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Doc. No.

:
SHUQAIQ STEAM POWER PLANT SSPP-11-PQP-Q-43-001-001
PROJECT
Rev. No. :
No. : A
Date: 30/12/2015
PROJECT QUALITY PLAN
Contract No. B1303A-A016

SHUQAIQ STEAM POWER PLANT PROJECT

PROJECT QUALITY PLAN

Rev. Date Reason for Issue Prepared by Checked by Approved by

 A 30/12/2015 Issued for Approval


Approval Aamir Faridi B.J. Jeon S.K. Choi

Informatics reference:
SSPP-11-PQP-Q-43-001-001 Rev.A Document date Printing Date
Project Quality Plan 12/30/2015 10:35 AM 12/30/2015 18:56

The content of this docum ent is strictly confidential.


The content cannot b e used, copied, or subm itted to third parties without written con sent of B ONGKYUNG CONSTRU
CONSTRUCTI
CTION
ON CO,
LTD. SHUQAIQ SAUDI ARABIA.

T h i s d o c u m e n t o r / an
an d h i s a t t a c h m e n t s a r e s u b j e c t e d t o r evev i s i o n s / m o d i f i c a t i o n s . B e f o r e u s i n g t h i s d o c u m e n t , p l e a s e
verify to have the updated docum ent.
W h o e v e r c o m e s i n p o s s e s s i o n o f t h i s e d i t i o n , i s o b l i g e d t o c a n c el
el o r d e s t r o y a n y p r e v i o u s c o p i e s i n h i s h a n d s o r
duplic ates subm itted of with he must have evidence tracking.

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Doc. No.:
SHUQAIQ STEAM POWER PLANT SSPP-11-PQP-Q-43-001-001
PROJECT
No. : A
Rev. No. :
Date: 30/12/2015
PROJECT QUALITY PLAN
Contract No. B1303A-A016

SECTIONS SUMMARY AND STATUS

SECTIONS EVISION
STATUS
SECTION DESCRIPTION
0
00 0A 0B 0C 0D 0E F

SECTIONS SUMMARY AND STATUS X

PREFACE X

PROJECT QUALITY POLICY STATEMENT X


CORRESPONDENCE BETWEEN ISO
X
9001:2008
PART –
PART – I
 I

QUALITY MANAGEMENT SYSTEM

1 GENERAL X

1.1 SCOPE AND OBJECTIVE

1.2 QUALITY PLAN MANAGEMENT


MANAGEMENT
1.3 GENERAL PROJECT SCOPE OF
WORK
1.4 TERMINOLOGY AND DEFINITIONS

2 PROJECT ORGANIZATION X

2.1 GENERAL

2.2 QA/QC PERSONNEL CHANGES


REFERENCE DOCUMENTS AND
3 PROJECT DOCUMENTATION/ X
ELIVERABLES
3.1 GENERAL

3.2 REFERENCE DOCUMENTS

3.3 From BKC

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Contract No. B1303A-A016

SECTIONS SUMMARY AND STATUS

SECTIONS EVISION
STATUS
SECTION DESCRIPTION
0
00 0A 0B 0C 0D 0E F

SECTIONS SUMMARY AND STATUS X

PREFACE X

PROJECT QUALITY POLICY STATEMENT X


CORRESPONDENCE BETWEEN ISO
X
9001:2008
PART –
PART – I
 I

QUALITY MANAGEMENT SYSTEM

1 GENERAL X

1.1 SCOPE AND OBJECTIVE

1.2 QUALITY PLAN MANAGEMENT


MANAGEMENT
1.3 GENERAL PROJECT SCOPE OF
WORK
1.4 TERMINOLOGY AND DEFINITIONS

2 PROJECT ORGANIZATION X

2.1 GENERAL

2.2 QA/QC PERSONNEL CHANGES


REFERENCE DOCUMENTS AND
3 PROJECT DOCUMENTATION/ X
ELIVERABLES
3.1 GENERAL

3.2 REFERENCE DOCUMENTS

3.3 From BKC

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Contract No. B1303A-A016

SECTIONS SUMMARY AND STATUS

SECTIONS REVISION
STATUS
SECTION DESCRIPTION
00 0A 0B 0C 0D 0E 0F

CONSTRUCTION PROGRAM PLANNING


4 AND CONTROL X

4.1 GENERAL

4.2 RESPOSIBILITIES

4.3 METHODOLOGY
METHODOLOGY

4.4 PLANNING, SCHEDULING,


PROGRESS & EVALUATION
REPORTING

5 DOCUMENT AND QUALITY RECORDS CONTROL X

5.1 SCOPE

5.2 GENERAL

5.3 DOCUMENT
DOCUMENT PREPARATION

5.4 CHANGES

5.5 RECEIPT

5.6 DISTRIBUTION

5.7 CONTROL AND PROTECTION OF


SEC ENGINEERING DATA

5.8 DOCUMENTS AND RECORDS ENTERS

5.9 PROJECT RECORD BOOKS

5.10 AS - BUILT DRAWINGS


DRAWINGS

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SECTIONS SUMMARY AND STATUS

SECTIONS REVISION
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SECTION DESCRIPTION
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PREPARATION AND MANAGEMENT SYSTEM OF


6 X
CONSTRUCTION WORKS QUALITY PLAN

6.1 SCOPE

6.2 REPONSIBILITIES
REPONSIBILITIES

6.3 INSPECTION AND TEST PLAN(ITP)

6.4 MANAGEMENTS OF INSPECTION POINTS

6.5 TEST AND INSPECTION DOCUMENTS


DOCUMENTS

6.6 TEST AND INSPECTION SCHEDULE AND STATUS

7 SITE TECHNICAL SUPPORT SERVICES X

7.1 SCOPE

7.2 RESPONSIBILITIES
RESPONSIBILITIES

7.3 PROCEDURES

8 QUALITY CONTROL ACTIVITIES X

8.1 GENERAL

8.2 INSPECTION AND TEST PLAN MANAGEMENT

8.3 QUALITY CONTROL ACTIVITY COORDINATION

8.4 INSPECTION AND LOG BOOKS

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SECTIONS SUMMARY AND STATUS

SECTIONS REVISION
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8.5 CONSTRUCTION MATERIAL CONTROL

8.6 DOCUMENT CONTROL

8.7 PROJECT RECORDS BOOKS

8.8 Quality Records Compiling and Filing System

8.9 SPECIAL PROCESS PROCEDURES

8.10 MANAGEMENT OF MEASURING AND


TESTING EQUIPMQNT

9 QUALITY ASSURANCE ACTIVITIES X

9.1 GENERAL

9.2 MANAGEMENT REVIEW

9.3 DOCUMENT REVIEW

9.4 QUALITY AUDITS AND QUALITY SURVEILLANCE

9.5 NON-CONFORMITIES

9.6 PREVENTIVE/CORRECTIVE ACTIONS

9.7 PERSONNEL QUALIFICATION AND TRAINING

9.8 STATISTICAL TECHNIQUES

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SECTIONS SUMMARY AND STATUS

SECTIONS REVISION
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10 CONTROL OF NON-CONFORMANCE PROCEDURE X

10.1 SCOPE

10.2 OBJECTIVE

10.3 REFERENCE

10.4 RESPONSIBILITIES

10.5 PROCEDURES

PART – II

QUALITY PLAN FOR PROCUREMENT &


MATERIALS MANAGEMENT

11 PROCUREMENT PLAN X

11.1 SCOPE AND PURPOSE

11.2 REFERENCE

11.3 BKC MATERIAL SUPPLY PORTION

11.4 RESPONSIBILITIES

11.5 PROCUREMENT PROCEDURE

11A MATERIALS MANAGEMENT PLAN X

11A.1 SCOPE AND PURPOSE

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11A.2 CORRELATION WITH OTHER


PROCEDURES/DOCUMENTS

11A.3 RESPONSIBILITIES

11A.4 MATERIAL IDENTIFICATION AND TRACEABILITY

11A.5 RECEIVING INSPECTION OF MATERIALS

11A.6 STORAGE

11A.7 PROTECTION AND PRESERVATION OF


MATERIALS DURING STORAGE AND
CONSTRUCTION PERIOD

11A.8 ISSUING AND INVENTORY CONTROL

11A.9 OVERAGES, SHORTAGE DAMAGES REPORT

11A.10 MATERIAL RETURN FROM SITE STORE

PART – III

QUALITY PLAN FOR CONSTRUCTION &


X
PRE-COMMISSIONING PLAN

12 CONSTRUCTION AND PRE-COMMISSIONING PLAN X

12.1 SCOPE AND PURPOSE

12.2 REFERENCE

12.3 RESPONSIBILITY

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12.4 QUALITY CONTROL PROCEDURES

12.5 HHI/SEC TYPICAL INSPECTION PLANS(ITP‟S)

12.6 PRE-COMMISSIONING PLAN

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PROJECT QUALITY PLAN
Contract No. B1303A-A016

PREFACE

This Project Quality Plan shall be used as reference during the implementation of BKC
Contract scope of HHI. Contract No. B1303A-A016. PERMANENT HOUSING
COMPOUND WORKS.

The preparation of this Project Quality Plan is correlated with BKC Established Company
Quality Manual and its Operating Procedures, which describes the Management Policies
and commitment of its resources to support the effectiveness of the Quality system
implementation in all of its business operations.

This Project Quality Plan is subdivided into three (3) parts, i.e.:

Part I Quality Management System

Describes the overall Management Functions and Quality system to be adopted


which covers organizational structures, planning and controlling of the resource
inputs and actions in satisfying the Quality objectives as set forth in the HHI
Contract No. B1303A-A016, Quality Inspection Procedure and Q uality Management
System- Requirements of ISO 9001:2008.

Part II Quality Plan for Material Procurement and Material Management

Describes the Quality Control Activities during the Procurement Phase and Material
Management at Site to Assure Procured Equipment, materials & services conform
to the sub-contract requirements. .

Part III Quality Plan for Construction and Pre-commissioning

Describes the Quality Control Activities or Quality System Procedures covering


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Contract No. B1303A-A016

each work phase i.e. Civil Works, Associated Civil Works, Special Works
Processes & Pre-commissioning that includes Inspection & Test Plans (ITP’s), and
the QP Management approach for the Readiness to Testing and Pre-
commissioning.

It is therefore expected that those who deal in the performance of this Contract job
shall adhere to this Project Quality Plan and thus, contribute to the attainment of
the Company’s expected quality standards and objectives of the overall  Project.

Engr. CHOI SEONG KYU- Project Manager

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Contract No. B1303A-A016

PROJECT QUALITY POLICY STATEMENT

BONGK YUNG CONSTRUCTION COMPANY. Is committed to maintain its proven

reliable performance with the Company and HHI for the Contract Job Execution for the
 project: PERMANENT HOUSING COMPOUND WORKS in

 Achieving the objectives of the Contract.

We, at BONGKYUNG CONSTRUCTION COMPANY are committed to:

1) Effective implementation of Quality Management system by involving all the


Employees and continually improve all the processes under the Scope.

2) Enhance the Customer Satisfaction by timely completion of the projects at affordable


cost.

3) Incorporate proper Training and safety consciousness in each Process.

Engr. CHOI SEONG KYU- Project Manager

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Date: 30/12/2015
PROJECT QUALITY PLAN
Contract No. B1303A-A016

CORRESPONDENCE BETWEEN ISO 9001:2008 & THIS

PROJECT QUALITY PLAN

ISO 9001:2008 Project Quality Plan


ISO 9001:2008 Clause Description
Clause No. Sections

4 Quality Management System

4.1 General Requirements This whole of PQP

4.2 Documentation requirements

4.2.1 General This whole of PQP

4.2.2 Quality Manual This whole of PQP

4.2.3 Control of documents Sections 3, 5 and 7

4.2.4 Control of records Sections 3, 5 and 7

5 Management Responsibility

5.1 Management commitment Section iii

5.2 Customer focus Section iii

5.3 Quality Policy Section iii

5.4 Planning

5.4.1 Quality objectives Section iii

5.4.2 Quality management system planning All the Sections of PQP

5.5 Responsibility, authority and communication

5.5.1 Responsibility and authority Section iii and 2

5.5.2 Management representative Section iii

5.5.3 Internal communication All Sections

5.6 Management Review

5.6.1 General Section 9 under 9.2

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Contract No. B1303A-A016

Section 9 under 9.2, 9.3


5.6.2 Review input & 9.4

Section 9 under 9.2, 9.3


5.6.3 Review output & 9.4

6 Resource Management

6.1 Provision of resources All Sections

6.2 Human resources

6.2.1 General Sections 2 & 9 under 9.7

6.2.2 Competence, awareness and training Sections 2 & 9 under 9.7

6.3 Infrastructure All Sections

 All Sections & Project Loss


Prevention Program
6.4 Work environment
Manual

7 Product Realization

7.1 Planning of product realization Sections 11 to 12

7.2 Customer related processes

Determination of requirements related to the


7.2.1 product Sections 11 to 12

7.2.2 Review of requirements related to the product Sections 7 & 11 to 12

7.2.3 Customer communication Section 7

7.3 Design and development

7.3.1 Design and development planning Not Applicable

7.3.2 Design and development inputs Not Applicable

7.3.3 Design and development outputs Not Applicable

7.3.4 Design and development review Not Applicable

7.3.5 Design and development verification Not Applicable

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Contract No. B1303A-A016

7.3.6 Design and development validation Not Applicable

7.3.7 Control of design and development changes Not Applicable

7.4 Purchasing

7.4.1 Purchasing process Section 11

7.4.2 Purchasing information - do -

7.4.3 Verification of purchased product - do -

7.5 Production and service provision

7.5.1 Control of production and service provision Sections 4, 6 & 11 to 12

Validation of processes for production and service


7.5.2 provision Sections 11 to 12

Section 11 & 11A under


7.5.3 Identification and traceability 11A.4

Section 11A under


7.5.4 Customer property 11A.5.2

7.5.5 Preservation of product Section 11A under 11A.7

7.6 Control of monitoring and measuring devices Section 8 under 8.10

8 Measurement, analysis and improvement

Section 9 under 9.2 &


8.1 General Sections 11 to 12

8.2 Monitoring and measurement

Section 8 under 8.4 &


8.2.1 Customer satisfaction Sections 11 & 12

8.2.2 Internal audit Section 9 under 9.4

8.2.3 Monitoring and measurement of processes Sections 11 to 12

8.2.4 Monitoring and measurement of product Sections 11 to 12

8.3 Control of non conforming product Section 9 under 9.5 & 9.6

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Contract No. B1303A-A016

8.4 Analysis of data Sections 8, 9, 11 to 12

8.5 Improvement

8.5.1 Continual improvement Section 9

8.5.2 Corrective action Section 9 under 9.5 & 9.6

8.5.3 Preventive action Section 9 under 9.5 & 9.6

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Contract No. B1303A-A016

 1. GENERAL

1.1 SCOPE AND OBJECTIVE

This document summarizes how BKC shall manage the Contract Agreement Work Scope
based on the Quality System as set forth in their Company‟s Quality Manual and
correlated with HHI / SEC‟s Documents which identifies the scope of   work.

