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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 Major–Excavated 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
New–Foundation 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. 184.108.40.206 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)
Major–Sand 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
Nair) New–Rejected Manhole was concreted by the Contractor: Under Package 9.New–Backfilled without Required FDT (Field Density Test): Under Package 3. (C.2.5.Velchez/A. Logbook entry was issued and Contractor NCR was issued. An NCR was issued PMT/contractor was informed. (R.Raquel/R.3. Contractor was advised for corrective action. Aromatics Unit: During site surveillance at CCR-131. A Log book entry was made and PMT/Contractor informed. RFI was rejected due to improper installation of waterstop. (J. 2011 .220.127.116.11 which states that water seal shall conform to company standard.3. 11. grid line C-13/16 and lintel beam door 2 & 3.18 was concreted without Satorp approval. Sec . These violate JERES-Q-001 Sec. 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. Port tank Farm and Loading Facilities: Manhole No. found that concrete structures and catch Basin been fully back filled around their adjacent surface without required compaction and density test.S. This is a violation of JERES-A-114.Akhtar) Page 3 of 20 March 23. This is a violation to JERES S-020 Para.2 & 6. Hayeki) New–Improper Water Curing for Concrete Beam: Under Package 4. Osorio/H.9.3.
2011 . Refinery Tank Farm (North): During surveillance.5.Naria/J. Rev. SA-JER-IP000-TPIT-193001.New–Insufficient Thickness on Pipe Rack Pedestal: Under Package 5A.Guiwa/M. This is unsafe practice and violation of JERES A-114 paragraph 5.Asiri) New–No shoring on Deep Excavation: Under Package 6. 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. (A. it was noted that excavation for manholes was more than (5) feet and no shoring were installed along the soil banks. Which state: when soil banks are greater that 5ft. (C. 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. This is in violation to General Note 12.Krishna) Page 4 of 20 March 23. Inter-connecting (Flare Line at Block 03 Area): During site surveillance.3 which state that the minimum thickness of grout is 25mm. shoring shall be installed. PMT/Contractor was informed to take action on this matter.3.2.
8f. This is a violation after the fact under JERES S-070 paragraph 19.Darell/M.Krishna) New–Unidentified Anchor Bolts: Under Package 7.Rashed) Page 5 of 20 March 23. 2011 . In this regards. (R.2 JERMS-M-2005. This violates Sec 5. Anchor bolts were rejected and logbook entry was raised to inform the PMT and the contractor.1. an NCR was issued and PMT/contractor is advice to submit procedure to comply with the requirements of said standards.2 of JERMS-M-2007 Rev 3.New–Coating Applied without Leak Test on Manholes: Under Package 6. 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. Refinery Tank Farm (North): Contractor has applied protective coating on manholes without conducting leak test.3. (C. 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.Naria/J. Which state: site testing shall take place prior to application of protective coatings.
This is a violation to Uniform Building Code 1997 section 2507. These are required as per IFC drawings SA-JER-CN081-TPIT-343006 and SA-JER-CNAAA-TPIT-66300. 2011 .Torne/A.3.Bhati) Page 6 of 20 March 23. Conversion: During site inspection at Unit 081 and Unit 181. The contractor has issued internal non conformity report and PMT were informed for follow up to propose corrective action.New–Misaligned Gypsum Board Installation: Under Package 2B. Logbook entry was made. it was noticed that vent hole for five pre cast Manholes were missed during pre cast. (F.Paramban) New–Missing Vent Hole on Precast Manhole: Under Package 2A. PMT and Contractors are informed. 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.2. (F.Caro/S.
Mechanical Major–Equipment Received Without Nitrogen Blanketing: Under Package 2B. (R. An LBE was issued and the PMT/contractor was notified. This violates Schedule Q Attachment IV Para 6.Rao/S.Paramban) Major–Welding Machines and Portable Ovens Without Valid Calibration: Under Package 4. and PMT and Contractor were informed.1 requirements. it was observed that the welding was done by machines (5Nos) and portable electrode ovens (4Nos) without valid calibration.2.5. Acid Gas Treatment (Site): During receiving inspection of equipments. Delayed Cooker Unit: During surveillance at NESMA Fabrication Shop at Dhahran. 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. it was observed that. (M.S. This is violating JERMS-D-3204. 2011 . A Log book entry was issued.Nair) Page 7 of 20 March 23. Para 19.
