1) Why are project objectives important? a) Clear project objectives are basis for realistic project planning and for defining the requirements/results to be implemented/achieved during the project. b) Clear project objectives avoid misunderstandings between the client (customer), other interested parties and the project organization at an early stage. c) Clear project objectives are the basis for project controlling and ultimately serve as an indicator of project success/failure. 2) When must project objectives be available? a) Project objectives are defined in the project planning phase and must be finalized before the project execution phase. b) Project objectives must be defined before the project starts but can also be fine-tuned during the project planning phase, after the project has already started. c) Project objectives can be defined or adjusted in each project phase. 3) The typical project phase in plant engineering and construction were explained by using the project example “New acetylene plant” Which results are expected, among others, at the end of the “project planning phase”? a) Detail engineering (status”Issued for Construction (IFC)”) and procurement completed, construction and commissioning of the plant performed according to schedule/quality/budget objectives, project “as-built” documentation finalized. b) Project objectives, project scope/boundaries and milestones are clarified, costs are roughly estimated (+ 30%) and the approved project application for the project planning is available for final approval. c) Project management plan, FEED package (status “Issued for Design (IFD)”), detailed project schedule, exact cost estimate (+10%) and the approved application for the project execution phase are available for final approval. 4) What is a FEED package (Front End Engineering Design - package) in plant engineering and construction, in which project phase is it prepared and what does it contain? a) The FEED package is the result of the basic engineering in the project planning phase and is the basis for the detail engineering in the project execution phase. b) The FEED package is the result of the detail engineering in the project planning phase and is the basis for procurement and assembling of equipment, pipelines, etc. on the construction site. c) The FEED package includes all technical documents of the engineering disciplines (like process engineering, civil engineering, mechanical engineering, electrical and process control engineering) as well as of the construction disciplines that reflect the technical and project specific requirements of the customer and the project location. d) The FEED package contains all discipline-specific work packages that define which engineering documents are to be prepared, at what level of detail, and by which deadline. 5) Which requirements does project management have for the FEED package in term of content, degree of completion and quality, in order to achieve, among others, the project objectives of costs deadlines? a) Content, degree of completion and quality of the documents in the FEED package should have reached the status “IFD (Issued For Design)”, as it is the basis for e.g., requests for proposals, scheduling and exact cost estimates. b) Content, degree of completion and quality of the documents in the FEED package should preferably have reached the ”as-built”, as it is the basis for exact cost estimates and scheduling. c) If content, degree of completion and quality of the documents in the FEED package do not meet status “IFD (Issued For Design)”, this could lead to significant changes associated monetary claims and delays in project execution phase. 6) What are “Gates” in project phases and what is the significance of the “Phase gate process” in project management? a) Gates are scheduled hold points/milestones at the beginning, within and/or at the end of a project phase, at which the originally planned targets are compared with the work results currently available. b) Gates are milestones in the project life cycle that mark the beginning and end of the project. c) A gate is a scheduled point of time at the end of a project phase when a decision is made as to whether the gate can be released or not be released for the following phase. d) The phase gate process is used in the project planning phase. After project approval and at the beginning of the project execution phase, the process is completed. e) The phase gate enables an early controlling intervention to avoid that omissions persist over the project lifetime or even potentiate their effects, which then lead to considerable cost/schedule risks. 7) A chemical company assigns the in-house project management department with the engineering and project execution of a new Which project organization is responsible for the project execution and for the achievement of the project objectives? production plant. The FEED package was created together with an external plant engineering and construction company whose process technology is used. After project approval, this company was contracted by the project management department to execute the project as EPC contractor. a) The EPC contractor is responsible for the project execution and for the achievement of the project objectives, as it has been contracted by the in-house project management department. b) The EPC contractor is only responsible for the project execution and achievement of the project objectives according to the EPC contract. The in-house project management department supervises all services of the EPC contractor according to the EPC contract and remains responsible to its management for overall project execution and for achievement of the project objectives according to the project execution and for the achievement of the project objectives according to the project application/approval. c) Both the in-house project management department and the EPC contractor are equally responsible for the project execution and for achievement of the project objectives according to the project application/approval. 