Complete Maco Quality Manual Vol. 1

8/2/2019 Complete Maco Quality Manual Vol. 1

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QUALITY ASSURANCE / QUALITYCONTROL (QA/QC) MANUAL

KINGDOM OF SAUDI ARABIA

P.O. BOX 10257, DAMMAM 31433


Tel. No. +966 3 8417007

Fax. No. +966 3 8423281

DOCUMENT NO. MACO-QM-001 REV.0

THIS QUALITY MANUAL IS THE ONLYCONTROLLED AND VALID VERSION.ALL OTHER VERSIONS ARECONSIDERED TO BEUNCONTROLLED AND MAY NOT BE

USED FOR WORK CONTROLLINGPURPOSES.DOCUMENT NO. MACO-QM-00101

thApril 2009


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(QA/QC) MANUAL

P.O. BOX 10257, DAMMAM 31433


Tel. No. +966 3 8417007

Fax. No. +966 3 8423281

1 ISSUED FOR APPROVAL Prepared By: CHECKED BY APPROVED BY APPROVED BY2 QA/QC Quality Manual APT YSB NMZ SMZ

3 SIGNATURE/DATE

REVISION HISTORY: Document Recipients:

1 Revision 1 April 1, 2009 1. Gen. Manager 4. Project Managers

2 2. Asst. Gen. Manager 5. QA/QC Department

3 3. Business Dev. Manager 6. Purchasing/Finance Depts.

DOCUMENT NO. MACO-QM-001 VOL. 1REV.

0

THIS QUALITY MANUAL IS THE ONLY

CONTROLLED AND VALID VERSION.ALL OTHER VERSIONS ARE

CONSIDERED TO BE

UNCONTROLLED AND MAY NOT BE

USED FOR WORK CONTROLLING

PURPOSES.

DOCUMENT NO. MACO-QM-001

01th

APRIL 2009


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Quality Manual MACO-QM-001

QUALITY ASSURANCE/QUALITY

CONTROLMANUAL

MACO-QM-001

VOL. 1

APPROVAL SHEET

-i-

Description Name Designation Signature Date

Prepared

By:A.P. Togle

QA/QC Senior Engineer

Manar Arabian Corp.

Approved

By:

Y. S.

Bahrawy Projects Manager

Approved

By:N. M. Zahrani

Assistant General

Manager

Approved

By:S. M. Zahrani General Manager


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Quality Manual MACO-QM-001

QUALITY ASSURANCE/QUALITY

CONTROL MANUAL

MACO-QM-001

VOL. 1

REVISION HISTORY

-ii-

Revision No. Purpose of Revision Issue Date

0 Submitted for Approval. April 01, 2009

1

2


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Quality Manual iii MACO-QM-001

TABLE OF CONTENTS

SECTION HEADING PAGE NO.

Approval Sheet i

Revision History Sheet ii

Table of Contents iii

1 Company Quality Policy 01

2 Project Scope 03

3 Normative References 03

4 Terms and Definitions 05

5 Quality Management System 09

5.1 General Requirements 09

5.2 Documentation Requirements 10

5.2.1 General 105.2.2 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 126.2 Customer Focus 12

6.3 Quality Policy 13

6.4 Planning 136.4.1 Quality Objective 13

6.4.2 Quality Management System Planning 14

6.5 Responsibility, Authority, and Communication 14

6.5.1 Responsibility and Authority 146.5.2 Appointing a Quality Manager/Management

Representative 19


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6.5.3 Internal Communication 196.6 Management Review 19

6.6.1 General 19

6.6.2 Review Input 19

6.6.3 Review Output 20

7 Resource Management 20

7.1 Provision Of Resources 207.2 Human Resources 20

7.2.1 General 20

7.2.2 Competence, Awareness and Training 217.3 Infrastructure 22

7.4 Work Environment 22

8 Project Execution/Product Realization 22

8.1 Planning of Project Execution 228.2 Customers Related Processes 22

8.2.1 Determining Project Requirements 22

8.2.2 Reviewing Project Requirements 238.2.3 Customer Communication 23

8.3 Design and Development 23

8.4 Purchasing 238.4.1 Purchasing Processes 23

8.4.2 Purchase Information 24

8.4.3 Verification of Purchased Products 24

8.5 Production and Service Provision 258.5.1 Control of Production and Service Provision 25

8.5.2 Validation of Processes for Production & Service 26

8.5.3 Identification and Traceability 268.5.4 Proponents Property 27

8.5.5 Preservation of Material and Equipment 27

8.6 Control of Monitoring and Measuring Devices 27

9 Measurement, Analysis, and Improvement 28

9.1 General 28

9.2 Monitoring and Measuring 299.2.1 Customer Satisfaction 29

9.2.2 Internal Audit 29

9.2.3 Monitoring and Measuring of Processes 309.2.4 Monitoring and Measuring of the Work 30

9.3 Control of Non-Conforming Product 31

9.4 Analysis of Data 31


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9.5 Improvements 329.5.1 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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QA/QC MANUAL Page 1 of 35 MACO-QM-001

SECTION 1: COMPANY QUALITY POLICY

The intent of this Quality Manual is to define the Quality Assurance/QualityControl requirements to be implemented within Manar Arabian Corporation

(MACO) and for each project, and to ensure that all Quality related activities are

planned adequately to cover all parameters specified in each contract.

