HALFAYA PROJECT SURFACE FACILITY

PHASE FOUR
WATER INJECTION WELLS TIE-INS IN Y2021

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HFY-CON/F&C1116-1139/01

WATER INJECTION WELLS TIE-INS IN Y2021

CORRECTIVE ACTION PROCEDURE

By ayman.abdelghany at 7:47 am, Dec 03, 2022

ISSUED FOR
0 01/12/2022 Gu Yongqiang Ramesh Krishinan Chen Jianda Jiang Xingke
CONSTRUCTION

REV. DESCRIPTION DATE PREP’D CHK’D REV’D APP’D

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REVISION HISTORY

Rev. Date Description of Change

A 21.10.2022 ISSUED FOR APPROVAL

0 01.12.2022 ISSUED FOR CONSTRUCTION

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CONTENT

1 GENERAL .................................................................................................................................................................... 4
1.1 PURPOSE ....................................................................................................................................................................................4
1.2 SCOPE .........................................................................................................................................................................................4
2 REFERENCES ........................................................................................................................................................... 4
3 DEFINITIONS AND ABBREVIATIONS ............................................................................................................... 4
3.1 DEFINITIONS .............................................................................................................................................................................. 4
3.2 ABBREVIATIONS ........................................................................................................................................................................5
4 RESPONSIBILITIES .................................................................................................................................................. 5
4.1 QA/QC DEPARTMENT ............................................................................................................................................................5
4.2 PROCUREMENT MANAGEMENT DEPARTMENT ................................................................................................................ 6
4.3 CONSTRUCTION DEPARTMENT ............................................................................................................................................ 6
4.4 DESIGN MANAGEMENT DEPARTMENT ............................................................................................................................... 6
5 PROCEDURE .............................................................................................................................................................. 7
5.1 GENERAL ....................................................................................................................................................................................7
5.2 ASSIGNMENT OF CORRECTIVE TASK .................................................................................................................................8
5.3 CAUSE ANALYSIS .....................................................................................................................................................................8
5.4 TAKING CORRECTIVE ACTIONS ........................................................................................................................................... 9
5.5 SUPERVISION OF CORRECTIVE ACTIONS ......................................................................................................................... 9
5.6 VERIFICATION OF THE EFFECTIVENESS OF CORRECTIVE ACTIONS ........................................................................ 9
6 EXHIBITS ......................................................................................................................................................................9
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1 GENERAL

1.1 Purpose

Purpose of this procedure is to establish the process to identify, track, documenting the
non-conformance and correct the causes of existing non-conformances including
complaints in products, processes and QMS in XYNM scope for WATER INJECTION
WELLS TIE-INS IN Y2021 Project and its implementation process. This procedure also
addresses requirement for investigation into the root cause of nonconformity and
analyse trends, in order to implement the necessary corrective and preventive action to
prevent occurrence of non-conformity.

1.2 Scope

This procedure is applicable for reporting controlling and monitoring of all nonconforming
materials,design, procurement, construction, commissioning and maintenance activities
and flaws and areas of improvement of Quality management system for all areas under
XYNM scope for WATER INJECTION WELLS TIE-INS IN Y2021 Project

2 REFERENCES

This procedure complies with the following contract specifications and international code:

 ISO 9000 Quality Management Systems – Fundamentals and Vocabulary

 ISO 9001 Quality Management Systems – Requirements

 ISO 19011 Guidelines for Management System Auditing

 HFY4-5165-01-QC-PLN-0001 Project Quality Plan

 HFY-CON/F&C1116-1139/01, Sec 4 Scope Of Work (QA & QC)

 HFY-FC-PM-PD-0015 Non Conformance Report Issuance and Close-Out Procedure

 HFY-GEN-GEN-SPC-0001 Specification for Quality Assurance

3 Definitions and Abbreviations

3.1 Definitions

Non-conformity: The Non-fulfilment of specified requirements in any subject such

as fabrication, inspection, documentations, etc. Also referred to
as a non-conformance.

Correction: Action to eliminate a detected nonconformity.

Non-conformance: Item, product, material or process does not meet the specified
requirements.
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Corrective Actions: The action taken to eliminate the cause(s) of nonconformities.

