Railway Line: Akko Carmiel Railway Line: Haifa Bet Shean Railway Line: Herzeliya Kefar Saba

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects REF: ISSUE: DATE: NI/QA/PLN...
Author: Myles Stokes
10 downloads 0 Views 3MB Size
NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Railway Line: Akko – Carmiel Railway Line: Haifa – Bet Shean Railway Line: Herzeliya – Kefar Saba Quality Assurance Plan NI Plan Number: NI/QA/PLN/001 Rev: P

Touchstone Renard Limited 123 Pall Mall, London SW1Y 5EA, United Kingdom Tel: +44 (0)207 101 0788

NI QA Plan Issue P

Page 1 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

ISSUE/REVISION SCHEDULE

Prepared By: Andy Josolyne Trevor Marshall

Principal Consultant Senior Consultant

…………………………………..

Date:

…………………………………… Checked by: Phil Austin

Touchstone Renard Ltd Director Date:

…………………………………… Approved on behalf of this project: Ilan Rozenfeld

NI Project Director Date:

…………………………………..

DATE

Issue

Revision

Comments

23/03/2012 10/04/2102 05/07/12 16/7/12 15/8/12

Draft Draft Draft Draft Draft

A B C D-J K

28/8/12 30/8/12 31/8/12 18/9/12 23/10/12

Draft Draft Draft Draft Draft

L L1 L2 M M

30/11/12 25/02/13

Revision Revision

N O

27/03/13

Revision

P

Issued for Internal Review and Comment. Review Comments added. Issued for Internal Review. TM&AJ Comments Internal AJ and TM reviews and developments TM updates after Skype call 13/8/12, incorporating PA comments and Ilan Rozenfeld’s comments. TM update to PA review comments. Footnotes updated TM & AJ updates TM update & inclusion of Technical Requirements TM document restructuring after Ilan Rozenfeld’s feedback TM & PA updates after Leonid Soskin and Ilan Rozenfeld’s comments, plus changes to clarify TAP, new NI logo and name. Extra changes made – document at first formal issue Minor changes made following WSP review and other reviewers comments – document at second formal issue Minor changes made to align with Contractor ITT documents.

This document is the property of NI. It shall not be reproduced in whole or in part, nor disclosed to a third party, without the written permission of NI. NI QA Plan Issue P

Page 2 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

CONTENTS 1.

ABBREVIATIONS AND TECHNICAL TERMS .............................................................................................................6

2.

INTRODUCTION ....................................................................................................................................................7

3.

THE PROJECT ........................................................................................................................................................9 3.1. 3.2. 3.3.

AKKO TO CARMIEL RAILWAY LINE ................................................................................................................................ 9 HAIFA TO BET SHEAN RAILWAY LINE .......................................................................................................................... 11 HERZELIYA TO KEFAR SABA RAILWAY LINE ................................................................................................................... 13

4.

APPLICABLE DOCUMENTS ................................................................................................................................... 14

5.

PARTIES INVOLVED IN THE PROJECT ................................................................................................................... 15

6.

PROJECT SCHEDULE, BUDGET AND MILESTONES ................................................................................................ 16 6.1. 6.2.

7.

SCHEDULE ............................................................................................................................................................ 16 BUDGET............................................................................................................................................................... 16

PROJECT ASSURANCE – QUALITY AND TECHNICAL.............................................................................................. 17 7.1. 7.2.

8.

GENERAL ............................................................................................................................................................. 17 TECHNICAL ASSURANCE PARTNERSHIP (TAP) .............................................................................................................. 17

PROJECT QUALITY ASSURANCE TEAM................................................................................................................. 19 8.1. 8.2. 8.3.

9.

STRUCTURE AND COMPOSITION ................................................................................................................................ 19 QA TEAM ROLES & RESPONSIBILITIES (DUTIES)........................................................................................................... 21 TOR QA TEAM AUTHORITY .................................................................................................................................... 22

QUALITY ASSURANCE - CONTRACTOR REQUIREMENTS ...................................................................................... 26 9.1. 9.2. 9.3. 9.4. 9.5. 9.6. 9.7. 9.8. 9.8.1. 9.8.2. 9.8.3. 9.8.4. 9.8.5. 9.8.6.

10.

REQUIREMENTS MANAGEMENT ............................................................................................................................... 26 COMPLIANCE WITH STANDARDS, NON-COMPLIANCES AND CONCESSIONS ........................................................................ 26 CHANGE CONTROL................................................................................................................................................. 26 PROJECT INFORMATION MODEL ............................................................................................................................... 26 ASSURANCE MANAGEMENT..................................................................................................................................... 27 REVIEW AND APPROVAL OF QA EVIDENCE ................................................................................................................. 27 CROSS-REFERENCES TO OTHER PROJECT PLANS ............................................................................................................ 28 CONTRACTOR QA PLAN AND GUIDELINES .................................................................................................................. 28 COMPETENCE OF CONTRACTOR QA/QC TEAM ....................................................................................................... 28 QUALITY CONTROL STAFF BRIEFING - COORDINATION MEETING EXPECTATIONS ............................................................... 30 SUBMISSION OF A QUALITY CONTROL PROGRAMME (QCP) ...................................................................................... 30 CERTIFICATION OF A QUALITY CONTROL PROGRAMME ............................................................................................. 31 PREPARING A CONTRACTOR’S QUALITY ASSURANCE PROGRAMME.............................................................................. 32 IMPLEMENTATION OF THE CONTRACTOR’S QUALITY ASSURANCE PLAN .......................................................................... 32

QUALITY ASSURANCE POLICIES & PROCEDURES ............................................................................................. 34

10.1. 10.2. 10.3. 10.4. 10.5. 10.6. 10.7. 10.8. 10.9. 10.10. 10.11.

QUALITY CONTROL ................................................................................................................................................ 34 QUALITY CONTROL REQUIREMENTS .......................................................................................................................... 34 QCP PREPARATION AND REVIEW ............................................................................................................................. 35 AUDIT FREQUENCY ................................................................................................................................................. 36 QA/QC MEETINGS ................................................................................................................................................ 36 CONSTRUCTION SITE VISITS ..................................................................................................................................... 36 EARLY CONTROL AND SAMPLE TESTING (CONTRACTOR) ................................................................................................ 37 EARLY CONTROL STAGE .......................................................................................................................................... 37 EXECUTION AND REPORTING OF SAMPLE TEST SECTIONS (CONTRACTOR) .......................................................................... 38 SAMPLE TEST, PRIOR APPROVAL AND EXECUTION OF THE TEST SECTION ........................................................................ 38 ROUTINE CONTROL PROCEDURE (CONTRACTOR) ..................................................................................................... 38

NI QA Plan Issue P

Page 3 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects 10.12. 10.13. 10.14. 10.15. 10.16. 10.17. 10.18. 11. 11.1. 11.2. 11.3. 11.4. 11.6. 12. 12.1. 12.2. 12.3. 12.4.

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

TEST STAGES AND BREAKPOINT TESTS .................................................................................................................... 39 TEST POINTS .................................................................................................................................................... 39 BREAKPOINTS ................................................................................................................................................... 39 REQUESTING SUPERVISION (QUALITY ASSURANCE AND TECHNICAL ASSURANCE) ........................................................... 42 DOCUMENTATION OF SUPERVISION REPORTS (CONTRACTOR)..................................................................................... 43 MANAGEMENT OF NON-CONFORMANCE REPORTS .................................................................................................. 44 CLASSIFICATION OF NON-CONFORMANCES BY DEGREES OF SEVERITY AND REPORTING ..................................................... 44

HANDOVER..................................................................................................................................................... 48 SCHEDULE ............................................................................................................................................................ 48 SUBSTRUCTURE TO SUPERSTRUCTURE ........................................................................................................................ 49 SUPERSTRUCTURE TO ISR ........................................................................................................................................ 51 HANDOVER & POST COMMISSIONING STRATEGY ......................................................................................................... 53 HANDOVER GENERAL ............................................................................................................................................. 56 PROJECT DOCUMENTATION ........................................................................................................................... 57 CURRENT REPORTING ............................................................................................................................................. 57 TESTS AND RESULTS ............................................................................................................................................... 57 QUALITY ASSURANCE AUDITS AND SURVEILLANCE ........................................................................................................ 57 DOCUMENT MANAGEMENT SYSTEM ......................................................................................................................... 57

13.

QUALITY ASSURANCE CHECKLISTS .................................................................................................................. 59

14.

ANNEX A - PROJECT DIRECTOR’S QUALITY STATEMENT .................................................................................. 60

15.

ANNEX B - PROJECT ORGANISATION CHART ................................................................................................... 61

16.

ANNEX C - EXAMPLE CHECKLISTS .................................................................................................................... 62

17.

ANNEX D - ISR ORGANISATION CHART ........................................................................................................... 77

FIGURES Figure 1: TOR ‘V’ Diagram for the NI Superstructure Project .............................................................................................. 8 Figure 2: Akko to Carmiel project area map ...................................................................................................................... 10 Figure 3: Haifa to Bet Shean project area map .................................................................................................................. 12 Figure 4: Herzeliya to Kfar Saba project area map (Red line = new tracks, Black line = Existing tracks) ........................... 13 Figure 5: Superstructure Project, Technical Assurance Partnership diagram .................................................................... 18 Figure 6: Structure of Superstructure Project Quality Assurance Team ............................................................................ 20 Figure 7: Contractor’s QCP and QAP approval chart.......................................................................................................... 32 Figure 8: NCR Report form ................................................................................................................................................. 47 Figure 9: Outline of Asset Transfer Plan timeframe ........................................................................................................... 56 Figure 10: Project Organisation Chart (Relationships) ....................................................................................................... 61 Figure 11: Quality Assurance Checklist .............................................................................................................................. 62 Figure 12: Signal or Sign Inspection form........................................................................................................................... 65 Figure 13: Trough Route Inspection Form ......................................................................................................................... 67 Figure 14: Electrification & Plant Design Approval form ................................................................................................... 69 Figure 15: Equipment Room/Unit Inspection form ........................................................................................................... 70 Figure 16: Example Checklists for breakpoints .................................................................................................................. 73 Figure 17: Example Checklists for Early Control................................................................................................................. 73 Figure 18: Example Checklists for Routine Control ............................................................................................................ 74 Figure 19: Example Checklists for QA/QC Surveillance ...................................................................................................... 75 Figure 20: Example Checklists for QC System test ............................................................................................................. 75 Figure 21: Example Checklists for QA System test ............................................................................................................. 76

NI QA Plan Issue P

Page 4 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

TABLES Table 1: Abbreviations and Technical terms ........................................................................................................................ 6 Table 2: Parties involved in the project ............................................................................................................................. 15 Table 3: Outline of rail engineering disciplines required by the Contractor ...................................................................... 24 Table 4: Cross Reference Plan Description ........................................................................................................................ 28 Table 5: Skill and Education Requirements of Contractor QA/QC team ............................................................................ 29 Table 6: Summary of checkpoints for Railway Infrastructure projects .............................................................................. 40 Table 7: Example of when QA Supervision may be implemented ..................................................................................... 43 Table 8: NCR Table ............................................................................................................................................................. 45

NI QA Plan Issue P

Page 5 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

1. ABBREVIATIONS AND TECHNICAL TERMS This section describes the abbreviations used in the QAP document and some of the associated technical terms. Table 1: Abbreviations and Technical terms

Term Asset

Contractor Critical DT EN FAT INECO ISR ITA NCR's NDT NI Nominated Contractors NSN PM QA QAC QAL QAM QAP QC QS ROL SAT S&C SCADA SIR SOAK test Substructure Superstructure TA TAE TAP TOR

NI QA Plan Issue P

Description For the purpose of this document the term ‘Asset’ means a group of railway system assets newly installed within a defined geographical area. These could be assets from a single discipline or a combination of disciplines. Term used for parties in direct contract with NI who are not Nominated Contractors. An item or process that has severe consequences if not used, installed or followed Destructive testing European Norm. Technical Standards commonly used within the European Union Factory Acceptance Testing Main Detailed design consultancy Israel Railways Independent Technical Assurance Non Conformance Reports Non-Destructive testing Netivei Israel - National Transport Infrastructure Company Contractors who were, or still are in direct contract, from the point of the appointment of the lead contractor and their reporting lines have changed over to the lead contractor, i.e. ELBIT, NSN, Motorola and Thales. Nokia Siemens Network Project Manager Quality Assurance Quality Assurance Coordinator Qualification Acceptance Log Quality Assurance Manager Quality Assurance Plan Quality Control Quality Surveyors Roads & Transportation (1986) Ltd Site Acceptance Test Switch and Crossing Supervisory Control and Data Acquisition Site Inspection Report Common term for the test period of signalling equipment before the commissioning period. The equipment is installed and run in a semi live mode for a period of approximately six weeks. Stage of the overall project that delivered the; ground clearance and formation construction. Also the construction of the Gilon Tunnel bores Stage of the overall project that will deliver the; track, signalling and supporting infrastructure to enable full operation for ISR. Technical Assurance Technical Assurance Engineer - by Engineering Discipline Technical Assurance Partnership Touchstone Renard Ltd

Page 6 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

2. INTRODUCTION This Quality Assurance Plan (QAP) details the Quality Assurance (QA) requirements for the Superstructure project that will produce three new operational railway lines; Akko to Carmiel, Haifa to Bet Shean and Herzeliya to Kefar Saba . The project is being managed and delivered by Netivei Israel (NI), the National Transport Infrastructure Company, who have been commissioned to do this work by the Israeli Government. On completion, the new railway lines will be handed over for operational use to Israel Railways (ISR). The three new railway projects include for the Design and Build of the Superstructure but this Project QA Plan does not address requirements for the Substructure which is by “others”. The appointed Preliminary Design and Detailed Design contractor design teams have completed the preliminary designs and detailed designs in compliance with the requirements of the NI tender documents and also in compliance with the scope and Terms and Conditions of the NI Contract Award to the designers. NI have assigned Touchstone Renard (TOR), a United Kingdom (UK) based company with extensive experience in Multi-Disciplinary Railway Infrastructure projects, to produce this QAP and to support QA throughout the lifecycle of this project. When the construction phase Contractors are awarded their particular project element by NI then the Construction Contractors shall mirror and follow the requirements of this QA Plan as a minimum. All Contractors and their sub-contractors shall implement a robust QA system and subsequent Quality Control (QC) regime in line with the requirements of this QAP. This QAP reflects the principles of NI’s QA and QC procedures, also the ‘Supreme QA’ of Israel Railways (ISR) and ISO 9001:2008 as its basis for structure. It defines “quality” in terms of the delivery of the built railway to the specified standards and legislation as well as meeting other boundary conditions specified; for example, engineering requirements, technical standards and stakeholder satisfaction. Appropriate QA processes identify and manage all quality related activities throughout the project stages including design, construction, installation, testing, and commissioning. This project is a complex railway systems undertaking that requires expertise in a wide range of railway systems disciplines including; track, communications (fixed and mobile), electrical, signalling, tunnelling, civil engineering, earthworks, drainage and temporary level crossings. In recognising these many different engineering disciplines involved there is a need to establish a technical assurance capability that can call upon relevant detailed technical competency to support QA activities. In addition, there is a need to ensure that relevant engineers, managers and staff from ISR (who will receive the project outputs) are involved in the process of delivering this project throughout. To date they have been continually and actively consulted during all aspects of the design and have received a document titled ‘IN_110860_230512_FINAL_PRODUCT_TO_ISR_05’ that explains what will be delivered for them to take over. To build upon the collaborative work carried out so far with ISR and to address the technical assurance needs of this technically complex and diverse project, it has been recommended that a ‘Technical Assurance Partnership’ (TAP) be established to ensure the ‘Technical Scope’ requirements of NI and inevitably the specifications of ISR, are met. The application of such a TAP is a well proven one having been used on many similar rail systems projects internationally.