MACO will ensure that vendors, suppliers, fabricators and subcontractors have

in place a Quality Assurance Program that meets applicable requirements of thisQuality Plan including conformity with the applicable requirements of ISO

9001/2000 and other applicable Engineering Standards of each Proponent.

The Quality Plan describes a system of QA/QC procedures and processes

encompassing documentation, material, engineering, procurement, construction,installation, testing and pre-commissioning.

The prime objective of the Management of MACO is to provide a uniform

system for the performance, monitoring, quality assurance, safety & lossprevention 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 MACO 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 MACO is based upon the requirements of

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

and Quality Construction Procedures of each contract.

MACO Quality Manual and the systems included therein, describe how the

quality assurance program of MACO is designed to ensure that all quality

requirements are recognized and that a consistent and uniform control of theserequirements is adequately maintained. MACOs Quality Manual also defines

how effective control is established.

No company can be successful without satisfied customers. Our success has been

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 conformanceto defined requirements. Moreover, we have adopted the premise that quality is

driven by and defined by the customer. In short, we have a strong customer focus

and 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 MACO. It serves as a reference between the Proponents QualityRequirements and MACOs internal Quality Management System. It is a

management tool to keep employees of MACO, as well as to its subcontractors,

aware of the responsibilities with the internal quality approach and can be usedfor 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 fundamentalconsideration in design, in the development and in the maintenance of the

system. The need to impose discipline, where it was previously not considerednecessary, 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 and will never gain experience.

However, the secret is to build upon ones 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 theirorganization and structure become more complex, the informal systems which

served MACO well when it was smaller can no longer be tolerated.

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

MACO. 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 willguard 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 sub-contractors and ourselves. This is fundamental to theeventual 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 Proponents Qualityrequirements.

This Quality Manual, and the typical procedures outlined herein describe howMACO Quality Management System is designed to ensure that quality

requirements are recognized and that consistent and uniform control of theserequirements is adequately maintained. The Quality Plan defines how effectivecontrol 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. Saeed Mohammad Al Zahrani Mr. Nabil Al Zahrani

General Manager Assistant General Manager


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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 andVocabulary

ISO 9001:2000 Quality Management Systems-Requirements. ISO 9002 Control Processes NEC National Electrical Code NFPA National Fire Protection Association NEMA National Electrical Manufacturers Association Saudi Government Safety and Security Directives ASTM American Society for Testing & Materials ANSI American National Standards Institute UL United Laboratories ASTM D638 Test Method for Tensile Properties of Plastics ASTM D1586 Standard Method for Penetration Test ASTM D2290 Standard Test Method for Apparent Tensile

Strength

ASTM D2412 Standard Test Method for External LoadingProperties of Plastic Pipe By Parallel Plate

ASTM D2487 Standard Test Method for Classification of Soilsfor Engineering Purposes


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ASTM D2583 Standard Test Method for Indentation Hardnessof Rigid Plastics by Means of Barcol Impressor

ASTM 2992 Standard Method for Obtaining HydrostaticDesign Basis for Fiberglass

ASTM D3567 Standard Method for Determining Dimensions ofFiberglass Pipe and Fittings

ASTM D3681 Standard Test Method for Chemical Resistanceof Fiberglass Pipe in a Deflected Condition

ASTM D3754 Standard Specification for Fiberglass Sewer andIndustrial Pressure Pipe

ASTM D4161 Standard Specification for Fiberglass Pipe JointsUsing Flexible Elastomeric Seals

ACI American Concrete Institute Royal Commission Guideline Specification Sections:

02722 Sewerage System

15060 General Requirement for Pipe Work

02220 Structure Excavating and Backfill

02221 Trenching, Bedding, Backfilling and Compacting

02210 Earthworks

03348 Cast-In-Place Concrete

02326 Road Crossings

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


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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

SECTION 4: TERMS AND DEFINITIONS

Appraisal: Assessment of a suppliers capability of controlling quality,

carried out before placing orders.

