Supervisor interview,

Audit Types,

1. External Audits
2. Internal Audits
3. Internal Revenue Service

What is Schedule Q?

Schedule Q is a Governing Saudi Aramco Document, which describes the minimum

Requirement for Contractor’s Quality System.

Contents of Schedule Q ?
1‐ General
2‐ Quality Management System Requirements
3‐ Documentations Requirement
4‐ Management Responsibility
5‐ Management resource
6‐ Project Execution
7‐ Measurement, Analysis and improvement

Attachments of Schedule Q?
Attachment I: Contarcto/Subcontractor Quality Personnel Qualification Requirement
Attachement II: Company Standards/Procedures containing Quality Requireemnt
Attachement III: Quality requirements for Contractor supplied material
Attachment IV:Quality requirement for Construction Phase
Attachment V: Summary of Quality system Deliverables
Attachment VI: Project Specific requirements

Summary of Quality System Deliverables?

1‐Quality Plan
2‐Organization Chart
3‐Personnel Qualification
4‐Quality Audit Schedule
5‐Audit Peport
6‐Contractor,Vendor and subcontractor non conformties
7‐Non Conformance Summary
8‐Management review results
9‐Quality Management Report
10‐Evidence of Manufacturer
11‐Inspection/Fabrication status report
12‐Inspection Assignment package
13‐Pre Inspection meeting and vendor inspection reports
14‐Two Week look ahead Schedule
15‐Inspection/Shipping Release
16‐Inspection Disposition Report
 17‐Special Process Procedures

What is PQP& Submission ?

PQP stands for Project Quality Plan; it is the document which describes that how contractor will
manage the scope of work based their Quality System correlated to Client’s Schedule Q.

PQP to be submitted within 30 Days after contract award and subsequent submission in 7days.

MQMR (Monthly Quality Managemnt Report)?

1st to submit it after 60 days after effective contract date.

What are the contents of MQMR?

1: General Items
(a): Listing of Quality audits completed (internal & Subcontractors), in progress and Planned for next
month.
(b): Status of open corrective actions for Non‐confirmance reports, audits and management reviews
(c): Quality Personnel listing by Dicipline
(d): Listing and Status of engineering waivers requested
2: Design& Procurement Phase Items
(a): Listing of supplier Surveys for the next month
(b): Planned surveys for the next month
(c): Listing of Pre inspection meetings conducted and Planned for next month
(d): Listing of Supplier inspections performed and those planned for next month
3: Construction Phase Items
(a): Listing and Disposition of all defective or rejected material or equipment received at Job site by
contractor / Sub contractor
(b): Welding Rejection rate reported in accordance with SAEP‐1160. A chart showing the Historical
performance during project shall be included.
4: Narrative section for Process improvement Activities
This section shall describe contartore/sub contarcator activities during the month to continually
improve its processes, correct and eliminate the Non confirmties, prevent potential probles and
improve schedules. It should include trend analysis for processes

QA Part : PROCUREMENT FLOW / PROCESS

1. First Detailed MTO (Material Take Off) .
2. Advance PR for Floating of RFQ to approved Vendors/Suppliers by SAPMT/SAVID
3. MR (Material Requisition) is prepared with complete requirements of Material, Certifications,
NMRs in Purchase Requisition Submittal subjected SAPMT Approval
4. RFQ (Request for Quotation) issued for Vendors as per RVL(Regulated Vendor List)
5. Approval of OPR (Order Placement Request) from SAPMT with SA Dummy PO No.
6. Issue PO to Vendors
7. Submitted PO, ITP, Qualification (Containing Operating Maintenance Manuals) of/from Vendor
Issuance of Approved NMRs(Non‐Material Requirements.) to Vendor (After SAPMT Review).
11.Holding of PIM (Pre Inspection Meeting) for In process inspection if level is 2,3,4
12. Post PO Expediting of Fabrication/Inspection activities
13.In Parallel Preparation of IAP (integrated Activity Plan), Review and approval from
SAPMT/SAVID(Saudi Aramco Ventures & Investment Division.).
14. FIDR (Field Integrity Data Review)&issuance of Product to site
15. Site inspection by Contractor
16. Final Inspection and clearance by SAPID at site
 What is Non Conformity?
Anything, which went Violate from the Project Specification/Standard/Code/Procedure, is none
Conformity, which need to recorded thru NCR.

