Project Quality Plan

PROJECT: Replacement of POM Screw Conveyor

CLIENT: SABIC IBN SINA

PR No: 5500383915

00 08-08-2021

REVIEWED BY APPROVED BY
REVISION DATE
Client Client

Uncontrolled if Printed
 Doc. No. ABIS/PQP-01
Page 2 of 25
Project Quality Plan Rev.00
Date:08/08/2021

Table of Contents

1 PURPOSE 3

1.1 Scope 3

2 DEFINITIONS / ABBREVIATIONS 4

3 PROJECT INFORMATION 4

3.1 Contract Information 4

3.2 Project Objectives 5
3.3 Project Scope & Special Requirements 5
3.4 Codes, Standards and Specifications 5
3.5 Reference 5

4 PROJECT MANAGEMENT 5

4.1 Project Organization, Roles and Responsibilities 5

4.1.1 Project Organization Chart 5

4.1.2 Roles and Responsibilities 5
4.1.3 Responsibility, Authority and Communication 5
4.1.4 Authority and Responsibility 5
4.1.5 Subcontractor / Vendor 6

4.2 Project Kick off Meeting 6

4.3 Project Execution Methodology 6
4.4 Pre-Mobilization 6
4.5 Project / Site manager is responsible to: 7

4.5.1 Project In charge 7

4.5.2 I/C Planning Responsibilities 7
4.5.3 I/C QA/QC Responsibilities 8
4.5.4 I/C HSE responsibilities 8

4.6 Quality Objectives 8

4.7 Monitoring and measurement of Construction Processes 9
4.8 Monitoring and measurement of work 9
4.9 Analysis of Procurement 9

5 Project Management Processes 9

5.1 Planning and Scheduling 9

5.2 Communication 10
5.3 Documentation 10

5.3.1 Document and Data Control 11

5.3.1.1 PQP Revision 11

5.3.1.2 Control of Documents 11

5.3.2 Control of Quality Records 14

5.3.3 Documents from Project Team to IBN SINA 15

Uncontrolled if Printed
 Doc. No. ABIS/PQP-01
Page 3 of 25
Project Quality Plan Rev.00
Date:08/08/2021

5.4 Resource Management 15

5.4.1 Manpower Mobilization & Training 15

5.4.2 Training and Education 15
5.4.3 E&P Mobilization and Maintenance 16
5.4.4 Material Handling 16
5.4.5 Control of Monitoring and Measuring Devices 17
5.4.6 Project Site Facilities (PSF) 17
5.4.7 Work Environment 17

5.5 Internal Quality Audit 17

5.5.1 Audit Schedule 18

5.5.2 Audit Preparation 18
5.5.3 Audit Execution 18
5.5.4 Audit Reporting 18
5.5.5 Corrective Action 19

5.6 Control of Non-Conforming Product 19

5.7 Corrective and Preventive Action 20

5.7.1 Corrective Action 21

5.7.2 Preventive Action 22

5.8 Management Review 22

5.8.1 Review Input 23

5.8.2 Review Output 23

5.9 Procurement 23

5.9.1 Requests for Quotations 23

5.9.2 Bid Evaluation 23
5.9.3 Purchase Orders Placement and Follow-up 23
5.9.4 Inspection and Testing 24

5.10 Statistical Techniques 24

5.11 Health, Safety and Environment 24

5.12 Project Windup 25

5.12.1 Demobilization of Equipment’s & Tools 25

5.12.2 Manpower Demobilization 25
5.12.3 Project Wind-up Report 25

6 Associated Documents 25

Uncontrolled if Printed
 PROJECT QUALITY PLAN
1 PURPOSE

This document details ABDULLAH A. AL BARRAK & SONS CO. and now onward (will be
used ABIS) commitment and plan to ensure project deliverables to the customers in a
systematic and planned manner as per company’s project management know how,
policies, systems, standard procedures, and internationally recognized best practices.
The document provides project core team the necessary framework to meet its internal
and external business needs. However, processes may be supported by IBN SINA
specific documents, if desired, super ceding company’s standard operating procedures.

The plan will be complemented by the following:

 Procedures approved by IBN SINA.

 Method statements approved by IBN SINA.
 Inspection test plan (ITP) approved by IBN SINA.

1.1 SCOPE

The intent of this Quality Plan is to construct as per scope of work and shall be carried in
accordance with IBN SINA, Project Specifications, Procedures and all applicable
regulatory requirements and which are used for the following purpose.

 To provide guidelines to all construction project team for the method of execution
and control of the work.
 Identify & define responsibilities of site key personnel.
 Ensure and to communicate the essential project quality plan requirements to
personnel working on site.
 To define the quality organization, and in particular inter-relationship with
subcontractors.
 To ensure that all Inspection Test Plan (ITP) are in place and utilized, as they
apply throughout all phases of the project.

The Project Quality Plan is to ensure that as per scope of shutdown/ project activities are
carried out in accordance with the approved standard Issued for Construction (IFC)
drawing, IBN SINA Specifications and relevant standards as required.

Detailed Project Instructions/Method of Statements pertaining to all categories of work

shall be prepared prior to the start of the work activities and support the requirements of
this plan. The project / SD specific procedures will be submitted to IBN SINA for approval
prior to start of work.