2011 .Major–Damaging Flange Face during Blasting (Serration): Under Package 1.Shahul/M.Yadav) Major–Incomplete Welding on the Pipe Supports: Under Package 2B.2.6 &Table. A logbook entry was made and PMT/contractor for corrective and preventive action. This is violating to JERMS-M-2007 Para: 6.5 Para 6. PMT and Contractor were informed.3 .2.5. Distillation and Hydro Treating: During Surveillance Inspection at TCF Sinopec fabrication Shop. (M.Jinnah/ S. it was noticed that.4. This is the violation against JERES L-109 Para9.3&7. Paramban) Page 8 of 20 March 23. 2” 150 Class Flange serration was damaged during the Blasting of 2”-Spool. A Logbook entry is issued. the Exceeding the limit of flange face (serration) damage shall not be permitted. (M. Acid Gas Treatment (Daelim Warehouse): During Material Receiving Inspection.3.Which states that. no seal or continuous welding is found of the Pipe Supports which is fabricated at vendor shop in Korea.6.2 and ASME B16.
Krishna) Page 9 of 20 March 23.3 Para 328.3 says connections. As per standard shall be T or reinforcement pad branch is required or without full penetration weld or Reinforcement pad. it was observed that piping branch was made with forged Tee for 4TH connection. PSCL fabrication shop.4 d indicates joints shall have full penetration weld. This violates ASME B31. A Log book entry was issued PMT and contractor advised to comply corrective and preventive action (S. 2011 . elbows and reducers are not permitted. Refinery Tank Farm: During surveillance at. This is violation of JERES-L-110 Para 12. A Log book entry was issued PMT and contractor was informed for corrective and preventive action (S. PSCL fabrication shop.Prabhu/J. such as those for branch connection on tees. it was observed that piping 4 way branches was done.5.Major–Wrong Piping Branch Connection Forged Tee: Under Package 6.Krishna) Major–Very Poor Piping branch Fabrications: Under Package 6. Refinery Tank Farm: During surveillance at.Prabhu/J.
Paramban) Page 10 of 20 March 23. PMT and Contractor were informed.6. 2011 . the open ends of pipes are closed by fire Blanket instead of thermal Insulation Material. Acid Gas Treatment (Site): During inspection of equipments 221-E-0003. A Log book entry was made and the contractor was advised to do full welding. (M. 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. (M.2. This is violating JERMS-D-2007. Para 7. Para: 14. Acid Gas Treatment (Daelim/MMG Lay Down): During Surveillance it was observed that during PWHT. which may lead to the entrapment of air through the fire blanket.Jinnah/S.Major–Improper Insulation at Pipe Ends During Local PWHT: Under Package 2B. 222-E-0003.Rao/S. it was observed that.6. Logbook entry is issued. This is violating to JERES-W-011.6. stainless steel plate (2mm) at base plate of equipment (at sliding side) are stitch welded instead of continuous welding.Paramban) Major–Equipment Received with Incomplete Welding on SS Sliding Plate: Under Package 2B. which is stating that.
Nair). (R. observed that “square butt” joints are welded without having root gap. Delayed Cooker Unit: During surveillance at NESMA Fabrication Shop at Dhahran. sub Para 17.1. It’s a violation as per JERES-W-017. 2011 . Yanbu Steel Co.Hanef/ W. Major–UT Carried out without approved Procedure From Company: Package 5B.. During witness point at Demineralized Water Storage Tank (Item No. Plant Utilities. SK E&C’s sub-contractor. 531-T-0002-A) observed that NDT contractor.1 joint design requirements.’s Tanks Erection Site).1. (M. This violates AWS D.Major–Weld Joint without Root Gap: Under Package 4. A Log book entry was made as a Violation & PMT / Contractor were informed. RISS has gone for UT on Plates of 8th Course Shell without having COMPANY’s approved procedure. 04. (EPC. An LBE issued and the PMT/contractor notified. Rev.Hamood) Page 11 of 20 March 23.S.1.
Jinnah/S. NCC (CD) Piping Fabrication & Erection Site noted that Calibration Procedure implemented in-house on Welding Machines is unapproved & done by COMPANY’s unapproved Calibration Technician.Jinnah/S.7 which is stating that. The Contractor shall segregate all other non-confirming materials and assemblies to a clearly designated rejection site.Paramban) New–Improper storage of Non Conforming Items: Under Package 2B. 2011 . This is a violation as per Sch.Hanef/W. A Log book Entry were made as Violations & PMT / Contractor was informed. A Logbook entry is issued. it was observed that Non-Confirming/rejected spools are stored with accepted spools without segregation. flanges. it was observed that Piping Spools are lying on the ground without any protection.New–Improper Storage & Handling of Pipes: Under Package 2B. threads and socket ends shall be firmly attached. The Pipes shall not be stored directly on the ground. Acid Gas Treatment (Daelim/MMG Lay Down): During surveillance. A Logbook entry is issued. (M. IV. Acid Gas Treatment (MMG Fabrication Shop): During Surveillance visit. PMT and Contractor were informed. (M. Plant Utilities (SK E&C’s sub-contractor. “Q”. sub Para 6. This is violating to Schedule-Q.Paramban) New–Calibration Procedure & Technician Not approved By Company: Under Package 5B.. Attach.3. (M. which is stating that.1 & 7. The pipes shall be placed on mounds or Sleeper &End protectors on pipes. PMT and Contractor were informed.4. This is violated to JERES-L-350 Para: 7. NCC CD): During surveillance Inspection at subcontractor. Para: 7.Hamood) Page 12 of 20 March 23.2. weld bevels.
