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1、MANUAL PROJECT QUALITY ASSURANCE DEP 82.00.10.10-Gen. December 1995 (DEP Circular 24/98 has been incorporated) DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell
2、 International Oil Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or
3、 transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Pro
4、ducts B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maint
5、enance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good d
6、esign and engineering practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth i
7、n these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operatin
8、g companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for thos
9、e requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility
10、, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, th
11、ree categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties
12、 who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of t
13、he said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoev
14、er as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of
15、 DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose f
16、or which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SI
17、OP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for D
18、evelopment (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs
19、 will gradually be replaced by DEPs. DEP 82.00.10.10-Gen. December 1995 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.5 1.1SCOPE 5 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS5 1.3DEFINITIONS 5 1.4ABBREVIATIONS6 1.5CROSS-REFERENCES6 2.THE ROLE OF QUALITY ASSURANCE7 2.1THE NEED FOR QUALITY A
20、SSURANCE7 2.2LINK WITH QUALITY MANAGEMENT.7 2.3THE ISO 9000 STANDARDS7 3.IMPLEMENTATION OF QUALITY ASSURANCE9 3.1ACTIVITIES. 9 3.2STAFF. 9 3.3DOCUMENTATION.9 4.QUALITY ASSURANCEOF PROJECT MANAGEMENT10 4.1THE QUALITY PLAN.10 4.2PREPARATION OF A QUALITY PLAN.10 5.QUALITYASSURANCEFORCONTRACTSANDPROCURE
21、MENT- GENERAL. 16 5.1SELECTING THE APPROPRIATE QUALITY PROGRAMME16 5.2DETERMINATION OF PRINCIPALS INVOLVEMENT.18 5.3MONITORING PERFORMANCE18 5.4QUALITY AUDITS AND REVIEWS.19 5.5CONTROL OF DEVIATIONS AND CONCESSIONS19 5.6CORRECTIVE ACTION19 5.7CONTROL OF STANDARDS20 5.8DOCUMENT CONTROL.20 5.9DOCUMENT
22、 VERIFICATION AND APPROVAL20 6.DESIGN QUALITY ASSURANCE.21 6.1BASIC QUALITY OBJECTIVES21 6.2SPECIFICATION CONTROL21 6.3INTERFACE CONTROL21 6.4ENGINEERING CHANGE CONTROLS22 6.5DESIGN REVIEW22 6.6RELIABILITY, OPERABILITY, MAINTAINABILITY (ROM) ENGINEERING.23 6.7DESIGN CONTRACTOR APPRAISAL AND EVALUATI
23、ON.23 6.8SOFTWARE 24 6.9WEIGHT CONTROL.24 7.PROCUREMENT QUALITY ASSURANCE25 7.1SUPPLIER AND CONTRACTOR APPRAISAL.25 7.2PROCUREMENT CONTROL25 7.3QUALITY CONTROL (QC)25 7.4MATERIALS CONTROL (PROCUREMENT)26 7.5APPRAISAL AND USE OF INSPECTION CONTRACTORS26 8.CONSTRUCTION AND COMMISSIONING QUALITY ASSURA
24、NCE.27 8.1(PRE-)FABRICATION/CONSTRUCTION CONTROL27 8.2CONSTRUCTION MATERIAL CONTROL28 8.3INSPECTION CONTRACTOR APPRAISAL.28 8.4COMMISSIONING CONTROL28 8.5HANDOVER CONTROL29 9.REFERENCES30 10.BIBLIOGRAPHY.30 DEP 82.00.10.10-Gen. December 1995 Page 3 APPENDICES APPENDIX APROJECT QUALITY PLANS.31 APPEN
25、DIX BPROCEDURES AND WORK INSTRUCTIONS.38 APPENDIX CTYPICAL QUALITY-RELATED ACTIVITIES.40 APPENDIX DDESIGN CONTRACTOR QUALITY PLAN41 APPENDIX EPROCUREMENT QUALITY PLANS42 APPENDIX FCONSTRUCTION AND COMMISSIONING QUALITY PLAN43 DEP 82.00.10.10-Gen. December 1995 Page 4 1.INTRODUCTION 1.1SCOPE This new
26、 DEP provides guidance on the implementation of Quality Assurance on a project. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined to companies forming part of the Royal Dutch/Shell Group or managed by a
27、Group company, and to Contractors and Manufacturers/Suppliers nominated by them (i.e. the distribution code in “F“ as described in DEP 00.00.05.05-Gen.). This DEP is intended for use by Group companies undertaking engineering projects. Refinery projects involving the MF Function will be guided prima
28、rily by MF 94-0135. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as reg
29、ards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the A
30、uthorities concerned with the object of obtaining agreement to follow this DEP as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or
31、operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and
32、 ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal. NOTE:Where in this DEP the words “Opco“, “SIOP/SIEP“ or “client“ are used,
33、these will have the same meaning as “Principal“. The word shall indicates a requirement. The word should indicates a recommendation. 1.3.2Specific definitions The following definitions are from ISO 8402 or the Group publication “Quality - Improving our Business“. Asset Holder - The position which is