8) What exactly is a project management plan (PMP) and what is its significance for the project organization? a) The PMP is an important project document for the project organization and other interested parties. b) The PMP is the planning result of the entire project organization and contains all project-relevant information that defines how the project is executed, monitored and controlled in the project phase. c) The PMP is a controlled project document, i.e., document creation, review, approval, changes and controlled. d) The PMP is submitted to the upper management level together with the project application for project approval. 9) Who in the project organization is responsible for the preparation review and approval of the project management plan (PMP) and for its communication within the project organization? a) The project steering committee has overall responsibility for the preparation content and approval of the PMP and its revisions. b) The project manager has overall responsibility for the preparation, content and approval of the PMP and its revisions. c) Members of the project management team support the project manager in preparing the PMP and in reviewing the respective chapters of their discipline. d) Nominated members of the project team are responsible for the preparation, content and approval of the PMP and its revisions, as only they know their discipline-specific and project-relevant information. 10) Which project-relevant information do you expect to find in the project management plan (PMP) at the end of the project planning phase of a plant engineering and construction project? a) Description of the project objectives, project scope/boundaries and the interfaces. b) Notes on applicable documents such as guidelines, specifications that must be considered during the project. c) Notes on significant deviations from standard processes of the organization with sufficient justification. d) Process description of the procedure in case of changes to project requirements and/or scope of deliveries/ services. e) References to other project plans concerning organizational structures, resources, deadlines, costs/budget, communication and risk management. f) Process descriptions for correspondence and document management as well as description of information protection requirements. 11) CD. Which project-relevant information do you expect to find in the project management plan (PMP) at the end of the project planning phase of a plant engineering and construction project? a) References to other project plans concerning quality management and environment/health/safety (EHS) management. b) References to other project plans concerning Detail Engineering, Procurement and Construction. c) Complete FEED package (Issued for Design status) with all the discipline-specific engineering documents that reflect the technical and project-specific requirements of the customer and the project location. 12) What description of the term “quality” do you agree with? a) Quality is the fulfillment of the highest possible requirements for a product or service. b) Quality is the consistent fulfillment of the highest possible requirements for a product or service. c) Quality is consistent fulfillment of defined requirements of a product or service and the perceived value and benefit for the customer. 13) What is a quality management system (QMS)? Which statement(s) do you agree with? a) QMS and quality management basically mean the same thing, there is no difference. b) A QMS is the systematic approach to quality management and provides a formal framework with principles for planning, executing, monitoring and improving the performance of quality management activities. c) A QMS essentially comprises the monitoring of all tasks, activities and resources in an organization that are necessary to achieve the quality objectives. 14) Which objectives does a company pursue with a quality management system (QMS)? Which statement(s) do you agree with? a) The objective of a QMS is to ensure consistent quality of products and services based on traceable and stable workflows (processes). b) The objective of a QMS is to continuously review, evaluate and improve the performance of the organization and avoid anything that does not contribute to the sustainable success of the company. c) The objective is of economic interest, because a well-implemented QMS means, for example, effective and efficient work processes that avoid non-conformity costs and thus lead to higher profits and market shares. 15) According to the standard DIN EN ISO 9001, the quality management system (QMS) of an organization follows the PDCA cycle (Deming cycle). What does that mean? a) The QMS is a dynamic system that develops through continuous improvement. b) The operational processes defined in the QMS are planned, implemented, periodically checked in terms of effectiveness and efficiency and - if necessary - adapted for improvement. This the so-called “PDCA cycle”: Plan-Do-Check-Act. c) The operational processes defined in the QMS are planned, implemented, reviewed and - if necessary - adapted once for improvement. From there, “Never change a running system” applies. 16) Does the PDCA cycle (Deming cycle) of a quality management system (QMS) also apply to the project management of a plant engineering and construction project? a) No, the so-called “PDCA cycle” applies exclusively to a QMS. b) Yes, because to achieve project objectives, the project management processes defined in the project management plan are planned, implemented, continuously checked in terms of effectiveness and efficiency and - if necessary - adjusted for improvements. c) Yes, according to the standard DIN ISO 21500 - Guidance on project management, this only applies to the “PDCA cycle” part: “Plan” and “Do”, see standard process group “Planning” and “Implementation”. 17) What do the principles of quality management (QM) (Customer focus, Leadership, Engagement of people, Process approach, Improvement, Engagement of people, Process approach, Improvement, Evidence-based decision making, Relationship management) have to do with project management (PM)? a) A) PM is based on and implements the principles of QM. PM is, among other things, leadership process-oriented (PM processes) and involves people (project organization). b) It is A) and PM is, beyond others, also relationship management (stakeholder management) evidence-based decision making (controlling) and involves continuous improvement (controlling & lessons learned). c) The principles of QM have nothing to do with PM, as the PM processes are systematically assigned to the process groups “Initiating/ Planning/ Controlling/ Closing” and the defined 10 subject groups. 