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.. Yanbu Steel Co.1.1.1 & 19. 04 sub Para 11. A Log book entry was made and Contractor/PMT was informed. This is violation as per JERMS-D-3204 Para. It’s a violation as per JERES-W-017 Rev. Continuous Blow down Drum 551D-0001A/B was found with rusted stud bolts and nuts. 2011 . (M. 19. (M.3.Hayeki). Yanbu Steel Co.Hanef/W. Fit Up (Tack Welds) inspection at Condensate Storage Tanks (Item No.3. A Log book entry was made PMT / Contractor. Plant Utilities (SK E&C’s sub-contractor. This is a violation of JERMS-D-3204 Para: 19. 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.1. 561-T-1001 & 1002) observed. A Log book entry was raised and PMT/Contractor was informed.Hamood) Page 13 of 20 March 23.1.Pramod/W. Plant Utilities (SKEC Lay down Area): During material receiving inspection.Hamood) New–Equipment received with Corrosion at Skirt: Under Package 3.Rama/H. that subcontractor.New–Improper Joint Cleaning: Package 5B. New–Rusted Stud Bolts and Nuts Of Blow Down Drum: Under Package 5B. (K.’s Tanks Construction Site): During witness point surveillance.
Krishna) New–Tank’s 7th Course Shell Plate: Under Package 6. This violates JERES-W-011 Para: 12.5. (SK E&C’s Sub contractor NCC Kaefer Painting Yard): During surveillance 2”.New–Bend Pipe Spool: Under Package 5B. & API 650 Para 7.6 mm of the inside diameter of the set-on member. 2011 . (A. Petrol Steel Co.8. or branch connections shall be ground smooth and the diameter of the hole shall be ± 1.18. All holes cut for set-on nozzles. This is a violation to JERES-W-017 para.6. A Log book entry was issued PMT and contractor was informed to comply corrective and preventive action (D.3. This is violation as per JERES-L-350 Para.1 Ragged and irregular edges shall be ground or machined to bright metal. (K. Refinery Tank Farm (EPC.Krishna) Page 14 of 20 March 23. Refinery Tank Farm (EPC. A log book entry was made and the Contractor shall make a corrective action and preventive actions. A Log book entry was made and Contractor/PMT was informed. 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. Plant Utilities.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.1.Khaliq/J.’s South Tank Farm): During Surveillance Inspection Tank #0001B 7th shell course plate were found bended after welding (75mm). Ramo/J. bosses.Pramod/W.Hamood) New–Improper Hole Preparation: Under Package 6.2.
This is a violation of section 6. leak was found on bell & spigot Joint No. PMT/Contractor been informed. (G. (A. (C.Plumbing/HVAC Major–Gravity Test on 800 mm Diameter Concrete Pipe White Water Sewer System: Under Package 6. Para 14. Refinery Tank Farm (North): During water tightness test for 4 hours.Hayeki) New–Improper Protection of installed RTR Pipes: Under Package 2A.3. (concrete Pipe Protection) was located. a pinhole leakage was noted on the adhesive joint of RTR Pipe 14” along the thrust block. Conversion: It has been observed that RTR lines installed in Unit 41 are not properly secured from debris ingress and edge damages.P. RFI was rejected. 4 from Manhole 252 where C.Torreliza/H.Bhati) Page 15 of 20 March 23. 2011 .Krishna) New–Hydro-Test Failure of RTR Pipes: Under Package 3.Managuelod/A. A log book entry was made and Contractor was informed to provide end caps.1 of JERES-S-020 Rev. Aromatics Unit: During hydro test of RTR pipe for CWR (Cooling Water Return) lines at PX Area. 2.P. This violates the requirements of JERES-S-070. A Log Book Entry was raise to notify the PMT and the contractor.Escleto/J.
