Procedure System of Inspection Management Procedure (Site)

Al-Jaber International Company
Procedure
System of INSPECTION MANAGEMENT PROCEDURE
(SITE)
1 Revision History
Revision Description of
DATE Initiated By Completed By
No# Changes
23th Management Integration for ISO Management
December Representative 14001 and OHSAS Representative
01
2018 18001 & ISO 31000
RISK MANAGEMENT
2 Distribution List
Sr. No/ Designation Issue Date Distributed by
Projects Manager Management

01 23th December 2018
Representative
Management Management
02 23th December 2018
Representative Representative
03 Management
CEO 23th December 2018
Representative
04 Management
Chairman 23th December 2018
Representative
Document Issue Revision Original Revision Document Document Document

Number Number Number Issue Date Issue Date Prepared By Reviewed by Approved By
Projects
Manager PM /MR / CEO Chairman
AJB-IMPS-
1.1 01 01-01-16 23-12-18
PR-01
Copyright
This document contains confidential information. It may be copied in full or in parts only by Al-Jaber
International Company and only for the purpose of Al-Jaber International Company related activities.
Disclosure of any information contained within this procedure to any person (s) outside the employee of Al-
Jaber International Company without written permission of the Top Management is strictly prohibited.
Page 1 of 13
Procedure
System of INSPECTION
MANAGEMENT PROCEDURE (SITE)
Original Issue Date: Revision Issue date:
Doc. No: AJB- IMPS -PR-01 Issue Number: 01 Revision Number: 01
01st January 2016 23th December 2018
TABLE OF CONTENTS
1. ACRONYM ................................................................................................................................... 5
2. INTRODUCTION .......................................................................................................................... 5
3. OBJECTIVE ................................................................................................................................. 6
4. SCOPE ......................................................................................................................................... 6
5. DEFINITIONS ............................................................................................................................... 6
5.1. EDMS .................................................................................................................................. 6
5.2. Inspection and Test Plan ..................................................................................................... 6
5.3. Inspection Checklist ............................................................................................................. 7
5.4. Inspection Request Form .................................................................................................... 7
5.5. Method Statements ............................................................................................................. 7
5.6. Nonconformity ..................................................................................................................... 7
5.7. Nonconformity Report .......................................................................................................... 7
5.8. Purchase Order ................................................................................................................... 7
5.9. Specifications ........................................................................................................................ 7
6. RESPONSIBILITIES .................................................................................................................... 7
6.1 Construction Manager.......................................................................................................... 7
6.2 Construction Site Supervisor................................................................................................ 8
6.3 Project Engineering Manager............................................................................................... 8
6.4 Quality Control Manager ...................................................................................................... 8
6.5 Quality Control Engineer/Inspector ...................................................................................... 9
7. REQUIREMENTS ......................................................................................................................... 9
7.1 General ............................................................................................................................... 9
7.2 Competency of Personnel .................................................................................................. 10
7.3 Inspection Point Types....................................................................................................... 10
7.3.1 Hold Point ........................................................................................................................ 10
7.3.2 Witness Point .................................................................................................................... 11
7.3.3 Surveilliance Point ............................................................................................................. 11
7.3.4 Record Review................................................................................................................... 11
7.4 Preparation of Inspection and Test Plan ............................................................................ 11
7.5 Preparation of Inspection Checklist .................................................................................... 11
This document is the property of Al-Jaber International Company. Any copying and distribution of this document
without the approval of the Management is prohibited. Page 2 of 13
Procedure
7.6 Inspection Request ............................................................................................................ 11
7.7 Performing On-Site Inspections ......................................................................................... 11
7.7.1 Inspections on Subcontracted Works ................................................................................ 12
7.7.2 Material Receiving Inspection ............................................................................................ 12
7.8 Performing On-Site Testing ............................................................................................... 12
7.9 NDE Management ............................................................................................................ 13
7.9 Initiation of Nonconformity ................................................................................................. 13
Procedure
1 ACRONYM
Acronym Description / Meaning
CAR Corrective Action Report
DCC Project’s Document Control Center
AGPS Aljaber Global Procurement System
MGH Mass Group Holding
IFC Issued for Construction
ECP Evaporative Cooler Project
IR Inspection Request
ITP Inspection and Test Plan
WAJV Wajdi Group W.T.E – AL JABER Joint Venture
MS Method Statement
MSDS Material Safety Data Sheet
NCR Nonconformity Report
NDT Non-destructive Test
PDS Product Data Sheet
PEM Project Engineering Management
PQM Project Quality Management
QC Quality Control
QCM Quality Control Manager
UOS&D Unsatisfactory, Over, Short and Damaged
SGPS Suleimanya Gas Power Station
Procedure
2 INTRODUCTION
The plant is located in the town of Chamchamal, which is located about 60 Km to the west of
Suleimanya city.
MGH has signed a contract with the Ministry of Electricity in Kurdistan Region to build SGPS with
a Capacity of 1500 MW on basis BOO (Build,Operate and Own). Work Started at site early 2008.
In the first and second phases (simple cycle), eight Frame-9E gas turbines were installed and
operated to produce 1000 MW and the contract for the simple cycle was signed with the
American Company GE and the German Company ABB.
As the Third Phase of the project, MGH started converting SGPS into a Combined Cycle with
additional 500 MWs capacity, by utilizing the gas turbine exhaust heat emissions to produce
steam in Heat Recovery Steam Generators (HRSG), which will used to generate electricity in two
steam turbines. This process increases the production efficiency without using extra fuel. It also
reduces the amount of CO2 emissions and frees the environment from combustion emission.
After the completion of the combined cycle, the plant capacity will be upgraded to 1500 MW.
It is worth mentioning that Sulaymaniyah power station is designed to operate on two types of
fuel, the prime fuel (natural gas) and secondary fuel (diesel).
The main parts of the Combined Cycle are:

