AQPQMDV Lessons Learned 2016 (Site)

1
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 1
ACHIEVE Quality Project
IMPLEMENT Companys Requirements

Common Quality Issues:
STANDARDIZE QA/QC & SAFETY Plan
1. Key Personnel
Criteria for Project Audit Planning:
2. Document management
1. New Contractors
3. Material management
2. Remote Area Projects
4. Standards / Specification /
3. All KSA Region Coverage Design
4. Contractor Performance 5. Workmanship

Monitoring for all Regions
5. Contractor/s with Poor Quality

workmanship & improvement
National GridGrid
Presentation 2
Audited Projects: 100+ Projects
Operating
Project Cities Contractor/s
Area
Riyadh Central,
Al-Kharj,
ABB, Al-Arrab, Al-Babtain, AlFanar, Al-Mashariq, Al-Ojaimi,
Hawtah,
COA Cogelex, Delta, SSEM, Services & Solution, Tareq Al-Jaafari, Al
Wadi-Dawasir,
Osais, Advanced Energy and Siemens
Qassim & Hail,
Jouf
Dammam,
Abahsain Consolidated Co., Advanced Energy, AlFanar, Al-Mashariq,
Al-Hassa,
EOA Al Sharif, Delta, Energy & Power Contracting Co., Capital Lights,
Jubail,
Tareq Al-Jaafari
Qatif & Khafji
Jeddah, Rabigh,
ABB, AlFanar, Al-Gihaz, Advanced Energy, Cogelex, ETA Star,
WOA Madinah,
Nesma, Nour Energy
Makkah, Taif
Jazan, Najran,
SOA ABB, Al-Fanar and Cogelex
Abha
National GridGrid
Presentation 3
1-Key Personnel (Quality & Safety)
Single - Project Key Personnel List (bidding document )
National GridGrid
Presentation 4
1-Key Personnel (Quality & Safety)
Multiple - Project Key Personnel List (bidding document )
National GridGrid
Presentation 5
2-Document Management
Problem / Non-conformity Description:
Non-availability of QA/QC records and documents
Latest version & approved drawings are not used
No proper documentation works
Root Cause Analysis :
Non-Availability of QA/QC engineer and document
controller
Awareness of QA/QC engineer on the records and
documentation requirements in Contract
Root Causes:
Non-compliance with the key personnel and QA/QC
requirements of the contract.
Recommendation / Preventive Action:
Arrange interview for evaluation and approval of
proposed project QA/QC engineers for each project
Give briefing and ensure that QA/QC engineer is aware
and fulfills all the QA/QC quality documentation
requirements.
Monitor the performance of QA/QC engineer.
National GridGrid
Presentation 6
2-Document Management
Poor
Document
systems
National GridGrid
Presentation 7
3-Material Management
Problem / Non-conformity Description: Analysis:

Poor material and equipment management; i.e. Is the activity on the project critical path?
Material/equipment stored outside the Substation perimeter No, it is floating activity with buffer= 80 days
Building/foundation not yet completed the equipment already Root causes:
delivered and being installed (ongoing building construction, Zero storage expenses and early invoicing for material.
excavation)
Cost driven based scheduling.
Recommendation / Preventive action :
Follow risk based scheduling and JUST IN TIME delivery.
National GridGrid
Presentation 8
Poor Material Handling Damages
National GridGrid
Presentation 9
Discoloration on power cable sheath.
National GridGrid
Presentation 10
LCC Panel SF6 Cylinder

HVAC Unit
National GridGrid
Presentation 11
National GridGrid
Presentation 12
Proper and Secured Storage area
National GridGrid
Presentation 13
Proper and Secured Storage area
National GridGrid
Presentation 14
4-STANDARD & SPECIFICATION/DESIGN
Poor Quality of Mimic Diagram Sample from other NG Project
National GridGrid
Presentation 15
13.8kV Switchgear
Non-Compliance of Mimic diagram Standard color as per rated Voltage

National GridGrid
Presentation 16
Non-Usage / Provision of approved power cable clamps (single / trefoil type)

National GridGrid
Presentation 17
` `
Power cable riser support and lighting inside the cable tunnel
National GridGrid
Presentation 18
Sample Video
Short circuit test using Cable tie and Cable clamp
APQMDV
National Grid SALessons Learned
Strategic PlanWorkshop
Presentation 19
Sample Video
Short circuit test for power cable clamp
APQMDV
Presentation 20
Sample Video
Short circuit test for power cable clamp
APQMDV
Presentation 21
Power Cable Color is RED for 13.8kV cables & BLACK for 34.5kV cables (11-TMSS-04 cl. 4.3.9)
National GridGrid
Presentation 22
Ceiling
Painting
National GridGrid
Presentation 23
Poor Design (extension box is not allowed unless supplied by the manufacturer.
No extension box shall installed on switchgear panel (bottom) unless supplied by the manufacturer.
National GridGrid
Presentation 24
MV Switchgear Incomer in conflict with Fire fighting pipe and nozzle

