Integrated Manual. Quality, Occupational Health & Safety and Environment. Code of Document: Issue No: Date of the next review: Eng. A.F. Kahale.

Transcription

1 Name of Document: Integrated Manual Code of Document: IM Issue No: 03 Date of Issue: Date of the next review: Controlled copy number: Uncontrolled Prepared by Reviewed by Approved by Name Eng. Tima Kahaleh Dr. Ahmad Abazid Eng. A.F. Kahale TK AA AK Signature Management representative QA/QC manager CEO Date Code: IM Rev: 03 Date: Modification: 1 Page i

2 Modifications list Serial number Modification content Place of modification Date of modification The management s representative signature 1 Addition of checkbox Cover page Code: IM Rev: 03 Date: Modification: 1 Page ii

3 Table of contents Code Contents Page 1 PART I Scope General Application Normative references Definitions and abbreviations 1 2 PART II Quality management system General requirements Documentation requirements Management responsibility Management commitment Customer focus Quality policy Planning Responsibility, authority and communication Management review Resource management Provision of resources Human resources Infrastructure Work environment Project realization Planning of project realization Client-related processes Design & development Purchasing 9 Code: IM Rev: 03 Date: Modification: 1 Page iii

4 2.4.5 Execution Control of measuring and testing equipment Measurement, analysis and improvement General Measurement and monitoring Control of non-conforming product Analysis of data Improvement 14 3 PART III Occupational Health & Safety and Environmental Management System General requirements Occupational health & safety and environmental policy Planning Implementation and Operation Checking 19 Appendix 1 List of procedures of IMS - Appendix 2 Integrated Policy - Appendix 3 KTG Organization Chart - Appendix 4 Interaction between processes of QMS - 16 Appendix 5 Matrix between IMS procedures and ISO 9001, ISO and OHSAS clauses - Code: IM Rev: 03 Date: Modification: 1 Page iv

5 Introduction Established in 1978 and classified as premium class contractor according to the ministry of construction classification; KTG (KAHALE Technical Group) is one of the leading electrical and mechanical consulting, engineering and contracting companies in Syria. KTG provides high quality EPC (Electrical Procurement Construction) electrical and mechanical services throughout the country. In tune with this perception KTG has been awarded the ISO 9001:2008 certificate as well as OHSAS 18001:2007 and is in the process of being awarded the ISO 14001:2004. From governmental to commercial, high technology, institutional, passing by industrial and residential projects, our capabilities and services cover all aspects of electrical and mechanical work. In addition, all mechanical works are undertaken according to ASME (American Society of Mechanical Engineers) requirements and if it were not for the embargo carried out by the USA, KTG would be a qualified ASME stamp holder. Code: IM Rev: 03 Date: Modification: 1 Page v

6 1.1 Scope PART I General: The company has established this Integrated Management System (IMS) to direct and control its activities with the aim of continually improving its performance. This manual will ensure that both client s and legal requirements are met in order to achieve the company s goals and objectives. It has been developed according to the international standard specifications in their newest issues ISO 9001:2008 and ISO 14001:2004 as well as OHSAS 18001:2007 and fulfills their requirements Application: This integrated management system is applied to the engineering contracting activities of the company and is adopted and understood by all company s personnel. 1.2 Normative references: The following documents are indispensable for the development and application of the manual. The first one provides basic definitions to help understand some key words used in the manual while the second one is used as a basis to build the manual. ISO 9000:2005, Quality management systems Fundamentals and vocabulary ISO 9001:2008, Quality management systems Requirements ISO 14001:2004, Environmental management systems Requirements with guidance for use OHSAS 18001:2007, Occupational health and safety management systems Requirements. The integrated manual excludes section 7.3 Design and development of the standard. 1.3 Definitions & abbreviations For the purpose of this document, the terms and definitions given in ISO 9000:2005, ISO 14001:2004 and OHSAS 18001:2007 apply. IMS, Integrated Management System: Quality, Health & Safety and Environmental Management Systems. KTG, KAHALE Technical Group Code: IM Rev: 03 Date: Modification: 1 Page 1 of 20

7 PART II 2.1 Quality management system (QMS) General requirements KTG has established and implemented a QMS that has been developed in accordance with ISO 9001:2008. The processes required for the correct implementation of the system are determined as well as their sequences and interactions. To ensure that the operation and monitoring of the processes are effective, KTG makes sure that necessary resources and information are available. Most of these processes are monitored, measured and analyzed. Several processes are outsourced/subcontracted; those include some maintenance works and nondestructive tests for the validation of processes. These processes are managed and controlled in accordance with procedure IP11 Subcontracting Documentation requirements General: The QMS is fully documented and structured in 3 levels: Level 1: The integrated manual, which includes in addition to the editorial pages- the integrated policy which aims to fulfill the requirements of the international standard ISO 9001:2008. It also references appropriate operating procedures. Level 2: The manual of procedures and the work instructions which includes the required measures according to the international standard ISO 9001:2008. They describe the actual steps which should be followed to carry out the different activities of KTG in order to develop and improve the performance in different fields. Level 3: Additional documents, records, models, etc necessary for the effective planning, operation and control of the processes Quality manual The IMS manual describes the interactions between the processes of the QMS and references all the documented procedures established for the correct operation of the QMS Control of documents Procedure IP01, control of documents, aims to facilitate the process of controlling the documents required by the QMS. It explains: How documents are approved prior to issue. How documents are reviewed and updated. How changes and amendments are dealt with. How documents are distributed and made available at points of use. What the conditions of keeping/eliminating the documents after their expiry are. How external documents are distinguished and distributed. What steps to take to avoid the unintentional use of obsolete documents Control of records Procedure IP02, control of records, aims to control all the records necessary for the proper documentation of the quality system. It defines the methods for the identification, storage, Code: IM Rev: 03 Date: Modification: 1 Page 2 of 20