NI QA Plan Issue P

Page 7 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Furthermore, because this is a multi-disciplinary project there must be an emphasis on the technical assurance ensuring that the client’s requirements are met by checking against the designs and technical requirements as they are being delivered by the appointed Construction Contractor. The rail systems engineering ‘V’ diagram captures how an effective cross check to the designs and requirements will be assured. Figure 1: TOR ‘V’ Diagram for the NI Superstructure Project

Validation

Functional Specification

Handover

Validation

Preliminary Design

Test & Commissioning

Validation Detailed Design

Construction

Contract Award

Adapted by Touchstone Renard, from BS EN 50126: 1999, for use on the NI Superstructure Project, October 2012

This QAP will detail the requirements for the two handover stages, these are; 

Substructure to Superstructure,



Superstructure to ISR

The Project Director’s Quality Statement can be found in Section 14 ANNEX A.

NI QA Plan Issue P

Page 8 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

3. THE PROJECT NI have been commissioned by the Israeli Government to deliver the construction of three new railway lines in Israel, Akko to Carmiel, Haifa to Bet Shean and Herzeliya to Kefar Saba, that will subsequently be handed over to Israel Railways for operational use. From a project perspective, these three new rail lines have been split by NI into two distinct projects, namely Substructure Project and Superstructure Project. Works are already underway by other contractors for the Substructure stage, including the land clearance, formation creation; tunnel bore works and other preparatory works that will enable the laying of tracks and the installation of an operational infrastructure during the Superstructure stage, which is the scope and focus of this QAP. So, this QA Plan is concentrated only on the Superstructure phase, which will receive the outcome of the Substructure phase as its base starting point. Detailed Design has now been completed for the Superstructure and the project is ready to move on to construction once all the required Contractors and sub-contractors are commissioned.

3.1. Akko to Carmiel railway line This line will enlarge the existing railway network to the East of Israel, providing connection between the coastal railway around Akko and Carmiel Station by means of an electrified double line. The Akko - Carmiel line is 21.6 km long, of double electrified track serving 2 stations (Achihud and Carmiel). It is expected that this line is going to be used by mixed traffic, passenger and freight trains. This line is expected to be fully operational by January 2017. The main characteristics of the line are: 

Double track,



Overhead Line Electrification,



Mixed traffic; passenger and freight trains,



Approximately 21km in length,



Slab track in the Gilon Tunnels (two single tunnels 4.6km in length) and Ballasted track for the rest of the line,



Fixed and Mobile Telecommunications for the whole line,



Tunnel systems integration (distributed control for security installations) including smoke and fire detection, ventilation, CCTV, ISR telephones, lighting, public address, energy supply, pumping water system and emergency communications,



Two stations; one in Achihud and the other in Carmiel, both constructed by ‘others’



The project will be split into four sections

A project area map of the line is provided on the next page.

NI QA Plan Issue P

Page 9 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN

REF: ISSUE:

NI/QA/PLN/001 P

Israel Railway Expansion Projects

DATE:

03/04/2013

Figure 2: Akko to Carmiel project area map

NI QA Plan Issue P

Page 10 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

3.2. Haifa to Bet Shean railway line The railway line Haifa-Bet Shean will spread the railway network to the East of Israel, providing connections between the coastal railway line around Haifa and Bet Shean station. It is intended to have a different configuration in two stages: o

1st stage: The line will operate in single track mode serving five stations. However, the embankments and cuttings are designed to have double track in the second stage. Bridges are designed just for a single track.

o

2nd stage: 2 additional stations and a second track will be assembled in the future so as to let the line operate in a double track configuration. New bridges shall be built for the second track.

The Line is 58 km long, of non-electrified single track and will be operated only with diesel trains, and is to be constructed on ballast. It is expected that this line will be used by mixed traffic, passenger and freight trains. This line is expected to be fully operational by April 2017.

The main characteristics of this line are: 

Single track with provision for second in future,



Not electrified,



Mixed traffic; passenger and freight trains,



Approximately 58km in length,



Ballasted track for the full line,



Fixed and Mobile Telecommunications for the whole line,



Five stations; Lev Ha' mifratz, Kefar Yehoshua, Kefar Baruch, Afula and Bet Shean, all constructed by ‘others’



The project will be split into eleven sections

A project area map of the line is provided on the next page.

NI QA Plan Issue P

Page 11 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN

REF: ISSUE:

NI/QA/PLN/001 P

Israel Railway Expansion Projects

DATE:

03/04/2013

Figure 3: Haifa to Bet Shean project area map

NI QA Plan Issue P

Page 12 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

3.3. Herzeliya to Kefar Saba railway line This line will enlarge the existing railway network for the sub-district of HaSharon, providing connection between the coastal railway and the metropolitan cities of Sharon. It is also expected to provide relief to the highway systems of highway 531 and 20. The line is 15 km long, of double track serving 2 stations in Ra’anana. It is expected that this line is going to be used by mixed traffic, passenger and freight trains. This line is expected to be fully operational by September 2016. The main characteristics of the line are: 

Double track,



Mixed traffic; passenger and freight trains,



Approximately 15km in length,



Ballasted track,



Fixed and Mobile Telecommunications for the whole line,



Two stations in Ra’anana, both constructed by ‘others’



The project will be split into three sections,

Figure 4: Herzeliya to Kfar Saba project area map (Red line = new tracks, Black line = Existing tracks)

Coastal Rail

Eastern Rail Ra'anana South station

Sokolov (Kfar Saba) Station

Nordu Station Herzeliya station - Western Entrance

NI QA Plan Issue P

Ra'anana West station

Page 13 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

4. APPLICABLE DOCUMENTS Applicable documents are key documents that can be referenced by the lead Construction Contractor and their sub-contractors (including nominated contractors) to ensure that their QA and QC arrangements are robust, meeting the requirements of this QAP. The main basis for this document is ISO 9001:2008 and then the principles of NI’s and ISR’s QA systems and relevant documentation. The basic list for reference is as follows: 

ISO 9001:2008 Quality Management System Requirements



ISO 10005: 2005 Quality Management Systems - Guidelines for Quality Plans.



EN 50126: 1999 Railway applications. The specification and demonstration of reliability, availability, maintainability and safety (RAMS)



Supreme QA arrangements for the Substructure project, provided by ISR (in Hebrew, part translated by TOR),



QC specification for ISR projects, version 2.0, July 2010 (in Hebrew, part translated by TOR),



NI General Specification Paving and Bridge Works - Chapter 0 - Sub-chapter 2 - QC by the contractor (in Hebrew, part translated by TOR),



Valley Line Project Section A4 Substructure QA Plan (in Hebrew, part translated by TOR),



INECO, IN_110860_230512_FINAL_PRODUCT_TO_ISR_05,



INECO, DD.110860.AKK.Detailed_Design-V01 September 2012,





o

Detailed Design Report and ANNEXES,

o

Technical Specifications,

o

Drawings,

o

Budget

INECO,DD.110860.HAI.Detailed_Design-V01 September 2012, o

Detailed Design Report and ANNEXES,

o

Technical Specifications,

o

Drawings,

o

Budget

Interface Management Plan and Interface Registers.

With such a technically complex and diverse railway systems project there are many technical standards, specifications, designs and guidelines that the lead Construction Contractor will need to understand and apply. These are referenced in the detailed design packages for each railway line. In particular, the ‘Technical Specifications’ prepared by the designer (INECO) for each line contains a list of all the technical standards that are required to be met by the lead Construction Contractor.

NI QA Plan Issue P

Page 14 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

5. PARTIES INVOLVED IN THE PROJECT To provide a better understanding of the relationships within the project and to see how the reporting channels for QA and QC will be formed a Project Organisation Chart has been created. This can be found in Section 15 ANNEX B. The primary client for this project is the Israeli government who have commissioned NI to deliver this project. NI will therefore be the lead Contractor’s client and ISR will be the end client and will receive the three new railway lines once all works have been completed and successfully handed over. Roads & Transportation (1986) Ltd (ROL) is project managing this project for NI and the Project Director is Ilan Rozenfeld. Touchstone Renard is providing the QAP and railway infrastructure projects specific QA support throughout the project to NI, reporting to the Project Director Ilan Rozenfeld. The following table lists the personnel involved in this project with regard to QA; Table 2: Parties involved in the project

Role Contractor’s Client

Name Erez Chochavi (Director of Rail Projects)

Project Director Head of QA

Ilan Rozenfeld (Managing Director) Leonid Soskin

Project QAD To be advised PM PM QAM PM PM To be advised To be advised To be advised To be advised Head PM

Phil Austin (Managing Director) To be advised Javier Calvo Jan-Dirk Schmidt Butbul Rami Moshe Hemyan Avi Shlomiuk To be advised To be advised To be advised To be advised Gregor Kaulhausen Shai Vaxam (Baran Company)

NI QA Plan Issue P

Company Netivei Israel (NI) - National Transport Infrastructure Company Roads & Transportation (1986) Ltd (ROL) Netivei Israel (NI) - National Transport Infrastructure Company Touchstone Renard Ltd (TOR) Israel Railways (ISR) INECO THALES MOTOROLA ELBIT NOKIA SIEMENS NETWORK LEAD CONTRACTOR TRACK CONTRACTOR CIVILS CONTRACTOR TUNNEL SYSTEMS CONTRACTOR ISR Electrification Programme ISR ELECTRIFICATION

Page 15 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

6. PROJECT SCHEDULE, BUDGET AND MILESTONES 6.1. Schedule The project schedule, which is described in more detail within the INECO Detailed Design Reports, has been constructed by taking into consideration all of the activities required for the new rail lines. The successful Contractor(s) will be expected to develop their project programmes to meet these timescales and to make the most of their resources to ensure that the target completion dates are met. They should also configure adequate time for the interface with, and handover from, the Substructure project. The Project calendar is divided into months, with calendar days used for each month. Akko to Carmiel – This line is expected to be fully operational by January 2017. Haifa to Bet Shean – This line is expected to be fully operational by April 2017. Herzeliya to Kefar Saba – This line is expected to be fully operational by September 2016.

6.2. Budget The budget for the Superstructure project is approximately €150,000,000.

NI QA Plan Issue P

Page 16 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

7. PROJECT ASSURANCE – QUALITY AND TECHNICAL 7.1. General There are two essential parallel parts to providing Project Assurance on a multi-disciplinary railway project: 

Quality Assurance - QA (is the systematic process of checking to ensure that the project is meeting the specified requirements, including audit & surveillance programme of agreed key contributor activities e.g. Construction Contractor, as well as the management of Non Conformance Reports (NCR’s))



Technical Assurance - TA (is the systematic process for verifying technical compliance for the works associated with the project thus ensuring that the technical integrity of the project is monitored and maintained and that any deviations and concessions are managed appropriately).

The provision of both QA and TA is independent of the Contractors work delivered. The rail systems engineering V diagram (as adapted and illustrated in section 2, which was extracted from EN 50126) shows how both verification and validation approaches are to be used. This means that: a) In essence, the evidence agreed with the client, provided by the Contractor, for acceptance shall be verified so as to confirm that it satisfies the defined requirements. b) Also, designs shall be validated to confirm that what is specified meets the ISR requirements. c) Products (outputs) shall be verified to confirm that they achieve the defined requirements. d) Verification shall be undertaken and witnessed by legitimate, qualified, project and client team’s personnel, and the related documentation identified, completed and provided. e) Approvers of assurance submissions shall be independent of the delivery processes for the product being assured. This QA Plan is focussed on ensuring Quality Assurance aspects are adequately delivered by the Construction Contractor and all other parties involved. In addition, a TA Plan will explain how Technical Assurance will be provided based around the following summarised Technical Assurance Partnership (TAP) method mentioned earlier. The presence of TAP throughout the construction process will enable NI to demonstrate to Israel Railways that compliance with the agreed project requirements and standards has been achieved. Independent Technical Assurance (ITA) is a standard rail industry method of formally demonstrating conformity of works. It is used to demonstrate that works, either undertaken or to be undertaken, meet all the required technical & engineering standards along with the clients project requirements brief. A subsequent TAP Management Plan will outline how this will work on this project. 7.2.

Technical Assurance Partnership (TAP)

The TAP will be responsible for delivering technical assurance that the new railway lines are constructed in accordance with the pre-approved list of technical standards meeting ISR’s agreed requirements. The TAP will operate between NI and ISR, be answerable to both companies and the members of TAP will be technically approved by ISR. The following diagram illustrates this arrangement:

NI QA Plan Issue P

Page 17 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 5: Superstructure Project, Technical Assurance Partnership diagram

PROJECT DELIVERY NI

OPERATOR ISR

Design Contractors

Technical Assurance Partnership

TAP

Main Construction Contractor

Lines of Communication Contractual Non - Contractual

The TAP will be headed by an agreed Accountable Person, with a Deputy Accountable Person, who manages TAP, advising and acting as the technical interface with ISR. A consistent approach will be followed by the TAP across the technical disciplines so that all areas are reviewed to the same level of scrutiny. As with the TOR QA Team, the independence of the TAP from the Contractors work is structural and agreed by all parties. The purpose, role and processes of TAP will be presented to all suppliers, clients, internal and external stakeholders. The TAP management plan will quantify the activity and establish the terms of reference for the function. The TAP role sits well alongside TOR’s QA role – this is a well established model for railway infrastructure projects where there are many diverse & complex technical disciplines needed to ensure the project achieves the agreed technical results. The workflow is essentially simple - the NI project produces specifications, drawings and construction contractor outputs (products) which are reviewed by TAP on ISR’s behalf against previously agreed standards. The volume of work and efficiency of reviews will be overseen by TAP and reported to ISR and NI. A construction verification of the Substructure projects(s) may be undertaken on behalf of TAP to independently identify the actual construction and then carry out a gap analysis between the as-build Substructure and the base-line start for the design assumptions of the Superstructure project. Then a Design Standards Manual needs to be setup and approved for the Superstructure project to ensure the technical standards being used are correct and current. Once the works enter the construction phase TAP will undertake review of the Contractor’s construction technical quality control procedures, carry out inspections of the site works and review the as-built records. A technical concession approval committee will need to be established for the technical approval of deviations to ensure the actual performance is not compromised. The responsibility for preparation of the concession will be with the Construction contractor/designer. The development of a suitable concessions procedure will be required. The TOR QA team will review all processes, procedures and their effectiveness in practice to deliver the required result. NI QA Plan Issue P

Page 18 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

8. PROJECT QUALITY ASSURANCE TEAM 8.1. Structure and composition The project quality assurance team includes all key contributors to delivering the Superstructure project resulting in the three new railway lines satisfactorily handed over to Israel Railways for operational use. The following diagram (structure of Superstructure project QA team) shows this illustrating the contributors and their relationships. The Quality Assurance Management and Professional Authority for this project starts with the NI (the national transport infrastructure company). As explained, NI have contracted with Touchstone Renard (TOR) to deliver the QA requirements of this project and to ensure it is delivered by the respective contractors and sub-contractors. Cooperation is required between Israel Railways, NI, the Project Management team ROL, the TAP and TOR to make sure that all QA/QC activities are coordinated and that information is shared. Touchstone Renard (TOR) are responsible for providing QA services for the project which includes preparing and maintaining this QA Plan, specifying the QA requirements to the main construction contractor, carrying out a programme of audit and surveillance on the quality management systems (QMS’s) of key agreed contributors, especially the contractor, and generally looking after the project from a QA perspective. The Touchstone Renard (TOR) QA team will work with NI and all other key contributors to establish a combined team so that all are informed and working together towards the same objective. Those deployed within the TOR team will all have rail project related expertise and experience covering all aspects of QA on rail infrastructure projects. They are competent as QA professionals, selected for their wealth of experience and knowledge of the practice of managing complex rail projects. The following make up the TOR Quality Assurance Team:     

Quality Assurance Director (QAD) – Phil Austin Quality Assurance Manager (QAM) – occupant to be confirmed Quality Assurance Auditor (QAA) for Haifa / Bet Shean Line – occupant to be confirmed Quality Assurance Auditor (QAA) for Akko / Carmiel Line – occupant to be confirmed Quality Assurance Auditor (QAA) for Herzeliya/ Kefar Saba – occupant to be confirmed

The lead Construction Contractor is required to establish its own QA/QC team that is capable of meeting the requirements of this QAP. Their direct reporting structure should be such that it fully supports the delivery of QA/QC and they shall recognise the professional authority of the overall QA being delivered by TOR. The lead Construction Contractor’s sub-contractors shall also have QA/QC arrangements and necessary personnel in place to meet the requirements of this QAP. Their direct reporting structure should also fully support the delivery of QA/QC and they shall also recognise the professional authority of the overall QA being delivered by TOR. All suppliers, manufacturers and factories are expected to be able to demonstrate their QA/QC arrangements and to agree to the necessary tests and sampling that this project will require. Contractors and their sub-contractors shall establish these agreements before entering into contract with these parties.

