project quatity plan

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K)

PROJECT QUALITY PLAN

PREPARED BY

QA / QC DEPARTMENT

License No. 153842-k

QA & QC DEPARTMENT


TABLE OF CONTENT

1.) INSPECTION TEST PLANT ( ITP ) & Q.C/Q.A . STANDARD MANUAL

2.) QUALITY ASSURANCE MANUAL

3.) CALIBRATION CERTIFICATE

4.) WELDING PROCEDURE SPECIFICATION (WPS)WELDER QUALIFICATION TEST ( WQT )

5.) WELDING PROCEDURE

6.) CLIENT SPECIFICATION

7.) NDT

8.) PAINTING PROCEDURE

PREPARED BY:

LIZAWATI BT SAMSUDIN QA/QC Representative

CHECKED BY :

( RAYMUND N.LING )QA/QC MANAGER

APPOVERD BY :

(CLIENT REPRESENTATIVE)

QA & QC DEPARTMENT


TUCK SIN PROJECT POLICY STATEMENT

TUCK SIN is fully committed to the high quality level objective of the Work Package for the STEEL STRUCTURE for the fabrication and erection of the structure steel in following with the requirements of standard coats and the Contractual Specification.

Tuck Sin’s combined experience, expertise and capability places particular emphasis on Safety, Reliability and Quality.

The objective of Tuck Sin is provide these services in a manner, which conforms to the specified requirements of the Client and all applicable Statutory and Regulatory requirements.

In order to achieve this objective, it is the policy of Tuck Sin to establish and maintain an effective and efficient Quality Management System planned and developed in conjunction with other management functions.

The assurance of Quality is fundamental to all work undertaken by Tuck Sin on the Project and is practised by all of our staff.

The defined commitment of each member of Tuck Sin is work as a Team to achieve the objectives of our Client.

RAYMUND N.LINGQA/QC MANAGER

QA & QC DEPARTMENT


1.0 INTRODUCTION

This Project Quality Plan has been developed by Tuck Sin in following with the basis Quality requirements of ISO 9002 Standard. This Quality Plan is tailored to satisfy the specific requirements in the fabrication and erection of the Work Package for the fabrication and erection of the Steel Structure.

1.1 Management Policy Statement

The Management of Tuck Sin having Executive responsibility have fully endorsed this Project Quality Plan as fully meeting the expectations of the client.

The policy of Tuck Sin is that an effective and efficient Quality System shall be utilised throughout all levels of the organisation in the executive of the Work Package.

1.2 Objective of the Project Quality Plan

The objective of the Project Quality Plan is ensuring that all phases of the Project are executed with the highest level of Quality and efficiency satisfying the Client’s requirements.

In this regard Tuck Sin’s Management has appointed a Project Quality Manager with the defined authority to ensure that the Project Quality Plan is implemented and maintained throughout all phases of the project.

The Quality Plan shall be implemented with the full support of all personnel engaged on the Project. Included in the Tuck Sin’s objectives is a commitment to execute the Project in accordance with all applying Regulatory Standards and Codes applying to the Project, on schedule and within the Contracted Budget.

That the completed “STEEL STRUCTURE” facility are turned over to the Client as a Safe, reliable and fully satisfying to the Specification for the Steel Structural according to Client or Standard Code.

QA & QC DEPARTMENT


2.0 ORGANISATION AND RESPONDSIBILITY

2.1 Scope

Executive Management has delegated responsibilities to Management levels of the Project staff with complete authority to take the necessary actions to ensure conformance by all staff members to the Quality System.

A detailed description of the duties to be performed by the positions shown in Attachment “A” identified as the “ORGANISATION CHART” and in the Responsibility Matrix shown in Paragraph 2.2 of this Plan.

To satisfy the purpose of this Project Quality Plan, the word “Responsibility” shall mean:

“The actions which nominated personnel are responsible and accountable for “.

The assignment of responsibilities is enhanced by the identification of four basic functions, which apply to each element of the Quality System.

The four basic functions of the System are:

a.) To Authorises and Approve – is preliminarily a Quality Assurance Management function associated with the development and the Continuous Improvement Process of the Quality System.

b.) Prepare and Issue – also a Quality Assurance Management function associated with the development and Communication of the procedures required for the Quality control of the various elements of the Project Quality System.

c.) Implementation and Co-ordination – is jointly a Quality Control (QC), Operations Management and Site Project Management function associated with the ongoing use and implementation of the Project Quality System.

d.) Quality Reporting – is a Quality Assurance function associated with documentation and monitoring the work process for conformance to the Project Quality System.