8 protection, retrieval, retention and disposition of records as well as ensures that the records are legible, readily identifiable and retrievable. 2.2 Management responsibility Management commitment The top management provides evidence of its commitment towards the development and implementation of the quality management system, and improving its efficiency continually by the means of: making every member of KTG staff aware of the importance of meeting the clients' needs as well as the legal and organizational requirements. developing suitable plans for quality, publishing and implementing them. establishing the quality policy and objectives. ensuring the availability of necessary resources. conducting management reviews Customer focus The top management of KTG commits itself to determine and to meet clients requirements, focusing on enhancing client satisfaction at all times Quality policy The top management is responsible for popularizing the integrated policy (Appendix-2-) in KTG and making sure that every member of KTG staff understands it. It also ensures that it includes a commitment to comply with requirements and provides a support for establishing and reviewing quality objectives. Moreover, the policy is regularly reviewed to ensure its suitability and validity at all times Planning Quality objectives The top management commits itself to set and develop quality objectives, in accordance with the quality policy, including objectives needed to meet requirements for products/services. Those objectives are set for KTG in general including all the different departments, sections and levels. Those objectives are reviewed, measured (to know to what extent the objectives have been achieved), and modified according to the decisions of the management review meetings (procedure IP05, management responsibility) Quality management system planning The quality system is implemented effectively in order to achieve the planned objectives of quality. The top management of KTG manages quality, in accordance with the plans; taking into consideration the other requirements of the system. All the steps concerning the quality management are documented. The top management of KTG commits itself to maintain completeness of the system, in case of making any change or any modification. Code: IM Rev: 03 Date: Modification: 1 Page 3 of 20

9 2.2.5 Responsibility, authority and communication Responsibility and authority The top management defines responsibilities and authorities for all members of KTG staff in the job description cards, according to the organizational chart of KTG and ensures that those are communicated within the company. The internal system of KTG includes complete descriptions for all the jobs in KTG with a clear definition of the responsibilities and the authorities for every job. It also includes the conditions for every job (required academic degree, experience, training, and skills). Appendix-3- presents the organization chart of the company detailing the main responsibilities and authorities Management representative Top management of KTG appoints a member of management who, irrespective of other responsibilities, shall have the following responsibilities: Ensuring that processes needed for the quality management system are established, implemented and maintained in accordance with the requirements of the international standard ISO 9001:2008. Reporting on the performance of the quality management system to top management and suggesting any need for improvement. Ensuring the promotion of awareness of client requirements throughout the sections and the departments of KTG. Coordinating the activities concerning implementation of the quality management system internally and externally Internal communication The top management ensures that appropriate communication processes are established, in order to demonstrate its commitment to quality, to deal effectively with the questions related to client satisfaction, to deal with the interested parties and to promote awareness of the importance of the quality objectives and the quality policy within KTG. The information transferred by the communication channels includes: Results of the quality management system performance. Effectiveness of the system (concerning achievement of the objectives). Results of the management reviews. Other data sent to the personnel for the purpose of stimulating them, and some sent to the beneficiary bodies in order to promote the performance of KTG Management review General The review team reviews the quality management system once every six months at least to ensure its continuing suitability, adequacy and effectiveness. In the case where unplanned changes are to be made to the system, a management review meeting is held, in order to ensure that the QMS meets the requirements of the international standard (ISO 9001:2008) and achieves the quality objectives effectively. Management responsibility procedure (IP05) explains the details of the management review meeting. Code: IM Rev: 03 Date: Modification: 1 Page 4 of 20

10 Records from management reviews are maintained according to the control of records procedure (IP02). It is the duty of the management representative to prepare the meetings, write the minutes book of the meetings, document the results of the meetings and supervise the implementation of the meetings decisions Review input The inputs to the management review, related to QMS, include information on: results of internal and external audits, customer feedback, product/service conformity, preventive/corrective and follow-up actions status, suggestions for improvement Review output The outputs from the management review include any decision or action related to: improvement of the effectiveness of the quality management system, improvement of product/service related to customer requirements, resource needs 2.3 Resource management Provision of resources KTG identifies, estimates and allocates the necessary resources, according to the development of work, in order to ensure that: The quality management system is implemented, maintained and continually improved. The client s satisfaction is enhanced by fulfilling his/her requirements Resource allocation and monitoring in project planning The allocation, control and monitoring of resources in a project are specific to each project and usually figure in the quality plan of the project. But as a general rule, while planning a project, the project manager takes the following steps: 1) The project s objectives are clearly defined (what is to be accomplished and overall time plan). 2) The activities to be carried out are analyzed. 3) The time and resources needed for each activity are estimated. 4) The risk involved is estimated and the allowances necessary to cover uncertainties are assessed. 5) Total time and cost involved are calculated. 6) All possible alternative methods of attaining the objectives are considered. 7) The method to be implemented is decided. Code: IM Rev: 03 Date: Modification: 1 Page 5 of 20