Preventive Actions: The action taken to eliminate the cause of potential

nonconformities or other undesirable potential situations.

Corrective Action Request: A report to document non-conformance of process or

procedure, root cause, proposed correction and procedure,
root cause, proposed correction and corrective actions
and verification that the proposed actions have been
implemented satisfactorily.

Continual Improvement: An ongoing effort for identifying opportunities and

implementing changes to improve system,product, service
or process. The cycle of continual improvements is based
on the “Plan-Do-Check-Act” (PDCA)Possible measures
include but are not limited to: self-assessments, internal
audits, lesson learned.

3.2 Abbreviations

List of the used abbreviations and definitions is given below:

 COMPANY: PetroChina International Iraq FZE, Iraq Branch

 PMC: Petrofac

 XYNM: Jiangsu Xinyang New Material Co., Ltd

 QA QC: Quality Assurance & Quality Control

 ISO International Organization for Standardization

 QMS Quality Management System

 EMS Environment Management System

 CAR Corrective Action Request

 PAR Preventive Action Request

4 RESPONSIBILITIES

4.1 QA/QC Department

The QA/QC Department is responsible for :

 Management of Corrective Action Request (CAR) of project;

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 Organize investigations and analyses of non-conformance items;

 Supervising and checking the implementation of corrective action;

 Preventive recurrence of the non-conformance.

QA/QC Department can issue Corrective action for non-conformance observed within
their functional area/ department or nonconforming process or procedures of other
department/ functional area and subcontractor, which can be affected directly or
indirectly to their function/department. Corrective Action Request (CAR) prepared in the
prescribed format (see APPENDIX – A) shall be forward to QA/QC Department for
evaluation, verification and if reasonable to issue a corrective action number and forward
to the concerned functional area/department for further action.

In case of NCR issued from PMC/PMT, XYNM shall prepare a comprehensive Root
Cause Failure Analysis (RCFA) to be conducted as a result of such quality related
deficiencies. The CAR for NCR will be communicated to PMC/PMT for review and
approval.

QA/QC Department will maintain CAR Log (see APPENDIX – B) for the records of all
corrective actions issued with status of corrective action implementation and close-out.

4.2 Procurement Management Department

Procurement Management Department is responsible for:

 Root Cause Failure Analysis (RCFA) for purchased nonconforming products;

 Prepare and implement the corrective action;

 The allocation of personnel, and team development;

 Continual improvement.

4.3 Construction Department

Construction Department is responsible for:

 Root Cause Failure Analysis (RCFA) for nonconforming products of construction;

 Conduct all the subcontractors to prepare and implement the corrective action;

 Monitoring, witnessing and inspection the corrective action;

 Continual improvement.

4.4 Design Management Department

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Design Management Department is responsible for:

 Root Cause Failure Analysis (RCFA) for nonconforming products of Design;

 Conduct design subcontractors to prepare and carry out corrective actions;

 Monitoring, witnessing and inspection the corrective actions;

 Continual improvement.

5 PROCEDURE

5.1 General

Corrective actions shall be taken for the following cases:

 Client feedback;

 NCR raised by PMC;

 NCR raised by XYNM;

 Recurring nonconforming items discovered in internal and external Audit.

The following basic steps are recommended for implementing an effective corrective
and/or preventive action plan capable of satisfying quality assurance requirements.

 Identify: Identify the nonconformity or potential nonconformity

 Define the nonconformity. This should include the source of the information, a
detailed explanation of the nonconformance, and the available evidence that a
nonconformity exists.

 Investigate: investigation with assignment of responsibilities to the appropriate staff

involved. Investigate the problem to determine the root cause.

 Evaluate: Evaluate the magnitude of the nonconformity, potential impact and actual
risk to the evidence, testing process, the results, and/or the report. Evaluate to
determine the level of action required.

 Analyze: Analyze the root cause, and brainstorm as a team. Consider all possible
solutions and narrow down to the most appropriate solution(s) for each
nonconformity.

 Correct: Create an action plan listing all the actions that must be completed to
correct and/or prevent the nonconformity.

 Control: Follow up with verification effectiveness of the action plan and the
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completion of all tasks within the agreed time frame.

 Closure: The Quality Director will review, approve, and bring closure to all corrective
actions.

