Quality Assurance Policy

We are focused on continual process improvement and exceeding our customer’s satisfaction.

Our goal is to exceed the quality requirements of our customers by utilizing Al Taknia’s Quality
Management System where the foundation is focused on continual process improvement and
exceeding our customer’s satisfaction.

POLICY

AL TAKNIA is a service-oriented company dedicated to delivering

the highest quality services in the telecommunication industry.
It is our goal to consistently meet or exceed our customer’s
expectations and requirements for on-time delivery of quality
services and products through continual improvement of the
quality management system.

OBJECTIVE

AL TAKNIA’s main objective is to provide the highest quality service with the least possible impact on
clients and their services. To ensure this objective is met, AL TAKNIA’s Quality Management Group
performs both in-process and final audits on each installation. The Quality Engineers and Inspectors,
who work in the field, report directly to the Quality Management Manager.
The Quality Management Group functions independently from the field work force so as to remain
unbiased, ensuring our objectives have been met.

PROCESS

AL TAKNIA Quality Engineers and Inspectors are responsible for conducting in-process safety, security,
documentation, workmanship audits, and final audits.
In addition, the Quality Engineers and Inspectors are responsible for providing on-the-job (OTJ) training
and installation and maintenance certification testing. The Field team’s leader also performs a final
quality audit upon completion of the installation or maintenance effort, prior to turning the job over to
the Quality Engineers and Inspectors.
We further accomplish our goals through development of partner-type relations with other operators
while accounting for Customers' needs and expectations, by cooperation with the leaders of the
telecommunications industry to deliver competitive and innovative solutions for our Customers and by
stimulation of innovation among employees and motivating the employees to constantly improve the
competences which are necessary for professional fulfillment of their duties.
QUALITY ASSURANCE MANUAL

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 QUALITY ASSURANCE MANUAL

APPROVAL SHEET

Description Name Designation Signature Date

Prepared By: Joerg Hofmann QM Manager

Approved By: Operations Director

Approved By: Vice President

Approved By: President

2
 REVISION HISTORY

Revision No. Purpose of Revision Issue Date

0 Submitted for Approval. 21/04/20014

1 Approved
2

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 TABLE OF CONTENT

Cover Page 01
Approval Sheet 02
Revision History Sheet 03
Table of Contents 04
Company Quality Policy 06
2 Project Scope 08
3 Normative References 09
4 Terms and Definitions 08
5 Quality Management System 09
5.1 General Requirements 09
5.2 Documentation Requirements 10
5.2.1 General 10
5.2.2 Quality Manual 10
5.2.3 Control Of Documents 10
5.2.4 Control Of Records 11
6 Management Responsibility 12
6.1 Management Commitment 12
6.2 Customer Focus 12
6.3 Quality Policy 13
6.4 Planning 13
6.4.1 Quality Objective 13
6.4.2 Quality Management System Planning 14
6.5 Responsibility, Authority, and Communication 14
6.5.1 Responsibility and Authority 14
6.5.2 Appointing a Quality Manager/Management Representative 19
6.5.3 Internal Communication 19
6.6 Management Review 19
6.6.1 General 19
6.6.2 Review Input 19
6.6.3 Review Output 20
Resource Management 20
7.1 Provision Of Resources 20
7.2 Human Resources 20
7.2.1 General 20
7.2.2 Competence, Awareness and Training 21
7.3 Infrastructure 22
7.4 Work Environment 22

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8 Project Execution/Product Realization 22
8.1 Planning of Project Execution 22
8.2 Customers Related Processes 22
8.2.1 Determining Project Requirements 22
8.2.2 Reviewing Project Requirements 23
8.2.3 Customer Communication 23
8.3 Design and Development 23
8.4 Purchasing 23
8.4.1 Purchasing Processes 23
8.4.2 Purchase Information 24
8.4.3 Verification of Purchased Products 24
8.5 Production and Service Provision 25
8.5.1 Control of Production and Service Provision 25
8.5.2 Validation of Processes for Production & Service 26
8.5.3 Identification and Traceability 26
8.5.4 Proponent’s Property 27
8.5.5 Preservation of Material and Equipment 27
8.6 Control of Monitoring and Measuring Devices 27
Measurement, Analysis, and Improvement 28
9.1 General 28
9.2 Monitoring and Measuring 29
9.2.1 Customer Satisfaction 29
9.2.2 Internal Audit 29
9.2.3 Monitoring and Measuring of Processes 30
9.2.4 Monitoring and Measuring of the Work 30
9.3 Control of Non-Conforming Product 31
9.4 Analysis of Data 31
9.5 Improvements 32
9.5.1 Continual and Improvement 32
9.5.2 Corrective Action 32
9.5.3 Prevent Potential Nonconformities 32
Attachment 1: Organizational Charts 34
Attachment 2: Resumes of Key Personnel 35

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SECTION 1: COMPANY QUALITY POLICY

The intent of this Quality Manual is to define the Quality Assurance/Quality Control
requirements to be implemented within AL TAKNIA and for each project, and to ensure that all
Quality related activities are planned adequately to cover all parameters specified in each contract.

AL TAKNIA will ensure that vendors, suppliers, fabricators and subcontractors have in
place a Quality Assurance Program that meets applicable requirements of this Quality Plan
including conformity with the applicable requirements and other applicable Engineering
Standards of each Proponent.

The Quality Plan describes a system of QM/QC procedures and processes encompassing
documentation, material, engineering, procurement, construction, installation, testing and pre-
commissioning.

The prime objective of the Management of AL TAKNIA is to provide a uniform system

for the performance, monitoring, quality assurance, safety & loss prevention reporting activities
and controlling of all contract and work activities in a manner, which conform to contractual
requirements.

In order to achieve this objective, it is the policy of AL TAKNIA to establish and maintain an
efficient and effective quality control and quality assurance program, planned and developed in
conjunction with all management functions. Determination of conformance of work to
contract requirements is verified on the basis of objective evidence of quality.

The quality assurance program of AL TAKNIA is based upon the requirements of Quality
Assurance and Quality Control, Inspection and Testing, and Quality Construction Procedures
of each contract.

AL TAKNIA Quality Manual and the systems included therein, describe how the quality
assurance program of AL TAKNIA was designed to ensure that all quality requirements are
recognized and that a consistent and uniform control of these requirements is adequately
maintained.
AL TAKNIA’s Quality Manual also defines how effective control is established.

No company can be successful without satisfied customers. Our success is achieved by a

continuing commitment, to our customers, to provide them with what was promised. This lies
at the very heart of our quality objectives. We have always taken on board the definition of
quality as being “first time conformance to defined requirements”. Moreover, we have adopted
the premise that quality is driven and defined by the customer. We have a strong customer focus
in addition, we are convinced that quality is what the customer says it is.

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The function of this Quality Manual (QM) therefore is to describe and set out the general quality
policies, Construction Procedures and practices of all Proponents and AL TAKNIA. It serves as
a reference between the Proponent’s Quality Requirements and AL TAKNIA’s internal Quality
Management System. It is a management ‘tool’ to keep employees of AL TAKNIA, as well as to
its contractors, aware of the responsibilities with the internal quality approach and can be used
for marketing. It is also a suitable training document. It can reduce the “learning curve” due to
employee turnover and can assist in the continuity of events in such case. Measurement of the
cost of quality must be a fundamental consideration in design, in the development and in the
maintenance of the system. The need to impose discipline, where it was previously not considered
necessary, can only be achieved if the potential rewards of improvement profitability and
turnover are appreciated by the ill-disciplined.

A person who makes no mistakes makes nothing wrong and will never gain any experience.
However, the secret is to build upon one’s mistake and never repeat them. This is the basic
principle of Quality Management and it is the prime reason why a formal Quality System
must be introduced.
As companies grow and their organization and structure become more complex, the informal
systems, w h i c h s e r v e d A L T A K N I A w e l l w h e n i t w a s s m a l l e r , can no longer be
tolerated.

Quality Management is a key ingredient in maintaining the continuous success of AL TAKNIA.

There will always be a danger that the discipline, which it imposes on us, will be regarded by
some as an additional layer of bureaucracy. This we will guard against at all times.
The principle of Quality Management must be company-wide. In fact, they must extend even
further and become a cooperative venture between our contractors and ourselves. This is
fundamental to the eventual success of sub-contracts since our sub-contractors must also take
on board our definition of quality and establish documents and maintain effective and
economical Quality Systems to ensure and demonstrate that products i.e. results of activities of
processes, conform to specified Proponent’s Quality requirements.

This Quality Manual, and the typical procedures outlined herein describe how AL TAKNIA
Quality Management System is designed to ensure that quality requirements are recognized and
that consistent and uniform control of these requirements is adequately maintained. The Quality
Plan defines how effective control is established by use of formal written procedures. The Quality
Manual System includes provision for prompt detection of discrepancies and for timely and
effective corrective action.

Mr. Mr.
President Vice President

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SECTION 2: PROJECT SCOPE

As per Project Scope of Work.

SECTION 3: NORMATIVE REFERENCES

ISO 9000:2000 Quality Management Systems-Fundamentals and Vocabulary

ISO 9001:2000 Quality Management Systems-requirements.

ISO 9002 Control Processes

NEC National Electrical Code

NFPA National Fire Protection Association

NEMA National Electrical Manufacturer’s Association

Saudi Government Safety and Security Directives

ASTM American Society for Testing & Materials

ANSI American National Standards Institute

ACI American Concrete Institute

Royal Commission Guideline Specification Sections:

15060 General Requirement for Pipe Work

02220 Structure Excavating and Backfill

02221 Trenching, Bedding, Backfilling and

compacting

02210 Earthworks

03348 Casts-In-Place Concrete

02326 Road Crossings

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09940 Surface Painting of Steel Supports

03245 Fusion Bonded Epoxy

02554/02555 Asphalt Road/Sub Grade Material

AWWA American Water Works

Association SAES Saudi Aramco Engineering

Standards

SAMSS Saudi Aramco Material Systems

Specifications SAER Saudi Aramco Engineering Requirements

SAEP Saudi Aramco Engineering Procedures

SATIP Saudi Aramco Typical Inspection Plans

SAIC Saudi Aramco Inspection Checklists

BICSI-TDMM Building Industry Consulting Services

International
Telecommunications Distribution Methods Manual

9
SECTION 4: TERMS AND DEFINITIONS

Appraisal: Assessment of a supplier’s capability of controlling quality, carried out before

placing orders.

Certification: The authoritative act of documenting compliance with requirements.

Note: The requirements can relate to personnel, processes, products,

organizations and services.

Compliance: An indication or judgment that the product or services meets the requirements
of the relevant specification or regulation; also the state of meeting the requirements.

Customer: Recipient of a product provided by the supplier. Notes:

1. In a contractual situation, the customer is called the

“COMPANY” i.e. Proponent.
2. The customer may be, for example, the ultimate consumer,
user, beneficiary or purchaser.
3. The customer can be either external or internal to the
organization.

Corrective Action: Action taken to eliminate the causes of an existing nonconformity, defect
or other undesirable situation in order to prevent recurrence.

Documentation: Any recorded or pictorial information describing, defining, procedures or

results.

Defect: Non-fulfillment of an intended use or requirement.

Design Control: The verification that design criteria comply with specified requirements;
that design data and methods are valid for the range of application; and that the completed design
satisfies the design criteria.

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Design Review: A documented, comprehensive and systematic examination of a design to
evaluate its capability to fulfill the requirements for quality, identify problems, if any, and
propose the development of solutions.
N ot e:

A design review can be conducted at any stage of the design process,

but should not in any case be conducted at the completion of this process.

Hold Point: Inspection or test may not proceed without the QM/QC organization
representative in attendance.
Improvement: Actions taken by AL TAKNIA to increase the effectiveness and efficiency of
activities and processes in order to provide added benefits to both AL TAKNIA and its Sub-
contractors.

Inspection Assignment Package: A set of documents that include the details of purchased
material/equipment and their quality requirements needed to perform full inspection at the
vendor/sub-vendor facility.

Inspection: An activity such as measuring, examining, testing or gauging one or more

characteristics of an entity and comparing the results with specified requirements in order to
establish whether conformity is achieved for each characteristic.

Non-conformity: Non-fulfillment of a specified requirement. Note:

The definition covers the departure or absence of one or more quality
characteristics (including dependability characteristics), or quality system
elements from specified requirements.

Pre-Commissioning: Testing of system components for continuity, operability and in the case
of the process plants, their ability to withstand operating pressure prior to the introduction
of feedstock or other final products into the facility.

Procedure: A specified way to perform an activity.

No
tes:
In many cases, procedures are documented (e.g. quality system procedures).
When a procedure is documented, the term “written procedure”
or “documented procedure” is frequently used.

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Product: Result of activities or processes. Notes:

1. A product may include service, hardware, processed materials, software

or a combination thereof.
2. A product can be tangible (e.g. assemblies or processed materials) or
intangible (e.g. knowledge of concepts), or a combination thereof.
3. A product can be either intended (e.g. offering to customer) or unintended
(e.g. pollutant or unwanted
effects).

Quality: The totality of characteristics of an entity that bear on its ability to satisfy stated and
implied needs.

Quality Policy: The overall intentions and direction of an organization with regard to quality,
as formally expressed by top management.

Quality Management: All activities of the overall management function that determine the
quality policy, objectives and responsibilities, and implement them by means of quality planning,
quality control, quality assurance and quality improvement with AL TAKNIA ’s Quality system.

Quality System: AL TAKNIA’s organizational structure, procedures, processes and resources

needed to implement quality management (e.g. ISO 9001:2000).

Quality Control: AL TAKNIA employs operational techniques and activities that are used so
that its operations and services conform to the quality requirements as laid down in Proponent’s
documents.

Quality Assurance: All the planned and systematic activities implemented within AL
TAKNIA’s Quality Management System, and demonstrated as needed, to provide adequate
confidence that an entity will fulfill requirements for quality.

Quality Plan: Is a document, specifying which procedures and associated resources shall be
applied by whom and when to a specific project, product, process or contract (according to
ISO).

Quality Audit: A systematic and independent examination to determine whether quality

activities and related results comply with planned arrangements and whether these arrangements
are implemented effectively and are suitable to achieve objectives.

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Repair: Action taken on a non-conforming product so that it will fulfill the intended usage
requirements although it may not conform to the originally specified requirements.

No
tes:
Repair is one type of disposition of a non-conforming
product.
Repair includes remedial action taken to restore, for usage, a once
conforming but now non-conforming product, for example, as part of
maintenance.

Review: An independent assessment undertaken by an individual or group for the area under
review.

Rework: Action taken on a non-conforming product so that it will fulfill the original
requirement.

N ot e:

Rework is one type of disposition of a non-conforming

product.

Safety-related: Pertaining to those items of plant, the satisfactory performance of

which is important to the prevention of consequences of such accidents.

Specification: The document that prescribes in detail the requirements with which the product
or service has to comply.

Shall: “Shall” expresses a provision that is binding between two or more parties.

Standard: A document approved by a generally recognized body which results from the process
of formulating and applying rules for an orderly approach to a specific activity.

Service: The results generated, by activities at the interface between the supplier and the
customer and by the supplier internal activities, to meet customer needs.
No
tes:
The supplier or the customer may be represented at the interface by personnel
or equipment.
Customer activities at the interface with the supplier may be essential to
the service delivery.
Delivery or use of tangible products may form part of the service
delivery.

13
A service may be linked with the manufacture and supply of tangible
products.

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Service Delivery: Those supplier activities necessary to provide the service according to the
customer needs.

Should: “Should” expresses a recommendation among other possibilities.

Supplier: Any individual or organization that furnishes items or services to a procurement

document.

N
ote:
An all-inclusive term that may be used in place of any of the following:
vendor, seller, contractor, fabricator, consultant and sub-tier levels.

Type Test: Test or series of tests directed towards approval of a design conducted to determine
that is capable of meeting the requirements of the product specifications.

Will: “Will” expresses a declaration of purpose or intent by one party.

Witness Point: It defines a point that provides QM/QC organization with the opportunity to
attend the Inspection or Test, at their option.

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SECTION 5: QUALITY MANAGEMENT SYSTEM

5.1 General Requirements:

AL TAKNIA has developed a quality system and implements quality procedures to describe its
standard operating practices (processes) that apply on various projects. The quality procedures
are included in this Quality Manual and cover the scope of works of each project.

In these projects, the subcontractors will perform work under their own Quality Management
System (QMS). QM Manager will review the subcontractor QMS Manual for conformance to
the ISO standards as it applies to the assigned scope of work. QM Manager will perform an
evaluation of the subcontractor's implementation of their QMS Manual at regular intervals.
Reports of such evaluations will be maintained by QM Manager for the duration of the project.
Any noncompliance will be resolved to the satisfaction of AL TAKNIA and records maintained.

5.2 Documentation Requirements:

5.2.1 General:
AL TAKNIA has established the following documentation for its quality management system:
• Quality policy and quality objectives
• This Quality Manual
• Documented procedures (The procedures have been attached)
• Planning, operation, and process control documentation such as:

Test and Inspection Plans

Work instructions
Records of internal reviews
Inspection and test reports
Internal/external audit reports and corrective action
Other documentation used to ensure effective planning operation and control.

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5.2.2 Quality Manual:
The Quality Manual identifies the scope of the Quality Management System, and any exclusion
to the requirements of ISO QM System and Proponent Quality Systems. It includes procedures
and documents covering work activities. It includes a description of sequences and interactions
of processes that fall under the scope of the Quality Management System.

5.2.3 Control of Documents:

The Quality Manual, referenced procedures and Inspection & Test Plans are controlled
documents. QM Manager is responsible to ensure the initial issue and subsequent changes are
acknowledged by those authorized to receive the Quality Manual.
A documented procedure has been established to control documents required for the Quality
Management System. Project documents will be maintained at the Project office of AL
TAKNIA Access to these files will be limited to Project Manager, QM Manager and
associated QM personnel.
Project Manager is responsible to review all project documents for conformance to
the contract prior to submitting to the proponent. This review will be indicated on each item by
signature. All documents transmitted to Proponent will identify the action taken by the engineer.
The document status will be updated based on the response.
Methods will be used to track the status of transmittals that require action by the recipient.
Each document transmitted to Proponent will be accompanied by a covering letter that identifies
the general nature of the document transmitted.
All original documents will be maintained by Document Controller as detailed in Document &
Data Control Procedure (AL TAKNIA – QMP-004). A list of all documents and its status of
revision will be maintained by Document Controller and updated every week.
Documents issued for construction will be approved by qualified and authorized individuals as
required by the contract as detailed in Quality Management Procedure QMP-004.
As-built documents will be maintained by Document Controller at AL TAKNIA Project Office.
An index of as-built documents will be maintained as part of the file. As-built conditions will
be recorded on project documents by redline. All documents will be verified for accuracy by
QM Manager or his assignee and will be transmitted to Proponent, by Project Manager at the
end of the project.
Only the latest authorized issue of project documents will be available for use by contractor
personnel. Documents not authorized for use, voided documents or superseded documents will
be marked and placed in a different file at a different location as a means to prevent use.
Project Manager is responsible for reviewing the contract and identifying submittals and
deliverables to be transmitted to Proponent.
A submittal log will be maintained by AL TAKNIA.

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Controls will be established to track the status of any item on the list that requires authorization
or approval. These items will not be released until approved or authorized.
A copy of the approved quality plan, procedures and Inspection & Test Plans for use will be
available at all locations where work is undertaken for this project.

5.2.4 Control of Records:

A documented procedure to control the identification, storage, retrieval, protection, retention
and disposition of quality records will be established. The procedure will be incorporated with
adequate requirements of Proponent applicable standards.
Project records will be stored in suitable environment to prevent damage or deterioration and to
prevent loss. Records will be filed by subject, date, file category, etc.
An index of project records will be part of the file. Responsibility for the accuracy and
completeness of the records is assigned to QM Manager. Access to records will be under the
control of Project Manager. Removal of records to a location other than the immediate area
where the file is located will be restricted to authorized persons like Project Manager, Project
Engineer and QM Manager. Measures to identify removed files and their current location will be
maintained.
Project Manager will identify those records to be transmitted to the proponent upon completion
of the project and transmit the appropriate records.
AL TAKNIA records that provide evidence of conformance to requirements and of the effective
operation of AL TAKNIA's quality management system will be identified, stored, protected, and
retained. Retrieval will be controlled. QM Manager is responsible for identifying the records
to be retained, retention time, disposal method, and for arranging for their protection and
controlled retrieval.