11 8) Time schedules for each activity are established. Almost certainly the initial estimates of time and resources will be inaccurate. Therefore, a refinement of the previous work is needed in which: Better work schedules are produced. The best way of utilizing resources is decided (possibly involving major/minor changes to the order in which activities take place). Better budgets for performing the work are established. Project costs are controlled by measuring cost progress and predicting the final project cost. Progress is reviewed. Points where delays would jeopardize the project objectives in time to permit corrective action to be taken are detected by re-allocation of available resources. The allocation of resources then depends on the final refinement of the analysis where a minimization of the project duration and a maximization of the use of the resources available are attained. During the life cycle of the project the analysis is reviewed constantly especially at important milestones. When any deviation from the original plan is detected, resources are re-allocated in order to cover for the deviation Human resources The top management performs a study of KTG s need for human resources which includes: Evaluating the need for skilled and qualified personnel who are able to perform the activities requiring a certain level of expertise. These activities outputs are influenced by the quality of performance. Making the plans and launching necessary programs for obtaining the required resources at a specific time, according to the suitable skills, experience, training, and education. Making the plan and launching appropriate training programs for every member of KTG staff including all levels in KTG (internally and externally). Evaluating the efficiency of the followed procedures regularly (Resources and training management procedure IP06). Ensuring that all personnel are aware of the influence of their performances on the quality of product and of their contribution in setting the objectives and achieving them. Keeping appropriate records of education, training, skills, and the initial and acquired experience Infrastructure The top management determines, provides and maintains the infrastructure needed to achieve conformity to product/service requirements. The infrastructure includes: buildings, workspace and associated utilities, process equipment (hardware and software), supporting services (transportation, communication, information systems). Code: IM Rev: 03 Date: Modification: 1 Page 6 of 20

12 2.3.4 Work environment The management determines and sets the appropriate work environment necessary for the achievement of conformity to product/service requirements and therefore client s satisfaction. This consists of: Creating the appropriate work environment that conforms to the necessary health and safety conditions. Offering the appropriate incentives to the personnel to motivate them in order to maintain the performance of the planned works and aiming to improve it continuously. Keeping the data and information necessary for the performance of work easy to access by the personnel. 2.4 Project realization Planning of project realization A service provision and planning procedure QP02 is established to provide a guideline of how quality plans should be developed and what their contents should be, including the inspection and test plan. This procedure applies to projects of all scales. A specific quality plan is developed for each project where the specific requirements of the project are determined. It also specifies the need to provide resources specific to the project, required verification, validation, monitoring and measurement activities, as well as all kinds of records and documents needed Client-related processes Determination of requirements related to the project Those can be categorized as: Requirements specified by the client, including the requirements for delivery and post-delivery activities (such as maintenance services, warranty provisions ). Requirements not stated by the client but necessary for specific and intended use. Statutory and regulatory requirements related to the project. Any additional requirements determined by the organization Review of requirements related to the project A documented procedure (Operations related to customer and tendering QP03) to review the contracts and coordinate among relevant activities is established. This procedure shall be conducted prior to the organization's commitment to supply a project to the client (e.g. submission of tenders, acceptance of contracts or orders, acceptance of changes to contracts or orders). KTG shall ensure that the requirements are defined and documented, that it has the ability to meet those requirements. Records and documents related to the review and emergency amendments should be maintained. When the client provides no documented statement of requirements, the client requirements shall be confirmed by KTG before acceptance. Where requirements are changed, KTG shall ensure that relevant documents are amended Code: IM Rev: 03 Date: Modification: 1 Page 7 of 20

13 and that relevant personnel and bodies are made aware of the changes Client communication Appropriate arrangements for communicating with clients are implemented. Arrangements include: communication related to project information, coordination of enquiries, contracts and their amendments, client feedback, including complaints, communication with the competent authorities in relation to the technical and legal matters. A documented procedure related to communication with clients is established (Communication procedure IP07) Design & development A documented procedure related to design and studies is establishes (Design and studies IP13) Design and development planning During the design and development planning, KTG determines: stages of the design and development process; required review, verification and validation act; responsibilities and authorities for design and development process; availability of resources Interfaces between different groups involved in design and development are managed to ensure effective communication and clarity of responsibilities Design and development inputs The requirements to be met by the design are defined and recorded and may include: performance requirements from customer; applicable regulatory and legal requirements; where applicable, requirements derived from previous similar designs; any other requirements essential for design and development. The inputs are reviewed for adequacy. Incomplete, ambiguous or conflicting requirements are resolved Design and development outputs The design outputs are recorded in such a way that enables verification against requirements (drawings, quantities table ). The outputs: meet the input requirements; provide appropriate information for purchasing and service provision. Code: IM Rev: 03 Date: Modification: 1 Page 8 of 20

14 Design and development review At different stages of the design, reviews are conducted to: evaluate the capability of the design to fulfill requirements; identify errors and propose solutions. Mechanical and electrical engineers participate in the review process Design and development verification Design verification is performed to ensure the output meets the input requirements Design and development validation Design validation is performed to ensure that the resulting drawings are capable of meeting the requirements for the intended use. In most cases validation is only possible after installation Control of changes Modifications according to client s demand are recorded after discussion and approved Purchasing Purchasing process A procedure concerning the purchasing process is implemented (Purchasing procedure QP04). It aims to ensure that the purchased products, services, and materials conform to the specified purchase requirements. This procedure includes the mechanisms which explain how the suppliers are selected and evaluated. The suppliers are selected based on their ability to supply product in accordance with the purchasing requirements. Also, KTG has determined the appropriate criteria for selection against which the suppliers are evaluated and re-evaluated Purchasing information The purchasing information is reviewed and adopted by the appropriate persons. It includes: Requirements for verification of product, procedures, processes and equipment. Quality management system requirements. KTG should make sure of the adequacy of purchasing data prior to sending it to the supplier Verification of purchased products The supplied materials and products are inspected, in order to ensure that they conform to the specified requirements. KTG shall maintain relevant documents (purchasing documents, supplier selection record and supplier evaluation record) Execution Control of execution KTG carries out its construction/ erection works in accordance with ASME requirements and follows documented procedures which represent written instructions such as the procedures for fabrication (QP09, QP10) and welding (QP11, QP12). Procedures QP09 and QP10 describe the code of practice for fabrication of piping, Code: IM Rev: 03 Date: Modification: 1 Page 9 of 20