BKC Quality Management System document‟s structure, this Project Quality Plan
describes the implementing procedures of the Company‟s general policies and procedures
covering the management functions of organizing, planning and controlling the required
resource inputs and specific actions to meet the objectives of the Procurement and
Construction activities of the Project pursuant to quality requirements.

The prime objectives of this Project Quality Plan is to ensure effective planning and
facilitate understanding of the specific quality practices, resources and sequence of
activities relevant to all phases of the Contract Job and thus, smoothly implement the plan
in timely manner and meet the overall quality goal of this project.

1.2 QUALITY PLAN MANAGEMENT

This document has been prepared by the QA/QC Department of BKC with the necessary
technical assistance from the key members of t he Project Team.

It has been initially reviewed and approved by BKC Corporate QA/QC Manager and
authorized by the Project Manager and subject for final review/approval by the HHI / SEC
 Authorized Representative and subsequent implementation by all concerned.

This Project Quality Plan shall be updated for whatever HHI comments and / or
improvements, and amendments / revisions shall be documented and duly approved by
the HHI / SEC. All new issues shall be provided to all concerned “Controlled Copy”
Holders of the Project Quality Plan as part of Document Control.

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Contract No. B1303A-A016

1.3 GENERAL PROJECT SCOPE OF WORK

The following WORKS shall be performed in accordance with the Contract Agreement
between BKC and HHI.

The General Project Scope of Work describes the contract coverage of work and Job
specifications drawing list and Standards. It also identifies all processes, operations
deemed as necessary for the execution of the Architectural, Civil, Electrical, and
Mechanical activities involved in the PHC AREA Scope as described in the Scope of work.

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Contract No. B1303A-A016

1.4 TERMINOLOGY AND DEFINITIONS

Words used in this Project Quality Plan and related Inspection Specification shall
have the same meaning or intent as correlated to ISO 9000:2000 (Quality Management
System – Fundamentals and Vocabulary).

1.4.1 CLIENT

Saudi Electricity Company (SEC)

1.4.2 HHI

Hyundai Heavy Industries Company (CONTRACTOR)

1.4.3 BKC

BONGKYUNG CONSTRUCTION CO, LTD.(SUB-CONTRACTOR)

1.4.4 VENDOR

Means any person, company, manufacturer, supplier or sub-supplier having a


contract or purchase order with HHI and /or BKC, for the supply of materials or
equipment for facilities, including, when necessary, services in connection with
the installation, testing, pre-commissioning and commissioning of any materials
or equipment.

1.4.5 QAS

Means Quality Assurance specification

1.4.6 CQP

Construction Quality Plan

1.4.7 QC

Quality Control specification

1.4.8 MILL TEST CERTIFICATE/ REPORT

Means a document generated by a manufacturer of material, which completely


identifies the supplied material and the specification under which it was produced
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and reports all required test values necessary to demonstrate compliance with the
specification.

1.4.9 REVIEW

Means examination of documentation issued by others for completeness


and correctness i.e. Inspection Reports, Technical Submittals, Mill Certificates, etc.

1.4.10 HOLD (H) POINT/S

Means the Hold (H) point/s during the stage of Inspection/Test activities
whereby Contractor Inspector cannot proceed with the inspection or test
without the presence of HHI/ Inspector/SEC Inspector. Notification to Main
Contractor/Company is required through written "Request for Inspection (RFI)

1.4.11 WITNESS (W) POINT/S

Means the witnessing (W) points during the stage of Inspection/Test activities
whereby Contractor Inspector may proceed with the scheduled inspection
and/or test after notifying HHI / SEC through written Request for Inspection
(RFI).

1.4.11 INSPECTOR

Means the person acting as the authorized representatives either by


Vendor, Sub Contractor, and Main Contractor, SEC or third party
commissioned by any of the contractual parties dispatched to the inspection
site to undertake inspection activities in their respective behalf

1.4.12 INSPECTION

 Activities such as measuring, examining, testing, gauging one or more


characteristic of a product or service and comparing these with specified
requirements to determine conformity.

1.4.13 NON- CONFORMITY

The non-fulfillment of specified requirements.

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2. PROJECT ORGANIZATION

2.1 GENERAL

The Project Organization to be adopted in this contract job is shown on the appendix of
this Section. This Project team is linked to BKC Head Office in JEDDAH to provide
technical and functional supportive roles to the project needs.

 At BKC JEDDAH Head Office, the Key Personnel to provide authoritative and
supportive roles for this contract job are as follows:

2.1.1 Corporate QA/QC Manager

This position is responsible directly to the Project Manager of BKC for the
overall design and preparation of appropriate Quality Control and Assurance
Program for any contractual services or job of BKC to its clients and its
implementation.

He has the full authority to exercise all the necessary actions for the
management to support the QA/QC group in attaining all the Quality Assurance
objectives cited in this section. He is also reviewing the audit results periodically
to verify the effectiveness of Implementation of Quality System.

He is responsible for setting-up and implementation of the Quality System


requirements of the project in accordance with the Contract Agreement
Provisions. He monitors the status of Non-Conformance Reports and Customer
Complaints for the effective closure of the same. The QA/QC Manager is also
responsible for the review of Project Specification Quality System as per
ContractAgreement.

2.1.2 Engineering Manager

Collaborates with HHI in ensuring that all the contract technical documents (Job
Specifications) issued to BKC are of the latest revisions. He provides technical
Support to the Project Construction Team. Refer to Procurement Plan for
detailed responsibilities.

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2.1.3 Procurement Manager

Is responsible for the management of procurement activities to meet the specific


material specifications of the project and serve them in timely manner. Refer to
section 11 Procurement Plan for detailed responsibilities.

 At site, Project Management Team of BKC in coordination with HHI/SEC has the
overall authority to administer the Project Site Management and fully supported
by the project key personnel, i.e.:

2.1.4 Site/Construction Manager

Has the full authority to administer the project scope undertakings. He


coordinates with HHI on all matters covering Project Contract Management
Collaborates with BKC functional Units, i.e., Procurement, QA/QC, Personnel,
Finance & Admin, Equipment, and Operation Planning & Resource Control for
all required supports to the project.

2.1.5 Site Superintendent/ Supervisor

Overall-in-charge of all Work Production Areas assisted by Work Foreman for


each engineering discipline or work phase.

2.1.6 Planning & Scheduling Engineer

In-charge of Work & Resource Planning and Scheduling, and Work Progress
Tracking and Accomplishment Reporting. Also in-charge of the preparation of
Progress Accomplishment Reports and Maintenance of Work Accounting
Ledger Books.

2.1.7 Material Management officer

Supervise Material Management at site. Refer to Sec. 11.A of the PQP for
detailed responsibilities.

2.1.8 Technical Support Services Supervisor (Resident Engineer)

In-charge of Site Technical Supports/ Coordination, Document Control and As-


built Drawings mark-ups. Specific services are mentioned in Section 7 of this
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PQP.

2.1.9 HSE Officer

In-charge of Safety, Health & Environmental Management Implementation at the


Project site.

2.1.10 Administrative Assistant/Secretary

In-charge of administrative functions for Personnel and secretarial works.

2.1.11 Project QA/QC Manager

Manages the implementation of Project Quality Plan and Quality Control


Procedures, direct all QC Supervisors/ Inspectors, prepare Two Week Look
 Ahead Inspection Activities and will be at project site on full time basis and
coordinates with Corporate QA/QC Manager at H. O.

2.1.12 QC Engineer

 Are the trained Engineer for each work discipline, who directly conducts
inspection, witness testing and monitoring of the product, fabrication and
installation process. They gather and maintain on orderly records necessary
during inspection and testing based on the pre-designed Inspection and Test
Plans (ITPs) or (ITP) and Method of statements. They are normally assigned at
site when their services are needed.

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Contract No. B1303A-A016

2.2 QA/QC Personnel Changes

Pursuant to Contract Agreement, BKC shall advise HHI at least thirty (30)
calendar days in advance for any replacements to QA/QC Personnel that are
scheduled for vacation, emergency leave, and temporary assignments or caused
by illness, employment termination and resignation.

3. REFERENCE DOC/PROJECT DOC/DELIVERABLES

3.1 GENERAL

This section generally describes the documents to be issued by HHI at this


Project to BKC as the base reference of contract job execution to attain the
objective of safety, quality standards and design requirements of the project. It
also includes the documents to be developed and submitted by BKC in the form
of Quality Plans and Procedures, submittals, etc. pursuant to ISO 9001:2008
Quality Management System (QMS) and all other deliverables required by the
contract provisions.

3.2 REFERENCE DOCUMENTS

3.2.1 Issued by HHI

 As mentioned in the Contract HHI and SEC the base reference documents consist but
not limited to the following:

a.) All Relevant Contract Agreement Specifications etc.

b.) IFC or Approved Drawings.

c.) SEC Standards, Specifications and procedures etc. as applicable to this project.

d.) Applicable international codes and industry practices

 All work on this Project shall be completed in accordance with the latest issue of SEC
Standards as applicable, upon award of the project including but not limited to the above
documents cross-referenced therein.

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3.3 From BKC

Project Quality Plan (This Document) which contains generally the quality management
System. specific Work Quality Plan / Inspection and Test Plan and describes the
elements of Quality Assurance and control, i.e.:

-  Organization
- Reference Documents
- Construction Program Planning & Control
- Procurement Plan
- Material Management Plan
- Preparation and Management System of Construction Works
- Site Technical Support Services
- Quality Control Activities
- Corrective and Preventive Action procedure
- Quality Work Plans / ITPs of each Engineering Discipline or Work
Phase.
 Manufacturer‟s Data (Drawings and Data Sheets Installation, Operation and
Maintenance Instructions, Parts list, other NMR documents, Operating
Instruction, etc.
 Material Technical Submittals.
 Qualification Records of Key Personnel and Specialized skilled personnel, i.e.
Welders, Critical Coating Personnel, Cable Splicer, Riggers, Heavy
Equipment Operators, etc.
 Third Party Testing Agency Pre-Qualification.
 Valid Certificate of Measuring and Testing Instruments.
 Other submittals required by the Contract Technical Documents.

The work Quality Control Procedures (QCPs) or Method of statements which are part of
Quality Procedures Deliverables are summarized as appended in Section 12 of this PQP.

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 4. CONSTRUCTION PROGRAM PLANNING & CONTROL

4.1 GENERAL

This section describes BKC methodology in the development of a workable


construction detailed schedule as required in Contract Agreement, HHI Works.

4.2 RESPONSIBILITIES

BKC Site Planning and Scheduling Unit shall be responsible for planning and
scheduling of work activities and required resources in the construction execution and
mechanical completion of the contract activities based on main Contractor‟s   Project
Critical Milestone Dates as shown in Contract Requirements. BKC Planning and
Scheduling Engineer shall coordinate with Main Contractor for any changes on
schedules in the work phases and shall make adjustment / updating on the current
project situation. He shall also be responsible for periodical progress reporting,
schedule updating and to include delay analysis if setbacks on schedules are
encountered during the contract execution. Any revisions to the Project Schedule shall
be subject to approval by Main Contractor.

4.3 METHODOLOGY

For an effective control of project activities, the Planning and Scheduling Unit will be
using the aid of MICROSOFT EXCEL or PRIMAVERA PROJECT PLANNER

SOFTWARE for the preparation of computer operated CPM and BAR Chart
Schedules as time saving and useful tool in Project Management. The planning phase
involves the listing of tasks of job, which must be performed to bring about the
completion of the project milestones. Resource requirements for materials,
equipment and manpower are determined in this phase and duration for each is made.
Scheduling is done by interconnecting of all the necessary activities of the project in
the logical order as input to the Computer Software Program with its corresponding
early and late occurrences of start and finish dates and the computer handles
processing of the data. Control is a function, which is a periodical review of the
difference between schedule and the actual performance as the aspect of review and

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evaluation and pursuing corrective actions to prevent overall delay impact to Project
Target Critical Milestone Dates.

4.4 PLANNING, SCHEDULING, PROGRESS AND EVALUATION REPORTING

4.4.1 General

This activity is to be collaborated with HHI Planning and Scheduling Specialist


who will provide technical guidance to meet the Client‟s Scheduling and
Progress Reporting requirements.

BKC Work Schedule shall be comprised of separable portions or aggregated


levels of detail of the integrated network as follows:

 Project milestone schedule (level II)


 Summary level schedule (level III)
 Project Control schedule (level IV)
 Manpower requirements forecast
 Manpower loading curve
 Work analysis breakdown

 All schedules, regardless of the level of detail, shall be supported by and


traceable to activities in the detailed Project Control

4.4.1.1 Construction Work Breakdown Structure (WBS) for Progress Reporting

Specific Construction Work Breakdown Structure (WBS) shall be prepared by


the P & S Engineer and submitted to HHI for review and approval, as basis of
progress evaluation and reporting.