SECTION 6: MANAGEMENT RESPONSIBILITY

6.1 Management Commitment:

The top management of AL TAKNIA is committed to the development and improvement of the
quality management system by:
Communicating the importance of meeting the proponents, regulatory, and legal requirements
by means of meetings and memos to the associated personnel.
Establishment of a quality policy and objectives.
Conducting m a n a g e m e n t r e v i e w s in accordance with this Quality Manual and other
Proponent quality documents.

Ensuring the availability of necessary resources in accordance with Section 7 of this Quality
Manual.

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6.2 Customer Focus:
AL TAKNIA ensures Proponent’s satisfaction by:

Reviewing contract requirements, Quality Management System, and procedures for compatibility
and submit modifications as appropriate.
Allocating trained and qualified staff resources in accordance with Attachment I of Schedule Q
and other documents to perform project tasks.
Schedule and reporting progress in sufficient detail to control project cost.
Training personnel as required.
Performing management reviews and internal quality audits as specified in Proponent’s quality
documents.
Establish a program for problem identification and resolution and problem prevention.
Maintaining data control systems and records of project activities.

6.3 Quality Policy:

AL TAKNIA has the following quality policy regarding the quality of the goods and services
we offer to our customers.
The quality assurance program of AL TAKNIA is based upon the requirements of ISO
Standards and Inspection and Testing of the contract.

AL TAKNIA Quality Manual and the systems included therein, describe how the quality
assurance program of AL TAKNIA is designed to ensure that all quality requirements are
recognized and that a consistent and uniform control of these requirements is adequately
maintained.
The AL TAKNIA Quality Manual also defines how effective control is established.

It is reviewed for relevancy and appropriateness of objectives at regular intervals and

communicated to those performing the work.

6.4 Planning:

6.4.1 Quality Objective:

Top management of AL TAKNIA has identified the following quality objectives for the
projects. The objectives are measurable, consistent with policy, relevant to the successful
completion of each project, and attainment of objectives is considered as part of our effort for
improvement.
The objectives include meeting contract requirements, resource allocation, and schedule control.

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6.4.2 Quality Management System Planning:
The elements that comprise the quality planning process are this Quality Manual, Proponent’s
Test and Inspection Plans, Project Organizational Charts that prescribe personnel allocations and
mobilizations, titles of individuals, subcontractors necessary to complete the Work, and the
integration of Quality improvement initiatives described in paragraph 6.6 Management Review
and 9.0 Measurement and Monitoring.
When conditions require change, the process is controlled and the integrity of the quality
management system is maintained. The changes to the quality system are controlled, i.e.,
allocation of resources, changes in work scope, internal procedures or work instruction
modifications are detailed in
AL TAKNIA - QMP-003 Procedure for Project Change Control.

6.5 Responsibility, Authority, and Communication

6.5.1 Responsibility and Authority:
AL TAKNIA‘s project organization chart has been attached along with this Quality Manual.
Project Manager is responsible for maintaining the organizational charts.
All QC personnel will functionally report to the Quality Management Manager.
While assigned to each project, quality personnel will be dedicated to the work and perform no
other function on any project.
AL TAKNIA has assigned responsibilities and authority in the following manner.
• Project Manager
• Project Quality Assurance/Quality Control Manager
• Project/Site Engineer
• Quality Control Engineer
• Supervisor/Foreman
• Document Controller
• Materials Controller
Project Manager

The Project Manager has overall authority and responsibility for all aspects of the Project.
His responsibilities include but are not limited to the following:

• Representation of AL TAKNIA towards Proponent for all matters relating to a

Contract
• Overall management of the project activities and control of the related personnel.
• Approval of the Project Master Schedule and control of its fulfillment.
• Implementation of any step which may be required to prevent or minimize
delays, budget over-running, conditions adverse to quality objectives.

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 • Submittal of progress reports.
• Maintenance and coordination of contacts with the local authorities for all matters
related to the work execution.
• The above task will be achieved by coordinating activities of the Project
Personnel.

Project Quality Assurance/Quality Control Manager

The Quality Assurance Manager directs activities of the Project Quality Organization, reporting
directly to the Management, but maintaining an operational link with the Project Sponsor. His
responsibilities include but are not limited to:

• Preparation, review, updating and distribution of the Project Quality Manual/Plan.

• Issue of Project Quality procedures, Project Inspection and Test Plans and forms.
• Review of Quality documentation issued by AL TAKNIA.
• Assignment of Quality related tasks within the framework of the project.
• Review of Inspection Reports and of related Non–conformance Reports.
• Evaluation of Suppliers/Sub-contractors’ Quality systems Verification, by means of a
planned Audit schedule that the established Quality Program is being implemented by
contractors.
• Verification by means of a planned Audit schedule that the requirements set
in the Quality Manual is met.
• Coordination and supervision of activities relative to the collation of the “Project Record
Books”.
• Determining and reporting to the Project Management, the principal causes of quality
losses.
• Determining with the Project Manager where improvements are required and where
necessary, recommending corrective action.

Project/Site Engineer

The Project Engineer directs and coordinates the engineering activities pertinent to execution of
the Project. His responsibilities include but are not limited to:

• Ensure the interdisciplinary coordination of the various specialist design groups and
optimization of solutions.
• Verify the compliance of design with the Project quality requirements and contractual
obligations.
• Ensure the timely availability of pertinent technical documents as per established
document release schedule.
• Promote any steps which may be required to prevent or minimize delays of
engineering activities.

•
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 • Analyze changes in the Scope of Work and assist the Project Manager/Project
Planning and Cost Control in assessing the relevant costs and implications.
• Issue of Purchase Requests for material and/or equipment related to the Project.

Quality Control Engineer/Inspector

His responsibilities include but are not limited to:

• Managing Quality Control functions for the Project including planning of Quality
Control inspections and preparation of reports
• Controlling corrective actions.
• Monitor inspections progress, review reports and documentation and verify, upon
completion of the work, that all requirements have been met and that the required
Quality records have been collated and filed.
• Monitoring on a day- t o - d a y case AL TAKNIA Project complaints with the approved
quality plan(s).
• Following a suitably start and approved procedure for the formal control of
deviation/waivers from the job specification.
• Review and approve as necessary, quality related procedures.
• Oversee the daily content and consistency of subordinate inspector’s daily inspection
logbooks.

Note: The Quality Control Engineer is supported by Supervisor and discipline inspectors.

Supervisor/Foreman/APR

He is responsible for coordinating and solving problems that may arise in connection with the
revision or updating of field engineering, during performance of the Work assigned to AL
TAKNIA. His responsibilities include but are not limited to:

• Monitor implementation and adequacy of the construction/installation procedures

established for the project.
• Receipt of all the technical documentation on site.
• Filing, reproducing and distribution of all technical documents required for performance
of the Work.
• Updating and revision of the drawings according to amendments and modifications
carried out in field.
• Verify the progress of work and collect planning and reporting documentation to be
included in the overall progress report.
• Evaluate site changes and if acceptable obtain Proponent’s approval.

22
 • Verify that the quality standard of work is in compliance with contractual
specification and approved procedures.
• Transmit to the Project Management offices all necessary documentation generated on
site.

Document Controller

The Document Controller will manage all the information concerning the Project. His
responsibilities include but are not limited to:

• Promote the formal management of the information system.

• Interface with peripheral units and sites to activate training on the use of the info
system.
• Record and manage incoming and outgoing correspondence.
• Distribute documents in a “controlled” manner.
• Organize the correspondence archive and make sure that this is aligned with the one on
site.

Materials Controller

The Materials Controller reports to the QM Manager. His responsibilities include but are not
limited to:

• Receiving inspection and record keeping of all material – both ‘free issue’ from
Proponent and AL TAKNIA supplied material.
• Reporting of non-conformances, the monitoring of careful segregation of quarantined
material and rectification of defects and clearance of material from quarantine.
• Assuring the traceability of uniquely identified critical materials while materials are in
storage.
• The monitoring and recording of the condition and state of preservation of materials
released from storage for processing and/or construction.
6.5.2 Appointing a Quality Manager:

AL TAKNIA has assigned Quality Management Manager as the management representative for
quality on each project. He will ensure the quality system is established, maintained and
implemented and will report to top management on a monthly basis and make
recommendations for quality system improvements. Reports will be issued in writing to top
management and maintained in an open status until the resolution of outstanding items. The
management representative for quality will assure that the project team is aware of customer
requirements regarding the project.

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6.5.3 Internal Communication:
The Quality Manager ensures the processes of the quality management system and their
effectiveness are communicated throughout the organization by distribution of audit reports,
management reviews procedures, and work instructions.

6.6 Management Review

6.6.1 General:
AL TAKNIA top management will review the Quality Management System at least once every
six months to ensure its suitability, adequacy, and effectiveness. The QMS, quality policy, and
quality objectives will be evaluated for any needed change. records of these reviews will be
maintained.

6.6.2 Review Input:

Management reviews will utilize:
• Internal and external quality audit results.
• Customer performance evaluation.
• Process performance and product conformance results.
• Preventive and corrective action status.
• Follow up on actions from previous management reviews.
• Other changes that could affect the QMS.

6.6.3 Review Output:

Results of management reviews will be recorded and addressed as appropriate:
• Improvements in the QMS and its processes.
• Improvements in project related to Proponent’s requirements.
• Resource needs.
Action items will be followed up on at subsequent management reviews to ensure closure. A
copy of the results of this Management Review will be forwarded to the Proponents within two
weeks after the management review meeting.

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SECTION 7: RESOURCE MANAGEMENT
7.1 Provision of Resources
Project Manager is responsible to assess organizational and project needs including oversight
functions and develop resource requirements in order to assure resources necessary to
implement and improve the processes of the QMS and address Proponent’s satisfaction
issues are provided in a timely manner.
7.2 Human Resources:
7.2.1 General:
AL TAKNIA will assign personnel to the project in accordance with Proponent’s quality
documents that is competent based on applicable education, training, skills, and experience. All
personnel assigned to each project will meet the minimum qualification and experience levels
specified in the Proponent’s quality documents. Project Manager is responsible to review the
contract to determine any customer requirement for competency level of personnel assigned
to the project and ensure that assignment of personnel including subcontractors meet the
requirements. Resumes of all quality personnel including sub-contractor quality personnel will
be submitted to Proponent for review and approval at least two weeks prior to the start of the
work. All procedures and personnel qualifications for special processes will be submitted 30
days prior to the start of work.
AL TAKNIA will provide on a monthly basis a listing of approved personnel forecast to be
mobilized in the next 60 days as well as list of personnel to be demobilized in the next 60
days.
AL TAKNIA planned staffing levels will comply with Proponent’s approved quality plan.
Reduction from required level of quality personnel will require Proponent’s written approval.
Anticipated changes in personnel due to vacation, temporary assignments or resignations will
be advised to Proponent at least 30 days in advance of the scheduled absence. All other changes
such as for illness and emergency leaves will be advised as soon as possible.

7.2.2 Competence, Awareness, and Training:

• AL TAKNIA has developed position descriptions for those personnel performing

activities affecting quality that identify competency requirements. Project Manager
maintains the latest issue of position descriptions.
• Project Manager is responsible to identify training needs and assure training is
performed. Personnel lacking required competencies will receive training such as
formal, informal, or on-the-job. AL TAKNIA will provide training as deemed
appropriate to satisfy competency needs or utilize external training sources.
• AL TAKNIA will evaluate the effectiveness of the training through periodic internal
audits, review and analysis of employee generated errors, omissions, rework, and
nonconformities.

25
 • AL TAKNIA employees and sub-contractors will be made aware of the project
quality requirements and how their work activities contribute to the achievement of
quality objectives.
• This is achieved through regular awareness presentations to personnel and
subcontractors, project kickoff meetings, project position descriptions, project
organization charts, toolbox meetings, newsletters, performance evaluations
• AL TAKNIA will maintain records of education, training skills, a n d experience for
personnel effecting quality. QM Manager is responsible to ensure appropriate record
including records of training activities and subject matter of the training are maintained.

7.3 Infrastructure
AL TAKNIA provides a work environment suitable for it to achieve its business objective and
satisfy project requirements. Workplace and associated facilities, equipment, hardware, software,
and support administrative services will be provided as required for the project. Accessibility
to computers, appropriate software and other tools will be issued to authorized personnel.

7.4 Work Environment

This section is addressed in the Safety and Fire Prevention Program Manual.

SECTION 8: PROJECT EXECUTION

8.1 Planning of Project Execution:

AL TAKNIA will plan and document the project execution process. The documentation for
project execution is stated in paragraph 5.2 of this Quality Manual.
The quality objectives for the design, procurement, and construction activities are
identified.
The design, procurement, construction, pre-commissioning processes, documentation,
resources, and facilities will be established for each project.
Acceptance criteria for the work will be developed where appropriate.
Records attesting to conformity of process and resulting Work will be maintained by QM
Manager.
Records include:
• Inspection reports and certificates.
• Disposition reports.
• Internal quality audit results and closures.
• Records of management reviews.
Project acceptance by Proponent will be documented by Mechanical Completion Certificate(s)
(MCC).

26
8.2 Customers Related Processes:
8.2.1 Determining Project Requirements:

AL TAKNIA will review the contract agreement to determine customer requirements. Project
Manager will evaluate these requirements and determine any additional requirements including
regulatory and legal ones, which may not have been identified by the proponent, and need to be
implemented to support the delivery of the Work.

8.2.2 Reviewing Project Requirements:

AL TAKNIA has assigned the responsibility to review the contract to Project Manager. The
Project Manager will ensure that the requirements are understood, and that we have the
capability of performing the work. The contract will be reviewed by Project Manager to ensure
any agreed-to changes have been incorporated. The review will be documented in the following
manner and records maintained. The procedure for contract review has been detailed in AL
TAKNIA-QMP-001 Procedure for Contract Review.
Changes to contracts will be controlled. The Project Manager is authorized to accept changes to
contracts, identify any restrictions or levels of acceptance.
Changes will be documented and issued to all staff responsible for execution of the
original contract by Project Manager.

8.2.3 Customer Communication:

Project Manager is responsible to establish and maintain communication with Proponent’s
Representative regarding engineering, procurement, inspection, or construction/pre-
commissioning activities. He will have weekly meetings with the Proponent Representative.
Project Manager is responsible for evaluation of the Proponent’s feedback/complaints and
responding to them.

8.3 Design and Development

The Quality Manual of AL TAKNIA contractor for Design and Development should be attached
with this Quality Manual.

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8.4 Purchasing:
8.4.1 Purchasing Process:
Where subcontractors and suppliers are engaged to work on each project, their capability to
perform the assigned scope of work is evaluated by Project Manager in accordance with
applicable quality documents. Physical surveys, when needed will be performed by a qualified
auditor and supported by a technical specialist for the equipment under consideration. Except as
provided in the quality document, evidence of qualification of subcontractors and suppliers will
be provided to Proponent.
Records of subcontractor and supplier performance will be maintained by Project Manager.
Subcontractors and suppliers with a record of poor performance will be excluded from future
consideration. Evaluation criteria are defined. Evaluation of subcontractor and supplier
performance will take place at regular intervals. Project Manager is responsible to follow up on
identified areas of poor performance.

8.4.2 Purchase Information:

In accordance with any pertinent documents, purchase orders with subcontractors and suppliers
will define service or product requirements, Quality management system requirements,
applicable procedures, and processes, equipment, and personnel qualifications in sufficient detail
to ensure the work performed, meets the purchase order requirements. All requisitions will be
reviewed by Project Manager for technical and quality requirements prior to submitting to
Proponent for review.
8.4.3 Verification of Purchased Products:
In accordance with Proponent’s related documents, work performed by the suppliers and sub-
suppliers will be reviewed for conformance to contract requirements and accepted by Project
Manager and documented by QM Manager.
Project Manager is responsible to ensure that the equipment and materials ordered for the project
under the contract meet contract requirements and are delivered on time. The following steps
will be taken to ensure that the suppliers are capable of providing appropriate items.
Supplier suborders will be reviewed for conformance to the original purchase order requirement
and document.
The manufacturer/supplier quality program in accordance with ISO standards will be verified
by QM Manager.
Manufacturer/supplier capabilities to supply items that meet technical requirement in a timely
manner will be evaluated. Once fabrications starts, progress will be reported on a weekly
inspection/fabrication status report to Proponent.
Applicable supplier process control procedures will be reviewed by QM Manager and
submitted to Proponent as required.
Equipment/material delivered for use on the project will be inspected by Project Manager at
the supplier/sub-supplier facilities in accordance with Proponent’s related document.

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Rejected material will not be allowed to be shipped. Non-conforming materials will be returned
to originator or marked in a manner that will prevent its use.

Records of supplier inspections will be prepared following each inspection or weekly for
resident inspectors and submitted to Proponent.
Inspection Disposition Reports will be prepared within two weeks following release to ship
material and submitted to the proponent.

8.5 Production and Service Provision:

8.5.1 Control of Production and Service Provision:

• AL TAKNIA has established the following controls applicable to services and service
provision activities. These activities are reflected in the detailed Proponent’s Test and
Inspection Plan and form part of this Quality Plan.
• Activities are planned.
• Activities are scheduled.
• Acceptance criteria are defined.
• Adequate resources (tools, equipment, trained personnel) are available to perform the
work.
• The work environment is safe and conforms to health and safety requirements in
the contract.
• Methods are employed to monitor resource expenditure against expected results.
• Procedures, work instructions, and/or installation instructions are available to the
workforce.
• Codes, standards and other references, including portions of the contract are available to
the workforce.
• Standards of workmanship are implemented.
• Where required, licensed or certified personnel are assigned to the project to perform
activities requiring such license or certification.
• A program to monitor the effectiveness of these process controls is in place and
implemented.
• Criteria for release, approval, and acceptance are established.

29
8.5.2 Validation of Processes for Production and Service:
The validation of the design is the constructed project that satisfies Proponent’s requirements.
The validation of certain construction processes can only be ascertained when load is applied or
operation is initiated. For the project, these processes include:

• Structural Concrete Placement.

• Paving and Asphalting.
• Coating.
• Tensioning etc.

AL TAKNIA assures these processes can achieve planned results through:

• Process qualification.
• Equipment and personnel qualification.
• Defined methods and procedures.
• Records will be maintained and revalidation performed as necessary.
Applicable construction process procedures identified in Proponent’s quality
documents, if
not included in this Quality Manual, will be submitted for Proponent’s review at least 30
days prior to start of the construction activity.

8.5.3 Identification and Traceability:

AL TAKNIA will develop and maintain a system to identify, design, or report documents so
they remain traceable to their originator and contain customer identification, as may be
required by the contract.
A Document Transmittal form has been developed for this purpose and is attached with this
Quality Manual.
AL TAKNIA will develop and maintain a system to identify construction materials and
equipment to the extent required by the contract or applicable codes and standards.
Nonconforming material will be identified or removed to prevent inadvertent use.

For this contract, the following will be included:

Tagging is employed to identify equipment and material on the project.

To the extent traceable in a contract requirement AL TAKNIA will develop and maintain a
system for unique identification of the work or batches. QM Manager is responsible for
implementing the system and retaining appropriate records. Nonconforming material will be
identified or removed to prevent inadvertent use.

30
8.5.4 Proponent’s Property:

AL TAKNIA will develop and maintain a system to receive, log, and maintain Proponent’s –
supplied documents, data. Project Manager is responsible for this function and will advise
the Proponent’s Representative of any items that are unsuitable for use, lost, or damaged.
All Proponent supplied material will be inspected against the shipping documents for accuracy
and damage, by Project Manager and stored in such a way to prevent damage or deterioration.
Project Manager is responsible for the final disposition of supplied items at the conclusion of the
project in accordance with contract requirements.

