SA1-6600033952

ANDR/SDGM/ABQ: BI-10-00791/00060
STANDARD VIOLATION INDEX LOG -OPEN
Department: CAT QA/QC As of Dec 30, 2017

Surveillance Date of Expected Completion Action Initiated

Sr.No No. Description Discipline Corrective Action Status Remarks Location
Issue Completion Date Date By By

As preventive action: A toolbox talk has been conducted by

On November 07, 2017 during shop surveillance of CAT Dammam the contractor QC with the concerned foreman & Crew.
laydown area. Inspection Department observed a number Fabricated spools flange faces are protected & QC
Completed pipe spools in the laydown area near HT shop and at inspectors will perform regular surveillance in order to
1 3899 11-Nov-17 9-Feb-18 Mechanical
ensure that preservation is meeting with client
SAPID Open ponciarv Fab-Shop
the back of Blasting shop without any suitable cover on the flange
ends and threaded connections. In spite of the two internal NCRs requirements, moreover final inspection of fabricated
and proactive notification repeated violation are still observed. spools to be done at the time of spool release. Responded
By:QCS-SA1-DMM-FAB-SHOP.

During the routine site visit dated on 03 December, 2017 for API 5L
X60 diameter 8 inch flow line for FZRN Well Head number 202,
Contractor CAT UNDER BI-10-01433-7268, Project Inspection The LBE being discussed last eek during the meeting and
representative observed that segment of flow pipeline is not it’s found that PID consider the sweet sand stacking same
12/21/2017, ACD
as ground while the standard allows to lay pipes on sweet
2 4000 properly preserved at the storage area, Which violating the 3-Dec-17 extended to 09 Mechanical
sand, for that we shall communicate CSD / PMT to verify
SAPID Open alimx1i Site
requirements of SAES L 450 Paragraph 8.3, which states that Pipe Jan'18
the ground meaning based on PID request. Replied by:
stacking shall be made in a manner which will not damage the pipe ABDALLAH KAMEL QA/QC MANAGER.
or the coating. The pipe joints shall not laid directly on the ground.
SAPMT advice to contractor to do corrective and preventive action.

During routine surveillance at 20 quot ABQQ SWD HEADR

Inspection representative noticed flow line has been placed in the
trench with insufficient sand padding violating the requirements of
This LBE is not valid since it is applicable in the installation
3 4024 SAES L 450 Para 14.10.3 which states that sand pads or sand 6-Dec-17 5-Mar-18 Mechanical
in rock areas
SAPID Open mohasx1i Site
bags shall be placed at approximately every 9 m to support the pipe
100 mm off the prepared bottom. Contractor is advised for
corrective and preventive action.

On December 13, 2017 during spools released inspection PID

observe two 2 spools with girth weld root pass reinforcement was
measured and evaluated with reinforcement was in excess of 1.5 ABOVE SPOOLS ARE INSPECTED AND ACCEPTED BY
mm exceeding code limits. The identified spools are intended for SAPID AS PER RFI# FZRN-MECH-SA1-104 & SHYBAH-
4 4079 13-Dec-17 3-Mar-18 Mechanical
MECH-2707. LBE CAN BE CLOSED. REPLIED BY: QC
SAPID open ponciarv Fab shop
FAZRAN and SHAYBAH with the following BB 267398 001 , TB
044864 001 F8 . PID has advice the Welding QC - Amair and WAQAS & IMMEDIATE SUPERVISOR: FAHEEM AHMED.
Coating QC 8211 Wakas to check the internal root pass
reinforcements with corrective action.
 SA1-6600033952
ANDR/SDGM/ABQ: BI-10-00791/00060
STANDARD VIOLATION INDEX LOG -OPEN
Department: CAT QA/QC As of Dec 30, 2017

Surveillance Date of Expected Completion Action Initiated

Sr.No No. Description Discipline Corrective Action Status Remarks Location
Issue Completion Date Date By By