2 DEFINITIONS / ABBREVIATIONS
PM Project Manager
CAR Corrective Action Request
HRD & ADMIN. Human Resource Development & Administration
ITP Inspection & test Plan
MS Method Statement
PSF Project Site Facilities
NCR Non-conformance reports
PAR Preventive Action Request
PQP Project Quality Plan
QA&QC Quality Assurance & Quality Control
HSE Health, Safety and Environment
SOP System Operating Procedure
DC Document Controller
PH Project Head
I/C In charge
QE Quality Control Engineer
QMR Quality Management Representative
SHPD Shop Drawings
DISGD Design Drawings

3 PROJECT INFORMATION

3.1 Contract Information (As per Project)

Contract Title: Replacement of POM Screw Conveyor

Project Start: 15 September 2021

Project Completion: 30 September 2021

Contract Period: As Applicable

Customer: IBN SINA

Owner: SABIC

Project Location: Jubail, KSA

3.2 Project Objectives

To achieve customer confidence, support and participation for promotion of quality

culture, ABIS has established a set of objectives, which are measurable and consistent
with the Quality & HSE policy. Here is mentioned some of objective

 To execute the project with ZERO DEFECT/ REWORK.

 To execute project with ZERO LTI (Lost Time Injury)
3.3 Project Scope & Special Requirements

As per Project Scope and specification

3.4 Codes, Standards and Specifications

Client Specifications
Reference DWGs (Provided by client)
ASME Sec II Part A, B for Ferrous & Nonferrous Materials Selection
ASME Sec V for NDE (Non-Destructive Examination)
ASME Sec IX for Welding Procedure & Welders Qualification
API-510 In-service Inspection, Repair & Rerating of Pressure vessel
API-570 In-service Inspection, Repair & Rerating of Pressure piping

3.5 Reference

ISO 10005:2005 Quality Management – Guideline for Quality Plans

ISO 9001:2015 Quality Management Systems – Requirements
ISO 9000:2015 Quality Management System – Fundamental and Vocabulary

4 PROJECT MANAGEMENT
4.1 Project Organization, Roles and Responsibilities

4.1.1 Project Organization Chart

Project specific organization chart has been developed showing position, functional
responsibilities, reporting channel and interfaces.

Please refer to Project Organization Chart (See Appendix-01)

4.1.2 Roles and Responsibilities

The roles and responsibilities of key personnel within the project are described in the
respective project specific JDs.

4.1.3 Responsibility, Authority and Communication

4.1.4 Authority and Responsibility
This Shutdown shall be under the administrative control of an assigned Project Manager
who shall be responsible of all aspects of the contracted work scope up to final
acceptance by the IBN SINA on achievement of agreed targets.
The Project Management Team is obligated to meet and satisfy the quality requirements
of the project and to implement in letter and spirit, to the requirements of the approved
PQP.

The ABIS Project Manager is responsible for maintaining the Project Organization Chart.
Project Manager shall act as Site manager, in addition to his routine charge, as well,
while at site and as such, shall keep constant surveillance and control over all of the
activities, going on at site, including Quality Assurance and Quality Control.

Project Manager shall also be responsible to ensure that Project In charge as well as
Quality Control Manager working at shutdown is functioning in line with Project and IBN
SINA’s Specified and scheduled targets and specifications.
Client satisfaction shall be the goal of the Project Manager who shall direct his Project
Team in such a manner that this requirement is installed in the minds of every member of
the project organization.

Supervisory staff shall be selected for their knowledge and experience. The ability to both
control and advise subordinates on matters associated with their discipline is paramount,
as is the need to instill and guide towards a Total Quality Philosophy.

Employees who require to have defined skill levels shall be judged competent by a
process of selection, which shall take cognizance of education, qualification and
experience in their skill discipline.

4.1.5 Subcontractor / Vendor

Any company that provides Material or subcontracted services to the project shall be
subject to the same controls that are imposed on ABIS’s own activities. Where
appropriate, or contractually required, these shall be proposed for IBN SINA approval in
accordance to Project Contractual requirements.

4.2 Project Kick off Meeting

The project kick-off meeting is the first meeting with the project team members to discuss
the project scope of work. In this meeting base element like project scope, costs,
schedule, project administration, meetings plan, communication plan, etc. are discussed,
members of the project team are introduced, and key role of each team member is
discussed.

4.3 Project Execution Methodology

ABIS Execution Methodology guides a project from inception to completion. Upon project
award an experienced project manager is assigned by ABIS Project Manager to lead the
project. The project manager assembles the project team and an internal kick-off meeting
is held. This meeting allows the transfer of project knowledge from project manager to the
project team.
The project team reviews the execution philosophy to improve project margin keeping in
view subcontracting work packages, execution scheme, hiring or purchasing of
equipment and plant, better mechanization of work to enhance the efficiency. The project
specific quality plan and project specific documents are prepared and submitted for
customer review and final approval. During the SD / project execution IBN SINA is offered
for stage inspection and corresponding documents will be signed and at the end of
project QA/QC dossier is submitted.

4.4 Pre-Mobilization

The period between award of the project and its starting date is called the pre-
mobilization period. The project team shall start working on various activities in parallel so
as to achieve timely commencement of direct work. Project Manager shall support to
Project Manager in process of Pre-mobilization.

4.5 Project Manager is Responsible For:

 Careful study of contract agreement for all the technical, commercial and legal
issues identifies the risks involved and mitigates and administers them. He will
 consult with Bidding Manager for any assistance on contractual matters. If
necessary, PM will get additional information or clarification from the customer.
 Submit all necessary documentation in time, required to be submitted to customer
before mobilization as per contract requirement.
 Timely arrangement of resources.
 Keep in close touch with the customer for any exposition and change / waivers
required for the project.
 In the absence of Project In charge I/C planning will be responsible of the site.

The nominated Project In charge will assist Project Manager for construction related
activities.