5.2 Assignment of Corrective Task

QA/QC Dept. shall directly assign corrective tasks to the departments of which the
unfavorable trend originates.

For problem on quality related to several departments, a quality analysis meeting on the
special subject shall be held by QA/QC Dept. and department managers concerned shall
be invited for the problem analysis. Records of the meeting shall be kept by QA/QC Dept.
Causes of the problems and a disposition shall be resolved by concerned departments.
Corrective actions shall formulated by department in charge.

5.3 Cause Analysis

A comprehensive Root Cause Failure Analysis (RCFA) to be conducted as a result of

such quality related deficiencies.

The result of such RCFA shall clearly mention the actual root cause background of this
violation, the proposed corrective action and preventive actions to ensure the elimination
of any potential re-occurrence.

The method of the required RCFA would be by means of :

A- Meeting/session to be conducted between Contractor, PMC & PMT decision makers

to discuss and agree of the root cause, corrective and prevention actions;

B- Re-evaluate the size of the Problem and decide if anything pending to be performed
before the close out of the session, OR Contractor to send an official letter describing all
the mentioned above.

According to responsibility, the related disciplines shall perform analyses and

investigations for the root causes of nonconforming items in the following respects: (Not
limited).

 Reliability of information and schedule requirement;

 Personnel’s skill, knowledge, and quality sense;

 Stability and adaptability of Equipment;

 Compliance of material or equipment supplied by vendor;

 The method or procedure used;

 Environment and surrounding where the work proceeds;

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 The measure/test equipments;

The related disciplines shall complete the CAR format relevant part.

5.4 Taking Corrective Actions

The related disciplines shall complete the CAR format relevant part, and the specific
contents of the corrective action shall include that as following at least.

 Corrective actions including rectification of non-conformity having occurred and

elimination of the cause.

 Implementation of plans for corrective action, including implementation, supervision

and control departments, personnel in charge of implementation of schedules, etc.

5.5 Supervision of Corrective Actions

For significant corrective actions, the QA/QC Manager shall convene a meeting for
progress inspection of the corrective actions for rectification and correction status reports,
given by department. Inter-departmental problems shall further be coordinated. The
QA/QC Dept. shall check corrective actions related to individual departments.

If the proposed resolutions are not acceptable the response will be rejected and returned
for further discussion between all parties prior to re-issue of the response. If accepted,
the response will be recorded in the “CAR Log” by the originator.

5.6 Verification of the Effectiveness of Corrective Actions

QA/QC Dept. shall verify the effectiveness of corrective actions and complete CAR
format relevant part. CAR should be distributed as necessary, original copy to QA/QC
department, copies to affected departments.

QA/QC Dept. shall maintain the Corrective Action Request Log. Maintenance of
corrective action documentation shall be according to the quality record control
procedures.

6 EXHIBITS

APPENDIX – A: Corrective Action Request (CAR Format)

APPENDIX – B: CAR Log

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APPENDIX – A Corrective Action Request (CAR Format)

CAR No :
Rev: A
CORRECTIVE ACTION REQUEST (CAR) Date:
Page: 1 of:
CAR Title:

CAR Issued to (recipient Dept./ Function): Receiver:

CAR initiated from (Audit/ Surveillance Ref No): Initiator:

Reference documents:
Nonconformity:
To be Filled by CAR Issuer

Issued By： Sign: Date:

Root Cause Analysis：

To be Filled by CAR Receiving Department

Responsible person： Sign： Date：

Proposed Corrective Actions:

Plan to Prevent Recurrence:

Planned Completion Date:

Responsible person： Sign： Date：
Corrective Actions Completed and verified: (Department / Function Received CAR )
Verification &
Close-out

Signature: Date:
Corrective Action Verified, accepted and CAR Closed Out: (CAR Issuer or QA/QC Department)

Signature: Date:
PMC-PMT

Corrective Action Verified, accepted and CAR Closed Out:

Signature: Date:
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APPENDIX – B CAR Log

PRID:5165-01 Project Name: WATER INJECTION WELLS TIE-INS IN Y2021

Updated date:
S.N. CAR No. NCR No. Subcontractor Issue Date Close Date Remark

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