Tubli WPCC Upgrading of Secondary Treatment Using HYBACS at Tubli WPCC 035-Q-7003

In the interests of conservation, this document has been prepared for doubled-sided printing.

Bluewater Bio 105 Wigmore Street London W1U 1QY Tel +44 (0)207 518 1726 Fax +44 (0)207 493 0071

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Project Quality Plan 035-Q-7003

This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project or purpose without obtaining prior written approval from Bluewater Bio Ltd. Bluewater Bio Ltd accepts no responsibility or liability for the consequences arising should this document be used for a purpose other than the purposes for which it was commissioned and intended. Any person using or relying on the document for such other purpose agrees and will by such use or reliance be taken to confirm his agreement to indemnify Bluewater Bio Ltd. for all loss or damage resulting therefrom. Bluewater Bio accepts no responsibility or liability for this document to any party other than the person for whom it was commissioned or intended.

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List of Contents
Sections and Appendices 1 Preface 1.1 Puprose of the Outline Project Quality Plan 1.2 Amendment Record 1.3 Distribution Record 2 Introduction 2.1 General 2.2 Reference Documentation 2.3 Contacts 2.4 Scope of Works Summary 3 Project Specific Requirements 3.1 Management Responsibility 3.1.1 Project Review 3.1.2 Design Reviews 3.1.3 Project Quality Plan Review 3.2 Contract Review 3.3 Design Control 3.4 Design Programme 3.5 Design Approval 3.6 Design Reviews 3.7 Design Variations 3.8 Document and Data Control 3.9 Selection & Control of Sub-Contractors 3.10 Product Identification and Traceability 3.11 Inspection and Testing 3.12 Inspection, Measuring and Test Equipment 3.13 Inspection and Test Status 3.14 Control of Non-conformances 3.15 Corrective and Preventative Action 3.16 Handling, Storage, Packaging, Preservation and Delivery 3.17 Quality Records iii
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1 1 1 1 2 2 2 3 3 4 4 4 5 5 5 5 6 6 6 7 7 7 7 8 8 8 8 9 9 9

3.18 Quality Audits 3.19 Training 3.20 Statistical Techniques 4 Project Organisational Structure 5 Project Reporting Appendix A Project Organisational Structure Appendix B Project Status Report Form Appendix C Report Data Input Table Do Not Delete from Electronic Document Tables No numbered tables Figures No numbered tables

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1.1

Preface
Puprose of the Outline Project Quality Plan

The purpose of this Project Quality Plan is to describe how the Bluewater Bio Quality Management System (QMS), will be applied to Upgrading of Secondary Treatment Using HYBACS at Tubli WPCC project. This is a key document within the QMS and identifies the particular responsibilities, procedures, method statements, inspection and testing requirements and records required to meet the project specification. 1.2 Amendment Record

Amendments made to this Plan are to be recorded below. Holders of controlled copies of this plan and those who may be affected by any changes must be informed of the revision update. Issue No
1 2 3

Date
31-10-2011

Amendment Authorised By
Matt Rolls

Pages Amended
n/a

Description
Contract Issue For Information

1.3

Distribution Record

Distribution of controlled copies of this plan is to be recorded below. Date 12-05-2010 31-10-2011 Distribution Authorised By Adrian Harris Matt Rolls Issue No. Distributed A 1 Distribution details (who,company,client.etc) Pre-Contract Issue to MoW For Information Contract Issue to MoW For Information

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2.1

Introduction
General

This Project Quality Plan, for the Upgrading of Secondary Treatment Using HYBACS at Tubli WPCC project has been produced in accordance with the requirements of the Bluewater Bio Quality Management System (QMS). 2.2 Reference Documentation

The Following documentation is to be read in conjunction with this outline Project Quality Plan: Project Execution Plan This plan is produced by Bluewater Bio, is the lead plan, and will detail the overall management of the project, interfaces with other plans, (commissioning, environmental, health & safety & sub-contractor supplied plans, etc.), and quality issues associated with the construction of the contract. Sections of this document are meant for Bluewater Bio internal use only and these will be omitted from any issue to external sources. Construction Health & Safety Plan This plan is produced by Bluewater Bio and deals with the health and safety issues and site management details associated with the contract. This plan is monitored and updated in accordance with developments of the project.