National GridGrid
Presentation 25
MV Switchgear control cable opening / access design miscoordination

National GridGrid
Presentation 26
MV Switchgear Incomer four (4) holes Terminals for cables 400mm and Up
National GridGrid
Presentation 27
MV Switchgear Capacitor Feeder four (4) holes Terminal for cables 400mm and Up
National GridGrid
Presentation 28
Power Transformer LV Cable Box 4 - holes Terminals for cables 400mm and Up
National GridGrid
Presentation 29
4 - holes Terminals lugs compliance

National GridGrid
Presentation 30
Transformer LV Cable Box Non-provision of Flexible link

National GridGrid
Presentation 31
support
Flexible link
support
Compliance for 4-holes terminal, flexible link and complete busbar support
National GridGrid
Presentation 32
Miscoordination/Poor Design (Not align)
LV Cable box alignment with cable sleeves

National GridGrid
Presentation 33
Non-Provision / Usage of Cable tray below the raised floor

National GridGrid
Presentation 34
Cable tray below the raised floor for proper cable segregation / laying & support
National GridGrid
Presentation 35
Cable Basements Poor design and non-compliance issues

National GridGrid
Presentation 36
Non-provision of safety end caps / cushions

National GridGrid
Presentation 37
Non-Provision of Battery room Eyewash and Exhaust fan

National GridGrid
Presentation 38
Capacitor Switchgear feeder interlock
Capacitor Fence gate interlock
Non-Provision of Capacitor Bank Gate access

Interlock with MV Switchgear Capacitor Feeder
National GridGrid
Presentation 39
Auxiliary Transformer Tap changer locking facility
National GridGrid
Presentation 40
Usage of Wooden support at Auxiliary Transformer

National GridGrid
Presentation 41
Secured installation for SAS - HMI Monitors

National GridGrid
Presentation 42
Substation Signboard - Issues

National GridGrid
Presentation 43
National GridGrid
Presentation 44
Door/Sump pit conflict with cable sleeves.

National GridGrid
Presentation 45
HVAC pad unsafe modification / mismatch

National GridGrid
Presentation 46
Parapet wall height falling risk
National GridGrid
Presentation 47
Low Staircase access height clearance

National GridGrid
Presentation 48
GIS Base plate exceeding floor installation tolerance

National GridGrid
Presentation 49
Proper floor clearance and quality mounting

National GridGrid
Presentation 50
Proper installation of GIS Baseplate

National GridGrid
Presentation 51
Poor design (HVAC duct should be kept away from Transformer Area)
HVAC Ducts in the Power Transformer Area Fire fighting wall requirements issue
National GridGrid
Presentation 52
National GridGrid
Presentation 53
5-Workmanship
Problem / Non-conformity Description: Root Causes:

In-adequate 132kV Gas Insulated Bus Duct supports. Non - availability of qualified & experienced site manager to handle
GIB support were mounted on Concrete Hollow Blocks (CHB) and/or the importance of correct execution of GIB supports.
light concrete wall Non-availability of qualified QA/QC Engineer to refer to prior
Root Cause Analysis: approved drawings and monitor the correct execution of GIB
Is the GIB loading in the wall incorporated in the civil design for safe supports.
installation? Miscoordination on the civil and electrical design interface.
Not clear and confirmed as there are no available clear approved Recommendation / Preventive action:
drawings and site engineer/s at site are not aware of such loading
Approved drawings for such sensitive/critical loads is required
requirement for the GIBs.
Ensure qualified key personnel to handle such sensitive tasks
National GridGrid
Presentation 54
5-Workmanship
Safe Dedicated column and foundation for GIB supports

National GridGrid
Presentation 55
5-Workmanship
Unsafe Modified / Extended and Short GIB wall supports

National GridGrid
Presentation 56
5-Workmanship
Top cover of Switchgear Panels damage/bended

National GridGrid
Presentation 57
5-Workmanship
Un-used floor holes on all panels should be sealed properly

National GridGrid
Presentation 58
5-Workmanship
Tight and blocked access ways

National GridGrid
Presentation 59
5-Workmanship
Transformer control panel pedestal

National GridGrid
Presentation 60
5-Workmanship
Cable ladder overloading / Poor design coordination with cable laying plan and ladder capacity
National GridGrid
Presentation 61
5-Workmanship
L.A. supports were mounted directly on the Power Transformers' radiator frames.
National GridGrid
Presentation 62
5-Workmanship
Scratches / Damages on Equipment

National GridGrid
Presentation 63
5-Workmanship
Scratches / Damages on Cables

National GridGrid
Presentation 64
5-Workmanship
Missing Grouting on outdoor structures unstable supports

National GridGrid
Presentation 65
5-Workmanship
Non-Usage of proper bends / tools exposes the cables to sharp edges

National GridGrid
Presentation 66
5-Workmanship
Poor Quality / Damaged Grounding installation

National GridGrid
Presentation 67
5-Workmanship
Slab cut-out / Core drill modification works.