15 including pipes bending, assembly and welding, heat treatment, mechanical check, nondestructive examination, documentation and certification. Procedure QP11 provides the manufacturer with the guidelines for the release of welding specification, section of welding filler materials, welding machines, edges preparation and tack welding, heat treatment and post weld heat treatment, as well as welding inspection. Procedure QP12 describes the welding consumable receipt, handling and distribution. The execution is carried out in accordance with the quality plan. KTG carries out several processes and different installations under controlled conditions. The controlled conditions include: the availability of information which describes the characteristics of the product, the availability of necessary work instructions, the use of suitable equipment, the availability and use of monitoring and measuring devices the implementation and organization of release, delivery, preservation, and postdelivery release. KTG makes every effort to improve the efficiency of the basic processes and backing processes continuously by: minimizing waste of time, effort and materials, training personnel and developing their professional skills continuously, dealing effectively with information, cooperating with suppliers and developing their abilities in order to fulfill the operating requirements of KTG, improving infrastructure and work environment, improving the ways of operating and developing the outputs of processes, modernizing and improving the ways and techniques of monitoring, measuring and operating Validation of processes A general validation of processes procedure QP07 is used to verify the validity of several processes. The following tests shall be carried out on the relevant equipment and facilities on site: equipment and materials reception at storage, checking for completeness, visual and dimension check at erection site (Visual examination QP14), non-destructive tests on the welding joints: to perform this type of testing and validation KTG has subcontracted the works to a third party inspection company (AKKILA trading and contracting/testing service) which is a corporate partner of ASNT (American Society for Nondestructive Testing). The relevant procedures (Magnetic particle inspection, liquid penetrant inspection, ultrasonic testing and radiographic examination procedures) are attached with QP07. hydrostatic test for piping systems, tanks etc (Field piping hydrostatic test Code: IM Rev: 03 Date: Modification: 1 Page 10 of 20

16 QP13), alignment checks for pumps, compressors, turbines, motors, generators etc, electrical grounding test, cathodic protection test and all other electrical tests required by the contract. The preparation of the test package for each piping system consists of the following: covering list pressure test report piping field test report list of open points list of test blinds pre-test check list post-test punch list list of supports certificate of pressure gauges field quality plan welding inspection record NDT (non-destructive test) reports (VT-Visual Test, RT-Radiographic Test, PT- Pentrant Test, UT-Ultrasonic test) Identification and traceability KTG has established a system to identify the places, locations of products. An identification and traceability procedure QP05 is available. However, most of the times, identification and traceability methods are imposed by the client or the contractor. Kahale Technical Group identifies all their documents by Kahale Technical Group logo. Quality plans are identified by code number and the logo as well. Construction sites are identified by the company logo, where applicable Client property The products which are provided by the client are verified regularly, whether they are equipments, programs, intellectual property or services. All these products are traced, inspected, tested, and their conformity to the specified requirements at receiving checked. Non-conforming cases are recorded and the client is informed about these cases. The products are preserved from loss, damage, or deterioration Preservation of product A stores and customer property procedure QP06 is established in order to control the activities related to receiving, storing, preserving, handling, and delivering products. These processes are checked continually, in order to preserve products and keep them from any damage or deterioration in their specifications during handling, storage, packaging and delivery. Code: IM Rev: 03 Date: Modification: 1 Page 11 of 20

17 2.4.6 Control of measuring and testing equipment KTG has established a procedure (Procedure for handling and calibration of measuring and testing equipment IP08) which includes determination and implementation of the monitoring and measuring processes. This equipment is used to verify and test the validation of products for the purpose of ensuring conformity to clients requirements. In order to ensure the validity of the data, measuring & testing devices shall be: calibrated and verified at specified intervals or prior to use, against measurement traceable to international and national measurement standards, adjusted or re-adjusted as necessary, identified to enable the calibration status to be determined, safeguarded from adjustments that invalidate the measurement results, protected from damage and deterioration during handling, maintenance, and storage. In addition, KTG shall assess and record the validity of the previous measuring results when the equipment is found not to conform to requirements. KTG shall take appropriate action on the equipment and any product affected. Records of the results of calibration, calibration certifications, and verification shall be maintained appropriately. 2.5 Measurement, analysis and improvement General KTG implements measurements in making the management decisions, therefore the effective processes for measurement have been established and the relevant data has been collected and analyzed in the different fields, like: measurement and evaluation of product, measurement of the ability of some processes, measurement of clients and the other interested bodies' satisfaction, measurement of the conformity of the quality management system, in order to continuously demonstrate and improve its efficiency. KTG uses the known statistical techniques in order to improve quality, like measuring and monitoring lists Measurement and monitoring Client satisfaction KTG has established a procedure related to clients (Operations related to customer and tendering procedure QP03) which aims to measure the clients' satisfaction, in order to improve KTG s performance in all fields and to enhance satisfaction. KTG gets the information from the following sources: clients opinion poll product feedback clients requirements and contractual information Code: IM Rev: 03 Date: Modification: 1 Page 12 of 20