Following entrance into the contract execution phase of the project, the following documentation will be produced: Project Environmental Plan This plan is produced by Bluewater Bio during the detailed design phase, will be the lead environmental plan, and deals with all significant environmental issues of the contract during the construction phase. Site Waste Management Plan This plan is produced by Bluewater Bio during the detailed design stage and will be developed as the contract progresses Commissioning Plan This plan is produced by Bluewater Bio and deals with the commissioning strategy for the HYBACS plant.

Although produced as individual plans, with them all interlinked with each other, they are issued as separate documents to concentrate on their specific subject and to ensure that all contract requirements and key activities are covered. All plans will include, where relevant, organisation charts, roles and responsibilities, references to standard procedures and process, and any project specific procedures or processes. Documentation

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produced in accordance with these plans will not normally become part of the plans, but will be referenced within the appropriate plan and stored separately. 2.3 Contacts Client Details Name Address Telephone Contact Name Position Name Address Telephone Contact Name Position Contractor Name Address Telephone Contact Name Position Site Manager Name Address Telephone Project Manager Position 2.4 Terence Hedley Project Manager Matt Rolls Senior Project Manager Richard Jones Bluewater Bio 105 Wigmore Street, London, W1U 1QY Bluewater Bio Zero Waste W.L.L. P.O. Box 3010, Manama, Kingdom of Bahrain Kay Uwe Bohlen Project Manager Ayman Shawkat Ahmed Tuffaha SEPPD Project Manager P2M Berlin P.O. Box 37316, Um Al Hassam, Manama, Kingdom of Bahrain Bahrain Ministry of Works P.O. Box 5, Manama, Kingdom of Bahrain

Client Representative

Lead Civil / Mechanical / Electrical Designer Details

Scope of Works Summary

The works involves of the design, construction, supply and install, testing and commissioning of the following, including all electromechanical equipment:
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New feed chamber and interception of existing flow at outlet of preliminary treatment plant

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New Grit Removal Plant New SMART Feed Pump Station New SMART Plant Modification to existing aeration tanks 9 and 10 into HYBACS configuration New FBDA system for aeration tanks 9 and 10 New Internal Recycle Pump Station within aeration tanks 9 and 10 New feed and distribution chamber for clarifiers 9 12 Modification to existing clarifier de-sludge pipework system New External Recycle & Surplus Sludge Pump Station New control panels for HYBACS plant, incl. GRP kiosk and associated services All associated mechanical works for HYBACS plant upgrade (pipework, supports, etc.) All associated electrical works for HYBACS plant upgrade (cabling, control system, etc.) All associated civil works for HYBACS plant upgrade (structures, access steelwork, etc.) 1 Years Operation & Maintenance of HYBACS plant from Take-Over

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3.1

Project Specific Requirements

Management Responsibility

Bluewater Bio will maintain an Authorised Signatory List on site. This will list the people together with a specimen signature/set of initials that can authorise various documents throughout the duration of the project. 3.1.1 Project Review

The project will be reviewed during two sets of regular meetings as detailed within the Project Execution Plan and listed below: Weekly Site Meetings: To be held on site and include the Contractors site manager, Client Representatives Site Engineer and representatives of the Clients on-site team. Additional attendees shall attend as required, these would include designers, project managers and representatives of sub-contractors.

