PROJECT QUALITY

PLAN Petron

Emirates Aluminium Smelter Complex

Alumina And Coke Silos

PROJECT QUALITY PLAN

AUTHORIZATION

Issue No : 01

Issue Date : 24 December 2008

Prepared by : QA / QC Engineer

Reviewed by : QA / QC Manager

Approved by : Project Manager

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Petron
Emirates Aluminium Smelter Complex
Alumina and Coke Silos

Project Quality Plan

Contents Amendment Record

This Project Quality Plan has been issued and amended as follows

Issue Description Date Signed

1 Submitted to SLWP for Approval 24.12.2008

TABLE OF CONTENTS

1.0 Introduction

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2.0 Scope of Work
3.0 Project Organization and Responsibilities
4.0 Project Quality Control
4.1 Document Control
4.2 Establishment of Method Statements and ITP
4.3 Temporary Works
4.4 Management of Design / Detailing
4.5 Inspection On / Off Site
4.6 Third Part Inspection / Test Agency
4.7 Sub Contractor Control
4.8 Monthly Quality Reporting
5.0 Management of Materials
5.1 Change Management
5.2 Updated Risk Analysis
5.3 Acceptance and Handover
5.4 Management System Review, Maintenance & Improvement
5.5 Audits
5.6 Non-Conformance reporting
5.7 MANAGEMENT Reviews
Appendix 1 – Petron Quality Policy
Appendix 2 – Petron ISO Certificate of Registration
Appendix 3 – Project Organization Chart
Appendix 4 – Quality Department Organization Chart
Appendix 5 – List of Method Statement
Appendix 6 – List of Major Suppliers / Sub Contractors
Appendix 7 – List of Forms / Records
Appendix 8 – Roles and Responsibilities of Key Personnel

1.0 introduction

This document, the Petron, Project Quality Plan describes Petron strategy for
controlling the project throughout the construction process from mobilization to
handover.

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The Project Quality Plan outlines the specific Quality Control measures, which
shall be developed and implemented. These shall principally comprise of Method
Statements, inspection and Test Plans and Guidance notes.

2.0 Scope of Work

The Scope of work includes construction of Alumina and Coke Silos including
related Structural Steel works for the following:

Alumina Silo

Coke Silo

Alumina Truck Loading Station

Alumina Truck Unloading Station

Coke Unloading Station

Dust Collector Station

A Frame Support of Boom Conveyor

The work under this contract includes, but shall not be limited to, the following
work items as indicated.

General Requirements:

Provide and establishment of site set up and necessary for the execution of works
in line with contract requirements.

Civil

General Site cleaning and grading.

Survey and site layout work.

General site excavation as necessary to execute foundation.

Pile head cutting and preparing Pile heads.

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Sheet Piling for Lift Pit

Preparing of sub grades including grading, leveling, compacting and testing.

Execution of Foundations.

Below Grade water proofing to foundations and other elements to be buried under
soil.

Execution of Silo Walls.

Structural Steel Works

Fabrication, Supply and Installation of Structural Steel members.

Supply of Cast in plates and anchors

3.0 Project Organization and Responsibilities

Appendix 3, 4 and 9 contains Petron staff chart, which details relationship

between the site Quality team and the rest of the Petron project team and their
Roles and Responsibilities.

4.0 Project Quality Control

4.1 Document Control

The Document Management and Control Procedures detailed within the Project
Procedures Manual will generally be adopted for this requirement.

These procedures are included in Appendix 5.

All documents, both incoming and outgoing, will be subjected to controls

applicable to their purpose. The type of document determines how it is to be dealt
with.

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“Controlled Documents” as distinct from correspondence, includes but is not
limited to drawings, specifications, quality documents, temporary works designs,
method statements, inspection and test plans, environmental, health and safety
plan, filing operations plans, fire plan, technical queries, instructions, contractual
documentation, records of samples and benchmarks.