4.4.1.2 Schedule Control and Progress Reporting

Shall follow the required contents pursuant to Sub-contractor agreement in line


with Civil Works including demolition, base course and Asphalt contract
specifications (as applicable) per BKC contract no. (B1303A-A016)

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 5. DOCUMENT CONTROL AND QUALITY RECORDS.

5.1 SCOPE

This section describes the management system to be adopted for project documents
and records control covering Construction Drawings, Specifications, other relevant
project technical documents and QA/QC records to include all submittals directed to
HHI.

 A close coordination between BKC Head Office and Site Office shall be observed on
issuance and receipts of approved and latest documents.

5.2 GENERAL

In general, field documents and record management shall be governed and be


handled according to the requirements of the following:

 Sub-contract agreement provisions


 Contract Schedules provisions
 HHI-SAES-128 Security Control of SEC Engineering Data outside of SEC
 This Project Quality Plan.

5.3 DOCUMENT PREPARATION

 All Project related Quality documents shall be prepared by the concerned QA/QC
Engineers or Site QA/QC Manager, which will be reviewed and approved by the
Corporate QA/QC Manager and Authorized by the Project Manager.

HHI/SEC review and approval of the document shall be sought prior to Implementation.

Construction related Quality Control Procedures or Work Instructions, Forms etc. shall
be prepared/revised by the concerned QA/QC Engineer in accordance with the
construction requirement during the execution of the Project.

 All the Quality System Documents shall have the revision status and the initial issue
shall be noted as „Rev.00‟ after approval, on the front sheet and on every sheet of the
Document.

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The Documents‟ identification No, (Doc. No.), Rev. No. , Date and Page shall appear at
particular location on each page of the Quality System Documents consistently.

The „Controlled‟ and „Uncontrolled‟ copies of all the Quality System documents shall be
stamped accordingly.

The Draft copies shall be stamped a s „DRAFT‟ and they shall not be used for
implementation or for reference purpose in other procedures or activities.

List of all Quality Documents with its revision Status shall be available in “Section and
summary status index in this PQP, which shall be prepared and maintained by the
Project QA/QC Manager, reviewed by the Corporate QA/QC Manager and approved by
the Project Manager.

The Project QA/QC Manager at Site shall maintain a separate Master list of forms with
its revision status.

5.4 CHANGES

The changes to the documents shall be carried out by the functional unit/discipline that
originally prepared, approved, and authorized the Documents unless specifically
designated otherwise. The designated functions shall be given access to pertinent
background information.

The nature of amendment/reason (description) in brief shall be mentioned in the


„Status‟ column of the cover sheet of the concerned document(s).

The amendment incorporated shall be identified by double vertical lines on right side
of the amended line, paragraph or page

When a paragraph is completely deleted, the number of the paragraph shall be


retained and the word „deleted‟ shall appear in its front and in addition to the double
lines on the right hand side of the number.

During subsequent amendments the new amendments shall be incorporated deleting


the existing double lines and paragraph(s) (mentioned „Deleted‟) and the paragraph(s)
renumbered.

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Quality Procedures, Work Procedures, Inspection and Test Plans, shall be reissued as
revision(s) after every amendment.

5.5 RECEIPT

Subsequent receipt from HHI is the responsibility of the Site Project Manager through
the Site Technical Support Supervisor.

 All incoming documents/drawing transmittals for this project are to be addressed to the
Site Manager, as BKC field representative. The document transmittal notes shall be
date-stamped on the date received and registered in Log Register Book. Distribution of
receipt documents is controlled by the Document Controller for established distribution
schedule under the directional responsibility of the Site Manager. In particular, the
following shall be observed in receiving documents/drawings:

a) Check the contents of the document transmittal to confirm:


 That all drawings/documents as stated were matching
 That the drawing numbers, sheet numbers and revisions match those
given in the document transmitted.

b) Log in all received drawings onto the computer, to include


 Drawing title for all new drawings
 Date of the revision
 Revision Number
 Document transmittal reference.
The document Log is interactive (both historical and live reference). No document shall
be deleted or deleted from the Log. When any drawing is superseded, it shall be noted
in the Log. Once the drawings/documents are registered, the Drawing/Document
Central File shall be provided a copy as the “Master Copy”, to replace superseded
revision of the previous “Master Copy” (applies to reused drawings).

One copy stamped „Superseded‟ is retained in a file for all superseded documents and
maintained by Site QA/QC Unit/Document Controller as applicable.

5.6 DISTRIBUTION

 At the start of site activities, the Document Controller shall establish the document
distribution schedule (Form No: Q-014) and classify it by type and mainly divides to
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internal and external to BKC in order to ensure that the current issues of all documents
are available at the pertinent locations. This will be discussed and cleared with BKC
Site Manager and other project key staff members to include Secretary/ Administrative
 Assistant, Construction Superintendents, P & S Engineer, QA/QC Engineer, Safety
Supervisor, etc.

 A copy of the document transmittal shall be circulated to each concerned


Engineer/Supervisor and initialed by them to indicate their awareness of the
new/revised drawing.

The Document Controller shall do distribution of the drawing/documents as per the


Distribution Schedule as “Controlled Copy”.

The Controlled copy holders shall destroy the superseded documents when the
revised documents are issued to them.

Documents shall be distributed to all concerned through “Document Transmittal”


(Form No.: Q-017)

The document controller shall maintain both the electronic version and hard copy of
the drawing register at the same status at all times.

5.7 CONTROL AND PROTECTION OF HHI / SEC ENGINEERING DATA

 All HHI / SEC Engineering Data, (those data classified and defined under SAEP-127)
are subject to proper control on its receipt, issuance and/or return/destroy after official
use by BKC authorized users.

BKC designated Resident Engineer (Technical Support Services Supervisor) shall


maintain a Document log Book/Registers of SEC Engineering Data on their dates of
receipt from HHI.

Receipt of these data shall be recorded in the log book/Register Sheets per
classification of documents/data (issued for construction/standard drawings, technical
specifications, Engineering Standards/Procedures, or any other technical information
in the form of paper, electronic copies, etc.). Entries shall include:

- Description of Data and Revision/Issue No.


- Number of copies/sets received
- Date received
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BKC is governed by Contract Agreement provisions covering the obligation of


contractor to prohibit for any unofficial reproduction of test data for any other purpose
except those warranted by the contract scope allowed by HHI. For this restriction, BKC
is liable to return to HHI these data upon Project Completion.

BKC shall maintain an orderly document control system in filing and issuing HHI / SEC
Engineering Data to authorized users (BKC Work Personnel, Engineers,
Subcontractors or Vendors)

 All issues of these data as distributed to authorized users are recorded and controlled
in a logbook.

 All authorized recipients of these Data are to be made aware of their obligation to
safeguard these data during the duration under their custody. These data should not
be allowed to remain and left in unsecured place nor seen scattered at the jobsite
exposed to risk of reaching to the wrong persons/unit or unauthorized users.

BKC file copy of HHI / SEC Engineering Data at jobsite control office shall be
maintained in orderly manner and updated accordingly to its latest revisions and re-call
those issued ones that were superseded.

 At the end of the Project Contract Completion, all the HHI / SEC Engineering Data
issued to BKC shall be returned except those, which will form part of the Mechanical
Completion Documents Package to be turned-over to SEC upon Final Project
Completion. Discarded or dilapidated documents/data of no use shall be completely
destroyed with prior approval and presence of HHI Authorized Representative.

5.8 DOCUMENTS AND RECORDS CENTERS

BKC shall maintain a dedicated room/place with ample space at the site office to serve
as the Central Filing Centre of all field master files of technical Drawings / Documents.
The files shall be coded properly for easy retrieval.

Field Quality Records and documents will be filed separately under the Project QA/QC
Unit with its own “Document Controller” who will liaise closely with the Technical and
Document Control Supervisor for incoming quality related documents from HHI.

 All correspondences will be filed separately under the Project Secretary Office.

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5.9 PROJECT RECORD BOOKS(Inspection Record Books)

Project QA/QC Manager will manage Field Inspection quality records. He shall be
supported by all discipline Superintendents/supervisors and QC inspectors for any
technical/quality matters to facilitate completion thereof.

 All quality records emanating from BKC that needs to be signed by authority
Inspectors from HHI / SEC shall have the original copy kept by BKC, which will be later
needed during the preparation of the Inspection Record Books.

The Procurement QC Supervisor / coordinator shall be responsible for the control of


procurement and quality documents & records covering Material Technical Submittals,
Vendor's Source Inspection Assignment Package and solicitation & filings of Vendor's
Quality Inspection & Test Records as described in the relevant sections of this Project
Quality Plan.

Refer to section-8 Quality Control Activities under paragraph 8.8 for detailed
procedure in compilation & filing system of quality records for procurement and
construction, which shall form part of I nspection Record Books per SAEP 122.

5.10 AS-BUILT DRAWINGS

BKC shall maintain an active set of Construction Drawings at Site Office, which will be
used as mark-ups of any changes during the entire construction period. It will be under
the responsibility of BKC Technical Support Supervisor. The mark-up is done by
utilizing the green color for all deletions and red color for all additions or changes.

BKC shall observe all the provisions set f orth in the management of As-Built Drawings
in Contract Requirements.

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 6. PREPARATION AND MANAGEMENT SYSTEM OF CONSTRUCTION


WORKS QUALITY PLAN

6.1 SCOPE

This section describes and outlines the system in the preparation of a Work Quality
Plan and its management. It covers the quality practices, resources required, the
planned sequential inspection, testing and documentation during each phase of
Construction process for every Work Discipline until it reached the Mechanical
Completion final stage and declares the contract job or portion of it ready for Pre-
commissioning and Commissioning.

6.2 RESPONSIBILITIES

This preparation of Work Quality Plan and its management during implementation is
vested primarily under the functional responsibility of BKC QA/QC Department and
Project Site‟s QA/QC Unit. They have the full authorities and responsibilities to perform
generally the following:

- Prepares QC Plan and Procedures for each Production Units or phases of


activity
- Initiate action to prevent the occurrence of non-conformity during the job
execution
- Identify and Record any quality problems during Procurement and
Construction phases or all work phases.
- Verify the implementation of solution
- Manage QA/QC documentation
- Exercises independent freedom to visit work sites and verify full compliance
in the implementation of the Company ’s Quality Management System and
Procedures and specifically the Project Quality Plan.

6.2.1 QA/QC Management Personnel

QA/QC Personnel performing quality functions shall have sufficient and well
defined authority, responsibility, qualifications and organizational freedom to
identify quality problems and areas of non-conformance and to initiate,
recommend and substantiate corrective actions as required by Sub-Contract
 Agreement. The detailed responsibilities and authorities of QA/QC personnel
are given in “section No. 2”.

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6.3 INSPECTION AND TEST PLAN(ITP)

BKC QA/QC Department shall utilize the suitable QC Inspection & Test Plan for each
phase of work disciplines as provided by HHI/SEC.

Based on the Issued for Construction Drawings (IFC) and Specifications, Inspection
and Test Plan shall cover the following requirements:

- Statement of specific referenced documents, i.e., IFC Drawings,


Specifications, applicable industry codes and/or specifically prepared Work
Procedures / Instruction / Methods as basis for job execution and
acceptance criteria during testing and inspection. Procedures referred as
acceptance criteria in ITPs can be either relevant HHI/SEC procedures or
BKC approved procedures, as applicable.
- Responsible persons involved in work execution and intervention of BKC,
and HHI Inspectors.
- Work Specifications (as described in job technical specifications) and Pre-
Qualified Procedures (e.g. Welding procedure etc.) to be observed and
followed during work execution.
- Qualification Certificates of Personnel who will perform delicate specialized
 jobs like Welders, H.V. Cable Splicer, etc.
- Test Procedures to be adopted stating test medium or power characteristics
and required environmental condition.
- Dimensional control to be adopted to ensure critical dimensions and
position of interface components are met.
- Inspection Check Items during the process of installation prepared in
appropriate forms.
- Environment conditions are checked to suitableness of performing delicate
work task.
- Applicable Test Record Sheet approved for use during Test Operations for
In- process and Final Test.
- Identification of test instruments to be used correctly calibrated and set.
- After construction or installation, the work shall be subjected to all final and
inspection required by HHI/SEC specifications.

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6.4 MANAGEMENT OF INSPECTION POINTS

6.4.1 Responsibility

The Procurement QC Supervisor shall review the requisitions and purchase


orders in compliance with applicable standards and conduct material
inspections per “Section 1” of this PQP. Refer to Procurement Plan Section 11
for the procedure for Vendors Source Inspection, as applicable, The Site QA/QC
Manager and QC Inspectors quality functions shall have sufficient and well
defined authority, responsibility, qualifications and organizational freedom to
identify quality problems and areas of non-conformance to initiate, recommend
and substantiate corrective actions as required by the Contract requirements.
The responsibilities of BKC QC Inspectors are to be involved at all stages of the
constructions, as well as at requested inspection. QA/QC Unit will notify to HHI
in case their participation, as a witness is required by the Inspection and Test
Plan ITP/ITP

6.4.2 Intervention of the QA/QC Inspectors of Construction Phase

Based on the Inspection and Test Plan ITP/ITP the Specific Work Discipline
Phase (i.e. CIVIL and Associated Civil / Structural Works, etc.), the Work
Production Units involve the intervention of BKC Site QA/QC
Supervisor/Inspectors during each stages of construction. The Work Discipline
Supervisor will raise an Internal Inspection Request (Form No. Q-019) to BKC

Site QA/QC Unit whenever a phase activity is required for Inspection / testing as
shown in ITP/ITP. This Inspection/Testing to be conducted is normally a
preliminary check/test conducted by BKC QC Inspector as an internal
verification whether the phase activity is ready for endorsement to HHI
Representative/Inspector for Inspection or not. If the initial inspection is
satisfactory,BKC QC Inspector proceeds to raising an RFI to HHI
Representative / Inspector. For unsatisfactory findings, the preliminary
inspected activity will require another re-inspection after rectification had been
done on observed deficiencies as recorded in the “Inspection Disposition” space
of the Internal Inspection Request Form. A major deficiency found during the

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preliminary inspection will be covered by a Non-Conformance Report (BKC


Form No. Q-005) issued to the concerned production unit who will take
necessary corrective action on the basis of the NCR report. Proceeding to the
next stage of activities will be on-hold until the cause of rejection is rectified,
inspected a new activity and accepted.

