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1. Scope 3
2. Normative Reference 3
5. Management Responsibility 11
5.1 Management Commitment 11-12
5.2 Customer Focus 12
5.3 Quality Policy and Operating Values 13
5.4 Planning 13
5.4.1 Quality Objective 13-14
. 5.4.2 Quality Management System Planning 14
5.5 Responsibility, Authority, and Communication 14
5.5.1 Responsibility and Authority 14-15
5.5.2 Appointing a Quality Manager/Management 15
Representative
5.5.3 Internal Communication 15
5.6 Management Review 15
5.6.1 General 15-16
5.6.2 Review Input 16-17
5.6.3 Review Output 17-18
6. Resource Management 18
6.1 Provision of Resources 18
6.2 Human Resources 18
6.2.1 General 18-19
6.2.2 Competence, Awareness, and Training 19
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Project Quality Plan - Manarah Al Jubail Const. Co.
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6.3 Infrastructure 19-20
6.4 Work Environment 20
7. Project Execution 20
7.1. Planning of Project Execution 20
7.2 Customers Related Processes 20
7.2.1 Determining Project Requirements 20
7.2.2 Reviewing Project Requirements 20
7.2.3 Customer Communication 21
7.3 Design and Development 21
7.4. Purchasing 21
7.4.1 Purchasing Process 21
7.4.2 Purchase Information 21-22
7.4.3. Verification of Purchased Products 22
7.5. Production and Service Provision 22
7.5.1 Control of Production and Service Provision 22-23
7.5.2. Validation of Processes for Production and Service 23
7.5.3. Identification and Traceability 23-24
7.5.4. SATORP Property 24
7.5.5. Preservation of Material and Equipment 24
7.6. Control of Monitoring and Measuring Devices 24-25
8.1 General 26
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1. Scope
The intent of this Quality plan by MCCL is to construct the Tank Foundations, Dyke/Bund
walls and all related civil works for the Jubail Export Refinery Project Package # 9 in
accordance with Project specifications, IFC drawings, JER Engineering Standards,
Procedures and all applicable regulatory requirements. This Quality Plan covers all the
aspects related to the quality during the phases of Procurement, Construction and Pre
commissioning.
2. Normative Reference
For the purpose of this Quality Plan the following terms and definitions in addition to
terms and definitions given in ISO 9000:2000, Schedule Q and JEREP-1154 shall apply
and have the meaning indicated in this section. No attempt is made to define ordinary
words which are used in accordance with their established dictionary meaning.
Quality Plan: Document specifying which procedures and associated resources shall
be applied by whom and when to a specific project, product, process or contract. [ISO
9000]
Quality Policy: Statement of commitment and objectives by the company regarding
quality.
Quality Manual: Documentation of the Quality Policy and the Quality System of the
Company.
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Quality Audit: Verification activity to check that the quality system or work procedure
continues to conform to requirements.
Verification: The formal processing of confirming & documenting compliance with the
acceptance criteria.
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.
Hold Point: Inspection or Test may not proceed without the QA/QC organization
representative in attendance.
Witness Point: It defines a point that provides QA/QC organization with the
opportunity to attend the Inspection or Test, at their option.
Shall: "Shall" expresses a provision that is binding between two or more parties.
The Management System describes the processes and instructions for the
performance of our business.
The Quality System describes the auditing procedures that allow us to measure
our performance with quantitative data, as well as the procedures for examining
non-conformances and opportunities for system improvements.
Our QMS documentation is accessible and controlled on our internal computer network.
GM Technical with the assistance of Quality department has the overall responsibility for
our QMS. He is responsible for ensuring resources are available, policies and objectives
are set and communicated, and system improvements are implemented. Managers have
measurable objectives to demonstrate that their actions are effective and that client
satisfaction is being achieved.
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Communicate our QMS and our commitment to meeting client and regulatory
requirements to all employees.
Enable our employees to give their full commitment to excellence by having a full
understanding of QMS and how their individual actions affect its success.
Establish and maintain a working environment that encourages the delivery of
quality workmanship through orientation, training, job preparation and safety
awareness.
Provide service that meet specified requirements or objectives as established at
the Management System Review, Quality Review, Marketing Review, and
Contract Review Meetings.
The details of the processes with respect to the scope of the Project are
discussed ahead with references of MCCL Quality Manual.