NI QA Plan Issue P

Page 19 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 6: Structure of Superstructure Project Quality Assurance Team

Client Quality Assurance ISR QA Representative: XXX

Project Management ROL PD: Ilan Rozenfeld

Head of Quality Assurance NI HQA: Leonid Soskin

Quality Assurance for the Project TOR Project QA Director: Phil Austin

TOR QAM

TOR QAA

TOR QAA

TOR QAA

Technical Assurance Partnership TAP ELBIT QAM

Thales QAM

MOTOROLA QAM

NSN QAM

Lead Contractor QAM: XXX

Contractors; QA/QC team, Engineering team, Testing & Commissioning teams

Subcontractors QC

Direct reporting Professional Authority

Subcontractors QC

Subcontractors QC

Subcontractors QC

Sub-Contractors; QC team, Engineering team, Testing & Commissioning teams

Cooperation required To be established

Suppliers Manufacturers Factories

NI QA Plan Issue P

Page 20 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

8.2. QA Team Roles & Responsibilities (Duties) The primary objective of the Quality Assurance team is to ensure that all activities required to implement a quality assurance plan and to promote quality assurance processes and quality controls are put in place and regularly monitored. They will not form part of the core project team and are present only to ensure that Quality Assurance and Quality Control is being exercised. The QA activities and scope of work that TOR will provide are summarised as follows: 

Quality Assurance for all the stages of the project (design, tender, construction).



Invitation to Tender preparation, including contributing to the QA evaluation criteria.



PQ and Tender checking, including contributing to the QA evaluation process.



Dealing with Bidders QA questions and providing answers.



QA Consulting during the construction period.

The TOR Quality Assurance team will also monitor and approve the Construction Contractors Quality Assurance and Quality Control staff involved in this project and approve any staff changes subject to them meeting the necessary criteria. They will also monitor and supervise (if necessary, supported by TAP experts) sample inspection and testing and make recommendations for corrective actions in the event of any Non Conformances. A TOR QA team member, usually a QA auditor, will be present on the Contractor’s project site(s). He will carry out audits of the Contractors QMS, at different locations, raise non-conformance reports (NCR’s) and check progress on the closing out of NCR’s by the Contractor. He will attend relevant meetings and compile a report for analysis by NI and other stakeholders. The TOR QA team members will also regularly liaise with the Contractors and sub-contractors QA/QC staff on general matters and to research and agree any improvements or enhancements that could be made to the QAP or QC systems for the good of the project. In support of their responsibilities (duties) the TOR QA team has established a Project Office and Administration/lines of communication. In addition, the TOR QA team will continually carry out the following as and when necessary throughout the remaining period of the project: a) Develop project work programme for TOR QA scope integrated, as necessary, with the overall project timescales for review and NI approval. b) Develop and implement QA Monitoring, Surveillance, Inspection and Audit programme. Regular detailed reports will be produced and circulated. c) Develop and issue QA sections for the Tender packages, with evaluation criteria. d) Evaluate proposals for QA as received and rank in order of preference with reasons why. e) Answer Bidders questions and answers within TOR’s QA scope of services. f)

Coordinate and review audit reports with NI for Non-Conformances and Corrective actions and time taken to close them out.

g) A risk register will be maintained in tabular format and be reviewed, and reported regularly. h) Ensure excellent co-operation with Israeli Companies. NI QA Plan Issue P

Page 21 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects i)

All of the above activities shall be completed by 4/2013.

j)

Provide consulting support during the construction period.

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

k) TOR shall be available for construction support during the period 7/2013 to 12/2016. Excellent interface management will be key to the success of this project and all parties must ensure that coordination and liaison between NI, Israel Railways and all contractors and consultants throughout all design and construction phases is truly effective with a positive, established and on-going project culture. Supported by competent technical experts from the Technical Assurance Partnership, the TOR QA auditors will carry out technical type audits and surveillance checks and may also accompany the contractors for Factory Acceptance Testing, where necessary, and may visit suppliers to sample test products against the declared and required specifications. The percentage of time that the QA auditors spend on this project conducting QA/QC activities will be dependent on the stage and the number of activities required to be monitored.

8.3.

TOR QA Team Authority

8.3.1. Touchstone Renard Quality Assurance Director The TOR QAD is fundamentally responsible for the overall successful resourcing and delivery of QA support to the project throughout its life cycle. 8.3.2. Touchstone Renard Quality Assurance Manager The TOR QAM is responsible for management planning, construction and implementation of the quality assurance plan and system that supports delivery of it. This will control the subsequent QC systems of the contractors and their sub-contractors. As previously mentioned the TOR QAM is not a core part of the Project Team delivering the works and his primary objective is to ensure that this project is delivered to the correct levels of quality. 8.3.3. TOR QAM authority The TOR QAM has the authority to; 

Recommend that an activity be ceased or that a supplier should no longer supply a product until such actions are put in place that prove beyond doubt that they are to the required specifications and quality requirements. The advice of the relevant TAP assurance engineer will be sought and considered in all relevant situations. The actual stoppage of such activity will be instructed via the Project Manager; unless delegation has been given by the PM for certain situations or it is evident that risk of serious injury or loss of life is imminent.



Review, approve, reject, and / or demand for replacement or an increase or reduction to the scope of the contractor’s QC personnel, including surveying teams and / or their presence on the project, depending on the stage in the project,



Approve, reject or request a revision to the contractor’s quality control program,



Review, approve, reject or request for replacement of the surveyors working for the quality control system in accordance with the QAP and Procedures,



Review, approve, reject or request for further information on Sample Testing organisations used by the contractor and/or their sub-contractor. The TOR QAM may also approve to limited testing until further information has been provided that supports the organisations credentials better,

NI QA Plan Issue P

Page 22 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013



Request that sample testing or factory acceptance testing be increased beyond the normal levels as part of a Non Conformance action, changes to product specification or other such information received that will ensure the correct levels of quality are being achieved,



Implement; random audits, increased surveillance and site presence due to concerns raised by other parties or issues witnessed,



Inspect; each area of work, product and installation visually to look for anything that is unsuitable or not homogeneous and provide periodic performance evaluations to suppliers, Contractors and subcontractors,



Set milestones for the Contractor at each stage of; stage works, a controlled process and installation, but that this is done in such a manner so as not to delay the progression of work unreasonably,



Visit the Contractor and have full access any time to review project documentation, reports and filing systems (electronic and hardcopy),



View the Contractor’s QC reports on their document storage system,



Audit the Contractor's quality control testing and other quality control system,



Request the use of special tests that are not mentioned in the contract,



Conduct comparison testing,



Recommend actions for discrepancies of various types, including; discrepancies that require the stopping of works, termination of contracts, assessing the quality assurance system, severe failures of the QC system being used, or serious discrepancies that are not being addressed properly and are a deviation from the programs, specifications, policy and / or procedures of NI.

8.3.4. Notice The TOR QAM will notify the Contractor at least two days in advance of a required review of their QA/QC system. Inspections, sample testing, partial tests of process control procedures, and quality testing results of the Construction Contractor’s work will be carried out at any time, without notice. The advice and support of the relevant TAP assurance engineer will be sought and considered in all relevant situations. If the current operation of the Contractor’s quality assurance system reveals a significant discrepancy, the Project Manager may order the holding of an NI quality assessment with a notice period of 24 hours.

8.3.5. Programme TOR will carry out a QA programme of audit and surveillance throughout the design and construction phases of the project. A programme of audits is in progress regarding the detailed design phase and once the Construction Contractor has been appointed a suitable programme of QA audits will be established. As part of this audit programme TOR will deploy rail systems experienced QA auditors who are able to raise any technical assurance issues for in depth consideration by the TAP.

8.3.6. Technical Assurance The TAP will operate as described earlier and in accordance with the associated TAP Management Plan and so will deploy appropriate technical discipline expertise as necessary to provide technical assurance. The rail technical disciplines on this project are diverse and extensive thus demonstrating the need for the TAP and the specialist discipline engineers to be available as necessary.

NI QA Plan Issue P

Page 23 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The following table provides an outline of the rail engineering disciplines and the technical assurance aspects to be monitored: Table 3: Outline of rail engineering disciplines required by the Contractor

Engineering Discipline Track

Engineering Items  Track,  Certification,  Construction,  Track fixings,  Welding,  Stressing,  Sample testing,  Switches,

      

Ballast, Slab, Sleepers, Supply chain, Documentation, Standards & Specifications Non Conformance Reports

Signalling

     

Signals, Interlockings, Cables, Construction, Operating interface, Equipment Rooms,

     

Train detection, Power feed, Supply chain, Documentation, Standards & Specifications Non Conformance Reports

Civils

                                

Signal bases, Signal posts, Troughing routes Ducting, Gantries, Under Track Crossings, Under Road Crossings, Equipment buildings, Culverts, Embankments, Cuttings, Excavations, Landfill, Formation stability, Culverts, Water systems, Water accumulation, Track drainage, Construction, Power supply, Power requirements, Power distribution, Cables, Construction, Plant type, Generators, Certification, Installation, Testing, Electrical Supply Fire Detection Sprinklers Computers

       

Staging works, Access roads, Walkways, Temporary works, Supply chain, Documentation, Standards & Specifications Non Conformance Reports

        

Construction, Supply chain, Documentation, Standards & Specifications Non Conformance Reports Supply chain, Documentation, Standards & Specifications Non Conformance Reports

        

Equipment rooms, Supply chain, Documentation, Standards & Specifications Non Conformance Reports Supply chain, Documentation, Standards & Specifications Non Conformance Reports

   

Earthquake Detection Drainage SCADA Falling Objects Detection

Earthworks* (Where works affect)

Drainage

Electrical

Plant

Tunnel Systems

NI QA Plan Issue P

Page 24 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects Engineering Discipline

Telecoms

Level Crossings (Temporary and Permanent)

Engineering Items  Ventilation/Air Conditioning  Mobile/Radio Coms  GSM  Lighting  Fixed Coms  Transmissions systems,  Hardware,  Software,  Cables,  Handsets & Consoles,  Equipment Rooms,  Construction,  Lights,  Barriers,  Audible alarms,  Monitoring,  Deck,  Operation,  Construction,

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

    

Electrification Earthing Supply chain, Documentation, Standards & Specifications Non Conformance Reports

            

Certification, Installation, Testing, Supply chain, Documentation, Standards & Specifications Non Conformance Reports Certification, Testing, Supply chain, Documentation, Standards & Specifications Non Conformance Reports

The QA auditors in the course of their duties will monitor and audit all disciplines with additional expertise from within the TAP as necessary. This is an efficient method for utilising their time and the sharing of information will be increased. Because this is a multi-disciplinary project there is also a need for the engineering activities to be coordinated amongst the varying contractors and the QA auditors / TAP experts will review these arrangements to ensure that they meet the overall requirements from a technical assurance point of view. The TOR QA auditors, supported by TAP input as necessary, have the authority to recommend that work is stopped or a supplier must cease manufacture or supply of a product until such time that the TOR QAM has been consulted and the required corrective action has been put in place. As with all project team members if any activity appears to threaten serious injury or potential loss of life it must be stopped immediately. The technical experts provided via TAP in support of technical assurance work will be competent to carry out at least the following. This will be explained further in the TAP management plan. a) Understand and maintain the technical standards, and provide assurance against these within an asset area across the project. b) Provide technical sign-off to the project for the asset area, as delegated by the TAP c) Carry out the technical assurance accountability for the assets through technical assurance standards and procedures including; sign-off, certification of approval and acceptance of new assets including technical safety intervention and waiver to system standards and processes. d) Produce and manage the technical content of project standards for the project in respect of the asset area in conjunction with the H&S and QA managers. e) Provide evaluation and approval for technical content of project and major maintenance processes, at initiation stage and on-going monitoring where required for the asset area. NI QA Plan Issue P

Page 25 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects 9.

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

QUALITY ASSURANCE - CONTRACTOR REQUIREMENTS

9.1. Requirements Management Assurance will be provided and received against the project and technical requirements. NI will provide assurance to ISR and will also be the receivers of assurance from the Contractors. The specification of requirements and the demonstration of compliance with them will be identified and agreed between providers and receivers of assurance. For this project, this involves the agreement of the project contract and technical requirements with NI. Such requirements include those that are ‘fixed’, including standards and other constraints, and those that are ‘project specific’. Project specific safety and technical requirements are specified in each contract package. 9.2. Compliance with Standards, Non-Compliances and Concessions Based on the detailed design deliverables, superstructure works shall be undertaken in accordance with all relevant Legislation, Regulations, International Standards, ISR/NI Standards, ISR/NI Procedures, ISR/NI Specifications, ISR/NI Practices, and ISR/NI Guidelines. All Construction Contractors shall prepare a list of all Legislation, Regulations, Standards, Procedures, Specifications, Practices and Guidelines relevant to their project activities. It is the responsibility of each Contractor to ensure that applicable documents are selected, applied and verified as part of all superstructure construction phases. All applicable standards shall be identified based on the document references contained in the detailed design deliverable packages. It is expected that some standards or clauses within standards may not be adopted and applied and this will be managed as part of the requirements management activity by all Contractors. Where Contractors have identified an existing or necessary deviation from specified ‘fixed’ requirements, the details shall first be recorded on the contractors non-compliance register and will remain ‘open’ until such time that the non-compliance has been resolved or a concession has been granted in writing from NI. Each non-compliance recorded that cannot be resolved shall be assessed to determine the level of risk to safety or quality and mitigated in accordance with the ALARP (as low as reasonably practicable) principle. For each of these non-compliances a concession shall be requested to obtain NI approval prior to the particular works starting. Prior to submission to NI, all concessions will be assessed by the Contractors Construction Manager. 9.3. Change Control All variations to the scope or programme, whether or not incurring additional cost and financial changes, shall be addressed and recorded in the Contractors Weekly Project Construction Meetings and controlled as per the change control process detailed in the Contractors Project Execution Plan. Changes shall be evaluated for their impact on the detailed design, including the validity of previous approvals. Changes that impact the detailed design will be managed by the Construction Contractors via the Requirements Management process. 9.4. Project Information Model A Project Information Model shall be operated by contractors as a central data store. The project shall also recognise the requirement to adequately manage registers, namely the hazard log, risk register, issues register and a register of assumptions, dependencies and caveats. Whilst all registers form part of the Project Information Model the management of these registers has been identified as a key process. NI QA Plan Issue P

Page 26 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

9.5. Assurance Management The phased compilation of QA evidence by Contractors to demonstrate to NI that project requirements have been complied with shall be done in accordance with the respective contractor project specific plans and associated procedures that form part of the certified contractors systems. The effectiveness of the QA processes will be independently assessed by the TOR QA Auditors through surveillance. QA evidence shall be provided by contractors as requested by NI. Assurance evidence arising from surveillance shall be addressed in the Surveillance Schedule to be developed and delivered by Contractors. 9.6. Review and Approval of QA Evidence All QA deliverables will be signed by Contractor authorised signatories as ‘submitted by’ the relevant discipline and ‘endorsed by’ the contractors construction manager, prior to final endorsement by the TOR QA Auditor, who has the decision making and management control of all QA arrangements and activities on the Project. Construction contractors are required to consider the following prior to their endorsement: 

That the detailed design has been implemented without exceptions;



Where there are exceptions to the detailed design they have been accepted by NI with an authorised NI signature;



Personnel and organisations contributing to the project are competent;



All required processes have been implemented;



Checks and approvals have been conducted;



All necessary reviews have been conducted;



Requirements have been managed commensurate with the construction phase;



Risks have been mitigated to ALARP (as low as reasonably practicable) and if not how risks will be managed;



Specified technical and other standards have been complied with or concessions have been identified accordingly;



Technical queries, issues and requests for information have been answered (covered by the TAP);



The QA Submission has been compiled and assurance evidence is available and readily verifiable;



Witness testing has been carried out as applicable and test certificates are available and signed by NI and contractors authorised signatories as accepted;



Construction interfaces have been integrated where possible.