Controlled Documents will be managed using the Share point/ Project based
documents flow chart document management systems such that reference
numbers, status, revisions, updates, issue, distribution and number of copies are
properly recorded. Document transmittals will be used.

Controlled Documents (As General Requirements)

Drawings for review will be designated APP, AAN, ANR, NR, NA status,
summarized as follows:

1 AAP Approved Means that fabrication,

manufacture, supply or Construction
can proceed.

2 AAN Approved as Noted Means that fabrication,

manufacture, supply or Construction
may proceed, provided that the
Contractor Complies with the
notations made in the submittal. If
for any reason, the Contractor cannot
comply with such notations, the
Contractor shall make revision and
resubmit.

3 ANR Approved as Notes Means that fabrication,

Resubmit manufacture, supply or Construction
may proceed only for the approved
items provided that the Contractor
complies with the Notation made in
the submittal and resubmit the
submittal for the non approved items
incorporating the notation made.

4 NR Not Required Means that the submission is

cancelled since the Scope of work
has been deleted or altered. Where
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the work is altered, the Contractor
shall initiate a new Submittal.

5 NA Not Approved Means that submittal does not

comply with the Contract and that
fabrication, manufacture, supply and
that fabrication, manufacture, supply
or Construction shall not proceed.
The Contractor shall Revise and
Resubmit.

This process and convention will also apply to “As Built” drawings

4.1.1 Working drawings

A schedule of working drawings will be produced together with issue dates as agreed by
the appointed Project Engineer. On site discussions will take place between the Design
Team and PETRON to establish lead time for drawing approvals.

4.1.2 Electronic drawings

A procedure for electronic transfer of design drawings will be established if considered

necessary.

4.1.3 Superseded drawings

Superseded drawings will be marked and segregated from current ones. The superseded
versions may be retained as required by the Commercial Department or disposed off.

Soft copies of superseded drawings will be kept in separate folders, drawing register is
available on document control drive to check the latest revision.

4.1.4 Specifications, Instructions and Programmes

These will be recorder using the appropriate software system enabling status, tracking,
recording and monitoring to be achieved. Responses to RFI’s will be received in
accordance with the Contract requirements and Project procedures.

4.1.5 Incoming correspondence and faxes

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All correspondences with Subcontractor – Copy for the day-file, original to Suppliers
Addressee

The distribution will be marked on the distribution stamp by the relevant Manager as
defined by the Document (Incoming) procedure. The Project Manager will sign financial
matters.
All relevant correspondence will be distributed, Distribution will be issued to others at
the discretion of Petron.

The originator will mark the internal distribution on the correspondence, which for
formal letters will only appear on Petron copy of document.

Central file will always receive a copy.

All outgoing correspondence will be given unique number together with the originator’s
initials as a reference and where applicable will refer to a package number.

Standard templates for letters, faxes, memoranda, minutes etc, are held by the
Administration Department. Petron personnel should use these standard templates when
they generate their own correspondence.

Outgoing faxes will be dealt with as normal correspondence. Acknowledgement Receipts

of outgoing faxes will be kept within the central filing system.

4.1.6 Filing System

The QS Department will be responsible for establishing the Filing system for the project
complete with a copy of the filing codes.

Document Control Department (except the private and confidential correspondences) will
scan the documents and link this flow chart: access to view these documents will be
available to all Petron staff.

4.1.7 E-mails

Incoming e-mails received by the individuals will be copies and treated as far original
correspondences (e.g. copies to Project Manager or nominee for stamping, distribution
and copying), a central email address if provided to ensure the central file receives a
copy. Confidential e-mail will be dealt by the addressee.

Outgoing e-mails will be dealt with as for outgoing correspondences ensuring authority
for signing and copied tom central file.
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It is the discretion of the employee to ascertain whether e-mail are to be filed as per the
above process.

4.1.8 Records and Data retention

There are two forms of records: those required for handover as part of the Final Record
Packages and those used during the construction process.

