Morpol Engineering Services Limited

QA/QC MANUAL

Approved by: ……………………………………………. Date:… ……………………………

Manager, Quality Assurance

CONTROLLED COPY No.: QA/QC 001/17

 Morpol Engineering Services Limited

Table of Contents

Section Title

1.0 Quality Policy

2.0 Organisation
3.0 Management Review
4.0 Quality System Documentation
5.0 Quality Planning
6.0 Contract Review
7.0 Document and Data Control
8.0 Purchasing
9.0 Customer Supplied Product
10.0 Product Identification and Traceability
11.0 Process Control
12.0 Inspection and Testing
13.0 Control of Inspection Measuring and Test Equipment
14.0 Inspection and Test Status
15.0 Control of Non-Conforming Material
16.0 Corrective and Preventive Action
17.0 Handling, Storage, Packaging, Preservation and Delivery
18.0 Quality Records
19.0 Internal Quality Audits
20.0 Training
21.0 Servicing

2 of 12
Quality Manual
 Morpol Engineering Services Limited
1.0 Quality Policy

We at MORPOL Engineering Services Limited are committed to providing quality Engineering,

Procurement & Construction (EPC) services, that meet our clients’ specification in the Oil and Gas,
Water, Process and Power Industries with a view to ensuring continuous and steady return on
investments to all its stakeholders and to be ranked among the Leading companies in Nigeria
providing EPC services to the industries we operate.
We establish measurable objectives at corporate, projects and departmental levels and review them
as the need arises, especially where our core processes change.

We are also committed to satisfying applicable requirements.

We are committed to continually improving the effectiveness of our Quality Management System
(QMS) including meeting statutory and regulatory requirements.

2.0 Organization

The Chief Executive Officer / Managing Director of MORPOL Engineering Services has
appointed a team of Senior Managers who are responsible for determining Quality Policy
and ensuring that adequate arrangements are made and resources available for its
implementation and achievement.

Our Executive Director Operations is appointed by the Management and has defined
authority for:

Ensuring that a quality system is established, implemented and maintained in

accordance with ISO 9001:2015.

Reporting on the performance of the quality system to the Senior Management

team for review and as a basis for improvement of the quality system.

3.0 Management Review

The Senior Management Team will conduct an annual review of the quality system to
ensure its continuing suitability and effectiveness in satisfying the requirement of ISO
9001:2015 and the objectives stated in the Quality Policy Statement.

The Quality System Reviews are directed towards:

i. Ensuring documented policies and procedures reflect the working methods and
business objectives of the organization.

ii. Revealing shortcomings within the system and initiating improvements.

iii. Confirming effective deployment of resources and identifying training needs.

3 of 12
Quality Manual
 Morpol Engineering Services Limited

iv. Ensuring that corrective/preventive action procedures are effective within each
department, review meetings are held at pre-defined intervals to consider quality
records relating to the departments and to initiate and monitor corrective and
preventive actions

Review meetings shall be documented and conducted against an established

agenda. If actions are designated by the review, these shall also be documented and
followed through to completion.

4.0 Quality System Documentation

The Quality System at MORPOL Engineering Services has been established to

effectively and economically control the quality of products and services and to ensure
that all deliverables comply with customer requirements, specifications and appropriate
standards as applicable.

The documentation of the system is split into two sections

namely:

i. Quality Policy Manual

The Quality Policy Manual includes a statement of policy and brief details of the
company's quality system and how it relates to the requirements of ISO 9001:
2015.

ii. The Procedures

The Procedures which are documented in departmental Manuals contains

those documents, which detail the procedures, controls and disciplines, which
are operative throughout the company and describe the way its business is
conducted.

5.0 Quality Planning

The documented Quality System is regarded as forming the Company’s normal Quality
Plan. The following activities have been taken into consideration where deemed
appropriate.

i. The preparation of quality plans.

ii. The identification and acquisition of any controls, processes, equipment, fixtures,
resources and skills that may be needed to achieve the required quality.
iii. Ensuring the compatibility of the design, the production process, installation,
servicing, inspection and test procedures and the applicable documentation.