Certification: The authoritative act of documenting compliance withrequirements.

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

organizations and services.

Compliance: An indication or judgment that the product or services meets therequirements 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 preventrecurrence.


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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 specifiedrequirements; that design data and methods are valid for the range of

application; and that the completed design satisfies the design criteria.

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.

Note: 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 QA/QCorganization representative in attendance.

Improvement: Actions taken by MACO to increase the effectiveness andefficiency of activities and processes in order to provide added benefits to both

MACO 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 eachcharacteristic.

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, operabilityand 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.


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Procedure: A specified way to perform an activity.

Notes: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.

Product: Result of activities or processes.

Notes:

1. A product may include service, hardware, processed materials, softwareor a combination thereof.

2. A product can be tangible (e.g. assemblies or processed materials) orintangible (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 andquality improvement with MACOs Quality system.

Quality System: MACOs organizational structure, procedures, processes and

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

Quality Control: MACO employs operational techniques and activities that

are used so that its operations and services conform to the quality requirementsas laid down in Proponents documents.

Quality Assurance: All the planned and systematic activities implementedwithin MACOs Quality Management System, and demonstrated as needed, to

provide adequate confidence that an entity will fulfill requirements for quality.

Quality Plan: A document specifying which procedures and associatedresources shall be applied by whom and when to a specific project, product,

process or contract (ISO 9001:2000).


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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.

Repair: Action taken on a non-conforming product so that it will fulfill the

intended usage requirements although it may not conform to the originallyspecified requirements.

Notes:

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.

Note:

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 orderlyapproach 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.


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Reports of such evaluations will be maintained by QA Manager for the

duration of the project. Any noncompliance will be resolved to the satisfaction

of MACO and records maintained.

5.2 Documentation Requirements:

5.2.1 General:

MACO 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.

5.2.2 Quality Manual:

The Quality Manual identifies the scope of the Quality Management System,

and any exclusion to the requirements of ISO 9001:2000 and Proponent

Quality Systems. It includes procedures and documents covering workactivities. 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. QA Manager is responsible to ensure the initial issueand 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


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the Project office of MACO. Access to these files will be limited to Project

Manager, QA Manager and associated QA personnel.

Project Manager is responsible to review all project documents forconformance to the contract prior to submitting to the proponent. This reviewwill 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 bythe 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 (MACO-QMP-004). A list of all

documents and its status of revision will be maintained by DocumentController and updated every week.

Documents issued for construction will be approved by qualified andauthorized individuals as required by the contract as detailed in Quality

Management Procedure QMP-004.

As-built documents will be maintained by Document Controller at MACO

Project Office. An index of as-built documents will be maintained as part ofthe file. As-built conditions will be recorded on project documents by redline.

All documents will be verified for accuracy by QA Manager or his assignee

and will be transmitted to Proponent, by Project Manager at the end of theproject.

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 adifferent 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 MACO.

Controls will be established to track the status of any item on the list thatrequires 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 thisproject.

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


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procedure will be incorporated with adequate requirements of Proponent

applicable standards.

Project records will be stored in suitable environment to prevent damage ordeterioration and to prevent loss. Records will be filed by subject, date, filecategory, etc.

An index of project records will be part of the file. Responsibility for the

accuracy and completeness of the records is assigned to QA Manager. Access

to records will be under the control of Project Manager. Removal of records toa location other than the immediate area where the file is located will be

restricted to authorized persons like Project Manager, Project Engineer and QA

Manager. Measures to identify removed files and their current location will be

maintained.

Project Manager will identify those records to be transmitted to the proponentupon completion of the project and transmit the appropriate records.

MACO records that provide evidence of conformance to requirements and ofthe effective operation of MACO's quality management system will be

identified, stored, protected, and retained. Retrieval will be controlled. QA

Manager is responsible for identifying the records to be retained, retentiontime, disposal method, and for arranging for their protection and controlled

retrieval.

SECTION 6: MANAGEMENT RESPONSIBILITY

6.1 Management Commitment:

The top management of MACO is committed to the development andimprovement 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 management reviews in accordance with this QualityManual and other Proponent quality documents. Ensuring the availability of necessary resources in accordance with

Section 7 of this Quality Manual.

6.2 Customer Focus:

MACO ensures Proponents satisfaction by:


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Reviewing contract requirements, Quality Management System, andprocedures for compatibility and submit modifications as appropriate.

Allocating trained and qualified staff resources in accordance withAttachment I of Schedule Q and other documents to perform projecttasks.

Schedule and reporting progress in sufficient detail to control projectcost.

Training personnel as required. Performing management reviews and internal quality audits as

specified in Proponents quality documents.

Establish a program for problem identification and resolution andproblem prevention.