The Contractors Systems Integration Manager is required to consider the following prior to endorsement: 

Systems Engineering Processes have been implemented;



Requirements have been captured and recorded;



Human Factors, EMC and RAMS requirements have been addressed;



Interfaces have been identified and integrated;



Inter-disciplinary design checks have been conducted;



Technical risks have been identified and recorded.

NI QA Plan Issue P

Page 27 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

9.7. Cross-references to other project plans Contractors and their sub-contractors shall provide cross references to all other project plans with links to Quality Assurance including the unique plan number used in each case. The list in the table below is offered as a guide and is not intended to be exhaustive and must be amended for each contractor QA Plan dependent upon the work scope involved for any particular Contractor/subcontractor. Table 4: Cross Reference Plan Description

No. 1. 2. 3. 4. 5.

Cross-Reference Plan Description Register of applicable Legislation, Regulations, Standards, Procedures, Specifications and Guidelines. Including ISR Standards and Specifications used. Health & Safety Plan Fire Evacuation and Emergency Response Plan Project Execution Plan Technical Assurance Plan

6. 7. 8. 9. 10. 11. 12. 14. 15. 16.

Safety and Validation of Change Plan EMC Plan RAMS Plan Human Factors Plan Systems Engineering Management Plan Risk Assessment Plan Value Engineering Plan Systems Recovery/Fallback Plan Testing and Commissioning Plan Interface Management Plan

9.8. Contractor QA Plan and Guidelines Implementation of the project quality assurance program includes, among others, the following activities required of the Contractors:

9.8.1. Competence of Contractor QA/QC team Contractors shall inform NI of specific proposed personnel and submit relevant CVs/details for NI authorisation. Any changes shall be proposed to and agreed by NI prior to implementing the change. The TOR QAM will review and approve the QA/QC personnel of the Contractor under the terms of the contract and according to the technical specifications required. The TOR QAM will also form a general impression from interviewing Contractor's quality control personnel to examine the level of professionalism and relevant technical expertise (in consultation with TAP experts) within the Contractor’s organisation and suitability for the project. If a QA/QC presence is required during works that are conducted on a shift basis then the Contractor or subcontractor shall provide personnel to cover those periods. At no time shall the QA/QC resource requirements go unfulfilled.

NI QA Plan Issue P

Page 28 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

All QA/QC personnel shall have autonomy whilst working on this project and shall not form part of the main project resource requirement. The following table lists the basic requirements for the Contractor QA/QC team. Table 5: Skill and Education Requirements of Contractor QA/QC team

Role Quality Assurance Manager (QAM)

Quality Control Manager (QCM)

Technical Assurance Coordinator (TAC)

Technical Assurance Engineer (TAE) Telecommunications

Technical Assurance Engineer (TAE) Track

Technical Assurance Engineer (TAE) Civils

Technical Assurance Engineer (TAE) Buildings

Quality Assurance Administrator & Document Controller

Minimum requirement for education and experience (cumulative) Registered and licensed Engineer in at least one railway discipline and also a qualified practitioner of Quality Assurance/Quality Control (QA/QC) with at least 5 years’ experience in the Railway construction sector. Registered and licensed Engineer in a railway discipline and a qualified practitioner of Quality Control (QC) with at least 5 years’ experience in the Railway construction sector. Qualified engineer with at least 5 years’ experience in the Railway Construction sector including 2 years involving QA/QC. Registered and licensed Telecommunications Engineer with at least 5 years’ experience in the Railway Construction sector including 2 years involving QA/QC Registered and licensed Track Engineer with at least 5 years’ experience in the Railway Construction sector including 2 years involving QA/QC Registered and licensed Civil Engineer with at least 5 years’ experience in the Railway Construction sector including 2 years involving QA/QC Registered and licensed Buildings Engineer with at least 5 years’ experience in the Railway Construction sector including 2 years involving QA/QC Experienced Project Professional with at least 2 years involvement in Railway Construction Projects. Will have worked in an Administrative Capacity or as an Assistant Project Manager. Good knowledge and understanding of QA/QC.

Minimum presence of staff necessary One QAM covering all 3 railway lines. Continuous and permanent throughout the project.

One for each of the 3 railway lines. Continuous and permanent throughout the project.

One TAC covering all 3 railway lines. Continuous and permanent throughout the project. Partly depending on the QC programme.

Partly depending on the QC programme.

Partly depending on the QC programme.

Partly depending on the QC programme.

One covering all 3 railway lines. Continuous and permanent throughout the project

Quality Assurance Manager (QAM) The QAM role is vital and will require a person that has led and implemented large scale QA programmes on major rail infrastructure projects. They must be able to demonstrate effective QA planning, management and coordination of QA/QC teams and also how they have dealt with any issues regarding team or individual competence and thus improved the situation for the benefit of the projects concerned. NI QA Plan Issue P

Page 29 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The QAM must be able to communicate with stakeholders at all levels, being able to deliver communications to senior management and client teams as well as on site work parties. They must also be able to demonstrate how they have effectively dealt with project issues caused by colleagues, contractors or subcontractors including resolving NCR’s in a timely way. The QAM is expected to hold the required qualifications and licences applicable to the project and preferably membership of a professional body that demonstrates an on-going passion for excellence. The QAM must be able to demonstrate competence and working experience of at least one rail engineering discipline and a strong familiarity with the other disciplines involved in a rail infrastructure project. Other Assurance Team Members Each contractor and sub-contractor shall submit QA/QC CVs to NI for approval of the personnel to occupy the roles required. In addition, the relevant Contractor / sub-contractor must appoint sufficient numbers of people occupying these roles in response to the need. If the Contractor wishes to change the QA/QC personnel they must do so after first agreeing with NI. NI will review and approve the CV of the proposed personnel. The change of personnel shall also be supported by the new incumbent receiving the project induction and a comprehensive handover.

9.8.2. Quality control staff briefing - coordination meeting expectations When the QC programmes are being developed the Contractor and subcontractors shall communicate and share their plans with each other so that the rail systems can be coordinated. Contractors QC personnel must be briefed on how this will be delivered taking into consideration the following: A. Documentation that forms the basis of their QA/QC systems, B. Details of the stages where early control is required; including approval of materials, approval of manufacturers / suppliers, materials, equipment and work teams, approval of subcontractors, etc. C. Details of their current control steps including test points and breakpoints, D. Checklists for each area/discipline, E. Monitoring and treatment including classification of non-conformances, F. Monitoring reports including current and periodic reporting method, G. Progressive site handovers and final handover procedures

9.8.3. Submission of a Quality Control Programme (QCP) Within 60 calendar days of contract award the Contractor shall submit a detailed QCP and associated implementation program. This shall be in accordance with the documents referenced in section 4. Under no circumstances shall the Contractor or their sub-contractors start work of any kind until these plans are accepted by the TOR QAM. The quality control program shall include at least the following: 

A general description of the nature of the project, which will include a plan of the project area on a map.

NI QA Plan Issue P

Page 30 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013



Details of the structure and scope of the organizational system of the quality management system including quality assurance managers, quality control managers, engineers, surveyors, testing arrangements/facilities and organizations and any other technical personnel required.



Details, including the responsibilities, authority, qualifications, CVs etc., of the quality assurance and quality control personnel.



Sample testing arrangements on site (including the organisations carrying it out). Also a testing program that will include all tests required in the project including the amount of tests and frequency.



Procedures for any inspection or surveying required and how these will be reported.



Details of how records will be stored and distributed.



Details of checkpoints and breakpoints in stages or work packages and how they are controlled, including who would participate in these events.



Details on the approval of subcontractors on the project.



Details of the preliminary stages of quality control, approval of the suppliers of materials and the carrying out of sample testing.



Details on the management of non-conformances.



Details of the events and arrangements for carrying out supervision and documentation of inspection reports.



Details of communications arrangements, how to contact site between the various entities both in quality control itself and in the overall scheme of the project including the interaction and details of the quality assurance, quality control, testing teams, project managers and surveyors.



Details of weekly and monthly reporting, including dates, report formats and any other relevant information.



Quality control procedures for each type of work that the contractor will be performing as per their tender, with the procedure and checklist attached.



Details of the Construction stages, progressive and final handovers; quality control procedures.



Details of any internal training programme for quality control personnel.



Details of the Contractors and their sub-contractors internal quality checks.



Details of the document management system for project data.

9.8.4. Certification of a Quality Control Programme The TOR QAM will review and approve the quality control programme of the Contractor within 20 calendar days from the date of its submission, allowing for the process of obtaining comments and applying the necessary updates to the quality control programme by the Contractor’s QCM. The advice of the relevant TAP assurance engineer will be sought and considered in all situations. Once the quality control programme is approved and implemented the Contractor’s quality assurance department will monitor and report on its progress and effectiveness to the QAM and relevant Project Manager(s).

NI QA Plan Issue P

Page 31 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

9.8.5. Preparing a Contractor’s Quality Assurance Programme The quality assurance programme will be developed with the successful Contractor as part of the post contract award activities. The programme must cover comprehensively the works that are being carried out by the respective contractor(s) and clearly indicate what are general checks or processes and those that are technical. Within a 30 day period after contract ward, as a prerequisite for the approval of the commencement of work, the Contractor shall submit a Contractor’s Quality Assurance Plan to the TOR QAM for the project. The Contractor’s QAP will be passed on to the Project Manager, the TOR QAM and the Quality Assurance department of NI. The advice of the relevant TAP assurance engineer will be sought and considered in all relevant situations. The QAP will be considered as final after a joint approval from the PM and NI has been received. The detailed quality assurance program will be approved by the PM within 20 calendar days of receipt and will allow for amendments and the provision of supplementary information. Once the quality assurance programme has been approved work may start. At the same time the quality assurance programme will be regarded as fully implemented. The following chart illustrates the approval process, as described in section 9. Figure 7: Contractor’s QCP and QAP approval chart

Superstructure Project Contractor's QAP & QCP approval timeline To be read in conjunction with main text Timeline (Calendar Days) Activity 0 10 20 30 40 50 60 70 80 90 100 110 120 ◊ Contract award ◊ Contractor drafting of QCP TOR QAM Review Contractor makes Amendments ◊ TOR QAM Approval ◊ QCP becomes live ◊ Contractor drafting of QAP TOR QAM Review Contractor makes Amendments ◊ TOR QAM Approval ◊ QAP becomes live

9.8.6. Implementation of the contractor’s quality assurance plan Once the detailed quality assurance programme has been received and work is started, the Contractor’s Quality Assurance Manager is to fully implement the quality assurance programme, and this will include at least the following:

NI QA Plan Issue P

Page 32 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013



Provide monthly reports to the TOR QAM, PM and NI Head of Quality Assurance, by the 15th of each month for the previous month, reporting will be as specified in section 10 of this QAP.



Rectify any QA/QC systems or processes that are not aligning with that of NI’s,



Monitor the Contractor’s quality control teams including testing teams and surveyors,



Inspect works, materials and plant.



Monitor the Contractor’s information collection,



Setting up / starting of sample inspection and testing frequencies against planned stopping points,



Testing and surveying requests for payment by the Contractor and recommending to NI whether payment should be made or rejected,



Confirm the structure of the Contractor’s QA/QC personnel is in place throughout the project,



Verify the testing of materials,



Authenticate and authorize the sources of supply, materials suppliers and services, provided by vendors and subcontractors.



In the early control period participate in the sample testing and surveillance for each approval of equipment and materials, including supporting their approval or rejection,



Monitor the management of the Non-conformances process looking for how these are detected, monitored, treated and closed. Provide corrective action reports,



Make random checks of the quality of materials and workmanship, and testing compliance with specifications and standards including; destructive and non-destructive testing (DT & NDT), testing materials, processes, plant and other suppliers,



Check the documentation of quality assurance procedures, records and the activities reported on sample tests,



After NCR’s have been raised check the computerized system to see how they are being managed and if any involve the supervision of planning officials monitor their progress,



Participate in regular meetings and weekly site meetings.



Making regular tours throughout the project checking and matching test outputs to the various performance specifications and implementation plans of the project,



Editing and submitting periodic quality assurance reports, including monthly reports, using the computerized system of the Company or any other means defined by NI,



Transferring reports to the project manager, coordinator, NI Head of QA and the TOR QAM,



The monthly reports shall include calculations for deductions in respect of quality defects in materials and workmanship. The reports shall include statistical analysis of the results of QC tests,



Filing of immediate reports for exceptional cases (breakpoints and / or due to safety). These must be submitted orally and in writing within 24 hours to the PM, TOR QAM and the Head of QA in NI,



Editing and submitting of reports to support the conclusion of the contract period.



Performance tests as specified in section 10 of this document.

NI QA Plan Issue P

Page 33 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

10. QUALITY ASSURANCE POLICIES & PROCEDURES 10.1. Quality Control NI require that all Contractors and sub-contractors produce Quality Control Plans that primarily reflect their competence to complete the work specified and, an understanding of, and a clear method of, adherence to NI required standards and processes. These requirements will also be linked to Israeli Laws and legislation and the Contractors and subcontractors should demonstrate within their documentation and processes their familiarity and understanding of these matters. The techniques used and activities carried out to ensure compliance and maintain quality of design, construction, commissioning and handover for the three rail lines shall also include monitoring and rectification processes so as to eliminate problems and to satisfy the requirements of ISR who are the end client. Due to the complexity of this project Contractors and sub-contractors should implement a programme of progressive assurance (as per the systems engineering V diagram in EN 50126) and a monitoring and audit regime linked to this. Progressive assurance simplifies the overall approach, while maintaining the necessary rigour. This helps to keep the process both manageable and simple. The fundamental requirement of any QCP is to ensure that; 

Materials are to specification



The supply chain is robust



The installation of materials is done to specification and that the combined product of various materials is to specification



That all construction is done to specification



That the QCP has clear targets and KPIs on which to measure its progress against criteria



That the final completion (in this case commissioning) of all work meets the specification of the remits and is delivered to the satisfaction of the end client (ISR).

