Quality Control Inspection (QCI)

Quality Control Inspection (QCI) Process for Aramco Projects in Saudi Arabia

1. Project Planning & Quality Assurance

• Aramco’s Specifications and Standards: Start by thoroughly reviewing the Aramco Engineering Standards (AES) and Aramco’s General Specifications (GS), as they define the minimum quality requirements for construction, testing, and materials.
• Quality Control Plan (QCP): The contractor must submit a detailed Quality Control Plan (QCP) for approval by Aramco, outlining procedures, responsibilities, and quality control activities for every phase of the project.
• Project Team Formation: Set up a dedicated Quality Control Team, including qualified QA/QC inspectors, engineers, and relevant personnel, with expertise in Aramco’s quality requirements.

2. Pre-Construction Phase

• Material Approvals: All materials to be used must be approved in advance by Aramco. The materials should meet international standards (e.g., ASTM, ISO) and must pass Aramco’s material approval process.
• Vendor Qualification: Vendors and suppliers must be approved by Aramco, ensuring that they meet the standards for material quality, testing, and delivery.
• Pre-Construction Inspections: Aramco performs a series of inspections and surveys before construction begins to ensure the site is suitable and ready for the project. These include geotechnical investigations, site surveys, and review of construction methodology.

3. Construction Phase - Inspection & Monitoring

• Ongoing Site Inspections: Aramco or an Aramco-appointed third party will perform routine inspections during the construction phase to monitor the adherence to construction methods, quality of work, and compliance with specifications.
• In-Process Testing: Several tests must be conducted during construction, including:
  • Concrete tests (e.g., slump test, compressive strength)
  • Welding inspections (using non-destructive testing methods like ultrasonic testing, radiographic testing)
  • Piping inspections (pressure testing, X-ray testing of welds)
• Safety Inspections: Aramco enforces strict safety and environmental compliance, with periodic safety audits and inspections.

4. Final Inspections & Handover

• Pre-Commissioning & Testing: Before final handover, systematic pre-commissioning checks are carried out. This may include checks for:
  • Electrical and mechanical systems
  • HVAC systems
  • Fire and safety systems
  • Piping and pressure systems
• Punch List Creation: After a final inspection, Aramco will create a punch list identifying minor defects or incomplete items that must be resolved before the final handover.
• Final Acceptance Testing: Upon completion of the punch list, final acceptance testing is conducted, and if all tests and inspections pass, the project is officially accepted.

5. Documentation & Certification

• Documentation Submission: The contractor submits detailed reports and documentation to Aramco, including inspection reports, material certificates, test results, and completion certificates.
• Final Handover: After completing all requirements, the contractor provides the final documents to Aramco for the official handover of the project.
  • Documents typically include as-built drawings, operational manuals, maintenance manuals, and warranty information.

6. Post-Construction Phase

• Warranty Inspections: Aramco may conduct follow-up inspections during the warranty period to ensure that the project is performing as expected.
• Corrective Actions: If any defects are discovered after handover, the contractor is required to take corrective action as per the warranty agreement with Aramco.
• Project Close-out: After successful inspections and corrections, the project is formally closed out, and all warranties and maintenance periods are managed.

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Aramco’s Key Standards and Documents for Construction and Quality Control

1. Aramco Engineering Standards (AES): These are Aramco's internal standards governing all engineering, procurement, and construction activities. They cover everything from materials and design to testing and installation procedures.
2. Aramco General Specifications (GS): Aramco GS defines requirements for materials, quality control, environmental concerns, safety, and inspections. This document is critical for contractors to understand before beginning work on an Aramco project.
3. Saudi Aramco Inspection and Test Plans (ITP): These plans outline the specific inspections and testing required throughout the project lifecycle. The ITP is used to ensure quality at every step and is a requirement for all projects.
4. Non-Conformance Reports (NCR): If quality issues are found during inspections, an NCR is generated. The contractor must address the issues and provide a corrective action plan.

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Key Considerations for Contractors Working with Aramco

• Aramco’s Project Oversight: Aramco has strict oversight throughout the project, including regular inspections and audits to ensure compliance with standards.
• Adherence to Safety Standards: Saudi Aramco has one of the highest safety standards in the world. Ensuring compliance with safety guidelines is essential.
• Documentation and Traceability: Accurate documentation is crucial. All inspection reports, material certifications, and test results must be archived and made available to Aramco upon request.
• Third-Party Inspections: Aramco often uses third-party inspection bodies to verify the quality of work and materials.

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If you need more specific details about a particular Aramco project, it may help to contact the relevant department within Saudi Aramco or the main contractor handling the project.