QMIS LBE Rev Mech Final Old

S#
Date
Location
Surveillance Description During site surveillance at well # 115,110 PID find that there are end pipes not covered and this is violation according SAES. All the pipes face should be covered at all the time. In spite of numerable instruction to the concerned QC personnel regarding the high weld repair rate for the project which is in alarming rate continuously (weekly as well as cumulative repair) for the OIL lines, the concerned QC in the Abkake Shop is not taking any suitable action to bring down the repair rate this cause concern for the PIDPMT requested to give strict instruction to the contractor to immediately remove those welders who cause high repair rate and carry out an internal focus assessment on the issue. Al-Barghash already installed the 16 Trunk lines inside the GOSP with flange connection under ground which is violate SAES-L-110 para.8.1. Responding to RFI for oil well head # 104, found that a tie-inn spool has been installed with the existing line without any approval of tie-inn nor hydro test for the spool this is violation against standard, all new construction spool, pipes shall undergo hoop stress 90% SMYS as per SAES L-150.. During site surveillance PID find that there are pipes not covered and this is violation according SAES. All the pipes face should be covered at all the time. SATIP-H-002-02, Item No. 3.7, Holiday Testing; SAIC-H-2016 & SATRH-2008 are HI (100% Hold Point for QC Inspection or Test). RHM was unable to produce Holiday Test records for a specific number of locations, where Pipeline has been backfilled. During surveillance inspection @ KM82 SJ-1 Pipeline, it has been noticed that, the Abrasive Blasting crew is trying to use SAND for blasting instead of approved abrasives. Findings: This clear violation against Saudi Aramco GI 6.021 Para 8.1. which states that "Silica sand is an extremely hazardous abrasive material. The use of silica sand for abrasive blasting operations is prohibited at all Saudi Aramco facilities and on all Saudi Aramco projects and construction sites. Safer alternative blasting agents are available". Corrective Action: The activity stopped immediately and instructed to the crew to remove all the sand and use the approved grit, which is available with the crew. Recommended Preventive Action: In order to avoid such situation in future, the crew and supervisor shall be undergo toolbox meeting. Also issue warning letter to the supervisor and crew, states that JCC will be revoked if the same violation repeated. Project Inspection witnessed the internal cleaning of P/L SJ-1, Seg1 (CS#109to136) from Km75 to 84.4 per RFI#701 and was found NOT ACCEPTABLE. It was noticed that huge amount of debris and hard rust powder found inside the pipe after initial pipe cleaning that could affect system integrity, photos was sent to SAPMT. PID advised Contractor QC to repeat the internal cleaning & to re-issue RFI. During surveillance inspection, PID found out all pipes and fabricated spools at site are without pipes ends protections, this is a violation of SAES-L-450 Para. 8.4 Inspection requesting contractor to immediately comply with standards and provide proper pipe ends protection as required
Category
SATIP
SAIC
Discipline
Standard Category
Standard
Para
Standard2
Para2
1/26/2009 4:52:11 PM
Violation-After The Fact
SATIP-L-410-01
SAIC-L-2084
Mechanical
SAES
SAES-L-450
8.4
11/19/2008 8:54:35 AM
SATIP-W-012-01
SAIC-L-2056
Mechanical
SAES
SAES-W-012
8.2
Schedule Q
7.5.4
6/22/2008 11:12:02 AM
Mechanical
SAES
SAES-L-110
8.1
11/18/2008 7:54:34 AM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-L-150
7.1
5/27/2008 9:48:05 AM
SATIP-L-450-04
SAIC-L-2112
Mechanical
SAES
SAES-L-450
1/31/2010 4:16:58 PM
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
4/8/2009 1:52:02 PM
ViolationPrevented Installation
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-201
7.2.5
2/9/2010 8:06:11 AM
SATIP-L-450-03
SAIC-L-2017
Mechanical
SAES
SAES-L-450
18.2
1/25/2010 1:35:33 PM
SATIP-L-450-03
SAIC-L-2112
Mechanical
SAES
SAES-L-450
8.4
10
8/5/2009 9:27:40 AM
During site visit, it has been noticed that, 1) Field Weld Joint # FW-8, during fit-up tapering done outside the pipe thicknes. Its reduced the minimum required wall thickness and violates the project requirements. 2) Bend pipes not matching as per the plot plan requirements Recommended Actions: 1) Cut & Re-weld FW-08 - to meet the minimum thickness 2) Cut & Re-weld FW-09 - to match the bend 3) Required survey report to verify the pipeline meets the plot plan bend requirement before fit-up. ON DATED 04.02.2010, PID FOUND THAT THE CONTRACTOR IS USING ELECTRODES FOR TEMP TIE-IN WELD FROM A IRON BOX WHICH CONTAINS LOW HYDROGEN ELECTRODES, CELLULOSIC(7010P1)AND ALSO SOME DAMGED ELECTRODES. THIS VIOLATES SATIP-W011-01, PARA 3.4. ON DATED 04.02.2010, PID FOUND THAT THE CONTRACTOR IS USING ELECTRODES FOR TEMP TIE-IN WELD FROM AN IRON BOX WHICH CONTAINS LOW HYDROGEN ELECTRODES, CELLULOSIC(7010P1)AND ALSO SOME DAMGED ELECTRODES. THIS VIOLATES SATIP-W012-01, PARA 3.4. During site surveillance at Kilometer 32 to 38 inspection observed that there were some welding activities on going on the said location PID has observed that contactor were continously welding the girth joint without using the protective sleeve or fire blanket around the coated end of the pipes this is a violation as per SAIC L- 2115 and the portable oven was removed from the power source During a routine site visit by APIU it was noted that structural welding was ongoing with out the presence of the welding inspector. See previous violation log book entries W-7 & 8. This is violation of Schedule "Q" Q-6 para 5.6. During a routine visit by APIU it was noted that welder ID CV was using low hydrogen electrodes for welding structural steels with out having them in a portable oven. This is in violation of SAES-W-011 para 6.2 "All consumables shall be stored and dried in accordance with the requirements of Table 1 for SMAW electrodes and Table 2 for other consumables." His JCC has been revoked. During a routine site visit by APIU it was found that the contractor was issueing & rebaking low hydrogen electrodes with out maintaining proper control. This is in violation of SAES-W-011 para 6.2 All consumables shall be stored and dried in accordance with the requirements of Table 1 for SMAW electrodes and Table 2 for other consumables and Schedule "Q" Q-IV-3 para 3.2. It has been noted that the contractor has had a hig rejection rate 80% of radigraphs submitted to SA RTFI for review. 40% for use of the incorrect grade / type of film used & 40% of low density. This is in violation of SAEP-1143 para 6 & 9. Please have the contractor reshoot these rejected radiographs on an urgent basis and re-submit to SA for review. It has been noted by APIU that the contractor QC manager is not dedicated to the project and is working on other projects. This is in violation of Schedule "Q" Q-6 para 5.6. The QC manager is conditionaly approved subject to his committment and being dedicated to the project, reference APIU response letter APIU/PMG-BI-00022001. *16" Sch 80- 1/3 without pipe end cover, end bevel damage >1.5 mm.
C2-NGL-001M
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
3.2
11
2/8/2010 11:21:34 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
12
2/8/2010 1:35:56 PM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-011
6.1
13
2/25/2009 3:16:20 PM
SATIP-W-012-01
SAIC-W-2049
Mechanical
SAES
SAES-W-012
10.2.1
SAES-W-012
APPENDIX 1
14
9/30/2006 7:28:27 AM
SATIP-M-001-01
Mechanical
ScheduleQ
Schedule Q
5.9
15
9/30/2006 6:58:22 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
16
9/30/2006 7:18:22 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
3.2
17
4/3/2007 10:23:56 AM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
SAEP
SAEP-1143
6&9
18
9/16/2006 12:58:08 PM
Mechanical
ScheduleQ
Schedule Q
5.9
19 20 21 22 23
1/7/2010 1:02:43 PM 8/30/2006 1:53:30 PM
ViolationPrevented Installation ViolationPrevented Installation ViolationPrevented Installation ViolationPrevented Installation ViolationPrevented Installation
SATIP-L-410-01
SAIC-L-2084
Mechanical Mechanical
SAES SAES SAES SAES ScheduleQ
SAES-L-450
8.4
CONTRATOR FOUND WITH THE FOLLOWING DISCRIPENCIES. 1INCONSISTENT SPOT AND BACK FILLING. 2-END CAPS WERE NOT FOUND ON PIPES FROM KM 06 TO KM 20( NOT FULLY CAPPED) LOWERING OF THE PIPE IN TO THE TRENCH PRIOR TO THE FINAL HOLIDAY DETECTION. 4- CONTRATOR SHOULD HAVE INSPECTOR COVERAGE AS PER AGREED PQP ON SITE ON FULL TIME BASIS
SATIP-L-410-01 SATIP-H-002-02
SAIC-L-2084 SAIC-H-2016
Mechanical Mechanical Mechanical
SAES-L-450 SAES-H-200 Schedule Q
8.4 7 5.9
24
6/20/2007 1:26:16 PM 2/27/2007 8:12:28 AM
25
26
The construction backfilled a 28" diameter FBE coated pipeline without holiday test conducted and this is an internal NCR#36 last issued last April 14, 2007. No action taken by the contractor FMQ to close thi issue up to date. C2-NGL-001- The contractor coating/wrapping crew had made wrapping to the FWM 2360, FW-2360A & FW-2363 without RFI The contractor coating/wrapping crew had made wrapping to the FW2360, FW-2360A & FW-2363 without RFI and Coating inspector to check there ativities, this is a violation of SATIP-H-002-09 in item 3.0 application.
C2-NGL-001M
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
SATIP-H-002-09
SAIC-H-2066
Mechanical
ScheduleQ
Schedule Q
1.7
SATIP-H-002-09
SAIC-H-2066
Mechanical
ScheduleQ
Schedule Q
5.9
27
11/13/2006 4:22:20 PM
Field weld FW#473, 474, 475 & 476 @KM 11+250 FW # 1064, 1065, 1069, 1080, 1085, 1093, 1096A, 1096B, 1097, 1097A, 1098, 1098A, 1276 @KM 12+000 TO 30+000 coated(STOPAQ)without raising RFI.The surface preparation and coating of these joints is carried out in absence of contractor coating inspector which is hold point for C2-NGL-001- contractor QC. This is violation against SCHEDULE Q ATTACHMENT-IV M (Contract No.6600013560)clause 1.2.3 Notification requirements for Request For Inspection (RFI) (minimum 24 hrs for site work) AND SATIP-H-002-11 Item No. 3.1, 3.2 & 3.3 - 100% Hold Point for contractor QC Inspection/Test as a contractor Inspection responsibility Contractor is suggested to arrange Coating inspector and raise RFI for coating activities. Field weld FW#473, 474, 475 & 476 @KM 11+250 FW # 1064, 1065, 1069, 1080, 1085, 1093, 1096A, 1096B, 1097, 1097A, 1098, 1098A, 1276 @KM 12+000 TO 30+000 coated(STOPAQ)without raising RFI.Contractor is suggested to arrange Coating inspector and raise RFI for coating activities. his is violation against SCHEDULE Q ATTACHMENT-IV (Contract No.6600013560)clause 1.2.3 Notification requirements for Request For Inspection (RFI) (minimum 24 hrs for site work)
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002
28
SATIP-H-002-11
SAIC-H-2082
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
29 30
6/11/2006 3:57:54 PM
C2-NGL-001M
1. Defective material is combined with good ones 2.no segrrgation (quarntine) of material for each BI 3. lots of the material is directly laid on the sandy floor 4. couple of material preservation for FMQ is really miss. * FMQ has to right isuue internal NCR The FMQ Mechanical QC issued an internal NCR #-35 on January 04, 2007 and no action taken by construction to close this issue up to this date for the Material recieving inspection as per SATIPS and SAIC. The Contractor FMQ, joint welding of 28" diameter FBE coated pipeline @ Km. 60+550, the welder were using cold electrodes which is the low hydrogen electrodes 7018 and with a holding oven but not plug to the generetor at site. This is a violation of SAES-W-012, Table 1, and SAPMT was informed to make 100% X-ray to the said 3 joint.
SATIP-L-450-03 SATIP-L-450-03
SAIC-L-2112 SAIC-L-2112
ScheduleQ ScheduleQ
Schedule Q Schedule Q
A IV Para 4.2 A IV Para 6
31
6/20/2007 2:55:28 PM
C2-NGL-001M
Mechanical
ScheduleQ
Schedule Q
7.5.4
32
1/20/2007 4:22:20 PM
C2-NGL-001M
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
A1
33
5/23/2006 4:17:49 PM
34
1/23/2007 8:20:00 AM
FMQ segment #1,2 high weld repair rate due to lack of Qulaity controle Management this is violation as per SCHD. Q para 5.6,5.3,5.1, pls. be advise contarctor to cover Welding activity in order to achive the requirement of repair rate as per HNRP Corporate Plan.(1% Linear basis) The two (2) welder symbol # AWN & MMC doing repair to FW-2056 & C2-NGL-001- FW-2054 of 24" diameter FBE coated pipeline @ KM. 49 +500 was not M using Wind shields or tent this is a violation in accordance with SAESW--012, paragraph 10.2.1.
C2-NGL-001M
Mechanical
ScheduleQ
Schedule Q
5.1& 5.9
SATIP-W-012-01
SAIC-W-2049
Mechanical
SAES
SAES-W-012
10.2.1
35
3/7/2007 6:41:37 PM
SURVEILLANCE: During VALVES Hydrotesting Inspection @ FMQ FABRICATION YARD, AIN-NAKEEL. SAPID/PPIU found that some of the Valves (2"-600# 2EA., 4"-600# 7EA., 10"-600# 3EA., 8"-600# 1EA.) FAILED during Testing, which contractor should repair and re-test it.
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7
36
8/8/2006 4:37:00 PM
it has been observed that contractor is NOT CONTROLLING WELDING ENVIRONMENT BY using proper field weld protective means(wind shiled,welding tent,canopy etc) againstany incelemental conditions and for the welder protection and confort as well,as per saic-w-2049 article. B1-Wind shields or tents are installed when the wind is strong enough to affect arc stability or shielding gas coverage, and also to prevent contamination from the environment, such as wind-blown sand B3-Welding is not done during inclement weather e.g., wind blown sand, rain etc. During witnessing hydrotest for Test Package N23-30-0-001-NAQ 7, several violations were noted. Several joints were buried under the insulation. It is a violation of SAIC-A-2009, item A10. 70% of the fillet weld joints were already painted. It is a violation of Aramco Letter # HNRFD/L-193/07 dated May 20, 2007. Contractor did not use the SAICA-2009 Verification of test preparation and test equipment. It is a violation of SATIP-A-004-01 (item # 3.3), Weekly Quality Meeting (MJF/AF/QC-116, item # 5.3) and MOM # M-JF/AF-168, item B-6). Test has been rejected as visual leak detection during the strength was not possible. During routine surveillance SAPID noticed that several drains and their valves handle in Area 221 are very close to fixed support. It is violation of SAES-L-310, Para 2.4 & 2.5. Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of all sizes, shall be located at a minimum horizontal distance of 12.5 mm (24 inches) from any fixed obstruction. This requirement can only be waived if thermal piping stress analysis determines that movement is minimal and away from the obstruction. However, at least 50 mm clearance shall be provided for inspection, maintenance and operation purpose. Contractor shall comply with standards requirement before hydrotest is commenced. During routine surveillance at Train # 3 it was observed that welding was performed on LTCS and Stainless Steel pipes but no HI (Heat input) was calculated by the only available Inspector at site. It is a violation of SAES-W-011 Para 19.4 and item G6 of SAIC-W-2006. As per Aramco standard The HI (Heat Input) of each production weld is calculated if notch-toughness tests are specified, and then conformed not to exceed the heat input limits listed in the WPS. Contractor shall comply with Aramco Standard to ensure the quality. 24 welders were found working in Train # 3 today, i.e. 25th January, 2008 while only 1 QC Mr. Phantian was available to cover whole area. Welding was being performed at various places including pipe racks and QC was unable to provide adequate coverage. It is violation of schedule Q Table VI-2 Construction Phase Quality Personnel Requirements. Contractor shall comply with Schedule Q requirement at all areas. Rain water can still be seen in many pipe fittings including stainless steels. It is violation of Schedule Q, Section IV, Para 5, SAES-L-350, Para 7.4 and SAES-A-007, Para 4&6. Contractor should realize that how harmful is raw water/rain water when it wets any Type 300-series or Type 400-series stainless steels. This is the reason that demineralized water is used for hydro testing of stainless steel. Contractor is advised to prepare a method statement to clean all the fittings filled with rain water and get water tested as pH value, SRB content and dissolved chloride ion content (not chlorine) are harmful for carbon as well as stainless steel. CSD may be contacted for advice on further cleaning/processing of pipe fittings if pH valu, SRB content dissolved chloride ion content are determined more than required limit.
SATIP-W-012-01
SAIC-W-2049
Mechanical
SAES
SAES-W-012
10.2.1
37
4/11/2008 5:42:46 PM
SATIP-A-004-01
SAIC-A-2009
Mechanical
SAES
SAES-L-150
7.3
38
4/11/2008 7:40:25 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
39
1/25/2008 10:20:50 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.4
40
1/25/2008 9:49:23 AM
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
41
1/6/2007 9:12:57 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.5
Schedule Q
A IV Para 6
42
3/30/2007 11:16:28 AM
CCCs QC Welding Supervisor Mr. Mohd. El Geliel Awad and Welding Inspector Gopal N. went on vacation and did not resume their duties on expected date. Welding Inspector Gopal N. left about 4 months ago but his name is still in Organization Chart. It is violation of Schedule Q Para 5.11. CONTRACTOR shall make quality personnel changes required due to vacations, illness, temporary assignments, emergency leave, resignations or other reasons as necessary to maintain required Quality coverage. CONTRACTOR shall advise the Company Representative of such personnel and quality coverage at least thirty (30) calendar days in advance of scheduled absences or changes and as soon as possible for other changes. Contractor shall update their Organization Chart to reflect actual figures and report it in Weekly Quality Meeting. CCCs Static Equipment Inspector, Mr. Raut Jayaram P. went on vacation couple of months ago and did not resume his duties on expected date. Mr. Raut Jayarams name is still in Organization Chart among people available at site. It is repeated violation of Schedule Q Para 5.11. CONTRACTOR shall make quality personnel changes required due to vacations, illness, temporary assignments, emergency leave, resignations or other reasons as necessary to maintain required Quality coverage. CONTRACTOR shall advise the Company Representative of such personnel and quality coverage at least thirty (30) calendar days in advance of scheduled absences or changes and as soon as possible for other changes. Contractor shall update their Organization Chart to reflect actual figures and report it in Weekly Quality Meeting. About 16 log book entries are still un-responded by contractor. Logbook entry No. 55966 dated 17th March, 2008 is regarding calibration of temperature gauges in holding ovens. Logbook entry was not responded in time. No corrective action was taken and ovens are still in use. Instead of taking corrective measure someone scratched the test dates tried to remove the sticker. It is violation of Schedule Q, Para 7.3.3. Repeated violations and no responding to logbook entries shows that Preventive actions are not identified and implemented and root cause is not identified and corrective action is implemented by the contractor in time. Two quivers were found unplugged with electrodes in it at Train 2 (on the scaffolding) & Train 1. It is violation of SAES-W011, Table 1. Quiver on Train 2 belongs to Welder # 111 while on Train 1 belongs to Welder # 97. Action shall be taken to avoid further repeated violation on consumable control. It was noticed during Focus Assessment that portable storage ovens are not being periodically checked at Fabrication Shop. Neither any instrument is available to check the temperature nor is record being maintained. This is a violation of item # 5 of SAIC-W-2032. Contractor is advised to calibrate all the portable ovens and maintain the record of periodical checkups. Baking oven is not available at Fabrication Shop for the baking of unused/returned low hydrogen electrodes. Baking is being performed in holding ovens which is a violation of item # 4 of SAIC-W-2032 and Para 6.6.1 of QCP-847-101 Rev 0. Contractor is advised to arrange Baking Oven at the earliest to comply with SAIC-W-2032 and QCP. No record of unused or leftover electrodes is being maintained by the contractor. It is a violation of Item # 10 of SAIC-W-2032 & Para 6.5.4 of QCP-847-101 Rev.0. Form FM-847-101C is being used which has no place to record number of returned electrodes. Contractor is advised to revise the said form to add a column to record number of unused/returned electrodes. Neither color marking is being done on unused/returned electrodes nor is a record of destroying maintained at Fabrication Shop. It is a violation of Item # 10 of SAIC-W-2032 & Para 6.5.4 of QCP-847-101 Rev.0. Contractor is advised to comply with the SAIC-W-2032 and strictly follow the route mentioned in Form FM-847-101A of QCP-847101 Rev 0.
Mechanical
ScheduleQ
Schedule Q
5.14
43
4/20/2007 5:55:21 PM
Mechanical
ScheduleQ
Schedule Q
5.14
44
4/5/2008 12:25:27 PM
Mechanical
ScheduleQ
Schedule Q
7.5.4
45
3/15/2007 7:39:50 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
46
5/22/2006 10:47:30 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
47
5/22/2006 11:27:04 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
48
5/22/2006 11:38:14 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
ScheduleQ
Schedule Q
3.1
49
5/22/2006 11:42:13 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
ScheduleQ
Schedule Q
3.1
50
12/30/2007 11:14:16 AM
N13-20-0
During Reinstatement verification , Cold shoes for the following Test Packages were found not properly installed per INDRA Installation/ Operation/ Maintenance Manual of Cold Shoes Reference Document No. EM-PUF-01 clauses 5, 6, and 7 and Vendors Drawing # P555200/ JGC Dwg # B74-M-BB-546121-081. Test Packages # 1)N13-20-0-035C 2)N13-20-0-054 3)N13-20-0-085 4)N13-20-0-089C and 5)N13-20-0117D. The cold shoes are neither vapor barrier repaired, layers of insulation not bonded nor bolts tightened. Schedule Q Section 3. DOCUMENTATION REQUIREMENTS states that "Contractor shall plan, organize, control and execute all WORK in accordance with CONTRACTORs Quality Plans, I&TP and documented procedures. Contractor should correct findings. RFI to be issued for each test package. During routine surveillance, at exactly 8:30 am, its raining and temperature is about 11 degrees C, it was observed that welding works are being performed at Train 2 without QC personnel around. This is in violation of Schedule Q Sect 5 para 5.1 Resource Management and Attachment IV para 2.1 Validation of Construction Processes. Contractor is advised to follow requirements. In Train-2 and Train-3 during Pneumatic testing, contractor using Household soap or detergents and are substituted for bubble testing. This is violation of ASME Sec-V, Article-10, Para: I-1032 and SAIC-A2021, item # A3. Contractor used water for Cryogenic blow down (Test package # N2230-0-001)is more than 50 mg/L. According to water analysis report from lab found 200 mg/L to 400 mg/L. This is violation of SAIC-A-2008 and SAES-A-007. Contractor has to take prompt action. Different revisions of drawings were found on site for the internals of Demethanizer, QC had current revision drawing while construction people were utilizing superseded drawing furthermore both QC and Construction holding this drawings were uncontrolled (photocopies) drawings. The drawing number are Koch-Glitsch D001 and D013,D019 this drawing collected from site are available with SAPID. This Contractor action is the repeated violation of Schedule Q Para 3.7 and SAEP-1154 Para 5.4.2.3. Contractor document control Department shall issue only control copies of the document and control documents shall be use for execution of work /inspection. If contractor feel necessity uncontrolled (photocopies) drawings collected from site can be presented by SAPID. It is notice in train1 that, many new spiral wound gaskets 24 and above were place in horizontal, sloping position & some are hanging on the scaffold/hand rails at workplace. Such method of storage/handling has the potential to damage the gaskets while violating the requirements SAEP-351 Para 4.1: Ensure that spiral wound gaskets are stored flat especially for large sizes, 24 inches and larger. Contractors preventive action is requested for such repeated violation. Pictures demonstrating the violation can be avail from SAPID if necessary. Without written procedure, Contractor tightening the flange joint stud bolts under pressure at 150PSIG for the test package # N23-20-0-005. This is violation of General Instructions G.I No.2.102, Para:5.17. It is noticed that, internal parts of the Demethanizer such as chimney riser, tray panels are not stored / preserved properly this is the violation of schedule Q attachment IV Para 5, that call for preservation to be performed per manufacturer recommendation and Aramco standard. If contractor feel necessity Photo of this violation can be presented by SAPID.
Mechanical
ScheduleQ
Schedule Q
3.1
51
1/11/2008 10:38:41 AM
NGL-2
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.2.2
Schedule Q
5.1
52
2/15/2008 2:12:38 PM
SATIP-A-004-01
SAIC-A-2021
Mechanical
other
ASME SEC V
ART 10
53
5/20/2008 1:52:29 PM
SATIP-A-004-02
SAIC-A-2008
Mechanical
SAES
SAES-A-007
6.1
54
6/27/2007 2:36:48 PM
Mechanical
ScheduleQ
Schedule Q
3.7
55
11/26/2007 10:23:21 AM
SATIP-L-410-01
SAIC-L-2007
Mechanical
SAEP
SAEP-351
4.1
56
4/5/2008 1:40:06 PM
Mechanical
SAEP
SAEP-351
57
6/27/2007 2:32:13 PM
Mechanical
ScheduleQ
Schedule Q
A VI Para 6
58
11/28/2007 4:42:59 PM
Pre-boxup inspection for Compressor suction drums B66-D-0112A/B & 0113A/B reveals that, vessels top manways M1 are boxed up without Utilizing of related SATIP/SAIC and without inspection for the vessels internal (mechanical integrity & cleanness), the Manway flange face & gaskets, which is the violation of Schedule Q attachment VI Para 4A and G.I 2.710-6 Para 5.10 e&f. contractor corrective and preventive action is requested. Installation of equipments Tag # B66-D-304 A-E carbon bed basket strainers are found improper, gap between the saddles and sliding plate & for D-304C saddle is position outside the sliding plate, equipment is already hookup with inlet & outlet piping, contractor corrective action is necessitate. It is notice that, for the train 1 Demethanizer internal deck type distributor and feed gallery installation, assembly & welding preparation activities contractor construction crew are utilizing uncontrolled documents (photocopies of uncontrolled drawings) such exercise to execute the work is REPEATED violation of Schedule Q Para 3.7 and SAEP 1154 Para 5.4.2.3 control documents shall be use for the execution of work. those uncontrolled documents were shown to JGC QCI on site. Corrective action with increase in QC vigilance is requested. It is notice in train1 on the carbon bed vessels that, the new spiral wound gaskets 24 and 12 (to be use permanent) were tied together and hanging on the platform hand rails while some were put down on the grating at workplace. Such method of storage/handling has the potential to damage the gaskets, this are the violation of SAEP-351 Para 4.1: Ensure that spiral wound gaskets are stored flat especially for large sizes, 24 inches and larger. Contractors preventive action is requested. On nozzle flange N4 of the exchanger B66-E-0302 an Unacceptable imperfection is noticed, imperfection deeper than serration depth of total length 13mm (2 scratches 6mm & 4mm with 3mm gap inbetween) were noticed, this is the violation of SAIC-L-2014 item A2, SAEP-351 Para 4.3 The flange facing, particularly the seating area, shall be visually examined for cleanliness and ensure that no damage, such as scratches exist. Contractors Corrective action and verification through SAPID is requested prior to connection of piping. Flange B-in 42 inch of exchanger B66-E-0213 and spool C of A231-B66P-1018 are stick together without any gasket in-between also minor scratch is noticed on the exchanger B-in flange means there have been strike during placing the spool, this is the repeated violation of SAES-L350 Para 8.1 all material shall be handle with care during fabrication and installation to prevent damage. Verification by SAPID representative of gasket seating area of all four flanges is required. Photos of these violations can be avail from SAPID, Contractors preventive action is requested. During the internal inspection of cold gas exchanger B66-E-0112, it was notice the micarta block (wooden insulation block) at elevation 4107.91 are loose and without micarta retainer (SS plate/cleat), which is violation of IFC drawing (detail 2 of vendor Drg number 15569W Rev C) that indicates the SS plate as micarta retainer to be welded on tube steel. Detail Inspection remarks can be seen on contractor report number 22306. Mr. Biplab Nokimuddin, # 7681, approved for touchup painting only was found painting the stainless steel lines with brush without any cleaning as per approved procedure. It is violation of item A1 of SAICH-2010 and many items of SAIC-H-2027. Contractor is advised to take necessary action by removing all paint and reapply as per approved with intimation to SAPID. Logbook entry will only be closed if inspected and verified by SAPID Inspector after rectification. Contractor CCC-Kabani, applied wrong coating system APCS 2A whereas the required coating system is APCS-26. Violation of Project Specification 1.CCC-A131-P-1028-Spools B/C & K. RFI is required to witness the correct coating system
SATIP-D-001-01
SATR-D-2003
Mechanical
ScheduleQ
Schedule Q
A VI Para 4
59
2/10/2008 4:40:56 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
9.3
60
12/8/2007 3:11:14 PM
Mechanical
ScheduleQ
Schedule Q
3.7
61
9/25/2007 11:35:15 AM
SATIP-D-001-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.1
62
10/1/2007 1:28:57 PM
SATIP-E-004-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
63
11/29/2007 9:38:33 AM
SATIP-E-004-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
8.1
64
9/4/2007 5:00:34 PM
Mechanical
Drawing
Schedule Q
1.3
65
1/8/2008 5:17:10 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.3.1
SAEP-316
3.1
66
7/22/2007 7:54:22 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
ScheduleQ
Schedule Q
1.3
67
6/13/2007 2:37:03 PM
During surveillance of SS damaged coated pipes touch up prior to Insulation in Train II , it was found that some body has done the touch up work in very bad manner without surface preparation and without finish surface. Painting contractor Kabbani and CCC are refusing to accept this work by saying that they have not done this job. Spool No.SS-CCC-A131-B66-P-1334A-Spool E-3SD0P This is violation of SAESH-100 Para 8.3 Contractor has repaired coating damages on few weld joints e.g. joints of line # A122-B66-P-1104 sh3/4 & joints of line included in N13-10-0023 at Train # 1 without following SAIC-H-2032 requirements. It is violation after-the-fact and rework is required. As per item B4 of SAICH-2032 "Areas greater than 0.1 m are blast cleaned to obtain the metal surface pre treatment originally specified...." and as per item B8 of SAIC-H-2032 "Coating for repair areas greater than 0.1 m are applied by spray method to the original specification ......). Contractor is advised to remove the paint and comply with item B4 and B8 of SAIC-H-2032. Coating works of lines 20"-A241-B66-R-2458 and 24"-A241-B66-R2455 at Train 1 are observed not in compliance of requirement per SATIP-H-100-1/ SAIC-H-2032, items A7, B4, B8, C1 and D1, reference to SAES-H-100 paras 8.4.4, 8.4.6,8.5 and 9.2. Found, paint damages on piping line number A31R-B66-R-1801 from PR column Nos. 1 through 39. Cold shoes located @ Column Nos. 15 through 24, 36, & 39 were installed without touching-up/repairing damage coating. Disassemble affected cold shoes, repair damaged piping coatings as per surface preparation and application requirements in the applicable APCS (per dwg specs) and the manufacturers technical data sheet. (SAES-H-100, Para. 8.5) During routine site visit found APCS-26 paint on stainless steel pipe welds for cryogenic blow down line # A331-B66-RLC-3390, 3392, 3265 & 3267. This is violation against ISO Drawing. Paint not required as per isometric drawing. Contractor has to remove paint before hydrostatic test. During surveillance in the Train-2, it was noticed that for few installed risers have no properly filled knifing compounds in their joints. This is a violation of Contractor procedure and a standard drawing DWG-AB036090 / Sheet 001. Rev.9. Above said problem was noticed on 8 Fire Water Riser which is repeated violation of previous entry on same subject. Contractor is recommended to check all the risers before field Hydrotest in order to avoid corrosion if compound is missing or before installation of Fire Hydrant. PZVs at Train 2 & 3 are not being stored, handled and preserved as per SAIC-J-2007 requirements. PZV are placed on the floor/grating in horizontal position. It is a violation item A1 of SAIC-J-2007 Relief valve stored in vertical position. Inlet & outlet flanges are also not protected. It is a violation item A3 of SAIC-J-2007 Inlet & outlet flanges shall be protected to prevent damage or entrance of foreign matter. Contractor shall comply with Standards requirements. TRAIN-1,Test package # N13-30-0-123, Hydrostatic test Pressure given 150PSIG. This is violation of SAES-L-150, Para 7.4.1. It states that Lube oil piping hydro test pressure shall be 1.5 times the design pressure or 100PSIG whichever is the greater.Contractor should verify hydro test package limiting factors before submitting to SAPID. During surveillance in Train-1, it was noticed that 2 & diameter weldolet metal pieces found in 10 diameter spool of line # A121-B66P-1120 Sheet 1 of 2, spool-A, and welding electrodes found in 30 diameter pipe of line # A121-B66-P-1024 Spool-D, near joint # 11. This is repeated violation of SAES-L-350 Para 15.2 & 15.3 and SAIC-L2017, Contractor is recommended to raise RFI for internal cleaning for those lines to witness Aramco PID.
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
9.2
Schedule Q
1.7
68
11/24/2007 7:17:56 AM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.4.4
69
11/29/2007 8:05:22 AM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
70
1/3/2008 6:08:16 PM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.5
71
6/17/2008 2:26:39 PM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-L-150
7.3
72
9/8/2007 10:28:19 AM
Mechanical
Drawing
AB-036090
73
4/12/2008 11:29:27 AM
SATIP-J-600-01
SAIC-J-2007
Mechanical
other
34-SAMSS-611
Section 5
74
9/13/2007 3:46:20 PM
Mechanical
SAES
SAES-L-150
7.4.1
75
6/5/2007 7:38:36 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.2
76
4/4/2008 1:14:50 PM
In train 2 Area 241 and south of A2PR04 it is noticed that few PZVs and butterfly valves (example: B66-42-PZV-049,050, B66-DCV-083 S.No 19693/41-2) are left uncovered, storage & handling is not as per the requirements of 04-SAMSS-035 Para12.2 and SAES-L-350 Para 7 & 8. Photos of such valves violating standards requirement can be avail from PID. Contractor corrective and preventive action is requested. During routine surveillance in Train-2 and Train-3 found that several valves are lay down on the ground with out any protective covering for valves. This is violation of SAIC-L-2041, Item # A9. Valve weld ends are likewise be fitted with plywood covers of matching outside diameter. The covers are securely attached to the valve by means of wire or steel banding. Contractor shall comply with standards requirement. Contractor is pulling the pipe on rack WITH OUT temporary rollers thereby by forming deep scratches. The above said problem was noticed on left and right side of joint#6 of 30 line, A31R-B66-P-1469, near column#31. Adjacent SS pipe is also badly scratched due to improper pipe pulling on racks. This is a clear violation of SAIC-L-2012, item # D7. Contractor is recommended to provide correct size of rollers as early as possible to pull the pipe to avoid repeated violation. During surveillance in Train-1 found that 2 branch connection coming from 16 line is located near to fixed obstruction (Support)and horizontal gap distance less than 610mm. This is violation of SATIP-L-350-01, SAIC-L-2013 and SAES-L-310 Para 12.5. Contractor counsel to do repair work according to Saudi Aramco standards. During the initial punching of Test Pack# N11-40-0-002, WEEP HOLE is not provided on the horizontal dummy support which is violation of SAIC-L-2018, Item# F2. Contractor is recommended to provide weep holes on vertical and horizontal dummy supports as per the checklist wherever it comes. Missing bolts are noticed during rinstatement for (Test Package No. N21-BO-0-021. This is violation of SAEP-351 During surveillance in train-1, it was observed that bolt tightening for two 60gate valves (6GV0C03B-P3FB230) and permanent gasket was being installed without any procedure and flange face inspection in line # A121-B66-P-1024. Piping QC and proper tightening tools were not available at site. Torque value for 2" bolt size is 3180 ft-lbs as per procedure MS-847-105. Tensioning of bolts with torque values of 800 ft-lbs and greater shall be achieved by means of hydra tight equipment (Ref: Para 7.3 of MS-847-105). This is violation of SATIP-L350-01, item # 3.10, SAIC-L-2014, SAEP-L-351 and MS-847-105. Contractor should raise RFI for flange face inspection and bolt tightening for both 60 gate valves in this line. Contractor is advised to follow the bolt tightening procedure to avoid any rework and delay. During surveillance in train-1, it was observed that bolt tightening for two 60gate valves (6GV0C03B-P3FB230) and permanent gasket was being installed without any procedure and flange face inspection in line # A121-B66-P-1024. Piping QC and proper tightening tools were not available at site. It was observed during surveillance that unacceptable tools (hammers) are being utilized for bolt tightening train #1 area. 24 butterfly valve was tightened with hammer while permanent gasket was there in line A132-B66-P-1458. It is violation of Contractors own procedure, SAESL-350 and SAIC-L-2014 & SATR-L-2001. All bolts shall be tightened by hand, numbered and then tightened with air impact wrench or equivalent following the bolt tightening sequence in stages as per Aramco Standard (Ref: item B4 , B5, B6, B7, B8, B9 & B10 of SATR-L2001/SAEP-351)
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
7.3
04-SAMSS035
12.2
77
5/11/2008 1:41:45 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
7.3
04-SAMSS035
12.2
78
9/3/2007 10:05:04 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
79
11/13/2007 7:38:11 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
80
9/12/2007 10:27:04 AM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-350
13.2.3
81
5/21/2008 2:14:23 PM
SATIP-L-350-01
SAIC-L-2022
Mechanical
other
GI-2.710-6
Item 1.j
82
8/27/2007 7:21:09 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
83
SATIP-L-350-01
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
5.1
84
9/7/2007 10:42:49 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
6.1 & 7
85
1/9/2008 5:36:58 PM
Found, Mixed Grade Bolting (B7 & L7) employed for Control Valve 41PV-574 flanged joint installed in-line A31R-B66-P-1187. Bolts should be all Grade L7 as per drawing specs, & SAIC-L-2043 Item B4. Found, Mixed Grade Bolting (B7 & L7) employed for Control Valve 41PV-861 flanged joint installed in-line A31R-B66-P-1490 and A31R-B66P-1493. Bolts should be all Grade L7 as per drawing at A31R-B66-P1493 flange conn., and Grade B7 as per drawing at A31R-B66-P-1490 flange conn.. During site surveillance at CCC fabrication shop# 2, contractor preparing to install / tack weld WN flange on spool for line 10" P-10103CA9P. As per approved isometric drawing this wn flange suppose to be low temp steel with grade LF2, but contractor was installing flange with material A105 gr BN. So notified contractor to use low temperature material flange and avoid rework. Also notified to verify all material prior to tack welding, especially low temperature steel. During surveillance inspection of Galvanized above ground vent pipes in CCC Fabricated Materials Yard, found that Contractor had Fabricated & welded Pipe & Fittings of Line Class 80CG0D1. This is violation of SAES-L-105-Line Class 80CGOD1 Para 11. Galvanized Carbon Steel Line Class 80CGOD1 is not welded and threaded joints are used for construction as per SAES-L-105, Table 1. This is a repeated violation after the fact. Please refer surveillance number 36775. During surveillance on Train-1 pipe rack, I have noticed that the CCC contractor was handling/lifting the Stainless steel piping spools with carbon steel chains directly at an area A11R and A132. This is violation according to SAES-L-350, Para 8.1 and scheduleQ. Contractor is counsel to follow all applicable Saudi Aramco standards & specifications and Schedule-Q, Attachment-IV, Para-5 during construction. On east side of Demethanizer 24 inch Nozzle a pipe Spool sticks without any gasket in-between and a dent mark outside the raise face area is notice and may have been strike during installation of spool, which is the violation of SAES-L-350 Para 8.1all materials shall be handled with care during fabrication and installation to prevent damage. The verification of gasket seating area of these flanges for any damage shall involve SAPID. If contractor feel necessity Photos of this violation can be presented by SAPID. Many flanges in RTR pipes, especially in Fire Water Lines in Train # 1 and Train # 2 area are open. It is violation of SAES-L-350, Para 15.2.3. Contractor is advised to keep all the pipe ends covered after cleaning. Found; Pipe bevel damage 13mm depth X 36mm long (Maximum for 2 locations) for Line 30 No. 232-B66-P-1239-Spl A. Saudi Aramco SAESW-011 11.3.2.3 allows only a minimum of 1.5 mm depth to be removed by grinding or machining. This shall be cut if there was no approved repair procedure for this matter. Found; Pipe fitting crew building up and grinding (without approved repair procedure or site instruction) pipe ends bevel damages ranging from >1.5 mm to 8 mm depth at various locations for Line 30 No. A232-B66-P-1177-Spl D. (Violation against Saudi Aramco SAES-W-011 Sec.11.3.2.3). During surveillance in Train-1 found that contractor has performed bolt tensioning by hydra-tight on 48 venture tube in line # A11R-B66-P1177 and 24flanges joint # 9 & 10 in line #A141-B66-R-2617, sheet 1 & 2 respectively. This is violation of SAEP-351 and SATR-L-2001. Bolt tensioning equipment such as HYDRATIGHT may be used for class 900 and above only resulting in a minimum residual bolt stress of 30000 psi and a maximum of 50,000 psi. Contractor shall be advised to stop bolt tensioning on less than 900 class flanges. Almost same number of threads should be exposed on both sides of the flange after bolt torquing.
SATIP-L-108-01
SAIC-L-2043
Mechanical
other
04-SAMSS003
5.3
86
1/9/2008 5:50:37 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
other
04-SAMSS003
5.3
87
1/17/2007 1:34:41 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
6.1
88
4/26/2007 4:33:50 PM
SATIP-W-011-01
SAIC-L-2037
Mechanical
SAES
SAES-L-105
11
Schedule Q
7.3.1
89
5/27/2007 6:44:00 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
Schedule Q
A IV Para 5
90
6/27/2007 2:25:57 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
8.1
91
9/7/2007 11:04:28 AM
SATIP-L-350-05
SAIC-L-2054
Mechanical
other
01-SAMSS010
10.4.1
SAES-L-350
15.2.3
92
9/24/2007 1:47:17 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
93
9/29/2007 5:19:01 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
94
10/7/2007 9:01:49 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
6.1
95
11/13/2007 10:30:36 AM
11-13-07 Found, almost all threaded pipe joints were damage due pipe wrench tooth (Contractor did not employ the right tools like the Strap wrench or pipe wraps for Instr. Air line installation). In many locations/joints almost all threads engaged, leaving no threads visible. This in violation to SAIC-L-2012 item C1/SAES-L-110 Section 7. During surveillance in Train-1, observed that some of the stainless steel elbows and flanges are corroded with brown red rusty spots for line # A132-B66-RLC-3311, A11R-B66-RLC-3237,3176 & 3142. This is violation of schedule-Q, attachment IV, Para-5. Contractor is advice to provide root cause and corrective action as stainless steel never rusted without contamination. Found Relief Valve PZV-306 layed horizontally at the platform grating with its in/out-let ports uncovered. In Handling RVs, Care should be maintained at all times that it is appropriately treated like a delicate mechanism and to be stowed in upright position with its ports covered until installed. Ref.: SAEP-319 Section 6. In train 1 near Dehydrators, butterfly valves (18 inch # 600 S.No 60110-006-007) are left uncovered since couple of days which got rusted mostly due to Hydrotest water blow and potential of other damages. To remain uncover the valves (prior to and after the valve testing) is violation of item # A4 of SAIC-L-2041(storage and preservation of valves), 04-SAMSS-035 Para12.2 Valve end flanges shall be fitted with plywood covers and SAES-L-350 Para 8.1 Contractors corrective & preventive action is requested. Photos of these repeated violations can be avail from SAPID. During installation inspection of PZV @ Train 1 for Relief Valves # B6641-PZV-074/ 078/ 085/ 088/ 095/ 107/ 116/ 120/ 121/ 124, items were found coating already damaged with exposed base metal had rusted caused by improper handling of the items during installation. Repair shall be done using the same specification of the PZVs coating specs. During surveillance it is notice that, 54 inch MOV-164 installed in line 54-P-1303- 3CS9P at battery limit have Hydra tightening Tag, but on one side all bolts are loose therefore flange face verification, correct gasket Verification and bolt tightening shall be performed with intimation to SAPID as it is hold point for the company. Found, overdue calibration of Torque Wrench (mark/ID: DCF-03904, tag Due date 16 Dec 07) from a torquing crew doing RVs flanged tightening at A11R, EL 118500 TOS. It was noticed during the course of RV Verification/Inspection on 1/17/08 @1045H. After the Fact Violation to: SAEP-351, Para. 6.3/SATR-L-2001 Item B3 (Flange Joint Tightening Inspection). Contractor installed Soft seated valves and control valves during flushing for the test package # N23-10-0-033 in Train-2. This is violation according to SAES-A-004. and Para: 7.1.3 says that, Soft seated valves and control valves shall not be installed until after the lines have been thoroughly flushed. Contractor action required. Interconnecting Line to A231-B66-RLC-3370 has missed welding at corner joint of pipe shoe to pipe.Verify if A231-B66-P-1555 was hydrotested. Weld pipe shoe to pipe and retest the line Interconnecting line to A231-B66-RLC-3396 is vertically misaligned. Verify if TP-N23-30-0-168 was hydrotested. Repair misalignment and retest TP-N23-30-0-168 It was noticed in train 3 that, construction crews are not handling and preseving valves through out intallation process, this is violation of SAES-L-350 Para 8.1 All materials shall be handled with care during fabrication and installation to prevent damage. Pictures of such repeated violation act can be avail from PID. Contractor corrective and preventative action is requested.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-110
SAEP-351
4.5
96
11/15/2007 8:00:45 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
97
11/23/2007 7:45:10 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.3
98
12/2/2007 5:04:51 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.3
SAES-L-350
8.1
99
1/8/2008 4:01:44 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.3
100
1/10/2008 5:58:22 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
other
ASME-B-31.3
335.2.3
SAEP-351
101
1/17/2008 4:05:14 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
6.3
Schedule Q
A IV Para 7.1
102
4/23/2008 11:33:36 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-A-004
7.1.3
103
5/3/2008 7:13:44 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1
104
5/3/2008 7:18:46 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
10.1
105
6/28/2008 10:55:27 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
106
2/19/2007 5:24:50 PM
At CCC SS fabrication shop lay down area noticed 24" B66-RLC-32861SDOP2 SPL-Q, A131-B66-P-1338A SPL-P, 36"-A132-B66-P-1226 SPL-J and various other spools with spots of contamination. This is violation to SAES-L-350 para-8.1. Notified contractor to protect SS pipe / fittings at storage and during shop fabrication to avoid contamination, also to clean contaminated spools. Observed and noted that during Hydro test of SS piping system, various reasons were given by Contractor regarding where the water comes from. Moreover, when SAPID asked for water analysis of test media, the Contractor has failed to comply. SAPID shall strictly enforce that NO water analysis of the test media, NO Hydro test of SS piping system at all times. On special cases, the Contractor shall comply to SAES A-007. SAPID has witnessed a threaded joint for PI (pressure indicator) which was part of the hydro test circuit (TP N21-80-0-001C) was found not in its final orientation. The Contractor QC commented that it will be fixed during reinstatement which was not acceptable. Therefore, the Contractor was advised to install all threaded joints as per drawing requirements at all times, and if it was part of the test limit, then after SAPID accepted the hydro test, there shall be no re tightening of threaded joints to bring it to the required orientation During surveillance it was observed that CCC welder S-092/W-226 welding electrical supports (M-NGo2-03-0020/21/17-873)using channel C100X50 at CCC Ware house with following violations: i) CCC contruction have not notified CCC-quality department, so no material inspection, no fit-up inspection and no welding inspection. ii) Welder was welding in open space so no wind protection. iii) Steel was coated, no proper cleaning prior to welding and after welding. This is violation to SAES-M-001 Para-9. It is noticed in Train 2 area 231 around Demethanizer, cold insulation is been performed on pipes by single layer 3.5 inch thick cellular/foam glass material instead of applying multilayer which is violation of Project specs B74-N-BE-548326 note 1 of table B or SAIC N-2007 & PIP INIC1000 Para 4.4.2.2 Contractor corrective and preventive action is requested. During surveillance in Train-1 found that the insulation sub-contractor BINZAGR was doing insulation work during raining. This is violation of BINZAGR insulation procedures. During surveillance in Train-1 found that the insulation sub-contractor BINZAGR was doing insulation work during raining. This is violation of BINZAGR insulation procedures. In Train-3, Test package # N33-20-0-066E, ISO # A331-B66-P-1008, Sheet # 6 & 8 found that Aluminum vapor seal is damaged for two installed cold shoes.It is violation of drawing # BB-546121-sheet No.081 and Vendors Doc. No. 5552.CF/01. RFI shall be issued to witness the repair and bolt tightening of the cold shoes. In Train-3, Test package # N33-20-0-035A, ISO # A331-B66-P-1414, Sheet # 1 of 2 and similar lines at pump area found that Aluminum vapor seal is damaged for more than five installed cold shoes. It is repeated violation of drawing # BB-546121-sheet No.081 and Vendors Doc. No. 5552.CF/01. RFI shall be issued to witness the repair and bolt tightening of the cold shoes. Cold shoes are being installed without following vendors recommendation, drawing as well as approved procedure. Damaged protective coating vapour foil barrier are not being recorded, reported or repaired as per procedure. It is violation of drawing # BB-546121, Sheet No 081, Revision-0F1, Drawing # P555200 Bonding details and document # P5552-EM-PUF-01.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
107
4/3/2008 11:11:56 AM
SATIP-A-004-02
SAIC-A-2008
Mechanical
SAES
SAES-A-007
6.1
108
4/5/2008 2:12:44 PM
SATIP-A-004-02
SAIC-A-2010
Mechanical
ScheduleQ
Schedule Q
1.3
109
2/26/2007 5:01:29 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
110 111
SATIP-W-011-01 SATIP-W-011-01
SAIC-W-2005 SAIC-W-2005
SAES SAES
SAES-W-011 SAES-W-011
11.2.1 11.3.1
112
3/12/2008 11:43:59 AM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
PIP INICI 1000
4.4.2.2
113
1/13/2008 5:05:45 PM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
PIP INSC 2000 PIP INSC 2000
5.1
114
1/13/2008 5:06:03 PM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
5.1
115
7/4/2008 11:44:52 AM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
7.7
116
7/10/2008 5:10:55 PM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
7.7
Schedule Q
1.3
117
8/25/2007 12:08:45 PM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
7.7
118
9/23/2007 11:36:46 AM
Please refer surveillance number 49041. During punch listing of hydrostatic test packages in Train-1 Dehydrator area 122, found that previously installed cold shoes were misaligned and aluminum vapor seal was damaged for these ISO lines. A122-B66-P-1169, A122-B66-P1170, A122-B66-P-1185 & A122-B66-P-1196. This is repeated violation as stated in surveillance # 49041. Contractor should start repair work immediately to complete this project in time. Prime contractor is not having RTFI since October 4, 2007. It is violation of schedule-Q, Table VI-2. Contractor is advice to arrange for RTFI at the earliest to comply with schedule-Q requirement. While routine site visit I have noticed that contractor NDT personnel was performed dye penetrant test with penetrant materials from different manufacturer. Penetrant and developer belongs to Magnaflux manufacturer and remover belongs to Ely manufacturer. Intermixing of penetrant material from different manufacturers are not permitted according to SAIC-L-2003, Item # A2 and ScheduleQ, Attachment IV Para 7.3 For the line# A331-B66-P-1381, Spl-E-EQP, Joint#20, 3SD0P2, no fitup signature was found and even then Welder#385 was welding this joint.For the 24 line# A231-B66-P-1009L-1471, Joint#13, no fit-up signature was found and even then Welder#360 was welding this joint and also joints are not being cleaned properly.This all are violation of our Sch-Q and Standards.The responsible QC for the above said SS fabshop is Mr. Alam. Seven below mentioned cold shoes installed in Train # 1 (Area 132B66) have aluminum vapor seal damaged and no proper bolt tightening. One of them has PUF damaged too. It is violation of drawing # BB 546121-sheet No. 081, Vendors Doc. No. P5552 EMPUF-01 and 5552.CF/01. Contractor is advised to repair the aluminum vapor seal and re-install the shoes as per vendors instructions before proceeding. RFI shall be issued to witness the repair and bolt tightening of the shoes. Details of cold shoes: 1 shoe is in P-1226, 2 are in P-1222, 2 are in P-1011, 2 are in P-1001 (1 has PUF damaged near B66-D-011) lines. There are more damaged cold shoes in the area and will be identified through QMIS. Each cold shoe shall be given a unique number for traceability Hundreds of valves have been dropped down from train # 2 & 3 for repair/re-test. As per schedule Q attachment IV Para 3.1.. Inspection status reports shall be kept current and shall be available for Saudi Aramcos review at all times. Therefore contractor is informed that Hydrotest and bolt torquing reports for these valves has been null and voids. Current reports shall be attached in related Hydrotest package before package is finally signed off. Many valves from Train # 2 have been taken out for re-testing/repair. These valves are being re-installed by contractor without PID involvement. It is a violation of SATIP-L-108-01, item 3.1 and SATIP-L350-02, item 3.12. SAPID shall be invited for flange face inspection, gasket verification and witnessing bolt torquing at the time of valve installation. It is worth mentioning here that Flange joint inspection is W1 for SAPID. Many valves from Train # 3 have been taken out for re-testing/repair. These valves are being re-installed by contractor without PID involvement. It is a violation of SATIP-L-108-01, item 3.1 and SATIP-L350-02, item 3.12. SAPID shall be invited for flange face inspection, gasket verification and witnessing bolt torquing at the time of valve installation. It is worth mentioning here that Flange joint inspection is W1 for SAPID. On site, Piping Pre-Installation ((SAIC-L-2011) and Pipe Laying, Spool Erection and Assembly on Pipe racks and Sleeper ways (SAIC-L-2012) are going on. Contractor did not raise any RFIs for the same. This is a violation of Schedule Q, Attachment IV and Para: 4A.