Hardcopy construction records will be kept as prescribed by the Contract. These will be
segregated by discipline or package, collected in order and suitably bound to avoid
inadvertent mix-up. Records will be housed in marked boxes with a register kept showing
their contents.

Electronic records will also be kept and boxed, labeled and a register kept. However, it is
the hardcopy versions, which will be used as master records.

Records will be archived to an archiving facility as established by the company.

A formal procedure for compilation and handover will be provided and agreed with
SLWP as soon as practically possible.

For ‘Document Control’ procedure refer to Appendix 5 of this Quality Plan.

4.2 Establishment of Method Statement and inspection and Test Plans

Method Statements are the prime documents for planning and execution of the
physical works. Each is accompanied by a risk assessment and inspection and
Test Plan. These documents are intended to describe and define safe working
systems describing the sequencing of engineering, management, construction and
safety actions. The management of the production of method statements,
including assignment of responsibilities, preparation, check, review, amendment
and submittal to the Engineer are identified within these method statements.
Method Statements are produced for all construction execution activities. Issue of
the documents is through Petron Document Control Department, who maintains a
register of method statement preparation and submittal.

The preparation of these method statements is the responsibility of the Project

Engineer and or his delegate and approved by the Project Manager. The quality
representative will conduct sample reviews as a minimum.

Method statements are required to be produced for all significant activities.

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All Method Statement will be checked by the Project Manager or Manager
responsible and formally approved. All Method Statements influencing either the
works or safety are to be submitted to EMAL / SLWP.

Each Method Statement will identify work procedures. Method of production,

temporary works, materials, standards, equipment, safety precautions, protection
and logistics involved. Provisions for inspection will be specified.

The construction department team is responsible for the successful

implementation and compliance with these documented requirements within the
Method Statement.

The Quality representative will conduct sample surveillance to verify compliance

as required.

Inspection and check list will form part of the documented evidence for
compliance.

Refer to Appendix 6 List of Method Statement and ITPs for the Project.

For works to be done by EMAL/SLWP nominated contractor the same will be

submitted by them to Petron, after review copy will be submitted to client for
approval.

4.3 Temporary Works

Temporary works will be executed, monitored and recorder by Petron. This

process will comply with the specific procedure developed for the project.

4.4 Management of Design / Detailing

Within Petron organization, all design/detail issues will be managed by site based
Design Coordinator/ Project Engineer. His prime responsibilities are:

 Providing engineering support to all facets of Petron Organization. This includes

review of design for build ability, proposing alternative design solutions and
coordination of all design queries. Formal communication within the Package is
managed through minuted bi-weekly meeting or as required. Formal
communication with EMAL/SLWP is managed via submittals. In addition a bi-

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weekly meeting may be convened between EMAL/SLWP and Petron Technical
personnel.

 Management of Shop Drawing Preparation, Management of this responsibility is

defined within the below reference procedure.

 Temporary Works Design. Management of this responsibility is defined within

the Site Procedure for Temporary Work Design.

 Management of As-Built records, in accordance with the contract Close-out

process.

 Management of Design by others. Where this option is exercised, specific Site

Procedures will be produced in order to define this activity.

4.5 Inspection on/Off Site

Inspection will be generally conducted by the relevant site engineer and for his
delegate. The quality representative will assist and conduct sample surveillance
and specific inspections as and when required.

‘Inspection Request’ will be forwarded to EMAL/SL for their

approvals/comments.

For works, which are not compliance with the requirements, these shall be
recorder and monitored under NCR system. The NCR system will record
discrepancies and analysis any trend for implementation of preventive measures.

In order to access the relevant checklist pertaining to the scope of work

undertaking, follow the access sequence under section 4.8 of this plan.

Project specific checklists will be as per EMAL/SLWP procedure.