6.4.3 Involvement of (HHI / SEC) Authority Inspectors

If the involvement of the Main Contractor/Client Inspector is required to witness


an inspection event or test, QA/QC will notify them for their presence and
involvement on disposition of inspection event and acceptance or rejection
depending on the outcome of the inspection and test conducted. QA/QC will
provide 24 hours‟ notice for required inspection during regular weekdays and 48
hours‟ notice during weekends.

6.4.4 Non-Conformance/Corrective Action Management

 All deviation or deficient job result encountered during installation process are
reported to BKC Site QA/QC Manager. These deviations are analyzed and
decided for non-conformance on the contractual technical specifications. If
found not complying, it is reported and described in the Non-Conformance
Report. BKC shall submit a copy of each NCR to Client within 48 hours as
required by The Company Contract Requirement. BKC shall respond to all NCR
issued by HHI in writing within 48 hours of receiving notification of non-
conformance, including proposed corrective action. All NCRs shall be
documented on a Non- Conformance Report Log, which is to be submitted at
the regular progress meeting. Refer to PQP section 10 under par. 10.5.1 and
10.5.2 for detailed NCR Procedure, which also described root cause analysis
and preventive action.

6.4.5 Disposition and Corrective Actions

BKC QA/QC Supervisor shall explain the disposition and draw corrective
resolutions. The Non-Conformance Report is forwarded to the HHI QC
Department for technical review of its recommended disposition.
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6.4.5.1 Levels of Disposition of Non-Conforming Materials and/or W ork item

Disposition for non-conformance shall be decided on the following levels of


courses of action pursuant to Schedule 'Q' par. 7.5.

- “ Proceed or Use as is ”

Disposition can be pursued if it can be concluded that the degree of


discrepancy cannot result to negative functional or operational use of the item
without adverse impact to performance, reliability and safety. This shall be
accepted after inspection by HHI/SEC. If item is considered usable, BKC shall
submit application for a waiver to HHI / SEC. The item may be used in the
WORK only if HHI / SEC approve the waiver.

- “ Rework”

Disposition may be imposed if redoing the process of work by the right


method within the allowable tolerance will not alter the integrity of the
materials on its strength workability and operational. This shall be subject to
re-inspection and acceptance by HHI / SEC.
- “Repair ” / Correction

Disposition can be imposed within the level of non-conformance does not


affect the reliability and safety of the item. These items found accepted after
re-inspection may be used in WORK.

- “ Re-graded”

This disposition can be effected if it can be concluded that the degree of


discrepancy cannot result to negative functional or operational use of the
item, if it is re-graded to suitable alternative level that ensures the
performance, reliability and safety.

If item is considered usable, BKC shall submit application for a waiver to HHI /
SEC. The item may be used in the WORK only if they approve the waiver.
This shall be accepted after Inspection by HHI / SEC.

- “ Rejected ”

This disposition shall be governed by Contract Provisions covering rejected


items not complying with SEC‟s standards. The following shall be observed.

 BKC shall segregate all other non-conforming materials and assemblies to


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a clearly designated rejection site. BKC shall track and


Control all rejected equipment or materials until it is re used, exported or
otherwise disposed of. All rejected materials shall be disposed of in
accordance with SEC‟s requirements. Disposition of all rejected material
shall form part of the Quality Management Reports.

6.4.5.2 Hold Marks

For adequate control of encountered non-conformance item by the QC


Inspector during performance of work activity,„ HOLD‟ is put on the item and
it can only be removed by the QC Inspector after deficiencies had been
corrected or rectified to required acceptable standards. Rejected items are
marked “REJECTED” and taken away from the production areas.

6.4.5.3 Corrective Actions

The QC Inspector shall emphasize on the Non-Conformance Report the


required rectification to be done on the Non-Conforming Items to avoid
repetitions of the defective or Non-Conforming work items. Corrective
actions done are monitored accordingly by the QC I nspector.

6.5 TEST AND INSPECTION DOCUMENTS

6.5.1 Scope

It defines the contents of the reports and certificates of Inspection Checks and
Tests to be implemented by BKC.

6.5.2 Contents of documentation

The documentation in the appropriate designed form shall include the following
information and/or data:

- Item being tested


- Type of check, inspection or test
- Person performing the test
- Instrument identification number (wherever applicable)
-  Witness
- Referenced documents for item identification and position
- Results of tests
- Applied test data and outputs

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-  Area/Location  –  signature of BKC/ HHI / SEC Inspectors

6.5.3 Test and Inspection Certification Documentation

a). Request for Inspection RFI/QMIS

b). BKC Classification of Quality Control Forms

c). Installation Checks and Tests for Correct Mechanical Installation

The document certification forms devised by BKC and to be used are titled and
coded as:

Quality Control Forms (like Installation Checklist, Test Report / Record) are
forms used for visual/physical confirmation checks or for recording test
results.

6.5.4 Testing and Pre-Commissioning Forms

HHI/SEC Forms and/or BKC approved forms will be used during the final stage
of Testing & Pre-Commissioning of the facilities covered under this contract job.
These forms will be made available to BKC from the HHI / SEC Project
Commissioning Team.

6.6 TEST AND INSPECTION SCHEDULE AND STATUS

 As part of quality control planning, BKC Construction QA/QC Supervisor


prepares Three Week Look Ahead Test and Inspection Schedule in
collaboration with the Work Planning & Scheduling Engineer and the Work
Production Units. Based on the updated Project Work Activities Schedule, the
Construction QA/QC Supervisor prepares the relevant Inspection Check and
Test activities. The actual date of each Inspection and Test activity shall be
confirmed through Request for Inspection (RFI)/QMIS for each Inspection and
Test activity that required presence of HHI/SEC representative/ Inspector for
their witnessing.

Status of performed test and related results will be monthly issued. This report
will make reference to (as applicable):

 Other test necessary for status reporting

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 7. SITE TECHNICAL SUPPORT SERVICES

7.1 SCOPE

This section describes the functions of Technical Support Services unit at the project
site. These technical services shall cover generally the following:

 To coordinate with HHI for all technical matters covering design


changes, technical queries, etc.
 Performs interface management between site organization and Home
Office Engineering Department.
 Prepares and Controls Field Material Requests for HHI supplied
materials in co-ordination with BKC Material Supervisor.
 Prepares and/or reviews, and controls Material Requisitions (MRs).
 Prepares proforma of “Purchase Requisitions” for materials showing
Non- Material Requirements (NMRs) covered by MRs for reference
use by Procurement Department (H.O.) for Vendor‟s solicitation. This
is collaborated with Engineering Department (H.O)
 Coordinates with Engineering Department Manager (H.O.) on the
preparations and control of “Purchase Requisition” submittals being
endorsed to HHI.
 Shop Drawing Preparations required for facilitating construction
activities only.
 Mark-ups on a living set of construction drawings to reflect the current
“as- built status” of the facilities under  construction
 Conducts surveillance checks in determining the soundness of IFC
drawings or the so-called “Constructability” if free from any conflicts
with interfacing work disciplines. This initiative is collaborated with the
concerned Discipline Work Supervisors.
 Raising “Request of a Waiver” in case departure f rom IFC drawing
and/or specification cannot be avoided.
 Document control covering an orderly system of receiving / Issuing
and filing of all Engineering Technical Documents and Security
Protection of Sensitive Company Engineering Data.
 Management and raising of Site Technical Query on technical
problems encountered which requires disposition / clarification from
HHI.
 Technical approval of non-conformance resolution before seeking
HHI final disposition.
 Manages Punch list Resolution.

7.2 RESPONSIBILITY

The Site Technical Support Services Supervisor (Resident Engineer) is responsible of


performing the above scope of technical services in coordination with BKC Engineering
Manager (B.O.), Site Construction Superintendent/Supervisors and HHI. He will be
assisted by technical staff members and/or draftsmen to perform effectively these

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technical services functions to include the scope of Technical Services as described in


Contract Schedules/Scope of Works.

7.3 PROCEDURES

7.3.1 Shop Drawings Preparation and As-Built Drawings Management


 Shop drawing preparation required only to facilitate fabrication and
construction activities shall include title block indicating shop drawing
nos., reference drawing / documents, description, revision no., date
and approving internal authorities. All shop drawings prepared by the
responsible draftsman shall be checked by Supervisor and reviewed
by the Site Manager for endorsement to main Contractor for final
review & approval (only on cases if ever warrants.)

Note: All shop Drawings shall be controlled in a log sheet Register


for monitoring of subsequent changes/revisions.
 All drawings listed in the drawing control document shall be included
in the “as-built”  set. Drawings shall be marked in red for additions or
changes, and green for deletions. All as-built drawings shall be in
accordance with HHI drafting manual and SEC Project Specification.

 The assigned draftsman responsible for the maintenance of required


sets of IFC drawings for mark-ups and current as-built conditions
ensures that;

 The Drawing Control Index List is updated to the latest revisions


.
 Mark-ups on a live set of IFC drawings, MTOs and data sheets
are on latest revised issues to include those instructions from
BKC and Main Contractor covering field modification/changes
and/or actual conditions.

 As-built mark-ups also include those revisions initiated by BKC and its
Vendors and/or with official concurrence from HHI.

 Upon completion of the contract job and prior to issuance of


Mechanical Completion Certificate (MCC), BKC shall submit this live
set of the marked-up as-built drawings, MTOs and data sheets to HHI
for review/comments and corrections needed.
 Any corrections/comments raised by HHI are incorporated in the final
reproduction of as-built mark-up drawings.

 After initiation of changes, all As-built drawings shall be submitted to


the Main Contractor endorsement to HHI in accordance with SEC
Project Specification.

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 The As-built drawings shall incorporate and mark the location of


under-ground obstructions, existing pipelines, and power cables in the
vicinity work sites encountered.

7.3.1 Management of Site Technical Query

7.3.1.1 General

Site Technical Query shall be raised by BKC, which normally arises during
contract execution on the following case situations,
 Verification on some conflicts and/or ambiguities between AFC
Drawings and Specifications
 Lack or absence of Construction detailed designed drawings.
 Encountered restraints or extreme difficulties in work place where
 AFC Drawings is not workable, i.e. space clearance limitation,
obstruction to existing facilities, etc.
 Violation of safety and/or maintenance code provision if AFC Drawing
or Job Specification will govern, thereby a clarification is needed.
 Other matters that are deem necessary to seek clarification for HHI /
SEC before work execution.

7.3.1.2 Procedure of Endorsement

 A Standard “Site Technical Query” Form (Q-007) is prepared to be filled-up


by the Originating BKC Discipline Engineer/Supervisor for submission to HHI
through BKC Technical Support Services Unit.
a) The Query‟s portion covers the following:
a).1 The Query‟s Brief Subject item

 Brief description of the item as the subject of the query, example


“Relocating of Lighting Post at Facility Plant A ”.

a).1.1 Referenced Contract Document/Dwg. No.


 The referenced document number where the subject of query is
encountered.
a).1.2 Site Location/Unit System
 The statement of place where the problem is encountered.
a).1.3 Statement of Query
 A complete description of the case situation, and can be appended by
an attached sketch drawing and technical narration.
a).1.4 Impact to other Discipline
 State if there is such and cite the effect in detail.
a).1.5 Recommended Solution
 A presentation of appropriate scheme to correct the problem situation
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indicating also if there ’s impact of Additional or none.


a).1.6 The originating BKC Discipline Engineer/Supervisor shall sign the Site
Technical Query and noted by the Site Manager for endorsement to HHI and
possibly SEC for disposition.

7.3.1.4 Disposition by COMPANY

The submitted Site Technical Query to HHI shall be reviewed and acted
upon on its disposition by the appropriate levels of their management
authority depending on the degree and impact of such change in the project.

7.3.1.5 Resolution

Resolution to the Site Technical Query shall be fed-back by HHI to BKC on


returned Site Technical Query with filled-up comments and/or disposition to
subject query for BKC implementation.

7.3.2 Management of Waiver Request

7.3.2.1 General

This section describes the procedure and documentation requirement in


pursuing a request for Waiver on Design, Standards or Specification
requirements by BKC from HHI.
The purpose of a Waiver Request is to seek a prior documented
authorization from HHI whenever BKC decides to depart or deviates
significantly from the specified contract requirements, i.e.:
 Changes in allowable tolerances
 Change in material sections and/or composition (for BKC Supplied
Portion)
 Changed in the Job Specification Procedures
 Proposed simplification of System Designed Installation
 Deletion of redundant design
 Other changes that will depart from the original Contract ’s Job
Specification

7.3.2.2 Procedure of Endorsement

 A standard Form for “Request for Waiver of SEC‟s Standards or


Specification Requirements” is prepared (see Appendix to this section) to be
filled-up by the originating BKC QA/QC Supervisor and approval
endorsement of its Construction Site Manager This waiver request shall be
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endorsed to HHI.
The Waiver‟s Particular shall indicate the following:
 Referenced Standard or Specification Affected
 Statement of Requested Waiver
 Brief statement of what should be waived
 Justification to Waiver
 A rational explanation to justify or give merits to the waiver or
proposed change from the SEC’s Standard or Specification
requirements.
 The originating BKC QA/QC Supervisor shall sign the waiver Request
and forward it to the Construction Site Manager for endorsement to
HHI.

