Complete Maco Quality Manual Vol. 1

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 th 01 April 2009
QUALITY ASSURANCE / QUALITY CONTROL (QA/QC) MANUAL
KINGDOM OF SAUDI ARABIA
P.O. BOX 10257, DAMMAM 31433 KINGDOM OF SAUDI ARABIA Tel. No. +966 3 8417007 Fax. No. +966 3 8423281
REV. 0
DOCUMENT NO. MACO-QM-001
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 th 01 APRIL 2009
QUALITY ASSURANCE / QUALITY CONTROL (QA/QC) MANUAL
P.O. BOX 10257, DAMMAM 31433 KINGDOM OF SAUDI ARABIA Tel. No. +966 3 8417007 Fax. No. +966 3 8423281
1 2 3 1 2 3
ISSUED FOR APPROVAL QA/QC Quality Manual SIGNATURE/DATE

REVISION HISTORY:
Prepared By:
CHECKED BY
APPROVED BY
APPROVED BY
APT
YSB
NMZ
SMZ
Document Recipients:
1. Gen. Manager 2. Asst. Gen. Manager 3. Business Dev. Manager 4. Project Managers 5. QA/QC Department 6. Purchasing/Finance Depts.
REV. 0
Revision 1 April 1, 2009
DOCUMENT NO. MACO-QM-001 VOL. 1
QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0
QUALITY ASSURANCE/QUALITY CONTROL MANUAL

MACO-QM-001
VOL. 1
APPROVAL SHEET
Description Prepared By: Approved By: Approved By: Approved By:
Name A.P. Togle Y. S. Bahrawy N. M. Zahrani S. M. Zahrani
Designation
QA/QC Senior Engineer Manar Arabian Corp.
Signature
Date
Projects Manager Assistant General Manager General Manager
-i-
Quality Manual
MACO-QM-001
QUALITY ASSURANCE/QUALITY CONTROL MANUAL MACO-QM-001

VOL. 1
REVISION HISTORY
Revision No. 0 1 2
Purpose of Revision Submitted for Approval.
Issue Date April 01, 2009
-iiQuality Manual MACO-QM-001
QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QM-001 Rev. 0
TABLE OF CONTENTS SECTION HEADING Approval Sheet Revision History Sheet Table of Contents 1 2 3 4 5 Company Quality Policy Project Scope Normative References Terms and Definitions Quality Management System
5.1 5.2 General Requirements Documentation Requirements 5.2.1 General 5.2.2 Quality Manual 5.2.3 Control Of Documents 5.2.4 Control Of Records
PAGE NO. i ii iii 01 03 03 05 09

09 10 10 10 10 11
Management Responsibility
6.1 6.2 6.3 6.4 Management Commitment Customer Focus Quality Policy Planning 6.4.1 Quality Objective 6.4.2 Quality Management System Planning Responsibility, Authority, and Communication 6.5.1 Responsibility and Authority 6.5.2 Appointing a Quality Manager/Management Representative
iii
12
12 12 13 13 13 14 14 14 19
MACO-QM-001
6.5
Quality Manual
6.6
6.5.3 Internal Communication Management Review 6.6.1 General 6.6.2 Review Input 6.6.3 Review Output
19 19 19 19 20
Resource Management
7.1 7.2 Provision Of Resources Human Resources 7.2.1 General 7.2.2 Competence, Awareness and Training Infrastructure Work Environment
20
20 20 20 21 22 22
7.3 7.4
Project Execution/Product Realization

8.1 8.2 Planning of Project Execution Customers Related Processes 8.2.1 Determining Project Requirements 8.2.2 Reviewing Project Requirements 8.2.3 Customer Communication Design and Development Purchasing 8.4.1 Purchasing Processes 8.4.2 Purchase Information 8.4.3 Verification of Purchased Products Production and Service Provision 8.5.1 Control of Production and Service Provision 8.5.2 Validation of Processes for Production & Service 8.5.3 Identification and Traceability 8.5.4 Proponents Property 8.5.5 Preservation of Material and Equipment Control of Monitoring and Measuring Devices
22
22 22 22 23 23 23 23 23 24 24 25 25 26 26 27 27 27
8.3 8.4
8.5
8.6
Measurement, Analysis, and Improvement

9.1 9.2 General Monitoring and Measuring 9.2.1 Customer Satisfaction 9.2.2 Internal Audit 9.2.3 Monitoring and Measuring of Processes 9.2.4 Monitoring and Measuring of the Work Control of Non-Conforming Product Analysis of Data
iv
28
28 29 29 29 30 30 31 31
MACO-QM-001
9.3 9.4
Quality Manual
9.5
Improvements 9.5.1 Continual and Improvement 9.5.2 Corrective Action 9.5.3 Prevent Potential Nonconformities
32 32 32 32
Attachment 1: Attachment 2:
Organizational Charts Resumes of Key Personnel
34 35
Quality Manual
MACO-QM-001
SECTION 1: COMPANY QUALITY POLICY

The intent of this Quality Manual is to define the Quality Assurance/Quality Control 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 this Quality 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 & 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 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 these requirements 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 conformance to 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.
QA/QC MANUAL Page 1 of 35 MACO-QM-001
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 Quality Requirements 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 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 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 their organization 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 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 sub-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 Proponents Quality requirements. This Quality Manual, and the typical procedures outlined herein describe how MACO 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. Saeed Mohammad Al Zahrani General Manager

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Mr. Nabil Al Zahrani Assistant General Manager

MACO-QM-001
SECTION 2:
PROJECT SCOPE
As per Project Scope of Work.
SECTION 3:
NORMATIVE REFERENCES
ISO 9000:2000 Quality Management Systems-Fundamentals and Vocabulary Quality Management Systems-Requirements. Control Processes National Electrical Code National Fire Protection Association National Electrical Manufacturers Association
ISO 9001:2000 ISO 9002 NEC NFPA NEMA
Saudi Government Safety and Security Directives ASTM ANSI UL ASTM D638 ASTM D1586 ASTM D2290 American Society for Testing & Materials American National Standards Institute United Laboratories Test Method for Tensile Properties of Plastics Standard Method for Penetration Test Standard Test Method for Apparent Tensile Strength Standard Test Method for External Loading Properties of Plastic Pipe By Parallel Plate Standard Test Method for Classification of Soils for Engineering Purposes
ASTM D2412
ASTM D2487
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ASTM D2583
Standard Test Method for Indentation Hardness of Rigid Plastics by Means of Barcol Impressor Standard Method for Obtaining Hydrostatic Design Basis for Fiberglass Standard Method for Determining Dimensions of Fiberglass Pipe and Fittings Standard Test Method for Chemical Resistance of Fiberglass Pipe in a Deflected Condition Standard Specification for Fiberglass Sewer and Industrial Pressure Pipe Standard Specification for Fiberglass Pipe Joints Using Flexible Elastomeric Seals American Concrete Institute
ASTM 2992
ASTM D3567
ASTM D3681
ASTM D3754
ASTM D4161
ACI
Royal Commission Guideline Specification Sections: 02722 15060 02220 02221 02210 03348 02326 09940 03245 02554/02555 AWWA SAES
QA/QC MANUAL
Sewerage System General Requirement for Pipe Work Structure Excavating and Backfill Trenching, Bedding, Backfilling and Compacting Earthworks Cast-In-Place Concrete Road Crossings Surface Painting of Steel Supports Fusion Bonded Epoxy Asphalt Road/Sub Grade Material American Water Works Association Saudi Aramco Engineering Standards
Page 4 of 35 MACO-QM-001
SAMSS SAER SAEP SATIP SAIC BICSI-TDMM
Saudi Aramco Material Systems Specifications Saudi Aramco Engineering Requirements Saudi Aramco Engineering Procedures Saudi Aramco Typical Inspection Plans Saudi Aramco Inspection Checklists Building Industry Consulting Services International Telecommunications Distribution Methods Manual
SECTION 4: TERMS AND DEFINITIONS