4.6 Third Party Inspection / Test Agency

A third party inspection/testing agency may be required in certain cases. Please

refer to specific inspection and Test Plans listed in Appendix 6 OF THIS Quality
Plan.

4.7. Sub Contract Control

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Major Sub Contractors, suppliers and service providers will be required to submit
a Quality Plan for Petron approval. These plans will identify all controllable
measures to be undertaken within their scope of works, identifying the interaction,
hold points, inspection points and surveillance requirements between all parties
concerned, from commencement through to handover.

These Quality plans shall also identify all methods and processes to ensure
compliance with specific project compliance and assurance of continual
monitoring (audit schedule)

Petron will control such suppliers by means of auditing their systems on a agreed
timescale, and by reviewing all applicable inspection points prior to further
submission to the clients representative.
A Quality monthly Report will be requested by all major suppliers/sub
contractors.

For a list of applicable major suppliers applicable to comply with this section,
refer to Appendix 7 of this Quality Plan.

For project specific ‘Sub Contract Control’ Procedure, refer to Appendix 5 of this
Quality Plan.

4.8 Monthly Quality Reporting

A Monthly quality report will be developed and distributed to the Project

Manager and relevant department heads for review and necessary action as and
when required. The report may include but is not limited to:

 Status of inspections

 Status of tests

 NCR’s raised and closed

 Audits conducted (any NCR’s raised during the audit)

 Identify any trends

 Handover status (during applicable stage of the project)

5.0 Management of Materials

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A wide variety of materials are required on the project. Prior to execution of the
construction, these are sourced primarily based on availability, capability for
supply of sufficient quantity, and compliance with specified technical
requirements. The procedure for procurement controls the management of the
procurement process. Details of materials proposed for use in the permanent
works, are submitted to the Engineer for approval. Where pre-construction trials
or mock-up are required, Method statements are produced and submitted to the
Engineer for approval. (For procurement details and control refer to the project
business plan)

5.1 Change Management

Change encompasses any or all the parameters of scope, cost, time, risk, quality
or other constraints. The system ‘Development Team Instruction’ (DTI) will
ensure that the proper authority is gained before a change is actioned and a
comprehensive and accurate audit trail is maintained.

A perspective process will be tailored in accordance with the agreed terms of

contract. As part of the evaluation process there will be input and consultation
with other members of the project team in respect of the following:

 Design and Quality

 Programme

 Costs

 Risk

 Safety

 Build ability

Members of the team will review the proposal in the ‘DTI’, Liaise with other
members as necessary and provide their input.

Together with the EMAL/SLWP team the responses will be coordinated complete
and the evaluation of the ‘DTI’ ready for approval by the client.

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5.2 Risk Analysis

Risk Assessment will be conducted on the project for various aspects of

construction. This may be used to produce agenda for regular Risk Management
Meetings chaired by the Project Manager (or his nominee) and attended by the
appropriate members of the project team.

Risk Management reports will be recording actions taken to address the risk
identified.

For ‘Risk Management’ procedure, refer to Appendix 5 of this Quality Plan.

5.3 Acceptance and Handover

The Project handover system will be developed by Petron to manage the process
of completing the work and archiving / recording closeout. It will be used to
manage outstanding works, defects and snagging process and enable us to monitor
the status of different packages, area and contractors.

Each element of the building services installation will be demonstrated to the

clients operational and maintenance staff. Preparation of operating and
maintenance documentation will commence with the placing of order. Draft
operation and maintenance documentation will be issued to the clients
representative in advance of the handover date. Any adjustment to the test and
system operation determined.

Liaison will be carried out with Engineer. The Quality Engineers will cover
separate areas of responsibility – their remit being to ensure compliance. They,
along with the Employer’s representative, have authority for acceptance of the
work.

A letter requesting inspection for Final Completion will be issued. On satisfactory

inspection EMAL/SLWP will issue Defect Liability Certificate.

