quality weekly highlights no. 1033 dated 18th mar., 2011[1]

8/4/2019 Quality Weekly Highlights No. 1033 Dated 18th Mar., 2011[1]

1/20

SATORP / IK-Construction Site_____________________Quality Weekly Highlights

March 23, 2011

Page 1 of20

PMT-Quality DepartmentAll Packages

Week Ending March 17, 2011Quality Weekly Highlights Number 1033

Weekly Highlight including:1. General Quality2. Civil3. Mechanical4. Plumbing/HVAC5. Electrical6. Telecommunication7. 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

CivilMajorExcavated Area without Erosion Control:

Under Package 6, Refinery Tank Farm(South Pump Station 9): During surveillance inspection, contractor has not complied to applyerosion control on slopes of excavated area at Pump Station 9. This is a violation to JERES-A-114 Para. 5.3.2 and logbook entry was issued. PMT/CONTRACTOR was informed to take thecorrective action.(J.Tayamin/J.Krishna)


2/20

March 23, 2011Page 2 of20

NewFoundation Footing Without Engineered Support System:

Major

Under Package 6, RefineryTank Farm (South Pump Station 9): During surveillance inspection, it was observed contractorhas 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 tointersect a 45-degree plane extending downward from the bottom edge of existing foundationsunless an engineered support system is in place prior to the start of work. A Logbook entry wasissued and PMT/CONTRACTOR was informed to take the corrective action.(J.Tayamin/J.Krishna)

Sand Bedding without Trench Dewatering:

Under Package 5C, Auxiliary Utilities:During Surveillance visit it was observed that Contractor started the sand bedding activity withthe entire length of the trench full of standing water. This is violation as per Sec 10.3 JERES-S-070, stating that bottom of trench must be sufficiently drained before the bedding layers areplaced. A Logbook entry was raised to inform the PMT and the contractor with regards to thismatter. (R.Darell/M.Faisal)


3/20


NewBackfilled without Required FDT (Field Density Test)

New

: Under Package 3, AromaticsUnit: During site surveillance at CCR-131, found that concrete structures and catch Basin beenfully back filled around their adjacent surface without required compaction and density test. Thisis a violation of JERES-A-114, Sec .6.3.2.2 & 6.3.3.3. An NCR was issued PMT/contractor wasinformed.(J. Osorio/H. Hayeki)

Improper Water Curing for Concrete Beam

New

: Under Package 4, Coker Unit: Duringsurveillance inspection to Substation 1201 it was observed improper water curing for the newlyconstructed 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/Contractorinformed. (R.Raquel/R.S.Nair)

Rejected Manhole was concreted by the Contractor:Under Package 9, Port tank Farmand Loading Facilities: Manhole No.18 was concreted without Satorp approval. RFI was rejecteddue to improper installation of waterstop. This is a violation to JERES S-020 Para.5.9.1 whichstates that water seal shall conform to company standard. Logbook entry was issued andContractor NCR was issued. Contractor was advised for corrective action.(C.Velchez/A.Akhtar)


4/20


NewInsufficient Thickness on Pipe Rack Pedestal:

New

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

No shoring on Deep Excavation:

Under Package 6, Refinery Tank Farm (North): Duringsurveillance, it was noted that excavation for manholes was more than (5) feet and no shoringwere installed along the soil banks. This is unsafe practice and violation of JERES A-114paragraph 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)


5/20


NewCoating Applied without Leak Test on Manholes:

New

Under Package 6, Refinery TankFarm (North): Contractor has applied protective coating on manholes without conducting leaktest. This is a violation after the fact under JERES S-070 paragraph 19.8f. Which state: sitetesting shall take place prior to application of protective coatings. In this regards, an NCR wasissued and PMT/contractor is advice to submit procedure to comply with the requirements ofsaid standards. (C.Naria/J.Krishna)

Unidentified Anchor Bolts:

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


6/20


NewMisaligned Gypsum Board Installation:

New

Under Package 2B, Acid Gas Treatment: Duringsurveillance it was observed that alignment at the expansion joint location on gypsum boards atElectrical Equipment room are around 4mm offset. This is a violation to Uniform Building Code1997 section 2507.3.2. Logbook entry was made, PMT and Contractors are informed.(F.Caro/S.Paramban)

Missing Vent Hole on Precast Manhole:

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


7/20


Mechanical

MajorEquipment Received Without Nitrogen Blanketing:

Major

Under Package 2B, Acid GasTreatment (Site): During receiving inspection of equipments, it was observed that, equipment221-E-0009A tube side pressure gauge damaged and Equipment 222-E-0012A tube and shellside pressure gauge readings were at 0 pressures. This is violating JERMS-D-3204, Para19.2.5. A Log book entry was issued, and PMT and Contractor were informed.(M.Rao/S.Paramban)

Welding Machines and Portable Ovens Without Valid Calibration:

Under Package 4,Delayed Cooker Unit: During surveillance at NESMA Fabrication Shop at Dhahran, it wasobserved 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 LBEwas issued and the PMT/contractor was notified. (R.S.Nair)