- 9E gas turbines manufactured by the American company (GE).
- The steam turbines of the type (C7) manufactured by the American company (GE).
- Boilers(HRSG) of Belgian company (CMI).
- Air cooling systems from the German company (Enexio).
- The main and subsidiary transformers of the French company (Alstom).
- The main control system of the American company (Emerson).
- Gas pressure reduction system from the German company Bilfinger-Rotring.
The substation accompanying the plant is 132 KV for a Simple Cycle and a 400 KV for the
combined cycle, both were supplied by the Swedish company ABB and the power is transferred
from the station site via fourteen high voltage lines connected to the national grid in the
Kurdistan region.
3 OBJECTIVE
The objective of this procedure is to explain the work process for achieving efficient
management of site inspection and testing processes to meet the requirements set forth in the
Procedure
Project Contract, while ensuring the quality of the material and workmanship is verified in such a
manner that the work meets the project requirements throughout the Project.
The implementation of Inspection and Testing process collectively constitutes the Construction
Quality Control System for construction activities associated with the permanent works of the
Project
4 SCOPE
MG and its subcontractors and suppliers of any tier engaged in supplying, manufacturing,
construction, installation and testing or any other service connected with the works which
require quality demonstration, shall comply with the requirements of this procedure.
This procedure is applicable to SGPS Evaporative Cooler Project.
5 DEFINITIONS
5.1. EDMS
E-Cloud is ALJABER’s electronic document management system used to transmit and
manage documents on Projects, within Corporate Groups, suppliers, Subcontractors and
Client as applicable.
5.2 Inspection and Test Plan (ITP)
An Inspection and Test Plan identifies the items of materials and work to be inspected or
tested, by whom and at what stage or frequency, as well as Hold and Witness Points,
references to relevant standards, acceptance criteria and the records to be maintained.
5.3 Inspection Checklist

