J3 Program

RIL, Jamnagar, India

Linde Engineering Selas-Linde GmbH ISBL Utilities, Steam
India Pvt. Ltd. Superheater
SL / LEI Project No.: 76183390 / 2410A0H8 Customer PO No.: 1J/MXU/7460777
SL / LEI Project Code: Jamnagar, LEI/RIL / Jamnagar_DTA_SH Customer Project Code: Steam Superheater
SL / LEI Doc. No.: GUG723 W-PQ 9009 Page 1 of 9

SITE QA/QC PLAN

0 17.06.2014 Issued for Implementation R.Tripathi/CNQ A.Fanse/CNQ A.Fanse/CNQ

Revision Date Description Prepared Checked Approved
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Contents

1 Introduction...............................................................................................................................................3

2 Scope...........................................................................................................................................................3

3 Purpose........................................................................................................................................................3

4 Terms and Definitions............................................................................................................................3

5 IMS PROCESS PORTAL.............................................................................................................................4

6 Quality management system..............................................................................................................4

6.1 General requirements............................................................................................................................4
6.2 Documentation requirements.............................................................................................................4
6.2.1 Construction Quality Plan.....................................................................................................................4
6.2.2 Quality Control Inspection Procedures...........................................................................................4
6.2.3 Control of Documents............................................................................................................................5

7 Inspection of construction work.........................................................................................................5

7.1 Inspection and Test Plans.....................................................................................................................5
7.2 Inspection and Test Records................................................................................................................5
7.3 Inspection and Test Status...................................................................................................................5
7.4 Pre-Inspection Meetings........................................................................................................................6
7.5 General field inspection and testing methods.............................................................................6
7.6 Welding inspection and testing methods.......................................................................................7

8 Measurement, Analysis and Improvement....................................................................................7

8.1 General........................................................................................................................................................7
8.2 Customer satisfaction............................................................................................................................8
8.3 Internal quality audits............................................................................................................................8
8.4 Control of nonconforming product....................................................................................................8

9 Materials required for the construction works.............................................................................8

1 Introduction

This Construction QA/QC Plan is the principal quality document for the construction
and pre-commissioning. It describes the Construction Quality requirements and the
resources and controls for its implementation. The Quality Management System for all
phases of the construction work shall be based on ISO 9001:2008, supplemented by
the project specific requirements.

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Refer to protection notice ISO 16016.

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2 Scope

The Construction QA/QC Plan specifies the quality requirements for the construction
realization by Contractor.
The Construction QA/QC Plan includes:
Quality related activities as defined in the contract
Subjects of ISO 9001:2008
Quality related work carried out by Contractor and approved subcontractors as
defined in purchase orders and Sub-Contracts.

3 Purpose

The purpose of the Construction QA/QC Plan is to ensure that:

Company's quality requirements are understood and met, with reference to the
contract.
Contractor's Quality Management System is planned, documented, communicated,
understood by construction personnel, implemented and audited.

4 Terms and Definitions

Company Reliance Industries Limited/Fluor

Contractor Linde Engineering India Pvt Ltd
Construction Term for pre-fabrication, site assembly, site
erection, pre-commissioning
ITP Inspection & Test Plan: A document which defines
or identifies in a tabulated form the inspections,
test method(s), procedures and acceptance
criteria to be utilized during, construction and
pre-commissioning
NCR Nonconformity Report
IMS Linde Integrated Management System. The IMS is
certified to ISO 9001:2008
QCP Quality Control Procedure

5 IMS PROCESS PORTAL

The management system provided within LEIs (Linde Engineering India) web based
integrated management system called IMS process portal. Within IMS process portal
all site management procedures are controlled and available to access by all site staff.
IMS (Integrated management system) process portal is a certified ISO 9001:2008
integrated management system. Internal audits will also conduct as per LEI ( Linde
Engineering India) organization requirements.

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IMS(Integrated management system ) process portal provides a single coordinated

overview of the processes and controls in the business. It comprises of following
sections:
Policy & strategy - Mission, vision, and strategic direction of the business
Group wide process - Value adding activities within the business (things we do) that
apply across the group.
Construction processes
Product processes
Service processes
Performance measurements - Roles and Responsibility for each staff.
Benchmarking - Comparison of performance between the business Units, and also
relevant industry norms, where available.
Review - Record of high level review for business performance and system.

6 Quality management system

6.1 General requirements

A quality management system shall be established, documented, implemented and
maintained throughout the duration of the construction work and continually improved
its effectiveness in accordance with ISO 9001:2008. Company requirements shall be
implemented as well. The management system shall define customer focus and provide
processes for achieving and monitoring customer satisfaction.