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
7.7
119
1/6/2008 6:06:44 PM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
120
6/20/2007 6:51:35 AM
SATIP-NDE-LPT-01
SAIC-LPT-2007
Mechanical
SAEP
SAEP-1145
4.4.2
Schedule Q
A IV Para 7.3
121
7/8/2007 5:34:32 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
122
9/5/2007 12:15:48 PM
SATIP-N-001-01
SAIC-N-2007
Mechanical
SAES
SAES-N-001
7.7
123
7/15/2008 5:10:15 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
ScheduleQ
Schedule Q
A IV Para3.1
124
7/15/2008 6:11:27 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
ScheduleQ
Schedule Q
1.7
125
7/15/2008 6:12:53 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
ScheduleQ
Schedule Q
1.7
126
1/7/2007 4:26:48 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
1.7
127
1/9/2007 10:09:32 AM
128
1/23/2007 9:57:52 AM
As of now (01-09-07) there are 29 pipe welders at SITE but the Contractor has provided only one Inspector for these welders. This is a clear violation of Sch-Q, Attachment VI Table 2 (Inspection Discipline: Welding) During Surveillance it is noted that, for TANKS there is no QC coverage from JGC. This is again a clear violation of Sch-Q- VI, Para: 2.1 The proactive log book number 25144 has been categorised as violation after the fact as contractor did not submit the repair procedure of cement lining until today which is a viloation of SATIP-L350-7 and Item #A1 of SAIC-L-2076. In Train-2, found that two shop butt welds were cut and re-welded without raising any RFI. These joints were accepted by Radiography in shop for line # A221-B66-P-1161, SBC # 006 and A21R-B66-P-1204, SBC # 038RW1. It is hold point H1 for Aramco inspection. This is violation of SATIP-W-011-01, Item # 3.17. Contractor has to fill SAICW-2036 and request for Radiography for these joints. It is repeated violation after the fact and refers previous Surveillance # 54084, 50339, 42982 & 35458. Since February 2007, these welders (W-150, W-167, W-211, W-212, W-215, W-224, W-225 and W-226) have not welded any single joint until now. If welders are not welding for more than three months, their validation will expire. Job clearance cards (JCC)shall be returned to the Project inspection department (PID)immediately. This is violation according to SAEP-324 Para 6.5.5. During focus assessment in Train-2 found that Post weld Heat Treatment (PWHT) was not carried out for the line # A213-B66-P1303, Joint # SBW-009 & FBW-012. These joints are Eccentric reducer to Pipe. Reducer thickness is 23.83mm and pipe thickness is 15.88mm. According to ASME B31.3, Para: 331.1.3 when dissimilar thickness components are joined by welding, the thicker component shall be considered for PWHT requirement. This is violation of ASME B31.3. Contractor shall verify all the joints in Train-2 and Train-3 and perform PWHT as per standards. During routine site visit in Train-1 found that some of the welding machines calibration/validation has been expired and NO calibration sticker available on the machine. This is violation of SATIP-W-011-01 Item# 2.3, SAIC-W-2011/SAES-W-011 Para: 19.2. Contractor should identify the machines require calibration/validation. Revalidation shall be performed at the earliest. In Train-2 found that Post weld Heat Treatment (PWHT) does not performed olet welds for the line # A21R-B66-P-1177, Joint # SOW005, 008, 012, 016, 019, 022 & 025. These joints are shop olet joints welded on 41.28mm thickness pipe of Diameter 48. According to ASME B31.3, Para: 331.1.3 (a) when the thickness through the weld in any plane through the branch is greater than twice the minimum material thickness requiring heat treatment. This is violation of ASME B31.3. During surveillance in Train-1, found cut and welded joints due to alteration in flanges (example is joint # 001 & 14A in line # A131-B66P-1001 & A131-B66-P-1020A respectively). The above said joints were cutout without raising any RFI to PID Aramco. It is hold point H1 for Aramco inspection. This is a repeated violation of SATIP-W-011-01, Item # 3.17. SAIC-W-2036 shall be completed. Work is being performed without approved procedure/method statement by item#A3 of SAIC-W-2036.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
SATIP-L-350-07
SAIC-L-2076
Mechanical
ScheduleQ
Schedule Q
A VI Para 5.3
129
2/28/2008 2:11:02 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
130
7/3/2007 11:20:11 AM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-324
6.5.5
131
3/4/2008 10:47:06 AM
SATIP-W-011-01
SAIC-W-2004
Mechanical
other
ASME-B-31.3
331.1.3
Schedule Q
1.3
132
10/10/2007 5:00:07 PM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
133
3/6/2008 3:20:54 PM
SATIP-W-011-01
SAIC-W-2004
Mechanical
other
ASME-B-31.3
331.1.3
Schedule Q
1.3
134
10/3/2007 7:11:08 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
135
2/28/2008 1:40:41 PM
Noticed that, weld joint # 2 of line A232-B66-R-2575 Spl A (TP: N2330-0-018) is cut and rewelding/rework is been performed after Hydrotest acceptance of line, rework with out information and approval to Aramco PID is violation of Schedule Q attachment VI Para 4A and SATIP-W-011-01/SAIC-W-2036.Contractor shall note this repeated violation and to perform required examination /testing and preventive action is also requested. Isometric A331-B66-P-1303 sh4/4 weld number 52 shop welded 36 inch diameter joint is cut and re-welded in field without PID inspection and not radiograph examined. It is the violation of Schedule Q attachment VI Para4A not utilizing SAIC-W-2036 and SAES-W-011 Para 18.4. Contractor corrective and preventive action on this repeated violation is requested. In train3 it is noticed that, weld joint 15A of ISO A331-B66-N-2339 (TP # N33-20-0-022) & weld joint 11 of ISO A331-B66-N-2339 (TP # N3380-0-001C) are cut & re-welded after acceptance of pneumatic test. Rework with out information and approval to Aramco PID is violation of Schedule Q attachment VI Para 4A and SATIP-W-011-01/SAIC-W2036.Contractor shall note this repeated violation and to perform required examination /testing and preventive action is also requested. During surveillance of SS-Fabrication / Welding shop, found that welders are storing GTAW wire (SS L 316) on the ground or inside pipes. Violation: SAES-W-011 Attachment 2, states that filler wires shall be stored in sealed Containers in a dry environment During surveillance of SS-Fabrication/Welding shop # 3, found Welder Symbol # 414 was welding without having JCC and . This is repeated violation of SESS-W-011 & Contractors approved Procedure QCP-847100-Rev 1. 10-CCC-A231-B66-P-1338ASpool H-Equip without QCs fit up and without displaying Welder Symbol During routine surveillance of CCC SS-Fabrication/ Welding shop, found that welders are storing GTAW wires (SS L 316) on the ground or inside pipes. This is repeated violation ref. to LBE-44344 of SAES-W011 Attachment 2. It is noticed in train 2 Demethanizer approximate EL +148000, large quantity of welding electrodes are stored in the scaffold pipes on site exposing to atmosphere and quivers are empty unplugged (numbers on quivers are W309 & 371). It is the violation of SAES-W-011 Para 6.2 6.1 and contractors QCP-847-101. Contractor corrective & preventive action is requested. During surveillance on site at utility area, it was observed that contractor kept plenty of Electrodes E-7018-1 were laying in the holding oven with out switching ON for the last whole night. As per SAES-W-011, 6.1, Electrode exposed to the atmosphere (more than eight hours) may be redried only once. CCC consumable control does not have any record or traceably (color coding) of reconditioning, it means these electrodes may be dried earlier. As Consumable Control Procedure, QCP-847-101 not followed, this is a repeated violation against the requirement. During surveillance inspection at site today i.e. Friday 20th April 20, 2007, it is observed that 13 welders in Train-1 and 6 welders in Utility were working after noon shift and no welding Inspector was available for welding inspection coverage. This is violation against sch Q Table VI-2. During routine surveillance of CCC-SS-Fabrication/ Welding Shop, it was found that Welders # 372, # 406, were welding following spools with Weld Weave Width of 10~12 mm. This is repeated violation ref. to LBE-44591 of WPS- 847-SS-003 Rev2, which allows maximum weave width of 2.5 X Electrode Diameter (3 mm). 1. CCC-42-A232B66-P-1242 -Spool A-3SD0P2-SBW-No weld number.
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
136
5/14/2008 9:49:08 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
137
5/19/2008 7:21:22 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
138
7/2/2007 6:01:50 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
139
7/26/2007 2:24:04 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
140 141 142

7/12/2007 5:55:44 PM
SAIC-W-2005 SAIC-W-2006 SAIC-W-2032
ScheduleQ SAES SAES
Schedule Q SAES-W-011 SAES-W-011
5.1 16.1 6.1
SATIP-W-011-01
143
4/1/2008 4:55:55 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
144
1/21/2007 1:38:46 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
145
4/20/2007 3:22:52 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
146
7/12/2007 5:23:50 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
147
7/12/2007 5:32:57 PM
During routine surveillance of CCC SS-Fabrication/ Welding shop, it was found that welding of small bore SS pipes was in progress without information i.e. no weld number, no welder symbol . This is violation of SAES-W-011 Para 16.1, which states all weld joints shall be marked for identification by a weld number & a welder symbol. 1. CCC-4-A231B66-P-1016-Spool N-6SD0P2 During routine surveillance of CCC-CS-Fabrication/ Welding Shop, it was found that adjacent base metal at least 25 mm from weld surface are not being cleaned from rust, scale etc prior to welding. This is violation of SAES-W-011 Para 11.3.1 Today, joint# 1 of A332-B66-P-1280 was welded in the fabshop with out procedure by welder# 380 which is a violation of SAIC-W-2006, item#A2 (SAES-W-011, Para:7.1.8). On 01/01/07 Large bore fabrication (outside). Preheating checked of following, which were not as per the requirement. (Violation against SAES-W-011 Para 12.2 C) i) Drg. No. A322-B66-P-1079 Spl B Joint No.-7 Preheating Temperature measured 65 degree instead of 130 degree Celsius requirement. ii) Drg. No. A331-B66-P-1025 Spl L Joint no.54 Preheating Temperature measured 65 degree instead of 130 degree Celsius requirement iii) Drg. No. B114-B69-CW-1531 Spl-C Joint No-13 Preheating Temperature measured 10 degree instead of 52 degree Celsius requirement On 02/01/07 i) Drg. No. A322-B66-P1177 Spl E Joint No.-23 Preheating Temperature measured 80 degree instead of 204 degree Celsius requirement Fab.shop inside. Drg.No.A11R-B66-RL-3008 Spl-D Joint No.22. Weaving measured 12MM instead of 6MM max. as per WPS No. 847LTCS-001. Drg. No. A 11R-B66-R-2579A Joint No.6, 7, 8, 9, 10, 11(all joints of spools) welded by filler wire (Batch no.EA 1264 tested with -30 degree Celsius ) against the requirement of LTCS filler wire (Batch no.EA 1261 with -45 degree Celsius ).This is violation against the requirement of SAES -W-011 par 6.4. Preheating was measured 40degree celsius instead of 163degree celsius for the spool#C, Joint#FBW.1 for the Drawing #A122-B66-P1024. This is clear violation of SAES-W-011, Table 3A. During surveillance Inspection at site train-1, it is observed that Numerical trunion (dummy) supports welded without QC inspection. There is no any fit up inspection carried out for the joints and also visually not checked by QC Inspector. Construction has not generated the Daily welding reports for the same joints. This is a Violation as per SAIC-W-2005 & SAIC-W-2007 Ref. to Fire water test pack no. TR1-FW-057 & TR1-FW-056, there is no traceability of joint welded. It is Violation of SAES-W-011. As per SAES-W-011 Para 16.1all weld joints shall be marked for identification by a weld number and welder symbol. Most of the Electrical supports are being welded in the utility piperack. After welding these supports, welders are not cleaning slags, spatters, and arc strikes. Contractor is painting these welded area with out proper cleaning. Incompleted welding also found where the contractor had already painted. This is the violation of our SAIC-W-2007, item #A1 and A2. During punch listing for the test package # N12-20-0-001 found that there is no welding was done for the joint # FFW-008 in line # A121B66-RL-3062. Contractor QC attached signed daily weld report and PT report (PT Report # FPT-4442) with this test package. This is violation of schedule-Q, attachment IV, Para 7.3 and SAIC-W-2007, item# A12 & A13. So it is advice to contractor that ensures all joints are completed and review/witness NDT test results by contractor QC inspector prior to submit Saudi Aramco.
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
16.1
148
7/12/2007 5:45:55 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.3.1
149
9/17/2007 5:03:03 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
7.1.8
150
1/2/2007 10:32:06 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12
151
1/2/2007 10:44:41 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.3
152
1/13/2007 4:27:49 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.4
153
1/14/2007 4:38:03 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.1
154
3/5/2007 4:25:13 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
5.1
155
3/14/2007 7:02:12 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
16.1
156
3/28/2007 5:30:39 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.4.2
157
11/15/2007 2:07:22 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
7.3
158
4/22/2007 10:53:19 AM
During routine inspection in Utility Area, found Welder Symbol# 165 was welding fabricated pipe spool with Cold LH Electrodes and Quiver was unplugged. This is again repeated violation of SAES-W-011 Table 1 Refer to LBEs 32561, 28126, 28092 & 34724. CCC-A132-B66-P-14176CS9A-3"-Spool C- Joint -14 During surveillance on site at Train-1 it was observed that contractor kept plenty of Electrodes E-7018-1 electrodes (4.0 & 3.2 mm dia Zulfi make) in the holding oven with out Baking. These electrodes are not hermetically sealed metal can. As per SAES-W-011, 6.1, prior to use all electrodes shall be dried at 260-430C for 2 hours minimum. This is a violation against the requirement. On Friday April 6, at 24.00 hrs,found welding of following fabricated spools was in progress without QC-Fit-up inspection. This is the clear violation of Contractors approved procedure QCP-847-100 Rev 1, Para 6.24.1. 1.8"-CCC-A232-B66-R 2495A, Spool F- 3CA9P -FW 34, 35 & 36 2.6"-CCC-A213-B66-RL-2948, Spool B- 1CA9P 3.4"-CCC-A241-B66-FW2008, Spool H- 12LCOU Line # A141-B66-R-2458, 3CA9P, Spool-A, Pipe support # 2, welder ID # 011, Contractor welding dummy pipe support without any root gap at bottom section and more than 10mm root gap at upper section. This is violation of SAIC-W-2005, Item- A4 and WPS # 847-CS-003. As per WPS, minimum root gap shall be 3.2mm 0.8mm. All support welding fit-up to be witness by contractor QC. During routine surveillance of CCC-SS-Fabrication / Welding Shop, found following Fit up joints with excess root gaps of 5~7 mm. This is violation of WPS-847 SS-003-Rev 2, which allows maximum root gap of 2~4 mm. 1. CCC-42-A322-B66-P-1467-Spool D- SBW-34 2. CCC-10A-21R-B66-RLC-3277-Spool Z-SBW-27 During routine surveillance of CCC SS-Fabrication/ Welding shop, it was found that welding of small bore SS pipes was in progress without QC fit up approval. This is repeated violation refer to LBE-1786 of SAICW-2005, Item A4 and Contractors own approved procedure. 1. CCC-2A221-B66-BD-1754-Spool D-3SD0P2-Welder Symbol #48 During routine surveillance of CCC-SS-Fabrication/ Welding Shop & Train 1, it was found that Welders # 371, #139,#274, were welding following spools with Weld Weave Width of 18~20 mm. This is violation of WPS- 847-SS-003 Rev2, which allows Maximum weave width of 2.5 X Electrode Diameter. 1. CCC-A231-B66-P-1222 -Spool P6SD0P2-SBW-69 2. CC-A132-B66-P-1222A-30-Spool C-6SD0P2-FBW-8 During routine surveillance of CCC-SS-Fabrication / Welding Shop, found following Fit up joints with excess root gaps of 5-6 mm. This is repeated violation ref to LBE-1805 of WPS-847 SS-003-Rev 2, which allows maximum root gap of 2~4 mm. CCC-6-A232-B66-P-1002-Spool A- SBW-Flange to pipe Weld. This fit up was accepted by night shift QCMr.Biju. Contractor is advised to take corrective action to avoid repeated violation. During surveillance at Train 2, it was observed at Equipment B66-E0217A that a spool for B66-P-1801 was fitted-up, restrained by steel angle bar, tacked to Carbon steel Pipe and there is no ID box to determine the welder who do the tacking. This is in violation of SAESW-011 para 11.5.1, "All tack welds shall be made by qualified welders." and para 11.5.2,"All tacks or temporary welds shall be performed with the same care, materials, electrodes, minimum preheat, and procedures that are used for permanent welds." Steel angle bar is mild steel, not same material as to pipe, and is not allowed to be tacked to carbon steel.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
159
1/24/2007 10:58:20 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
160
4/8/2007 7:06:19 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
161
7/5/2007 2:34:29 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
162
7/5/2007 3:17:16 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
163
7/5/2007 3:52:04 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
164
7/5/2007 3:57:52 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
165
7/8/2007 7:16:50 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
166
7/8/2007 5:11:22 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 11.5.1 and 11.5.2
167
7/11/2007 5:31:23 PM
During routine site visit in Train-1, found that Line # A113-B66-P1256, 16inch diameter, schedule-20, Joint # 08, was tack welded by non-qualified welder (welder ID # W-080) on stainless steel pipe. This welder has been qualified only on carbon steel WPS # 847-CS-001. Electrode was used ER70S-6 on SS piping. This is violation accordance with company standard SAES-W-011, Para: 11.5.1 & 11.5.2 and SAICW-2005, Item # A18 & A19. Contractor QC should check their Job Clearance Card (JCC) prior to start tack welding. For the line # A11R-B66-RL-3042, Spool:C, 1CA9P, 8-Sch-40, Joint # 015, requested for Radiography but there is no welder identification and final visual inspection was carried out by contractor QC. For the line # A142-B66-R-2468, Spool-A, 4diameter, there is no fit-up signature, joint number, welder ID and final visual inspection by contractor QC for four joints. These all are violation of our Sch-Q and SAES-W-011, Para: 16.1 & 17.5.1.1. In Train-2, Welding has been completed without fit-up joint inspection sign from contractor QC and missing welder identification of A231-B66P-1227A, Spool-A, FBW # 001 and A231-B66-P-1510,FBW#001. This is violation of SATIP-W-011-01, SAIC-W-2005 and SAES-W-011 Para: 16.1. This is repeated violation (Surveillance # 55822) of fabrication shop WELDING. Shop Welding was carried out for Train-3 spools of line # A321-B66-RL-3061,SPL-A and A341-B66-RL-3056, SPL-B without contractor QC-Inspector, fit-up joint inspection sign. This is violation of SATIP-W-011-01 and SAIC-W-2005. During surveillance noticed contractor CCC welding 54" AIIR-B66-P1303 SBW-5, required preheat for this joint was 177 C and measured preheat was 29 C, which is violation to SAES-W-011, sect-12. This is repeat violation. Contractor, s QC not measuring / checking pre-heat for weld joints. During rotine shop visit observed following violations: i) Spool B66-D102B SBW# B with root concavity(visually reject) accepted by QC inspector (Kamlesh) ii) A31R-B66-P-1196A SPL-C SBW-16 and SBW-17 with lack of fusion(between two weld passes)in capping, so viually reject. These both welds were accpted / signed off by QC inspector (Bijoy). iii)A31R-B66-P-1196A SPL-C SBW-16 & SBW-17 are marked as (on spool)welded by welder # 35, as per daily weld Report these both welds were welded by Welder # 205, so no proper traceability. iv) One 4" diameter spool with Lack of fusion between weld metal and parent metal (bevel edge) in capping. So visually reject. This weld was accepted / signed off by QC inspector (Kamlesh). These are the violations to SAES-W-011 para-16 and 17. During site visit found out fabrication crew is not maintaining required minimum preheat at CCC big bore fabrication shop. It was found that welders were welding A-232-B66-P-1177 SBW-14, 42 mm thickness (Reducer to Tee), measured preheat was 72 C and required minimum preheat was 163 C. During site surveillance noticed CCC welder preparing to weld 2" A222B66-P-4194-6CS9P SPl-A SBW-5 at CCC fabrication shop pipe spool lay dow area (by bunkers)and required NDT (MPI) was not done, as this weld was the cut and re-weld due to repair. so MPI was required as per SAES-W-011. During surveillance it was observed that welder welding 2" butt joint (SBW-89) on 36" RL-3017 Spool-N and fit-up insection of this joint is not done by CCC QC inspector. This branch was not aligned, so completed welding with bend (dog-leg) in this lateral branch. this is violation to SAES-W-011 para-9 and 11. Inspected Completed welds of spools A-321-B66-A-175-1CS9P SPL-B, A221-B66-BD-1759-1CA9P SPL-D and found weaving 10 to 13 mm. As per WPS CS-001 and LTCS-001 maximum 6.25 mm weaving is allowed. so this is clear violation to approvec WPS.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 11.5.1 and 11.5.2
168
7/23/2007 5:53:16 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1 and 17.5.1.1
169
3/12/2008 4:47:04 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 16.1
Schedule Q
5.1
170
3/28/2008 2:35:19 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
171
1/18/2007 1:41:15 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 12.1 and 12.2
172
2/24/2007 11:28:34 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
16 and 17
173
3/1/2007 10:54:11 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 12.1 and 12.2
174
3/5/2007 4:36:17 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
11.3.3
175
3/11/2007 5:01:59 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
9.3
176
3/17/2007 1:42:11 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
177
3/20/2007 5:12:00 PM
During site visit it was observed that low hydrogen electrodes (E7018)were issued to Welder S-139 and Welder W-167 at lunch time and not recorded in the issue log. This is violation to consumable control procedure. During site noticed welder W-105 welding (for repair) A121-B66-P1024 spl-G SBW-18 with out pre-heat. also there was no QC coverage for this area. During surveillance it was observed that portable oven of welder W240 (with E-7018 elecrodes)was not connected and all electrodes were cold. This is violation to SAES-W-011 para 6.2.Notified contractor to strictly follow the storage requirements of low hydrogen elecrodes. At CCC SS fabrication shop it was observed that plasma cutting is contaminating pipes internals with cutting slag / dross, contractor is cleaning / grinding the internals of affected spools, in addition to this contractor is cleaning affected spools using fluoric / nitric acid paste. Again rust is coming back after few days. This shows initial buffing and cleaning is not adequate. Noticed 24 A113-B66-P-1009 SPL-B and 30 A132-B66-P-1004 SPL-A-EQP showing rust after buffing and acid cleaning. Contractor shall develop a procedure to clean these spools permanently. During review of welders weekly repair rate report found out that 10% RT is not covered for total 52 welders. Out of these W-024, W-092, W094, W-099, W-145, W-152, W-154, W-157, W-163, W-176, W-179, W199, W-241, W-268, W-272 and W-273 with high repair rates, contractor must cover minimum 10% RT for these welders on priority bases. This is the requirement of B31.3 Para: 341.4. Contractor CCC / JGC conducting welder qualification on 5/17/07 at welder qualification / training area and RFI was not issued to SAPID for this activity which is the violation to approved QCP / ITP. During surveillance in the Train 3, it was noted that Joint#06 (pipe to pipe)of A31R-B66-R-2470 near column 45, welded by W#32 is not straight (dog leg) which was accepted by the concerned contractor QC which is a violation of QCP-847-100 Rev.1, Para 6.24.2. Contractor is recommended to cut the joint and re do welding. Joint #26 of A213-B66-RLC-3283 was visually accepted and signed by the contractor QC which actually required one or more passes. The acceptance of incomplete weld is a violation of QCP-847-100, Para: 6.24.1. During reviewing the test pack # N13-10-0-009, it was noted that contractor didnt perform RT for the joint#11 after doing PWHT on 2804-2007. For the said joint, RT was last accepted on 06-04-2007. This is a clear violation of ASME 31.3, NOTES FOR APPENDIX A TABLES, General Note#11 which states--For use under this Code, radiography shall be performed after heat treatment. Found one welder named Mohammad Siddique (CCC Employee) without Saudi Aramco JCC CARD doing Instrumentation conduit supports welding attached to the column of platform for B66-E-304 Area 31R. VIOLATION against SAIC-W-2006 item A3/SAEP-324 Sestion 5. In fabrication shop, Welding is being progressed without RFI, QCInspector, fit-up joint inspection, weld number identification of each joint for Train-3 spools. Line numbers are A322-B66-N-2402-SPOOLA2, A321-B66-ME-2134-SPOOL-E, A321-B66-P-1084J-SPOOL-B, A321B66-RL-3061-SPOOL-A1 and A321-B66-A-3695-SPOOL-A4. This is violation of SATIP-W-011-01 and SAIC-W-2005.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
178 179
3/26/2007 6:01:47 PM
SAES ScheduleQ
SAES-W-011 12.1 and 12.2 Schedule Q 5.1
180
4/3/2007 1:26:27 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
181
4/18/2007 2:15:54 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.1
182
5/13/2007 8:35:59 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
other
ASME-B-31.3
341.4
Schedule Q
1.3
183
5/17/2007 11:14:56 AM
SATIP-W-011-01
SAIC-W-2035
Mechanical
ScheduleQ
Schedule Q
1.7
184
9/2/2007 12:49:45 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011 9.3
185
9/6/2007 4:43:47 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1
186
9/12/2007 4:29:21 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.3
187
10/28/2007 6:31:00 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
188
3/12/2008 1:53:02 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
189
3/13/2008 2:23:27 PM
190
7/3/2008 11:25:04 AM
It is noticed that, in train II around Pipe rack A2PR13/14 welder W 362 was welding on structural steel member by SMAW process but the welder is qualified only for GTAW process. Welder shall perform the welding job as per welder qualification. This type of site welding activity is violating Aramco specs 12-SAMSS-008 referring to AWS D1.1 Sec 6 part A. Contractor corrective and preventive action is requested. It has been noted that contractor is performing Stainless Steel Welding activities on small bore pipes without performing PMI of the welded joints. One hundred percent PMI testing (each component and weld is tested) shall be performed on all pressure components and welds of alloy materials (as per SAES-A-206, Para 6.2). However, In cases where PMI testing of the completed weld is not possible because of geometry (e.g., small fillet welds and narrow root beads), PMI testing of filler metal lots and visual inspection of electrodes as described in 6.7.1 and 6.7.2 is an acceptable substitute for testing of the completed weld (as per SAES-A-206, Para 6.7.3). Contractor shall comply with Para 6.7.2 of SAES-A-206 and provide PMI test report of an electrode or wire sample conducted immediately prior to welding or during the welding process. Contractor welding 54" A213-B66-P-1303 SBW-20, required preheat for this joint was 150C and measured preheat temperature was 54C, violation to SAES-W-011 sect-12. During surveillance in Train-1, found cut and re-welding for line # A131-B66-P-1510, Joint # 1 and A131-B66-P-1227A, Joint # 1 after hydro test acceptance. The above said joints were cutout without raising any RFI to PID Aramco. It is hold point H1 for Aramco inspection. This is a repeated violation of SATIP-W-011-01, Item # 3.17. SAIC-W-2036. Work is being performed without approved procedure/method statement by item#A3 of SAIC-W-2036. Contractor has to perform re-hydro test for these two lines. In Train-1, Inlet and out let flanges of Demethanizer pumps B66-GM110A/B, 111A/B, 112A/B & 113A/B were modified by contractor after hydro test (Refer to log book # 54084 and subsequent email on the subject). Contractor is advised to submit all related hydro test packages and arrange for re-hydro test. HT package # N33-10-0-089: during review & to release for Hydrotest notice that, radiography test is not performed for repaired weld joint # 006RW of line number A322-B-66-N-2287 Rev 0B, which is the violation of SAES-W-011 Para 18.4 All repaired welds shall, as a minimum, be inspected using the original testing method. Contractor corrective action is requested. During surveillance, it was observed that welding is on-going for B211B67-RLC-1898R-1SDOP2. When checked, the piping internals were dirty full of sand. The matter was brought to attention of JGC Construction but replied "No problem". This is in violation of SAES-L350 Construction of Plant Piping Section 15-Cleaning, which says "para 15.2 Prior to Installation: As a minimum and prior to installation and/or erection of pipe spools on the pipe racks and pipe supports the following shall be conducted: 15.2.1 All pipes shall be internally cleaned by air blowing. In addition, for large diameters pipes rag cleaning should be conducted if found practical. 15.2.2 All prefabricated pipe spools shall be visually inspected for cleanliness, and shall have foreign material removed from the inside. 15.2.3 The piping ends shall be covered after inspection to prevent unauthorized removal of the end cover prior to making the joint to the succeeding section of piping."
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
SATIP-W-011-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
191
12/7/2006 4:12:16 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 12.1 and 12.2
192
1/1/2008 12:35:04 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
5.1
193
1/21/2008 4:49:52 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
5.1
194
2/15/2008 2:11:29 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
195
5/28/2007 2:18:20 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15.2
196
9/18/2007 1:17:21 PM
B67
During Surveillance at Surge Area, the following lines were observed cold shoes not properly installed per INDRA Installation/ Operation/ Maintenance Manual of Cold Shoes Reference Document No. EM-PUF01 clauses 5, 6 and 7 and Vendors Drawing # P555200/JGC Dwg B74M-BB-546121-081: a)24"-P-1001R/1003R b) 12"- P-1012R/1035R c)12"- P-1008R/1121R . Schedule Q Section 3. DOCUMENTATION REQUIREMENTS states that "CONTRACTOR shall plan, organize, control and execute all WORK in accordance with CONTRACTORs Quality Plans, Inspection and Test Plans (ITP) and documented procedures." Contractor should correct the findings. During surveillance inspection visit on Friday 2nd March 3, 2007, two quivers (one S-036 and another with out no.) were left unplugged with so many electrodes (E-7018-1) in utility area. Electrodes found exposed to atmosphere more than four hours. This is violation against SAIC-W-2032 Para. B7. Flange facing including the raise face area is coated (also suspicious about blasting) for two nozzles F 2 inches of the CPI tanks B67- S0111A/B in surge area. This is the violation of SAIC-L-2014 item A3 the gasket seating areas of the flanges are not coated and SAEP-351 Para 4.3 the flange facing, particularly the seating area, shall be visually examined for cleanliness and ensure that no damage, such as scratches exist. contractors corrective and preventive action is requested. While attending the RFI for NGL Pipeline pump and its lube oil skid B67G-0102 A/B/C. Noticed that the control document (Vendor drawing) doesnt indicates the orientation (plant Northing) for installation of pump and lube oil skid, which is the violation of API standard 610 Para 9.3.2.1 and also a photocopy of drawing (uncontrolled as-build) indicating the northing on drawing by JGC field engineer was found which is the violation of SAEP-1154 Para 5.4.2.3 d Review and reapprove document changes. As per surveillance at Surge Area this morning, 2 spools B67-P-1026 and B67-P-1032 were found installed in the pipe rack without internal cleaning, sand and debris are still prevalent, and pipe ends were not covered . This inside cleaning before installation was requested to Construction group three days ago, but not followed. This violation is already a repetition to surveillance # 41337, per SAES-L-350 para 15.2, 15.2.1, 15.2.2 and 15.2.3. During routine site visit, it was noticed that a sockolet installed at line 14" SS pipe (13211-B67-P-1123R)is very near the piperack horizontal beam support and cold shoe. Not far from this, a drain was installed at 2" SS line also near the piperack horizontal beam support. As per SAICL-2013 Item B3 and SAES-L-310 Para 12.5 "Branch connections 4 inch and smaller (drain and vent valves and drip legs of all sizes excluding dummy legs) are spaced a minimum horizontal distance of 24 inches from fixed supports/obstructions." Contractor JGC/CCC should make necessary correction for these. As per assessment, Constructor CCC is not using SATIP and SAICs for their Cement Lined Pipe installation. Joint installation was already done without issuing SAIC-L-2075 for initial witness of SAPID. Schedule QVI-4.A specifies Contractor shall utilize the Saudi Aramco Typical Inspection Plans (SATIP) for construction activities included herein, along with the referenced checklists in the TIPs. The SATIPs and Checklists will replace the ITPs required by sec. 1.1 of attachment IV.
SATIP-L-350-01
SAIC-L-2018
Mechanical
ScheduleQ
Schedule Q
197
3/3/2007 8:09:33 AM
O10-10-0
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
198
10/2/2007 1:30:22 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
199
4/25/2007 11:23:18 AM
SATIP-G-005-01
SAIC-G-2021
Mechanical
SAEP
SAEP-1154
5.4.2.3d
200
7/14/2007 2:16:17 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15.2
201
9/5/2007 10:49:04 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
202
4/15/2007 5:49:52 PM
SATIP-L-350-07
SAIC-L-2075
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.1
203
2/13/2007 1:04:21 PM
During surveillance at CCC fabrication shops 1 and 2 noticed CCC crews installing cement lined sleeve joint using joints sealing compounds with following violations: i) There is no procedure at shop and no one knows about any procedure including QC inspectors (piping/welding). ii) QC inspectors are not checking this activity, as per SATIP-L-350-7 item 3.1 this activity is W1 for contractor, checklist SAIC-L-2075 was not filled up for last one week. iii) As per SA standard DWG-AB036090, this sealing compound to be applied as per manufacture specification, CCC QC inspectors, QC engineer were unable to find it. iv) Buffing dust /Rust in the pipe and crews are applying sealing compound, so no proper cleaning. v) Pipe bevel ends not prepared as per standard drawing SA AB036090. As per CCC field change sheet 37 V-bevel is changed to plane end joint and it is approved by SAPMT. This is violation to Schedule Q, para 3.1. SAPID conducted surveillance on ACBI Quality System Implementation, based from PQI Guidelines Items 2.2 & 2.3. Observation: In Documentation Control Procedure during retrieval of obsolete or superseded documents and re-issuance of revised documents, there should be a record to document this system or procedure. A transmittal sheet should cover this system to ensure that the latest revision of documents is at hand in the field/fab shops. Since ISO 9000:2000 calls more prevention than correction, preventive action or measures should be included in ACBIs Non-Conformance Report Sheet. ACBI should prepare necessary plan-of-action in regards to Non Conformance Report. SAPID have found that items 2.2 & 2.3 were not properly met and that this entry calls for the concern to take action to prevent installation rework in future which arises from usage of obsolete/superseded drawings. Discrepancy is notice in utility B69 Area between civil support foundation drawing and mechanical drawing for 1st and 2nd Pass R.O Module Equipment B69-D-0108A/B/C and 0110A/B/C, Equipment is provided with four number of anchor bolt holes whereas six number of anchor bolts are installed on foundation as per civil Drawing, moreover the dimensions of anchor bolts on foundation and anchor bolt holes on equipment are not the same. It is notice for the 20% caustic storage tank B69-D-0134, the design data indicates PWHT as Yes for the vessel, but the vessel name plate indicate NO for STRESS RELIEF and there is no PWHT caution indicated on the vessel. Contractor is requested to verify and produce the PWHT record. If PWHT work on the vessel is justified than provide painted sign on the vessel as per 32-SAMSS-004 Para: 15.6 "CautionVessel Has Been Postweld Heat Treated-Do Not Weld". It was noted on the equipment B69-D-0118, contractor has enlarged the hole on one anchor chair using gas cutting troche moreover it is not equally finished to the shear appearance. Painting on top portion is done which mask this repair, SAPID did not received the procedure for such activities. This is the violation of: 1. SAIC-M-2008 item A5: Enlargement of holes shall be made by reaming or drilling only. Flame cutting, burning, gouging, chipping, or drift punching shall not be permitted. . . As per SAES-D-001, Para 3.2 Anchor bolt holes shall be within the 1/8" of the specified location. 2. SAIC-D-2002 item A38: Arc strikes, gouges, and other indications of careless workmanship were removed by grinding. 3 Schedule Q Para 7.3.5 CONTRACTOR shall rework or repair and reinspect items in accordance with SAUDI ARAMCO approved procedures 4
SATIP-L-350-07
SAIC-L-2075
Mechanical
ScheduleQ
Schedule Q
1.3
204
4/16/2006 4:56:28 PM
Mechanical
ScheduleQ
Schedule Q
205
2/6/2007 6:16:05 PM
SATIP-D-001-01
SAIC-D-2006
Mechanical
ScheduleQ
Schedule Q
1.3
206
9/4/2007 3:02:39 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
1.3
207
1/9/2007 10:07:43 AM
SATIP-D-001-01
SAIC-M-2008
Mechanical
other
12-SAMSS008
208
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
7.3.5
209
5/7/2007 2:13:13 PM
210
5/14/2007 1:52:07 PM
While attending the RFI # 39344 and 39345 , it is notice that Contractor Construction crew and QC personnel are utilizing uncontrolled documents(photo copy of plan/layout drawing) for the execution of work and inspection instead of proactive notifications (QMIS # 900,12859) and verbal advises, this is the violation of Schedule Q Para 3.7 and SAEP-1154 Para 5.4.2.3. Control documents shall be use for execution of work and inspection. Examples of documents collected from site are B69-L-BA-546462 sheet 041 Rev000 It was revealed during the internal inspection of the Compressed air receiver that the drums B69-D-0101A/B are not internally coated, which is the violation of SAES-J-901 Para 4.4.4 The air receiver shall be internally prepared and coated in accordance with SAES-H-100 and SAES-H-101, APCS-2A. Contractor is requested to comply with the SAESs. For the pumps B69-G-0113 B/C it was noticed that, suction side nozzles are uncovered, probably nozzle blind is removed by piping crew, this situation will allow debris/foreign material to enter the casing and create big trouble. These were noticed on Friday 1st June and it is unknown since how long this exists as no work was performed at these pumps on friday. This is the violation of SAES-L-350 Para 8.1all materials shall be handled with care during fabrication and installation to prevent damage. The verification of pump casing internal for cleanliness shall involve SAPID. Contractor CCC paint touch up workers are doing paint touch up of damaged coating areas of utility Fire water piping system in Utility Tank Area without using proper cleaning tools. This is violation of SAESH-100 Para 8.3.2, & Paint Manufacturer Hampels Data Sheet APCS-26. All the touch-ups done are rejected During surveillance it was noted that the end of the 2" underground instrument air pipe near Central Control Building is not protected in order to prevent sand and other debris which is a violation of SAIC-L2017 item# B3.b. During surveillance on site at cement-lined firewater distribution piping in utility area, I have noticed that the CCC contractor was handling/lifting the exterior coated piping spool with steel chains. This is violation as per SAES-H-200, Para 5.1.1 & 5.1.2, and SAES-L-350, Para 8.1 & 8.2. Contractor is counsel to follow all applicable Saudi Aramco standards & specifications and Schedule-Q, Attachment-IV, Para-5 during construction. On line number: B112-B69-HWS-2123 Spool B two large diameter flanges are sticks without any gasket in-between and which means there may have been strike during installation, which is the violation of SAES-L-350 Para 8.1all materials shall be handled with care during fabrication and installation to prevent damage. The verification of gasket seating area of these flanges for any damage shall involve SAPID. The gasket installed between the SS and CS flanges of B69-D-134 (Caustic Vessel in Utility Area) is not PIKOTEK gasket which is a violation of SAIC-L-2014, item# E4. During routine site visit, it was noticed that many drain vales installed in utility area near G-0141 (B69-80-FV-012A) are very close to fixed supports. As per SAIC-L-2013 Item B3 and SAES-L-310 Para 12.5 "Branch connections 4 inch and smaller (drain and vent valves and drip legs of all sizes excluding dummy legs) are spaced a minimum horizontal distance of 24 inches from fixed supports/obstructions." Contractor should take necessary correction action to resolve this issue. In utility area B1PR09/B1ST03 near B69-E-103A/B a beam installed at elevation approximate 110.500mt was found damage/bend most probably due to additional force on it by piping, it is the violation of SAIC-M-2005 all materials shall be stored and handle in a manner that will prevent distortion, deterioration or damage. This issue was notified to Contractor through E-mail dated 19th Mar07 but didnt received any response.
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAEP-351
5.4.2.3
Schedule Q
3.7
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-J-901
4.4.4
211
6/2/2007 2:31:16 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
212
6/30/2007 7:40:04 AM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.3.2
213
4/18/2007 6:28:12 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.2.3
214
4/9/2007 12:55:31 PM
SATIP-L-350-07
SAIC-L-2074
Mechanical
SAES
SAES-H-200
5.1
SAES-L-350
215
6/2/2007 2:24:22 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
216
9/1/2007 12:26:48 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
11.4.2
217
9/7/2007 9:58:16 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
218
3/27/2007 4:38:56 PM
SATIP-M-001-01
SAIC-M-2005
Mechanical
SAES
12-SAMSS007
6.3.2.2
219
4/19/2007 1:40:40 PM
Today I have received two test packages (U21-50-0-004 & U21-50-0014) for reinstatement to do final inspection. I have revealed both test packages are having same P&ID drawing number BA-543290 and sheet number 017 but different revision numbers 0F3 and 0F4. This is violation according to schedule Q Para 3.7. Contractor is recommend to provide current revision of all P&ID and Isometric drawings to ARAMCO-PID for clarification in future test packages. Contractor has installed rejected 20"x150 GateValve (Tag# 6GV0C03AP3FJ531)on 12CG0U line n Utility. Drawing # is B114-B69-CWR-1622. This misunderstanding occured due to the lack of specific quarantine area for the rejected items which is a violation of Schedule Q, para 7.3.7. Due to wrong material installation of Y- Type Strainer (1x3/4), drwg#B121-B69-SA-2565, the welded fillet joint has been found cracked. This is clear violation of Sch-Q, Attachment IV and Para: 7 which states, CONTRACTOR shall visually inspect all incoming equipment for damage and for conformance to all applicable requirements, including the supplier inspection release with verified Material Test Reports (MTR). If the equipment does not have the required inspection release and MTR, CONTRACTOR shall verify and document the compliance of the equipment with applicable standards and specifications prior to release to be used as part of the WORK. On Friday Dec 29, 06, it was very cold at 7.15 A.M and atmospheric temperature was 5~6 C and welders W # 088 & W # 026 were continuously welding spool No.30" B112-B69-HWS-2124-3CS9P Spool l, FBW # 35 without preheating. No preheating equipment & temperature indicating contact Pyrometer were available at work area. It was also confirmed from both the welders that no preheating was done. This is the violation of SAES-W-011 Para 12.2 & 12.4 During Hydrotest witness of Test pack# U51-20-0-001 it was noticed that all the high point vents [J#17 & J#54 of B122-B69-ME2273],[J#005 of B122-B69-ME-2292] have been seal welded before hydrotest which is a clear violation of ISO drg and SAES-A-004, Para: 9.3 which states that vents and drains used only for the pressure test shall be plugged, seal welded and penetrant tested after completion of Pressure Test. Contractor is recommended to avoid such practice in future to avoid repeated violation. During punch listing for Test package # U16-10-0-029, Line # B112B69-N-2405, Weld # 04, diameter 3cut out without raising any RFI to PID Aramco. This weld joint already accepted by radiography earlier (RT report # 2627) This is violation according to SATIP-W-011-01, Item # 3.17, SAIC-W-2036. Contractor welded stainless steel (alloy 20) with bronze (ASTM B62) in B69 area without approved WPS for this type of dissimilar materials. This is violation of SAES-W-011 Para 7.1.8 (SAIC-W-2005, Item # A3). One inch alloy-20 line was welded with Y type strainer (Body material is bronze). Weld cracked after welding. Contractor should get WPS approved by Aramco before welding stainless steel (alloy 20) with Bronze (B62) While attending the RFI for some equipment alignment and elevation check like B69-D-0149 it was noted that, there is a discrepancy between civil and mech (piping) drawing for about 150mm elevation difference, also Contractor fails to note and resolve the discrepancy prior to installation. More ever there was a proactive notification # 20382 on such issue were contractor reply they will record such discrepancies and resolve prior to installation of equipment. Contractors corrective and preventive action is request as this is a repeated violation. (Ref: QMIS # 29427, 33952, 33956, 33958)
SATIP-L-350-01
SAIC-L-2022
Mechanical
ScheduleQ
Schedule Q
3.7
220
3/7/2007 7:30:51 AM
SATIP-L-350-01
SAIC-L-2031
Mechanical
ScheduleQ
Schedule Q
7.3.7
221
6/19/2007 4:23:07 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 7
222
1/2/2007 1:29:49 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.2 & 12.4
223
9/15/2007 5:32:02 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
9.3
224
6/18/2007 2:07:25 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
225
6/21/2007 4:02:01 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.5 & 7.1.8
226
3/25/2007 4:25:03 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
ScheduleQ
Schedule Q
1.3
227
2/28/2007 8:27:41 AM
While attending the RFI #32065 and site surveillance, it is notice that Contractor Construction crew and QC personnel are utilizing uncontrolled documents(drawings) and photo copy of controlled drawing for the execution of work /inspection instead of proactive notifications (QMIS # 900,12859) with verbal advises, this is the violation of Schedule Q Para 3.7 and SAEP-1154 Para 5.4.2.3. Contractor document control Department shall issue only control copies of the document and control documents shall be use for execution of work /inspection. Examples of documents collected from site are B66-D-JGC-CCC-0297-003,006 and V-2158-251-A-202. All the damage/dent on the flanges race face or gasket seating area are considered as non conformance to SAPID for which Contractor has generated discrepancy reports such as DR-M-071, 079,086,111,181 etc contractors engineering analysis, its repair work and closing of such DRs shall involve SAPID acceptance. On 16th March 08 it was noticed that, calibration date were expired for two temperature gauges FS-TG-002 & 003 mounted on electrode ovens in CCC fabrication shop, the previous calibrated date read on these instrument was 14th May 2007. This is the violation of Para 6.1 of attachment IV to schedule Q that states calibration cycle shall not exceed six months, contractor corrective action is requested. It is notice on horizontal vessels like B66-D-0114A/B that, the vessel base plate at the sliding saddle is entirely covered with fireproofing including sliding plate this is the violation of SAES-B-006 Para 5.3.3c 30mm clearance shall be provided between a sliding surface and fireproofing on sliding support. Contractor is requested perform a site assessment on equipment fireproofing work and take corrective action on all such equipments that have violated the standard requirement. It is notice that, motor internal space heater of many pumps and compressors in Train 1, 2 & 3 and surge area are NOT energized, even though Contractor is advice and reminded constantly (proactive notification # 27441 & 33341), this is violating the requirement of API 686 Chapter 3 Para 1.20.2.7 when a spacer heater is provided by manufacturer, it shall be connected, energized and operated continuously until the motor becomes operational and Project Specification B74-A-PP-007964 Para 7.1.1 the heaters shall be energized after receipt at work site. Unexercised to energize space heater has the potential to reduce efficiency of the motor. The discharge nozzle flanges of few pumps such as B67-G-0105A/B/C are not blind and welding/grinding activities were ongoing around these pumps. This is the violation of API 686 Para 4.1.8 and 4.1.6 and SAES-L-350 Para 8.1 which all states for extreme care. It is the repeated violation observed (Previous QMIS # 41693), Contractors corrective and preventive action is requested including increase QC vigilance. During abrasive blsting activites, it was found that contractor is using wet Garnet Material for abrasive blasting. Found four (4) bags with wet abrasive garnet material. This is the violation of SAES-H-100 Para 5.2.1, which states that abrasive shall be kept dry and clean Contractor started Abrasive & Painting activities without completing forms related to Quality Control Records Attachments B, C, D & Daily Job Log prior to job start-up.These forms shall have been completed on daily basis and signed by coating supervisor and then signed by SA Inspector. This is clear violation of SAES-H-100 Para 9.2 Contractor CBI has painted Tank exteriors including drip rings with approved APCS-4 coating system. As pr 32-SAMMS-005 Para 3.3.5.5, the top of the drip ring & 75 mm (3 inch) height of the tank exterior shall be painted with a 250~300 microns (10~12 mils) thick expoxy coating in accordance with SAES-H-001.
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAEP
SAEP-351
5.4.2.3
Schedule Q
3.7
228
5/29/2007 11:00:22 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
229
3/17/2008 5:34:13 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
A IV Para 6.1
230
9/4/2007 7:14:24 AM
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
SAES-B-006
5.3.3C
231
4/10/2007 11:37:27 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
other
API 686
Chapter 3 para 1.20.2.7
Schedule Q
1.3
232
10/2/2007 1:35:27 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
API 686
4.1.8 & 4.1.6
233
4/19/2007 5:18:41 PM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
5.2.1
234
2/4/2007 10:24:54 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
9.2
235
3/17/2007 7:33:04 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
other
32-SAMSS005
3.3..5.5
236
5/23/2007 1:55:38 PM
During routine surveillance of coated materials in CCC/JGC storage yard,following discrepancies were noted: 1.2-CCC-A121-B66-P-1129Spool B, DWG-546202- Sheet # 35. As per approved DWG the coating system required is APCS 11A whereas painting Contractor Kabbani has applied APCS-26. 2.Kabbani/CCC is releasing coated materials from painting yard to storage yard without touch up the missing/damaged areas. 3.Contractor is using the same coating system for fabricated spool as well as welded pipe support. As per DWG coating system for spool under insulation is APCS 2A whereas for pipe support it is APCS 26. CCC-A132-B66-3CA9P-R-2484-Spool E. All spools painted with APCS 26 instead of APCS 11A and supports painted with APCS 2A instead of APCS 26 are rejected. This is violation of SAEA-H-101 & Project Specification Table A (DWG-548320 Sheet # 15) During routine inspection of storage of coated pipes at site, found following APCS 26 coated pipes are lying on ground with ends open. These pipes are lying on the ground since long time and coating is already seriouly damaged. This is violation of SAES-H-200 Para 5.2.1 & 5.2.2.3 This is repeated violaion ref to LBE-19324 & 33222. 1. 4"-CCCA132-B66-N-2314 Spools D & A-1CS9p Sub Contractor doesnt comply with Schedule Q Table VI-2 Construction Phase Quality Personnel Requirements, subcontractor kabbani coating company require a coating inspector to monitor/inspect their coating activities, contractor early action is requested as work is being performed without Kabbani QC. In CCC valve testing yard (excluding subcontractor SAECO area) many different sizes of valve flanges are left uncovered and no people were working in this area since Thursday shift end, which was noticed on Friday noon 13th April. To remain uncover the valves (prior to and after the valve testing) is violation of item # A4 of SAIC-L2041(storage and preservation of valves), 04-SAMSS-035 Para12.2 Valve end flanges shall be fitted with plywood covers. That means the valves are uncovered since after completion of the Thursday shift. It is also to concern there was a heavy sand storm since Thursday which may has adverse affect on valve operation. Fireproofing damaged is noticed on few control valves such as B67-51ZV-004/ ZV-001 found in surge area,B66-42-PV-553 in valve testing shop and B66-41-PV-887 in train1, Which is the violation of SAES-L350 Para 8.1all materials shall be handled with care during fabrication and installation to prevent damage. It was noticed in CCC valve testing shop that, when leakage was noticed during the valve hydro testing from the flange the construction crew have tightened the blind flange by hammering while the hydro testing process is ongoing (test pressure was 2000psi). This the violation of contractors own QCP-847-136 Para 9.14.1.3 During bolt tightening inspection at train 3 battery limits dated 2/28/2008 found, one of the torque wrench without calibration sticker on it and also no calibration certificate was available with the crew performing the work, this is the violation of SAEP-351, Para. 6.3/SATRL-2001 Item B3 and Schedule Q attachment IV Para 6. It was highlighted to Contractor site QC with identification of Torque wrench and corrective action is requested.