Appraisal: Assessment of a suppliers capability of carried out before placing orders. controlling quality,
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. 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/QC organization representative in attendance. Improvement: Actions taken by MACO to increase the effectiveness and efficiency 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 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. 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, 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 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 requirements as laid down in Proponents documents. Quality Assurance: All the planned and systematic activities implemented within 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 associated resources shall be applied by whom and when to a specific project, product, process or contract (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. 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. 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 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.
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Notes: 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. A service may be linked with the manufacture and supply of tangible products. 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. Note: 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 QA/QC organization with the opportunity to attend the Inspection or Test, at their option.
SECTION 5: QUALITY MANAGEMENT SYSTEM

5.1 General Requirements: MACO 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). QA Manager will review the subcontractor QMS Manual for conformance to the ISO 9001/2000 standards as it applies to the assigned scope of work. QA 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 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 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. QA 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 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 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 (MACO-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 MACO 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 QA 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 MACO. 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 QA 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 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 proponent upon completion of the project and transmit the appropriate records. MACO records that provide evidence of conformance to requirements and of the 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, 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 MACO 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 management reviews 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. 6.2 Customer Focus: MACO ensures Proponents 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 Proponents 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: 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 the quality assurance program of MACO is designed to ensure that all quality requirements 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 is considered as part of our effort for improvement. The objectives include meeting contract requirements, resource allocation, and schedule control.
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 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 MACOQMP-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 Quality Manual. Project Manager is responsible for maintaining the organizational charts. All QC personnel will functionally report to the Quality 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 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 MACO towards Proponent for all matters relating to a Contract.
QA/QC MANUAL
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. 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 MACO. Assignment of Quality related tasks within the framework of the project. Review of Inspection Reports and of related Nonconformance 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 Subcontractors.
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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. 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.
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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 been met and that the required Quality records have been collated and filed. Monitoring on a day to day case MACO 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 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 inspectors 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 MACO. 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.
QA/QC MANUAL
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 Proponents approval. Verify that the quality standard of work is in compliance with contractual specification and approved procedures. Transmit to the Project Management documentation generated on site. offices all necessary
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. His responsibilities include but are not limited to: Receiving inspection and record keeping of all material both free issue from Proponent and MACO supplied material. Reporting of non-conformances, the monitoring of careful segregation of quarantined material and rectification of defects and clearance of material from quarantine.
QA/QC MANUAL
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: MACO has assigned Quality Assurance 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. 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:
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 be evaluated for any needed change. Records of these reviews will be maintained. 6.6.2
QA/QC MANUAL
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. Review Output:
6.6.3
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 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.
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 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 Proponents quality 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 the Proponents 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. 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 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:
MACO 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. 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 periodic internal audits, review and analysis of employee generated errors, omissions, rework, and nonconformities. MACO 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 MACO will maintain records of education, training skills, and experience for personnel effecting quality. QA Manager is responsible to ensure appropriate record including records of training activities and subject matter of the training are maintained.
QA/QC MANUAL
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 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 (MACOSFPP-001).
SECTION 8:
8.1
PROJECT EXECUTION
Planning of Project Execution:
MACO 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 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
QA/QC MANUAL
Determining Project Requirements:

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 be implemented 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 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 MACO-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 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
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 Proponents 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 QA Manager. Project Manager is responsible to ensure that the equipments 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 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 by Project 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 to construction 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 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.
QA/QC MANUAL
A program to monitor the effectiveness of these process controls is in place and implemented. Criteria for release, approval, and acceptance are established. Validation of Processes for Production and Service:
8.5.2
The validation of the design is the constructed project that satisfies Proponents 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: Welding. Structural Concrete Placement. Paving and Asphalting. Coating. Bolt Tensioning. Process qualification. Equipment and personnel qualification. Defined methods and procedures. Records will be maintained and revalidation performed as necessary.
MACO assures these processes can achieve planned results through:
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 the construction 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 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. MACO will develop and maintain a system to identify construction materials and equipments 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 MACO will develop and maintain a system for unique identification of the work or batches. QA Manager is responsible for implementing the system and retaining appropriate 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 maintain Proponents supplied documents, data. Project Manager is responsible for this function and will advise the Proponents Representative of any items 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 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, MACO 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. 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 being implemented 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. The detailed 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 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 such equipment and instruments, frequency of calibration, and evidence calibration took place. Calibration frequency will be based on the most stringent 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 Proponents approved 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 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 MACOQMP-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.
9.2
Customer satisfaction. Internal audits. In-process reviews/inspections/tests. Control of nonconformities. Data analysis. Corrective, preventive, and improvement activities. Monitoring and Measuring 9.2.1 Customer Satisfaction:
MACO has developed the following methods to obtain data and monitor customer 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 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 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 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. 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.
QA/QC MANUAL
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. QA 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 Proponents 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: MACO will establish, maintain, and implement a program to control the development, review, and release of designs that are in conformance with Proponents 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, and construction 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 into construction. When material is received without Inspection Release, the QA 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 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
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 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. QA Manager is responsible to supervise and accept or reject all contractorperformed inspections and tests. 9.3 Control of Non-Conforming Product:
MACO 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 MACO. Any nonconformance discovered by outside sources will be processed by QA 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. 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) 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:
MACO 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, QA Manager is responsible for the effort and to ensure closure where QMS improvements are warranted.
QA/QC MANUAL
Conformity of products to requirements. Measuring and monitoring data. Trends of both positive and negative compliance.
9.5
Internal quality audit data. 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 planning for 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, 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:
MACO 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.
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MACO-QM-001
DOCUMENT TITLE:
ATTACHMENT 1
ORGANIZATIONAL CHARTS
DOCUMENT NO.: MACO-ORG-001
QA/QC MANUAL
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MACO-QM-001
Mohamma Saleh Al Zahrani ad PR RESIDENT
Saeed M Mohd. Al Zahrani Gen neral Manager
EXTERNAL AUDITOR
QA/QC/SAFETY Manager
Nabil M Mohd. Al Zahrani Assistan Gen. Manager nt

