COMPANY QUALITY PLAN
Quality Plan For Electrical And Instrumentation Works
CONTENTS
1. INTRODUCTION 2. PURPOSE 3. SCOPE 4. REFERENCES 5. ORGANIZATION 6. QUALITY SYSTEM DOCUMENTATION 7. MANAGEMET REVIEW OF CONTRACT REQUIREMENTSS 8. REVIEW OF CONTRACT REQUIREMENTS 9. DOCUMENT CONTROL 10. PROCUREMENT OF MATERIALS 11. PRODUCT IDENTIFICATION AND TRACEABILITY 12. PROCESS CONTROL 13. INSPECTION AND TESTING 14. CONTROL OF INSPECTION, MEASURE AND TEST EQUIPMENTS 15. IDENTIFICATION OF INSPECTION / TEST STATUS 16. CONTROL OF NON-CONFORMING PRODUCT 17. CORRECTIVE AND PREVENTIVE ACTION 18. HANDLING, STORAGE, PACKAGING, PRESERVATION 19. CONTROL OF RECORDS 20. TOOLS AND EQUIPMENT 21. SAFETY AND RISK ASSESSMENT 22. INTERNAL QUALITY AUDITS 23. TRAINING
ANNEXURE A – INSPECTION & TEST PLAN / CHECKLIST FORMS QUALITY PLAN
1. INTRODUCTION
The intention of this Quality Plan is to direct the staff of our Company with regards to their required duties and to provide sufficient assurance that the work undertaken will achieve acceptable standards and meeting Company's Policy and its objectives stated as follows: - Provide Quality Products and Services to satisfy our customers' requirements. - Strive for continuous improvement through a focused and Process Oriented Quality Management System. This Quality Plan defines procedures to be followed to ensure and control the quality of all construction activities and describe the responsibilities in the organization for the assigned contract. Quality plan will be updated as necessary during the contract. It is the responsibility of all Ampere Electromechanical Engineering staff to understand and conform to the requirements of this Quality Plan and its associated documents.
2. PURPOSE
The purpose of this Quality Plan is to ensure that the supply and installation of materials and equipments meet the required quality standards and contractual requirements.
3. SCOPE
This quality plan will be applied to the supply, installation, testing and pre-commissioning of Electrical and Instrumentation works. This plan will cover the following activities for the complete duration of the contract as mentioned on the above specification but not limited to: Electrical and instrumentation works involving: - Engineering and documents [applicable design work, and data according to document requirements and specifications - Mobilization and Demobilization As Built Drawings - Engineering & Design Services - Electrical - Substation (supply and install) - Bus Duct Cable Tray and accessories - Cable, Termination and accessories - Upgrade existing Compartments - Isolator with emergency stop and all auxiliaries - Opening, Closing and Sealing of Draw pit - Substation (supply and install) - Bus Duct Cable Tray and accessories - Isolator with emergency stop and all auxiliaries - Opening, Closing and Sealing of Draw pit - Equip space compartment - Electrical Disconnection and Removal - Instrumentation - Bus Bar Monitoring System - Quality, Testing and Commissioning - Spare Parts
4. REFERENCES
- Ampere Electromechanical Engineering Assurance Manual - Project Specifications - Approved Drawing
5. ORGANIZATION
The Ampere Electromechanical Engineering staff in charge of the various quality related functions shall have knowledge to identify problems, to recommend solutions and to prevent further problems. The functions, duties and responsibilities of Ampere Electromechanical Engineering site personnel involve are as follows:
(i) Project Manager – Responsible for overall execution of the project and reports to the Construction Manager. His objectives are to ensure that the contract works are executed in accordance with the specifications and schedules in full respect of quality and safety requirements and to liaise with AEE, Subcontractors, and Suppliers as well as with other departments within Ampere Electromechanical Engineering.
(ii) Site Engineer – Supervises Site Supervisors and construction teams reports to Project Manager. He will also coordinate inspection and test activities in the field.
(iii) QA/QC Engineer – Responsible in conducting inspection, monitoring, witnessing, initiating snags item, preparing necessary quality documentations. Ensure that compliance to quality requirements / project specifications /approved drawings on site are implemented / followed. Coordinates all QA/QC related site activities with the Construction team and AEE. Function administratively under the Project Manager at site but reports directly to QA/QC Department Head.