SATIP-H-100-01
SAIC-H-2031
Mechanical
Drawing
Schedule Q
1.3
237
4/18/2007 7:31:10 AM
SATIP-H-100-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
SAES-H-200
5.2.1 & 5.2.2.3
238
1/20/2008 6:59:21 AM
SATIP-H-100-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.1
239
4/13/2007 5:06:01 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
32-SAMSS035
12.2
240
9/22/2007 10:51:16 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
8.1
241
9/22/2007 1:12:27 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
ScheduleQ
Schedule Q
1.3
242
2/29/2008 10:10:27 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
6.3
243
6/3/2007 5:43:20 PM
In train1 a structural member/ main girder at A1PR06, column BJ gridline 126 & A1PR06 column BI gridline 126 empty bolt holes are noticed and at A1PR04 column AS gridline 127 bolts are not full thread engaged with nuts (not tighten) all the items are at above +118000 elevation. These all are for the inspection passed steel structures, its alarming to note such structural members shall never be use by other discipline as a support, These are the violation of SAIC-M-2009 item A11 & A15, PIPSTS05130 Para 4.1.5 and 6.2.5, Schedule Q Para 7.3.2/7.3.5.These are the repeated violation, reference QMIS item number 41410 . Unassembled cold shoes are kept on the floor, even at sand and not being handled and stored in proper way. This is a violation of Vendors Doc: # P5552 EM-PUF-01/JGC Doc # V-216G-504-A-801, Rev.4. As per the Para 3.1 of the above procedure, items shall be stored in their original packaging, under cover and protected from exposed to direct sunlight, wind and water and as per Para 3.2, items that have been removed form their original packaging shall as a minimum be stored off the ground and under sheeting. This is a repeated violation after the fact recently, refer surveillance number 37789. Today I have received two test packages (TR3-FW-088 & TR3-FW-090) for pretest punch listing to do document review and walk through inspection. I have revealed both test packages are shows same P&ID drawing number BA-543205 and sheet number 005 but different revision numbers 0F3 and 0F4. This is violation according to schedule Q Para 3.7. Contractor is recommend to provide latest revision of all P&ID and Isometric drawings to ARAMCO-PID for clarification in future test packages. During Surveillance of control of welding electrodes, found one unplugged quiver containing 35~40 nos Cold LH Electrodes was used by W # 121( 16.30 PM-3/19/07). This is fourth repeated violation of SAES-W-011 Table 1. Ref. to repeated violation nos.32561, 28126 & 28092 Joint#1 of A232-B66-P-1257, spl-EQP, was relased for welding WITH OUT fitup signature by contractor QC personnel. This is repeated violation of QCP-847-100. More than 50 joints have been welded without approved procedure even though SAPID highlighted to submit the procedure. Welding with out procedure is a violation of SAIC-W-2006, item#A2 (SAES-W-011, Para: 7.1.8). Contractor is advised to identify these joints and take required necessary action to resolve this issue. During focus assessment on PMI in the Fabshop, it was found that the contractor is not performing PMI on inside weld surface wherever accessible. This is a violation of SAIC-L-2010; item #B-9. Contractor is advised to perform PMI on inside weld surface wherever accessible. All joints made by newly approved procedure WPS-847-SS-010, Rev.1 shall be 100% PMIed on both sides as per pre condition of welding procedure is accessibility. During surveillance inspection on Friday 11/24/06, it was found that 2 welders Mohd Yunous & Mohd Azhar Tanveer (CCC-ID Nos 56252 & 56253) were welding supports without JCC. This is violation of SAES-W011 Para 8.1 & 11.5.1 & SAEP-323 Para 6.4.1 During Surveillance of CCC-Fabrication Shop on 1/25/07 at 21.00 Hrs, found 22 welders were working in night shift and were using welding consumables (Low Hydrogen Electrodes) without any control. Welders were taking & returning electrodes directly from storage oven without requisition and without any control. There was no logging and issue of welding consumables by Storekeeper. This is the violation of Contractors approved Welding Consumables Control Procedure QCP847-101 Rev 1
SATIP-M-001-01
SAIC-M-2009
Mechanical
other
PIPSTS05130
4.1.5 & 6.2.5
Schedule Q
7.3.2 & 7.3.5
244
8/25/2007 6:59:52 AM
SATIP-N-001-01
SAIC-N-2005
Mechanical
SAES
SAES-N-001
245
4/24/2007 10:14:20 AM
SATIP-L-350-01
SAIC-L-2022
Mechanical
ScheduleQ
Schedule Q
3.7
246
3/20/2007 7:20:31 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
247
9/4/2007 11:20:55 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
248
10/6/2007 1:21:04 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
7.1.8
249
11/17/2007 8:50:53 AM
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
9.8
250
11/25/2006 6:02:57 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1 & 11.5.1
SAEP-323
6.4.1
251
1/28/2007 7:42:48 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
252
1/13/2008 5:34:21 PM
During reinstatement inspection at NGL Train 1, the following test packages were found cold shoes calling for rectification: N13-20-0117A/ 117B/ 042A/ 074/ 117C/ 009/ 081/ 049/ 008/ 019C/ 066D/ 083/ 087/ 066B/ 092/ 015/ 035A/ 019D/ 029A/ 029B. The said shoes were installed not in compliance with INDRA doc # EM-PUF-01, Vendors dwg # P555200 and JGC dwg # B74-M-BB-546121. Contractor should make plan of actions to rectify/ repair the mentioned cold shoes before closing the insulation. The morning temperature is less than 10 degrees Centigrade. Surveillance was conducted in Train 2 and the following were observed in non-compliance to welding requirements: 1. Pre-heating and interpass heating are not being performed 2. There is no available temperature measuring device during surveillance. Contractors attention was immediately called and advised to follow requirement. Contractor is installing resilient or soft seated ball valves on large diameter piping in area B63 & B64 before cleaning or flushing the systems. This is in violation to the requirements of SAES-A-004 Para 7.1.3. Resilient seats can get damaged by any hard matter inside the uncleaned pipe. This concern is required to be addressed ASAP. The supports are not setting properly on sleepers, portion of supports overhang see photo exibit attached. This is a violation of approved for construction drawing no. BD-453788, sht. 5/10, rev. 3, SAIC-L-2018 item A12/A13. Sleepers for rectification to conform the said drawing mentioned above. Contractor cut the pipe FGL-1085 near joint FB32 on Aug. 15, 2007 after hydrotest. The said FGL-1085 is part of package B64-127/2" FGL1363 which was hydrotested and successfully passed the testing on July 3, 2007. Second hydrotesting is necessary due to this violation. Therefore, package B64-127 is null and void in terms of hydrotesting acceptability. Prime contractor has not provided a replacement for the position of RTFI technication during the vacation of their regular RTFI Mr Biju, Radiographic films are not being evaluated by prime contractor since 18 Dec 2007, which is in violation to the requirement of Schedule-Q Attachment VI, Table VI-2. Job surveillance was conducted at Snamprogetti Warehouse and found out that manny of the pipes are no end cover especially pipes and fittings with original bevel and stainless steel contaminated with rust.Violation of SAES-L-350. Contractor advice to follow strictly the Aramco standards and stop that kind of practice in handling and lifting of materials. found out on GAMA Fab-Shop that manny of the 36" pipes had damages on the bevel due to improper handling and lifting. Contractor advice to follow strictly the Aramco standards and stop that kind of practice in handling and lifting of materials. Lube Oil Piping - Line No 35A & 35B of Regen Compressor K102 A & B with a design pressure of 2500 Psi and piping class 15SD0P was found with 1" Gate Valve of 800 Rating installed on its drain, where as the Iso-Drawing item No 9 specifies a 1500 Rating Valve. Consequently the line could not be tested at 1.5 the design pressure of 3700 Psi, (800# rating valve can not take this pressure) Arrange to replace the valve of correct rating (1500Psi rating) and test the piping circuits on Hydro test Package # B64-LOSK-03 /04 Surveilance conducted at B64 area and found out that the contructor are installing additional sockolet for vent and drain. The line is already tested and accepted with test pack no. 904D line no. 30"-RL-2642. The contructor was advise to re-test the line. RFI no. 32340 for hydro test of this line is null and void. Relief Valves installed in B64 area are not provided with secured taggs, the RV # are not stamped on out let flange of RV, vent piping of the bellows type RV should be directed away from equipment and walk ways, coating color to be corrected for non bellows type RVs as per the requirements of SAEP-318, para 9.1, 9.3,9.5,9.6.
Mechanical
Drawing
Schedule Q
1.4
SAES-L-350
10.3
253
1/26/2008 1:35:38 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.1 & 12.4
254
5/1/2007 9:12:02 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-A-004
7.1.3
SAES-L-350
14.2
255
5/20/2007 5:01:13 PM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
14.2.2
256
8/16/2007 7:53:10 AM
Mechanical
SAES
SAES-L-150
5.8
SAES-W-011
18.5
257
1/12/2008 11:47:46 AM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q
A VI Para 2
258
4/13/2006 1:28:17 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.4
259
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
8.1
260
4/30/2008 3:36:54 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
Drawing
Schedule Q
1.4
261
9/25/2007 5:19:52 PM
Mechanical
SAES
SAES-L-150
5.8
SAES-W-011
18.5
262
11/14/2007 9:34:51 AM
SATIP-J-600-01
SAIC-J-2009
Mechanical
SAEP
SAEP-318
9.1, 9.3, 9.5 & 9.6
263
8/13/2007 2:37:07 PM
Utility stations installed in B64 area and near the Sales Gas Compressors are lower than the minimum requirement of 600mm. Saudi Aramco Standard SAES-L-310 Para 19.5 specify the elevation of utility stations from 600mm to 1200mm. Contractor is advised to make a survey of all the utility stations installed and rectify those with incorrect elevations. Saudi Aramco Standard SAES-L-310 Para 19.5 specify the elevation of utility stations from 600mm to 1200mm. Utility stations installed in B64 area and near the Sales Gas Compressors are lower than the minimum requirement of 600mm refer to attached pictures. Contractor is advised to make a survey of all the utility stations installed and rectify those with incorrect elevations. Branch connections installed on the piping circuits given below: B64 P1031- Adjacent to SB 61 & B64 P-1091-Adjacent to SB 54, are in violation to the spacing requirements specified in SAES-L-310 Para 12.5 i.e. Branch connections shall be provided a clearance of 24 from any fixed obstruction. Dummy leg supports installed on a lage number of piping circuits are not provided with Weep holes as per the requirement od SAES-L-350 para 13.2.3 " A 6 mm weep hole shall be drilled for all dummy supports. The weep hole shall be located near the base plate for all vertical dummy supports, and near the run pipe at 6 oclock position for all horizontal dummy support" It is reminded that this activity should be completed prior to PMCC to aviod delays. INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY AND BOLT TORQUE TIGHTENING OF TEST PACKAGE NO. B64-504, LINE NO. 1"LO-1452-15SD0P1,Contractor has installed 150# spiral wound Gasket on 1500# Raised face flange connection to compressor. The gasket shall be replaced with correct rating Gasket. violation was recorded on test package dated 6/8/2008. Installed location of pipe support no. 1001009 already welded at column 27, B64 area for 48" P-1001 is not in accordance with the latest drawing i.e. BD-453751 Sht. 5/12 Rev. 2A. Instead it was installed based on previous revision. Justification is requested. Follwing soft seated valves/control valves are installed with instrumentation final connection and accepted by SP QC as per my verification with FAFCO supervisor :B64-21-ZV-002, 48"/21-ZV-023, 56"/22-ZV-031, 48"/22-ZV-013, 48"/26-ZV-002, 24". First and foremost "soft seated valves and control valves shall not be installed until after the lines have been THOROUGHLY FLUSHED". Its a violation of Aramco standard SAES-A-004 para. 7.1.3. Therefore, the lines shall be thoroughly flushed and clean prior to installation of soft seated valves and control valves. Following MOV/Soft seated valves are installed a clear violation of SAES-A-004 para 7.1.3. Quote: " Soft seated valves and control valves shall not be installed until after the lines have been thoroughly flushed". 6 nos. 36" size i.e. 1) 21-MOV-001 LINE P-1003 2) 21-MOV002 LINE P-1006 3) 21-MOV-012 LINE P-1012 4) 21-MOV-013 LINE P1016 5) 21-MOV-023 LINE P-1001 6) 21-MOV-024 LINE P-1019 and 1 no. 48" S/N 39/0023 GA-E-60412 P-1030 at SB02 Spl. A, sht. 1/2. Saudi Aramco Standard mentioned above is clear in its requirement, therefore soft seated valves described above shall be removed and will be re-installed after the lines are thoroughly flushed/clean. 3 Nos. of 2" drains installed one each on lines P-1001, P-1057 & P1042 are closed to girder beam less than the required minimum distance of 614mm as per Standard SAES-L-310 para. 12.5 which states: Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of all sizes, shall be located at a minimum horizontal distance of 610 mm (24 inches) from any fixed obstruction. This requirement does not apply to that part of the support which is attached directly to the piping, such as horizontal and vertical dummy extensions. Contractor shall modify and solved the problem.
SATIP-L-350-06
SAIC-L-2068
Mechanical
SAES
SAES-L-310
19.5
264
8/13/2007 2:44:54 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
265
11/14/2007 8:56:48 AM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-350
13.2.3
266
7/5/2008 6:15:06 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.1
267
4/9/2007 1:17:24 PM
Mechanical
ScheduleQ
Schedule Q
1.4
268
7/24/2007 5:18:16 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-A-004
7.1.3
269
7/28/2007 8:19:31 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-A-004
7.1.3
270
9/5/2007 1:11:29 PM
Mechanical
SAES
SAES-L-310
12.5
271
9/8/2007 7:19:40 AM
Pipe components and its drains connection violates standard SAES-L310 para. 12.3 which states: Above-grade piping shall be supported to provide a minimum of 300 mm clearance between bottom of the pipe and the finished grade. Pipe installation in violations are: P-1010, P1009, P-1124 including installed drains at B64-D-101A, at B64-D-101B pipe and its drains even less than 10mm from finish grade lines P1013, P-1014 and at B-64-D-101C lines P-1021 and P-1020 and its drains. Contractor shall verify the requirement of the said standard. Sept. 16, 2007 air blowing was conducted for Test Pack B64-140 with in line MOV/ZV valves, a violation to aramco standards SAES-L-350 para. 14.1 and SAES-A-004 para 7.1.3. Note: During airblowing ZV012 valve was partially open a violation to SAES-L-350 see appendix A. Air blowing was conducted for test package B64-101-1/48" P-1001 with in line soft seated valves by SP pre-commissioning. Violations to standards SAES-L-350 para. 14.1 and SAES-A-004 para. 7.1.3. Bolt torquing and reinstatement was conducted and witnessed on August 20, 2007. It was found on Sept. 19, 2007 that bolts and nuts were being removed, no advice and no advance information whatsoever from Snam and GAMA. 5 nos. of 2" pipelines resting on pipe branches P-1041 spools E & F under footbridge south of PR 11-12. The 5 nos. 2" pipelines are: B64-P1040, B64-P-1038 spl.C, B64-RLC-1630 spl. K, B64-P-1119 and B64-P1039. A violation to SAES-L-310 para. 12.4 which states: A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe. 2" pipeline B64-RLC-1630, spl. K, sht. 3/8 is out of square alignment and it is distorted as it goes up and down from its support. Need to be corrected. Following joints were cut and reweld after the system was successfully hydrotested passed and accepted. The hydrotest conducted on June 26, 2007 and part of package no. B64-TLTP-002. Re-hydrotesting is required after modification and when the system is ready. Cut & Reweld of line FGH-1345 joints FB-45, SB1-42, SB-41 after the hydrotest at B64-KO-D-108. Part of package no. B64-tltp-001 which successfully hydrotested and accepted on June 26, 2007. The lines under the package shall be re-hydrotested after modification and when it is ready. The following major punch items were generated for TP B64-120 during Final Inspection (Reinstatement). 1. Wrong gasket installed for RL-1586, RL-1570, RL-1211 2.Missed bolt torque RL-1570, RL-1586, RL-1597. Contractor to rectify the incorrect direction installation of low temp. valve 2" LCB 150 lbs as it is against the flow and in opposite direction flow of the next check valve. During inspection on Reinstatement for TP B64-122/122A the following deficiencies were recorded: The flow direction of 2 dia Globe Valve was wrong as per Isometric Drawing. The bolts as installed in 2 dia Gate Valve flange at line interface between 6CA9P and 6SD0P2 was wrong (i.e. L7 instead of B7 as installed). SS piping was not resting on CS pipe support CS pipe guide as installed was not as per SP pipe support standards ( i.e. wrong diameter of round steel was installed) Flow direction of the piping circuit as per P&ID is in conflict with Isometric Drawing, thereby affecting the installation of Globe Valve. SP has replaced a 1/2" valve on sampling line P-1137-6CA9P, and have cut rewelded socket welds FS-32RW & FS-33RW, contracter shall either hydrotest the line @ SAES-L-150 Para 5.4 or complete the requirements of SAES-L-150 Para 9.2.
Mechanical
SAES
SAES-L-310
12.3
272
9/16/2007 5:53:44 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-350
7.1.3 & Appendix A
SAES-A-004
14.1
273
9/23/2007 7:10:05 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-350
14.1
SAES-A-004
7.1.3
274
9/23/2007 7:14:50 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-450
9.4
275
10/24/2007 1:44:27 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
276
10/24/2007 1:52:29 PM
Mechanical
SAES
SAES-L-350
277
10/25/2007 10:18:12 AM
Mechanical
SAES
SAES-L-150
5.8
SAES-W-011
18.5
278
10/28/2007 1:39:48 PM
Mechanical
SAES
SAES-L-150
5.8
SAES-W-011
18.5
279
11/10/2007 5:47:52 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
280
2/4/2008 5:56:28 PM
Mechanical
ScheduleQ
Schedule Q
1.4
281
12/18/2007 1:00:34 PM
Mechanical
Drawing
Schedule Q
1.4
282
7/11/2008 10:06:49 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-L-150
5.4 & 9.2
283
2/18/2008 11:15:37 AM
During routine site visit I found Gama the sub-contractor was grind the welding joint at the line# P-1086 20" which connected to K-102A.The work was done with out inform Project Inspection. Also the SP.QC he dos not have any information about this job. Please I need respond as soon as you can. Thanks Inspection conducted on the alignment and Levelness of the DGA STRIPPER Reflux drum B65-D-202 and found out that 25 mm deviation on the require elevation of the centerline of the vessel. Elevation of the foundation checked and found acceptable. Since the foundation cannot be rectify and the drawing of foundation and the vessel are not mach its others, the contractor was advised to revise the piping drawing before the fabrication to avoid rework on installation. Found; Root Gap of 5.2 of Weld joint SB-7 (30" B65-A P-1002 SHT 11/14) did nOt conform with the the weld joint details of the approved WPS-1112-003. fOR FIT-UP Refer to: SAIC-W-2005 item #A4-d) Acid K.O Drum B65-D-211: The vessel when installed showed that north side saddle support was not sitting in full contact with base a gap of 16 mm was observed between the saddle baseplate and the imbedded plate. Contractor has cut the saddle base and tack welded it to the impedded plate to rectify this deviation, the gap created between the base and the web plate of saddle support is excessive (18mm) contractor shall submit a method statement for PID approval to conduct this rectification. INLET FILTER SEPERATOR B65-D-205: Two 4 connecting flanged Nozzles are found out of alignment after installation of two stacked vessels , measured, gaps between flange faces, bolt holes off set & flange tilt are above the tolerances specified in SAES-L-350 Para 9.4 & 9.5. Contractor shall provide a rectification procedure in consent with Vessel vendor. Visual inspection of weld joint between ring plate and additional plate was found acceptable. However, the Contractor, in violation with SAES W-011 requirements of conducting a penetrant test prior to welding of the reverse side of a full penetration double side welding , has missed the NDE requirements. To resolve this issue , SAPID wants RT in lieu of missed PT on all double sided weld joints. Contractor has installed a piping spool between FFS 21A & FFS-21B with material not in compliance to the piping class 6SD0P1 shown on the Iso-Metric Drawing. The material used is single grade S/S 316L it can not take the test pressure of 2175 PSI. Our comments has been recorded on the punch list of the test package No B65-2-ATM-TP057 and sholud be addressed. Prime Contractor Snamprogetti is violating the requirements of Schedule-Q Table VI-2 by removing its supervising Inspector for the activities of piping punch listing prior to hydro-testing and piping reinstatements after hydro-testing which is having adverse effect on the quality of works, SAPID is finding more violations and defeciencies during their check for the same activities. Seperate survillance enteries will be registered for these observed violation. Inspection has noted during the reinstatement of Test Package B65-2523 that Piping DGA-1427 is gone out of level when connected to closed DGA system. Levelness of the piping shall be corrected, welds will be cut and rewelded piping is required to re-hydro tested. Spectacle blinds installed on the stainless steel piping 1" diameter 150, 300 & 600 rating are with out any identification of Manufacturer, material grade, size & rating which is in violation to the requirement of ASME B16.48 Para 6.1 Contractor shall provide its input to resolve this issue.
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.4
284
1/13/2007 1:11:19 PM
B65-D-202
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
285
4/21/2007 11:49:05 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.8
286
4/9/2008 7:00:07 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
287
4/10/2008 8:13:18 AM
SATIP-D-001-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4 & 9.5
288
7/12/2007 3:00:52 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.3.4
289
4/6/2008 1:56:16 PM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-L-150
7.1
290
3/20/2008 1:06:54 PM
SATIP-L-350-01
SAIC-A-2010
Mechanical
ScheduleQ
Schedule Q
A VI Para Table -2
291
4/7/2008 11:41:31 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4C
292
4/6/2008 1:42:17 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-350
6.1
ASME B 16.48
6.1
293
9/16/2006 6:51:51 PM
Materials receiving inspection and a subsequent review of mill test certificates have shown that 38 plates of various thicknesses purchased by subcontractor GAMA under P.O # HAWIYAH/06/452 are manufactured under specification JIS 3131. Procured plates are not equivalent to ASTM A 36 approved for supports fabrication.(Yield and ultimate Tensile Strength for JIS 3131 material is lower than that specified for ASTM A 36) Referenced material is unacceptable, and shall not be used for pipe supports fabrication, this non-conforming material shall be Quarantined. Soft seated MOV Valves i.e. 36" B65-31-MOV-001 lying on ground with no end flange covers. Dust is building up inside much more due to sand storms. Valves with no end covers is violating Aramco Standards SAMMS-04-035, para. 12.2. Contractor shall clean inside valves without damaging the seat. Tee branch connection at B65-A, column 11, drawing no. BD454485 sht. 2/4 (see photo attached) from line TW-1816 near joint FB 28 is a violation. Please refer standard SAES-L-310 para. 12.5. Joint no. SB13 of FGL-1543 under test pack B65-1-539 was cut on Sept. 22, 2007, the cutting is a violation. Because said test pack B65-1539 was tested and successfully passed the hydrotest conducted on Sept. 2, 2007. Therefore, SP shall re-test the said test pack and to be witnessed again by SAPID. Field Joint # FB-50 of piping W-1932 has been radiographed and reported as an original or new weld, however signs of rework are visible on this joint, please check and confirm when this re welding was carried out and by which welder, also the joint has to be reradiographed to verify the soundness of the repaired area. Referenced piping joints / butt welds has leaked during the Hydro-test, contractor shall investigate these abnormal failures, and submit a report following shall be included: Welding record showing the welders worked, WPS used, NDT applied, joint materials heat #, filler material batch #, Mill test certificates, for base metal & filler. Following tests shall be applied witnessed by PID, Dye-Penetrant Test, RT on failed joint some additional RT ahall be taken from the same lot (2" P-10176SD0P1 SB108,SB101, 2" DGA-1432-3SD0P Joints before and after the failed weld)PMI test of the joint materials and failed welds. Piping sections of the failed joints shall be seggregated and kept safe for any investigation reqired by CSD. Contractor has cut and repaired the welds on 2" P-1017-6SD0P1 W/O informing / involving SP & PID which is a violation of QCP. Flanges connections of lines B65A-1356 to B65A-1361 and DGA-1431 to DGA-1436 and DGA-1485 to DGA-1496 at top portion of FIN FAN cooler B65-STR-72A are having missmatch some are 10 to 15mm difference. A violation to SAES-L-350 para. 9.4. Two pipes are overlapping each other with only 15mm clearance. The pipes are: DGA-1327, spl. R, near SB60 and DGA-1354 near FB21. A violation to SAES-L-310 para.12.4. 6" DGA-1371,sht. 3 of 6, spool I to K is 3mm close to 3 number columns. A violation to Aramco standard SAES-L-310 para. 12.4. SP to verify for possible modification. Pipes are used as support to another pipes. The lines are: 1)DGA1287,near FB-07 col. 7 south. 2) DGA-1338 bet. columns 7-8 & 9. 3) DGA-1413 8" bet. col. 6 & 7 middle column. 4) DGA-1293 20" bet. col. 11 & 12 south. 5) DGA-1327 16" bet. col. 19 & 20 north bet. PR 15-15 and fin fan cooler. 6) DGA-1299 24" bet. B65-C-102 and PR 15-16 and on the support one rusty cs bolt is touching the ss pipe 24". These are violations to SAES-L-310 para. 16.1.2 Two installations that needs modification: 1) Pipe 2" CS, DGA-1482 spl. AI is clashing with 1" SS pipe DGA-1459 spl. C. Note: DGA-1482 not yet installed when DGA-1459 was hydrotested. 2) 1" SS pipe DGA1459 spl. B - is resting on supports without SS pad. SP to modify installation.
SATIP-L-350-08
SAIC-M-2003
Mechanical
other
12-SAMSS007
7.6
294
7/5/2007 1:55:06 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.2
295
8/23/2007 10:40:49 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
296
9/24/2007 2:04:02 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-L-150
5.4
297
4/9/2008 6:37:32 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-L-150
5.4
298
3/12/2008 7:29:44 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.7 & 17.1.8
299
10/24/2007 2:11:14 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
300
10/25/2007 7:12:29 AM 11/11/2007 6:51:19 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
301
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
302
11/25/2007 5:17:42 PM
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAES
SAES-L-310
16.1.2
303
11/27/2007 1:00:19 PM
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAES
SAES-L-310
16.1.2
304
12/30/2007 7:09:19 AM
Remove fabricated reducer connected to thermal oxidizer stack B65-F104. Violations to SAES-L-105, SAES-L-310, SAES-L-101. Reducer to be installed shall comply ASME B 16.9 / ASTM A403 WP316 WX-WLDD. Entire steam line header S-1781 has been fully insulated prior to pressure testing. This is a violation to SAES-L-150 para 7.3. All joints shall be exposed prior to pressure testing. Contractor has pressure tested test pack B65-2-TLTP-050 with lube oil as test medium instead of demin water as per approved test pack. Contractor shall issue RFI for cleaning and degreasing the whole spools. Found, MAC Welding Machine with overdue calibration (SN: 496R10031, Model: Mega Arc 5040D, LAST CALIBRATION: 27 Jun 2006) Schedule for re-calibration ASAP, Accomplish; SAIC-W-2011, & SATR-W-2011. 42" Valve 64-ZV-01 installed on piping # 42" P-1297 showed leakage from body joint during the Hydro-testing of the piping system Test Package # B68-2-603. The valve shall be removed and repaired in an approved valve shop. Field hydro-testing shall be applied on the valve prior to its installation in the system. Please confirm by test records that this valve was hydrotested previously. Contractor GAMA has demobilized all its welding, piping, and Mechanical Inspectors with out following any demobilization plan, prior to the competion of construction activities violating the requirement of Schedule-Q. Problems are being faced to verify the remaining construction activities such as installation of PZV, reinstatement of lines and closing the packages. SP is requested to look in this matter. Contractor has proceeded for chemical cleaning even though the hydrotesting was not accepted by ID. It is SAPMT and contractor responsibility to repeat the test (for the small section that failed) or provide the waiver as per last meeting with PQM. Otherwise, the whole job will be rejected and MCC will not be signed This is with reference Sales Gas Compressor after cooler B68-E-102 A/B/C/D. Approved Drawings for 2 Vent & Drain Nozzles of the Tube Bundles show LWN flanges of 600# rating while the Flanges installed are ASME B16.5, 300# rating. Vendor Nuovo Pignone has provided the calculations and revised the drawings supporting this change of flange rating. It is advised that design calculations submitted for 300# Flanges should be reviewed and approved by CSD. Surveillance conducted on B68-1 area found out that during reinstatement the contractor are using teer pull and come along to align the two flanges. The piping circuits are 48" with line no. P-1003 and P1007. Misalignment tolerance as per SAES-L-350 was 2.4 mm and actual dimension for misalignment is 100 mm. Contractor are not requesting for any inspection for flange alignment and parallelism. The contractor was advised not to force the line that will affect for the pipe stress. Contractor shall issue RFI for the alignment and will be a hold pooint for PID Inspection of Strainers for the suction piping of compressors B68K101/102 has shown that partially cut wires of the screen, gas cutting/welding flux deposits entrapped inside the corners of strainers. These debris can get detached and enter the compressors and cause damage to the machine. It is advised that the strainers installed on the suction piping 48" P-1029-3CS9P & 42" P-1297-6CS9P shall be removed and inspected for mentioned defeciencies to avoid any damages to machine. The welds made between the frame and ring shall also be verified for completness and profile.
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-110
12.4
ASME B 16.9
305
1/23/2008 7:05:09 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.3
306
1/29/2008 7:55:30 AM
SATIP-A-004-02
SAIC-A-2008
Mechanical
ScheduleQ
Schedule Q
1.3
307
4/14/2007 11:48:33 AM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
Schedule Q
A IV Para 7.1
308
4/9/2008 7:18:25 PM
SATIP-L-108-01
SAIC-A-2042
Mechanical
SAES
SAES-L-108
4.7.3
309
7/24/2008 8:30:23 AM
SATIP-L-350-01
SAIC-L-2022
Mechanical
ScheduleQ
Schedule Q
A VI Para 5.1
310
12/12/2007 11:02:16 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
1.4
311
8/13/2008 2:48:06 PM
SATIP-K-402-01
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
1.3
312
1/5/2008 7:26:03 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
313
1/19/2008 1:30:23 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
314
4/10/2008 7:47:07 AM
FB-30 & FB-31 of piping 2" IA-1586-3SD0P showed leaks during the Pneumatic testing at 125 Psig test pressure. The number of 2" diameter stainless steel butt welds that leaked during pressure testing is now 7 and the recent leaks like previous welds are from the edje of the weld. Although failure analysis results are awaited from CSD we should complete the necessary investigation from our side.Welding Records, Material certificates, welding consumables certificates and fillers from the same batch shall be collected. Leaking weld shall be DP tested & Radiographed and shall not be repaired till results are received from CSD. Surveillance conducted and found out damage face on check valve when disconnected prior to hydro test.Transverse scractch found caused by welding spatter. The contractor advised to repair/reface the flange before instalation. 2x2- Seal drain lines buckled up to approximately 7450mm (1st Riser) elevation and a 3" flange detached from its tack welds during the course of rigging, mounting of the stack risers (1-5) to its anchor bolts/foundation. During the inspection for FAFCO record for humidity and temp we found them copy paste from last three days, because they dont have instrument for that. Snam. Should take immediately action about the contractor and the QC. Blasting garnet in the coating yard shall not be stored on the ground. This does not comply with SAES-H-100 para.5.2.1 It has been observed that burried Pipe lines crossing the fence with roads on both side of it are placed on concrete pedastals. This is in violation to SAES-L-460 Para 10.2 and Standard Drawing AC-036660 sheet 4. Concrete Pedastals can cause damage to the coating which should be avoided. While conducting Surveillance at pipe rack no. 8 & 7 the GAMA are pulling 24" double ended coated pipe and found out that the paint are been damage not only scratches but severe damage. The paint crack and peeling-off not only top coat but primer also. Its been observed that the rollers are not fitted to used for heavy pipes with coating ( Epoxy Paint ) The contractor advised to use another type of roller like rubber or equivalent materials to avoid worst damage on paint or submit new procedure. 4 double ended 36" pipes that already cleared on RT are already delivered at site with out cover at the end and already have debris inside. Violation on Aramco Standard SAES-L-350. The contractor already adviced. Petrol Valve Gate Type 40" Diameter 150# showed a leakage from a through defect from cast steel body of ASTM 350 CF8M material on application of test pressure of 425PSI specified for shell testing. This faillure is not acceptable as per the requirements of 04-SAMSS-048 Para 6.11 & 6.12, API-598 Para 3.9, ASME B 16.34 Para 7.1.3. referenced valve is rejected. Contractor is completing Flange Joint with out implementing the flange Joint Assembly procedures approved for the project and the requirements of SAEP-351. NO RFI is submitted for PID violating the requirements of SATIP-L-350-01 and SAEP-1150 Para A.12.1 & A.14.1
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.7 & 17.1.8
315
12/4/2007 7:25:03 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
316
5/15/2007 6:33:44 PM
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.2
317
9/12/2007 9:36:42 AM
ViolationPrevented Installation Violation-After The Fact
SATIP-H-100-01
SAIC-H-2026
Mechanical
ScheduleQ
Schedule Q
1.3
318
9/11/2006 9:01:09 AM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
5.2.1
319
2/18/2007 6:58:25 PM
SATIP-L-350-01
SAIC-L-2019
Mechanical
SAES
SAES-L-460
10.2
320
5/27/2006 3:34:57 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
Section 8
321
4/18/2006 2:29:59 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
322
6/30/2007 7:53:35 AM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.6
04-SAMSS048
6.11 & 6.12
323
5/15/2007 9:15:22 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
3.2.2
SAEP-1150
A12.1 & A14.1
324
4/3/2007 1:53:46 PM
After thorough inspection, lot of welding machines are in violation of Sch. Q pertaining to calibration. See Sch. Q attachment IV para. 6.1 therein specify " calibration cycle of any equipment not covered by standards shall not exceed 6 months. For GAMA: 9 each no calibration stickers, 1 each cal. expired and 5 each with 1 year calibration. For FAFCO: 8 each no calibration stickers and 4 each calibration expired. We asked FAFCO supervisor Mr. Jojo how the W. machines are being used without calibration, he replied calibration is not required for welding structural supports and has been agreed by Aramco 10 months ago, FAFCO must produce copy of said agreement. W. machines shall be calibrated properly and shall have six months calibration cycle. GAMA must take action immediately for the calibration of W. machines as welds rejection rate is alarming at 4.08 % and maybe this phenomenon is one of the causes. Snam Welding Inspector Mr. Laksmananan Manikandan is currently conducting inspection in main pipe rack and he is signing WDR. This is in violation of Sch. Q para. 5.2, 5.6. Pipe support sadle #SU-013 not in full contact with the support/rack and do not carry the load. During the review of drawings for the utility piping systems prior to hydro testing it was observed that no Root Valves are provided on the take off connection from main header as per the requirement of SAESL-310 para 19.6. Further the Contractor shall verify that ALL the reqirements specified on section 19 of SAES-L-310 are completed prior to submission of utility piping for Hydro testing No Flange end covers of 3 nos. Masonellan MOV valves, 6" class 600, dust is building up inside due to continuous sand storm. A clear violation, much more for this type of MOV valves. See SAMMS-04-035 para. 12.2. Note these valves was installed in line on FGH-1131, but was removed due to the flushing activities of the line, but it was layed down nearby without paying attention to cover it properly despite repeated instruction from PID. During water filling of line P-1049 it was discovered that 36" valve S/N 50461, Tag no. VS-GA-E-60144RF, SAECO tag. no. 4679 has leakage through pinhole on bonnet, see 5 photos attached. It is believed that it has been filled hyddro tested by SAECO noting that it bears SAECO tag number 4679. The incident shall be investigated by SP with participation of SAPID/SAPMT. Installed size of pipe branch P-1103 is 1" and was based on old isometric dwg. no. BD-455411 dated May 2006. Whereas, new revision no. "OA" of same drawing and P&ID dwg. no. B72-ba-540838-002-0F3 indicate that the pipe for branch P-1103 shall be 2". Sp to verify and modify the line. Note: Branch P-1103 is part of test pack B72-014/3"-P1035 which was successfully passed the hydrotest on July 31, 2007 with RFI dated July 30, 2007. Test pack B72-014 shall be rehydrotested after modification is done on the subject branch P-1103. Cut and reweld of joints FB26, SB29 at K.O. 72-D-101 after it was successfully hydrotested and accepted. The joints are part of package no. B72-900B which was hydrotested on Sept. 9, 2007. Re-hydrotest is required after modification and when system is ready. Miss match of flanges not acceptable as per standards SAES-L-350 at line BD-1301, FB-16 & BD-1303, FB-01 connected to pump flanges B72-G-101B. A violation to SAES-L-350 para. 9.4. Flanges shall be corrected by SP. Original installation of branch B72-P-1103 was 1" based on old IFC ISO dwg. BD-455411 sht. 1/2 dated May 24, 2006. The subject branch was changed from 1" to 2" on last week of October 2007 based on latest revision of ISO dwg. The concern branch was part of header 3" P-1035 under package B72-014 which was successfully hydrotested and accepted on July 31, 2007. SP to conduct retesting the lines. See also punch item 11041 dated July 24, 2007 of PMC 15-72DG00.
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
Schedule Q
A IV Para 6.1
325 326
4/7/2007 5:42:09 PM 4/11/2007 8:54:22 AM
Violation-After The Fact Violation-After The Fact
SATIP-W-011-01 SATIP-L-350-01
SAIC-W-2005 SAIC-L-2012
ScheduleQ SAES
Schedule Q SAES-L-310
5.6 14.2.2
327
4/26/2007 4:09:42 PM
SATIP-L-350-09
SAIC-L-2080
Mechanical
SAES
SAES-L-310
19.6
328
6/27/2007 7:50:08 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.2
329
8/21/2007 6:58:34 AM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.6
04-SAMSS048
6.11 & 6.12
330
9/9/2007 7:25:48 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
ScheduleQ
Schedule Q
1.3
331
10/25/2007 10:51:22 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-150
5.8
SAES-W-011
18.5
332
10/28/2007 1:48:16 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
333
11/5/2007 7:36:22 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
ScheduleQ
Schedule Q
1.3
334
11/13/2007 6:42:09 AM
During Reinstatement Inspection for TP B72-072 conducted on 09 Nov 2007, PID Inspector has found a wrong valve installed on line 2" RL2671, wherein the installed valve was Globe Valve and required valve should be Gate Valve. There was no pretest punch, and the installed valve is complete with the correct gasket (yellow colored handle) and bolts on final torque . GAMA and SP inspectors has missed this item but was caught during Reinstatement inspection of the line. On the job surveillance at GAMA Shop it was found out that one of the 36" pipe that already fitted had been damage in hauling which is acceptable but the worst thing was the damage inside. It was intentionally grinded with a 30mm x 50mm approx. The pipe is now rejected. The contractor violate SAES-L-350. PMCP packages are submitted with out any punch list from the contractor side violating the requirements of GI-2.710 and quality item of PQI. Welding department of GAMA is operating W/O an approved "Welding Engineer" violating the requirements of Schedule Q Attachment VI Para 2 & Table VI-2. GAMA has not provided any replacement for the Welding Engineer who was approved for the project and left on emergency leave. Welding reject rate is steadly rising and there is no effective action from GAMA side to control it. Root causes of weld failures need to be analyzed and corrective & Preventative measures need to be strictly implemented.Further Non Approved persons are cetifying the welding documentation. Weld joint is directly on top of girder (col 51) where support should be placed, this is not allowed. To rectify the problem, GAMA is to cut out the pipe 600 mm see RFI 21682 at weld joint FB-74 near col. 52 without approve TQ/SI by Snam engineering. This is a violation of SCH.Q para 1.3 & 1.4, quote 1.3 " contractor shall be totally responsible for the quality of work, quote 1.4 "in conformance with all drawings". But it seems that GAMA is carrying the rectification by themselves, because the drawing used doesnt have red line from Snam engineering attested by PMT & PID through TQ/SI. Noting that the rest of pipe will move after cutting, so clearance must be secured first from Snam engineering. Also, Snam welding engineers shall instruct GAMA that they have to conduct lamination test of re-cut weld joint as per SAES-W-11 para 11.3.3 42" SS spool was installed on line # RL-2639 without providing the bottom drain line 2"-B72-BD-1359-ISD0P shown on the drawing referenced above. Since the materials of the drain attachment are ASTM A312 TP 316L, welding works will require back purging. Contractor shall provide its technical expalanation (a method statement) how the required back purging can be achieved on the installed piping. Also, contractor shall submit RFI for verification of Pikotek gasket, insulation kit, stud bolts & nuts, lubrication and applied bolt torque. Face of flanges damage (accross the flange face) violation as per SAEP 351 para. 4.3 and SAES-L-109 para. 8.2. Also, micro serration groove of four raise face flanges have been removed by hand power buffing tool, line HWS-2178 column 39 ground level west side reference spool E-sht.2/3 SB-15. Pipes operating above 70C, in operation 90% of the time and covered by Insulation are being coated with Coating System APCS-17A CSD response for above: Coating is not required for insulated piping operating above 70 C for the main reason of cathodic reversal. At more than 80 C, zinc becomes the cathode, and the carbon steel corrodes in preference to zinc in the presence of moisture, causing pits in the steel. The moisture present could be introduced during construction or by rain or condensation during downtime. Hence we recommend that application of APCS-17A / Inorganic Zinc Primer shall be discontinued. All the piping systems operating at mentioned service conditions and insulated shall be identified and segregated under NO COATING slot.
SATIP-L-350-01
SAIC-L-2022
Mechanical
ScheduleQ
Schedule Q
1.4
335
4/27/2006 4:21:25 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
8.1
336
5/15/2007 6:56:07 PM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-A-004
5.6.1
337
9/29/2007 2:59:38 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A VI Para Table -2
338
4/4/2007 7:39:22 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
14.2.2
Schedule Q
1.3 & 1.4
339
6/19/2007 6:26:48 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.4
340
5/2/2007 1:28:34 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
8.2
SAEP-351
4.3
341
4/12/2006 9:25:39 AM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-101
342
4/7/2007 11:00:04 AM
Flange should not be painted, however during Inspection of pipe spools for release to site , it was noted that spool A of B64 P1072 SB1 and spool AB of B64 P1002 SB 119 were painted. Should we continue this practice, flange face may be damaged during removal of paint. It was noted that storage for prefabricated pipework was inconsistently complying to the requirements of SAES L-350 regarding the provision of end protectors on pipes, weld bevels,socket ends, and flanges. Any flanges that may be damaged during handling and installations shall be replaced. During my witness of RFI for spool release at the laydown area , the following flanges with paint has catched my attention. Extra precautions is advised during paint removal , otherwise any damages on flange face in the form of deep scratches shall be rejected during installation works. SP Paint inspector has to explain why flange face is being painted. Witnessed during loading to truck of 36 " dia stainless steel prefabricated pipework that pipe ends has struck the flange face of the 36" dia RF flange which at that time has no end protection. The flange face was damage and was part of spool BW/BV of line 36" dia RLC2769 under Release Report SR-366 . Visual inspection of 33 Nos. dummy pipe support shows that the weld joint has no root penetration. Since these supports was prefabricated in Gama Fab shop in Jubail , it was highlighted that there was no visual inspection conducted on these supports by Gama Welding Inspector. As these supports arrived in HNRP-GTC , SP Welding inspector has accepted the delivery with no comments not until SAPID has brought into the attention of Mr. Bijo (SP) to reject the support in question. SP Welding inspector did not perform 100% visual inspection on weld joint of support and classified as violation of SAES - W011 par 17.6.3.1 The following stainless steel welders except G-021/G-023 who has only 26 mm thick qualifications have welded 33 mm thick P8 materials as follows: B65B P1052 FB33/SB34 G-084/G027 B65B P1052 FB24/SB25 G-084/G027 B65B P1052 SB11 G-084/G027 B65A P1022 SB34/FB33 G017/G021 B65A P1022 SB20/SB8 G-084/G027 B65A P1022 SB34/FB33 G-017/G021 B65A P1022 SB6 G-084/G027/G019 B65A P1022 FB25 G017/G021/G023 To clear this violations, proposed solutions are as follows 1) Take 100 per cent RT on all joints involved. 2) Grind 10 mm of weld metal and reweld using other stainless welder. Welding inspector Mr. Najaragan is hereby warned that if such violations were repeated , he will be commended for termination. Document review on Welders performance for week ending 20 May 2007 have shown that the following welders has continued production welding without RT acceptance of their first 3 joints. These welders were G-095,G-106,G-132,G-144,G-150,G-154,G-180,G-193,G-196,G207,G-223,G-230, and G-239 and they have violated the requirements of SAEP 323 par. 6.2.2 regarding acceptance of radiograph for the first 3 joints before they will be permitted to continue production welding. Therefore, all joints welded by these welders other than the first 3 joints shall be subjected to 100 per cent radiography. SAPID has monitored their arrival and they arrived at 7:30 am , but unfortunately on Mr. Suresh has come out to his workplace and the the other inspectors stay in the QC office. Unfortunately SP Welding inspector is also not present on fab shop and arrived only at 8:00 am. SAPID has made final visual inspection at random and found that 3 joints of 6" dia pipe were welded using GTAW process and WPS GAMA 111-002 applies only to 4" dia and below. Moreover, 1 joint of weldolet has no root penetration which violates SAES W-011 par.17.6.3.2. These were all attributed to lack of welding inspectors wherein welding works is ongoing. GAMA Welding inspectors Mr Suribabu, Mr Nagarajan and Mr Suresh were always found inside fab. shop QC office writing Daily welding inspection report.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
8.2
SAEP-351
4.3
343
3/28/2007 11:39:53 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
344
4/24/2007 6:40:00 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
8.2
SAEP-351
4.3
345
5/9/2007 11:11:24 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
346
5/21/2007 5:57:39 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.6.3.1
347
4/16/2007 10:56:01 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
348
5/24/2007 1:37:10 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAEP
SAEP-323
6.2.2
349
5/26/2007 9:53:19 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.6.3.2
350
It was observed and noted that when SAPID arrived in GAMA Fabrication shop at 6:30 am there was no GAMA welding inspector on shop No. 1 , 2 and outside the shop area Document review for welders rejection rate on a weekly basis have shown that welders G-073 and G-082 has accumulated rejection rate calculated on a linear basis of 5.2 per cent (week ending 25 March 07) and 13.3 per cent(week ending 18 March 07). As todate , welders were continously welding despite violation as stated on SAES W-011 par. 8.4 regarding the maximum weekly repair rates for each welder. Observed and noted that the use of oxygen analyzer was not enforced to ensure that the back purge for stainless steel has reduced the oxygen level below 0.5 per cent as stated in SAES W-011 par. 11.4.5 An increase in oxygen level in back purge may promote root oxidation and will not be acceptable. Physical verification of calibration of Welding machines in use in Fabrication shop shows that Calibrations of Welding Machines with tag No. LF 310119C and LC 034583 were both expired on 25 March 2007 and were calibrated on 29 March 2007 and 01 April 2007 respectively. Such practice is in violation with the requirements of Schedule Q Attachment IV. Moreover, SP Welding Inspector is not aware on the expiration of calibrations for welding machines in use. It was observed at the inspection of materials that contractor has modified (36 Nos) raised face flanges by machining the raised face to provide flat face flanges for the riser spools of fire water piping. How ever machining has created a smooth finish on the flange faces. Contractor is informed before installation and welding of the referenced flanges that serrations need to be provided on the flat face per the requirements of ASME B 16.5 Para 6.4.5.3. All the 36 flanges required to be corrected as mentioned. The length and type of stud bolts installed are incorrect. It is a violation as per SAES-L-109 para. 12.1 and SAIC-L-2014 section F. Stud bolts and nuts not in accordance with SAES-L-109 must be replaced. Each Furnace Side Wall Panel has plenty of Anchors by welding. After gritblasting, immediately protection coat was applied without conducting Hammer test for the Anchors, so all Anchors should be Hammer tested and check for any welding stregnth/Anchors and damages on the Anchors, because two Panels were checked and at least three Anchors are either became shorter or completely removed for the welding attachment. New Anhors with in-kind should be welded replacing the removed ones. The fabricated shoes were installed for piping in GT #3 & Inlet Area without copletion of the fillet weld on the side plates with the Saddle from inside. The fillet weld should be completed from inside. 1 1/2 drains are provided in eccentric reducers ( 12x 8) for the following line 12-H48-DGA-6034-84-6SAOP which has been covered by the test package GT6-DGA-001 . It is in violation with the requirments of para 12.3 of SAES-L-110. It is a repeated violation . SINOPEC/TRG are requested to provide corrective action . It has been found the following in GT 5 of Area A . Welding a weldolet on a 4 piping spool( 4-H48-P-5103-33-C) which had kept blinded on all openings and filled completely with water. The root pass of the weldolet has been completed when the water level up to the groove of the weld joint. It is a clear violation as per para 11.2.1. of SAES W011. All the weld joints made on the piping spool need to be Inspected by 100 % relevant NDT to ensure that the weld joints , HAZ zones are free from defects. Contractor need to investigate further and take necessary actions to avoid reoccurrence.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
351
4/3/2007 10:57:33 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
8.4
352
4/4/2007 7:24:49 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.4.5
353
4/7/2007 10:51:52 AM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
354
10/3/2006 3:26:10 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-109
8.1
SAES-L-350
6.2 & 6.3
355
3/31/2007 6:03:33 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.1
356
4/19/2008 3:36:29 PM
Mechanical
SAES
357
2/3/2008 11:06:18 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.7 & 17.1.8
358
11/9/2008 12:29:52 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.3
359
9/24/2008 7:25:26 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.1
360
6/11/2009 5:34:06 PM
Leakage is observed from the weep hole of a 8"x1" lateral connection in the line 12"-H49-RL-5559-02-1CT2P covered by the test package H49-DD5-RL-002. This is located at EL+ 114179 , E 11451753 & N 7497000. Leakage was occured during pressurisation at about 400 psi while the line required to be tested at 450 psi. TRG is requested to investigate for the root cause of the leakage and provide necessary corrective action at the earliest. During routine surveillance of quality control records, found that TRG/Sinopec are not utilizing quality control attachments A, B, C & D. This is repeated violation; refer to LBE-4483 of SAES-H-100 Para 9.2. During re-instatement the following has been observed. Test pack # H46-IA-P-10.3 (ISO H46-P-7022-31-3CT2P Item # 10 at M1) 6 spiral wound gasket AISI 316L/graphite installed 300 class in place of 600class. This is violation against SAEP-351 4.1 and ISO drawing. Contractor is advice to take corrective action immediately. The length of the segmental wear Padis 300mm while the width of the I-Beams is 300mm. About 15 saddles were already welded to the 20" pipe, 12 Beams are with 300mm width and 3 Beams are with 280mm. There is zero tolerance for expansion and this is violating Standard Drwing (AD-036555)that the length of the segmental wear Pad is 355mm SAPID has witnessed Material Inspection for Tie In H46-025 and H46027 which includes prefabricated slip blinds , gasket, bolts and nuts. During inspection, it was identified that the bolts is A193 Gr. B7M with nuts A194 Gr L7 againsts the required A193 Gr B7 bolts and A194 Gr. 2H nuts. Material substitution may be permitted if the same or higher grade. A193 Gr B7M can be accepted but A194 Gr L7 is rejected to replace the required nuts (A194 Gr. 2H) Delivered prefabricated pipe spools at Area B plant H46 were found lying on the ground wherein ends of pipes, flanges, weld bevels, threads, sockets were not protected for possible damage and accumulation of foreign materials inside . This negligence on the part of the Contractor violates the requirements of SAES L-350 par 7.4 .Moreover, prior to piping erection , all pipe spools shall be internally cleaned by air blowing . A segmental wear Pad is missing for Location #6 counting from east on the Line (20"-H46-P-0112-63-6CT2P1) feeding D-049 A segmental wear Pad is missing for Location #6 counting from east on the Line (20"-H46-P-0112-63-6CT2P1) feeding D-049 On top of Air cooler H46-E-59 it is noticed that, PZVs & gate valve are laying horizontally mixed with debris/scarp material, left uncovered since two days, storage & handling of PZVs are not done as per the requirements .This is violation of SAES-L-350 Para 7 & 8 and 04SAMSS-035 Para12 also refer to lessen learn sapd-096 Date: 6/18/2008. PZVs Photos captured on site can be avail from PID if required. Contractor corrective and preventive action is requested. (21PZV-829A/B & Gate Valve) During surveillance of welding activities of socket joints in Area BH46 (D006C), found that no QC from TRG / Sinopec is verifying axial gap 1.5 mm minimum ~ 3 mm maximum between male & female components prior to welding. Found gap either small or more than 6 mm. This is repeated violation of SAES-L-110 Para 5.2.3 & SAIC-W2037 Item B3. Corrective Action: 1.Use SA check list. 2.TRG/Sinopec QC should make fit up inspection and verify the axial gap prior to welding. 3.Take 5 % RT to verify the gap. 4.All socket joints not meeting the requirements are cut and rewarded. 5.RFI to be raised to verifying the gap
SATIP-A-004-01
SAIC-A-2021
Mechanical
SAES
SAES-A-004
6.3.2
361
11/24/2007 12:31:34 PM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-100
9.2
362
3/30/2009 11:28:45 AM
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAEP
SAEP-351
4.1
363
2/26/2008 8:00:31 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-L-110
12.1.2
364
5/11/2008 5:38:17 PM
SATIP-L-350-01
SAIC-L-2008
Mechanical
SAES
SAES-L-350
6.2
365
5/14/2008 5:15:44 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.4
366 367
5/25/2008 3:41:39 PM 5/25/2008 3:41:39 PM
SAES SAES
SAES-L-110 SAES-L-110
12.1.2 12.1.2
368
8/12/2008 7:05:15 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
7&8
04-SAMSS035
12
369
8/16/2008 5:47:52 PM
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.3
370
8/19/2008 4:45:53 PM
It is notice in Area - B that, many new pikotek Spiral wound gaskets 24 & above was place in horizontal, sloping position in unsafe condition, & some are hanging on the scaffold/hand rails at workplace. Such method of storage/handling has the potential to damage the gaskets while violating the requirements SAEP-351 Para 4.1 Ensure that spiral wound gaskets are stored flat especially for large sizes, 24 inches and larger. SAES-L-350 Para 8.1 all material shall be handle with care during fabrication and installation to prevent damage. Contractors corrective & preventive action is requested. Pictures demonstrating the violation can be avail from SAPID if necessary. For piping associated to H46-E-059 Stainless steel line # P-805631/32, P-8057-31/32 & P-8033-31/32 Joint assembly of flange joint are done without proper alignment of joints and bolting is done by apply force while full Strain is on bolts and equipment nozzle & piping installation is first started from equipment nozzles. This practice is violation ASME B31.3 Para 335.1 (a) joint assembly which introduces a detrimental strain in equipment or piping component is prohibited & (c) before bolting up flange faces shall be aligned to the design plane.Contractor QC vigilant and corrective action is requested prior hydrostatic test of line. It is noticed that, minimum distance between 16 inch piping flange and vertical structure is not maintained for stainless steel line # H46-P8056-32 spool-I, the flange touches with structural column. This is violation to SAES-L-310 Para 12.4 A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). Contactor corrective action is requested prior to Hydrotest of piping. Noticed that, for distortion of piping & to bring it in alignment Contractor has heated the pipe/fitting & force by hammering and masked by buffing the heated/effected area on Package H46-P-028 (2 inch line # H46-P-7006-82 weld # 36,35 & 34), such practice has potential of thermal cracking and effect on material properties . This is the violation of SAIC-W-2036 item # A7 Welds requiring re-work by heating shall require approval by CSD and SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5.Contactor corrective and preventive action is requested for such repeated violations. Noticed that, spool I of 42-H46-RL-7001-01 is used to support other 24 inch pipe (line # 24-H46-RL-7001-33). This is violation to SAES-L350 Para 11.2 unless consult & approved by chairman of piping standards committee. Contractor action is requested prior to perform welding activity. Noticed that, line # 24-H46-P-0110-81(Package H46-P-005) was tested with 24inch valve item # 18 as test removed (RT) now it is observed that 24 inch valve is placed with unacceptable offset with the pipe flanges and . This is the violation of SAES-L-350 Para 8.1. Contractor is requested to verify gasket seating area for any damage utilizing SAIC-L-2014 and avoid bolting the flanges by force without proper alignment for all the valves to installed in this package and any modification / cut and re- welding need Aramco approval. one end of the valve stick without any gasket in-between which means there have been valve & pipe flange strike during installation
SATIP-L-350-01
SAIC-L-2007
Mechanical
SAES
SAES-L-109
11
SAES-L-350
8.1
371
8/23/2008 5:38:13 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
ASME B31.3
335.1a
372
8/27/2008 10:43:22 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
373
9/2/2008 1:11:48 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
7.3.5
374
9/28/2008 10:45:45 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
11.2
375
10/12/2008 5:12:34 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
376
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
8.1
377
10/16/2008 3:42:49 PM
36 Venturi 21-FE-102 Inlet area: unacceptable imperfection (deep scratches) on flange face is noticed, this is the violation of SAEP-351 Para 4.3 The flange facing, particularly the seating area, shall be visually examined for cleanliness and ensure that no damage, such as scratches exist and also observe some of orifice flanges & valves are store directly on concrete, violation of SAES-L-350 Para 8.1 all material shall be handle with care during fabrication and installation to prevent damage. Imperfection shall be repaired with Aramco approved procedure Contractors Corrective action and verification through SAPID is requested prior installation of venturi. In the Fabshop, more than 200joints have been branch welded and so far contractor didnt perform DPT on SS and MPI on CS branch joints which is a violation of SAES-W-011. Contractor is recommended to perform NDT ( as per the line class(10% or 100%) calls for) to the above said branch connections with intimation to Aramco Inspection. In inlet area facility it is noticed that, shop welded joint Line number: H46-P-8047-32 6CT2P 16 inch dia are cut and re-welding/modification of joint in field was in process without pre-welding & joint fit-up inspection as required by SATIP-W-011-01 item 3.6 & 3.7 and not utilizing of SAIC-W-2036 and SAES-W-011 Para 18.4 by Contractor is the violation of Schedule Q attachment VI Para 4A. Contractor corrective and preventive action is requested. During routine inspection visit, the following has been observed. Electrodes oven for drying and holding in area B (Near SWS) is not properly controlled and maintained as per the requirement. There is no record of low hydrogen 5.1, 5.5 and stainless steel electrode drying for two hours at 260-430, 370-430 and 120-250 degree Celsius respectively. All electrodes E 8013, E 316 and E 309 are kept in same oven and some electrodes E 309 and E 316L electrodes are kept both together in same place. Too many cellulose electrodes E 6010 also kept inside with E 7018 in oven which are not require any storage and conditioning. There is no record of electrodes returned on an end of shift and re-conditioning of these electrodes. Periodic checks of the temperature achieved with each portable oven are not carried out. These are all violation against SAES-W-011 (6.1). Contractor is advice to take corrective action immediately. During surveillance of Storage & exposure of filler wires- ER 70S2,found that filler wires are being stored in work areas in open containers & in open environment. These wires are getting rust/ contamination, and which is one of the root causes of root porosity and high WWR. As per SAES-W-011, Attachment 2, which states all electrodes & wires, shall be stored in sealed containers in dry environment. Any wires that have visible rusting or contamination shall not be used and shall be discarded. Field Welding by SMAW process was ongoing by unqualified welder T115 JCC # 228, weld joint # 71 line number 24- H46-P-0110-83. NPS of joint is 24 thickness 24.6mm were as welder is qualified to weld for maximum thickness 11.5mm in SMAW and the weaving width of the hot-pass by this welder was notice 15mm that violates WPS. Also no identification marking for welder, fit up check & WPS is notice adjacent to weld joint. These are the violation to SAES-W-011 Para 8.1 and Para 16.1 and violation to SATIP-W-011-01. Contractors corrective on action/examination and preventive action is requested.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
8.1
SAEP-351
4.3
378
1/16/2008 9:41:15 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5
379
8/12/2008 7:01:33 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.4
Schedule Q
A VI Para 4
380
3/29/2009 1:12:58 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
381
11/20/2007 8:30:55 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
382
8/19/2008 4:37:24 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
383
3/9/2009 11:39:42 AM
During surveillance inspection visit in Inlet area (Area B), Drawing no. 36-H46-P-7000-6CT2P joint no. 36 cut being rewelded by welder no.T-074 & T-034. The following observed has been found 1) No information was made to cut the joint 2) Joint not having any traceably joint no, line no, wps no. 3) Joint was not inspected and 10mm high low measured 4) Preheating was not done as confirm by welder 5) Welder was not having welder ID 6) Welder was using cold electrode 7) Electrode was used E-8013 C3 instead of E-7018 as per WPS- CS04A 8) This is absolutely violation against SAES-W011, SAIC-W-2005 & 2006 and WPS. Contractor is advice to take correction action immediately. No welding coverage from TRG and Sinopec welding inspector During walk through of test pack # H46-IA-P-020, the weldolet joint # 9A found lack of fusion at root (Drg.BB-250248-023). This is violation against SAIC-W-2007. Contractor is advice to repair immediately and also require more vigilant for Visual inspection. Noticed that, PWHT is not performed on welds that required PWHT but Contractor submitted false/corrupt record. Not performing PWHT is violating SATIP-W-011-01 item 3.14 requirement & such practice is violation of Schedule Q attachment VI Para 4A & IV Para 7.2. Contractor corrective and preventive action is requested with root cause analysis. Weld numbers for such concerns are 36-H46-P-700082 Field welds # 96,100,102.24-H46-P-7046-31 Field welds # 1.24H46-P-7047-31 Field welds # 1.24-H46-P-7031-31 Field welds # 1. Noticed that, 30- H46-P-7001-31 joint # 02 & 03 (30 inch heavy thickness pipe 26.97mm) were field welded and PWHT activity is started without joint fitup, pre-heat control, in-process welding, weld visual inspection and no welder identified on joint. Joint number 02 shown as shop weld in ISO drawing is welded in field and other joints indicated as shop weld in ISO are to be welded in field. Not performing inspection by Contractor QC is the Violation of not implementing SATIPW-011-01 item 3.6, 3.7& 3.9. Contractor is requested to perform NDE (RT) for above two welded joint irrespective of line class NDE requirement. Contractor is also requested to perform welding inspection as per SATIP in SWS & Thermal oxidizer areas. In area B, Contractor hasnt started radiography, which now became a RT backlog of more than 100joints, which is a violation of SAEP-324, Para: 6.2.7 and SAIC-W-2015. This condition shall affect the trend analysis of weld rejection rate and the early detection of nonconforming welders and weld joints. So the contractor is recommended to start radiography as early as possible to reduce the backlog and pull out bad welders. For Leakage noticed from HAZ of welded joint # 2003 line BB250248093 (HT Package H46-IA-P-035) during HT preparation, The weld joint is begin cut-out in spite of proactive/request by SAPID to investigate the root cause, verify PMI, welding & NDE records/film (as the weld joint was RT accepted) and Aramco approval prior to proceed for repair activity as per SA procedures/ Schedule Q Para 7.3.4 & 5 and utilizing SATIP-W-011-01/SAIC-W-2036.Contractors prompt corrective and preventive action is requested . Many weld joints in field are cut and re-weld/modification of joint in field are performed without pre-welding & joint fit-up inspection as required by SATIP-W-011-01 item 3.6 & 3.7 and not utilizing of SAICW-2036 and SAES-W-011 Para 18.4 by Contractor is the violation of Schedule Q attachment VI Para 4A. (Example: H46-SOW-7001-31 shop weld # 01, weld joints of line H46-P-8031-33, H46-P-8045-32 & H46SOW-7000-33 joint connecting 7001-31 line) Contractor corrective and preventive action is requested for such repeated violation.