4.2. Responsibility
4.2.6. In the event that processes, which affect product conformity, are outsourced,
Quality Assurance via Supplier Quality establishes and implements the necessary
controls for approval processes to ensure conformance to specified requirements.
These implemented controls however do not absolve MCCL from the responsibility of
providing services that meet customer requirements.
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4.3.1 General
The MCCL has established the following documentation for its quality management
system:
Records
o Test Certificates.
o Non-Conformance Reports.
o Approved Subcontractors/Suppliers.
o Personnel Qualifications.
o Calibration Certificates
The MCCL has established a Quality Plan for the Jubail Export Refinery Project
(Package 9). The Quality Plan identifies the scope of the Quality Management System,
and any exclusion to the requirements of ISO 9001:2000 and Schedule Q. It includes
procedures and documents covering work activities. It includes a description of
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sequences and interactions of processes that fall under the scope of the quality
management system.
4.3.3. Exclusions
The Engineering design Phase, a part of the ISO 9001-2000 QMS, is not incorporated in
this Project Quality Plan, because the design responsibilities lies with the main
contractor DPL.
4.3.4.2. General
The Quality Plan, referenced procedures and Inspection & Test Plans are controlled
documents. The Quality Manager is responsible to ensure the initial issue and
subsequent changes are acknowledged by those authorized to receive the Quality Plan.
A documented procedure has been established to control documents required for the
Quality Management System. Project documents shall be maintained at the following
Locations;
Access to these files shall be limited to the senior management, the Project Manager,
the Quality Manager and persons authorized by the Project Manager/Quality Manager.
Only the latest authorized issue of project documents shall be available for use by
contractor personnel. Documents not authorized for use, voided documents shall be
marked “SUPERSEDED“ in red and placed in a separate folder meant for the purpose to
avoid the use.
All documents transmitted through DPL to SATORP for review shall use a transmittal
form which identifies the item transmitted and the action to be taken by SATORP. The
document status shall be updated based on transmittal information.
The Quality Assurance Manager is responsible for reviewing the contract and identifying
submittals and deliverables to be transmitted to SATORP through DPL. For this purpose
a submittal/deliverable log shall be maintained in accordance with the schedule Q of this
contract.
Controls shall be established in accordance with the requirements of SATORP in order
to track the status of any item on the list that requires authorization or approval. These
items shall not be released until approved or authorized.
A copy of the approved quality plan, procedures and Inspection & Test Plans for
SATORP use shall be available at all locations where work is undertaken for this project.
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Documents issued for construction will be approved by qualified and authorized
individuals as required by the contract.
4.3.4.3. Responsibility
The Project Manager is responsible to review all project documents for conformance to
the contract prior to submitting to SATORP through DPL. This review shall be indicated
on each item by imposing the company stamp and the signature of the Project Manager.
As-built documents shall be maintained by the Project Manager at the Site Office and
will be kept in the MCCL record room after the completion of the project. An index of as
built documents shall be maintained as part of the file. All documents shall be verified for
accuracy by the Quality Manager and finally by the Project Manager and shall be
transmitted to SATORP through DPL by the Project Manager at the end of the project.
Overall responsibility for planning and control of the document control system shall be
assigned to the Quality Manager.
The Technical Staff shall be responsible for the registration and distribution of contract
specifications, contract drawings and approved shop drawings.
The Technical Staff shall be responsible for the submission of the request for change or
clarification to the client.
4.3.4.4. Procedure
o Contract Specifications
o Contract Drawings
o Approved Shop Drawings
o Project Quality Plan
o Loss Prevention Plan
o As-Built Drawing
Registration shall include recording the following information relating to the document:
o Drawing Register
- Contract Drawings
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- Approved Shop Drawings
Each recipient shown on the distribution list shall be responsible for removing
obsolete drawings from the point of use.
One copy of the obsolete document shall be kept in a master set maintained by
the Quality Assurance Manager.
The Quality Assurance Manager shall carry out a monthly check of MCCL
drawing register using the most recent approval register from the DPL/SATORP.
MCCL shall maintain records to support and substantiate all planned activities related to
the Quality system.
These records will provide objective evidence to the SATORP that the quality of the
Project is in accordance with the specified requirements.
The originals of all records pertaining to the acceptance of permanent project works shall
be transmitted to the SATORP through DPL as soon as practical, following the
completion and acceptance of the work. MCCL shall only retain copies of the records
generated.