(iv) Planning Engineer – Responsible for preparing site program planning / scheduling. Monitor periodic progress. Site progress submittal as per AEE requirements. Re￾scheduling of programs if changes occurs. Forecasting monthly progress. Reports to Project Manager
(v) Site Supervisor / Foreman – Supervises field construction team, reports to Site Engineer. His objectives are to supervise the site installation in accordance with the approved drawings / specifications, Quality Plan and relevant procedures. He will inspect and ensure that proper materials are being used in installations. He will also ensure that safe working practices are strictly observed/ followed by his subordinates. Reports to Site Engineer
(vi) Safety Officer – Implement Safety rules where necessary. Ensure that all site Personnel and visitors adhered to the Safety rules. Carry our site surveys on a daily basis and weekly basis. Inspect tools/equipments and personal protection equipment arriving on site prior to issue/ use or during and when required. Conduct safety
(vii) Training programs and weekly safety "Tool Box Talk." Record and analyze accidents, injuries and damages
(viii) As and when they occur. Initiate/prepare safety risk assessment as or when required. Reports to Project Manager.
(vii) Storekeeper – Responsible in receiving and issuing of all materials involved on site erection including consumables, tools, testing equipments. Ensure the safe keeping of all materials at the store provided with proper identification as per project specification requirements. Generates reports to any damage or shortage of materials received as well as the status of materials issued and balance. Responsible in maintaining of all relevant material documents. Reports to Project Manager.
6. QUALITY SYSTEM DOCUMENTATION
The quality system comprises Quality Plan, Inspection and Test Plan, Method Statement and supporting procedures. Completeness and currency of the documentation for the project will be the responsibility of Ampere Electromechanical Engineering.
7. MANAGEMENT REVIEW OF THE QUALITY SYSTEM
The quality documents, quality systems and its implementation will be reviewed monthly by Ampere Electromechanical Engineering General Manager. Other meetings will be convened as ad hoc when issued relating to quality need to be addressed and cannot be held over till the next scheduled meeting.
8. REVIEW OF CONTRACT REQUIREMENTS
Contract requirements shall be reviewed to determine whether or not they are adequately defined. If not, technical queries will be raised to obtain the necessary information or clarification from the client. The capability of our company will also be reviewed to ensure that the specified requirements of the project can be met. If not, necessary steps / actions will be taken to meet the requirements.
9. DOCUMENT CONTROL
A list of all the people who possess a copy of documents effecting quality shall be maintained, so that they will receive an up-to-date copy of revised documents to prevent the use of obsolete information. Transmittals of the documents will be submitted using a document transmittal form. Approved drawings are to be marked with "For Construction" and one copy to be maintained in the office which is marked with "OFFICE COPY", and one copy to be issued to construction team which is marked with "SITE COPY". Drawing index / register showing copy holder to be generated and issued to site construction bi-weekly basis or a required for verification and checking of latest drawings. Old revision drawings shall be marked with 'SUPERSEDED" and kept for future reference. Field changes against approved drawings shall be marked up / reflected in the drawing with red ink by Supervisor in charge and submit to Engineering for AS-Built and be submitted to AEE at the completion of the project. "Red Line" drawing to be hand over to AEE on the completion of site installation prior to the final "As-built" that will follow.
10. PROCUREMENT OF MATERIALS
The contract specification and the contract drawings shall be reviewed to identify material requirements. The potential suppliers of materials shall be assessed for their capability, materials quality and service promptness. Materials to order will be checked against the approved material submittal sheet prior to placing the order. For the necessary materials, technical data shall be collected and reviewed for its quality and performance. It will be submitted to AEE for the approval to use it in the project. As soon as the approval is received from them, materials shall be ordered considering its delivery period.
11. PRODUCT IDENTIFICATION AND TRACEABILITY
Materials delivered to the stores are stored separately with tags which show material description, job number and quantity, so that it can be easily identified by site personnel and to ensure that correct material is installed. The site storekeeper keeps a record of all the materials available on site for each area / project. Circuit in the distribution board / junction boxes will be suitably identified during installation by the Site Supervisor.
12. PROCESS CONTROL
This is to ensure that materials and equipment are received, stored, erected and commissioned in accordance with applicable internal and/or contractual specifications and requirements. Site Engineer / QA/QC Engineer or Site Supervisor and Storekeeper shall: - verify that the received materials are acceptable and in compliance with the electrical Code in effect - verify that the electrical installation work is in accordance with the specified requirements (including Electrical Code requirements - verify that the records documenting the inspection activities and traceability of the materials/ equipments is maintained. Site personnel shall be given proper training for fixing and connection methods if they encounter with new system wiring or installation of sophisticated electrical equipment. The method statement shall be referred for specific tasks.
