Symmetrical Group
Policies and Procedures
OHS&E\MANAGEMENT PLANS
SG-MP-31-06 Quality Management Plan
5.6 Safety/Environmental Supervisor
5.6 QA/QC & Material Co-Ordinator
6.0 Management responsibilities
9.0 ENGINEERING AND dETAILED DESIGN
10.0 DOCUMENTation and Records Management
11.0 Procurement and Subcontract Management
12.0 control of construction activities
14.1 Construction Verification
14.3 Operational Commissioning
14.4 Inspection and Performance Testing
15.0 CONTROL OF NON-CONFORMING PRODUCT
This Quality Management Plan was prepared to provide Symmetrical Group Pty Ltd “the Contractor” and the Company with a clear understanding of the resources and planning required to achieve quality on the project.
The scope of work consist of Structural. Mechanical, Piping, Electrical and Instrumentation.
Project: A set of coordinated and controlled activities with start and finish dates, undertaken to achieve an objective conforming to specific requirements, including the constraints of time, cost and resources.
Subcontractor: An organisation that provides a product and/or service to Symmetrical Group
Shall: To express a provision that is binding between two or more parties.
Will: To express a declaration of purpose or intent by one party.
Should: To express a recommendation among other possibilities.
May: To indicate a course of action permissible within the limits of the quality plan.
The Managing Directors will assign the Project responsibilities (refer to Exhibit A).
The responsibilities of this position, include:
The issues that affect the project will be reported to the Managing Directors.
The Site Superintendent has the overall responsibility for the installation of the works including:
The Site Supervisor will report to the Project Manager
The Site Supervisor has the overall responsibility for the installation of the works including:
The Site Supervisor will report to the Site Superintendent
5.6 Safety/Environmental Supervisor
The responsibilities of this position include:
The Safety Supervisor shall report to the Managing Directors and Project Manager.
5.6 QA/QC & Material Co-Ordinator
The responsibilities of this position include:
The QA/QC & Material Co-Ordinator shall report to the Managing Directors and Project Manager.
Managers will ensure that all personnel working on the Project follow this plan, the management system procedures, protocols and policy (refer Exhibit B)
Managers shall ensure that all personnel working on the project are trained and competent to perform the work that they are assigned.
Reference: SG-PR-51-05
Procedure Deliverables: Confirmation of Qualifications and Training
Following contract award the Contractor will review the contract documents with the tender submission.
All queries shall be agreed in writing with the Company Representative before the contract is handed over to the Project team.
The project shall not commence without the Directors approval.
Reference SG-PR-21-02
Procedure Deliverables Scope and Budget Estimating
The project manager shall plan, organise, monitor, and control all aspects of the project to achieve its objectives.
Contract documents including revisions will be registered by document control and filed in the project directory.
A filing system shall be established for project documents.
A budget will be prepared to control project costs.
Schedules will be prepared to in MS Project
Reference SG-PR-21-03 to 05
Procedure Deliverables. Contract Award
Pre Mobilisation
Mobilisation and Installation
Commissioning
The work shall be carried out in accordance with Rio Tinto Standards, Australian Standards, State and Commonwealth Acts and Regulations and International Codes reference in the contract documents (latest edition)
All documentation shall be submitted in the English language.
The SI system of units shall be used.
The Company Representative shall approve the formats and templates for the handover documents.
Shall be supplied as per the approved MDR index and contain all approved documentation for the project. Completed MDR will be submitted in .pdf format once the approved version is returned.
Drawings and documents listed in the MDR shall be submitted the Company Representative for review
Returned documents will be identified with a stamp to indicate that a review was performed
Vendor data will be submitted and reviewed by the Company Representative in accordance with the Vendor Data Specification.
The Project Manager is the contact point for all correspondence and documentation that is received or issued for the Contract.
Document control will register all incoming documents and drawings. Documents and drawings shall be issued under cover of a document transmittal.
