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SATORP / IK-Construction Site_____________________Quality Weekly Highlights

PMT-Quality Department All Packages Week Ending March 17, 2011 Quality Weekly Highlights Number 1033

Weekly Highlight including: 1. General Quality 2. Civil 3. Mechanical 4. Plumbing/HVAC 5. Electrical 6. Telecommunication 7. Instrumentation Classifications of the Highlight: Major -- Major violation observed and need attention for PMT. New -- New Violation observed. Closed -- This issue was closed after the contractor correction. Information -- Just for information

Civil MajorExcavated Area without Erosion Control: Under Package 6, Refinery Tank Farm (South Pump Station 9): During surveillance inspection, contractor has not complied to apply erosion control on slopes of excavated area at Pump Station 9. This is a violation to JERES-A114 Para. 5.3.2 and logbook entry was issued. PMT/CONTRACTOR was informed to take the corrective action. (J.Tayamin/J.Krishna)

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March 23, 2011

NewFoundation Footing Without Engineered Support System: Under Package 6, Refinery Tank Farm (South Pump Station 9): During surveillance inspection, it was observed contractor has not complied to provide engineered support system for foundation footing at Pump Station 9. This is a violation to JERES-A-114 Para. 5.5.3.1 that states Excavations are not allowed to intersect a 45-degree plane extending downward from the bottom edge of existing foundations unless an engineered support system is in place prior to the start of work. A Logbook entry was issued and PMT/CONTRACTOR was informed to take the corrective action. (J.Tayamin/J.Krishna)

MajorSand Bedding without Trench Dewatering: Under Package 5C, Auxiliary Utilities: During Surveillance visit it was observed that Contractor started the sand bedding activity with the entire length of the trench full of standing water. This is violation as per Sec 10.3 JERES-S070, stating that bottom of trench must be sufficiently drained before the bedding layers are placed. A Logbook entry was raised to inform the PMT and the contractor with regards to this matter. (R.Darell/M.Faisal)

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March 23, 2011

NewBackfilled without Required FDT (Field Density Test): Under Package 3, Aromatics Unit: During site surveillance at CCR-131, found that concrete structures and catch Basin been fully back filled around their adjacent surface without required compaction and density test. This is a violation of JERES-A-114, Sec .6.3.2.2 & 6.3.3.3. An NCR was issued PMT/contractor was informed. (J. Osorio/H. Hayeki)

NewImproper Water Curing for Concrete Beam: Under Package 4, Coker Unit: During surveillance inspection to Substation 1201 it was observed improper water curing for the newly constructed concrete beam BB1 @ grid line 13-C/E, grid line C-13/16 and lintel beam door 2 & 3. These violate JERES-Q-001 Sec. 11.3. A Log book entry was made and PMT/Contractor informed. (R.Raquel/R.S.Nair)

NewRejected Manhole was concreted by the Contractor: Under Package 9, Port tank Farm and Loading Facilities: Manhole No.18 was concreted without Satorp approval. RFI was rejected due to improper installation of waterstop. This is a violation to JERES S-020 Para.5.9.1 which states that water seal shall conform to company standard. Logbook entry was issued and Contractor NCR was issued. Contractor was advised for corrective action. (C.Velchez/A.Akhtar) Page 3 of 20 March 23, 2011

NewInsufficient Thickness on Pipe Rack Pedestal: Under Package 5A, Inter-connecting (Flare Line at Block 03 Area): During site surveillance, insufficient thickness between the top of concrete pedestal and base plates were noticed for some pedestals which are the actual is less than the required thickness. This is in violation to General Note 12.3 which state that the minimum thickness of grout is 25mm, SA-JER-IP000-TPIT-193001, Rev. 04 while other construction group (NSH) is kept on erecting of the steel pipe rack structures. A Log Book Entry was placed and informed contractor for corrective action. (A.Guiwa/M.Asiri)

NewNo shoring on Deep Excavation: Under Package 6, Refinery Tank Farm (North): During surveillance, it was noted that excavation for manholes was more than (5) feet and no shoring were installed along the soil banks. This is unsafe practice and violation of JERES A-114 paragraph 5.5.2.3. Which state: when soil banks are greater that 5ft. shoring shall be installed. PMT/Contractor was informed to take action on this matter. (C.Naria/J.Krishna)

