PROJECT QUALITY PLAN rev-00

PORT TANK FARM & LOADING FACILITIES (PACKAGE-9)

Project Quality Plan - Manarah Al Jubail Const. Co. Ltd.

Table of Contents

1. Scope 3

2. Normative Reference 3

3. Terms and Definitions 3-4

4. Quality Management System 44.1 General Requirements 4-54.2. Responsibility 64.3 Documentation Requirements 6

4.3.1 General 64.3.2 Quality Plan

6-74.3.3. Exclusions 74.3.4. Control of Documents 7

4.3.4.1. Purpose and Scope 74.3.4.2. General 7-84.3.4.3. Responsibility 84.3.4.4. Procedure 9

4.3.5. Control of Quality Records 94.3.5.1 Purpose and Scope 94.3.5.2. Responsibilities 104.3.5.3. Procedures 10-11

5. Management Responsibility 115.1 Management Commitment 11-125.2 Customer Focus 125.3 Quality Policy and Operating Values 135.4 Planning 13

5.4.1 Quality Objective 13-14. 5.4.2 Quality Management System Planning 14

5.5 Responsibility, Authority, and Communication 145.5.1 Responsibility and Authority 14-155.5.2 Appointing a Quality Manager/Management 15 Representative5.5.3 Internal Communication 15

5.6 Management Review 155.6.1 General 15-165.6.2 Review Input 16-175.6.3 Review Output 17-18

6. Resource Management 186.1 Provision of Resources 186.2 Human Resources 18

6.2.1 General 18-196.2.2 Competence, Awareness, and Training 19

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6.3 Infrastructure 19-206.4 Work Environment 20

7. Project Execution 207.1. Planning of Project Execution 207.2 Customers Related Processes 20

7.2.1 Determining Project Requirements 207.2.2 Reviewing Project Requirements 207.2.3 Customer Communication 21

7.3 Design and Development 217.4. Purchasing 21

7.4.1 Purchasing Process 217.4.2 Purchase Information 21-227.4.3. Verification of Purchased Products 22

7.5. Production and Service Provision 227.5.1 Control of Production and Service Provision 22-237.5.2. Validation of Processes for Production and Service 23

7.5.3. Identification and Traceability 23-247.5.4. SATORP Property 247.5.5. Preservation of Material and Equipment 24

7.6. Control of Monitoring and Measuring Devices 24-25

8. Measurement, Analysis & Improvement 26

8.1 General 26

8.2. Customer Satisfaction 268.3. Internal Audit 26-27

8.4. Monitoring and Measurement of Processes 27

8.5. Monitoring and Measurement of Production Processes 27-288.6. Control of Nonconforming Product

28-29

8.7. Analysis and Use of Data 29

8.8. Improvements 29-30

8.8.1 Continual Improvement 30

8.8.2. Corrective Action 31

8.8.3. Preventive Action 31-32

9. Project Quality Control Plan 33

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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

Schedule Q Quality Assurance and Control, Inspection and TestingJEREP – 1154 Guide lines for Contractor’s Quality PlanISO 9000:2000 Quality Management Systems – Fundamentals and

VocabularyISO 9001:2000 Quality Management Systems – Requirements

3. Terms and Definitions

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.

Inspection Assignment Package: A set of documents that include details of purchased Material/equipment and their quality requirements needed to perform full inspection at the vendor/sub-vendor facility.

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.

Quality System: Organizational structure, procedures, processes and resources needed to implement quality management. [ISO 9000]

Quality Control: The part of the Quality System, which, through checks, review, measurement test and inspections, determines that specified requirements are achieved.

Quality Assurance: The Planned and systematic process of producing of objective evidence (By use of the Quality System) to verify specific requirements are being achieved. It is a management system, which increases confidence that the materials and work conforms to requirements.

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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.

Pre-Commissioning: Testing of system components for continuity, operability and in the case of the process plants, their ability to withstand operating pressure prior to the introduction of feedstock or other final products into the facility.

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.

Will: "Will" expresses a declaration of purpose or intent by one party.

Should: “Should" expresses a recommendation among other possibilities.

4. Quality Management System

4.1 General Requirements

The Quality Management System (QMS) of MCCL consists of 3 parts. The Quality Manual describes our Company policy and objectives, our

documentation requirements, our responsibilities and authority, our resources and our measurement and control requirements.

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.

Specifically, management will

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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

4.2.1. It is the responsibility of the Management Representative and Department Heads to ensure that the sequence and interaction of processes or activities of this Quality Management System are determined in a suitable manner, utilizing tools such as process maps, quality plans, flow charts, operating procedures, etc.

