manager shall be responsible as the focal point to perform the
contract review from all aspect, i.e.: technical, commercial and legal. QA/QC
Coordinator, and/or job leader shall review the contract with respect to activity
related to their scope of work.
All clarification, negotiation and response shall be compiled and made form apart to
the contract. Any development to the contract during the project execution due to
changes of the scope shall be governed as the original contract review and the result
shall be amended.
All activities relate to inspection and testing shall be performed in a systematic and
controlled manner in order to provide confidence that the products and or services
is delivered with the desire quality level All materials and workmanships shall be
subject to inspection, examination and test by client in accordance with establish
procedure.
A variety of methods are used during the execution of inspection and testing
activities to verify the integrity of the product during the manufacturing, or
construction/ installation stages. These methods shall be utilized in a controlled
manner to assist with the interpretation of the results and shall include but not be
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All received goods shall be inspected on receipt and verified for acceptability.
Receiving product may not be used or processed without prior verification, in
accordance with the relevant procedures to ensure that it conforms to the specified
requirements.
Final inspection of the product / item shall ensure that all the appropriate tests, such
as Non Destructive Examination / NDE, pressure testing, visual and dimensional
checks have been carried out and that the inspection and test plans applicable to the
product / item have been signed as necessary and that all objective evidence
required has been provided and is acceptable to the requirement No product shall
be released until all the inspection and testing has been verified.
Throughout stages of production and installation, the inspection and test status will
be maintained as necessary to identify the status of verification activities and
illustrate any failure of the product to meet the required criteria. The status of
inspection and test shall be dearly marked to ensure that the products have passed
the required subsequent inspections and test.
Any product or service that fails to meet the requirements will be suitably controlled
and rectified to ensure that no defective products and or services are delivered to
client. The non conformance and its resolution shall communicate to all relevant
parties and as necessary including the client. Rejected material shall be satisfactorily
replaced with proper material without charge therefore by PP - EPC, and PP - EPC
shall promptly segregate and remove the reject material. Any non-conforming
product shall be identified and segregated with other product.
8. Product Preservation
All products: equipments, materials and spares items shall be suitably protected at
all times to prevent product degradation. All materials and equipment shall preserve
and have adequate protection during transportation, storage, and installation prior
to start up to ensure that the condition would allow it to function as per the initial
requirements. Vendor/subcontractor shall provide methods and means of handling
to prevent damage or deterioration.
Instrument type,
All quality problems which are require investigation and corrective actions to eliminate and
minimize a recurrence of the problem. Any non-conformance will be investigated to
determine the root cause, and various data available will be used to determine opportunities
for improvement through CA Tracker form. Comments on the causes any corrective actions
shall be distribute to the relevant groups who perform similar work. Work processes,
records and Client's feedback are analysed to detect any sources of potential problem, and
preventive action is implemented before the problems occur. Control is applied to ensure
that corrective and preventive action is implemented and that they are effective. The cause
of non-conformance shall be investigated and corrective actions shall be undertaken by
authorized personnel to prevent repetition. Audits and or analysis of all processes, work
operations, concessions and quality records shall be made to detect and eliminate potential
and actual causes of non-conformance. All investigations shall be conducted through the
corporate and/or project quality system to identify any common causes.
1. Corrective Action
Shall be at a level that corresponds to the risks encountered and address such
factors as safety, production costs, quality costs and performance and shall be to the
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satisfaction of the interested parties and adequate in their content to ensure that
persons are fully aware of the requirements and methods to be implemented to
ensure satisfactory rectification of the non conformance.
2. Preventive Action
Maintain and submit the relevant records of all investigations and analysis
on actions taken for management review.
2. Inspection Testing
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Receiving inspection and testing Incoming material, fabricated item and equipment
will not be processed until it has been inspected or otherwise verified as conforming
to specified requirements.
The QC Personnel is responsible for ensuring the status of inspection and test of
construction activities is monitored and report of such inspection shall be verified
before proceeding with the remaining job. When sample inspection/ test are
conducted, each lot is clearly defined and traceability between representative
sample and items included in the lot is established.
No processed item shall be dispatched until approval of final inspection has been
satisfactorily completed.
Inspection report result & summary data of its which will identified that the product
is verified and already comply with inspection and test requirement. The PM/ CM
shall be the person authorized to release the product for further processing to use or
install and shall be in consultation with QC Personnel.
6. Non-conformity
All managers and supervisor should maintain the records pertinent to his department to
provide evidence of conformity to requirements. Records shall remain legible, readily
identifiable and retrievable. On completion of erection and start up, appropriate documents
shall be collected and passed to client as turn over package (TOP). Records required to be
turned over to client shall be defined at an early stage of the work by mutual agreement
between client and PP EPC. Records shall be made available to client upon request within
the retention period
XIII. Quality Audit
Internal quality audit will be conduct at minimum once per project. The schedule shall be
defined on proposed quality program on project or follow EPC division quality audit.
XIV. Attachment