4.5.1 Project In charge:

 Responsible for all aspects of successful site execution of a Project
 Responsible for identifying HSE Hazards in all activities under him, and
Subsequently minimizing risk for loss prevention. Wherever required, assistance
can be taken from HSE in this regard.
 Capable of project progress measurement at any given time and able to take
remedial measures whenever necessary in order to ‘pull' the project back on
schedule.
 Deals with the IBN SINA Management in a manner that enhances their trust in
the Company.
 Ensures good working relationships amongst all the discipline involved in the
Project and strives to maintain good moral of the construction team
 Ensures implementation of work schedules.
 Ensures that QA/QC & Safety Procedures are implemented.

4.5.2 I/C Planning Responsibilities:

 Revision of initial level-3 plan.
 Revision of project Organ gram.
 Mapping of Work Break down Structure (WBS) and Organization Break down
Structure (OBS).
 Prepare Material Requirement Plan.
 Determine BOQ and BOM from drawings.
 Preparation of Work Packages.
 Raise queries for clarification from customer.
 Highlight critical path, anticipate bottlenecks and mitigation of risks involved.
 Track changes in material delivery schedule.
 Calculate cost to complete the project.
 Follow up customer for drawings delivery schedule.
 Spool and Joint Marking on drawings.

4.5.3 I/C QA&QC Responsibilities:

 Prepare Project Specific PQP.
 Prepare Project Specific QIP’s.
 Prepare Project Specific documents related to QA&QC.
 Collect Codes and Standards relevant to the project.
 Arrange courses / training required to his team regarding project.
 Doc. No. ABIS/PQP-01
Page 9 of 25
Project Quality Plan Rev.00
Date:01/12/2013

 Ensure Instrument Calibration execution by accredited third party as and where

applicable.
 Ensure all NDE activities and qualification.
 Prepare and submit documents for QA/QC records.
 Prepare and submit documents for approval of material as per codes, standards
and project specifications. For instance, electrode / filler wire, surface preparation
/ protective coating, pipes, steel structure, civil and electrical & instrument items (If
any).

4.5.4 Section Head HSE Responsibilities:

 Prepare the HSE plan.
 Coordinate with procurement for (Personal Protective Equipments) PPE’s required
at site.
 Arrange courses and trainings if it is a contract requirement.
 Permit to work (PTW) system orientation.

4.6 Quality Objectives:

The Project Manager and Manager QA/QC of ABIS are totally committed for achieving
quality as per standard specifications and IBN SINA specifications.
The objectives of this Quality Plan are:

 To ensure that approved methods and procedures are in place and utilized, as
they apply, for Site activities.
 To ensure that quality requirements are determined and satisfied throughout this
phrase of contract performance, including, as applicable, Construction.
 To minimize scrap and rework during the Site Works.
 To comply with International & IBN SINA codes & standards.
 To demonstrate the fulfillment of IBN SINA requirements.
 To maintain an effective and economical program for quality, to satisfy IBN SINA
requirements as defined in Project Contractual Requirements/ (Quality Assurance
and Control, Inspection and testing).
 To ensure that approved practices, procedures, inspection and test are in place
and are being utilized, as they apply, throughout Site Construction phases of the
project from time to time.
 To provide for early and prompt detection of deficiencies and for timely and
effective corrective action.

4.7 Monitoring and Measurement of Construction Processes:

The monitoring and measurement of Construction Processes is made by the means of:

 Inspection of all incoming equipment for damage and for conformance to all
applicable requirements, including the supplier inspection release and verified
Material Test Reports (MTR). (if purchased by contractor)
 The Monthly Materials Procurement status report, which includes data concerning
receiving inspections. (Where Applicable)
 ABIS and ABIS’s subcontractor test reports. Review, witness and acceptance by
ABIS of all NDT test results performed by subcontractors and / or third parties
before submitted to the Customer.

Uncontrolled if Printed
 Doc. No. ABIS/PQP-01
Page 10 of 25
Project Quality Plan Rev.01
Date:01/12/2013

4.8 Monitoring and Measurement of Work:

Project Inspection Test Plans (ITP) has been addressed for ensuring that incoming
equipment and materials are inspected and accepted for project use prior to incorporation
into construction. All tests and Inspections shall be strictly overseen and monitored by I/C
QA/QC of Project.

4.9 Analysis of Procurement:

I/C Project Procurement with the coordination of project team contribute in a manner:

 Obtain the project budget w.r.t. material along with requirement schedule and
budgetary values for advance procurement planning; tapping sources of
procurement, obtaining rates and getting delivery schedules.
 Request for quotations from pre-qualified suppliers / vendors and evaluate
supplier/vendors based on supplier’s evaluation form. Coordinate with QC
representative for inspection.
 Issue Purchase Order to the selected supplier / vendor.
 Coordinate with finance department for release of payment to the suppliers /
vendors.

5 Project Management Processes:

ABIS provides a clear trajectory for efficient planning, scheduling, execution and variance
management of the systems, products and processes from start to the end of the project.
It contributes to a close grip on the project with respect to resource management,
communication and documentation throughout the project.

5.1 Planning and Scheduling:

To fulfill the needs of project stakeholders and to achieve quality in project management,
a realistic planning and scheduling is desired. A systematic approach is required to
achieve the project specified quality of deliverables with minimum/ no rework.

Primavera Project Planner is a useful tool being used worldwide to carry out effective
planning and scheduling. ABIS has trained personnel to carry out planning and
scheduling using Primavera.

Once the project is awarded, Level-03 plan is prepared based on Level-02 “Fit-for-
Purpose” plan prepared at proposal stage. In case there is difference in scope of work
and deliverables etc. between Bidding documents and the final contract documents, then
a new Level-03 plan is prepared keeping in view latest available information. Level-03
schedule covers all major activities (also called Cost Center) in each area / zone. This
plan defines Work Breakdown Structure (WBS), which will agree of IBN SINA. The
schedule will highlight the Critical Path and is resource loaded in terms of manpower and
Qty.