Safety Engineers/Supervisors Safety Inspectors
EXECUTIVE SECRETARY
QA/QC Engineers/Supervisors QA A/QC Inspectors
YASSER BA AHRAWY Jubail Ind. Div Projects v. Manag ger Purchasing M Manager Abdul llah El-Hossin Fina ance Manager
Ad Al Zahrani del Operations Manager
Hisham Ibrahi im Technical. Engg. M Manager
Saad Al-Zahrani HR Public Affairs Manager
Reda Gameel SEC/STC Projects Manager Drawing Office Supervisor
Adel Subaie Water & Sewage Project ts Manager
Clerk
Tamer Ezzat T Chie Accountant ef
Quantity Surveyor
Alaa Kamel/Moeed Al-Zahrani Secretary/Clerk
Accountant/Admin.
Project/Site Engineers (6)
Project/Site Engineers (4) (
Local Purchas sers (2) Acc countants (5)
CAD Operators (3)
Estimation Engr. Civil
Secretary/Receptionist
Saeed Abd. Al-Zahrani Public Relations Officer
Workshop Manager
Purchasing Supervisor
Foremen (37)
Foremen (10)
Cashier
Estimation Engr. Mechanical
Estimation Engr. Structural
Dakeel Al-Zahrani Public Relations Officer
Local Purchaser
Skilled Craftsmen (40)
Skilled Craftsmen (40) ) Estimation Engr. Electrical Estimation Engr. Instrumentation
Khamis Al-Zahrani Public Relations Officer
Project M Manager
Labors (118)
Labors (150) Hassan Al-Zahrani Public Relations Officer
Electrical Site Engr.
Mechanical Site Engr.
Electrical Site Foremen
Mech. Site Foreman
Osama El Sawy Bldg. Construction Manager
Yousef Mohammad er Hassa Projects Manage
Badr Al-Z Zahrani Workshop/Motor rpool Manager
Electrical Technicians
Mechanical Technicians
Project/Site Engineers
Project/Site Engineers s
Workshop Foreman
ORG GANIZATION CHA ART
Labors Foremen
Labors
Foremen
Skilled Mechanics (10)
Civil Site Engr.
Instrumentation Site Engr.
Skilled Craftsmen
Skilled Craftsmen
Labors (10)
Civil Site Foreman
Inst. Site Foreman
Skilled Craftsmen
Skilled Craftsmen
Labors
Inst. Technicians
Labors
DOCUMENT TITLE:
ATTACHMENT 2
RESUMES OF KEY PERSONNEL
DOCUMENT NO.: MACO-CV-001
QA/QC MANUAL
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QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-TOC Rev. 0
TABLE OF CONTENTS QUALITY MANAGEMENT PROCEDURES
SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
PROCEDURE DESCRIPTION CONTRACT REVIEW QUALITY ASSURANCE IN DESIGN PROJECT CHANGE CONTROL DOCUMENT AND DATA CONTROL CONTROL OF QUALITY RECORDS SELECTION OF VENDORS AND SUBCONTRACTORS PREPARATION, STYLE AND FORMAT OF PROCEDURES PURCHASING HANDLING, STORAGE, PACKAGING AND DELIVERY RECEIVING INSPECTION MATERIAL IDENTIFICATION AND TRACEABILITY CONTROL OF CUSTOMER SUPPLIED PRODUCT PROCESS CONTROL CORRECTIVE AND PREVENTIVE ACTION CONTROL OF NON-CONFORMANCE CONSTRUCTION INSPECTION INTERNAL QUALITY AUDITS
DOCUMENT NO. MACO-QMP-001 MACO-QMP-002 MACO-QMP-003 MACO-QMP-004 MACO-QMP-005 MACO-QMP-006 MACO-QMP-007 MACO-QMP-008 MACO-QMP-009 MACO-QMP-010 MACO-QMP-011 MACO-QMP-012 MACO-QMP-013 MACO-QMP-014 MACO-QMP-015 MACO-QMP-016 MACO-QMP-017
Quality Manual
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MACO-QM-001
QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-TOC Rev. 0
TABLE OF CONTENTS QUALITY MANAGEMENT PROCEDURES
SL NO. 18 19 20 21 22 TRAINING
PROCEDURE DESCRIPTION
DOCUMENT NO. MACO-QMP-018 MACO-QMP-019 MACO-QMP-020 MACO-QMP-021 MACO-QMP-022
SPECIAL PROCESSES CONTROL OF INSPECTION, MEASURING AND TEST INSPECTION AND TEST STATUS INSPECTION AND TESTING
Quality Manual
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MACO-QM-001
DOCUMENT TITLE:
ATTACHMENT 2
RESUMES OF KEY PERSONNEL
DOCUMENT NO.: MACO-CV-001
QA/QC MANUAL
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MACO-QM-001
DOCUMENT TITLE:
PROCEDURE FOR: CONTRACT REVIEW
DOCUMENT NO.: MACO-QMP-001

Index 1 2 3 4 5 6 Purpose: Scope: References: Definitions: Procedure: Documentation: Page 2 2 2 2 2 6
001 ISSUE NO.
04/01/09 ISSUE DATE
MACO-QMP-001
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
DESCRIPTION
Page 1 of 6
MACO-QMP-001
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.
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.
REFERENCES None
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.
PROCEDURE 5.1 Proposal Stage 5.1.1 Where practical, intended Project personnel shall be involved with the valuation of the Proponents Invitation to bid and the preparation of documents for the Proposal.
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MACO-QMP-001
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 Manar Arabian Corp. (MACO) 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, 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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MACO-QMP-001
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 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 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 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
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MACO-QMP-001
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 Clients 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. 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 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 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.
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MACO-QMP-001
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 coordinate 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 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 MACOs standards and procedures which are applicable to their Scope of Work.
DOCUMENTATION 6.1 Contract Document Transmittal 6.2 Contract Review Meeting
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MACO-QMP-001
DOCUMENT TITLE:
PROCEDURE FOR: QUALITY ASSURANCE IN DESIGN

001 ISSUE NO.
04/01/09 ISSUE DATE
MACO-QMP-002 DESCRIPTION
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Page 1 of 9
MACO-QMP-002
PURPOSE To define the Quality Assurance in Design in order to satisfy MACO 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.
SCOPE This Procedure covers design and development stages, including the review, optimization, standardization, verification and approval.
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 QA/QC is achieved by MACO 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. MACO 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. MACO 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 QA 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. Design Control as practiced by MACO is the quality control of design. MACO will verify that design criteria comply with the Proponents specified requirements, that
Page 2 of 9 MACO-QMP-002
design data and methods are valid for the range of application, and that completed design satisfies the design criteria. MACO 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 MACO 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, MACO will take into account their probable magnitude in design optimization. To ensure satisfactory installation performance, MACO will ensure that the Quality Program is adequate. For low-cost systems and equipment, MACO 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 shut-downs are reduced. Standardization-MACO will ensure that the design of structures and systems are coordinated to ensure that the number of different materials, components and equipments 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-MACO will ensure that original design is independently verified to comply with specified criteria, and all work documented and filed. MACO will justify design methods, selection of structure and system configuration, equipments and material, if required in Schedule B. MACO 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. MACO 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 MACO 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 MACO will be based on adequate documentation. System descriptions are key documents which MACO 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 MACO will implement their Quality Plan through the Proponents approved QA 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, MACO 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, MACO will prepare a program for its scope of work based on our organization in a number of discrete design packages. For each design package MACO will develop a design plan which will include an initial review and one more intermediate review depending on the requirements of the contract. MACO 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. Intermediate design reviews will be held by MACO at intervals of one to three months and will consider the following: Results and Action from previous reviews Optimization Verification Documentation
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MACO-QMP-002
Final design reviews will be held by MACO 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. 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 Checkers marks on the Check Print and personally making or supervising the update of the Document Original. Back-Checker color is green only. Originator/Back-Checker: Check marks in green each of the Checkers 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 Checkers red-marked changes that both he and the Checker at that point agree should not be changed. The BackChecker 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 BackChecker 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 editors 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. 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.
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MACO-QMP-002
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 Proponents 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 Managers knowledge and consent. 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.
DOCUMENTATION NONE
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MACO-QMP-002
DOCUMENT TITLE:
PROCEDURE FOR:
PROJECT CHANGE CONTROL

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Project Change Control
Page 1 of 5
MACO-QMP-003
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.
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 Proponents 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.
REFERENCES None
DEFINITIONS Baseline Documentation In the context of this procedure, Baseline Documentation will be Manar Arabian Corp. (MACO) 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.
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MACO-QMP-003
Drawings.
Engineering Changes A change to baseline documentation for reasons such as; Mandatory Safety Operability Certification (via Proponent) Proponents 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.
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MACO-QMP-003
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 MACO 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 MACO scope of work shall be evaluated for engineering changes. The results shall be recorded. Quality Assurance
QA 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
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MACO-QMP-003
necessary, with engineering specialist. QA shall also be responsible for design audits to ensure procedure compliance. 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 MACO engineering change proposals. Change Identification Major Changes Requirements for a change may be identified by either MACO or the Proponent. Change identification shall be registered in the form of a fax, letter, or marked up documents or drawings. MACO 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 MACO personnel start work on the change following instructions from the Project Engineer.
DOCUMENTATION 6.1 6.2 Change Request Authorization Form Design Modification Request
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MACO-QMP-003
DOCUMENT TITLE:
PROCEDURE FOR: DOCUMENT AND DATA CONTROL