The quality management system shall identify the processes needed to realize the
construction work. It shall define the sequence and interaction of these processes and
the criteria and methods needed to ensure the operation and control of these processes
is effective. The system will ensure the continued availability of resources and
information necessary to support the operation and monitoring of these processes. The
quality management system shall integrate these requirements, and shall aim at a
smooth, auditable construction implementation.

6.2 Documentation requirements

6.2.1 Construction Quality Plan

A Project specific Construction Quality Plan shall be prepared to address specific work
practices, procedures, and audit plan, allocation of resources, responsibilities and
authority for the phases of the work.
The Quality Plan shall be based on the guidelines within ISO 10005:1995. This plan shall
be maintained as a live document throughout the duration of the Construction. Based
on this detailed quality plans respective Inspection and Test Plans (ITP) shall be
developed.

6.2.2 Quality Control Inspection Procedures

Preparation and control of:

Inspection and test plans
Materials inspections upon receipt
Material traceability, including Positive Material Identification where

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Required by the applicable project specifications

Welding procedure specifications (WPS) and procedure qualification records (PQR)

6.2.3 Control of Documents

The requirements for document control and traceability are in line with ISO 9001:2008
clause 4.2 and are applicable to all phases of the construction work.
The Site Manager will nominate a person to be responsible for document and data
control on construction site.
Construction documents as defined by this Construction QA/QC Plan shall be issued on
controlled distribution.
Controlled documents shall have a revision status.
The document control process shall ensure that any document changes will go through
the same review and issue procedure, by the same people, as the original document.
Copies of superseded documents shall be destroyed. Superseded masters shall be
marked Superseded .

7 Inspection of construction work

7.1 Inspection and Test Plans

The inspection and test plans shall be agreed with Company and documented prior to
the start of fabrication activities and shall be detailed enough to serve as a working
document to be used for quality control and monitoring purposes.
The Plan shall set out in matrix form the sequence of inspection steps, specific quality
control requirements, notification requirements for Company inspections,
responsibilities, applicable procedures, acceptance criteria, verifying documents,
review, witness, hold points . ITPs shall be prepared and approved before start of
work.
Adequately qualified Inspection personnel will be assigned.
Inspection forms referenced in the Inspection and Test Plan shall be completed
successively as work proceeds. The Inspection and Test Plan is to be used as a plan
only and acceptance signatures shall be obtained on the inspection reports. Signing off
and submission to Client/PMC (if required) shall follow directly after the work is
completed.
Company shall have the right to witness testing and inspection, if stipulated in the
contract. Advance notification for Client inspection shall then be provided .

7.2 Inspection and Test Records

Inspection and test records such as non-destructive test reports, heat treatment
charts, loop check records etc, shall be compiled as specified.

7.3 Inspection and Test Status

The inspection and test status of materials and work within the contract scope shall be
known and verifiable at all times.

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7.4 Pre-Inspection Meetings

Prior to start of construction work, a pre-inspection meeting shall always be held for
the various disciplines.
A pre-inspection meeting shall be held in order to:

clarify the construction requirements and the Client/PMC requirements with

regard to fabrication, inspection, examination and testing
identify situations or conditions at the site, which could adversely affect quality
or contractual commitments such as weaknesses in quality control inadequate
facilities, housekeeping, environmental and safety performance
finalize the inspection and test plans if still required
identify local laws, regulations and statutory requirements applicable to the
construction
confirm inspections that the Contractor and other parties will carry out
confirme non-destructive examinassions qualifications
confirm material certification requirements
Clarify documentation requirements, communication, reporting, interfaces
between key-parties etc.
review sub-contracts and suborders
review and check approval status of vendor's manufacturing, welding,
inspection and testing procedures

7.5 General field inspection and testing methods

Procedure, and inspection and test plans shall be agreed with Client before the
applicable construction Work commences.

Field inspections and tests in accordance with Procedure and inspection and test plans
agreed with Company shall be carried out to demonstrate compliance with the Project
requirements in order to:

prove that materials comply with the applicable Project Specifications and
Are suitable for the intended duties
comply with statutory requirements and to facilitate obtaining permits for the
Construction and operation of the Project.
ensure the use of correct materials as specified and to identify and demonstrate
Traceability of materials.
Materials shall be uniquely identified and inspected at appropriate stages to
ensure that they conform to requirements and have been installed in accordance
with drawings and specifications.

Company may witness these inspections and tests. In case of Hold and witness points
indicated on the inspection and test plans the or shall notify Company in time before
inspection and/or testing is due to commence.

Company shall be provided free and safe access to all parts of the Work at all times in
order to carry out inspections, as and when desired by Company.

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Testing, measuring and calibration facilities, tools and equipment, including welder's
qualification test facilities shall be provided.

Monitoring and measuring devices shall be controlled. Test results shall be recorded
with calibrated devices in accordance with the requirements of section 7.6 of ISO
9001:2008.

