ALBE
ADVAN ADVANCED LINK BRIDGE ENTERPRISES
QUALITY CONTROL PLAN
PROJECT NAME PO - 018550 PR - 006365 Design, Fabrication and Installation of RMU Shelters
at ULFA and SAMHA Wellheads
CLIENT CC Energy Development
Doc. No. ALBE-QMS-F110
DATE 05/02/2020
REV. NO. DATE ITEM DESCRIPTION PREAPRED BY REVIEWED BY APPROVED BY
A 12/12/2019 Issued for Review VK Ahmed
B 05/02/20 Issued for Approval VK Ahmed
C 09/02/20 Issued for Approval VK Ahmed
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Contents
1. PURPOSE........................................................................................................................................2
2. SCOPE............................................................................................................................................2
3. DEFINITIONS / ABBREVIATIONS.....................................................................................................2
4. REFERNCES....................................................................................................................................2
5. RESPONSIBILITIES..........................................................................................................................2
6. GENERAL........................................................................................................................................2
7. PROJECT QC DOCUMENTS AND RECORDS.....................................................................................2
8. EQUIPMENT CALIBRATION............................................................................................................2
9. MATERIAL CONTROL......................................................................................................................2
9. 1 Receiving of Materials......................................................................................................2
9. 2 Material Handling & Storage............................................................................................2
9. 3 Issue and Return of Material............................................................................................2
10. QUALITY CONTROL – WORKSHOP FABRICATION.......................................................................2
10. 1 Pre-fabrication of Steel Members/Parts........................................................................2
10. 2 Fabrication of Steel Members/Parts..............................................................................2
10. 3 Non-destructive Examination (NDE)..............................................................................2
10. 4 Coating of Fabricated Steel Items..................................................................................2
10. 5 Release for Delivery/Clearance......................................................................................2
11. QUALITY CONTROL – SITE..........................................................................................................2
12. MATERIAL TRANSPORTATION AND LOADING............................................................................2
13. PAINT AND COATING TOUCH UP BY CCED.................................................................................2
14. CONTROL OF NON-CONFORMI ITEMS.......................................................................................2
15. ATTACHEMENTS........................................................................................................................2
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1. PURPOSE
The purpose of this procedure is to describe the minimum requirement in the quality control
inspection during the fabrication and Installation of RMU Shelters at ULFA and SAMHA
Wellheads to ensure that the project requirement and applicable codes and standards are
met.
2. SCOPE
The Quality Control Plan is applicable to all structural steel fabricated and Installation of RMU
Shelters at ULFA and SAMHA Wellheads done at ALBE workshop.
3. DEFINITIONS / ABBREVIATIONS
CLIENT: CCED
MAIN CONTRACTOR: ALBE
PROJECT: PO - 018550 PR - 006365 Design, Fabrication and Installation of RMU Shelters at ULFA and
SAMHA Wellheads.
ALBE: Advanced Linked Bridge
ITP: INPECTION & TEST PLAN
QC: QUALITY CONTROL
RFI: REQUEST FOR INSPECTION
WPS: WELDING PROCEDURE SPECI FICATION
PQR: PROCEDURE QUALIFICATION RECORD
WPQ: WELDERS PERFORMANCE QUALIFICATION RECORD
IR: INSPECTION REPORT
DWG: DRAWING
QHSE: QUALITY & HEALTH, SAFETY & ENIVORNMENT
MTC: MATERIAL TEST CERTIFICATE
NDE: NON-DESTRUCTIVE EXAMINATION
MT: MAGNETIC PARTICLE TEST
TPI: THIRD PARTY INSPECTOR
DFT: DRY FILM THICKNESS
WFT: WET FILM THICKNESS
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ADVAN ADVANCED LINK BRIDGE ENTERPRISES
NA: NOT APPLICABLE
4. REFERNCES
1. JS1006-X-S01-6612
2. JS1006-X-G02-0003
5. RESPONSIBILITIES
Deputy CEO
The Deputy CEO is responsible for forming and evaluating the company’s goal, direction and
strategies. He collaborates with the management team to carry out the set goals.
Project Manager
The Project Manager shall be ultimately responsible for the planning, executing and finalizing
projects according to strict deadlines and within budget. This includes acquiring resources and
coordinating the efforts of team members and third - party contractors or consultants in order to
deliver projects according to plan. The Project Manager will also define the project’s objectives and
oversee quality control throughout its execution.
QHSE Manager
The QHSE Manager is the Management Representative with the necessary authority and
responsibility for ensuring that the requirements of this Quality Control Plan are established,
implemented and maintained. He is the final authority on quality matters and represents ALBE on all
Quality Issues pertinent to the project’s scope. He ensures that safety systems are implemented on
site and ensure the provision of continued on-site support by means of inspections, follow-up and
internal audits.