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Document and Data Control
Page 1 of 6
MACO-QMP-004
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.
Document and Data Control Page 2 of 6 MACO-QMP-004
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. Outgoing Correspondence will be: - Route through Project Secretary, who will number, log and deliver.
REFERENCES
SAEP 128 Security and Control of Saudi Proponent Engineering data Outside of Saudi Proponent or any related quality document from other Proponents.
DEFINITIONS This procedure uses definitions in front of the Quality Plan and ISO 8402 Quality Management and Quality Assurance Vocabulary.
PROCEDURE Document Handling All documents transmitted to MACO 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.
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 Project Engineer Engineering Manager Procurement Manager Engineering (Civil) Engineering (Mechanical) Engineering (Elect./Comm./Inst.) Quality Assurance Manager
DRAWINGS All All All Civil Mechanical Elect./Comm./Inst. All
No. Of Copies 1 2 2 2 2 2 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 Proponents authorized representative. Note: All project correspondence to the Proponent shall be routed through Project Secretary. 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, CDs 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.
CADD 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.
DOCUMENTATION None
Document and Data Control
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MACO-QMP-004
DOCUMENT TITLE:
PROCEDURE FOR: CONTROL OF QUALITY RECORDS

Index 1 2 3 4 5 6 Purpose Scope References Definitions Procedure Documentation Page 2 2 2 2 2 3
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Control of Quality Records
Page 1 of 3
MACO-QMP-005
PURPOSE To provide a procedure for performing and controlling the filing and holding of Quality Records & Documents.
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.
REFERENCES SAEP-122 Project Records (Or any related document from other Proponents)
DEFINITIONS Where appropriate, definitions used are based on ISO 8402 Quality Records Documents which furnishes objective evidence of activities performed or results achieved.
PROCEDURE Responsibilities The Quality Assurance 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. 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 shall be made by cutting it with a single cross line and shall be initialed by the originator.
Page 2 of 3
MACO-QMP-005
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. 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. 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. MACO will ensure that one copy of the Inspection Record Book is forwarded to Proponent for review / approval as per SAEP 122. Document Disposition The period of retention of the documents is determined by the Project Manager, based on Contract Requirements. 6 DOCUMENTATION None
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MACO-QMP-005
DOCUMENT TITLE:
PROCEDURE FOR: SELECTION OF VENDORS AND SUBCONTRACTORS

Index 1 2 3 4 5 Purpose Scope Responsibility Procedure Attachments Page 2 2 2 2 4
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Selection of Vendors and Subcontractors
Page 1 of 8
MACO-QMP-006
PURPOSE To ensure that the vendors and subcontractors selected by MACO conform to specified project requirements.
SCOPE The procedure applies to the assessment of vendors and subcontractors under each contract.
RESPONSIBILITY The QA/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.
PROCEDURE A vendor or subcontractor is selected based on his capability to meet Proponent requirements, standards and specifications. The method of establishing this 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 vendors capability and/or quality system at their facilities. 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. New Vendors Potential new vendors and subcontractors must complete and return a Vendor QA Questionnaire. Preference is given, where practicable, to those approved to ISO9000 Series Standards or National Equivalent. Approval of a new vendor is based on the following criteria:
Page 2 of 8
MACO-QMP-006
Technical and financial capability Classification to ISO-9000 Series Standards or other standards Market reputation Experience with MACO and Proponent. Staffing and Facilities QA/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: Not approved Approved. Representatives of MACO 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 QA/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 QA/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. 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, Proponents approved vendor's list is used for identification of Proponent approved manufacturers who will be included in the bidding process as applicable.
Page 3 of 8
MACO-QMP-006
ATTACHMENTS : FORMS 5.1 Vendor QA Survey MACO-QMP-006-A1
Page 4 of 8
MACO-QMP-006
MACO-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? 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 1.4 How many personnel does your company employ: __________ How many personnel in the Quality Department? QUALITY CONTROL/INSPECTION QUALITY ASSURANCE TOTAL ___________ ___________ __________ Yes / No
Page 5 of 8
MACO-QMP-006
SECTION 2 Do you have a quality system that conforms to a recognized national or international standard? (E.g. BS, ISO, etc.) Have you ever supplied products to Proponent in the past? Yes / No
Yes / No
If Yes on which contract and which product: ________________________________________ ________________________________________ ________________________________________ Which Proponent Material Specification have been applied to the above products. __________________________________________ __________________________________________ __________________________________________ 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. If No 2.2 Are you preparing quality system for subsequent registration Has an assessment date been arranged? Date: ____ If not, when is an assessment proposed? Date: ____ What will be your proposed standard and scope of supply? ___________________________________________ ___________________________________________ ___________________________________________
Yes / No
Yes / No Yes / No
2.3
2.4
Page 6 of 8
MACO-QMP-006
SECTION 3 Do you have documented procedures to cover any of the following: 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Purchasing and Order Processing Goods inwards Handling, Storage and Disposal In-process Inspection Final Inspection Identification of non-conforming products Product Identification and Traceability Analysis of failures and resultant corrective action Yes/No/NA Yes/No/NA Yes/No/NA Yes/No/NA Yes/No/NA Yes/No/NA Yes/No/NA Yes/No/NA
SECTION 4 4.1 Are all gauges, measuring and test equipment calibrated at defined intervals? Are calibration results traceable to National Standards?
Yes/No Yes/No
4.2
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
Page 7 of 8
MACO-QMP-006
COMPILED BY: ________________ SIGNATURE: _______________ POSITION: _____________________ DATE: ________________ -----------------------------------------------------------------------------------------------------------------------VENDORS/SUB-CONT. APPROVED COMMENTS: __________________________________ __________________________________ __________________________________ __________________________________ Yes/No
NAME: _________________________ QC Representative Signature: __________________________ Manar Arabian Corp. (MACO) Date: ____________
Page 8 of 8
MACO-QMP-006
DOCUMENT TITLE:
PROCEDURE FOR: PREPARATION, STYLE AND FORMAT OF PROCEDURES

Index 1 2 3 4 5 6 Purpose: Scope: References: Definitions: Procedure: Documentation Page 2 2 2 2 2 3
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Preparation, Style and Format
Page 1 of 3
MACO-QMP-007
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 MACO 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 MACO departments and disciplines without exception. 3 REFERENCES None 4 DEFINITIONS 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. Procedure Format The cover page of the procedure shall be completed with the following information: Preparation, Style and Format
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 righthand 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
DOCUMENTATION Procedure cover page.
Preparation, Style and Format
Page 3 of 3
MACO-QMP-007
DOCUMENT TITLE:
PROCEDURE FOR: PURCHASING

