Antecedentes de la investigación

The Contractor's Project Team under the responsibility of the Project Director shall plan and control the construction, inspection and testing activities ensuring the following:

• Availability of specifications, plans, drawings, procedures, processes and work instructions that define the characteristics of the construction, inspection and testing.

• Availability, use and maintenance of suitable construction, installation, inspection and testing equipment.

• Availability and use of suitable measuring and monitoring equipment.

• Availability of work force with proper qualification. Operators /Technicians shall be qualified to internationally recognised standards and or to the satisfaction of Company.

• Implementation of suitable monitoring and measurement activities.

• Implementation of processes for release ,delivery and/or installation of product and/or service including applicable post-delivery activities.

Further details shall be provided in the following:

5248-00-FA-4005 Construction Inspection Procedure 5248-00-FA-4004 Construction Co ordination Procedure 5248-00-FA-4000 Construction Execution Plan.

8.5.2 Vendor Inspection Management Philosophy

The following philosophy shall be applied for inspection and certification of equipment and materials.

8.5.2.1 Inspection Classification

The level of QA/QC applied to procured items shall be determined with reference to the item criticality. The criticality assessment establishes the importance of an item with respect to design, procurement, manufacturing & operation and the consequences of its failure. The inspection classes will be determined based on the criticality rating and will be shown in the Purchase Requisitions for various project equipment and materials.

8.5.2.2 Contractor’s Own Resources

Contractor shall review the Criticality Rating of the equipment and materials and decide whether to use own resources or utilise a 2nd party for inspection, including deployment of Resident Inspectors at manufacturing facilities. A program for the inspection shall be developed by the Contractor during the procurement phase of the Project. Refer 5248-00- EA-4002: P Vendor Shop/Source Inspection Procedure.

8.5.2.3 Second Party Inspection Services

Since the procurement shall be done from different countries it is not practical for the Contractor to employ it’s own resources everywhere. Hence Second Party Inspection services will be used for carrying out inspection of certain equipment and bulk materials. The requirement for Second Party Inspection shall be clearly defined in the Purchase Orders issued to the Vendors.

8.5.2.4 Consistency in Inspections

As stated above, Contractor shall be deploying a large number of Inspectors at various Vendor locations, from own resources and from inspection agencies. In order to bring consistency in inspections, the Contractor shall ensure applicable ITPs and QCPs provide the inspection and testing requirements in sufficient details. Contractor’s QC Engineers, during the review/approval of ITPs and QCPs, shall also consider inputs from the Lessons Learned (from previous projects) and the known flaws for equipment/materials to establish the intervention points.

Contractor shall provide copies of unpriced Purchase Orders, ITPs and vendor details to Company as required.

8.5.2.5 Equipment/Material Release

Irrespective of the usage of direct resources or hired resources for inspection, the Contractor will establish an inspection release system which identifies all documents are approved and there are no outstanding technical queries, nonconformances or concessions not fully closed-out. To ensure this, the Inspection Relese Note will be issued by Project Inspection Manager only once the final inspection status is reported as acceptable. The Inspection Release Note is used as a trigger to initiate the Shipping Release process. Contractor shall advise Company of status of Inspection Release Notes on a regular basis.

8.5.3 Site QC Enhancement

The Site Quality Manager shall be delegated the clear power and immediate access to Contractor’s senior management to stop any works that are nonconforming. Weekly Quality Team Meetings shall be held at site, Company Quality Representatives shall be invited, in order Company and Contractor personnel are updated about all QC matters and nonconformances.

Inspection and surveillance during the Construction phase shall be enhanced by assigning qualified and specialised QC Inspectors in different disciplines and by taking the following measures:

• The inspection and testing requirements shall be detailed in the Inspection and Test Plans for each process, indicating which record/verification document is produced for each stage.

• Contractor’s intervention points shall be marked against each activity/stage in the Inspection and Test Plans during the document approval stage to establish the QC involvement.

• Detailed QC procedures shall be developed for all critical processes, also considering the Lessons Learned from previous projects.

• Subcontractor staff shall be provided with training and/or awareness on handling special material and processes involved in the Project.

• All QC activities and their history/records shall be compiled on a database referencing the ITP/QC Procedure/Certification so that the status can be generated at any time. Primary control of this function will be Petro-PCS

• All critical processes shall be continuosly monitored until the process performance is satisfactory to achieve project quality objectives.