Reports of inspection and tests shall be provided in accordance with the Project
Specification and statutory, insurance party requirements, where applicable..

7.6 Welding inspection and testing methods

Welding consumables shall be of the type and brand approved by an Company.

Issuing of welding consumables shall be strictly controlled.

Upon arrival at site welders shall have valid qualification certificates in accordance
with the applicable codes specified in the Project Specifications.

Test material and test facilities shall be provided to conduct welder skill tests at the
work site acc. contract specification.
Records of these tests are to be made available for review by Company.

The interpretation of radiographs inspection shall be carried out by qualified and

certified welding and non-destructive examination inspectors. The qualification and
certification of these inspectors shall be in accordance with the relevant codes and
standards specified in the Project Specifications. Records shall be maintained.

The methodology of all non-destructive examination and the acceptance criteria shall
be in accordance with the applicable codes specified in the Project Specifications.

Contractor shall maintain a relational database of welder performance, including

identification of welders, welded joints, non-destructive examination results,
additional non-destructive examination in case of repairs in accordance with the
applicable code, weld rejection rate .

8 Measurement, Analysis and Improvement

8.1 General

The Contractor shall apply suitable methods for measuring and monitoring of those
realization processes necessary to meet customer requirements. These methods shall
confirm the continuing ability of each process to satisfy its intended purpose.

The Contractor shall collect and analyze appropriate data to determine the suitability
and effectiveness of the quality management system and to identify improvements
that can be made. This includes data generated by measuring, monitoring and quality
surveillance activities and other relevant sources such as NDT results, welder
performance and non-conformances. The Contractor shall analyze this data to provide
information on:

Customer satisfaction and/or dissatisfaction

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Conformance to customer requirements

Characteristics of processes, product

8.2 Customer satisfaction

The Contractor shall implement a process for monitoring Company perception, at

prescribed intervals during the project, as to whether Contractor is meeting
contractual requirements.

8.3 Internal quality audits

The Contractor shall schedule and conduct audits covering the elements of their
respective project quality management systems. The audits shall be timed to provide
maximum benefit to the process being audited. If the results identify non-
conformances corrective and preventive actions shall be taken immediately, thereby
minimizing adverse effects downstream. Contractor shall also conduct audits on its
vendors and subcontractors.

Audits shall be planned conducted and reported in accordance with the guidelines in
ISO 19011:2002.

In case any activity is suspected of adversely affecting the quality requirements of the
work , Company has the right to initiate/request Contractor to audit that area of
activity on a priority basis.

Audits shall be conducted by qualified auditors.

Company may elect to attend audits as per contract as observers and will be given
adequate notice of audit dates and if the occasion arises, rescheduled his audit dates.

Contractor shall ensure that audit findings are recorded and followed up to confirm
timely close out.

Company shall be provided with a copy of audit reports.

8.4 Control of nonconforming product

A nonconforming product shall be recorded and controlled to prevent unintended use

when identified. The disposition of each nonconforming product shall be categorized
as follows by authorized personnel:

Rework product will be reworked to meet the specification or be scrapped and

replaced with conforming product
Repair product will be reworked to bring it to an acceptable state but not to
specification
Use as is product will not be reworked.

Use of nonconforming product in the category of Repair and Use as is require

agreement by Company, which shall be received before proceeding to the next stage
in the process with the nonconforming product.

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The Contractor shall maintain a database record of nonconforming product to control

the distribution. The database will be used to produce reports allowing analysis of
nonconforming product.
Nonconformity data shall be reviewed and appropriate action shall be taken to
minimize the severity and frequency of nonconformity occurrence. NCRs shall be kept
as part of the quality records.

9 Materials required for the construction works

All the materials procured shall be stored/stacked as per the standard norms and as
recommended by various clauses of relevant codes and contract document. The
storage of material shall be such as to avoid damage to life/properties (physical and
chemical) of the materials. The storage shall not cause deterioration, rusting, mix-up
etc. and hamper the other related works in any way. LEI (Linde Engineering India)
shall submit his detailed warehouse plan for CLIENT approval to manage above in
open/covered areas.

The materials susceptible to fire shall be kept away in a separate protected place. In
general, the material shall be kept systematically in order of their class, batch number
and identification number, so that they are accessible for the inspection by CLIENT
whenever required and to avoid the mix up in those materials.

The materials shall be stacked in such a way that the lot, which is procured first, will
be consumed first. For materials which are having specific expiry date/ shelf life
shall not be used beyond that date and shall be removed from site. Wherever
there is any doubt about the change in properties of the materials, such materials
shall be sent to reputed approved laboratory for testing and acceptance.

Whatever LEI (Linde Engineering India Pvt. Ltd) will receive construction materials on
site. LEI (Linde Engineering India) will submit the incoming material inspection report
to Client for their review and approval.

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Refer to protection notice ISO 16016.