18 markets needs information that has been gathered about the companies similar products in the local and international markets Internal audit A documented procedure (Internal audit procedure IP03), which aims to plan and implement the internal audit in order to determine whether the quality management activities and their results conform to the planned arrangements, is available. It provides a basis to check the efficiency of the quality system and to create appropriate chances for improvement. The management representative classifies areas of the internal audit based on their importance, the internal audits are then conducted by an independent team, the results are documented, and finally the heads of the audited divisions are informed about the results in order to take appropriate corrective actions. Also, the management of KTG is informed about the results during the management review meetings in order to make the appropriate arrangements for dealing with the recurring faults Monitoring and measurement of processes KTG monitors all its processes. The ways of measuring the processes are determined in the quality plan. The monitoring and measurement actions are taken in order to evaluate the performance of processes and to demonstrate the abilities of the processes to achieve the planned results. The measurement results are used to take corrective and preventive actions, and to determine the chances of improvement Monitoring and measurement of service The requirements of the service (including the acceptance criteria of its basic characteristics) are determined. Different measurements are conducted in order to verify that the requirements of the competent authorities have been fulfilled. When KTG has determined the ways of measuring the conformity of the service to clients' requirements and expectations, it has taken the following matters into consideration: The characteristics of the service which shall be measured, the sort of measurement, the way of measurement, the required accuracy, and the required skills. The required equipment, programs, and tools. The sites of measurements during the different stages of erection. The characteristics which shall be measured in every point, the used documents and the acceptance criteria. The inspection points and monitoring during the stages of erection. Where and when KTG will meet the requirements of clients and the competent authorities concerning inspection, monitoring, and measurement. Qualifying persons, materials, products and processes. A final inspection is carried out in order to verify that all the previous activities have been performed and that they conform to the acceptance criteria. All the results of measurements shall be registered in the appropriate records which are Code: IM Rev: 03 Date: Modification: 1 Page 13 of 20

19 defined in the quality plan Control of non-conforming product A documented procedure for the control of non-conforming products QP01 is established by KTG management to prevent the use of non-conforming products at any stage of production and/or erection. This procedure documents the non-conformity case; its segregation and elimination from the production or erection process. Causes of non-conformities shall be studied, corrective and preventive actions taken in order to avoid the occurrence of such non-conformance in the future Analysis of data The appropriate data which has been collected during the different processes of production, monitoring, examination and test is determined. The ways of analyzing and dealing with that data are defined in the data analysis procedure IP12 in order to evaluate the performance in comparison with the plans, goals and objectives. This procedure aims also to determine the extent of improvement necessary in order to fulfill the requirements of the clients and other relevant bodies. The results of data analysis are used for: defining and evaluating trends. measuring the clients' and other relevant bodies satisfaction. evaluating suppliers achieving the goals of quality, improvement and other indicators Improvement Continual improvement KTG attempts continuously to improve the effectiveness of its processes through taking steps to improve the actual performance, carrying out specific projects in the different fields or by improving the quality policy, quality objectives, analysis of data, corrective actions, preventive actions and results of the management review meetings. A continual improvement procedure IP09 is established in order to plan, evaluate and develop the steps to be taken towards continual improvement Corrective action A documented procedure for corrective and preventive actions IP04 is available. This procedure is applies continuously in order to eliminate the causes of nonconformities and to reduce the level of risk which causes problems to the products and services of KTG. The procedure includes: dealing effectively with the clients complaints. Investigating the causes of non-conformities and recording results. Determining the required corrective actions. Using the techniques of control Recording the results of the applied corrective actions. Reviewing these actions regularly and inferring the results. Code: IM Rev: 03 Date: Modification: 1 Page 14 of 20

20 Implementing any changes made to the procedures or to the documented processes due to the preventive action Preventive action The same procedure discussed above is used for the preventive action (IP04). It is applied continuously to eliminate the causes of non-conformities in order to avoid their occurrences. The protective action shall be appropriate to the effects which could occur due to the potential non-conformities. The procedure includes the following: Using all sources of information to determine potential non-conformities and their causes Evaluating the need for action to prevent occurrence of non-conformities Determining the stages of handling any problem that requires a preventive action and taking the appropriate action which shall be documented Reviewing preventive actions taken and inferring the results Implementing any changes made to the procedure due to the action and keeping records of that action. Code: IM Rev: 03 Date: Modification: 1 Page 15 of 20

21 PART III 3.1 Occupational Health & Safety and Environmental Management System General requirements The organization has established, documented, implemented, maintained and continually improved an occupational health & safety and environmental management system in accordance with the requirements of OHSAS 18001:2007 and ISO 14001: Occupational health & safety and environmental policy Top management has defined the organization's integrated policy as per (Appendix-2-) and published it within the organization. The policy is reviewed regularly during management review meetings Planning Planning HSE management in projects A procedure for the preparation of HSE plans HSEP05 is established to provide a guideline of how HSE plans should be developed and what their contents should be. This procedure applies to projects of all scales. A specific HSE plan is developed for each project where the specific requirements of the project are determined. It also specifies the need to provide special resources specific to the project, required assessments, emergency plans, monitoring and measurement activities, as well as all kinds of records and documents needed Identification of environmental aspects and hazards, and risk assessment The organization has established, implemented and maintained a procedure HSEP01 for the ongoing hazards identification, risk assessment, and determination of necessary controls. This procedure also explains the identification of environmental aspects (emissions, pollution, wastes, and resource consumption) and their impacts on the environment. The organization has documented this information and will keep it up to date Legal and Other requirements The organization has identified and accessed the legal and other HSE requirements according to HSEP03 The organization has kept this information up-to-date. The organization shall ensure that these applicable legal and other requirements to which the organization subscribes are taken into account in establishing, implementing and maintaining its integrated management system. The organization has communicated relevant information on legal and other requirements to persons working under the control of the organization, and other relevant interested parties Objectives, targets and program(s) Depending on the applicable legal and other requirements, its technological options, its financial, operational and business requirements, and the views of interested parties, the organization has established, implemented and maintained a procedure IP05 to document its OH&S and environmental objectives and targets, at relevant functions and levels within Code: IM Rev: 03 Date: Modification: 1 Page 16 of 20

