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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
National SA Strategic
SA PQMDV Plan Presentation
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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 3
1-Key Personnel (Quality & Safety)

Single - Project Key Personnel List (bidding document )

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 4
1-Key Personnel (Quality & Safety)

Multiple - Project Key Personnel List (bidding document )

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 6
2-Document Management

Poor
Document
systems

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 8
3-Material Management

Poor Material Handling Damages

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 9
3-Material Management

Discoloration on power cable sheath.

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 10
3-Material Management

LCC Panel SF6 Cylinder


HVAC Unit

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 11
3-Material Management

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 12
3-Material Management

Proper and Secured Storage area

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 13
3-Material Management

Proper and Secured Storage area

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 14
4-STANDARD & SPECIFICATION/DESIGN

Poor Quality of Mimic Diagram Sample from other NG Project

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 15
4-STANDARD & SPECIFICATION/DESIGN
13.8kV Switchgear

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


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 16
4-STANDARD & SPECIFICATION/DESIGN

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


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 17
4-STANDARD & SPECIFICATION/DESIGN

` `

Power cable riser support and lighting inside the cable tunnel
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
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
National Grid SALessons Learned
Strategic PlanWorkshop
Presentation 20
Sample Video
Short circuit test for power cable clamp

APQMDV
National Grid SALessons Learned
Strategic PlanWorkshop
Presentation 21
4-STANDARD & SPECIFICATION/DESIGN

Power Cable Color is RED for 13.8kV cables & BLACK for 34.5kV cables (11-TMSS-04 cl. 4.3.9)

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 22
4-STANDARD & SPECIFICATION/DESIGN

Ceiling
Painting

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 23
4-STANDARD & SPECIFICATION/DESIGN

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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 24
4-STANDARD & SPECIFICATION/DESIGN

MV Switchgear Incomer in conflict with Fire fighting pipe and nozzle


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 25
4-STANDARD & SPECIFICATION/DESIGN

MV Switchgear control cable opening / access design miscoordination


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 26
4-STANDARD & SPECIFICATION/DESIGN

MV Switchgear Incomer four (4) holes Terminals for cables 400mm and Up
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National SA Strategic
SA PQMDV Plan Presentation
Presentation 27
4-STANDARD & SPECIFICATION/DESIGN

MV Switchgear Capacitor Feeder four (4) holes Terminal for cables 400mm and Up
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 28
4-STANDARD & SPECIFICATION/DESIGN

Power Transformer LV Cable Box 4 - holes Terminals for cables 400mm and Up
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National SA Strategic
SA PQMDV Plan Presentation
Presentation 29
4-STANDARD & SPECIFICATION/DESIGN

4 - holes Terminals lugs compliance


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 30
4-STANDARD & SPECIFICATION/DESIGN

Transformer LV Cable Box Non-provision of Flexible link


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 31
4-STANDARD & SPECIFICATION/DESIGN

support
Flexible link

support

Compliance for 4-holes terminal, flexible link and complete busbar support
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 32
4-STANDARD & SPECIFICATION/DESIGN

Miscoordination/Poor Design (Not align)

LV Cable box alignment with cable sleeves


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 33
4-STANDARD & SPECIFICATION/DESIGN

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


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 34
4-STANDARD & SPECIFICATION/DESIGN

Cable tray below the raised floor for proper cable segregation / laying & support
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 35
4-STANDARD & SPECIFICATION/DESIGN

Cable Basements Poor design and non-compliance issues


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 36
4-STANDARD & SPECIFICATION/DESIGN

Non-provision of safety end caps / cushions


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 37
4-STANDARD & SPECIFICATION/DESIGN

Non-Provision of Battery room Eyewash and Exhaust fan


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 38
4-STANDARD & SPECIFICATION/DESIGN

Capacitor Switchgear feeder interlock

Capacitor Fence gate interlock

Non-Provision of Capacitor Bank Gate access


Interlock with MV Switchgear Capacitor Feeder
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 39
4-STANDARD & SPECIFICATION/DESIGN

Auxiliary Transformer Tap changer locking facility

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 40
4-STANDARD & SPECIFICATION/DESIGN

Usage of Wooden support at Auxiliary Transformer


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 41
4-STANDARD & SPECIFICATION/DESIGN

Secured installation for SAS - HMI Monitors


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 42
4-STANDARD & SPECIFICATION/DESIGN

Substation Signboard - Issues


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 43
4-STANDARD & SPECIFICATION/DESIGN

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 44
4-STANDARD & SPECIFICATION/DESIGN

Door/Sump pit conflict with cable sleeves.


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 45
4-STANDARD & SPECIFICATION/DESIGN

HVAC pad unsafe modification / mismatch


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 46
4-STANDARD & SPECIFICATION/DESIGN

Parapet wall height falling risk

National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 47
4-STANDARD & SPECIFICATION/DESIGN

Low Staircase access height clearance


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 48
4-STANDARD & SPECIFICATION/DESIGN

GIS Base plate exceeding floor installation tolerance


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 49
4-STANDARD & SPECIFICATION/DESIGN

Proper floor clearance and quality mounting


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 50
4-STANDARD & SPECIFICATION/DESIGN

Proper installation of GIS Baseplate


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 51
4-STANDARD & SPECIFICATION/DESIGN

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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 52
4-STANDARD & SPECIFICATION/DESIGN

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National SA Strategic
SA PQMDV Plan Presentation
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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 54
5-Workmanship

Safe Dedicated column and foundation for GIB supports


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 55
5-Workmanship

Unsafe Modified / Extended and Short GIB wall supports


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 56
5-Workmanship

Top cover of Switchgear Panels damage/bended


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 57
5-Workmanship

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


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 58
5-Workmanship

Tight and blocked access ways


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 59
5-Workmanship

Transformer control panel pedestal


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 60
5-Workmanship

Cable ladder overloading / Poor design coordination with cable laying plan and ladder capacity

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 61
5-Workmanship

L.A. supports were mounted directly on the Power Transformers' radiator frames.

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 62
5-Workmanship

Scratches / Damages on Equipment


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 63
5-Workmanship

Scratches / Damages on Cables


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 64
5-Workmanship

Missing Grouting on outdoor structures unstable supports


National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 65
5-Workmanship

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


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 66
5-Workmanship

Poor Quality / Damaged Grounding installation


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 67
5-Workmanship

Slab cut-out / Core drill modification works.


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 68
5-Workmanship

Poor slab core drill / sleeve preparation & modification works.


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 69
5-Workmanship

Non-completion of weatherproof and fire retardant sealing works


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 70
5-Workmanship

Non-completion of weatherproof sealing works basement flooded


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 71
5-Workmanship

Incomplete Trench covers


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 72
5-Workmanship

Poor Quality / Irregular and Incomplete Trench covers / Supports


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 73
5-Workmanship

Mis-coordinated openings for Fire Fighting piping systems


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National SA Strategic
SA PQMDV Plan Presentation
Presentation 74
CORRECTIVE ACTIONS:

Before After
GIB flange embedded in wall GIB flange module replaced
Maintenance access difficulty Accessible maintenance

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National SA Strategic
SA PQMDV Plan Presentation
Presentation 75
CORRECTIVE ACTIONS:

Before After
Non Conformance to TMSS requirements Compliance to TMSS requirements.
regarding epoxy floor painting.

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National SA Strategic
SA PQMDV Plan Presentation
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
National SA Strategic
SA PQMDV Plan Presentation
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
National SA Strategic
SA PQMDV Plan Presentation
Presentation 78
National GridGrid
National SA Strategic
SA PQMDV Plan Presentation
Presentation 79