Maintaining data control systems and records of project activities.6.3 Quality Policy:

MACO has the following quality policy regarding the quality of the goods and

services we offer to our customers.

The quality assurance program of MACO is based upon the requirements of

ISO 9001/2000 Standards and Inspection and Testing of the contract.

MACO Quality Manual and the systems included therein, describe how thequality assurance program of MACO is designed to ensure that all qualityrequirements are recognized and that a consistent and uniform control of these

requirements is adequately maintained. The MACO 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 MACO 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 isconsidered 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, Proponents Test and Inspection Plans, Project Organizational Chartsthat 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 ofthe 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 MACO-

QMP-003 Procedure for Project Change Control.

6.5 Responsibility, Authority, and Communication

6.5.1 Responsibility and Authority:

MACOs project organization chart has been attached along with this QualityManual. Project Manager is responsible for maintaining the organizational

charts.

All QC personnel willfunctionally report to theQuality Assurance Manager.

While assigned to each project, quality personnel will be dedicated to the work

and perform no other function on any project.

MACO 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 ControllerProject 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 MACO towards Proponent for all matters relating toa Contract.


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Overall management of the project activities and control of the relatedpersonnel.

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 qualityobjectives.

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 theProject 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 anoperational link with the Project Sponsor. His responsibilities include but are

not limited to:

Preparation, review, updating and distribution of the Project QualityManual/Plan.

Issue of Project Quality procedures, Project Inspection and Test Plansand forms.

Review of Quality documentation issued by MACO. Assignment of Quality related tasks within the framework of the

project.

Review of Inspection Reports and of related NonconformanceReports.

Evaluation of Suppliers/Sub-contractors Quality systems Verification,by means of a planned Audit schedule that the established Quality

Program is being implemented by Subcontractors.


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Verification by means of a planned Audit schedule that therequirements set in the Quality Manual is met.

Coordination and supervision of activities relative to the collation of theProject Record Books.

Determining and reporting to the Project Management, the principalcauses of quality losses.

Determining with the Project Manager where improvements arerequired 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 specialistdesign groups and optimization of solutions.

Verify the compliance of design with the Project quality requirementsand contractual obligations.

Ensure the timely availability of pertinent technical documents as perestablished document release schedule. Promote any steps which may be required to prevent or minimize

delays of engineering activities.

Analyze changes in the Scope of Work and assist the ProjectManager/Project Planning and Cost Control in assessing the relevantcosts and implications.

Issue of Purchase Requests for material and/or equipment related to theProject.

Quality Control Engineer/Inspector

His responsibilities include but are not limited to:

Managing Quality Control functions for the Project including planningof Quality Control inspections and preparation of reports.


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Controlling corrective actions. Monitor inspections progress, review reports and documentation and

verify, upon completion of the work, that all requirements have beenmet and that the required Quality records have been collated and filed.

Monitoring on a day to day case MACO Project complaints with theapproved quality plan(s).

Following a suitably start and approved procedure for the formalcontrol of deviation/waivers from the job specification.

Review and approve as necessary, quality related procedures such as: Welding procedure specifications Welding procedure qualifications Welder qualification NDT procedures Heat treatment procedures Cleaning and pressure testing procedures Preservation procedures

Oversee the daily content and consistency of subordinate inspectorsdaily 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 MACO. His responsibilities include

but are not limited to:

Monitor implementation and adequacy of the construction/installationprocedures 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.


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Updating and revision of the drawings according to amendments andmodifications carried out in field.

Verify the progress of work and collect planning and reportingdocumentation to be included in the overall progress report.

Evaluate site changes and if acceptable obtain Proponents approval. Verify that the quality standard of work is in compliance with

contractual specification and approved procedures.

Transmit to the Project Management offices all necessarydocumentation 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 Construction Manager. Hisresponsibilities include but are not limited to:

Receiving inspection and record keeping of all material both freeissue from Proponent and MACO supplied material.

Reporting of non-conformances, the monitoring of careful segregationof quarantined material and rectification of defects and clearance of

material from quarantine.


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Assuring the traceability of uniquely identified critical materials whilematerials are in storage.

The monitoring and recording of the condition and state of preservationof materials released from storage for processing and/or construction.

6.5.2 Appointing a Quality Manager:

MACO has assigned Quality Assurance Manager as the management

representative for quality on each project. He will ensure the qualitysystem is established, maintained and implemented and will report to top

management on a monthly basis and make recommendations for qualitysystem improvements. Reports will be issued in writing to topmanagement and maintained in an open status until the resolution of

outstanding items. The management representative for quality will assurethat the project team is aware of customer requirements regarding the

project.