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
16 & 17
384
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
385
3/11/2009 1:02:18 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.7 & 17.1.8
386
11/5/2008 4:25:58 PM
SATIP-W-011-01
SAIC-W-2004
Mechanical
SAES
SAES-W-011
3.14
Schedule Q
A VI Para 7.2 &4
387
10/12/2008 4:42:15 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16 & 17
388
2/26/2008 10:12:51 AM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAEP
SAEP-324
6.2.7
389
8/17/2008 2:02:29 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
7.3.4 & 5
390
8/19/2008 4:54:05 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.4
Schedule Q
A VI Para 4
391
8/25/2008 5:50:30 PM
Noticed that,for distortion of piping and in some case to bring joint assembly into alignment Contractor is heating the pipe/fitting and quenching by using flame cutting torch and applying water on it to cool, such practice has potential of thermal cracking and effect on material properties. (Example of this practice line # H46-SOW-700031, SOW-7003/4-33 in Inlet area) this is the violation to SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5. And such violation activity was highlighted to TRG QC.Contactor corrective and preventive action is requested prior to Hydrotest of such piping system. Noticed that,for distortion of piping and in some case to bring joint assembly into alignment Contractor is heating the pipe/fitting and quenching by using flame cutting torch and applying water on it to cool, such practice has potential of thermal cracking and effect on material properties. (Example of this practice line # H46-SOW-700031, SOW-7003/4-33 in Inlet area) this is the violation to SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5. And such violation activity was highlighted to TRG QC.Contactor corrective and preventive action is requested prior to Hydrotest of such piping system. On stainless steel line # H46-P-8056-32 welds 39, 40, & 41 noticed that, for distortion of piping and/or to bring joint assembly into alignment Contractor has heated the weld joints by using flame cutting torch and applying water on it to cool, such practice has potential of thermal cracking and effect on material properties. This is the violation of SAIC-W-2036 item # A7 Welds requiring re-work by heating shall require approval by CSD and SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5.Contactor corrective and preventive action is requested for such repeated violations .( refer related Surveillance Number: 12611, 13074 & 12867). Noticed that on line # H46-SOW-7002-31 Orifice flange, Contractor heated the pipe nipple/fitting by using flame cutting torch and twisting to position it, such practice has potential of thermal cracking and effect on material properties. This is the repeated violation to Schedule Q Para 7 .3.5 and refer to SAES-W-011 Para 18.5.Contactor corrective & preventive action and TRG assessment to fine the widespread of such problem is requested. Notice that, many weld joints marked as shop weld in IFC isometric are been welded on site example of PID observation are stainless steel 316L 4 line H46-VT-D049-44-6SD0Z weld # 123,138,122 & 134.also noticed contractor is using superseded ISO/documents and unavailability of WPS, SATIP on the work site etc this is violation of SAEP-1154, Para 5.4.2.3c Provide correct versions of documents at point of use and also Schedule-Q, Para 3.7. Contractor is requested to perform NDT on all such field welded joints (marked as shop joints in ISO) as per line class requirement. TRG QC vigilance on such amendment welding practice and providing applicable document on work site and document control is requested. During final review of TRG accepted weld summary in HT Packages noticed that, many weld joints cut and re-weld/modification in field without pre-welding & joint fit-up inspection and mention as shop weld in weld summary. These are the violation of SATIP-W-011-01 item 3.6 & 3.7 and not utilizing of SAIC-W-2036 and SAES-W-011 Para 18.4 by Contractor is the violation of Schedule Q attachment VI Para 4A. (Example is HT packages H46-S-001, H48-FG-02/03) Contractor corrective and preventive action is requested for such repeated violation.
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
392
8/25/2008 5:50:38 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
393
8/27/2008 10:38:42 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
394
9/13/2008 1:23:52 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
395
10/16/2008 4:15:24 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAEP
SAEP-1154
5.4.2.3C
Schedule Q
3.7
396
10/29/2008 2:26:08 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.4
Schedule Q
A VI Para 4
397
10/30/2008 3:05:55 PM
Repeated violations are noticed in field Area B & C for not performing inspection (welding activities) by Contractor QC particularly for SATIPW-011-01 item 3.6, 3.7, 3.9 & 3.17 (joint fitup up to weld completion and verification of welder). PID current observation are 24- H46-P7001-01 Rev B joint # 39 & start of repair activity for 42- H46-P-801001 42inch Tie in flange (also No approved repair procedure) and many many welds cutout & modification in SWS area. Contractor is requested for prompt corrective and preventive action on such repeated violation. Notice that, second time PWHT/heating done in field for some shop welded & heat treated joints probably for alignment. This is the violation of SAES-W-011 Para 13.10 & SAIC-W-2036 item # A7 welding or heating after the final PWHT is not permitted if the PWHT is required for service.. Weld numbers for such concerns are 24H46-P-7047-31 welds # 5.36-H46-P-7000-81 welds # 81.18-H46-P7035-31 welds # 9.36-H46-P-7000-01 welds # 56. Contractor corrective and preventive action is requested with root cause analysis. During final review of TRG accepted weld summary in HT Package H46P-004 noticed that, many weld joints cut and re-weld/modification in field without pre-welding & joint fit-up inspection and without PWHT, NDE (as applicable). These are the violation of SATIP-W-011-01 and not utilizing of SAIC-W-2036 and SAES-W-011 Para 18.3 & 18.4 by Contractor is the violation of Schedule Q attachment VI Para 4A. (Example is 24-H46-P-7031-31 welds # 4.18-H46-P-7031-31 welds # 17, 18.16-H46-P-7047-33 welds # 61 & 73.16-H46-P-7047-32 welds # 35, 46, 45, 27& 38.) Contractor corrective and preventive action is requested for such repeated violation. Generally, some branches connection were made either without reducing Tee, weldolet or no reinforcement pad which are violating Saudi Aramco Standard, SEAS-L-110 , Paragraph 12.1.1 (Chart 1.). Some spools are listed below: 1).6-H46-RL-3603-31-1CT2P-C (Two 2 Branches have no Reinfo. Pad) 2).8-H46-S-3605-83-1CSIS-I (One 6 Branch has no Reinfo. Pad) 3). 6-H46-W-3604-81-1CS2P-E (One 6 Branch has no Reinfo. Pad) 4).24-H48-DGA-5022-01-1T9P1-MP (One 16 Branch as no Reinfo. Pad) 5).3-H49-S-5169-02-1CS2S-C (One 2 Branch has no Reinfo. Pad) 6).12-H49-RL-5559-02-1CT2PF (One 6 Branch & one 8 Branch have no Reinfo. Pad) Line # H46-P-3614-07 Rev C SWS area noticed that, to compensate the distortion of piping construction crew heated the pipe/fitting on pipe at sockolet joint item # 3 weld # 74B(as mention near joint). This is the repeated violation to SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5. Also noticed that many welders in SWS area are not using portable quivers/ovens to handle LH electrode and placing electrode in scaffold pipes and utilizing it and such violation activity was highlighted to TRG QC.Contactor corrective and preventive action is requested. During routine surveillance, found that Contractor TRG/ Sinopec are continuously fabricating/Welding branch connections without reducing Tee, Weldolet or reinforcement pad. This is repeated violation refer to LBE-W-48, of SAES-L-110, Paragraph 12.1.1-Chart 1. All branch connections without reducing Tee, Weldolet or reinforcement pad are rejected. During surveillance in GT-5 found that 3 branch connection coming from 30 line. This branch connection is located near to fixed obstruction (Support)and horizontal gap distance is less than 610mm. This is violation of SATIP-L-350-01, SAIC-L-2013 and SAES-L-310 Para 12.5. Contractor counsel to do repair work according to Saudi Aramco standards. During routine site visit in GT-5 found that, the Blow down Line # 3H48-BD-5001-01-1CT2P, pipe supporting from another utility pipe. This is violation of SAES-L-310 Para: 16.1.2. LSTK contractor TRG is responsible to take immediate corrective action.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
398
11/6/2008 7:08:18 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
7.3.5
399
11/6/2008 1:20:10 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.4
Schedule Q
A VI Para 4
400
10/29/2007 4:18:53 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12.1.1
401
2/15/2009 9:51:05 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
7.3.5
402
11/8/2007 9:07:21 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12.1.1
403
11/3/2008 11:25:11 AM
PIPERACK
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
404
11/29/2008 1:31:12 PM
PIPERACK
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAES
SAES-L-310
16.1.2
405
1/25/2009 11:15:45 AM
During PMCC walk through in GT-5 noticed that the 2 diameter nozzle was cutout and removed from column H48-C-502 near TE-300. This is violation of vendor drawing. TRG has to take immediate action to complete the repair work as soon as possible with out delaying the project. On Thursday 21st August during inspection of hydrostatic test for piping system H48-C-003 at test pressure 900 psi in GT6 Area, TRG & PID Inspector noticed that access to perform inspection on weld joints & even to reading pressure gauge was unsafe, without safe scaffolding / handrail or life line. It is high potential safety hazard to work in such unsafe place which was highlighted to TRG onsite & shock to see contractors unsafe work practice. Contractor is requested to provide safe access to perform work activity & avoid any violating action to Aramco / project Safety procedures. It is found that the TRG/SINOPEC have forwarded the Test package GT6DGA -035 to PID for final review with out completion of A items . Moreover, the line has been modified and the welding is not completed . The additional joints are not reflected in weld summary record. No evidence of completion of NDT requirements is seen. The flow chart of test package indicates that the Contractor QC has cleared A items and the flow chart is duly signed by all the concerned parties. It is in violation with the requirement of Schedule Q. TRG/SINOPEC have to ensure completion of all quality requirements and forward the Test package to PID. It is hereby advised TRG/SINOPEC to find out the root cause for occurrence of this violation and to take necessary measures to avoid reoccurrence. With respect to Test Package GT6-P-008 , the flushing of the lines have been carried out with out removal of Soft seat valves from the lines. Two soft seated valves namely MOV 121 & MOV 141 were Installed in the lines 30-H48-6002-34-6SDOZ and 30-H48-6002-336SDOZ respectively which have been covered by the above referenced Test package. Performing the flushing operation by keeping soft seated valves in the lines may damage the seat of the valves . And this is in violation as per requirements of Para 7.1.3 and 7.1.4 of SAES-A004. Hence SINOPEC/ TRG have been requested to provide corrective action for the violation at the earliest. It was identified during the closure inspection of DGA Stripper Reflux Drum H48-D-603 that Nozzle N3 has not been completed as per drawing, weld overlay is missed out on the Nozzle Neck carbon steel periphery area inserted on the shell and required to be corrected. Contractor TRG should provide a resolution at the earliest Carbon Steel piping material (ASTM A 105 Flanges & pipe nipples) are installed on level Gages against the Stainless Steel material (1/6SD0Z) specified on the P&IDs, the process requirements also mandates the use of stainlesssteel materials.Following areas show this deficiency in GT-6 area. H48-D-603 -Level Gages 414 A/B & 415 B/C. H48-D601A/B -Level Gages 011, 021, 022, 042. Contractor to provide corrective action. C-601(DGA CONTACTOR) was noted that insulation has started today (24 February 2008) while on the ground. It was not a normal practice to proceed to insulation while the vessel was not installed to its final alignment. The alignment error that may be found employing this method of installation may affect internal tray and piping installation works. Preservation of installed pumps at Area A were not attended yet by the Contractor. It shall be noted that if Vendor has no recommendations on the preservations procedures for pumps prior to its final operations , then the Contractor may use as a minimum the requirements as stated in API 686. Prolonged negligence not to rotate pump shaft every week may affect operations in the future. The Contractor was advised to prepare a log sheet for the preservation of pump at Area A.
SATIP-W-010-01
SAICLW-2073
Mechanical
ScheduleQ
Schedule Q
1.4
406
8/23/2008 2:13:03 PM
SATIP-A-004-02
SAIC-A-2001
Mechanical
other
G.I.2.102
5.2 t
407
11/12/2008 11:19:20 AM
SATIP-A-004-01
SAIC-A-2010
Mechanical
ScheduleQ
Schedule Q
1.4
408
12/1/2008 4:06:59 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
Appendix A
SAES-A-004
7.1.3 & 7.1.4
409
11/4/2008 6:52:41 PM
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-W-014
6.9
Schedule Q
1.3& 1.4
410
2/17/2009 10:41:25 AM
SATIP-D-001-01
SAIC-D-2008
Mechanical
ScheduleQ
Schedule Q
1.3
411
2/24/2008 5:23:05 PM
SATIP-D-001-01
SAIC-N-2006
Mechanical
SAES
SAES-N-001
1.2
412
2/24/2008 7:10:38 AM
SATIP-G-005-01
SAIC-G-2003
Mechanical
international Standard
API 686
1.5
413
11/24/2007 12:05:39 PM
During surveillance of abrasive materials in Sinopec blasting/coating shops, found some wet abrasive material. This is violation of SAES-H100 Para 4.2.1, which states abrasive shall be kept dry and clean. Contractor is advised to remove wet abrasive from the working area and to avoid repeated violation. During surveillance of DGA -vessels H48-C-602 & 501, found external Coating is damaged and getting severe rust caused during transportation / installation and civil work activities near the vessel. This coating damage includes foundation ring, 2 meters of external shells, lifting lugs, stiffeners & man hole etc. This is violation of SAES-H100-Para 1 and contractor shall repair coating damages as per requirements of SAES-H-100. Contractor is also advised to take care of other coated equipments to avoid any coating damages and to avoid rework. During surveillance of backfilling of FBE coated line-6-DGA in Area AGT5,found FBE coating damages. Contractor is back filling line after 48 hours. As per SAIC-H-2018 item A3, states Holiday tested line shall be immediately backfilled. If line left open for some time after holiday test was performed are re-holiday tested before backfilling. This violation of SAES-H-200 Para 7, which states the coated pipe shall be 100% inspected with a pulse type DC holiday detector immediately prior to burial. As per SATIP-H-002-02, it is hold point for contractor & Saudi Aramco. During surveillance of storage of externally coated pipes, found TRG/Sinopec are storing coated pipes directly on wooden skids this causes damages to the coating. This is violation of SAES-H-200, Para 5, which states pipes shall be placed at least 150 mm off the ground on either earthberms or on padded skids spaced and leveled so that pipe are supported without damaging the coating. Sinopec approved QC-coating inspector (Mr. Wang Xiuo Long) is not available at site since last week. There is no replacement as necessary to maintain required quality coverage. This is repeated violation of Schedule Q Para 5.11; refer to LBE-H-743 Combustion air blower H48-K-618C: notice two north-side anchor bolts on the foundation are damage (bend due to which nuts cannot be fixed on blower base plate), Contractor is requested to repair and fix prior to performing grouting activity with Aramco approved procedure to avoid any further damage on threads of anchor bolts. During routine surveillance found that the test package # GT5-P-021 reinstatement completed with out Flushing. This is violation of SAIC-L2017. Contractor has to complete the flushing for this test package to close this violation presence of SAPID inspector. During surveillance of internal cleaning verification in Area A-GT6, found stones, flame cuted metal pieces and sand, inside spool no: 24H48-S-5010-83-1CS1S- Spool W- in Area A-GT6. This is repeated violation of SAES-L-350-Para 15. Corrective Action: Prior to installation of valve contractor shall raise RFI to verify internal cleaning . Sinopec welder T-097 was caught by PID on the act of welding SS root pass using purging gas other than as approved in the method statement for SS welding. The weld joint SBWW-17 Line H48-DGA0048-32 1SA0P-D was advised to be cut and re fit up prior to welding using the approved method statement for SS welding only. Any other method of SS welding shall be reviewed and approved by PID prior to its applications on site welding works. T-097 is hereby warned for such violations and any repetition thereof, the welder T-097 shall be recommended for the revocation of his JCC.
SATIP-H-100-01
SAIC-H-2024
Mechanical
SAES
SAES-H-100
4.2.1
414
4/8/2008 5:31:16 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
SAES-H-100
415
5/29/2008 2:16:21 PM
SATIP-H-002-02
SAIC-H-2018
Mechanical
SAES
SAES-H-200
416
10/25/2007 9:30:30 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-H-200
SAE-L-350
417
12/11/2007 11:31:49 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
418
11/3/2008 9:30:18 AM
SATIP-K-402-01
SAIC-K-2004
Mechanical
other
31-SAMSS001
419
4/28/2009 2:20:46 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
420
6/24/2008 2:47:18 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
421
2/5/2008 10:12:04 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.7
422
2/17/2009 2:38:33 PM
Flange Joint Bolt Torque verification inspection has shown that incorrect Rating Gasket has been installed on 30 P-6000-6SD0Z at two flanges of Valve ZV-103. The gasket installed is of 300# Rating while the Valve Flange Rating is 600#, bolt torquing of the flange joint was also completed. Contractor should replace and install the correct rating gasket and survey other flange joints to ensure the installation of correct gaskets. A root cause analysis shall be made for this failure in Quality System and preventive measures shall be applied to avoid reoccurrence. 2" Branch was welded on the 30" Header (30"-H48-P-6002-6SD0Z) without a reinforcement. As per the construction Drawing (BB-250270196-009) the Reinforcement is mentioned to be done and also as per SAES-L-110 Chart 1, the Reinforcement is required. During surveillance of welding activities of socket joints in Area A-GT5, found axial gap of 6mm between male & female components. This is repeated violation of SAES-L-110 Para 5.2.3 & SAIC-W-2037 Item B3. 16-H46-DGA-5023-85-1CT9P1 (By pass line 1-1/2-H48-DGA5025-1SD0P) Corrective Action: 1. Use SA check list. 2. TRG/Sinopec QC should make fit up inspection and verify the axial gap prior to welding. 3. Take 5 % RT to verify the gap. 4. All socket joints not meeting the requirements shall be cut and rewelded. 5.RFI to be raised to verifying the gap During surveillance of internal cleaning of piping installation prior to Hydrotest in Area A (GT-5), pipes are not being cleaned prior to fit up/ welding & QC is not doing internal cleaning inspection. Found Sand, metal pieces, metal grinding particles, small stones etc in following pipe installations: 1.30-H48-DGA-5033-81-1CT9P (D-502) This is repeated violation of SAES-L-350, Para 15.3.2, SATIP-L-350-01, SAIC-L2017. Corrective Action: 1.Remove the Valve number:TR-319/ V-3413. 2.Clean the line both Down/UP stream of the valve. 3.This is hold point; send RFI to verify cleaning & to close LBE. 4.TRG inspection coverage is required to avoid repeated violation. Header Line 12"-H48-DGA-6030-83 and 82 3SA0P was noted with weld defect known as Linear Misalignment caused by lack of pipe support during welding and may be caused by continous welding of branch pipe. Heating to correct linear misalignment is not allowed in SS piping. Spool release shall be witheld pending repair of the defect. Contractor has welded 2" pipe branch connection near to the fixed support which is a violation of SAES-L-310, Para: 12.5. The line class is 1CS1S, near to column # 52 of GT-3 pipe rack. Contractor is recommended to take corrective action as early as possible. Storage requirements for prefabricated SS pipe spools at Sinopec Fabrication Shop Laydown area were inconsistently complying to the requirements of SAES L-350 par 7. The SS pipe spools were directly laid on the ground with end protectors on pipe, weld bevels, and flanges. Pipe spool was filled with sand, stones, welding rods, and other debris. It was observed that Line H-48-DGA-5021-81-1CT9P has violated the requirements of SAES L-310 with regards to Line spacing of branch connections to a fixed obstruction. The Contractor design is only 300 mm from the beam where pipe support will rest, however, using pipe support with pad and a saddle, then welding of pad will encroach weldolet SAES L-310 requirement is 600 mm from a fixed obstruction Branch connections as noted in Line 10 H49-RL-5052-31-1CT2P (10x10) and 6-H48-DGA-5040-03-1CS2D (6x6 and 6x4) were not in accordance with the requirements of SAES L-110 . The required branch connections for 10x10 and 6x6 shall be Equal TEE and for 6x4 shall be Reducing TEE. Instead the Contractor were using branch weld with reinforcing pad.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.1
423
6/16/2008 2:59:59 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12
424
3/22/2009 2:05:57 PM
SATIP-W-011-01
SAIC-L-2037
Mechanical
SAES
SAES-L-110
5.2.3
425
3/28/2009 8:14:10 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
426
2/5/2008 10:38:46 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.1
427
2/11/2008 10:17:49 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12.5
428
2/12/2008 7:04:30 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
429
2/17/2008 7:07:44 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12
430
2/27/2008 2:47:59 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12
431
2/29/2008 7:37:22 AM
432
5/13/2008 2:02:27 PM
It was observed on HGPE-Area A that branch connection for 12x4 and 12x2 branch weld on Line 12-H48-P-6029-38-1SD02 has no reinforcing pad. Non provision of reinforcing pad on branch weld is a violation to SAES L-110 requirements. All branch connections using branch weld shall require reinforcing pad as stated in Chart 1. Standards other than Saudi Aramco regarding branch connection selections shall be approved by CSD. 10" Long Pipe Shoe was seen welded on the 16"-H48-HW-6005-3CS1S While the shoes on other two lines similar to it in size & in service were seen with 16" long, so this violate Standard Drawing DE-950021 which asks to have 12 inch the minimum. During surveillance of Valve installation in GT-6 Area, found, 16 Class 300 Gate Valve (TR-266-V-1617) is installed in Line Class-16H48-HW-6003-1C1S-Spool O without verifying internal cleaning. As per SA check list it is Hold Point for TRG/SA. Prior to installation of valve found sand, heavy meal grinding particles etc inside the pipe. This is repeated violation (LBE-10079) of SAES-L-350, Para 15.3.2, SATIP-L-350-01, SAIC-L-2017 Contractor has to submit method statement of Internal cleaning and send RFI to verify internal cleaning as this is HOLD point for Saudi Aramco. contractor has no control over the storage and handling of fabricated pipes, fittings and valves. They have been stored on ground with out placing wooden blocks and with out end covers. This is a violation of Aramco standard. Contractor has backfilled 6 and 4 underground DGA line in GT-5 and GT-6 area with out checking the elevation of the pipe. This is the violation of the IFC drawing. During surveillance of internal cleaning of 24/16--H48-S-5038-801CS1S- Area A GT 5, Contractor installed the valve 16-V-4623, TR3552 without sending RFI to verify internal cleaning. A proactive LBE-L525 was made on 7/3/08 to avoid violation. This is repeated violation refer to LBE-11387 (L-499 dated 6/24/08) of SAES-L-350 Para 15. Noticed during punch listing in Area-A, Test package # GT6-S-005, ISO# 6-H48-S-6001-82-6SD0Z, 1.5drain welded on reducer (6x3). This is violation of SAES-L-110, Para: 13.3. Contractor corrective action is required. D-503, DGA Reflux Drum & E-505, DGA Reclaimer: The Jackscrews were made at wrong orientation on some flanges which violating Saudi Aramco Standard. 3-H48-5025-32-1CT2P at 12 and 6 oclock position 3-H48-5055-32-1CT2P at 12 and 6 oclock position 2 Steam line associated on D-503 south/west side at 12 and 6 oclock position. As per SAES-L-109, Paragraph 10.3, Jackscrews shall be installed at 3 and 9 oclock positions. During routine surveillance in GT-5 found that the installed piping and valves were covered with sand. Line # 3-H48-DGA-5019-31-6CT9P and 3 valves (Sr # 3600, 3602 & 3613). This is violation of SAES-L350. Contractor has to clean this piping internally and externally and valves to be re-hydro tested after proper maintenance. Line # 2-H48-S-5007-81-1CT9P1, Joint # FFW-1A is not yet welded and contractor prepared weld summary sheet and signed by Sinopec/TRG QC inspectors. In addition to that this joint has been Penetrant tested (PT report # VPT-P-220) by NDT sub-contractor Vetco. PWHT also completed for 7 joints even line class is STEAM and pipe thickness is 11.07mm.This is violation of Schedule-Q.Contractor has to submit root cause of this issue to close this violation.
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12
SATIP-L-350-01
SAIC-L-2013
Mechanical
ScheduleQ
Schedule Q
1.4
433
5/29/2008 11:53:36 AM
ViolationPrevented Procurement
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
434
6/15/2008 2:51:17 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
435
6/15/2008 2:53:02 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
ScheduleQ
Schedule Q
1.4
436
8/3/2008 7:56:11 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
437
9/6/2008 10:39:03 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.3
438
9/21/2008 7:04:34 AM
SATIP-D-001-01
SAIC-D-2008
Mechanical
SAES
SAES-L-109
10.3
439
11/8/2008 1:32:29 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
15
440
11/9/2008 11:26:42 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.4
441
11/10/2008 3:51:11 PM
During routine surveillance of Joint preparation of Cement Lined Piping fabrication and application of Hempels Knifing compoundin fabrication shop, found following violations: 1. Knifing compound applicator is not qualified 2. Surface preparation is not as per Hempels approved data sheet. 3. Knifing filler compound is not completely filled with compound after welding. 4. Piping ends are not beveled by 30 to 37.5 Degrees. 5. TRG QC is not making surveillance. 6. No approved procedure & DWG is available at site. Violation: SAIC-L-2075, Contractors approved procedure & Std DWG: L-AB-036090 Corrective Action: 1.Knifing compound applicator should be qualified as per SAEP316 2.QC should be available at shop. 3.Approved procedure # DWG should be available at site. 4.Joints not meeting the requirements to be cut & rewelded. -4-H48-FW-5023-11-12LCOU-Spool A, BWJ # 10 -4H48-FW-5027-11-12LCOU-Spool A, BWJ # 12 -4-H48-FW-4031-1112LCOU-Spool A. BWJ # 13 Found; 1.) Item Nos. 59 (24 whole lot), &54 (20 3 nos.). Pipe end bevel damages ranging from >1.5mm to 7mm depth. Saudi Aramco SAES-W-011 Sec 11.3.2.3 allows only a minimum of 1.5 mm depth to be removed by grinding or machining. 2.) Item Nos. 46 (2 4 nos )bended or out of line of intolerable proportion. Those damage pipes shall be cut off if there was no approved repair procedure for this matter or be returned to the supplier. Submit NCR. An elbow in the drain line of E 603 which is covered in the Test package GT6-P-017 found to be having crack during pressurisation for Hydro test. The details of the elbow are as following .Size : 2 and Material : SS 316 L No Markings on the elbow are noted .The line is required to be hydro tested at a Pressure of 350 PSI . While the leakage occurred from the elbow due to crack at a Pressure around 50 PSI . TRG is required to investigate and find the root cause for the occurrence and the necessary corrective action to be taken to avoid recurrence. It has been noted during walk through of Pressure Test package GT6DGA-013 that the wedling was completed for 2 SS lines with a 1 SS sockolet . The length of 2 pipe is 350 mm and at the middle the 1 sockolet is welded. It got distorted and the piece is out of plumb for about 25 mm. There are 12 nos of similar lines and the line nos are : 4-H48-DGA-6088- 35, 37,39,41,43,45,48,50,52,54,56,58 -3SAOP . Hence it is a violation and TRG/SINOPEC have been requested to provide corrective action Contractor has erected some Fabricated Steel Structure material at site for Main Pipe Rack without raising RFI for material verification. This is the violation of SAIC-M- 2004-Item 3 & 12-SAMSS-007 Para 6.5.1 & 6.3.2.1. Contractor is advised to raise a RFI for the verification of the remaining material laying at receiving material yard. Contractor installed equipment on incomplete structure and without plumbed, leveled. This is violation of PIP STS 05130 Para 6.2.5 & 6.3.2 During routine surveillance of Area A-GT-5-Cooler Fin fans- E-501, Contractor installed equipment without raising RFI for structural alignment// bolt tightening . Found structure was incomplete & several bolts were missing. This is repeated violation; refer to LBE-4780 (10/28/07) & LBE-4781 (10/28/07) of SAIC-M-2009 & PIP-STS-05130 Para 5.2.5 & 6.3.2 Contractor has erected steel structures without qualified and approved Strucural Inspector. This is violation of Schedule Q Para 5.1 & 5.2. Contractor has to mobilize a qualified personnel immediately
SATIP-L-350-07
SAIC-L-2075
Mechanical
other
Std. Drg L-AB036090
SAES-H-002
APCS-103 Para 2
442
9/25/2007 4:59:54 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8 & 15
SAES-W-011
11.3.2.3
443
10/15/2008 4:50:40 PM
SATIP-L-350-01
SAIC-A-2013
Mechanical
ScheduleQ
Schedule Q
1.4
444
11/22/2008 8:18:21 AM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-W-011
17.1.2
445
1/14/2007 6:34:46 AM
SATIP-M-001-01
SAIC-M-2004
Mechanical
ScheduleQ
Schedule Q
1.7
446
10/28/2007 2:42:52 PM
SATIP-M-001-01
SAIC-M-2007
Mechanical
other
PIP STS 05130
6.2.5 & 6.3.2
447
11/15/2007 4:00:34 PM
SATIP-M-001-01
SAIC-M-2009
Mechanical
other
PIP STS05130
5.2.5 & 6.3.2
Schedule Q
1.8
448
1/9/2007 6:51:10 AM
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
5.1
449
2/17/2008 6:52:31 AM
Area A- GT6 West Auxiliary Piperack located near Fin Fan Cooler H48-E603 was loaded with SS pipes (8 dia) wherein the Column was not yet grouted. SAPID has received RFI 7430 for bolt torquing on 14 February 2008 with the pipes already loaded on the Piperack even before bolt torquing works. Grouting was completed on 16 February 2008. It shall be noted that loading of pipes on Piperack shall require clearance from structural section to ensure that any loading on the Piperack were directly transferred to the foundations. At HGPE Area A GT5 -West Auxiliary Piperack near E-503 was noted to have been laid with CS piping wherein the final bolt torquing was not completed yet. SAPID does not receive any RFI todate for the final bolt torquing inspection. The bolts may be snug tight but not torqued as required. The Contractor was advised to plan ahead and wait for the structural release prior to loading of pipe. In area GT-5 it is observed that, locations on H48-E-501, 503, C-501 & C-502 walkway handrails and on structure handrails angle supports of utility stations (US # 25, 26, 28, 29, 20 & 23) for plant air piping are supported on structural hand-railing. This is violation of SAES-B-054 (Section 7 Para 6.16) - PIP STF05520 4.8 The minimum clearance between handrail or the top rail of stair railing/standard railing and any obstruction shall be 3 inches (75 mm).and SAES-B-054 (Section 7) 6.19 The handrail shall offer no obstructions to a smooth, continuous surface along both sides and the top. Contractor corrective action & further surveillance is requested for these repeated violation. During test package review in GT-6 found two joints were rejected by Radiography on Nov-20-2008 for the welder T-152. Radiography report number is SRT-6313. Line # 4-H48-P-6106-57-1SD0Z, Joint # 43A & 2047. These RT rejected joints are not traceable in weekly welder performance report against welder T-152 (Refer: MOM 104). This is violation of schedule Q, Attachment IV, Para: 3.3. LSTK contractor TRG shall maintain weekly weld rejection for each welder. Upon receiving RFIs sent by Contractor, it was noticed that 24 hours noticed is not followed. A number of RFIs issued on 28 Oct. at 9:00 9:30 AM and schedule for inspection 28 Oct. at 10:00 10:30 AM. It is violation to Schedule Q, Attachment IV, Para. 1.2.3. Contractor shall follow required timing of RFI issuance in order that SAPID can inspect the RFIs. The welding work is progressing in the Area A; so far Contractor did not assign a welding QC which is a violation of Schedule Q. Contractor is recommended to assign one welding QC for Area A. Contractor, TRG, did not assign RTFI personnel for reviewing, ensuring or auditing RTFI which is a violation of Sch Q, Attachment-1, and Para: 3.3.15.2. Therefore the Contractor is recommended to arrange one Radiographic Film Interpretation Technician at the earliest to meet requirement of Sch-Q. Contractor has not maintaining controlled copy of isometric drawings as well as pipe support drawings either in H46 or in H48 or in H89 which is violation of schedule Q, para: 3.7. Contractor is recommended to provide the controlled copy of drawings (ISO & Pipe Support) in each area to avoid repeated violation. As the welding work is increasing, there was no welding QC assigned from Sinopec in GT-5 area for the last three days, which is a violation of Sch-Q. This condition is because the subcontractor is utilizing welding QCs as permit receiver in the night, which is not acceptable. Contractor is recommended not to put welding QCs as permit receivers with out assigning another welding QC.
SATIP-M-001-01
SAIC-M-2007
Mechanical
other
12-SAMSS008
450
2/24/2008 7:24:50 AM
SATIP-M-001-01
SAIC-M-2007
Mechanical
other
12-SAMSS008
451
4/1/2009 1:53:41 PM
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-B-054
6.16
PIP-STF 05520
4.8
452
12/2/2008 5:02:11 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
453
10/28/2008 5:59:59 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
454
1/7/2008 8:04:15 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
455
1/9/2008 1:53:06 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A 1 Para 3.3.15.2
456
2/5/2008 10:29:54 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.7
457
6/26/2008 8:40:36 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
458
11/26/2008 2:58:45 PM
Contractor is not selecting penalty joints as per SAES-W-011, Para: 17.1.9. During reviewing the hydrostatic test package GT6-P-016 found the line # 4-H48-P-6016-81-1SD0Z, Joint # FBW-17 (100% RT line) is selected as penalty joint for line # 3-H48-DGA-5073-311CT9P, Joint # 15 which is repaired initially. Contractor requested to provide all repaired joints and their penalty joints for SAPID verification and to close this violation. During routine surveillance of welding activities in Area A GT5, found following field butt weld was 50% cut & re-welded due to alignment or deformation without any information. 1.6-H48-P-501134-1CT2P-FBW # 76. This is repeated violation of SATIP-W-011-01, item 3.17 & SAIC-W-2036. Corrective Action: 1.This weld is rejected, to be cut, rewelded & 100% RT is required. 2.Sinopec/TRG QC should make surveillance to avoid reoccurrence. 3.RFI to be raised to close LBE. 4.Isometric DWG should reflect this reweld. During routine surveillance of welding activities in Area A GT5, found following field butt weld was 50% cut & re-welded due to alignment or deformation without any information. 1.2-H48-P-503506-3CS1P1-FBW # 93. This is repeated violation of SATIP-W-011-01, item 3.17 & SAIC-W-2036. Corrective Action: 1.This weld is rejected, shall be cut, rewelded & do 100%RT. 2.Sinopec/TRG QC should make surveillance to avoid reoccurrence. 3.RFI to be raised to close LBE. 4.Isometric DWG should reflect this reweld. During routine surveillance of cut & reweld modification activities in GT5 (D-502), found following repeated violations: 1.No fit-up / welder symbol / FBW # / WPS/ Line number etc. was displayed. 2.No NDT of cut surface of elbow was carried out prior to welding. These are repeated violation of SAES-W-011 Para 11.3.3 / 16.1, SATIP-W-011-01 & SAIC-W-2036 Corrective action: 1. All the welds are rejected & shall be cut & re-welded. (2-H48-DGA-5044-01-1CT2P1) 2. All the rewelds to be 100% RT. 3. QC should make pre-welding & fit up inspection prior to welding and should sign. 4.RFI shall be raised to close LBE. During surveillance of cut & re-welding in GT-5 (D-502), welding was in progress without Sinopec / TRG fit- up approval. Found excess root gap 8~12 mm whereas WPS-CS-02 root gap acceptable is max 3.2 mm. Following cut & re-welds with excess root gap to be 100 %RT: 1.16-H48-RL-5019-31-1CT2P-FBW # 1110 2. -32-1CT2P-FBW # 100, 1082 3. -35-1CT2P-FBW #1005 4. -33-1CT2P-FBW #1086 Contractor has cut and re-welded SW 75 previously accepted 2joint on line No 24 H48-RL-6019-04-1CT2P Drawing No BB-250271 with out issuing any RFI, and involving Quality Control for fit up check and other verifications violating the requirements of SATIP-W-011-01 item 3.7 & SAIC-W-2036 repeating the violation for which Saudi Aramco NCR No 005 was previously issued. This half completed weld when checked from the root side was found with incomplete penetration, the main reason is that required Quality Control for joint preparation and fit up was not applied. TRG also submitted the package of the same piping circuit to PID to clear it for Hydro-testing with weld summary sheet showing Joint No 75 as Shop completed Weld. Referenced Joint No75 should be cut and re-welded following the project approved Quality procedures. Prime contractor TRG should investigate the root cause and provide the preventive measures to avoid the violations that are occurring again and again. In GT-5, found that 30 diameter shop butt weld was cut and rewelding without raising any RFI. Line # 30-H48-P-5009-01-1CT2P, Joint # 18.It is hold point H1 for Aramco inspection. This is violation of SATIP-W-011-01, Item # 3.17. Contractor has to fill SAIC-W-2036 and request for Radiography for this joint. It is repeated violation after the fact.
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAES
SAES-W-011
17.1.9
459
3/30/2009 3:03:46 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
460
3/30/2009 3:15:22 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
461
3/12/2009 2:14:11 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011 11.3.3, 16.1 & 18
462
3/1/2009 1:58:21 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
463
11/24/2008 6:46:31 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
464
11/3/2008 1:26:09 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.8
465
12/26/2008 10:53:15 AM
During routine site visit in GT5 noticed that the completed hydrostatic test piping (TP # GT5-DGA-027 & GT5-FG-003) cut out with out any information to SAPID. Line # 8-H48-DGA-5001-34-1CT2P1-Spool-K and 1-H48-FG-5015-82-1CT2P-Spool-J & K. This is violation of SAESW-011 and SAIC-W-2036. Contractor has to avoid such type of repeated violations and shall take immediate action. During routine surveillance in GT6 found, the lifting lug welded directly on elbow long seam for line # 46-H48-P-6073-31 at top of the column C-602. This line has been hydro tested earlier. Contractor is doing welding after hydro test with out any information to SAPID. This is repeated violation of SAIC-W-2036. Re-hydrostatic test has to be done for this elbow of test package # GT6-P-015. Contractor is carrying out Butt welding of 1/2 Diameter Piping, in spite of several reminders contractor has not provided certification records for any welder qualified for this diameter range. It is informed that welds made with non qualified welders are in violation to the requirements of SAES-W-011 Para 8 and will not be accepted. During routine site visit in GT-5 found that an unqualified welders T-21 & T-175 were welding with filler wire ER-NiCrMo-3 (F-number F43) for material UNS-31254 of line # 8-H48-DGA-5030-59-1CT9P & 3-H48DGA-5157-31-1CT9P respectively. These welders are qualified for Fnumber F6 filler wire only. This is violation of SAES-W-011. Contractor has to either cutout all these joints and re-weld with qualified welder or qualify those welders as per WPS-SS-07 with same F-number F43 and 100% NDT to be completed. During surveillance of CS Fabrication / Welding shop found welder was welding without JCC Card. This is repeated violation of SAES-W-011 Para 8.1 Corrective action: Remove welder from site and cut out the following weld. 1.2-H48-6068-81-3CT2P-P-Spool L Weld # 48 During routine surveillance of welding activities in Area A GT5, found following field butt weld was 50% cut & re-welded due to alignment or deformation without any information. 1.6-H48-P-501134-1CT2P-FBW # 76. This is repeated violation of SATIP-W-011-01, item 3.17 & SAIC-W-2036. Corrective Action: 1.This weld is rejected, to be cut, rewelded & 100% RT is required. 2.Sinopec/TRG QC should make surveillance to avoid reoccurrence. 3.RFI to be raised to close LBE. 4.Isometric DWG should reflect this reweld. Contractor QC doesnt have a pyrometer to check the preheat or interpass temperature which is a violation of SAIC-W-2006, Item#D4. Contractor is recommended to arrange a pyrometer to the Concerned QC at the earliest to avoid repeated violation. Stainless steel line H48-SOW-6504-33 (BB-250270-020) butt joint # 74 was cut and rewelding was in-process by welder T-050 with out preparation of building bevel angle on pipe edges, pipe edges has gap of 10mm (root gap) and without fit-up inspection, these are violation to applied WPS SS-03 which states bevel angle and provide 2 to 4 mm root gap and violation to SAIC-W-2036. This violation was noticed & welding was stopped by PID, and TRG QC, TRG supervisor & Sinopec QC manager was requested on site and shown to witness the violation. TRG corrective & preventive action and TRG QC vigilance is requested.
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.8
466
2/14/2009 5:44:40 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.8
467
12/3/2008 3:05:06 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
468
2/22/2009 6:36:27 AM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
469
12/11/2007 11:36:42 AM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
470
2/15/2009 4:29:53 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
471
1/15/2008 10:08:29 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.4
472
9/9/2008 11:20:12 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
7.1.8
473
11/17/2008 1:57:55 PM
We have inspected the root of some small bore 11/2 drain and vent branch connections using inspection mirror and found incomplete root penetration on piping/joints numbers mentioned below. These are dissimilar metal welds between SS sockolets of ASTM A182 GR F44 material and CS pipes: 1) 10 H48-DGA-5054-32 SW12. 2) H48-DGA5054-32 Downstream PZV623B. 3) 12 DGA-5024-34 Downstream FV442. 4)12 DGA-5024-34 Upstream FV447. 5) 24DGA5070Downstream of MOV 551. Observed defects are in violation to SAES-W011, Para 9.2 & 17.6.3.2 and are required to be corrected. Further contractor should determine the root cause of this violation and provide us with an inspection plan to verify & ensure that other constructions of this type are free of these deficiencies. During routine site visit in GT-5 observed that welding is being performed with out preheat for the line # 24-H48-DGA-5034-826CT9P, Joint # 1132, Thickness 31mm, Welders T-096/T-616. This is violation of SAES-W-011, Section 12 & Table-3A and approved Welding procedure Specification (WPS). Prime contractor TRG is the responsible to perform preheat as per WPS during this cold weather. TRG/Sinopec is issuing RFIs but they are not utilizing SAIC-W-2007. Contractor is releasing material for RT/ painting and installation in GT3-Main Pipe Rack without TRG & PID inspection. This is repeated violation of SAIC-W-2007. Contractor is advised to take Corrective action by Utilizing SAIC and get inspection from TRG & PID other wise all material will be on Hold. It has been observed that on piping circuits of piping class 1CT9P, 1CT9P1, 3CT9P, & 6CT9P for Train GT-5, with main piping of Carbon Steel material, the drain & vent connections are provided of Stainless Steel materials using DISIMILAR METAL WELD JOINTS. Gas Treat -5 processes Rich DGA, which is considered to be a SOUR SERVICE and DISIMILAR METAL WELD are not permitted as per the requirements of SAES-W-011, Para 6.4.2. Contractor shall consult it process engineering identify the areas / piping having SOUR SERVICE and record all DISIMILAR METAL WELDS made on such piping circuits. Contractor should resolve this violation at earliest; this issue has been discussed in QC meetings for last four weeks with out any resolution from contractor side further delays can impact the project schedule. During routine surveillance of GT-3 & outside Shop Fabrication areas, found FBW are changed to SBW in all areas. As per Sch Q, SAES-W011, Sec 17.6, PFI-ES-43 Section 1 (Piping Fabrication Institute)& SAICL-2031, which states Contractor/Subcontractor fabrication shop are an indoor/outdoor fabrication facilities approved by SA Inspection to assure meeting quality requirements. Following are some examples where contractor has changed the status of FBW to SBW: 1.12-1SDOP-Spool G-SBW #32, 30, 31 2. 30--6SD0Z-Spool-W/A/K1/K/WSBW # 6, 1, 56, 50, 49, 47, 16. 3. 18--3CS1Z-Spool A SBW # 2, 3 1 4. 12 x 16--3CA1J-Spool A-SBW # 36, 37 5. 3-3CA1J-Spool D/H/FSBW # 8, 17, 16, 12. 6. 6-3CA1J-Spool A/B-SBW # 3, 1 4, 4 7. 43CA1J-Spools.E/C/U/W-SBW # 15, 10, 38, 45 As per SAES-W-011, Para 17.5.2.1 & TRG/Sinopec Piping Material Class NDT rate, Contractor has to comply RT% as per SBW & FBW respectively : During surveillance of welding activities at GT-3-Main Pipe Rack Area, found Sinopec is installing & welding 24 pipe saddle supports without surface cleaning (i.e. mills scale, tight rust etc). This is violation of SAES-W-011, Para 11.3.1, which states oil, moisture, rust, scale, paint & other foreign matter shall be removed from the weld surface at least 25 mm of adjacent base metal prior to welding. 1. 24-H-48-RL-601903-1CS2P. Contractor is advised to remove all installed saddle supports and comply with the requirements of SA Standard. JCC of the welders involved to be withdrawn. RFI is required to verify the work and to close LBE. No QC-WI-Sinopec/TRG was available.