Inspection Checklist is a record that demonstrates the work performed has been tested,
inspected, and verified as stipulated in the Project Requirements, by Quality Control and the
Client (if stipulated in the Project Contract).
5.4 Inspection Request Form (IR)
Inspection Request Form is used to notify the relevant inspection parties in advance, i.e.
ALJABER Quality Control Team, the Client Representative and/or Client’s Engineer, and/or
the Client’s Consultant, on the activities that are about to be undertaken, while specifying
activities to be inspected, location, type of inspection, expected inspection date and time.
5.5 Method Statement (MS)
Method Statements are used in construction to give specific instructions on how to safely
perform a work related task, or operate a piece of plant or equipment. It should also be born
in mind that a MS is a part of site safety plan. Therefore, Work Method Statements must be
readily understood by all employees, including employees with low literacy/ numeracy skills.
5.6 Non-conformity
Nonconformity: “Non-fulfilment of a requirement”.
Procedure
The term “nonconformity” as used within this procedure shall be understood as; a case
where any data, results or findings obtained as a result of the performed Quality Control or
Quality Surveillance Actions (such as tests, experiments, examinations, inspections, etc.)
fails to fulfill the Project Contract Requirements.
5.7 Nonconformity Report (NCR)
NCR is a report that defines a Nonconformity while providing a documented correction
method, cause of a Nonconformity and corrective action for the resolution.
5.8 Purchase Order / Subcontract
The document used to contract for the supply of goods and services.
5.9 Specification
Technical document provided by the Client or prepared by Engineering Department which
defines the technical requirements for selected commodities.
6 RESPONSIBILITIES
6.1 Construction Manager
The primary responsibility of the Construction Manager is to achieve quality in construction
through the use of proven process procedures, competent personnel, adequate planning,
suitable equipment and tools, current project drawings and specifications, appropriate
supervision and technical direction in accordance with sound construction methods,
techniques, and practices.
Construction Manager shall also:
 Ensure the construction processes and activities are controlled in accordance with the
project requirements, i.e. contract, project procedures, method statements, inspection
and test plans, work instructions,
 Provide technical direction and interpretation, particularly to the construction team, in
accordance with the requirements established in the design drawings, method
statements, technical specifications and inspection & test plans,
 Ensure the work is verified by quality control as per the ITPs. The Client’s team
participation to those verifications can also be required, if stipulated in the Contract.
6.2 Construction Site Supervisor
Construction Site Supervisor shall be responsible for:
 Assigning qualified craft to perform the work,
 Providing supervision to the assigned craft to achieve the required work quality,
Ensuring the construction activity performed in accordance with the project requirements,
i.e. contract, project specification, project procedures, method statements, work
instructions, inspection and test plans, applicable standard(s) and approved drawings,
Procedure
Method statements and inspection & test plans shall strictly be followed by the Site
Supervisors to achieve the required construction quality,
 Ensuring that the work is completed in accordance with the latest issued design
documents,
6.3 Project Engineering Manager
Project Engineering Manager shall ensure that all ECP are reviewed in line with the Project
Design Requirements; i.e. Project Specifications, Drawings, Referenced Standards,
Calculations, and are approved by the relevant engineering group in a timely manner.
6.4 Quality Control Manager
The primary responsibility of the Quality Control Manager is to execute site inspection,
examination, and testing activities in accordance with the requirements of this procedure and
to verify the quality of the work as per the project requirements, while ensuring to maintain
inspection records properly as detailed in this procedure and which shall be readily available
upon requested as a demonstration of the quality of the work.
Quality Control Manager shall be responsible for:
-Ensuring the effective implementation of the Quality Control System,
-Establishing appropriate procedural and administrative controls to ensure the effective
preparation and implementation of the approved ECP at the construction site,
-Managing the implementation of the quality control system at the jobsite by providing
technical and administrative direction to Quality Control Engineers, Site Supervisors and
administrative staff, ensuring that personnel have the required training and experience
necessary to implement the requirements of this procedure,
-Providing oversight of subcontractors in terms of quality control system, in accordance with
this procedure,
-Ensuring the verification of construction quality is documented at all stages of the Project,
-Verifying the quality control performance,
-Establish and maintain the quality control system for controlling nonconforming items,
-Ensure nonconformity reports are initiated in cases where the work is not complying with
the requirements,
-Verify the corrections of nonconforming product and/or process,
-Monitoring and managing internal nonconformities and Company issued nonconformity
reports
-Planning QC inspection and test programs, activities and schedules,
-Following up day-to-day activities and performances of the QC Engineers / Inspectors,
-Ensuring the permanent plant materials are quality control inspected upon receipt at site,
Procedure
-Ensuring the progressive acceptance of the work and the compilation of acceptance
dossiers,
-Reviewing and approving supplier/subcontractor submitted Inspection and Test Plans,
-Ensuring the subcontractors’ non-destructive test (NDT) examiners engaged in the
examination are qualified and competent, and shall review their qualifications while
supervising their operation,
-Implementing the requirements of the welding control procedures, including approving weld
procedures, testing welders as part of the weld qualification process, and weld inspection,
- Performing surveillance inspections with regards to the established QC program to ensure
that site activities are performed in accordance with the project requirements and ECP,