What is Aramco Contractor NCR Ratio?

1:20

What is NCR?
NCR stands for Non Conformance Report;

Who are authorized to issue NCR?

All QA/QC personnel can issue NCR

What is the timeline for INCR (Internal NCR) to be forwarded to client?

Contractor shall forward all INCR to Client within 48 hours of issuance.

What are the content of NCR ?

Description of Non‐Conformity
Root Cause Analysis(to find the cause of Non‐Conformity)
Corrective Action(action taken on the system / product to debug the errors)
Preventive Action(Proactive measures to avoid the non‐conformity)

What is the timeline for Root Cause Investigation and initiate corrective
action?
Within 7 days of issuance

What is the timeline to respond clients NCR?

It must be responded in written within 48 hours

How is Disagrement?
5% is Disagreement for RT Third Part/GCC/ARAMCO RTFI

Rejection Rate?
Maximum 5% on Joint basis and 2.5% linear basis

Welder Performance weekly?

Refer to SAEP 324 Appendix 1 (5% on Joint basis and 2.5% linear basis)

What is SATIP?
Saudi Aramco Typical Inspection Plan
 Qualification of QA/QC Manager, Supervisor & Inspector?
QA Manager shall have demonstrative knowledge and training in ISO 9001
internation Standard. He shall have University Degree or equivalent with min 10 YrsExp out which 5
Yrs must be in managing Quality system related to Contract.
QC Manager shall have University Degree or Equivalent with 7 Yrs Experience or
High School Diploma with 10 Yrs Experience out of which 5 Yrs should be directly supervion of
Construction activities.
QC Supervisor He shall have University Degreeor or Equivalent with 7 YrsExp or
High School Diploma with 10 Yrs Inspection Experience out of which 3 Yrs directly related to
Supervision of construction activities in scope of contract.
QC Inspector shall have High school Diploma or Equivalent, shall be able to read,
write and speak English. Shall be fully conversant with applicale Industrial Standards and Specifications.

Special Process Procedures?

Special Procedures Processes are which required Review &
Approval 30 days ahead prior to commence the work.
1‐Field Engineering Change Control (A)
2‐Welding & Brazing (A)
3‐Non Destructive Testing (A)
4‐Positive Material Identification(PMI) &Clor code verification. (A)
5‐Heat Treatment & Associated Hardness Testing (A)
6‐Pressure Testing (A)
7‐Coating & Lining (A)
8‐Gasket Installation (A)
9‐Gap control (A)
10‐ Hot Taps (A)
11‐ RTR Pipe work (A)

What are the responsibilities of a mechanical inspector?

To Conduct Inspection of all mechanical activities
To witness testing and monitoring of the product, fabrication and installation process
Record keeping per SATIP
Mechanical inspector is responsible to implement the quality system ,he is responsible to
Compliance of Saudi Aramco standard , procedure and specific requirements,

What are the Inspection levels / Responsibilities during construction

phase?
Surveillance:
QA/QC organization to monitor work in progress without notice from Construction Organization
Witness:
QA/QC organization shall be notified of the timing of Inspection or test in advance. However, the
inspection or test shall be performed as scheduled if the QA/QC organization representative is
not
present.
Hold:
QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or
test shall not be carried out without the QA/QC organization representative in attendance.