8/20


MajorDamaging Flange Face during Blasting (Serration):

Major

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

Incomplete Welding on the Pipe Supports:

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


9/20


MajorWrong Piping Branch Connection Forged Tee:

Major

Under Package 6, Refinery TankFarm: During surveillance at, PSCL fabrication shop, it was observed that piping branch wasmade with forged Tee for 4TH connection. This is violation of JERES-L-110 Para 12.3 saysconnections, such as those for branch connection on tees, elbows and reducers are notpermitted. A Log book entry was issued PMT and contractor was informed for corrective andpreventive action (S.Prabhu/J.Krishna)

Very Poor Piping branch Fabrications:

Under Package 6, Refinery Tank Farm: Duringsurveillance 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 penetrationweld or Reinforcement pad. This violates ASME B31.3 Para 328.5.4 d indicates joints shall havefull penetration weld. A Log book entry was issued PMT and contractor advised to complycorrective and preventive action(S.Prabhu/J.Krishna)


10/20


MajorImproper Insulation at Pipe Ends During Local PWHT:

Major

Under Package 2B, Acid GasTreatment (Daelim/MMG Lay Down): During Surveillance it was observed that during PWHT, theopen ends of pipes are closed by fire Blanket instead of thermal Insulation Material, which maylead 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 draftsor air circulation that could lower the temperature on the inside surface of the joint. Logbookentry is issued, PMT and Contractor were informed.(M.Jinnah/S.Paramban)

Equipment Received with Incomplete Welding on SS Sliding Plate:

Under Package2B, Acid Gas Treatment (Site): During inspection of equipments 221-E-0003, 222-E-0003, it wasobserved that, stainless steel plate (2mm) at base plate of equipment (at sliding side) are stitchwelded instead of continuous welding. This is violating JERMS-D-2007; Para 7.2.6.6. A Logbook entry was made and the contractor was advised to do full welding. (M.Rao/S.Paramban)


11/20


MajorWeld Joint without Root Gap:

Major

Under Package 4, Delayed Cooker Unit: Duringsurveillance at NESMA Fabrication Shop at Dhahran, observed that square butt joints arewelded without having root gap. This violates AWS D.1.1 joint design requirements. An LBEissued and the PMT/contractor notified.(R.S. Nair).

UT Carried out without approved Procedure From Company:

Package 5B, PlantUtilities, (EPC, SK E&Cs sub-contractor, Yanbu Steel Co.s Tanks Erection Site). During witnesspoint at Demineralized Water Storage Tank (Item No. 531-T-0002-A) observed that NDTcontractor, RISS has gone for UT on Plates of 8th Course Shell without having COMPANYsapproved procedure. Its a violation as per JERES-W-017, Rev., 04, sub Para 17.1.1. A Logbook entry was made as a Violation & PMT / Contractor were informed. (M.Hanef/ W.Hamood)


12/20


NewImproper Storage & Handling of Pipes:

New

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

Improper storage of Non Conforming Items:

New

Under Package 2B, Acid Gas Treatment(MMG Fabrication Shop): During Surveillance visit, it was observed that Non-Confirming/rejectedspools 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-confirmingmaterials and assemblies to a clearly designated rejection site. A Logbook entry is issued, PMTand Contractor were informed.(M.Jinnah/S.Paramban)

Calibration Procedure & Technician Not approved By Company:

Under Package 5B,Plant Utilities (SK E&Cs sub-contractor, NCC CD): During surveillance Inspection at sub-contractor, NCC (CD) Piping Fabrication & Erection Site noted that Calibration Procedureimplemented in-house on Welding Machines is unapproved & done by COMPANYs unapprovedCalibration Technician. This is a violation as per Sch., Q, Attach. IV, sub Para 6.2. A Log bookEntry were made as Violations & PMT / Contractor was informed. (M.Hanef/W.Hamood)


13/20


NewImproper Joint Cleaning:

New

Package 5B, Plant Utilities (SK E&Cs sub-contractor, YanbuSteel 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 sub-contractor, Yanbu Steel Co., has not removed Paint from the Roof Plates for Fillet Welds at Roofto Crown Plate Lap Joints, WL-21 & WL-23 before going for Tack Welds. Its a violation as perJERES-W-017 Rev. 04 sub Para 11.3.1. A Log book entry was made PMT / Contractor.(M.Hanef/W.Hamood)

Equipment received with Corrosion at Skirt:

New

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

Rusted 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 551-D-0001A/B was found with rusted stud bolts and nuts. This is violation as per JERMS-D-3204Para. 19.1.1. A Log book entry was made and Contractor/PMT was informed.(K.Pramod/W.Hamood)