7.3.2.3 Review and Disposition by HHI/

The review and disposition of Waiver Request by HHI shall be in


accordance with SEC Project Specification which is normally endorsed by
the Project Manager of the originating organization represented by HHI.

 8. QUALITY CONTROL ACTIVITIES

8.1 GENERAL

During the contract job execution, BKC QC activities will be performed in accordance
with this Project Quality Plan, which are in conformance with HHI Contract Agreement.

BKC shall perform the following QC activities:

a). Material Control, preservation and handling as elaborated in this Project


Quality Plan, Section 11, Material Management Plan
b). Adherence to all required NDT / NDE procedures and other QC procedures
as referred in the W ork QCPs and Inspection and Test Plans (ITPs) / ITP.
b).1 Quality Control Activity Executions i.e. Civil and Associated Civil Works.
b).2 Management of Laboratory (personnel, equipment and activity)
b).3 Pre-Commissioning Works Quality Control Activities

8.2 INSPECTION AND TEST PLAN MANAGEMENT

8.2.1 General

BKC shall ensure that all necessary resources and quality control initiatives are made
available and/or performed based on the Work QCPs and ITP.

a) Inspection and Test Activity Planning, Scheduling and Implementation, and


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QC Reports and Coding


The detailed procedure is comprehensively explained in this Project Quality
Plan Section 6, Preparation and Management of Construction Work Quality
Plan specifically under Paragraph 6.4 and 6.5.

8.3 QUALITY CONTROL ACTIVITY COORDINATION

BKC shall perform the required QC co-ordinations among its subcontractors / vendors.

The prescribed attendance of BKC representatives during coordination meetings (kick-


off, regular and special meetings) shall strictly be adhered.

BKC shall ensure attendance of SEC representatives on all Hold Points and Witness
Points as per relevant ITP / ITP on Construction Phase by raising RFI at QMIS least 24
hours during regular days and 48hours during weekends before the scheduled date of
witnessing.

On Procurement Phase, HHI is notified to minimum of 5 working days for supplier /


Vendor ITP's inspection witness and hold points as per Contract Provisions.

8.4 INSPECTION LOG BOOKS

BKC Site QA/QC Supervisor shall review logbook entries on daily basis and pursue
immediate resolutions or corrective actions on any observed negative remarks.

BKC shall prepare weekly status report of logbook action, items pertinent to observed
weak areas or deficiencies to be rectified, which is to be highlighted during Site Weekly
Coordination Meeting with Main contractor.

8.5 CONSTRUCTION MATERIAL CONTROL

Refer to Section 11 of this Project Quality Plan for detailed procedure of material
control in compliance with SEC Material Control requirements.

8.6 DOCUMENT CONTROL

Refer to Section 5 of this Project Quality Plan for BKC Document Control Management.

BKC shall abide on the QC activities in the form of ITP / ITP or Commissioning Plan for
“PERMANENT HOUSING COMPOUND AREA” Testing, Pre-Commissioning and

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Commissioning Work, which is governed by SEC Project Specification. Refer to


Section 12.6 for the management approach.

8.7 PROJECT RECORD BOOKS(Inspection Record Books)

8.7.1 General

BKC shall follow the guidelines set forth in SAEP 122 (Project Records) on the mode of
preparation of gathering the contents and indexing of the Inspection Record Books,
which will be eventually part of the final documents to be transmitted to Saudi Armco
during the Project Completion period and / or one (1) month prior to Plant Start-up.
Basically, the following shall be observed:

▶ Inspection Record Books- The contents shall generally include S e l e c t e d


Drawings, supplier information, inspection and
test records, etc.

The completed Project Inspection Record Books shall be bound in accordance with
Drawing Number specified by the Company.

The identification of the Project Record Books shall be identified by the equipment
plant number, the name of the facility and the Project record number.

The assembly of the Project Record Books (Inspection Record Books) by section shall
follow the indexing shown in COMPANY Standard Drawing, as applicable per Plant
Facility. This indexing shall be agreed and discussed between HHI and BKC later
which should be correlated with the Construction drawings and quality records
covering those test & inspection activities mentioned in the Project Quality Plan and
approved Vendor's Inspection Assignment Packages shall form part of the contents of
Inspection Record Books.

The procedure of gathering and compiling the quality records during the course of
contract job execution is described hereinafter (section 8.8.2 & 8.8.3).

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8.8 Quality Records Compiling and Filing System

8.8.1 General

From the commencement of the contract job, BKC- PHC Site QA/QC Unit shall
organize and maintain adequate space at the site office equipped with enough shelves,
cabinets and necessary folders to be used and dedicated only for filing Quality
Records in an orderly manner and easy traceability and retrieval.

8.8.2 Procedure

8.8.2.1 Compilation of Quality Records, Storage and Retention

a-1. During Procurement Stage


 All inspection and test records conducted at Vendor's source by BKC
assigned QC Inspector shall be compiled by the respective QC Inspector
and submitted to BKC Procurement QC Supervisor who is responsible for
consolidation and filing to its respective Inspection Record Book.

a-2. During In-Process Construction / Installation


 All inspection and test reports / records and relevant document being used
while in the process of job construction and installation are compiled in
provisional book files per job work disciplines and work areas in accordance
with the Inspection and Test Plan as prepared for the specific project. These
will be the sourced back-up quality record documents to be used for the next
milestone phase of the project when it reached the Plant System Testing and
Pre-Commissioning stage prior to Mechanical Completion. These quality
records are filed with proper book identification and safely stored in shelves /
cabinets for easy retrievable or traceability. Original copies of these quality
records shall be filed in their assigned book files.

a-3. During Plant System Testing and Pre-Commissioning Prior to


Mechanical Completion.
 All plant system test and pre-commissioning quality records shall be
organized in accordance with the Plant Facility / System Mechanical
Completion Checklist Packages which will form part of t he whole project‟s Pre-
Commissioning Plan.

Relevant in-process installation quality checks and test records required to


form part of the Mechanical Completion Checklist Package per Plant System
shall be in the form of “migrated photo copies” in order to retain the original
copies intended for Project Inspection Record Books on a separate indexed
form & filing.

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a-4. Pre-Commissioning / Commissioning Inspection Record Book


(Project Quality Records)
The final Quality Record documents are packaged based on agreed
indexing and book packaging to be agreed later with HHI.
b. Readiness of Quality Records for System Pre-Commissioning
Package Preparation
 All pertinent inspection and test records shall be ready from BKC for System
Test Package preparation prior to whole or part of Plant System Facility to be
pre- commissioned and eventual commissioning. This System Test Package
preparations as part of turn-over procedure will be a joint undertaking of the
whole project team represented by HHI.

c. Distribution and Filing


One completed copy of Inspection Record Books shall be forwarded to
theInspection Dept. for review / acceptance and distribution to the appropriate
Inspection Unit.
The Final copy after review shall be produced to the required number of sets
(SAEP-122) and submitted to HHI. BKC shall retain one (1) copy for filing.

d. Quality Records Storage and Retention


 All Quality records as mentioned in above paragraph 8.8.2 (a) shall be stored
adequately safe, legible for traceability and irretrievability which is made
available for evaluation by HHI and / or representatives during and after the
Contract period as agreed upon. After the project final completion, one (1) set
of all the Project Quality Records are maintained in BKC JEDDAH Head Office.

 Archive room for a retention period of Two (2) years or as required by HHI /
SEC whichever is longer.

8.9 SPECIAL PROCESS PROCEDURES

 As required by the Company Contract Requirements, BKC shall establish quality
procedures for special process activities associated with the contract Works such as
coating application, welding, cable splicing/termination, concrete batching, cable
conduits seals, cleaning and specific NDT/NDE that are required by the job
specifications as shown under table.

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Work

procedure Qualification
Personal

 Approval (A) Procedure Qualification


Code Special Process
or Review  Approval  Approval

(R) Required`
Required

Required

Welding & Brazing A Yes Yes

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Non Destructive testing  A Yes* Yes

/ Examination

Concrete & Asphalt Mix  A No No

Design

Concrete Installation R No No

Structural Bolt R No No

Tensioning

Refractory Installation A No No

Coatings A No No

8.11 MANAGEMENT OF MEASURING AND TESTING EQUIPMENT

8.10.1 General

Pursuant to the Contract Agreement, BKC shall observe proper control of its
measuring and testing equipment to ensure certainty is known and consistent with the
required measurement capabilities.

8.10.2 Responsibility

Instrument Laboratory in-charge is responsible for the control and management of


Measuring and testing equipment and ensures proper control is done per the
prescribed procedure. QA/QC Supervisor shall originate, maintain and provide all
documentation as required for the purpose of calibration.

8.10.3 Control Procedures

- All measuring and test equipment f or use in BKC scope works shall be calibrated by
an outside Certified Calibration Authority/Agency duly accredited by SEC

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- On receipt of the calibrated test and measuring instruments (with validated calibration
certificate), they are recorded in the list of calibrated measuring and test equipment‟
showing also the interval of re-calibration in accordance with Vendor but not more than
six (6) months. Refer to Appendix of this Section for the appropriate Form to use.

- The QC Inspector shall check and ensure that only properly calibrated equipment is
used by personnel performing test inspection operations both in the construction field
or site laboratory.

- When deficiencies are found in equipment, the deficient equipment shall be


immediately segregated from the construction work to prevent inadvertent further use
of the equipment until repaired and/or re-calibrated.

- The list of calibrated measurement and test equipment shall be immediately updated
to reflect disposition of the non-conforming equipment.

- To the extent possible, previous inspection measurements made with the deficient
equipment shall be rechecked with calibrated equipment to verify accuracy of previous
measurement.

- All calibrated inspection, measuring and test equipment are identified with a label
sticker with its date of calibration and expiry.

- In case calibration validity of the original test instrument used cannot be verified
during a particular inspection already done, re-inspection shall be pursued using
another test instrument with valid calibration certificate.

 9. QUALITY ASSURANCE ACTIVITIES

9.1 GENERAL

BKC Corporate QA/QC Manager and Project QA/QC Manager shall monitor its Quality
System Management by the following QA activities:

- Document Review
- Quality Audits and Quality Surveillance
- Non Conformity Management
- Corrective / Preventive Action(s)

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9.2 MANAGEMENT REVIEW

Pursuant to Contract Agreement, BKC Senior Management shall conduct Management


Review. The project specific Quality System is reviewed every six (6) months to verify
and ensure that the system is effectively implemented for its suitableness. This project
Quality system review is normally incorporated in BKC Quality Management Review
Meeting held twice a year which is chaired by either the Vice President and/or General
Manager which also highlights the results of the Internal Quality Audits conducted at
the project. The Corporate QA/QC Manager prepares the agenda & outcome of the
Management Review Meeting covering the necessary action plans for quality system
improvements.The project internal audit report is the source information and/or part of
the Management Review results and recommended actions to be presented /
submitted to HHI within 14 days after the actual review date.

9.3 DOCUMENT REVIEW

In general, Document Review is a continuous process of determining that all Project


Documents are updated and properly managed. Required project documents are to be
well known and identified to its intended usage. Section 3 (Reference and Applicable
Documents) of this Project Quality Plan enumerates all the basic documents to be
referred. Section 5 (Document Control) of this Project Quality Plan describes BKC
system of document control management in the project to ensure an orderly system of
meeting the quality objectives of the project.

BKC QA/QC Manager and Document Controller shall ensure that all required
documents in the form of Project Execution Plans and Procedures, etc. are made
available for its intended usage. All project documents emanating from HHI shall be
regularly checked on its latest issues / revisions especially IFC Drawings and job
specifications which are essential referenced documents to assure of meeting the
specified job acceptance criteria.

BKC Project Manager, as the company‟s representative at site, regularly reviews the
contract documents and ensures that changes and/or deviations on actual job
executions are properly documented and covered by Change Orders to protect the
business interest of the Company.
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9.4 QUALITY AUDITS AND QUALITY SURVEILLANCE

Pursuant to the requirements of Contract Provisions, Contract WORK Phases


(Procurement & Construction) shall be subject to audit by the Auditing Authorities of
BKC with HHI participation or his nominee.

BKC Internal Quality Audit shall be performed as planned, in accordance with the
Projects Internal Quality Audit Procedure. A copy of this procedure is appended in this
section.

BKC Project QA/QC Manager is responsible of organizing and planning the internal
quality audit of the project, and assisted by the Company‟s trained auditors/Third party.
The general objective of this internal audit is to verify and confirm the compliance,
effectiveness and adequacy of the quality management system operating within the
project site.BKC/third party Quality Assurance Auditors or qualified as per Contract
Requirements, shall conduct the Internal Quality audits required by Contract
Provisions, Auditors to be assigned to perform audits are not directly involved in the
project WORK Phase operations to be audited and shall follow BKC Internal Quality
 Audit Procedure.

9.5 NON-CONFORMITIES

For BKC Non-Conformities Management of its construction activities, refer to Section

10 of this Project Quality Plan, which describes comprehensively how non-


Conformances are identified, reported, and the manner of documenting its clearances

and closures. BKC QA/QC Manager is responsible for the non-conformities


management in this contract job.

NCR issued by HHI shall be resolved by BKC following the procedure.


  Refer to Section 10 par. 10.5, how external sourced NCRs are resolved and cleared
by BKC.

9.6 PREVENTIVE / CORRECTIVE ACTIONS

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Corollary to non-conformities management, BKC shall implement its prepared


Corrective and Preventive Actions as described in Section 10 "Non-Conformance
Procedure" of the Project Quality Plan. In this Procedure, it explains how Corrective
and Preventive Actions are reported with illustrative examples of differentiating
between Corrective Action and Preventive Action. This is an element of the quality
system, which serves as a tool to eliminate recurrence of defects during the
construction process.