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4.3.5.2. Responsibilities
The Quality Assurance Manager shall plan, establish, and maintain a filing system for
the collection and preservation of the documents generated by the quality system.
MCCL records, that provide evidence of conformance to requirements and of the
effective operation of its quality management system shall be identified, stored,
protected, and retained. Retrieval shall be controlled. The QA Manager is responsible for
identifying the records to be retained, retention time, disposal method, and for arranging
for their protection and controlled retrieval.
4.3.5.3. Procedures
Documents shall be generated in compliance with the activities described in the Project
Quality Plan. These documents are termed the quality records and shall be retained and
filed for the use of MCCL, DPL and the SATORP only.
The Quality Assurance Manager shall collate and maintain the Quality Records in an
indexed readily accessible filling system.
Project records shall be stored in safe filing cabinet to prevent damage or deterioration
and to prevent loss. Only copies being used for the day-to-day reference/work purpose.
Records shall be stored in chronological order commencing with the oldest and
progressing through to the most recent.
The Quality records to be collected and stored shall include the following:
o Test Certificates.
o Non-Conformance Reports.
o Audit Reports
o Approved Subcontractors/Suppliers.
o Personnel Qualifications.
o Calibration Certificates
The filling system shall be established and maintained in the following format:
A. General Files
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a) Test Certificates
d) Correspondence
5. Management Responsibility
The top management of MCCL is committed to the development and improvement of the
quality management system by:
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The MCCL Management ensures that procedures for determining and meeting SATORP
requirements and standards are established and implemented. MCCL ensures SATORP
satisfaction by:
In time completion of every activity of the project as per the approved project
schedule.
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The MCCL has the following policy regarding the quality of the goods and services we
offer to our customers.
&
“TO MAINTAIN AND CONTINUALLY IMPROVE THE EFFECTIVENESS
OF OUR QUALITY MANAGEMENT SYSTEM.”
5.4 Planning:
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Meeting our safety targets (measured by accident reports).
Meeting our quality targets (measured by the no. of NCRs)
As well, our operating objective for this project is to be focused on the following
Contract Requirements
SATORP Standards
Resource Allocation
Quality Control
Cost Control
Schedule Control
Continual Improvement
The objectives are measurable, consistent with policy, relevant to the successful
completion of the project, and attainment of objectives is considered as part of our effort
for improvement.
The elements that comprise the quality planning process are this Quality plan, Inspection
& Test Plans, project organization 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 this quality plan (reference
paragraph 5.6 Management Review and 8.4 Measurements and Monitoring).
In the first and the third quarter of the year, the Management Representative calls for a
meeting of the Department Heads with the purpose to review, coordinate and plan the
efficiency and effectiveness of the Quality Management System and the realization of
established quality objectives of the departments, as well the coordination of
improvement opportunities.
The output of these planning activities includes the identification of required resources.
As appropriate, results from audits of the Quality Management System are considered.
Planning activities are documented and are consistent with other requirements of the
Quality Management System.
It is the responsibility of the Management Representative to ensure that resulting
organizational changes and their consequences are identified and defined, that changes
resulting from planning activities are coordinated and implemented in a controlled
manner, that changes to the Quality Management System are documented,
implemented and approved, and that the Quality Management System is properly
maintained during these changes.
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The QA Manager shall have organizational authority at least to that of the line managers
responsible for the execution of the work. All QC personnel shall functionally report to
the QA Manager. While assigned to the project, quality personnel shall be dedicated to
the work described in Schedule Q and perform no other function on this project.
Effective internal communication is essential for the proper functioning of the Quality
Management System. The Quality Assurance Manager, with the assistance of the
Project Manager, ensures that required communication and information between
different sections of the project is defined in documented procedures, memos, forms
and/or documents, and staff meetings. Any communication problem regarding the
Quality Management System is reported to the Management Representative for
corrective action.
The QA Manager ensures the processes of the quality management system and their
effectiveness are communicated throughout the project team by conducting the in house
quality meetings and distribution of audit reports, management review procedures and
work instructions.
