AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04

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QUALITY MANUAL CONTRACT NO.20705 BITUMEN STORAGE FACILITY AT PORT KHALID SHARJAH

DESIGN CONTROL PROCEDURE : 04

INDEX: 4.01 Responsibility 4.02 Scope 4.03 Purpose 4.04 Organizational and Technical Interface 4.05 Design and Development Planning 4.06 Design Review 4.07 Design Verification and Validation 4.08 Control of Design Changes 4.09 Records

18-12-2006 Date

0 Revision

M.D Prepared by

D.L Reviewed By

W.D Approved By

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04

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4.1

RESPONSIBILITY: 4.1.1 The TECHNICAL COORDINATOR, being the head of the Engineering Department is responsible for the technical aspect of projects assigned to the department requiring product design and or development of shop drawings.

4.2

SCOPE: 4.2.1 Assigned projects involving structural design activities. 4.2.2 Assigned projects involving shop drawing development activities. 4.2.3 Coordination for changes, and modifications from design input to output. 4.2.4 Approval of design and development output.

4.3

PURPOSE: 4.3.1 To provide a product designed to meet customers approval as well as satisfying applicable statutory and regulatory codes and standards. 4.3.2 To design a product that would guarantee safety and proper function during production, installation and service.

4.4

ORGANIZATIONAL AND TECHNICAL INTERFACE: 4.4.1 Coordination with the GENERAL MANAGER for review of tender packages and technical specifications. Provide preliminary designs if required. 4.4.2 Approval and or submittal of technical documents to the customer may be coordinated by the SITE ENGINEER or with the PROJECT COORDINATOR which ever may apply. 4.4.3 Provide the Project Coordinator with updated status of the project design plan and master drawing list upon request or as agreed in the project opening meetings. 4.4.4 Coordination with the FACTORY MANAGER for revised shop drawings under production. 4.4.5 Table of Organization

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04

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ENGINEERING DEPARTMENT
Table Of Organization

4.4.6

Document Control Flow Chart

Technical Coordinator Senior Designer Senior Detailer

Detailer 1

Detailer 2

Detailer 3

Detailer 4

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04

Customer Tender, Specs

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Techincal Co-ordinat or Review tender and associat ed specifications. Est ablish Feasibilit y for Design (Sec. 4.1) Inform ambiguous or conflict ing design requirements t o Operat ions Manager. Operat ions Manager To resolve ambiguous / conflicting design requirements wit h the Client. Quot at ion Ref. P rocedure 03 "Cont ract R eview"

R eview Tender Requirement s

No

Cont ract Awarded? Yes

Prepare Schem atic

Drawings

Technical Co-ordinat or Review Client drawings and cont ract specificat ion/requirement s Raise P roject Design P lan (Ref. Sec. 4.2) Prepare Design Drawings Technical Co-ordinat or Verify and approve Design drawings Verify and approve struct ural calculat ions (reference Sec. 4.5) Design R eview (Sec. 4.4) Project Co-ordinat or Arrange for client validat ion of design drawing and calculat ions (where specified wit hin contract )

Project Design P lan Design Drawings Struct ural Calculat ions

Approved Design Drawings and Calculations

Prepare Shop Drawings

St ruct ural E ngineer Prepare Mast er P acking List , Det ail and Erect ion Det ail Drawings drawings based upon approved Design drawings and calculations. Submit t o Technical Co-ordinat or for verification and approval. Technical Co-ordinat or Verify and approve Mast er P acking List , Det ail and Erection drawings. (Reference Sec. 4.5) Conduct Design R eview (Sec. 4.4) if necessary Project Co-ordinat or Arrange for client validat ion of det ail and erect ion drawings. (where required)

Hold

Approved Det ail drawings

Developm ent of Fabrication

Drawings

Design Det ailer Prepare Fabricat ion drawings, based on approved Master P acking List , Design Det ail and Erection drawings. Submit to T echnical Co-ordinator for verification and approval, prior t o issue to Project Co-ordinat or. Technical Co-ordinat or Verify and approve Fabricat ion drawings (R eference Sec. 4.5) Conduct Final Design Review (Sec. 4.4) Project Co-ordinat or Obt ain Client validat ion where required Technical Co-ordinat or Endorse Fabricat ion drawings t o P roject Co-ordinat or (R eference P rocedure 05 "Document and Data Cont rol") Project Co-ordinat or Issue fabrication drawing to concern (R eference P rocedure 05 "Document and Data Cont rol")