6.5.3 Internal Communication:

The Quality Manager ensures the processes of the quality managementsystem 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:

MACO 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 beevaluated 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.


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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 Proponents requirements. Resource needs.Action items will be followed up on at subsequent management reviews toensure closure. A copy of the results of this Management Review will be

forwarded to the Proponents within two weeks after the management

review meeting.

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 resourcesnecessary to implement and improve the processes of the QMS and address

Proponents satisfaction issues are provided in a timely manner.

7.2 Human Resources:

7.2.1 General:

MACO will assign personnel to the project in accordance with Proponentsquality documents that is competent on the basis of applicable education,

training, skills, and experience. All personnel assigned to each project will

meet the minimum qualification and experience levels specified in theProponents 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


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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 forspecial processes will be submitted 30 days prior to the start of work.

MACO 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.

MACO planned staffing levels will comply with Proponents approved

quality plan. Reduction from required level of quality personnel will

require Proponents written approval.

Anticipated changes in personnel due to vacation, temporary assignments

or resignations will be advised to Proponent at least 30 days in advance ofthe scheduled absence. All other changes such as for illness andemergency leaves will be advised as soon as possible.

7.2.2 Competence, Awareness, and Training:

MACO has developed position descriptions for those personnelperforming 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 assuretraining is performed. Personnel lacking required competencies willreceive training such as formal, informal, or on-the-job. MACO will

provide training as deemed appropriate to satisfy competency needs or

utilize external training sources.

MACO will evaluate the effectiveness of the training through periodicinternal audits, review and analysis of employee generated errors,

omissions, rework, and nonconformities.

MACO employees and sub-contractors will be made aware of theproject quality requirements and how their work activities contribute tothe achievement of quality objectives. This is achieved through regular

awareness presentations to personnel and subcontractors, projectkickoff meetings, project position descriptions, project organization

charts, toolbox meetings, newsletters, performance evaluations

MACO will maintain records of education, training skills, andexperience for personnel effecting quality. QA Manager is responsible

to ensure appropriate record including records of training activities andsubject matter of the training are maintained.


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7.3 Infrastructure

MACO 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 requiredfor 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 (MACO-SFPP-001).

SECTION 8: PROJECT EXECUTION

8.1 Planning of Project Execution:

MACO will plan and document the project execution process. The documentation forproject 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

QA 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).

8.2 Customers Related Processes:

8.2.1 Determining Project Requirements:


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MACO 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 beimplemented to support the delivery of the Work.

8.2.2 Reviewing Project Requirements:

MACO has assigned the responsibility to review the contract to Project

Manager. The Project Manager will ensure that the requirements areunderstood, 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 contractreview has been detailed in MACO-QMP-001 Procedure for ContractReview.

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 forexecution of the original contract by Project Manager.

8.2.3 Customer Communication:

Project Manager is responsible to establish and maintain communication

with Proponents 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 Proponents feedback/

complaints and responding to them.

8.3 Design and Development

The Quality Manual of MACO sub-contractor for Design and Development

should be attached with this Quality Manual.

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


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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 ofsubcontractors 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 criteriaare 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. Allrequisitions 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 Proponents related documents, work performed by thesuppliers and sub-suppliers will be reviewed for conformance to contract

requirements and accepted by Project Manager and documented by QA

Manager.

Project Manager is responsible to ensure that the equipments and materialsordered 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 originalpurchase order requirement and document.

The manufacturer/supplier quality program in accordance with ISO

9001:2000 will be verified by QA 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.


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Applicable supplier process control procedures (i.e., welding, heat

treatment, NDT, refractory installation) will be reviewed by QA Manager

and submitted to Proponent as required.

Equipment/material delivered for use on the project will be inspected byProject Manager at the supplier/sub-supplier facilities in accordance with

Proponents related document. 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:

MACO has established the following controls applicable toconstruction and construction management activities. These activities

are reflected in the detailed Proponents 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 safetyrequirements in the contract.

Methods are employed to monitor resource expenditure againstexpected results.

Procedures, work instructions, and/or installation instructions areavailable 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.


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A program to monitor the effectiveness of these process controls is inplace and implemented.

Criteria for release, approval, and acceptance are established.8.5.2 Validation of Processes for Production and Service:

The validation of the design is the constructed project that satisfies

Proponents requirements.

The validation of certain construction processes can only be ascertainedwhen load is applied or operation is initiated. For the project, these

processes include:

Welding. Structural Concrete Placement. Paving and Asphalting. Coating. Bolt Tensioning.MACO 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 Proponents

quality documents, if not included in this Quality Manual, will be

submitted for Proponents review at least 30 days prior to start of theconstruction activity.

