Quality Manual PHE

|DOCUMENTUM|1/25/2012|Paper Copies are Uncontrolled|
PT. PHE ONWJ Quality Manual
Revision Log Register
Document Number : PHEONWJ-I-PRC-001 1
Document Title : Quality Manual
Revision : 0
Page Date Revise PHE ONWJ Reviewer
PHEONWJ-I-PRC-001 1 Rev. 0 Page 2 of 26
Table of Contents
Revision Log Register .......................................................................................................................... 2
Table of Contents
............................................................................................................................... 3
1. Background
............................................................................................................................ 4
2. Purpose .................................................................................................................................. 4
3. Scope ..................................................................................................................................... 4
4. References
.............................................................................................................................. 4
5. Abbreviations.......................................................................................................................... 5
6. Definition
............................................................................................................................... 6
7. Goals & Objectives

................................................................................................................. 7
7.1 Goals
.............................................................................................................................. 7
7.2 Objectives
........................................................................................................................ 7
8. Quality Management System ................................................................................................... 8
8.1 Strategies
......................................................................................................................... 8
8.2 Quality Management System Implementation

.................................................................... 8
8.3 Quality Management System Processes

............................................................................. 9
8.4 Planning & Engineering

.................................................................................................. 10
8.5 Procurement
................................................................................................................... 11
8.5.1 Review contractor and supplier Quality Management................................................ 12
8.5.2 RFQ Review

............................................................................................................ 13
8.6 Construction ................................................................................................................... 13
8.6.1 Factory Acceptance Test (FAT) or Site Acceptance test (SAT)

...................................... 13
8.6.2 Receiving Materials & Equipments Checking

............................................................. 13
8.6.3 Fabrication .............................................................................................................. 13
8.6.4 Installation .............................................................................................................. 14
8.7 Commissioning
.............................................................................................................. 16
9. Organization And Accountabilities

......................................................................................... 18
9.1 Organization
.................................................................................................................. 18
9.2 Accountabilities
.............................................................................................................. 18
9.2.1 QA/QC & Inspection Manager ................................................................................ 18
9.2.2 QA/QC Lead

.......................................................................................................... 18
9.2.3 Project/maintenance QA/QC Engineer .................................................................... 19
9.2.4 Fabrication QA/QC Engineer .................................................................................. 19
9.2.5 Certification Engineer .............................................................................................. 19
9.2.6 Certification Administrator ....................................................................................... 20
9.2.7 QA/QC Inspector ................................................................................................... 20
9.2.8 NDE Technician ...................................................................................................... 21
1 0. Handover Certification System ............................................................................................... 21
11. CONTRACTOR Quality Plan ................................................................................................. 21
1 2. Personnel Competence And Training

..................................................................................... 22
1 2.1 Personnel ....................................................................................................................... 22
1 2.2 Specialist Expertise .......................................................................................................... 22
1 2.3 Training
......................................................................................................................... 22
1 3. Quality Review And Audit ...................................................................................................... 22
1 4. Information Management ...................................................................................................... 22
1 4.1 Control of Documents, Data, and Records

...................................................................... 25
1 4.2 Related Documents