All procedures, documents or drawings, prepared for the project will be reviewed and approved by qualified and authorised personnel within the organization.
When the Project is complete document control will collect and prepare all project records for archiving.
Reference: SG-PR-61-01 to 04
Procedure Deliverables: Document and Data Control
Filing and Records Management
Email Retention and Archiving Policy
Antivirus Software
Where possible equipment and fabricated components for the project will be purchased through the Contractors list of approved suppliers.
The Project Manager will issue a technical and quality specification with the tender documents and no order shall be placed with a supplier or subcontractor without the Company Representatives prior approval
The Project Manager will specify in the subcontract document details of the product markings and the traceability requirement in accordance with the Company procedure.
When full traceability is required, the item will be identified from the drawing material list and matched with the material certificate.
All structural steel members and piping supplied shall be identified with the drawings by hard stamping or metal tagging.
All welding, hydro-testing and non-destructive testing shall be carried out in accordance with the specifications referenced in the contract.
All welds failing to meet the permissible levels of imperfections allowed in the welding standard shall be removed or repaired to achieve the acceptance standard
A testing laboratory registered by the National Association of Testing Authorities of Australia, or other approved authority shall carry out non-destructive testing.
Contractor and the Company Representative shall review and approve Inspection and test plans, weld procedures and welder qualifications before the subcontractor commences work.
The subcontractor’s works will be monitored via the inspection and test plans and production schedule.
Note: Company Representative requires (14) days written notice of witness and hold points and confirmation of the stage 72 hours prior to undertaking the activity.
Workshop inspections and progress monitoring shall be document and the reported to the Project Manager.
All lifting lugs welded to the structure shall be approved by the Design Engineer and tested for compliance by a NATA endorsed operator.
Sling marks shall be shown on loads over 5 tonnes.
The Project Manager will inform the subcontractor of the special requirements for handling, storage, packing, preservation or delivery of the product via the subcontract agreement and the Shipping and Packaging Instruction issued by the Company Representative for the contract.
Contractor and the Company Representative Inspectors shall ensure that the finished product is packed and preserved for long-term storage in a hot, wet and dusty environment.
Gearbox internals shall be treated with a corrosion inhibiting fluid as recommended by the gearbox manufacturer.
The internals shall be immersed in the fluid for a minimum of thirty minutes and the primary shaft rotated to ensure that the internal components make contact with the fluid.
To prevent bearing brinelling and degradation during transport, all motors and/or machines with rotors shall be secured by a retaining plate or shaft lock prior to shipment.
Where noted in the Inspection and Test Plan, Contractor and the Company Representative Inspectors shall witness the truck being loaded.
If the product is damage during loading Contractor Inspector will inform the Project Manager, record the details on the Delivery Docket and raise a Non-Conformance report.
The Project Manager shall advise the Company Representative of actual or anticipated late deliveries including the cause of the delay and the corrective action that is in place or intended.
Packing lists shall be prepared for each delivery in accordance with the Company Representative Shipping and Packaging Instructions.
Where the purchase order states that spare parts such as gaskets are to be supplied as a percentage of the total supplied, then the packing list shall clearly state both the quantity being supplied and the percentage of the total that this constitutes.
All accessories, loose parts, items and / or spare parts and special tools, will be tagged with an indestructible label showing:
Manufacturer’s Data reports shall be progressively compiled and checked by Contractor and the Company Representative inspectors.
Contractor inspector will prepare a release certificate following review of the MDR and acceptance of the goods from the supplier. Product shall not be released without the Company’s written authorisation and endorsed release note.
Reference: SG-PR-23-01 to 03
Procedure Deliverables: Select Suppliers
Preparing Order
Confirming Receipt of Goods and Conformity of Supply
The contract, specifications, drawings, schedules, inspection and test plans, procedures and quality plan will establish the controls on the construction site.
Welding shall be performed using qualified personnel and procedures in accordance with the welding Standard.