QA & QC DEPARTMENT


2.2 Responsibility Matrix

TITLE MAIN FUNCTION SECONDARY FUNCTION1. Operations

General Manager(Reports to Tuck Sin Managing Director)

Project Management Direction to Project

Engineers Control of Project

Activities Response for Site

Quality/Safety Control of Project Costs Liaison with Government

Authorities

Liaison with Client Representative

Safety management Reporting to the

managing Director

2. Site Project Manager(Reports to the Operations Manager)

Management of all erection activities

Review of Proposed Contract Change

Manpower and Equipment Resource Audits

Fabrication and erection Controls

Scheduling and Work Controls

Worker Training Program Approvals

Liaison with Client’s Representative

Supervision in Implementation of Work Instructions

Enforcement of Safety Rules

Welding Supervision Supervision of Site

Activities Supervision of erection

work

3. Safety Officer(Reports to the Managing Director)

Responsible for site Safety

Monitoring for Safety Procedures

Liaison with Client’s Safety Manager

4. Quality Assurance Manager(Reports to the Managing Director)

Responsible for Quality at all areas of Project Activity

Internal Quality Audits on PQP

Guidance to Site Inspectors

Monitor all site Quality System

Implementation Interpret Project

Quality Training Development of Quality

plans and Procedures Supplier Audits as

necessary Preparation of new work

instruction Liaison with engineering

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) Specifications

5. QC Supervisor and the Inspectors(Reports to QA Manager)

Responsible for inspection of work both in the shop and at site

Assistance to the Safety Officer Conduction QA Audits

6. Design Engineer(Reports to the Managing Director)

Responsible for the engineering

Design in all aspects of the Project.

The review of shop drawings and Site erection drawings

Provide guidance to engineers

Develop monthly engineering Reports

Provide guidance to site Erection in engineering

matters

7. Welding Engineer (Reports to Design Engineer)

Develop Welding Procedures

Resolve welding problems

Assists design to engineer Monitors material analysis

and Metallurgical problems

8. Document Controller (Reports to the QA Manager)

Responsible for the control and filing of all Quality related documentation

Assist the Material Controller

9. Material Controller(Reports to the QA Manager)

Responsible for material receipt

Recording issue of materials

Monitoring material quality

Assist the QC Inspector at site

QA & QC DEPARTMENT


2.3 Quality Assurance Manager

2.3.1Scope of Responsibilities

The Project Quality Assurance Manager reports to the Managing Director. His responsibilities and authority with regard to Quality matters are directly delegated from Management on all the Project activities. His specific responsibilities are: -

The preparation and issue Method Statements, Work Procedures and Work Instructions in the following with the Project Specification…

Take follow-up action on unresolved problems areas. To review the qualifications of all inspection and Test Personnel. Develop action Plans on reoccurring problems. Monitor/Supervise Third Party Inspection activities. Issue reports to the Managing Director on the implementation of the Project

Quality Plan, the Quality System and Method Statements. Conduct periodic Internal Audits to ensure conformance to all applying BS

Standards referenced in the Project Specification – approved Project Quality Plan. Ensure the complete identification and traceability of structural steel used on the

work. Review all Non-Conformance Reports and expedite the resolutions for corrective

action.

2.4 Design Engineer

2.4.1Scope of Responsibilities

The Design Engineer is responsible for aspects for engineering activities as follows: -

The preparation of design drawings and calculations in accordance with BS 5950.

QA & QC DEPARTMENT


The preparation of shop drawings as built drawings

Identify any steel member greater than 30mm for testing in accordance with Specification.

Keep the Operations Manager fully advised on all design activities.

Prepare erection plans and erection instructions in following with regard to dimensions and tolerances.

Anticipate erection problems before they occur and implement corrective actions.

Maintain close liaison with the Operations and QA Managers to avoid erection problems or delays in the work.

Provide guidance in the resolutions of Non-Conformance and recommend corrective actions.

To incorporate all Quality and Safety features into the design work.

To liase with the Client any engineering problems that may arise during the design stage.

2.0 QUALITY SYSTEM 2.1 General

The Project Quality Plan is supported by Tuck Sin’s Quality Manual and Internal Company Procedures.

3.2 Quality System Procedures

This Quality Plan applies to all Suppliers and Sub-Contractors where need the relevant in regard to Quality aspects of the for Structural Steel Work.

3.3 Project Quality Control Plans

Quality Control Plans shall provide details of actual work related activities that shall be performed to fulfil the requirements of the contract. The activities shall be in a logical sequence covering all erection phases.

3.4 Fabrication Quality Control Plan

The Fabrication Quality Control Plan consist of two sections as applied to the fabrication process at the factory as follows:

Section 1

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) An index of procedures or instructions giving the document number and descriptive title for each procedure to be employed by the factory during the various stages of fabrication, shop inspection and testing.