10.2. Quality Control Requirements The Contractors QCP shall detail the proposed methods or processes of providing quality control for all work products. The plan shall include, but is not limited to, the following areas: 

Plans and Specifications comply with all aspects of the required quality



Organization, (the quality control staff will be completely separate from the Contractor control team) including the requirements for ‘in house’ QC service



Skills, expertise and training requirements



QC reviews



Setting a clear plan of inspection and testing



Sampling and testing (including methods for identifying and ensuring traceability)



Proposed method of documentation of comments, coordination responses and QA records



QA certification



Ensure effective work processes and the product is compliant with the specifications

NI QA Plan Issue P

Page 34 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013



Procedures and checklists, i.e. Method Statements and Task Briefing sheets



Selection of sub-contractors



Identification, treatment and repair of non-compliance



Determine ways to improve work processes in order to avoid repetition of non-compliance quality.

The Contractor shall perform the QC activities of taking samples, performing tests, registration and reporting, as part of the project schedule and these activities shall not delay the work stages or cause any delay to the project schedule. The QC requirements are applicable to any sub-contractor employed by the Contractor, and they are required to ensure that they comply with the stated requirements. 10.3. QCP Preparation and Review Plans prepared by suppliers must, as a minimum, follow the procedures set forth in this document. Contractor approved QCP’s, with completed QA Checklists for all applicable disciplines, are to be signed and dated by the authorised person, and be submitted as a pdf file and hardcopy with the review to demonstrate that all items were checked. So as to achieve a comprehensive and compliant QCP each supplier, Contractor or sub-contractor should cover the following elements in their documents. 

They use ISO 9001:2008 and ISO 10005 as the base structure for their QCPs



The organisation demonstrates it’s competency in the required area of work



The organisation references the QC system that they use



The organisation lists their qualifications and licences appropriate to this type of work



They reflect their understanding of the scope of work required



They list the internal and external standards that they work to



They detail the resources that will be involved in delivering QC



They illustrate their QC audit schedules



They describe their rectification and improvement processes (this could include FMEA or other system)



They explain how they will interface their QC systems with that of NI or ISR and other suppliers, Contractors and sub-contractors



They detail (where it is relevant) by discipline the specifics of their plans for the following areas: o Track o Civils o Electrification and Plant o Signalling o Telecoms o Structures (Tunnels, Bridges, Gantries, Buildings etc.)



They describe their sample testing processes and subsequent cross or trend analysis



They describe their methods for storage, handling, tagging, packing and delivery



They detail any regular training requirements and necessary cascade briefing arrangements

NI QA Plan Issue P

Page 35 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013



They detail the management of working hours so as not to compromise the quality of workmanship (or safety)



They provide templates for their audit forms and written reports that will be used during this project



They detail records storage, referencing and numbering arrangements



They describe their arrangements for the management of non-conformance reports to fit with NI requirements



They describe QC arrangements for any other systems or processes that are considered unique or bespoke to this project that is being delivered by them



They supply the necessary QC flowcharts to support their plans.

10.4. Audit frequency The Contractor’s and sub-contractors QC teams are to have a rigorous audit regime that reflects a daily presence on the project. The QC team shall carry out these activities on a daily basis, consisting of audits, surveillance checks, factory acceptance testing, sample tests and analysis. These activities shall cover all project disciplines in line with the QAP. Audits are required to be completed internally and the TOR QA team will also carry out audits to satisfy their requirements on behalf of NI. 10.5. QA/QC meetings Regular meetings with the TOR QA team / TAP experts will be required to discuss all aspects of QC and any improvements that are agreed. The frequency should be agreed to match project needs on an on-going basis. 10.6. Construction Site Visits The purpose of site visits during construction is to demonstrate that NI/ISR and the Contractor’s or subcontractor’s management teams are taking quality control seriously. It is an opportunity to see the processes being carried out and for the project management teams to make general observations so that improvements could be made and to capture any good practices that could be shared throughout the whole of the project. The frequency of these visits will be agreed with the lead Contractor and sub-contractors for regular visits and they should also be arranged for key milestone events. This also supports and can be aligned to progressive assurance and handover as the project completes key stages. NI & ISR will carry out site visits at least on the following aspects;

NI QA Plan Issue P



Track



Systems



Civils



Tunnel Systems



Drainage



Level Crossings



Telecoms



Structures



Signalling



Site offices/compounds

Page 36 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

10.7. Early Control and Sample testing (Contractor) The early control procedure is to be conducted by the Contractor and their sub-contractors, and is divided into two parts, as described in the following sections. Quality Assurance checks each step of the QC implementation process. This early control will be carried out before work in any kind of activity starts, using construction documents as required and the appropriate flowchart that is displayed in the contractor’s quality control procedures. The Contractor’s Quality Assurance team will ensure that the Contractor confirms the attendance of the participants for these checks according to the list defined in the quality control program for each of the topics audited. Participants that should be included are project manager, project planner, site manager, construction manager, safety manager, engineer(s), document controller, foreman, works contractor / subcontractor, representative of the quality control of the Contractor and subcontractor and / or the plant providers (if the work involves the quality control of the factory or manufacturer).

10.8. Early Control Stage The Early Control Stage will be conducted by the Contractor’s quality control manager of the project and he will report to the Contractor’s quality assurance manager in an orderly manner: The early control stage will include amongst other items, the following topics: A. The Contractor’s Quality Assurance Manager will ensure that the project’s quality control manager has studied and applied all of the contract requirements and work procedures and that these are detailed in the quality control program and various specifications and plans for the execution of the project. This includes production requirements, distribution, storage, assembly and transportation of materials and products delivered to site. B. Concessions may be permitted to the factories producing ballast, sleepers, aggregates, track, cables, concrete products/bases, precast elements, appliances, earthworks retention, prefabricated stage works equipment, landscaping elements, troughing, ducts, drainage systems, and other industrial products designed for installation on the site, so long as they meet the required technical and quality specifications/standards. C. Approval of suppliers including control of products and materials to the site. This will also include early testing of concrete bases, troughing routes, sleepers, ducting, cables, signalling equipment, ballast, aggregates, electrical products, drainage systems, earthworks retention, landscaping, safety products and signage. He should also test products of different types purchased with a manufacturer's warranty (if not already done so). D. Check for quantity, quality and availability of materials and equipment including approved items. E. Approval of sub-contractors, including approval of the Contractor’s equipment and work crews. F. Check that designated work areas are available for work to commence and that all pre-work arrangements have been made. G. Determine the size and location of the test section. Coordinate and arrange these events. At the end of this early control stage the Quality Control Manager will provide a summary report to the Quality Assurance Manager with the accompanying certificates to confirm the suitability of the Contractor / supplier / product, along with a dedicated checklist. NI QA Plan Issue P

Page 37 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

10.9. Execution and reporting of Sample test sections (Contractor) Before carrying out any new type of activity, it is a requirement of this project that quality assurance carry out a sample test. The sample test section will be used to check the personnel, equipment and materials required. The Project Manager and Quality Assurance Manager may waiver this test, or require the holding of extra sample test sections and / or repeat test sections, to achieve the required quality. Execution times of the test sections will be informed in writing by the quality assurance representative and project manager at least 48 hours in advance. After completion of the test section the quality control manager shall submit a summary report to the quality assurance representative. The quality assurance report shall include all information related to the experimental section and at least the following data: 

A list of the participants that performed the sample test section.



Elements, equipment and / or materials in which the sample test was carried out, prior approvals including elements and / or equipment and / or materials used.



Work equipment, tools or other means used by the Contractor performing the sample test section and comparing specification(s).



Description of the method of implementation of the sample test section.



All tests and measurements made by the sample test section.



Analysis of the test results and measurements from engineering specifications and appropriate referencing.



Possible improvements and recommendations for implementation.



Conclusions about the sample test section and substantial comments from the participants of the sample test.



Details of any malfunctions that occurred and / or that have been suggested may occur during execution. And how it will be possible to prevent it.



The report will be attached for reference / comments to the quality assurance representative’s report.

This report will confirm the Quality Assurance representative’s completion of the requirements for approval of the team, workmanship, materials and equipment required for the job.

10.10. Sample test, prior approval and execution of the test section All parties participating in this sample test section shall provide their prior approval for the test to be carried out. This shall be treated as a breakpoint as defined in 10.14. This prior approval ensures the observance of the quality control procedures by all of the participants.

10.11. Routine Control procedure (Contractor) The Contractor’s QAM must continuously examine the quality assurance system of the project through all of the controls, work practices, reports, forms and test results as reported by the quality control. Site tours must be made examining the quality of work and performance of the Contractor and subcontractors. This must be done in accordance with the quality assurance system for the routine control stage. NI QA Plan Issue P

Page 38 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Any deviation from these procedures, requirements and specifications, or error in judgment of quality control, in handling a report to the customer and/or from the contractor must be dealt with by the generation of a non-conformance report (NCR) as described in Section 10.17. Cases of recurring errors in the functioning of the quality system, such as approval of sections with missing sample tests, forms not completed or incomplete, lack of control of the source materials, etc. must be reported immediately and the relevant parties will be invited to attend a discussion on the subject. The results and progress of the above shall be captured in a monthly QA report for all control activities.

10.12. Test stages and breakpoint tests Milestones will be determined during the routine control which will include "test points" and “breakpoints”. The dates will vary depending on the progress of the project and the outputs from regular weekly meetings.

10.13. Test Points Test points, are events in the project works that require appropriate preparation of an array of equipment and materials. The quality assurance representative(s) shall notify the relevant parties of the test point at least 48 hours in advance. The quality assurance representatives will decide on the nature of the activity in each case. The Contractor is not obligated to delay any activity on this occasion. Examples of test points are first laying of a track section (500 metres or 1km), checking linear measurements, rail cant, first signal construction, new ballast layers, first tamping run (500 metres or 1km). Note: At any time during this project NI are entitled to change the definition of test points and breakpoints. 10.14. Breakpoints 

Breakpoints - events taking place as part of construction and require the presence and involvement of a representative of the client and senior engineering and quality team before continuing work.



Breakpoints can be determined by the Client, the Head of Quality Assurance in NI and the TOR QAM as acceptance criteria and approved by the project manager and quality assurance manager.



Some breakpoints are normal phases of work requiring attendance and examination of the representative of quality control and quality assurance and some are not pre-planned points arising as a result of a malfunction in the quality of the work or through carrying out corrective actions.



Some breakpoints also require the presence of the planner. The request for their attendance will be made by a representative of the Quality Assurance team at least 48 hours in advance.



Breakpoints will be specified in the quality control program as a stop and a requirement for supervision such as full systems commissioning, passing through of first tamper and track stabilisers, powering up of main electrical supplies etc.



In the case of these planned breakpoints the client’s representative is given notice by the quality assurance representative at least 48 hours in advance.



In all cases described above, the Contractor shall not stop works before receiving the approval of the project manager to do so. The contractor shall take all necessary measures to provide prior notice of the forthcoming breakpoint(s), so as to perform the actions required and have the work approved without any delay.

NI QA Plan Issue P

Page 39 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The following table illustrates some of the checkpoints that can be conducted on railway infrastructure projects. The list is not exhaustive and can be expanded according to the requirements of the client’s engineers and issues generated by multi-disciplinary construction. The Contractor shall be expected to provide a comprehensive list indicating ‘test point’ or ‘break point’ detailing when the client, their engineers and QA/QC personnel will be required on these occasions. Table 6: Summary of checkpoints for Railway Infrastructure projects

Category

Checkpoint

Track

Setting out stations

Signalling

Test Point # #

Deep Dig completion

#

Membranes

#

Bottom ballast

#

Subsequent ballast layers

#

Track Section FATs

#

Track section laying

#

Welding, first sections then agreed thereafter

#

Stressing, first sections and then agreed thereafter

#

Drainage (also Civils)

#

Tamping

#

Track Stabilising

#

Installation of switches

#

Slab Track laying

#

Test train run

#

Main Cable laying, at agreed intervals

#

Tail Cable laying, at agreed intervals

#

Equipment FATs

#

Off-site fabrications, first then agreed thereafter

#

On-site fabrications, first then agreed thereafter

#

Signal construction, first and then agreed thereafter

#

Axle Counter installation, at agreed intervals

#

Local Control Units, off-site FATs

**

Local Control Units, site installation, first and then agreed thereafter

#

Warning systems, off-site FATs

#

Warning systems, site installation, first and then agreed thereafter

#

Power Supply Points, site installation, first and then agreed thereafter

#

Operator’s interface, off-site FATs

#

Operator’s interface, site installation

#

Operator’s interface, main commissioning Equipment rooms, fitting out, at agreed intervals

NI QA Plan Issue P

Break point **

** #

Equipment Rooms, commissioning

**

Turning on power supply

**

Mains system commissioning

** Page 40 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

Category

Checkpoint

Civils

Laying of Troughing routes, first 100 metres and then at agreed intervals

Earthworks

Drainage Electrical

Plant

NI/QA/PLN/001 P 03/04/2013 Test Point # #

Installation of Ducts, first 100 metres and then at agreed intervals

#

Construction of Under Track Crossing installation

#

Construction of Under Road Crossing installation

#

First signal bases and then at agreed intervals

#

Construction of staging, dependent on complexity

#

Large structure construction

#

Drainage system operation

#

Initial supply of materials/concrete

#

Equipment room bases

#

Stage construction of Equipment buildings

#

First cuts into embankments, first and then agreed thereafter

#

First cuts into formations, first and then agreed thereafter

#

First cuts into cuttings, first and then agreed thereafter

#

Works affecting restraining systems, first and then agreed thereafter

#

Operation of track drainage system

#

First assemblage of drainage sections

#

Cable laying

#

Installation of local power distributions

#

Commissioning of local supply

**

Commissioning of full system

**

Initial usage, and then agreed thereafter

#

Full system commissioning Tunnel Systems

Initial supply of materials

** #

Commissioning of independent systems Installation of equipment affected by ‘Piston affect’, first and then agreed thereafter Commissioning of the SCADA

** #

Installation of Electrification protection equipment

#

First installation of drainage system, subsequent at agreed intervals

#

**

Fire Brigade inspection Telecoms

**

Cable laying

#

Section construction of transmission system, at agreed intervals

#

Installation of handsets/receivers etc., first and then agreed thereafter

#

Main system commissioning

NI QA Plan Issue P

Break point **

**

Page 41 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

10.15. Requesting Supervision (Quality Assurance and Technical Assurance) The request for supervision is normally made for occasions where it is felt that a senior presence is required at site for what is considered to be a significant event in the project. The objective of this is to have the correct personnel to hand to assist and offer guidance to the teams normally carrying out such works and to also include the client teams to ensure that the works are meeting their specifications. This process ensures that such requirements are met and that the project’s quality is maintained. The circumstances in which supervision can be implemented are; 

The Contractor’s quality assurance representative has a list of pre-defined stopping points requiring supervision due to them having higher specifications and complex implementation requirements. This will be brought to the attention of the planner. The planner will be required to incorporate these into the project’s programme.



The Contractor’s quality assurance and control representatives on monitoring an activity discover errors and inconsistencies in the work being carried out and will report that a corrective action is required. The corrective action may be supervised according to the conditions set by the QA/QC personnel.

An example of occasions when supervision may be required is detailed in the table below. It is important to note that at the time of writing this document the project is completing the design stage and that the events requiring supervision may change and increase.