5.6.1 General
The MCCL top management conducts a formal meeting after every six months to
discuss and review the continuing effectiveness and adequacy of the Quality
Management System. This is a planned affair and shall be informed to the
DPL/SATORP in advance in order to have their representation. The review includes the
evaluation of the need for changes to the Quality Management System, the Quality
Policy and quality objectives, as well as the assessment of improvement opportunities
based on the review and analysis of performance trends, achievement of quality
objectives and customer satisfaction, and the cost of poor quality.
This review covers all clauses of the Quality Management System. As required,
Department Heads, Project Manager and employees are invited to attend the meeting
when issues of his area of responsibility are discussed.
The Management Representative, with the input from management, prepares the
agenda of upcoming meetings, ensures that the required data and documents are
available for management review, writes the minutes of the meeting and informs results
to the Department Heads and individuals concerned and follows-up on required actions
resulting from these meetings. Management is kept informed on the status of follow-up
activities. Records of management reviews are maintained.
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The following topics will be reviewed during the meeting in addition to the agenda
proposed by the Quality Manager/Management Representative.
As a minimum, the following inputs are to be considered for at least one meeting after
every six months:
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statistical results of operational performance, based on the analysis of collected
data, which includes:
o customer complaints
o suppliers performance
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6. Resource Management
The 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 DPL
satisfaction issues are provided in a timely manner.
6.2.1 General
The MCCL shall assign personnel to the project in accordance with Schedule Q that is
competent on the basis of applicable education, training, skills, and experience. All
personnel assigned to this project shall meet the minimum qualification and experience
levels specified in Schedule Q.
The QA 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 shall be submitted to
SATORP through DPL for review and approval at least two weeks prior to the start of the
work. All procedures and personnel qualifications for special processes shall be
submitted 30 days prior to the start of work.
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MCCL shall 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
sixty days.
MCCL planned staffing levels shall comply with the SATORP approved quality plan.
Reduction from required level of quality personnel specified in Schedule Q shall require
SATORP written approval.
Anticipated changes in personnel due to vacation, temporary assignments or
resignations shall be advised to DPL/SATORP 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.
The MCCL has developed position descriptions for those personnel performing
activities affecting quality that identify competency requirements. QA Manager
maintains the latest issue of position descriptions.
The Q/A Manager is responsible to identify training needs and assure training is
performed. Personnel lacking required competencies shall receive training such
as formal, informal, or on-the-job. MCCL will provide training as deemed
appropriate to satisfy competency needs or utilize external training sources.
MCCL shall evaluate the effectiveness of the training through periodic internal
audits, review and analysis of employee generated errors, omissions, rework
and nonconformities.
MCCL employees and sub-contractors shall be made aware of the project quality
requirements and how their work activities contribute to the achievement of
quality objectives. It can be achieved by the following practices
Quality Awareness Presentations
Project Kick off Meetings
Project Position Description
Project Organization Chart
News Letters
Toolbox Meetings
Performance Evaluation
6.3 Infrastructure
The MCCL provides a work environment suitable for it to achieve its business objective
and satisfy project requirements. A proper site office shall be established along with a
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DPL PMT office equipped with all the necessary fixtures and equipments considering the
safety and quality requirements of SATORP. The workstations shall also be provided for
the MCCL site office. The MCCL is committed to provide a very congenial and safe
working environment at the project site for its employees.
7. Project Execution
The quality objectives for the (procurement, construction activities, etc.) are identified in
the Schedule Q. The documentation, resources, and facilities shall be established for
this project. (Reference paragraph 4.3. and 6 of this quality plan).
Verification and validation are incorporated into the planning process by considering the
acceptance testing, planned inspections, approvals.
Acceptance criteria for the work will be developed where appropriate.
Records attesting to conformity of process and resulting Work shall be maintained by
Manager Quality Assurance. Records include:
Inspection reports and certificates
Disposition reports
Internal quality audit results and closures
Records of management reviews
The MCCL will review the contract agreement to determine DPL/SATORP requirements.
The Group Commercial Manager will evaluate these requirements and determine any
additional requirements including regulatory and legal ones, which may not have been
identified by the DPL, and need to be implemented to support the delivery of the Work.
The MCCL has assigned the responsibility to review the contract to the Technical
Manager. The Technical Manager shall ensure that the requirements are understood,
and that we have the capability of performing the work. The contract shall be reviewed
by Director Projects to ensure any agreed-to changes have been incorporated. The
review shall be documented and records maintained.