8.5.5 Preservation of Material and Equipment:

During the development of the plans and specifications, AL TAKNIA will evaluate construction
material and equipment and include in the plans and specifications any requirements for handling,
storage, packaging, preservation, and delivery necessary to ensure requirements are met.
Procurement Manager is responsible for this activity. Equipment suppliers will be requested to
provide storage and preservation procedures for purchased equipment.
QM Manager will review the construction contract and ascertain through the inspection process
that requirements for handling, storage, packaging, preservation, and delivery necessary to ensure
requirements are being implemented by the subcontractors, and suppliers. Nonconforming
conditions will be documented.
AL TAKNIA will establish, maintain and implement a program for handling, storage, and
preservation of equipment and material for this project. The detailed procedure for the above
mentioned activities are described in Quality Management Procedure.

8.6 Control of Monitoring and Measuring Devices:

AL TAKNIAO will establish, maintain, and implement a written program to identify, control,
and calibrate measurement and monitoring devices used to assure conformity of work as
required by the contract. The program will contain the following elements:
• Identification of what equipment needs to be monitored and measured.
• Identification of equipment and instruments that require calibration to maintain
capability.
• Listing of s u c h e q u i p m e n t a n d i n s t r u m e n t s , f r e q u e n c y o f c a l i b r a t i o n ,
a n d evidence calibration took place. Calibration frequency will be based on the most
stringent of Proponent’s standards, other applicable standards, or manufacturer
recommendations. If no standards apply, the calibration cycle will not exceed six
months.
• Unless equipment calibration is performed by the manufacturer or Proponent’s approved
agency, the following will apply:
•

31
 • Availability and use of calibration instructions, manufacturers' instructions, codes, or
national standards for calibration.
• A program of corrective actions to repair or replace items that do not meet
acceptance criteria.
• A program to ensure measuring and monitoring devices are protected from damage
deterioration and unauthorized alterations of settings.
• A program of corrective actions for previously accepted work, if defective
equipment and instruments were used to inspect or test the work.
• Confirmation that computer software used as a basis of product acceptance is
acceptable for the intended application. Confirm prior to use and as necessary
thereafter.
• Records to demonstrate calibration and verification.
The detailed procedure has been described in Quality Management Procedure.

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SECTION 9: MEASUREMENT, ANALYSIS AND IMPROVEMENT

9.1 General:
AL TAKNIA has defined, planned and implemented the following measurement, monitoring,
analysis and improvement activities to assure conformity and achieve improvement.

• Customer satisfaction.
• Internal audits.
• In-process reviews/inspections/tests.
• Control of nonconformities.
• Data analysis.
• Corrective, preventive, and improvement activities.

9.2 Monitoring and Measuring

9.2.1 Customer Satisfaction:

AL TAKNIA has developed the following methods to obtain data and monitor customer
satisfaction and/or dissatisfaction.

• Weekly meeting minutes.

• Correspondence.
.
9.2.2 Internal Audit:
AL TAKNIA has established, and will maintain, and implement an internal quality audit
program to verify that quality activities and related results comply with planned contractual
arrangements and to determine the effectiveness of the quality program and associated
procedures. The internal quality program has the following attributes:
• Internal procedures govern these activities.
• Internal audits will be scheduled based on requirements of Proponent’s quality
documents. The schedule will be transmitted to the Proponent’s Representative within
30 days of the effective date of the contract.
• Personnel conducting internal audits are capable of objectivity and impartiality in
conducting audits. They will not audit their own area.
• Reports of internal audit results will be generated and issued to affected departments.
Company management and the proponents will receive copies of report within two weeks
of audit completion.

33
 • Corrective action will be monitored and brought to a close.
• Follow-up internal audits will be conducted as appropriate, to ensure implementation
of corrective action, and the results reported to Company management and to
Proponent.
• The activities of subcontractors working under this quality management system will be
included in the audit program.
• The activities of subcontractors working under their own quality management system
will be audited. As a minimum, such subcontractor quality audits will be conducted
every six months.
• QM Manager is assigned responsibility to implement the internal quality audit program.

9.2.3 Monitoring and Measuring of Processes:

The project execution processes described in Section 5.7 of this Quality Manual necessary to
achieve Proponent’s requirements are measured and monitored. These methods will confirm the
continuing ability of each process to satisfy its intended purpose. When planned results are not
achieved, corrective preventive actions will be taken to assure conformity.

9.2.4 Monitoring and Measuring of the Work:

AL TAKNIA will establish, maintain, and implement a program to control the development,
review, and release of designs that are in conformance with Proponent’s requirements. The
program will be controlled by written procedures, instructions, or checklists as appropriate.
Results will be recorded, authenticated, and distributed in accordance with written procedures.
The measurement, monitoring, and acceptance of the design are addressed in the design and
development section.
AL TAKNIA will establish, maintain, and implement a program to control procurement,
inspection and acceptance of equipment, material, and construction activities performed by AL
TAKNIA's own work forces or its subcontractors. Records will be maintained.

QM Manager will ensure that incoming equipment and materials are inspected and accepted for
project use prior to incorporation into the projects.

When material is received without Inspection Release, the QM Manager will perform
inspection against the purchase order requirements and verify that the equipment and material
meets the specified standards. The process will be documented during Project duration.

34
QM Manager will inspect the quality of the construction effort through regular inspections of
the work in progress, as agreed to in the respective Test and Inspection Plan, approved by the
Proponent. Activities will be recorded via inspection and test reports attached to relevant
procedures and work instructions and acceptance verified against written acceptance criteria
obtained from applicable contract documents or referenced codes and standards.

QM Manager will notify Proponent by initiating Requests for Inspection (RFI) for all
inspection points coded as Witness or Hold.
Testing, if required in the contract, will be performed by qualified personnel to
written procedures, with acceptance criteria defined and results identified and transmitted to
Proponent.
All test results will be documented on forms appropriate for the tests, and dated and signed by
the test personnel. Results will be issued as required by the contract.
QM Manager is responsible to supervise and accept or reject all contractor- performed
inspections and tests.

9.3 Control of Non-Conforming Product:

AL TAKNIA has a program to detect and correct nonconforming conditions in design and
relating to work output of its own staff or others under contract to AL TAKNIA.
Any nonconformance discovered by outside sources will be processed by QM Manager.
During procurement and construction, any conditions that do not meet contract requirements and
that cannot be corrected by the end of the workday will be rejected and documented.
QM Manager will track the condition until restoration to the designed conditions or until the
"as-installed" condition is accepted by Proponent. All violations of the Proponent’s standards
and specifications that result in "as-installed" or "use-as-is" recommendations will be
documented as Waiver in accordance with Proponent’s quality documents.
The Proponent will be notified of all (AL TAKNIA and subcontractor) nonconformance reports
within 48 hours of issue and prior to closing of the NCR.
Corrective action will be implemented as described in paragraph 8.3.
9.4 Analysis of Data:
AL TAKNIA collects and analyzes appropriate data to determine the suitability and effectiveness
of its quality management system and to identify where improvements can be made in the
quality management system.
The following data are gathered and analyzed, QM Manager is responsible for the effort
and to ensure closure where QMS improvements are warranted.
• Conformity of products to requirements.
• Measuring and monitoring data, and Internal quality audit data
• Trends of both positive and negative compliance.

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9.5 Improvements:
9.5.1 Continual and Improvement:
AL TAKNIA facilitates continual improvement of the quality management system and acting
upon the following:
• Quality policy changes.
• Goal/objective changes.
• Implementation of the results of management review, audit findings.
• Analysis of nonconformities.
• Corrective action and preventive actions implemented.

AL TAKNIA will establish measurement systems and track performance for any Proponent’s
specified improvement initiatives in accordance with Proponent’s quality related document.
Project Manager is responsible to assure implementation of this planning for improvement
effort.

9.5.2 Corrective Action:

AL TAKNIA has established a corrective action program to eliminate the causes of the
nonconformity and prevent its recurrence.
Corrective action will be appropriate to the severity of the nonconformity identified.
A documented procedure for corrective action has been established and is included in this Quality
Manual.
The procedure addresses nonconformity identification (including customer complaints), cause
determination, action to prevent recurrence, identifying and implementing the corrective action,
recording results, determining if the corrective action was implemented and effective in
resolving the nonconformity.

9.5.3 Prevent Potential Nonconformities:

AL TAKNIA has a program of preventive action, which anticipates the potential causes of
nonconformities and works to reduce or eliminate these potential causes.
A documented procedure for preventive action has been established and is included in this
Quality Manual.
The procedure identifies potential nonconformities, their probable cause, determination of
preventive action needed, implementation of preventive action, and determining if the preventive
action was effective in preventing the nonconformity.

36
 DOCUMENT
TITLE:

ATTACHMENT
1

ORGANIZATIONAL
CHARTS

37
 TABLE OF CONTENTS

QUALITY MANAGEMENT PROCEDURES

NO. PROCEDURE DESCRIPTION DOCUMENT NO.

1 CONTRACT REVIEW QMP-001

2 QUALITY ASSURANCE IN DESIGN QMP-002

3 PROJECT CHANGE CONTROL QMP-003

4 DOCUMENT AND DATA CONTROL QMP-004

5 CONTROL OF QUALITY RECORDS QMP-005

6 SELECTION OF VENDORS AND SUBCONTRACTORS QMP-006

7 PREPARATION, STYLE AND FORMAT OF PROCEDURES QMP-007

8 PURCHASING QMP-008

9 HANDLING, STORAGE, PACKAGING AND DELIVERY QMP-009

10 RECEIVING INSPECTION QMP-010

11 MATERIAL IDENTIFICATION AND TRACEABILITY QMP-011

12 CONTROL OF CUSTOMER SUPPLIED PRODUCT QMP-012

13 PROCESS CONTROL QMP-013

14 CORRECTIVE AND PREVENTIVE ACTION QMP-014

15 CONTROL OF NON-CONFORMANCE QMP-015

16 INTERNAL QUALITY AUDITS QMP-016

38
NO. PROCEDURE DESCRIPTION DOCUMENT NO.

17 TRAINING QMP-018

18 SPECIAL PROCESSES QMP-019

19 CONTROL OF INSPECTION, MEASURING AND TEST QMP-020

20 INSPECTION AND TEST STATUS QMP-021

21 INSPECTION AND TESTING QMP-022

39
 DOCUMENT
TITLE:

PROCEDURE FOR:
CONTRACT REVIEW

DOCUMENT
NO.:
QMP-001

Index Page

1 Purpose: 2
2 Scope: 2
3 References: 2
4 Definitions: 2
5 Procedure: 2
6 Documentation: 6

40
1 PURPOSE

1.1 To define the responsibility and methods to be used for ensuring a review of the contract
documentation and scope is undertaken immediately following award of contract by the project
and lead engineering team to promote a working understanding of the technical basis and
identify any needs for clarification or additional information.

2 SCOPE

2.1 This procedure describes the requirements for a formal Contract Review
immediately following transfer of documentation from the Proposal
Department to the Project Manager after Contract Award, to ensure the
following:

• That all contract requirements are clearly understood by the Project Team disciplines
lead staff and any supporting corporate Supervisors involved in the project initiations.
• That any changes to standard work practices are recognized and accepted by the
Project Manager and all affected corporate supervisors.
• That any clarification or outstanding information required from the Proponent is
identified and actioned by the Project Manager.

3 REFERENCES

None

4 DEFINITIONS

4.1 Definitions relevant to this procedure are listed in Section 2.4 of the
Quality
Manual and in ISO-8402, Quality Management and Quality Assurance
Vocabulary.

5 PROCEDURE

5.1 Proposal Stage

5.1.1 Where practical, intended Project personnel shall be involved

with the valuation of the Proponent’s Invitation to bid and the
preparation of documents for the Proposal.

41
 5.1.2 On Proposals for major projects, the nominated Project Manager
should if practicable prepare and issue a Project Execution Strategy
to summarize the manner in which AL TAKNIA would execute the
contract if it were awarded. This document normally forms part of the
Proposal Submission.

5.2 At Contract Award

Upon award of the contract, the appointment of the Project Manager is confirmed in writing,
by distribution to Department Managers of the Project Handover Meeting Report.

The Project Manager shall be advised by the Proposal Manager and/or Commercial
Department of any special requirements he should comply with regarding Project execution
arising since Proposal Submission. He should meet as necessary, with the Proposal Manager
and relevant team members to discuss any questions he may have with regard to the contract
specifications, errors or omissions and Client involvement.

5.3 Handover to Projects

The Project Manager shall receive from the Proposals Manager a complete Package of Proposal
documentation, including all subsequent submissions and correspondence. Collectively, this
now comprises the “contract documentation package”, and is passed over by the Proposal
Manager under cover of a completed Project Handover Meeting Report.

The Package shall include:

The original proposal files with all supporting documentation. Estimate/Budget and scope of
work, presented with all associated backup and explanation including contributions from all
disciplines and Departments.

In addition, as necessary the following:

Amendments made during the negotiations.

All Proponents’ correspondence and meeting notes. All internal meeting notes.
All technical and commercial documentation. Final Contract (if
available).

The Project Manager shall be responsible for distribution within the Project team and to other
parties involved.
The Project Manager shall thoroughly review the documentation and become familiar with the
contents of the contract and all related documents.

5.4 Meeting Preparation

42
The activities listed below should preferably be started before the Effective Date of the
contract but in any case, not later than 5 working days after the effective date.

The Project Manager, having acquired a sound knowledge of the contract requirements and the
relevant Proposal Documentation, will allocate his Project Team responsibilities.

The Project Manager will uniquely identify parts of the contract documentation package plus
the AL TAKNIA Contract Execution Strategy (if prepared for inclusion in the proposal) and
determine the necessary distribution as appropriate to all project team members using the
transmittal in Appendix 1.

The transmittal will also:

State the planned date for the Contract Review Meeting.

State whether or not the Project Manager wishes to receive responses in writing before the
above meeting.

Each recipient shall critically review the supplied documents, listing any items not fully
understood or where a possible misunderstanding may arise and any information or clarification
is required from the Proponent.

These listings shall be made in the form of written specific queries.

Particular attention shall be paid to ensure the following:

Lines of communication – That these are clearly defined by means of organization chart,
job descriptions are understood and workable.
Interfaces – That these are clearly defined understood and include interfaces of disciplines
with each other, with third parties and with the client.
Work Scope – That the Design Criteria including the scope of work which shall constitute
the design database, are established, agreed with client and issued and understood by those
responsible for the work.

For projects with, a large multi-volume Contract Documentation package a member(s) of the
Project Team will extract the Design Data Base utilizing the Contract Documentation
package, in logical sequence, related to the overall process basis and engineering disciplines
involved. A full index to identify the location of each data category will be prepared – if not
included in the Client’s Documentation.
This Design Data Base will be issued to all attendees of the Contract Review Meeting,
supplementing information distributed direct from the Contract Documentation Package.

That the issued Execution Strategy, if prepared and Quality Plan clearly indicate where the
contract work instructions differ from the standard working practices.

43
That the Contract Execution Strategy is prepared and that Planning Schedules and Work
Packages are understood by those responsible for the work. That any identified needs for the
development of procedures, work instructions and design brief, are identified and included in
the agenda for the Meeting.

5.5 Contract Review Meeting

The timing of the Contract Review meeting must be considered balance between just sufficient
prior time for the preparatory activities stated in 2.4 above and the need to hold the meeting
before actual contract work commences in detail, e.g. process system calculations. The
Meeting should normally take place not later than 10 working days after Effective Date of
Contract.

The Contract Review Meeting shall be chaired by the Project Manager, who will ensure that
the minutes of meeting are taken, using Appendix 2 as an immediate record/cover sheet.

The relevant Proposals Manager and other previously involved Proposal staff shall attend
the Meeting at the request of the Project Manager.

The agenda for the Meeting will either be based on the responses received in advance (if
requested by the Project Manager), as per 5.3 & 5.4 above, or will be tabled by the Project
Manager.

All assigned Lead Proposal Staff will have prepared a statement of all criteria for their
discipline prior to any start of any project (contract) activities.

Items discovered (omissions, discrepancies, clarifications, etc) during the meeting preparation
phase shall be discussed, resolved and mounted, during the meeting. Where necessary, formal
requirements for clarification and further information shall be compiled at the meeting as
an addendum to the Minutes for subsequent follow-up by the Project Manager as per sections
5.3 & 5.6 below.

During the Meeting, any changes required in relation to standard working practices to
satisfy the requirements of the project (e.g. Specialist Sub-Contract requirements) will be
reviewed and responsibilities assigned for the preparation of adequate project specific
instructions, including procedures and technical guidelines. (Such project specific requirements
will be subsequently issued to the Project Manager for review and approval for use on the
project). The project specific instructions prepared above will be forwarded to Document
Control need.

5.6 Follow-up Action

After the Meeting, the Project Manager, or his assigned Project Engineer will co- ordinate
resolution of any points in 5.3, 5.5, and 5.6, which can be handled within AL TAKNIA.

44
A letter to the Client is then prepared by Project Manager or his assigned Project Engineer,
explaining all requests for clarification information, which cannot be handled internally. This
letter is compiled within 5 working days maximum after the review meeting. The Project
Manager will maintain an action log until the queries are satisfactorily resolved.

A response is expected from the Proponent in the normal turn-around time for project
correspondence as defined for the contract.

Each department and or discipline will maintain a file of, or have access to, the relevant
documents i.e. works scope, Proponents’ specifications, Proponents’ philosophies, regulatory
requirements, relevant national and international standards, and AL TAKNIA’s standards and
procedures which are applicable to their Scope of Work.

6 DOCUMENTATION

6.1 Contract Document Transmittal

6.2 Contract Review Meeting

45
 DOCUMENT
TITLE:

PROCEDURE FOR:
QUALITY ASSURANCE IN DESIGN

DOCUMENT
NO.:
QMP-002

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 6

46
 1 PURPOSE

To define the Quality Assurance in Design in order to satisfy AL TAKNIA senior management
and Proponent that the design will satisfy all aspects of the requirements, and to detect and
correct the errors which do occur as early as possible.

2 SCOPE

This Procedure covers design and development stages, including the review, optimization,
standardization, verification and approval.

3 REFERENCES

Schedule “B” Job Specification

Schedule “Q” Quality Assurance and Control, Inspection and Testing

ISO 9001/2000 Quality Systems Model for Quality Assurance in Design, Development,
Production, Installation and Servicing.

4 DEFINITIONS

This procedure uses definitions in the form of the Quality Plan and ISO 8402 Quality
Management and Quality Assurance vocabulary.

5 PROCEDURE

Design QM/QC is achieved by AL TAKNIA by its selection of competent engineers and/or

sub-contractors in accordance with the contract and using suitable procedures approved by
different Proponents. An essential part of the quality system is independent verification and
reviews of design at appropriate stages during the Design Phase.

AL TAKNIA will ensure that as a minimum, these reviews are completed prior to Proponents’
scheduled Design Reviews stated in Schedule “B” or any other related document on the Contract.
AL TAKNIA shall maintain records of these Design Reviews including solicitation, recording and
resolution of comments. To this end, any action required will be assigned to individuals.

The QM Department will be responsible for confirming by the audit that any such assigned
actions have been satisfactorily dealt with by the person or persons concerned.

47
Design Control as practiced by AL TAKNIA is the quality control of design. AL TAKNIA
will verify that design criteria comply with the Proponents’ specified requirements, that
design data and methods are valid for the range of application, and that completed design satisfies
the design criteria. AL TAKNIA will achieve this by preparation of written procedures as described
in the Project Quality Plan, which are themselves subject to Quality Management Audits.

Optimization – when specified in Schedule “B” of the Contract is for AL TAKNIA to select or
develop a design, which satisfies the specified quality requirements at minimum lifetime costs.
The lifetime cost attributable to an item consists of the following.