NI QA Plan Issue P

Page 42 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Table 7: Example of when QA Supervision may be implemented

X

X

X

NCR Discrepancy level 3

X

X

X

X

X

X

X

X

X

X

Test sections

X

X

X

X

X

X

X

X

X

X

Snagging list walk through

X

X

X

X

X

X

X

X

X

X

Test Train running

X

X

X

X

X

X

X

X

X

X

Factory Acceptance Tests (FATs)

X

X

X

X

X

X

X

X

X

X

Local handover

X

X

X

X

X

X

X

X

X

X

Full project handover

X

X

X

X

X

X

X

X

X

X

Large structure construction

X

X

Full system power up

X

Ballast check before track section laying

X

Operation of switches

X

First manufacture of sleepers

X

First Rail production

X

First Signal construction

X

X

X

X

X

Level Crossings

X

Telecoms

X

Tunnel Systems

X

Plant

X

Electrical

X

Drainage

X

Earthworks

X

Civils

Main commissioning

Signalling

Category Track

Topic

X

X

X

Localised power up of cables First drainage section

X

X

First troughing route

X

X

First concrete base

X

Local commission of telecoms system Commissioning of each of the separate tunnel systems Fire Brigade inspection Powering up of the Overhead Electrification system New contractor team on established site

X

First cut into pre-formed earthworks

X

X

X

X X X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

10.16. Documentation of supervision reports (Contractor) The Contractor quality assurance representative will check and verify the following: A. All supervision reports are recorded and sent to the project manager. Also that quality is maintained through the information management system and / or method to display the approval of NI and details of the contractor's procedures. Reports will be supplied via the internet within three calendar days. B. Documentation must include the date of any revisions and the actual closing of corrective actions, etc. C. A detailed report is provided covering all of the supervision reports listing all of the corrective actions still to be completed. NI QA Plan Issue P

Page 43 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

10.17. Management of Non-Conformance Reports The Contractor is responsible for establishing controls to ensure that products not conforming to the specified requirements are identified, segregated and controlled to prevent inadvertent use. In the event that the Contractor identifies a non-conformance affecting delivered products, they shall notify the TOR QAM and withhold further deliveries until authorised by the TOR QAM. In the event that material/manufactured items/work carried out are found not to comply with specification but which the particular contractor considers acceptable or can be recovered then application for ‘Derogation’ shall be made to NI. The same process shall be followed for requests to deviate from specified requirements prior to manufacture, usually for manufacturing convenience. In the case of non-conformances the quality assurance representative shall also monitor the quality control measures put in place, examining the proposed solutions, duration of treatment and monitoring the implementation of the required changes. The Contractor’s QAM will report on all NCRs raised on a monthly basis to the TOR QAM using a table format acceptable to NI. The Contractor shall ensure that: 

Actions for the treatment of NCRs are carried out to their closure and reporting accordingly.



Processes for identification, treatment and correction of non-conformances in the work processes and the quality of the finished product are implemented.



Ways to improve work processes in order to avoid a repetition of the non-conformances are determined.

Incompatibility of different elements in the project quality levels required under the contract may be detected at each stage of the control of the project. Therefore, the Contractor must make sure that quality assurance is maintained by implementing methods to identify, control and monitor all cases of nonconformances.

10.18. Classification of non-conformances by degrees of severity and reporting Discrepancies in the project will be classified according to three levels of severity: 

Level 1: a slight discrepancy, which can be solved by simple means such as rework or repair, without the supervision of the TOR QAM. This may also result in the PM seeking a reduction in the cost of the works. Needs to be resolved within the agreed timescales and no longer than 40 calendar days.



Level 2: a slight deviation to the specifications, requirements and standards. This may also result in the PM seeking a reduction in the cost of the works. Needs to be resolved within the agreed timescales and no longer than 20 calendar days.



Level 3: a significant deviation from the requirements, specifications and standards that requires repair, or an on-going series (or group) of Level 2 non-conformances. Such a non-conformance requires the intervention of the PM, QAM and/or the planner. Needs to be resolved within the agreed timescales and no longer than 10 calendar days.

A Level 3 non-conformance will normally result in a breakpoint in the programme of works.

NI QA Plan Issue P

Page 44 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The Contractor quality assurance representative will ensure that all non-conformances, regardless of the severity level will be recorded and reported to the PM and the TOR QAM using the systems approved by NI. These must be provided via the internet within 2 working days. In addition to classifying the non-conformances by the levels of severity, they shall be classified according to the problem (suspect materials or products, subcontractor, staff or other work, etc.) and shall specify the measures taken to prevent recurrence of the problems. If during the course of monitoring activities by the PM or quality assurance team various inconsistencies are discovered, the Contractor will include in the report, the "corrective action requirements" relating to the defects discovered. The Contractor will carry out the corrective actions according to the criteria listed above. The Contractor will have to create the appropriate level of non-conformance if they receive a demand from the PM or TOR QAM that exceeds current requirements and specifications.

10.18.1. Documentation and tracking of project non-conformances The Contractor’s quality assurance representative will ensure that the Contractor documents and regularly updates the status of non-conformances and corrective actions. The reports must not be accepted as complete unless they include all details of the non-conformances, how they were treated and an accurate reflection of their status. The reports must include details of; 

The type of failure and the nature of it,



The location and type of element,



The date of discovery of the non-conformance and the date it was reported,



The severity level,



The estimated date for rectification,



The date of amendment (if amended),



The closure date etc.

10.18.2. Quality assurance manager reports non-conformances in the project The Contractor’s QAM is to report and document non-conformances as follows: A. Report and update non-conformances using the company's SAP* system compatible with that of NI’s, using the latest format as illustrated below: Table 8: NCR Table Road Number: Project manager name: QA:

#

NCR SAP's Numbe NCR r Number

Specification Opening item number: Date:

NI QA Plan Issue P

Open by: QA / QC

Responsible NCR for defect Level (design, (1,2,3) execution, supplier):

Section Location (road, ramp, From cut To cut bridge ...):

Project Description: Contractor Name: QC: Part: Offset (L,R,CL):

Structure / Layer

Element

SubElement

NCR Description

Responsible NCR Details of Required for corrective Estimated Actual performance treatment: action: (person Closing closing date corrective action: name): Date

Remarks

Page 45 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

B. Every Wednesday, or on another date to be determined by the Quality Assurance Department of NI. The QAM will report the status for non-conformances in the project. The report will include details of the total number of non-conformances in the project, an update of the number of open nonconformances and degree of severity. The report shall be forwarded to the PM, NI QAM, TOR QAM, QCM and the Contractor’s representative. C. The opening, closing or update of the non-conformance opened by the QAM or a representative shall also be included in the report. D. When the initial non-conformance is found and a ‘Corrective Action’ is agreed the QAM shall record this on using the template form below. *The TOR QAM will update the NI SAP system with all of the NCR information. The Contractors are required to use a system that is compatible with NI’s system to help with the efficient transfer of data via the TOR QAM.

10.18.3. Successful closure of an NCR Once an NCR has been raised and the Corrective Action (CA) agreed the party responsible for completing the CA must produce satisfactory evidence, and if necessary demonstrate that the action is complete to the Contractor’s QA team. When the Contractor’s QA team are satisfied that the CA is complete they must contact the TOR QA team and seek a closure of the NCR. Dependent on the circumstances or severity of the NCR the TOR QA team may support the closure based on the submission of evidence by email or seek further evidence by demonstration or conducting a break point supervised event. The specific details of how each NCR is closed must be agreed at the time the NCR is created and be a part of the CA.

NI QA Plan Issue P

Page 46 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 8: NCR Report form

NCR/Corrective Action Request Form Date of Audit:

Audit Number: Corrective Action Number: Name of Lead Auditor: Name of Auditee:

CAR Category: Level 1 Level 2 (Minor) Level 3 (Major) Findings:

NCR Level:

Standard Reference:

1

2

3

Clause / Section:

Agreed:

Maximum Calendar Days for closure Not Agreed:

10

20

Auditee Signature: …………………………….

Lead Auditor Signature: ……………………….

40

Corrective Action Proposed by Auditee:

Agreed Closure Date:

Actionee Signature:

Preventative Action: (To be completed by Auditee Management)

Action Plan Manager Name: Corrective Actions Complete: YES / NO Corrective Action(s) have been completed and implemented satisfactorily.

Lead Auditor Signature:

Date:

Preventive Actions confirmed by: REVIEW / FOLLOW-UP Lead Auditor Signature: Preventive Action(s) have been completed and implemented satisfactorily.

Date:

TOR Project Trend Code: NI QA Plan Issue P

Page 47 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

11. HANDOVER The Handover Strategy shall be agreed between the Contractor, ISR and NI. A site meeting between ISR, NI and Contractor will be arranged so that the documentation can be 'signed off' by authorised signatories as required by the NI Contract. The handover for the Substructure Project to the Superstructure Project and the Superstructure Project to ISR shall be comprised of the following items; 

Document library



Designs



Construction Drawings (As Made)



Defects liability documentation



Progressive handover from site walkouts



Asset Register of ‘fixed’ and ‘removable’ assets



Asset Maintenance Regimes, plus manuals and certification of any required training being delivered



Asset Spares (as agreed within the contract)



Completion of any operational training required



Completion of agreed paperwork with authorised signatories (including any regulatory bodies)



Completion and receipt of Health & Safety File, including full project risk register



Compilation and agreed rectifications for snagging lists



Completion of full project area handover certificate



Final Accounting

All shall be as agreed with NI and in conformance with Israeli law, regulations, and procedures and otherwise agreed standards. Once handover has been completed ISR will become the custodian of the three new railway lines and all responsibility for maintenance, efficient operation and safety will transfer to ISR. The arrangements for discharging these responsibilities shall be provided by ISR, where required, so that the necessary personnel (or companies) are involved in this process as befits their future duties on these lines. NB. Any agreed temporary systems, especially those that enable safe systems of work, must remain in place until such time as agreed with NI or ISR and a suitable permanent alternative has been provided.

11.1. Schedule Akko to Carmiel – This line is expected to be fully operational by January 2017. Haifa to Bet Shean – This line is expected to be fully operational by April 2017. Herzeliya to Kefar Saba – This line is expected to be fully operational by September 2016. Each handover strategy and programme must be aligned with these dates and the handovers conducted in such a manner so as not to jeopardise a timely project completion. NI QA Plan Issue P

Page 48 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

11.2. Substructure to Superstructure 11.2.1. Acceptance Criteria NI requires the Lead Superstructure Contractor to conduct a comprehensive handover from the Substructure Contractor(s). This will be delivered in the form of a progressive site handover (section by section) with supporting documentation. All Substructure activities/engineering disciplines will be covered by this handover and the relevant key personnel (QAM, PM, QS and Engineers) shall be present for all handover events. Site handover forms shall be created to record the handover and signed by each authorised person. Documented evidence shall be produced confirming that all substructure components have been delivered in accordance with the specified ‘Technical Requirements’. The following aspects shall be inspected, discussed and agreed as compliant to specification of the substructure works: 

Strata/Bedrock/Substrate preparation,



Earthworks cleared to specified areas away from superstructure construction area required,



Membranes/sheeting laid and restrained to specification,



Aggregates laid and compacted to specification,



Retaining walls, rock face restraining completed to specification,



Embankments prepared, restrained (where required) to specification,



Boundary fencing, walling and access gates provided to specification,



Temporary Level Crossing surfaces, equipment and monitoring devices provided to specification,



Access roads, temporary structures provided (with supporting designs) to specification,



Associated designs (As Constructed Drawings) provided with full signatures and latest issue,



Asset information for each section provided,



Full asset register provided for the whole project,



All relevant asset ‘life’ documentation provided (warranties, defects liability statements etc.),



Structures completed to specification,



List of any outstanding snagging provided with rectification actions and target dates for close out,



Drainage completed to specification,



Any prepared areas: troughing, catch pits, structure bases etc. have their status shown and are clearly marked as hazards (if necessary) and are protected/cordoned as required,



Health & Safety File completed

The Lead Superstructure Contractor shall also observe the requirements of the Technical Specifications of the Substructure project and ensure that they have the relevant, qualified and experienced personnel present for each of the site handovers.

NI QA Plan Issue P

Page 49 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The Superstructure Contractor shall provide adequate personnel to carry out this handover process and provide a robust and comprehensive programme that meets with NI’s requirements. 11.2.2. Completion of Work The Lead Superstructure Contractor shall ensure the following; 

The Substructure contractors shall complete the earthworks in compliance with the construction standards specified in NI Technical Standards.



On completion of work, the Contractor shall leave the whole site neat and tidy. All cess drains, catch drains and toe drains shall be cleared to the correct section, and any damage caused by the Contractor shall be repaired.



Completion of the Work for the purposes of the Contract will not occur until NI has confirmed that the earthworks are constructed in accordance with the nominated NI Standards.



The Contractor shall undertake a final survey of the completed earthworks by a registered surveyor to certify that the earthworks have been placed within specified tolerances to the design location. The Contractor shall submit the results to NI.

11.2.3. ‘As-Made’ Drawings The Lead Superstructure Contractor shall ensure the following; 

The Contractor is to provide ‘As Made’ Drawings for the substructure. These drawings are to be submitted in AutoCAD format and in accordance with NI requirements. The updated drawings are to include, but be not limited to, the updating of the ‘Approved for Construction’ (AFC) Drawings and any additional necessary Drawings to depict the as-constructed works.



Subsequent to Commissioning of the Works, as a condition precedent to the achievement of Practical Completion, the Contractor shall revise all drawings and documentation to show the Works as finally installed, modified and adjusted to achieve commissioning to the satisfaction of NI.



The Contractor shall submit preliminary copies of the drawings for review by NI that will indicate their acceptability or alternatively indicate the required modifications.

11.2.4. Maintenance Period and Standards The Lead Superstructure Contractor shall ensure the following; Prior to issuing the Final Certificate, the Contractor shall maintain the drainage so that it remains compliant with the requirements for newly constructed earthworks. 11.2.5. Defects Liability Period The Lead Superstructure Contractor shall ensure the following: The Contractor shall maintain the substructure for a period as specified in the contractual requirements from practical completion date. Items to include, but be not limited to: 

Faults in any materials supplied and installed by the Contractor (excludes any Free Issue Material).



Any failure of the formation attributed to poor workmanship by the Contractor as determined by Superstructure Contractor or client ISR.



As defined in the Conditions of Contract.

NI QA Plan Issue P

Page 50 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

11.2.6. Handover documentation The Lead Superstructure Contractor shall ensure the following; The Contractor shall provide a handover package containing, but not limited to, the following data: 

Request for Information, Non Conformance Reports, Test certificates and other forms as nominated in the Contractor’s Project Quality Plan



NI published requirements associated with QA & QC are to be supplied in the stated format



Inspection and Test Plans (signed off by the Principal or its Representative)



Records: a scanned copy of all the records in an approved format on a CDRom or DVD.



Health and Safety File or its equivalent.

11.3. Superstructure to ISR 11.3.1. Basic Responsibilities NI will ensure, via the Lead Superstructure Contractor, that: 

The planning, design, maintenance, installation and commissioning shall be undertaken by organisations that are able to demonstrate competence in these disciplines.



The project fully complies with the contractual requirement at handover.



The testing of the project shall be undertaken by individuals certificated as competent to test the systems concerned.



The procedures are in place for post commissioning support appropriate to the project.

11.3.2. Acceptance Strategy As a minimum the following procedures and processes shall be put in place by the contractor: 

Risk Assessment,



Phased Implementation,



Testing Procedures,



Commissioning Standards,



Maintainability,



Access requirements

11.3.3. Risk Assessment This process is to permit ISR to determine and ensure that the new project or system will not import an unacceptable degree of risk to the Railway, to staff, or to public.