The Project Master Schedule / Direct work Execution Plan, and mobilization plan will be
developed and updated as per actual work done on the ground.
 Doc. No. ABIS/PQP-01
Page 11 of 25
Project Quality Plan Rev.01
Date:01/12/2013

5.2 Communication

Method Purpose Responsibility Frequency Audience

Publicly state the project is
Project Kick-Off Meeting Executive At the start of Executive
beginning. management project. management, project
manager, project team
Communicating project scope, and all parties
costs, schedule, project involved.
administration, meetings plan,
communication plan, etc.

Project status review Report status and progress of Project manager Monthly Project manager,
meeting scheduled milestones and functional managers,
activities. and concerned
supervisors
Identify and discuss problems
and solutions for project
obstacles.

Project team meeting Report status and progress of Project manager As needed Functional managers,
scheduled milestones and (weekly, and supervisors
activities. monthly,
Identify and discuss project quarterly, or
issues and corrective actions. ad hoc)

Customer and/or supplier Involve external customers and Project manager, As needed All concerned parties.
meeting suppliers in the project functional
managers

Correspondance (lettres, Document status of action All responsible As needed All responsible
faxes, emails, etc.) items, decisions made, and persons persons
problems encountered.

5.3 Documentation:

Project team has to interact with vendor /subcontractor head office, Suppliers and IBN
SINA. Proper documentation enables better communication of intent and consistency of
action. Various daily, weekly, monthly and annually reports are generated to ensure the
effective planning, operation and control of processes. Documentation spells in a two-way
channel and each side provides different documents to each other.

5.3.1 Document and Data Control:

5.3.1.1 PQP Revision
If significant changes occur, then Site Manager shall review the quality plan and discuss
with project manager. The PQP shall be revised and controlled by QA/QC department.

5.3.1.2 Control of Document

a) Responsibilities & Approval

All documents covered by this PQP shall be handled by the Document Controller/ QC
Engineer/ QMR. The Project Manager shall be responsible for overall control of
documents covered by this procedure.
All controlled documents must be reviewed & approved by competent authority as
defined below

Uncontrolled if Printed
Level Document Type Prepared by Reviewed Approved
By
L1 Quality Objectives Site In charge QMR PM / Client
Project Quality Plan/ QA/ QC In
L2 QE/ QMR PM / Client
Procedures charge
L3 Work Instructions QE/ QMR HOD PM / Client
QA/ QC System
L4 Quality Records / Forms QE/ QMR PM / Client
In charge

b) Controlled Document

 A Controlled Document is defined as a document which is part of Quality

Management System or the document which can affect Quality of the product
directly or indirectly and fall under the scope of the procedure of Document and
Data Control. All such documents require approval by the appropriate authority
before issuance and amendments can be made e.g. all procedures and forms.
 All controlled documents are identified by “Controlled Copy” at the footer part of
each page shown below as Figure (1).
 A register of holders of controlled documents is maintained and the holders are
advised and updated with any amendments issued.

Figure (1) “ Controlled Copy ”

c) Uncontrolled Documents

 An Uncontrolled Document is a document that does not come under the scope of
Document And Data Control Procedure or can not produce any effect on the Quality
of the product directly or Indirectly.
 The documents that are defined uncontrolled but are issued by Quality Management
System on understanding that are not maintained nor holders notified and can be
issued with any amendment. All such documents are identified as “ Uncontrolled
Copy” as shown below in Figure (2).
 The documents that are not defined as controlled can be photocopied.

Figure (2) “ Uncontrolled Copy ”

d) Obsolete Documents

 Obsolete Documents are documents that were produced and implemented during
the establishment of the Quality Management System but amended after some
time and have no value at present.
 All those documents would be considered obsolete which were issued for
execution of projects but amended after some time and not applicable any more.
 All Obsolete documents must be destroyed and should not be kept by any holder
other than QMR for reference.
 A stamps as mentioned in Figure (3) must identify all Obsolete documents.
 Figure (3) “ OBSOLETE “

e) Document Identification

Project Quality Plan

PQP-01

“PQP” stands for ABIS Project Quality Plan.

“01” is a unique number is given to each projects

Procedures

QSP-XX

“QSP” stands for Quality System Procedures.

“XX” is a unique number given to each procedure.

Form Identification Description

QRD-DD-XX Quality Assurance Record

Where, “DD” stands for Dept / Division name and “XXX” indicates unique record
# and “QRD” stands for ABIS Quality Record

External Origin Documents

QRD-EOD-XXX Quality Record-External Origin Document-001

Where, “EOD” stands for unique Project identification and “xxx” indicates the
unique # of the document.

f) Drawing Control
Planning section at site will control the drawings issued for construction. The client is
responsible for providing the drawings to planning section.

g) Filing

 The Document Controller DC/ QE/ QMR shall define and document a filing system
to enable rapid accessing of all documents under his responsibility.
 All files shall be clearly marked to show their contents.
 All filing closets shall be lockable. All documents shall be under surveillance at all
times during the working hours and kept locked outside working hours.
 Obsolete documents drawings are removed from files in circulation and filed under
special files until the end of liability period.
h) Document Distribution Control

 The QA/ QC Incharge shall approve all requests for any controlled documents.
 On approval of request, DC/QE/QMR arranges for necessary documents to be
copied and distributed.
 All controlled documents are issued and distributed by DC/QE/QMR.

i) Amendments / Revision Control

 All types of amendments and revisions in Documents / Forms are controlled.