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.2 & 17.6.3.2
474
12/14/2008 5:46:01 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12
475
12/15/2007 2:54:45 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.7
476
11/24/2008 8:54:28 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
6.4.2
477
12/3/2007 4:07:32 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAEP
SAEP-1160
6.2
PFI-ES-43
Sec I
478
12/23/2007 5:02:38 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.1
479
12/23/2007 5:07:02 PM
During surveillance of welding activities in Main Pipe Rack Area A, found Sinopec is installing 24 pipe saddle supports without removing paint. This is violation of SAES-W-011, Para 11.3.1, which states oil, moisture, rust, scale, paint & other foreign matter shall be removed from the weld surface at least 25 mm of adjacent base metal prior to welding. 1. 24-H-48-RL-6019-03-3CS2P. Contractor is advised to remove all installed saddle supports and comply with the requirements of SA Standard. JCC of the welders involved to be withdrawn. RFI is required to verify the work and to close LBE. No QC- WI was available at site from Sinopec/TRG. This is repeated violation LBE-5756. During surveillance of welding activities in Sinopec shops, found following discrepancies: Fabricated spool no.6-H48RL-6020-311CT2P-Spool D 1.No welder Symbol was displayed. 2.No. WPS was displayed 3.Weld Number was displayed # 16 & 14 (Not identified Field or Shop). 4.Mr. Wang Tao-QC Sinopec signed fit up without checking fit up and also no fit up record was available in his daily fit up sheet. 6.It was windy at 11.AM and no proper shielding was available. This is repeated violation of SAES-W-011 Para 16.1 Mr. Wang Tao is working since last six months and showing no progress. Above mentioned welds to be 100% RT and QC to be removed from shop. No Sinopec QC was available at site. Incomplete penetration for 1sockolet welds found in GT-5, for line# 4H48-RL-5000-32-1CT2P near PZV-112A, Quadrants East: 11282266, Noth: 7643496 and Elevation: +116502. This is violation of SAES-W011 Para: 9.2 and 17.6.3.2. Contractor has to take immediate action. Incomplete penetration and out of center for two sockolet weld joints were found in GT-5 of 30X20 reducer near FV-105 for line # 30-H48P-5004-82. This is violation of SAES-W-011 Para: 9.2 and 17.6.3.2. Contractor has to take immediate action. Area-A, GT5, Line # 30-H48-DGA-5033-31-1CT9P, Joint # 18 found the socket weld flange to pipe#1 axial gap is 10mm. This is violation of SAES-L-110, Para: 5.2.4 the axial gap between male and female components shall be maximum of 3 mm and minimum of 1.5 mm. Contractor has to take immediate action as soon as possible. Contractor TRG/Sinopec is executing welding activities in night shift without submitting plan to ensure that quality personnel are effective and work is completed in strict compliance. This is violation of Schedule Q.3.1 & Attachment IV Para 1.1 Contractor is advised to assigned approved quality personnel to avoid any rework. During routine surveillance of preheating activities at 6.00 A.M prior to welding, found welding was in progress without preheating. It was cold & metal temperature was < 10 Degrees C. This is repeated violation of SAES-W-011 Para 12.2, which state minimum preheat shall not be< 10 Degrees C. No QC personnel were available at this time. 1.12-H48-DGA-5024-81-1CT9P-J, Weld # 41 (Welder # T-003) 2.24H46-P-7003-32-3CT2P-C (Welder# T-004) 3.24/16-H48-DGL-604731-1SD0P-B(Welder # T-050) During surveillance of welding activities at GT-3-Main Pipe Rack Area, found Sinopec is installing & welding 24 pipe saddle supports without surface cleaning (i.e. mills scale, tight rust etc). This is violation of SAES-W-011, Para 11.3.1, which states oil, moisture, rust, scale, paint & other foreign matter shall be removed from the weld surface at least 25 mm of adjacent base metal prior to welding. 1. 24-H-48-HW-650103-3CS1S 2. 24-H-48-HW-6500-02-3CS1S Contractor is advised to remove all installed saddle supports and comply with the requirements of SA Standard. JCC of the welders involved to be withdrawn. RFI is required to verify the work and to close LBE. No QC was available.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.1
480
4/19/2008 11:45:33 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1 & 11.2.2
481
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
482
12/23/2008 2:04:23 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.2 & 17.6.3.2
483
1/21/2009 7:16:50 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.2 & 17.6.3.2
484
3/4/2009 7:24:36 AM
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.4
485
11/19/2007 5:02:53 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
3.1 & Attachment IV Para 1.1
486
12/1/2007 11:28:54 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-001
12.2
487
12/4/2007 9:12:49 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.1
488
12/4/2007 11:57:49 AM
During routine surveillance of Main Pipe Rack Area A welding activities found welder# T 035 was welding without fit-up approval, and without any information. QC was not available since morning. JCC card of the above welder is withdrawn. This is repeated violation refer to LBE # 4923 & 4926 of SAIC-W-2005 & Contractors own approved procedure QI-8420-009 Para 4.2. 1.4-H48-W-6002-01-6CS2P1-RWeld # 100 2.6-H48-W-6001-01-6CS2P1- -Weld # 13 During routine surveillance of preheating activities prior to welding due to cold weather at 6.00 A.M where metal temperature is < 10 Degrees C, found Contractor is welding without preheating. This is repeated violation refer to LBE-5681 (12/1/07) of SAES-W-011 Para 12.2 All field & shop welds welded without preheat to be 100 % MPI on contractors expenses. RFI to be raised to verify 100% MPI and to closed LBE. Contractor QC doesnt have a welding gauge and a hi-low gauge in order to do his welding inspection properly which is violation of our schedule-Q, Attachment-IV, Para: 6.1. Contractor is recommended to provide all necessary tools to the concerned QC. During surveillance in the Area A (GT-6), it was noted that Joint# SFW 14 (6x4) of H-48-DGA-6062-01-1SD0Z, welded by T-019, is not straight (dog leg) which was released to the site from the fabrication shop, is a violation of the standard. Before releasing the spool to site, prime contractor QC has to check all the spools and for the above said violation, Contractor is recommended to cut the joint and re do welding before the spool gets erected on rack. Contractor is welding on 30" and 24" pipes on the highly elevated pipe rack with out using a remote current control which is a clear violation of SAES-W-011 and as well as a major safety concern. Contractor is recommended to provide Remote Current Control wherever the welders are welding at highly elevated place. Contractor so far didnt keep a HOLDING OVEN on site (Area B) which may create joints to be rejected due to poor consumable control which is violation of SAIC-W-2032. Since there was no radiography taken to the welded spools in Area B other than Tie-In joints, Aramco Inspection presume that the rejection may go high at site. Contractor has to comply with the requirement at the earliest. Contractor is welding sliding plate (Stainless Steel) underneath of the pipe support wherever is required as per the drawing, but in the drawing it is not mentioned what type of SS grade has to be used. So far contractor didnt confirm the SS grade from their engineering. So Contractor is recommended to confirm that what type of grade has to be used for SS sliding plate from engineering and do PMI on welded SS sliding plates. It was observed and noted that spool 12-H48-DGA-6022-33 3SAOP-H was contaminated with rust along the HAZ and weld joint itself. .The Contractor has to verify this issue which may be in relation with the CS and SS piping prefabrication works in only one roof. Saudi Aramco approval is required and the Contractor is in violation to SAES W-011 par. 17.6.1.3.1 and SATIP L-350-08-08. Aramco Inspection found one quiver filled with cold 7018 electrodes in GT-3 which was left by one of the welders. This poor consumable control is a repeated violation of QI-8410-001.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
489
12/9/2007 9:04:22 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.2
490
1/15/2008 10:20:11 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
491
1/18/2008 11:01:01 AM
SATIP-W-011-01
SAIC-W-2068
Mechanical
SAES
SAES-L-350
492
2/5/2008 10:37:04 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.1
493
2/5/2008 11:00:36 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
494
2/5/2008 11:21:26 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.4
495
2/10/2008 4:39:24 PM
SATIP-L-350-08
SAIC-L-2031
Mechanical
SAES
SAES-W-011
11.4.3
496
2/11/2008 10:26:01 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
497
2/26/2008 5:55:09 PM
Special pipe support EE-0026 to be employed for line 24 RL-5019 at GT5 Main piperack was inspected during welding works and was found using intermittent weld on welding SS plate under pipe shoe saddle. Moreover, even the Lubrite plate which was Vendor supply was tack welded. Detail drawings were checked and was found that there was no detail on welding requirements for SS plate but the Lubrite plate has to be full welded. Saudi Aramco standards ( i.e. 12SAMSS07 and SAES-L350) does not permit spot welding on structural support During surveillance it was noted that, 1 DRAIN welded to the 6" line (6-H48-W-6001-33-6CSZP1-P) on east end of GT-6 pipe rack, coming 601-C and 601-B have inadequate fillet welding which is a clear violation of SAES-W-011. As per the standard MINIMUM two passes are required. The concerned QC is recommended to take corrective action for the socket welds as early as possible. During surveillance, it was noted that contractor is not maintaining a log for RETURNED electrodes which is a violation of SATR-W-2010. Prime contractor QC is recommeded to monitor and implement the issued and returned welding electrode log book update. Today one joint was found with out QC fit up signature on 46-H48-P6073-31-1SDOZ, FBW#6 in the south side of GT-6 area. Welding already reached to capping. Now this joint either cutoff or 100% RTd. One Mr. Jimmy is the concerned QC from TRG side in GT-6 area. During inspection of trays, it was noted that contractor has intermittently tack welded the bottom of the 21st tray with out submitting any method statement or procedure which is a violation of Sch-Q. Welding details are not mentioned in the drawing. The intermittent tack weld they provided is not in correct length and pitch. For the FBW joint# 55, Line# 36-H48-P-5035-31-3CS1P1, Welder#154 has made weld weaving of 15mm which is above the acceptable limit of WPS-CS-02, is a clear violation. The acceptable limit of weaving is 9.6mm maximum. Contractor is recommended to monitor welder closely during welding to avoid this type of violation in the future. During surveillance of welding activities in GT-5 Area A, Welder Symbol # T-619, was using SMAW Electrode E 8018-03-H4R. As per applicable WPS-CS-02 & WPS-CS-04, E 7018 to be used. This is violation of SAES-W-011 Para 7.13 & WPS-CS-02 / WPS-CS-04 16H48-DGA-5023-81-1CT9P1-Spool Number 1E-SBW #14 (FBW # 14). Contractor is again making repeated violation by writing SBW # instead of FBW #. Corrective action: 1. TRG/ Sinopec should make surveillance & comply with the applicable WPS. 2. Use correct Butt weld numbers. Noticed that, for distortion of piping to bring joint assembly into alignment Contractor has heated the pipe/fitting and masked by buffing the heated/effected area on 2 inch line # H48-SOW6503/6504/6500 -31, such practice has potential of thermal cracking and effect on material properties. This is the violation of SAIC-W-2036 item # A7 Welds requiring re-work by heating shall require approval by CSD and SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5.Contactor corrective and preventive action is requested for such repeated violations. During surveillance of welding activities in Area A GT-6, found following repeated violations: 1.Welding was in progress without Sinopec/TRG QC fit-up approval. (SAIC-W-2005/2006) 2.Welder was not having JCC card. ( Mr. Fan Xiao Han T#086) (SAIC-W-2035) 3.Field Butt Welds were marked as Shop Butt Welds (SAIC-W-2005). Above are repeated violations of SAES-W-011. 17.5.2.1, SATIP-W-01101, SAIC-W-2005/2006. Following are the spools numbers: 1.16-H48DGA-5023-81-1CT9P1- Spool - BS.-SBW 192, SBW 191(FBW 192, 192). 2.16-H48-DGA-83-5023-1CT9P1- Spool AQ SBW 2001, SBW201 (FBW 2001, 200). 3.16-H48-DGA-83-5023-1CT9P1- Spool APSBW 197 (FBW 197).
SATIP-M-001-01
SAIC-M-2012
Mechanical
SAES
SAES-L-350
11.3
12-SAMSS007
5.2.3.3
498
5/26/2008 6:41:45 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.1
499
5/26/2008 9:21:40 AM
SATIP-W-011-01
SATR-W-2010
Mechanical
SAES
SAES-W-011
6.1
500
6/15/2008 2:48:02 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.3
501
6/15/2008 2:55:37 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.1
502
6/26/2008 8:51:50 AM
SATIP-W-012-01
SAIC-W-2049
Mechanical
ScheduleQ
Schedule Q
1.3
503
8/14/2008 4:47:59 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
7.4.5
504
8/28/2008 1:54:44 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
7.3.5
505
9/20/2008 2:10:42 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
17.5.2.1
506
10/19/2007 2:35:59 PM
507
11/16/2008 8:14:32 AM
During surveillance of structural pipe supports welding in Sinopec Fabrication/Welding shop, found Welders Symbol #T- 037 & #T-042, were welding structural pipe supports without surface preparation of Base Metal. This is violation of AWS D1.1/D1.1 M-2004, which statessurfaces on which weld metal is to be deposited shall be smooth, uniform and free from loose or thick scale. JCCs of above welders are withdrawn Noticed that, to bring it in alignment Contractor has heated the pipe/fitting Package H48-P-003 (2 inch line # H48-P-6004-03 elbows at weld # 90, 98, 101,), such practice has potential of thermal cracking and effect on material properties. This is the violation of SAICW-2036 item # A7 Welds requiring re-work by heating shall require approval by CSD and SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5.Contactor corrective and preventive action is requested for such repeated violations. :During routine surveillance of welding activities in Area A GT5, found modification of 6-H48-RL-5001-31-1CT2P-(D-503) & welding was in progress without Sinopec/TRG fit up inspection & without NDT of cut surfaces. No any information was displayed on the weld. This is repeated violation of SATIP-W-011-01, item 3.17 & SAIC-W-2036. JCC card T-216 is withdrawn. During routine surveillance found that the carbon steel nipple installed and welded instead of stainless steel nipple in line # 6-H48-P-5016-311CT9P, item # 10. Drawing # BB-250270-512, Revision-E. This is violation against ISO drawing. Contractor immediate action is required. It was windy at 14.00 hrs, found welding activities in piping shops, pipe supports shop,SS piping shop & outside shop areas. There were not enough wind shields to protect from the environment in all areas. This is again repeated violation of SAES-W-011 Para 11.2.1 & 11.2.3. This is the main root cause of porosity. Contractor is advised to use adequate wind shields all the times. Contractor TRG/Sinopec at present has 74 active approved JCC Welders working in Area A Main pipe rack/ AreaB Main pipe rack/ SS WeldingShop/ CS welding shop & outside shops (Field Weld). As per Schedule Q-VI-2, Subcontractor Sinopec should have one Inspector per 13 welders for shop welding, one Inspector per 10 welders for field welding. Primary Contractor TRG should have one Inspector per 8 subcontractor Inspectors for Shop & one Inspector per 5 subcontractor Inspectors for Field . Violation: Schedule Q-VI-2 It is observed during walk through of the Pressure Test package H48GT6-DGA-002 which covers the line 12DGA6034-81-6SDOZ , Sheet 299, Rev 00C that three additional butt weld joints have not been reported in the Weld map. The test package belongs to GT 6 of area A. These joints were ignored during walk through of SINPEC/TRG and the package forwarded to PID. This is violation against the requirements of SAESW-011 & SAEP-1160 . The line conforms to SS 316 L material and the joints were welded in field. As such these joints have to be reported in weld map and in weld summary as well as the relevant NDT need to be performed . At south of DD#4 where the Three Tie-ins (TIE-IN -856 TIE-IN -857 TIE-IN -858) were made, a 3 CPVC Drinking Water is found at the top of the New Fire Water RTR piping and only 30mm clearance distance between them at tow locations which violating Saudi Standard. As per SAES-S-040, Paragraph 5.5.12, the minimum clearance distance between the Raw and Drinking Water shall be 300mm.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.1
AWS D1.1
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
7.3.5
508
1/31/2009 9:26:57 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.1
509
3/24/2009 7:52:20 AM
Mechanical
Drawing
510
11/22/2007 3:52:42 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011 11.2.1 and 11.2.3
511
12/9/2007 4:42:23 PM
Mechanical
ScheduleQ
Schedule Q
A VI Para 2
512
10/20/2008 1:24:58 PM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
17.6.1
SAEP 1160
6.1
513
1/1/2009 4:38:03 PM
FIRE WATER SYSTEM
Mechanical
SAES
SAES-S-040
5.5.12
514
6/10/2009 1:53:50 PM
It is noted that two different piping specifications have been combined in a Pressure Test package (H49-DD5-BD-002) for the blow down lines . The test package consists of 1CA1J and 3CA1J piping specifications with design pressures 250 psi and 450 psi respectively and provided the test pressure 450psi which does not meet the requirement. This is not acceptable as per para 7.1 of SAES-L-150 and hence the package need to be split as per piping specifications and provide suitable test pressure as per the SAES-L-150. It is noticed that, since long time manway of Vessel H49-D-564 is left open unattended, this is the violation of schedule Q attachment IV Para 5. Contactor corrective and preventive action is requested to preserver equipment manways properly. In area DD-5 it is noticed that, for exchanger H49-E-545 Name plate is not readable due to obstacle by structural members, which is violating requirement of 32-SAMSS-004 Para17.3 Nameplates and nameplate mounting brackets shall be located such that they will not be covered by insulation and are easily readable from grade or a platform.. contractor corrective action and further surveillance for any other equipment is requested. During visual inspection of H85-K-00F upon removal of wooden box, found sixteen leveling jackscrews were found missing. Contractor had stored hydrostatic tested vale unattended in lay-down area A , valves end flanges are uncovered with plywood covers, raised face portion of the flanges are not covered with heavy grease, no heavy adhesive tape is used around the complete circumference of the plywood cover and the valves end connection. This valve N0: H49TR-240, Size 24 Class # 150 Gate Valve was shop tested on Oct 5, 2008, is continuously stored in open area and valve is completely rusted inside body. This is repeated violation of 04-SAMSS-035, Para 12.1, 12.2, 12.3, SAIC-L-2041 and contractors approved procedure QI-8410-005 Rev A, Item 4. Corrective action: 1.Contractor should retest this valve in shop. 2.Re-dry lay- up and use SAIC-L-241& approved procedure. 3.RFI to be raised to verify the rework. During flame cutting of vertical pipes down & upstream of 12 MOV in Area A (DD-5), pipes are not being internally cleaned prior to fit up/ welding & QC is not doing internal cleaning inspection. Found, molten metal pieces, metal grinding particles, sand, etc in following pipe modification & installation: 1.12-H49-S-5806-32-6CSiV-Spool-J. This is repeated violation (Ref: to LBE-525, 1837) of SAES-L-350, Para 15.3.2, SATIP-L-350-01, SAIC-L-2017. Corrective Action 1.Remove 12 MOV Valve. 2.Send RFI to verify internal cleaning. 3.TRG/Sinopec QC should make surveillance. It is found that , low temperature carbon steel materials (LTCS) installed in the piping circuits of DD5 does not have any traceability for confirmation. As per schedule Q , para 3 of attachment IV , contractor shall implement an identification procedure for all materials ,parts and components including partially fabricated assemblies. Also, the traceability shall be maintained in the project . Hence , absence of identification on LTCS piping is a violation. Therefore , contractor is requested to provide immediate corrective action . Contractor did not perform any PMI on stainless steel consumables so far which is a violation of SAIC-L-2010, Item# B2. Contractor is recommended to perform PMI for one electrode and one filer wire from each lot.
SATIP-A-004-01
SAIC-A-2003
Mechanical
SAES
SAES-L-150
7.1
515
3/15/2009 11:43:58 AM
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
516
3/16/2009 11:17:21 AM
Mechanical
other
32-SAMSS004
517
10/8/2007 2:45:47 PM
SATIP-K-402-01
SAIC-K-2002
Mechanical
other
31-SAMSS001
518
4/12/2009 7:56:25 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
519
5/3/2009 11:20:09 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
520
5/12/2009 7:52:35 AM
SATIP-L-350-01
SAIC-L-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3
521
1/7/2008 7:42:09 AM
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
7.7.2
522
3/4/2009 4:35:02 PM
Noticed in DD5 area that, few valves installed in piping circuit without gasket not even temporary gasket and bolts are snug tighten, which also include stainless steel valve flange joint with carbon steel piping flange such practice will damage flange face violating SAES-L-350 Para 8.1 all material shall be handle with care during fabrication and installation to prevent damage. Example: line 12-H49-S-5806-32 MOV-891 & 24-H49-S-5802-32 MOV-892. Contractor corrective & preventive action is request per SAES-L-350 Para 8.1. Noticed in DD5 area that, ISO drawing indicates Stainless steel A182 material drain valves where as actual installed & welded gate valves are carbon steel material ISO drawings # H49-P-5504-32 item 26, H49P-5504-37 & H49-P-5535-31 1 & size valves. Contractor further surveillance & engineering review and corrective & preventive action are request with Aramco approved procedure is requested. Noticed in DD5 area that, axial gap between socket weld flange welded to pipe are excessive around 10 to 15mm in many cases violating the requirement of SAES-L-110, Para: 5.2.4 which permits maximum 3mm axial gap, Example: 14H-49-P-5503-45 spool CC , 16H49-P-5504-37 spool AU # 182 & package P-020 item F6 contractor further surveillance and corrective/preventive action is requested. Noticed in DD5 area that, Dummy spools installed in piping circuit without gasket not even temporary gasket and bolts are snug tighten, the same was shown to TRG on site. Such practice will damage flange face violating SAES-L-350 Para 8.1 all material shall be handle with care during fabrication and installation to prevent damage. Example: line 30-H49-P-5006-05 one near FBW # 120 & another near SBW # 97. Contractor corrective & preventive action is request per SAEP-351 Para 4, please inform PID for verification of flange face. It is notice that Contractor Construction crew and QC personnel are utilizing uncontrolled documents (photo copy/superseded of ISO) for the execution of work and inspection specially concern are many weld joints marked as shop weld in uncontrolled ISO are been welded on site many such violation are highlighted to TRG & PMT representative on site, this is the violation of Schedule Q Para 3.7 and SAEP-1154 Para 5.4.2.3. TRG QC vigilance on such amendment welding practice and performing NDE and providing applicable document on work site and document control is requested. In DD5 area: since a week insufficient TRG piping QC coverage is noticed only ONE piping QC is working part time means after lunch hours QC is assigned to cover daily piping activities and walk through package, this is violation of Schedule Q requirement attachment VI and contractor agreement in meeting to assign one piping QC for daily activities and one for walk through package fulltime. Contractor immediate action is requested to ensure Aramco standard / procedure implementation. Repeated violation are noticed in DD5 area that, few valves and Dummy spools installed in piping circuit without gasket not even temporary gasket and bolts are snug tighten, Such practice will damage flange face violating SAES-L-350 Para 8.1 all material shall be handle with care during fabrication and installation to prevent damage. Example: line H49-P-5006-01 spool L, H49-P-5567-01 spool F, H49-P-5507-01 spool I, H49-P-5571 -01 spool B, H49-P-5571-03 spool L Contractor corrective & preventive action is request per SAEP351 Para 4, please inform PID for verification of flange face.
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
8.1
04-SAMSS -035
12.2
523
3/4/2009 4:55:53 PM
Mechanical
Drawing
Schedule Q
1.3
524
3/4/2009 5:02:10 PM
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.4
525
3/9/2009 3:27:19 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
8.1
SAEP-351
526
3/11/2009 4:39:49 PM
SATIP-W-011-01
SAIC-W-2001
Mechanical
ScheduleQ
Schedule Q
3.7
527
3/11/2009 5:14:34 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
528
3/16/2009 11:30:46 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
8.1
529
3/19/2009 4:11:48 PM
Notice in DD-5 area, for piping branch connection 16x12 reinforcement (RF) pads are not provided also RF pads not shown for the same in ISO 16-H49-P-5503-33 Rev D, P-5503-37 & P-5503-36 having line class 3CS1Z. Such branch connection without RF pads is violation of materials specification for piping falling line class 3CS1Z. Contractor corrective action and investigation to locate and rectify any such violation is requested. On the flange of control valve 45-FV-112 (ISO: 30-H49-P-5006-03) imperfection is noticed at the gasket seating area, this is the violation of SAIC-L-2014 item A2, SAEP-351 Para 4.3 The flange facing, particularly the seating area, shall be visually examined for cleanliness and ensure that no damage, such as scratches exist. Contractors verification and Corrective action requested and please inform PID inspector prior to final connection of piping. The fabricated and welded branch connections by the contractor TRG/Sinopec are conflicting with Aramco standard. This is the violation of SAES-L-110, Chart-1. Contractor has to submit the waiver if any or else Aramco standard has to be followed as early as possible in order to avoid rework and delay in the project. Many spools not kept in safe places are found in different places of area DD5 and thrown directly on the ground without end protectors on pipes or flanges. These are some of examples: 3"-H49-CS-5020-311CS2D-A 3"-H49-CS-5020-31-1CS2D-B 8"-H49-LO-5862-31 This is a violation as on paragraphs 7.1 & 7.4 of SAES-L-350 For the Weekly Welder Repair Report and Project Weld Status Report, Contractor is not utilizing our (SATR-W-2013) & (SATR-W-2019), which come under SATIP-W-011-01, is a violation of Schedule Q. The contractor is recommended to use our checklist and test reports wherever applicable other wise it will be a repeated violation. It is notice that Contractor Construction crew and QC personnel are utilizing uncontrolled documents/ISO on site which doesnt indicates weld numbers, this repeated violation is highlighted to TRG QCIs on site(example : 6-H49-P-5046-33-3CA2J), this is the violation of Schedule Q Para 3.7 and SAEP-1154 Para 5.4.2.3. TRG QC vigilance on such amendment welding practice and performing NDE and providing controlled document on work site is requested There is no weld identification marked while welder was making welding for a joint on spool 30"-H49-P-0024-31-30S1P. This is a violation as on paragraph 16.1 of SAES-W-011 Noticed in DD5 area that, for distortion of piping & to bring it in alignment Contractor has heated the pipe & force by hammering (Reducer near valve # 1160 line 3-H49-P-5037-31 and one 2inch line near eastside of Column C-551), such practice has potential of thermal cracking and effect on material properties . This is the violation of SAIC-W-2036 item # A7 Welds requiring re-work by heating shall require approval by CSD and SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5.Contactor corrective and preventive action is requested for such repeated violations. Noticed in DD5 area that, to compensate for distortion of piping & to bring it in alignment Contractor has heated the pipe (H49-C-5171-311CS2P spool A # 2, DD5 north-eastside), such practice has potential of thermal cracking and effect on material properties. This is the violation of SAIC-W-2036 item # A7 Welds requiring re-work by heating shall require approval by CSD and SAES-W-011 Para 18.5 and Schedule Q Para 7 .3.5.Contactor corrective and preventive action is requested for such repeated violations.
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.1.1
530
3/24/2009 10:58:42 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
531
3/16/2008 8:14:57 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.1.1
532
11/23/2008 6:13:15 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
7.1 and 7.4
533
1/7/2008 7:33:01 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAES
SAES-W-011
8.4
534
3/24/2009 11:30:12 AM
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAEP
SAEP-1154
5.4.2.3
Schedule Q
3.7
535
11/24/2008 3:44:13 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
16.1
536
3/9/2009 12:50:16 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
6.3
537
3/11/2009 4:15:27 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
Schedule Q
6.3
538
7/24/2008 3:51:34 PM
2" Line
A 50cm long PUP piece was welded on the 2" new line near TIE-INH85-402 and this portion is not itted proprly, the line got a sagging area in the welded portion, becas=use the Flare Line shall have a slope wrading to the west, so this portion needs to be fit properly to avoid stagnation which casing corrosion. Contractor TRG is providing H.T Packages & to proceed for Hydrotest of piping system with out indicating limiting factor for HT pressure and/or attaching safety instruction sheet SIS in the HT packages, this is the violation of SAES-L- 125 Para 6.2 & its attachment A-1 item 25 and refer to SAES-L-150 Para 7.1.Contractors prompt corrective action is requested to avoid any untoward incident. During surveillance of paint repair touch up activities in Sale Gas 2 Area, found paint touch of damaged & field welded areas was in progress without surface preparation (without cleaning tools) and. . . 1.12:-H85-RL-6600-31-1CT2P- Spool B 2.8-H85-RL-6602-31-1CT2P 3.30-H85-RL-6602 Repeated Violation: SAES-H-100, Para 8.4.4, SATIP-H-100-01, Item 3.6 & SAIC-H-2032 Corrective Action: 1.All the touch up work is rejected. 2.Touch up workers to be qualified as per SAES-316 3.Utilize SATIP , SAIC 4.Issue RFI prior to touch up 5.Approved Sinopec / TRG QC to be assigned for touch up work & should be available at site.. without JCC-paint touch up card No Sinopec/ TRG QC were available & no QC is assigned for this job No RFI was issued to witness surface preparation prior to touch up A lot of fabricated piping Spools (SS & CS) were storing TWO LOCATIONS in Area B (EAST OF DD & Sales Gas), most of them setting on soil withtout covers in their ends. These piping should be away from from the soil for 16 inch above the ground level and should cap ended. Not more than 1/2" clearance spacing was seen between the horizontal Beam and the new Inlet Line (30-H85-P-5000-85-3CS1P) top Elbow of Sale Gas #1 New Compressor and about less than1" clearance spacing in Sale Gas #2 New Compressor Inlet Header. These piping will be insulated and there is no adequate clearance spacing for the insulation and for the movement During witness of hydrotest for TP-SG-LO-004 (225 psig) and TP-SGLO-006 (100 psig), it was found that NO NDT was taken on this piping system. The Contractor QC has shown TRG NDE table wherein Lube Oil system has No NDT requirements at all and that is true for Category D fluid service. However, for a fluid service to fall under Category D as stated in ASME B31.3 par 300.2 all of the following criteria shall apply 1. the fluid handled is nonflammable, nontoxic, and not damaging to human tissues 2. the design gage pressure does not exceed 150 psig and the design temperature is from -29C through 186C. Therefore, assigning Lube Oil to Category D is wrong instead it shall be interpreted under Normal fluid service wherein 10% RT on shop and 100%RT on field weld joints shall apply. There are some nipples about 6 meters away from the Compressors have no bracing gussets. As per SAES-L-310, Paragraph 20.2, Branch connections (2" & smaller) in piping connected to rotating equipment or in location where vibration can occur such as near control valves shall meet Paragraph 20.2.3, saying "all Branch connections shall be braced in accordance with Standard Drawing AB-036521" To avoid and/or minimize the potential of noise and piping vibration due to high velocities, slug flow, two phase flow, acoustic fatigue, etc, piping system in gas service.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
9.3
539
8/10/2008 10:03:15 AM
H85 Hydrotest
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-L-125
6.2
SAES-L-150
7.1
540
11/3/2008 11:38:58 AM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.4.4
541 542 543
SATIP-H-100-01 SATIP-H-100-01 SATIP-H-100-01
SAIC-H-2010 SAIC-H-2032 SAIC-H-2032
SAES ScheduleQ ScheduleQ
SAEP-316 Schedule Q Schedule Q
3.1 A VI Para table 2 A VI Para 1.2.3
544
5/18/2008 1:50:17 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
7.1
545
5/18/2008 4:27:45 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
546
6/2/2008 2:22:29 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.2.1
547
7/26/2008 10:36:27 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
20.2
548
7/29/2008 2:19:25 PM
Hollow plugs (Caps)were seen used on 1" Purge Gas Line, 1 BD Line & 1" SC Line at top platfrom of Sale Gas #5 which violate Saudi Aramco Standard. As PER SAES-L-007, Paragraph 5.6, piping plugs for use in steel shall be solid body, bar, round -tock or steel forged steel plugs in accordance with ASME B16.11. When the plugs installed in insulated lines, they shall be long enough to extend through the insulation. Most of threaded connections on 2" & smaller Galvanized piping for Air, LP Steam and Utility Stations were seal welded. Visual inspection revealed irregular welding, not cleaned and exposed threads. As per 01 samss-017, Pargraph 6.3.4, and shlla be followed by NDT (VT/PT). Also, patch repair shall be done for external coat. Seal weld on threaded connections shall cover all exposed threads Most of threaded connections on 2" & smaller Galvanized piping for Air, LP Steam and Utility Stations were seal welded. Visual inspection revealed irregular welding, not cleaned and exposed threads. As per 01 samss-017, Pargraph 6.3.4, and shlla be followed by NDT (VT/PT). Also, patch repair shall be done for external coat. Seal weld on threaded connections shall cover all exposed threads During surveillance of welding activities in Gas Compression 2 Area B,found following repeated violations: 1.Welding was in progress without preheating, no Welders Symbol, No WPS. 2.Asked welders to show JCC, but welders did not show. 3.No QC from TRG/Sinopec was available. 4.Weld Numbers are marked as SBW whereas these are field welds and should have marked as FBW. 5.No WPS is available at site. All above are the violations of SAES-W-011 -30-H85-P-6001-82-6CS1PSpool C SBW # 8 & 9 Corrective Action: I. JCC of waders to be taken back. II. Welds to cut & rewelded. III. All SBW # to be changed to FBW # & 100% RT to be taken (This is serious violation) RFI to be raised to verify the rework. Inside Plant Eastside to Sale gas-1Area, Hydrostatic test for three test manifolds at testing pressure of 2800 psi was performed with few incomplete fillet weld (single pass welds), without NDE (which is required as specified in package), without even TRG QC released & signature on Weld summary sheet attached to test package and incomplete information in package G.I sheet for test pressure limiting factor and without HT warning signs/barricade. These are violation to SATIP-L-350-01 item 3.18 SAIC-A-2010 item B1 and project specs/G.I 2.102. Testing was immediately stop through pressure release by SAPID & TRG QC and was highlighted to TRG/Sinopec of violation and high potential safety hazard on the incomplete fillet welds. Contractor corrective and preventive action is requested. Circumferential / butt weld (FBW # 2004A line number H85-P-601432) is partially covered under the pipe support saddle pad. The support is installed & welded with out inspection for flatting weld crown at contact support surface & any NDE test on it. Overlook of visual & NDE inspection on weld surface is violation to SAIC-L-2012 item B2 ---contact to support surface by flat topping the weld crown, performing visual weld exam and any required NDE, PWHT and supplemental surface NDE method such as MT or PT. Contractor corrective action is requested prior performing Hydrostatic test for this line. Sub Contractor-Gulf Elite, has laid down Fire Water line, west of E-503, line# 4F-FW-5009 & 5010, below the OWS line, which is a violation of approved IFC drawing. Contractor is recommede3d to take corrective action as early as possible.
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-007
5.6
ASME B16.11
549
8/3/2008 4:02:10 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
other
01-SAMSS017
6.3.4
550
SATIP-W-011-01
SAIC-L-2037
Mechanical
SAES
SAES-W-011
11.15.3
551
8/3/2008 4:02:43 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
other
01-SAMSS017
6.3.4
552
SATIP-W-011-01
SAIC-L-2037
Mechanical
SAES
SAES-W-011
11.15.3
553
8/10/2008 8:38:04 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.1
Schedule Q
A VI TABLE 2
554
8/25/2008 11:31:01 AM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-W-011
17.6
555
8/23/2008 1:41:16 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
14.2.2
556
5/24/2008 9:11:43 AM
Mechanical
ScheduleQ
Schedule Q
1.3
557
4/29/2008 5:11:41 PM
Contractor has welded many saddle pipe supports on 24" lines in sales gas-1. During surveillance, it has been noted that the leg length is not adequate for the support and it is violating IFC support drawing. Contractor is recommended to provide adequate fillet weld for the saddle pipe support as early as possible. During surveillance, it was noted that one of the joints (24"-H85-P6009-38-6CS1P, FBW#113) in sales gas-2 was being welded with out QC fit up signature. No proper QC coverage also was noted which results in other butt welds being welded with out initial fit up inspection, which is violating of Aramco Standard and Sch-Q. Contractor is recommended to provide one subcontractor welding QCs in each location PERMANENTLY. Low Hydrogen Electrodes (E7018) inside the portable oven (no identification) and unplugged was found at the back of electrode store in Area B plant H-85. This is a major violation since using over exposed low hydrogen electrodes on welding high pressure piping will result to porosity and the worst will lead to Hydrogen Induced Cracking. During surveillance inspection it is found that weld joints are being heated to correct the misalignment (Drg no. - H85 -P- 6009-346CS1P). This is violation against SAES-W-011 Para 18.6. Contractor should have approved repair and inspection procedure prior to undertaking the repairs. Contractor is advised to submit the repair procedure immediately. In H86-SRU-4 found that the contractor is not performing Dry Lay-up as per company requirement. Total 33 hydrostatic test packages have been hydro tested until today. This is violation of SAES-A-007. Contractor has to take corrective action as soon as possible. Test package # H86-SR-BD-004/007/012/019/021/026, BFW002/004/007/009/013, P-001/029/030.1/030.2/038/, S007/008.1/008.2/012/015/019/020/021, SC-007/010/020, SF002/003/004/005/006 & SOW-011. During walk through of Test pack # H86-SR-BD-004, BD-005, BD-007, BD-008, BD-012, BD-013, it is found that contractor have not attached latest revised IS drawing. This is a violation as per SCH Q for the control of documents. Contractor is advised to take corrective action Immediately. Air Preheater Furnace (F-401) at Area B plant H86 was designed and fabricated by TECHNICAL, a subsidiary of Technicas Reunidas Group. It was noted that the radiant Coils that branch out from the Manifold(API-5L Gr B) has no reinforcing pad on branch weld. This branch connection type violates the provisions of SAES L-110 par 12.1 Contractor TRG/Sinopec started Abrasive & Painting activities without completing forms related to Quality Control Records Attachments B, C, D & Daily Job Log prior to job start-up. These forms shall have been completed on daily basis and signed by approved coating supervisor & then signed by SA Inspector. This is clear violation of SAES-H-100 Para 9.2 During surveillance of abrasive blasting activities in blasting area, contractor blasted & painted Cement lines & other fabricated spools without inspection and without using Saudi Aramco checklists/ Attachments A, B, C & D. This is repeated violation (LBE-17612, 18391 dated 2/7/2009 & 3/15/2009) of SATIP-H-100-01, SAIC-H-2027/ 2029 & 2031 & SAES-H-100, Para 9. Following spools are rejected: 1.6-H86UW-41000-01-12LCOU- Spool P 2. do- -02- .Spool H 3.4-H86- -08- Spool V 4. do- -015 -Spool AD 5. do- -04- -Spool R During routine inspection visit, it is found that too many spools end are not covered/protected and having lot of foreign materials and debris inside the spools in SRU 4 area B. This is violation against SAES-L-350, 15.2 Contractor is advice to take corrective action immediately.
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.8
558
4/29/2008 5:27:13 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
559
5/13/2008 11:10:21 AM
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES
SAES-W-011
6.1
560
10/12/2008 5:17:53 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.6
561
5/28/2009 2:00:58 PM
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.3.2
562
5/6/2009 2:00:25 PM
SATIP-A-004-02
SAIC-A-2003
Mechanical
ScheduleQ
Schedule Q
1.3
563
5/14/2008 4:42:44 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.1.1
564
10/14/2007 8:29:11 AM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-100
9.2
565
3/22/2009 3:07:21 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
566
3/19/2009 7:29:05 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.2
567
10/2/2007 8:35:29 AM
568
8/17/2009 4:01:45 PM
569
11/27/2007 3:23:48 PM
570
7/7/2009 3:00:13 PM
571
7/12/2009 1:24:59 PM
Above mentioned 2o" Gate Valves were inspected at TRG Material receiving yard and found to be accepted. As per SAES-L-108, Para 4.7, these valves shall be subjected to field pressure Hydrotest prior to installation. Flange Joint inspection has shown that incorrect Rating Gasket has been installed on F-401 furnace piping flanges 46 inch & 42 inch, test package # H86-SR-F401-1. The gasket installed is of 150 # rating while the Flange Rating is 300#, bolt torquing of the flange joint was also completed and inspection record signed by Sinopec & TRG QC. Contractor corrective & preventive actions are requested for such repeated violation. During surveillance of storage fabricated pipes, found that fabricated materials are stored in various areas in very poor & careless manner. 1.Pipes are stored directly on the ground. 2.Pipes are stored on each other. 3.No end covers on pipes, flanges, weld bevels, threads, sockets etc, end Shall be firmly attached. This is violation of SAES-L350, Para 7. Extra long nipples has been used between the run pipe and the valve for the drains installed on the Fuel gas line to Thermal Oxidizer creating a dead leg. Contractor should rectify this violation of SAES-L310 Para 114.3 In SRU-4, Dead leg found in caustic line around 12 meters long. Line # 3/4-H86-CA-41033-22-1CS2C1 & 3/4-H86-CA-41033-23-1CS2C1. (Quadrants: East: 11019476, North: 7736770 at Elevation: +104329. This is violation of SAES-L-310, Para: 11.4.3.Contractor has to take immediate action. During surveillance of welding activities of socket joints in Area C Fabrication/Welding shop, found axial gap of 1.5 mm minimum ~ 3 mm maximum is not being verified between male & female components prior to welding & found some components with Zero gap. (3/1-1/2-H86-SC-41166-33-6CS2S-Spool 1ASFW # 6. This is repeated violation of SAES-L-110 Para 5.2.3 & SAIC-W-2037 Item B3. Corrective Action: 1. TRG / Sinopec QC should make fit up inspection and verify the axial gap prior to welding. 2. Take 5 % RT to verify the gap. 3. Any socket joint not meeting axial gap to be cut and re-welded. 4. RFI to be raised to verifying the gap During surveillance of welding activities of socket joints in fabrication shops, found that no QC from TRG / Sinopec is verifying axial gap 1.5 mm minimum ~ 3 mm maximum between male & female components prior to welding. Found axial gap than 5 mm and also cut ends of pipes are not ground. This is repeated violation of SAES-L-110 Para 5.2.3 & SAIC-W-2037 Item B3. Corrective Action: 1.Use SA check list. 2. TRG/Sinopec QC should make fit up inspection and verify the axial gap prior to welding. 3. Take 5 % RT to verify the gap. 4. All socket joints not meeting the requirements should be cut and rewelded. 5.RFI to be raised to verifying the gap 1.6-H86-S-41020-81-1CS1SV- SSW # 38 (1 ). 2.6-H86-FG-41017-24-1CS1Z- Spool # C I pipe nipple thickness require with S160, where actual found under size of S80. This is violation as per SAIC-L-2011 and ISO drg. Contractor is advised to take necessary action to replace the pipe as per requirement In SRU-4, found that two shop butt welds were cut and re-welded in the field in order to get proper alignment. These joints have been accepted by Radiography in shop for line # 2-H86-SOW-41040-311CT2P, Joint # 16 and 2-H86-SOW-41041-31-3CT2P, Joint # 04. Contractor did not change the joint-type from Shop butt weld (SBW) to Field butt weld (FBW) in the weld summary sheets. It is hold point H1 for Aramco inspection. This is violation of SATIP-W-011-01, Item # 3.17. Contractor has to fill SAIC-W-2036 and request for Radiography for these joints. Contractor has to avoid such type of repeated violations and shall take immediate action.
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.1
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
572
8/20/2008 2:34:51 PM
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.3
573
9/11/2008 12:55:10 PM
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.3
574
2/14/2009 5:26:02 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
1.3
575
6/11/2009 3:04:54 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
576
3/1/2009 2:49:58 PM
577
2/18/2009 11:18:46 AM
During surveillance of Jacketing welding activities in Main Fabrication/ Welding Shop,found following repeated violations: 1.No Sinopec / TRG QC were available to cover quality coverage. 2.Welding was in progress without removing rust/scale at least 25 mm of adjacent base metal prior to welding. 3.Excess Root Gap of 10~15 mm whereas WPSCS-02 root gap acceptable is max:3.2 mm. 4.No each weld pass was thoroughly cleaned. Violations: SAES-W-011 Para 11.3, 11.4.1 & WPSCS-02 1.8-H86-SJ-41024-32-1CS1S 2.8-H86-SJ-41024-27-1CS1S, SBW# 84 3.8-H86-SJ-41024-21-1CS!S , SBW# 10 Corrective Action: 1.All the above & identified welds to be cut & rewelded. 2.Full time QC shall be available as there are 10 active welders. 3.QC. Supervisor TRG was informed and he should make surveillance. 4.RFI to be raised to closed this LBE. During surveillance of welding activities in fabrication/ welding shop, welding of cement lined spools was in progress out side the shop during wind-blown sand without use of adequate shielding. No QC from Sinopec / TRG was available to prevent by the use of shielding.. All the welds are rejected, to be cut & reweld and JCC # CT-073 is withdrawn. 4-H86-UW-41000-08-12LCOU Spool Numbers # D, V & AL This is repeated violation of SAES-W-011 Para 11.2.1 Corrective Action: 1.All the welds to be cut & rewelded. 2.JCC # CT-073 is withdrawn. 3.QC should make surveillance. 4.Wind shield should be provided. During routine surveillance of welding activities in Fabrication/welding , found that welding was in progress without use of adequate sheilding during wind-blown sand. This is violation of SAES-W-011 Para 11.2.3. In SRU-4 noticed that, Contractor is not performing Positive Material Identification (PMI) at root-side for larger diameter piping joints where accessible. This is violation of SAES-A-206 Para: 9.8. Contractor has to perform PMI as soon as possible before installing the larger diameter spools. During routine visit, the following shop weld 56 dia spools (H86-P41009-32, H86-P-41012-31, H86-P-41015-31) in SRU 4 area found with 8 to 10 mm high low (mismatch), lack of fusion and root under flush. This is violation against SATIP-W-011 and SAIC-W2007.Contractor is advice to repair all defects immediately. During routine inspection, the following has been observed. 54 Dia spool Drg. No H86-P-41005-31-1CS2P1 joint# 1 and 5 having many defects like lack of penetration, lack of fusion, excess penetration at root. Visual inspection is not done by Sinopec/T RG QC Inspector properly. Depth of lack of penetration is more than 2mm and length is more than 50 mm. These all defects are not acceptable as per ASME B 31.3 Table 341.3.2 acceptance Criteria for Welds and violation as per SAES-W-011 17.5. Both joints are flange joints (open joints) and accepted in radiography. Contractor is advised to take action immediately. . During surveillance of storage of Low Hydrogen Electrodes on Oct 10, at 5.30 AM, found following violations: 1.Welder Symbol # T-026 Welder left LHE electrodes in unplugged Quiver at site instead of returning back to storage oven. 2.Found ~ 400 LH Electrodes were stored exposed in storage container instead of storing in storage oven at 120 degrees C. This is repeated violation Refer to LBE-4169 dated 9/24/07 of SAES-W-011, 6.1. During surveillance of storage of Low Hydrogen Electrodes on Oct 13, 07 at 7.00 A.M,found ubcontractor Sinopec stored big quantity of LH Electrodes in the holding storage ovens without electric power for long time. These electrodes should have been stored continuously in ovens at 120 Degrees C but electrodes found were cold. This is again repeated violation; refer to violation nos.4469/4469 of SAES-W-11, Attachment I. All the electrodes as mentioned above shall be discarded. NCR will be issued if no corrective action is taken.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.8
Schedule Q
A VI Table 2
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.3
Schedule Q
A VI Table 2
578
10/8/2007 2:17:18 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.3
11.2.1
579
5/19/2009 7:54:15 AM
SATIP-W-011-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
9.8
580
3/18/2009 5:34:18 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011 17.1.7 and 17.1.8
581
3/28/2009 5:16:54 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011 17.1.7 and 17.1.8
582
10/11/2007 7:30:40 AM
SATIP-W-011-01
SAIC-W-2010
Mechanical
SAES
SAES-W-011
6.1
583
10/14/2007 10:00:10 AM
SATIP-W-011-01
SAIC-W-2010
Mechanical
SAES
SAES-W-011
6.1
584
6/22/2009 11:30:08 AM
During routine site visit in SRU-4 found that two welding ovens (S.No # 4-137 & 4-138) calibration were expired last week. This is violation of Schedule-Q, Attachment-IV, and Para: 6.1. Recalibration required every six months and CONTRACTOR shall provide backup equipment when the primary equipment is being calibrated or tested. During routine surveillance of Fabrication/Welding shop, found welding was in progress without Welding Inspector -Fit-up approval. This is violation of SA Check list SAIC-W-2005, Item A4 & Contractor TRGs own approved procedure QI-8410-009-Rev A, Para 4.2. All welds without W.I approval will be rejected or subject to 100% RT on contractors expenses. During routine surveillance of Sinopec Fabrication shops, found welding was in progress without Welding Inspectors Fit-up approval/ Welders Symbol & WPS. This is repeated violation of Saudi Aramco Check List SAIC-W-2005, item A4 & Contractor TRG-own procedure QI8410-009-Rev, Para 4.2. (See LBE-4526 Dated 10/16/07). All welds without W.I approval are rejected or subjected to 100% RT on contractors expenses. JCCs of following welders are withdrawn: 1. T005 2. T-047 3. T-026 4. T-044 5. T-006 6. T-034 7. T-022 8. T-004 During surveillance in SRU-4 found that the full encirclement sleeve was installed for lateral branch connection on line # 4-H86-BD-4102932-1CS2S is not as per drawing AB-036719. The following violations were associated. 1. Four reinforcement pads were installed and did not provide vent hole on each segment. . All above violations were of ASME B31.3, SAES-W-011 and Drawing # AB-036719. Contractor has to take corrective action as soon as possible. 2. Between two sleeves, back-up strip did not used during welding. 3. Unacceptable fit-up. 4. Around 30mm gap was weld build up done with out approval It has been learnt that approved QC-Welding Inspector Mr.Saifi had left for vacation without replacement as necessary to maintain required quality coverage. This is violation of Schedule Q Para 5.11, which states that contractor shall advise the company representative of such personnel and quality coverage at least thirty (30) calendar days in advance of scheduled absences or changes and ASAP for other changes. During surveillance of Jacketing welding activities in Main Fabrication/ Welding Shop, found following repeated violations: 1.No Sinopec / TRG QC was available to cover quality coverage. -16-H86-SJ-4103631. Corrective action: 1.Full time QC shall be available in shop. 2.All pressure containing welds shall be made with multiple passes (minimum two passes). 2.Slip-on Flange Weld was made with single pass.Violations: SAES-W011 Para 9.1 states all pressu containing welds shall be made with multiple passes. During surveillance of Jacketing welding activities in Main Fabrication/ Welding Shop on Friday, found following repeated violations: .. 3. LHCold Electrodes and quivers were not working. . Violations: SAES-W011 Para 9.1/ 8.1& 6.1, states all pressure containing welds shall be made with multiple passes, all welders shall be qualified & electrodes are continuous stored in portable electrode oven heated to 65 degrees C. Corrective action: 1.All pressure containing welds shall be made with multiple passes (Minimum two passes). 2.QC should make surveillance to check JCC & Quivers. 1. Slip-on Flange Weld were made with single pass 2. Two non JCC welders are continuously doing welding 4. Sinopec / TRG QC were available in shop but no one take any corrective action During Hydro test witness of test pack no.H88-UA-W002, it is found that preliminary check for leaks at 50% of strength test pressure and after each step in pressurization and holding 10minutes for inspection is not done by TRG QC/Construction. This is violation against SAIC-A2020 and safety violation. Contractor is advice to take immediate action in this matter.