11.3.4. Phased Implementation Due to the scale and complexity of this project it will be necessary to stage the commissioning and the implementation. NI QA Plan Issue P

Page 51 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

11.3.5. Testing Procedures The Contractor shall provide a robust test plan for all stages of the project, which will then culminate in the commissioning stages. NI and ISR will be invited to review the proposed plans so as to ensure that all eventualities have been catered for. The plan shall only be implemented with the agreement of NI and ISR. A formal record of testing and commissioning shall be maintained to record the “as delivered” status of the project. The basis for any testing plan should take into consideration the following testing events; 

A factory acceptance test



A functionality test



An integrity test



A component test



A sub component test



An assembled asset test



A Soak test



A partial systems test



A full systems test.

Each testing procedure shall rigidly follow the specifications required for that engineering discipline/equipment and shall also cater for the ‘combined’ configuration of the newly constructed asset(s). The tests shall only be conducted by personnel qualified to do so and all records must be signed and dated by the testing personnel and Authorised Persons. All records will be handed over to NI/ISR once the tests are complete and at the agreed point in the handover process. The normal flow of equipment and systems testing is for the item (component, sub component etc.) to be tested; 

after manufacture,



at site before installation,



once installed,



A final test as a part of the complete system.

Each testing phase must allow for the correct procedures to be followed and in the time intervals dictated. Aligned to this must be suitably qualified resources and suitable test conditions that simulate normal and perturbed operation of the infrastructure.

11.3.6. Testing and Commissioning Stage(s) Commissioning is the process that completes the testing stages. Once a full (or part) system has been tested to the required specifications, by the correct personnel and has run through an operational sequence this completes the testing cycle and the equipment will be ‘Commissioned’.

NI QA Plan Issue P

Page 52 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

This process is to be organised such that ISR is satisfied that the project is delivered to specification, and can be successfully transferred to operations. Contractors shall undertake thorough testing of all systems and installations before they are put into service. Project Commissioning and Testing Plans shall be prepared by Contractors and shall be approved by NI before implementation. The Contractor shall submit a Testing and Commissioning Plan that covers all necessary Testing and Commissioning stages and engineering disciplines. This shall not be implemented until it has been approved by NI and ISR. The Testing & Commissioning stage is expected to be staged to cater for the complexity and the multiple engineering disciplines involved.

11.3.7. Maintainability The maintenance policy shall be such that system degradation shall not increase the risk beyond acceptable limits. The graceful degradation of modern technology may permit insidious (proceeding in a gradual, subtle way, but with harmful effects) reductions in performance, thus for safety a policy of maintenance checks against initial test data should be considered. A review shall be carried out to ensure that the cost of ownership over the life of the system is acceptable to the client. Factors to be considered shall include the provision of adequate spares backup, suitable test equipment, and an agreement with the appropriate service provider in respect of fault clearance and routine maintenance. This is of special importance from a safety point of view where new technology is involved, and the reliability may be such that no routine maintenance is recommended by the supplier. Training required for support of a new project shall be completed before transfer of maintenance responsibility from the contractor to ISR.

11.3.8. Access Requirements All contractors and their sub-contractors shall provide method statements detailing arrangements for access to stations, tunnels, bridges, track and other engineering disciplines. These method statements must be completed with the consultation of the relevant point of contact ‘Landlord’ for each of the locations listed.

11.3.9. Certificates 

Construction completion certificate



Taking over certificate



Defect identification and completion certificate



Final Certificate

11.4. Handover & Post Commissioning Strategy 11.4.1. Warranty The warranty is a contractual arrangement between NI and ISR, but the latter should satisfy themselves that there is adequate cover for: 

Material Replacement;

NI QA Plan Issue P

Page 53 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects 

Repair;



Defect Reporting in the Warranty Period.

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Failure to observe those aspects in a warranty may import an unacceptable risk to safe operating. 11.4.2. Documentation A formal documented handover process shall be put in place where the contractor, client, and maintenance service provider are represented at an appropriate level and contractually binding signatures shall be obtained. All project documentation shall be written in English with key documents that are required for ISR maintenance department and manuals provided in Hebrew. 11.5. The Process (Asset Transfer) – Superstructure to ISR (Conducted by NI with ISR and supported by the Lead Superstructure Contractor) As part of the overall handover of the Superstructure Project to ISR this process will form the basis of asset transfer. The rationale for implementing this process is to ensure a comprehensive and progressive transfer of the new Railway lines to ISR and to make sure that each of the relevant departments are satisfied that they have received the asset and all necessary documentation. On agreement with ISR the Contractor shall create a series of forms that will cover the steps in the process and a suggested time frame for the delivery of this process will also provide a clear structure to carry out this asset transfer. The contractor shall notify (via NI) the relevant department within ISR of all project work involving the provision of new assets within their area of responsibility, detailing: 

the extent and nature of the project area and;



planned commencement/completion dates and;



The scope of the asset transfer plan to be used for that project.



Notification to ISR by the project shall be: o

in accordance with NI project timelines and,

o

within sufficient time to enable the asset transfer plan to be implemented.

ISR shall need to create and hold a register of these details provided by each project area for their respective departments/maintenance areas. The planned commencement date for each project area shall be notified to the agreed point of contact within ISR by the Project Manager. This must be recorded on an appropriately referenced form and an extract of the project area work plan where appropriate. 11.5.1. Provision of an asset transfer plan The Contractor shall create an asset transfer plan, in accordance with this process The asset transfer plan shall be agreed with the ISR and shall: 

detail the project works;



Identify the new assets being brought into operational use such that they can be incorporated into the maintenance regime for the respective departments.

Once prepared the asset transfer plan shall be subject to version control by the project. NI QA Plan Issue P

Page 54 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The Contractor shall create the appropriate forms to deliver this process. These need to be controlled by the relevant Senior Engineer within the Contractor’s organisation and with the support of NI. These shall normally be adopted when producing an Asset Transfer Plan. 11.5.2. Deliverables The Contractor (via NI) shall agree with ISR, and include within the asset transfer plan, a schedule of the deliverables required for assets prior to, on and after their introduction into operational use in accordance with this process. Each identified deliverable shall include details of the source of deliverable and the delivery timetable. The Contractor shall supply to ISR all asset data deliverables as outlined in the Handover Process and in accordance with NI and ISR standards on the provision of data Management prior to the introduction into operational use of any assets. 11.5.3. Transfer of asset responsibility to ISR ISR, NI and the Contractor shall agree how responsibility will be transferred from the project to ISR. The agreed process shall be documented in the asset transfer plan. Maintenance responsibility shall transfer to ISR only if either: 

The deliverables have been provided, or



An agreed contingency plan is implemented.

11.5.4. Introduction into operational use If any deliverables are missing and the agreed contingency plan cannot be fulfilled then the Contractor and NI shall agree with ISR whether to postpone or restrict the operational use of the assets. 11.5.5. Special Arrangements for Stations The Stations for this project are being delivered by the Substructure Project Management teams and the handover arrangements to ISR shall be agreed with them separately from this Superstructure project. 11.5.6. The Asset Transfer Plan The Asset Transfer Plan is primarily the schedule of assets that ISR will be receiving from the project. The Plan will indicate the timescales for the handover and be divided up into project areas so as to support a progressive handover, in agreement with the wishes of ISR. The plan should also document the people responsible for the delivery of this transfer from within NI, ISR and the appointed Contractors. The plan can also have other project documentation accompanying the transfer of assets such as the Health & Safety File, Defects Liability Records and Warranty Documents. This list is not exhaustive. 11.5.7. Timescales The following is a suggested timescale illustration that can be modified on the agreement of ISR and NI.

NI QA Plan Issue P

Page 55 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 9: Outline of Asset Transfer Plan timeframe

11.6. Handover General At the end of the agreed sections of work and before the completion of the agreed milestones the contractor shall submit for approval, to the quality assurance representative and PM, all required evidence that will support the request for payment. NI QA Plan Issue P

Page 56 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

In addition to the required evidence the Contractor’s QAM/QCM shall provide a summary on the following topics; A. Paper copy and electronic copies of all audits, sample tests, FATs and their results, B. All relevant NCR information and proof of closure, C. A comprehensive list prepared by the appropriate qualified and competent personnel, in a format agreed with NI, of materials, equipment, ‘As Made’ drawings and certificates for each section to be handed over. This shall be accompanied by electronic maps and the necessary electronic information, D. Statements from the delivery team on the completion of the works.

12. PROJECT DOCUMENTATION 12.1. Current Reporting The Contractor’s quality assurance and quality control teams shall communicate on a daily basis and throughout all stages of the project, with each other and if necessary with NI’s quality assurance team. Non Conformances shall be reported immediately and if necessary a report shall be provided to the PM.

12.2. Tests and Results The Contractor’s shall record all test results and communicate these results throughout all stages of the project, with each other and to the TOR QAM and NI when required.

12.3. Quality Assurance audits and surveillance Programmes are to be developed that reflect the appropriate level of Assurance required. These programmes test not only compliance with relevant standards but also look at the level of concentration on those functions identified as presenting the greatest risk to safety. In addition to the above, other surveillance is carried out including Technical Audits by TAP members, including intrusive and non-intrusive inspections, and Systems Audits.

12.4. Document Management System All records required to demonstrate conformance to the Contract requirements shall be kept by all Contractors and their sub-contractors and submitted ‘on request’ to NI for relevant stages and audit purposes. The Contractor must employ a person for the three railway lines to fulfil this role of ‘Document Controller’ who must be of suitable experience and if given other tasks must still be able to fulfil the duties required of this position without jeopardising quality assurance. All documentation shall be indexed, filed, maintained and stored in a manner that shall make them readily available for inspection and audit purposes. These records shall be held, in conjunction with any associated correspondence files by the Contractor and their sub-contractor.

NI QA Plan Issue P

Page 57 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

The contractor Document Controller(s) shall ensure that records are compiled coincidental with the work order to which they relate. All records, including any generated by subcontractors/suppliers shall be compiled, indexed and uniquely identified. The Contractor shall select a suitable software package for the storage and distribution of project documentation. The following software applications are listed, although the contractor can suggest an alternative with the agreement of NI; • BCS o http://www.unit4collaboration.com/products/bcsix • Aptus o http://www.aptus.co.uk/?gclid=CJH56frXjLICFcfKtAod9HkAUw • Fabasoft: o http://www.foliocloud.com/lp-document-managementsystem.html?gclid=CIK127PajLICFcUPfAod8U8Avg • Mclaren: o http://www.mclarensoftware.com/solutions.aspx • DOORS: o http://www-01.ibm.com/software/awdtools/doors/productline/ The Contractor shall also provide free access (at their own expense) for NI, TOR and ISR personnel to view and obtain documents from the selected system. This includes all drawings and supporting documents. Once the contract has been awarded the Contractor shall have the agreed system in place, with access available for all required personnel, within 90 calendar days.

NI QA Plan Issue P

Page 58 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

13. QUALITY ASSURANCE CHECKLISTS All checklists will be provided by the Contractor’s quality assurance and quality control teams using the details provided in the contract specifications, the information found in the relevant standards and the INECO Detailed Design reports and supporting Technical Specifications as listed earlier in this QAP. Example checklists shall be provided by the contractors as part of the ITT process and the final versions agreed with NI, ISR and the TAP team when the successful Contractor is appointed. Once this is completed they must be provided as annexes to the approved QAPs and QCPs. The checklists must cover the following occasions; 

Early Control



Routine Control



Test Points



Breakpoints



Audits



Surveillance



Sample Testing



Supervisions

Examples of some checklists (for information only) can be found in section 16 ANNEX C.

NI QA Plan Issue P

Page 59 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

14. ANNEX A - PROJECT DIRECTOR’S QUALITY STATEMENT The NI Contract Management Team is fully committed to implement the respective policies and procedures required to ensure the quality of this project. The Team will also carry out its activities in a manner which complies with the quality principles identified within each Quality Management System and will meet the requirements of any associated Technical Specification as applicable to their area of activity/operations. Responsibilities The NI Contract Management Team accepts their responsibilities identified in their respective policies and specifically for this contract is accountable for ensuring: 

Any activity carried out under the contract does not compromise quality,



Compliance with all relevant; o

Technical Specifications,

o

Standards,

o

Legislation,

o

Israeli Laws



NI have effective processes in place to ensure compliance with NI’s Policies and key requirements within the contract,



Effective interface between NI and contractors throughout all phases of the project such that quality will be ensured and any risk of it being compromised is kept as low as possible,



The provision of a contractor workforce consisting of managers, engineers, supervisors and employees, trained and re-trained to the appropriate levels to work and to use tools and equipment so as to deliver projects to the prescribed quality levels,



Plans, procedures, methods of work, instructions and information and revisions thereof, are developed by contractors to meet the changing work activities,



The audit by corporate management and the Quality Assurance Professionals at regular intervals to ensure that this statement is being upheld,



Duties and responsibilities defined under Regulations are allocated and implemented,



The review of the Quality Assurance Systems, programmes and policies at least every six months, to ensure that the project objectives and targets are being achieved.

NI QA Plan Issue P

Page 60 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

15. ANNEX B - PROJECT ORGANISATION CHART Figure 10: Project Organisation Chart (Relationships)

Israel Government

National Transport Infrastructure Company (NI)

Israel Railways (ISR)

ISR (Electrification)

Electrification Designer YANI

ROL

Touchstone Renard

INECO

Superstructure Lead Contractor

Designers

Thales (Signalling)

MOTOROLA

ELBIT

Nokia Siemens Network

Key: Direct reporting

Track Contractor

Civils Contractor

Tunnel Contractor

Electrical Supply

Lighting

Fire Detection

Fixed Coms

Water Supply System

Earthquake Detection

Computers

Stray Current Anti-Corrosion

Ventilation Air Conditioning

Drainage

Mobile/Radio Coms

SCADA

GSM

Falling Objects Detection

In Contract with IN and report to ROL Cooperation required

Notes: *The sub-structure project will be installing bases for the stanchions for the Electrification *Thales, Motorola, Elbit and Nokia can choose to use the Lead Contractor or other subcontractors *Operational Control will be installed in the existing ISR buildings, although an ISR project to construct a new Control Building may be ready at the same time this Superstructure project commissions

Electrification Earthing

NI QA Plan Issue P

Page 61 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

16. ANNEX C - EXAMPLE CHECKLISTS Figure 11: Quality Assurance Checklist

TOR QA Ref. 1

2

3 4 5 6 7

8 9 10 11

12

13 14 15 16 17 18 19 20 21 22 NI QA Plan Issue P

Check

Y/N

Evidence

Is the correct project documentation available;  Technical  Managerial  Safety Is the scope of the project known to a sufficient level of detail and has it been briefed to the appropriate personnel? (See organisation chart) Are the projects quality deliverables listed and referenced? Has the project got a Quality Management System and is it adequate? Is the Quality Management System approved by the client? Is there a Quality Management Statement available? Is there a document library available of applicable documents that support the QAP and QA/QC system? Is there a copy of the Project Organisation chart available and is it up to date? Is there an up to date copy of the project programme available? Does the project programme have QA/QC events listed and scheduled? Are each of the Engineering Disciplines involved in this project represented in this project’s QA system? Is there a QA/QC team in place? Do the members’ responsibilities support the QA system? Have they been approved by the client? Is there a list of requirements provided by the client? Have these been correctly interpreted by the contractor? Is there a list of standards applicable to this project provided by the client? Have these been correctly listed by the contractor? Has the contractor implemented an approved change control process? Has the contractor implemented an approved Project Information Model? Has the contractor implemented a system for the review and approval of QA/QC evidence? Has the contractor implemented a Cross referencing system for other project plans? Do the contractor’s QA/QC team hold the required qualifications and experience? Page 62 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects TOR QA Ref. 23