8.5.3 Identification and Traceability:

MACO will develop and maintain a system to identify, design, or report

documents so they remain traceable to their originator and containcustomer 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.

MACO will develop and maintain a system to identify construction

materials and equipments to the extent required by the contract orapplicable codes and standards. Nonconforming material will be identified

or removed to prevent inadvertent use.


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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 MACO will develop and

maintain a system for unique identification of the work or batches. QA

Manager is responsible for implementing the system and retainingappropriate records. Nonconforming material will be identified or removed

to prevent inadvertent use.

8.5.4 Proponents Property:

MACO will develop and maintain a system to receive, log, and maintainProponents supplied documents, data. Project Manager is responsible

for this function and will advise the Proponents Representative of anyitems that are unsuitable for use, lost, or damaged.

All Proponents 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 atthe 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, MACO willevaluate construction material and equipment and include in the plans andspecifications 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 forpurchased equipment.

QA 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 beingimplemented by the subcontractors, and suppliers. Nonconforming

conditions will be documented.

MACO will establish, maintain and implement a program for handling,

storage, and preservation of equipment and material for this project. Thedetailed procedure for the above mentioned activities are described in

Quality Management Procedure MACO-QMP-009.


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8.6 Control of Monitoring and Measuring Devices:

MACO and sub-contractor(s) will establish, maintain, and implement a written

program to identify, control, and calibrate measurement and monitoring devices usedto assure conformity of work as required by the contract. The program will containthe 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 such equipment and instruments, frequency of calibration, andevidence calibration took place. Calibration frequency will be based on the moststringent of Proponents 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 Proponentsapproved agency, the following will apply:

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 meetacceptance criteria.

A program to ensure measuring and monitoring devices are protected fromdamage deterioration and unauthorized alterations of settings.

A program of corrective actions for previously accepted work, if defectiveequipment and instruments were used to inspect or test the work.

Confirmation that computer software used as a basis of product acceptance isacceptable for the intended application. Confirm prior to use and as necessarythereafter.

Records to demonstrate calibration and verification.The detailed procedure has been described in Quality Management Procedure MACO-

QMP-020.

SECTION 9: MEASUREMENT, ANALYSIS AND IMPROVEMENT

9.1 General:

MACO has defined, planned and implemented the following measurement,monitoring, analysis and improvement activities to assure conformity and achieve

improvement.


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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:MACO has developed the following methods to obtain data and monitorcustomer satisfaction and/or dissatisfaction.

Weekly meeting minutes. Correspondence.9.2.2 Internal Audit:

MACO 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 theeffectiveness 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 Proponents

quality documents. The schedule will be transmitted to the Proponents

Representative within 30 days of the effective date of the contract.

Personnel conducting internal audits are capable of objectivity andimpartiality in conducting audits. They will not audit their own area.

Reports of internal audit results will be generated and issued to affecteddepartments. Company management and the proponents will receivecopies of report within two weeks of audit completion.

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 toCompany management and to Proponent.


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The activities of subcontractors working under this quality managementsystem will be included in the audit program.

The activities of subcontractors working under their own qualitymanagement system will be audited. As a minimum such subcontractor

quality audits will be conducted every six months.

QA Manager is assigned responsibility to implement the internalquality audit program.

9.2.3 Monitoring and Measuring of Processes:

The project execution processes described in Section 5.7 of this QualityManual necessary to achieve Proponents requirements are measured and

monitored. These methods will confirm the continuing ability of eachprocess 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:

MACO will establish, maintain, and implement a program to control the

development, review, and release of designs that are in conformance withProponents 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.

MACO will establish, maintain, and implement a program to control

procurement, inspection and acceptance of equipment, material, andconstruction activities performed by MACO's own work forces or its

subcontractors. Records will be maintained.

QA Manager will ensure that incoming equipment and materials are

inspected and accepted for project use prior to incorporation intoconstruction. When material is received without Inspection Release, the

QA Manager will perform inspection against the purchase orderrequirements and verify that the equipment and material meets thespecified standards. The process will bedocumentedduring construction.

QA 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


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and standards. QA 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 qualifiedpersonnel 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 requiredby the contract.

QA Manager is responsible to supervise and accept or reject all contractor-

performed inspections and tests.

9.3 Control of Non-Conforming Product:

MACO has a program to detect and correct nonconforming conditions in design andrelating to work output of its own staff or others under contract to MACO.

Any nonconformance discovered by outside sources will be processed by QA

Manager.

During procurement and construction, any conditions that do not meet contractrequirements and that cannot be corrected by the end of the workday will be rejected

and documented.

QA 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

Proponents standards and specifications that result in "as-installed" or "use-as-is"recommendations will be documented as Waiver in accordance with Proponents

quality documents.

