Quality Plan Temp

7/30/2019 Quality Plan Temp

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INSPECTION ASSESSMENT GROUP

NOTICE

This Quality Plan Template is provided by Saudi Aramco and is intended toprovide guidance for contractors in the development and preparation of theirQuality Plan.

Saudi Aramco has adopted the basic framework and definitions of theInternational Quality System Standard ISO-9000 series within this template.

The content and presentation of this template is based on a fictional company

(XYZ) and is in no way intended to reflect or restructure contractors corporateand project organizations responsible for managing, performing and verifying theworks.

Use of this template will in no way provide automatic approval of contractorsQuality Plan by Saudi Aramco.

It would be expected that the structure and content of Contractors Quality Planwould differ from this template as Contractor Quality Plan will be project specific,indicating his own organizational structure, procedures, processes and resourcesrequired to meet contractors contractual obligations.

COMMENT
http://engsvcs.aramco.com.sa/id/iag_qpt_comments.htm


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XYZ COMPANY

DOCUMENT TITLE

PROJECT QUALITY PLAN TEMPLATE

DOCUMENT NO.

Index Page

1.0 Quality Polity Statement: 5

2.0 Introduction: 63.0 Management Responsibility: 13

4.0 Quality System Outline: 255.0 Quality System Procedures: 48

6.0 Inspection and Test Pla n 50Attachments 51

ISSUE

NO.

ISSUE

DATE

DESCRIPTION PREPARED

BY

CHECKED

BYAPPROVED

BY


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TABLE OF CONTENTS

SECTION 1: QUALITY POLICY STATEMENT1.1 Statement of Authority

SECTION 2: INTRODUCTION2.1 Amendments and Re-issue

2.2 Manual Amendment Record document

2.3 Quality Objectives

2.4 Wording and Definitions

2.5 Distribution List

SECTION 3: MANAGEMENT RESPONSIBILITY3.1 XYZ Company Quality Policy

3.2 Organization

3.3 Means and personnel for verifications

3.4 Management Review

SECTION 4: XYZ COMPANYS QUALITY SYSTEM OUTLINE

4.1 Management responsibility

4.2 Quality System

4.3 Contract Review

4.4 Design Control

4.5 Project Change Control

4.6 Documents and Data Control

4.7 Purchasing

4.8 Control of customer -supplied product4.9 Product identification and traceability

4.10 Process control

4.11 Inspection and testing

4.12 Control of inspection, measuring and test equipment

4.13 Inspection and test status

4.14 Control of non-conformance

4.15 Corrective and preventive action

4.16 Handling, storage, packaging, preservation and delivery

4.17 Control of quality records

4.18 Internal Quality Audits4.19 Training

4.20 Statistical Techniques

4.21 Quality Management Reports

4.22 Procedure for preparation, style and format of procedures


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SECTION 5: XYZ COMPANY QUALITY SYSTEM PROCEDURES

SECTION 6: INSPECTION AND TEST PLAN


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PROLOGUE

This Quality Plan Template provides guidance for Contractors for developing qualityplans. It applies to hardware, software, processed material and services. A quality plan

is a requirement of Schedule Q (Rev5/00) Quality Assurance And Control, InspectionAnd Testing. This Quality Plan Template must be read in conjunction with ISO 10005:1995 Quality Management Guidelines for quality plans.

Contractors project quality plan should include, or refer to, a detailed Inspection andTest Plan or details of any design reviews to be carried out. It should define thefrequency of audit.

Quality plans only need to be as complex and extensive as the project demands.Whatever the project size, the quality plan and its content need to be appropriate to themanagement of quality in that project. It should be noted that although this quality planTemplate is provided by SAUDI ARAMCO, ownership of the program lies with theContractor. Moreover, the requirements contained in Contractors quality plan shall takeprecedence over those in Contractors quality system.


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SECTION 1: QUALITY POLICY STATEMENT

The XYZ Company Limited specializes in the design, procurement, fabrication,construction and installation of facilities to the oil/gas and related industries. The nature

of the company and activities places particular emphasis upon experience, expertise,capability, reliability and quality.The prime objective of the management of The XYZ Company Limited is to provide

facilities and associated services in a manner which conform to contractual requirements.

In order to achieve this objective, it is the pol icy of The XYZ Company Limited to

establish and maintain an efficient and effective quality assurance program, planned and

developed in conjunction with all management functions. Determination of conformance

of work to contract requirements is verified on the basis of objective evidence of quality.

The quality assurance program of The XYZ Company Limited is based upon the

requirements of ISO 9001:1994 Quality SystemsModel For Quality Assurance In

Design, Development, Production, Installating And Servici ng and Schedule Q Quality

Assurance and Control, Inspection and Testing of the contract.

The XYZ Company Limiteds Quality Plan and the systems included therein, describe

how the quality assurance program of The XYZ Company Limited is designed to ensur e

that all quality requirements are recognized and that a consistent and uniform control of

these requirements is adequately maintained. The XYZ Company Limiteds Quality Plan

also defines how effective control is established.

Signed: _________________________

Name: _________________________

Title: _________________________

Date: _________________________


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SECTION 2: INTRODUCTION

No company can be successful without satisfied customers. Our success has beenachieved by a continuing commitment, t o our customers, to provide them with what waspromised. This lies at the very heart of our quality objectives. We have always taken on

board the definition of quality as being first time conformance to defined requirements.Moreover, we have adopted the premise that quality is driven by and defined by thecustomer. In short, we have a strong customer focus and are convinced that quality iswhat the customer says it is.

The function of this Quality Plan (QP) therefore is to describe and set out the gener alquality policies, procedures and practices of the XYZ Company.

This QP has been compiled on the basis of ISO 10005. It also serves as a referencebetween ISO 10005 and XYZ Companys internal Quality Management System. It is amanagement tool to keep employees of XYZ Company aware of their responsibilitieswith the internal quality approach and can be used for marketing. It is also a suitabletraining document. It can reduce the learning curve due to employee turnover and canassist in the continuity of events in such cases.

Measurement of the cost of quality must be a fundamental consideration in the design, inthe development and in the maintenance of the system. The need to impose discipline,where it was previously not considered necessary, can o nly be achieved if the potentialrewards of improved profitability and turnover are appreciated by the ill disciplined.

A person who makes no mistakes makes nothing and will never gain experience.

However, the secret is to build upon ones mistakes and ne ver repeat them. This is thebasic principle of Quality Management and it is the prime reason why a formal QualitySystem must be introduced as companies grow and their organization and structurebecome more complex. The informal systems, which served XYZ Company well when itwas smaller, can no longer be tolerated.

Quality Management is a key ingredient in maintaining the continuing success of XYZCompany. There will always be a danger that the discipline, which it imposes on us, willbe regarded by some as an additional layer of bureaucracy. This we will guard against atall times.

The principles of Quality Management must be company wide. In fact, they must extendeven further and become a co -operative venture between our sub -contractors andourselves. This is fundamental to the eventual success of sub -contracts since our sub -contractors must also take on board our definition of quality and establish, document andmaintain effective and economical Quality Systems to ensure and demonstrate thatproducts i.e. results of activities or processes, conform to specified Saudi AramcoSchedule Q requirements.

This QP, and the typical procedures outlined herein describe how XYZ Company Quality


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Management System is designed to ensure that quality requirements are recognized andthat consistent and uniform control of these requirements is adequately maintained. TheQP defines how effective control is established by use of formal written procedures. TheQM System includes provision for prompt detection of discrepanc ies and for timely andeffective corrective action.

2.1 Amendments and Re-issue

Quality Assurance Department shall review the Quality plan periodically with

other departments to re -affirm its adequacy and conformity to Saudi Aramco

requirements. The minimum frequency for review of the Quality Plan is once

every 6 months.

Amendments to the Quality Plan are made as required to reflect the current quality

assurance program. The amendments are made by replacement of the applicable

page (s). Each amended page is identified by amendment number and date ofamendment.

Amendments are numbered consecutively until such time as a new issue

incorporates all such changes. When changes affect a considerable number of

pages, and in any case after not more than ten amend ments to one issue, the

Quality Plan is re-issued. Issues are identified by numbers in numerical order.