5.4 Management System Review, Maintenance and Improvement

Petron management system is under continual review, Where areas requiring

maintenance and / or improvement are identified, this will be on effect. The principal
method poof performing this process are:

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 Audits

 Planning

 Execution

 Reporting

 Correction, Prevention and Close-Out

 Inspections

 Management Reviews

5.5 Audits

Audits are conducted under the control of the Quality Assurance Manager. These
include internal audits of Petron organizational, departments, process and
operations, as well as external audits of Supplier and Subcontractors. A schedule
of programmed audit is produced. This submitted for information to Department
Managers, relevant Subcontractors, Suppliers,. Written confirmation is provided
to the auditee in advance of the audit. Unscheduled audits may be conducted at
the discretion of Quality Assurance Manager. Audits are planned, executed and
conducted in accordance with the Audit procedure as per ISO requirements.
Corrective, Preventive measures, as well as audit close-out, are also managed in
accordance with this management procedure.

5.6 Non Conformance reporting

The manager responsible for the area of the work will raise a Non-Conformance
Report Form (NCR) in instances where the specified requirements have not been
met and cannot be corrected by simple adjustment. A register of NCR’s will be
maintained to ensure that the approved corrective action (CA) has been
completed, and the Preventive Action (PA) agreed.

Steps in the process include:

Clear identification and description of non-conformance

Corrective action plus approval authority and timescale for implementation

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Segregation, if practical, of non-conforming materials and their identification
until authorized for use or disposal.

Verification of acceptability of rework or repair materials, workmanship,

components, systems and structure by re-injection.

Re-inspections performed in accordance with written instructions will be

documented.

Details of preventive actions to avoid reoccurrence

Where an NCR has been raised on Petron work, the responsible manager will
prepare the formal Corrective Action proposal, together with a proposal for the
Preventive Action to be taken to ensure that the not does not recur. This will be
passed to the appropriate authority for that package of work. This may be a
member of the Design Team.

When an NCR has been raised against sub contractors work, the sub contractor
will propose a Corrective Action, which will be agreed by Petron. Where
appropriate the Design Team may be involved in approving the CA on the NCR
form or may use an equivalent system, which is dealt with in the same manner.

Remedial work requires will not be undertaken unit the necessary approvals have
been granted. A copy of the NCR and CA will be copied to the QS Department.
Sub Contractors will be required to operate a formal Non Conformance system
using their own approved documented system. Where this does not exist, they will
use Petron system. The subcontractor will deal with these internally in the same
way as described previously.

For ‘Non Conformance Control’ Procedure, refer to Appendix 5 of Quality Plan.

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5.7 Management Reviews:

A management review of the Project Quality Plan is performed once per year. The
Project Manager and relevant management representatives attend this review. The
detailed review agenda is based on the headings identified in this quality plan,
considering the result of audits, inspections, non conformances and personal
experiences. Recommendations for process and/or system improvements are
identified through analysis of trends (e.g. repetitive non-conformances). The
Management Review is minuted, and management action assigned.

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APPENDIX 1 – PETRON QUALITY POLICY

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Our quality policy and quality objectives are as follows:-

CORPORATE QUALITY POLICY

At Petron, we will provide our customers with the highest quality of service to meet their
requirements and maintain our position as a leading construction professional.

Through our commitment and compliance with the requirements of ISO 9001:2000,
continuing improvement, development, quality procedures, client support and increasing
investment in people and facilities, our quality objectives will be achieved. Reviews and
improvement of system are part of our strategy.

PROJECT QUALITY POLICY

 To establish, implement and maintain an efficient and effective quality management

system that achieves the quality objectives, meets contractual and project
requirements and complies with ISO 9001:2000
 To implement by all project personnel and subcontractors the quality management
system on all activities and operations that affect quality of the product and services
provided under the contract.
 To review and monitor the project quality management system at regular intervals
throughout the project execution to improve the system, monitor and correct any
adverse trends by taking necessary corrective preventive action.