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March 23, 2011

NewCoating Applied without Leak Test on Manholes: Under Package 6, Refinery Tank Farm (North): Contractor has applied protective coating on manholes without conducting leak test. This is a violation after the fact under JERES S-070 paragraph 19.8f. Which state: site testing shall take place prior to application of protective coatings. In this regards, an NCR was issued and PMT/contractor is advice to submit procedure to comply with the requirements of said standards. (C.Naria/J.Krishna)

NewUnidentified Anchor Bolts: Under Package 7, Permanent Infrastructure: SATORP observed during anchor bolts material receiving inspection of M27 x 785 mm intended for jib crane at MIE Building that there was no marking on the anchor bolts. This violates Sec 5.2 JERMS-M-2005. It was also noticed that the anchor bolts assembly was delivered unpackaged in a rigid and weatherproofed container which is in contrast of Sec 7.3.1.2 of JERMS-M-2007 Rev 3. Anchor bolts were rejected and logbook entry was raised to inform the PMT and the contractor. (R.Darell/M.Rashed)

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March 23, 2011

NewMisaligned Gypsum Board Installation: Under Package 2B, Acid Gas Treatment: During surveillance it was observed that alignment at the expansion joint location on gypsum boards at Electrical Equipment room are around 4mm offset. This is a violation to Uniform Building Code 1997 section 2507.3.2. Logbook entry was made, PMT and Contractors are informed. (F.Caro/S.Paramban)

NewMissing Vent Hole on Precast Manhole: Under Package 2A, Conversion: During site inspection at Unit 081 and Unit 181, it was noticed that vent hole for five pre cast Manholes were missed during pre cast. These are required as per IFC drawings SA-JER-CN081-TPIT-343006 and SA-JER-CNAAA-TPIT-66300. The contractor has issued internal non conformity report and PMT were informed for follow up to propose corrective action. (F.Torne/A.Bhati)

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March 23, 2011

Mechanical MajorEquipment Received Without Nitrogen Blanketing: Under Package 2B, Acid Gas Treatment (Site): During receiving inspection of equipments, it was observed that, equipment 221-E-0009A tube side pressure gauge damaged and Equipment 222-E-0012A tube and shell side pressure gauge readings were at 0 pressures. This is violating JERMS-D-3204, Para 19.2.5. A Log book entry was issued, and PMT and Contractor were informed. (M.Rao/S.Paramban)

MajorWelding Machines and Portable Ovens Without Valid Calibration: Under Package 4, Delayed Cooker Unit: During surveillance at NESMA Fabrication Shop at Dhahran, it was observed that the welding was done by machines (5Nos) and portable electrode ovens (4Nos) without valid calibration. This violates Schedule Q Attachment IV Para 6.1 requirements. An LBE was issued and the PMT/contractor was notified. (R.S.Nair)

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March 23, 2011

MajorDamaging Flange Face during Blasting (Serration): Under Package 1, Distillation and Hydro Treating: During Surveillance Inspection at TCF Sinopec fabrication Shop, it was noticed that, 2 150 Class Flange serration was damaged during the Blasting of 2-Spool. This is the violation against JERES L-109 Para9.2 and ASME B16.5 Para 6.4.6 &Table.3 .Which states that, the Exceeding the limit of flange face (serration) damage shall not be permitted. A logbook entry was made and PMT/contractor for corrective and preventive action. (M.Shahul/M.Yadav)

MajorIncomplete Welding on the Pipe Supports: Under Package 2B, Acid Gas Treatment (Daelim Warehouse): During Material Receiving Inspection, no seal or continuous welding is found of the Pipe Supports which is fabricated at vendor shop in Korea. This is violating to JERMS-M-2007 Para: 6.2.3.3&7.2.6.5. A Logbook entry is issued, PMT and Contractor were informed. (M.Jinnah/ S. Paramban)

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March 23, 2011

MajorWrong Piping Branch Connection Forged Tee: Under Package 6, Refinery Tank Farm: During surveillance at, PSCL fabrication shop, it was observed that piping branch was made with forged Tee for 4TH connection. This is violation of JERES-L-110 Para 12.3 says connections, such as those for branch connection on tees, elbows and reducers are not permitted. A Log book entry was issued PMT and contractor was informed for corrective and preventive action (S.Prabhu/J.Krishna)

MajorVery Poor Piping branch Fabrications: Under Package 6, Refinery Tank Farm: During surveillance at, PSCL fabrication shop, it was observed that piping 4 way branches was done. As per standard shall be T or reinforcement pad branch is required or without full penetration weld or Reinforcement pad. This violates ASME B31.3 Para 328.5.4 d indicates joints shall have full penetration weld. A Log book entry was issued PMT and contractor advised to comply corrective and preventive action (S.Prabhu/J.Krishna)