The Proponent will be notified of all (MACO and subcontractor) nonconformancereports 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:

MACO collects and analyzes appropriate data to determine the suitability and

effectiveness of its quality management system and to identify where improvementscan be made in the quality management system.

The following data are gathered and analyzed, QA Manager is responsible for the

effort and to ensure closure where QMS improvements are warranted.

Conformity of products to requirements. Measuring and monitoring data. Trends of both positive and negative compliance.


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Internal quality audit data.9.5 Improvements:

9.5.1 Continual and Improvement:

MACO 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.MACO will establish measurement systems and track performance for any

Proponents specified improvement initiatives in accordance with

Proponents quality related document.

Project Manager is responsible to assure implementation of this planningfor improvement effort.

9.5.2 Corrective Action:

MACO 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, identifyingand 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:

MACO has a program of preventive action, which anticipates the potentialcauses 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.


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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.


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DOCUMENT TITLE:

ATTACHMENT 1

ORGANIZATIONAL CHARTS

DOCUMENT NO.:

MACO-ORG-001


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YASSE

RBA

JubailInd.

Di

Mana

eceptionist

Pro

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pManager

alSiteEngr.

SiteEngr.

ricalSite

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teForeman

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Accountant/Admin.

HRAWY

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ger

PurchasingSupervisor

LocalPurchaser

anager

MechanicalSiteEngr.

InstrumentationSite

Engr.

Mech.SiteForeman

Inst.SiteForeman

Mechanical

Technicians

Labors

Inst.Technicians

Ad

Ope

EXECUTIVESECRETARY

EXTERNALAUDITOR

OsamaElSawy

Bldg.

ConstructionManager

RedaGameel

SEC/STCProjectsManager

Project/SiteEngineers(6)

Foremen(37)

SkilledCraftsmen(40)

Labors(118)

Project/SiteEngineers

Foremen

SkilledCraftsmen

SkilledCraftsmen

elAlZahrani

rationsManager

AdelSubaie

Water&SewageProjec

Manaer

Foremen(10)

SkilledCraftsmen(40

Labors(150)

Project/SiteEngineers

YousefMohammad

HassaProjectsManage

Project/SiteEngineer

Foremen

SkilledCraftsmen

SkilledCraftsmen

Moham

mP

NabilM

Assista

Saeed

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hanics(10)

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anager

sers(2)

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efAccountant

countants(5)

Cashier

OR

HishamIbrah

Technical.Engg.M

QA/QCEngineers/Supervisors

SafetyEngineers/Supervisors

DrawingOfficeSupervisor

CADOperators(3)

EstimationEngr.Mechanical

EstimationEngr.E

lectrical

ANIZAT

QA/QC/SAFETYManager

imanager

QuantitySurveyor

EstimationEngr.C

ivil

EstimationEngr.S

tructural

EstimationEngr.

Instrumentation

QSa

IONCH

SaadAl-Zahrani

HRPublicAffairsManager

AlaaKamel/MoeedAl-Zahrani

Secretary/Clerk

SaeedAbd.Al-Zahrani

PublicRelationsOfficer

/QCInspectors

fetyInspectors

DakeelAl-Zahrani


KhamisAl-Zahrani


HassanAl-Zahrani


RT


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DOCUMENT TITLE:

ATTACHMENT 2

RESUMES OF KEY PERSONNEL

DOCUMENT NO.:

MACO-CV-001


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Doc. No. MACO-QMP-TOC

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Quality Manual Page 1 of 2 MACO-QM-001

TABLE OF CONTENTS

QUALITY MANAGEMENT PROCEDURES

SL NO. PROCEDURE DESCRIPTION DOCUMENT NO.

1 CONTRACT REVIEW MACO-QMP-001

2 QUALITY ASSURANCE IN DESIGN MACO-QMP-002

3 PROJECT CHANGE CONTROL MACO-QMP-003

4 DOCUMENT AND DATA CONTROL MACO-QMP-004

5 CONTROL OF QUALITY RECORDS MACO-QMP-005

6 SELECTION OF VENDORS AND SUBCONTRACTORS MACO-QMP-006

7 PREPARATION, STYLE AND FORMAT OF PROCEDURES MACO-QMP-007

8 PURCHASING MACO-QMP-008

9 HANDLING, STORAGE, PACKAGING AND DELIVERY MACO-QMP-009

10 RECEIVING INSPECTION MACO-QMP-010

11 MATERIAL IDENTIFICATION AND TRACEABILITY MACO-QMP-011

12 CONTROL OF CUSTOMER SUPPLIED PRODUCT MACO-QMP-012

13 PROCESS CONTROL MACO-QMP-013

14 CORRECTIVE AND PREVENTIVE ACTION MACO-QMP-014

15 CONTROL OF NON-CONFORMANCE MACO-QMP-015

16 CONSTRUCTION INSPECTION MACO-QMP-016

17 INTERNAL QUALITY AUDITS MACO-QMP-017


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Quality Manual Page 2 of 2 MACO-QM-001

TABLE OF CONTENTS

QUALITY MANAGEMENT PROCEDURES

SL NO. PROCEDURE DESCRIPTION DOCUMENT NO.