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The Project Manager is responsible to establish and maintain communication with the
DPL representative regarding procurement, inspection, or construction/ pre-
commissioning activities. This can be achieved through weekly progress meetings and
written correspondence.
The Project Manager is responsible for evaluation of DPL feedback/complaints and
responding to them.
7.4. Purchasing
The Manager Quality Assurance is responsible for the effective and efficient operation of
purchasing functions and activities and will be assisted by the Material department of
MCCL.
Where subcontractors and suppliers are engaged to work on this project, their capability
to perform the assigned scope of work is evaluated by the Manager Quality Assurance in
accordance with Schedule Q. Physical surveys, when needed shall be performed by a
qualified auditor and supported by a technical specialist for the equipment under
consideration. Except as provided in Schedule Q, evidence of qualification of
subcontractors and suppliers shall be provided to DPL/SATORP.
Records of subcontractor and supplier performance shall be maintained by Supervisor
Procurement Quality Control.
Subcontractors and suppliers with a record of poor performance shall be excluded from
future consideration. Evaluation criteria are defined. Evaluation of subcontractor and
supplier performance shall take place on a quarterly basis. The Supervisor Procurement
Quality Control is responsible to follow up on identified areas of poor performance.
The data describe and identify clearly the product to be ordered, requirements for the
SATORP approval of product, procedures, processes and equipment, statutory and
regulatory requirements, requirements for qualification of personnel, and Quality
Management System requirements, as applicable. As appropriate, standards or other
documents are referenced. The adequacy of specified purchase requirements is
ensured prior to submission to the supplier.
In accordance with Schedule “G” of the Contract, 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 shall be reviewed by Manager Quality Assurance for
technical and quality requirements prior to submitting to DPL for review.
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In accordance with JER Form SA-175, work preformed by the suppliers and sub-
suppliers shall be reviewed for conformance to contract requirement and accepted by
Manager Quality Assurance and documented.
He is responsible to ensure that the equipment and materials ordered for this project
under this contract meet contract requirements and are delivered on time. The following
steps shall be taken to ensure that the suppliers are capable of providing appropriate
items:
Supplier suborders shall be reviewed for conformance to the original purchase
order requirement and document.
The manufacturer/supplier quality program in accordance with ISO 9001:2000
shall be verified by Manager Quality Assurance.
Manufacturer/supplier capabilities to supply items that meet technical
requirement in a timely manner shall be evaluated. Once fabrications starts,
progress shall be reported on a weekly inspection/fabrication status report to
DPL.
Detailed Inspection and Test Plans for all equipment and material with Inspection
Levels 2, 3, or 4 per “JERER-1972” shall be prepared by Suppliers and submitted
to SATORP with the Inspection Assignment Package three weeks prior to start of
fabrication.
Applicable supplier process control procedures (i.e., welding, heat treatment,
NDT, refractory installation, PMI) shall be reviewed by Manager Quality Control
and submitted to DPL as required.
Equipment/material delivered for use on the project shall be inspected by QC
Inspector at the supplier/sub-supplier facilities in accordance with JERER 1972.
Rejected material shall not be allowed to ship. When no Form JER-175 exists,
material shall be inspected upon receipt at site. Non-conforming material shall be
returned to originator or marked in a manner that shall prevent its use.
Records of supplier inspections shall be prepared following each inspection or
weekly for resident inspectors and submitted to DPL per Schedule Q.
Inspection Disposition Reports shall be prepared within two weeks following
release to ship material and submitted to DPL.
The MCCL has established the following controls applicable to construction and
construction management activities. These activities are reflected in the detailed
Inspection and Test Plans along with the quality procedures and shall be submitted to
DPL/SATORP for approval prior to the start of the subject activity.
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.
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Methods are employed to monitor resource expenditure against expected results.
Procedures, work instructions, and/or installation instructions are available to the
workforce.
Codes, standards and other references, including portions of the contract are
available to the workforce.
Standards of workmanship are implemented.
Where required, licensed or certified personnel are assigned to the project to
perform activities requiring such license or certification.
A program to monitor the effectiveness of these process controls is in place and
implemented.
Criteria for release, approval, and acceptance are established.
The validation of the design is the constructed project that satisfies the SATORP
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
Heat Treatment
Nondestructive testing (NDT)
Structural concrete placement
Concrete and Asphalt Mix Design
Coating
Bolt tensioning
Pipe work
The MCCL assures these processes can achieve planned results through
Process qualification
Equipment and personnel qualification
Defined methods and procedures
Records shall be maintained and revalidation performed as necessary.