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March 23, 2011

MajorImproper Insulation at Pipe Ends During Local PWHT: Under Package 2B, Acid Gas Treatment (Daelim/MMG Lay Down): During Surveillance it was observed that during PWHT, the open ends of pipes are closed by fire Blanket instead of thermal Insulation Material, which may lead to the entrapment of air through the fire blanket. This is violating to JERES-W-011, Para: 14.6, which is stating that, the ends of open lines shall be closed off in order to eliminate drafts or air circulation that could lower the temperature on the inside surface of the joint. Logbook entry is issued, PMT and Contractor were informed. (M.Jinnah/S.Paramban)

MajorEquipment Received with Incomplete Welding on SS Sliding Plate: Under Package 2B, Acid Gas Treatment (Site): During inspection of equipments 221-E-0003, 222-E-0003, it was observed that, stainless steel plate (2mm) at base plate of equipment (at sliding side) are stitch welded instead of continuous welding. This is violating JERMS-D-2007; Para 7.2.6.6. A Log book entry was made and the contractor was advised to do full welding. (M.Rao/S.Paramban)

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March 23, 2011

MajorWeld Joint without Root Gap: Under Package 4, Delayed Cooker Unit: During surveillance at NESMA Fabrication Shop at Dhahran, observed that square butt joints are welded without having root gap. This violates AWS D.1.1 joint design requirements. An LBE issued and the PMT/contractor notified. (R.S. Nair).

MajorUT Carried out without approved Procedure From Company: Package 5B, Plant Utilities, (EPC, SK E&Cs sub-contractor, Yanbu Steel Co.s Tanks Erection Site). During witness point at Demineralized Water Storage Tank (Item No. 531-T-0002-A) observed that NDT contractor, RISS has gone for UT on Plates of 8th Course Shell without having COMPANYs approved procedure. Its a violation as per JERES-W-017, Rev., 04, sub Para 17.1.1. A Log book entry was made as a Violation & PMT / Contractor were informed. (M.Hanef/ W.Hamood)

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March 23, 2011

NewImproper Storage & Handling of Pipes: Under Package 2B, Acid Gas Treatment (Daelim/MMG Lay Down): During surveillance, it was observed that Piping Spools are lying on the ground without any protection. This is violated to JERES-L-350 Para: 7.1 & 7.4, which is stating that, The Pipes shall not be stored directly on the ground. The pipes shall be placed on mounds or Sleeper &End protectors on pipes, flanges, weld bevels, threads and socket ends shall be firmly attached. A Logbook entry is issued, PMT and Contractor were informed. (M.Jinnah/S.Paramban)

NewImproper storage of Non Conforming Items: Under Package 2B, Acid Gas Treatment (MMG Fabrication Shop): During Surveillance visit, it was observed that Non-Confirming/rejected spools are stored with accepted spools without segregation. This is violating to Schedule-Q, Para: 7.3.7 which is stating that, The Contractor shall segregate all other non-confirming materials and assemblies to a clearly designated rejection site. A Logbook entry is issued, PMT and Contractor were informed. (M.Jinnah/S.Paramban)

NewCalibration Procedure & Technician Not approved By Company: Under Package 5B, Plant Utilities (SK E&Cs sub-contractor, NCC CD): During surveillance Inspection at subcontractor, NCC (CD) Piping Fabrication & Erection Site noted that Calibration Procedure implemented in-house on Welding Machines is unapproved & done by COMPANYs unapproved Calibration Technician. This is a violation as per Sch., Q, Attach. IV, sub Para 6.2. A Log book Entry were made as Violations & PMT / Contractor was informed. (M.Hanef/W.Hamood)

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March 23, 2011

NewImproper Joint Cleaning: Package 5B, Plant Utilities (SK E&Cs sub-contractor, Yanbu Steel Co.s Tanks Construction Site): During witness point surveillance, Fit Up (Tack Welds) inspection at Condensate Storage Tanks (Item No. 561-T-1001 & 1002) observed, that subcontractor, Yanbu Steel Co., has not removed Paint from the Roof Plates for Fillet Welds at Roof to Crown Plate Lap Joints, WL-21 & WL-23 before going for Tack Welds. Its a violation as per JERES-W-017 Rev. 04 sub Para 11.3.1. A Log book entry was made PMT / Contractor. (M.Hanef/W.Hamood)

NewEquipment received with Corrosion at Skirt: Under Package 3, Aromatic Unit: During site surveillance notice that there are corrosion/rust and paint damages on skirt internal and external surfaces on the two Clay Treaters received at site. This is a violation of JERMS-D-3204 Para: 19.1.1 & 19.3. A Log book entry was raised and PMT/Contractor was informed. (M.Rama/H.Hayeki).