 The QMR is responsible to distribute the latest versions of the Quality Documents
and to retrieve back the previous obsolete documents from the point of use.
 He keeps only one obsolete document stamped "Obsolete" for reference and
destroys others.
 In case of any change in any portion of a document, the whole document will be re-
issued and the issue # and issue date will be changed and all the changes in the
recent document will be underline for easy comprehension for the users. But when
another revision of the same document will be issued, these underlines contents
will not remained underline and new changes in the documents will be underlined.

Original Quality management system documents are maintained by QA/ QC

department in Head Office.

5.3.2 Control of Quality Records

 Maintenance of quality records is the responsibility of the concerned departments.
 The “List of Quality Records” shows the place of storage, the retention period, the
department responsible for retention and the method of disposition. Main quality
records shall be kept for a minimum period of one year form the end of the
concerned activity. Other records will be maintained until the end of the defect
liability period, by then they can be archived.
Please refer to Document Quality Record List (QRD-QS-03)
 It is the responsibility of the QA/ QC In charge/project manager/ site engineer/
department heads to identify their quality records along with their retention time.
Detailed list to be maintained, which must be filed in such a way to prevent loss or
damage and facilitate easy retrieval.
 To reduce the amount of retained hard documentation copies where space is
limited, each department responsible for document retention may use electronic
media. When doing so it must be ensured that unlicensed operations to quality
files are completely avoided.
 Where the contractual or customers expressed retention, period exceed those on
the disposition list of quality records, due note should be made on the files to
prevent
 early disposal. In addition, if contractually agreed, the customer will be afforded
the right of access to quality records for the stipulated retention period.
 Upon completion of an activity, all employees should ensure that quality records
are given to the appropriate person(s) so that they can be stored together with
other quality records as required. For each Project, the Site/Project Manager
(SPM) and the Site Discipline Engineers (SDEs) must ensure that the relevant
records, especially test and inspection records and completed quality plans, are
returned to the Central Unit for retention and archiving together with other records
that are generated on site and not held in the Central Unit files.
 No quality records should be removed or destroyed without the expressed
permission of the concerned department manager/SPM/SDEs controlling those
records. When quality records become due for disposal, checks should be made
with the QA/ QC In charge to ensure that no unusual circumstances require
further extension of the retention period.
 Handling, maintaining, and destroying quality records should always respect
company and customer reserved rights and confidentiality.

5.3.3 Documents from Project / TA Team to IBN SINA:

ABIS delivers and fulfills the documentation requirement of the customer that
commensurate with agreed contract agreement and customer specifications. Such as:

 Drawings & Documents

 HSE feed back
 QA & QC feed back
 Project Specific Method Statements
 CARs/PARs or NCR
 Progress Reports
 IBN SINA Supplied Material status.

5.4 Resource Management:

Core team of the project shall be selected out of the existing pool of staff and/or through
the external sources. Person with adequate experience shall be assigned as I/C
Mobilization.
Different craftsmen like technicians, fabricators, fitters etc. are selected through
interviews by the concerned area in charges / supervisors. Welders are selected through
welders’ qualification test conducted by QA&QC department in liaison with customer
according to the project specifications and applicable code.

5.4.1 Manpower Mobilization & Training:

Mobilization plan developed at the proposal stage is fine tuned to have an improved
mobilization.
5.4.2 Training and Education
 The minimum education, qualification and experience for process and
maintenance personnel selected by Project Manager.
 The Project In charge identify any possible training needs based upon information
derived from Informal discussions with individuals, difficulties encountered in
carrying out the task records generated, establish opportunities to improve
potential and optimize the contribution of employees, work records generated.
 Based on the above inputs along with the basis of employee’s responsibilities,
authorities, educational background, experience and performance the training
needs are identified, where the Quality division create annual Training Plan in
coordination with Operations department to address the training requirements,
including training session conduct Internally (In-House) , and/or by External body.

Please refer to Training Schedule (QRD-HR-02)

 In case of On-Job / Internal Training session, effectiveness of the training will be

evaluated by the Department Head or by the immediate supervisor of the trainee
which can be judged through his work performance or during the internal auditing
of his quality systems. If the effectiveness of the training is found not satisfactory,
then the assessor will inform his immediate supervisor/head of the department for
the root cause analysis and corrective actions.

Please refer to Training Evaluation Sheet (QRD-HR-03)

 In case of External Training session, effectiveness of the training will be evaluated

by the course result including qualification / merit certificates issued by the
external institute / supplier, wherever applicable.

 All training records for employees shall be kept for the whole duration of
employment of the respective plus one year with the HR department in individual
file of an employee, wherever applicable.

Please refer to Training Record (QRD-HR-01)

 The Course Attendance Sheet along with training material can be log as Training
completion record for In-House / Internal training session, wherever applicable.

5.4.3 Equipment Mobilization and Maintenance:

In charge Transport and maintenance will ensure efficient and effective mobilization of all
construction equipment, plant and tools at site as per project schedule and cost.

5.4.4 Material Handling:

There shall be permanent and consumable material at the project. Permanent material
may be either Customer supplied or by AL YAMAMA procured or even by both.

Generally, the consumables are ALYAMAMA own supplied except some specialized
ones. Consumables are purchased and controlled by AL YAMAMA itself through its own
system and procedures.
ABIS supplied permanent material shall be procured as per commercial procedures and
stacked as per the store procedures. Customer supplied material shall be collected from
the customer warehouse.
The material shall be issued and documented in order to reconcile at the end of the
project as per Stores Procedure.

Execution teams shall have Material Coordinators who shall put their request to the
Material Controller. Using the information available in his database he shall submit a
material issuance request to the Customer as per the procedure agreed at the start of the
job.