Each issue cancels and replaces all previous issues and amendments.

The Quality Plan Amendments Record indicates all the amendments to the latest

issue of the Quality Plan.

A complete list of Quality Plan holders is retained by the Quality Assurance

Department. Amendments and re -issue of the Quality Plan are automatically

distributed to all registered holders.

2.2 Quality Plan Amendment Record Document

The Quality Plan Amendments Record indicates all the amendments to the latest

issue of the Quality Plan.

When the Quality Plan is revised, sections so affected shall be inserted and thesuperseded sections shall be removed and destroyed. Any additions or alterations

to the test on any page shall be highlighted by underlining or by the inclusion of a

vertical line in the right hand margin.


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QUALITY PLAN AMENDMENT RECORD DOCUMENT

DATE SECTIONS/PAGES OF QUALITY

PLAN EFFECTED

REV.

NO.

ISSUE

NO.

MODIFICATION AND

/OR ADDITION

SIGNED

10.30.00 Initial issue 0 0 NoneA. N.

Other

11.28.00 Sect. 4/pg 2 & 3 1 0Pg 2 & 3 modified

Para 1& 5

A. N.Other

2.3 Quality Objectives

The objectives of the Quality P lan are:

?? To ensure that approved methods and procedures are in place and utilized, as theyapply, for each phase of a project.

?? To optimize the reliability, operability and maintainability of the facilities.

?? To optimize the planned production profiles and installation availability within

the constraints of the respective availabilities of the facilities.

?? To minimize scrap and rework during the life of a project.

?? To ensure that the safety of personnel, the facilities and environment have beencarefully considered and that the appropriate measures have been implemented.

?? To comply with international and Saudi Aramco codes and standards.

?? To demonstrate the fulfillment of Saudi Aramcos requirements.

?? To maintain an effective and economical program for qu ality, to satisfy SaudiAramco requirements.

?? To demonstrate both recognition of the quality requirements of the project and an

organized approach to satisfy these.

?? To ensure that quality requirements are determined and satisfied throughout allphrases of contract performance, including, as applicable, design, developing,procurement, construction and pre -commissioning.


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?? To maintain an effective and economical program for quality, to satisfy Saudi

Aramco requirements as defined in Schedule Q Quality Assurance and Control,Inspection and Testing.

?? To demonstrate both recognition of the quality requirements of the project and anorganized approach to satisfy these.

?? To ensure that approved practices, procedures, inspection and test plans and Auditprogram are in place and utilized, as they apply, throughout all phases of a project.

?? To provide for early and prompt detection of deficiencies and for timely and effectivecorrective action.

2.4 Wording and Definitions

Those Quality Management and related terms used in this Quality Plan are definedbelow. Wherever possible, reliance is placed on ISO 8402 Quality managementand quality assurance Vocabulary, and if a term is defined therein, the definitionis quoted, with explanatory notes as relevant.

Appraisal: Assessment of a suppliers capability of controlling quality carried outbefore placing orders.

Certification: The authoritative act of documenting compliance withrequirements.

Note: The requirements can relate to personnel, processes, products,organizations and services.

Compliance: An indication or judgment that the product or service meets therequirements of the relevant specification or regulation; also the state of meetingthe requirements.

Customer: Recipient of a product provided by the s upplier.

Notes:

?? In a contractual situation, the customer is called the COMPANY ieSaudi Aramco.

?? The customer may be, for example, the ultimate consumer, user,

beneficiary or purchaser.?? The customer can be either external or internal to the organization.

Corrective Action: Action taken to eliminate the causes of an existingnonconformity, defect or other undesirable situation in order to prevent recurrence.


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Documentation: Any recorded or pictorial information describing, defining,procedures or results .

Defect: Non-fulfillment of an intended usage requirement or reasonable

Design Control: The verification that design criteria comply with specified

requirements; that design data and methods are valid for the range of application;and that the comple ted design satisfies the design criteria.

Design Review: A documented, comprehensive and systematic examination of adesign to evaluate its capability to fulfill the requirements for quality, identifyproblems, if any, and propose the development of so lutions.

Note:A design review can be conducted at any stage of the design process, but

should in any case be conducted at the completion of this process.

Hold Point: work will be held until the inspection or test has been satisfactorilycompleted.

Improvement: Actions taken by XYZ Company to increase the effectiveness and

efficiency of activities and processes in order to provide added benefits to both

XYZ Company and its Sub-contractors.

Inspection: An activity such as measuring, examining, testing or gauging one or

more characteristics of an entity and comparing the results with specifiedrequirements in order to establish whether conformity is achieved for eachcharacteristic.

Non-conformity: Non-fulfillment of a specified requirement.

Note:The definition covers the departure or absence of one or more quality

characteristics (including dependability characteristics), or qualitysystem elements from specified requirements.

Procedure: A specified way to perform an activity.

NOTES:In many cases, procedures are documented (e.g. quality systemprocedures).When a procedure is documented, the term written procedure or

documented procedure is frequently used.

Product: Result of activities or processes.


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NOTES:1. A product may include service, hardware, processed materials,

software or a combination thereof2. A product can be tangible (e.g. assemblies or processed materials)

or intangible (e.g. knowledge of concepts), or a combination thereof.3. A product can be either intended (e.g. offering to customers) or

unintended (e.g. pollutant or unwanted effects).

Quality: The totality of characteristics of an entity that bear on its ability tosatisfy stated and implied needs.

Quality Policy: The overall intentions and direction of an organiza tion withregard to quality, as formally expressed by top management.

Quality Management: All activities of the overall management function that

determine the quality policy, objectives and responsibilities, and implement themby means such as quality planning, quality control, quality assurance and qualityimprovement with XYZ Companys Quality System.

Quality System: XYZ Companys organizational structure, procedures, processesand resources needed to implement quality management.

Quality Control: XYZ Company employs operational techniques and activitiesthat are used so that its operations and services conform to the qualityrequirements as laid down in Saudi Aramcos documents.

Quality Assurance: All the planned and systematic activities implemented withinXYZ Companys quality system, and demonstrated as needed, to provide adequateconfidence that an entity will fulfill requirements for quality.

Quality Plan: A document setting out the specific quality practices resources andsequence of activities relevant to a particular product, service, contract or product.

Quality Audit: A systematic and independent examination to determine whetherquality activities and related results comply with planned arrangements andwhether these arrangements are implem ented effectively and are suitable toachieve objectives.

Repair: Action taken on a non -conforming product so that it will fulfill theintended usage requirements although it may not conform to the originallyspecified requirements.

NOTES:Repair is one type of disposition of a non-conforming product.

Repair includes remedial action taken to restore, for usage, a onceconforming but now non-conforming product, for example, as part of


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maintenance.

Review: An independent assessment undertaken by an individ ual or group thearea under review.

Rework: Action taken on a non -conforming product so that it will fulfill theoriginal requirement.

NOTE:Rework is one type of disposition of a non-conforming product.

Safety-related: Pertaining to those items of pla nt, the satisfactory performance ofwhich is important to the prevention of consequences of such accidents.

Specification: The document that prescribes in detail the requirements with whichthe product or service has to comply.

Standard: A document appro ved by a generally recognized body which resultsfrom the process of formulating and applying rules for an orderly approach to aspecific activity.

Service: The results generated, by activities at the interface between the supplierand the customer and by supplier internal activities, to meet customer needs.

NOTES:The supplier or the customer may be represented at the interface bypersonnel or equipment.

Customer activities at the interface with the supplier may be essential to the

service delivery.Delivery or use of tangible product may form part of the service delivery.

A service may be linked with the manufacture and supply of tangible product.

Service delivery: Those supplier activities necessary to provide the service.

Supplier: Any individual or organization that furnishes items or services to aprocurement document.

NOTE:An all-inclusive term that may be used in place of any of the following:vendor, seller, contractor, fabricator, consultant and sub-tier levels.

Test: The determination or verification of the capability of an item to meetspecified requirements by subjecting the item to a set of physical, chemical,environmental or operating conditions.

Witness Point: The inspection will be witnessed by inspection of QC staff.


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2.4 Distribution List

Quality Plan holders are assigned specific numbers for the copies retained.