What are the Inspection levels for contractor supplied materials per SAER
1972?
 Level 0:
Documentation Requirement only; no vendor inspection required
Level 1:
Only final inspection is required prior to shipping
Level 2:
Includes, as a minimum, pre inspection meetings, one or more unspecified in progress
surveillance /
visits, all witness and hold points, final inspection and release for shipment
Level 3:
Same as Level 2, except that in progress surveillance shall be on regular basis (Daily, Weekly or
Biweekly)
Level4:
Resident Inspector continually monitoring the work

What are the SA‐ 175 forms?

SA‐175 forms establish minimum inspection and testing requirements for procured inspect‐ablematerial and
equipment. As per SAER 1972

What minimum amount of Documents do you need to inspect a Material?

Related Drawing (IFC and Controlled)
Material Take off (IFC and Controlled)
Material Requisition and its approval
Purchase Requisition and its approval
Purchase Order
Packing List / Tally Sheet
Material Test Certificates
Vendor Inspection Report
Inspection Disposition Report / Inspection Release Note
Delivery Note
What is the timeline to award an ACD to LBE, NCR and Worksheet?
Within 05 working days

PQP,
PQP, to be content and expedite the next issues but not less than.
1. Quality Assurance Manual
2. Quality Objectives
3. Project Quality Activities Matrix
4. QA/QC Organizational Chart 0
5. Audits Schedule
6. ISO Certificate
7. Contract Review Post Award
8. Documented Information and Data Control
9. Purchasing
10. Competency & Training
11. Internal Quality Audit
12. Corrective Action, Risks and Opportunities
13. Control of Nonconformance
14. Retention and Control of Documented Information
15. Customer and External Provider Relations
16. Control of Monitoring & Measuring Resources
 17. Subcontractor Control
18. QAQC Department Personnel Responsibilities

Quality Objectives-
1. Request for Inspection (RFI) rejection shall be less than or equal to 5% of the
overall number of RFI’s.
2. Welding Repair Rates
3. The efficient monitoring or processes and highlighting of Nonconformance
4. Manufacturer Quality performance
5. Performance of Subcontractor NDT Personnel
6. Quality Training hours

QA/QC supervisor Responsibilities:

 Ensuring that, all construction & Quality works procedures are in position and approved before starting the work
activates.

 Reviewing & approvals for the submitted quality Docs. Construction MST.s and other related Docs,
• coordinate with the QC inspector, and supervise the construction activities, including the installation, testing, and
inspection.
• Supervisor on-site, ensuring that construction activities align with project standards and approved procedures.

• Ensure coordination, the construction execution, and follow-up of all installation, pre-commissioning, and commissioning
activities it done in compliance with detailed AFC design DWG and project specifications.

• Interface with QC inspector to address quality issues, site construction problems and figure out with the Engineering
DPT to be are solve.
 Attend the Site walk through weekly and monthly then raise the Quality site concerned and observation and close out
with the QC inspectors.
• attend, weekly, and monthly quality progress meetings as required, reviewing and following for the M.O.M.

 Reviewing, & approvals for the quality Submittals, releasing works, H.T Packages and the final handover filling
package.
 Figure out the punch list and categorization for the items one by one that is to be bunched as grade A or B or C.

 Following up with the QC inspector to close out the punch list.

3. Quality Assurance and Control KPIs

Defect Density: Measures the number of defects per unit (often per million or thousand units) of production, such as
defects in pipes, drilling equipment, or refined products.

Non-Conformance Rate (NCR): Percentage of products or processes that do not meet quality standards or specifications.

Inspection Pass Rate: Percentage of products or processes that pass quality inspections on the first attempt.

Construction Quality Index” (CQI)

In general, a "Construction Quality Index" in a refinery context would likely measure factors
such as:
1. Structural Integrity: Assesses the durability and strength of materials and structures to
withstand operational pressures and environmental conditions.
2. Compliance with Standards: Ensures alignment with international and ARAMCO‐specific
standards like API, ASME, and ISO, for safety, environmental protection, and efficiency.
 3. Operational Readiness: Measures whether the construction meets the functional
requirements for operations to start smoothly, safely, and on schedule.
4. Safety Standards: Rates the adherence to safety protocols during construction, ensuring
minimal risks to workers and the environment.
5. Cost and Schedule Adherence: Examines whether the project remains within budget and
on schedule, crucial for avoiding unnecessary costs or delays.
6. Environmental Impact: Evaluates the construction practices in terms of environmental
protection, waste management, and emissions control.