Index 1 2 3 4 5 6 Purpose: Scope: References: Definitions: Procedure: Documentation Page 2 2 2 3 3 7
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Purchasing
Page 1 of 8
MACO-QMP-008
PURPOSE To define the respective responsibilities and procurement activities and define interfaces between the Proponent and MACO. To ensure that within the defined parameters of the prime contract and MACO agreements and initiatives, equal opportunity is provided to all qualified Bidders to provide equipments at best available quality & cost.
SCOPE This procedure relates to MACO 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
REFERENCES NONE
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 MACO.
Purchasing
Page 2 of 8
MACO-QMP-008
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 Preparation of the Procurement Plan The Procurement Manager will review the Proponents 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 MACO 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 MACO (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. 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 Proponents 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 MACO agreement are used for
Purchasing
Page 3 of 8
MACO-QMP-008
reasons of schedule where competitive bidders is not sought, the reason will be noted on the bidders list.
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. 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 technical/commercial/contractual questions. responses to bidders'
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 and, Engineering.
Receipt and Review of Bids
Purchasing
Page 4 of 8
MACO-QMP-008
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. 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 MACO Procurement Manager. Prior to placing the purchase order, MACO will submit a copy of its requisition and vendor's technical submittal to the Proponent for review and comment. Relevant Proponents comments will be incorporated prior to issuing a purchase order. Preparation and Issue of Purchase Orders
Purchasing
Page 5 of 8
MACO-QMP-008
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. MACO will review and approve purchasing documents for adequacy of the specified requirements prior to release. 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 MACO request or initiated by the Seller. 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
Page 6 of 8
MACO-QMP-008
Purchasing will maintain, on a current basis, a PO file to include all pre and post commitment correspondence relating to that file or order.
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. 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 Vendor name and location Inspection Assignment Package submittal date Level of inspection as specified in contract schedule Pre-inspection date Fabrication start date Scheduled and forecast delivery date Inspector and agency Special fabrication procedure approval status Open and closed NCR's Closeout date Disposition report
The Proponent shall have access to all purchase order inspection report files.
DOCUMENTATION None
Purchasing
Page 7 of 8
MACO-QMP-008
DOCUMENT TITLE:
PROCEDURE FOR: HANDLING, STORAGE, PACKAGING PRESERVATION AND DELIVERY

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Handling, Storage, Packaging, Preservation and Delivery
Page 1 of 3
MACO-QMP-009
PURPOSE To provide a procedure for handling, storage, preservation, packaging and delivery of products, systems, components, or installation material on receipt at company sites.
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 MACO scope of work.
REFERENCES None
DEFINITIONS This procedure uses definitions in the front of the Quality Plan and ISO 8402 Quality Management and Quality Assurance Vocabulary.
PROCEDURE Responsibilities Material 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. Handling Selected employees are instructed, as required, in proper methods of material handling before any actual handling of material occurs. To prevent damage during material handling the following devices may be used:
Page 2 of 3
MACO-QMP-009
Manual lifts and cranes for heavy equipment. Storage Tags & labels affixed to the outer box or storage rack identify the contents and physical characteristics of store items. The material controller shall perform regular monitoring on the material stored to verify their condition. 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. Packaging and Delivery Whenever materials are transported from sites, the material controller ensures proper packaging and delivery. The Material Controller also verifies the contents before sealing the package and prepares a Material Transmittal.
DOCUMENTATION None
Page 3 of 3
MACO-QMP-009
DOCUMENT TITLE:
PROCEDURE FOR: RECEIVING INSPECTION

Index 1 2 3 4 5 Purpose Scope Responsibility Procedure Documentation Page 2 2 2 2 4
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Receiving Inspection
Page 1 of 4
MACO-QMP-010
PURPOSE To establish a system for ensuring that Incoming items meet the specified contract and Quality requirements.
SCOPE All items received which are intended for use in producing finished product are covered by this section. 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
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.
PROCEDURE: INCOMING INSPECTION 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 construction.
Page 2 of 4
MACO-QMP-010
Receiving personnel notifies the QC Inspector that materials/equipment have arrived and arranges for Inspection.
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. 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. POSITIVE RECALL Products which are not fully inspected may be released for construction by the QC Inspector, with the Project Manager and Proponents 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
Page 3 of 4
MACO-QMP-010
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
Page 4 of 4
MACO-QMP-010
DOCUMENT TITLE:
PROCEDURE FOR: MATERIAL IDENTIFICATION AND TRACEABILITY DOCUMENT NO.: MACO-QMP-011

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Material Identification and Traceability
Page 1 of 4
MACO-QMP-011
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.
SCOPE This procedure applies to all systems, products, or components purchased for fabrication and/or installation.
REFERENCES None
DEFINITIONS This procedure uses definition in the front of the Quality Plan and ISO 8402 Quality Management and Quality Assurance Vocabulary.
PROCEDURE Responsibilities The Material Controller is responsible for the following; To maintain the database, which provides necessary identification and traceability of materials. To provide identification documents/certificates. for materials, to correlate with the relevant
It is the responsibility of Quality Department to ensure the identification and traceability of the item delivered for construction.
Material Identification and Traceability Page 2 of 4 MACO-QMP-011
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 Materials Controller. The inventory system tracks items received from the vendor by associating to the purchase order number, item serial number and placement location. The Material Controller 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 Heat/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
Material Identification and Traceability Page 3 of 4 MACO-QMP-011
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.
DOCUMENTATION None
Material Identification and Traceability
Page 4 of 4
MACO-QMP-011
DOCUMENT TITLE:
PROCEDURE FOR: CONTROL OF CUSTOMER SUPPLIED PRODUCT DOCUMENT NO.: MACO-QMP-012

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Control of Customer Supplied Product
Page 1 of 4
MACO-QMP-012
PURPOSE The purpose of this procedure is to set out the formal methods and planned actions to be taken by MACO to ensure that Proponents supplied materials and equipments are handled with care, identified, verified, protected and safeguarded.
SCOPE This procedure covers the inspection, storage of Proponents 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.
REFERENCES MACO-QMP-010 - Inspection and Testing
DEFINITIONS This procedure uses definitions in the front of the Quality Plan and ISO 8402 Quality Management and Quality Assurance-Vocabulary.
PROCEDURE Initial Inspection Upon receiving material at the Site Material Yard or warehouse, an initial Inspection is carried out by the Materials Specialist, and MACO Quality personnel according to procedure MACO 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.
Page 2 of 4
MACO-QMP-012
Any action to be taken in such cases will be coordinated with the Proponent. Material Control and Issue All material arriving at the Site Material Yard is logged and stored. MACO 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. 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. MACO quality personnel will be onsite for the required inspection. Any violation concerning the Proponent supplied materials will be reported to the Project Manager. Material Receipt The MACO 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.
Page 3 of 4
MACO-QMP-012
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. MACO will store all materials and equipment in accordance with the Proponents requirements and in such a way as to protect them from damage, deterioration, contamination and loss of identification. MACO will make special provision for sensitive items such as welding consumable, equipment or sprayed, galvanized or painted. MACO 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. MACO 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 MACO lay down Area. MACO 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. MACO 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, MACO will ensure that identification is intact prior to dispatch. MACO will also ensure that such material is accompanied by full certification when received from the Proponent. 6 DOCUMENTATION Material Receipt and Inspection Report
Page 4 of 4
MACO-QMP-012
DOCUMENT TITLE:
PROCEDURE FOR: PROCESS CONTROL DOCUMENT NO.: MACO-QMP-013

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Process Control
Page 1 of 4
MACO-QMP-013
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.
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.
REFERENCES The following documents are referenced: MACO-QMP-016 Schedule Q Control of Quality Records Quality Assurance and Control, Inspection and Testing
DEFINITIONS This Procedure uses definition in the front of the Quality Plan and ISO 8402 Quality Management and Quality Assurance vocabulary.
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:
Process Control
Page 2 of 4
MACO-QMP-013
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. 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. 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 Works Mechanical Works Piping Works Communication Works Instrumentation Works Electrical Works 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. MACO will ensure that these special processes are carried out under controlled conditions.
Process Control
Page 3 of 4
MACO-QMP-013
MACO 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. Records and status logs are maintained for approved processes, equipment and personnel, as appropriate. MACO 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 MACO, 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 MACO-QMP005. 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.
DOCUMENTATION None
Process Control
Page 4 of 4
MACO-QMP-013
DOCUMENT TITLE:
PROCEDURE FOR: CORRECTIVE AND PREVENTIVE ACTION