Serialization and accountability is the responsibility of the Quality ManagementDepartment. Amendments and re -issue to Quality Plan holders are also theresponsibility of Quality Management. This Quality Plan shall be held by thefollowing people who will be responsible for inserting revised and removing anddestroying obsolete pages.

Controlled copies of the Quality Plan must be RED STAMPED by QualityManagement with the individual assigned serial number (below) entered in Red.Uncontrolled copies of this QM Plan will be stamped in blackUNCONTROLLED.

SERIAL NO.: ____________________ CHECKED BY: _________________

ISSUE NO.: ____________________ APPROVED BY: ________________

ISSUE DATE: ____________________

The list of holders of controlled copies of the Quality Plan include:

Name of Holder Serial No.

Project Manager XYZ Company 1Deputy Project Manager XYZ Company 2Construction Manager XYZ Company 3Procurement Manager XYZ Company 4Project Engineer XYZ Company 5Quality Assurance Manager XYZ Company 6Client XYZ Company 7Client XYZ Company 8Client XYZ Company 9

Note: Additional copies of the Quality Plan shall be issued to key personnel on aneed to know basis.


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SECTION 3: MANAGEMENT RESPONSIBILITY

3.1 XYZ COMPANY Quality Policy

Managements statement concerning the quality policy is given under section 1.

3.2 Responsibility & Authority

This section of the Quality Plan sets forth the organizational arrangementemployed by XYZ Company in providing support services and in executingprojects they undertake. It also defines the organizational relationship,responsibility, authority and lines of communication of the QualityManagement function. (See Figure I & II)

In providing effective management of projects and support services, XYZCompany assures optimum use of manpower, technological and financialresources utilizing expertise fr om a variety of disciplines to meet therequirements of their customers. Such expertise is developed around highlycompetent, technical and managerial personnel experienced in engineeringand construction techniques. These personnel comprise of affiliatedorganizations.

To this end, XYZ Company has an obligation to ensure that the finalproduct i.e. result of activities or processes meets its fitness for purposeand has been carried out in accordance with the Job Specification and isconsistent with desig n requirements.

XYZ Company organization consists of the following:

?? Project Manager?? Deputy Project Manager?? Project Contract Engineer?? Project Quality Assurance Manager?? Project Planning and Cost Engineer?? Project Engineer

?? Construction Manager?? Material Inspector?? Quality Control Supervisor?? Field Engineer?? Supervisor at Sub-contractors works?? Construction Superintendent?? Document Controller?? Materials Controller

?? Coating and Painting Inspector


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?? Procurement QC Supervisor

Project Manager

The Project Manager has overall authority and responsibility for all aspects

of the Project.

His responsibilities include but are not limited to the following:

?? representation of XYZ Company towards Saudi Aramco for allmatters relating to a Contract.

?? overall management of the project activities and control of therelated personnel

?? approval of the Project Master Schedule and control of its

fulfillment?? implementation of any step which may be required to prevent or

minimize delays, budget over-running, conditions adverse toquality objectives

?? submittal of progress reports the Client

?? coordination and supervision of activities of the Consortiumpartners

?? maintenance and coordination of contacts with the localauthorities for all matters related to the work execution

The above task will be achieved by coordinating activities of the ProjectPersonnel.

Deputy Project Manager

The Deputy Project Manager report directly to the Project Manager and

assists him in the day-to-day execution of the Project activities. During the

absence of the Project Manager, the Deputy Project Manager shall be the

Representative of the XYZ Company.

Project Contract Engineer

The Project Contract Engineer shall be responsible for:

?? Assistance and support to Project Manager for any contractual

matter

?? Coordination of Contract Review activities

?? Control of correct issuing of Change Order Requests, Change Orders


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and Claims.

?? Maintenance of correct flow of Project Correspondence

?? Preparation of minutes of meeting.

Quality Assurance Manager

The Quality Assurance Manager directs activities of the Project Quality

Organization, reporting directly to the Project Manager, but maintaining an

operational link with the Project Sponsor.

His responsibilities include but are not limited to:

?? Preparation, review, updating and distribution of the Project Quality

Plan.

?? Issue of Project Quality procedures, Project Inspection and Test

Plans and forms?? Review of Quality documentation issued by XYZ Company

?? Assignment of Quality related tasks within the framework of the

project

?? Review of Inspection Reports and of related Non -conformance

Reports

?? Evaluation of Suppliers/Sub-contractors Quality systems

?? Verification, by means of a planned Audit schedule that the

established Quality Program is being implemented by Sub-

contractors

?? Verification by means of a planned Audit schedule that therequirements set in the Quality Plan are met.

?? Coordination and supervision of activities relative to the collation of

the Project Record Books.

?? Determining and reporting to the Project Manage r the principal

causes of quality loses.

?? Determining with the Project Manager where improvements are

required and where necessary, recommending corrective action.

Project Planning and Cost Control

The Project Control Engineer is responsible for control aspects of the

project.


?? Preparation of scheduling and cost control procedures in

conformance with the requirements of Saudi Aramco and with the


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in-house standards

?? Preparation, in collaboration with the Project Manager, and updating

of the Project Master Schedule

?? Monitoring the progress of the Project activities, indicating where

corrective actions are required

?? Preparation of the Progress Reports for the Project Management andfor Saudi Aramco

?? Monitoring of the Project financial performance and updating of the

budget

?? Assistance to the Project Manager in assessment of cost and time

impact of work changes

Project Engineer

The Project Engineer directs and coordinates the engineering activities

pertinent to execution of the Project.


?? Ensure the interdisciplinary coordination of the various specialist

design groups and optimization of solutions

?? Verify the compliance of design with the Project quality

requirements and contractual obligations

?? Ensure the timely availability of pertinent technical documents as

per established document release schedule

?? Promote any steps which may be required to prevent or minimizedelays of engineering activities

?? Analyze changes in the Scope of Work and assist the Project

Manager/Project Planning and cost Control in assessing the relevant

costs and implications

?? Issue of Purchase Requests for material and/or equipment related to

the Project

Construction Manager

The Construction Manager controls and coordinates all Work activitiescarried out in the construction site.


?? Establishment and implementation of procedures for execution of

the Work

?? Cooperation in the definition and u pdating of the detailed

construction schedule, including redesignation of priorities where


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necessary

?? Control and coordination of the work entrusted to Sub -contractors

?? Planning and scheduling of the work force and equipment demand

?? Cooperation in definition of the materials delivery schedule

?? Preparation of data required for compilation of the Work Progress

Report

?? Preparation of the change order proposals

?? Assistance to the Project Manager in discussions with Saudi Aramco

Note: The Construction Manager is assisted in the above tasks by

Discipline Superintendents and Supervisors.

Quality Control Manager


?? Managing Quality Control functions for the Project including

planning of Quality Control inspections and preparation of reports

?? Controlling corrective actions.

?? Assigning Quality Control personnel to various areas of activity

Monitor inspections progress, review Inspectors reports and

documentation and verify, upon completion of the work, that all

requirements have been met and that the required Quality records have

been collated and filed

?? Monitoring on a day to day case XYZ Company Project complaints

with the approved quality plan(s)

?? Following a suitably start and approved procedure for the formal

control of deviation/waivers from the job specification.

?? Review and approve as necessary, quality related procedures such

as:

- Weld procedure specifications

- Weld procedure qualifications

- Welder qualification

- NDT procedures

- Heat treatment procedures

- Cleaning and pressure testing procedures- Preservation procedures

?? Oversee the daily content and consistency of subordinate inspectors

daily inspection logbooks.

Note: The Quality Control Manager is supported by Supervisor and

discipline inspectors.


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Procurement Quality Control Supervisor


?? Review requisitions and purchase orders for compliance withcontract requirements

?? Preparation of purchase order(s) inspection assignment packages

?? Review of sub-vendors quality procedu res

?? Establish agenda for pre -inspection meetings

?? Scheduling and coordination of source inspection

?? Ensure inspection assignment packages are correctly distributed

?? Assist QC inspectors in all aspects of their work to ensure that all

project requirements are fulfilled and that all inspections required are

carried out and correctly recorded.