where related report(s) shall be issued and maintained.
-Performing surveillance inspections of subcontractors to ensure they are performing in
accordance with their quality program and to the ECP,
-Managing site laboratory activities as per the established project procedures, through
laboratory supervisor,
-Ensuring measuring & test equipment used in the project is calibrated or verified,
-Stop the work or operation immediately, in cases where the work is not conforming to the
project requirements.
6.5 Quality Control Engineer / Inspector
Quality Control Engineer / Inspector are responsible for:
-Developing and implementing ECP effectively to meet the project quality control
requirements,
-Verifying the construction quality through inspection, examination, testing, and monitoring of
work activities,
-Stop the work or operation immediately, in cases where the work is not conforming to the
project requirements,
-Keeping the inspection checklists until the relevant work is completed and signatures are
taken,
-Delivering completed inspection checklists to DCC for maintaining on ADMS,
-Supervising Quality Control Technicians.
Procedure
7. REQUIREMENTS
7.1 General
Verification of construction quality is achieved through inspection, examination, testing,
monitoring of work activities, subcontractor oversight/surveillance, NCR/CAR and through
review and documentation as necessary.
The intent of the inspection and testing system is to build quality control in the work and
product, and to establish confidence while demonstrating that the work is properly performed
and documented.
Inspection and Test Plans, when properly implemented, help to ensure and verify that work
is performed in compliance with the Project Requirements (i.e. Design Basis, Project
Technical Specifications, Relevant Codes and Standards), and such demonstration records
constitute the basis for handing over the works to the Client.
Inspections and tests shall be conducted in accordance with the relevant Inspection and
Test Plans, which are developed by Quality Control Team. The Quality Control Team shall
record the completion of inspections and tests and identify records of the results.
In cases, where nonconformity in a work item is detected as a result of conducted inspection
or testing, a corrective action shall be raised in accordance with the details set forth in the
Control Procedure for Corrective Action (Doc. No: AJB-CFCA-PR-01)
7.2 Competency of Personnel
Staff and craft nominated for undertaking sampling, inspection, and testing activities shall be
trained and competent to carry out the particular activities to which they have been assigned.
Project Quality Manager shall take the lead on providing training and ensuring competency
of his team. The records of training and competence shall be maintained throughout the
Project.
The competency of the Quality Control personnel is identified in the relevant job description
forms, where the personnel selection, evaluation and hiring is carried out against the
competency criteria set by the Project which are documented on the job descriptions.
7.3 Inspection Point Types
Types of inspection points are designated by the relevant inspection parties (MG Site QC)
on ECP
7.3.1 Hold Point
A critical construction activity in which, by prior agreement, the party responsible for the
execution of activity is obligated to notify the relevant designator of the Hold Point, a
reasonable time in advance of the operation, so that the item may be visually examined,
tested, or measured to verify conformance to quality requirements by the inspector.
All inspection marked as H- “Hold Point” for Company inspection means the work shall not
proceed without Company’s approval and comments. Advance notice shall be advised to
any of the parties in case of any changes with the scheduled inspection either from the part
Procedure
of the Contractor or from the Company, all responsible QC Engineers / Inspectors shall be
present during inspection with the Company. In addition, if the Company notifies the
Contractor for the absence prior to the inspection then the QC Team decision will be valid for
the relevant Hold Point.
The work shall not proceed without presence and approval of the relevant designator of the
Hold Point.
7.3.2 Witness Point
A construction activity in which, by prior agreement, the party responsible for the execution
of activity is obligated to notify the relevant designator of the Witness Point, a reasonable
time in advance of the operation, so that the item may be visually examined, tested, or
measured to verify conformance to quality requirements by the inspector.
The work may proceed beyond a “Witness Point” in cases where the inspection witnessing is
waived by the relevant inspector or the inspector does not show up for the inspection.
7.3.3 Surveillance Point
Surveillance Point inspection is a point during construction activities where measurement,
witnessing, or inspection takes places without prior notification. Work may proceed without
requesting an approval.
7.3.4 Record Review
Record review involves reviewing test reports (test record, quality checklist, MC Checklist),
relevant cross referenced (IFC drawing, specification and related standard/code) documents
and ECP, etc. in terms of completeness, accuracy and compliance to the Project’s
Requirements related to the activity that is being inspected and/or tested.
Records shall be mandatorily available at the inspection location to proceed with the
inspection.
7.4 Preparation of Inspection and Test Plan
ECP have the role of guidance to conduct and record results of all inspection and testing
activities. ECP lists the inspection point types; Record Review, Surveillance, Witness and
Hold Points, as well as referencing the relevant standards, acceptance criteria and the
records to be maintained.
ECP and Inspection Checklists (in accordance with mechanical completion check lists of
Company) shall be developed for each discrete scope of work within each of the disciplines
(civil, structural, architectural, electrical, and mechanical) based on the Project Contract
Requirements.
ECP, regarding the direct hired works, shall be prepared by the Quality Control Team in
liaison with the relevant Department or Division Managers, by using Attachment A – ECP
Template for MG.
No work shall commence before the relevant ECP have been accepted by MG and
Company.
Procedure
ECP must be in place and agreed by all concerned parties prior to the commencement of
any construction activity on site.
7.5 Preparation of Inspection Checklist