Transmittals will be prepared for all drawings and documents including revisions issued to the construction site by Head Office.
Site correspondence will be placed in files (original) and copied to the other disciplines and subcontractors working on the site (as required).
Electronic media will be placed in directory files in accordance with MSP-9 and protected by weekly CD backup.
Site progress will be recorded and reported to Head Office on a daily basis.
Site deliveries shall be checked against the delivery docket and cross-referenced with the piece mark identification on the drawing. The delivery docket will be stamped with the goods received stamp by the person who accepts the delivery.
Missing items will be reported to the supplier and unmarked items will be identified with a hold tag.
Non-conformances will be tagged and reported to the Project Manager in accordance with SG-PR-23-03
Site inspectors will perform dimensional inspections and / or trial fit pins and shafts before the equipment is lifted into position.
All site welds shall be visually inspected for compliance with the welding standard.
Non-compliant welds will be marked-up for re-work and re-inspected after they have been repaired.
Welds that require non-destructive testing (UT, MPI, RT, DP) will be identified with a weld number and traced to a test report issued by the testing authority.
The acceptance criteria for an inspection or test will be established by the specifications, drawings, codes and standards issued to the site
When an inspection or test has found that the acceptance standard was not achieved, a non-conformance report will be prepared and issued to Head Office.
Non-conforming product will be identified with a hold tag and placed out of service.
Technical queries will be prepared and issued to Head Office for clarification of the design issues that occur on the site
Site inspection will include continuous surveillance of all the construction activities, including:
Commissioning procedures will prepared by the Company.
Where possible, software programs used to operate the machine will be checked by confirmation of the factory acceptance test prior to installation. Final adjustment and validation will be performed during commissioning.
Commissioning tests shall be carried out in the following stages:
Commissioning will not commence without verification of the construction activities including but not limited to:
The dry commissioning program shall include all checks and tests including:
All drives and motion control systems shall have checks performed which address:
Results from the checks completed shall be recorded and marked-up on check sheets, drawings and operation and maintenance manuals. All checks shall be repeated in all operating modes as appropriate.
Operational commissioning shall be completed by the company with assistance from the contractor.
In accordance with regulatory requirement, Contractor will ensure that Company has the information to operate and maintain the machine safely
MDR Deliverables: Weld Procedure Qualification Record
Weld Procedure Specification
Weld Procedure Register
Welder Qualification Register
Inspection and Test Plan
Inspection and Test Checklists
Weld Test Request
Weld Maps
Flange Closure Reports (include map)
Hyrdo Test Reports
Calibrated Equipment Register
Commissioning Records
Construction Schedules
Progress Reporting
Purchasing Records
Technical Query
Product Non Conformance Report
Release Certificate
Certificate of Practical Completion
Contractor shall have a system in place to control non-conforming product.
All non-conformances will be directed to the Project Manager for approval of the disposition.
If the disposition alters the design specification the non-conformance shall be issued to the Company Representative for approval.
Reference: MSP-10
Procedure Deliverables: Non-conformance report
Non-conformance register
CORRECTIVE AND PREVENTIVE ACTION
The records and data collected from previous projects identifies the potential for non-conformances and the avoidance of a loss-making situation through preventive action
Records for evaluation include:
The Project Manager shall evaluate the data, document the findings and issue the information to the people working on the project to implement the preventive action in the tasks they perform.
All personnel have the authority to raise a corrective action.
Corrective actions shall be registered by the Quality Department.
The departmental Manager will evaluate and establish the cause of the non-conformity before corrective action is implemented.
Contractor shall audit the Project to verify that the management system and quality plan are established.
Reference: SG-PR-23-01 to 03
Procedure Deliverables: Identifying Root Cause when things go wrong
Product Recall
Inspecting and Testing
Date published: 25/07/2013
Document ID: |
442 |
Last reviewed: |
04/07/2012 |
Revision No: |
4 |
Approved by: |
.. |
* -25/07/2013 12:27:06 PM