The management of Non-Conformance through preventive / corrective actions is under


the responsibility of BKC Site QA/QC Manager and shall coordinate closely with all
Work Discipline Supervisors for whatever interfaces needed to assure effective
implementation of the procedure.

9.7 PERSONNEL QUALIFICATION AND TRAINING

9.7.1 General

BKC personnel to be assigned in this contract project shall possess the required skills
qualification and experience of similar job undertakings.

The basic minimum requirements for the personnel ability to comprehend instructions,
interpret basic documents, read and communicate shall be adhered on selection and
appointing personnel to their respective functional position.

To assure smooth job execution, personnel shall be familiarized on specific project


programs and relevant documents. Examples of these are:

 Project Loss Prevention Program


 SEC documentation and system of coordination
 Project plans and programs relevant to personnel position / functions.
Development of personnel capabilities shall be enhanced by on-the-
 job training provided to employees.
 Training on specific subject.

9.7.1.1 On-the-Job Training

 As a general policy of BKC on Human Resources Development, all Work


Supervisors are obliged to provide guidance and skill-enhancement to their
workers and cost- effective methods or best practices in accomplishing
assigned task. This can be effectively achieved through on-the-job training.

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9.8 STATISTICAL TECHNIQUES

Due to the nature of BKC business which is confine in construction services with
changing job environment and varied contract conditions, the implementation of
statistical technique on Products/services characteristic is not applicable and useful.
BKC concerns in measuring process capability are taken during interim period and/or
after completion of each project. Performances of BKC services are evaluated using
ratios, i.e.:

 Man-hours expended per unit of Work or each Equipment Installed.


 Average actual Revenue yielded per expended Direct Man-hour.
 Actual ratio between total Expended Indirect Man-hour vs. Direct
Man-hour Optional only if possible to account specifically for Major
activities that will
 Influence significant cost deviation to budget.

The above useful data is gathered and acquiring by the cost control unit during
the contract life deviation.

9.8.1 Statistical data is generated on the following:

 Numbers of Punch list and NCRs issued by Client as indication of


quality performance.
 Safety Statistics record as reported monthly based on OSHA
requirements.

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 10. CONTROL OF NON-CONFORMING PRODUCT

10.1 SCOPE

This section describes the procedure of initiating, implementing and documenting


corrective and preventive actions as an effective means to eliminate the causes of
actual or potential non-conformities that are identified / reported either from internal or
external sources of origin. It also serves as the management procedure for non-
conformities applicable in this contract job.

10.2 OBJECTIVE

To have a clear understanding on the proper control of non-conformances and


systematic approach and documented records in pursuing and resolving corrective and
preventive actions in order to attain effectively the required or improved level of work
quality standards and thus, avoid completely any occurrences or recurrences of non-
conformities.

10.3 REFERENCE

 Client's Contract requirements


  Company’s Quality Manual
 Company Operating Procedure for Corrective & Preventive Action
Procedure

10.4 RESPONSIBILITIES

10.4.1 Project QA/QC Manager (Site Office)

Participates on advisory functions covering the investigation of identified non-


conformities and complaints through Non-Conformance Reports (NCRs), or Corrective
 Action Requests (CARs) raised by the Originators and seeks/ oversees appropriate
resolutions by the concerned action persons for its remedial actions and closure.

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10.4.2 Site QC Manager / QC Inspectors

 As part of their primary functions, are authorized persons for raising Non-
Conformance Reports (NCRs) to the concerned responsible person of a production or
functional unit/area where the non-conformities/complaints are identified, and required
from them to monitor actions needed for its resolutions.

The Site QC Manager is the representative of Corporate QA/Qc Manager at site to


implement this procedure at site on proper documentation and reporting required
covering encountered non-conformities at the project site.

10.4.3 Construction Site Manager / Superintendents / Supervisors

 Are responsible for entertaining identified Non-Conformance items under their


respective areas and pursuing corrective and preventive actions, based on agreed or
appropriate resolutions in order to clear and close those issued NCRs.

10.4.4 Internal Quality Auditors

 All pre-selected company‟s employees who are trained as internal quality auditors
whose ad-hoc responsibility is to conduct quality management system auditing to
company‟s various functional support and production areas. They are authorize d by
the management to issue Corrective Action Requests (CARs) to audited areas where
non-compliance to company‟s quality policies and procedures are identified. They are
qualified as per the requirement of Contract Provisions for Quality System Auditors.

10.5 PROCEDURES

10.5.1 Identification of Non-Conformance

In accordance with Contract Requirements, BKC shall exercise proper control and
disposition of identification and documentation of non-conformances, corrective actions
and waivers of contract requirements. These non-conformances possible occurrences
are inadvertent use of design documents, materials, parts, components, services or
workmanship not conforming to the requirements of the contract.

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Source and/or areas where non-conformities are identified from the materials and/or
services supplied by BKC Vendors / Subcontractors and BKC in-process construction /
installation activities. The control and management of non- conformances on the
specific process work areas are described as follows:

10.5.2 Materials

Detection of non-conformance of materials is controlled by relevant procedures for


materials classified as levels 1, 2, 3 & 4 that are inspected at Vendors Source location
following the specific Inspection Assignment Package submitted by BKC and approved
by HHI / SEC Project Inspection Division. Level 1 does not require pre-inspection
meeting. For materials classified as level 0, inspection is done once the materials
arrived at site. Reporting and documenting Non-Conformance at Vendor's source
during in-process inspection and once it received at site is described in the proceeding
paragraph 10.5.2(b) under this section. Detection of non-conformances of all materials
received at site and segregation of non- conforming materials procedures is described
fully under section 12 of this Project Quality Plan. Levels of disposition on identified
Non-conformance per Contract Agreement are described in detail under par. 10.5.7 of
this Procedure. Disposition of all rejected materials shall be reported to HHI / SEC and
shall form part of the Monthly Quality Management Report.

10.5.2.1 In-Process Installation / W ork Phase Activities

Detection of Non-Conformance of in-process installation or any phase of work


activities during the process of fabrication/installation/testing occurring at the
work places are primarily highlighted by BKC QC Inspectors or HHI Project
Representatives/Inspectors in their course of inspections. BKC QC
Inspectors or Other authorized NCR originators accomplish Non-
Conformance Report (Form No.Q-005) in reporting encountered non-
conformities or deficiencies.

10.5.2.2 Customer Complaints

In-order to effectively handle customer Complaints, BKC shall be pro-active to


identify these non-conformities and Document its resolution using the same
NCR. Client‟s Project Representatives / Inspectors usually report and
document their observed non-conformities / deficiencies addressed to BKC,
either in any of the following written documented forms of
communication/records, i.e.:

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  Client ’s issued Non-Conformance Report (Client ’s Standard NCR


Form)
 Formal business correspondence letters
 Project logbooks/E.log book normally maintained at project site
 Complaints rose during regular coordination or special meetings with
the client and recorded in the minutes of meetings.
  Construction Punch List and/or Exception List that highlights
observed items of non-conformities or deficiencies to specified
contract requirements when job is nearing completion. It is only
confined to major ones that cover gross- violation to work/item
specific criteria of acceptance and/or job specification on its observed
completed stage of production/installation.

10.5.2.3 Reports of Internal Quality Audits

These are operational deficiencies or non-conformities reported by assigned


internal quality auditors during internal audits to various production and
functional support units. Refer to BKC internal quality audit procedure as
appended to section 9 of this Project Quality Plan describing the procedure in
carrying out and reporting internal quality audits.

10.5.2.4 Procedures and Forms used in identifying and reporting non-


Conformities

For purpose of clarity and common understanding, there are two (2) forms to
be used by BKC in the implementation of this “Corrective and Preventive
 Action Procedure”. These forms and its usage application are:

a) Corrective Action Request (CAR), Form No.Q-003


This form is used in documenting and seeking resolution to identified non-
compliances or non-fulfillment to Company‟s Quality Manual and Operating
Procedures (in accordance to ISO 9001:2008 Quality Management System),
which were approved and issued by management for implementation to
concerned Production Operating Units and functional support departments. For
distinction of its usage, this CAR form is intended only for use by the internal
quality auditors during the internal quality audit operations to various functional
dept. / units and project sites, which are programmed twice per year. The use
of this form is comprehensively described in BKC Project's Internal Quality
 Audit Procedure; a copy is appended in Section 9 of this Project Quality Plan.

b) Non-Conformance Report (NCR), Form No.Q-005 

b).1 Scope of Usage and Definitions


Like the Corrective Action Request (CAR) form, this form is used in
documenting and seeking resolution to identified non-conformities. In specific
statements, it describes the nature of non-compliances / Customer Complaints
which can be classified as:

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 Non-fulfillment of a specified requirement as specifically shown on the


issued for construction drawings, specifications, established
standards, procedures, etc. in accomplishing a particular task/item of
work, or a particular product.
 Deviation from the standard or normal industry codes and practices,
which in some cases are not explicitly prescribed in the pre-planned
arrangement of performing a task that will lead to a defective
product/job.

c). Investigation / Analysis


c).1 Customer Complaints & Non-Conformities are analyzed and investigated
for the root causes of the problem depending upon the nature of Complaint
i.e., whether relating to Product, Process and Quality System.

c).2 All appropriate sources of information such as processes and work


operations which affect product quality, concessions, audit results, quality
records, service reports and customer complaints shall be utilized to detect,
analyze, and eliminate potential causes of nonconformities.

c).3 The person responsible for the area is responsible for analysis of the root
cause of problem in co-ordination with the person responsible/knowledgeable
on the nature of Problem.

c).4 Collection of data and statistical analysis shall be done where feasible.

c).5 The results of this investigation shall be recorded in the “brief statement
of Non-conformance” space provided in the NCR Form. A copy of each NCR
shall be submitted to the Company Representative within 48 hours.

d). Corrective and Preventive Actions


The NCR highlights the Corrective Action and Preventive Action needed from
the addressee. To have a clearer understanding on the proper usage of this
NCR form to serve its purpose, the term Corrective Action and Preventive
 Action are define simply as:
d).1 Corrective Action
 Action to be taken to eliminate the causes of an existing non-conformity,
defect or other undesirable situation in order to prevent its recurrenceThe
corrective action required shall be determined by the person responsible for
the area based on the investigations done and shall be recorded in the NCR
form.
i) All necessary Control Mechanisms to ensure the effectiveness of Corrective
 Action shall also be entered in the NCR form.
ii) The NCR originator prior to the closure of the NCR shall review
effectiveness of this Corrective action taken along with the control

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mechanism.

d).2 Preventive Action


 Action taken to eliminate the causes of potential non-conformity, defects or
other undesirable situation in order to prevent its occurrence.The Preventive
action required shall be determined by the person responsible for the area
based on the investigations done and shall be recorded in the NCR form.
i) All practical steps / methods to implement this Preventive Action shall be
described by this column to ensure that the preventive action can be
implemented without ambiguity.
ii) All necessary Control Mechanisms to ensure the effectiveness shall also be
entered in the NCR form.
iii) The NCR originator prior to the closure of the NCR shall review
effectiveness of this Preventive Action taken along with the control
mechanism.

d).3 Who are authorized to raise NCR?


The Corporate QA/QC Manager of BKC authorizes and entrusts to all
personnel under the Project's QA/QC Unit to issue NCRs to concerned
production or support units, either directly identified by them or through an
external/clients sources of complaint.
d).4 Monitoring Non-Conformance Resolution Activities & NCR Closures
To effectively handle the customer complaints / Non-conformities and to keep
track of activities covering resolutions to Non-Conformities on issued NCRs to
various addressees responsible for the Corrective/Preventive actions, Project
QA/QC Manager maintains a “Register of Non -Conformance Reports (NCRs)
and Status” (Form No.Q-015). This register shall be updated regularly to show
in summary the status of outstanding and closed NCRs at current date. The
copy of this form is appended in this section.

Note: For issued NCR, refer to SAEP 1150 par. 9.6 for the procedure,
clearance and closure to be observed.

QA/QC Manager shall submit “The Register of Non -Conformance Reports


and Status” for Management Review along with all copies of NCR / Customer
Complaints.

d).5 Distribution Copies of Closed NCRs


Original Copy  –  BKC QA/QC Unit File under the custody of Project QA/QC
Manager.

Copies Distribution:

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1 – NCR Originator

1 – NCR Addressee

1 – Site Manager

1 – HHI

d).6 Disposition of NCRs and Corrective Actions


BKC QA/QC Manager shall explain the disposition and draw corrective
resolutions. The Non-Conformance Report is forwarded to the HHI ‟s
Inspection Unit for technical review of its recommended disposition.

e). Hold Marks


For adequate control of encountered non-conformance item by the QC
Inspector during performance of work activity, „HOLD‟ is put on the item and it
can only be removed by the QC Inspector after deficiencies had been
corrected or rectified to required acceptable standards. Rejected items are
marked REJECTED and taken away from the production areas

f). Levels of Disposition of Non-Conforming Materials and/or Work item

Disposition for non-conformance shall be decided on the following levels of


courses of action pursuant to Contract Requirements.

“Proceed or Use as is”


Disposition can be pursued if it can be concluded that the degree of
discrepancy cannot result to negative functional or operational use of the item
without adverse impact to performance, reliability and safety. This shall be
accepted after inspection by HHI. If item is considered usable, BKC shall
submit application for a waiver to HHI. The item may be used in the WORK
only if COMPANY approves the waiver.

“Rework”
Disposition may be imposed if redoing the process of work by the right
method within the allowable tolerance will not alter the integrity of the
materials on its strength workability and operational. This shall be subject to
re-inspection and acceptance by HHI / COMPANY.

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“Repair” / Correction
Disposition can be imposed within the level of non-conformance does not
affect the reliability and safety of the item. These items found accepted after
re-inspection may be used in WORK.