Inspection Check lists shall be prepared in accordance with mechanical completion check
list provided by Company, as applicable.
Accomplished inspection checklists are the demonstration records for compliance to the
requirements of the work performed, hence shall be maintained as a part of hand over
records pertaining to the inspections and testing of materials, product and workmanship.
7.6 Inspection Request
Inspection Request Form is initiated by MG Site Supervisors, Subcontractors, or Suppliers to
notify the relevant parties, i.e. MG Quality Control Team, the Company Representative, the
Company`s Engineer, and/or the Company`s assigned third party, for the planned “Hold
Point” and “Witness Point” inspections on the activities that are about to be undertaken.
Prior to the issue of an IR; MG Site Supervisor, Subcontractor, or Suppliers shall ensure
work is performed in accordance with the requirements, where MG-DC JV QC Team shall
inspect and verify the work prior to issue of IR to the Company. All responsible parties
identified in the ECP shall sign the IR accordingly.
Inspection request is provided in advance of 24 working hours prior to the inspection activity
in question can commence.
7.7 Performing On-Site Inspections
To achieve the required construction quality, work method statements and inspection & test
plans shall strictly be followed by the Site Supervisors, subcontractors and suppliers, who
have the primary responsibility for the performance of the work activities, whereas quality
control inspectors perform inspections, examinations, and testing activities to verify that the
required quality is achieved.
The minimum acceptance criteria used for quality verification and surveillance inspection
activities of both permanent and temporary works, are defined through Inspection & Test
Plans.
The frequency of follow-up observations and inspections shall depend on the degree of
confidence gained by MG QC Team and the Company. The emphasis shall be on the quality
of the work, rather than extensive inspection and documentation.
7.7.1 Inspections on Subcontracted Works
Achieving consistent and effective administration of inspection and testing process for the
subcontracted works requires imposing the Project Inspection and Testing requirements
upon subcontractors, suppliers, manufacturers and any other parties associated with the
Project, that are involved in the Works.
Procedure
All subcontractors, suppliers, and manufacturers shall be responsible for demonstrating that
the works have been completed in accordance with the Project Requirements and shall
produce records that provide clear evidence of conformance as stipulated on ECP. This
demonstration includes the implementation of surveillance and other effective controls to
ensure that the checking, review, inspection and testing of the works are completed and
satisfactory.
All work performed on-site shall be properly inspected by subcontractors at its expense and
shall at all times be subject to quality surveillance and/or verification by MG, Company or
their authorized representatives who, upon reasonable notice, shall be afforded full and free
access to the site, shops, factories or other places of business of subcontractor and its
lower-tier suppliers (if any) for such quality surveillance, and/or verification. If any work is
determined by MG or Company to be defective or not in conformance with the subcontract
agreement, MG may reject that part of the work by giving notice to the subcontractor, with
reasons. The subcontractor shall then promptly make good the defect and ensure that the
rejected part complies with the subcontract, at his own expense.
7.7.2 Material Receiving Inspection
All project materials to be incorporated into the permanent works, are subject to be
inspected and verified on receipt at the jobsite, for ensuring that purchased product meets
specified purchase requirements.
The quality and quantity of purchased materials are controlled as per the inspection methods
defined in the relevant ECP.
Material Receiving Inspection shall be performed in accordance with “Receiving Inspection
Procedure (Site) Doc. No: AJB-IMS-PR-02.
7.8 Performing On-site Testing
Unless otherwise stipulated in the Project Contract Agreement, all on-site testing can be
carried out by trained and competent employees of MG.
Off-site testing criteria shall depend on the requirements set forth in the Project Contract
Agreement and Project Specifications.
Testing and sampling methodologies shall be in accordance with the standards contained in
the Project Requirements (i.e. Contract, Specifications), unless otherwise specified or
agreed in writing by the Client and the Contractor.
7.9 NDE Management
The non-destructive examination process will be managed in accordance with the project
specific non-destructive examination procedures, which are to be agreed with the Company
prior to their utilization.
7.10 Initiation of Nonconformity
Non-conforming products shall be segregated and evaluated in accordance with Control
Procedure for Non Conformance Procedure and Corrective Action Procedure (Doc. No: AJB-
CFNCC-PR-01/ Doc. No: AJB-CFCA-PR-01)

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Al-Jaber International Company

Projects Manager Management

Document Issue Revision Original Revision Document Document Document

The main parts of the Combined Cycle are:

5.3 Inspection Checklist

7.5 Preparation of Inspection Checklist

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