14/20


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 pipespool has been found with a bend pipe and Contractor Proceed with coating without CorrectiveAction. This is violation as per JERES-L-350 Para.8.1. A Log book entry was made andContractor/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 intermediatecoating for 28 piping spools it was noticed flame cutting of holes for 3 location 1 bossesconnection is unclean burrs internal. This violates JERES-W-011 Para: 12.3.2.1 Ragged andirregular 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 andcontractor 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 SteelCo.s South Tank Farm): During Surveillance Inspection Tank #0001B 7th shell course platewere found bended after welding (75mm). This is a violation to JERES-W-017 para.18.6. & API650 Para 7.5.2. A log book entry was made and the Contractor shall make a corrective actionand preventive actions.(A.Khaliq/J.Krishna)


15/20


Plumbing/HVACMajorGravity Test on 800 mm Diameter Concrete Pipe White Water Sewer System:

New

UnderPackage 6, Refinery Tank Farm (North): During water tightness test for 4 hours, leak was foundon bell & spigot Joint No. 4 from Manhole 252 where C.P.P. (concrete Pipe Protection) waslocated. This is a violation of section 6.3.1 of JERES-S-020 Rev. 2. A Log Book Entry was raiseto notify the PMT and the contractor.(A.Escleto/J.Krishna)

Hydro-Test Failure of RTR Pipes:

New

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)

Improper Protection of installed RTR Pipes:

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


16/20


NewMishandling of RTR Pipes:

New

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

RTR Pipes without Proper End Protection:

Under Package 5A, Interconnection: Duringsite surveillance at Block 1 area, 36 inch RTR pipelines and branch line were found withoutproper end protection .It causes many foreign materials like wooden block, hand gloves, plasticwaste and sand found inside the installed pipes. It is violating JERES-S-070 Para 10.4. It statesthat at the end of every work shift, personal performing the pipe installation shall ensure that thepipe ends are capped to prevent the egress of foreign materials, and the piping is anchored toprevent floatation. A Log book entry was made and informed to PMT/Contractor.(G.Mahalingam/M.Asiri)


17/20


Electrical

MajorIncorrect Electrical Duct bank Installation:

Major

Under Package 4, Delayed Coker Unit.During surveillance at Merox area, it was discovered that electrical duct bank no. D-42 hadinsufficient concrete cover on one side. This is violates JERES-P-104, Para 6.4.10.3.Whichrequires 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)

Undocumented Equipment were Installed:

Mounted at the top of foundation without RFI for MRR prior to erection.

Package -5B- Plant Utilities (Contractor-SK-E&C) Unit 551-STG (Steam Turbine Generator). During our surveillance at site of Unit 551for Steam Turbine System, it was observed that equipment (with Tag No. 551-X-0002-A, B) wasalready:

The equipment delivered to the site directly without any technical document related to theequipment.This is a violation to ITP, QLT, and ISO-9001 Para. 8.3. A Log book entry was made andPMT/Contractor was informed for immediate action.(E.Sanjorjo/W.Hamood)


18/20


NewPoor Handling of PVC Conduits And Fittings:

New

Under Package 3, Aromatics Unit:During inspection at Kettaneh lay down yard, notice that many PVC conduits and fittings werewithout covers and were being stored directly exposed to sunlight. This is a violation schedule.Qpara.5, of Attach. IV. Contractor & PMT were already notified for corrective action. (S.Aromin/HHayeki)

Insulated Grounding Grid: Under Package 8, Pipeline & Offplot Facilities: During

inspection for material receiving of grounding cables 1C x 70 mm2, CQT observed that cablesare insulated, which is a violation to JERES-P-111 Para 7.3. A LBE was made as a violation andPMT/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 thatthe strands of the grounding cable were damaged and blackened by fume. This violates theContractors approved QCP SA-JER-DSAAA-TRJR-509244 for Grounding System. EPCContractor issued NCR to have corrective & preventive action for the same. (Mohammed S.Ahmed / M. Yadav)


19/20


Telecommunication

NewContractor Failed to Provide Telecom Conduit End Caps:

New

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

Two Drums of Defective Cables:

1. Cable physical description does not conform from the manufacturer material description.(Cable manufacturer failed to provide flooding gel inside the core area)

Under Package 10, Permanent CommunicationFacilities: During FOC on-reel continuity test at Technip warehouse, it was observed that thereare two defective reels out of 27 . Following discrepancies were spotted:

2. JERES-T-928, paragraph 5.24, which requires All direct buried cables shall be filled coretype.

PMT/Contractor was informed in above violations. (J.Hatamosa)


20/20


Instrumentation

NewInconsistent Cable Tray & Raised Floor Elevations:

Under Package 4, Delayed CokerUnit: During review of IFC drawings for cable tray layout at PIB 08, it was noted that theelevation of the top cable tray is almost the same with the elevation of the raised floor. With a50mm difference, the top cable tray is not accessible especially that cable trays are to beinstalled below cabinets and due to the cabinet frame supports. This is a violation to IEC 60364-1 Para 132.12 requiring accessibility for electrical equipment and maintaining work spaces. Alogbook entry was made and the Contractor was informed to consider design review fornecessary changes.(R.Abaa/R.S.Nair)

quality weekly highlights no. 1033 dated 18th mar., 2011[1]

Documents