NewRusted Stud Bolts and Nuts Of Blow Down Drum: Under Package 5B, Plant Utilities (SKEC Lay down Area): During material receiving inspection, Continuous Blow down Drum 551D-0001A/B was found with rusted stud bolts and nuts. This is violation as per JERMS-D-3204 Para. 19.1.1. A Log book entry was made and Contractor/PMT was informed. (K.Pramod/W.Hamood)

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March 23, 2011

NewBend Pipe Spool: Under Package 5B, Plant Utilities, (SK E&Cs Sub contractor NCC Kaefer Painting Yard): During surveillance 2- N2L-551161312 R02-SPL 02 carbon steel pipe spool has been found with a bend pipe and Contractor Proceed with coating without Corrective Action. This is violation as per JERES-L-350 Para.8.1. A Log book entry was made and Contractor/PMT was informed. (K.Pramod/W.Hamood)

NewImproper Hole Preparation: Under Package 6, Refinery Tank Farm (EPC, PSCL Lay down Coating and Blasting Area): During Inspection of surface preparation prior to intermediate coating for 28 piping spools it was noticed flame cutting of holes for 3 location 1 bosses connection is unclean burrs internal. This violates JERES-W-011 Para: 12.3.2.1 Ragged and irregular edges shall be ground or machined to bright metal. All holes cut for set-on nozzles, bosses, or branch connections shall be ground smooth and the diameter of the hole shall be 1.6 mm of the inside diameter of the set-on member. A Log book entry was issued PMT and contractor was informed to comply corrective and preventive action (D. Ramo/J.Krishna)

NewTanks 7th Course Shell Plate: Under Package 6, Refinery Tank Farm (EPC, Petrol Steel Co.s South Tank Farm): During Surveillance Inspection Tank #0001B 7th shell course plate were found bended after welding (75mm). This is a violation to JERES-W-017 para.18.6. & API 650 Para 7.5.2. A log book entry was made and the Contractor shall make a corrective action and preventive actions. (A.Khaliq/J.Krishna)

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March 23, 2011

Plumbing/HVAC MajorGravity Test on 800 mm Diameter Concrete Pipe White Water Sewer System: Under Package 6, Refinery Tank Farm (North): During water tightness test for 4 hours, leak was found on bell & spigot Joint No. 4 from Manhole 252 where C.P.P. (concrete Pipe Protection) was located. This is a violation of section 6.3.1 of JERES-S-020 Rev. 2. A Log Book Entry was raise to notify the PMT and the contractor. (A.Escleto/J.Krishna)

NewHydro-Test Failure of RTR Pipes: Under Package 3, Aromatics Unit: During hydro test of RTR pipe for CWR (Cooling Water Return) lines at PX Area, a pinhole leakage was noted on the adhesive joint of RTR Pipe 14 along the thrust block. RFI was rejected, PMT/Contractor been informed. (C.Torreliza/H.Hayeki)

NewImproper Protection of installed RTR Pipes: Under Package 2A, Conversion: It has been observed that RTR lines installed in Unit 41 are not properly secured from debris ingress and edge damages. This violates the requirements of JERES-S-070, Para 14. A log book entry was made and Contractor was informed to provide end caps. (G.Managuelod/A.Bhati)

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March 23, 2011

NewMishandling of RTR Pipes: Under Package 5B, Plant Utilities: During surveillance inspections at Area 501, it was observed that some laid RTR pipes in the open trenches are with accumulation of debris and stones, inadequate sand beddings and some pipes had been long exposed to sunlight. This violates JERES-S-070 Para. 10.8. A violation Log book entry was initiated. The PMT/contractor was advised to strictly comply to the requirements and corrective actions with immediate effect. (C.Torreliza/W.Hamood)