Field Engineer

He is responsible for coordinating and solving problems that may arise in

connection with the revision or updating of field engineering during

performance of the Work assigned to XYZ Company.


?? Monitor implementation and adequacy of the

construction/installation procedures established for the project?? Receipt of all the technical documentation on site

?? Filing, reproducing and distribution of all technical documents

required for performance of the Work

?? Updating and revision of the drawings according to amendments and

modifications carried out in field

Depending on the project complexity, the field Engineer i s assisted on field

by Technical Clerks and Document Control.

Supervisor at Sub-contractors Works

The supervisor is XYZ Company project representative and shall liaise with

Saudi Aramcos representative at the Sub -contractors premises.


?? Verify the progress of Sub -contractors work and collect planning

and reporting documentation to be included in the overall progress


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report

?? Evaluate site changes proposed by Sub -contractor and if acceptable

obtain Saudi Aramcos approval.

?? Collect all Sub-contractors Quality Records

?? Verify that the quality standard of Sub -contractors work is in

compliance with contractual specification and approved procedures

?? Transmit to the Project Management offices all necessary

documentation generated by the Sub -contractor.

Construction Superintendent

The Construction Superintendent is responsible for the performance of the

part of the works assigned to XYZ Company according to the established

construction/installation procedures a nd in house standard criteria.

He shall manage the personnel and equipment available to carry out thecontractual works and, in particular, shall coordinate the pertinent logistic

activities.

During the execution of offshore operations, he shall maintain overall

supervision and coordination of the operations spread composed of the

various vessels and /or organizations involved the works execution.

Document Controller

The Document Controller shall manage all the information concerning theProject.


?? Promote of the formal management of the information system

?? Interface with peripheral units and sites to activate training on the

use of the info system

?? Record and manage incoming and outgoing correspondence

?? Distribute documents in a controlled manner

?? Organize the correspondence archive and make sure that this is

aligned with the one on site

Materials Controller

The Materials Controller reports to the Construction Manager.


?? Receiving inspection and record keeping of all material both free

issue from Saudi Aramco and XYZ Company supplied material.


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?? Reporting of non -conformances, the monitoring of careful

segregation of quarantined material and rectificat ion of defects and

clearance of materials from quarantine.

?? Assuring the traceability of uniquely identified critical materials

while materials are in storage.

?? The monitoring and recording of the condition and state ofpreservation of materials released fro m storage for processing and/or

construction.

Welding/NDT Inspector

The Welding/NDT Inspector reports to Quality Control Supervisor.


?? Reviewing quality related procedures?? Ensuring that accurate, conc ise records of approved welding, NDT

and heat treatment procedures are maintained by XYZ Company.

?? Ensuring that accurate records of welder qualifications and

performance are maintained, such that welder traceability and poor

performance trends are readily identifiable.

?? Endures that qualified and competent operatives undertake NDT

work. Advises where NDT techniques are considered unsuitable and

where the competency of the operative might be questionable.

?? The Inspector shall ensure that Construction Contract or complies

with the requirement of the approved contract quality plan, includingall the sequential inspection operations associated with weld

preparation, fit up, weld execution and testing. All non -

conformances shall be reported and recorded. The Insp ector shall be

available for formal stage witness inspection defined within the XYZ

Companys Inspection & Test Plan.

?? Report daily a description of each days work.

Coating and Painting Inspector

The Coating and Painting Inspector reports to Quality Co ntrol Supervisor.


?? Monitoring XYZ Companys compliance with the requirements of

the contract scope of work, technical specifications and contract


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quality plan insofar as it applies to:

- Coating work (cement weight coating and bitumastic or

epoxy systems of coating and wrapping);

- Painting work;

- Insulation work;

- Temporary preservation work using coating and wrappingmaterials.assisting the Material Inspector in the task of overseeingfinal dimension checking, positive identification and preservation

of completed coated pipe joints.


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Figure I

XYZ COMPANY PROJECT ORGANIZATION CHART

Off Site

On Site

[b1]

Project QA Manager

Deputy Project Manager

Project Manager

Construction Manager QC ManagerSafety

Mana er

Procurement

Manager

Safety Officer Material Supervisor QC Supervisor &QC Organization

Material Engineer

Planning & Cost EngineerSuperintendentProject Engineer

Personnel Officer

Asst. Superintendent Asst. Superintendent

Mechanical SupervisorChief Surveyor Electrical Supervisor

Civil SupervisorInstrumentation Supervisor

SAUDI ARAMCO

Corporate QA Manager

Engineering

Manager


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XYZ COMPANY QC ORGANIZATION CHART (Figure II)

Sr. Matl.

ReceivingInspector

Matl.

ReceivingInspector

QC

Inspector

Structural

(2 ea.)

QC

Inspector

Mech./

Piping

(3 ea.)

QC Inspector

Painting

(2 ea..)

Technical

Clerk

QC InspectorE & I

(3 ea.)

QCSupervisor

QC Manager

Senior QC

Inspector(1)

QC

InspectorWelding

(4 ea.)

NDT

Subcontractor

Procurement

Manager

Procurement

QCSu ervisor

Vendor

Inspectors

(8 ea.)


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?? Reporting both verbally and in writing any non-conformancediscovered.

?? Reporting daily a descriptive of each days work.

3.3 Resources

Means and personnel for verification are located within the XYZCompanys departments and reflected in the project plan.

The XYZ Company shall be responsible for maintaining up-to-dateprocedures for his area of management, including procedures for:

- The checking of such documents as drawings, data sheets, calculations

and specifications.- The control of design or construction work by use of philosophies,

procedures and standards.- Standard preparation methods for specification, data sheets, drawings

and work packages.

XYZ Companys discipline engineer shall ensure that all significantactivities are properly conducted and documented throughout a project,verifying that:

- All necessary data, specifications, standards and other documents areavailable before the start of any activity.- All the required work, drawings, report and calculations are in fact

produced during each activity.- Any deviation from the above requirements is properly documented. All

documents are systematically numbered or otherwise ident ified, filed,updated as required, and held securely in a system which ensures thatthey are readily available upon request to assist reviews or audits by theproject team and the Quality Assurance Manager.

3.4 Management Review

A Quality Management Committee, which comprises the senior executivesof XYZ Company, shall be formed to monitor and systematically reviewthe continued effectiveness of XYZ Companys QM System.

The Quality Assurance Manager, who shall be responsible for thepreparation of the agenda and the writing of the minutes, shall convene


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meetings at approximately six monthly intervals. Lead or Senior Engineersshall report to this committee on specific issues, for example, sub -contractor strategy, quality awareness, and non -conformance costmeasurement.

These management reviews are additional to, and use the findings of,internal audits conducted to ensure continued adherence to the system.

Both reviews and internal audits shall be positive and not conducted solelyas a matter of expediency r esulting from Quality problems.

The Management Review shall:

- Ensure that management quality policy objectives, assignments,delegations and methods are achieving the required results.

- -Reveal defects or irregularities in any of the elements examined- Indicate possible improvements.- Check on the effectiveness of management at all levels.- Uncover potential danger spots and eliminate waste or loss.- Examine the registered complaints from customers.- Verify that corrective action procedures are effective.

XYZ Company will ensure that Senior Management Reviews are scheduled

events included in the quality audit schedule approved by Saudi Aramco

Representative in accordance with Paragraph 5.3.2 of Schedule Q.

XYZ Company will make presentation of the results a nd recommend

actions of such reviews to the Saudi Aramco Representative within three

(3) weeks after the schedule review date. Changes to the Quality System

that result from XYZ Companys Senior Management Reviews shall be

incorporated in the project Qual ity Plans, with the approval of Saudi

Aramcos Representative.

SECTION 4: XYZ COMPANYS QUALITY SYSTEM OUTLINE

GeneralThis section outlines the primary functions of XYZ Company necessary to comply withthe criteria of ISO standard 9001. It includes the controls to be exercised on those aspectsof the functions which have an effect on quality of the activities, service or process, toensure conformance to contractual requirements. References are made to written qualityprocedures related to applicable functions. Each quality procedure shall describe indetail what is to be done, how itshould be done, who should do it and when it should bedone.