During the routine site visit dated on 16 December, 2017 for RTR
job at ANDR WELL HEAD 594 for contractor CAT under BI number
10-01433-7145, Inspection department representative found that
QC Personnel for RTR have no training or certification for High
pressure RTR piping. This is a clear as per Schedule Q attachment The below LBE the said inspector is an approved RTR
VI Table number VI-1 which states RTR Inspector shall be certified inspector and previously approved by project inspection
5 4086 by SAUDI ARAMCO, for RTR Material manufacturing, handling, 17-Dec-17 31-Dec-17 Mechanical minimum twice at maintain potential project for that we SAPID open alimx1i Site
and installations. He shall be able to demonstrate a thorough would notify that the below LBE is invalid. Replied by:
working knowledge of international codes and standards related to ABDALLAH KAMEL QA/QC MANAGER.
inspecting RTR System and its components, such as RTR
preservation, material handling, installation, repairing and hydro
testing. SAPMT advice to contractor for a suitable corrective and
preventive action.

During the routine site inspection dated on 18 December, 2017 for

6 Inch RTR flow line for Contractor CAT UNDER BI-10-01433-7145
at ANDR Well Head 594, Project Inspection representative found
that Contractor was using uncertified personnel for installation of
RTR pipe. It was found that 02 installers were working without
JCCs for RTR. This is violation of SAES-S-070 section 8.4
requirements which states that training certificate or a proof of
6 4120 19-Dec-17 31-Dec-17 Mechanical SAPID open alimx1i Site
training for installing RTR piping system must be obtained from any
RTR Saudi Aramco Approved Piping Manufacturer and Certification
shall be submitted to Saudi Aramco Inspection Department for
review and concurrence and a job clearance card JCC validity is for
mentioned project only shall then be issued to each qualified pipe
and fitting installer. SAPMT advice to contractor to do corrective
and preventive action.

During site visit at ABQQ GOSP 5 SWD 20 Inch line Inspection

department representative noticed contractor failed to use roller
supports or side booms with cradles during the installation of 20 Internal NCR have been issued to Construction Dept. and
also, tool box meeting conducted to Foreman and crews to
7 4123 inch dia pipe at thrustbore and pipe string was laid which violates 19-Dec-17 19-Mar-18 Mechanical
avoid recurrence. Replied by: ROD P.VILLAR QC
SAPID open mohasx1i Site
SAES L 470 Para 6.3.9.2 The pipe string shall be laid over roller SUPERVISOR.
supports or held with side booms with cradles. Holding the pipe
string by belts through cranes or side booms is not permitted.

During surveillance at flow line of Abqaiq 48, Inspection

representative noticed that contractor failed to wrap protective
sleeve around the coated ends while welding FW-42, drawing External coating adjacent to FW 42 will be check for
number TA-053206 Sheet 001 violating requirement of SAES-H- possible weld spatter damaged and this will be applied
using FBE coat (APCS 104) and to be check with holiday.
8 4134 200 paragraph 6.2.1 which states that protective sleeves made 23-Dec-17 11-Feb-18 Mechanical
Tool box meeting will be conducted to welders/foremen to
open khanma2y Site
from welding blankets at least 0.5 m wide shall be wrapped around avoid recurrence. Replied by: ROD P.VILLAR QC
the coated ends of the pipes adjacent to girth weld area while SUPERVISOR.
welding to prevent weld spatter from burning through the coating.
Contractor shall take corrective and preventive actions.
 SA1-6600033952
ANDR/SDGM/ABQ: BI-10-00791/00060
STANDARD VIOLATION INDEX LOG -OPEN
Department: CAT QA/QC As of Dec 30, 2017

Surveillance Date of Expected Completion Action Initiated

Sr.No No. Description Discipline Corrective Action Status Remarks Location
Issue Completion Date Date By By

During the routine site visit dated on 26 December, 2017 for API 5L
X60 diameter 8 inch WT 0.5 inch for FZRN well head number 207
UNDER BI-10-01433-7275 for contractor CAT, Inspection
department representative found that ends of pipeline strings are
opened and not covered by an appropriate source near Joints
number FW 09, FW 14 and FW 18. This is a clear violation as per
9 4151 27-Dec-17 11-Jan-18 Mechanical open alimx1i Site
SAES-L-450 Para 11.4 which states Open ends of pipeline strings
shall be capped to prevent entry of debris or animals and birds. The
protection end caps shall cover the pipe ends. It may be made from
low density polyethylene or equivalently durable material. They
shall be ultraviolet UV and weather resistant. SAPMT to advise
contractor for suitable corrective and preventive action.