• Cost of Procurement.
• Extras for Changes.
• Related costs of interfacing items.
• Cost of Installation.
• Maintenance, repair and replacement costs.
• Consequential costs of lost production due to non-availability.

Although it is not possible to estimate these costs precisely, AL TAKNIA will take into account
their probable magnitude in design optimization.

To ensure satisfactory installation performance, AL TAKNIA will ensure that the Quality
Program is adequate.

For low-cost systems and equipment, AL TAKNIA will advise the proponent that investment in
enhanced quality will be beneficial to overall installation economics. If, for example, protection
system of high reliability is specified, both maintenance costs and spurious shutdowns are
reduced.

Standardization-AL TAKNIA will ensure that the design of structures and systems are coordinated
to ensure that the number of different materials, components and equipment used throughout the
installation are kept to a minimum. Additional types will not be introduced to make small savings
in first costs. This will facilitate procurement, material control and maintenance.

Verification-AL TAKNIA will ensure that original design is independently verified to comply
with specified criteria, and all work documented and filed. AL TAKNIA will justify design
methods, selection of structure and system configuration, Equipment and material, if required in
Schedule “B”. AL TAKNIA will use proven design methods wherever possible so as to minimize
the probability and magnitude of error and uncertainties.

Established codes and Standards will be used.

48
AL TAKNIA will check all calculations by approximate methods and compare results with any
obtained previously from similar calculations.

Important calculations will be independently verified using different methods if possible. Care will
be taken to ensure that computer programs are not used outside of their range of validity and new
methods will be subject to formal review before they are applied. The type and extent of design
verification carried out by AL TAKNIA depend on the design status and originality, and
importance to safety and reliability of the item under consideration.

System Descriptions – Design control carried out by AL TAKNIA will be based on adequate
documentation. System descriptions are key documents, which AL TAKNIA will prepare during
Conceptual Design for each system of installation. System Descriptions are developed throughout
the duration of the Project and show the current status of the systems at any time.

Review and Approval – AL TAKNIA will implement their Quality Plan through the
Proponents’ approved QM Program. This program will provide for the effective verification of all
design and supporting documentation, and internal review and approval before submission for the
Proponents’ approval.

As Specified in the contract, AL TAKNIA will maintain a copy of all applicable standards,
drawings and reference code standards (National/International) in accessible area to ensure
optimum design activities

Design Reviews

Design Reviews will be facilitated by the use of checklists. At the start of the contract, AL
TAKNIA will prepare a program for its scope of work based on our organization in a number of
discrete design packages. For each design package, AL TAKNIA will develop a design plan,
which will include an initial review and one more intermediate review depending on the
requirements of the contract. AL TAKNIA will hold initial design review as soon as possible after
completion of the design plan and will review the plan for:

• Definition of scope and interfaces;

• Identification of design inputs;
• Compliance with Job specifications;
• Compliance with the Quality Plans;
• Acceptability of design proposals;
• Integration into Project program.

49
Intermediate design reviews will be held by AL TAKNIA at intervals of one to three months and
will consider the following:

• Results and Action from previous reviews

• Optimization
• Verification
• Documentation

Final design reviews will be held by AL TAKNIA when the design is nearing completion and will
consider:

• Results and action from previous reviews

• Design adequacy as basis for the next project phase.

When review identifies serious deficiencies in design or there are many actions unresolved, a
special follow-up review after the final review to ensure that all actions are satisfactorily
completed.

Completing Documents

When Documents have to be submitted to the Proponent, the following steps apply. As each
document is completed in the final format and deemed ready for checking, the originator will sign
or initial in the title block of drawings, at the top of calculation sheets or in otherwise provided
appropriate space, as directed by the Project Manager or Engineering Manager (as applicable).

The Originator:

• Makes a check print copy of the document.

• Affixes “Check Print” stamp provided on the print of each drawing, the copy of each
single-page document, or the face of each multi-page document. In case of single page
documents, the stamp may be affixed to the back of the check print, if there is room in the
face.
• Enters the document into a log to be maintained by the originator in order to monitor the
checking process.
Checking:

The checker will review the Check Print of the documents for technical adequacy and conformance
to any applicable standards and format and performs specific accuracy checks required for that
type of document. Checking activity will be recorded directly on the Check Print. If the document
is a drawing, the checker is responsible for ascertaining that the drawing is consistent with the
corresponding calculations, and signing off that such calculations have been properly checked.
Checker colors are yellow and red only.

50
The Checker shall:

• Determine if the document conforms to good engineering judgment and practice and is
suitable and adequate to accomplish the required function.
• The checker does not, in order to satisfy personal preferences; revise a document,
which is already adequate to meet project requirements.
• Highlight in yellow on the Check Print each part checked that is found to be correct.
• Marks in red on the Check Print corrections, additions, or deletions deemed to
be required.
• Red or yellow should not be used to note comments or instructions. These colors
are reserved for the checking process.
• Comments or instructions should be written in black pencil. Resolves significant
differences with the Originator, if necessary, the Checker refers any issue to the Section
Chief, or Project Manager (in that order) for final resolution before continuing the
checking activity. The check Print must reflect resolution of these differences by
means of a green checkmark, affixed by the Originator next to the Checker red marks.
Signs and dates the stamp blanks provided for confirmation that the calculations on
which drawing is based have been checked; initials and dates the stamp blank opposite
‘checked”; and then forwards the Check Print to the Originator for back-checking.
• If no correction is necessary, the Checker should sign and date as above. In addition, the
Checker should enter N/A in the spaces provided for the Back-Checker and Verifier, since
these functions are superfluous if there are no corrections. The Checker should then sign
or initial and date the title block of drawings (“Checked by”). At the top of calculation
sheets or in otherwise provided appropriate space as directed by the Project Manager.
• The Check Print should then be sent to the Originator (acting as Back-Checker).

Back – Checking:

• The Originator (acting as Back-Checker) is responsible for reviewing the Checker’s marks
on the Check Print and personally making or supervising the update of the Document
Original. Back-Checker color is green only.

51
 Originator/Back- Checker:

• Check marks in green each of the Checker’s red-marked changes if in agreement that the
original should be changed, and adds in green any additional changes not picked up by the
Checker.
• Consults with the Checker, if not in agreement with some of the red marked changes,
or if additional changes are necessary. Resolves differences with the Checker or if
necessary, refers to the Project Engineer, Section Chief, or Project Manager (in that
order) for final resolution before completing the Back-Checking.
• Every red marked change made by the Checker should have a green check next to it (by
the Back-Checker); and every additional change made in green by the Back Checker
should be highlighted in yellow by the Checker to signify concurrence.
• Crosses out in green, each of the Checker’s red-marked changes that both he and the
Checker at that point agree should not be changed. The Back- Checker should not obliterate
the Checkers marks, but rewrite in green, next to the crossed out red marks the original
information that is to remain unchanged. All such green marks put on the documents by
the Back- Checker must be yellowed by the Checker.
• In the case of specifications, where entire paragraphs may be involved in this process, it
will be acceptable, in lieu of re-writing in green the original text that is to remain, to write
an instruction to the typist, in black, with conventional editor’s marks, such as “stet”. The
instruction should have a green check marked placed by the Checker; the green
checkmark should be yellowed on by the Back-Checker/Originator.
• Personally updates the Documents Original when practical, or has the Document
Original updated under supervision to include the agreed to changes. If a drafter
does the updating, this individual should circle in blue, on the Check Print, each item
as change is made on the originals. Signs and dates stamp on the Check Print and
forwards the check Prints to the Checker for verification.
• If the changes in the documents were so extensive as to make it difficult to follow them on
the original Check Print, the checker will obtain a second copy of the original which will
be labeled No. 2 and proceed with checks.

Verifying Original Check Print

The Checker, acting as the Verifier, compares each of the Checkers’ marked changes on the
second copy labeled No. 2 with the revised part of the updated documents.

If agreed-to changes have been accurately made on the original the

Checker/Verifier circles changes in green on the back-checked print.

52
 Verifying New Check Print

If the agreed-to changes have been accurately made on the updated document, the Verifier:

• Checks that each correction, addition, or deletion, and each part that has been redrawn,
relocated, rewritten, retyped, or recalculated, has been correctly transferred to the original
from the previous Check Prints.
• Circles in green on the new Check Print of the updated document all corrections that were
marked on the Check Print.
• Marks in red on the new Check Print each required correction, addition or deletion that was
not picked up from the back-checked Check Print; or
• Returns the stack of Check Print to the Back-Checker, who will “green check’ the red
marks (if found correct) on the new print marked by the Verifier, and sends the stack of
Check Prints for drafting.

When all the changes marked in the latest Check Print have been circled in green, the checking
process has been completed. The Checker/Verifier signs or initials in the title block of drawings,
at the top of the calculation sheets, or in other spaces designated for the Checker.

Signs and dates the Check Print stamp on the line designated for the Verifier, signs off drawings
or calculation sheets, and forwards the Check Print to the Originator of the document. This
completes the Checking Process if, due to Proponent’s dictated reasons or other similar
circumstances, further changes become necessary at a later time, they shall be processed on a new
Check Print in the manner previously described for the Check Print. Only the new changes need
to be checked, but the Designer and the Checker are responsible to make sure that any interface
areas that are affected by the changes are fully checked.

Disposition of the Checked Documents

The Section Heads are responsible for disposition and control of all documents originated by
their discipline and signs off that the checking process is complete.

If the document represents design calculations, analysis, or other work not requiring project
management review, the Project Engineer places all Check Prints in the project files with the
Documents Originals.

The Section Head/Project Engineer maintains Document Originals in limited-access files so that
they may be changed only with Project Manager’s knowledge and consent.

53
 Exceptions:

If for some extenuating reasons, documents must be sent to the Proponent before this procedure
has been fully implemented the following apply:

The Engineering Manager must notify the Project Manager that the documents have not been
checked and reviewed and explain the reasons.

Before transmittal of such unchecked documentation, written permission of the Project Sponsor
must be obtained.

After written permission has been obtained, the documents must be stamped “UNCHECKED”-
For Information Only”. If a single or limited number of copies of unchecked documents are to
be submitted to the client for review, these may be stamped “REVIEW COPY” –For
Information Only”. If unchecked documents are to be submitted to the client for bidding
purposes, they should be stamped “For Bidding Purposes Only— Not To Be Used For
Construction”.

The Proponent will be notified in the transmittal letter that the checking and review process has
not been completed.

6 DOCUMENTATION

NONE

54
 DOCUMENT TITLE:

PROCEDURE FOR:
PROJECT CHANGE CONTROL

DOCUMENT NO.:
QMP-003

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 4
6. Documentation: 5

55
 1 PURPOSE

The Purpose of this procedure is to provide a systematic method of controlling change on a project,
change being a revision to current Project Scope of Work, methods of working, budget or schedule. To
define the responsibility and methods of working which ensures that effective control of changes is
applied to a project.

2 SCOPE

This procedure applies to engineering changes made to baseline documentation. Engineering change
control is applied to all phases of a project.

This procedure sets out the guidelines followed in the processing of engineering changes to satisfy
Quality requirements for a systematic and controlled system of:

• Identification, notification and recording of changes;

• Assessment, rejection, or approval and incorporation of changes to baseline documentation
following the Proponent’s approval.

This procedure uses definitions in front of the Quality Manual together with the following

• Engineering Scope of Work

• Project execution schedule and project cost is outside the scope of this procedure.

3 REFERENCES

None

4 DEFINITIONS

Baseline Documentation

In the context of this procedure, Baseline Documentation will be AL TAKNIA contractual Scope of
Work, against which changes will be assessed and evaluated for impact such as;

Design narratives embodied in the scope of work;

• Work packages.
• Specifications, standards and procedures and Drawings

56
 Engineering Changes

A change to baseline documentation for reasons such as;

Mandatory
• Safety
• Operability
• Certification (via Proponent)
• Proponent’s instructions (variations to scope of work)

Non-Mandatory

• Good Engineering practice

• Vendor, fabricator, sub-contractor request for change
• Inadequacy, inaccuracies to scope of work documentation or design contractor documentation.

Change Request Authorization

A one page change order used on ‘minor’ changes (up to 50 man-hours). Change Order Request
A request is raised in order to obtain permission to commence work on a major engineering change
immediately prior to a formal change order being prepared if the scope demands immediate
implementation.

Design Modification Request

A form used as part of a package to present the full change order documentation for major change.

Engineering Change Control

Development, proposal, evaluation, approval and implementation of engineering changes shall be

conducted in a consistent manner.

Major Change

A change having a significant effect on baseline documentation, cost or schedule and constitutes more
than 50 man-hours to effect.

57
 Minor Change

A change having little effect on the baseline documentation; normally with little or no “Knock-on”
effect and usually to correct minor changes in drawings or engineering documentation. This change
will be no more than 50 man-hours to effect.

5 PROCEDURE

Responsibilities:

Project Services Group

Engineering Change Control is administered by engineers.

The Planning and Cost Engineer of AL TAKNIA Project Team will participate in the review of all
major changes to assess and advise impact on cost and schedule. They shall also review minor changes
as appropriate.

The Project Planning and Control Engineer shall be specifically responsible for coordinating the
receipt, registration, distribution, collation, and submission for review of all notified changes.

Engineering

The Project Engineer shall be responsible for the review of the technical impact of all changes and
for the preparation of the Change Order documentation. He shall give specialist advice to Quality
Assurance Manager in the evaluation of the impact of changes on the quality criteria.
The Project Engineer shall be responsible for obtaining review by Drafting and Material Take-off.
Project Engineers shall also ensure that engineering changes, which have a “knock-on” effect to
interfacing Third Party designed items, are identified and advise the Project Engineer who will advise
the Quality Assurance Engineer. All Third Party design documents and drawings forming part of the
baseline documentation and revised during the execution of AL TAKNIA scope of work shall be
evaluated for engineering changes. The results shall be recorded.

Quality Assurance

QM shall have responsibility for evaluation of quality criteria including reliability, operability, and
maintainability, safety, and weight control (where applicable). In fulfilling this specific responsibility,
they shall liaise, as is necessary, with engineering specialist. QM shall also be responsible for design
audits to ensure procedure compliance.

58
 Project Management

The Project Engineer is responsible for the preparation of the Change Request and Change Order
documentation arising from instructions for Proponent or Third Parties. The Engineering Coordinator is
also responsible for initial screening and review of AL TAKNIA engineering change proposals.

Change Identification

Major Changes

Requirements for a change may be identified by either AL TAKNIA or the Proponent. Change
identification shall be registered in the form of a fax, letter, or marked up documents or drawings.
AL TAKNIA initiated changes may originate from the Drafting Squad Leader. The Originator is
responsible for recording the change by completing the Design Modification Request form and
submitting it to the Project Engineer.

Initial Review and Interim Approval - The Project Engineer will review the proposed change with
affected Discipline and Project Services to obtain a preliminary feel for the effect of the change.

All changes will be subject to the Change Request Authorization form. Only after approval of either the
Change Request Authorization or Design Modification Request shall AL TAKNIA personnel start work
on the change following instructions from the Project Engineer.

6 DOCUMENTATION

6.1 Change Request Authorization Form

6.2 Design Modification Request

59
 DOCUMENT TITLE:

PROCEDURE FOR:
DOCUMENT AND DATA CONTROL

DOCUMENT NO.:
QMP-004

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 3
4. Definitions: 3
5. Procedure: 3
6. Documentation: 5

60
 1 PURPOSE
This Procedure describes the procedures and responsibilities for the receipt, control and distribution,
and revised control of all Technical Documents and Drawings, pertaining to a project.

2 SCOPE

This Procedure shall be applied to the following project related documents:

• Request for Bid and Bid Proposals

• Contracts / Scope of Work
• Specifications
• Standards
• Work Instructions
• Project Quality Plans
• Drawings
• Bill of Materials (BOM) Component Specification
• Sheets Drawings / Specification Clarifications
• Submittals
• Purchase Orders
• Original Equipment Manufacturers (OEM) Manuals
• Subcontractor/Vendor Qualification
• Reports Inspection Reports
• Spare Parts Data Package

This Procedure shall not be applied to routine correspondence.

Note: Routine Correspondence shall be handled as follows: Incoming

Correspondence will be:

• Time and date-stamped, entered into the Incoming Correspondence Log and distributed to
the concerned, as advised by the Project manager.

61
Outgoing Correspondence will be:

• Route through Project Secretary, who will number, log and deliver.

3 REFERENCES

SAEP 128 Security and Control of Saudi Proponent Engineering data Outside of Saudi Proponent or
any related quality document from other Proponents.

4 DEFINITIONS

This procedure uses definitions in front of the Quality Plan and ISO 8402 Quality Management and
Quality Assurance Vocabulary.

5 PROCEDURE

Document Handling

• All documents transmitted to AL TAKNIA shall be addressed to the Project Manager.

• Receipt, issue and usage of these documents shall be controlled.
• The Documents shall be Date Stamped, on receipt and entered into corresponding log.
• The Documents on issue shall be stamped, “CONTROLLED COPY”.
• Only controlled copy of the documents shall be used for construction.
• Photocopying of the controlled copy is not permitted.
• Sufficient numbers of controlled copy shall be issued to construction crews to perform
their job.
• The distribution shall be made under the cover of a Document Transmittal.
• In case of revisions, revised copy shall be distributed to all the original recipients.
• Any individual assigned to have a sensitive document (either the original or a copy), will use it
only at his designated workstation.
• Sensitive Documents are to be kept in the Project Office when not in actual use.
• The Project office will be locked when not attended to.
• All originals of the Proponent drawings shall be controlled in accordance with SAEP-128 or any
other quality document from other Proponents.

62
Project Drawings

• Project drawings shall be received by the Document Control Clerk (DC). All project drawings
shall be entered into a Drawing Register.
• The drawings shall be filed in an easily identifiable sequence and stored in a proper condition to
protect from damage or loss.
• Copies of the Project Drawings shall be issued to the following personnel.

RECIPIENTS DRAWINGS No. Of Copies

Project Engineer All 1
Engineering Manager All 2
Procurement Manager All 2
Engineering (Civil) Civil 2
Engineering (Mechanical) Mechanical 2
Engineering (Elect./Comm./Inst.) Elect./Comm./Inst. 2
Quality Assurance Manager All 1

Note: Distribution, other than the above shall be made by the DC upon specific request.

Recipients of the revised drawings shall destroy the previous issue or mark them as ‘SUPERSEDED’.

Shop Drawings

• Preparation and issue of the shop drawings shall be controlled by the Discipline Engineer.
• Distribution shall be as per requirement.
• Revision to the shop drawings shall be controlled by the Discipline Engineer.

Documents Transmittal to Proponent

• Preparation and issue of the shop drawings shall be controlled by the Discipline Engineer.
• Prepare the Document Transmittal / Submittal.
• Assign a correspondence number to the Document and enter in the log.
• Hand over to the Proponent Secretary on site.
• The Transmittal addressee will in all cases be the Proponent’s authorized representative.

Note: All project correspondence to the Proponent shall be routed through Project Secretary.

63
Documents Storage

• Preparation and issue of the shop drawings shall be controlled by the Discipline Engineer.
• The document shall be stored in a lockable room. The entry on this room shall be restricted.
• Magnetic Media back-up tapes, floppies, CD’s will be stored:
• Either off-site in a location approved by the Project Manager, or;
• In a fire-resistant safe on-site, as directed by the Manager.

CAD Drawing Access

• Preparation and issue of the shop drawings shall be controlled by the Discipline Engineer.
• Control their usage only during the assignment of the personnel to the project.

Document Disposal

• Preparation and issue of the shop drawings shall be controlled by the Discipline Engineer.
• The method proposed is via shredding. The shredding of Documents shall be witnessed by
the Project Manager or his designated Representative, and the Document/Drawing Control Log
shall be signed “Document Destroyed”.
• No Documents / Drawings will be disposed of, by any means, without authorization of the
Project Manager.
• Documents/Drawings shall not be removed from contractor office, except by authorization
transmittal, or proper disposal.