The shop foreman shall be advised of all witness points at the various stages of the work while it is in progress.

Section 2

The Project Inspection and Test Plan shall list all activities involved from testing of materials to shop fabrication and despatch at site. Particular attention shall be given to Final Inspection and the testing to be performed prior to despatch.

The Quality Assurance Manager shall specify the Inspection Activities, which shall be considered as “Hold Points” both during fabrication and erection.

For each Quality activity the appropriate specification or procedure shall be identified together with how the result is recorded and stages where specific records, reports or certificates are produced.

3.5 Format and Approved Inspection and Test Plan

The content and format of all Fabrication/Site Inspection and Test Plan shall not be revised without prior consultation and approval of the Client.

Deviations from approved Plans shall be subject to discussion and agreement by the Client prior to implementation.

3.6 Preparation of Inspection and Test Plans

Inspection and Test Plans shall be submitted to the Client for approval prior to implementation.

Test Plans shall reference any relevant working instruction such as weld procedure number, assembly procedure reference number, etc.

National Standards and Codes shall be listed, together with reference to any particular relevant sections or tables.

Verifying documents produced and signed off, as proof of acceptance by the Project Inspector shall be listed, e.g. material test certificates, NDT results (MPI, UT, PT, etc.).

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) Where necessary, separate procedures shall be developed for special processes that are not covered by routine procedures. Such procedures shall be subject to approval by the Quality Assurance Manager.

The procedure shall then become part of the Project Quality System and Project Quality Records.

All Inspection and Test Plans shall reference, where necessary, the applying paragraph of the Project Specification.

4.0 PROCESS CONTROLS

4.1 General

The Site Project Manager shall ensure that all site erection activities are performed in accordance with the requirements of:

a.) Relevant sections of the Specificationb.) Approved fabrication and construction drawings (Latest Revision).c.) Approved Fabrication/Construction Procedures and Specifications (Latest).d.) The Project Quality Plan, relevant Inspections and Test Plan and Supporting

Procedures.e.) When necessary, special Quality procedures.

4.2 Erection Quality Plan

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) As early as possible, prior to the commencement of any construction work, the Operations Manager shall prepare an Erection Plan along with any necessary supporting Construction Instructions.

Immediately upon approval of the Erection Quality Plan, all members of the erection Team shall be instructed in the implementation of the Plan. All personnel subsequently assigned to the team shall undergo the same instruction prior to commencement of work on the project.

4.3 Control Over Erection

Control over the erection work shall be governed by Method Statements, procedures and approved drawings, which define the parameters of the work to be performed in accordance with standards, and defined work practices. Suppliers’ documents shall subsequently be checked to ensure specifications, etc. is being followed. When surveillance checks during erection.

Erection of material at site shall be performed to documented Work Instructions which defines the work activity, the personnel responsible, any special equipment involved and the verifications checks and the quality Records to be produced,

Where critical work processes and equipment are in use, these shall be evaluated by authorised personnel and formally approved.

4.4Special Process

Special processes, such as welding, non-destructive testing, protective coating testing, etc. shall require Special Procedures to be developed and approved by the Client. Where necessary the operators shall be qualified in accordance with the applicable standards.

Qualification Test Records or results for special processes, equipment and personnel (e.g. welding, non-destructive testing, etc.) shall be kept current and available for verification by authorised personnel.

All NDT procedures and personnel shall be approved by the QA Manager and the Client prior to starting NDT work.

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) All control gauges for special processes, e.g. measuring equipment, shall be certified and approved and thereafter included in a calibration programme.

The overall responsibility for the control of all major processes at site is that of the Site Project Manager who shall maintain close contact with the QA Manager so that any required qualification tests for a Special Process can be conducted.

5.0 PRODUCT IDENTIFICATION AND TRACEABILITY

5.1 All items of equipment and materials shall have an identification number for traceability purposes. Tuck Sin procedures require that these item numbers and other relevant identification numbers are stated on the design and procurement documents as such traceability is imposed on Suppliers and Site Construction staff as necessary.

5.2 Materials and items identified as requiring traceability are positively identified at all times during manufacture, fabrication, storage, handling, transport,

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) construction, commissioning and use. This allows traceability to a specified source and to relevant Certification.

5.3 Identification is maintained by heat number, part number, serial number, etc. on the material or item or on a tag securely attached and always on documents and records traceable to the material and item. Physical identification is used wherever possible within the limits of requirements imposed by relevant codes, standards or specification.