IEP (Inspection Execution Program)

1. Planning Phase

Objective: Define inspection scope, set objectives, allocate resources, and plan for the required
inspection procedures.
Activities:
Review historical inspection data and previous findings.
Assess risk factors, inspection priorities, and determine inspection intervals.
Develop inspection plans and assign resources, equipment, and personnel.

2. Execution Phase
Objective: Conduct physical inspections and tests as per the planned schedule.
Activities:
Perform on-site inspections using various techniques (e.g., visual inspection, non-destructive
testing like ultrasonic testing, radiographic testing).
Collect data on equipment condition, detect anomalies, and document findings.
Adhere to safety standards and quality control guidelines throughout the process.

3. Data Analysis Phase

Objective: Evaluate collected data to assess equipment health and determine maintenance
needs.
Activities:
Analyze inspection results to identify trends, degradation patterns, and potential failures.
Compare data with industry standards, historical trends, and risk thresholds.
Prepare detailed reports that include findings, assessment results, and any recommendations for
maintenance or repair.

4. Reporting Phase
Objective: Communicate findings, recommendations, and any urgent issues to relevant
stakeholders.
Activities:
Compile comprehensive reports that include all data, analysis, and maintenance
recommendations.
Conduct meetings with management, engineering teams, and operations personnel to discuss
findings.
Document required corrective actions, compliance issues, and prepare an action plan.
 5. Follow-up and Remediation Phase
Objective: Implement corrective actions and track the resolution of identified issues.
Activities:
Carry out maintenance, repairs, or replacements based on inspection results and action plans.
Verify that all issues identified during inspections have been adequately resolved.
Update asset records to reflect the inspection findings and repairs conducted.

6. Review and Optimization Phase

Objective: Evaluate the IEP process itself to identify potential improvements for future
inspections.
Activities:
Assess the effectiveness of the inspection process, techniques used, and outcomes achieved.
Gather feedback from inspection teams and stakeholders.
Make improvements to inspection methodologies, tools, and resource allocation to optimize future
inspections.

Quality System Documents (QMS):

1.1 Project Quality Plan
1.2 Project Organization Chart
1.3 QMS Procedures, work instructions etc.
1.4 Manufacturers and Subcontractor’s Quality Plans
1.5 Qualifications and CV’s of Quality personnel.

Pipeline construction Execution activates.

Electrical works,
1- Earthing
2- Cathodeic
Civil Works,
1-Right of Way (ROW) of Pipeline Procedure.
2-Site Surveying Control of Pipeline Procedure_00
3-Excavation, Bedding, Padding & Backfilling Procedure.
Mechanical works,
1- Material Handling and Transportation of Pipeline Procedure.
2- Stringing of Pipeline Procedure.
3- Welding Execution Plan Procedure of Pipeline.
4- NDT of Pipeline Welding Procedure like VT, RT, MT, DPT.
5- Field Joint Coating for Underground Pipeline Procedure.
6- Lifting and Lowering- In of Pipeline Procedure.
7- Pipeline reinstatement producer
8- Hydrostatic Test Procedure for the Crossing portions.
9- Hydrostatic Test Procedure for the underground pipeline.
10- Pipeline Cleaning, drainage, flushing, drying Procedure.

Coating sys,
1-PRIMER,
Using TWO COMPONENT EPOXY 100% VOLUME SOLIDS
2-External, final
Using a spiral wrap HEAT SHRINKABLE SLEEVE and CLOSURE SEAL TAPE.
3-Examination and testing,
Porosity test (holiday detector) & Peel strength in accordance with project SPC,