22 the organization. The organization has established programs also for achieving its objectives and targets that show designation of responsibility for achieving objectives and targets at relevant functions and levels of the organization, and the means and time-frame by which they are to be achieved Implementation and Operation Resources, Roles, Responsibility and Authority Management has provided the resources required to establish, implement, maintain and improve the occupational health and Safety, and environmental management system. Resources include human resources and specialized skills, organizational infrastructure, technology and financial resources. The organization has defined, documented and communicated roles, responsibilities and authorities in order to facilitate effective OH&S and environmental management. The organization's top management has appointed a management representative(s) who, irrespective of other responsibilities, has the following responsibilities and authorities: ensuring that the HSE management system is established, implemented and maintained in accordance with this OHSAS and ISO 14001Standards; ensuring that reports on the performance of the HSE management system are presented to top management for review and used as a basis for improvement of the management system Competence, Training and Awareness The organization has established IP06 to identify training needs associated with its hazards, environmental aspects and HSE management system. It has also provided training or taken other action to meet these needs. The procedure also defines the method to ensure that any person performing tasks for it or on its behalf, or that has the potential to cause an impact on OH&S or a significant impact on the environment are aware of: The OH&S consequences, actual or potential and the significant environmental aspects and any related actual or potential impact, associated with their work activities, their behavior; and the OH&S and environmental benefits of improved personal performance; Their roles, responsibilities and importance in achieving conformity to the HSE policy and procedures and to the requirements of the HSE management system, including emergency preparedness and response requirements. The potential consequences of departure from specified procedures Communication, Participation and Consultation a) Communication With regard to its HSE hazards and management system, the organization has established, implemented and maintained a procedure IP07 for: Internal communication among the various levels and functions of the organization; Communication with contractors and other visitors to the workplace; Code: IM Rev: 03 Date: Modification: 1 Page 17 of 20

23 Receiving, documenting and responding to relevant communications from external interested parties. Decision to communicate externally its significant environmental aspects. b) Participation and consultation The organization has established, implemented and maintained a procedure IP07 for: The participation of workers by their: Appropriate involvement in hazard identification, risk assessments and determination of controls; Appropriate involvement in incident investigation; Involvement in the development and review of HSE policies and objectives; consultation where there are any changes that affect their HSE; Representation on HSE matters. Workers have been informed about their participation arrangements, including who is their representative(s) on HSE matters. Consultation with contractors where there are changes that affect their health and safety. The organization shall ensure that, when appropriate, relevant external interested parties are consulted about pertinent HSE matters Documentation The organization has defined its HSE management system documentation as follows: Manual, procedures, work instructions, documents, including records, emergency plans, and external documents: - legal and other requirement - Standards Control of documents Documents required by the HSE management system and by the standards OHSAS and ISO are controlled as per IP Operational control The organization has identified and planned those operations that are associated with the identified hazards and significant environmental aspects where the implementation of controls is necessary to manage the OH&S risk and environmental aspect consistent with its policy, objectives and targets, in order to ensure that they are carried out under specified Code: IM Rev: 03 Date: Modification: 1 Page 18 of 20

24 conditions, by establishing, implementing and maintaining a documented procedure HSEP03 to control situations where their absence could lead to deviation from the policy, objectives and targets, and stipulating the operating criteria in the procedure(s), and establishing, implementing and maintaining procedure HSEP01, identified significant environmental aspects, hazards and risk assessment of goods and services used by the organization and communicated to suppliers, including subcontractors Emergency preparedness and response The organization has established, implemented and maintained a procedure HSEP02 to identify potential emergency situations and potential accidents that can have an impact on the HSE and how it will respond to them. Emergency plans include: Defining responsibilities Way of responding and tasks Ways of communication during emergencies Training The procedure determines also how to revise its emergency preparedness and response procedures, in particular, after the occurrence of accidents or emergency situations Checking Monitoring and measurement The organization has established procedure HSEP03 to monitor and measure, on a regular basis, the key characteristics of its operations that can have an effect on OH&S or a significant environment impact. It also determines the documenting of information to monitor performance, applicable operational controls and conformity with the organization's HSE objectives and targets Evaluation of compliance The organization has determined its compliance with applicable legal requirements and other requirements to which it subscribes as per HSEP Incident Investigation, nonconformity, corrective and preventive action a) Incident Investigation The organization has established, implemented and maintained a procedure HSEP02 to record, investigate and analyze incidents in order to: Determine underlying OH&S deficiencies and other factors that might be causing or contributing to the occurrence of incidents; Identify the need for corrective action; Identify opportunities for preventive action; Identify opportunities for continual improvement; Communicate the results of such investigations. The results of incident investigations have to be documented and maintained. Code: IM Rev: 03 Date: Modification: 1 Page 19 of 20

25 b) Nonconformity, corrective action and preventive action The organization has established, implemented and maintained procedures HSEP02 and IP04 for dealing with actual and potential nonconformities and for taking corrective action and preventive action. HSEP02 and IP04 defines requirements for identifying and correcting nonconformity and taking action to mitigate their impacts on HSE investigating nonconformity, determining their cause and taking actions in order to avoid their recurrence, evaluating the need for action to prevent nonconformity and implementing appropriate actions designed to avoid their occurrence, recording the results of corrective action and preventive action taken, and reviewing the effectiveness of corrective action and preventive action taken. Actions taken shall be appropriate to the magnitude of the problems, the hazards caused and the environmental impacts encountered. The organization shall ensure that any necessary changes are made to HSE management system documentation Control of records The organization has established a procedure IP02 that defines: Records as necessary to demonstrate conformity to the requirements of its HSE management system Identification, storage, protection, retrieval, retention and disposal of records Internal audit The organization conducts internal audits of the HSE management system to ensure the conformity with requirement of OHSAS and ISO as per IP03 which explains: Planning for internal audit, and audit frequency taking into consideration the importance of risk assessment and the environmental importance of the operation concerned and the results of previous audits auditors criteria: objectivity and the impartiality of the audit process reporting results and retaining associated records, determination of audit criteria, scope, frequency and methods Management review Top management reviews the organization's HSE management system each six months as stated in IP05 to ensure its continuing suitability, adequacy and effectiveness. Reviews include assessing opportunities for improvement and the need for changes to the HSE management system, including the policy and objectives and targets. The outputs from management reviews include any decisions and actions related to possible changes to policy, objectives, targets and other elements of the HSE management system, consistent with the commitment to continual improvement. Code: IM Rev: 03 Date: Modification: 1 Page 20 of 20