Design Engineer
The Design Manager is responsible for the approval of design calculations, construction drawings
and technical delivery conditions of material. He will coordinate with the CLIENT on engineering
reviews or changes and communicating all changes to Project Manager, Fabrication Manager
and QHSE Manager for incorporation in the construction or repair program.
Fabrication Manager
The Fabrication Manager shall be responsible for workshop production activities of assigned
projects. He shall be the focal point for fabrication, welding & other shop activities to ensure
construction and completion of inspection stages as per approved ITP and procedures.
Project/Site Engineer
The Project/Site Engineer is responsible for the coordination of all technical activities on assigned
projects. He plans and coordinates assigned engineering work which includes monitoring of works
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to applicable standards and codes. He ensures effective communication and coordination between
all disciplines and all project participants.
QC Engineer
The QC Engineer shall establish the necessary documentation (QCP, ITP, Procedures, etc.) for the
duration of the project. He shall coordinate closely with the QC Inspector to ensure that required
documentation and records are maintained.
QC Inspector
The QC Inspector is responsible for the quality control activities such as verification and
implementation of inspection plans within the assigned project. He monitors the performance and
overall progress of construction inspections to ensure adherence to the quality plan. He maintains
quality records in support of activities in area of responsibility.
Fabrication/Erection Foreman
The Fabrication/Erection Foreman is responsible for supervising the daily activity of the workers
(fabricators, welders, etc.) to ensure that their works are in compliance with the project
requirements. He coordinates closely with the Project/Site Engineer.
HSE Officer
The HSE Officer is responsible for the workshop/site inspection to ensure that safety procedures
and regulations are strictly followed. He assists in helping the workforce understand job hazards and
safety precautions.
Store Officer
The Store Personnel shall be responsible for the maintaining and updating of material inventory. He
shall be responsible for the verification of supplied materials against the purchase order.
Document Controller
The Document Controller maintains and updates all project related records and documents.
6. GENERAL
a) Stage inspection shall be done as per the approved ITP and RFI shall be raised by ALBE
according to the intervention points of the designee.
b) All relevant inspection reports / records shall be signed by the respective designee.
7. PROJECT QC DOCUMENTS AND RECORDS
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a) All external QC documents/records (like Client Specification, Drawings, and MTC from
suppliers, etc. and internal QC documents (generated by ALBE) shall be controlled and filed
as applicable.
b) Project QC records including shop drawings, shall be retained in accordance with the
contract requirements. If retention time was not given by CLIENT, they shall be maintained
for a minimum period of 3 years.
c) Project QC documents like ITP, QC Procedures, etc., shall define the actions needed to meet
the project’s quality requirement, and the records that need to be prepared to ensure
compliance.
d) Approved QC documents with latest revision status shall be ensured at the point of use. Any
records of distribution of QC documents (Controlled Copy) shall be controlled by the QC
Department. Shop drawing distribution shall be controlled by the Engineering or
Design Department’s Document Controller.
8. EQUIPMENT CALIBRATION
ALBE shall ensure that monitoring and measuring equipment used for this project are
suitable and calibrated at regular intervals as per the defined time period. The list of
monitoring and measuring equipment used shall be logged and updated as necessary.
9. MATERIAL CONTROL
9. 1 Receiving of Materials
a) All material approval sheet shall send to CCED for approval before start
fabrication. Fabrication materials received (such as plates, hollow
sections, etc.) and welding/painting consumables (like electrodes, filler wires,
paint etc.) shall bear the appropriate identification marking traceable to the
MTC & Inspection Report provided.
b) QC Inspector shall check the materials received as per the LPO/Delivery
Note and verify that the material corresponds with the MTC & Inspection
Reports and inspection result shall be record in material inspection report.
c) Dimension and visual check shall be conducted and result shall be
compliance with the required standard or specification of the material.
Fabricated items delivered to site (from ALBE workshop) shall be subjected
only for visual inspection t o check for possible damage during the delivery,
loading and unloading.
d) All MTC shall be approved by Client prior to the fabrication.
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9. 2 Material Handling & Storage
a. All materials to be used in fabrication shall be handled properly to prevent
damage, like providing wooden piece or pallets to support the materials,
use of proper chain sling or rope during lifting, providing suitable pads for
painted items, etc.
b. Bundled material i.e. pipes, tubes, section, prefabricated sub-assemblies or
bundles/ stacks of plates etc. shall be handled carefully by taking into
consideration the total weight of bundle.
c. Storage areas are designated for each type of material and materials are
stored in the designated areas. Suitable identification is provided for easy
identification of materials.
d. Outside storage shall provide protection for materials and equipment. The
storage areas shall have a grid network of access roads to facilitate
transportation and handling equipment.
e. Packaged items are retained in the original packaging until required for use.
Items are stored in areas appropriate for their type affording adequate
protection from accidental damage and in conditions, which will not
compromise the item’s expected shelf life (including temperature control).