6 DOCUMENTATION

None

64
 DOCUMENT TITLE:

PROCEDURE FOR:
CONTROL OF QUALITY RECORDS

DOCUMENT NO.:
QMP-005

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 3
4. Definitions: 3
5. Procedure: 3
6. Documentation: 3

65
1 PURPOSE

This procedure d e s c r i b e s performing and controlling the filing and holding of Quality Records
& Documents.

2 SCOPE

This procedure is used for completion and retention of documents pertaining to Design,
Procurement, Construction and Pre-commissioning Phases of a project, which attest to the quality
aspects of materials & workmanship.

3 REFERENCES

SAEP-122 Project Records (Or any related document from other Proponents)

4 DEFINITIONS

Where appropriate, definitions used are based on ISO 8402

Quality Records – Documents, which furnishes objective evidence of activities, performed

or results achieved.

5 PROCEDURE

5.1 Responsibilities

The Quality Management Manager is responsible for maintaining inspection and test records of
materials, equipment and field activities
The Document Control Clerk is responsible for the control of drawings and documents related to
the contract.

5.2 Compilation of Quality Records

The Quality Assurance Manager or his representative shall progressively compile and maintain all
Inspection and Test Records in accordance with SAEP-122 Project Records, or any related
documents from other Proponents.
The documents shall be prepared either in A4 size or letter size paper.
All reports shall be in the English language, legible and clear in its content.
Corrections, if any necessary, shall be made by crossing out with a single cross line and shall be
initialized by the originator.

66
No corrections shall be made after the client has signed off a document.
The document shall be filed in accordance with individual discipline or activity. The documents
shall be compiled on standard box files 2" or 3" thick.
An index shall be prepared on top of the file.

5.3 Storage

The documents shall be stored properly to prevent damage, deterioration or loss. The documents
shall be well protected from unauthorized access.
Confidential / important documents shall be stored under lock. Quality records are stored in a
readily retrievable manner.
Where computerized, Quality Records follow an established Backup procedure.

5.4 Project Documents

Project Documents are protected from damage & loss as follows: Original records are filed in the
Document Library as permanent records. Access to the Document Library is controlled.
AL TAKNIA will ensure that one copy of the Inspection Record Book is forwarded to the Proponent
for review and/or approval.

5.5 Document Disposition

The period of retention of the documents is determined by the Project Manager, based on Contract
Requirements.

6 DOCUMENTATION

None

67
 DOCUMENT TITLE:

PROCEDURE FOR:
SELECTION FOR VENDORS
AND SUBCONTRACTORS

DOCUMENT NO.:
QMP-006

Index Page

1. Purpose: 2
2. Scope: 2
3. Responsibility: 2
4. Procedure: 2
6. Attachments: 4

68
1 PURPOSE

To ensure that the vendors and subcontractors selected by AL TAKNIA conform to specified
project requirements.

2 SCOPE

The procedure applies to the assessment of vendors and subcontractors under each contract.

3 RESPONSIBILITY

The QM/QC Engineer is responsible for Quality Program assessment of vendors and
subcontractors based on their ability to meet the specified requirements of the contract.
Commercial and Technical evaluation is the responsibility of Procurement and Engineering Staff.

4 PROCEDURE

A vendor or subcontractor is selected based on his capability to meet Proponent requirements,

s t a n d a r d s a n d s p e c i f i c a t i o n s . The m e t h o d o f e s t a b l i s h i n g t h i s capability may
include any combination of the following:

• Past history with the same vendor

• Evaluation of vendor's quality system based on established questionnaires
• Pre-assessment and evaluation of vendor’s capability and/or quality system at their facilities

4.1 Current Approved Vendors

Current approved vendors and subcontractors have been selected based on their ability to meet the
specified requirements and a review of their previous performance. All vendors and subcontractors
are recorded on an approved list maintained by the Procurement Department.

4.2 New Vendors

Potential new vendors and subcontractors must complete and return a Vendor QM Questionnaire.
Preference is given, where practicable, to those approved to ISO Series Standards or National
Equivalent.

69
Approval of a new vendor is based on the following criteria:

• Technical and financial capability

• Classification to ISO Series Standards or other standards
• Market reputation
• Experience with AL TAKNIA and Proponent. Staffing and Facilities
• QM/QC Programs

In selecting new vendors and subcontractors or extending the scope of supply and work of
existing ones, the following controls apply:

The questionnaire is assessed and graded accordingly:

• Approved
• Not-Approved

Representatives of AL TAKNIA may visit the vendor or subcontractor to establish his scope of supply
and/or work and suitability. The questionnaire may be completed at this time and a vendor audit carried
out at the discretion of the QM/QC Engineer. Corrective Action Request may be made to a Vendor
before acceptance of his product and/or workmanship. Vendor surveys are conducted when:

• Quality Management System based on ISO-9000 is not previously evaluated.

• Vendor is newly established
• Vendor is not listed on Marafiq Report

The QM/QC Engineer will review survey reports and may, after discussion with the vendor, take
the following actions:

• Approve the Vendor

• Request changes in the product/documentation, level of inspection etc. by the vendor
• Revert to trial lots
• Reduce the scope of supply
• Remove the vendor from the list

70
A Vendor may be removed from the approval list if any product is found not to conform to the specified
requirements at any stage from order through final acceptance by Proponent.

In addition, Proponent’s approved vendor's list is used for identification of Proponent approved
manufacturers who will be included in the bidding process as applicable.

5 ATTACHMENTS : FORMS

5.1 Vendor QM Survey - QMP-006-A1

71
 QMP-006-A1

VENDOR QUALITY ASSURANCE SURVEY

NAME AND ADDRESS OF COMPANY:

TELEPHONE NO.
TELEFAX NO.

SECTION 1

1.1 Do you have Quality Manager? Yes / No

Name:

If not, who has the responsibility?

NAME: POSITION:

1.2 To whom does the Quality Manager or Quality Representative report to?

POSITION:

1.3 How many personnel does your company employ:

1.4 How many personnel in the Quality Department?

QUALITY CONTROL/INSPECTION
QUALITY ASSURANCE

TOTAL

72
SECTION 2

Do you have a quality system that conforms to a recognized Yes / No

national or international standard? (E.g. BS, ISO, etc.)

Have you ever supplied products to Proponent in the past? Yes / No

If Yes on which contract and which product:

Which Proponent Material Specification has been applied to the above Product?

If Yes:

Please ignore Sections 3, 4 & 5 and forward a copy of your Registration Certificate(s) and /
or supporting documentation that identifies the Assured body and your scope of supply.
Yes / No

If No:

2.2 Are you preparing quality system for subsequent registration Yes / No

2.3 Has an assessment date been arranged? Date: Yes/ No

If not, when is an assessment proposed? Date:

2.4 What will be your proposed standard and scope of supply?

73
SECTION 3

Do you have documented procedures to cover any of the following?

3.1 Purchasing and Order Processing Yes/No/NA

3.2 Goods inwards Yes/No/NA

3.3 Handling, Storage and Disposal Yes/No/NA

3.4 In-process Inspection Yes/No/NA

3.5 Final Inspection Yes/No/NA

3.6 Identification of non-conforming products Yes/No/NA

3.7 Product Identification and Traceability Yes/No/NA

3.8 Analysis of failures and resultant corrective action Yes/No/NA

SECTION 4

4.1 Are all gauges, measuring and test equipment calibrated

at defined intervals? Yes/No

4.2 Are calibration results traceable to National Standards? Yes/No

SECTION 5

5.1 Do you maintain comprehensive records of inspections and tests? Yes/No

5.2 Do you maintain records of performance of suppliers and provide subsequent

grading for quality? Yes/No

SECTION 6

6.1 Would you provide access at any reasonable time for

our staff to view your quality system? Yes/No

74
COMPILED BY: SIGNATURE:

POSITION: DATE:

-------------------------------------------------------------------------------------------------------------------

VENDORS/SUB-CONTRACTOR APPROVED Yes/No

COMMENTS:

_________________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

NAME: ________________________________________
QC REPRESENTATIVE

SIGNATURE: ___________________________________ DATE: ___________________

AL TAKNIA

75
 DOCUMENT TITLE:

PROCEDURE FOR:
PREPARATION, FORMAT AND STYLE OF
PROCEDURES

DOCUMENT NO.:
QMP-007

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 3
4. Definitions: 3
5. Procedure: 3
6. Documentation: 3

76
 1 PURPOSE

The purpose of this procedure is to describe the method of preparation, style and format of all
procedures established for use by the AL TAKNIA departments and/or disciplines.

This procedure shall be used as an example of such preparation, style and format.

2 SCOPE

This procedure shall apply to all documents, which identify the activities and functions of a department
or group and shall be observed by all AL TAKNIA departments and disciplines without exception.

3 REFERENCES

None

4 DEFINITIONS

4.1 Procedure: A document that details the purpose and scope of an activity and
specifies how it is to be properly carried out.

5 PROCEDURE

Authorization to proceed

The need for procedure shall be identified by the department or Discipline Manager concerned and the
development of such agreed with the appropriate discipline Head.

Once the requirement has been agreed and an author delegated, the author shall obtain a definitive
procedure number from the document control center.

This procedure number shall be unique for the procedure to which it is to be applied and shall not be
used to identify any other document. In the event that the decision to proceed with the procedure is
rescinded, then the document control center shall be so advised and the number reinstated for future
use.

77
 Procedure Format

The cover page of the procedure shall be completed with the following information:

• Document number
• Document title
• Index
• Cover page/revision status
• Revision and approval box

The cover page and all subsequent pages shall be identified by number and shall carry the appropriate
document identification and revision in the bottom right- hand corner.

Procedure Content

All procedures shall carry the same content, which shall be as follows:

• Purpose – this outlines the object or intention of the document.

• Scope – this outlines the object or intention of the document.
• References – which detail other documents which have a bearing on the activities within the
procedure
• Definitions – which explain a work or action not universally understood, or which may have a
specific interpretation in the procedure.
• Procedure – this details the actions of those personnel involved in the activity. This section
shall identify wherever possible who does what and also how, when where and why the activity
is carried out.
• Documentation – this lists any appendices referred to within the procedure.

The procedure's index shall always include the content as detailed in clause 5.3 above in the event that,
for example, there are no references or definitions, then under the applicable heading the word NONE
shall be inserted.
In the event that additional details are required to be incorporated as a supplement to the procedure, then
these shall be incorporated as an appendix to the procedure

6 DOCUMENTATION

Procedure cover page.

78
 DOCUMENT TITLE:

PROCEDURE FOR:
PURCHASING

DOCUMENT NO.:
QMP-008

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 3
6. Documentation: 6

79
1 PURPOSE

To define the respective responsibilities and procurement activities and define interfaces between the
Proponent and AL TAKNIA. To ensure that within the defined parameters of the prime contract and
AL TAKNIA agreements and initiatives, equal opportunity is provided to all qualified Bidders to
provide equipment at best available quality & cost.

2 SCOPE

This procedure relates to AL TAKNIA procurement Team Member and covers all Purchasing
activities to be performed on the project.

The activities covered in this procedure are:

• Preparation of the Master Purchase Documents

• Preparation and Approval of Bidders' Lists
• Preparation, Approval and Issue of Enquiries
• Enquiry Period Communications
• Receipt and Review of Bids
• Recommendation and Approval
• Preparation and Issue of Purchase Orders
• Purchase Order Administration
• Spare Parts
• Reporting

3 REFERENCES

• NONE

4 DEFINITIONS
Where appropriate, definitions used are based on ISO 8402 and ISO 9001:2000.

Purchase Order: The document used to contract for the supply of goods and materials.
Material Requisition (M/R): Document prepared by Engineering which defines goods
and materials on which procurement action is required.
Client: will mean the Proponent.
Seller: The bidder awarded a purchase order from AL TAKNIA.

80
Master Purchase Documents (MPDs): The enquiry and order documents developed for use on
the project.
Procedure – A document that details the purpose and scope of an activity and specifies how,
what, when, where and by whom the activity shall be carried out.

5 PROCEDURE

5.1 Preparation of the Procurement Plan

The Procurement Manager will review the Proponent’s prime contracts, scope of work, and
equipment lists and prepares its Procurement Plan in accordance with Schedule 'G' of the Contract.
The Procurement Plan will be based on AL TAKNIA models developed to include specific project
requirements and will comprise standard documents, optional documents, clauses or modifications to
documents and clauses to be utilized on specific Enquiries/Purchase orders as appropriate.
On completion of the draft Procurement Plan, it will be circulated to appropriate organizations within
AL TAKNIA (Project Manager, Legal and Insurance, and Engineering) for review and comment.
Purchasing will incorporate comments into the Procurement Plan and issue to the Proponent for
review and approval prior to implementation on the project.
Modifications to the approved MPDs will be processed as above.

5.2 Preparation and Approval of Bidders' Lists

Purchasing will prepare a list of potential bidders covering the categories of material required for the
project, in accordance with Prime Contract and in consideration of the Proponent’s Regulated Vendors
Lists (RVL) and approved qualified sources for none RVL materials.

On receipt of each Material Requisition (M/R) for quotation, Purchasing will, using the prepared
"Project Bidders List", prepare an enquiry package.
Each specific Bidders list will contain sufficient bidders. In circumstances with only a single Bidder, a
restricted bidder list or AL TAKNIA agreement are used for reasons of schedule where competitive
bidders is not sought, the reason will be noted on the bidders list.

81
 5.3 Preparation, Approval and Issue of Enquiries

In accordance with the project schedule, Engineering will issue each Purchase Memorandum, M/R
and attachments for review by the Quality Manager or his designee and Purchasing.

Prior to engineering issuing the M/R for quotation, they will check with Purchasing to ascertain the
number of copies required for issue to bidders and for standard distribution, and issue sufficient
quantities. On receipt of the M/R approved for quotation, Purchasing will add the project standard
commercial portion of the enquiry package and issue to the required Bidders.

5.4 Enquiry Period Communications

• All communication to and from bidders will be through Purchasing.

• Purchasing will forward Bidders' queries to the appropriate member of the project team.
• Purchasing will receive and coordinate responses to bidders' technical/commercial/contractual
questions.
• The appropriate member of the project team will promptly develop a response to bidders'
enquiries and forward the response to purchasing for issue.
• Responses to any bidders' enquiry that are relevant to other Bidders will be issued
simultaneously to all bidders with copies of technical responses to Engineering.
• Engineering will expeditiously prepare and obtain necessary approvals for technical addenda
to the bid package as necessary and forwarded to Purchasing with a revised M/R.
• Purchasing will prepare as required, commercial addenda to enquiry packages with assistance
as necessary from Finance, Business Management, Legal and Insurance, Operation and
Engineering.

5.5 Receipt and Review of Bids

Bidders will be required to submit one priced original and sufficient copies of their bids so as to reach
the Procurement Manager by the bid due date. The bids will be received by the project Procurement
Manager, Date stamped and passed to the purchasing supervisor for records.
Sealed bids will be opened by a group comprising a representative from Procurement,
Business Manager and Engineering.
Prior to award of an order, no details of the bids will be publicly announced. Each member of the
project involved in an evaluation will be responsible for the maintenance of bid security and for
reporting of any instance of a breach in the bid security.

82
 5.6 Evaluation of Bids

For each material requisition, bids shall be tabulated and analyzed in accordance with the following:
Purchasing with assistance from finance and Business management shall notify Engineering of the
price ranking of Bidders after opening sealed bids or receipts of all unsealed bids. Engineering shall
evaluate their technical evaluation concurringly with the commercial evaluation on selected Bidders.
Purchasing shall commence full evaluation of the selected Bidders. Clarification and or further
development of the bidders' proposal may be requested by procurement or by engineering through
Purchasing.
All communications and meetings with bidders shall be arranged and conducted by Purchasing.
The formal summary of the bids shall be completed and issued as combined presentation with the
technical evaluation.
Purchasing shall obtain the necessary approvals of the recommendation for award from AL TAKNIA
Procurement Manager.
Prior to placing the purchase order, AL TAKNIA will submit a copy of its requisition and vendor's
technical submittal to the Proponent for review and comment. Relevant Proponent’s comments will
be incorporated prior to issuing a purchase order.

5.7 Preparation and Issue of Purchase Orders

After approval of bid summary, Purchasing shall notify Engineering of the successful bidder for
engineering to issue accordingly a Material Requisition for Purchase, which shall incorporate all scope
or technical changes from original material requisition and including all changes agreed during
evaluation with the successful bidder.
Purchasing will prepare and issue the confirming Purchase Order (PO) together with all relevant
commercial and technical attachments on receipt of the Material Requisition for Purchase from
Engineering.
Purchasing will ensure that all awards are documented by written PO issued to the Bidder together
with the acceptance to be countersigned and returned by the Bidder.
AL TAKNIA will review and approve purchasing documents for adequacy of the specified
requirements prior to release.

5.8 Purchase Order Administration

After award of an order, Purchasing is responsible for commercial administration of the order.
Expediting is responsible for progressing of the order to meet delivery dates and Supplier Quality
is responsible for supplier's compliance with quality requirements. Any formal changes to the
price, delivery, scope or condition of purchase is commercial administration and the responsibility of
Purchasing.
A revision to the purchase order will be processed to cover the price, scope or condition of purchase
changes. The request for change can either be a Seller response to a AL TAKNIA request or initiated
by the Seller.

83
Immediately upon receipt of a request for a change order, Purchasing will log the request; attach
supporting Correspondence/document and issue for review and approval.
In the event of an Engineering originated change to the Purchase Order, Purchasing will submit the
change to the Seller, and request the commercial and technical effect to be submitted to Purchasing by
a given date.
Purchasing will ensure that all necessary comments and approvals are received prior to revising the
PO. A PO revision shall be issued in accordance with the company rules.
Engineering will raise an M/R for Purchase Order Revision to incorporate any major Engineering
relegated changes prior to issue of any PO revision.
Purchasing will maintain, on a current basis, a PO file to include all pre and post commitment
correspondence relating to that file or order.
5.9 Spare Parts

Bidders shall be required to complete sufficient information in accordance with prime contract for
evaluation purposes, for the start-up spares and capital spares as detailed and included in the M/R
package at the bid stage.
Subsequent to the issue of the PO for Parent equipment and submission by the bidder of the spare
parts data package, Engineering shall submit the completed spare parts to the client.

5.10 Reporting

Purchasing will establish and maintain reports logs in accordance with project procedure, such as
weekly status report, which is used to record detailed information to support the procurement status.
The report shall include, as a minimum, the following information for each purchase order:

• Purchase order number and date

• Material description and Vendor name and location
• Inspection Assignment Package submittal date
• Level of inspection as specified in contract schedule
• Pre-inspection and Fabrication start date
• Scheduled and forecast delivery date
• Special fabrication procedure approval status
• Open and closed NCR's
• Closeout date and Disposition report

The Proponent shall have access to all purchase order inspection report files.

6 DOCUMENTATION
None
84
 DOCUMENT TITLE:

PROCEDURE FOR:
HANDLING, STORAGE, PACKING, AND DELIVERY

DOCUMENT NO.:
QMP-009

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 3

85
1 PURPOSE

To provide a procedure for handling, storage, preservation, packaging and delivery of

products, systems, components, or installation material on receipt at company sites.

2 SCOPE

This procedure applies to all systems, components, and/or installation materials

purchased, and/or used by the company.
Packaging and delivery are normally not part of AL TAKNIA scope of work.

3 REFERENCES

None

4 DEFINITIONS

This procedure uses definitions in the front of the Quality Plan and ISO 8402 Quality
Management and Quality Assurance Vocabulary.

5 PROCEDURE

5.1 Responsibilities

Store Keeper/Controller:

Handle and store materials as per procedure and manufacturers' instructions. Preserve
and protect materials at warehouse / lay down yard.
Package and deliver the items, when required.

Site Supervisors/Foremen.

Ensure proper handling, storage and preservation of materials/equipment issued at work sites.
Quality personnel monitor the condition of storage and preservation.