18) You are employee in a company that has established a certified quality management system (QMS) according to DIN EN ISO 9001. You want to know more about it. Which statement(s) do you agree with? a) The company’s QMS must be documented. It can be provided in paper form or via the company intranet. b) The QMS describes the attitude of the company management towards quality (quality policy) and the resulting requirements/processes which are necessary for organization in the context of quality-oriented performance. c) The QMS documentation must be available to every employee. This also applies to all other applicable documents. d) The QMS documentation is a controlled document. This means that the document creation, review, approval, changes (revisions) and its communication within the company are documented, monitored and controlled. 19) The procurement department wants to contract the equipment manufacturer that has established a certified QMS and asks you which QMS applies to the project? What’s your answer and how do you justify this? a) Of course, the equipment manufacturer works according to our quality management system because we are the client ( customer) and responsible for the project. b) Both, us as the client and the equipment manufacturer work each with its own quality management system, because that’s the one the employees of the respective organization know and must follow. c) To achieve the project objectives, the relevant processes and applicable documents of both systems must be used in such a way that they work together in the project. d) To achieve the project objectives, we must provide our QMS to the equipment manufacturer and train their staff accordingly. 20) By a project member, you are asked what quality management (QM) in the project comprises. What would you answer? a) It is often referred to as quality assurance or quality control and mainly includes the checking of results in the project planning/execution phase to ensure that the quality requirements are met. b) It is often referred to as quality planning or quality improvement and mainly includes the checking of results in the project planning/execution phase to ensure that the quality requirements are met. c) It comprises coordinated activities for managing and controlling a project organization regarding quality and includes quality planning, quality assurance, quality control and quality improvement. 21) There is both quality assurance (QA) and quality control (QC) in the project. Which statement(s) do you agree with? a) QA includes communicating the quality objectives and all planned execution processes and resources in the project as well as ensuring their implementation as the project progresses. b) QA and QC is the implementation of quality planning. c) QC is part of quality assurance in the project. d) QC includes reviews/inspections/tests during production/provision of products/services to ensure that they consistently meet quality requirements. Identified non-conformities are analysed and corrected. 22) Who in the project organization is responsible for quality planning and for the preparation and the approval of the project quality plan (PQP)? a) Quality planning as well as the transfer of the results to the PQP is the task of each discipline in the project organization under the leadership of the project quality manager. b) Quality planning as well as the transfer of the results to the PQP and its approval is essentially the task of the project quality manager. c) The project manager has overall responsibility for the creation, content and approval of the PQP and its revisions. 23) You are a new member in a plant engineering and construction project. What project-relevant information do you expect to find, among other things, in the project quality plan (PQP) at the end of the project quality plan (PQP) at the end of the project planning phase for the project execution phase? a) Notes on significant deviations from QMS standard process with sufficient justification. b) Requirements and process description regarding QM communication (meetings and reporting). c) Process descriptions for document management such as document creation, review, release, filing/archiving, distribution as well as description of information protection requirements. d) Complete FEED-Package (status “Issued for Design”). e) Process description regarding control of changes in requirements. f) Process description regarding control of Lessons Learned. 24) You are the “Lead Engineer - Static Equipment” within the owner’s project organization at the beginning of the project execution phase. An EPC contractor has already been contracted. Which statement(s) about the quality planning process do you agree with? a) At the beginning of the project execution phase, the EPC contractor prepares its project quality plan (PQP) on the basis of its QMS and the owner’s QM requirements agreed upon in the EPC contract. b) In the project execution phase, only one PQP is valid, namely the one of the owner’s project organization, because it includes all relevant QM information which the EPC contractor has to implement. c) For successful quality management in the project, it is important that QM processes in the owner’s PQP are aligned in detail with those of EPC contractor PQP. d) The detailed planning of the joint QA/QC measures - e.g.,the inspection and test plan for the equipment manufacturing - must be completed before the services are carried out. 25) What is the significance of the inspection and the inspection and test plan (ITP) in quality assurance using the example of the fabrication of a pressure vessel in the workshop? Which statement(s) do you agree with? a) The ITP describes the QC process during the fabrication of the pressure vessel in the workshop, which has been jointly defined between the client and manufacturer and involved notified body before work begins. b) The ITP describes in detail what, by whom, when and how must be checked/inspected/tested during production or construction, which requirements must be must be and know the results must be documented as quality record. c) Not following an approved ITP inevitably leads to additional costs in quality assurance and to delays in scheduling. 