Monthly Progress Meetings: To be held at a location requested by the Client and will be attended by the Clients project manager, Client Representative Project Manager and Contractors Project Manager as a minimum. Prior to the monthly Progress Meeting, the Bluewater Bios Project Manager will review the progress of the project. This review may include, but not be limited to; programme and progress; design issues; construction, safety, environmental and quality issues; outstanding queries; variations and their resultant effects; sub-contractor and supplier procurement; and complaints from the public or stakeholders.
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All relevant points from this review will be included within Bluewater Bios Monthly Status Report. Where this review identifies issues of significant importance that requires action by Bluewater Bio or another party, details of these issues will be given, together with any proposals to rectify the situation. This will include any issue where work has been identified as being non-compliant with the requirements of the contract. Agreement to any rectification methods or corrective action will be recorded in the minutes of the meeting. 3.1.2 Design Reviews

Undertaken at regular intervals by Bluewater Bio, these meetings will review the design process, the design output, design approval and co-ordination, and any other design related issues. The results of these meetings will be recorded with agreed actions noted. All design matters will be recorded and included on the relevant detailed design documentation and will be submitted to the Client Representative for Client approval in accordance with the project programme. Where the design issues have significant effect, or require input from a wider panel of personnel, these will be recorded in our weekly report and discussed at the Progress Meeting. 3.1.3 Project Quality Plan Review

Formal reviews are undertaken quarterly, but this document remains live throughout the project to reflect current status at all times during the project life cycle. Where significant changes have occurred prior to the quarterly review, the plan will be revised and re-issued. Where applicable, these changes shall be subject to the approval of the Client / Client Representative. 3.2 Contract Review

Following the receipt of first draft project specific contract documentation from the Client, the project team will meet to review the requirements of this documentation. The review meeting will be attended by key personnel associated with this project, and will discuss the Contract requirements, design, safety, environmental and quality requirements, and the method and programme of construction. Where applicable, Bluewater Bio will revert to the Client with comments, amendments and qualifications on the draft contract documentation with a view to finalising the content of the final contract. Upon finalisation of the contract documentation, Bluewater Bio will proceed with final subcontractor negotiations. 3.3 Design Control

Where Bluewater Bio, or their sub-contractors, is responsible for design, the design process will be managed as detailed below:

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Work Scope - check that the scope of works to be designed is fully defined and understood and any discrepancies brought to Clients attention. Specifications and Standards - check that the specifications and standards listed as applicable within the contract agreement and that the works are to be designed to are fully defined, applicable and available. Receipt of Information - check that the receipt of information (drawings, specifications) is complete and correct and can allow the full scope of the works to be progressed. Design Philosophy - check for any design philosophy requirements or any specific restrictive regulation or obligation. Design Team Organisation - identify from the above the design activities required and assign appropriate qualified staff. Check all design information has been issued to sub-contractors and has been understood Attend design meetings as required to liaise with Client / Client Representative. Ensure design has gone through the Bluewater Bio quality management system procedures prior to issue to Client and sub-contractors. Ensure that all design output is checked to ensure that it has been compiled in accordance with design input information and specified requirements. Design Programme

3.4

A design programmes is produced and is kept as a live document throughout the project life cycle. The design programme is incorporated into the overall project programme and this will be distributed to all required parties, including the Client / Client Representative with the Monthly Status Report. Ensure that all the design programmes are co-ordinated between each party and satisfy the Contract Programme requirements. Design Approval

3.5

Submit For Construction design documentation to Client Representative for approval Receive co-ordinated comments on submitted design data within 21 days Where applicable, forward co-ordinated comments onto relevant sub-contractors Where applicable, revise design in accordance with comments received from Client Representative Where applicable, re-submit For Construction design to Client Representative for approval Following approval of For Construction design, all future issues of design documentation to be issued as For Information until As Built phase. Design Reviews

3.6
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Design Input confirm receipt of information required, including approved copies of drawings from sub-contractors, and highlight any interface problems. Design Programme ensure design output complies with the agreed design programme requirements.