34、 accorded single point accountability by the Company chief executive for all aspects of the management, including budgetary control, of a clearly defined asset or group of assets, over part or all of its lifecycle in order to achieve corporate objectives. Customer - Recipient of a product provided b
35、y the Supplier (ISO 8402). The product may be a piece of hardware or a service. Quality - Meeting agreed customer requirements. Quality Assurance - All the planned and systematic activities implemented within the quality system, and demonstrated as needed, to provide adequate confidence that an enti
36、ty will fulfil requirements for quality. (ISO 8402) DEP 82.00.10.10-Gen. December 1995 Page 5 Quality Control - Operationaltechniquesandactivitiesthatareusedtofulfilthe requirements for quality. (ISO 8402) Quality Improvement - Actionstakenthroughouttheorganisation,toincreasethe effectiveness and ef
37、ficiency of activities and processes to provide added benefits to both the organisation and its customers. (ISO 8402) Quality Management - All activities of the overall management function that determine the quality policy, objectives and responsibilities, and implement them by means such as quality
38、 planning, quality control, quality assurance and quality improvement within the quality system. (ISO 8402) Quality Planning - Determining and defining the customers needs, and framing the objectives, standards and controls to meet them. Quality Plan - A document setting out the specific quality pra
39、ctices, resources and sequence of activities relevant to a particular product, service, contract or project. (ISO 8402). The plan for the project as a whole should be termed the Project Quality Plan; plans prepared by Contractors or Suppliers may then be termed Contractor or Supplier Quality Plans (
40、4.2). Quality System - Organisational structure, procedures, processes and resources needed to meet the quality objectives. (ISO 8402) Standard - A document providing rules, guidelines or characteristics for activities or their results, aimed at the achievement of the optimum degree of order in a gi
41、ven context. Other Quality terms are defined in ISO 8402. 1.4ABBREVIATIONS HSE-Health, Safety and Environment (including Welfare) QA-Quality Assurance QC-Quality Control ROM Engineering-Reliability,Operability and MaintainabilityEngineering 1.5CROSS-REFERENCES Where cross-references to other parts o
42、f this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (9). DEP 82.00.10.10-Gen. December 1995 Page 6 2.THE ROLE OF QUALITY ASSURANCE 2.1THE NEED FOR QUALITY ASSURANCE Quality is meeting agreed customer requirements, and quality
43、management aims to do this at the lowest overall cost. For an engineering project, the ultimate customer is the Asset Holder, but there are also internal customers; for example the fabricator is a customer of the designer. Management systems should be used to assure technical integrity, since qualit
44、y failures result in cost and schedule over-runs and lead to higher operating costs and safety or environmental risks over the whole of the lifecycle. Operational quality failures are equally serious in cost and risk terms, and the QA approach forms the basis for sound HSE and general operations man
45、agement. In addition, there is an increasing need to make management of the business transparent to regulators and to others. This DEP provides guidance to all staff who are setting up project management systems, or have to evaluate a Contractors or Suppliers system. The principles described herein
46、apply to the management of any aspect of a project, for example safety, environment, organisation, information, cost/budget and schedule. 2.2LINK WITH QUALITY MANAGEMENT Quality Management embodies three interlinked elements: Quality Planning, Quality Control and Quality Improvement. The overall aim
47、 for a company is to achieve continuous performance improvement through the management of the underlying business processes, as described in EP 92-0945. From the perspective of an individual project, however, the emphasis will be upon Quality Assurance (QA), which is the combination of Quality Plann
48、ing and Quality Control. Although most lessons learned during project execution will be fed back into the organisation, leading to improvement in subsequent projects, some may be incorporated into the project itself. 2.3THE ISO 9000 STANDARDS The ISO 9000 Standards for QA have wide applicability, bu
49、t are written in a general way, identifying some 20 elements which make up a complete system for a company. They are summarised in Figure 1. DEP 82.00.10.10-Gen. December 1995 Page 7 FIGURE 1ELEMENTS OF THE ISO 9000 STANDARDS ISO 9004 provides guidance on the implementation of a quality management system. ISO 9001 defines requirements for assurance throughout design, manufacture, installation and servicing. ISO 9002 deals with manufacturing and installation and ISO 9003 covers simpler items in which quality can be verified by final inspection and test only. DEP 82.00.10.10-Gen. Decem
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