Storage of flammable items (i.e. paints, gas) should be as per manufacturer’s
recommendation. Material storage as per manufacturer recommendations.
9. 3 Issue and Return of Material
a. Storekeeper shall issue for fabrication, production or erection only those
materials which have been inspected and accepted by QC Inspector.
Material Consumable requisition (MCR) shall be the basis of issuance of
material by storage to the shop floor or site.
b. Usable cut-off material with proper identification is returned to store for proper
storage. The stock level of the returned materials shall be updated accordingly by
the store-in- charge.
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10. QUALITY CONTROL – WORKSHOP FABRICATION
10. 1 Pre-fabrication of Steel Members/Parts
a. Visual and dimensional check shall be performed by the QC Inspector after
each stage of pre-fabrication (like cutting, bending, edge preparation, rolling,
marking, etc.) for all steel items as per the approved shop fabrication
drawings.
b. Material traceability to be verified by the QC Inspector during this activity.
10. 2 Fabrication of Steel Members/Parts
a.Visual and dimensional check shall be performed by the QC Inspector after each stage
of fabrication (fit-up assembly, preparation for welding, etc.) for all steel items as per
the approved shop fabrication drawings.
b.Only CCED approved WPS with supporting PQR and other documents shall be used
during the welding of the fabricated items.
c. Welders with approved WPQ will only be allowed to weld.
d.Welding Inspector shall verify the following during the welding stage:
Availability of WPS on shop floor/ site
Calibration Sticker for the Welding Machines and Holding & Baking
Ovens
Welder ID
MTC for the Welding Consumables used is available
Baking & drying of electrodes / fluxes prior to use.
e.100% visual examination shall be carried out on all welds.
f. Acceptance Criteria for the visual examination shall be as per Project Specification or
AWS D 1.1
10. 3 Non-destructive Examination (NDE)
a)NDE shall be carried out by NDE Technician qualified to minimum NDT Level II
Certification or equivalent.
b) NDE requirement shall be
Fillet Welded Joints - 10% MT
Butt Welded Joints –10%MT
-10% of the butt welds within the compression zones of structural elements and with full
penetration shall be radio graphed. All buy joints within the tension zone of structural
elements and with full penetration shall be radio graphed examined for the 100% of
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the entire length of the weld.
c)Acceptance Criteria shall be as per Project Specification or AWS D1.1. and as per CCED
Spec: JS1006-X-S01-6612.
10. 4 Coating of Fabricated Steel Items
a) Approved paint system/schedule shall be available on the shop floor prior
to start of painting application. All paint system shall be as per CCED
Specification JS1006-X-G02-0003-C3
b) Surface Profile, prior to paint application, shall be checked as per the
required surface preparation. 50 to75 μm.
c) WFT shall be verified by conducting spot check during the course of painting
application. DFT shall be documented after the application of each coat.
d) All Paint system shall be approved by client prior to the application
f) Paint thickness shall be as per Manufacturer recommendation for each coat.
g) Primer, intermediate coat and top coat all DFT shall be minimum 200 Micron
minimum.
h) Coating application details for each layer including painting material to be sued &
required minimum DFT
1st Coat (Primer) NATIONAL RED OXIDE PRIMER Minimum DFT= 40
2nd Coat (intermediate) NATIONAL GUARD Minimum DFT=100
UNDERCOAT H.
Top coat NATIONAL GUARD TOPCOAT Minimum DFT=50
10. 5 Release for Delivery/Clearance
a) Final clearance/ release report shall be generated prior to release or delivery.
11. QUALITY CONTROL – SITE
Not included in the contractor (ALBE) scope.
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12. MATERIAL TRANSPORTATION AND LOADING
All material shall be properly tie and covered with packing material prior to
loading and placing to the trailer to avoid damages.
13. PAINT AND COATING TOUCH UP BY CCED
-Affected areas of steel components that require paint touch-up or repair shall
be checked. Areas less than 5in2 shall be cleaned to ST3 hard wire brush or
ground back to the metal surfaces using atleast an 80 grit disc sander. Edge
shall be feathered back at least 50mm beyond the clean metal surface. Areas
greater than 5 in2 shall be blast cleaned.
-Any painting or coating activity shall undergo QC inspection
14. CONTROL OF NON-CONFORMI ITEMS
a) ALBE shall ensure that the item which does not conform to the requirements is
identified, documented, evaluated, and segregated for disposition to the
concerned departments/ sections.
b) It is the responsibility of all employees to report discovered or potential
nonconformities at any stage of the processes to prevent unplanned use,
application or installation of nonconforming product / service. Non-
conformity register is maintained and all the above types of non-conformities
observed, action taken will be recorded.
15. ATTACHEMENTS
-Paint QC form (FM-ALBE-001)
-Painting Data sheet
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