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 3.7

Design Output ensure it technically complies with specified requirements. Design Changes ensure all design changes have been properly incorporated and recorded. Design Review Meetings hold regular meetings with all designers. Design Co-ordination Meetings hold regular design co-ordination meetings with all parties. Design Variations

All variations will be managed in accordance with the requirements of the Clients Standard Contract Agreement and Conditions of Contract. 3.8 Document and Data Control

The approval, issue and change to the Project Quality Plan, and any standard proformas used on this project, will be in accordance the standard procedures contained in Bluewater Bios QMS. Method Statements, Risk Assessments and Inspection and Test Plans will be received by the Site Manager and the Project Manager and submitted for approval. Documentation produced to verify all detailed inspection and tests, together with their file location, will be noted on the relevant Inspection and Test Plan. The Project Manager, who maintains the document register and ensures that the latest revisions are issued to all relevant parties, will control the master set of drawings. Recipients of drawings are responsible for maintaining their own sets and for the removal of superseded copies. 3.9 Selection & Control of Sub-Contractors

All Sub-Contractors required to work on the Project will complete the Sub-Contractor Approval protocol in accordance with Bluewater Bio Quality Management System procedure and be entered onto preferred contractors database Prior to commencement of any works on site, contractors competence and training records will be reviewed. Risk assessments and method statements will be agreed and approved. 3.10 Product Identification and Traceability

All products delivered to site will be identified and traced using the product delivery ticket. These tickets will be traced back to the relevant orders and requisitions to ensure the correct products have been delivered. All correspondence and records associated with this project will be identified and traced by use of the Bluewater Bio contract number (035).

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3.11

Inspection and Testing

Inspection and Test Plans shall be produced that cover all relevant activities of the Works and will identify all pre-planned inspection and tests that have to be undertaken to verify conformance to the requirements of the specifications and contract documentation. Inspection and Test Plans will indicate each inspection stage, the relevant specification reference, the person responsible for the inspection or test, the frequency of the inspection or test, the verifying document produced, and file where the document is stored. Registers and copies of all current Inspection and Test Plans, Methods Statements and Risk Assessments will be maintained and kept up to date by the Site Manager. These documents will not form part of this plan, but will be stored in a designated location specified by the Site Manager. 3.12 Inspection, Measuring and Test Equipment

All equipment supplied for use by Bluewater Bio, or where applicable their nominated subcontractors, will be checked to ensure that it has a current calibration certificate traceable to National Standards, is fit for its intended purpose and that it is regularly checked for accuracy. An initial check will be made upon receipt and thereafter at the stipulated intervals detailed within standard procedures or work instructions. Any equipment that is found not to have a valid calibration certificate, is damaged, or outside the specified accuracy parameters, will be withdrawn from use, quarantined, and returned to the provider for re-calibration. All measuring, inspection and test equipment, when not is use, shall be stored in a secure manner and in accordance with the manufacturers recommendation, ideally in the provided box. Equipment that is provided and utilised by a sub-contractor for measuring, inspection or test purposes shall be checked by a Bluewater Bio person prior to its use on site. This check shall ensure that equipment has a valid calibration certificate, is fit for its proposed purpose, is undamaged and checked for accuracy on a regular basis. 3.13 Inspection and Test Status

The inspection and test status of the Works can be ascertained from the relevant inspection records, which will be retained and filed by the Site Manager, or his nominee. Inspection records may take the form of, but will not be limited to; Bluewater Bio Inspection Record Sheets; sub-contractors records and documentation; signed off schedules of work; or Certificates of Conformity / Compliance. 3.14 Control of Non-conformances

Where a product or material is found to be non-compliant upon delivery, the material or product shall not be accepted. The delivery ticket shall be marked as such and the goods returned to the Supplier. Where a product or material is found to be non-compliant after delivery has taken place, it shall be segregated and quarantined from conforming material to ensure that it is not incorporated into the
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works. Such material shall be clearly labelled. All non-conformances shall be recorded on a nonconfromance report and a non-conformance register shall be maintained. Where a product or material is found to be non-compliant after installation and during inspection, the Bluewater Bio inspection personnel will record the details on a Non-conformance Report, maintaining a Non-conformance Register, and seek the necessary corrective action from the relevant Supplier or sub-contractor. Upon rectification, the product or material will be re-inspected to close out the nonconformance. Where a concession is required, the Employers Project Managers consent / approval will be sought. 3.15 Corrective and Preventative Action