......................................................................................................... 25
1 5. Quality Continuous Improvement .......................................................................................... 26
1 .
Background
QA/QC Team is the front line agent in PHE ONWJ to preserve the quality in all new projects and routine corrective
maintenance activities, through the engineering/planning until handover to operation, and also ensure that all
relevant documents are prepared, recorded, and properly handed over between processes by relevant authorities.
To preserve the quality, QA/QC Team develop this Quality Manual enclosing Quality Management System to
ensure quality processes are performed using the same information, methods, skills and control, and in a consistent
manner.
2.
Purpose
This manual is intended to be the main reference in achieving and maintaining the required level of quality
assurance and control in PHE ONWJ Facility Engineering & Construction Department during new projects and
routine corrective maintenance activities. Any divergences from this manual and its derivative documents are
allowable providing the appropriate acknowledgement, assessment, and precautions are performed and recorded.
This manual is also intended to provide assurance to Management that Quality Management Systems is in place
and set to be implemented in projects and routine corrective maintenance activities.
This manual is not intended to be distributed to CONTRACTOR as their reference. Each project/routine corrective
maintenance activity shall develop its own specific & detail Quality Plan, and deliver to CONTRACTOR.
3.
Scope
This Quality Manual covers the quality preservation strategy for new installation, repair, in-kind replacement, and
modification activities in new projects - which is defined either as a new development, additional facilities, and non-
routine activities, and routine corrective maintenance activities, to meet PHE ONWJs specifications and
requirements.
4.
References
This document is developed in accordance with latest revision of below references. This document shall not
reproduce the text of those references, but incorporate them as references only.
1 .
API Specification Q1 , Quality Programs for the Petroleum, Petrochemical and Natural Gas, Seventh Edition,
June 2003.
2.
BS ISO 9000, Quality Management System.
3.
FE&C Business Process Manual, PHEONWJ-I-PRC-001 4.
4. Handover Certification Manual, PHEONWJ-I-PRC-0362.
5.
Technical Document Control Procedure, PHEONWJWJ-G-PRC-01 01 .
5.
Abbreviations
API American Petroleum Institute
ASME American Society of Mechanical Engineers
FAT Factory Acceptance Test
HC Handover Certification
HCP Handover Certification Packs
HSSE Health, Safety, Security and Environment
ITP Inspection and Test Plan
ITS Inspection and Test Summary
IRN Inspection Release Note
MDR Manufacturer Data Report
MIRC Material Inspection Release Certificate
MT Material Transfer
MPI Magnetic Particle Inspection
NCR Non Conformity Report
NDE Non Destructive Test
ONWJ Offshore North West java
PFD Process Flow Diagram
PHE Pertamina Hulu Energi
P&ID Piping & Instrumentation Diagram
PO Purchase Order
PT Penetrant Technique
PWHT Post Weld Heat Treatment
QA Quality Assurance
QC Quality Control
QP Quality Plan
RFQ Request for Quotation
RT Radiography Technique
SAT Site Acceptance Test
WPS Welding Procedure Specification
6.
Definition
Alteration
A physical change in any component that has design implications that affect the pressure-containing capability
or flexibility of a pressure system beyond the scope described in existing data report or its original design. The
following should not be considered alterations: any comparable or duplicate replacement, the addition of any
reinforced nozzle less than or equal to the size of existing reinforced nozzles, and the addition of nozzles not
requiring reinforcement.

Audit
A planned, independent and documented assessment to determine whether agreed-upon requirements are
met.

Certification
Refers to the issuing of written assurance (the certificate) by an independent, external body (i.e. Government)
that has audited an organizations management system and verified that it conforms to the requirements
specified in the standard.

Contractor
Manufacturer, supplier, vendor, fabricator, and service provider.

Criticality Assessment
A formalized technique for measuring the relative importance to be assigned to a system or item of equipment
based on a number of risk factors which include HSSE, technical integrity, reliability, design maturity,
manufacturing complexity, cost and schedule.

Non Conformity
Non-fulfillment of a requirement such as work standards, practices, procedures, regulations, management
system performance, etc.

Procedure
Document that provides information about how to perform activities and process consistently.

Quality
The totality of features and characteristics of a product or service that bear on its ability to satisfy stated or
implied needs (i.e. conformity to stated requirements).

Quality Assurance
All those planned and systematic actions necessary to provide adequate confidence that a product or service
will satisfy given requirements of quality.

Quality Control
The operational techniques and activities that are used to fulfill the requirements of quality.

Quality Manual
A document that provides consistent information, both internally and externally, about the organizations
Quality management System.

Quality Plan
A document setting out specific quality practices, resources and sequence of activities relevant to a particular
product service, contract or project.

Quality System
The organizational structure, responsibility, procedures, processes and resources for implementing quality
management.

Record
Document that provides objective evidence of activities performed or results achieved.

Specification
Document states requirements.
7.
Goals & Objectives
7.1
Goals
The goals of PHE Quality Management System implementation are to:

Meet PHE ONWJ quality requirements and expectations stated in specifications and procedures.

Meet PHE ONWJ Vision and Mission stated in FE&C Business Process Manual.

Fulfill industrial standards/codes requirements and governments/statutory regulations.
7.2 Objectives
The minimum objectives of PHE Quality Management System implementation are:

To define and apply Quality Management System and processes.

To clearly identify quality organizational capabilities, accountabilities, and responsibilities.