“Re-graded”
This disposition can be effected if it can be concluded that the degree of
discrepancy cannot result to negative functional or operational use of the item,
if it is re-graded to suitable alternative level that ensures the performance,
reliability and safety.
If item is considered usable, BKC shall submit application for a waiver to SP.
The item may be used in the WORK only if COMPANY approves the waiver.
This shall be accepted after inspection by HHI / COMPANY.

“Rejected”
This disposition shall be governed by Contract Requirements covering
rejected items not complying with COMPANY Standards. The following shall
be observed.

  BKC shall segregate all other non-conforming materials and


assemblies to a clearly designated rejection site. BKC shall track and
control all rejected equipment or materials until it is re used, exported
or otherwise disposed of. All rejected materials shall be disposed of in
accordance with COMPANY Standard Procedure of documentation.
Disposition of all rejected material shall form part of the Quality
Management Reports.

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 11. PROCUREMENT PLAN

11.1 SCOPE AND PURPOSE

This Procurement Plan describes and outlines the procurement and QA/QC
procedures to be followed for BKC supplied materials for this Sub-contract job in order
to ensure that the materials are procured in accordance with the Sub-contract
 Agreement technical job specifications and standards and timely availabilities at the
project site.

11.2 REFERENCE

The procurement procedures described in this plan shall be implemented in


conjunction and/or referred in the following procedures/documents.

 HHI
 COMPANY Contract Schedules

 Sub-contract Schedules

 Contract Documents, Specifications & Drawings, Codes & Standards.

11.3 BKC MATERIAL SUPPLY PORTION

BKC shall supply all the required materials of the sub-contract job in accordance with
the Construction Scope of Work of this Project under Contract No. (B1303A-A016)

11.4 RESPONSIBILITIES

11.4.1 BKC Engineering Department Manager 

 As technical support to procurement functions, his main responsibilities are:

 Reviews the Sub-contract / bid Documents comprising BKC materials


supply portion and generate a Master List of these items for issue to
Site Technical Support Services Unit as base reference in t he
preparation of Materials Requisitions, and required Material Technical
Submittals to HHI.

  Assists Procurement Manager in Technical evaluation of Vendor‟s bid


proposal and soliciting the required Non-Material Requirements
(NMRs) i.e. Product Technical Data Sheet / Brochures, Catalogue

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Cuts, Material Test Certificates, etc.


 Regulatory requirements) complete with required NMRs and
Inspection & Test Requirements (S.A. Form 175s).

 Reviews and checks the Material Requisition (MR) prepared by


disciplined Engineer/Technical Support Services Supervisor
approved by HHI.

11.4.2 BKC Procurement Department Manager

Is responsible for the management of procurement activities to meet the specified


material specification of the project and serve them in timely manner. His main roles
are:

 Solicits bid proposals from pre-qualified SUPPLIERS / VENDORS.


 Evaluates bid proposal on the commercial, delivery and technical
aspects
 Issues Purchase Orders to complying Bidders
 Monitors Procurement and Delivery Status and coordinates closely
with Site/Construction Manager for updated Material Delivery
Schedule job requirements

11.4.3 BKC Site QA/QC Manager

 As QA/QC support to procurement functions, responsibilities are:

 Provides checks and/or verification on Purchase Requisition (PRS)


Submittals on the correct compliance to job specifications and
required NMRs and Inspection Requirements (S.A. Form 175) and
other requirements that may apply.
 Conducts checks on PRS and MRs prepared by Technical Unit and
ensures its full compliance to Client‟s quality requirements.
  Prepares purchase submittals package (for level „0‟) and Inspection
 Assignment Package (IAPs) for level „1‟ through level 4 Inspection
item categories.
 Initiates action to prevent non-conformances, identify and record
quality problems, issue NCR and monitors its resolutions and/or
corrective action.
 Conducts random surveillance, inspection and verification activities at
material transit delivery points (BKC JEDDAH Central Warehouse)
prior to final delivery to site.
 Coordinates closely with construction QA/QC Supervisor for matters
related to procurement activities.

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11.4.4 BKC Site/Construction Manager 

BKC designated Site/Construction Manager for this contract job shall be responsible to
oversee that the administration of this Procurement Plan is implemented in
collaboration with the Engineering Manager, Procurement Manager and Corporate
QA/QC Manager.

He sees to it that the necessary planned resources and actions to effectively


implement this procurement plan are provided and continuously supported by BKC top
management.

11.5 PROCUREMENT PROCEDURE

11.5.1 General

BKC shall be governed by the Sub-contract Provisions on “Contractor‟s Procurement


Responsibility” as described in Project Quality Management System (QMS)-
Requirements, ISO 9001:2008, and other requirements set forth therein of Sub-
contract Agreement.

11.5.2 Material Requirement Identification

BKC Engineering Department shall identify, take off and prepare a list of all the
materials and equipment required as per the Sub-contract Scope of Work, which shall
be referred to the approved, and Issued for Construction Drawings. This list shall
contain the following information as minimum:

 Item Description

 Location of use

  Quantity

 SEC Engineering Specifications/Standards (applicable to Items)

 SEC Material Supply (SAMSS) stock number (if applicable)

 Compliance to specific International Codes / Standards

 Recommendation for capital spare parts (may not be applicable for


BKC scope since no parent equipment is included in its supply scope)
 Commodity Code Classification number assigned by
SEC for the Material/Equipment item.

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BKC Procurement Department shall use this list as the master guideline for the
Procurement of all the items as indicated on the list. HHI/ SEC shall provide BKC the
formats for the Purchase Order Control Log and Material Technical Submittals as may
be appropriate.

11.5.2.1 Priority Listing and Long Lead Items

The master procurement list prepared by Engineering Department shall be


reviewed by the Planning and Scheduling Unit to establish the priority listing as
per the schedules. The Procurement Department identifies the long lead items
from the master list.

11.5.2.2 Vendor Sources, Qualification and Quotation Request

BKC Procurement Department shall select its Vendor sources from the list of
(HHI) approved manufacturers. It shall be the responsibility of Procurement
Department to ensure the technical and quality requirements, and sound
financial capabilities of all Vendors prior to placement of any Purchase Order.

BKC Procurement Department shall give special emphasis to ensure that all
materials to be purchased are from local suppliers (stockist) as preference and,
are manufactured by approved sources

If Vendors are not listed in SEC and BKC intends to propose their product,
BKC shall pre-qualify this Vendor & its source supplier and follow the
requirements set forth in Sub-contract Schedule. HHI & SEC shall be notified
at least three (3) weeks ahead of the planned supplier survey.

11.5.2.3 Purchase Requisition Submittals (PRS) of Materials - Submittals for

HHI and SEC Review and Comments.

BKC Engineering Department/Technical Support Unit shall submit to HHI/


SEC, a request for technical approval of material/equipment on a prescribed
submittal format preferred, showing material item/CCC and proposed
Vendor/Supplier. Prior to purchase, all materials must be approved, except
consumables, to meet HHI / SEC technical requirements per applicable
Standards etc.

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11.5.2.4 Material Requisition (MRs)

Upon receipt of approval of PRS from HHI, BKC Engineering Dept./Technical


Support Services Unit, initiate Material Requisition and forward to QA/QC Dept.
for review for correctness and passed to Procurement Department as basis for
the preparation of Proforma Purchase Order (P.O.) to be included in the
preparation of Purchase Requisition Submittal by BKC QA/QC Unit. The
Material Requisition shall be checked per the following:

 Complete description of materials Quantities


 Non Material Requirements (NMRs)
 Inspection requirements
 Copy of approved PRS as attachment to MR.
 Spare Parts (as applicable data requirements)

11.5.2.5 Expediting

BKC shall ensure that the Inspectors and/or expediters of HHI/ SEC and/or
those appointed by them shall have free access to BKC and its Vendor‟s
offices and works.

During HHI expediting, BKC shall be responsible for giving complete and
reliable information on the purchase order status. The information will
include shipping Schedule, issuance and progress status of any orders, critical
orders and the expected arrival dates.

BKC shall prepare and forward at regular intervals to HHI/ SEC, an up-to-date
status report of Vendors.

BKC shall expedite all purchase orders, revisions and amendments (including
vendor‟s quotations, any applicable engineering design calculations , drawings,
spare parts data, installation, operating and maintenance instructions, other
Non- material requirements, invoices etc.) after placement of purchase orders.
BKC shall verify with vendors, before placement of an order that their deliveries
meet the required shipping schedule.

BKC shall maintain control of delivery dates established for the project.

BKC shall ensure that all vendors meet the applicable quality assurance
requirements of Sub-contract Agreement and BKC Quality Assurance and
Quality Control Procedures, as set forth in the Project Quality Plan.

BKC shall expedite the review and approval of all Non-Material Requirements
received from the vendors. These include, but are not limited to, Design
Calculation, Drawings, Spare Parts Data, Special Tools (if any), spare parts
recommendations (if applicable) and other data generated by vendors requiring
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approval by BKC and/or HHI/ SEC

11.5.2.6 Control of Manufacturing Processes during Procurement

Prior to commencement of any manufacturing (for Vendor‟s Source Inspection


items) by BKC Vendors/Manufacturers, BKC shall submit to HHI/ SEC for
review & approval such as Welding Procedure, Welding repair, NDT, PMI,
which also include quality personnel qualification requirements and out of
Kingdom NDT. These submittals are waived if Vendor/Manufacturers are
already accredited by HHI/ SEC, but shall form part of in-process Inspection
Documents review and included in the Final Disposition Report.

11.5.2.7 Inspection and Testing

 As may be applicable, BKC QA/QC department shall prepare Inspection


 Assignment Package for items subjected to inspection levels 1, 2, 3 and 4
pursuant to Sub-contract Requirements. Materials classified as Level 1 are
exempted from pre-inspection meeting. Final Inspection is only required for
Level.
1 items prior to release at Vendor's shop and is governed by Inspection
Requirements, Form 175, Materials categorized as Level 0 are exempted for
HHI Inspection Division monitoring Inspection but require QC documentation
i.e. Material Test Certificates and/or Product Data Sheet, etc.

The Inspection Assignment Package (applicable to level 1, 2, 3 & 4) to be


submitted to HHI Inspection Division for review and approval for each item
shall include:

 BKC un-priced Purchase Order or subcontractor with complete


attachment.
 Copies of sub-supplier un-priced Purchase Orders (if applicable).
 Inspection requirement as specified in the Applicable S.A. Form 175.
 Inspection Assignment Sheet specifying the Inspector(s) that will
perform the inspections.
 Inspection and Test Plan (ITP).
 The level of BKC and Client's (Buyers) Inspection Intervention as
confirmed by HHI / SEC Inspection Division.
 Agenda for Pre-Inspection Meeting.

Vendor's ITP (for level 2, 3 & 4 only) included in the Inspection Assignment
Package contains the followings:

 Process Description.
 Quality Control Reports.
 Notification Requirements for Vendors inspection witness & hold
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points (minimum 5 working days).


  Responsibilities
 Applicable Procedure
 Acceptance Criteria
 Verifying Documents
 Inspection points
 Hold point

BKC assigned Vendor's Inspector or its approved Third Party Inspector shall
schedule & perform source inspection at Vendor or sub-supplier fabrication
shop as specified in the approved ITP.BKC shall submit to HHI/ SEC the
Vendors test reports.

11.5.2.8 Inspection Schedule and Status

BKC shall submit each week a Three Week Look Ahead Schedule of planned
QA/QC activities for procurement and status of resolution on issued NCRs to
Vendors / Subcontractors. BKC QA/QC department is responsible for its
preparation and control. The forms to be used are shown in the appendix of
this section. The format of these forms (Q-020 & Q-015) is subject to
acceptance by HHI/ SEC and electronic copy to be provided to them
accordingly.

11.5.2.9 Procurement Inspection and Test Records

Prior to release of Vendor's item at their Production Location and after


successful test & inspection, BKC shall require the Vendor to submit all
relevant manufacturing test reports as specified on Purchase Order
requirement in
Reference to HHI acceptance criteria. These reports shall be submitted to HHI
with the Inspection Disposition Report.

11.5.2.10 Final Disposition Reports

Within two (2) weeks after acceptance of the materials from Vendor, BKC shall
prepare Inspection Disposition Report to HHI / SEC which shall include:

 Copies of approved Waivers to HHI/ SEC


 BKC witnessed inspection record.
 Copies of Vendors quality records.
 Copies of all NCRs with final disposition and resolution.
 Copies of Inspection Release Certificates (IRC) as evidence of positive
disposition on the inspected materials.

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11.5.2.11 Packing

BKC and/or its Vendor shall ensure that the packing shall be capable of
withstanding all hazards normally encountered during transportation including
loading and unloading operations. It should protect goods from weather
conditions.
Spare parts shall be packed separately from the equipment, which they are
referred to.

The packing list (not made on headed paper) shall bear:

 BKC Purchase Order reference


 HHI/ SEC reference number
 Gross, net weights and dimensions for each package
 Description of goods as per P.O.

11.5.2.12 Shipping and Invoicing

BKC Vendor shall be responsible for shipping the material from the country of
origin to Saudi Arabia, in accordance to BKC shipping and invoicing
instructions as attached to the Purchase Order. This includes, but not limited to
ocean freight, airfreight, export packing, insurance (if any), and export licenses,
authorization and all associated documentations required. The shipping
documents compiled by BKC and/or its Sub-vendor shall include, but not
limited to the following:

i) Invoices - Made on sub-vendor‟s headed paper, and shall bear the


BKC purchase order reference, HHI ref. no., and final destination of
goods and description of goods as per Purchase Order.

ii) Packing list - In accordance with section 11.5. and above

iii) Certificate of origin - For all materials manufactured outside the Kingdom of
Saudi Arabia, Vendor shall obtain a certificate of origin issued by chamber of
commerce in the manufacturer ’s country.