36 inch RTR pipelines and branch line were found without proper end protection . and the piping is anchored to prevent floatation. personal performing the pipe installation shall ensure that the pipe ends are capped to prevent the egress of foreign materials. (C.New–Mishandling of RTR Pipes: Under Package 5B. It is violating JERES-S-070 Para 10. It states that at the end of every work shift.Mahalingam/M.8. A violation Log book entry was initiated. it was observed that some laid RTR pipes in the open trenches are with accumulation of debris and stones. plastic waste and sand found inside the installed pipes. hand gloves. inadequate sand beddings and some pipes had been long exposed to sunlight.Torreliza/W. Plant Utilities: During surveillance inspections at Area 501. 2011 . (G.Asiri) Page 16 of 20 March 23. Interconnection: During site surveillance at Block 1 area. 10.Hamood) New–RTR Pipes without Proper End Protection: Under Package 5A.It causes many foreign materials like wooden block. A Log book entry was made and informed to PMT/Contractor. The PMT/contractor was advised to strictly comply to the requirements and corrective actions with immediate effect. This violates JERES-S-070 Para.4.
• The equipment delivered to the site directly without any technical document related to the equipment.Sanjorjo/W. A contractor NCR was again issued & the said duct bank was rejected and replaced. This is violates JERES-P-104.Plant Utilities (ContractorSK-E&C) Unit 551-STG (Steam Turbine Generator).4. 551-X-0002-A. QLT. A Log book entry was made and PMT/Contractor was informed for immediate action.3. This is a violation to ITP. it was observed that equipment (with Tag No. During our surveillance at site of Unit 551 for Steam Turbine System. B) was already: • Mounted at the top of foundation without RFI for MRR prior to erection. 8.Aromin/RS. (E. and ISO-9001 Para. This is a repeated violation.Electrical Major–Incorrect Electrical Duct bank Installation: Under Package 4. D-42 had insufficient concrete cover on one side.Which requires a minimum concrete cover of 160 mm from the outer surface of a duct to any conduit & Spacing. 2011 .10. During surveillance at Merox area.Nair) Major–Undocumented Equipment were Installed: Package -5B.3. (S. it was discovered that electrical duct bank no. Para 6. Delayed Coker Unit.Hamood) Page 17 of 20 March 23.
SS-1611. it was observed that the strands of the grounding cable were damaged and blackened by fume. EPC Contractor issued NCR to have corrective & preventive action for the same. 2011 .3. Ahmed / M. IV. This violates the Contractor’s approved QCP SA-JER-DSAAA-TRJR-509244 for Grounding System.Aromin/H Hayeki) New–Insulated Grounding Grid: Under Package 8. Distillation and Hydro Treating: During inspection of Cad weld for grounding system at Area 151. Contractor & PMT were already notified for corrective action. notice that many PVC conduits and fittings were without covers and were being stored directly exposed to sunlight. This is a violation schedule. (Mohammed S. of Attach. which is a violation to JERES-P-111 Para 7. Yadav) Page 18 of 20 March 23. A LBE was made as a violation and PMT/Contractor were informed to change them.5.Batran/I. CQT observed that cables are insulated. (S.Rajeh) New–Improper method used for Cad-weld: Under Package 1. Pipeline & Offplot Facilities: During inspection for material receiving of grounding cables 1C x 70 mm2.Q para. (H. Aromatics Unit: During inspection at Kettaneh lay down yard.New–Poor Handling of PVC Conduits And Fittings: Under Package 3.
1 which requires that all conduit entering buildings must be sealed at all times to prevent sand or debris from entering the duct. and protection of PVC conduit.24. which requires “All direct buried cables shall be filled core type. it was observed that the contractor failed to provide appropriate end caps. paragraph 5. Log book entry was made and informed PMT/Contractor. it was observed that there are two defective reels out of 27 . (J.3. 2011 . (J. Cable physical description does not conform from the manufacturer material description. JERES-T-928. Interconnecting: During site surveillance at the three substation. These are in violation to JERES-T-628 paragraph 5. Permanent Communication Facilities: During FOC on-reel continuity test at Technip warehouse. (Cable manufacturer failed to provide flooding gel inside the core area) 2.Telecommunication New–Contractor Failed to Provide Telecom Conduit End Caps: Under Package 5A.” PMT/Contractor was informed in above violations.Hatamosa/M. Following discrepancies were spotted: 1. SS 01. SS 12 and SS 16.Hatamosa) Page 19 of 20 March 23. telecom conduit entrance opening.Asiri) New–Two Drums of Defective Cables: Under Package 10.
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.S. (R. This is a violation to IEC 603641 Para 132. 2011 . A logbook entry was made and the Contractor was informed to consider design review for necessary changes.Instrumentation New–Inconsistent Cable Tray & Raised Floor Elevations: Under Package 4.Nair) Page 20 of 20 March 23.Abaa/R. the top cable tray is not accessible especially that cable trays are to be installed below cabinets and due to the cabinet frame supports. With a 50mm difference.12 requiring accessibility for electrical equipment and maintaining work spaces.
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