To ensure that both PHE ONWJ and its Contractors are aligned on all quality issues including:
x
Quality Assurance, Quality Control and surveillance philosophies
x
Requirements for Auditing, Inspections and Testing.

To ensure that practices, processes, and procedures meet specified requirements.

To Minimize Non Conformity during new projects and routine corrective maintenance activities.
8.
Quality Management System
8.1
Strategies
The following strategies will be applied to support the implementation of this Quality Manual:

Ensure relevant procedures to support this Quality Management System implementation are available.

Each project and maintenance activity shall develop a Project Quality Plan and/or Inspection & Test Plan (ITP)
that is applicable to the scope of work.

Encourage contractors to develop a detail and rigorous Quality Plan that is applicable to their scope of supply
or service.

Develop Non-Conformity Management Guideline to verify actions in ensuring that quality is not compromised
for the sake of cost and schedule. Refer to Non Conformity Management Guideline, PHEONWJ-I-PRC-001 5.

Implementing Handover Certification System to manage Inspection & Test activities, to administer handover
process between phases, and to ensure all as built documents are well-maintained towards the end of project
life.

Conduct regular review and audit against internal PHE ONWJ and contractors processes and practices. Refer
to Quality Audit Procedure, PHEONWJ-PRC-001 3.
8.2
Quality Management System Implementation
Quality Management System will be implemented during below phases in new project and routine corrective
maintenance activities, which are:

Planning & Engineering.

Procurement.

Fabrication.

Installation &.Pre-commissioning

Commissioning.
Figure 1 below illustrates the common activities during new project and routine corrective maintenance.
Start
Planning /
Engineering
Procurement
Fabrication
No
IRN OK
Yes
Installation/
Precommissioning
No
MC1 OK
Yes
Commissioning
No
SH1 OK
Yes
Start Up
Finish
Figure 1 Common activity in new project and routine corrective maintenance
8.3 Quality Management System Processes
Scheme below shows the key quality processes that are common across planning & engineering, procurement,
fabrication, installation and pre-commissioning, and commissioning. These processes should be used together to
plan, assure, and verify the delivery of quality objectives.
Figure 2 Key quality processes

Quality Management
The coordinated activities including Quality Assurance and Quality Control which direct and manage the
identification and control of quality requirements.

Quality Planning
Focuses in setting quality objectives and necessary process to delivery and assure the objective and
requirements are met.

Quality Assurance
The part of quality management activities that puts in place processes and procedures that provide assurance
that each quality requirement has been met.

Quality Control
The part of Quality Management focused on verifying quality requirements.

Quality Improvement
Focuses on increasing the ability to meet quality objectives and requirements.
The degree of Quality Management System implementation through project phases and routine maintenance
activities should be in reference to the criticality assessment.
8.4
Planning & Engineering
The key processes are:

Review quality related documents (plans, procedures, etc.).

Ensure all drawing and non-drawing documents are reviewed, verified, and validated by relevant discipline
engineer and interrelated engineering disciplines.

Develop Quality Plan and Inspection and Test Plan.

Develop Handover Certification system.

Perform audit, if necessary.
The key deliverables are:

Approved documents.

Quality Plan, covering procurement and construction.

Inspection & Test Plan.

Handover Procedure and HCP (Handover Certification Packs).

Audit result/report
PHEONWJ-I-PRC-001 1 Rev. 0 Page 1 0 of 26
Figure 3 Planning & Engineering flowchart
8.5
Procurement

Review contractor and supplier Quality Management capability to meet PHE ONWJ requirements.

RFQ review.

Conduct audit

Qualified contractor and supplier.

Reviewed RFQ.