5.4 The location and method of identification does not affect the function or quality of the material and the identification will be unambiguous, legible and clear. Material identification that is hidden or obliterated during manufacture, assembly or installation is transferred to a more suitable location. When a material is sub-divided, its identification is transferred to its daughter materials. Operations involving transfer or identification are itemised on Quality Plans and are verified.

5.5 Correct identification of materials and items and traceability to their documents and records is verified prior to acceptance and use.

6.0 NON-DESCTRUCTIVE TESTING

The frequency of non-destructive examination shall be in accordance with BS 5135 : 1984

QA & QC DEPARTMENT


TYPE OF WELD INSPECTION

Full Penetration Welds

Fillet Welds and Partial Penetration Weld

100% ultrasonic testing for each welder.

Random 20%Dye penetration Examination on fabricated items.

Test and examinations of all the welds shall be performed in accordance with the AWS D1.1.

The NDT inspector shall be an independent licensed agency.

6.1 Identification and Traceability

Each assembled truss shall be given a unique numbering system for tracebility

6.2 Painting Inspection and Tolerance

Minimum Protective coating shall be a three coat protective system. Surface conciliation frequency 100% as per SIS 05 5900 SA25. Paint systems to be applied as per manufacturer’s specification. Humidity shall not more than 85% for each application. Final paint inspection to be recorded as per specification.

6.3 Final Inspection/Delivery

QA/QC personnel shall ensure that all inspection process pertaining to outgoing products has been performed and documented.

Final Release Note shall be performed before any delivery.

7.0 INSPECTION AND TEST STATUS

7.1 General

QA & QC DEPARTMENT

TUCK SIN Engineering & Construction Sdn. Bhd. (153842-K) The Site Inspector shall be responsible for monitoring the status of all Inspection and Test that are required to be performed throughout the different phases of the erection work. The system for identifying the status of inspection and/or Testing shall be by reference to the documented inspection records. The records shall be maintained in accordance with Project Specifications.

For the purpose of controls a Master Chart shall be developed by the Inspection Department showing Inspection and Test Status and the due dates of each Inspection or Test.

7.2 Inspection and Test Plan

The QA Manager shall develop and issue Inspection Check Lists or Inspection and Test Plans show inspection requirements during fabrication and erection. Inspection status shall be indicated by the inspector’s signature and date adjacent to the operation on the List or Plan.

Where possible visible identification labels, tags or other suitable identification shall be placed on the product on acceptance by the Inspector.

QA & QC DEPARTMENT


8.0 CONTROL OF NON-CONFORMING PRODUCTS

8.1 Purpose

The purpose of this Section is to ensure that Non-Conforming items or processes are clearly and easily recognised by all concerned so that they are not inadvertently used on the project. It is the responsibility of site QC to ensure that the necessary controls are in place to satisfy the requirements of this Section and Project Specifications.

8.2 Methodology

When detected, non-conforming products shall be identified by clear physical marking, tagging and, if possible, segregated to prevent unauthorised use, shipment or mixing with conforming material.

No further work shall be progressed on the product pending a decision on its further disposition by QA Manager in consultation if necessary with Engineering, Construction of the Client as necessary.

8.3 Disposition

According to the circumstances, disposition decisions shall include: -

Scrap and Replacement Repair Rework Use-as-is

Quality Control is responsible for ensuring that all Non-Conformance Reports are recorded. All disposition decisions shall be properly recorded and filed with the Project Quality records.

Objective evidence shall be maintained to substantiate that repair and reworked items have been re-inspected or re-tested and found acceptable.

The QA Manager shall be informed of all incidents of non-conformance for monitoring purposes and the assessment of trends.

8.4 Re-inspection

It is responsibility of site QC to ensure that all Non-Conforming products are re-inspected by the same method that detected the original discrepan

QA & QC DEPARTMENT


9.0 QUALITY RECORDS

9.1 General

It is the responsibility of the Site QC Manager or his designated Inspector to ensure that all site developed Quality Records are complied, maintained and collated as the work is performed throughout the duration of the Project. These records provide objective evidence of the Quality of work produced and testifies that the work is in compliance with contractual requirements.

9.2 Records

Such Quality records shall contain all data and information required by the Project Specifications, Codes, Standards and the PQP.

Records shall be legibly hand written Inspection Forms other acceptable material Certificates, which shall comprise of the original documents or authenticated copies.

Records shall be retained for the minimum period specified in the procedures, or as required by law.

The Document Controller is responsible for maintaining the Quality Record System.

9.3 Quality Records

It is the responsibility of the site QC Manager to ensure that copies of all Quality Records are sent to the Document Controller for compilation into the Quality Record Dossier.

QA & QC DEPARTMENT


QA & QC DEPARTMENT

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