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4.1 Management Responsibility

This Quality Plan Template identifies those authorized and responsible for:

- Ensuring that the activities required by XYZ Companys QualityManagement System are planned implemented and controlled and theirprogress monitored.

- Communicating requirements and resolving problems acrossorganizational interfaces, both within and extern al to XYZ Companysorganization, including defining methods of interacting across theseinterfaces.

- Review of audit results to achieve quality improvement.- Details of who, what, how and when shall be defined in written

procedures and other referenced XYZ Company documents (XYZ -

QMP-001).

4.2 Quality System

4.2.1 XYZ Company has structured the Quality System employed on the projectin accordance with the guidelines of ISO Guide 10005, ISO Standard 9001 1994, and Schedule Q . As such, the Quality System is d esignedprimarily to satisfy the managerial needs of XYZ Company and that ofSaudi Aramco.

4.2.2 XYZ Companys Quality Management System is described in this QualityPlan and includes organization charts giving key job titles, job descriptions,details of how the levels are tiered, with the necessary references toprocedures, structures, routines and administrative documentation.

4.2.3 Excessive detail has been avoided as it is counter productive for thisQuality Plan to be subject to frequent amendments Only the wor kingdocuments (procedures, job descriptions, work instructions, organizationsetc.) shall be subject to change as and when necessary

4.2.4 XYZ Company shall submit the Design Phase Quality Plan to the Saudi

Aramco Representative for review and approval no late r than forty-five(45) calendar days after the effective date of the Contract.

4.2.5 XYZ Company will submit its Quality Plan(s) to Saudi AramcoRepresentative for review and approval a minimum of thirty (30) calendardays prior to the scheduled start date of t he procurement, construction andpre-commissioning phases as specified in the WORK Schedule provided in


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Schedule A.4.2.6 Moreover, the Quality System described in the Quality Plan demonstrates

that XYZ Company has a planned and systematic approach to obtainin gand maintaining quality. It shows that personnel have the necessary training

to perform their work and definitions for quality and quality relatedactivities are reflected in the documented system and represent XYZCompanys interpretation to suit its ow n objectives.

4.2.7 Details of who, what, how and when shall be defined in written proceduresand other referenced XYZ Company documents (XYZ -QMP-002).

4.2.7.1 The quality system employed on this project, as per this Quality

Plan is based on the guidelines as set down by ISO 9001 - 1994:

quality system Model for quality assurance in production,

installation and servicing.

4.2.7.2 The establishment and maintenance of this Quality System shall be

conducted in accordance with Procedure 4.2 - Quality System.

4.2.7.3 Subcontractor shall submit the names, qualifications and locations

of all Quality personnel and agencies, including independent test

laboratories; those shall be used during the construction phase.

4.2.7.4 The Project Manager shall be responsible for the overall

performance of the P roject.

4.2.7.5 The Project Engineer shall control the Site activities.

4.2.7.6 The Quality Manager shall be responsible for ensuring the

implementation of this Quality Plan.

4.2.7.7 At least 30 days prior to any activity,

4.2.7.8 Will designate one qualified personnel as Project Qua lity

Representative and submit his qualifications to Purchaser for

concurrence.

4.2.7.9 The Quality Manager shall hold regular scheduled meetings with

the XYZ Company Quality Department to review outstanding

items, upcoming activities, etc.


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4.2.7.10 The Quality Manager shall be responsible for the daily site Quality

activities to establish and maintain the project Quality program.

His responsibilities include:

4.2.7.10.1 Controlling site inspection and test activities.

4.2.7.10.2 Establishing and implementing the inspection plans and

procedures as required.

4.2.7.11 Project Inspection, witnessing, monitoring, and signature shall be

in accordance with the approved inspection and test plan. Refer

section 6 of the Quality Plan.

4.2.7.12 The inspection and testing requirements shall be carried out in

accordance with procedure 4.11: Inspection and Testing.

4.2.7.13 Request For Inspection (RFI), procedure will detail the

responsibilities for the following:

4.2.7.13.1 Initiation of the RFI,

4.2.7.13.2 Acceptance of the works, and

4.2.7.13.3 Closing out of actual inspection.

4.2.7.14 Master index and Revision control Log shall be maintained to

update the revisions, as per Section 1.1 of this Project Quality

Plan.

4.2.7.15 A 2-week look ahead schedule and a weekly Inspection Schedule

shall be submitted to the Purchaser to schedule the inspection

activities.

4.2.7.16 Copies of the approved Quality plan shall be issued to the Projects

Manager, Engineering/Procurement Manager, Project Enginee r

and Quality personnel.

4.2.8 Quality System Documents

4.2.8.1 Level 1 Quality system documents


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4.2.8.1.1 The Project Quality Plan is the level I and governing

document of the quality management system.

4.2.8.1.2 The PQP makes reference to the scope of work.

Project Specifications, Quality Procedures and WorkInstructions meeting the requirements of the Project

Quality Statement.

4.2.8.1.3 The Quality Manager shall review and update the

Quality plan based on the comment from the project

teamand Purchaser, to ensure that it reflects the actual

functioning of the project.

4.2.8.2 Level 2 Quality System Document

Quality Procedures and Project P rocedures employed by the

subcontractor form the Level 2 Quality Management System

4.2.8.2.1 Quality Procedures are issued by the Quality

Department as the general quality control tool. Project

Procedures shall be prepared by the relevant personnel

within the project team to supplement the quality

procedures or to develop specific procedures for

operational and quality activities applicable to the

project.

4.2.8.2.2 Level 2 Quality system documents are shown in

Section 5 Quality Procedures.

4.2.8.3 Level 3 Quality System Documents

4.2.8.3.1 Work Instructions and Inspection & Test Plans form

the level 3 documents.

4.2.8.3.2 Work instructions are prepared based on the Project

Specification.

4.2.8.3.3 The Inspection and Test Plan and acceptance criteria

are covered in this section.


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4.2.8.3.4 Level 3 documents a re contained in section 5 Work

Instructions and Section 6 Inspection and Test plan

of this Quality Plan.

4.2.8.4 Level 4 Quality System Documents

4.2.8.4.1 All quality records generated by XYZ Company will

be legible and be stored and retained for easy

availability.

4.2.8.4.2 Level 4 Quality System Documents, for handover to

Saudi Aramco, will be compatible with SAEP-122

Project Records.

4.3 Contract Review

XYZ Company shall establish and maintain procedures to ensure:

- That XYZ Company has the capability to meet the requirements of thecontract.

- That such requirements are adequately defined documented and agreed.- That any future requirements differing from those of the contract are

resolved and documented.- Formal lines of communication- Records are maintained of such r eviews.

Whatever the situation may be, a Contract Review shall be carried out after XYZCompany has indicated (in whatever way) its intention to accept a bid or proposaland before any form of agreement/contract is finalized. A similar Contract Reviewshall be carried out whenever any change, perhaps to the scope of work, or theoriginal contract, is proposed. Such a review shall take place at the bid/proposalstage in cases where the proposal is likely to form part of the final agreement.

Contract Reviews shall be carried out under the following main headings using astandard form or checklist for the purpose. Much of the information in the contract

will be relevant to the Project Quality Plan. If fully detailed in the contract, it shallsimply be called up in the Project Quality Plan.

4.3.1 Conditions of engagement

Any ambiguities, disagreements to the contract will be identified and recorded and

transmitted to Saudi Aramco for resolution.


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4.3.2 Definition of duties

The scope of services to be provid ed shall be reviewed and recorded including the

role of other suppliers (if any) appointed by XYZ Company.

4.3.3 Technical requirements

All technical requirements forming part of the contract shall be identified,reviewed, confirmed as acceptable or for further negotiation and recorded. Theseshall include as applicable:

- Work scope.- Technical standards or specification to be followed- Space, loading and environmental requirements.- Equipment specified by Saudi Aramco.- Saudi Aramco supplied product/services/ information of any type, e.g.

standard drawings or details, standard specifications.- Use of methods of analysis specified by Saudi Aramco.- Regulatory requirements.

4.3.4 Project program

Key dates for delivery of documents and drawings shall be review ed, confirmed as

acceptable or for further negotiation, and recorded.