The MCCL shall 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 (Reference paragraph 4.3.4. of this quality plan).
MCCL shall develop and maintain a system to identify construction materials and
equipment to the extent required by the contract or applicable codes and standards.
Nonconforming material shall be identified or removed to prevent inadvertent use. For
this contract, the following shall be included:
Tagging
Placement of Non conforming material at a separate place
Information regarding such material to the workforce at the project site.
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There is no data, material and equipment provided by SATORP for this project.
MCCL shall plan and implement a system on this project to ensure that material storage,
handling and preservation is controlled to present misuse, damage, deterioration or loss.
The Procurement supervisor is responsible for this activity. Equipment suppliers shall be
requested to provide storage and preservation procedures for purchased equipment.
The Quality Assurance Manager shall ensure that special handling, storage and
preservation requirements are included in the subcontract documents/purchase orders.
The Quality Assurance Manager shall check that special handling, storage and
preservation requirements are included in the subcontract documents/purchase orders.
The Supervisors shall be responsible for monitoring the routine handling, storage and
preservation techniques required ensuring that these activities do not contribute to the
misuse or deterioration of components and materials. Where necessary the Non-
Conformance Report shall be issued by the Quality Assurance Manager.
MCCL shall 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 shall 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 shall be based on the
most stringent of SATORP standards, other applicable standards, or
manufacturer recommendations. If no standards apply, the calibration cycle shall
not exceed six months.
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To ensure accurate and reliable monitoring and inspection results at this project, the
Quality personals ensure that monitoring and measuring equipment and devices are
controlled, calibrated and maintained.
The type of monitoring and measuring equipment/device/software to be used and the
required accuracy of these monitoring and measurement activities are defined during
quality planning and specified in the specifications plan, process traveler and/or
inspection reports. It is the responsibility of the applicable department to ensure that
monitoring and measuring processes are capable for their intended purpose and are
performed in a manner that is consistent with requirements.
To ensure valid results, measuring equipment is
In the event that monitoring and measuring devices are found out of calibration, previous
measuring results are reviewed regarding their validity. Corrective action on the
measuring device or product affected is taken, including recall of nonconforming product,
if required.
Prior to the use of computer software for monitoring and measuring activities, it is
verified and confirmed that the software produces defined results. Records of these
verifications are maintained.
8.1 General
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develops and distributes quarterly statistics. These statistics are analyzed by
Department Heads and corrective and preventive action for the continual improvement
of the Quality Management System is taken as appropriate. The focus of their analysis is
on the following:
The MCCL 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 shall be scheduled based on requirements in Schedule Q.
The schedule shall be transmitted to the DPL 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 shall be generated and issued to affected
departments. Company management and DPL shall receive copies of
report within two weeks of audit completion.
Corrective action shall be monitored and brought to a close.
Follow-up internal audits shall be conducted as appropriate, to ensure
implementation of corrective action, and the results reported to Company
management and DPL.
The activities of subcontractors working under this quality management system
will be included in the audit program.
Following the established documented Internal Quality Audits, the Manager Quality
Assurance is responsible for internal audits. Internal audits are planned and scheduled
in such a way that all applicable clauses of ISO and other additional quality system
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requirements are audited regarding compliance with this implemented Quality
Management System and ISO.
Records of internal audits are maintained. As appropriate, management is informed of
the results of audits and follow-up audits and takes additional corrective action. The
Management Representative ensures that audit results are part of Management Review.
MCCL shall establish, maintain, and implement a program to control the development,
review, and release of designs that are in conformance with SATORP requirements. The
program shall be controlled by written procedures, instructions, or checklists as
appropriate. Results shall be recorded, authenticated, and distributed in accordance with
written procedures.
To verify process capability and provide additional input for process control, the quality
planning team arranges for the monitoring of construction processes. Results are
documented and include instructions for production processes, verification and
maintenance as well as objectives for production process capability, reliability,
maintainability and availability.
Product ensures that processes are implemented according to control plans and other
applicable procedures or documents in order to ensure that process capability and
process performance is maintained according to customer part approval process
requirements.