As noted above, non-conforming material or products will be recorded on a Non-conformance Report with the proposed corrective and preventative actions sought from the relevant Supplier or subcontractor. Where a concession is required, consent/approval will be sought from the Client Representative. Reviews of the Project Quality Plan will take due cognisance of any Bluewater Bio Non-conformance Reports and Corrective Action Requests that have been raised. During the weekly review, the Project Team will consider all non-conformances raised, and where relevant, will include a section in the weekly report noting the reasons for the defects and the proposed remedial measures being taken. 3.16 Handling, Storage, Packaging, Preservation and Delivery

All materials that Bluewater Bio and their nominated sub-contractors are directly responsible for will be stored in accordance with the manufacturers recommendations to prevent damage, loss and contamination. Where materials have a defined shelf life, the Site Manager will ensure that they are stored in a way to ensure that those with the shortest remaining shelf life are used first. All products will be handled on site in accordance with the manufacturers recommendations, and in accordance with local Health and Safety legislation, to ensure that the product is not damaged during handling, nor are site personnel put at risk. Where it is considered necessary, Bluewater Bio, or the relevant sub-contractor, will produce a risk assessment and method statement to cover the delivery, storage, handling and installation of specific products. Where the sub-contractor is responsible for the storage of materials, Bluewater Bio will make random inspections to ensure that the materials are being stored in the correct manner. 3.17 Quality Records

All quality records will be filed, indexed and stored in accordance with their relevant procedure.

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3.18

Quality Audits

Independent Auditors appointed by the Project Manager will carry out regular internal Q&E Site Inspections. Should these site inspections find major deficiencies or omissions then a full audit will then be undertaken. All site inspection & audit reports will be maintained on site, with the originals being filed & retained by the Project Manager. 3.19 Training

Project specific training, for example site inductions or toolbox talks, are to be identified and addressed by the Project Team upon commencement of the site activities. 3.20 Statistical Techniques

Statistical techniques will be used to monitor, review and interpret results for the following items, but not limited to; non conformance reports; corrective action requests; waivers, etc.

Project Organisational Structure

Please refer to Appendix A for a copy of the Project Organisational Structure.

Project Reporting

Daily Construction Logs will be completed by the Site Manager at the end of every working day and submitted to the Project Manager. The Project Manager will review and submit to the Client on a weekly basis. A monthly status report will be submitted to the Client in accordance with the Clients standard completion report system. A template of the Monthly Status Report can be found in Appendix B.

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Appendix A

Project Organisational Structure

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Appendix B

Project Status Report Form

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Appendix C

Report Data Input Table Do Not Delete from Electronic Document

Note: 1 To change a field in any particular row in the right-hand (5th) column, place the cursor in the same row in the 4th column headed X, right click and then left click on Update Field. The field must contain at least one character which must be a space if no entry is required. Item Main Title first line Main Title second line Main Title third line Left Hand Header upper line Location Pages i and ii Pages i and ii Bookmark name T1 T2 X1 Record of input
Tubli WPCC

Pages i and ii Left aligned in headers - upper line

T3 HL1

Left Head Header lower line Firms Name Client/Associate (where applicable) Project Number Report Number Revision Letter

Date of issue or report

Left aligned in headers lower line Right aligned in headers first line Right aligned in headers second line Footers Footers Issue and Revision Record on page ii and footers Page i, Issue and Revision Record on page ii and footers

HL2 HR1 HR2 PRJNR RPTNR REV

HYBACS Secondary Treatment Plant Upgrade Project Quality Plan Tubli WPCC HYBACS Secondary Treatment Plant Upgrade Project Quality Plan Bluewater Bio Zero Waste W.L.L. Bahrain Ministry of Works 035 /Q/7003 1

DATE

October 2011

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