4.3.5 Resources allocation

A preliminary assessment shall be made of suppliers staff resources to satisfySaudi Aramcos requirements within the time allowed for execution. The re sult ofthis assessment shall be recorded.

Details of who, what, how and when shall be defined in written procedures andother referenced XYZ Company document (XYZ -QMP-003).

4.4 Design Control

XYZ Companys Qualify Management System shall ensure that design anddevelopment is a controlled function. Procedures shall be established andimplemented that assure activities are performed effectively and efficiently inaccordance with ISO 9001 and Schedule Q.

XYZ Company ensures that design decisions are mad e by authorized qualifiedpersonnel who are in possession of or have access to the pertinent design criteria,


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contractual requirements, codes, regulations, standards and guidelines.

Essential design considerations, calculations and decisions are clearly, completelyand precisely documented in design documents, such as design calculation sheets,

specifications, drawings, computer programs, documented quality procedures andinstructions, that are free of ambiguities and conflicting requirements and conformto all governing standards and system procedures for such documents.

Design documents and the design concepts and requirements expressed therein,are subjected to review and approval by qualified personnel, other than those whodid the original design, wit h clearly designated responsibility and authority to doso, prior to release for purchasing, fabrication or construction.

Design approvals are based on one or more of the following:- Valid related experience.

- Independent review of the analysis and calculat ions involved in thedesign concepts and decisions.

- Appropriate test. Demonstrations.- Other appropriate and adequate objective evidence that the design

criteria and documentation requirements have been satisfied.

Essential aspects of the design shall als o be reviewed independently byappropriate representatives from XYZ Company.

Design documents shall identify those items of the design that are crucial to its

safe and proper functioning and specify the quality standards to which these itemsshall be produced. Deletions from and additions and changes to designdocuments, subsequent to approval for release shall be identified and documented(see Section 4.5).

Deviations from the requirements of design and contract documents, includingdesignated quality standards, shall be subject to the same authorizations as therequirements involved.

Incomplete, ambiguous, or conflicting requirements shall be resolved by thoseresponsible for generation and approval of the requirements.

In order to control and verify the design of products to meet the criteria as citedabove, XYZ Company shall implement and operate design controls to provide forthe following:

?? Design Interface Control which shall define the methods andresponsibilities to control the interfaces betw een systems, contractors,


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regulatory authorities, etc.

?? Initial Checking of Design Documents which shall define theresponsibilities and general methods whereby design documents are

subjected to a systematic initial check within the original disciplines.

?? Interdisciplinary Checking which shall define the responsibilities andgeneral methods whereby documents with design interfaces are checked bythe interfacing disciplines.

?? Authorization and Revision Status Identification of Documents whichshall define the necessary authorization of documents including standardmethods of adding and identifying revisions.

?? Internal Design Review which shall define the responsibilities and

general methods whereby a formal documented and systematic criticalstudy of a design is carried out. XYZ Company will perform its ownindependent design review prior to submitting its design to Saudi Aramcoas specified in Schedule B and will maintain record of its DesignReviews including solicitation, recording and resolut ion of comments.

?? Design Feedback which shall ensure that problems reported at all stagesof a project, or contract, from procurement through assembly, installation,commissioning and servicing, receive attention in such a way as to avoid arepetition of past problems and promote future improvements.

Details of who, what, how and when shall be defined in written procedures andother referenced XYZ Company documents (XYZ -QMP-004).

4.5 Engineering Change Control

XYZ Company shall implement and operate a system which shall control changesfrom wherever they originate and which shall ensure they are channeled throughone recording area both in and out

The system shall also ensure that all changes are correctly documented and have

received authorization fro m the original design source to be actioned.

Where design interfaces were involved in the original design, then changes to suchdesign shall include a review by the interfacing disciplines.

Engineering change control will provide for four categories of change as follows:


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Category I which is an addition to the contracted scope of work and whichresults in changes to the specifications.

Category 2 are changes to specifications that become necessary to maintain thedesign integrity.

Category 3 are changes to specifications that are proposed as desirable to meetnew or additional requirements relating to safety, efficiency, costand schedule, and also those which became necessary to meetinternal and external customer requirements resulting from mark etresearch.

Category 4 are changes to the original scope of work due to the activities ofthird party sources, which result in excess variations to cost, timeand resources.


4.6 Document and Data Control

All essential documents affecting quality shall be reviewed for adequacy andapproved for release by authorized personnel.

XYZ Company shall make the applicable issues of such documents based on thecontractual freeze date available at all functional areas and inspection and testpoints where they apply so they are readily accessible to the personnel concerned.

The issue, control and recall of all engineering documents , is under the jurisdictionof the Engineering Manager. Inspection and Test Plans and other relatedinstructions shall be prepared and issued by the Quality Assurance Department.Test Reports shall be prepared and issued by Discipline and Quality Control.

Note: Reporting lines for document and data control may differ fromproject to project.

The system of documentation and data control shall ensure that essential drawings,technical requirements, contract change information, inspection instructions,specifications or any other document required by Quality Management, are

available at the time and place of the operation.

Approved Quality Procedures, of the latest issue, shall be distributed by theQuality Department to all locations where required for the effective functioning ofthe Quality Program.

All changes to documents shall be implemented in writing and processed in a


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manner, which ensure prompt action at the specified locations. Changes todocuments shall receive the same authorizations as the orig inal documents.Records shall be maintained of changes as they are made.

Provision shall be made to promptly remove obsolete documents from all points ofissue and activity locations

XYZ Company shall ensure that contractors prepare and submit request fo rchanges to Saudi Aramcos documents when required.

Details of who, what, how and when shall be defined in written procedures and

other referenced XYZ Company documents (XYZ -QMP-006 and XYZ-QMP-

007).

Note: Engineering documents include drawings, specifications, data

sheets, procedures, instructions, etc.

4.7 Purchasing

Supply of raw material, fabrications, services and finished items shall beprocessed from acceptable suppliers.

To the extent practical, XYZ Company will procure its equipment and ma terialfrom Saudi Aramco approved sources. Alternative sources for material identifiedin Saudi Aramcos Regulated Vendors Lists (RVL) shall be approved by Saudi

Aramco prior to placing of purchase orders. Other sources for material selected byPurchasing shall be evaluated and approved by XYZ Companys QualityAssurance (QA) Department prior to placing them on the acceptable sub -contractors list. Material, for which inspection requirements are specified onSaudi Aramco Form 175, shall be evaluated as specified in Schedule Q, paragraph4.1.

The extent of control over purchasing includes quality surveys and monitoring atthe suppliers premises as required.

A current list of acceptable suppliers for parts and processes shall be maintainedand distributed by the Purchasing Department.

Contracts/purchase orders shall be reviewed and endorsed by the QA Departmentto the extent required to ensure that all pertinent drawings, specifications andcomplete information relative to the item(s) procured are listed and that thesources of supply have all the data required to supply goods of an acceptablequality


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All purchase orders and associated reference data shall be available for review bySaudi Aramco when requested. XYZ Company QA Department shall review allprocurement documents prior to release to Saudi Aramco to assure that the

appropriate quality levels are designated for materials or services purchased.

QA Department shall evaluate all purchased items where any of the followingconditions apply.

- Inspection of quality characteristics cannot be verified duringsubsequent processing or would require destructive testing.

- Inspection is necessary to verify that specific processes, tests orinspections required of the supplier were adequately accomplished.

- Inspection at any other point would destroy or require the replacementof costly packaging materials

Amendments to the purchase orders (PO) shall be processed in the same way asthe original with reference made to the original PO.

Records shall be maintained to substantiate vendor quality performance.

Details who, what, how and when shall be defined in written procedures and other

referenced XYZ Company documents (XYZ-QMP-008.

4.8 Control of Customer-Supplied Product

XYZ Company shall establish and maintain procedures for the verification,storage and maintenance of Saudi Aramco supplied product such as equipmentand material, information and data supplied by the customer, which shall beincorporated into the work.

This may include:

- Long lead equipment and/or Free-issued material- Conditions of contract.- Specifications, or parts of.

- Drawings, design or particular details.- Specialized equipment and related specifications, drawings, etc.- Survey data.- Soil information.- Results of specialist investigations.- Feasibility study reports.- Computer software.