SATIP-W-011-01
SAIC-W-2011
Mechanical
ScheduleQ
Schedule Q
A IV Para 6.1
585
10/16/2007 4:59:59 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
586
11/1/2007 4:26:04 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
587
6/16/2009 7:42:57 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
other
01-SAMSS010
6.1.2
ASME B31.3
588
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.8
589
10/14/2007 10:28:39 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.11
590
3/10/2009 9:52:16 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
591
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.1
592
3/14/2009 7:52:33 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
593 594 595
SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01
SAES SAEP ScheduleQ
SAES-W-011 SAEP-324 Schedule Q
9.1 5 A VI Para table 2
596
3/10/2009 5:57:01 PM
UTILITY AREA
SATIP-A-004-04
SAIC-A-2020
Mechanical
other
G.I.2.102
5.16
597
2/19/2008 5:05:42 PM
UTILITY AREA
The contractor does not maintain the preservation of five pumps installed in utility area. This is the violation of QI-8410-005 and SAIC-G2003. Manufacturer recommendation shall be carried out for preservation and all the five pumps shall be covered with proper tarpaulin. Test pack # UW-001, 6-H88-UW-100-01 joint # 66 cut and rewelded after Hydro test. Radiography carried out in place of rehydro test with out prior approval. This is violation as per SAES-A-004, 5.6.2. Contractor is advice to take corrective action. As per Standard Drawing, it is not required to install the center gaurd protection Flat bar if the height between the Stair Step & the Stair Hand Rail pipe is 850mm, but the Height in the Tecnicas Reunidas Drawing (N1335-4-B-011) is 1100mm height bigger than the Standard Drawing (DC-950102) by 250mm height which make the area more risky, So a center guard protection Flat Bar is required to be welded in the Stairway for safety purpose. Below deficiencies were revealed responding to RFI (hard copy) for visual & dimensional inspection of Re-use water tank H88-D-180. Please attend it prior to start filling water for Hydrotest. 1. Installation & welding of few attachments on tank shell (outside) to be completed. 2. Visual defects (porosity, undercuts) were observed on pads of nozzles/attachments, need to be rectify and Re-perform PT. 3. Incomplete welding at drip ring/plate. 4. Tank internal to be prepared for cleaning visual inspection (with providing internal inspected acceptance record). 5. Drain/leak detection pits and drip ring juncture area to seal with sealant. 6. Bolts on 4 free vent nozzle to be tightened. Sinopec approved QC-coating inspector (Mr. Wang Xiuo Long) is not available at site since last week. I have come to know that he is in Khobar and there is no replacement as necessary to maintain required quality coverage. This is repeated violation of Schedule Q Para 5.11. During surveillance of painting activities in Sinopec painting shops on 11/25/07, at 9.00, it was strong windy weather and Sinopec was painting following spools in adverse weather condition. 1. 4-H-89-CW0001-05-1CT2P-Spool J 2. 4-H-89-CW-0001-05-1CT2P-Spool I 3. 4-H89-CW-0001-05-1CT2P-Spool G 4. 4-H-89-CW-0001-05-1CT2P-Spool F 5. 4-H-89-CW-0001-05-1CT2P-Spool H 6. 4-H-89-CW-0001-051CT2P-Spool D This is violation of SAES-H-100 Para 8.1.d All the above coated spools are rejected and to be reworked & QC should be available at the time of painting. No QC was availablefromTRG/Sinopec. During surveillance of storage of Low Hydrogen Electrodes (E 7018) on 9/23/07 at 5.30 A.M, it was found that following 4 welders left portable electrode ovens unplugged for long time in workshop. These LHE electrodes should have been returned back to a holding oven continuously maintained at 120 Degrees minimum. This is violation of SAES-W-011, Attachment I 1. Welder Symbol # T-017 2. # T-038 3. # T-005 4. # T-035 During routine visit it is found that welding activities is not monitor by Contractor QC Inspector. This is violation against W-011. Contractor advised to assign Inspector immediately. During routine surveillance of welding activities in Utility Area H 88, installation & welding is in progress in Pipe Rack without Quality coverage of Sinopec / TRG -QC. This is repeated violation of SATIP-W011-01 & related SAICs. Line Number: - 6-H88-W-0470-05-1CS2S - 3H88-UW-1001-03-1CS2S Corrective Action: 1.Welding activities without quality coverage is not acceptable. 2.Sinopec/TRG QC to be available at site. 3.Welds completed without pre-inspection & fit up are rejected, to be cut & re-welded. 4.Welders JCC to be withdrawn. -T075, T-066, T-089
SATIP-G-005-01
SAIC-G-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
598
5/12/2009 7:46:07 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
599
1/2/2009 11:04:46 AM
Mechanical
ScheduleQ
Schedule Q
1.3
600
10/9/2008 4:43:28 PM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
601
11/24/2007 12:54:49 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
602
11/26/2007 8:57:37 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
8.1.1
603
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
604
9/24/2007 11:25:46 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
605
1/1/2009 10:22:10 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.11
606
12/18/2008 8:39:44 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.11
607
12/12/2007 1:24:51 PM
608 609
11/28/2007 1:55:17 PM
Contractor TRG/Sinopec welded about 50~60 Welds of Line Class20/30-H89-S-0005-02-6CS1SV in night shift without approved Welding Procedure Specification (WPS) . This is the violation of SAESW-011 Para 7.1, which states that all welding procedures to be used shall be submitted as a complete package to Saudi Aramco for the technical approval prior to start of work. All the welds done are rejected and to be rewelded after approval of WPS & PQR & Welders JCC & without JCC Welders Up to date, no Sinopec Coating Inspector and Now adays, the coating activities are going on without presence of the coating Inspector. Also, coating job was done for 6 pipes (4")in early morning while the temperature is low, moisture & humidity without coating & QC Inspectors. During surveillance of abrasive blasting activities in blasting area, contractor is continuously blasting & painting activities without quality coverage from Sinopec & TRG . This is repeated violation (LBE-18977, 18562, 18391, 19315) of SATIP-H-100-01, SAIC-H-2027/ 2029 & 2031 & SAES- H-100, Para 9. Corrective Action: 1.Utilize all the check lists 2.Utilize attachments A, B, C, and D prior to start of work and verified by TRG QC. 3. Raise RFI as per SATIP 4.QC should make surveillance During surveillance of abrasive blasting activities in blasting area, contractor blasted & painted Cement lines & other fabricated spools without inspection and without using Saudi Aramco checklists/ Attachments A, B, C & D. This is repeated violation (LBE-17612, 18391 dated 2/7/2009 & 3/15/2009) of SATIP-H-100-01, SAIC-H-2027/ 2029 & 2031 & SAES-H-100, Para 9. Corrective Action 1.All the material in painting area is rejected. 2.All the rejected material to be reworked. 3.Sinopec/TRG should provide quality coverage. 4.Use SATIP / SAIC 5.Send RFI . During surveillance of blasting activities in Sinopec Blasting Area,found following repeated violations: 1.Non qualified abrasive blaster was doing blasting work. Violation: SAEP-316 Para 1.1 & 4.3, SAES-H-100 Para 5.2 & Schedule Q. Corrective Action: 1.Abrasive blaster shall be qualified. 2.Abrasive material shall be kept dry. 3.QC,s should make surveillance. 4.Use SA Check lists prior to abrasive blasting & coating 5.All the blasting & work done on 3/3/08 is rejected. TRG QC Supervisor was informed of violations for corrective action. 2.Wet abrasive material was used for abrasive blasting. 3.No quality coverage from Sinopec /TRG QC.
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
7.1
SATIP-W-011-01
SAIC-W-2006 SAIC-H-2027
SAEP ScheduleQ
SAEP-324 Schedule Q
5 5.11
SATIP-H-100-01
610
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
8.1.1
611
5/9/2009 4:30:02 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
612
4/12/2009 8:08:40 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
613
3/4/2009 11:11:47 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
1.1
614 615
2/7/2009 2:03:13 PM
SATIP-H-100-01 SATIP-H-100-01
SAIC-H-2027 SAIC-H-2027
SAES ScheduleQ
SAES-H-100 Schedule Q
5.2 5.11
616
Contractor released Stop Work Alarm Post ( 2 numbers) to Area "B" without inspection and without using Saudi Aramco checklists: This is violation of SATIP-H-100-01, SAIC-H-2027/ 2029 & 2031. During surveillance of abrasive blasting activities in blasting area, contractor blasted & painted Cement lines & other fabricated totaling 68 spools without inspection & released to site without using Saudi Aramco checklists/ Attachments A, B, C & D. There is no quality coverage from Sinopec/TRG QC. This is repeated violation (LBE-18977, 18562, 18391) of SATIP-H-100-01, SAIC-H-2027/ 2029 & 2031 & SAES- H-100, Para 9. Corrective Action: 1.Utilize all the check lists 2.Utilize attachments A, B, C, and D prior to start of work and verified by TRG QC. 3.Raise RFI as per SATIP 4.QC should make surveillance.
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
1.4
617
4/28/2009 2:14:32 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
618
4/19/2009 9:03:48 AM
During surveillance of repair & touch-up of coating work in GT-5 (Area A) & Area B, it is observed that contractor is doing the work without complying the requirements of SA Checklist & manufacturer data sheet: Following discrepancies were observed: 1.Paint is being applied during adverse weather condition ( Sand Storm) 2.Gloss of existing coating is not being removed by sanding prior to over coating. 3.Paint material for touch-up is not supplied by the same Manufacturer. 4.No SATIP & SAIC is being used. Paint Data Sheet for the coating system (APCS) is not available at site. Violation: SATIP-H-100-01/ SAIC-H2032 & SAES-H-100. Corrective Action: 1.Only qualified people to made touch up work 2.All cleaning tools should be available with worker (Wire brush, sand paper, cloth etc). 3.Prior to touch up, surface preparation should be approved. 4.Use SATIP & SAIC and paint data sheets. During routine surveillance of Grit Blasting at Sinopec Blasting/Painting shops,found after blasting contractor is not taking care of blasting material to keep surface neat & clean prior to application of coating. Blasted pipes are not being transferred to coating areas with care, pipes are getting scratches of fork lift/ Nylon belts/ Pipe stands are not celaned and there is no rubber pad sheet on pipe stands to avoid surface marks etc. This is violation of SAES-H-100 Para 5. This is responsibility of Crew Supervisor and QC to maintain required surface cleanliness & surface profile prior to primer coat. During surveillance of abrasive blasting activities in blasting area, contractor blasted & painted Cement lines & other fabricated spools without inspection and without using Saudi Aramco checklists/ Attachments A, B, C & D. This is repeated violation (LBE-17612 dated 2/7/2009) of SATIP-H-100-01, SAIC-H-2027/ 2029 & 2031 & SAES-H100, Para 9. Corrective Action: 1.Utilize all the check lists 2.Utilize attachments A, B, C, and D prior to start of work and verified by TRG QC. 3.Raise RFI as per SATIP. 4.QC should make surveillance. During surveillance of painting activities in Sinopec painting shops on 2/29/08, at 8.30 A.M, it was strong windy weather and Sinopec was painting spools in adverse weather condition. This is violation of SAESH-100 Para 8.1.d All the above coated spools (12 Nos)to be reworked. No QC was available from TRG/Sinopec. It has been learnt that approved QC-Painting Inspector Mr.Tian Yu is not available at site since last two weeks without any information and without replacement as necessary to maintain required quality coverage. This is violation of Schedule Q Para 5.11, which states that contractor shall advise the company representative of such personnel and quality coverage at least thirty (30) calendar days in advance of scheduled absences or changes and as soon as possible for other changes. Contractor TRG/Sinopec is executing grit blasting activities in night shift without submitting plan to ensure that quality personnel are effective and work is completed in strict compliance. This is violation of Schedule Q.3.1 & Attachment IV Para 1.1 Contractor is advised to assigned approved quality personnel to avoid any rework. During painting material receiving & storage inspection found following discrepancies: 1.There is no electric power in the paint material storage container. 2.There is no ventilation. 3.Paint materials are stored in scattered manner and various pain materials are not segregated and are stored together. 4.Paint Container is not marked with SAMSS-Stock number 5.Paints log is not available. Violation SASESH-100 Para 6.1 & 09-SAMSS-060 Para 5.1 During surveillance of handling & storage of coated pipes in Sinopec painting shop, found coated pipes are being stored in very careless manner, this is causing severe coating damages. This is repeated violation of SAES-H-200 Para 5
SATIP-H-100-01
SAIC-H-2023
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.1
619
12/23/2007 8:31:46 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
620
3/15/2009 11:24:24 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
621
2/29/2008 9:56:02 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
8.1.1
622
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
623
3/25/2008 2:00:51 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
624
3/25/2008 2:08:31 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
625
4/6/2008 7:57:26 AM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
09-SAMSS060
5.1
626
4/11/2008 7:26:51 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
SAES-H-200
627
4/24/2008 4:25:45 PM
Sinopec is doing External FBE coating of field welds & repair work of damaged coating in GT-5 Area -6 DGA- System.. During surveillance of FBE coating work found that Contractor is not complying the requirements of repair method as described in SAES-H-201, Para 8.5 & SAES-H-100 Para 8.3.. All repair work done is rejected and shall be repaired in accordance with the criteria and methods described in Para 8.5 & 8.3. It was windy and sandstorm at 8 A.M , and Sinopec painted following spools in presence of QC Mr. Wang Yunfei. This is repeated violation of SAES-H-100 Para 8.d. 1.6-H48- RL-6005-01-1CT2P- Spool C 2.20H46-P-0112-82-6CT2P1-Spool R 3.52-H46-P-5073-31-1CT9P- Spool A1 4.52-H46-P-5073-31-1CT9P - Spool- A 5.48-H48-RL-50141CT2P- Spool A 6.30-H48-P-5008-04-1CT2P- Spool S 7.30-H48-P5008-02-1CT2P Spool J All the spools are rejected and QC & Painter are revoked . During surveillance of coated pipe materials storage in Area A, found coated pipes/ Pipe supports are being stored in very careless manner; this is causing severe coating damages. This is repeated violation of SAES-H-200 Para 5. During surveillance of painting storage materials, found following Discrepancies: 1.Sinopec/TRG storing painting materials outside storage container in Blasting & Painting areas for long time. 2.Contractor has still not installed exhaust fan to circulate fresh air inside storage. 3.Contractor is using paint materials whose shelf life is exceeding as mentioned in Data Sheets. Above discrepancies are repeated violations of SAES-H-100 Para 6. If Sinopec/TRG is not going to take immediate corrective action an SA-NCR will be issued. Sinopec approved QC-coating /Insulation inspector (Mr. TIANYU) is not available at site since last 3 days. It has been come to know that he is in Rabigh - Sinopec another project and there is no replacement as necessary to maintain required quality coverage. This is 4th repeated violation of Schedule Q Para 5.11. During surveillance of painting storage materials, found following Discrepancies: 1.Sinopec/TRG storing painting materials in unapproved storage container near Machine Blasting & Painting areas for long time. 2. There is no exhaust fan to circulate fresh air inside storage area. 3. No air conditioner is installed as the atmosphere temperature is more than 45 Degrees. Above discrepancies are repeated violations of SAES-H-100 Para 6. If Sinopec/TRG is not going to take immediate corrective action an SA-NCR will be issued. During surveillance of painting storage materials found, Petro Steel, subcontractor for Reuse Water Tank is storing painting materials since long time in unapproved area in atmosphere temperature more than 45 Degree C. This is repeated violation of SAES-H-100 Para 6. Corrective Action: 1. Send RFI to check painting material. 2. Move painting material to approved area. 3. Provide Paint Material LOG book. During surveillance of coated pipe materials in Area A-GT- 5, found 1.6"-H48-DGA-5005-32-1CS2P1-DWG-BB-250261 Sheet # 75 Rev00A As per ISO, the Design Temperature is 150 F, according to SAES-H001, Para 7, the painting system APCS-1B is required, where as the contractor has applied APCS-11A which is approved for temperature 150 ~ 400 Degrees C. 2.24-H48-DGA-5030-63-1CT9P-DWG-BB250261 Sheet # 602 Rev 00C. As per ISO, the Design Temperature is 274 Degrees F. according to SAES-H-001,painting system APCS-11A (150 ~ 400 Degrees C) is required where as contractor by mistake has applied both systems separately i.e APCS-1B & 11A. Corrective Action:1. bring back material to blasting area & reblast. 2. apply the required APCS. 3. send RFI to verify the rework
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-201
8.5
SAES-H-100
8.3
628
5/2/2008 9:49:20 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
8.1.1
629
5/4/2008 7:20:47 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-H-200
SAES-L-350
630
5/9/2008 9:26:29 AM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
09-SAMSS060
631
6/28/2008 3:56:14 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
632
7/4/2008 9:49:29 AM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
09-SAMSS060
633
7/11/2008 9:52:04 AM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
09-SAMSS060
634
7/23/2008 9:25:14 AM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-101
635
8/9/2008 11:51:49 AM
Sinopec approved QC-coating /Insulation inspector (Mr. TIANYU) is not available at site for painting/insulation quality coverage since last 5 days. It has been come to know that he is doing only office work and other outside Sinopec business assignments. There is no replacement as necessary to maintain required quality coverage. This is 5th repeated violation of Schedule Q Para 5.11.which states contractor shall make quality personnel changes required due to temporary assignments as necessary to maintain required quality coverage & shall advise of such personnel and quality coverage. Corrective Action: Required replacement as soon as possible for quality coverage. During surveillance of paint repair activities in Area A GT-6 on Friday, it was found that paint repair work is in progress without QC supervision, no surface preparation prior to touch- and no cleaning tools are available at site & no personnel is qualified. This is repeated violation of SAES-L-100 Para 8.3, SAIC-H-2032 & SAES-316. All the repair work is rejected. Corrective Action: 1. TRG / Sinopec Painting should be available at site to verify the work 2. Personnel to be qualified or demonstrate the repair work 3. Cleaning tools should be available with paint applicator. 4. Utilize SAIC-H-2032 During surveillance of paint damages of shop weldmedication (24 spools) touch up activities in blasting/painting shop, without sending RFI / information.Contractor Sinopec / TRG is not complying with the requirements of paint repair procedure & also not utilizing Saudi Aramco check lists. Violation: SAES-H-100, Para 8.3.3, SATIP-H-10001, SAIC H-2032, which states that areas greater than 0.1 square meter, be blast clean to original specified. Corrective Action: 1.Send RFI prior to start repair work. 2.Use SATIP & SAIC. Contractor Sinopec / TRG are using non-qualified coating inspector Mr. Chen Bin, in Blasting/Paint shop who is approved as Insulation Inspector (TRG-700 Dated 8/25/08). This is repeated violation of Schedule Q Para 3.3.7, which states inspector shall be qualified per the requirement of SAESP 316 Corrective Action: 1. Mr. Chen Bin shall be removed immediately from painting job. 2.TRG Coating Inspector should be aware of this violation 3.Blasting & Coating activities to be stopped up. :Contractor Sinopec / TRG are continuously using non-qualified coating inspector Mr. Chen Bin, in Blasting/Paint shop. This is repeated violation of Schedule Q Para 3.3.7; refer to LBE- H-1615 dated: 11/12/08. Corrective Action: 1. Chen Bin shall be removed immediately from painting job. 2. Approved painting inspector to be assigned. 3. TRG Coating Inspector is not available in shop. 4. Blasting & Coating activities to be stopped. During routine surveillance of coating activities in Sinopec Painting shops, found painting work is not going smooth due to following reasons: 1.APCS- 1B, found DFT of every coat either it is too low or very high. 2.APCS- 11A, found DFT of every coat is either low or high. During application of painting, QC is not available and no wet film thickness (WFT)is being measured during application to get required Dry Film Thickness (DFT). This is violation of Manufacturers Data Sheet, which states to measure WFT during application to get the required DFT
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
636
8/30/2008 1:50:52 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
637
10/28/2008 8:46:49 AM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.3.3
638
11/12/2008 11:43:10 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
3.3.7
639
11/15/2008 7:39:02 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
3.3.7
640
12/23/2007 8:04:46 AM
SATIP-H-100-01
SAIC-H-2034
Mechanical
ScheduleQ
Schedule Q
5.1
641
1/9/2008 8:13:21 AM
. During routine surveillance of Air supply compressor, found following violations: 1.Air receiver between compressor and the blasting pot isnot manufactured and stamped in accordance with ASME Sec.VIII, Div 1.(SAES-H-102 Para4.4.1.4). 2.Air receiver has not been hydro tested at 250 psig. 3.Certificates of pressure relief valve and pressure gauge show that the calibration has not exceeded one year. 4.Pressure gauges and relief valve are tagged with the expiration date if calibration. 5.Minimum air pressure measured at the blasting nozzle side of the blasting hose shall be 90 psig. 6.Air supply hose should be 3 times the nozzle orifice (1-1/2 or 2).(SAES-H-100.Para 5.4.2) 7.Safety pressure relief valves set at 5000 psig or less are provided on outbound side of the pressure pumps. (SAES-H-102. Para 44.4.5) During surveillance of Blasting / Coating activities in Sinopec painting shops, found no QC was available from Sinopec & TRG. Sinopec QC is not available since since last 3 weeks and TRG QC just left on vacation for 2~3 weeks without replacement. This is 4th repeated violation; refer to LBEs-4985, 5524 & 5937. Violation: Schedule Q Para 5.11. During surveillance in Gas Compression Area (Area B), Area A & DD-2, found contractor is continuously making following repeated violations by dispatching hydro tested valves from valve testing shop area without raising RFI. 1. Valve ends are not covered with plywood sheet. 2. Valves are not dry lay up, found water traces inside body. 3. Valves are getting rust. 4. Thick layer of sand/ dust inside/outside. 5. Some Valves are stored directly on the ground. These are repeated violations of 04-SAMMS-035 Para 12.1, 12.2 & 12.3, Contractors Approved procedure-QI-8410-005 Rev A, Item 4 & SAIC-L-2041. Valves Numbers: - TR-264 / V-1195, TR-264 / V-1186, TR-263 / V1775, TR-263 / V-1185, TR-411 / 2595 & TR-412 / 2616. Corrective Action: 1.All valves to be re-dry layup, cleaned & covered. 2.RFI to be raised to verify the work. 3.Sinopec / TRG to make surveillance to comply with requirements. During surveillance of internal cleaning prior to installation of valves in GT5 (Area A), it is found that Sinopec/TRG is not complying and is installing valves without verifying internal cleaning. 1.16-H48-DGA5023-81-1CT9P1 2.16-H48-DGA-5023-83-1CT9P 3.6-H48-P-5011-811CT2P 4.16-H48-DGA-5031-36-6CT9P This is repeated violation of SAES-L-350, Para 15.3.2, SATIP-L-350-01, SAIC-L-2017. Corrective Action: 1.Remove all the valves and verify internal cleaning. 2.Sinopec/TRG QCs should make surveillance. 3.RFI to be raised to close LBE. 4.Test Package of this line will be on hold until the LBE is closed. During surveillance of fabricated & welded material (CS & SS), it was observed Contractor TRG/Sinopec are releasing material from fabrication shops to site without utilizing Saudi Aramco SATIP-L-35008, & related SAICs to release material to site without raising RFI to verify the work. This is violation of SAIC-L-2038 During surveillance on PMI in the Fabshop, it was found that the contractor is not performing PMI on inside weld surface wherever accessible. This is a violation of SAIC-L-2010; item #B-9. Contractor is advised to perform PMI on inside weld surface wherever accessible. During surveilance of 4" Galvanized vent pipes at GT-3 Area, found that contractor is welding threaded socket to threaded galvanized pipe causing damages to Galvanized coting both inside & outside. Contractor is advised not to weld galvanized pipe.
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-100
5.4.2
SAES-H-102
4.4.1.4
642
12/19/2007 12:08:40 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
643
11/18/2008 1:50:53 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
644
3/2/2009 8:52:48 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
645
1/23/2008 8:16:11 AM
SATIP-L-350-08
SAIC-L-2038
Mechanical
ScheduleQ
Schedule Q
1.4
646
3/24/2008 2:21:13 PM
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
9.8
647
3/30/2008 9:20:08 AM
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-136
6.10
648
4/21/2008 5:22:33 PM
During surveillance of Abrasive blasting/ Painting activities, following fabricated spools are not internally cleaned and found garnet, stones, welding rods, cut pieces of metals etc. 1.36H46-P-8000-02-6CT2P----Spool M 2.36H46-P-7000-32-6CT2P-----Spool C 3.36H46-P7000-31-6CT2P-----Spool B 4.30H49-P-5001-02-6CS9P-----Spool B This is violation of SAES-L-350 Para 15 Contractor is advised to clean pipes prior to shipment to site. It is found that TRG/Sinopec is not following stud bolt tightening sequence of Valves for Hydrostatic Test and also not using SAIC-L2014. This is violation of SAEP-351 Para7. Contractor is advised to stop this unsafe practice and to avoid any injury. During surveillance of fabricated pipe spools end covers in Lay down Area & painting shops, found pipes are released from Fabrications shops to lay down & painting areas with out end covers. This is repeated violation of SAES-L-350 Para 7. 1.Bridge Tacks- Found outside the weld groove, is not acceptable, RefSAES-W-011 Para 11.5.6. -30-H48-P-60081-1SDOZ-Spool H, FBW #43 (GT-6). -4-H48-P-6063-32-6SD0Z-Spool B- SBW # 7 2.Fabrication Shop- SS-Socket Fittings welding Found pipe cut surfaces of SS pipes, edges and burrs are not ground to smooth prior.to fit up. Ref. SAES-W-011 Para 11.3.2.4. Contractor is storing hydrostatic tested vales on ground unpadded, unatteneded,scattered in Testing shop/ lay-down area/ Area A GT5 & 6, valves end flanges are uncovered with plywood covers, raised face portion of the flanges are not covered with heavy grease, no heavy adhesive tape is used around the complete circumference of the plywood cover and the valves end connection. In lay-down area valves are not stored in shipping crates or on racks. Vales are covered with thick layer of sand & dust outside & inside shell. This is repeated violation of 04-SAMSS-035, Para 12.1, 12.2, 12.3, SAIC-L-2041 and contractors approved procedure QI-8410-005 Rev A, Item 4. Corrective action: Contractor should do re-dry lay- up and use SAIC-L241& approved procedure. RFI to be raised to verify the rework. During surveillance of welding activities in Main Fabrication / Welding Shop, found Contractor TRG / Sinopec is continuously fabricating & welding branch connections without using standard reducing tees. This is repeated violation of SAES-L-110 Chart 1 (Branch Connections). 1.3H86-FG-41011-96-1CS1Z- Spool S (Number of branches 6) 2.3-H86FG-41010-94-1CS1Z- Spool W (Number of branches 6). 3.4-H86-S41120-21-1CS1SV-Spool S (Number of branches 5) During surveillance of Storage /cleaning & preservation of Hydro tested Valves at Valve testing shop, found TRG/ Sinopec is CONTINOUSLY dispatching valves to Area A GT 5,without issuing RFI & without verifying cleaning & preservation. Following vales are dispatched from valve testing area without plywood covers & found with thick layer of dust/sand inside shell & flanged faces: 1.10 # 150Valve Number- TR-326-V-1691 2.6 # 150- Valve Number- TR-437-V2705 3.10 # 150- Valve Number- TR-326-V-1688 4.3 # 150- Valve Number- TR-322-V-1759
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
15
649
4/27/2008 8:03:29 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
650
5/4/2008 7:35:38 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7 and 15
651
6/13/2008 9:20:26 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.2.4 and 11.5.6
652
6/27/2008 8:34:49 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
653
7/1/2008 3:20:36 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
chart 1
654
7/22/2008 1:59:45 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
655
8/10/2008 8:24:43 AM
During surveillance in Gas Compression Area (Area B), found contractor is continuously making repeated violations by dispatching Hydro tested Valves from Valve Testing Shop to Area A & B without raising RFI. 1.Valves end covers are covered with plastic sheets instead of plywood sheet. 2.Valves are not dry lay up, found water traces inside body. 3.Valves are getting rust. 4.Thick layer of sand/ dust inside/outside. 5.Some Valves are stored directly on the ground. These are violations of 04-SAMMS-035 Para 12.1, 12.2 & 12.3, Contractors Approved procedure-QI-8410-005 Rev A, Item 4 & SAIC-L2041 Valves Numbers: - TR-349, V3442 Area- B- Gas Compression Area - TR-349, V3450 - TR-348, V0203 - TR-349, V3437 Corrective Action: - All valves to be re-dry layup,cleaned & covered. - RFI to be raised to verify the work During surveillance in Gas Compression Area (Area B), found contractor is continuously making repeated violations by dispatching Hydro tested Valves from Valve Testing Shop to Area A & B without raising RFI. During surveillance in Valve Test Shop Area, contractor is continuously making following repeated violations by storing Hydro tested Valves from Valve Testing Shop to storage area: 1. Valves end covers are covered with plastic instead of plywood sheet. 2. Valves are not dry lay up, found water traces inside body. 3. Valves are getting rust. 4. Thick layer of sand/ dust inside/outside. 5. Some Valves are stored directly on the ground. These are violations of 04-SAMMS-035 Para 12.1, 12.2 & 12.3, Contractors Approved procedure-QI-8410-005 Rev A, Item 4 & SAIC-L-2041 Valves Numbers: - (1). TR-249, V-1016. (2). TR-249, V1015 3. (3) TR-327, V1709 (4) TR-3542, V4866 (5)TR-134, V-4862 Corrective Action: - 1.Follow check list 2.Raise RFI to verify During surveillance in Gas Compression Area (Area B), Area A & DD-2, found contractor is continuously making following repeated violations by dispatching hydro tested valves from valve testing shop area without raising RFI. 1. Valve ends are not covered with plywood sheet. 2. Valves are not dry lay up, found water traces inside body. 3. Valves are getting rust. 4. Thick layer of sand/ dust inside/outside. 5. Some Valves are stored directly on the ground. These are repeated violations of 04-SAMMS-035 Para 12.1, 12.2 & 12.3, Contractors Approved procedure-QI-8410-005 Rev A, Item 4 & SAIC-L-2041. Valves Numbers: - TR-264 / V-1195, TR-264 / V-1186, TR-263 / V1775, TR-263 / V-1185, TR-411 / 2595 & TR-412 / 2616. Corrective Action: 1.All valves to be re-dry layup, cleaned & covered. 2.RFI to be raised to verify the work. 3.Sinopec / TRG to make surveillance to comply with requirements. During surveillance of storage of shop tested valves in Area A & B, contractor is continuously making following repeated violations by storing Hydro tested Valves from Valve Testing Shop to site areas: 1. Valves ends are covered with plastic without laying up. 2. Valves are not dry lay up, found water traces inside body. 3. Valves are getting sever rust. 4. Thick layer of sand/ dust -inside/outside. 5. Some Valves are stored directly on the ground 6. Some valves are stored without end covers 7. Valves are delivered to site without inspection. These are violations of 04-SAMMS-035 Para 12.1, 12.2 & 12.3, Contractors Approved procedure-QI-8410-005 Rev A, Item 4 & SAIC-L-2041 Corrective Action: 1. Follow check list 2. Raise RFI to verify lay-up (SAES-A-007). 3. Sinopec / TRG QC have to verify lay-up prior to RFI. During surveillance of Steel Structure installation & welding of gusset plates in Inlet area found Contractor Gulf Elite approve JCC welder Par deep Kumar is leaving his LHE electrodes portable oven at site. These electrodes should have been stored continuously in ovens at 120-200 Degrees C minimum. Violation SAES-W-011 Attachment I. JCC card of the welder is withdrawn and all the LHE to be discard.
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
656
Mechanical
ScheduleQ
Schedule Q
1.7
657
9/25/2008 11:37:01 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
658
11/18/2008 1:53:18 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
659
12/11/2008 8:09:10 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1, 12.2 and 12.3
660
12/11/2007 11:57:30 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
661
12/13/2007 4:33:04 PM
Found two non -qualification welders were welding structural cable supports. This is repeated violation in one week and corrective action is taken by TRG/Sinopec. All the supports welded are rejected. This is repeated violation of 12-SAMMs-007 Para 7.5 : During surveillance of Inlet MP Rack area, HG Plant, welding activities of Gussets & Stiffners, found one non-qualified welder of Gulf Elite was welding structural Supports. This is violation of 12-SAMMS-007, Para 7.5 During routine surveillance of welding activities in Inlet Area (Area B), found Steel Structure Contractor Gulf Elite was cutting new holes by flame torch in Beam and plugging holes without information & approval of method statement of modification/repair of steel joint. This is violation of 12-SAMMS-008, Section I & SAIC-M-2008, PIP STD 05130 Para 5.8.2,which states the erector shall make no modification or repair of steel joint without written approval. Modified Item: J-2630, IInlet-13-BH 9-INLET PIPE RACK E058. No QC from Gulf Elite / TRG was available at site. During routine surveillance of welding activities of walk way/ stair structure in GT-5 (Lean DGA Cooler E-501), found Steel Structure Contractor Gulf Elite was cutting new holes by flame torch in structures and plugging holes without information & approval of method statement of modification/repair of steel joint. This is repeated violation (Ref LBE-16085 dated 12/7/2008) of 12-SAMMS-008, Section I & SAIC-M-2008, PIP STD 05130 Para 5.8.2, which states the erector shall make no modification or repair of steel joint without written approval. No QC from Gulf Elite / TRG was available at site. Corrective action: 1.Utilize SAIC-M-2008. 2.Gulf Elite / TRG QC should be available. 3.Method statements of Modification/repair work shall be approved. 4.Plugging the holes by approved material. 5.Holes shall be made by drilling. Insulation & Cladding work is in progress in DD-5 & GT-5 Area without Sinopec Quality coverage. It is observed that Mr. Li-Shi Hua, approved Sinopec insulation inspector had been mobilized to other Sinopec Project in Jubail with out advising & without maintaining required quality coverage. This is repeated violation of Schedule Q Para 5.11, which states Contractor, shall advise of such personnel & quality coverage. Corrective Action: 1.Report & update in weekly progress meeting. 2.Provide personnel & quality coverage. Sinopec approved Insulation/ Painting Inspector Mr. Wang Yunfei is not available at site as he has already left on vacation on 6/27/2008 without advising Saudi Aramco at least 30 days in advance. Contractor should have made quality personnel changes as necessary to maintain required quality coverage. This is 3rd repeated violation of Schedule Q Para 5.11 During surveillance of securing piping hot insulation material in GT-5, found that Sinopec / TRG are using CS wires for securing insulation material in position. This is violation of SAES-N-001, Para 1.2, PIPINSH200-Para 5.2.1 & SAIC-N-2014,Item C10, states that insulation material up to 12 (300 mm) shall be held in place with 16 Gauge (1.5 mm) type-304 SS Tie Wire applied over the tape.. NO Sinopec / TRG Insulation QC are making surveillance to avoid this violation. Corrective Action: 1.All the securing CS wires to be removed. 2.SS type 304 -16 Gauge type wire to be used. 3.QC should make surveillance to avoid reoccurance. 4.Contractor should utilize SA Check list SAIC-N-2014 During surveillance it was observed that Sinopec QCs are not utilizing their Quality Log Book as well as NCRs, it is required as per Sinopecs approved Quality Plant- HWY-SINOPEC-QP-020-Para 4, all the QC personnels need to identify their LBEs & non-conformities to ensure the quality of work.
SATIP-W-011-01
SAIC-W-2006
Mechanical
other
12-SAMSS007
7.5
SAES-W-011
662
12/27/2007 4:54:47 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
other
12-SAMSS007
7.5
SAES-W-011
663
12/7/2008 1:53:31 PM
SATIP-M-001-01
SAIC-M-2008
Mechanical
other
12-SAMSS008
Section 1
664
3/8/2009 4:51:57 PM
SATIP-M-001-01
SAIC-M-2008
Mechanical
other
12-SAMSS008
section 1
665
5/9/2009 10:55:03 AM
SATIP-N-001-01
SAIC-N-2006
Mechanical
ScheduleQ
Schedule Q
5.1
666
6/28/2008 4:00:45 PM
SATIP-N-001-01
SAIC-N-2006
Mechanical
ScheduleQ
Schedule Q
5.1
667
3/11/2009 8:20:01 AM
SATIP-N-001-01
SAIC-N-2014
Mechanical
SAES
SAES-N-001
1.2
668
8/10/2008 8:46:53 AM
Mechanical
ScheduleQ
Schedule Q
A VI Para 4.3
669
5/4/2008 7:12:01 AM
During surveillance of RTR pipe storage and handling in area A, found following violations: 1.RTR pipes are stored in open area under direct sun. As per AES-S-070 Para 5.2, states RTR pipes shall be stored out of direct sunlight in a building or under a cover that allows free air circulation. 2.AES-S-070 Para 5.2, states RTR fittings shall be stored in their original containers. Fittings shall be stored in a building or under cover that allows free air circulation. 3.Found RTR pipe in trench since long time under direct sun containing stones, debris etc causing damage to RTR pipe and there is no bedding layer of 150 mm in depth as per SAES-S-070 Para 9.7.2. During surveillance of storage of Bondstrand Adhesive Kit (RP48) for bonding of Fiberglass pipe and fittings, found contractor is continuously storing adhesive kitat site temperature of 45 Degrees C and above. This is violation of manufacturers recommendation storage temperature min.21 Degrees C up to max.38 Degrees C. During surveillance of welding activities in Main Pipe Rack-Area A, found metal temperature ~6 Degrees C and no preheat equipment & no contact pyrometer was available at site. This is repeated violation of SAES-W-011 Para 12. No QC Welding Inspector was available at site from Sinopec/TRG. During surveillance of Storage & exposure of LHE electrodes in Area GT-5 (4/10/2009), found Steel Structure Contractor Gulf Elite & Sinopec is storing electrodes in wooden boxes & tool rooms at work areas. Welders are taking cold electrodes directly from these wooden boxes to work areas by hand. Storage oven is available at site but was unplugged, non -calibrated & without temperature gauge. No TRG /Gulf Elite/Sinopec QCs are making surveillance to stop this practice & no corrective action from TRG. This is repeated violation of SAES-W011. 6.1. Corrective Action: 1. Cold electrodes to be discarded. 2. Electrodes to be stored continuously at 120 Degrees C in storage oven. 3. QCs should make surveillance to avoid reoccurrence 4. Storage oven should be calibrated with temperature gauge. During routine surveillance of Storage of LHE electrodes in Area A,found following repeated violations: 1.Cold electrodes in unplugged quivers and outside quivers. 2.No identification is marked on quivers to identify the welder. 3.No entry of returned electrodes is made in log book. 4.Welders are storing their quivers in wooden boxes instead of return back to storage oven. 5. Welders are taking quivers from their boxes in the morning and plugging to power to show that electrodes are warm. 6. GTAW filler wires are stored in open areas. 7. No Sinopec / TRG surveillance to stop this repeated violations. Violation: SAES-W011, 6.1, SAIC-W-2032 & SATR-W-2010. Corrective action: 1.All quivers should be available at electrodes issuing area after working hours.. 2.Sinopec / TRG should verify & sign electrodes issuing & returning back. 3.Welder Symbol should be marked on his assigned quiver. 4.GTAW fillers to be stored in containers and dry atmosphere During surveillance of Holding & Backing Electrodes ovens, found calibration validation of all the three ovens is already expired in November, 07.As per Schedule Q Para 6.1,the calibration cycle shall not exceed 6 months. A proactive LBE-5095 was made on 11/8/2007, but TRG/Sinopec has not taken any corrective action. This is violation and contractor is advised to get equipment calibrated or to stop use of ovens. TRG/Sinopecs Third Party NDT (VETCO) is utilizing Non-approved PMI Technician Mr. Resituto G.Dungo for PMI work. This is violation of Schedule Q Para 3.3.4 Contractor is advised to get approval prior to start PMI
SATIP-L-350-05
SAIC-W-2054
Mechanical
SAES
SAES-S-070
5.2
670
7/6/2008 5:39:23 PM
SATIP-L-350-05
SAIC-W-2054
Mechanical
SAES
SAES-S-070
5.6
671
12/24/2007 8:16:19 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
12
672
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
673
4/12/2009 8:26:37 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
674
2/14/2009 8:10:55 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
675
12/14/2007 10:06:35 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
ScheduleQ
Schedule Q
6.1
676
12/15/2007 3:42:49 PM
SATIP-L-350-01
SAIC-L-2010
Mechanical
ScheduleQ
Schedule Q
A 1 Para 3.3.4
677
12/19/2007 11:54:53 AM
During surveillance of Cable supports welding activities in Fabrication/Welding shop, found one non-qualified welder was welding structural cable supports. This is 3rd repeated violation in two weeks and no corrective action is taken by Sinopec / TRG. Refer to violation nos: 4581 & 6009. Violation: 12-SAMMS-007, Para 7.5 During surveillance of Cable supports welding activities in Fabrication/Welding shop, found one non-qualified welder was welding structural cable supports. This is 3rd repeated violation in two weeks and no corrective action is taken by Sinopec / TRG. Refer to violation nos: 4581, 6009 &.W-108. Violation: 12-SAMMS-007, Para 7.5 Contractor TRG/Sinopec is welding Stainless steel at Fabrication shop as well at Main Pipe Racks without using Oxygen Analyzer to determine oxygen level in the pipe during purging. This is required as per SAESW-011 Para 11.14.5 Contractor TRG/Sinopec fabricating / Welding Stainless Steel without Positive Material Identification (PMI) to ensure that the nominal composition of the alloy components and associated welds have been correctly supplied and installed as specified. This is violation of SAES-A206Para 5.1.3 / 7.1 and 7.2 During surveillance of welding activities, found welder Symbol # 045 was using cold LH Electrodes and also Quiver was unplugged and electrodes were cold. JCC card of this welder is withdrawn and is not allowed to do any welding activities. Repeated Violation: SAES- W-011 6.1 During surveillance of welding activities of Main Pipe Rack Area A,it was raining & cold, found welder Symbol # T-048 was welding structural pipe saddle support on wet and exposed surface to rain. Sinopec QC was there but he did not take any action. Violation: SAESW-011 Para 11.2.2. JCC of the above welder is withdrawn and is not allowed to weld. Pipe structural support to be removed and rewelded During surveillance of welding activities in Area B- GT-3-Main Oxidizer Pipe Rack,found field welding on an elevated pipe rack is in progress using welding power source at a distance of more than 30 metres without using remote Current controls. This violation of SAES-W-011 Para 19.1 During surveillance of welding activites in Pipe Rack 1, found LHE.Quiver No.T055 was unplugged and electrodes were cold. Welder# T-055 was using cold electrodes in Tie- In Area. Sinopec / TRG QC inspector did not take any action This is repeated violation of SAES-W-011-6.1 During routine surveillance of welding activities, found Contractor TRG/Sinopec commenced fabrication & welding of API-5L-X60-Piping Class 20/30-6CS1SV without approved WPS & PQR. This is violation of Schedule Q, Attachment IV Para 2.1, which states, all procedures shall be submitted to review and/or approval. : During surveillance of Cable supports welding activities in Fabrication/Welding shop, found one non-qualified welder was welding structural cable supports. This is 4th repeated violation and no corrective action is taken by Sinopec / TRG. Refer to violation nos: 4581 & 6009. Violation: 12-SAMMS-007, Para 7.5 During surveillance of welding activities in Sinopec shops, found that Contractor is continuously fabricating, installing & welding branch connections (Vertical & Lateral) without standard fittings & without reinforcement pad or full encirclement sleeve. This is repeated violation of SAES-L-110, Chart 1 (Branch Connecrtions). During surveillance of GTAW FILLER WIRES in Area Awelding activities, found that Sinopec is still using wires with visible rust & contamination. This is repeated violation of SAES-W-011 Attachment 2, which states any wire shows visible rust rusting or contamination shall not be used and shall be discarded. This violation was brought to TRG/Sinopec QCs.
SATIP-W-011-01
SAIC-W-2006
Mechanical
other
12-SAMSS007
7.5
SAES-W-011
678
12/20/2007 4:57:09 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
other
12-SAMSS007
7.5
SAES-W-011
679
12/25/2007 2:08:01 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.14.5
680
12/25/2007 2:38:25 PM
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
5.1.3, 7.1 and 7.2
681
1/12/2008 11:16:07 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
682
1/13/2008 4:28:45 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.2
683
1/19/2008 2:36:12 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.1
684
1/23/2008 11:23:39 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
685
1/27/2008 4:45:46 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
686
2/25/2008 10:54:33 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
other
12-SAMSS007
7.5
SAES-W-011
687
3/18/2008 11:13:40 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
chart 1
688
4/11/2008 9:08:12 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.1
689
4/21/2008 11:11:55 AM
During surveillance of Area H46, found one unplugged Quiver full of Low Hydrogen Electrodes under Equipment-H46-D-062. Electrodes were cold and no body was available in this area. These electrodes should have returned back to storage oven to keep maintain the required temperature. This is repeated violation of SAES-W-011 6.1. Contractor QC & Supervisor was informed of violation. All LHE to be discarded and severe action to be taken against the welder During surveillance of welding activities in Fabrication shop, found Welder# T-110, welding careless and found deep arec strikes. Violation: SAES-W-011 Para 11.6 18"-H49-P-5501-31-3CA1J- Spool C No Sinopec QC was available. Corrective action- Grind arc strikes and do MPI. During Surveillance of Welding activities in UG Shop, found one Unplugged LHE (E-8081-C3) Quiver containing 50 Cold Electrodes. This is 2nd repeated violation by Welder # T -096. This is repeated violation of SAES-W-011 6.1 Sinopec QC Supervisor & TRG QC Supervisor was informed of repeated violation. No Surveillance of Electrodes is being carried out by Sinopec/TRG QCs. It is windy and sand storm at 8.30 mornings, found Welding activities were on going outside Main Fabrication /Welding shop without adequate wind protection shielding.. Sinopec & TRG concerned supervisors was informed. This is repeated violation of SAES-W-011 Para 11.2.1 No Sinopec/ TRG QC were available. All todays welds to be 100 % RT or Cut & re-welded. 1. During surveillance of welding activities in Sinopec Fabrication Shops found Bridge Tacks of SS pipes are located outside groove. This is repeated violation of SAES-W-022 Para 11.5.6. Such bridge tacks to be removed and to be re tacked and located above the root area. 30H48-P-6505-81-1SD0Z- Spool A. 2.Welding was in progress in SSSmall Fabrication Shop during wind blowing sand without wind shields. This is repeated violation of SAES-W-011 Para 11.2 During surveillance of welding activities in area A-GT-5, CS/SS Big Fabrication shop found welding was in progress with a single weld bead of weaving width 20 mm where as per WPS it should not be greater than 3 times electrode diameter i.e. 12 mm. This violation of approved WPS. 1.24-H48-DGA-5034-05-6CT9P-Spool Q-FBW-# 71Welder T-156. 2.16-H49-P-5503-03-3CS1Z-Branch Connection weld.Welder #071 Corrective action: To be cut & rewelded & RFI to be raised. During surveillance of Conditioning, Storage & exposure of SS Electrodes, found Storage Oven was not working and electrodes were cold. Electrodes were issued to welders in cold condition & no QC from TRG / Sinopec was verifying the issuing & receiving electrodes log book. As per SAES- W-011, 6.1, these electrodes should have been dried at 120-200 Degrees C minimum prior to use. This is repeated violation. Corrective action: All the SS electrodes which are not stored continuously in oven at 120-200 Degrees C to be discarded. During surveillance of welding activities in SS small fabrication /welding shop, found following SBWs were in progress with single bead weave width 20 mm, as per approved WPS, it shall be not greater than 3 times filler diameter i.e. 12 mm. This is repeated violation of WPS and also works showing poor work man ship. 1.24-H46-P-8058-336SD0Z1-Spool O-SBW # 75- No Welder Symbol was marked. 2.24H46-P-8056-33-6SD0Z1-Spool O-SBW 74 & 76-Welder T # 076 & 062. Corrective action: - Welds are rejected and to be cut rewelded. - JCC of the welders to be revoked as this is repeated violation..
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
690
5/16/2008 9:39:27 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
691
5/17/2008 11:10:22 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
692
5/21/2008 2:36:10 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.1
693
6/15/2008 4:10:50 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11
694
6/19/2008 2:43:48 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
695
6/19/2008 4:34:52 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
696
6/20/2008 7:52:58 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
697
7/5/2008 11:47:27 AM
During surveillance of LHE storage in Area A-GT6, found one Cold LHE storage quiver with open cover and unplugged. This is repeated violation of SAES-W-011 Attachment I, which states electrodes shall be stored continuously in a portable electrode oven heated to 65 degrees centigrades minimum. No QCS from TRG/Sinopec are making surveillance to check electrodes being used at site. During surveillance of Gas compression area found, Sinopec Welder Symbol # T-205. as per JCC he is qualified for P8 Material (SS) and GTAW Welding Process was welding CS Material using SMAW Process for Instrument Cabinet pipe support & reinforcement Patch with Structural Column. This is violation of SAES-W-011 Para 8.1, SAEP-324 Para 6 & SAIC-W-2035. Corrective action: Welder JCC to be withdrawn and all work done is to be reworked. During surveillance of SS material welding activities in Fabrication shop Area C, found welding of CS material is in progress without any partition between SS material & CS material. This is repeated violation of SAIC-L-2031, Item F6 & PFI-ES-43 Section 2.4 Corrective Action: Move all SS materials to SS shop. During surveillance of GTAW filler wires in Area A-GT-5, found Welder Symbol T # 017 was welding SS socket fittings with GTAW filler wires which were stored on the muddy ground with contamination. This is repeated violation of SAES-W-011, Attachment 2, which states, all wires shall be stored in sealed containers in dry environment. Sinopec QC was there but he did not made any surveillance. This is serious violation & warning letter to be issued to welder & all GTAW wires storing on ground to be discarded. All Sinopec / TRG QCs should make surveillance to stop this repeated violation. During surveillance of quality personnel in all fabrication shops, found there are 18 active welders and only Sinopec QC (Mr. Peng Xiao Long) is covering all the shops. This is violation of Schedule-Q Table VI-2. As per Sch. Q-sates one QC per 13 welders is required so in this case 2 Sinopec QCs are required. Corrective Action: Contractor shall assign Saudi Aramco approved quality personnel to meet quality requirements. During surveillance of SS Fabrication / Welding shop, Welder Symbol # T-095 was welding SS pipe & Fittings on ground & material was stored directly on the ground. This is Violation of SAES-L-350 Para 8.1 & SAICL-2034 Item A3. Corrective Action: All materials in Fabrication shops is not to be stored on the ground. During surveillance of pipe supports welding shop, found two welders were welding pipe supports without JCC. (Mr. Du Guo Chung & Mr. Pei Tao). This is 4th repeated violation of SAES-W-011 Para 8.1, which states all welders shall be qualified. Corrective Action: 1. Welders to be removed immediately. 2. Only qualified & JCC welders are allowed to weld. 3. TRG / Sinopec QC should make surveillance to stop this repeated violation. During surveillance of consumables in all Fabrication / Welding shops, found there is no surveillance by TRG / Sinopec, found cold electrodes, quivers unplugged, LHE are lying on the ground, filler wire are stored on the ground or inside pipes, no verification / signing of consumables issuing & returning log book. This is repeated violation of SAES-W-011 6.1 & SAIC-W-2009. Corrective Action: 1.TRG / Sinopec QC should monitor & sign issuing /receiving log book on daily basis 2.Electrodes / Filler wires to be stored only in plugged ovens or in original boxes. 3.If found storage is not as per requirement, shall be discarded.
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11
698
7/10/2008 5:15:15 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
SAEP-324
699
7/21/2008 4:45:20 PM
SATIP-L-350-08
SAIC-L-2031
Mechanical
other
PFI-ES-43
2.4
700
7/22/2008 10:45:56 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.1
701
7/26/2008 10:55:42 AM
ViolationPrevented Engineering
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
702
7/26/2008 2:28:00 PM
SATIP-L-350-01
SAIC-L-2034
Mechanical
SAES
SAES-L-350
8.1
703
8/14/2008 4:19:43 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
704
8/20/2008 3:07:49 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
705
9/19/2008 9:55:29 AM
During surveillance of welding activities (Friday) in Pipe supports shop, found one non JCC (non qualified)welder was tack welding . 1.This is violation of SAES-W-011 Para 8.1 which states tack welder shall be qualified. 2.Violation of SAES-W-011 6.1 No Sinopec/TRG QC was available at shop. Corrective Action: 1.Tack welder to be qualified 2.Electrodes to be discarded, 3.QC shall be available & also found unplugged LHE portable oven (T-037) containing cold electrodes During surveillance of welding activities in Sulfur Area (Area B), found following repeated violations: 1.Welder Symbol: T-107 - Welding was in progress without Sinopec/TRG QC fit- up. - No information was displayed (No WPS/ No FBW/ No Welder Symbol/ No Line Number). LHE Quiver was unplugged & Electrodes were cold.( Welder Symbol # T-111) - No surveillance by Sinopec / TRG QCs. Violations: SAES-W011 Para 16.1/16.2, 6.1, SATIP-W-011-01 & SAIC-W-2005. Corrective Action: - Welders JCC is withdrawn - Electrodes to be discarded. Sinopec / TRG QC should make surveillance to avoid repeated violations. During surveillance of welding activities in Fabrication Shops, found following repeated violations: 1.Weld Modification after weld acceptance is in progress. 2.As per SATIP-W-011-01 Para 3.17. it is Hold Point for Contractor/ PID. 3.No information / RFI had been submitted. 5.No Sinopec / TRG QC were available in shop. Repeated Violation: SAES-W-W-011 Para 18.4, SATIP-W-01, Para 3.17 & SAIC-W2036. Corrective Action: 1.Provide revised DWG:/ISO 2.Comply with Saudi Aramco checklist- SATIP-W-011-01 & SAIC-W-2036. 3.QCs should be available in shop. 4.Material is send direct to blasting area for touch up paint without inspection. During routine surveillance of GT-6 A, following repeated violations were found: 1.Welder Symbol # T-215 (Zheng Jun) was welding socket fittings without JCC.. Violation: SAES-W-011 Para 8.1 & Attachment 2. Corrective Action: 1. Welder JCC shall be available at all times with the times at the work location. 2. QCs should make surveillance to avoid repeated violation 3. Welder should be given warning letter. 4. CS / SS -GTAW filler wires should be stored separately. 5. Wires containing rust / contaminations should be discarded. 2.GTAW Filler Wires CS & SS were stored in the same container. 3.GTAW CS fillers were found with visible rust & contaminations. 4.No Sinopec / TRG QCs were available During surveillance of Storage & exposure of LHE electrodes in Cable structural supports shop, found welder symbol # T-121 is taking LHE electrodes directly from backing oven without noting in log book,carrying electrodes in hands and storing in cold unplugged quiver in welding area. This welder was given verbally warnings to stop this practice, but all went in vain. No Sinopec / TRG QCs are making surveillance to stop this repeated violation. Violation : SAES-W-011, 6.1. Corrective Action: 1.Welder # T-121, JCC card is withdrawn. 2.Sinopec/ TRG QCs should monitor storage / exposure of electrodes. 3.Electrodes log book should be verified by QCs on daily basis.