Control plans and process flow diagrams are implemented, including adherence to
specified measurement techniques, sampling plans, acceptance criteria and reaction
plans. It is the responsibility of construction quality control to monitor process capability
and to ensure that process capability and performance is according to applicable control
plans. In case of nonconformity of processes, defined reaction plans are followed.
Important events that are occurring during construction, such as down times are
recorded. If identified characteristics on the control plan become unstable or non-
capable, the applicable reaction plan is followed. If appropriate, these reaction plans
include containment of produced parts or products and 100% inspection. Corrective
action is taken as per established procedure in order to restore required process
capability and product quality. If required, these corrective action plans are reviewed with
and approved by the customer. Effective dates of process changes are documented by
Manufacturing.
During construction QC Inspector shall inspect the quality of the construction effort
through regular inspections of the work in progress, as agreed to in the respective
Inspection and Test Plans, approved by DPL. Activities shall be recorded via inspection
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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. Manager Quality shall notify DPL by initiating
Requests for Inspection (RFI) for all inspection points coded as Witness or Hold. All test
results shall be documented on forms appropriate for the tests, and dated and signed by
the test personnel. Results shall be issued as required by the contract.
MCCL has a program to detect and correct nonconforming conditions in relating to work
output of its own staff or others under contract to the MCCL.
Any nonconformance discovered by outside sources shall be processed by Manager
Quality Assurance. All procurement and construction nonconformities shall be
documented in written form by Manager Quality Assurance and tracked to closure.
Documentation shall be a nonconformance report. The purpose of this procedure is to
provide a vehicle for the resolution and correction of any items, procedures, materials, or
equipment identified as not conforming to Project Documents.
All Project Staff employed by MCCL shall be responsible for the identification of
items, procedures, materials, or equipment not conforming to
contract/subcontract documents.
The Project Manager shall be responsible for assigning the responsibility for
action to correct the non-conformance once the corrective action, as submitted
has been approved.
In the event of an issuance of an NCR the supervisor in-charge of the area work
will take the responsibility for the corrective action, which will be reviewed and
verified by MCCL QA/QC and DPL.
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Upon receipt of the Non-Conformance Report with an approved resolution, the
Project Manager shall issue instruction to implement the required corrective
action.
8.8. Improvements
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Nonconformities and deficiencies are analyzed; root causes are determined and
required action is taken or recommended as appropriate.
As required and/or decided by management, selected Quality Improvement Proposals
are referred to the Quality Planning Team for review regarding their feasibility and
benefits.
The planning, coordination and control of activities for continual improvement is the
responsibility of the Management Representative and the Quality Team. Continual
improvement activities include – but are not be limited to – the following:
Customer Satisfaction
Evaluation of suppliers
The objectives of the corporate Quality Policy are taken into consideration for planning of
improvement. During Management Reviews, the effectiveness of continual improvement
is reviewed and opportunities for improvement are identified.
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8.8.2. Corrective Action
The MCCL 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.
It is the responsibility of the Project Manager to implement and maintain the documented
procedure Corrective Action that defines a corporate approach for corrective action.
Following the established procedure for corrective action, nonconformities are identified,
root causes are determined, corrective action is evaluated and defined, recurrence of the
nonconformity is prevented, corrective actions and their results are recorded, and the
effectiveness of corrective action taken is reviewed. Corrective actions are appropriate to
the importance and impact of the addressed nonconformity.
It is the responsibility of the Manager Quality Assurance to inform the management of all
customer complaints and related corrective actions and he shall also establish and
maintain records of corrective actions and their results.
It is the responsibility of the Manager Quality Assurance to implement and maintain the
documented procedure Preventive Action that defines a corporate approach for
preventive action to prevent the occurrence of potential nonconformities, deficiencies or
problems. Any employee can suggest a preventive action to the Project Manager by
initiating a Preventive Action Report.
The process of preventive action includes the following steps:
Project Manager analyzes and evaluates data of statistics and performs periodic reviews
of procedures in order to detect deficiencies and problems and to take preventive action
as required.
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It is the responsibility of the Manager Quality Assurance to establish and maintain
records of preventive actions and their results. The Management Representative
ensures that relevant information on preventive action is on the agenda of management
reviews.
END OF DOCUMENT
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PROJECT MANAGER
PROJECT MANAGER
QUALITY CONTROL
QUALITY CONTROL
MANAGER
MANAGER
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