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The certificate of origin must show:

  Consignee
 BKC Purchase Order reference
 Client‟s reference no.
reference no.
 Materials, type of
of packages and total gross net weight
 The full name
name and address
address of the manufacturer

iv) SASO Certificate (if applicable only)

Saudi Arabian Standard Organization‟s (SASO) certificate of conformity


to standard specifications for items that may be required in the Sub-
contract job specification.
specification.

v) Packing Marking

Each package shall be well marked visibly on three sides.

11.5.2.13.Receiving

For materials directly purchased from foreign Vendors/Suppliers, BKC


Procurement Department shall be responsible for clearing the material through
Saudi Arabian customs, offloading, and inspection on receipt, delivery to the
BKC warehouse BKC shall inform HHI the st atus of received material.

11.5.2.14 Materials Procurement Status

To ensure delivery of materials will be at site during the scheduled need on its
respective activity use,BKC normally monitors Procurements Status following
the matrix form shown in the Appendix Section.
 A copy of Procurement
Procurement Status Report shall be highlighted during Weekly
Progress Meeting and included in the minutes.

11.5.2.15 Quality Management Reports

Pursuant to sub-contract schedule, BKC shall prepare and submit monthly


quality management report to HHI covering the following, for distribution to
concerned HHI / SEC Inspection
Inspection Units:

 Listing of supplier
supplier surveys performed
performed with a summary
summary of findings.
 Listing of
of Pre-inspection
Pre-inspection Meeting
Meeting conducted.
 Listing of supplier
supplier inspections performed versus scheduled
scheduled inspections.
 Non-conformance
Non-conform ance reports issued to vendors: number issued, closed out,
and pending for t he month.
month.
 Listing of quality
quality audits completed
completed (internal and subcontractor).
subcontractor).

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 Welding rejection rate reported on a per joint basis for structural, and alloy
welds. A chart showing the historical performance during the project shall
be included.
 Listing and status of engineering waivers requested.
 QA/QC Personnel
Personnel Listing by Discipline
Discipline as specified
specified in Sub-Contract
Sub-Contract
Requirements.

 11A. MATERIAL MANAGEMENT PLAN

11A.1 SCOPE AND PURPOSE

This material management plan describes and outlines the procedures for material
identification & traceability, receiving, storing & protection and preserving and
safeguarding, accounting and record control, issuing to production units, and
preparation of all necessary reports required for the proper management of materials
for BKC supplied materials/items
materials/items intended for this particular contract.

11A.2 CORRELATION WITH OTHER PROCEDURES/DOCUME


PROCEDURES/DOCUMENTS
NTS

This Material Management Plan shall be applied in conjunction with the following
relevant procedures:

11A.2.1 HHI Contract Provisions

 Company Standards & Specifications


Specificat ions
 Sub-Contract Agreement
Agreement
 Sub-Contract
Sub-Contr act Requirements

11A.2.2 BKC Procedures

 This Project Quality Plan


 Non-Conformance
Non-Conformance Procedure, Section 10 of
of this Project Quality Plan.

11A.3 RESPONSIBILITIES
RESPONSIBILITIES

BKC Material Supervisor is the overall-in-charge and responsible for the material
management
management at Project Site covering the following specific functions:

 Receives BKC supplied materials in accordance with the Company‟s


procedures and documentation.

 Collaborates
Collaborates with
with BKC QA/QC Inspector in seeking
seeking checking and

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clearance of quality acceptance of materials being delivered to site


before receiving.

 Generally manages materials storage, receiving and issuing functions


and maintained an orderly record of its proper documentation.
Designate a warehouse assistant and delegate his functional duties
during his absence at site.

 Prepares all the necessary


necessary reports pertinent
pertinent to materials.

11A.4 MATERIAL IDENTIFICATION AND TRACEABILITY

The Material Supervisor shall be guided on Materials Identification System being


observed by BKC as a normal Industry practice which is very essential for traceability
during the stages of production, delivery, receiving & storing and installation. Refer to
the "Guidelines for Material Identification and Traceability"
Traceability" appended to this section.

11A.5 RECEIVING AND INSPECTION


INSPECTION OF MATERIALS
MATERIALS

11A.5.1 BKC Supplied


Suppl ied Materials
Mater ials

BKC Material Supervisor accomplishes Material Receiving Report Form (WF-


10) after receipt of materials at site and signed-off clearance from BKC QC
Inspector who examined acceptability conditions and compliance with the
material specification.
specification. BKC QA/QC Inspector
Inspector accomplishes
accomplishes the Material
Material
Inspection Report Form (Q-006).

11A.5.2 Main Contractor Supplied Materials

11A.5.2.1 Material Take-offs

BKC Technical support services shall verify HHI material take-off with respect
to IFC drawings and report all shortages and excess materials to HHI indicating
Description, Quantity, Technical specification, HHI / SEC Materials
Specification stock number (if any) provisions for material handling and storage
until installed (i.e. indoor or outdoor).

11A.5.2.2 Coordination HHI / SEC and contractor 

BKC Material Supervisor will coordinate


coordinat e with HHI
HHI material Supervisor and/or
Material Coordinator affecting the smooth transfer of all material supplied by
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HHI.

11A.5.2.3 Physical Receipt of Materials

1) Pursuant to Sub-Contract
Sub-Contr act agreement, HHI supplied materials shall be
delivered to site. To ensure proper safekeeping, protection and control,
BKC Material Supervisor shall classify materials to sensitive and non-
sensitive items. For sensitive items i.e. electronic equipment like DCS shall
be stored in Air conditioned storage to prevent damage during storage and
if possible arrange delivery direct to Control Room.

2) Copies of the material receipt shall be retained and filed by both HHI and
BKC. The document to be provided to BKC shall contain the following.
following.
a.) Delivery Note
b.) Material Receiving Report
c.) Vendor Inspection
Inspection Release Note; Note; (For Inspectable
Inspectable Materials /
Equipment Only).
d.) Material Certifications
Certifications or Manufacturing
Manufacturing Data Records.

3) Any identified
identifi ed non-conforming
non-conformi ng item discovered during detailed materials
check shall be segregated at the BKC Lay-down Yard and/or at the
Delivery Points (Project Site). HHI shall be notified immediately of non-
conforming material items. Forms shall be utilized to maintain constant
control of materials as well as non-conforming material. Non-conformance
findings as reported by BKC QC Inspection shall only be limited to
quantities physical damage or wrong items against Delivery Note.

 A non-conformance
non-conformance report shall be made for all identified non-conformance
non-conformance
materials, a copy of which shall be submitted to HHI, second copy shall be
retained by QA/QC and third copy shall be placed in a plastic folder and
attached to the material. The material shall be marked with red paint as reject
and removed from Site Storage Yard and store in area meant for non-
conformance material.

Final disposal of all non-conformance materials shall be in accordance with


Instructions of HHI Representative.
Representative.

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11A.6 STORAGE

11A.6.1 Warehousing Facilities

b) Storage includes all materials, tools and equipment received and held until
they are issued for installation. BKC will submit to HHI a Material Storage
Plan to show material arrangement in segregated manner for each
classification. Refer to appendix of this section showing "Guideline for
Material Storage Warehousing" indicating mode of storage for each item
classification.

c) Indoor storage shall be by the use of steel van containers equipped of with
shelves and bins to maintain proper segregation of materials by usage
 jurisdiction and classes. All items retained their Purchase Order or Tag
Identification for retrievability and inventory control. These containers are
weather-tight, well lighted and ventilated and laid to ground with timber or
any other supports and not subjected to surface water run-off. Outdoor
Storage shall be the designated lay-down area by HHI and constructed
with seclusion fence and padlock. The area should be well drained, free
from traffic and work interface operation.

11A.6.2. Housekeeping, Storing and Identification of materials

1) Proper stacking practices will be implemented.

2) Inside and outside storage areas (aisles, bin sections, yard plots etc.) will
be clearly defined and identified with appropriate storage location signs.

3) All materials will be stocked and maintained in accordance with acceptable


safety standards in a neat orderly manner to provide efficiency in physical
checking and movement and in a manner to ensure proper protection from
damage, deterioration, or pilferage. These includes:

 Use of adequate storage bins and racks.


 Use of pallets and stringers
 Proper stacking
 Maximum utilization of inside or other protection storage and lock-up
areas.
 Closing and locking containers or vans.

4) All weather sensitive materials like instruments, small tools, electrical wires
and delicate equipment and specialty items shall be stored in weather
proof container.

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11A.6.3 Stock Location

The Material Supervisor shall establish a grid type (i.e. row/shelf/bin. etc.)
locator plan for each storage location. Appropriate signs shall be posted to
identify area. The storage location designated shall be indicated on the
Material Receiving Report/Daily Register.

11A.7 PROTECTION AND PRESERVATION OF MATERIALS DURING STORAGE


 AND CONSTRUCTION PERIODS

Refer to Appendix of this section f or guidelines to be observed.

11A.8 ISSUING AND INVENTORY CONTROL

11A.8.1General

BKC Material Supervisor maintains file of material documentation and


inventory control for BKC Supplied Materials. All materials stored in the
warehouse custody have formally passed the QA/QC Inspection and those
rejected ones are segregated separately and returned.

11A.8.2Issuance

Issuances of materials to construction level are covered by warehousing


proper procedure. The withdrawals of material from the warehouse or storage
areas are covered by Material Requisition Slip initiated by the responsible work
supervisor. The request identifies the material and applicable references to a
drawing and Material List except for equipment, which is by equipment
number. The warehouse distribution personnel process the form through the
established system and release the materials to the requisitioned.

The Material Supervisor posts on a daily basis all issues, returns, receipt and
balances of materials through a manual cardex system of control.

11A.8.3 Stock Location System

 An accurate stock locator system is to be maintained for all items stored at the
storage site.
a) File folders for receiving records will be established including location areas
for the material.
b) Any relocation of material will be recorded.
c) A card file with a record card for each storage plot or areas will be
established. This card file will be updated constantly to reflect any changes
in material storage locations.

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d) Storage locations will be entered on all receiving documents covering items


to be held in storage.
e) Inventory records should be maintained and updated for all materials. They
must be compatible with the mode of physical storage and have storage
location entered thereon, In and out activity, and balance are to be
maintained to permit accurate accountability.

11A.9 OVERAGES, SHORTAGES, DAMAGES REPORT

Wherever a discrepancy in a shipment occurs, the Material Supervisor prepares the


report of Unsatisfactory Over, Short, Damaged materials, within 7 days of receipt.

a) Overages
If the discrepancy is over shipments, BKC SITE Office is to be consulted as to whether
to retain, or to return the materials.

b) Shortage
In the event material called for on applicable shipping documents cannot be located, it
is the responsibility of the Material Supervisor to take the necessary steps to protect
the company‟s interest and proceed with the proper documentation of the shortage. If
the shortage is apparent at delivery, it is very important that the proper-signed notation
be entered to the delivery receipt or freight bill indicating the extent of the shortage.
The carrier‟s delivery agent must sign this document. This is very important, without
this documentation, any future claim action may be invalid. It is important to take time
at delivery to make an accurate piece count.

c) Damages
The handling of received damaged materials pose many problems in material receiving
and the proper handling of this problem are very important. In the event material
received is in damaged condition, it is the responsibility of the Material.

Supervisor to take the necessary steps to process the proper documentation and
reporting to the Site Manager who will take appropriate action.

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11A.10 MATERIAL RETURN FROM SITE TO STORE

a) Material shall be issued only through Material Issue Slip signed by


concerned Forman/Supervisor.

b) Excess Construction materials received by construction team can be


returned to Inventory Store for possible disposition.

c) Concerned Supervisor shall prepare a Construction Material Return


Voucher (From Site to Ware House)

d) aterial Department shall arrange for inspection of these items by sending


this voucher to QA/QC.

e) Material Department Head or his nominee can inspect the returned


Consumables for physical condition prior to taking into stock.

f) All accepted Materials shall be taken into Stock and Stock file updated

g) Rejected materials shall be sent to Rejection Yard.

 12. CONSTRUCTION AND PRE-COMMISSIONING PLAN

12.1 Scope and Purpose

This portion describes the specific and extent of work covered by the phase sections
being addressed in this part of the construction work quality plan. It establishes the
basis of requirements for the preparation of inspection and Test Plan (ITP)/ITP
Checklist, procedures and acceptance criteria.

12.2 References

Defines all relevant document i.e. codes, standards, specifications, etc. to be referred
with for the correct execution of the job to conform with the contract technical
requirements for the specific work item covered by the construction work quality plan
as basis of criteria of acceptance.

 Sec. 3.0 of this PQP

 Sub-Contract Agreement

 Contract Documents, Specifications & Drawings

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12.3 Responsibility

Defines the performing units/persons responsible for the correct execution of the job
and required interfaces of Inspection Units/Persons to control and ensure attainment of
the required Quality Standards.

12.4 Quality Control Procedures/Method of statements

 All method of statement/(QCP) and corresponding Inspection & test Plans (ITP)
referred in Section 3.0 of this PQP shall be submitted accordingly as required in Sub-
Contract Agreement, Relevant procedures applicable under each sections of the
Construction Work Quality Plan which normally address but not limited to the f ollowing:

 Materials to be inspected and tested.

 Inspection and test methods, plans and procedures.

 Off site location of established pre-fabrication/assembly of items prior


to delivery to site.

 Acceptance criteria for each critical phase of activities during the


course of Construction/Installation.

 Third Party Inspection Companies and the services they will provide.

 Work Procedures for specials process activities like concreting


Protection, Critical Coating, Cable Splicing/Termination, cable/conduit
seals etc. are described and established to ensure the job are
accomplished under controlled conditions in accordance with all
applicable Standards and Specifications.

12.5 Inspection and Test Plans ITPs

Inspection and Test Plans is the quality plan for each construction work phase
discipline showing in details the methods and timing for examinations, measurement or
tests to assure compliance with contract job requirements. In a m atrix presentation, the
ITPs shows the following:

 Task descriptions

 Acceptance criteria (Checked per applicable Specifications, Codes,


Standards, Procedures or IFC Drawing etc.)

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