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
SAEP-324
706
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
707
10/28/2008 8:37:29 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1 and 16.1
708
10/28/2008 8:41:47 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.4
709
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.1.1
710
11/5/2008 2:18:50 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
SAEP-324
711 712
SAES ScheduleQ
SAES-W-011 Schedule Q
6.1 A VI Para table 2
713
11/18/2008 1:45:36 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
714
12/13/2008 9:27:08 AM
During surveillance of welding consumables in Area B, found that contractors TRG / Sinopec & Gulf Elite are making repeated violations by using cold electrodes without plugging quivers to 65 degrees C minimum. Electrodes are being stored at work areas in quivers without maintaining temperature instead of returning back to storage ovens. Also electrodes are being stored in opened electrodes containers in open atmosphere. This is repeated violation of SAES-W-011 Table 1, SATIP-W-011-01 & SAIC-W-2032. No TRG / Sinopec QCs are making surveillance of electrodes handling/ storage etc. Following welders JCC Cards are withdrawn who are not storing / using electrodes properly. 1.T-074 -Sinopec 2.T-120 Sinopec 3.T-096 - 4.ATAK- Gulf Elite During surveillance of Storage & exposure of LHE electrodes in Area DD5, found Steel Structure Contractor Gulf Elite is storing electrodes in wooden boxes at work areas. . Welders are taking cold electrodes directly from these wooden boxes to work areas by hand. No storage oven is available at site to keep electrodes continuously at 120 degrees C. No TRG /Gulf Elite QCs are making surveillance to stop this practice. This is repeated violation of SAES-W-011 6.1. Corrective Action: 1.Cold electrodes to be discarded. 2.Electrodes to be stored continuously at 120 Degrees C in storage oven. 3.QCs should make surveillance to avoid reoccurrence. Many times, we noticed that the deadman attaching with the Blast nozzle is without a remot control shut-off Lutch, they tyed it with a rubber for continuous operating and also the ground wire was disconnected which violating Saudi Aramco. As per SAES-H-102, 4,4,2,1, Blasting nozzle shall be equipped with a remote shut-off dead man and Paragraph 4.4.2.2, saying that the Blast nozzle shall have electrically connected to external ground in order to prevent electrical discharges or shocks to operator personnel. The area utilizing for coating between Grit blasiting area A and Grit Blasting Area B is not accepted to be used, because Grits, Garnet dust/debris, sand escaping & flying all around area and sticking on the wet coating. Again,on Thursday (November 22, 2007) they did applied coating for 12 pipes which are rejected. Recoating is required. The coating area should be separated or this Area has to be cleaned and all gritblasting job must be stopped when the coat was applied. The intermediate coat was applied for a bout 12 new fabricated spools (6", 8" & 24")in the early morning and the application was completed at 07:15 while the Subtrate Temperature is less than 10C which violating Saudi Aramco Standard, SAES-H-001. Blasting & coating shall not be performed if the subtrate temperature is less than 10C Two branches of 10" Dia. were est on the 12" Dia. Header and saddle sleeves were welded around both Branches which violating Standard Drawing (AB-036719)that requires Full encirclement sleeve when the Branch size is greater than 70% of the Run Size and vilating Saudi Aramco Standard (SAES-L-110, Paragraph 12.1.1 Chart 1 which require Reducing Tee. Many fabricated piping spools were accumulated over each other causing damage to the flanges, the branches as well as to the surfaces & to the ends, also creating unsafe area. All fabricated spools should be segregated, arranged and put on pallet in grouping manner to avoid damage and make a safe area. During PWHT going on for Tie-in--022 Spools joints, Wooden pieces were used supporting the spool & holding the Blanket, so from the heat, the Wood got ignited; moreover; the blanket removed and an open was created violating SAES-W-011. The wood should not be used. Also supervision must be all the time and all opnes should be closed asper SAES-W-011.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
715
3/16/2009 4:39:04 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
716
11/19/2007 3:49:53 PM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-102
4.4.2.1 and 4.4.2.2
717
11/23/2007 5:24:06 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
8.1.1
718
12/17/2007 2:42:11 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
8.1.1
719
1/6/2008 1:52:25 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12.1.1
720
11/19/2007 3:25:44 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
721
11/19/2007 2:44:46 PM
SATIP-W-011-01
SAIC-W-2004
Mechanical
SAES
SAES-W-011
13.18
722
2/3/2008 10:49:44 AM
Almost all fabricated shoes have incomplete fillet weld for the side plate with the saddle plate from inside, only about 1" wide. As per the Drawings, a complete fillet weld should be done for the sides plates with the Saddles. No NDT (VT/PT) was conducted for some Branch Tie-ins attachment joints (6"-h48-rl-5012-02-1CT2P, 6"-h48-rl-5001-02-1CT2P & 6"-H48RL-5010-05-1CT2P)and the Pads were attached & welded. VT/PT should be conducted for all the Branche Tie-ins attachment joints and make the NDT report, sign and then the sleeve can be welded, if the joint is accepted. In SINOPEC Shop, improper tool (Torch) was used for preheating the welding joints prior to starting the welding. A proper heat burner should be used (more than one) to do even preheating for all joints before starting welding. Also timpelistics or other tools for measuring the surface temperature should be available. See AE-036451 In TRG RTR materials Yard, the contractor was caught many times doing loading & unloading the RTR pipes by the Forklift without using Pad and informed them that all the surfaces will come to be contacted with the pipe should be padded as per the Bondstrand Company Installation Guide Catalog. Also some marks of damage & scratched were seen on some piping. It is found that the TRG/SINOPEC have forwarded the Test package GT6HW-002 to PID for final review with out completion of A items. . Also 12 additional joints welded in the line due to modification are not reflected in weld summary record. No evidence of completion of NDT requirements for the additional joints is seen. The flow chart of test package indicates that the Contractor QC has cleared A items and the flow chart is duly signed by all the concerned parties. It is in violation with the requirement of Schedule Q. TRG/SINOPEC have to ensure completion of all quality requirements and forward the Test package to PID. It is hereby advised TRG/SINOPEC to find out the root cause for occurrence of this violation and to take necessary measures to avoid reoccurrence. The contractor grout slide saddle support( teflon tape Embedded ) and cannot move violating SAES E-004 Para. 9.3.1 Horizontal exchangers shall be supported by at least two saddles. The exchanger shall be fixed at one saddle and free to move in the longitudinal direction, due to thermal and pressure differentials, at the other saddle. During focus assessment PID found that ISO drawings for SS line not mark for coating under insulation. Violation of Par. 5.6.2 of SAES-H002 No coating required when continuous operating temperatures exceed 70C and the facility is in service at least 90% of the time. Otherwise, obtain coating requirements from the RSA. For Stainless Steel pipes, consult the RSA for coating material selection. During our review of ISO drawings (example # RB-737435 -001 00, 737437-001-00) for steam condensate we found that mention paint N/A violating SAES H-002 Para. 5.1.4 Plant piping and other above grade pipelines in industrial or marine exposure shall be externally coated as required in this standard or other Saudi Aramco standards, specifications, mandatory drawings, scopes of work, or similar mandatory documents. During our surveillance at site it is noticed that line#4-SC-80841CS9P/4-SC-8094-1CS9P Iso#RB-737442-004-00/RB-737452-003-00 respectively having obstruction with existing electrical conduit.These lines require insulation(EC-1 1/2).This violates SAES-310 para12.4(A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe).
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.8
723
11/23/2007 5:11:32 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-W-011
9.8
724
11/13/2007 1:54:43 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
12.4
725
11/12/2007 5:32:26 PM
SATIP-S-070-02
SAIC-S-4056
Mechanical
SAES
SAES-S-070
5.8
726
11/12/2008 4:09:47 PM
SATIP-W-011-01
SAIC-W-2008
Mechanical
ScheduleQ
Schedule Q
1.4
727
2/22/2010 8:56:00 AM
SATIP-E-004-01
SAIC-E-2002
Mechanical
SAES
SAES-E-004
9.3.1
728
3/7/2010 3:44:23 PM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.6.3
729
2/27/2010 9:38:37 AM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.1.4
730
3/14/2010 8:59:58 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
731
9/5/2009 9:03:26 AM
During Surveillance Inspection at Al Hammam Fabrication shop at Jugahyma PID found that the contractor have fabricated pipe spools and the spools are not preserved properly, all the spools are dumped one over another inside and outside (lay down yard) the shop, this will lead the pipe spools to bend due to over load applications, this is a violation against SAES L 350 section 7 and Para 8.1.Inspection requires the contractor QC Manager to take immediate corrective action against preserving of Aramco materials and assure NO DAMAGE for any materials (pipe, fittings & spools) during fabrication. contractor missing oily water sewer drain for the Hot water pump at SRU 100 ,200 and 300 violating SAES S-020 Para. 4.8.1 Drains shall run to the nearest catch basin or manhole through a sealed. connection at the catch basin or at the manhole Location: BGP (44% Completion) During quality documents reviews inspection found out that the contractor reported the latest weld rejection rate to be 0% while during the review of RT reports PID found many rejected joints which were not reported in the project (SATR W 2019, project weld status report) nor counted in the total WRR, this is violation of Saudi Aramco Sch. Q Para. 1.3 & SATR-W2019. Furthermore PID will conduct an audit on the projects quality welding requirements implementation. PID requires: Contractors QC manager to investigate the root cause of this violation and report the result to PID Contractors QC manager to propose a corrective action. Contractor shall provide a preventative action to assure the nonoccurrence of this violation in the future. RB-737452-001, Rev 00, Line No 4"-SC-8094-1CS9P, Spool No 809404, Train T-200 : SW-22 was shop fabricated with 90 degree Elbow with wrong orientation. This was observed while checking the Refit-up of Shop Weld Cut out joint SW-19. The shop fabricated Joint SW-22, needs to be cut out and a fresh weld to be made with correct orientation. Contractor QC has to check thoroughly. This Violates SATIP-W-011-01 para 3.9. RB-737452-001, Rev 00, Line No 4"-SC-8094-1CS9P, Spool No 809404, Train T-200 : SW-22 was shop fabricated with 90 degree Elbow with wrong orientation. This was observed while checking the Refit-up of Shop Weld Cut out joint SW-19. The shop fabricated Joint SW-22, needs to be cut out and a fresh weld to be made with correct orientation. Contractor QC has to check thoroughly. This Violates SATIP-W-011-01 para 4.10 PID observed that FW-72 is having dog leg with the ISO 2"-S-80571CS9P, RB-737481, Sht 002, for train T-300, this violates SAES-W-011. Affected joint to be cut out and replaced by a fresh weld. During our surveillance at Olayan Descon shop we found small jacketed pipes installed distance between parallel butt welds less than three times the wall thickness of the joint violation to SAES W-011 Para 11.16.1 (The minimum distance between parallel butt welds shall be 20 mm or three times the wall thickness of the joint, whichever is greater). Location ODECO FAB. SHOP Date: Feb 24, 2010 During surveillance inspection at CS fab shop PID noted that there is a manifold under fabrication without notification to PID and after investigation we found that this manifold is belongs to other project and there are using AHC welders on this concern PID immediately requesting the contractor to remove it and verbal warring was giving to AHC QA/QC organization of this issue. This is a violation of Sch Q attachment IV PID requires : Contractor has to apply the quality on this project. Contractors QC manager to investigate the root cause of this violation and report the result to PID. Contractors QC personnel should follow Aramco procedures
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7 and 8.1
732
2/24/2010 10:58:51 AM
SATIP-S-020-01
SAIC-S-4064
Mechanical
SAES
SAES-S-020
4.8.1
733
11/22/2009 10:44:30 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
1.3
734
2/1/2010 11:09:57 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-L-310
735
2/1/2010 11:10:17 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-L-310
736
2/9/2010 7:42:43 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.3
737
2/13/2010 8:27:31 AM
SATIP-W-010-01
SAIC-W-2068
Mechanical
SAES
SAES-W-011
11.16.1
738
2/25/2010 9:45:31 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
A IV
739
3/7/2010 11:32:37 AM
PID requested the Contractor AHC to submit QC Supervisor for (Olayan Descon) AHC Shop to meet the Sch Q requirements. and it was on the Quality minutes of meeting but AHC has no action on this concern which is required This is a violation of Sch Q Para 5.2 and attachment IV (Quality Requirements for the construction Phase) PID requires : Contractor AHC has to submit immediately new resume for QC Supervisor as soon as possible for review by PID to comply with the requirement of Sch Q Para 5.2 and attachment IV (Quality Requirements for the construction Phase) . Location: BGP During Surveillance inspection at project site PID found out that the QC welding (Mohammed Kamal Uddin SAP# 70007432) is absent without any notification to PID this is a violation to Sch Q 5.11 PID requires: SAPMT to investigate this lack of contractors communication with Saudi Aramco. Contractors QC Manager to provide root cause for this repeated violation. Contractors QC Manager to immediately provide a corrective action and preventative action to solve this problem. 1. The Shop weld Joint SW-07, Dwg No RB-737481, Sht 001, Rev 0, in train T-300, Line No 2"-S-8057-1CS9P, is cutout and re welded, after the spool has been shop fabricated and field erected. The reason behind cutout of this joint is due to change in design/modification as per site condition. 2. The Shop weld jts SW-38 and SW-39, Dwg NO RB-737452, Sht 002, rev 0, in train T-100, Line No 4"-SC-8094- 1CS9P are cutouts and fresh welds were made after the line has been shop fabricated and field erected. The reason behind cutout of these joints is due to shorter in length (Pup piece), which was replaced by an actual length, as per site condition. The joints above in Para 1 and 2 were modified and re welded without prior information/notification to PID (Inspection Department).violates SATIP-W-011-01, Item No 3.17.Action:1. RT to be done for the above mentioned Welds.2. In addition to all cut out joints on the above AHC QC has to verify for any modifications, if any. Accordingly PID to informe 1. Violations after the fact : ISO Line No : 4-A-8174-12CGOU, DWg. No RB-737475, Sht. 006, Rev. 00, in train T-300, spool No 8174-32, Indicating two 45 degree Elbows with Joint Nos- 62, 63, 64, 65 were welded. Now this spool was modified by Al-Hammam Co. with two 90 degree elbows without prior notification or documentations to PMT & PID. The new modified joint nos FW-62, FW-63, FW-64 and FW-65 whose fit-up reports are missing. And weld joint no FW-63 is never been reported after welding. Violation :- This Violates SATIP-W-01101, Item No 3.1.7. Violation Prevented Installation: ISO Line No : 4-SC-8094-1CS9P, Dwg No RB-737452, Sht. 002, Rev.00, in train T-100, spool No 8094-09 on weld joint FW-34 , is tilted(The pipe spool is not straight) .The affected area has to be cut and replaced by a new pipe. This Violates Welding standard SAES-W-011. Location: ODESCON Fab Shop During inspection surveillances at ODECO shop PID found out that AHC Welder (S-336) were completed 5 weld joints without evaluation the first 3 production weld joint as per SAEP-324 Para 6.1.5 PID holding the welder JCC till the contractor providing the RT report for The first three (3) production welds PID requires: 1.Contractors QC manager to investigate the root cause of this violation and report the result to PID 2.Contractors QC personnel should follow Aramco procedures. 3.Contractor shall provide a preventative action of this violation in the future. 4.Toolbox meeting shall be carried out for Contractors QC personnel at sub. Contractor side .
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.2
740
11/22/2009 5:13:42 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.11
741
12/28/2009 8:17:19 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.8
742
1/9/2010 9:19:56 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.8
743
1/9/2010 9:25:47 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
744
1/20/2010 5:27:27 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAEP
SAEP-324
6.1.5
745
9/5/2009 8:52:54 AM
During Surveillance Inspection at Fab shop-Jugahyma PID found contractor fabricated pipe spools nearly 200 300 weld joints (including pre-welding & post welding) for stream line as per drg, but no reports for these joints were available. The QC Welding Insp has failed to prepare the report, as of 09-02-09 no reports were available. This is a violation against SchQ Para 1.3 and SATIPW1101 Item # 3.6. PID requires contractor QC Mang. to investigate and find the root cause for violation and take corrective action and to undergo 20% of required NDT to ensure the welded joints During Surveillance Inspection at Al Hammam Fabrication shop at Jugahyma PID found lot of un-used low-hydrogen welding electrodes near welding area, the electrodes are not properly controlled by the QC Inspector welding, the responsibility of a welder is to return back the un-used electrode to the controller and this activity has to monitored by the QC Inspector, SATR W 2010 (Issuance & Conditioning of welding electrodes) is not maintained by the QC Inspector. This is a violation against SAES W 11 6.1 and SATIP W 011 01 Item # 3.4. Inspection requires the contractor to comply with the SATIP requirements for welding consumables and assure that such violations are controlled in the future APIU have noted that the QA Manager Mr Shree Puranik proceeded out on vacation but failed to return and no replacement has been provided. This is in violation of Schedule Q QC manpower requirements. IMAD must source a QA manager immediately. IMAD have failed to produce or maintain project inspection record books in accordance with SAEP-122 for the PMCCs for SRU 1, 3 & 4. Continuing failure of IMAD failure of the very documents will result in NGPIU cancelling the approval of the QC manager & QC supervisor & will elevate this QMIS entry to an NCR. IMAD released their valve inspector Mr. Isfaq Hussain on emergency leave on 1/19/09 without SA approval. To date he has not returned to site and IMAD have failed to provide a return date or provide for his replacement. If this inspector does not return nor a suitable replacement is provided by 2/25/09. NGPIU will elevate this QMIS after the fact violation entry to a higher level. IMAD have recieved 5 major equipment from GULF HEAVY INDUSTRIES at their laydown yard with out completing recieving inspection or maintaining preservation in accordance with Schedule "Q" , applicable standards & manufactures manual recomemdations. Reference: Receiving Inspection of all condensers: RFI 640, 641, 642, 643, & 644 Related documents reviewed & found in order. However, an approved procedure for Storage, Handling & Preservation, is not available with IMAD. This is in violation to the requirements of Sch. Q Attach. IV Sec 5 & 6. The contractor is advised, through SAPMT, to submit the procedure immediately for approval & preserve these major equipments accordingly. Observed that some of the Piping Spools are stored directly on the ground. & the flange gasket faces are not protected with wooden/plastic/metallic covers. This is in violation as per the requirements of SAES-L-350 para 7 Contractor IMAD is advised, through SAPMT, to strictly adhere to the quality requirements. During surveillance at the Lay down Yard, observed that the traceability of the structural material during the fabrication is not maintained. This is in violation as per the requirements of Sch. Q Attach. IV Sec 3 The contractor IMAD is advised, through SAPMT, to comply with the standard quality requirements at all time. IMAD QC Manager was not present on site on Jan 3rd 2009, where he is required to be available at any and all time as per the general requirement of the Schedule Q.
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
1.3
746
9/5/2009 8:57:51 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
747
6/23/2008 1:34:25 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
A VI Para 5.1
748
2/16/2009 6:26:38 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
1.5
749
2/23/2009 1:58:42 PM
SATIP-L-108-01
SAIC-L-2040
Mechanical
ScheduleQ
Schedule Q
5.1
750
1/26/2009 1:19:29 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
751
2/23/2009 7:51:13 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
752
3/29/2009 5:37:21 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
753
6/15/2009 4:32:13 PM
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 4.2
754
1/3/2010 2:04:09 PM
ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.3
755
1/26/2009 1:26:58 PM
Due to the failure of IMAD mobilizing their required QC personnel (QC Equipment Inspector) to site in accordance with Schedule "Q" requirements & as per QMIS violation after the fact entry. Major vessels have now been recieved without recieving inspection. Continuation of this violation by IMAD will result in the issuance of a SA / NGPIU NCR within 7 days. During rotine site visit it has been noticed that the welging fit up has been done and the root gap more than the required according to IMAD WPS-1.contractor has to correct the root gap distance accordance to approved WPS. During the surveillance at the Lay down Yard, observed the following. 1.) Electrode heating oven is not switched on - the electrodes are not baked & stored properly. This is in violation as per the requirements of SAES-W-011, para 6.2. Also, as a temporary supports, non compatible materials like steel bars are welded to the structurals. The contractor IMAD is advised, through SAPMT, to comply with the standard quality requirements. During the surveillance at the Lay down Yard, observed the following. During the fit up of Pipe to Elbow of 48 size, 1) Electrodes not stored in portable ovens & is not available at the working area. 2) Electrodes are mixed up & kept in an open box. (6010 & 7018). This is in violation as per the requirements of SAES-W-011 Also note that the above is a repeated violation. (Ref: Surveillance Number-517, dated 06/15/2009) The contractor IMAD is advised, through SAPMT, to comply with the standard quality requirements. Un approved welder have been used for making temporary tacks & Electrode holder thrown carelessly inside the pipe. Incompatible material welded to pipe & elbows (for clamping) During routine site visit it has been noticed that. 1- Welding ongoing without using Wind shields or tent to protect the welding form windblown sand. This is violation of SAES-W-011 para 11.2.1 . Torch has been used to making holes instead of drilling this is violation of AWS-D1.1. 1. No Baking oven/ baking record and handling / issuance record. Recommendation. All previous joints, whether they are RT/Hydro has been finished, Do the Hardness/MPI to all joints. The joints comes under 10% RT scope, will be 100% RT. 2. Contractors QC did not comply / and shown Unawareness to welding activities. 3. 48 dia joint, found hi-low above the tolerance. The weekly welder performance records have been reviewed and noted the following. The repair rate of Welder No 3210( L.E. Gonzaga) is about 40 % on joint basis and 0.5% on liner basis for the week (9to15 Feb 2010). The above welder exceeded the limit of repair percentage and as such the welder approval is being revoked. IMAD is advised to submit the JCC of the welder to us at the earliest. The welder can be reinstated later upon receipt of written proof of training and the successful completion of recertification test. The weekly welder performance records have been reviewed and noted the following. The repair rate of Welder No 1780 is about 40 % on joint basis and 0.5% on liner basis for the week (9to15 Feb 2010). The above welder exceeded the limit of repair percentage and as such the welder approval is being revoked. IMAD is advised to submit the JCC of the welder to us at the earliest. The welder can be reinstated later upon receipt of written proof of training and the successful completion of recertification test.
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
756
1/26/2009 1:26:58 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
757
3/29/2008 3:13:49 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
other
WPS
IMAD WPS-1
758
6/15/2009 4:22:48 PM
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES
SAES-W-011
6.1
759
6/15/2009 4:22:48 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.10
760
7/20/2009 1:30:52 PM
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES
SAES-W-011
6.1
761 762
7/20/2009 1:30:52 PM 7/20/2009 1:30:52 PM
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SAES SAES
11.5.1 11.10
763
4/19/2008 1:02:55 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES international Standard SAES
SAES-W-011
11.2.1
764
4/19/2008 1:02:55 PM
NA
NA
Mechanical
AWS D1.1
765
12/20/2009 7:29:47 AM
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES-W-011
6.1
766 767
12/20/2009 7:29:47 AM 12/20/2009 7:29:47 AM
NA SATIP-W-011-01
NA SAIC-W-2005
ScheduleQ SAES
Schedule Q SAES-W-011
5.5 9.3
768
2/21/2010 11:05:05 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-324
6.1.9
769
2/21/2010 10:47:20 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-324
6.1.9
770
2/24/2010 11:11:31 AM
During surveillance, it is found that the contractor has installed Carbon steel tube instead of Stainless steam tube for the steam connections to jacketed piping. As per drawing BB-885444 Sht 001 Rev B, a Stainless steel tube confirming to ASTM A 269, TP 316 shall be installed between the jacketed line 4x3-A-12122-1CC4P1 to the jacketed valves. IMAD installed a carbon steel tube conforming to A 106 Gr B . This is in violation to the IFC drawing. Contractor is requested to replace the carbon steel tube with the stainless steel tube to meet the requirement of IFC drawing. Also, IMAD is advised to prepare the root cause analysis for this occurrence of violation and to take necessary preventive actions to avoid recurrence. Violation-after-the-fact is being issued against contractors piping inspector for not adhering to the requirement of SAES-A-004. Test package has to be submitted and approved by PID prior to commencing to hydrostatic testing. In spite of repeated reminder to the piping inspector that hydrotesting may only proceed after hydrotest package is approved he procedeed with the activity. Review of submitted Hydrotest Package-001 was conducted to ensure that the contractor is in compliance with the requirements of pressure testing in reference to Saudi Aramco Engineering Standards. It was found out that the correctness of the attached Safety Instruction Sheet (SIS) for critical piping was not verified by the contractor. SIS indicated that the limiting factor for this test is the pipe wall thickness, however, the proposed test pressure of 450 psi is based on Flange (Rating - 150). Computation was not presented to support and verify that the pipe wall thickness is indeed the limiting factor for this pressure test. Contractor neglected the safety consideration in preparing pressure test package by incorrectly defining the SIS test limitation and test pressure to be employed, therefore violating the General Requirements of SAES-A-004 and Saudi Aramco GI-1.103 Pressure Testing Safely. Inspection of Field Hydrotesting of 12",16", 10" and 3" line inside Uthmaniyah Gas Plant was conducted to ensure that procedure is being caried-out safely and correctly as required by applicable standards. Inspection showed that the blind that was installed is not acceptable since it was only 5 mm, shop-fabricated plate and therefore not rated to withstand the test pressure required for this test. This is a violation to SAES-A-004 Para 8.3 which states that "Blind flanges, paddle blinds or spectacle blinds shall be used to isolate the test sections. They shall be the same class rating of the system or may be fabricated from verifiable identification of base material and approval of calculations by the Supervisor, CSD Piping Unit". Inspection of pre-installation of 15 psi condenser was conducted and found out that there is no available contractor Mechanical Inspector at the site duly approved by SGPIU. This is a violation of Schedule "Q" Para. 5.1 which states that "Contractor shall provide resources to implement Quality System as set forth in this Contract. For all procurement,construction, and pre-commissioning activities, sufficient Saudi Aramco Quality personnel identified in Attachment VI of this schedule shall be on-site prior to the start of the applicable work". Conducted surveillance on the Material Storage of fabricated piping spools on IMAD laydown yard and found out that materials are not properly stored. Sand accumulation inside the fabricated spools are evident due to the unprotected/uncovered ends and loose end protectors. This is a violation against SAES-L-350 Para 7.4
SATIP-W-011-01
SAIC-W-2005
Mechanical
Drawing
Drawing BB885444 Sht 001 Rev B
NA
771
11/11/2009 3:11:48 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.7
772
9/26/2009 3:20:40 PM
SATIP-A-004-02
SAIC-A-2003
Mechanical
other
SAES-A-004
5.6.1
773
11/29/2009 1:43:51 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
7.3
774
11/5/2009 2:15:05 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
775
9/1/2009 11:06:11 AM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.4
776
9/8/2009 4:04:37 PM
Focussed assesment was conducted to determine contractors compliance to existing Saudi Aramco standards focussing on the Installation of On-Plot Piping. In reference to SATIP-L-350-01, it was found out that RFI was not raised for the Piping Pre-Installation Inspection utilizing SAIC-L-2011. Failure on the part of the contractor to issue such RFI violates SAES-L-350 and Schedule Q Para 1.8 "For any inspection or any test required to be witnessed by Saudi Aramco, including any required by applicable laws, rules and regulations of Saudi Arabia, CONTRACTOR shall provide notice of said inspection or test as specified in the approved lnspection and Test Plans (ITPs) to enable the Company Representative to attend...." Inspection of on-going activities at UGP showed that RFI was not raised for the Piping Tie-in Installation for Plant Piping as required by SATIP-L-350-02. SAIC-L-2014 requires inspection for threaded joints connections and SAIC-L-2015 for the inspection of bolted flange assembly. This is a violation on their Quality Plan (ITP) and Schedule Q Para 1.8 which states that "For any inspection or any test required to be witnessed by Saudi Aramco, including any required by applicable laws, rules and regulations of Saudi Arabia, CONTRACTOR shall provide notice of said inspection or test as specified in the approved lnspection and Test Plans (ITPs) to enable the Company Representative to attend ....." Violation-After-the Fact is being issued against the contractor QC Personnel (Mechanical Inspector and QC Supervisor) for failure to recognize the potential danger that can possibly happen in utilizing incorrect test pressure because of their negligence in giving enough attention in reviewing the Safety Instruction Sheet for critical piping where the required test pressure and test limiting factor are computed and derived from. Action to verify the proposed test pressure and limiting factor was not done. Mechanical Inspector showed no vigilance with regards to this concern, thus, effective immediately contractor is advised to provide for his replacement. As per Schedule "Q" Attachment I, contractor shall provide a Q/C Supervisor for the project belong construction phase. Now almost 12% completed without Q/C supervisor. Contractor asked to verify Schedule "Q" requirements. Welding Q/C shall be avilable at the shop while wlding on process. He should be easy to be invited to witness and control the on going welding. Contractor didnt match Sch. Q QA/AC manpower requirements while Coating & Insullation QA/QC is not avilable at the site full time at UGP. Quality assesment was carried out to verify contractors compliance to the construction phase specific quality requirement as required by Schdule Q. As found out, Piping Inspector is not available at the site considering that construction phase is already at its peak stage. Contractor failed to meet the manpower requirements as stipulated in Schedule Q Attachment VI Table VI-2, thus, violation to the contract was committed. Routine site visit was conducted for the final acceptance of tie-in installation inside Uthmaniyah Gas Plant. I have asked Mechanical Inspector to assist me to show the locations of tie-in points as specified in the attached IFC drawings in the tie-in packages. Considering that he has already affixed his signature in the packages, I believed that he is fully aware of the various locations of the tie-in joints. However, when I asked at the site he told me he doesnt know the locations of the tie-ins. This is only shows that he is not doing his job as inspector and tried to mislead PID by signing the packages even he has not inspected the activities.
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
Schedule Q
1.7
777
11/19/2009 2:05:17 PM
SATIP-L-350-02
SAIC-L-2014
Mechanical
SAES
SAES-L-110
SAES-L-350
9 & 11
778
9/26/2009 4:23:24 PM
SATIP-A-004-02
SAIC-A-2003
Mechanical
SAES
SAES-A-004
5.6.1
Schedule Q
5.5
779
3/17/2008 3:39:24 PM
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
A1
780
10/20/2008 10:59:42 AM 6/24/2009 12:51:21 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
781
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
782
9/8/2009 4:38:48 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
783
11/19/2009 11:05:10 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.9
784
3/13/2010 3:32:21 PM
During surveillance, it is noted that there are about total 35 work men involved in the piping related activities. The piping work is being carried out at two locations, i.e at SRU Unit 1 and at Fabrication yard. One piping inspector is covering the fabrication, installation and piping Hydro test activities. The activities involved are valve testing, piping hydro testing and fabrication and Installation of piping. It is required to have one piping Inspector for each activity as mentioned above. Also, one QC supervisor for the Mechanical /Piping discipline is required. This is as per Attachment 6 , para 2 of schedule Q and the same is not being fulfilled . Hence, IMAD is required to provide at least one more QC Inspector for piping and QC supervisor for Mechanical /piping discipline in order to maintain Quality requirements During document review, it is found that the post welding inspection reports are not being prepared in the format SATR-W-2007, which is a requirement of SATIP-W-011, Rev 2. Also, not being offered to SGPIU for inspection on regular basis. However, Daily welding inspection reports are being prepared on a format which is not approved by SGPIU . And the post welding inspection activities are not offered to SGPIU for Inspection. It is required to generate the daily welding Inspection reports by IMAD as per the approved format as it is a hold point as per the above SATIP. And , it is required to offer for inspection on regular basis to SGPIU with immediate effect. During document review, it is noted that the Welding procedure Specifications are not having the weld and line designation table with the relevant piping classes. The piping classes involved in the project are 1 CS1P2, 3CS1P2, 1CC4P1, 1A1JT and 12 CGOU. Weld and line designation tables as per the attachment B of SAES-W-011 are to be prepared for all the Welding procedure specifications with the relevant information and to be submitted to SGPIU for our review as well as approval with immediate effect. A Focus Assessment has been conducted to verify the involvement of prime contractor (IMAD) in the verification of approval status of NDT personnel. It has been noted that the contractor does not have evidence to prove that the performance of NDT Technicians is being monitored. It is required to monitor the performance of NDT technicians by the IMAD Company as per requirement of Schedule Q (Note 1, Table 5.2, and Attachment VI). Hence , It is hereby advised that the IMAD Company shall devise a system to monitor the NDT technicians approval and their performance in order to ensure and maintain the quality of the project. Mech. Inspector has visited the materials store and noted that there are a sensitive materials are exposed to dust. Contractor asked to refere to the material storing and recieving applicable standard and comply. During surveillance on flare area found that 36 relief line fit up ( RB728541-198-02) FG -01 Bevel angel , root face and gap is not maintained as per requirements even several instruction . It is not acceptable as per SAES W 011 ( joint details).Need to rectify RFI were raised (e.g. RFI No. 24641) with two different activities were enter, Inspection of Surface Preparation (SATIP-H-100-01,Item 3.1) and Touch up painting (SATIP-H-100-01, Item 3.6) Hence, only one check list attached (SAIC-H-2027) and so on with the other activities.
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
785
3/9/2010 2:47:02 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011 17.1.7 & 17.1.8
786
3/9/2010 3:09:45 PM
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
7.1.3 & 7.1.4
787
2/9/2010 2:28:14 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Table 5.2
788
10/20/2008 11:33:30 AM
ViolationAfter The Fact ViolationPrevented Installation
SATIP-L-350-01
SAIC-L-2009
Mechanical
SAES
SAES-L-350
6&7
SAES-L-109
Sec 11
789
8/5/2009 5:43:35 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
790
2/28/2010 2:18:46 PM
Standards Violation
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
791
1/4/2010 11:50:26 AM
During surveillance in 415 (DGA) Plant, it was found that the contractor installed 6 lines(2") which attach with the civil foundation with only 10 mm clearance but according to Para 12.4 SAES-L-310 the minimum clearance shall be 50 mm. These lines are: 1-415-DGA-108801(RB-728841-017) Connected with 415-KF-0103/N5 2-415-DGA-1106Standards 01(RB-728841-040) Connected with 415-KF-0101A/N5 3-415-DGAViolation 1103-01(RB-728841-039) Connected with 415-KF-0101B/N5 4-415DGA-1107-01(RB-728841-041) Connected with 415-KF-0203/N5 5-415DGA-1181-01(RB-728841-044) Connected with 415-KF-0201A/N5 6415-DGA-1180-01(RB-728841-043) Connected with 415-KF-0201B/N5 Junction box supports @ SRU were being coated without proper surface preparation, contaminants were visible Contractor received some pipe supports at fabrication shop fabricated in NESMA Dammam. 1)PID was not noticed for receiving inspection (there is no RFI for receiving inspection for the material before fabrication). 2)This activity was not included in two weeks look ahead. Contractor fabricated the saddle support not as per aramco drawings. a)All welding shall be sealed weld. b)Open window has sharp edge shall be ground radius. During TIE-IN (J06-19, J06-20, J06-21, J0-15) fire water system inspection, it was found that the contractor decided to do service test .But according to Para 12.6 SAES-B-017 it is required to do hydro test to 200 psi for 4 hours. During TIE-IN (J06-19,J06-20,J06-21,J015 ) fire water system inspection, it was found that the flange under the fire hydrant become under ground, but according to Para 7.2.2 & fig 1 SAES-B-017 this flange should be above ground with 100 mm. During witnessing of gravity test in Hydrogen plant (J06) for test packages J06-VG-01,J06-VG-002&J06-VG-003 , It was found that the PMT decided to the contractor to make the test without closing the end of the line inside the manhole as shown in the P&ID ,and this just for 15 minuets for every test ,but this is not acceptable according to Para 18.7 & 18.8 SAES-S-070. During surveillance in J06 (Hydrogen plant) , it was found that the distance between 2 valves is less than 760mm in the walk way which is not acceptable according to Para 4.7.1 SAES-B-054.The 2 valves are : 1- valve item number 10 (Line number J06-RL-2251-02 & ISO drawing J06-RB-728641-082) 2- valve item number 15 (Line number J06-RL2216-02 & ISO drawing J06-RB-728641-036) During surveillance in J78 (SWS) Plant, it was found that there are 2 valve branch connections which located at distance less than 610 mm from fixed beam which is not acceptable according to Para 12.5 SAESL-310.The 2 branch connections are: 1-Item number 8 (Line number J51-FLO-1025-06&ISO drawing J51-RB-728741-006) 2- Item number 9 (Line number J78-SPO-1530-03ISO drawing J78-RB-728741-029) During surveillance in J06 (Hydrogen plant), it was found that most of Dummy support not provided with 6 mm weep hole which is not acceptable according to Para 13.2.3 SAES-L-350 For example: Support number S15 (Line number J06-RL-2242-02 & ISO drawing J06-RB728641-071) & Support number S13 (Line number J06-RL-2251-02 & ISO drawing J06-RB-728641-082). During surveillance in J06 (Hydrogen plant) , it was found that the distance between 3 lines and stair way are less than 760mm in the walk way which is not acceptable according to Para 4.7.1 SAES-B054.The 3 lines are : 1-Line number J06-OWS-2309-01 & ISO drawing J06-RB-728641-066) 2- Line number J06-OWS-2310-01 & ISO drawing J06-RB-728641-067) 3- Line number J06-OWS-2305-01 & ISO drawing J06-RB-728641-062)
Standards Violation Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
792
12/6/2009 7:58:09 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
793
6/14/2009 7:47:29 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
794
6/14/2009 7:47:29 AM
NA
NA
Mechanical
Drawing
SASD# AD036990-001 SAES-B-017
NA
795
11/21/2009 2:18:24 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
12.6
796
11/21/2009 2:30:40 PM
Standards Violation
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-B-017
7.2.2
SAES-L-450
9.4
797
2/11/2010 4:49:52 PM
Standards Violation
SATIP-S-020-01
SATR-S-4001
Mechanical
SAES
SAES-S-070
18.7 & 18.8
798
2/17/2010 3:58:12 PM
Standards Violation
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-B-054
4.7.1
799
2/17/2010 4:04:50 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
800
2/17/2010 4:07:08 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
14.7.2
SAES-L-350
13.2.3
801
2/17/2010 4:08:49 PM
Standards Violation
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-B-054
4.7.1
802
2/17/2010 4:11:01 PM
During surveillance in J06 (Hydrogen plant) , it was found that there is no enough space to install one drain valve of item number 13 (Line number J06-LO-2207-01 & ISO drawing J06-RB-728641-048).which is not acceptable according to Para 12.4 SAES-L-310 . During receiving inspection for Lean amine cartridge filter ( 415 KF 0201A/B ) found that name plate paint peel off and need to rectify by painting with correct specification During installation of degassing contactor in SRU ( J87 C 0104 ) Found that jacketed drain l;ine ( Liquid out line ) is inclined for about 7mm . It is possible for the drain liquid to be stagnated during non operational condition . This discrepancy need to be rectify by proper approval from vendor . Drain jacketed line = Inside pipe 2 Outside casing 3" During survillence found that in SRU, Equipment Temper water surge drum ( J87 D 0108 ) Name plate Install in up side down . It need to be rectify. During survillence found that in SRU, Equipment Temper water surge drum ( J87 D 0108 ) Name plate Install in up side down . It need to be rectify. During survillence found that in SRU Area Equipment -Temper water surge drum ( J87 D 0108 ) Name plate Install in up side down . It need to be rectify During survillence found that in SRU -Equipment J87 D -0101( Amine acid ko drum) steam coil line 1/2 outlet of the vessel is contact with the side of the skirt vent . there is no space to insulate steam line . It need to be rectify by proper approval from vendor with repair procedure During surveillance in SRU - area for the alignment of Equipment 2 & 3 condensor( J87 - E - 0107/109 ) found that foundation is 40mm in lower level.Need to be rectify By adjusting spring support knob ( or) adjust with pipeline to equipment. In SRU Furnace chamber ( J87 F -0101 ) refractory production samples for castable there is discrepancy in laboratory test report for casting , it is not meeting as per Aramco standard mentioned in SAES N-110 Para 11.3.4. The values is outside the acceptance range due to sample examined in room temperature instead of drying at 110 degree centigrade as per vendor recommendation. During surveillance in SRU found that furnace chamber J87 F 0101/102 foundation bolt threaded length is not enough. It is short for 70 mm and it need to be rectify or discuss to vendor for further action. During receiving inspection of flare stack ( J89 F- 101 and J89 F102 ) found that bottom liquid seal drum drain line have flanges located inside the skirt. As per standard SAES- D- 001 PARA 7.1.13 states that flange connection should be outside the skirt . As per this criteria the equipment is not matching with our requirements. Need to be rectify During elevation witnessing of phosphate injection unit ( J87 U- 0301 ) in SRU AREA ,found that foundation is 16mm lower level as per surveyor report. Informed to contractor QC and need to rectify Painting Material stored by OTC in steel box this is the violation of SAES-H-100 PARA 6.2 ,Should be store at site fully vantilled coverd by convas at working site Hydro test Package No - J87-RL-008. Contractor construction personnel (Name dong lee) signing in Pre test punch list form SATRA-2007 in verified complete by QC Column which is violates as per attachment VI Project Specific Quality Requirements Para No 2 & 2.1 of Schedule Q.
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
803
8/29/2009 2:08:32 PM
Standards Violation
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
5&8
804
12/14/2009 10:51:03 AM
Standards Violation
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
32-SAMSS004
8.1.2
805
8/18/2009 11:47:43 AM 8/18/2009 11:47:46 AM 8/23/2009 11:27:50 AM
Standards Violation Standards Violation Standards Violation
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
32-SAMSS004 32-SAMSS004 32-SAMSS004
17.3, 17.4 & 17.5 17.3, 17.4 & 17.5 17.3, 17.4 & 17.5
806
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
807
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
808
1/15/2010 11:15:59 AM
Standards Violation
SATIP-N-001-01
SAIC-N-2006
Mechanical
SAES
SAES-N-001
1.2
809
9/15/2009 12:08:28 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2006
Mechanical
Drawing
IFC Drawings
NA
810
12/13/2009 7:30:22 AM
Standards Violation
SATIP-N-110-01
SAIC-N-2024
Mechanical
SAES
SAES-N-110
9.1.2
811
2/8/2010 2:38:24 PM
Standards Violation
SATIP-F-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.8.1
812
10/15/2009 8:31:51 AM
Standards Violation
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
SAES-D-001
7.1.13
813
8/16/2009 11:24:03 AM
SATIP-D-001-01
SAIC-D-2006
Mechanical
Drawing
IFC Drawings SAES-H-100
NA
814
3/8/2010 7:48:08 AM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
6.1 & 6.2
815
2/24/2010 2:15:36 PM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
816
1/18/2010 7:09:25 AM
In SRU area during gasket installation it was found that serration roughness on flange face was damaged. It is a violation of Aramco standard refers to SAES- L-109 Para 8.2. This stated that flange face serration should be Smooth machine finish 3.2 to 6.4 micrometers Ra (ASME B46.1) for spiral wound gaskets. The details of the flanges are given below. RB-728441-088-01, J87-RL-0523-02, Spool 01 joint No. SG-05, Diameter 3 Class 150 RB-728445-016-02, spool 01, joint noGS-03, diameter 2inch, class-600, schedule, 80. In SRU area the jacketed spool installation it was found that spool misaligned approximately 6mm. it is not acceptable as per SAES L- 350 Para 9.1 the details of the spool as bellow. RB-728443-411 J87-60S0618-02 It is observed that several spools are laying directly contact to the ground without end cover & flange face not protected by wooden sheet. It is a violation of SA standard ref:-SAES L-350 Para 7.1&7.4. During surveillance it was found that in SRU area three welding machine calibration date expired on 11-12-09, but contractor proceed the work without recalibrating the welding machines. It is violated as per SAES-W-011 para, 19.2 and Schedule Q para 6.1., Machine details are given below DW-016, DW-A21and DWA27. RB-728441-015-01 line no:-J87- 15s-1621-01 spool 03, diameter 8 is coming close to beam In SRU area. Gap between pipe and beam only 10 mm. This line is coming from E-0114 fin fan cooler. This is a violation of Aramco standard SAES-L-310 Para 12.4 which stated that minimum gap between pipe and any permanent obstruction should be 50mm. RB-728445-078-02 line no:-J87-HSG-0207-01 SPOOL-2, diameter 30 inches is coming close to structure cross bracing. The gap between pipe and cross braces only 20 mm. This line is coming from J87-E0107/9 connected toJ87-C-0101; while as per isometric line it will be insulated. This is a violation of Aramco standard refer SAES-L-310 Para 12.4 which stated that minimum gap between pipe and any permanent obstruction should be 50mm. During routine surveillance , it was found that piping spools stored not properly and directly attaching on the ground which is not permited by SAES-L-350 para 7 and not properly end coverd pipe .(by AMIT SHAH) In SRU area it was found that two check valves have wrong oriented flow arrow direction. This is not matching with given flow arrow direction in isometric and P&ID drawing, that line is already connect with G-0107A/G-0107B.drawing details given below. Drawing no:-RB728450-027, line no:-J87-TPW-0791-01, size inch diameter, class 800. Drawing no:-RB-728450-028, line no:-J87-TPW-0793-01, size inch diameter, class 800. In SRU area jack screws in orifice flange is located at 6 and 12 o clock position which is contradicting with Aramco standard SAES-L-109 Para 10.3. As per Aramco standard for orifice flange jack screws should be installed at 3 and 9 o clock position. The detail of orifice flange is given below. Drawing no RB-728449-017 and Line no J87-60C-1269-01 Spool No-01/02. Joint no SG 02 and SG05M. Issued by: AMIT SHAH.
Standards Violation
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-109
8.1
02-SAMSS011
Sec 10
817
2/16/2010 5:28:45 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
9.1
818
11/19/2009 7:20:22 AM
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
819
12/14/2009 7:21:34 AM
Standards Violation
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
Schedule Q
A IV Para 7.1
820
1/31/2010 12:48:22 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
821
11/24/2009 4:06:07 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
822
12/20/2009 3:43:02 PM
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
823
3/6/2010 4:19:21 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2022
Mechanical
Drawing
P&ID#RB- Line#J87-TPW728450-027 0791-01 & 87& 28 TPW-0793-01
824
2/28/2010 6:55:57 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
5.6.2
825
3/14/2010 6:03:41 PM
In SRU area During surveillance it was found Dummy type pipe support already welded without weep hole. Which details of Drawing no J87-RB728447-001-02 and Line no J87-15C-1371-01 and support no S34 Standards (BG1-EW). It is violated as per SAES-L-310 Para no 14.7.2. Which Violation state A 6mm weep hole is drilled for all dummy supports located near the base plate for all vertical dummy supports, and near the run pipe at 6 oclock position for all horizontal dummy supports.
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
14.7.2
SAES-L-350
13.2.3
826
2/11/2010 4:42:52 PM
During reviewing the hydro test packages of Low Pressure steam (LPS) For TIE-IN number J87-005 & Plant SRU hydro test package number Standards J87-LPS-009, it was found that the required test is Service test and the Violation design pressure more than 60 Psig, but according to Para 7.4.5.b SAESL-150 the service test only for LPS designed for 60 PSIG or less . Drawing no J87-L-RB-728443-225-02, Line no J87-SF-0603-03, Spool No 01. Drawing no J87-L-RB-728443-332-02, Line no J87-60S-060303, Spool No 02. During site surveillance it was found that clearance between above mentioned two spools are less than 50 mm which is the contradicting SAES-L-310 PARA 12.4. During site surveillance it was found that clearance between 4 150# ball valve and structure & 4 150# check valve and structure is less than 50mm(approx. 20mm) Reference Drawing no RB-728441 Sheet No. 066 Rev. No. 02 line no J87-FG-0130-02 and Spool no 01 which violates SAES L-310. Para no -12.4 which states At least 50mm clearance is required for inspection and freedom of pipe movement. Issued By: AMIT SHAH
SATIP-L-350-02
SAIC-A-2003
Mechanical
SAES
SAES-L-150
7.5.5.b
827
2/24/2010 11:28:51 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
828
3/2/2010 5:00:12 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
829
3/14/2010 12:49:48 PM
Jacketed Inner Line no J87-SF-0602-01 (Drawing No J87-RB-728443221-02) starting from equipment no. J87-M-0103/N2 (SULFUR LEG) and connects to the Line no J87-60S-0602-02 (Drawing no J87-RB728443-328-01). The clearance between branch connection Joint no Standards SF10/ FF11 (dia) of this connecting line and finished ground is Violation found 20mm will be having insulation of 40mm as per drawing no. J87RB-728443-328-01, which violates as per SAES L - 310 Para No 12.3. The same problem is found with line no. J87-60S-0608-02, J87-60S0604-02 and J87-60S-0606-02 also. Spools are received from shop are not properly placed on the wood and directly lying on the ground which cause the soil into the spool and lots of spool are open the end covered. This is violation as per SAES-L350, PARA 7.4 & 7.1 In J-53 area near the bridge crossing it was found that, Drawing number RB-728961-222-04 line number J87-600s-1413-11, 6 stream line have 3 drip leg. The drip leg bottom end is directly touches with existing Stainless steel line. This is a violation as per SAES 310 Para 12.5. In SRU area it was found that 6inch stem line beam support distance (before the road crossing) not matched with isometric drawing(J87-RB728961-222- and line number 600S-1413-11) Support no S14. Applied support is misallocated as per isometric drawing. This is contradicting with SAES L-350 Para 5.1, 5.2. Equipment foundation of Blow down Drum (J87-D-0106) noticed that foundation is with installed form works and soaking ready for grouting activities, DHC-PIU during inspection noticed that top reinforcing bars was exposed which clearly shows that concrete cover was not attained. SAMPT and Contractor are requested to investigate and give solution to the violation prior for grouting. it is observed that several spool are laying directly contact to the ground inside and outside the fabrication shop, flange face also not protected with plywood. this is a violation of aramco standard refer to SAES-L-350 PARA 7.1 and 7.4. During survillence found that electrode was find in cold condition in portable oven due to not plug in power at SRU area.It is voilation as per standard SAES- W- 011 Attachment -1 ( faiz pid )
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.3
830
2/23/2010 6:06:37 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
831
3/2/2010 7:49:34 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
832
2/23/2010 11:18:33 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2018
Mechanical
Drawing
SIO#J87-RBSupport # S14 728961-222
SAES-L-350
5.1 & 5.2
833
8/15/2009 3:08:03 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.3.2.a
834
9/22/2009 9:16:00 AM
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
835
9/29/2009 4:51:21 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES
SAES-W-011
6.1
836
2/6/2010 4:24:44 PM
It has been observed in some of the test packages that test package flow chart is signed in QC signatory block by SSA personnel who is not approved for the job. This is a clear violation of Schedule para 5.2. wherein CONTRACTOR Quality personnel shall be apporved and approved by SAUDI ARAMCO prior to the start of work for each individual. These are official documetation and critical jobs which shall not be signed off by any unauthorized personnel without prior approval from Aramco. Samsung has failed to monitor and control such test packages intensionally knowing such contractual requirements. Samsung QC shall be responsible for the involvement and clearing of punch list items before submitting the packages to Saudi Aramco. They shall use the right qualified personnel for such important job as per the contract. Using such personnel who seems not part of QA/QC organization is not acceptable. ISOFAB Weld Tracking System was evaluated and found that records of several weld joints are not properly documented. This shows that the ISOFAB is not reliable in tracking weld joint history throughout fabrication and installation in non-conformance with Sch. Q, Attach.IV, Para. 3.3. Deficiencies found are: 1. Data entered in ISOFAB is not matching with the daily weld report. 2. Welds are in the ISOFAB Reports. 3. RT results are showing inconsistent reports or are missing. Note: A final assessment report was issued detailing the specific deficiencies and recommendations for corrective action. ISOFAB Weld Tracking System was evaluated and found that records of several weld joints are not properly documented. This shows that the ISOFAB is not reliable in tracking weld joint history throughout fabrication and installation in non-conformance with Sch. Q, Attach.IV, Para. 3.3. Deficiencies found are: 1. Data entered in ISOFAB is not matching with the daily weld report. 2. Welds are missing in the ISOFAB Reports. 3. RT results are showing inconsistent reports or are missing. Note: A final assessment report was issued detailing the specific deficiencies and recommendations for corrective action. ISOFAB Weld tracking System was evaluated and found records of several weld joints are not properly documented which shows that the ISOFAB is not reliable. Deficiencies found are as follows: 1. Data entered in ISOFAB is not matching with the daily weld report. 2. Welds were missing in the ISOFAB report. 3. RT results are showing inconsistent results or are missing. NOTE: A final assessment report was issued detailing the specific deficiencies and the recommendations for corrective action. Recommendation:
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
837
6/11/2009 12:37:33 PM
001
Standards Violation
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
4.3
838
6/11/2009 12:40:15 PM
001
Standards Violation
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
839
6/11/2009 12:17:09 PM
001
Standards Violation
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
840
During suveillance it was found that,the contractor is not maintaining the design criteria for check valves to provide the turbulence free minimum distance of 5 pipe dia upstream and 2 pipe dia down stream of the check valves as per SAES-108 para, 6.3.4. The contractor has to clarify any non compliance to saudi aramco engineering standards. 1/5/2010 J88-P-0828The following drawings are some of the findings: RB-728347-059-01, 12:51:41 PM 01,J88-DG J88-DGA-0236-01, spool 02. RB-728347-060-01, J88-DGA-0232-01, spool 02 RB-728347-043-02, J88-DGA-0224-01, spool 04 RB-728347049-02, J88-DGA-0225-01, spool 01 RB-728345-085-02, J88-P-091402, spool 03 RB-728343-108-03, J88-P-0821-05, spool 03 RB-728343119-03, , spool 03 By Fahad Al-Mahashir Zeeshan rasool During internal inspection of LP AMINE OBSORBER ( J88 C 303 ) tray no 8 - down comer plate attached with shell found that welding is missing in one side. Particularly in this tray down comer plate is with two pieces groove taken, welded at the middle and missed in opposite side. It is violation as per standard 32 samss 020 para 12.2.2 states that it needed full welding skip welding is not permitted
Standards Violation
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.4
841
1/28/2010 1:50:19 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2003
Mechanical
other
32-SAMSS020
12.2.1 (2)
842
2/20/2010 2:51:44 PM
During internal tray fixing for equipment HP AMINE ABOSRBER ( J88 C 0301 ) Found that in Toricone area internal surface of the shell contains mill scale and rust.Even proper cleaning it never removes. It is violation as per 32 SAMSS 004 PARA 16.2.9 & 19.1.2 .vendor need to confirm and rectify these discrepancy Upon request by PMT to inspect equipment pedestal (D-0304Coalescer Drum) on Aug-15, PID found the followings; 1- Additional grout for the modification of shim plates is not properly cured for the last three days after grouting. 2- Anchor bolts located south side of fixed saddle are not plumbed and they have been bent in order to meet the horizontal distance. 3- Projection of anchor all bolts found not enough to accommodate base plate, washer and two nuts. Contractor is requested to analyze for root cause analysis and initiate a corrective action. During receiving inspection found that coalescer drum ( J88 D -304 ) saddle under bottom plate is heavly corroded and need to be proper cleaning and painting before installation. per 32 SAMSS 007 PARA 11.1.10 PAGE 39 Most of the static equipment in DHT found that in skirt area for fire proofing insulation used 13 mm square nuts spaced 450 mm center in both direction per international standard PIP VEFV1123, But in aramco standard SAES B 006 specifies to refer aramco standard drawing AC 036915 mention bolt space 300 mm . As action we need to follow our standard before fire proofing starts. During survillence in DHT found that LP AMIINE OBSORBER ( J88 C303 ) for fixing internal trays griding done in welding portion of shell and rings it is possible to reduce the throat thickness of weld . As per saes w- 011 para 13.11 states after equipment PWHT should not heating or welding in the equipment. Need vendor confirmation During survillence in DHT found that HP AMINE ABSORBER KO DRUM ( J88 D 107 ) for fire proofing guage steel flashing ( ring attached with skirt ) missing in the equipment.Need to confirm from the vendor. During internal tray fixing in stripper(J88 C 302 ) found that in tray no 26 & 27 ring attach with down comer plate missed with welding one side and before installing these trays we need to confirm with vendor(GHI -JUBAIL)for is approval and action.As per standard 32 samss 020 para 12.2.1.2 states that it needed full welding, skip welding is not permitted During surveillance in DHT found that internal tray fixing of stripper at tray no 23 & 24 ring attached with shell flatness reading shows 13mm which is out of tolerance nearly 6 mm . As per standard drawing SAD036981 and 32 SAMSS 20 acceptable tolerance mentioned only 5mm. It need to rectify By vendor . During alignment inspection of static equipment - vapour trim cooler in DHT ( J88 E 107 AB & CD- sewon collen corp korea ) found that in slidling end the saddle is not resting uniformly in structural support. Nearly 10mm gap find in between saddle and structural. It shows that saddle is not 100% flat and it get distortation . As per standard drawing for saddle it not mentioned the tolerance. Need to get information from vendor. During installtion of feed stripper bottom exchanger ( J88 E 303 AK ) in DHT area found that water is coming out from the equipment while removing the cover plate from nozzle in shell side. It shows that after Hydrotest of equipment water Is not fully drained from the system It need to be dry layup while shipping from orgin. Ref in standard SAES A 007 dry layup 5.2.3 . During receiving inspection found that physical damage in equipment 1. Feed stripper bottom exchanger ( shell side ) J88 E - 303 C 2. Lean DGA charcoal filter ( external ) 415 KF 0202 Need to rectify with proper instruction from vendor
Standards Violation
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
16.2.9 & 19.1.2 SAES-W-010
11.6
843
8/16/2009 9:13:21 AM
Standards Violation
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.3.2. (a)
844
8/26/2009 1:46:14 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS007
11.1.10
845
11/11/2009 7:28:39 AM
Standards Violation
SATIP-B-006-02
SAIC-B-2006
Mechanical
Drawing
Drawing#AC036915
NA
846
1/15/2010 11:06:14 AM
Standards Violation
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-W-010
13.11
847
1/28/2010 2:06:56 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
1.3
848
2/28/2010 12:55:07 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2003
Mechanical
other
32-SAMSS020
12.2.1 (2)
849
3/3/2010 6:04:47 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2009
Mechanical
other
32-SAMSS020
9.1.4
Drawing#SA D-036981
NA
850
11/29/2009 3:11:18 PM
Standards Violation
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
PIPVEFV110 2
NA
851
9/2/2009 1:40:20 PM
Standards Violation
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.3
852
8/22/2009 7:17:40 AM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
853
2/13/2010 8:15:15 AM
During flange connection found that liquid seal drum drain line flange face serration Was totally damage and need to replace with new flanges . It is violation as per Standard SAES L 350 PARA 7.4 During surveilance found that equipment 1. phosphate injection package,2. corrossion inhibitor and 3.antifoaming unit for these three equipment side glass vent line 1/2 ss threaded joint broken. Need to rectify. Genral recomandation for all weld joints for surface prepration contractor shall be use spot blast to bare steel weld joints for blasting, feather edge the coating at least 50 mm beyond bare metal . During surveillance inspection in DHT, for Galvanized pipe, coated with APCS 113A, I notice that during tightening, the tooth of the wrench they used leaves sharp marks to the pipe and causes damaged to the coating and pipe surface. Touch up repair were executed without any inspection for the surface preparation. Therefore, the integrity for the repair area is questionable. This is in violation to SATIP-H-100-01/a 3.6 (Nesma/SSA Hold point and SA is Witness point). This LBE is entered on behalf of Dino-Coating Inspector. During receiving inspection of CCR OFF GAS BOOSTER COMPRESSOR (JO6 K- 0101) Found following discrepancies. 1. Name plate for gearbox ( BHS GETRIEBE ) , Not available on the equipment. For compressor lub oil piping, matching flanges are SS ( stainless steel ) and some dissimilar( CS & SS ) but bolts used in this flanges are CS. The actual condition at site now is rust and corroded.
