Khalda Petroleum Company Kalabsha Projects Department Inspection Report No. 3 Kalabsha FWKOD (04 January 2018) Introduction: ‘The FWKOD skids identified below were delivered to the Kalabsha Site in late 2017 and were installed on their foundations in December 2017. When starting to install the Inlet piping it was noted that the 16” process inlet flanges on the skids (Photo 1) were not vertical which left upstream piping level unacceptable. PTJ Katamia personnel were called to the site to investigate the situation and determine the root cause. Katamia personnel were only shop personnel and not able to investigate the problem as required. KPC Project Engineers investigated the large diameter piping on the skid and determined that the flanges are not vertical for several reasons. The findings are provided in the following inspection. Tag No. 100-V-201-8 Manufacturer : Petrojet Year Built: 2017 Scope of Inspection: * Skid inspection ‘* Supports inspection * Flange verticality checks * Piping fiange inspections Summary of Inspection External Visual Inspection: 1. The 16” process inlet flange on the edge of the skid was confirmed to not be vertical (photo 2) 2. The bolts on the pipe support connected to the skid frame (at the first elbow) were loosened as were the flange bolts on both sides of the Inlet ESDV. 3. The ESDV was supported by the crane and the piping spool and ESDV were otated enough to bring the first flange back to vertical. The flange bolts were then tightened. 4. With the first flange now in the vertical position, gaps were found under the pipe support flange under the elbow and the cantilever support under the spool downstream of the ESDV (photo 3) 5. The Katamia personnel inserted pieces of junk steel using them as shims. (photo 3) 6. The necessity for shims was unacceptable for KPC and further dimensional checks were performed. These checks revealed that the cantilever support dimensions were not to the design requirements and furthermore the support, DCC Jan,2018 7:43 AMwas found to be not level (photo 4) demonstrating either poor construction or bad design. 7. The support dimensions were found about 1.7cm shorter in length (photos 5 & 6) than the design drawing requirements and the angle was not 90°. Both supports need to be properly installed. (attachment 7) 8. Dummy leg supports for the inlet piping were found to be installed incorrectly or at least deflected due to poor design. Other supports were not supporting the piping at all 9. Additional checks on the skid revealed at least 1 — 2 loose stud bolts on each flange checked by hand. (photo 8) Conclusior 1 2. 6. 7. The design and installation of the large diameter pipe supports are inadequate and not supporting the on-skid piping properly. The cantilever support is not a proper design with the weight being supported and must be supported on both sides of the pipe (not just one side) The existing supports are marginally supporting the pipe at this time and will probably deform even further when the vessel / piping is loaded with liquids under dynamic conditions. ‘The ESDV has a beam under it that appears large enough to support the weight of the valve and piping with the other piping support / dummy leg. The problem is that cable tray (with cables) is located directly under the valve. The location of the cable tray is poor and will not allow access to the cables later on, The vessel and associated piping will not contain pressure during the leak testing scheduled for commissioning A\llissues found on Train B skid are expected to be found on Skid A and C. Recommendations: 1 2 All piping and valve flanges must be checked with flange management system with proper stud bolt lubrication and torque. PTJ Katamia engineering / fabrication engineers need to prove that the existing supports are per the design, will perform under dynamic load conditions, supporting piping on level surfaces and not only at single points, and any modifications will not disrupt ongoing erection work Katamia engineering should keep a representative on site until all piping is ‘connected at the edge of the skids. We await your further instruction. eee Abdel Aziz Fathy David Corzine Western Area Development Project Western Area Development Project Deputy Construction Manager Construction Manager DCC Jan,2018 7:43 AMPhoto 1 DCC Jan,2018 7:43 AM