5.2 Handling

Selected employees are instructed, as required, in proper methods of material handling

before any actual handling of material occurs.
86
To prevent damage during material handling the following devices may be used:

• Manual lifts and cranes for heavy Equipment.

5.3 Storage

Tags & labels affixed to the outer box or storage rack identify the contents and physical
characteristics of store items.
The Store Keeper shall perform regular monitoring on the material stored to verify their condition.

5.4 Preservation

Materials / equipment requiring special storage conditions shall be stored in accordance with
manufacturer's instruction.

Heat sensitive items shall be stored under temperature control.

Materials provided with preservatives during storage shall be verified for proper packaging and
storage.
The Material Controller, based on the input from the equipment supplier, will prepare and maintain
a list of all equipment subject to preservation, including frequency and the type of preservation to
be used. Condition of equipment and material in storage will be checked periodically to prevent
deterioration and identify non-conforming conditions.

5.5 Packaging and Delivery

Whenever materials are transported from sites, the material controller ensures proper
packaging and delivery.

The Store Keeper also verifies the contents before sealing the package and prepares a Material
Transmittal.

6 DOCUMENTATION

None

87
 DOCUMENT TITLE:

PROCEDURE FOR:
RECEIVING INSPECTIONS

DOCUMENT NO.:
QMP-010

Index Page

1. Purpose: 2
2. Scope: 2
3. Responsibility: 2
4. Procedures: 3
6. Documentation: 4

88
1 PURPOSE

To establish a system for ensuring that Incoming items meet the specified contract and
Quality requirements.

2 SCOPE

All items received, which are intended for use in producing finished product, are covered
by this section.

2.1 ASSOCIATED MATERIAL:

• Incoming Inspection Report

• Material Rejection Report
• Material Test Reports
• Bill of Material
• Drawings
• Unpriced Copy of Purchase Order
• Receiving Manifest
• Identification Tags
• Approved Procurement Procedure

3 RESPONSIBILITY

• The receiving Personnel are responsible for receiving inspection as detailed in this Procedure.
• The QC Inspector is responsible for verifying the findings of the receiving personnel; he is also
responsible for final approval of materials/equipment.
• For major item, the site engineer will participate in receiving.
• Inspection.

89
 4 PROCEDURE: - INCOMING INSPECTION

4.1 RECEIVING INSPECTION

• Receiving personnel will receive and verify all materials/equipment against the Purchase
Order, count and check for damage, and if in order and acceptable, complete and sign the
receiving manifest.
• All materials/equipment designated to be held in Stores for Incoming Inspection by instruction
on the Purchase Order is held in a receiving area pending QC Inspector approval and where
required the Proponent's QR Inspection, and acceptance, prior to release for operation.
• Receiving personnel notifies the QC Inspector that materials/equipment have arrived
and arranges for Inspection.
4.2 QUALITY INSPECTION

• Site QC Inspector will check the objective evidence as provided by a Supplier to

determine that adequate quality verification was exercised, for example, review inspection and
test reports, MTR's, etc...
• The QC Inspector will examine all material for conformity to the Purchase Order and drawings.
This examination should cover but not be limited to the following:

• Dimensions, marking and condition

• Name Plate
• Quantity and Quality of Product
• Quality Records
The findings should be recorded on the Receiving Inspection Report Form from the approved
Procurement Plan. This report will be interfaced with the use of Quality Plan.

4.3 SUPPORTING DOCUMENTATION

• Prior to final acceptance of material/equipment, the QC Inspector will verify that supporting
documentation has been received and accepted, and for the ASME Code application, the heat
number from the material is identical to that identified on the Material Test Reports.
• MTR's should be verified by the QC Inspector for accuracy of Heat Numbers or
Identification numbers, his verification should cover chemical composition, physical and
mechanical properties. Approved MTR's should be signed and dated by the QC Inspector and
filed in the Quality Records. Approved MTR's must be annotated with Contract No., P.O. No.,
P.O. Item No., and Project Name.

90
 4.4 POSITIVE RECALL

• Products, which are not fully inspected, may be released for construction by the QC Inspector,
with the Project Manager and Proponent’s concurrence, under the condition that they can be
recalled if the complementary inspection shows that the items do not conform to the specified
requirements.
• The use of this procedure will be restricted to material/components for which quality
documentation from a supplier is not available for review and acceptance by QC Inspector.
The supplier will be contacted to confirm that all required inspections/tests have been carried
out, accepted and available for submission and review. The affected item will be released
from the segregated hold area but hold tags attached will remain until final disposition of the
nonconformity
• If the QC Inspector decides to release the material/component on a recall basis, he should
inform the Site Construction Manager in writing.
• The QC Inspector records the identification of the material components to be released, and if
necessary makes additional identification either directly on the material/components or on a Tag
in such a way that it is possible to trace and to identify, if they should have to be recalled.

If the complementary inspection shows that the material/components do not conform to the specified
requirements, the QC Inspector will recall the material/component and inform the Site Construction
Manager.

The materials/components are brought back to the segregated hold area and processed.

5 DOCUMENTATION

NONE

91
 DOCUMENT TITLE:

PROCEDURE FOR:
MATERIAL IDENTIFICATION AND TRACEABILITY

DOCUMENT NO.:
QMP-011

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 3

92
 1 PURPOSE

The purpose of this procedure is to:

• Identify material from receipt through installation;

• Maintain historical records of the materials
• Be able to trace assemblies and selected subassemblies through identification and marking
• Define the methods to be used to provide material identification and traceability
• Provide procedures for identifying and tracking major components, modules, tests results and
products during all stage of fabrication and installation.

2 SCOPE

This procedure applies to all systems, products, or components purchased for fabrication and/or
installation.

3 REFERENCES

None

4 DEFINITIONS

This procedure uses definition in the front of the Quality Plan and ISO 8402 Quality
Management and Quality Assurance Vocabulary.

5 PROCEDURE

5.1 Responsibilities:

The Store Keeper/Controller is responsible for the following;

• To maintain the database, which provides necessary identification and traceability of

materials.
• To provide identification for materials, to correlate with the relevant documents/certificates.

It is the responsibility of Quality Department to ensure the identification and traceability of the item
delivered for the operational projects.

93
 • System, Components and Installation Materials
• System, equipment, component or parts shall be traceable to manufacturers’ serial number.
Manufacturers’ serial number shall be provided on the items by nameplates, metal tag,
engraving or stickers.
• An inventory shall be prepared for such materials and shall be identified by the serial
number.
• This information shall be maintained jointly by the Quality Procurement and Store
Keeper.
• The inventory system tracks items received from the vendor by associating to the purchase
order number, item serial number and placement location.
• The Store Keeper applies serialization tags, on items requiring individual traceability and
documents it, as required by contract.

Construction Materials:
• The materials shall be traceable to the heat numbers, cast numbers or lot numbers.
• Material Test Certificates shall be identified on at least one piece or through tags tied on to
the lot.
• For batch traceable materials, individual pieces going into the construction shall not be
separately identified.
• Color-coding shall be followed to identify different grades of similar materials.
• For batch traceable materials, individual pieces going into the construction shall not be
separately identified.
• Materials requiring full traceability shall be individually identified by their H eat/Cast/Lot
number and they shall be individually traceable to their reference documents.
• The identity shall be provided through hard stamping, metal tag or any other suitable means of
providing required identification.
• Whenever traceability is required, a material identification register shall be maintained to
record each piece of the material.
• Traceability during Construction During construction, the components shall be identified by
the drawing number, part number or serial number.
• The items shall be traceable to their material certificates.
• Wherever required, tags shall be provided to identify the components.

6 DOCUMENTATION

None
94
 DOCUMENT TITLE:

PROCEDURE FOR:
CONTROL OF CUSTOMER SUPPLIED PRODUCT

DOCUMENT NO.:
QMP-012

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 4

95
1 PURPOSE

The purpose of this procedure is to set out the formal methods and planned actions to be taken
by AL TAKNIA to ensure that Proponent’s supplied materials and equipment are handled with care,
identified, verified, protected and safeguarded.

2 SCOPE

This procedure covers the inspection, storage of Proponent’s supplied material and equipment
provided for incorporation into the Work. It also covers action to be taken when any such material
and equipment are damaged or otherwise unsuitable.

3 REFERENCES

QMP-021 - Inspection and Testing

4 DEFINITIONS

This procedure uses definitions in the front of the Quality Plan and ISO 8402
Quality Management and Quality Assurance-Vocabulary.

5 PROCEDURE

5.1 Initial Inspection

• Upon receiving material at the Site Material Yard or warehouse, an initial Inspection is
carried out by the Quality Engineer, and AL TAKNIA Quality personnel according to
procedure AL TAKNIA QMP-012.
• Any damage shall be immediately documented and reported to purchasing and Project
Management who will in turn notify the Proponent.
• All such information and descriptions will be noted on the Material Receipt and Inspection
Report form (MRIR).
• Material items that can be unpacked, prior to their need for construction, are inspected to
ascertain compliance with requirements.
• Any missing parts or deviations will be immediately reported to the Proponent.
• Any action to be taken in such cases will be coordinated with the Proponent.

96
 5.2 Material Control and Issue

• All material arriving at the Site Material Yard is logged and stored.
• AL TAKNIA will notify the purchase of all materials received without appropriate
inspection records or client inspection release.
• An updated Logging System is maintained by showing:
• The type and Quantity of each material item in the yard or warehouse.
• Quantity of damaged, or unusable materials, will be shown in the Materials Receipt
Inspection Report form.

5.3 Material items found damaged or unsuitable during installation will be:

• Immediately reported by the Onsite supervisor to the Materials Specialist, who will in
turn, notify quality personnel of the event.
• Such items will be replaced unless modifications or repairs can be satisfactorily
demonstrated to the Proponent.
• Construction Material received during the construction phase will be inspected
for compliance to the applicable standards, codes, specifications, and for any damage.
AL TAKNIA quality personnel will be onsite for the required inspection.
• Any violation concerning the Proponent supplied materials will be reported to the Project
Manager.

5.4 Material Receipt

• The AL TAKNIA Material Team will check and verify all materials received and subject
them to Goods Receiving inspection in accordance with this approved procedure.
• This check will be a physical inspection and it will be noted with the appropriate
corresponding documents and MRIR is generated.
• This physical inspection will ensure that we have received the correct product that the
product is in compliance with the materials description such as: Field tags, stamps, and any
marking of identity.
• Uncertified materials will be kept in quarantine and the MRIR will be promptly and
accurately filled out.
• AL TAKNIA will store all materials and equipment in accordance with the Proponent’s
requirements and in such a way as to protect them from damage, deterioration,
contamination and loss of identification. AL TAKNIA will make special provision for
sensitive items such as welding consumable, equipment or sprayed, galvanized or painted.

97
 • AL TAKNIA will document receipt of materials as per 5.1.3, with their precise location
within the lay down area and will ensure that materials of different types, grades and
specifications are segregated.
• AL TAKNIA will use Material Requisition to release materials or items from the
laydown/storage area for fabrication/construction operations. These will be submitted for
review and approval by the Proponent prior to the subject material being issued from AL
TAKNIA lay down Area.
• AL TAKNIA will ensure that the material/equipment is correct for the intended application,
that is full and correctly documented and identified and that its issue is recorded.
• AL TAKNIA will then issue the material/item ensuring that no damage or loss of
identification is incurred during any loading, off-loading, slinging or other handling
operation.
• In the case of materials issued and loaded for dispatch to a sub-contractor, AL TAKNIA
will ensure that identification is intact prior to dispatch.
• AL TAKNIA will also ensure that such material is accompanied by full certification when
received from the Proponent.

6 DOCUMENTATION

Material Receipt and Inspection Report

98
 DOCUMENT TITLE:

PROCEDURE FOR:
PROCESS CONTROL

DOCUMENT NO.:
QMP-013

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 4

99
1 PURPOSE

The objective of this procedure is to ensure that processes during Design, Procurement,
Construction, and Pre-commissioning work shall be controlled and carried out in accordance with
project requirements.

2 SCOPE

This procedure describes the system by which processes shall be controlled with reference to
project requirements.

Processes shall be controlled through the issuance of Procedures, Work Instructions and
Method Statements.

3 REFERENCES

The following documents are referenced:

QMP-005 Control of Quality Records

QMP-002 Quality Assurance and Control,
QMP-021 Inspection and Testing

4 DEFINITIONS

This Procedure uses definition in the front of the Quality Plan and ISO 8402
Quality Management and Quality Assurance vocabulary.

5 PROCEDURE

• The Project Management Team prepares and reviews all procedures to ensure that these
comply with the project requirements.
• The Quality Management ensures that procedures will result in the respective work being
in compliance with project requirements.
• The Safety Engineer ensures that implementation of the procedures will be in compliance
with the project safety requirements.
• Relevant discipline Managers/Lead Engineers are responsible for identification, planning
and servicing of processes directly affecting quality, and ensuring that these processes are
carried out under controlled conditions, which include the following requirements:
• Document procedures/Work instructions specifying the method of fabrication and
installation, in particular at those points in the process where inadequate control could affect
quality.

• The correct workplace, equipment, processes and production of installation procedures.

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 • Relevant procedures, data sheets, checklists, test and acceptance forms, safety instructions
etc, are procedures to the project requirements and national and international standards and
codes.

5.1 Adequate Monitoring Control of Activities

The relevant certification, measurement, calibration, approval of processes, procedures, equipment,

and personnel.
Standards, specifications, or other criteria for workmanship, which are either written or expressed
through QC Procedures or Work Instructions.
The appropriate maintenance of equipment and Supplies.

Various processes will be covered in detailed procedures for the following work areas:

• Civil Works Structural

• Civil Works OSP
• Works Mechanical
• Works Piping Works
• Communication Works
• Instrumentation Works
• Electrical Works
• Installations Works

5.2 Special processes:

• Special Processes, defined as having results which cannot be fully verified by inspection
and testing of the activity and where problem may become apparent only after the
object or activities is placed in use, and are subject to number of extra rules and safeguards.
• Special Process shall be controlled with documented procedures, to ensure that the
special requirements are met.
• AL TAKNIA will ensure that these special processes are carried out under
controlled conditions.

• AL TAKNIA will submit all Special Process procedures and personnel qualifications
as listed in Schedule ‘Q’ Appendix 4, to the Proponent for review and/or approval at least
(30) calendar days prior to start of work.
• Special processes should be carried out and monitored by qualified personnel using
documented work instructions.

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• Records and status logs are maintained for approved processes, equipment and personnel,
as appropriate.
• AL TAKNIA will issue instructions, as part of its quality system requirement to all vendors
and subcontractors to control special processes.
• Where detailed procedures are required from vendors or subcontractors, or AL TAKNIA,
they will be reviewed by the Project Management and Quality Assurance Department, and
records of status maintained.
• The vendor will be continuously monitored for adherence to the approved procedure.
• Records referencing the approval of such special processes will be maintained in the Quality
Assurance files with the parameters laid down in QMP-005.
• Inspection of all works will be carried out in accordance with respective approved
procedures. These inspections will be recorded by means of Relevant Inspection
Records.

6 DOCUMENTATION

None

102
 DOCUMENT TITLE:

PROCEDURE FOR:
CORRECTIVE AND PREVENTIVE ACTION

DOCUMENT NO.:
QMP-014

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 4

103
 1 PURPOSE

To provide procedures for corrective action in the resolution of quality problems.

To analyze and resolve quality problems so that recurrence, nonconformance or potential
nonconformance can be prevented.

2 SCOPE

This procedure shall be applied to work performed both by AL TAKNIA and its
subcontractors.
Any written or oral expression of dissatisfaction by the Proponent related to the quality, reliability,
or performance of any product or service offered by AL TAKNIA will be subjected to investigation
for root cause and required corrective action.

3 REFERENCES

None

4 DEFINITIONS

Corrective Action: Action taken to eliminate the cause of an existing nonconformity.

Preventive Action: Action taken to eliminate the cause of a potential nonconformity.
Nonconformance: The non-fulfilment of a specified requirement as indicated by
an observation or test result.

5 PROCEDURE

5.1 Responsibilities

The QM Manager shall be responsible for documenting, investigating and follow-up of customer
complaints and reports of product, process, or service nonconformities in
AL TAKNIA, and/or at vendor or subcontractor.

• Corrective and preventive action may be initiated by anyone at any level, or at any stage
of the work.

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• Corrective Action Request form shall be used to identify problems in the quality system, or
to request changes, or improvements to the quality system.
• Nonconformance Reports shall be used to identify and report quality problems on product
and processes.
• The QM Manager shall receive data from all corrective and preventive action systems, and
analyze this with the concerned to resolve the same and initiate process improvements.
• This analysis includes data on all critical nonconformities, time required to process
nonconformities, trend analysis, and excessive delays in resolving nonconformities.
• The objective of the analysis is to establish confidence in the system and product quality.
• The implementation of all corrective and preventive action shall be verified by the QM
Manager.

5.2 Corrective Action Request

• The Corrective Action Request form shall be used to record the deficiency observed on a
process or procedure and proposal from the originator on the required improvements.
• The Corrective Action Request can also be the result of either an internal or external audit.
In this case, the Quality Assurance Manager shall propose the required corrective action.
• The Corrective Action Request shall be discussed in the management review meeting and
necessary decisions are taken for process improvement.
• The board considers a number of factors such as cost/benefit scheduling priority and
resources, before deciding the improvement.
• The required changes to the procedure and processes shall be recorded and revised
procedures shall be issued to all concerned.

5.3 Nonconformance Reports

• Nonconformance Reports contain the nature of the nonconformity and its possible cause.
• For recurring type of nonconformities, the Quality Assurance Manager analyses the root
cause of the nonconformity, including analysis of the product or service specifications,
processes, operations, inspection records, etc.
• Logbook entries, Nonconformance Reports and Worksheet from the Proponent are also
reviewed for the type and nature of nonconformity.
• The analysis considers frequency of occurrence as well as their relationship of cause and
effect.
• The required corrective and preventive actions are reviewed in the management review
meeting.

5.4 Corrective Action

• The required corrective action to eliminate the cause of a recurring nonconformity or

deficiencies observed on a process or procedure shall be implemented.
• The QM Manager shall follow up the corrective action, which is reviewed and finalized
in the review meeting.
• On implementing the corrective action, its effectiveness is monitored.
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• If after implementing the corrective action any recurrence of the nonconformity is observed,
further investigations shall be carried out. These shall be discussed in special review
meeting and the required corrective action shall be implemented.
• Any changes required to the procedures or processes shall be documented and necessary
implementation shall be verified.

5.5 Preventive Action

• Preventive action shall be discussed and implemented to eliminate the potential cause of
nonconformity.
• The required changes to the development process, product specifications to quality
system shall be made to prevent such nonconformities.
• The preventive action taken shall be suitable to the magnitude of the problem.
• The analysis of preventive action taken shall be reviewed in the subsequent
management review meeting.

6 DOCUMENTATION

Corrective Action Request Form.

106
 Corrective Action Report
Project: Assessment Report Number
BI Number:
Contract No:
Contractor: Assessment Date(s):
Location:
Contractor Representative: Lead Assessor:

Nonconformity:

Assessor: Date:

Contractor Acknowledgment: Date:

Proposed Corrective Action:

Agreed Implementation Date:

Action to Prevent Recurrence:

Date:

Contractor Representative: Date:

Originator/Inspector: Date:
Contractor Reply is Satisfactory
Contractor Reply is not Satisfactory
Action Taken is Satisfactory: Implementation Date:
Verified by:

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 DOCUMENT TITLE:

PROCEDURE FOR:
CONTROL OF NON-CONFORMANCE

DOCUMENT NO.:
QMP-015

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 4

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 1 PURPOSE

The purpose of this procedure is to identify document and control non-conforming items, identify
the authority for approval and document all re-inspection results.

2 SCOPE

This procedure describes the control and documentation of non-conforming items to prevent their
inadvertent use in project X phase.
The requirements and instructions contained in this procedure include provisions for identification,
documentation, segregation, distribution of non-conforming reports (NCR) for notification and
disposition by affected groups or organizations. It also includes provisions for inspection of
repaired or reworked items and the conditional release of non-conforming items for installation
and further work.