4.2.2. It is the responsibility of the Management Representative and Department Heads to apply the necessary techniques and criteria in order to verify that established processes/activities and their implemented controls are effective.

4.2.3. It is the responsibility of the GM Technical/MD, Management Representative and the Department Heads to ensure that the necessary human and material resources, as well as the necessary information, are available to ensure the effective operation and control of the processes of the Quality Management System.

4.2.4 It is the responsibility of the Management Representative and Department Heads to ensure that the processes / activities which are part of the Quality Management System are monitored, measured and analyzed regarding their achievement of planned results.

4.2.5 As required, the Management Representative and Department Heads ensure that action is taken to obtain expected results of processes/activities, as well as the continual improvement of these processes/activities.

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.

4.3 Documentation Requirements

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4.3.1 General

The MCCL has established the following documentation for its quality management system:

Quality policy and quality objectives

This Quality Plan

Documented procedures/Method statements of typical project activities (Attached as Annexure A)

Planning, operation, and process control documentation such as:

o Inspection & Test Plans (ITP)o Work instructionso Records of internal reviewso Inspection and test reportso Internal/external audit reports and corrective actiono Other documentation used to ensure effective planning operation and

control

Records

o Test Certificates.

o Checklist from Inspection Activities.

o Non-Conformance Reports.

o Technical Submission and Written Approval.

o Approved Subcontractors/Suppliers.

o Personnel Qualifications.

o Statutory Authorities Certificates (when applicable)

o Calibration Certificates

4.3.2 Quality Plan

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. Control of Documents

4.3.4.1. Purpose and Scope

MCCL’s document control system ensures that:

Documents are approved by the DPL prior to issue for construction. The latest issues of approved documents and drawings are used in the work

face. Documents are complete and unambiguous.

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;

Site Office (DPL PMT Office) MCCL Head Office

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

The following documents shall be controlled in accordance with this procedure:

o Contract Specificationso Contract Drawingso Approved Shop Drawingso Project Quality Plano Loss Prevention Plano As-Built Drawing

Upon approval of controlled documents prepared by MCCL or receipt of DPL/SATORP controlled documents, registration using the document control log sheets shall be carried out.

Registration shall include recording the following information relating to the document:

o Document reference Numbero Document titleo Current Revision Numbero Date of Issue/Revision

For the purpose of recording, the following register shall be used:

o Project Document Register - Contract Specification - Project Quality Plan

o Drawing Register- Contract Drawings

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- Approved Shop Drawings

Upon completion of registration, controlled documents shall be issued to those personnel or organization identified to the “Distribution List” shown on the applicable register.

Controlled documents shall be issued internally under cover of the memorandum.

Controlled documents shall be issued externally under cover for a Document transmittal or letter.

The person responsible for distribution shall prepare the memorandum, document transmittal or letter.

Each recipient shown on the distribution list shall be responsible for removing obsolete drawings from the point of use.

When it is possible to remove obsolete drawing, the word “SUPERSEDED” shall be marked in red on the document such that the word is clearly visible and thus mistaken use is not possible.

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.

All requests for change or clarification of contract documents shall be forwarded to the SATORP through DPL in correspondence signed by the Project Manager. A register/log book of all correspondence, incoming, and outgoing shall be maintained and regularly reviewed for reply by the Project Manager.

4.3.5. Control of Quality Records

4.3.5.1 Purpose and Scope

MCCL shall maintain records to support and substantiate all planned activities related tothe 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 Checklist from Inspection Activities.

o Non-Conformance Reports.

o Audit Reports

o Technical Submittals and Written Approval.

o Approved Subcontractors/Suppliers.

o Personnel Qualifications.

o Statutory Authorities Certificates (when applicable)

o Calibration Certificates

The filling system shall be established and maintained in the following format:

A. General Files

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B. Construction Process File

A. General Files / Subdivisions

A1) Project Quality Plan

A2) Audits Reports and Follow-ups

A3) Inspection Measuring and Testing Equipment’s Calibration

A4) Statutory Authority Approval

A5) Non-Conformance Reports

A6) Punch Listing

A7) As-Built Drawing

A8) Loss Prevention Plan

B. Construction Process Files

Construction Process Files shall be established as follows:

B1) Civil Works

B2) Mechanical Works

B3) Electrical Works

Subdivision shall be established within each Construction Process File:

a) Test Certificates

b) Completed Checklist and Reports

c) Approvals / Technical Submittals

d) Correspondence

The Project Manager shall identify those records to be transmitted to DPL/SATORP upon completion of the project and transmit the appropriate records.