24 25 26 27 28 29 30

31 32 33

34 35 36 37

38 39 40 41 42 43 44 45

46 47 NI QA Plan Issue P

Check

REF: ISSUE: DATE: Y/N

NI/QA/PLN/001 P 03/04/2013

Evidence

Has the contractor made arrangements for the coordination and briefing of other QA/QC systems in use by other contractors on this project? Does the contractor have an approved QCP? Does the contractor have an approved programme for QC? Does the contractor have an approved programme for QA? Does the contractor have evidence that the QA plan is being followed? Are the materials to specification? Is there evidence that the supply chain is robust? Is the installation of materials being carried out to specification and that the combined product of various materials is to specification? Is construction being carried out to specification? Does the QCP have clear targets and KPIs on which to measure its progress against criteria? Is the work meeting the specification of the remits and is it being delivered to the satisfaction of the end client? Does the contractor have a comprehensive QCP? Does the contractor have a comprehensive audit regime in place and is it being carried out? Does the contractor have regular QA/QC meetings with clear outputs and closed actions? Is the contractor carrying out construction site visits by their management team and inviting the client team also? Has the contractor carried out an early control review? Has the contractor kept records of their early control checks? Has the contractor conducted any sample tests? Has the contractor kept records of their sample tests? Have the correct personnel been involved in the carrying out of the sample test section? Has the contractor carried out a programme of Routine Control inspections and surveys? Has the contractor kept records of these inspections and surveys? Have any NCRs been generated as a result of these inspections and surveys and have they been managed accordingly? Have Test Points been programmed for the project? Do they cover all project disciplines and stages? Page 63 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects TOR QA Ref. 48 49 50 51 52

53 54 55 56 57 58 59

60 61 62

63

64 65 66 67 68 69 70 71

72 73

NI QA Plan Issue P

Check

REF: ISSUE: DATE: Y/N

NI/QA/PLN/001 P 03/04/2013

Evidence

Have Break Points been programmed for the project? Do they cover all project disciplines and stages? Has the contractor requested supervision for any key stages in the project? Have the correct personnel been present at these events? Have all the supervised visits been recorded properly and signed off by the correct personnel? Has the contractor implemented an approved system for the management of NCRs? Are they being recorded and reported correctly? Are they being closed out in a timely manner? Has the contractor been subject to any fines through not closing NCRs? Has the contractor developed a programme for the handover (receipt) of the substructure? Has the substructure handover (receipt) been conducted successfully Have all snagging issues been captured from the substructure handover and has a programme of rectifications works been agreed? Are works being completed to the specifications? Are ‘As Made’ drawings being provided and do they agree with the physical completion? Are the details for the Defects liability periods provided and have they been agreed with the client? Has all handover documentation been provided from the substructure to the superstructure contractor? Has the contractor developed and agreed an acceptance strategy for handover to ISR? Has the contractor created a comprehensive testing programme? Has this been agreed with NI and ISR? Has the contractor developed a commissioning programme? Has this been agreed with NI and ISR? Has the contractor supplied all necessary certificates to support the handover? Have all warranties been provided that support the full handover of the project? Has all relevant documentation been provided by the contractor to ISR to support a full handover? Has a list of deliverables been agreed for the handover to ISR? Has the contractor concluded all applications for payment via the QA team to NI?

Page 64 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects TOR QA Ref. 12. 12. 13. 13.

Check

REF: ISSUE: DATE: Y/N

Has the contractor implemented a robust and comprehensive document management system? Are reports being provided at the prescribed frequency by the contractor’s QA and QC teams? Has the contractor provided copies of the QA checklists to be used for approval by NI? Has the contractor supplied copies of completed QA checklists to support inspections carried out?

NI/QA/PLN/001 P 03/04/2013

Evidence

The QAP makes insufficient ref here to QC to use the term separately. QA covers. As above.

Figure 12: Signal or Sign Inspection form

Project Name: Inspection carried out by: Site Name: Scope of Inspection:

Description

1

2

3 4

5

6

7

8 9

Signal ID:

Contractor: Inspection date:

Compliance Y / N / NA / NC *

Actions Required

Actions By:

Complete On:

Signal / Sign concrete base has been installed to approved sighting? Signal / Sign profile is as shown on the approved sighting form and scheme plan (longitudinal position, clearances, profile, id plate secure, anti-vandal measures, OHLE Cage, return wire taped etc). Signal Painted/galvanised & free from damage Identification plate mounted clear of signal head sighting hole where ground mounted. Concrete base coated with bitumen prior to signal being erected Liquid grout installed between base & signal post (where required). Signal holding down bolts are tight & covered with self-amalgamating tape View of signal is unobstructed Signal structure has been installed correctly

NI QA Plan Issue P

Page 65 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects Description

10

11

12

13 14

15

16 17

18

19

20

21

22 23

24

25

Compliance Y / N / NA / NC *

Actions Required

REF: ISSUE: DATE: Actions By:

NI/QA/PLN/001 P 03/04/2013 Complete On:

Signal ladders and platforms conform to specifications and are secure. Un-commissioned signals / signs are covered & marked with a white cross (signals only) Correct signal lenses have been installed & hot strips are correctly aligned. Signal lamps are focused correctly. Signal head secured with the correct nuts and bolts in the correct orientation. Signal access doors are free to open & have padlock provided Signal cable entries have been sealed with foam. Cables to signals are secured, labelled, terminated, cores numbered & clamped in the unit. Multi-aspect signal lamp holders are fitted with disconnection links. Any spare un-terminated cable cores are insulated/bomb-tailed. Terminations are clean & treated with protective agent Signal post telephone installed according to approved SSF. Driver’s walkway installed as stated on SSF. Cables crossing tracks are clipped to the sleeper with suitable securing clips. Maintenance Record Cards are on site and complete. Are there records of Contractors Quality Inspections?

NI QA Plan Issue P

Page 66 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 13: Trough Route Inspection Form

Project Name: Inspection carried out by: Site Name: Scope of Inspection:

Description

1 2

3

4 5 6

7

8

9 10

11

12 13

Line ID: Mileage:

Compliance Y / N / NA / NC *

Contractor: Inspection date:

Actions Required

Actions By:

Complete On:

Troughing correct type as specified. Installed trough route has 25% spare capacity available. Installed trough route is 2metres from nearest rail (wherever possible). Trough route installed to standard. Trough route alignment & level correct. Galvanised supports installed where required & are free from damage. Trough route has retaining pins installed where specified in the design. Dry mix troughing has blowholes of less than 10mm; smooth internal walls & is undamaged. Trough lidding has been secured where required. Tee sections have been installed where required, lids fitted & are undamaged. Ballast boards installed where required to correct height & are correctly supported and undamaged. Trough lidding overlaps any joint. Curves are installed where required & cut to length.

NI QA Plan Issue P

Page 67 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects Description

14

Trough lidding installed at ground level if in walkway and has tactile surface.

15

Troughing in public walkways has been installed 700mm below ground. Troughing has been protected where adjacent to buffer stops or catch points Troughing installed under sidings is 600mm below sleepers and fitted with double lids Trough route is clean of debris prior to cable installation. Open ends of trough routes are sealed with foam. UTXs and URXs are installed correctly, free from obstructions & have draw wires. Cable chambers are installed & have secure lidding. Cable chambers have concrete base installed & has water 'soakaway' sump fitted. Plastic cable chambers have external metal ring bolted to frame. Brick cable chambers are as design & covers are haunched adequately with cement. Draw rope is installed where lids are glued or secured. Are there records of Contractors Quality Inspections?

16

17

18

19

20

21

22

23

24

25

26

NI QA Plan Issue P

Compliance Y / N / NA / NC *

Actions Required

REF: ISSUE: DATE: Actions By:

NI/QA/PLN/001 P 03/04/2013 Complete On:

Page 68 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 14: Electrification & Plant Design Approval form

Technical Approval of Electrification and Plant Asset Design - Engineering Design Statements Project Name Contractor

Design Name/Number

Version Number Designer

The designer confirms that this Electrification / Plant* design has addressed the key design requirements stated below: *(delete as appropriate) Tick as appropriate, if any boxes are ticked "No" then details of the deviation shall be provided. Design Statement Yes No Details of deviation The scheme complies with the requirements of the remit and the design concept is appropriate for its purpose, location and site conditions. The requirements of ISR/NI standards are adequately addressed, with any deviations justified. Product Acceptance requirements are identified Any significant design issues not covered by standards are adequately addressed. Interdisciplinary design checks and review are satisfactorily completed. The effects of the scheme on existing infrastructure have been adequately considered. The Design is robust and offers value for money Health, safety and environmental implications of the construction, maintenance, removal and disposal are satisfactory.

NI QA Plan Issue P

Page 69 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 15: Equipment Room/Unit Inspection form

Project Name: Inspection carried out by: Site Name: Scope of Inspection:

ID: Mileage:

No

Description

Compliance Y / N / NA / NC *

1

Concrete base/foundations as shown on drawings. Structure constructed as shown on form drawings. Unit secured to concrete base & anti-litter skirt fitted. Unit internal/external walls are free from damage. Internal walls are plastered or are left fair faced & are free from damage. Access steps have been provided (where required). Air conditioning/heating has been installed, is working correctly, free from damage and is not aimed directly at equipment. Ambient temperature controlled between 19 and 21 ºC without ‘hotspots’. Max/Min thermometer or similar provided. Access to Unit is as per the ground plan & free from obstructions. Handrails have been provided (where required). Unit has been fitted with the correct door locks & emergency push bars (where required). Fire & Intruder alarms are fitted and working (where required). Unit lighting is as design and adequate.

2 3

4 5

6 7

8

9 10

11 12

13

14

NI QA Plan Issue P

Contractor: Inspection date:

Actions Required

Actions By:

Complete On:

Page 70 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects No

Description

15

Unit has only one main earth point (PME OR Gapped).

16

Main earth & Test earth bus -bars cannot be touched at the same time. Palisade perimeter fencing has been installed (where required). Palisade fence cut ends have been protected against rust. Palisade access gate has hinges facing opposite directions & correct padlock fitted. Equipment installed correct to diagram & specification and all labelled. Equipment racking installed to diagram, is secure and earthed. Unit wall mounting bars have been earth bonded. Cables installed correct to diagram, moisture barriers fitted and labelled correctly. Cables are clamped and entry holes sealed with foam. Cable/wire ties are fitted correctly & have external serrations. Cable cores are terminated and identified. Un -terminated cable cores have been bomb-tailed (purple). Power cables over 200volts have been placed in unslotted trunking. PVC & Rubber cables/wires have been segregated where in same trunking. EPR wire does not react with PVC. Cables have been megger tested & record sheet completed. Binding post terminals are fitted with RED dome nuts.

17

18

19

20

21

22 23

24

25

26 27

28

29

30

31

NI QA Plan Issue P

Compliance Y / N / NA / NC *

Actions Required

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Actions By:

Complete On:

Page 71 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects No

Description

32

Wiring ducts/trunking has been installed with no sharp edges, plastic bolts have been used; corners have protection fitted and holes have grommets.

33

Correct wiring has been installed, crimped correctly & identified. Test crimps have been made & are on site. All record cards have been completed and are on site. Shelf type relay terminals have been fitted with shrouds (where required). Earth leakage detectors are correctly set & are working (where required). Timer relays are set correctly & double sealed with corrugated wire wrapped around relay retaining wire. Wiring ducts/trunking are not over full and are of the correct type Fuses fitted are the correct type. Health & Safety signs have been displayed (where required). Safety equipment is provided (where required). Batteries installed to diagram, racks secured to floor. Batteries are free from damage & in good condition. All exposed terminals have been coated with Tectyl rust inhibitor. Wiring diagrams are on site and correct version. Desk provided for technicians to view diagrams fully opened & adequate storage provided. Unit is clean and tidy.

34 35 36

37

38

39

40 41

42 43

44

45

46 47

48

NI QA Plan Issue P

Compliance Y / N / NA / NC *

Actions Required

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Actions By:

Complete On:

Page 72 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects No

Description

49

Emergency panel correctly installed, correct to faceplate design and free from damage (where required). Maintenance Record Cards are on site and complete. Local panel separated from technical area by locked door/gate. All phones labelled correctly. Are there records of Contractors Quality Inspections?

50 51

52 53

Compliance Y / N / NA / NC *

REF: ISSUE: DATE:

Actions Required

NI/QA/PLN/001 P 03/04/2013

Actions By:

Complete On:

Figure 16: Example Checklists for breakpoints

Site

Contract No

Project Name

QAM

Project Director

QCM

Contractor

Break point Date

No

Topic

Breakpoint info

1

Identifiers

2

Reason for breakpoint

3

Sample test results

4

NCR info

5

CAR info

6

Programme amendments

7

QA Decision

Comments

Figure 17: Example Checklists for Early Control

Site

Contract No

Project Name

QAM

Project Director

QCM

Contractor

Early Control Date

No

Subject for review

1

Specifications understood

2 3

Pre start meetings held, arrangements made Materials and Plant approved

4

Required sample tests completed

NI QA Plan Issue P

QCM

QAM

Comments

Page 73 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects No

Subject for review

5

Sample test framework in place

6

Required notifications made

7

Contractor teams approved

8

Equipment approved

9

Test area selected and marked out

10

QC checklist includes a test section

11

Required parties prior approval

QCM

REF: ISSUE: DATE: QAM

NI/QA/PLN/001 P 03/04/2013 Comments

Figure 18: Example Checklists for Routine Control

Site

Contract No

Project Name

QAM

Project Director

QCM

Contractor

Inspection Date

Activity Inspected

Prior Inspection Details

No

Subject for review

NI QA Plan Issue P

Score/Rating

Comments

NCR

Page 74 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 19: Example Checklists for QA/QC Surveillance

Site

Contract No

Project Name

QAM

Project Director

QCM

Contractor

Inspection Date of QA

Activity Inspected

Prior Inspection Details

Supplier QC System Description of surveillance/test Date:

QA System Description of surveillance/test Date:

Findings, Outputs and Conclusions NCR details (if required) Decision

Findings, Outputs and Conclusions NCR details (if required) Decision

CAR (if required)

CAR (if required)

Approval to continue working

Approval to continue working

Comments

Figure 20: Example Checklists for QC System test

Site

Contract No

Project Name

QAM

Project Director

QCM

Contractor

Inspection Date of QC

Activity Inspected

Prior Inspection Details

Supplier Description

Specifications

Results

Date of QC inspection

Date

Certificate No

Conclusions

Comments

NI QA Plan Issue P

Page 75 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

Figure 21: Example Checklists for QA System test

Site

Contract No

Project Name

QAM

Project Director

QCM

Contractor

Inspection Date of QA

Activity Inspected

Prior Inspection Details

Supplier Description

Specifications

Results

Date of QA inspection

Date

Certificate No

Conclusions

Comments

NI QA Plan Issue P

Page 76 of 77

NETIVEI ISRAEL (NI) – National Transport Infrastructure Company QUALITY ASSURANCE PLAN Israel Railway Expansion Projects

REF: ISSUE: DATE:

NI/QA/PLN/001 P 03/04/2013

17. ANNEX D - ISR ORGANISATION CHART

Internal Auditor

Board of Directors

CEO Freight Dev.

Passenger Service Dev.

VP Development

Coordination & Control Dep.

High speed line Administration

Rolling Stock Dev.

Infrastructure

Communication

Dev.

Projects Dep.

Lines and Sites Execution Operational Control Dep.

Safety, Security & Environment Div.

Electrification Administration

Sites Development

Dep. Operational Development

Dep.

Dep.

Rolling Stock Dev.

Business Development Div.

Planning Dep.

Finance, Economics & Contracts Div.

HR and Logistic Div.

Marketing and Service Dep.

Legal Adviser

Spokesperson

IT Dep. Secretary

Strategic Planning

NI QA Plan Issue P

Page 77 of 77

Suggest Documents