Audit result/report
8.5.1
Review contractor and supplier Quality Management
Contractor and supplier quality management is very essential to ensure the delivery of product and service in timely
manner and highly quality. By selecting proper contractor and supplier, significant time, energy, resources, priorities
and focus could be redirected and optimized on another important aspect.
Figure 4 Procurement flowchart
8.5.2
RFQ Review
RFQ is the basis for Vendor/Supplier/Contractor/Manufacturer to submit their bid. Therefore, QA/QC Team will
scrutinize all requirements in RFQ regarding personnel competence, tools, and quality related documents to ensure
appropriateness by referring to current update PHE ONWJ standards and specifications.
8.6 Construction
8.6.1 Factory Acceptance Test (FAT) or Site Acceptance test (SAT)
FAT or SAT is the final test held by manufacturer to determine and record the equipment performance according to
its design specification and Purchase Order, and meet the intended purpose, prior to be delivered to PHE ONWJ
receiving facility. PHE ONWJ will constantly require certain involvement level during the manufacturing process and
final testing of each material and equipment. This level will be clearly mentioned in Inspection and Test Plan (ITP).
Refer to FAT Guideline document, PHEONWJ-I-PRC-0020.
8.6.2
Receiving Materials & Equipments Checking
All incoming materials and equipments are inspected and verified in according to Receiving Materials and
Equipments Inspection Procedure, PHEONWJ-G-PRC-01 04.

Verify documents, such as MT, PO, Mill Certificate, Warranty Letters, Letter of Compliance, drawings, etc.

Conduct visual inspection for each material and equipment, to ensure its conformity to codes and standards.

In case of non-conformity, raise NCR. Refer to Non-Conformity Management Guideline, PHEONWJ-I-PRC-
001 5.

Material Inspection Release Certificate (MIRC)

Inspection report.
8.6.3
Fabrication
In this Process the new manufactured materials/equipments are inspected and tested in contractors workshop
based on Fabrication ITP document.

Check fabrication documents availability

Verify materials quality and supporting documents completeness

Check the personnel competence to perform fabrication specific job

Supervise the fabrication process

Witness the testing process

Manufactured equipment and materials quality and quantity meet PHE ONWJ requirements

Inspection Release Note (IRN) certificate.
8.6.4
Installation
During this Process the equipment is installed, inspected and tested.

Check installation documents completeness such as installation procedures, P&ID, One-line Diagram, Tie-in
procedure, etc.

Ensure the tie-in is properly done.

Check the personnel competence to conduct installation specific job

Supervising the installation and hook up process.

Ensure all modifications are recorded in as-built documents

Inspection progress report during installation

Handover certificates such as MW1 , MP1 , CC1 , AS1 , EE1 , etc.

Mechanical Completion certificate (MC1 ) and all supporting records.

As-built documents
Figure 5 Construction Flowchart
8.7
Commissioning

Witness leak or service test activity.

Witness function test.

Raise SH1 certificate as the commissioning activity is completed.

Ensure all modifications are recorded in as-built documents

Inspection progress report during commissioning process.

Handover certificate such as SL1 , SC1 , JI1 , etc.

System Handover certificate (SH1 ) and all supporting records.

As-built documents
Figure 6 Commissioning Flowchart
9.
Organization And Accountabilities
9.1
Organization
The following figure 7 describes the organizational structure and reporting hierarchy of QA/QC Team.
Figure 7 PHE ONWJ QA/QC Team Organization
9.2
Accountabilities
QA/QC Team assists Operations Department in the development of quality systems and conduct periodic audits to
assure that those systems are implemented faithfully and effectively. QA/QC Team main responsibilities are:

Identify and evaluate quality-related problems.

Advise solutions on quality problems and verify that any problems have been resolved (corrective action).

Initiate action to prevent the occurrence of quality problems (preventive action).
This part will identify all accountabilities and detail job descriptions of QA/QC Team.
9.2.1
QA/QC & Inspection Manager

Ensure that a Quality Manual is developed and implemented.

Facilitate QA/QC staff training and development program.

Define QA/QC Team roles ad responsibilities.

Organize and manage QA/QC resources and activities to meet quality goals and objectives.
9.2.2 QA/QC Lead

Develop Quality Plan.

Ensure that Handover Certification System is prepared and implemented during Project and routine corrective
maintenance activities.

Ensure integrated quality assurance of design, procurement, fabrication and installation

Provide resolution of non-conformities.

Develop staff training and development program.
9.2.3
Project/maintenance QA/QC Engineer

Develop Quality Plan and/or review contractors Quality Plan for specific project.

Ensure all quality related personnel are certified and qualified.

Ensure that only materials and equipments conforming to PO and PHE ONWJ specification are used.

Ensure that all measurements and test equipments are properly maintained, calibrated, and certified, whenever
appropriate.

Ensure Quality Plan (QP) and Inspection & Test Plan (ITP) shall be implemented on fabrication activities.