During the Hydro test inspection dated on 28 December, 2017 for

API 5L X60 diameter 8 inch WT 0.5 inch drawing number BB-
993214-001 Well Head Piping at ANDR Well Head 1219 for
contractor CAT under BI number 10-01277-6226, Inspection
department representative found leak in flanged Ball Valve 9 inch
diameter API CL3000, Body seat surface specification API A350
10 4161 28-Dec-17 18-Jan-18 Mechanical open alimx1i Site
LF2 during hydro test. This is a clear violation as per SAES-L-150
Para number 7.2 which states that the test pressure shall be
maintained for a sufficient time, but shall not be less than 30
minutes, to determine that there are no leaks. SAPMT advice to
contractor before raising any RFI they need to make sure by
themselves that job is ready for inspection.
 SH-1A
SHYB: BI-VARIOUS
STANDARD VIOLATION INDEX LOG -OPEN
Department: CAT QA/QC As of Nov 24, 2017

Surveillance Date of Expected Completion Completion Action

Sr.No Description Discipline Corrective Action Status
No. Issue Date Date By

HOT PASS NOT ADDED FOR MORE THAN TWO HOURS and
LIFTING OF PARTIALLY WELDED PIPE SPOOL, TB-044862-001-
F5-SW 20 On Sep 30, 2017 during surveillance at Cat fabrication
shop Dammam, Inspection representative found that contractor not
added the hot pass more than two hours, after that it is added
without MT and preheat for the joint, lifted partially root welded
2inch pipe spool. This is in violation to SAES-W-012 Para 10.7.2
and 10.7.5 which states that second or hot pass shall be added as
soon as possible after the completion of the root pass, but shall not Acknowledge, the subjected joint ( TB-044862-001 F5 SW-
1 3469 2-Oct-17 31-Dec-17 Mechanical SAPID Open
exceed 5 minutes for vertical down welding with cellulosic 20 ) has been RT done and accepted by Saudi Aramco.
electrodes or 15 minutes for vertical up welding. If a production joint
exceeds the specified time lapse, then magnetic particle
examination of the root pass shall be conducted and the joint
preheated to 60 176 C minimum or the preheat specified in the
procedure, whichever is greater, prior to making the hot pass, the
pipe shall not be lifted or moved during welding and partially welded
joints shall not be lifted. contractor 8217 s corrective and preventive
action is required.

During review of monthly quality management report for the month

of October,2017 submitted by contractor Br.CAT in Shaybah.
SAPID observed that preceding internal audit was conducted on
31st October 2016, despite of proactively highlighted this issue in
2 3661 weekly quality meeting contractor failed to conduct internal audit 15-Nov-17 6-Dec-17 Mechanical SAPID Open
after one year which is violation of Schedule Q para 7.2.1 states
that at a minimum contractor shall conduct an internal audit of the
contract once in a year. Contractor herby advised to conduct
internal audit to avoid escalation of this violation as per SAEP-381.

On November 21, 2017 PID on document Review with PMT

Transmittal no SyO amp GUPD SHAYBAH L-0927 2017 of welders
qualification certificate prior approval and issuance of Job
Clearance card. PID has rejected 15 welders out of 23 welders
3 3693 21-Nov-17 19-Feb-18 Mechanical SAPID Open
submitted because the welders were qualified to a WPS that were
not used in MP projects fabrication shops. PID has proactively
advise Welding QC Coordinator to qualify the welders based on MP
project requirements.