Each material coordinator shall deliver the material to site sub store, from where it shall
be issued to the field staff through store document as per the site requirement.

Project In charge, In charge Planning, In charge Stores shall keep very close watch on
movement and built up of inventory. The target should be to have ‘zero’ left over at the
end of the project.

5.4.5 Control of Monitoring and Measuring Devices:

All precision Inspection measuring & testing equipment will be calibrated through a 3rd
party Calibration Agency, before their due dates, using calibrated and traceable
references. I/C QA&QC ensure the calibration validity of monitoring and measuring
devices.
Stores shall be responsible for the care and custody of all inspection, measurement and
test equipment, required to be maintained as part of the Company's resources.
Documented procedures shall be maintained to control movement and calibration, and
inspection of all measuring and test equipment used by the Company.
Equipment shall be handled in a manner that these shall be protected against damage
due to weather and transportation. In case the equipment is damaged, the same will be
immediately withdrawn and tagged, identifying clearly unsuitability of such equipment for
use in the process.

5.4.6 Project Site Facilities (PSF):

Prior to start Construction work at site, AL YAMAMA will Construct at site their site office,
Toilets, Material store, warehouse & Vehicle, Maintenance shop. I/C site Administration
will arrange mobilization of portal cabins and/or construction of the blocks and workshop
structure, warehouse, etc. of the temporary facilities as per the project budget and the
schedule.

5.4.7 Work Environment:

PM ensures a safe, clean environment to work for all employees. Site Administrate as
well as HSE both are equal responsible for providing, maintaining and ensuring that the
environment is conducive for achieving conformity to product/service requirements.

5.5 Internal Quality Audits

Scheduled Internal Quality Audits are conducted for Project. These schedules are
planned by QA/ QC department at head office. If required, follow up audits will be
undertaken to strike out non-conformities. Only management representative or Head
Quality Assurance has the authority to close the system non-conformities.
5.5.1 Audit Schedule
 Prepare an Audit Program setting out the schedule of audits covering every
procedure. At least one audit will conduct for one project.

Please refer to Internal Audit Schedule (QRD-QS-13)

 The PM. QA/ QC In charge and/or QMR shall approve the schedule.
 The project audit program shall ensure a full systems audit against Quality
Management System Manual and the requirements of ISO 9001:2015.

5.5.2 Audit Preparation

 The proposed dates of audit shall be informed to the auditors and Audit at least
one week before the audit, wherever applicable.
 The nominated auditor is responsible for the preparation, co-ordination, and
performance and reporting of the audit to the Management Representative.
 Standard checklists shall be prepared by the qualified auditors and approved by
the Management Representative. Copy of this checklist shall be used by the
auditors to perform the task. Original checklist shall be retained by the QMR,
wherever applicable. Whenever there is revision of the document, the check list
also shall be revised to reflect the current scope.

Please refer to Audit Plan Checklist (QRD-QS-10)

5.5.3 Audit Execution

 On arrival at the area to be audited, meet the project head to fix the time scale of
the audit and escort / guide, if required.
 Conduct the audit using check list and record observations of the respective area
on the checklist as appropriate.
 Any non-compliance found shall be marked on the checklist and a Non-
Conformance Report shall be raised at the end of audit detailing the non-
conformance.
 When the audit is complete, the Auditor shall hold an exit meeting with the Audite
and give a verbal summary of his findings. Any NCR raised during the audit shall
be passed on to the Auditee for his acknowledgment signature to indicate his
acceptance of the non-conformance.

5.5.4 Audit Reporting

 Prepare an internal audit report. It shall contain the audit report number which was
already issued by Management Representative. Original audit report filled
checklist and copy of NCRs shall be submitted to Management Representative. A
copy of audit report and originals of NCRs shall be passed on to the concerned
project head.

Please refer to Internal Audit Report (QRD-QS-07)

Please refer to Non-Conformance Report (QRD-QS-06)
  Update the internal audit schedule and NCR status log to indicate audit status.
Follow up audits, if any, shall be indicated on the status log.

Please refer to Non Conformance/CPAR Status Log (QRD-QS-01)

5.5.5 Corrective Action

 Corrective / Preventive action to be taken within propose completion date which
shall be agreed between the Project Head / Project Manager and Management
Representative.
 When corrective actions are implemented, Project Head / Project Manager shall
indicate the same on NCR and pass on to Management Representative.

5.6 Control of Non-Conforming Product

It shall be the responsibility of QC Dept / Project Manager / Site In charge and

supervisors to ensure compliance of this PQP and reporting of any non-conforming
product. Therefore, Site In charge / Supervisor are the Process Owner where he is
responsible for:

 Ensuring that holding / quarantine area is identified

 Ensuring that his staff aware to use the holding area only for non-conforming
material / product.
 Deciding the method of disposition of non-conforming products / materials.
 Monitors the progress and follow up corrective actions.
 Approving the non-conformance reports.

5.6.1 All identified non-conforming products shall be documented on a Non-

Conformance Report (N.C.R.) and investigated, analyzed, action taken to prevent
recurrence and close-out accordingly.

Please refer to Non-Conformance Report (QRD-QS-06)

5.6.2 All non-conforming products e. g Operation failure or equipment must be

immediately reported to the Site Store Supervisor, Project Manager, and project in
charge in the earliest. Non-conforming products and/or equipment must be
identified and labeled with a status sign or label, and if possible, shall be put into
an “equipment not in use” area until the nonconformance has been acted upon.