Coordinate and control quality and certification activities within projects.

Maintaining registers of corrective actions and non-conformities for trending and analysis purposes.

Ensure Handover Certification scheme is well-implemented, maintained, and reported.

Liaise with inspector in implementing Handover Certification system during work preparation and execution.

Document and report inspection and test results.

Review Projects closure documents.
9.2.4
Fabrication QA/QC Engineer

Ensure QP and ITP is implemented on fabrication activities.

Sign and approve Inspection Release Note (IRN) for all fabricated material and supporting equipment. Spot
witnessing fabrication activities as required by ITP, such as, receiving material, surface preparation & primer
coat, testing, PWHT, dimensional check, and packaging prior to delivery.

Review of procedures of blasting, painting, NDE, welding maps, Welding Procedure Specification (WPS),
welder qualification, testing, PWHT, and dimensional check.

Review reports and records of blasting, painting, NDT, welding maps, WPS, welder qualification, testing,
PWHT, and dimensional check.

Review and approve welder qualification test and result.

Monitor welders performance by reviewing the welding repair rate.

Ensure all supporting equipments for both Onshore & Offshore (i.e.: welding unit, air compressor, scaffolding,
rigging tools, etc) meet and comply with PHE requirements.

Prepare and submit regular report to PHE QA/QC Lead, cc. QA/QC & Inspection Manager.

Participate on Contractor quality and safety audit and ensure all finding and recommendation of the audit are
followed up.

Update Contractor Quality Issue in weekly basis (such as NCR, material fabrication defect, etc).

Review Contractor QA/QC personnel qualification.
9.2.5
Certification Engineer

Prepare Inspection Test Summary (ITS)

Together with commissioning Authority and field Engineer Develop Limit system for Mnemonic number

Make sure that the HCP will meet all integrity authority and legislative requirement of the country or state
whose jurisdiction the installation is subject.

Control the issuing and deletion of the unique system handover numbers (SH1 s).

As SPA the mediator for handover certificate to be signed by the all authorities between work project phases

Compile and integrate the whole SH1 .

Monitoring update certification Data Base.

Review and monitor all of the certificates (MC1 , SH1 , PL1 , etc.) already signed by the respective person.

Conduct verification and auditing of the certification process.

Ensures all inspections & tests are complete and presents the results.

Ensure all of Inspection activities have been done based on inspection test summary, the entire certificate shall
be raised.
9.2.6
Certification Administrator

Prepare the HCP (Handover Certification Pack).

Insert the appropriate certificates into the HCP.

Compile and integrate the whole SH1 .

Update certification Data Base.

Transmit the HCPs to the site.

Update the Handover Certificate data Base of HCPs during the progression of works.

Maintain punch list items and track closing process.

Transmit the copies HCPs already sign / completed to the site / operation

Up date punch list items and track closing process.
9.2.7
QA/QC Inspector

Interpretation of the Requirement of codes and Standards

Ensuring that approved procedure is available.

By referring to ITP, ensuring the fabrication activities has been performed according to procedures,
specifications, and drawings.

By referring to ITP, ensuring the installation activities has been performed according to procedures,
specifications, and drawings.

Ensure all applicable equipments have been calibrated prior to usage.

Ensure that the appropriate requirements of electrical specifications and procedures are carried out.

Ensure all tests are performed according to specification, and approved procedure..

For product acceptance test, approval of IRN certificate prior to delivery.

Regularly reporting to QA/QC representative in Fabrication workshop, site, or Head Office.
9.2.8
NDE Technician

Conduct Non-Destructive Examination using various techniques such as RT, UT, PT, MPI, and etc., on pressure
vessel, pipes, and structural steel.

Ensure all NDE equipments are calibrated prior to utilization.