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Any such product that is lost damaged or is otherwise unsuitable for use shall berecorded and reported to the Customer. Any such records shall form part of XYZCompanys quality records.

XYZ Companys procedure shall set out details of verification to be carried out onreceipt of any Saudi Aramco-supplied product. It might require the Design Teamleader, in consultation with leaders of any other disciplines involved, to determinethe extent of verification r equired in order to satisfy himself, so far as this ispossible, as to the suitability/accuracy, and so on, of the Saudi Aramco suppliedproduct.

XYZ Company shall also set out in the procedure what is to happen when anyunsuitable Saudi Aramco-supplied product is found. This might lead to thatproduct being suitably marked or segregated, that a record be made of the finding,and that the finding being reported to Saudi Aramco.

Details of who, what, how and when shall be defined in written procedures an dother referenced XYZ Company documents (XYZ -QMP-009.

4.9 Product Identification and Traceability

XYZ Company shall establish and maintain systems that:- Identify each item (lot, component or part) to the applicable drawing,

specification or other tech nical document, from receipt through

fabrication and construction.

- Assign to each item a unique identification, which shall distinguishthose items which are otherwise identical, but which have beenproduced in separate batches. Record this identification on all process,inspection and test records where traceability is specified.

- Ensures alloy steels, stainless steel or non -ferrous alloys in contact withservice fluids are tested for positive material identification per SAES A-206.

XYZ Company traceability system shall operate from the specification of thematerial through its manufacture to its inclusion as a finished product in a facility,pipeline or platform. Such a system thus impacts upon a large number of projectand supplier activities, e.g. pu rchased materials, equipment packages andconstruction.


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XYZ Company traceability requirements shall be kept to the minimum consistentwith the safe and efficient operation of the installation concerned, and shall onlybe applied when failure of the equipment or material could result in a hazard topersons or the environment, or a significant loss of production output.

Details of who, what, how and when shall be defined in written procedures andother referenced XYZ Company documents (XZY -QMP-010)

4.10 Process Control

XYZ Company shall develop and implement effective procedures for controllingall fabrication, construction and testing processes, which will be clearly identifiedwith key parameters/variables affecting quality as specified in the appropriat e JobSpecifications or instructions. XYZ Company shall verify all fabrication andconstruction processes initially, and regularly monitor all process parameters

thereafter.

Such procedures shall provide for witness points to independently verify criticalwork phases, such as pipe bends etc. before proceeding with the Work.

Special Processes

Measures shall be established and documented to ensure that special processes asidentified in Schedule Q, Attachment IV are performed by qualified personnelusing approved written procedures and controlled equipment. All process

parameters shall be identified with acceptance criteria specified and monitored.These written procedures, personnel qualifications and personnel qualificationprocedures shall be submitted to Saudi Aramco review and/or approval at leastthirty (30) days prior to the start of the WORK.

The following list identifies some special processes:- -Welding- Coating application.- -Cable splicing/termination.- -Heat treatment- -Cable/conduit seals installation.

- -Non-destructive testing/examination.- Alloy verification- Concrete Mix Design- Asphalt Mix Design- Gasket Installation- Concrete Installation- Structural Bolt Tensioning


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- Gap Control for socket weld and back welded threaded fittings- Hydrostatic Testing- Hot Tap Procedures (Calculation Sheets)- Refractory Installation

Authorized personnel shall keep qualification results for processes,equipment and personnel current and available for verification

Details of who, what, how and when shall be defined in writ ten procedures andother referenced XYZ Company documents (XZY -QMP-011).

4.11 Inspection and Testing

XYZ Company and its suppliers shall develop Inspection & Test Plans and QCProcedures describing in detail the method and timing for examinations,

measurements or tests to assure compliance with contract requirements. They shallbe responsible for all required inspection tests and material examination. This shallinclude documentation for receiving, in -process and final inspections.

Specific inspection po ints shall be indicated in the Quality Inspection and TestPlan which shall be included in the Quality Plan (See Section 6). XYZ Companyand Suppliers approval to proceed shall be documented prior to the continuation ofwork beyond the designated Inspecti on point.

Inspection and Test Plan and related procedures shall include provisions for

ensuring and recording that prerequisites for any given test have been met, thatadequate and calibrated instrumentation is available and used, and that thenecessary inspection is performed.

Depending on the performance and control exhibited by XYZ Company workforces, XYZ Company surveillance activity will be adjusted to provide varyingdegrees of first -line inspection. Where XYZ Company performance and control isdeemed as adequate, the surveillance is oriented towards verifying XYZ Companycompliance to the QA Program requirements. Conversely, where XYZ Companyperformance and control is evaluated as marginal or below, the surveillance effortis focused towards hardw are inspections and a more detailed review of

documentation.

Surveillance of Contractors operations shall be performed in accordance with pre -established Inspection and Test Plans prepared by XYZ Companys. These aredeveloped around applicable technical specifications, drawings, referenced codesand standards as well as the XYZ Company accepted QA program and inspectionroutines.


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XYZ Company shall submit to Saudi Aramco each week a two -week look aheadschedule of all planned QUALITY activities during pro curement, construction andpre-commissioning Work phases as specified in Scheduled Q . The schedule

shall be sent electronically in a format acceptable by Saudi Aramco.


4.12 Control ofInspection, Measuring and Test Equipment

All inspection, measuring and test equipment and devices used to determineconformance to XYZ Companys specification, including that used for weldin g,nondestructive testing, dimensional control, pressure testing, coating thickness,shall be controlled, calibrated and maintained with an established written

calibration and maintenance schedule.

Primary master standards shall be calibrated and certified by approved facilitieshaving standards traceable to National Standard. Where no National Standardexists the basis employed for calibration shall be documented. Records shall beevaluated periodically to ascertain adequacy of inspection intervals pre sently inuse. The system shall be designed to ensure all measurement resources have thecapability of making measurements within limit designated as appropriate to theserequirements. It shall provide in the prevention of inaccuracy by prompt detectionof deficiencies and timely action for their correction.

All measuring and test equipment and devices having an effect on quality shallbear a tag, sticker or other suitable marking, indicating calibration status. Thevalidity of previous inspection and test results when measuring and test equipmentare found be out of calibration shall be assessed and documented. The standardsand masters shall be made available for verification by Saudi Aramco.

Equipment and devices used for measuring, testing and inspecti on shall require aninitial inspection for accuracy, or shall be proven prior to release for use onproduction.

The system shall provide for a pre -planned calibration frequency chart showing allapplicable test and inspection equipment, calibration freque ncy and status. In nocase shall calibration cycles exceed six months.



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4.13 Inspection and Test Status

A positive system shall be maintained forsignifying the status of inspection. Thisshall be done by the use of markings, stamps, tags, labels, routing cards, inspection

records, Inspection Disposition Reports, physical location or other suitable means,which can indicate the acceptability or non-conformance of items with regard totests and inspection performed.

The identification of inspection and test status shall be maintained throughoutfabrication, construction, installation and operation of the items to ensure that onlyitems that have passed the required inspection and test are used, installed andoperated.

Vendor inspectors shall forward Inspection Disposition Reports to the job site toclearly show inspection status and facilitate with receiving inspection.

Metal inspection stamps used on items should be Low -stress (Round Nose). Whendirect use of the inspection stamp is not possible the stamp impression shall beplaced on the package, tag, or label.

The authority for application or removal of any inspection st atus indicators such astags, labels, stamps etc. is Quality Assurance.

Details of who, what, how and when shall be defined in written procedures andthere referenced XYZ Companys documents (XYZ -QMP-014).

4.14 Control of Non Conformance

Any element of work not meeting the specified standards shall be rejected. XYZCompany shall issue Non-Conformance reports for all violations by XYZCompany, its sub-contractors, manufacturers or suppliers to contract requirementsand Saudi Aramco approved XYZ procedur es.

All non-conformities shall be identified by marking, tagging or physicalsegregation where practicable from the work to prevent their inadvertent, use orinstallation. No further processing, completion or delivery of such products shall

be carried out until the non-conformance is removed or adequately dispositioned.