PROJECT QUALITY OBJECTIVES

 To produce a quality product and ultimately customer and end-user satisfaction. This
will be achieved by measuring work trends, non-conformities, customer complaints
and commitment.

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 To achieve the programme target for completion by monitoring performance with
regard to identified milestones and productivity.
 To complete on budgeted costs against budget to monitor project margins and
forecasting total project cost with costs to complete will be the key performance
measure.

APPENDIX 21 - PETRON ISO CERTIFICATE

OF REGISTRATION

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APPENDIX 3 – PROJECT SITE

ORGANIZATION CHART

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APPENDIX 4 – QUALITY DEPARTMENT

ORGANIZATION CHART

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APPENDIX 5 – LIST OF SELECTIVE QUALITY

MANAGEMENT SYSTEM PROCEDURES

A.1. Document and Data Control

A.2. Management of Suppliers and Sub Contractors

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A.3. Control of Non Conformance Reporting

A.4. Risk Management

A.5. Project Close Out (Task Management)

A.6. Change Management

A.7. Management of design / detailing

A.8. Monthly Quality Reporting

A.9. Contracting Planning

A.10. Quality Audit Management

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APPENDIX 6 – LIST OF METHOD

STATEMENTS

Schedule of method statements and associated ITPs which are included but are not
limited to:

Ref. No. Rev Description

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MS200-01 0 Method statement to blinding to underside raft

MS200-02 0 Excavation of Soil

MS200-03 0 Waterproofing of Substructure

MS200-04 0 Sheet Piling

MS200-05 0 Construction of Foundation

MS200-06 0 Pile head cutting

MS200-07 0 Backfilling

MS200-08 0 Concrete Repairs

Ms200-09 0 Method Statement, inspection Test Plan and Risk Assessment

for Construction of Pit below raft bottom level.

MS200-10 0 Structural Steel Works

MS200-11 0 Slip forms

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APPENDIX 7 – LIST OF MAJOR SUPPLIERS /

SUB CONTRACORS

List of Major Suppliers/Sub-Contractors shall be submitted separately.

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APPENDIX 8 – LIST OF FORMS / RECORDS

List of Forms / Records

 Method Statement

 Contractor Request for Inspection

 Daily Activity Report Sheet

 Accident Report and Investigation

 Request for Information (RFI)

 Control Sheet

 Change Proposal Sheet

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 NCR Format

 Supplier Pre-Qualification Questionnaire

 Submittal Transmittal Sheet

 Sample Tag Submittal

 Inspection Request Schedule

 NCR Log Format

 Variation Summary Sheet

 Taking over certificate

APPENDIX 9 – ROLES AND

RESPONSIBILITIES OF KEY PERSONNEL
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Roles and Responsibility of Key Personnel:

 Project Manager: All aspects of contract delivery, design management, programme,

procurement methodology, risk management, management of financial matters and
profitability, quality, documentation, project records, project progress and other
reports, training and handover. The site team reports to Project Manager.

 Project Engineer: Ensure all technical information is available when required for the
delivery of design and/or construction, Early identification and resolution of non
conformance, effective deployment, monitoring, supervision and guidance to less
experienced engineering staff, Resolution of site based QUALITY ISSUES.

 Safety Officer: Implementation of Safety Management system for the project, ensure
risk to third parties / other parties are understood, provides recommendations for
safety procedures to construction team / business, promotes zero tolerance of unsafe
practice, ensure appropriate timely investigation and reporting of accidents and
incidents and identifying underlying causes and action to prevent reoccurrence.

 Quality Engineer: Implements and maintains the Quality Management System.

Organizes Surveillance inspections and conducts audits ad reviews of the quality
systems as well as sub contractors and supplier audit where appropriate: Liaising with
Managers and external organization/Consultant on issues related to Quality. Non

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conformance reporting: close outs and corrective actions: NCR trends: review of
quality related documentation including sub contractors Quality plans and ITPs.

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