001 ISSUE NO.
04/01/09 ISSUE DATE
MACO-QMP-014
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
DESCRIPTION
Corrective and Preventive Action
Page 1 of 6
MACO-QMP-014
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.
SCOPE This procedure shall be applied to work performed both by MACO 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 MACO will be subjected to investigation for root cause and required corrective action.
REFERENCES None
DEFINITIONS Corrective Action: Preventive Action: Nonconformance: Action taken to eliminate the cause of an existing nonconformity. Action taken to eliminate the cause of a potential nonconformity. The nonfulfilment of a specified requirement as indicated by an observation or test result.
PROCEDURE Responsibilities The Quality Manager shall be responsible for documenting, investigating and follow-up of customer complaints and reports of product, process, or service nonconformities in MACO, and/or at vendor or subcontractor. General
Page 2 of 6
MACO-QMP-014
Corrective and preventive action may be initiated by anyone at any level, or at any stage of the work.
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 Quality Assurance 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 Quality Assurance Manager. 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.
Page 3 of 6
MACO-QMP-014
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. 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 Quality Assurance 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. 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. 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.
Corrective and Preventive Action Page 4 of 6 MACO-QMP-014
The analysis of preventive action taken shall be reviewed in the subsequent management review meeting.
DOCUMENTATION Corrective Action Request Form.
Page 5 of 6
MACO-QMP-014
AL MANAR ARABIAN CORPORATION
Project: BI Number: Contract No: Contractor: Location: Contractor Representative: Nonconformity:
Corrective Action Request Assessment Report Number
Assessment Date(s): Lead Assessor:
Assessor: Contractor Acknowledgment: Proposed Corrective Action:
Date: Date:
Agreed Implementation Date:
Action to Prevent Recurrence: Date: Contractor Representative: Date: Originator/Inspector: Date: Contractor Reply is Satisfatory Contractor Reply is not Satisfactory Action Taken is Satisfactory:
Implementation Verified by:
Date:
Cc: Project Mgr., _______________________Project, BI ______________ Supt., VID, E-1340A, Dha. Supt., PID, E- 1340B, Dha. Assessment File,IAG
Corrective and Preventive Action Page 6 of 6 MACO-QMP-014
DOCUMENT TITLE:
PROCEDURE FOR: CONTROL OF NON-CONFORMANCE

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Control of Non-Conformance
Page 1 of 5
MACO-QMP-015
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.
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.
REFERENCES None
DEFINITIONS Nonconformity The non-fulfillment of specified requirements.
PROCEDURE Responsibilities The Quality Assurance Manager or his designated nominee is responsible for raising NCRs 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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MACO-QMP-015
Depending on the source of the NCR (procedural, working practice, material etc.) corrective actions may be proposed by the Quality Assurance Manager, Engineering or relevant Discipline Engineer. 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 Suppliers 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 Suppliers 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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MACO-QMP-015
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.
Control of Non-Conformance Page 4 of 5 MACO-QMP-015
All NCRs including the Proponent issued NCRs, will be logged in the Nonconformance Report Register by the Quality Assurance Manager or his designated representative.
DOCUMENTATION None
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MACO-QMP-015
DOCUMENT TITLE:
PROCEDURE FOR: CONSTRUCTION INSPECTION

Index 1 2 3 4 5 Purpose Scope Responsibility Procedure Documentation Page 2 2 2 2 4
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Construction Inspection
Page 1 of 4
MACO-QMP-016
PURPOSE To ensure that all items meet specified requirements through all stages of fabrication/construction in accordance with Proponent Test and Inspection Plans.
SCOPE This procedure covers all contract work where compliance with the Project Quality Plan is required. ASSOCIATED MATERIAL Special Processes Procedures Design Drawings Shop Drawings Test Procedures In Process Inspection Reports
RESPONSIBILITY Construction Personnel are responsible for completing fabrication and construction in accordance with the drawings, engineering instructions, and Proponent Standards and Specifications. The Construction Foreman has the responsibility for ensuring that fabrication and construction on site are performed in accordance with the drawings, engineering instructions and Proponent standards and specifications. He is also responsible for ensuring that qualified personnel are performing Special Processes. The Site Engineer is responsible for ensuring that fabrication and construction are completed in accordance with the drawings and engineering instructions and that special procedure are processed and distributed in accordance with the Project Quality Plan. He ensures that fabrication and construction are in accordance with Proponent Standards and Specification, and meet applicable code requirements.
PROCEDURE: IN-PROCESS INSPECTION
INTRODUCTION Parts, components, sub-assemblies, and assemblies will be inspected, tested and identified during various stages of construction in accordance with the ITPs.
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MACO-QMP-016
For parts, components, sub-assemblies and assemblies where inspection is not feasible, Q.C. Inspector will monitor process methods, developing documentation to suit. INSPECTION & TEST PLAN The Proponent Test and Inspection Plan (ITP) is the Master document for controlling construction Operations, including inspections, examinations, tests and assembly operations. The Proponent Test and Inspection Plan perform the following functions; List the mandatory sequence of individual operation; Describes each operation; Identifies the Inspection operations including NDE; Explains the methods of Inspection, extent of inspection, and what type of report is required; Defines the acceptance criteria, drawings or specification number. Provides space for indicating operation, hold points and witness points. Provides space for signature for (MACO) QC Inspector, & Proponent QR. The Proponent Test and Inspection Plan should show in detail the methods and timing for examinations, measurements or test to assure compliance with contract requirements. MACO will be responsible for required inspection, tests and material examination at work site. This will include receiving, in process and final action. Specific inspection points will be indicated in the Quality Plan and related procedures where MACO inspection is mandatory. MACO approvals to proceed should be documented prior to continuation of work. Proponent Test and Inspection Plan and related procedures will include provisions for ensuring and recording that prerequisites for any given test have been met, that adequate and calibrated instrumentation is available and used and that the necessary inspection is performed.
QUALITY CONTROL INSPECTOR The Q.C. Inspector utilizes Quality Control Operations as listed in the Inspection and Test Plan for effective control the purpose of these operations is to: Ensure that the equipment is constructed in accordance with jurisdictional, contractual, and quality control requirements. Instill in all MACO personnel the basic fact that each one is responsible for the quality of every part, function or service that they work on or perform.
Page 3 of 4
MACO-QMP-016
Factually document the identity of individuals performing specific operations, and the identity of measuring and test equipment used in specific tests. Maintain summary reports on operation, and include all reports in the quality record as evidence that the product meets contractual obligations and applicable jurisdictional requirement. NON-CONFORMITY The functions/responsibilities of QC Inspectors Civil, Mechanical, and Electrical are further explained in details in Project Procedures (Inspection & Test Plan). 5 DOCUMENTATION
None
Page 4 of 4
MACO-QMP-016
DOCUMENT TITLE:
PROCEDURE FOR: INTERNAL QUALITY AUDITS