NewRTR Pipes without Proper End Protection: Under Package 5A, Interconnection: During site surveillance at Block 1 area, 36 inch RTR pipelines and branch line were found without proper end protection .It causes many foreign materials like wooden block, hand gloves, plastic waste and sand found inside the installed pipes. It is violating JERES-S-070 Para 10.4. It states that at the end of every work shift, personal performing the pipe installation shall ensure that the pipe ends are capped to prevent the egress of foreign materials, and the piping is anchored to prevent floatation. A Log book entry was made and informed to PMT/Contractor. (G.Mahalingam/M.Asiri)

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March 23, 2011

Electrical MajorIncorrect Electrical Duct bank Installation: Under Package 4, Delayed Coker Unit. During surveillance at Merox area, it was discovered that electrical duct bank no. D-42 had insufficient concrete cover on one side. This is violates JERES-P-104, Para 6.4.10.3.Which requires a minimum concrete cover of 160 mm from the outer surface of a duct to any conduit & Spacing. A contractor NCR was again issued & the said duct bank was rejected and replaced. This is a repeated violation. (S.Aromin/RS.Nair)

MajorUndocumented Equipment were Installed: Package -5B- Plant Utilities (ContractorSK-E&C) Unit 551-STG (Steam Turbine Generator). During our surveillance at site of Unit 551 for Steam Turbine System, it was observed that equipment (with Tag No. 551-X-0002-A, B) was already: Mounted at the top of foundation without RFI for MRR prior to erection. The equipment delivered to the site directly without any technical document related to the equipment. This is a violation to ITP, QLT, and ISO-9001 Para. 8.3. A Log book entry was made and PMT/Contractor was informed for immediate action. (E.Sanjorjo/W.Hamood)

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March 23, 2011

NewPoor Handling of PVC Conduits And Fittings: Under Package 3, Aromatics Unit: During inspection at Kettaneh lay down yard, notice that many PVC conduits and fittings were without covers and were being stored directly exposed to sunlight. This is a violation schedule.Q para.5, of Attach. IV. Contractor & PMT were already notified for corrective action. (S.Aromin/H Hayeki)

NewInsulated Grounding Grid: Under Package 8, Pipeline & Offplot Facilities: During inspection for material receiving of grounding cables 1C x 70 mm2, CQT observed that cables are insulated, which is a violation to JERES-P-111 Para 7.3. A LBE was made as a violation and PMT/Contractor were informed to change them. (H.Batran/I.Rajeh) NewImproper method used for Cad-weld: Under Package 1, Distillation and Hydro Treating: During inspection of Cad weld for grounding system at Area 151, SS-1611; it was observed that the strands of the grounding cable were damaged and blackened by fume. This violates the Contractors approved QCP SA-JER-DSAAA-TRJR-509244 for Grounding System. EPC Contractor issued NCR to have corrective & preventive action for the same. (Mohammed S. Ahmed / M. Yadav)

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March 23, 2011

Telecommunication NewContractor Failed to Provide Telecom Conduit End Caps: Under Package 5A, Interconnecting: During site surveillance at the three substation; SS 01, SS 12 and SS 16, it was observed that the contractor failed to provide appropriate end caps, telecom conduit entrance opening, and protection of PVC conduit. These are in violation to JERES-T-628 paragraph 5.3.1 which requires that all conduit entering buildings must be sealed at all times to prevent sand or debris from entering the duct. Log book entry was made and informed PMT/Contractor. (J.Hatamosa/M.Asiri)

NewTwo Drums of Defective Cables: Under Package 10, Permanent Communication Facilities: During FOC on-reel continuity test at Technip warehouse, it was observed that there are two defective reels out of 27 . Following discrepancies were spotted: 1. Cable physical description does not conform from the manufacturer material description. (Cable manufacturer failed to provide flooding gel inside the core area) 2. JERES-T-928, paragraph 5.24, which requires All direct buried cables shall be filled core type. PMT/Contractor was informed in above violations. (J.Hatamosa)

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March 23, 2011

Instrumentation NewInconsistent Cable Tray & Raised Floor Elevations: Under Package 4, Delayed Coker Unit: During review of IFC drawings for cable tray layout at PIB 08, it was noted that the elevation of the top cable tray is almost the same with the elevation of the raised floor. With a 50mm difference, the top cable tray is not accessible especially that cable trays are to be installed below cabinets and due to the cabinet frame supports. This is a violation to IEC 603641 Para 132.12 requiring accessibility for electrical equipment and maintaining work spaces. A logbook entry was made and the Contractor was informed to consider design review for necessary changes. (R.Abaa/R.S.Nair)

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March 23, 2011

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