26) The owner’s project organization has contracted the equipment manufacturer to produce a column (pressure vessel acc. to pressure vessel directive (PED)). Who in the project is responsible for creating, reviewing and approving the Inspection and Test Plan (ITP)? a) The ITP is prepared by the contracted column manufacturer and coordinated with the QA/QC project team of the owner and with notified body (e.g., TUV). The ITP must be checked/approved by all parties involved at the latest before work begins. b) The ITP is prepared, reviewed and approved for production by the contracted column manufacturer. A copy of the approved ITP is sent to the owner’s QA/QC project team and - in the case of pressure vessels - to the notified body (e.g.,TUV). c) The ITP is prepared by the owner’s QA/QC project team, as he is the client. Therefore, he also specifies the scope of inspection and testing in the column manufacturing process. 27) What is the objectives of “risk-based quality assurance (QA)” in the plant engineering and construction project? Which statement(s) do you agree with? a) Risk-based QA intends to intensify the scope of inspections/testing, the necessary resources and the documentation effort where particular risks exist in the design, manufacture/ production, assembly or operation of plant components. b) Risk-based QA intends to minimise the scope of inspections/testing, the necessary resources and the documentation effort where particularly few risks exist in the design, manufacture/ production, assembly or operation of plant components. c) Risk-based QA intends to plan and implement the quality assurance process in the project as effectively and efficiently as possible. 28) You are a new member of the project team “QA/QC Static Equipment” within the owner’s project organization. The manufacturer of the column has already been contracted by EPC contractor. What information would you ask for to get a quick overview of the project? a) Owner’s project management plan incl. project organization chart. b) Owner’s project quality plan (PQP). c) FEED package of the project execution phase. d) Owner’s monthly project reports from the project planning phase. e) EPC contractor’s project quality plan (PQP) incl. project organization chart. f) Technical data sheet form the column 29) CD. You are a new member of the project team “QA/QC Static Equipment” within the owner’s project organization. The manufacturer of the column has already been contracted by EPC contractor. What information would you ask for to get a quick overview of the project? a) EPC contract part - “Quality Management”. b) Inspection and test plan (ITP) from the column, if already submitted by the manufacturer for review. c) Manufacturing schedule from the column, if already submitted by the manufacturer for review. 30) An important process in quality assurance is the “control of changes in requirements”, also called “deviation request”. What does it mean? a) A contractor or supplier would like to deviate from one or the other contract requirement before starting to work and proposes an alternative. b) A contractor or supplier explains that he deviated from one or other of the contract requirements and informs the client for approval. c) The procedure - starting with the deviation request, its review, approval and documentation - is a process within and between the owner’s project organization and the contractor or supplier. d) Without review & approval by Owner’s project organization and written approval by the project manager, the implementation of a requirement change is not permitted. 31) During inspection on the construction site, you realize that the column assembly was carried out incorrectly by the contractor. You documented the nonconformance in a “Nonconformity Report (NCR)”. What information do you expect at the end of the NCR process? a) Detailed description of the nonconformity by owner’s QA/OC team. b) Contractor’s assessment of NC impact on project EHS, cost, schedule or quality. c) Contractor’s information on NC cause. d) Contractor’s information on NC correction, incl. responsibilities and deadlines. e) Definition of NC correction by owner’s QA/QC team, incl. responsibilities and deadlines. f) Contractor’s information on corrective actions to eliminate the identified cause of the NC in order to prevent its recurrence. 32) CD. During inspection on the construction site, you realize that the column assembly was carried out incorrectly by the contractor. You documented the nonconformance in a “Nonconformity Report (NCR)”. What information do you expect at the end of the NCR process? a) The documentation of the inspection/ assessment of the NC correction by contractor’s QA/QC team and the NCR closure by signature of contractor’s project manager. b) The documentation of the inspection/assessment of the NC correction by owner’s & contractor’s QA/QC team and the NCR closure by signature of the project management of both parties. 33) What for is the Lessons Learned (LL) process in the project and what significance does it have for the quality management system (QMS) of a plant engineering and construction company? a) Each project organization will gather positive and negative experiences during all project phase. These lessons drawn from a project - also called “Lessons Learned” - are valuable knowledge for your own project but should also be available and used by other projects. b) The LL process in the project is part of the PDCA cycle in project management. The lessons learned are valuable knowledge for the project and are only used by the project itself. c) The learnings from the LL process are used not only for quality improvement in projects but also for continuous improvement of the performance and effectiveness of the organization’s QMS. d) The suitability, adequacy and effectiveness of the QMS is reviewed and evaluated by the organization’s top management once a year within the framework of a “Management Review”. Findings from the LL process are irrelevant.

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