5.6.3 It shall be the responsibility of Concern project manager, site in charge,

supervisors or the QUALITY DEPARTMENT Personal to raise, log and document
any Non- Conformance Report (N.C.R). All reports shall be dispositions as
follows:

 Rework / repair.
 Accept / use-as-is.
 Scrap.
 Return to vendor.
 Re-grade.
 Customer concession required.

5.6.4 Once the Non-Conformance Report has been dispositioning and downgraded,
QA/ QC In charge shall review actions taken and to prevent recurrence, agree or
reject
 report and sign report, if rejected the report shall be returned to person who
originated report.

5.6.5 Damage Report will be filled by relevant user during accidental / non-avoidable
circumstances situation, for identifying and controlling the damage.

Please refer to Damage Report (QRD-ST-05)

5.6.6 When all actions have been satisfactorily completed the Project Manager, Site In
charge, Supervisor and the QA/ QC In charge shall finally close-out report by
signing and dating the report. The Non-Conformance Log will be updated regularly
by the Quality Department.

Please refer to Non-Conformance Log (QRD-QS-01)

All reports shall be noted with: -

 Non-conformance report number.

 Non-conformance issue date.
 Originator of the non-conformance.
 Root Cause of the non-conformance
 Corrective Action taken / disposition record.

5.6.7 If any non-conforming product or service during operations can still perform the
operations but does not conform to specified requirement by contract then a
customer concession must be obtained.

5.6.8 All Non-conforming products that require repair or re-work shall be re-inspected or
tested prior to use.

5.7 Corrective Action

a) Correction and corrective actions are measures intended to deal with non-
conformances or client complaints.

b) Non-conformances may result from:

 Ordering or receipt of non-conforming material or product

 Incorrect handling or storage of correctly received materials
 Inappropriate inspection procedure
 Application of improper installation procedures or use of incorrect
drawings
 Incorrect procedure during testing and/or hand over
 Other factors

c) Raising a non-conformance may be in one or more of the following ways:

 Observations noticed by the QA/QC In charge, the QA/QC engineer,

the site engineer, or any of the involved staff.
 Results of internal audits
 Client complaints
  Other ways

d) The correction is undertaken to eliminate the cause of the non-conformance and

not limited to the curative measures intended to correct the non-conforming
output.

e) The corrective action is intended to eliminate potential causes of non-

conformities.

5.7.1 Correction

a) Upon completion of a project, all customer complaints - verbal or written – are

addressed to the QA/ QC In charge. These complaints are logged on by the
QAE on the “Customer Complaint Record” Corrective/preventive actions are
studied, implemented, and followed-up by the QA/ QC In charge.

Please refer to Non-Conformance/Corrective preventive action request (QRD-QS-06)

b) Observations, comments, and remarks of non-conformances raised by any of

the project members/client representative shall be addressed - verbally or in
writing - to the QA/ QC In charge/site manager. The observations and
comments may be logged in the project quality log or issued in a memorandum
to the concerned personnel or addressed under a corrective action request.
Observations and comments affecting the quality shall be filed and maintained
by the Quality Assurance Engineer (QAE).

c) Results of internal audits are filed by the QAE.

d) The QAE, the PM, the QCEs/Site Engineers (SE) are jointly responsible to
proceed with an effective study, investigation, and analysis to determine the
probable cause of non-conformity related to products, processes and quality
system. The results shall be recorded.

e) The QAE/SPM will decide the curative measures and corrective action required.
The decision shall consider the magnitude and consequence of the non-
conformance and shall define the method of recording it, whether on the project
quality log or in a memorandum or work instruction or by issuing a request for
corrective action.

 In case the QAE, after discussion with the PM, decides to issue a request for
corrective action, this request should determine precisely the action required to
eliminate the cause of non-conformity.
 Whether a memorandum, work instruction or corrective action is issued, a
method of control is required to ensure that the implemented corrective action is
effective and results in eliminating the non-conformance.
 Correction may be submitted to the client for approval, if required by the
contract.
 Corrective actions with considerable impact on quality plan and construction
schedule shall be raised for management review.
5.7.2 Corrective action

a) Corrective actions are required to deal with situations which, based on reliable
sources of information, may potentially lead to a nonconformity.

b) Many of the cases requiring correction may as well require corrective action to
avoid recurrence.

c) The QAE jointly with the PM shall:

 Use reliable sources of information like project daily reports, frequent contact
with QCE, periodic visits to stores and construction area, customer complaints,
etc., to detect the potential cause of non-conformances which require preventive
actions.
 Investigate each cause or reason which may lead to nonconformance,
before determining the steps needed to deal with any problem requiring
corrective action.
 Establish a control procedure to ensure the effectiveness of the corrective
action once it is initiated.

5.8 Management Review

The Project Team conducts a management review meeting with respect to quality
at least 01 time per Project. Each attendee has designated responsibilities for
presenting specific review meeting inputs and for providing related
recommendations for review and action. The QA/ QC department Representative
Document’s management review minutes. Approved actions are entered into the
corrective and preventive action system to ensure follow up and effective
implementation in accordance with provisions stated in QMS documents. The QA/
QC In charge assesses the effectiveness and efficiency of the management
review process through self-assessment and/or as a result of internal audits
conducted per Internal Audit Procedure, initiates appropriate corrective/preventive
actions and provides trend data and related recommendations to project team for
review and action per provisions of this procedure.

5.8.1 Review Inputs

The Project Team Review meeting includes a review of current performance and
opportunities for improvement in an open discussion format to foster idea
generation. The agenda for the Management Review meeting is prepared by the
QA/ QC department as per standard requirements and distributed to the
participants at least one week prior to the meeting, wherever applicable.