4 of 12
Quality Manual
 Morpol Engineering Services Limited

iv. The updating, as necessary, of quality control, inspection and testing techniques
including the development of new instrumentation.

v. The identification of any measurement required involving capability that exceeds the
known state of the art, in sufficient time for the needed capability to be developed

vi. The identification of suitable verification of appropriate stages in the realization of

product.

vii. The clarification of standards of acceptability for all features and requirements,
including those, which contain subjective elements.

viii. The identification and preparation of quality records.

6.0 Contract Review

Before submission of a tender, or acceptance of a contract or order, a review of the

customer’s requirements shall take place by authorized personnel, to ensure that the
requirements are adequately defined and that the resources are available to fulfill the
customer’s expectations. Some features of an order may need to be referred to
specialists, and include technical, quality and/or legal and commercial requirements.

Where there are differences between the tender and confirmation details then these
differences shall be resolved before a contract is entered into.

Any amendment to an order is subject to the same disciplines as outlined above.

Records confirming that a review has been satisfactorily completed will be retained.

7.0 Documents and Data Control

Documented procedures are established and maintained to control all documents and data
including procedures, standards, drawings and electronically stored data where
appropriate.

Issues of documents and data are made available in all areas where operations essential to
the effective functioning of the quality system are performed.

All documents and data are reviewed and approved for adequacy by authorized personnel
prior to issue. Changes to documents and data are reviewed and approved by the same
functions/organizations that performed the original review and approval.

Master Lists, identifying the current revision status are maintained and readily available to
prevent the use of invalid or obsolete documents.

5 of 12
Quality Manual
 Morpol Engineering Services Limited

8.0 Purchasing

In any business operation, it is essential that the quality of materials/services acquired

meet the specified requirements. In order to ensure this happens, purchase orders in
respect of product related items or services are placed only on those suppliers/sub-
contractors who can demonstrate an effective quality system, or who are capable of
satisfying all contract requirement
Only those suppliers/sub-contractors whose names appear on the Approved Supplier List,
maintained by the Company shall be used except in such situations where prevailing
realities or circumstances of the job dictate otherwise.

All purchase orders shall adequately define the article or service to be purchased and
contain sufficient detail, and supporting documentation, e.g. drawings or specifications, to
ensure all contractual requirements can be met.

All suppliers/sub-contractors non-conformance will be documented and monitored and

the data shall provide the basis for assessment of the capability and performance of
suppliers/sub-contractors. All non-conformances will be reported to the suppliers/sub-
contractor in writing.

MORPOL Engineering Services reserves the right to visit its suppliers/sub-contractors

for the purpose of product verification. Such visits do not relieve the supplier/sub-
contractor of their responsibility to provide acceptable product or service.

9.0 Customer Supplied Product

Customer supplied items for incorporation into products are subjected to the same
procedures and disciplines for control, protection and storage as for other materials.

10.0 Product Identification and Traceability

There is a requirement for product to be identified by suitable means by receipt, and

during all stages of production through to delivery to the customer. The methods of
product identification vary between the different products and the means of identification
are clearly defined within the relevant Departmental Procedures.

When required, traceability is provided by unique individual serial number or heat

number or foundry code, either stamped into the casting or firmly attached by stainless
steel tag.

Product certification, certificate of conformity o r f o u n d ry c e r t i f i c a t e etc. are

retained in the order file for a determined period (in line with Morpol’s document retention
policy) and cross referenced by serial number.

6 of 12
Quality Manual
 Morpol Engineering Services Limited

11.0 Process Control

MORPOL Engineering Services has established procedures to ensure that manufacturing

and amendment operations are carried out under controlled conditions.

The Engineering Department receives from the client specifications of the product,
suitable assembly equipment, specific inspection requirements and documented test
procedures. To ensure that these specifications are closely followed, the department
has a coherent package of controls. Those practices and procedures, which have an
impact on quality and are implemented by departmental personnel, have been
documented in the form of assembly instructions.