5. Management Responsibility

5.1 Management Commitment

The top management of MCCL is committed to the development and improvement of the quality management system by:

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Communicating the importance of meeting SATORP, regulatory and legal requirements by conducting regular meetings and through memorandum with the project Quality and Execution staff.

Establishment of a quality policy and objectives.

Conducting management reviews in accordance with Schedule Q and paragraph 5.6 of this Quality Plan.

Ensuring the availability of necessary resources.

5.2 Customer Focus:

The MCCL Management ensures that procedures for determining and meeting SATORP requirements and standards are established and implemented. MCCL ensures SATORP satisfaction by:

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

Allocating trained and qualified staff resources to perform project tasks.

Schedule and reporting progress in sufficient detail to control project cost.

Training of personnel during the project as required.

Performing management reviews and internal quality audits as specified in Schedule Q and paragraph 8.3 of this Quality Plan.

Establish a program for problem identification and resolution and problem prevention.

Maintaining data control systems and records of project activities.

Timely submittals of deliverables in compliance with schedule Q.

In time completion of every activity of the project as per the approved project schedule.

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5.3 Quality Policy and Operating Values

The MCCL has the following policy regarding the quality of the goods and services we offer to our customers.

“TO RESPONSIBLY PROVIDE TIMELY, COST EFFECTIVE QUALITY GENERAL CONSTRUCTION AND RENOVATION SERVICES WHILE MAINTAINING OUR OPERATING VALUES.”

&

“TO MAINTAIN AND CONTINUALLY IMPROVE THE EFFECTIVENESS OF OUR QUALITY MANAGEMENT SYSTEM.”

Our operating values at MCCL are to

Continuously exceed the expectations of our clients, staff and our community

be an innovator and leader in all corporate endeavors understand our clients’ priorities and problems and create a relationship

built on Mutual trust and respect promote growth, mutual respect, common core values, safety and open

communication with our staff Make a profit.

It is the responsibility of MCCL’s management to implement and maintain this Quality Policy. The Quality Policy includes MCCL’s commitment for continual improvement, for meeting internal requirements and customer requirements, and provides a basis for the establishment and review of quality objectives. The Quality Policy is made known within the organization and understood and adhered to by employees. During management reviews, the Quality Policy is reviewed for its continuing suitability.

5.4 Planning:

5.4.1 Quality Objective

We commit to maintain and continually improve the effectiveness of our Quality Management System. We will set objectives and measure our success. For example, client satisfaction and long term relationships are achieved by

performing up to and beyond client expectations (measured by customer satisfaction reports),

offering competitive pricing (measured by quotation success) Meeting our safety targets (measured by accident reports). Meeting our quality targets (measured by the no. of NCRs)

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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.

5.4.2 Quality Management System Planning

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.

5.5 Responsibility, Authority, and Communication

5.5.1 Responsibility and Authority

It is the responsibility of the Management Representative to develop and maintain an organization chart of MCCL. Updated charts are distributed to Department Heads and are available to employees on a need to know basis.

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

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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.

5.5.2 Appointing a Quality Manager/Management Representative

The MCCL has assigned Quality Assurance Manager as the management representative for quality on this project. He shall ensure the quality system is established, maintained and implemented and shall report to top management on a weekly basis and make recommendations for quality system improvements. Reports shall be issued in writing to top management and maintained in an open status until the resolution of outstanding items. The management representative for quality shall assure that the project team is aware of SATORP requirements regarding the project.

5.5.3 Internal Communication

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 Management Review

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. The following topics will be reviewed during the meeting in addition to the agenda proposed by the Quality Manager/Management Representative.

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Review of the minutes of the last meeting. Review of the quality policies and quality objectives. Results of internal and extrinsic audits. Non-conformity reports and corrective action taken. Customer complaints. Status on preventive actions. Adequacy of existing quality system and proposed improvements and changes

as needed. Process performance and product conformity. Training requirements. Date of next Management Review Meeting

Minutes of meeting shall include action related to improvement of effectiveness of the Quality Management System and improvement of work result related to customer requirements (corrective action, preventive action and resources needed)

5.6.2 Review Input

As a minimum, the following inputs are to be considered for at least one meeting after every six months:

performance of production processes, product conformity, including performance trends

status and effectiveness of corrective and preventive actions follow-up actions from previous management reviews planned changes that could affect the Quality Management System assessment of improvement opportunities and recommendations for

improvements employees’ knowledge, understanding and adherence to quality policies,

directives and procedures, and their involvement in the quality improvement process

availability and effectiveness of internal and external information within the company, at all levels

human resources, training and staffing requirements suitability of working environment availability of material resources effectiveness of quality planning (quality system, design/development of products

and processes) achievement of corporate quality objectives, including those specified in the

business plan achievement of departmental quality objectives effectiveness of continual improvement activities of products, processes, and