5.8.2 Review Outputs

Outputs from Management Review meetings will be documented in the meeting

minutes prepared and issued by QA/ QC representative. Output will include any
corrective, preventive or other actions required for improvement of the QMS and
its processes, improvement of product related to customer requirements, and
provision of resource needs. System changes, issues requiring further
investigation, or recommendations for improvements will also be documented on a
 Corrective/Preventive Action Request (CPAR) in accordance with provisions
contained in procedure, to ensure implementation and follow-up. Minutes of the
meeting are documented and distributed to members of project team members
and any other attendees, wherever applicable.

Please refer to Minutes of Meeting (QRD-QS-14)

5.9 Procurement:

Procurement is carried out in accordance with the relevant specifications and is executed
in the cost effective and efficient manner as per material requirement plan.

5.9.1 Requests for Quotations:

I/C procurement upon receipt of Material Indent ensures adequacy of information
according to the requirement. If the information is inadequate, then the correct information
is obtained.

Inquiries are prepared and floated to approved suppliers / vendors for the quotations / bids.

5.9.2 Bid Evaluation:

Suppliers/vendors are evaluated on the basis of quality system, past performance and /
or evaluation of samples. Performance of supplier is continuously monitored for ensuring
that only competent suppliers stay on the list of pre-qualified suppliers.
Comparative statement is prepared and sent to management for approval.
Records of all correspondence concerning quality and delivery problems are maintained
by the Procurement Department and made part of individual assessment of suppliers.

5.9.3 Purchase Orders Placement and Follow-up:

I/C Procurement issue the PO to the selected vendors/suppliers upon approval of the
selected supplier/vendor.

After issuance of PO, procurement team expedite, track and follow-up for timely delivery
and also coordinate with QA&QC for pre-shipment inspection.

5.9.4 Inspection and Testing:

QA&QC ensures that receiving inspection of material and equipment is carried out at
receiving store in conformity with the applicable specifications. In charge site QA&QC is
responsible for inspection of all incoming materials at Site. At the time of inspection, he
ensures that procurement of materials/services is being carried out from pre-qualified
suppliers.

5.9.4.1 Inspection & Test Plan (ITP):

Inspection & Test Plan is the document that describes the surveillance of all the
stakeholders involved in inspection and testing activities.
Inspection and Test co-ordination and interfaces of all parties involved are defined and
implemented through ITP as a guiding document for QA&QC activities. QA&QC team
prepares ITP’s to ensure and monitor the conformity of all activities to the required
standards and specifications as mentioned in the contract. I/C QA&QC (site) check and
review these ITP’s before submitting to the customer for approval.
QA&QC team for final quality dossier submission as referred in ITP maintains all
Inspections & Test records on approved formats.

5.10 STATISTICAL TECHNIQUES

Statistical techniques are used by planning to effectively monitor the progress of

project as per plan and to forecast critical activities and resource requirements. These
requirements are met by generating s-curves and histograms.

5.11 Health, Safety and Environment:

A Health, Safety and Environment Plan for the project shall be developed and
implemented. The implementation of the HSE Plan will be monitored through regular HSE
audits. HSE is a line function; everyone is responsible for the HSE issues at site.

The HSE Department shall conduct initial orientation of all individual before such an
individual takes over responsibility. Under this program, general HSE rules and
regulations shall be explained to all personnel who shall be made aware of all potential
hazards involved in their job along with ways to protect themselves as well as their
environment.

Various types of HSE courses shall be arranged to inculcate HSE awareness amongst
every employee and to make him “HSE conscious”. Employees shall also be provided
with HSE literature, brochures, HSE rules, etc. to enhance their knowledge and
confidence in their jobs. Regular HSE Toolbox talks shall be conducted by line
Supervisors and In charge Site HSE, identifying site hazards and to avoid the same using
craft safe work practices.

ABIS’s commitment to prevent harm to people, environment and community can be

viewed from the HSE Injures statistics and a professional implementation of HSE plan at
site.

Project Manager shall ensure that Project Management Team (PMT) in coordination with
HSE team undertakes whole sole responsibility of ensuring that all of applicable project
activities are executed successfully and safely without loss of man-hours and property. All
documented HSE Manuals are properly adhered to and work is done in accordance with
project HSE standards and recognized safe practices.

5.12 Project Windup:

5.12.1 Demobilization of Equipment’s & Tools:

Demobilization of Equipment, tools, plant, store material and consumables, temporary
site facilities etc. starts as soon certain resources are free from their intended work scope.

5.12.2 Manpower Demobilization:

Demobilization of Manpower shall be carried out according to the plan issued by Project
In charge.

5.12.3 Project Wind-up Report:

After successful completion of execution project manager is responsible for acquiring of
the Acceptance Certificates from the customer. A project wind up report is prepared as
per the list of content. Project planning engineer/ In charge planning will prepare and
compile the wind-up report. The purpose of this report is to know the performance of
various
resources at the project, negative and positive points of the project and the lessons learnt
for future reference.

6 Associated Documents

External Document Log QRD-EOD-01

Transmittal QRD-QS-12
Document Distribution Log QRD-QS-05
Document Change Note QRD-QS-02
Quality Record List QRD-QS-03
Training Schedule QRD-HR-02
Training Evaluation Sheet QRD-HR-03
Training Record QRD-HR-01
Internal Audit Schedule QRD-QS-13
Audit Training Record QRD-QS-08
Audit Plan Checklist QRD-QS-10
Internal Audit Report QRD-QS-07
Damage Report QRD-ST-05
Non-Conformance / CPAR Log QRD-QS-01
Non-Conformance/Corrective preventive action request QRD-QS-06
Management Review Meeting Agenda QRD-QS-16
Minutes of meeting QRD-QS-14
Client Complaint