Submit report at the end of NDE activity.
1 0.
Handover Certification System
PHE ONWJ uses Handover Certification as the tool for handover mechanism between Processes during new project
and routine corrective maintenance activities. Refer to PHEONWJ-I-PRC-0362, Handover Certification Manual.
1 1 .
CONTRACTOR Quality Plan
CONTRACTOR shall be requested to develop a Quality Plan which clearly addresses all the issues stated in
contract. This requirement shall be clearly stated in project/activity Quality Plan, a document that provides
guidance for subcontractors and sub-suppliers as well. Furthermore, project/activity Quality plan shall provide
assurance for PHE ONWJ on THE CONTRACTOR capability to accomplish all scope of works in contract by yet
referring to international codes and standards, and PHE ONWJ requirements.
Contractor Quality Plan shall outline the following, but not limited to:

Organization

ITP

Non Conformity handling, including corrective and preventive actions

FAT

Materials and equipments traceability plan

Materials and Equipments handling, storage, packaging, and Shipping

Quality Audit for internal contractor organization, subcontractors and suppliers

Personnel competence development and preservation

Documentation and reporting

PHE ONWJ Completion and Handover System
Refer to Quality Assurance Requirement for Contractor, PHE-ONWJ-X-YYY-001 2 (Draft).
1 2.
Personnel Competence And Training
1 2.1 Personnel
Personnel allocated to key tasks shall have qualifications and experiences commensurate with those given on the
applicable job description. Development of PHE ONWJ personnel shall follow a structured competence assurance
process, and CONTRACTORs shall be instructed to ensure the competency of their personnel by referring to
Contractor Technical Competency Guideline Procedure, PHEONWJ-G-PRC-0355.
1 2.2 Specialist Expertise
Whereas required, specialist expertise should be deployed.
1 2.3 Training
All personnel shall be properly trained to ensure their technical competency meet PHE ONWJ Quality
requirements. Document No. PHEONWJ-G-PRC-0355, provide the guidance about the process to ensure the
contractors employee technical competency. The process is focused on contractors which their works affect the
technical integrity of PHE ONWJ facilities.
The accurate records of all required trainings and completed trainings by personnel shall be maintained. The
training record shall be detailed and tracked in a training matrix.
1 3.
Quality Review And Audit
Internal quality review and audit on the suitability and effectiveness of the Quality Management System and
implementation, take place at least once per year based on activity or project requirements.
Regular quality review and audit against contractor shall be performed to assess their capability and capacity to
meet PHE ONWJ quality requirements based on certain considerations or according to activity or project
requirements. All contractors are responsible for developing and maintaining a schedule of quality audit reflecting
their contracted work scope. Each of these schedules is to be issued to the PHE QNWJ QA/QC Team for review
and monitoring.
Refer to Quality Audit Procedure, PHEONWJ-I-PRC-001 3, for detail elaboration.
1 4.
Information Management
Management of information is critical to the success of project and routine maintenance activities. It is essential to
define what data and documents are needed for operational activities and for each of the project or routine
maintenance activities.
Project and routine maintenance activities are a large initiator of information. Typical examples are:

Commercial information

Administrative information

Engineering information

Operations and Maintenance information
Information generated during the project and routine maintenance activity, particularly engineering information, is
of value throughout the entire lifecycle of the asset. Although some information such as isometric drawing, 2D, and
3D representations are not used during the operation of the asset, any refurbish work in the future will need this
original engineering information. If this information is not available, then any future project will require a
comprehensive, and expensive, on-site survey before any new design work can commence. Therefore, any
information handover from a project/activity team to TDC (Technical Document Control) shall ensure information
availability to be re-used in the future.
Figure 8 shows the information management flowchart.
Figure 8 Information Management Flowchart
1 4.1 Control of Documents, Data, and Records
Control of documents, data, and records, is an essential part of quality management. Below are several documents
that can directly influence the quality of the product and/or service, such as:

Drawings
P&ID
PFD

Isometric drawing

Hook up drawing

Termination drawing

One Line Diagram

Electrical Equipment Layout Drawing

Cable Layout drawing

Non Drawings
Specifications
Project Execution Plan

Quality Plan

Procedures

Work instructions

Inspection and Test Plans

Equipment Datasheet

Manual
All documents, data, and records for new project and routine corrective maintenance activity shall be well-
preserved and controlled by referring to Technical Document Control Procedure, PHEONWJ-G-PRC-01 01 .
Document controller has vital role to monitor, log, and co-ordinate the flow of documents for review and approval
within the project and routine activities to ensure quick response, prevent delay and backlog, document update,
and maintain delivery due date.
1 4.2 Related Documents
Listed below are documents linked to this Manual:
PHEONWJ-G-PRC-01 04