Process equipment employed during operations, which have a significant impact on the
achievement of product quality, are subject to planned maintenance to ensure continuing
process capability.

Records of final tests are retained by the quality department and reviewed as part of the
departmental management review process.
12.0 Inspection and Testing

To ensure that products offered by MORPOL Engineering Services are fit for purpose,
various inspection/verification and/or testing activities are undertaken prior to dispatch.

Receiving Inspection

All incoming product items shall be inspected or otherwise verified to ensure

conformance to purchase order requirements.

In-Process Inspection

Inspection during project duration is a continuous process and is undertaken by suitably

trained personnel.

Final Inspection

All deliverables are subject to a final test by suitably trained personnel. Final product
audits may be performed by the Quality Assurance Manager, Engineering Manager,
Project Engineer or the Client.

The results of such inspections shall be signified on the appropriate project

documentation and shall identify the inspection authority responsible for the final work
certification.

7 of 12
Quality Manual
 Morpol Engineering Services Limited

13.0 Control of Inspection Measuring and Test Equipment

For any measurement to be meaningful, there must be a degree of confidence that the
equipment used for measurement is accurate. To fulfill this requirement MORPOL
Engineering Services has established a control system for calibrating all inspection,
measuring and test equipment.

All equipment subject to on-site calibration is allocated a unique record sheet on which
shall be recorded details of all calibration results, frequency of checks, check method and
acceptance criteria.
All on-site calibrations are carried out against documented procedures.

The actions to be taken when results are unsatisfactory are defined within the
documented procedures.

All measuring equipment used for on-site calibration purposes shall be traceable to
national standards, but it is not considered necessary for any special environmental
conditions to be used.

Off site calibrations shall be carried out by nationally accredited test organizations.

14.0 Inspection and Test Status

The inspection and test status shall be apparent on all deliverables throughout the work
process to indicate the conformance or non-conformance of the product or plant
equipment with regard to inspections and tests performed to ensure that only a product,
service or work item that has passed the required inspections and tests is dispatched.

The method of identifying the inspection and test status of deliverables will vary
according to the project but will be defined within the Departmental Procedures. These
procedures will also define who has responsibility for final work certification to the
customer.

Any finished component/product, which cannot demonstrate its known inspection status,
shall be considered unfit for purpose and returned to ensure it is appropriately
reworked or returned to the original supplier for replacement before re-inspection and
certification.

15.0 Control of Non-Conforming Material

Where product items do not conform to specified requirements, it is important to identify

and segregate those items from those whose quality is assured. The method of

identifying non-conforming items depends on the nature of the product. The method will be
defined within the Departmental Procedures.

8 of 12
Quality Manual
 Morpol Engineering Services Limited

The non-conforming items shall be held until the disposition is defined.

Non-conforming items shall be reviewed in accordance with documented procedures but
will be either:

i. Reworked t o meet specification requirement. if rectification is possible,

supervisor or the Project Engineer will sanction it. After work has been carried out
to rectify the fault, the items will be submitted for a second assessment.

ii. If concession action is possible, it will be authorized by the Project Engineer or

Client and carried out in accordance with documented procedures.

iii. If the non-conformance is of a level, which renders the items to scrap, they will
be identified as such and be disposed of.

Non-conformance investigations will be recorded.

Non-conforming items returned from customers shall be fully investigated and the results
documented.

16.0 Corrective and Preventive Action

Documented Procedures exist for establishing the causes of actual or potential non-
conformities in the Product, Process and Quality System.

The degree of corrective or preventive action will be dependent on, and directly related to
the risk, size and nature of the problems, and direct effect on product quality.

Typically, some non-conformity will be of a minor nature and corrective actions will be
taken on an informal basis and formal documentation of the actions taken is
inappropriate.

Where the non-conformities are of a more serious nature, then a formal system of
recording the result of the investigation into the cause of the non-conformity and the
corrective action taken to eliminate the cause of the non-conformity is instituted.