National GridGrid
Presentation 68
5-Workmanship
Poor slab core drill / sleeve preparation & modification works.

National GridGrid
Presentation 69
5-Workmanship
Non-completion of weatherproof and fire retardant sealing works

National GridGrid
Presentation 70
5-Workmanship
Non-completion of weatherproof sealing works basement flooded

National GridGrid
Presentation 71
5-Workmanship
Incomplete Trench covers

National GridGrid
Presentation 72
5-Workmanship
Poor Quality / Irregular and Incomplete Trench covers / Supports

National GridGrid
Presentation 73
5-Workmanship
Mis-coordinated openings for Fire Fighting piping systems

National GridGrid
Presentation 74
CORRECTIVE ACTIONS:
Before After
GIB flange embedded in wall GIB flange module replaced
Maintenance access difficulty Accessible maintenance
National GridGrid
Presentation 75
CORRECTIVE ACTIONS:
Before After
Non Conformance to TMSS requirements Compliance to TMSS requirements.
regarding epoxy floor painting.
National GridGrid
Presentation 76
CORRECTIVE ACTIONS:
Before After
No proper material management Proper material handling, tagging, safe keeping
(segregation, tagging, safe keeping and access). and access.
Theft and damage risks Theft and damage risks preventive measures.
National GridGrid
Presentation 77
CORRECTIVE ACTIONS:
Before After
Tight space / Obstruction for GIS clear access. Relocate maintenance access ladder
Panic Accident risks Clear Panic Access way
National GridGrid
Presentation 78
National GridGrid
Presentation 79

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1

IMPLEMENT Companys Requirements

4. Contractor Performance 5. Workmanship

5. Contractor/s with Poor Quality

Single - Project Key Personnel List (bidding document )

Multiple - Project Key Personnel List (bidding document )

Problem / Non-conformity Description: Analysis:

Poor Material Handling Damages

Discoloration on power cable sheath.

LCC Panel SF6 Cylinder

Proper and Secured Storage area

Proper and Secured Storage area

Poor Quality of Mimic Diagram Sample from other NG Project

Non-Compliance of Mimic diagram Standard color as per rated Voltage

Non-Usage / Provision of approved power cable clamps (single / trefoil type)

MV Switchgear Incomer in conflict with Fire fighting pipe and nozzle

MV Switchgear control cable opening / access design miscoordination

4 - holes Terminals lugs compliance

Transformer LV Cable Box Non-provision of Flexible link

Miscoordination/Poor Design (Not align)

LV Cable box alignment with cable sleeves

Non-Provision / Usage of Cable tray below the raised floor

Cable Basements Poor design and non-compliance issues

Non-provision of safety end caps / cushions

Non-Provision of Battery room Eyewash and Exhaust fan

Capacitor Switchgear feeder interlock

Capacitor Fence gate interlock

Non-Provision of Capacitor Bank Gate access

Auxiliary Transformer Tap changer locking facility

Usage of Wooden support at Auxiliary Transformer

Secured installation for SAS - HMI Monitors

Substation Signboard - Issues

Door/Sump pit conflict with cable sleeves.

HVAC pad unsafe modification / mismatch

Parapet wall height falling risk

Low Staircase access height clearance

GIS Base plate exceeding floor installation tolerance

Proper floor clearance and quality mounting

Proper installation of GIS Baseplate

Problem / Non-conformity Description: Root Causes:

Safe Dedicated column and foundation for GIB supports

Unsafe Modified / Extended and Short GIB wall supports

Top cover of Switchgear Panels damage/bended

Un-used floor holes on all panels should be sealed properly

Tight and blocked access ways

Transformer control panel pedestal

Scratches / Damages on Equipment

Scratches / Damages on Cables

Missing Grouting on outdoor structures unstable supports

Non-Usage of proper bends / tools exposes the cables to sharp edges

Poor Quality / Damaged Grounding installation

Slab cut-out / Core drill modification works.

Poor slab core drill / sleeve preparation & modification works.

Non-completion of weatherproof and fire retardant sealing works

Non-completion of weatherproof sealing works basement flooded

Incomplete Trench covers

Poor Quality / Irregular and Incomplete Trench covers / Supports

Mis-coordinated openings for Fire Fighting piping systems

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