8.5.4 Material & Equipment Management at Construction Site

Site Material & Equipment Control System shall be established for Material Control, Storage, Issue, Preservation and Traceability at construction site to cover all disciplines: Piping, Mechanical (Static & Rotating), Civil/Structural, Electrical, Instrumentation and Telecom. The process starts from MTO phase where materials are allocated with tag numbers,material codes etc. on construction drawings, which in turn are stamped/stencilled and colour coded as per contract requirements.

The Construction Director, Construction Manager, Material Control Manager, QC Inspector and subcontractor teams in full co-ordination shall manage the Material Control and Traceability at field. The efficient implementation of Site Material & Equipment Control methods shall enhance construction management to meet project schedules. Refer work procedures 5248-00-FA-4013: Material Traceability Procedure and 5248-00-FA-4012: Material Handling Procedure.

8.5.5 Validation of Processes for Production and Service Provision

All those processes, where the resulting output cannot be verified by subsequent monitoring or measurement, such as welding, concrete mixing etc. shall be validated and Company approval obtained prior to their use. The validation measures include the following actions: • Identification, preparation and approval of the procedure specifications (e.g. WPS); • Verification and acceptance of materials (the same type of material will be used for

production);

• Process qualification using approved equipment and qualified personnel;

• All qualification records (e.g. visual, destructive and non destructive testing) generated, approved and maintained;

• Revalidation when any essential variable is changed.

In case of welding, the welder/operator and welding procedure specification may be simultaneously qualified. Welding procedure, performance qualification tests and field joint procedure qualification tests shall be considered as Company witness points and coordinated accordingly with Company.

8.5.6 Identification and Traceability

The identification and traceability system shall be applied for the following: • Pipes, valves, fittings, GRE and accessories, welding consumables. • Welded joints and welders

• Other permanent items / equipment incorporated in the construction • Inspection, test and quality verification status

Products and construction activities shall be identified during all phases of product realisation by means of legible and durable markings maintained from initial receipt to final destination

and/or by using relevant follow-up documentation.

The identification of items of equipment and certified materials, ITP and all test records shall be maintained by the project. Material certificates, construction welding book and inspection reports are supporting elements for identification and traceability of products.

Responsibilities for identification and traceability are as follows:

• Engineering Discipline Lead specifies identification requirements in purchase documents. • Material Controller verifies the required identification during material receipt.

• Site QC establishes and ensures appropriate system for identification and traceability. • Construction team implements measures for identification and traceability.

8.5.7 Company's Property

Company's property shall be identified, verified, stored, protected and maintained by the Contractor, while under the Contractor’s responsibility.

Products supplied by the Company shall be inspected and accepted prior to acceptance into the stores by the Material Controller where it will be identified and stored in a manner avoiding damage and deterioration.

Company supplied products that are lost, damaged or unsuitable for use, shall be recorded, and reported to the Company in order to find required solutions.

8.5.8 Preservation of Product

Products are protected from deterioration or damage during identification, handling, packaging, storage, construction and up to delivery of the installations to the Company in accordance with the procedure 5248-00-FA-4035: Equipment Maintenance and Inspection Procedure.

The Construction Director/Construction Managers/Construction Superintendent shall ensure appropriate facilities are made available for handling, packaging, storage and preservation of products.

The Material Controller shall be responsible for carrying out handling, packaging and storage activities.

Handling

All incoming materials and provided items shall be handled with care by suitable means to prevent any damage to the products. For this, depending upon the nature of the item to be handled, different devices such as cranes fitted with spreader bars, slings or hooks with soft protection, as required, are employed.

Packaging

Packaging and marking of all materials to be sent to the site shall be controlled by the Procurement Manager to ensure compliance with specified requirements and proper identification.

Storage

Secure storage areas shall be identified for storage purpose, with suitable access routes to them, including covered and uncovered areas and the type of materials to be stored in each location. The storage areas on site shall be suitably protected to prevent entry of unauthorised persons.

Storage of pipes shall be done considering the size, safety aspects and safe preserving methods. Stainless steel, Alloy steel and Carbon steel pipes shall be segregated.

Vendors' recommendations with regard to storage and preservation of the equipment shall be strictly adhered to.

Goods, which fall under statutory regulations for dangerous goods, shall be packed, marked, and stored separately in accordance with the relevant regulations.

Protection

Protection of the items during storage or handling shall be done as per instructions obtained from the Vendors.

Delivery

The delivery of completed facilities with associated documentation and their acceptance shall be organised by the Project Director in co-ordination with the Company.