3 REFERENCES

None

4 DEFINITIONS

Nonconformity – The non-fulfillment of specified requirements.

5 PROCEDURE

5.1 Responsibilities

• The Quality Assurance Manager or his designated nominee is responsible for raising NCR’s
with regard to non-conforming items and submitting waiver requests to the Proponent if
required.
• The discovery of non-conformance that may occur at any time during the project life cycle
is the responsibility of all project personnel finding a substantial nonconformity to report
this to Discipline Engineer and quality personnel.
• The Quality Assurance Manager or his designated nominee is responsible for verifying
the disposition of the non-conforming item and closing out the NCR.

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 • Depending on the source of the NCR (procedural, working practice, material etc.) corrective
actions may be proposed by the QM Manager, Engineering, Operation or relevant
Discipline Engineer.

5.2 General

All items, processes or activities that do not conform to the specified requirements will be
identified, reported and recorded. These non-conforming items will be marked/tagged with a
“HOLD” card and quarantined in order to prevent use until their disposition has been determined
and approved. Further work activities on quarantined material shall be suspended until the
resolution of the NCR.

Disposition of non-conforming products will be determined as follows: Rework to meet the specified
requirements.
• Accept with or without repair, concession request shall be required.
• Re-grade for alternative applications.
• Concession request may be required.
• Reject or scrap.

If the nonconformance is identified by someone other than QC Supervisor, then that person shall
bring the matter to the notice either the Quality Assurance Manager or his nominee, who will
raise the NCR.
Items requiring correction rework or repair shall be re-inspected as per the applicable procedure
for compliance with the applicable requirements prior to reintroduction into the process. Upon
receipt of satisfactory results of such inspection, the project Quality Assurance Manager shall
authorize the removal of the “HOLD” tag.

In all cases where a Supplier’s product nonconformity is identified, an NCR will be raised by the
Quality Assurance Manager or his nominee and the item or product shall be quarantined until action
has been taken and the NCR has been closed out.

A copy of the NCR will be returned to the Supplier for action. The Supplier’s proposed corrective
of the corrective action will be verified by the Quality Manager or his designated nominee prior
to close out of the NCR. Further copies will go to the Procurement Department for information and
a copy will be maintained in the Project File.

When a nonconformance is noted during production/construction, a NCR will be raised by the

Quality Assurance Manager or his nominee and the corrective action taken as defined by the
Discipline Manager.

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If rework is within the specification requirements, the rework will be carried out as defined in the
NCR. The Engineering Manager will be responsible for defining the rework requirements.

If the rework is outside the specification requirements a corrective action request shall be raised
Quarantining the item.

A waiver request, including the proposed repair procedure, shall be forwarded to the Proponent for
their approval or recommendations. The item will remain quarantined until the disposition of the
Corrective Action has been agreed.

Items considered not acceptable for correction, rework or repair shall be tagged
‘REJECTED’ and shall be removed as soon as possible from the work site and destroyed if and
when necessary. Client rejected materials shall be kept in a suitable and properly delimited
segregation area until their final destination has been decided.

The QC Inspector shall inspect all rework against the original standards or specifications and the
original acceptance criteria shall be used to verify the acceptability of the rework. The NCR will
then be signed-off when found to be acceptable. If the items have been reworked, the rework
procedures will be noted on the NCR.

All information relevant to rejected materials shall be noted for materials reconciliation purposes.
The Project Quality Assurance Manager shall ensure the follow-up of the Corrective Action. The
Quality Assurance Manager may check on the remedial or corrective action completion by a check
visit on site or through notes from the concerned Responsible Personnel informing him on the
achievement of the action.

The Quality Organization shall maintain records of all Nonconformance and Corrective Action
Forms, this shall include:

• Objective evidence or remedial actions to substantiate that corrected / reworked items have
been re-inspected and/or re-tested according to applicable procedures;

In case of re-occurrence of specific nonconformity (trend), the Quality organization shall provide
for auditing of the activity. Audit Report, and if necessary, Corrective Action Request shall be
issued in this respect.

All NCRs will be filed and maintained for each project. These NCRs will form a part of the project
quality records.

111
All NCRs including the Proponent issued NCRs, will be logged in the Nonconformance Report
Register by the QM Manager or his designated representative.

6 DOCUMENTATION

None

112
 DOCUMENT TITLE:

PROCEDURE FOR:
INTERNAL QUALITY AUDITS

DOCUMENT NO.:
QMP-016

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 3
6. Documentation: 10

113
 1 PURPOSE

To define a uniform and controlled method to be employed for planning, scheduling, coordinating
and performing Quality audits and to assign responsibility for these activities.

2 SCOPE

This procedure applies to Internal Quality Audits conducted by the Quality Management
Department, w h i c h may utilize trained and experienced auditors from other departments
within AL TAKNIA to verify implementation and effectiveness of the formal quality systems and
approved procedures. It also establishes the requirements for planning, preparation, performance,
reporting, follow-up and close out of the Quality Audit.

3 REFERENCES

None

4 DEFINITIONS

Where appropriate, definitions used are based on ISO 9001-2000.

Quality Audit – A systematic and independent examination to determine whether quality activities
and related results comply with planned arrangements and whether these arrangements are
implemented effectively and are suitable to achieve objectives.

System Audit – An audit used to assess whether the documented quality system is adequate to meet
the functional requirements of AL TAKNIA and whether procedures have been developed to provide
objective evidence of the management systems.

Compliance Audit – An audit used to verify whether the quality plans, processes, procedures and
job specifications are actually being complied with and to assess their effectiveness.

Auditor – An individual who has the qualifications and experience to perform quality audits.

Lead Auditor – A quality auditor designated to manage a quality audit.

Auditee – 'Organization being audited'.

Corrective Action –'An action taken to eliminate the causes of an existing nonconformity, defect or
other undesirable situation in order to prevent recurrence.

Nonconformity – 'The non-fulfillment of a specified requirement'. A deficiency in characteristic,

documentation, procedure or process, w h i c h renders the quality of an item or service
unacceptable.
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 • Examples of nonconformity include: departure from approved procedures, contravention
of AL TAKNIA specification requirements, non-compliance with applicable codes and
standards, deviation from approved quality plans and incorrect or inadequate documentation.

Quality Plan – 'A document setting out the specific operating procedures, practices, authority,
responsibilities, resources, and sequence of activities relevant to a particular product, service,
contract or project'.

Quality System – 'The organization structure, responsibilities, procedures, processes and

resources for implementing quality management'.

Observation – An observed practice of the auditee which may become a problem in the future if
left unattended and for which early attention is recommended.

Procedure - A document that details the purpose and scope of an activity and specifies how, what,
when, where and by whom the activity shall be carried out.

5. PROCEDURE

The main steps of the audit performance shall be:

• Planning and Scheduling;

• Audit team selection;
• Audit preparation
• Entry meeting;
• Execution of the audit;
• Post audit meeting
• Preparation of Corrective Action Requests (CAR's);
• Exit meeting
• Audit reporting
• Audit follow-up and close out.

5.1 Planning and Scheduling

The Quality Assurance Manager or his nominee shall plan and schedule internal audits for the
various groups and projects. Such audits shall be scheduled on the basis of contract requirements,
status and importance of the activity and of sufficient scope to ensure that all aspects of the Quality
system are audited during the lifetime of projects.
The Audit Schedule (see attachment 6.7) shall be approved by the QM Manager and authorized by
the Project Manager.

The QM Manager shall review the Audit Schedule on a regular basis and update it as necessary. The
review shall be based on the quality system requirements and specific projects requirements as well
115
as the audit history. The date of each review shall be recorded on the Audit Schedule. Any significant
changes to the Audit Schedule shall be authorized by the Project Manager.

5.2 Audit Team Selection

The QM Manager shall define the audit team size and composition, and formally assigns a Lead
Auditor and any other team member(s). The Lead Auditor shall be normally an experienced/trained
auditor of at least QM Engineer status. Exceptionally, engineers from other disciplines may be asked
to assists in audits and it may also be necessary to obtain specialist support from group supervisors
when auditing outside the audit team's direct working experience. Auditors shall have the
experience/training commensurate with the scope, complexity or special nature of the activities
to be audited. The audit team will normally be informed of their selection at least two weeks before
the audit.

5.3 Audit Preparation

The Lead Auditor shall for each audit:

Obtain the serial number from the "Audit Status Log" (see attachment No. 6.8) maintained by the
QM Manager

Contact the Auditee ’s at least one week in advance and confirm the arrangements, i.e. the audit
scope, agenda, the date(s), time and place, in writing (reference attachment No. 6.1 'Audit
Arrangement Record')

Obtain copies of all relevant documents, e.g. contract, procedures, correspondence, quality plans,
standards and earlier audit reports etc.

Prepare an audit plan detailing the appropriate time, subject or activity and person present at each
stage of the audit

Prepare (or cause to be prepared) audit checklists (see attachment No 6.9) from the applicable
documents defined above. The checklist shall identify the specific requirements to be evaluated and
shall be a guide to the continuity and depth of the audit.

Prior to developing the checklists, the auditors shall read the relevant documents (e.g. procedures)
thoroughly. Checklist questions shall address each significant area of the procedure or system
and shall elicit a direct answer that can be substantiated by documentary evidence. Documented
evidence of activities shall be examined in accordance with the requirements of the quality system.

116
However, the auditors shall have flexibility to determine whether an activity is acceptable or not,
rather than recording a strict "Yes" or "No".

Should a serious deficiency to a procedure become apparent during routine operations the QM
Manager shall initiate an Unscheduled Audit. When completed the Unscheduled Audit shall also be
shown on the Audit Schedule (see attachment No. 6.7) as having taken place.

5.4 Opening Meeting

The Lead Auditor shall convene a brief meeting between the audit team and appropriate
representatives of the Auditee' Management.

The purpose of the meeting shall be to:

• effect introductions
• circulate an attendance sheet (see attachment No. 6.3);
• investigate all outstanding actions from previous audits
• and secure their close-out (where applicable);
• discuss briefly the scope and purpose of the audit
• confirm the audit timetable and work program
• establish the sequence of events and individuals involved
• arrange escorts for the audit team and the use of an office for audit team meetings
• Establish a provisional time for the exit meeting and invite the Auditee Management to attend

5.5 Execution of the Audit

Audits shall be conducted using the prepared checklists (see attachment 6.9). The checklists shall
assure thoroughness and continuity during the audit. The checklists shall be used only as a guide,
and will be expanded, if additional questions arise. Objective evidence, which is usually in the form
of documents, shall be examined and essential information recorded.

In completing the audit checklist, under the heading "Activity Compliance", the auditors shall state,
"Yes", "Acceptable", "Not Acceptable" (NA), or "See Comment". The "Comment/Remarks" column
shall be used to expand on the activity or to reference nonconformities and objective evidence so
that an overall view of the Auditee QM performance is readily seen (Attachment No. 6.9 refers).

Wherever possible, auditors shall obtain auditee agreement that significant nonconformities exist at
the time they are discovered. Auditors shall not however tell the auditee that Corrective Action
requests (see attachment No.6.2) will be issued before the audit team has had an opportunity to
discuss all the audit findings.
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 5.6 Post Audit Meeting

Upon completion of the audit investigation and prior to the exit meeting, the Audit Team shall meet
together to check and evaluate their findings and complete Corrective Action Requests (CAR's).

Objective evidence of a deviation from approved procedures, quality plans and/or other applicable
documents shall be considered as valid justification for the preparation of a CAR.

5.7 Corrective Action Requests (CAR's)

CAR's shall be raised using the form shown in attachment No. 6.2 in preparation for discussion and
agreement at the exit meeting.

CAR's shall be numbered sequentially, e.g. for Audit No. 12, CAR 12/1, CAR12/2 etc.

CAR's shall define precisely the person(s) involved or present when the deficiency was identified,
the time and location, and any procedure reference. However, auditors should avoid naming those
involved and should preferably use job titles.

The auditors shall complete the CAR only as far as the non-conformity section, and both
auditor and auditee shall sign it to confirm that the non-conformity is recorded correctly.

All findings shall be reviewed and provisionally categorized as follows:

Category 1: Non- compliance of major significance requiring "stop work" recommendation

and the institution of agreed corrective action measures during the audit.

Guide
The non-compliance can be system or procedure, which has not been adequately documented or
implemented such that the item or service has a major non-compliance, or is reasonably suspected.
Closeout of the findings shall be by re-audit. The QM Manager shall be advised and his authority is
required to recommend "stop work". The QM Manager shall consult with the appropriate department
and others as necessary in AL TAKNIA and notify the Project Manager without delay.

Category 2:Non-compliance of major significance, which requires corrective action, measures to

be taken in a meaningful timescale so as to be effective for the relevant contract.

Guide

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As for category 1 with the exception that no major non- compliance has been found in the
item or service or is reasonably suspected, close-out of the finding shall be by re- audit. Where
there are several related category 2 findings so that collectively the conditions of category 1 exist,
then a category 1 finding shall be additionally raised.

Category 3:Non-compliance of minor significance.

Guide
Systems or procedures not adequately documented or implemented but which have little effect on
the quality of the item or service: or a minor, isolated product noncompliance of a disciplinary
nature. Closeout by follow-up and verification. A category 2 finding shall be additionally raised
where several related category 3 findings collectively meet category 2 conditions.

Category 4: Observations

Observations are general remarks or comments reflected in the audit report that may be incorporated
into a system for improving the Quality Program performance, but which are not obligatory.

5.8 Closing Meeting

Following the Post-Audit Meeting, the Lead Auditor shall convene the Exit Meeting with
management representatives of the Auditee, and shall record on the Attendance Sheet (Attachment
No. 6.3) names of those present. At the meeting, the Lead Auditor shall:

• present an objective summary of the audit

• discuss audit findings and ensure that they are understood by the Auditee
• obtain signature of the Auditee representative on CAR's (if any);the Auditee signs to
indicate that he understands and acknowledges the non-conformity described
• give the Auditee copies of acknowledged CAR's
• state the intended issued for the format audit report and agree
• corrective actions or the date by which the Auditee will respond with his proposed corrective
actions
• thank the auditee as appropriate for their cooperation

5.9 Audit Reporting

Following the completion of the audit, the Lead Auditor with the assistance of other members of
the Audit Team, shall prepare the formal report.

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The Audit Report shall comprise the following:

• audit report – lead sheet (refer to attachment No. 6.4)

• audit report – continuation sheet (refer to attachment No.6.5
• corrective action request (refer to attachment No. 6.2)
• attendance sheet (refer to attachment No. 6.3)

The results of the audit shall be summarized on the Lead Sheet and any audit findings (CAR's)
shall be itemized.

The audit shall be reported on the report sheets and shall include some or all of the following:

• the Auditee' names and internal department;

• the location at which the audit was performed;
• the contract number and title
• the scope of the audit
• pre-audit activities (e.g. the Audit Arrangement Record)
• audit team members
• persons contacted during the Entry meeting and Exit Meeting; and individuals
participating in the audit process
• summary of audit results including an evaluation statement regarding the effectiveness
of the elements audited
• specific findings of non-conformance and CAR's issued,
• entry and exit meetings and general observations

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Audit reports shall be numbered consecutively using one of the following sequences:

AL TAKNIA xxx/00 – (x)

I = Internal
F = Follow-up
Year of Audit
Number (sequential) Starting with 001 at
The Beginning of each year
Auditing Organization

Before the formal Audit Report is released and distributed the entire Audit Team shall review it to
check that the statements made are fair, complete and true.

After this review, the Lead Auditor shall sign the completed Audit Report on the cover sheet on
behalf of the entire Audit Team and shall forward the report to the QM Manager for review.
After the report has been reviewed and the contents are acceptable, the QM Manager shall sign off
the Lead Sheet.

The original of the audit Report and Audit checklists shall be filed by the QM Manager. This will
enable further copies to be produced at a later date if they are needed.

The original of any Corrective Action Request raised as a result of the audit shall accompany the
copy of the Audit Report sent to the Auditee.

The QM Manager shall ensure that a copy of the completed Audit Report is issued to the Auditee
under a covering memorandum within seven (7) days of the final date of the Audit. The internal
memorandum shall identify the final date by which responses are required for any Corrective Action
Requests.

When the audit report has been issued and copies distributed as specified by the QM Manager, he
shall complete the following:

• audit report status log (see attachment No. 6.8);

• audit schedule (see attachment No. 6.7);
• corrective action request status log

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 5.10 Audit Follow-up and Close-out

The audited area/discipline shall be permitted seven days to respond to any outstanding findings
where corrective actions have not been agreed at the Closing Meeting. The response shall include
the proposed corrective action and anticipated dates when such action will have been executed.
The Lead Auditor shall evaluate the response and if acceptable, he shall signify agreement to
the Auditee immediately. If the response is unacceptable, the Auditee shall be notified to that effect
with specific reasons. The matter shall be promptly discussed and resolved.

When eventually acceptable, the Lead Auditor shall complete the "Proposed Follow-up Date"
section on the returned Corrective Action Request Form and update the CAR status Log.

On the "Proposed Follow-up Date" and in accordance with the requirements of this procedure, re-
audited shall be undertaken to verify the implementation and effectiveness of the corrective action
taken by the Auditee.

If the Follow-up Audit indicates that the action taken has corrected the deficiency, then the CAR
can be closed out and this shall be stated in the last section of the CAR form.

If however, the Follow-up indicates that action taken does not correct the deficiency of the CAR(s)
has not been implemented within the agreed timescale, the Lead Auditor shall state this on the CAR
form and re-identify the deficiency using a revision to the CAR and agree with the Auditee a new
timescale. The Lead Auditor shall notify the QM Manager of all outstanding CAR's.

If the CAR is not closed out at the second follow-up date, the Lead Auditor shall discuss the matter
with the QM Manager to seek agreement to call in support from senior management.

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 6. DOCUMENTATION

Audit Arrangement Record (attachment No. 6.1 Form no. QM/001)

Corrective Action Request (attachment No. 6.2 Form No. QM/002)

Attendance Sheet (attachment No. 6.3 Form No. QM/003)

Audit Report Lead Sheet (attachment No. 6.4 Form No. QM/004)

Audit Continuation Sheet (attachment No. 6.5 Form No. QM/005)

Observation Sheet (attachment No. 6.6 Form No. QM/006)

Audit Schedule (attachment No. 6.7 Form No. QM/007)

Audit Report Status Log (attachment No. 6.8 Form No. QM/008)

Internal audit Checklist (attachment No. 6.9 Form No. QM/009)

CAR Status Log (attachment No. 6.10 Form No. QM/010)

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 DOCUMENT TITLE:

PROCEDURE FOR:
TRAINING

DOCUMENT NO.:
QMP-017

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 4

124
 1 PURPOSE

To ensure that the personnel performing work, affecting quality is competent on the basis of
education, training, skills and experience. Training courses for AL TAKNIA personnel will be
staged to ensure the highest possible service to Proponent. This will include assurance and
maintenance of a high personnel qualification and quality motivation as well as the promotion and
training of our staff members.

2 SCOPE

The scope of this procedure lays down the parameters in which AL TAKNIA will determine the
necessary competence for personnel performing work-affecting quality and provide training or take
other activities to satisfy those needs.

3 REFERENCES

None

4 DEFINITIONS

This procedure uses definitions in front of the Quality Plan and in ISO 8402 Quality Management
and Quality Assurance Vocabulary.

5 PROCEDURE

Responsibility for training within each department of AL TAKNIA is with the respective
Department Manager.

AL TAKNIA, through the process of the Project Manager regularly liaising with the departmental
managers, identifies and reviews the training needs of group and individual employees. Employee
appraisal schemes are used, where appropriate, to assist with the identification of training needs.

Following the identification of training needs the respective Department Manager prepare an
AL TAKNIA Training Plan by the following processes:

Recommending to the Project Manager proposed solutions to meet the training needs identified.
Recommending to the Project Manager where, and how, such training should be carried out i.e.
internal course, external course, etc.
Costing and training plan and submitting his proposals to the Project Manager.
Obtain the Project Manager’s agreement on training costs and priorities in keeping with AL
TAKNIA’s business plan and employee training requirements.