26 List of procedures of the Integrated Management System Procedure Code Procedure Code Control of documents IP01 Operations related to customer and tendering QP03 Control of records IP02 Purchasing QP04 Internal audit IP03 Identification and traceability QP05 Preventive and corrective actions IP04 Stores and customer property QP06 Management responsibility IP05 Validation of processes QP07 Resources and training IP06 General welding specifications for equipment and piping QP11* Communication IP07 Welding consumables receipt, handling and distribution QP12* Handling and calibration of measuring and testing equipment IP08 Field piping hydrostatic test QP13* Continual improvement IP09 Visual examination QP14* Infrastructure IP10 Identification of environmental aspects and hazards, and risk assessment HSEP01 Subcontracting IP11 Response to emergencies and nonconformities HSEP02 Data analysis IP12 Monitoring, measurement and compliance HSEP03 Design and studies IP13 Operational control HSEP04 Control of non-conforming products QP01 Preparation of HSE Plan HSEP05 Service provision and planning QP02 *adopted during execution of Deir Ali 1 Code: IM/App1 Rev: 03 Date: Page 1 of 1

27 Integrated Policy (Quality, Health & Safety and environmental policy) At KTG we are commited to fulfilling our clients requirements and constantly enhancing their satisfaction with regard to our products & services quality and our performance. We understand that quality, occupational health & safety and environmental management are an integral part of every project and therefore is the responsibility of all employees. We shall ensure that this policy is communicated and understood at all levels within the company. All operations are conducted in the safest and most responsible way under a well-established integrated managmenet system that complies wih the requirements of: ISO 9001: 2008, ISO 14001:2004 and OHSAS 18001:2007. We also undertake to work with our employees, suppliers and clients to improve our quality, environmental and occupational health and safety performance through the following objectives: To meet clients requirements and strive to exceed their expectations. To meet deadlines and budgets. To upgrade technology and improve techniques, systems and procedures in order to carry out innovation and constantly meet client's changing needs. To fulfill the legal and other requirements and to conform with decisions concerning environment and occupational health & safety related to our activities and products at least. To commit to continual improvement and ensure that the IMS is regularly reviewed to guarantee its continuing suitability and effectiveness. To conserve the environment and to reduce pollution. To create a healthy environment therefore preventing accidents and cases of work related ill-health. To determine and define environmental aspects and impacts, hazards and risks of our company's activities, products and services and to continually work on eliminating, reducing or controlling them. To reduce or, if possible, recycle waste where it is practicable. To reduce, when possible, the consumption of natural resources to the minimum level and to lessen the uses of dangerous materials through trying to find alternatives. To monitor and control the emission of gases and water discharge. To prioritize the implementation of the conditions of occupational health & safety when making any decisions related to the work. To provide resources and training to meet quality, health and safety and evironmental commitments. To provide all what is required to ensure the safety and protection of all staff, employees, persons, contractors, visitors and any person at the workplace. To involve our workers in improving work procedure and conditions which are based on the company's concept of the continual improvement and development. To attempt to satisfy all the dealers with our company: customers, suppliers, workers and other interested parties. To carry out periodical internal audits and reviews of our quality, environmental, and occupational health & safety management systems. To provide the public with the information regarding the environment and occupational health & safety. To developing highly motivated and skilled human resources imbued with a strong sense of values and commitment to quality, health and safety and environment. Therefore, all staff are responsible for: Fully understanding all the procedures related to their jobs. Carrying out all the requirements specified in procedures, work instructions and test methods. Fully cooperating and reporting all quality, health & safety and environment concers to anappropriate person. Eng. Abd Alfatah Kahale CEO Code: IM/App2 Rev: 03 Date: Page 1 of 1