13. INSPECTION AND TESTING
For inspection and testing refer to our 'Inspection and Test Plan.' Once materials are delivered to the stores, it will be checked against LPO, Delivery Order and physically verified that the correct materials with required quality and quantity are delivered. Furthermore, all deviation s in respect to quantities, conditions and requirements as specified by purchase order such as losses, damages, overages, shortages, not ordered shall be noted. This Information is immediately then passed on to the SLE / Purchase Officer for further action and rectification. A detailed inspection will be performed on all materials (For Free Issued and Ampere Electromechanical Engineering Supply) received at job site and installed by the Site Supervisor in order to assure that only acceptable items are used in a proper manner. Any damage / defective materials received will immediately reported to AEE for necessary actions. All installation performance shall be checked and are recorded in Inspection Records pertaining to that system / operation. Periodic inspections will be carried out in between each phases of installation. The contractor shall offer regular stage inspections to the Client throughout the installation period or prior to any testing with at least 24 hour notice thru "RFI" (Request for Inspection)". An overall pre-commissioning test will be carried out in the presence of clients authorized personnel with the same notification as above and the reports shall be made and get assigned off by the witnessing party. A final inspection shall be offered to the Engineer accompanied by a list of items that are outstanding at the time of the inspection.
14. CONTROL OF INSPECTION, MEASURE AND TEST
EQUIPMENT Test equipments necessary for testing and commissioning will be provided and are given with a unique identification. Test equipments to be used for testing will be calibrated and will be maintained in good condition. List register of all equipments will be provided for proper tracking of calibration / expiry date. Validity of calibration will be one year or as per manufacturer's recommendation. When deviations occur, test equipments will be re-calibrated and be returned to site. For all test equipments for re-calibration, one week notice shall be given to the site users by the Company stores Department Head. Replacement of the same will be arranged when necessary to avoid site work interruptions.
15. IDENTIFICATION OF INSPECTION / TEST STATUS
The primary identification of inspection / test status will be through inspection records. If any of the electrical system found to be faulty, it will be recorded in Inspection Records and shall be marked on the electrical equipment so that accidental energize is prevented.
16. CONTROL OF NON-CONFORMING PRODUCT
If material is found to be non-conforming, it shall be recorded and the material kept aside and marked to avoid any accidental installation. If any installation / product found to be con-conforming, it will be recorded in a "Non-Conforming Report" (NCR) form. Whenever necessary, corrective action shall be taken as soon as possible to close the issue. NCR's shall be recorded in the NCR log / register for easy tracking / verification purposes. If it is considered that a particular non-conforming product can be used, concession request will be send to AEE requesting authorization to use that product.
17. CORRECTIVE AND PREVENTIVE ACTION
If a non-conformance is identified a short term corrective action will be taken to locate the fault and the faulty parts will be replaced and retested for its conformity. If a fault occurs regularly, long term corrective action will be taken (i.e. the fault origin will be analyzed so that necessary action may be taken to eliminate that particular fault).
18. HANDLING, STORAGE, PACKAGING,PRESERVATION AND DELIVER Equipment and materials shall be protected in good condition against dust and extreme climatic conditions by storing them in available covered storage / suitable environment, and locations are provided with proper labels / identification (i.e. sign boards, etc.) for easy traceability and retrieval. All materials and equipment shall be stored properly before installation according to manufacturer's recommendation. These materials shall then be delivered for installation as per the site requirement.
19. CONTROL OF RECORDS
Appropriate inspection records and Drawings, "Red line As-Built Drawings" will be maintained. All records will be filed systematically will be submitted to AEE prior to the final hand over of the project. Contractor also shall retain the necessary documents for any clarification in the maintenance period at least one year.
20. TOOLS AND EQUIPMENTS
Proper tools and equipments will be utilized on site. Consistent checking of tools will be maintained, most especially on Electrical tools / sockets, testing equipments, moving and stationary equipments.
21. SAFETY AND RISK ASSESSMENT
The contractor shall be responsible for all necessary safety measures at all times. All related works shall be executed in accordance with AEE Health and Safety Requirements. Ensure that Personal Risk assessment will be initiated on site prior to start of work and as or when required.
22. INTERNAL QUALITY AUDITS
Internal audits will be carried out to check the timely completion of the quality records and their concurrence when the inspection requirements of various types of work. Audits will also be carried out to verify that site personnel are issued the latest applicable documentation to be submitted to AEE prior to start of field work.
23. TRAINING
The training needs for each level within the company to maintain the quantity standards will be assessed. Training will be provided to meet any identified needs. Training plan or manuals shall be submitted to AEE for approval