125
The training plan will typically cover the following training activities:

• Management training and development through the use of in-house courses on areas such
as management techniques (leadership, delegation Quality awareness, etc.) and by using
selected external courses at recognized management training centers.
• Project Management supervisors and key staff shall receive complete training on the
approved Quality Plan to ensure awareness of the assigned responsibilities and consequently
compliance to Proponent procedures and standards.
• Technical training and updates for the Company’s experienced engineering, project
management and specialist staff.
• As determined by Project Manager or Department Managers, Field personnel shall
undergo focused training in the area of responsibility to produce quality work and
eliminate workmanship problems.
• Administrative training covering departments such as Accounting, Data Processing,
personnel, etc.
• Graduate training and development including program agreed with professional
engineering institutions to ensure the young engineer is able to become a member of the
institution relevant to his disciplines. Training programs will include overview of the AL
TAKNIA’s business, commercial training, site experience and technical specialist training.
• Training of junior technical and administrative personnel including attendance at relevant
day release classes as and when appropriate.
• Initial and continuation training of personnel performing welding, NDT and coating
operation & inspection.
• Training of internal and external QMS auditors.

The Department Managers and the Project Managers to ensure its continued relevance to the
needs of AL TAKNIA and its employees regularly review the training plan.

AL TAKNIA has specific procedures to cover training on all of the above activities to ensure a
consistent and professional approach to this important area of its business.

The Human Resources Department is responsible for maintaining centralized training records for
each employee and for supplying this information to Department Managers and Supervisors as
required.

Department Managers and Supervisors are responsible for coordinating with the Human Resources
Department in relation to any training activities.

Department Managers and Supervisors are also required to inform the Human Resources Department
on any seminars, conferences, etc. for which arrangements to attend were made by Department
Managers and Supervisors and which should be entered into the training records.

126
The information contained in these records lies within the responsibility of the Department Managers
and an update is performed every six months.

Immediately after the employment of new staff members the Department Manager determines the
respective training needs.

Personnel performing specific assigned tasks will be qualified on the basis of appropriate education,
training and/or experience.

6 DOCUMENTATION

Staff Members Qualifications Profiles

Training Program

127
 DOCUMENT TITLE:

PROCEDURE FOR:
SPECIAL PROCESSES

DOCUMENT NO.:
QMP-018

Index Page

1. Purpose: 2
2. Scope: 2
3. Responsibilities: 2
4. Procedure: 3
6. Documentation: 4

128
1 Purpose

To ensure that special processes are accomplished under controlled conditions by qualified
personnel using qualified documented procedures and equipment in accordance with applicable
codes, and Proponent Standards and Specifications.

2 Scope

All special process is covered by this section.

2.1 Definitions

A special process is a process requiring special training, qualification, and or extreme care to
successfully accomplish. A production or a construction process is a special process when
specific detailed instructions are required to satisfactorily perform it.

A special inspection process is an inspection process requiring specialized inspector skills,

equipment or techniques.

2.2 Examples of Special Processes

All welding operations

Non-destructive
examination Painting
Performance Tests (covered by Specification for Specific
Item)

3 Responsibility

All special processes will be accomplished under controlled conditions using qualified process
procedures, documentation and equipment according to specified requirements and established
criteria.
Where applicable, operator qualifications procedures and equipment will comply with codes,
standards and government acts and regulations.
Welding procedure specification and welder's qualifications will be in accordance with Proponent
Engineering Standards.
Quality control will maintain qualification records for qualified personnel, process procedures,
documentation and equipment according to the requirements of applicable codes and standards.

129
Methods of inspection and monitoring will be clearly defined by Quality control to conform to
specifications and each circumstance.
Procedures will define the necessary qualifications of personnel and equipment and the requirements
for documentation. Special attention is required for special processes not covered by existing codes
and standards or where quality requirements exceed the requirements of established codes and
standards.
Corrective measures will be taken when noncompliance occurs.
Construction site supervision will issue periodically summary report on special process personnel
to the Project Manager and Quality Control.

4 Procedures

All welding process will be accomplished under controlled conditions by qualified personnel using
qualified documented procedures and equipment in accordance with applicable codes and Proponent
Standards and specifications.

Welding Procedure
Specifications

The QM/QC Engineer is responsible for preparing and qualifying Welding Procedure Specifications
(WPS). The welding procedure specification will be submitted to Proponent for review and approval
before start of the work. All procedures will be made available at work site for use of the welder and
for review by Proponent Inspector.

Welding Procedure
Qualification

The QM/QC Engineer is responsible for arranging the qualification of the Welding
Procedure Specification and preparation of the Procedure Qualification Record

Welder
Qualification

The Construction Manager will be responsible for arranging the qualification of the welders in
accordance with Welding Procedure Specification (WPS). The Qualification Tests will be
monitored by an independent testing facility approved by Proponent. All other welding
requirements will be in accordance to Proponent Engineering Standards.

130
 Non-Destructive
Examination

All non-destructive examination will be performed in accordance with ASME Section V and other
applicable codes and standards. The non-destructive examinations may be subcontracted to
Proponent approved third party organization using their qualified procedures. The N.D.E.
Procedures will be reviewed and approved by QM/QC Engineer. The N.D.E. Procedures and
personnel qualifications will be submitted to Proponent for review and approval. All equipment used
for NDE will be maintained by QM/QC Engineer.

Paint
ing

All painting requirements will confirm to Proponent Engineering Standards. The surface
preparation prior to painting will be done in accordance to the type of coatings as per
Proponent Standards. All records of painting instructions are filed in applicable project files and
kept by QM/QC Engineer / Inspection. Recording forms will contain atmospheric conditions,
surface preparation and equipment as required by Proponent.

5 DOCUMENTATION

N
on
e

131
 DOCUMENT TITLE:

PROCEDURE FOR:
CONTROL OF INSPECTION, MEASURING AND
TEST

DOCUMENT NO.:
QMP-019

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 4

132
 1 PURPOSE

To establish a system by which inspection, measuring and test equipment are controlled,
calibrated and maintained.

2 SCOPE

This procedure shall be used for all inspection, measuring and test equipment requiring
calibration.

3 REFERENCES

None

4 DEFINITIONS

Where appropriate, definitions used are based on ISO 8402.

Calibration – Activity performed to verify the accuracy of inspection, measuring and test
equipment.

5 PROCEDURE

5.1 Responsibilities

The user department is responsible for maintaining the calibration of all inspection and test
equipment under their custody, including AL TAKNIA assets, rented equipment, Proponent’s
supplied equipment and software test programs.

QC personnel are responsible for ensuring the use of only calibrated equipment and maintaining
the calibration records of all inspection, measuring and test equipment.

Users of calibrated equipment will safeguard all IM & TE from adjustments, which could validate
the calibration setting.

5.2 Calibration Control

Calibration status of all inspection, measuring and test equipment are controlled and reported through
a tracking system.
The user verifies that the inspection, measuring or test equipment used for an activity is in
accordance with the approved test procedure or work instruction.

133
 5.3 Calibration Services

Only the Proponent’s approved metrology whose standards are traceable to recognize national or
international standards laboratory, shall be engaged for calibration of any inspection, measuring and
test equipment.

Such an approved laboratory applies weather resistant calibration labels with the following
information, as a minimum:

• Equipment control number

• Calibration date
• Date of next calibration

The approved metrology laboratory provides calibration reports with the following information as
a minimum:

• Report number
• Control number of test equipment
• Condition of equipment at time of calibration
• Description of repair, if any Calibration standards used
Calibration data
• Environment condition at time of calibration
• Calibration procedure used
• Calibration date
• Signature of calibration technician

5.4 Calibration Status

Calibration status is identified on a calibration status label affixed to the equipment.

Calibrated equipment shall be segregated and separately stored from those, which are out of
calibration or do not require calibration.

AL TAKNIA will safeguard inspection, measuring and test facilities, including both test hardware
and test software from adjustments, which would invalidate the calibration setting.

5.5 Calibration Intervals

Newly purchased equipment, which requires calibration are obtained with calibration or calibrated
by a calibration agency. Their calibration is recorded in the calibration log.

Periodic calibration is then scheduled based on the assigned calibration interval.

134
Whenever equipment is damaged, suspected to be damaged or tampered with in any way, it is
submitted for re-calibration prior to further use.

Calibration intervals shall be based on contract requirements, manufacturer recommendations or

other technical data.

Intervals may be revised based on demonstrated performances, but in no case shall the calibration
intervals exceed six (6) months.

5.6 Recall

Equipment is recalled in accordance with the data provided in the calibration control pile
including periodic inspection results.

Users return the equipment to stores when they are scheduled for re-calibration.
When test equipment is found to be out of tolerance during use, the user department
identifies the equipment the measurement capability, out of tolerance and the variation from
the standard.

The equipment is then taken out from service, the work/material is put on hold, and the validity of
previous inspection is evaluated before final acceptance of the work or material.

5.7 Continued Suitability of Software Test Programs

Continued suitability of software test programs shall be ensured by revision and access control.

6 DOCUMENTATION

FORM QM/015 - CALIBRATION LOG

135
 TEST EQUIPMENT CALIBRATION LOG

Project: Current as of :

Model
Cal. Cal. Cal.
& Certificate
ID Description Manufacturer Owner Freq. Last Due Remarks
Serial No.
(Days) (Date) (Date)
No.

136
 DOCUMENT TITLE:

PROCEDURE FOR:
INSPECTION AND TEST STATUS

DOCUMENT NO.:
QMP-020

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 3

137
 1 PURPOSE

To ensure that the inspection and test status of all inspect able activities are identified and
recorded.

To ensure that only activities, which pass the required inspections and tests, are processed for
further construction activities.

2 SCOPE

This procedure shall be applied to all activities requiring inspection and testing.

3 REFERENCES

QMP-015 Control of Non-Conformance.

4 DEFINITIONS

None

5 PROCEDURE Responsibilities

The Quality Manager is responsible for:

• Identifying all operations that require inspection and testing throughout the
manufacturing process.
• Developing test and inspection procedures for required operations.
• Ensuring that personnel who perform tests and inspections are trained according to
documented procedures and accepted by the Proponent.

The QC personnel inspect/test all products according to work and instructions checklists.

The QC supervisor maintains inspection and test record as appropriate.

The Store Keeper and procurement QC supervisor maintain the records of equipment and
material inspection as required.

138
 5.1 Receiving Status

Material Controller/Store Keeper:

On receipt at site and prior to inspection, the materials shall be identified by a "for inspection"
tag.

Accepted materials and equipment shall be stored in the Lay down area or warehouse specified for
the items. The inspection status on these items shall be verified on the material receipt and
inspection report.
Defective materials shall be either stored in a separately marked quarantine area or identified by
"hold' tag.
Only "accepted" equipment and materials shall be issued for construction activities.

5.2 In-process Status and Final Status

For systems, components or activities installed at the site:

• QC personnel perform the required stage inspection and prepare the corresponding
Inspection Checklist.
• The inspection status shall be recorded on the inspection checklist.
• Final inspection and tests performed shall also be recorded in the corresponding
inspection test reports.
• The inspection status shall also be recorded on summary reports prepared by the QC
personnel
• Wherever required, the acceptable components will be identified by an "accepted" tag.

5.3 Nonconformance

Any system, component or workmanship not conforming to project requirements and

specifications, shall be rejected and its status identified by "hold" tag.

A nonconformance Report shall be prepared for such items and will be handled in accordance
with QMP-015, Control of Non-Conforming Products.

6 DOCUMENTATION

None

139
140
 DOCUMENT TITLE:

PROCEDURE FOR:
INSPECTION AND TESTING

DOCUMENT NO.:
QMP-021

Index Page

1. Purpose: 2
2. Scope: 2
3. References: 2
4. Definitions: 2
5. Procedure: 2
6. Documentation: 3

141
142
 1 PURPOSE

To establish a close control on the quality level of all procured equipment and material, fabricated
components, parts, materials, and workmanship.

To inspect, test and verify a product according to the project quality and/or documented procedures.

To identify nonconforming product.

To ensure that all required inspection and tests have been performed during construction and the
work comply with all project specifications and drawing requirements.

2 SCOPE

This procedure applies to all systems, components and materials received from suppliers and used
in the assembly and construction and installation activities. These procedures cover all work
performed by AL TAKNIA, its sub-contractors, vendors and suppliers.

3 REFERENCES
The following documents are referenced:

QMP-020 - C o n t r o l o f I nspection, Measuring and Test Equipment

QMP-015 - Control of Non-conformance
Schedule 'Q' Quality Assurance and Control Inspection and Testing.

4 DEFINITIONS

This procedure uses definitions in the front of the Quality Plan and ISO 8402 Quality
Management and Quality Assurance – Vocabulary.

5 PROCEDURE

5.1 Inspection of Material

The Quality Manager ensures that the quality levels required by contract specifications are in place
and that the required inspection and tests are performed and are documented.

143
The procurement QC Supervisor is responsible for inspecting, testing and documenting the
results in accordance with approved procedures.

The Project Manager will submit to the Proponent each week a two-week look- ahead schedule of
all planned Quality Assurance and Quality Control activities during the Procurement, Construction
and Pre-commissioning Phases as specified in Schedule 'Q'. This schedule will be sent in electronic
format.

AL TAKNIA will ensure that the suppliers issue inspection records according to the
Proponent's requirements.

The procurement QC Supervisor reviews and approves the inspection data.

Receiving Inspection:

The Receiving Inspector is responsible for performing incoming inspections. All materials are held
until inspection and tests are complete.

The Receiving Inspector verifies the received product using the incoming Inspection Checklist and
follows the approved procedure for the applicable test and inspection.

AL TAKNIA will provide adequate storage and stockyard facilities to store all materials and
items in such a way as to protect them from damage, deterioration, contamination, electrical
equipment or sprayed, galvanized or painted items will be made.

AL TAKNIA will document receipt of the materials and their precise location within the
stockyard/storage area and will ensure that materials of different types, grades and specifications are
segregated.

AL TAKNIA will ensure that all inspection related documents e.g. the inspection disposition report
including material certificates etc. are available on site when the material and equipment arrive.

Nonconforming Materials

Nonconforming materials shall be quarantined and segregated and handled in accordance with the
approved procedure QMP-015.

144
 Request for Inspection (RFI)

Requests for Inspection of critical activities, which must be done on weekends or holidays,
will have to be approved, in advance, by the Proponent. AL TAKNIA will notify the
Proponent 48 hours in advance of the inspection.

AL TAKNIA will adhere to the rules and regulations of the Proponent in preparing
Request for Inspections (RFI's).

All inspection requests will be submitted as follows:

At least twenty four (24) hours prior to the time of the inspection for normal work hours (7:00
AM – 4:00 PM, Saturday through Wednesday), or according to the Proponent’s Schedule.

Forty-eight (48) hours for weekend or holidays.

Remote Areas: A minimum of 48 hours advance notice is required except when air travel is
required. In this situation, a minimum of seven (7) days advance notification is required.

Initial Inspection and Test

AL TAKNIA will compile and forward to the Proponent no later than twenty-one (21) calendar
days prior to the pre-inspection meeting and start of fabrication, either at prime supplier or at
major sub-supplier, three (3) sets of AL TAKNIA's Inspection Assignment Package in
conformance with the requirements of Schedule 'Q'.

AL TAKNIA shall perform initial Inspection and test on all phases/segments of work. The

purpose of this initial inspection is to determine that the following complies

with specifications:

• Methods
• Techniques
• Workmanship planned or conducted

Vendor's ITPs shall include, as a minimum, all the inspection activities shown on the
respective SA 175 and PO special requirements, or similar documents from other Proponents.
Stage Inspection

Stage inspections will be performed on a daily basis or more frequently if

necessary, to ensure that the construction work is proceeding in accordance
with the contract requirements. This inspection will be done prior to
requesting an inspection from the Proponent.

145
Each Request for Inspection form will have an identifying number clearly marked on the top
right corner. The numbers shall begin at "01" for each discipline separately, and continue
consecutively, until the end of the project.
A register for RFI will be maintained to record the: Number and
Date of Issue
Date of Inspection
Request
Details of Inspection
Activity
Date of completion and the inspectors who perform
the inspection.
Rem
arks

Typical Inspection Hold/Witness Points

The following is a listing of common inspection points. These hold/witness points should be
incorporated, as required, into the Inspection and Test Plan, Refer Section 6 of the Quality
Manual.

Civil Works.

• Survey and Layout

• Prior to closure of Form Work
• Prior to Concrete Placement and Grouting
• Prior to asphalt roofing placement
• Prior to Commencement of the initial bending of epoxy coated
rebar
• Prior to closure of walls and ceilings. After Preparing the
bottom of foundations Before backfilling around structures
• After preparing the existing sub-grade
• Sand cover of "Piping" Concrete prior to any repair Masonry
• Tilling
• Dry Walls
Structural Work
• Foundation
• Elevation, Level and plumb
• Metal decking

146
Mechanical Work
• Equipment foundation Location, level and alignment
• Equipment assemblies
• Functioning of controls and valves
• Duct work
• Testing and balancing

Piping
• Qualification of WPS and welders
• Fit-up and welding
• Orientation, elevation, slope, etc of installation
• NDE
• Pressure Testing Hydro gravity Testing Repair of cracked
welds Post weld head treatment
• Surface preparation for coating
• Pipe bending Piping lay-up Gasket installation Bolt
torqueing
• Socket weld gap & engagement
• Holiday testing

Electrical & Communication System

• Buried Cable
• Trench before installation of the sand pad
• Cable during placing
operation
• Marker tape placement
• Underground Conduit
• Trench before installation of the conduit
• Conduit before concrete encasement including mandrel
testing
• Orange dye placement

Manholes

• Excavation for bracing/shoring when depth reaches 5'

and until completion.
• Internal formwork before pouring concrete for
duct terminators, inserts, etc.
• Ground connections when rods are outside of
manhole. Ring and cover frame installation.

Underground Cable Placing

• Reel setup and choice of duct

• Mandrel test ducts
• Cable and cable pulling

147
 • Underground – Check cable racking in
manhole. Cable splicing – all splices
• Splice connectors
• Completed splice before closing case
Buildings

• Closet/Equipment room requirement prior to and

during construction.
• Distribution system design before start of
installation. Before closing of walls/ceilings, which
will hide communications/electrical/mechanical.
• Underground entrance conduit before concrete
encasement, including mandrel testing.

Cable Testing

• Check Test setup before start of Tests.

Calibration of Inspection, Measuring and Test Equipment

Refer Procedure QMP-020 – Control of Inspection, Measuring, and Test Equipment. The
Quality Manager is responsible for maintaining the necessary Test Equipment in the calibration
system. He is also responsible for the maintenance of the calibration records (log and history).

In-Process Inspection and Testing

In-process inspection and test shall be performed in accordance with the approved procedures,
work instructions and inspection and test plan

QC Inspectors will witness the test setup and results for conformity to the
specifications, prior to submitting RFI to the Proponent.

The Quality Manager is the AL TAKNIA approval authority for the inspection and test
activities, and shall sign the inspection reports.

If any deviation is observed during the in-process inspection, the following occurs:

An NCR is issued.
Resolution shall be by appropriate corrective and prevention action. Completion and
verification of the disposition.

148
 Final Inspection and Test

Final inspection and tests are performed in accordance with approved inspection and test plan
and procedures.

The Quality Manager is responsible for preparing and obtaining approval for the test
procedures.

The QC Inspector is responsible for ensuring and documenting the required inspection
and test.

The QC Inspector will also ensure the test equipment is calibrated. Calibration status of
equipment is noted on the applicable final test datasheet.

Records will identify the inspection authority responsible for the release of the product.

6 DOCUMENTATION

Records and standard forms applicable for Inspection and Testing are included with
individual procedures. In addition, the following pertain:

• Quality Monitoring Report

• Weekly Inspection Look-ahead Schedule

149