28 سياسة المتكاملة سياسة جودة والبيئة والصحة والسالمة المھنية إن سياسة في KTG تلبية متطلبات ورغبات الزباي ن والسعي لتطوير أداي نا وتقديم منتجات متميزة بجودة وحسن أداء الخدمات كما تقدم إدارة الجودة والبيي ة والصحة والسلامة المهنية الا ج ارءات الداعمة لكافة العاملين مع الشرح الكامل للنظام وهو جزء لا يتج أز في كل مشروع وهذا يقع على عاتق جميع الموظفين بالشركة حيث نلتزم بتطبيق والمحافظة على عمليات نظام إدارة الجودة والبيي ة والصحة والسلامة المهنية استنادا لمتطلبات المواصفات 18001:2007: ISO 9001: 2008, ISO 14001:2004 and OHSAS كما نتعهد بالعمل مع موظفينا وموردينا وزباي ننا لتطوير الا داء البيي ي وأداء الصحة والسلامة المهنية للشركة وذلك من خلال الا هداف التالية: تلبية متطلبات الزباي ن والسعي لتجاوز توقعاتهم. الالت ازم بالمواعيد المحددة والمي ازنيات. رفع مستوى التكنولوجيا وتحسين تقنيات وأنظمة وا ج ارءات من أجل تنفيذ المتطلبات وتلبية احتياجات الزبون. الالت ازم بتلبية المتطلبات التنظيمية والقانونية وكذلك المطابقة مع القوانين والق ار ارت الخاصة بالبيي ة والصحة والسلامة المهنية والمتعلقة بمجال أنشطتنا ومنتجاتنا كحد أدنى وغيرها من المتطلبات. الالت ازم بالتطوير المستمر لفعالية أنظمة الا دارة المعتمدة بالشركة وللا داء البيي ي وأداء الصحة والسلامة المهنية للشركة. الالت ازم بالحفاظ على البيي ة والحد من التلوث. خلق بيي ة صحية لمنع وقوع الحوادث والعمل المتواصل لتخفيف من حالات اعتلال الصحي. تحديد وتعريف الا بعاد والتا ثي ارت البيي ية لا نشطة ومنتجات وخدمات شركتنا والعمل على إلغاي ها أو تخفيضها أو التحكم بها. تخفيض أو إعادة استخدام أو إعادة تصنيع النفايات الناتجة حيث يكون ذلك ممكنا. نتطلع إلى تخفيض استهلاك الموارد الطبيعية إلى الحد الا دنى وتخفيض استهلاك المواد الخطيرة والسعي إلى إيجاد البداي ل لها. م ارقبة والتحكم بالا نبعاثات الغازية والطرح الماي ي. إعطاء الا ولوية لتطبيق شروط الصحة والسلامة المهنية عند اتخاذ أي ق ار ارت متعلقة بالعمل. تنمية مها ارت العاملين بالشركة وتدريبهم على إج ار ارت الجودة والبيي ة والصحة المهنية. تا مين كافة المتطلبات لضمان سلامة وحماية العاملين والموظفين والا شخاص المقاولين والزوار وأي شخص في مكان العمل. إش ارك العاملين في تحسين شروط وا ج ارءات العمل انطلاقا من مفهوم الشركة في التطوير المستمر والتنمية. العمل على إرضاء جميع المتعاملين مع شركتنا من زباي ن موردين عاملين والجهات المهتمة الا خرى. تنفيذ و أداء الم ارجعات الدورية لنظام إدارة تزويد العامة بالمعلومات الخاصة بالبيي ة والصحة والسلامة المهنية.. الجودة والبيي ة والصحة والسلامة المهنية في شركتنا. تدريب وتوعية جميع العاملين و تحديد مسؤولياتهم بما يخص الجودة البيي ة والصحة والسلامة المهنية. إن مسؤولية جميع الموظفين في الشركة هي : الفهم الكامل لكافة الا ج ارءات المتعلقة با عمالهم. الا تباع والالت ازم بالمتطلبات المحددة في الا ج ارءات وطرق العمل وتعليمات الاختبار. التعاون بشكل كامل لتقديم التقارير للشخص المناسب عن المخاوف التي تخص الجودة والصحة والسلامة المهنية. المدير العام م. عبد الفتاح كحالة Code: IM/App2 Rev: 03 Date: Page 1 of 1

29 KTG Organization Chart CEO Eng. Abd Alfatah Alkahale Projects Management QA / QC Manager Adm. Manager Comm. Manager Sales Dept. Financial Manager Eng.Dept. HSE Manager Dr. Ahmad A. Zeid Mr. M.Sh. Mousa Mr. Fouad Karam Eng.Tala Kahale Jozeph Ashi Eng. Ali Sheikh Omar Hossein Azadi Projects Consulting Dr. Ahmad A. Zeid Projects Coordinator Eng. Tima Kahale Deir Ali II CCPP Dier Ali I CCPP Tishreen CCPP Railway C 27&28 Jandar CCPP Al Jobeh Cordoba Doha Mall Fadi Bara Rima Fatoom Joumana Alawad Eg. Abd Arazak Milato Ahmad Almounjed Eng. Ahmad Alsakaty Hossein Hamadani P.M P.M P.M P.M P.M P.M P.M P.M Mr. Fouad Karam Eng. Raed Alsoufi Eng. Mutaz A. Sammad Eng. Fayz Kahale Eng. Raed Alsoufi Eng. Abd R. Nader Eng. Emad Madi Eng. Abd Arazak Milato Noora Mahmoud Gassan Yazghi Faten Yousef Mohammad Shehab Janet Armoush Eng. Moustafa Kadri Alaa Zen Alabdeen Site Manager Eng. Hisham Blani Site Manager Eng. Mustafa Arkawi Site Manage Eng. Raed Lifa Site Manage Emad Haka Site Manage Eng. Ghasan Mousa Site Manage Eng. Mozhar Heloun Site Manage Eng. Ahmad Eid Site Manage Eng. Bilal Shama Mohamad Tinawy Yousef Khahlil Mahmmoud Khalil Bassam Hawari Bassel Abo Hammoud Eng. Fouad Awad Abd Al.Khankan Deir Ali II CCPP : Electromechanical works for Combined Cycle Power Plant 701 MW / Main Contractor : METKA Deir Ali I CCPP : Electromechanical works for Combined Cycle Power Plant 750 MW / Main Contractor : Siemens Tishreen CCPP : Electromechanical works for Combined Cycle Power Plant 450 MW / Main Contractor : MAPNA Railways ( C27&28) : Signaling & Telecommunication of Syrian Railways network / Main Contractor : Siemens Jandar CCPP : Electromechanical works for Combined Cycle Power Plant 450 MW / Main Contractor : MAPNA Al Jobeh : Supply & Erection of elctromechanical works for Al Jobeh irrigation plant / Client : Water Supply & Sewerage Authority Cordoba : Supply & Erection of elctromechanical works for Cordoba Residential Complex / Main Contractor : LAMA Doha Mall : Supply & Erection of elctromechanical works for Doha mall Code: IM/ App 3 Rev. 03 Date: Page: 1 of 1