An applicable Non Conformance Report (NCR) shall be completed identifying theproduct, deviation or discrepancy and forwarded to Quality Assurance for reviewat which point the product i s classified as follows:

- Rework.- Use as is or repair by concession


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- Reject or scrap.

This shall be done all in accordance with documented procedures. XYZ Companyshall submit a copy of each NCR to Saudi Aramco within 48 hours.

Quality personnel responsible for dispositioning non -conformities shall ascertainthat the deviation or discrepancy is clearly described relative to the acceptancecriteria.

Where for reasons of urgent production purposes continuation of processing isdeemed necessary, XYZ Company shall have the authority to release the material,providing that it shall be positively identified and recorded in order to permitimmediate recall in the event of a reject disposition.

Decisions on XYZ Companys non -conforming product shall be subject t o

approval by Saudi Aramco.

Contractors shall maintain objective evidence to substantiate that repaired andreworked products have been re -inspected or re -tested according to applicableprocedures.

XYZ Companys Quality Assurance shall maintain a system of on-going analysison non-conformities in order to isolate sensitive areas and/or trends ofdeterioration.


4.15 Corrective and Preventive Action

Conditions such as item and equipment malfunctions, deficiencies, deviations andnon-conformance adverse to the achievement of quality requirements shall beidentified and corrected. For significant conditions adverse to qualityrequirements, Quality Assurance shall determine the cause of such conditions andobtain necessary corrective action from the responsible supervisor and ensure theappropriate action is taken to prevent repetition.

The identification of the significant cond itions adverse to quality, the cause of thecondition and the corrective actions taken shall be documented and reported to theappropriate Discipline Head.

Quality Assurance shall continue to monitor processes and work operations andanalysis of records t o detect and eliminate potential causes of non -conforming


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product.

Trend analyses reports shall be made for deficiencies and made available to XYZCompanys upper management.


4.16 Handling, Storage, Packaging, Preservation and Delivery

A system shall be maintained for the handling, storage and shipping, includingcleaning, packing and preservation of all items through the e ntire manufacturingand construction process. All precautions shall be taken to protect material fromabuse, mis-use, damage, deterioration and unauthorized use.

Items subject to deterioration or corrosion due to environment, shall be cleanedand preserved to fully protect at all times.

The responsible inspector in the particular area shall monitor handling andmarking of parts during construction/installation.

Unsatisfactory conditions shall be brought to the attention of the QualityAssurance Manager for corrective action.

Suspect items shall be placed on Hold and transferred to a restricted storage area

until acceptability is established or other disposition arranged.

Restricted storage areas shall be made available for the isolation and protection ofaccepted raw material, semi-finished parts and finished parts pending use orshipment.

XYZ Company will develop and maintain procedures for handling, storage andpreservation of all material and equipment.

For critical, sensitive, perishable or high -value items, specific written proceduresshall be used. Handling tools and equipment shall be provided and controlled as

necessary to ensure safe and adequate handling.

Where preservation and/or packaging are disturbed, it shall be restored to itsoriginal condition unless other appropriate and acceptable storage arrangementshave been made.

To prevent deterioration, items in stock shall be inspected periodically for


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condition or shelf life expiry.

Data concerning, handling storage and preservation shall be included on theMonthly Materials Procurement Status Report as specified in Schedule G.


4.17 Control of Quality Records

Quality Records shall be generated and maintained to adequately support andsubstantiate inspections and tests performed. These records shall provide evidenceof the quality of the item and testify directly and indirectly that it is in compliancewith contractual requirements.

Quality Records shall be maintained forall pertinent elements such as:

- Design Review Reports.- Inspections performed as per Inspection and Test Plan (I &TP).- Approved Suppliers List.- Material Test Certifications.- Production reco rds of in process inspection.- Calibration Records.- Non-Conformance Reports.- Corrective and preventive actions of discrepancies.

- Preservation Logs.- Certifications for approval of personnel and processes.- Inspection Reports- Audit reports.- Waivers.- Functional test reports and data.- Quality Management Reports.- Management Reviews Reports.

Accumulated Quality Records shall be received and evaluated by responsibleQuality Assurance personnel for the purpose of improving systems, records etc.

Inspection records s hall identify the item, applicable requirements, inspectionsperformed, date of inspection and inspector, result obtained and the feedback oncorrective action generated by the records. Where measurements are not practicalthe results shall include the number of conforming items, the number rejected andthe nature of the defects. Results of inspections for interchangeability of parts orcomponents are recorded.


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XYZ Company shall keep active records for the minimum period specified incontracts and shall be made available upon request by Saudi Aramco.

Records shall be stored in a suitable environment to minimize deterioration ordamage and to prevent loss.

Care shall be taken to distinguish what might be called project records fromquality records. XYZ Company shall compile its project record books on an on -going basis in accordance with XYZ -QMP-016.

Details of who, what, how and when shall be defined in written procedures andother referenced XYZ Company documents (XYZ -OMP-018).

4.18 Quality Audits

The Quality Assurance Manager shall establish, document and implement a planfor audits that shall objectively evaluate the effectiveness and adequacy of thefunctions, systems and procedures as referenced in this Quality Plan andsubcontractors Quality Plans.

The audit plan shall define:- The functions, systems and procedures to be audited.- Those personnel qualified to perform audits.- Frequency of audits.

- Method of reporting findings and recommendations (cross refer tocontrol of non conforming product ( 4.14) and corrective and preventiveaction (4.15) both of which can be applied to function and systemaudits).

- The means for having corrective actions agreed upon and implemented(also cross refer to 4.14 and 4.15).

XYZ Company shall submit a quality audit schedule to Saudi Aramco for reviewand approval within 60 calendar days from effective date of the Contract. As aminimum audits shall be carried out at twenty-five percent (25%) and seventy five(75%) of completion stage for design, procurement and construction WORK

phases.

Audits shall include an evaluation of:- Activities, processes, work areas, items and services being produced.- Quality practices, systems, procedures and instructions.- Certification documents and records.


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Audits shall be performed in accordance with documented procedures andchecklists that identify essential characteristics.

Personnel performing audits shall not have direct responsibility for the areas being

audited.

Management responsible for the area audited shall review, agr ee and correctdeficiencies revealed in the documented audit results

All action taken to correct deficiencies shall be re -audited to verify complianceand a close out report issued.

XYZ Company shall submit to Saudi Aramco a copy of each report within tw o (2)weeks of its completion.


???? ? Training

Personnel performing specific assigned tasks affecting quality shall be qualified on

the basis of appropriate education, training and/or experience.

A formal training program is essential to ensure that all staff receives thenecessary training to supplement their existing expertise and experience to enable

them to perform their dutie s as well as for their acquisition of qualityconsciousness.

The extent of education or experience required shall be determined by therespective discipline Supervisor in consultation with the Project Manager. Theresponsibility for ensuring that employee s attend the approved training courses,schemes or seminars rests with the appropriate discipline Supervisor.

Job proficiency obtained by experience shall be considered adequate for personnelcarrying out quality related activities not requiring specialist knowledge or skills.New personnel for such positions shall receive on -the-job training under thesupervision of experienced personnel. Such training is designed to ensure asatisfactory skill progression for employees.

As a need arises, external trai ning sessions/courses shall be arranged between theProject Manager and discipline Supervisor, who shall maintain records of alltraining undertaken to demonstrate the adequacy of personnel for delegated tasks.


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4.20 Statistical Techniques

Statistical Techniques, properly used, provide excellent process controlprocedures, analysis of variations data summation etc. Where app ropriate XYZCompany shall take care in selecting in order to suit the application and to producethe necessary objective.

The use of statistical methods by XYZ Company can be beneficial to assist inmaking best use of XYZ Companys requirements and exp ectations, in processcontrol, in defect avoidance, in problem analysis, in finding root causes, processlimits, forecasting, verification, measurement or assessment of quality.

Selection shall be made wherever possible from recognized published technique sor, if not, it is essential that the validity of the tool in use has audit traceability tobase statistical theory.

Application shall include the following:

- Data analysis/performance assessment/defect analysis

Statistical techniques may include the following:

- Weld rejection rate- Welder performance analysis- Analysis of variance/regression analysis.- Safety evaluation/risk analysis.- Tests of significance- Quality control charts- S

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