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Internal Quality Audits
Page 1 of 20
MACO-QMP-017
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.
SCOPE This procedure applies to Internal Quality Audits conducted by the Quality Management Department which may utilize trained and experienced auditors from other departments within MACO 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.
REFERENCES None
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 MACO 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.
Page 2 of 20
MACO-QMP-017
Nonconformity 'The non-fulfillment of a specified requirement'. A deficiency in characteristic, documentation, procedure or process which renders the quality of an item or service unacceptable. Examples of nonconformity include: departure from approved procedures, contravention of MACO 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. 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.
Internal Quality Audits Page 3 of 20 MACO-QMP-017
The Audit Schedule (see attachment 6.7) shall be approved by the QA Manager and authorized by the Project Manager. The QA 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 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. Audit Team Selection The QA 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 QA 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. 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 QA Manager; Contact the auditees 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. 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 QA 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. Opening Meeting The Lead Auditor shall convene a brief meeting between the audit team and appropriate representatives of the Auditees' 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's Management to attend. 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's QA performance is readily seen (Attachment No. 6.9 refers). Wherever possible, auditors shall obtain auditee's 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.
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. 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, CAR 12/2 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.
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MACO-QMP-017
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. Close-out of the findings shall be by re-audit. The QA Manager shall be advised and his authority is required to recommend "stop work". The QA Manager shall consult with the appropriate department and others as necessary in MACO 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 As for category 1 with the exception that no major noncompliance has been found in the item or service or is reasonably suspected, close-out of the finding shall be by reaudit. 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. Close-out 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. 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 auditees as appropriate for their cooperation. 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. 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 Auditees' 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; entry and exit meetings; general observations;
CAR's issued. Audit reports shall be numbered consecutively using one of the following sequences: MACO 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 QA Manager for review. After the report has been reviewed and the contents are acceptable, the QA Manager shall sign off the Lead Sheet. The original of the audit Report and Audit checklists shall be filed by the QA 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 QA 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 QA 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 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 QA 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 QA Manager to seek agreement to call in support from senior management. DOCUMENTATION Audit Arrangement Record (attachment No. 6.1 Form no. QA/001) Corrective Action Request (attachment No. 6.2 Form No. QA/002) Attendance Sheet (attachment No. 6.3 Form No. QA/003) Audit Report Lead Sheet (attachment No. 6.4 Form No. QA/004) Audit Continuation Sheet (attachment No. 6.5 Form No. QA/005)
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MACO-QMP-017
Observation Sheet (attachment No. 6.6 Form No. QA/006) Audit Schedule (attachment No. 6.7 Form No. QA/007) Audit Report Status Log (attachment No. 6.8 Form No. QA/008) Internal audit Checklist (attachment No. 6.9 Form No. QA/009) CAR Status Log (attachment No. 6.10 Form No. QA/010)
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MACO-QMP-017
AUDIT ARRANGEMENT RECORD

To: Department: Project Date: Date: Reference No.: Proposed Nature of Audit: Areas to be examined and Agenda Scope of Audit: Date: Time: Duration: Referenced Documents:
Audit Team and Their Allocation: Lead Auditor: Auditor: Observer: Special Notes
Please sign this document to signify your agreement and return it to Quality Assurance Group.
Agreed: Signature: Name: Date: For:___________________________ (Quality Assurance Department) For:____________________________ (Department Group Audited)
Form No QA/001
Attachment No. 6.1
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MACO-QMP-017
CORRECTIVE ACTION REQUEST: Project/Area Audited: ____________________ CAR No.:_______________________ Auditee: _______________________________ Auditor:________________________ Nonconformity:
Signature of Auditor: _____________________
Date:__________________
Signature of Auditee: _____________________
Date: __________________
Proposed Corrective Action: Date of Completion of Corrective Action: ____________________________
Signature: ____________________________ (Project/Area Representative)
Date:___________________
Corrective Action Taken and Action to Prevent Recurrence:
Signature: ____________________________ (Project/Area Representative) Follow-up Action and Close-out: Proposed Follow-up Date: Follow-up Details:
Date: __________________
Signature of Auditor: _____________________

Form No. QA/002
Close-out Date: ________________

Attachment No. 6.2
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MACO-QMP-017
Internal Quality Audit Attendance Sheet
MANAR ARABIAN CORP. (MACO)
Project: _________________________ Audit No.: _______________________ Type of Audit: ___________________
File Ref.: ________________ Date of Audit: ____________
Name
Signature
Position
Form No QA/003
Attachment No. 6.3
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MACO-QMP-017
AUDIT REPORT
(Lead Sheet) AUDIT NO.: Report No.: ___________ Page _____ of _________
Form No QA/004
Attachment No. 6.4
Page 15 of 20
MACO-QMP-017
AUDIT REPOR AUDIT REPORT

(Continuation Sheet) AUDIT NO.: Report No.: ___________ Page _____ of _________
OBSERVATION
Observation No.: _____________________ Auditor: ______________________ Audit Report No.: _____________________
COMPANY / PROJECT AREA / DISCIPLINE
Description of Item / Activity:
Location: Summary: Full Description: Originator's Signature: _____________________________
QM Manager's Signature: __________________________ Date: ______________

Forward Response to QM Group by:
Recipients Response:
Name: _____________________ Signature: ____________________ Date:_____________ QM Comments:
Name: _____________________ Signature: ____________________ Date:_____________ Verification of Completion (by QM)
Name: _____________________ Signature: ____________________ Date:_____________

Form No QA/005 Attachment No. 6.5
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MACO-QMP-017
AUDIT SCHEDULE
Audit Scheduled Report Issued Year Month Audit Completed Audit Performed
ACTIVITY TO BE AUDITED
W/E Wk. No. Contract No.
5 10
1 2 1 1
19 12
2 6 1 3
2 1 4
9 15
1 6 1 6
2 3 1 7
30 18
7 19
14 20
21 21
28 22
4 23
11 24
18 25
25 26
ENGINEERING MANAGEMENT 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015
Prepared by: Reviewed by: Approved by: Authorized by:
FormNo.QA/007
Attachment No. 6.7
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MACO-QMP-017
AUDIT REPORT STATUS LOG

AUDIT REPORT NO. AUD. TYPE LEAD ADTR. AUDIT DATE PROJ./ AREA/ DISCIPLINE AUDITED PROCEDURES / CRITERIA AUDITED PROJ. NO. DATE AUDIT REPORT ISSUED CAR'S ISSUED
FormNo.QA/008
Attachment No. 6.8
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MACO-QMP-017
INTERNAL AUDIT CHECKLIST

Location Audited Audit No. Contact Date of Audit Lead Auditor Auditors : _____________________ : _____________________ : _____________________ : _____________________ : _____________________ : _____________________
Item No.
Subject / Requirement
Document Source
Activity Compliance
Comments / Remarks
CAR
Form No. QA/009
Attachment No. 6.9
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MACO-QMP-017
CORRECTIVE ACTION REQUEST STATUS LOG

Audit Report CAR No. Agreed Corrective Action Date Findings Target Completion Date Revised Completion Date Date CAR Closed Verified by
Form No. QA/010
Attachment No. 6.10
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MACO-QMP-017
DOCUMENT TITLE:
PROCEDURE FOR: TRAINING

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Training
Page 1 of 4
MACO-QMP-018
PURPOSE To ensure that the personnel performing work, affecting quality is competent on the basis of education, training, skills and experience. Training courses for MACO 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.
SCOPE The scope of this procedure lays down the parameters in which MACO will determine the necessary competence for personnel performing work affecting quality and provide training or take other activities to satisfy those needs.
REFERENCES None
DEFINITIONS This procedure uses definitions in front of the Quality Plan and in ISO 8402 Quality Management and Quality Assurance Vocabulary.
PROCEDURE Responsibility for training within each department of MACO is with the respective Department Manager. Manar Arabian Corporation, 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 a MACO 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.
Training
Page 2 of 4
MACO-QMP-018
Obtains the Project Managers agreement on training costs and priorities in keeping with MACOs business plan and employee training requirements. 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 Companys 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 MACOs 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 MACO and its employees regularly review the training plan. MACO have 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.
Training
Page 3 of 4
MACO-QMP-018
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. 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. Survey of Training Program.
Training
Page 4 of 4
MACO-QMP-018
DOCUMENT TITLE:
PROCEDURE FOR: SPECIAL PROCESSES