Receiving Materials & Equipments Inspection Procedure
PHEONWJ-G-PRC-0355

Contractor Technical Competence Guideline Procedure

PHEONWJ-I-PRC-001 3 Quality Audit Procedure

PHEONWJ-I-PRC-001 4 FE&C Business Process Manual

PHEONWJ-I-PRC-001 5 Non Conformity Management Guideline

PHEONWJ-I-PRC-0020 Factory Acceptance Test Guideline

PHEONWJ-I-PRC-0362 Handover Certification Manual

PHEONWJ-I-PRC-001 2 Quality Assurance Requirement for Contractor (Draft).
1 5.
Quality Continuous Improvement
QA/QC Team commit to seek to continually improve the effectiveness of Quality Management System, focusing on
removing the causes of the failures and deficiencies. This must be represented within all project/activity quality
plans, contractor/supplier quality plans, and the interface document between the two. Therefore, the team will:

Encourage individuals to identify areas where improvement may be made.

Develop and implement a program to review, audit, and analyze the practices, processes and specifications.

Register lesson-learned to be used in improving the on-going and future activities performance.

Utilize databases to ease the data maintenance and tracking process.

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|DOCUMENTUM|1/25/2012|Paper Copies are Uncontrolled|

PT. PHE ONWJ Quality Manual

Revision Log Register

Document Number : PHEONWJ-I-PRC-001 1

Document Title : Quality Manual

Page Date Revise PHE ONWJ Reviewer

PHEONWJ-I-PRC-001 1 Rev. 0 Page 2 of 26

|DOCUMENTUM|1/25/2012|Paper Copies are Uncontrolled|

PT. PHE ONWJ Quality Manual

Revision Log Register .......................................................................................................................... 2

7. Goals & Objectives

8. Quality Management System ................................................................................................... 8

8.2 Quality Management System Implementation

8.3 Quality Management System Processes

8.4 Planning & Engineering

8.5.1 Review contractor and supplier Quality Management................................................ 12

8.5.2 RFQ Review

8.6 Construction ................................................................................................................... 13

8.6.1 Factory Acceptance Test (FAT) or Site Acceptance test (SAT)

8.6.2 Receiving Materials & Equipments Checking

8.6.3 Fabrication .............................................................................................................. 13

8.6.4 Installation .............................................................................................................. 14

9. Organization And Accountabilities

9.2.1 QA/QC & Inspection Manager ................................................................................ 18

9.2.2 QA/QC Lead

9.2.3 Project/maintenance QA/QC Engineer .................................................................... 19

9.2.4 Fabrication QA/QC Engineer .................................................................................. 19

9.2.5 Certification Engineer .............................................................................................. 19

9.2.6 Certification Administrator ....................................................................................... 20

9.2.7 QA/QC Inspector ................................................................................................... 20

9.2.8 NDE Technician ...................................................................................................... 21

1 0. Handover Certification System ............................................................................................... 21

11. CONTRACTOR Quality Plan ................................................................................................. 21

1 2. Personnel Competence And Training

1 2.1 Personnel ....................................................................................................................... 22

1 2.2 Specialist Expertise .......................................................................................................... 22

1 3. Quality Review And Audit ...................................................................................................... 22

1 4. Information Management ...................................................................................................... 22

1 4.1 Control of Documents, Data, and Records

1 4.2 Related Documents

1 5. Quality Continuous Improvement .......................................................................................... 26

PHEONWJ-I-PRC-001 1 Rev. 0 Page 3 of 26

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PT. PHE ONWJ Quality Manual

and set to be implemented in projects and routine corrective maintenance activities.

4. Handover Certification Manual, PHEONWJ-I-PRC-0362.

PHEONWJ-I-PRC-001 1 Rev. 0 Page 4 of 26

|DOCUMENTUM|1/25/2012|Paper Copies are Uncontrolled|

PT. PHE ONWJ Quality Manual

API American Petroleum Institute

ASME American Society of Mechanical Engineers

FAT Factory Acceptance Test

HCP Handover Certification Packs

HSSE Health, Safety, Security and Environment

ITP Inspection and Test Plan

ITS Inspection and Test Summary

IRN Inspection Release Note

MDR Manufacturer Data Report

MIRC Material Inspection Release Certificate

MPI Magnetic Particle Inspection

NCR Non Conformity Report

NDE Non Destructive Test

ONWJ Offshore North West java