Fabricat ion Drawings

Hold

Endorsem ent of Fabrication

Drawings

Issue for Fabricat ion

4.5

DESIGN AND DEVELOPMENT PLANNING:

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04

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4.5.1 For any assignment to the Engineering Department where structural or mechanical design is a major requirement in the project, The Technical Coordinator shall oversee that a documented Project Design Plan is provided in the project file. He shall: a) Ensure that the following details are properly addressed in the plan: Job reference Design Activity Review of design Verification of design Validation of design Development of Shop Drawings Activity Verification of shop drawings Validation of shop drawing Time duration for each activity if applicable b) Assign designers responsible for design activities if applicable. c) Assign Detailers responsible for development of drawings if applicable. d) Task assignment may be identified individually however in multitask environment, designers and detailers must sign his initials on every completed document. e) Update the project design plan as the design and or development progresses. 4.5.2 Projects requiring direct application of customers design data, specification and standards to the development of shop drawings, Special format for reporting purposes may also be generated when the above forms do not apply to the project. 4.5.3 Design calculations where applicable.

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04 4.6 DESIGN REVIEW:

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4.6.1 In as much as majority of projects comprises mainly of standard structural steel mills and buildings, vertical and horizontal cylindrical steel storage tanks, design formats generated are also following internationally accepted codes and standards and customer specifications derived from the same standard. Design verification therefore takes more weight than reviews. However, when a certain project calls for non-standard designs, reviews must be conducted. 4.6.2 At appropriate stages of the design, an assigned member of the design team or the Technical Coordinator may conduct design reviews. 4.6.3 Reviews conducted internally by the Engineering Department design team shall be identified. 4.6.4 Reviews conducted involving customer representative and design team shall be documented in black and white as minutes of reviews or meetings and shall be maintained in the project design file. 4.6.5 Reviews resulting in document change or modification shall be registered.

4.7

DESIGN VERIFICATION AND VALIDATION: 4.7.1 For every completion of design and development of shop drawings, verification and validation must be performed to ensure that the design input meets the desired output. 4.7.2 Completion of verification activity shall be identified by signing on the completed document i.e. drawings and calculations. 4.7.3 Verified documents shall also bear the stamp and initials indicating verification was conducted and approved by the Technical Coordinator 4.7.4 When validation of design or shop drawings is performed by the customer or his representative, validation results shall be registered (Validations Log). In the event that customer validation is not required, design calculations shall be maintained in the project file and shop drawings to be stamped with approval and signed by the Technical Coordinator.

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04

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4.7.5 Verifications conducted involving customer representative and design team shall be documented in black and white as minutes of or meetings and shall be maintain project design file. 4.7.6 Verifications resulting in document change or modification. 4.8 CONTROL OF DESIGN CHANGES: 4.8.1 For every change or modification in the design or drawing, the Technical Coordinator shall assess the implications of the proposed change. If deemed necessary, customer approval shall be sought for every changes or modification prior to implementation. Assessment shall take into account the following : a) Function / Performance requirements b) Safety c) Statutory or Regulatory requirements d) Cost 4.8.2 Request for changes to the design or shop drawings which is of inter-disciplinary origin but not from the design team, shall be agreed by the coordinating party and the Technical Coordinator. This shall be accomplished by (Design Change Request) and approved by the Technical Coordinator. 4.8.3 Changes and modifications to the design or drawings which is a result of a customer review, verification and or validation shall be accomplished (Design Change Notice). 4.8.4 The Technical Co-ordinator shall assign personnel to incorporate the desired change in the document. 4.8.5 Review and approve all subsequent amendments to the affected design calculations and drawings to ensure proper implementation of change requirements.

AL JABER PRECISION ENGINEERING PROCEDURE: DESIGN CONTROL NUMBER: 04 4.9 RECORDS:

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4.9.1 The Technical Coordinator shall establish and maintain a Project Design File, for each assigned project. This shall include the following: a) Customer Contract / Specifications b) Project Design Plan c) Master Drawing List and Status d) Design Review Meeting/Verification Minutes e) Validations f) Deviations g) Incoming and outgoing correspondences h) Original Calculations and Shop Drawings 4.9.2 Collect and Index the above document where applicable to ensure ease of retrieval. 4.9.3 Control the issuance of drawings/specifications to affected personnel. 4.9.4 Retain all records associated with this procedure for a period of two (2) years.