Index 1 2 3 4 5 Purpose Scope Responsibility Procedures Documentation Page 2 2 2 3 4
001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Special Processes
Page 1 of 4
MACO-QMP-019
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.
Scope All special process is covered by this section. Definitions A special process is a process requiring special training, qualification, or extreme care to successfully accomplish such process. 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. Examples of Special Processes All welding operations Non-destructive examination Painting Performance Tests (covered by Specification for Specific Item)
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.
Special Processes
Page 2 of 4
MACO-QMP-019
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 a 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 equipments in accordance with applicable codes and Proponent Standards and specifications. Welding Procedure Specifications The QA/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 QA/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. 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
Special Processes Page 3 of 4 MACO-QMP-019
procedures. The N.D.E. Procedures will be reviewed and approved by QA/QC Engineer. The N.D.E. Procedures and personnel qualifications will be submitted to Proponent for review and approval. All equipments used for NDE will be maintained by QA/QC Engineer. Painting 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 QA/QC Engineer / Inspection. Recording forms will contain atmospheric conditions, surface preparation and equipments as required by Proponent. 5 DOCUMENTATION None
Special Processes
Page 4 of 4
MACO-QMP-019
DOCUMENT TITLE:
PROCEDURE FOR: CONTROL OF INSPECTION, MEASURING AND TEST EQUIPMENT

001 ISSUE NO.
04/01/09 ISSUE DATE
MACO-QMP-020
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
DESCRIPTION
Control of Inspection, Measuring and Test Equipment
Page 1 of 5
MACO-QMP-020
PURPOSE To establish a system by which inspection, measuring and test equipment are controlled, calibrated and maintained.
SCOPE This procedure shall be used for all inspection, measuring and test equipment requiring calibration.
REFERENCES None
DEFINITIONS Where appropriate, definitions used are based on ISO 8402. Calibration Activity performed to verify the accuracy of inspection, measuring and test equipment.
PROCEDURE Responsibilities The user department is responsible for maintaining the calibration of all inspection and test equipment under their custody, including MACO assets, rented equipment, Proponents 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. Calibration Control Calibration status of all inspection, measuring and test equipment are controlled and reported through a tracking system.
Page 2 of 5
MACO-QMP-020
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. Calibration Services Only the Proponents approved metrology whose standards are traceable to recognized 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 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. MACO will safeguard inspection, measuring and test facilities, including both test hardware and test software from adjustments which would invalidate the calibration setting.
Page 3 of 5
MACO-QMP-020
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. 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. 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. Continued Suitability of Software Test Programs Continued suitability of software test programs shall be ensured by revision and access control.
DOCUMENTATION FORM QA/015 - CALIBRATION LOG
Page 4 of 5
MACO-QMP-020
TEST EQUIPMENT CALIBRATION LOG

Project: Current as of :
Model Cal. Cal. Cal. Certificate & Due Remarks Last Freq. Owner ID Description Manufacturer No. Serial (Days) (Date) (Date) No.
Page 5 of 5
MACO-QMP-020
DOCUMENT TITLE:
PROCEDURE FOR: INSPECTION AND TEST STATUS

001
04/01/09
MACO-QMP-021
APT
GJR
NZ
ISSUE NO.
ISSUE DATE
DESCRIPTION
PREPARED BY
CHECKED BY
APPROVED BY
Inspection and Test Status
Page 1 of 4
MACO-QMP-021
PURPOSE To ensure that the inspection and test status of all inspectable activities are identified and recorded. To ensure that only activities which pass the required inspections and tests are processed for further construction activities.
SCOPE This procedure shall be applied to all activities requiring inspection and testing.
REFERENCES MACO-QMP-015 Control of Non-Conformance.
DEFINITIONS None
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.
Page 2 of 4
MACO-QMP-021
The material controller and procurement QC supervisor maintain the records of equipment and material inspection as required. 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. 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.
Page 3 of 4
MACO-QMP-021
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 MACO-QMP-015, Control of Non-Conforming Products. 6 DOCUMENTATION None
Page 4 of 4
MACO-QMP-021
DOCUMENT TITLE:
PROCEDURE FOR: INSPECTION AND TESTING

001 ISSUE NO.
04/01/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Inspection and Testing
Page 1 of 8
MACO-QMP-022
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.
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 MACO, its sub-contractors, vendors and suppliers.
REFERENCES The following documents are referenced: MACO-QMP-020 Inspection, Measuring and Test Equipment MACO-QMP-015 Control of Non-conformance Schedule 'Q' Quality Assurance and Control Inspection and Testing.
DEFINITIONS This procedure uses definitions in the front of the Quality Plan and ISO 8402 Quality Management and Quality Assurance Vocabulary.
PROCEDURE 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.
Page 2 of 8
MACO-QMP-022
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 lookahead 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. MACO 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. MACO 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. MACO 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. MACO 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 MACO-QMP015.
Page 3 of 8
MACO-QMP-022
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. MACO will notify the Proponent 48 hours in advance of the inspection. MACO 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 Proponents 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 MACO 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 MACO's Inspection Assignment Package in conformance with the requirements of Schedule 'Q'. MACO 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.
Page 4 of 8
MACO-QMP-022
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. 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. Remarks 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
Page 5 of 8
MACO-QMP-022
Structural Work Foundation Elevation, Level and plumb Metal decking 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 torquing 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
Page 6 of 8
MACO-QMP-022
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 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 MACO-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).
Page 7 of 8
MACO-QMP-022
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 MACO 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. 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
Page 8 of 8
MACO-QMP-022

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THIS QUALITY MANUAL IS THE ONLY CONTROLLED AND VALID VERSION.

QUALITY ASSURANCE / QUALITY CONTROL (QA/QC) MANUAL

KINGDOM OF SAUDI ARABIA

DOCUMENT NO. MACO-QM-001

QUALITY ASSURANCE / QUALITY CONTROL (QA/QC) MANUAL

ISSUED FOR APPROVAL QA/QC Quality Manual SIGNATURE/DATE

Revision 1 April 1, 2009

DOCUMENT NO. MACO-QM-001 VOL. 1

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QUALITY ASSURANCE/QUALITY CONTROL MANUAL

Description Prepared By: Approved By: Approved By: Approved By:

Name A.P. Togle Y. S. Bahrawy N. M. Zahrani S. M. Zahrani

Projects Manager Assistant General Manager General Manager

QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0

QUALITY ASSURANCE/QUALITY CONTROL MANUAL MACO-QM-001

Purpose of Revision Submitted for Approval.

Issue Date April 01, 2009

-iiQuality Manual MACO-QM-001

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PAGE NO. i ii iii 01 03 03 05 09

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Project Execution/Product Realization

Measurement, Analysis, and Improvement

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Organizational Charts Resumes of Key Personnel

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SECTION 1: COMPANY QUALITY POLICY

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Mr. Saeed Mohammad Al Zahrani General Manager

Mr. Nabil Al Zahrani Assistant General Manager

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As per Project Scope of Work.

ISO 9001:2000 ISO 9002 NEC NFPA NEMA

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SAMSS SAER SAEP SATIP SAIC BICSI-TDMM

SECTION 4: TERMS AND DEFINITIONS

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SECTION 5: QUALITY MANAGEMENT SYSTEM

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SECTION 6: MANAGEMENT RESPONSIBILITY

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Quality Management System Planning:

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SECTION 7: RESOURCE MANAGEMENT

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Determining Project Requirements:

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