Corrective actions may be instituted in the following cases:

i. An in-house conformity relating to product, process and quality system.

ii. A rejection from a customer.

iii. A non-compliance identified during an internal or external audit.

Records relating to the performance of the product are analyzed regularly, normally at the
Departmental Quality Review Meeting, to detect any trends and to identify areas of risk
that may lead to potential non-conformities.

9 of 12
Quality Manual
 Morpol Engineering Services Limited

Records reviewed will include:

i. Customer complaints.
ii. Test and inspection results.
iii. Audit results.
iv. Quality records.

v. Concessions.

vi. Supplier performance.

Corrective and Preventative Actions shall be reviewed as to their effectiveness by the

Quality Department.

17.0 Handling, Storage, Packaging, Preservation and Delivery

17.1 Handling

Suitable transport and lifting equipment is provided where required to prevent

damage and deterioration to products at all stages of the process from receiving to
delivery.

17.2 Storage

Storage facilities exist to ensure that the condition of any item is not subject to
unnecessary damage and/or deterioration. The nature of the storage facility is
determined by the requirements of the individual items to be stored.

Stored materials is subjected to periodic inspection to verify that no deterioration

has taken place with particular attention being given to any item identified as
having a limited shelf life.

17.3 Packaging

Packaging will be in accordance with appropriate standards or engineering

standards unless otherwise specified by the customer.

17.4 Preservation

All products are given adequate protection from receipt through to delivery. This
includes steps to prevent rusting. In addition, measures are taken to prevent
ingress of foreign bodies and protect exposed features as appropriate.

17.5 Delivery
Delivery shall be by means of approved carriers. Where special instructions are
required to preserve product quality these shall be included with the delivery
documentation.
10 of 12
Quality Manual
 Morpol Engineering Services Limited

18.0 Quality Records

Records are the objective evidence of the operation of a good quality system at all stages
and will be retained to prove the effectiveness of the implemented system.

All records designated for storage shall be identified within the departmental procedures.

Quality records will be maintained in a media, which allows them to be:

i. Protected from damage, loss and deterioration due to environmental conditions.

ii. Indexed and readily retrievable.

iii. Clearly identified as to the product or service applicable.

Within MORPOL Engineering Services all essential records shall be retained for a
minimum of five years unless there are contractual agreements or legal requirements for
records to be retained longer.

19.0 Internal Quality Audits

To ensure continuing effectiveness of its quality system the company carries out periodic
audits of all parts of the system. Audits will be carried out against a published plan
generated by the Quality Assurance Manager and agreed at the Annual Management
Review. The Plan anticipates that all activities linked to quality will be audited at least
once a year.

The audits will be carried out by members of an audit team. Audits will only be carried
out by those personnel who have received appropriate training and are independent of the
activity being audited.

All audits will be documented including all observations and objective evidence seen.

Non-conformances found during audits will be subject to documented corrective action.

follow up audits shall be carried out to verify that the proposed corrective actions have
been implemented and are effective.

Completed audits shall form part of the Management Review.

20.0 Training

The availability of adequately trained and experienced employees at all levels is of

critical importance to the effective operation of the company.

Each Manager or Supervisor is directly responsible for the training and development of
all subordinates, and for implementing training policy within their own area of

11 of 12
Quality Manual
 Morpol Engineering Services Limited

responsibility.

Individual employees have a responsibility to do their best to develop their own ability
and experience and to take advantage of training facilities made available or offered.

The Manager specifically charged with training shall be responsible for compiling an
overall company training plan identifying training undertaken and forwarding needs.

Records of training shall be retained in an easily retrievable form so that records can be
updated and weaknesses in training can be readily identified.

21.0 Servicing

Product Servicing and Maintenance is a key aspect of our company strategy. Regular
Servicing and Maintenance aims to enhance the clients’ investment in our products and
helps to reduce the long term of cost of ownership.

Servicing and Maintenance operations will be identified and surveyed by MORPOL

Sales staff in the course of their duties while the actual service work will be undertaken
by the Engineering Division or by the client’s approved contractor.

12 of 12
Quality Manual