Quality Management System results of internal and external audits of the quality system, incl. audits of

manufacturing processes statistical results of operational performance, based on the analysis of collected

data, which includes:

o quality system audits

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o internal quality audits

o customer satisfaction surveys and other customer feedback regarding customer satisfaction

o customer complaints

o suppliers performance

o product and service quality and nonconformities

o direct and indirect costs and benefits of the quality system (relation cost – benefit)

o Cost of poor quality – scrap, rework, returns, warranty repairs, excessive freight charges, etc.

o analysis of field-failures (returns, warranty repairs), their impact on quality, safety, environment

o the impact or potential impact of changes that could affect the Quality Management System

o opportunities for improvement resulting from additions or changes

5.6.3 Review Output

Results of the assessment and conclusions of management reviews include the following output:

Effectiveness of corrective and/or preventive actions

The suitability and effectiveness of the Quality Management System

improvement of the effectiveness of the Quality Management System and its processes

improvement of product with focus on customer requirements

availability of human and material resources

suitability of the corporate Quality Policy

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frequency of Management Reviews

required corrective and or preventive actions regarding items reviewed

Results of management reviews shall be recorded and address as appropriate:o Improvements in the QMS and its processeso Improvements in project related to SATORP requirementso Resource needs

Action items should be followed up on at subsequent management reviews to ensure closure. A copy of the results of this Management Review shall be forwarded to DPL within two weeks after the management review meeting.

6. Resource Management

6.1 Provision of Resources

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 Human Resources

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.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.

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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.

6.2.2 Competence, Awareness, and Training

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

MCCL shall maintain records of education, training skills, and experience for personnel effecting quality. Commercial Manager is responsible to ensure appropriate record including records of training activities and subject matter of the training are maintained.

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 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.

6.4 Work Environment

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This section is addressed in the Loss Prevention Manual.

7. Project Execution

7.1. Planning of 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

Project acceptance by DPL shall be documented by Mechanical Completion Certificate(s) (MCC).

7.2 Customers Related Processes

7.2.1 Determining Project Requirements

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.

7.2.2 Reviewing Project Requirements

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.

7.2.3 Customer Communication

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.

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7.3 Design and Development

The design responsibilities lie with DPL.

7.4. Purchasing

7.4.1 Purchasing Process

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.

7.4.2 Purchase Information

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.

7.4.3. Verification of Purchased Products

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

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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.

7.5. Production and Service Provision

7.5.1 Control of Production and Service Provision

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. 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.

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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.

7.5.2. Validation of Processes for Production and Service

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.

Applicable construction process procedures identified in Schedule Q, shall be submitted for SATORP review at least 30 days prior to start of the construction activity.

7.5.3. Identification and Traceability

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.

7.5.4. SATORP Property

There is no data, material and equipment provided by SATORP for this project.

7.5.5. Preservation of Material and Equipment

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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.

7.6. Control of Monitoring and Measuring Devices

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.

Unless equipment calibration is performed by the manufacturer or a SATORP approved agency, the following shall apply:

Availability and use of calibration instructions, manufacturers’ instructions, codes, or national standards for calibration.

A program of corrective actions to repair or replace items that do not meet acceptance criteria.

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

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

Confirmation that computer software used as a basis of product acceptance is acceptable for the intended application. Confirm prior to use and as necessary thereafter.

Records to demonstrate calibration and verification.

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

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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

Calibrated and/or checked in defined intervals or prior to use, and according to a recognized standard; where no recognized standard is used, the basis applied for the calibration is documented.

adjusted and re-adjusted as necessary to ensure required accuracy

Identified with a unique identification number and the current calibration status.

Kept in a secure and restricted location to prevent misuse and improper adjustments that could invalidate calibration settings.

protected from damage and deterioration during handling, maintenance and storage

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. Measurement, Analysis & Improvement

8.1 General

In order to demonstrate the conformity of product, the conformity of the Quality Management System and its continual improvement, the Management Representative 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:

Customer satisfaction surveys Internal audits

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In-process reviews/inspections/tests Control of nonconformities Data analysis Corrective, preventive, and improvement activities

8.2. Customer Satisfaction

Periodic customer satisfaction surveys are conducted by management to verify if customer satisfaction has been achieved. Survey results, which include customer complaints and feedback, customers’ business disruptions, customer returns of nonconforming product and delivery performance are analyzed and evaluated. As required, management takes corrective or preventive action. The Management Representative monitors the effectiveness of these corrective or preventive actions.Particularly on this project the MCCL will get the feedback regarding DPL satisfaction through weekly meetings, correspondence and inspection results.