18 TRAINING MACO-QMP-018

19 SPECIAL PROCESSES MACO-QMP-019

20 CONTROL OF INSPECTION, MEASURING AND TEST MACO-QMP-020

21 INSPECTION AND TEST STATUS MACO-QMP-021

22 INSPECTION AND TESTING MACO-QMP-022


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DOCUMENT TITLE:

ATTACHMENT 2

RESUMES OF KEY PERSONNEL

DOCUMENT NO.:

MACO-CV-001


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Page 1 of 6 MACO-QMP-001

DOCUMENT TITLE:

PROCEDURE FOR:

CONTRACT REVIEW

DOCUMENT NO.:

MACO-QMP-001

Index Page

1 Purpose: 2

2 Scope: 23 References: 2

4 Definitions: 25 Procedure: 2

6 Documentation: 6

001 04/01/09 MACO-QMP-001 APT GJR NZ

ISSUENO.

ISSUEDATE

DESCRIPTIONPREPARED

BYCHECKED

BYAPPROVED

BY


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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 ofcontract 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 Departmentto the Project Manager after Contract Award, to ensure the following:

That all contract requirements are clearly understood by theProject 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 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 withthe valuation of the Proponents Invitation to bid and the

preparation of documents for the Proposal.


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5.1.2 On Proposals for major projects, the nominated Project Manager should ifpracticable prepare and issue a Project Execution Strategy to summarize

the manner in which Manar Arabian Corp. (MACO) would execute the

contract if it were awarded. This document normally forms part of theProposal 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 withregarding 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 oromissions 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 documentationpackage, 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, neatly presented with all

associated backup and explanation including contributions from all

disciplines and Departments.

And 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.


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The Project Manager shall thoroughly review the documentation and becomefamiliar with the contents of the contract and all related documents.

5.4 Meeting Preparation

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 effectivedate.

The Project Manager, having acquired a sound knowledge of the contract

requirements and the relevant Proposal Documentation, will allocate his ProjectTeam responsibilities.

The Project Manager will uniquely identify parts of the contract documentationpackage plus the Manar Arabian Corp. (MACO) 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 meansof organization chart, job descriptions are understood andworkable.

Interfaces That these are clearly defined understood and includeinterfaces 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


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Contract Documentation package, in logical sequence, related to the overallprocess basis and engineering disciplines involved. A full index to identify the

location of each data category will be prepared if not included in the Clients

Documentation.

This Design Data Base will be issued to all attendees of the Contract Review

Meeting, supplementing information distributed direct from the ContractDocumentation Package.

That the issued Execution Strategy, if prepared and Quality Plan clearly indicate

where the contract work instructions differ from the standard working practices.

That the Contract Execution Strategy is prepared and that Planning Schedules and

Work Packages are understood by those responsible for the work. That anyidentified needs for the development of procedures, work instructions and design

briefs, 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 theneed 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 immediaterecord/cover sheet.

The relevant Proposals Manager and other previously involved Proposal staffshall 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 betabled 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 informationshall 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.


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During the Meeting, any changes required in relation to standard workingpractices 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 technicalguidelines. (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

Manar Arabian Corp. (MACO).

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 afterthe 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 forproject correspondence as defined for the contract.

Each department and or discipline will maintain a file of, or have access to, therelevant documents i.e. works scope, Proponents specifications, Proponents

philosophies, regulatory requirements, relevant national and international

standards, and MACOs standards and procedures which are applicable to theirScope of Work.

6 DOCUMENTATION

6.1 Contract Document Transmittal

6.2 Contract Review Meeting


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DOCUMENT TITLE:

PROCEDURE FOR:

QUALITY ASSURANCE IN DESIGN

DOCUMENT NO.:

MACO-QMP-002

Index Page

1 Purpose: 22 Scope: 2

3 References: 24 Definitions: 2

5 Procedure: 2

6 Documentation: 9

001 04/01/09 MACO-QMP-002 APT GJR NZ

ISSUE

NO.

ISSUE

DATEDESCRIPTION

PREPARED

BY

CHECKED

BY

APPROVED

BY


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1 PURPOSE

To define the Quality