8.3. Internal Audit

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 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.

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8.4. Monitoring and Measurement of Processes

During Quality Management System Planning, and based on statistics of operational performance and the achievement of quality objectives, the processes of the Quality Management System are analyzed by the Management Representative and responsible Department Heads regarding their effectiveness. As required, corrective action is implemented to achieve planned results and product conformity, to correct nonconformities or to improve the operational effectiveness and efficiency of the processes of the Quality Management System.

8.5. Monitoring and Measurement of Production Processes

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 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.

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8.6. Control of Nonconforming Product

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.

The Non-Conforming Control mechanism does not apply to quality related matters, which can resolve through normal working channels.

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.

Where a non-conformance has been identified the Project staff member responsible shall inform the Quality Assurance Manager. He shall initiate a Non-Conformance Report and shall forward copies of the Non-Conformance Report to DPL within 48 hours of the occurrence.

The original Non-Conformance Report shall be returned by Quality Assurance Manager and the details available shall be entered in the log. The non conformance report(NCR) shall be closed by submitting the proper documents regarding the job/work and incorrect job will be rectified by proper procedure or method statements.

Upon receipt of the Non-Conformance Report with an approved resolution, the Project Manager shall issue instruction to implement the required corrective action.

Upon completion of the approved corrective action, the Quality Assurance Manager shall sign and date the original Non-Conformance Report and a copy shall be forwarded to DPL/.

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The original Non-Conformance Report shall be reviewed by the Quality Assurance Manager and the detailed corrective action report shall be entered to update and close out the Non-Conformance Report Log for that particular NCR.

8.7. Analysis and Use of Data

The Management Representative issues statistics regarding the performance of the Quality Management System through the analysis and use of data. Ratings on supplier performance are issued by Purchasing and/or Quality Assurance. The statistics are analyzed by the Management Representative regarding the effectiveness, suitability and opportunities for improvement of the processes of the Quality Management System, and by Department Heads regarding the performance and suitability of activities and processes under their responsibility. This includes the analysis of DPL/SATORP complaints. A summary report is issued by the Management Representative, providing information on DPL/SATORP satisfaction or dissatisfaction, product quality, characteristics and trends of processes and products including opportunities for preventive action, and supplier performance. The Management Representative controls and coordinates the implementation of required corrective or preventive actions. Analysis results of statistics and actions are reported by the Project Manager to the Management Representative who monitors the progress and results of these actions. In addition, trends in quality and operational performance are compared with progress toward objectives and lead to action to support: the development of priorities to resolve customer-related problems, to determine customer related trends and correlation for status review, decision making and longer term planning, and an information system for reporting of product information related to usage.

8.8. Improvements

It is the responsibility of the Management Representative to form and implement a Quality Planning Team for the handling of assigned activities related to the Quality Management System. Members should be from Quality Assurance, Engineering, Purchasing and any other additional members deemed necessary. The purpose of the Quality Planning Team is to review, analyze and make final decisions on Corrective Action Requests and Quality Improvement Proposals, to make recommendations for preventive actions and quality improvements, to coordinate and implement preventive actions and quality improvement projects, monitor results, and to provide a forum for any quality issue which requires a cross-functional approach. 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.

8.8.1 Continual Improvement

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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:

Activities of the Quality Team under the responsibility of the Management Representative

Actions on results from analysis of data

Customer Satisfaction

Evaluation of suppliers

Achievement of departmental quality objectives

Trends of both positive and negative compliance

Results from internal quality audits

Quality improvement proposals

corrective actions and preventive actions

Periodic review of controlled documents

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.

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

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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.

8.8.3. Preventive Action

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:

identify potential nonconformities, deficiencies or problems

determine the root causes

determine the necessary preventive action

implement the action

Follow-up on status and results

review the effectiveness of preventive action.

update all related documents with preventive action taken

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. 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 QUALITY CONTROL PLAN

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PROJECT MANAGERPROJECT MANAGER

QUALITY CONTROL MANAGER

QUALITY CONTROL MANAGER

QUALITY CONTROL INSPECTORS, CIVIL

QUALITY CONTROL INSPECTORS, CIVIL QUALITY CONTROL

INSPECTOR, BUILDINGS

QUALITY CONTROL INSPECTOR, BUILDINGS