Standards Violation
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-109
8.1
02-SAMSS011
Sec 10
854
7/20/2009 7:26:45 AM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
855
3/16/2010 9:04:04 AM
Standards Violation
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
8.4.3
856
8/17/2009 7:31:06 AM
Standards Violation
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.3.2
857
7/13/2009 11:18:40 AM 7/13/2009 11:18:40 AM
Standards Violation
SATIP-K-402-01
SAIC-K-2002
Mechanical
other
32-SAMSS001
1st para
858
Standards Violation
SATIP-G-115-01
SAIC-G-2014
Mechanical
Drawing
P&ID
NA
859
2/7/2010 7:28:47 AM
In DHT area it was found that some welded joints are cut out after acceptance without any information and re-welded these joints without any penetrant testing on the fitting bevel which is the requirement of SAES W-11 para 11.3.3 which stated that fitting that are re-cut or reStandards bevelled shall have the cut surfaces examined for lamination with NDT. Violation The details of joints are as below. RB-728347-76-02,J88-H-0469-02,FF7 RB-728347-75-02,J88-H-0469-02,FF-25 RB-728344-053-01,J88-N0578-03,F11 and F12 RB-728344-012-01,J88-60S-3092-03,FF-4 During surveillance in J88 (DHT) Plant, it was found that after 5 PM ,there is no inspection coverage from NESMA side ,while working is going on up to 7:45 And according to Table VI-2 schedule Q this is not permitted. In DHT it was found the in cement line RB-728351-011-05,J88-CWS0158-02 epoxy knifing filler is not applied inside all around the two joints which is contradicting with the Aramco standard drawing AB036090.Contractor is already notified for corrective action and RT and of some other selected joints for conformation.
Standards Violation
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.3
860
12/23/2009 12:49:46 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
861
2/8/2010 4:05:02 PM
Standards Violation
SATIP-L-350-07
SAIC-L-2073
Mechanical
Drawing
Drawing # AB-033090
note 2
862
1/6/2010 4:55:39 PM
RB-728341-144-03 J88-P-0870-01 Above mentioned line have orifice flanged joint which is not matching with isometric drawing. Flanged Standards joint have two orifice taps which is contradicting with the isometric Violation drawing which required four orifice taps. This is violated as per SAES L350 para 5.1,5.2 RB-728341-144-03 J88-P-0870-01 RB-728341-145-03 J88-P-0871-01 During surveillance it was found that above mentioned spools have two orifice flanged joints in two adjacent parallel lines. Both flanged joint are not staggered 1 meter apart which is the contradiction of SAES J-100 para PIP 3.1.3.9.3. Which stated that orifice flanges in two adjacent lines should be staggered so that no two pairs of orifice flanges are less than one meter apart. RB-728343-182-01, J88-P-1042-01. During site visit it was found that clearance between above mentioned spool and concrete foundation is less than 50mm which is the contradicting SAES L-310 para 12.4. as per Aramco standard at least 50mm clearance is required for inspection and freedom of pipe movement
SATIP-L-350-01
SAIC-L-2009
Mechanical
SAES
SAES-L-350
5.1 & 5.2
863
1/6/2010 4:39:57 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2016
Mechanical
SAES
SAES-J-100
PIP 3.1.3.9.3
864
1/11/2010 11:01:19 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
865
10/17/2009 4:39:23 PM
durring rutine site vist it was observed that the spools are laying direct on the ground and als not protected by end covers which cause the soil and other foriegn materials in to the spools.this may also cause the flange face serration damge. this is voileted as per SAES L-350 para 7.1, 7.4, 7.2 2) On so many isometric drawing weld map is not reflecting the modification of the spools which has done at site. This is contradicting the SAES W-11 para 16.1 and 16.2. e.g RB-728348-25-01 joint No. 8M RB-728348-033-03 joint No. 12M, 13M RB-728347-157-01, joint No. 6C, 7C RB-728348-185-01, Joint No. 9M 3) Piping inspector is not inspecting the spools with isometric drawing which is causing the wrong orientation of the spools later on need modification. 4) On the spools drawing No, welder No. and weld identification is not available which is creating difficulties in finding the spools and causing the wrong information in the welding report as well as isofab.this is violated SAES W-11 para 16.1 During site visit it was observed that calibration of 5 welding machines expired but contractor still using those machines without calibration of the machines. it was violated as per W-11 para 19.2 Durring site visit it was observed that CS rollers and lifting chains are used for stainless steel pipes handling. this is not permitted due to metllurgical view. 1) RB-728353-063-02,J88-0600-3002-02,spool 2 welder = 29362 was doing welding without QC piping and welding inspection and no joint detail is available on the spool.
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
866
2/13/2010 6:42:49 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1 & 16.1
867
12/12/2009 3:53:01 PM 11/23/2009 1:33:16 PM 12/17/2009 1:20:07 PM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
868
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.5
869
SATIP-W-011-01
NA
Mechanical
ScheduleQ
Schedule Q
5.1
870
12/17/2009 1:20:07 PM
RB-728341-333-03, J88-UW-1701-01, cement line Spools No. 5,4,3 RB728341-334-03, J88-UW-1701-02, cement line spools No. Ia and 2 The above mentioned spools welded without QC piping and welding Standards Violation inspection. On the spool joint numbers details are not found and No QC from Nesma and Samsung witness the epoxy filler in the cement line joints which is the witness point as per SATIP L-350-07 During site visit in DHT found that flange face in pipe is totally damaged due to sand blasting. As per SAIC L 2014 attachment 2 it is not acceptable and need to be rectify .- SEBASTIN -PID In DHT are area jack screws in orifice flanges are located at 6 and 12 o clock position which is contradicting with Aramco standard SAES L109 para 10.3. As per Aramco standard for orifice flanges jack screws should be installed at 3 and 9 o clock position. The details of orifice flanges are given below. RB-728345-036-02, J88-DGA-0227-01 RB728347-126-02, J88-P-0979-02 RB-728341-146-03, J88-P-0874-01
Standards Violation
SATIP-L-350-07
SAIC-L-2073
Mechanical
Drawing
Drawing # AB-033090
note 2
871
12/16/2009 12:56:36 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
872
1/4/2010 4:14:06 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
5.6.2
873
3/3/2010 12:41:56 PM
It was found that (RB -728341-253-03, J88-RL-1401-03) clearance between structure and spool is not meeting standard criteria i.e. SAES L-310 Para .12.4 As PER ARAMCO standard A minimum clearance of Standards 50 mm shall be provided for inspection and freedom of pipe movement Violation between above ground piping crossing with any structure Issued By: DIPAK JOSHI. In DHT area one piping inspector from Nesma and one from Samsung are working. Their work activities are concentrated on the gasket installation and most of other piping works are going on without inspection. As per schedule Q one piping inspector is required from contractor for 25 workers but in DHT 105 fabricator/fitters from Nesma are working so additional inspectors are required to comply the requirement and to cover all inspection activities. Contractor has proceeded with modifications of extended body valves with an approved repair shop agency without prior approval from Saudi Aramco. The contractor proposed Al Najim as official request for the valve modifications and proceeded with a different company. This is violation to Saudi Aramco Schedule Q, 3.3
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
874
12/17/2009 1:10:37 PM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
875
1/9/2010 7:20:02 AM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.3
876
2/22/2010 4:22:40 PM
During surveillance in FLARE AREA J89 found that steam line 8( Draw RB 728541-056) dummy support given for the line is 6 but actual as per IFC drawing it specifies 4and support is not resting with center of the foundation .As per design support draw BG-2 it need to replace with 4support. In flare area J89 found that there is design problem in isometric IFC drawing shows 1 ignition line ( 4 nos ) is connecting to 1 pilot gas line instead of connect to ignition line near flare stack ( both stack).This discrepancy can seen in drw J89 RB 728541 SHT136 REV 02 . Need to change design as per requirements
Standards Violation
SATIP-L-350-01
SAIC-L-2018
Mechanical
Drawing
Design Support drawing BG2 Drawing#J8 9-RB728541SHT136-Rev 02
NA
877
2/22/2010 4:39:12 PM
Standards Violation
NA
NA
Mechanical
Drawing
NA
878
2/23/2010 5:34:44 PM
Spools are received from shop are not properly placed on the wood and directly lying on the ground which cause the soil into the spool and Standards lots of spool are open the end covered. THIS IS A VIOLATION of SAES- Violation L-350, PARA 7.4 & 7.1 (Initated By : Deepak Joshi) During surveillance in J88 (DHT) Plant at 6.30 PM, it was found that the contractor using one portable oven contains electrodes (E7018) which are cooled and oven is not plugged in the power source. And according to 6.1 SAES-W-011 this is not permitted. In DHT area during gasket installation it was found that serration roughness on flange face was damaged. It is a violation of Aramco standard refers to SAES- L-109 Para 8.2 the details of the flanges are given below. RB-728348-134 SP-01 & SP-01-A Total 8 flanges In DHT found that 3 & 8 lateral joint connected with 36 header are not staraight .As per drawing it shows all lateral joints should be 45degree and including 8 lateral joint is fouling in 24 RL line which connected in main header. It is not as per drawing and need to revise by Samsung design before continuing welding in this joints During walk thru and punch listing in J89- FLARE AREA found that weld joint for the reducer ( Drawing no RB- 728541-099-03 ) has been cutoff with out the permission of QC NESMA, SSA & PID.It is violation as per SAES W- 011 PARA 18.6.Need to cutoff and reweld for particular joint.
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
879
12/22/2009 4:45:40 PM
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES
SAES-W-011
6.1
880
1/31/2010 8:05:08 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-109
8.1
02-SAMSS011
Sec 10
881
3/3/2010 1:03:04 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2013
Mechanical
Drawing
Drawing#
NA
882
3/4/2010 4:39:57 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
18.6
883
12/8/2009 11:39:46 AM
surveillance inspection, it was noticed that both the contractor and subcontractor are not meeting Schedule Q requirement for QC coverage. Standards Violation The available Piping QC inspectors are monitoring gasket installation activities and not fully attending piping inspection activities. 1) In DHT area it was found that a lot of spools are re-cutout after visual acceptance without any information and PT which is violated SAES W-11 para 11.3.3. The detail is as below. RB-728348-185-01, Standards Joint No. 4, 5, 9, 11 RB-728347-157-01, joint No. 6, 7 RB-728348-033- Violation 03, Joint No. 29, 30,31,12,13 RB-728348-024-01, Joint No. 3, 4, 5 RB728348-015-01, Joint No. 21 RB-728348-25-01, Joint No. 8, 7, A) In DHT area welding inspectors are not verifying the welding report in the field and blindly sign the documents which is contradicting the SAES W11 para 17.1.2 CThis causing the wrong information in the welding report and in Isofab. Some examples are given below. 1) RB728353-044-02, joint No.21C and 13C is welded by the 14661 welder but in welding report the welder No. 26227 is reported and wrong WPS is mentioned in welding report. 2) RB-728341-185-01,joint No. 17 reported on 7/02/2010 but welded today dated on 9/2/2010. 3) RB728341-184-01,joint No.17 reported on 7/02/2010 by 30818 but welder No.29863 is doing welding today dated on 9/02/10. On so many joints weld identification, drawing No. and welder No. is not available which is the contradicting SAES W-11 para 16.1. Welding inspector is not controlling the welders which have the higher rejection rate more than required %age. In DHT area welders 14400, 11953 was doing welding without any shielding which is causing the porosity and hence increase the repair rate. This contradicting the SAES W-11 para 11.2.1.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
884
2/13/2010 6:39:40 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.3
885
2/9/2010 5:07:14 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.2
886
2/9/2010 5:07:14 PM 2/14/2010 4:44:32 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1 & 16.1
887
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.1
888
2/14/2010 4:44:32 PM 12/23/2009 1:48:11 PM
889
In so many fitup it was found that one inch cleaning is not done on both side the joint which is causing the porosity and contradicting the SAES W-11 para. 11.3.1 During surveillance in J88 (DHT) Plant, it was found that after 5 PM ,there is one SSA helper was doing welding on the support without issuing JCC and according to Para 6.2.4 SAEP-324 this is not permitted. Welder # 28040 was welding joint number FG# 10 on spool number RB-728341-116-02 line class 1CC2P01 without fit-up inspection and without signature of welding inspector or piping inspector. Inspector: Deepak Joshi mobile number: 0560047978 During surveillance in FLARE J89 found that welder ID =TBA not plugged the quicker oven ( portable oven ) while electrode present inside and it not maintain in exact temperature . As per standard SAES W- 011 ATTACHMNET 1 electrode need to be maintain 65C min The door of baking oven for welding consumables in the DHT area is not locking properly. The sub-contractor consumables issuer has to kick the door to close it properly or sometimes he keeps it partially open. Sub-contractor should fix the door and align it properly. 1. Welders, not Welding Foreman, checking out rods from issuer. 2. No records of 70S wire being recorded when issued or returned. This will result in traceability issues. 3. Logs are not being signed. 4. Scratch paper is used as the daily log prior to transferring the paperwork. 5. The consumable issuer was an assistant and Nesma said the original issuer was no longer there. The assistant had limited knowledge to be in this position. 6. Discussions at the site proved that the responsible individuals were not aware of their roles and responsibilities. 1.A scratch paper was being used on a daily basis and the proper log was filled in at the end of the day. Persons other than the Welding Consumable Controller were signing out electrodes. 2.Welding consumables were issued directly to welders and not the Welding Foreman/supervisor as required. Welders were also returning their own rods. 3.Sign-out of the 70S wire was not always recorded in the log. 4.At times the welding foreman would just walk into the room and grab a new box of wire and bring it to the field without having it recorded in the log. 5.While we were there, two welders came in for electrodes and the issuer was going to issue them even after our discussion. This action was stopped. 6.The Consumable Controller is not signing the daily log reports as required. Some previous days logs have not been signed. 7. During surveillance in DHT area near ( electrode storage oven) found that welder using cooling fans during welding . As per aramco standard it is violated to use any forced or accelerated cooling while welding ( REF SAES W- 011 , Para 11.8 page 27 ) During surveillance in J06 & 50,51 Areas , it was found that the contractor using expired welding power supplies machines and the welding machine customer serial are (PM-5750, PM-5799 , DW 124) IN J06 area and (PM-5626,PM-5800) in 50 ,51 area , and this is standard violation according to Para 19.2 SAES-W-011.
J78
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.3.1
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAEP
SAEP-324
6.2.4
890
6/23/2009 4:01:00 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
891
3/13/2010 11:42:32 AM
Standards Violation
SATIP-W-011-01
SAIC-W-2009
Mechanical
SAES
SAES-W-011
6.1
892
6/23/2009 1:32:25 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2009
Mechanical
ScheduleQ
Schedule Q
A IV Para 7
893
6/13/2009 1:51:46 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
894
6/13/2009 2:05:17 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
895
7/13/2009 11:39:57 AM
Standards Violation
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.18
896
12/12/2009 3:51:52 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.2
897
2/8/2010 2:14:03 PM
898
2/17/2010 3:53:27 PM
In J78 it was found that following socket joints are welded without any spacer which is violated Quality control procedure para 5.2.contractor is already notified about it for corrective action. RB-728741-01502,joint,7-1,5-1,6-1 During surveillance in J78 (SWS) Plant, it was found that there is no enough support to the line number J51-FLO-1025-03 (ISO drawing J51RB-728741-003 ) where is distance 6450 mm without any support which make the line easily swing and this is not acceptable according to Para 13.6 SAES-L-350.
Standards Violation
SATIP-W-011-01
SAIC-W-2037
Mechanical
other
QCP
5.2
SAES-L-110
5.2.4
Standards Violation
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-350
13.6
899
2/21/2010 5:49:33 PM
During surveillance in J78 (SWS) Plant, it was found that there are 2 lines are not aligned properly and the clearance between them is less than 50 mm which is not acceptable according to Para 12.4 SAES-L310. These 2 lines are: 1-8"Line number J78-SOW-1520-03 &ISO DWG J78-RB-728741-21(between FG-03&SG-04) 2-10 "Line number J78SOW-1522-02 &ISO DWG J78-RB-728741-25(between FG- 14&SG-13) During TIE-IN (J78-19, J06-10, J06-11, J0-13) fire water system inspection, it was found that the contractor decided to do service test .But according to Para 12.6 SAES-B-017 it is required to do hydro test at 200 psi for 4 hours. and up till now there is no replay for this issue from contractor side. The Welding Procedure Specification (WPS) for welding the bottom plates had wrong information in the polarity, which was not in accordance with the PQR or the actual welding activity. The WPS states straight polarity, however, the PQR and the actual welding in the field was reverse polarity. Action should be taken to revise the WPS and have it reviewed and approved by CSD. Electrode control procedure is not adhering to SAES-W-010. Electrodes are being stored in ovens set @ 260 degrees celcuis and then the power is not available overnight, therefore, the ovens are left to cool down. The unused electrodes should be kept in the mother oven which is set @ 120 degrees celcius, continuously, and not to be allowed to cool down. Moreover, welders should be using portable ovens when they have electrodes in the site exposed to atmosphere more than 4 hours after they are taken out of the hermetically sealed container. After 8 hours in the field, the unused electrodes should be baked one time only in the baking oven set between 260 to 430 degrees celcius for two hours, and then they should be transferred to mother oven set at 120 degrees celcius. Therefore, permanent power supply should be available to the ovens to prevent power outage. @ SRU, J87-D-0104 and J87-D-0108 were both coated with Sigma Paints APCS 17A and APCS 2A respectively, while during the touch up repair for J87-D-0104 Ameron paint were used while J87-D-0108 were SIPCO paints, RB-728443-315-02 line no:-J87-60S-0601-02 SPOOL-01, diameter 4 inches is coming close to structure cross bracing. Gap between jacketed line and cross braces only 25mm.This line is coming from J87E-0104 going into the sulfur pit; while as per isometric line it will be insulated. This is a violation of Aramco standard refer SAES-L-310 Para 12.4. It was observed that the NESMA piping QC inspector coverage at J87 SRU area is not in compliance to Table VI-2 of Schedule Q, construction phase quality personnel requirements. Nesma should comply with Schedule Q and provide sufficient piping QC coverage. Initated By: Amit Shah PID Piping Inspector Contractor was noticed performing welding on structural steel angel plate in SRU Substation Building with the following violations:1)Welding of structural steel was done by a new welder who has not started the first production welds for piping and only qualified for the specific job as per the JCC card. The welder is only approved to weld maximum of 6mm thickness and found welding 20mm thick structrula angle plate. JCC card is only limited to the job that it was meant for. Welding of galvanized steel without proving the proper cleanliness/ removal of the galvanized layer. 3)Samsung failed to raise RFI to Aramco inspection for the welding activity of the structural angel plate. Violation of SAES-W-011 & SAEP324 @SRU J87-F-0104 Thermal Oxidizer, for fireproofing were coated with APCS 11A, as per SAES-H-001 para 7.0 E fireproofing shall be APCS 1B, hince, CSD requirements if APCS 11A were used, product shall be Sigmatherm 540 or equivalent with respect to curing. SSA shall provide painting documents/details for SAPID verification
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
900
12/12/2009 3:58:33 PM
Standards Violation
SATIP-A004-02
SAIC-A-2015
Mechanical
SAES
SAES-B-017
12.6
901
5/13/2009 8:21:55 AM
Standards Violation
SATIP-W-017-01
SAIC-W-2075
Mechanical
SAES
SAES-W-017
7.1.1
902
5/4/2009 4:10:18 PM
Standards Violation
SATIP-W-017-01
SAIC-W-2081
Mechanical
SAES
SAES-W-017
6.2
903
10/26/2009 10:39:11 AM
Standards Violation
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-001
A1
904
2/18/2010 5:21:41 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
905
2/18/2010 5:09:41 PM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
906
3/23/2009 3:35:34 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-324
6.2.4
907 908
3/23/2009 3:35:34 PM 3/23/2009 3:35:34 PM
SATIP-W-011-01 SATIP-M-001-01
SAIC-W-2005 SAIC-M-2012
SAES ScheduleQ
SAES-W-011 Schedule Q
11.3.1 1.7
909
1/21/2010 10:12:15 AM
Standards Violation
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-101
910
7/12/2009 3:51:44 PM
1. NAME PLATE FOR GEARBOX MISSING. 2.FOR COMPRESSOR LUB OIL PIPING, MATCHING FLANGES ARE SS AND SOME DISSIMILAR, BUT BOLTS USED IN THIS FLANGES ARE CS. THE ACTUAL CONDITION AT SITE NOW IS " RUST AND CORRODED. @ DHT,SRU and Flare area, flanges were installed without coating. eg. J88-DGA-0286-01, SP-04, Flange above J88-C-301, J87-RL-0525-01 SP01 and along the 8" dia flare line. This is clear violation of SSA Painting SPecs para 5.1 @ DHT, J88-D-0102, Feed Surge Drum skirt (inside and outsite) for fireproofing were coated with APCS 11A, as per SAES-H-001 para 7.1.E fire proofing must be APCS 1B newly installed Electrical support @ DHT near the J88-D-301 Knockout drum, from ground going to the structure, touch up were not done properly, corossion still visible. rectify and invite PID for visual inspection. SSA QC painting inspector inspected and accepted this item before. @ DHT head of J88-D-0302 8" dia flange were coated and installed with offering for inspection and no coating inspection report, this is for the closure of surv # 24768 Painted spools/flanges were laying on the ground without proper support, proper handling shall be observe by the contractors @ J88-D-0302 head side, 8" dia flanges were instaled without coating, this violates SSA specs para 5.1, Dino Dabatos During surveillance in J88 (DHT) Plant, Tie-in number J88-017 OF line number (J88-CWR-0081-010),it was found that the contractor used 2 gaskets for flange joint connection number F9 & F9* (24" ( and this is not permitted according to Para 11.1 SAES-L-109(no more than one gasket shall be used between mating surfaces) During routine surveillance , it was found that piping spools stored not properly and directly attaching on the ground which is not permited by SAES-L-350 para 7.1. During fabrication yard visit, it was observed that Aramco supplied materials were placed in a manner that does not reflect the actual status of the received material either none inspected, inspected or rejected. This action makes it difficult to trace and identify the material either suitable for use or not. Eventually, this may end up with using a non-inspected material in the site. Schedule Q attachment IV section 3 specifies the implementation of such identification and traceability system of materials. Contractor shall adhere to this statement in order to accomplish a controlled quality system of material traceability and identification. During Inspection @ J88-C-0302, it was noticed that the electrical support was welded near to the sheel (40mm,50,,), this give no suffecient distance for the insulation that required 75mm for EC. SSA Inspector should Inspect the item prior to send the RFI. After rectification, visual inspection shall be done by PIU. SSA had only one Inspector for the site which cover Tape Wrapping, Insulation and Coating, this is a vioaltion to Schedule Q Para 5.6 pages Q-6 of 13 During routine site visits to flare area, it was observed that straight coated pipes were not handled with care during installation. As a result, many pipes were observed with scratches and minor marks on coated surfaces. SSA and subcontractor shall adhere to Saudi Aramco standards of handling and lifting pipes in particular coated pipes. Good control in handling and preservations of pipes will result in fewer repairs. - Contractor shall use padding and rubber covered rollers, rubber slings or so to eliminate any damages to the coated surface. Defected areas shall be repaired. Reference: SAES-L-350 @ Flare Area, J89-D-0101 shell area, grease were visible, clading were damage and platform installation were very close to SS cladding material. this clearly violates SSA spec para 5.1.1
Standards Violation
SATIP-K-402-01
SAIC-K-2002
Mechanical
other
31-SAMSS001
911
2/14/2010 10:50:29 AM 1/6/2010 8:02:55 AM 2/24/2010 10:20:19 AM 2/21/2010 10:26:12 AM 1/21/2010 10:05:41 AM 2/14/2010 11:02:59 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
other
Schedule Q
1.3
SAES-H-001
912
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-001
7.1E
913
Standards Violation
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-100
9.2
914 915 916
SATIP-H-100-01 SATIP-L-350-08 SATIP-H-100-01
SAIC-H-2027
SAES SAES other
SAES-H-100 SAES-L-350 Schedule Q
9.2 7.1 & 7.4 1.3 SAES-H-001 5
917
1/12/2010 4:02:13 PM
Standards Violation
SATIP-L-350-02
SAIC-L-2010
Mechanical
SAES
SAES-L-109
11.1
918
9/9/2009 1:44:41 PM
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
919
3/9/2009 5:00:59 PM
Standards Violation
SATIP-L-350-08
SAIC-L-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 4
920
2/21/2010 10:22:41 AM 2/21/2010 10:29:52 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
921
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
922
5/12/2009 3:26:13 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
SAES-H-200
5.1.1
923
2/14/2010 11:00:16 AM
Standards Violation
NA
NA
Mechanical
other
Schedule Q
1.3
924
6/9/2009 8:06:33 AM
During routine site visit for flare area, it was found that 36" relief line # J89-RL-0101-14 with drawing number RB-728541 SHEET 197 and joint number FG-09 having fit up not done properly. Bevel angle and root gap was not maintained as per WPS and standards. This is violating SAES-011, approved WPS & ASME B31.3 Chapter V. Actions to be taken:- - QC shall take correct measures as per standards to avoid such violations. Also, the joints shall be prepared by competent and experienced fitters and grinders. During surviellance in Flare area it was observed that the welding machines parameters are not matching with the approved WPS. The QC was instructed to use an ameter to test the current output from the machine. The result obtained was not matching with actual settings. Recommended actions: The welding machines in flare area shall be calibrated again to match the actual settings with the actual output. During surveillance activities in flare area it was found that the welding quivers (Portable Ovens) were not functioning properly. Electrodes were checked and found in cold condition. This is a repeated violation for using quivers not functioning properly. These electrodes will be used for 36" Pipe in flare area. Standard violation SAES-W-011 6.1, condition and storage of SMAW electrodes Action Required: 1)Malfunctioned Portable Ovens to be calibrated. 2)All electrodes to exceeding 8 hours to be sent to baking oven. 3)QC shall and welders shall check such portable ovens before starting any welding activities frequently to avoid such violations. During our visit Yesterday June 13,2009 to NESMA Fab. Shop @ Dhahran We found non-conformities as follows: 1)There is no QC available. 2)WPS is not posted at fab. Shop. 4 welders have no Aramco JCC. Baking/holding ovens are not working.(calibration sticker expired). 5)Welders used electrode 7018 without portable ovens (quivers). Nesma failed to notify Saudi Aramco of the vacation of Mr. Khalid Shubbar, Supervisor of QC in Nesma Fabrication Shop, at least 30 days ahead of his vacation. This violates Schedule Q. During visual inspection on 12 DGA Service line in R51 area, it was found that three welded joints were having multiple undercut defects in the base metal. The final capping was found not acceptable. The welder was instructed to repair the defects and avoid recurrence of such poor performance of the final capping. Unfortunately, the result after repair was not accepted. SSA was informed earlier on Thursday through hard copy log book (Violation after the fact). Actions:- Welder to be replaced by a competent and well skilled welder proven to have excellent performance. - Welded joints with defects to be repaired. ASME B31.3, Table 341.3.2 @ SWS Tank, the following observation shall be rectified, 1. under the stair, at shell side, touch up repair must be done. 2. Prpoer touch uo must be done to Electical/Instrumentation support 3. Electrical pole were installed, and contact point with safety handrail were coated without proper surface preparation, e.g. no feathering on edges. This is a violation to SAES-H-100 para 8.3. contractor are advice to check and repair with approved applicator. 4. Some part of the handrail needs repair/touch up. Calibration for the inspection instrument are required. And compressor and airless spray machine calibration certificates and tags were not available. @ DHT Area, the following violation were found for cable tray and junction box support. 1. Unacceptable Surface preparation; 2. Sagging were visible and insuffecient DFT g
Standards Violation
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
WPS
NA
925
5/17/2009 2:39:06 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.2
926
6/21/2009 4:27:55 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
927 928 929
6/14/2009 11:47:40 AM 6/14/2009 11:47:40 AM 6/14/2009 11:47:40 AM 6/20/2009 8:24:27 AM
Standards Violation Standards Violation Standards Violation Standards Violation
SAIC-L-2031
ScheduleQ SAES SAES
Schedule Q
5.1 11.5.1 6.1
SAIC-W-2005
SAES-W-011
SAIC-W-2032
SAES-W-011
930
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
931
6/13/2009 11:17:44 AM
Standards Violation
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.7 & 17.1.8
932
2/28/2010 2:07:18 PM
Standards Violation
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.2
933
9/14/2009 3:48:13 PM 10/22/2009 9:51:18 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 7
934
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.3
935
10/18/2009 3:09:10 PM
PIU found that at Fab. Shop of RT/DHT Project, 12 flange raised face Serration has been damage during blasting violating SAEP-351 Para. 4.3 And SAIC L-2014 item A2. Flange face particularly the seating area shall be no damage or as per Accepted Value of (MSS-SP-44steel pipe line flange) 2001. List of spools and flange size attached. PIU found that at Fab. Shop during hydro testing 3 valves # VT -1672 Size 14x600, VT 1698 Size 18x150 and VT - 1699 Size 18x150 have Rust on flange raised face Serration has been damaged more than Accepted value of (MSS-SP-44- steel pipe line flange) 2001. Violation of SAEP-351 Para. 4.3 Flange face particularly the seating area Shall be no damage or as per (MSS-SP-44- steel pipe line flange) 2001. All three valves rejected. During seat hydro test, we found one gate valve has leakage through the behind seat rings. As per API 598 is not permitted see 3.9.2. We reject that valve as details given below. TAG NO AF4VH3N, VT NO 448, Size 4 inch diameter, rating 600, body heat no 22D37,P/O NO:4500042444/CRC1-M98-04-V003-DA,valve manufacturer name :PKVALVE CO.,LTD During the reviewed of Hydrotest package # 1; it was found out that the contractor submitted the package with many violations: 1-The Hydrotest package services was not identification. 2-The test package flow chart were not completed (not signed) by the designated responsible agency as indicated. 3-Contractor QC inspector did not provide pre punch list items. 4-Contractor QC inspector did not fill all the applicable SAIC requirements in the package. 5-Some of required certifications and drawings were not provided. Inspection requires: Contractors QC manager to conduct root cause analysis and provide corrective action to solve this violation. Contractors QA manager to provide a preventative action to assure the non occurrence of this violation in the future Contractors QC personnel shall adhere to the project quality requirements. Cont resubmitted the HP#1&was found still has many standard violations&very poor work was done by cont QC where they just signed all the documentations&checklist off & forwarded to insp even before any activity yet done to this test package.The P flow chart was fully signed off all the way up to the reinstatement stage by cont construction&quality personnel without any actual work done to this package;this is falsifying quality documentations by cont.All the required quality check list were already singed off without conducting the actual activity yet Some of required certifications & drawings were not provided.Some of SA checklists required as SATIP-A-004-02 were not provided,Therefore PID required.Since cont do not have a QCmanager tocontrol&implement the required quality as per Sch.Q;the cont QAmanager is requested to investigate this violation &clear lack of quality implementation &provide a root cause analysis to PID.Cont QCmanager to assure that the mandatory project quality Leaks were observe during the filling and pressurization of 10"-OWS113-FEOU pressure line. As the grouting work is in progress, and 1st step of grouting is about to complete as per manufacturar recomendations. Advice contractor to fill all the base plate in second step as shown & advised in NMR drawing & step # 6 ,7 & 8. Anoxic/Aeration Tanks have been installed without following the SATIPD-109-01 and all Inspection checklists & records for alignment of new installed tanks.
Standards Violation
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
936
10/18/2009 3:12:39 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
937
9/22/2009 9:35:19 AM
Standards Violation
SATIP-L-108-01
SAIC-L-2042
Mechanical
API 598
3.9.2
SAES-L-108
4.7.5
938
9/17/2008 12:39:36 PM
SATIP-A-004-02
SAIC-A-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.7
939
9/27/2008 10:24:13 AM
SATIP-A-004-02
SAIC-A-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.7
940
8/25/2008 1:03:29 PM 11/4/2009 3:19:27 PM 12/3/2008 7:48:59 AM
ViolationAfter The Fact ViolationPrevented Installation ViolationPrevented Installation
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004 NMR Drawing
7.3
941
NA
NA
Mechanical
Drawing
step 6,7 & 8
942
SATIP-D-109-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
943
12/3/2008 7:48:59 AM
PID inspection of tanks showed that Anchor bolts were not located on the correct positions causing miss-alignment of tanks in reference to Violationthe other equipments around it. These equipments are inter-connected Prevented with each other through piping spools which are pre-fabricated from Installation the manufacturers shop. This will cause problems during installation of piping spools and other auxiliary parts.
SATIP-D-109-01
SAIC-D-2006
Mechanical
SAES
SAES-D-109
14
DRAWING
944
7/22/2008 11:19:48 AM
Installation of 4pcs. 6" gate valves & 1pc. 6" check valve at Duba Bulk Plant without field hydrotest is a clear violation of SAES-L-108, para. 4.7 & 04-SAMSS-048. Pressure value should be according to what is stated on Project package & duration of test should be according to standards. Valve (Gate & Check) of different sizes have missing nameplates as per 04-SAMSS-035, sec. 11.2. This problem is existing to both Duba & Tabuk received valve which will be used for oily & sanitary waste line. Construction of valve boxes for non-metallic pipes at duba Bulk plant are completed without the concrete support for the valves. This is a violation of SAES-L-610, section 4.3.5. Concrete pedestals shall be integrated in valve boxes as per approved IFC. Two pressure gauages serial # 08010101 and 08010102 were found to be calibrated for six months period. The required calibration period is only one month as per SAES-A-004 section 7.1.5 Pressure gauges and pressure recorders shall be calibrated before the tests. a) The calibration interval shall not exceed one (1) month. Calibration certificates shall be made available to Inspection personnel prior to commencement of the pressure test. Stickers shall be applied indicating the latest calibration date. During site visit PID didnt find Mech.QC. at site to follow up mechanical works at NJBP.
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7
945
7/28/2008 2:50:30 PM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
11.2
946
7/28/2008 2:54:53 PM
NA
NA
Mechanical
SAES
SAES-L-610
4.3.5
947
1/10/2008 3:07:22 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
8.1.5
948
7/13/2009 8:59:10 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
949
3/27/2008 11:24:50 AM
The following comments were raised during review of the subcontractor KHI Quality Plan: 1- Submit Hydrostatic Test Procedure along with the test water diposal plan for each site. 2-Include the data sheet for the tanks being constructed in accordance with SAES-D-100 3- Include Saudi Aramco Form-2693 Data and Operating Limits Sheet for tanks being constructed. 4- Submit tank foundation acceptance form 5- Submit Survey Report Form (level,roundness and verticality) 6- ViolationPrevented Submit resumes of all Subcontractor personnel for review and Installation approval. 7- During all phases of the WORK Contractors QC Supervisors shall report to the Contractor Quality Assurance Manager or Quality Control Manager. The submitted organization chart shall be resubmitted to clearly reflect this requirement. 8- The submitted Qualified Welders List does not contain a qualified welder for GTAW process, only such qualified welders shall be allowed to perform GTAW procedures. The Material Specification document presented is not related to the Violationmaterial under inspection (31-SAMSS-004 Centrifugal Pumps) The RFI Prevented is rejected pending submittal of correct Material Specification Installation documents. I was found Leaked point when i was inspect RECOVERED OILY SUMP ALONG ROUTE B BESIDE TANK 111 & 112. This RFI Rejected Because During inspected this Concrete CB No.12 at Tank 102. I was found some leak. Contractor must be remove water, repair it accordance to aramco standard, and retest it again Found leak in all 4 sides of CB NO 12 at tank 102 contractor must remove water, repair it as per aramco Standard, and retest it again. Piping system coming out of Treated water Tank X07-D-0301 and going to facility pumps X07-G-0306 A & B should be Internally FBE coated, all the pipe used is internal coated however all the "Butt Welded" portions are not internal coated. This is in violation to SOW # X07-L-VB-338604-001 line designation 12LE0U for line # 6"-SWS-87812LE0U This is in violation to SAES-L-105 Para 11 Table-1 This is in violation to SAES-L-105 Para 12.2 Advice contractor to rectify the situation at ASAP bases. PID didnt find Mech.QC. at site to follow up mechanical works as per Aramco Standard and Schedule Q
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.5
Schedule Q
5.12
950
2/5/2008 8:35:40 AM 5/30/2009 7:32:46 AM 6/11/2009 7:34:05 AM 6/24/2009 3:34:24 PM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
3.15
951
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
7.3
952
SATIP-A-004-006
NA
Mechanical
SAES
SAES-A-004
7.5
953
SATIP-A-004-006
NA
Mechanical
SAES
SAES-A-004
7.5
954
5/11/2009 4:35:42 PM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-002
5.3
955
7/18/2009 7:27:57 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
956
12/20/2009 10:06:33 AM 2/23/2008 11:34:27 AM
contractod was do TIE IN y54 . of CS pipe line NO.10" ows - 660 for East Process lift station Drowing No. VA-133243 Sht.003 Rev.00F1 with out informing PID as per Sch Q 1.8 and ATT IV 1.2.3 . 1- End protectors were not used to protect the pipe ends from weathering of machined bonding surfaces may be caused by ultraviolet exposure. 2- The pipes were laid directly on the ashalted area without wooden protection Tie In spools fabricated have partially used slip on flanges for Diesel lines tins , As per SAES-L-109 primary selection should be Weld Neck flange, as used on one side of spool. Kindly verify with designer for the applicability of Slip on flange, & rectify the situation. All Concrete Top Slab for all Centrifugal Pump Vertical Suspended (CPVS) at Turaif Bulk Plant have violated Drawing # VA-338742 & Pump supplier installation requirements.
FIREWATER PROT SYS (
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-L-350-02
NA
Mechanical
ScheduleQ
Schedule Q
1.7
Schedule Q
A IV Para 1.2.3
957
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
958
12/13/2009 12:40:23 PM 4/13/2009 10:18:57 AM
SATIP-L-350-02
NA
Mechanical
SAES
SAES-L-109
6.1
959
NA
NA
Mechanical
Drawing
Drawing# VA-338742
NA
960
10/21/2008 4:37:23 PM
During my site visit I found that the welding activity is going on on aindar GOSP6,But there is no heating oven there.It voilates the Saudi Aramco Standard SAES-W-11. Contracator should care of this.And provide oven where the welding activity is going on. In Aindar Gosp 6 tie in activities is finished without the approval of tie in package from NGPIU. I DID THE FOCOUSS ASSEMENT ON THE WELDING IN AINDAR GOSP3, WHER I WAS FOUND THAT THE CONTRACTOR(METSCO) WAS DOING THE WELDING BUT THERE WAS NOT BACKING OVEN THERE IT VOILTES SAUDI ARAMCO STANDARD SAES-W-017.ALSO NO WPS WAS AVAILABLE ON THE SITE AS WELL.PLEASE INSURE THAT IN FUTURE BACKING OVEN MUST BE AVAILBLE AND WPS MUST BE ON THE SITE. In my site visit at Aindar Gosp 3.It was observed that the oven was not functioning well,there was no calibbration certificate of the oven. Again In the WPS# MET-06-95 Rev-02 Mentioned the root pass electrode is E-6010 size 2.5 mm,But the welders are using E7018 size 2.5 mm.It voiletes ASME Section IX.As per ASME Section IX QW404.4 AND 404.14, I is seential varible. And the welder are using 4mm electrode for filling but acording to their WPS, It should be 3.2 mm it voilates ASME Section IX QW 253. I noticed that in one area fabricator was doing the tag welding.Its serious voilation of ARAMCO standrad.Plz Take Care of that. During a review of Project QA/QC Organizational Charts with Maintain Potential Project Inspection Group, we found the following QA/QC personnel list: 1) R V Antonio (QC Manager) (SAP # 70001151) 2) N C Macaranas (Elect/Instrument Inspector Inspector) 3) M G Apolinario (Welding Inspector) 4) H. Hingpit (Civil Inspector) are working in two different BIs (Maintain Potential Project & 10-0009) This is Considered as a violation on SCHEDULE "Q" para 5.6 that mention (CONTRACTORs Quality personnel shall be dedicated to the WORK described in this Schedule Q and shall perform no other function on this Contract) SAPMT is advice and inform to solve this matter with the contractor to avoid any quality violations and delay of the project.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
961
2/17/2009 9:00:54 AM
SATIP-L-350-02
SAIC-L-2025
Mechanical
other
Best Practice
NA
962
10/27/2008 8:41:48 AM
SATIP-W-017-01
SAIC-W-2083
Mechanical
SAES
SAES-W-017
A1
963
10/27/2008 8:41:48 AM 11/30/2008 2:51:23 PM
SATIP-W-017-01
SAIC-W-2085
Mechanical
SAES
SAES-W-017
7.1.8
964
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
965
11/30/2008 2:51:23 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ASME Sec IX
QW 404.4 & 404.14
966
11/30/2008 2:51:23 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.1
967
7/12/2008 10:04:15 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.9
968
Inspection was conducted in connection to the Surveillance /Pro-active Notification issued to the contractor (Surveillance # L-58, May 09, 2009). It was found out that the contractor did not comply with the Pro-Active Notification issued to them. Pipes and fittings are still not properly covered and protected. Some are directly placed in the 5/21/2009 FIRE WATER 4:12:55 PM ground. This is a violation to SAIC-L-2074 and AWWA C205 Sec 6.2 which states that "Plastic end caps are securely fastened to ends of completed pipe for protection of the cement-mortar lining. End caps are maintained in place until time of installation. SAES-L-350 Para. 7.3 "Fittings shall be stored in shipping crates or on racks".
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
969
2/15/2010 5:34:34 PM
During the site visit in QA 4, Pipeline Rehabilitation- Phase VI @ KM 48+00, it was found that girth weld coating (STOPAQ APPLICATION) of FW 185,190,203,204 and 206 have been damaged due to sand accumulation near the coating and the thermal expansion of the pipeline. Coating repair shall be performed as per the SAES H-002V Para. 5. Backfilling can be performed immediately after the applied coating system has been checked, inspected, and approved by the inspector SAES H-002V Para 4.6 (g). Contractor QC personnel shall visit at the site periodically to observe such damages and take corrective action.
SATIP-H-002-11
SAIC-H-2083
Mechanical
SAES
SAES-H002V
4.6 & 5
970
3/8/2010 7:45:10 AM
During the surveillance visit it was found that SIGNIFICANT AMOUNT OF SAND IS ACCUMULATED AT STOPAQ COATED JOINT Nos. FW402, FW523, 524, 538, 539, 540, 541, 542, 543 AND ALSO AT THE UNCOATED JOINT Nos. FW 544, 546, 560 & 561. This can lead to the Coating damage as it has happened on 3 other joints where the Violationdamage occurred due to sand accumulation and subsequent thermal Prevented expansion and contraction (due to temperature changes in day and Installation night). Also the uncoated joints can get more corroded due to the moisture entrapped in the accumulated sand. Contractor is required to take immediate action for removing the sand from the strings and especially from the joints. Regular monitoring and prompt action in this regard is required in future. During the walkthrough for punch listing of Hydro test package# 5, it Violationwas noticed that the contractor used different sized bolts. Also the After The Flange joint tightening repot (SATR-L-2001) was not filled properly. Fact This action violates SAEP-351 Para 4.2. During surveillance inspection along QRT-6 P/L @ KM 15 near Awamia road, it has been found that some 40" pipes are touching the ground Violationand there are no sufficient protection. It is a violation to Saudi Aramco After The Standard SAES-H-200 Para 5.2.1 and SAES-L-450 Para 14.10.4. The Fact contractor was asked to elevate the pipes from the ground at least 150 mm. During the inspection visit in BinQuraya AinNakhil Yard for pipeline re habilitation project (10-00094-0001), it was found that some fabricated spools ( HB-426154-001-00 Spl # 154A,E etc) of QA 4 & ViolationQRT 6 have been kept without the end protector and FBE coated After The spools have been kept on the beam directly without the rubber Fact padding. It violates the SAES L 350 Para 8.4 and 8.2. All spools shall be elevated minimum 150 MM from the ground and ends shall be protected. During the surveillance visit in QA 4, Pipeline Rehabilitation- Phase VI Violation@ KM 48+00, it was observed that the pipe string has no end cap at Prevented the joint FW 184. Open ends of the string shall be end capped as per Installation the SAES L 450 paragraph 11.4. it was noted that 40X 0.312 External FBE coated pipe (Pipe # 2513/047 HT # 818031) had been rolled from the tire supports. ViolationPrevented External coated pipe string shall be kept as per the SAES-H 200 Installation paragraph 5.3. Damaged coating shall be repaired as per the Saudi Aramco standards. During the inspection visit in QA 4 (BI-10-00094-0001) @ Km 58 & 65, it was found that, wrong WPS (approved for higher grade API X65) has been used to weld the 40X API Grade 52 to 2 A105 (Weld boss) material in the existing line while separate lower grade (X52) procedure qualification is required as per SAES W 12. Para. 7.4.1 (ii) & API 1104 Para.5.4.2.2. During the welding production of 30 SURGE SKID Jump over (HB-426326-001-Rev 00) procedure for higher grade (X65 to X65) has been used instead of lower grade (X60). It violates the Saudi Aramco Engineering standards and international standards.
SATIP-H-002-11
SAIC-H-2083
Mechanical
SAES
SAES-H002V
4.6 & 5
971
1/17/2010 11:02:56 AM
SATIP-L-450-04
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.2
972
12/12/2009 8:19:37 AM
SATIP-L-450-03
SAIC-L-2112
Mechanical
SAES
SAES-H-200
5.2.1
SAES-L-450
14.10.4
973
12/24/2009 2:23:46 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-450
8.2 & 8.4
974
2/15/2010 5:40:23 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
975
2/15/2010 5:40:23 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.3
976
2/22/2010 10:00:45 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
7.4.1
API 1104
5.4.2.2
977
2/25/2010 8:26:43 AM
During hydrotest of 30" spool, leak was found @ weld # SW-8B (1" weldboss-threadolet to 1" gate valve for drain). Following are the discrepancies found & contractor is required to act accordingly: 1- MPI report from VETCO attached in the hydrotest package showed that no relevant indication found (Accept). RT & MPI was done after the leakage, at 2 joints (SW-2B & 8B) and the reports describe the finding of linear indication, slag, porosity & internal undercuts (Reject). This shows the workmanship incompetency of the NDT company. Contractor is required to STOP any further NDT from Vetco on this project. 2- RT also detected the threads insufficient engagement that was also the factor for leak. Contractor is reqrd to perform 10 % RT on all threaded joints. 3- Contractor failed to produce the welding record (Daily Weld Fit-up Report SATR-W-2006)&(Daily Weld Production Report SATR-W-2007) for the joints SW-2B & 8B, but these joints were added hand written to the Weld Summary Sheet W-2008. With reference to the RFI PID witnessed the Paint shop for receiving inspection of paint materials for structural steel items for this project at Rahima yard, while verifying PID found that the contractor is implementing a wrong coating process APCS 6 instead of APCS 26 as per SAES H 001 and Schedule Q Para 1.3 it is a violation. Inspection Requires, The QC Manager to find the root cause of the violation and take an immediate corrective action The procured paint materials to be shifted to Quarantine area and comply with the SA requirements During Regular Site Visit (on saturday), Inspection Rep.noticed that contractor was installing a 24" SS pipe Spool with out clearence from NDE and PMI violating the requirements of Section 9 of SAIC-L-2038. Contractor was told that the location where this Pipe Spool is being Installed (In underground Trench) makes Conducting NDE and Repair of Weld Defects ( If Required ) very difficult and Time Consuming. Contractor was adviced strongly to follow all the requirements of Aramco Standards to meet Quality and avoid delays in Project Schedule. Contractor is reminded to provide a Qualified Supervisor meeting all the requirements of Schedule "Q" immediately since the approved supervisor is not present. Location Al-Khathlan Shop Date:10/09/2008 During inspection coverage for RFIs # W-08 & W-09 (In Process and Pre welding inspection of Structural Supports for Cable Trays & Pipes) it was found that The Contractor QC didnt fill the required checklist (SAIC-W-2006) PID requires 1.Contractor shall fill the applicable quality documents prior issuing the RFIs 2.Contractor QC shall do his job as per SATIP and other SA requirements 3.Contractor to issue another RFI to inspect the welding complying with approved WPS requirements During one of our regular site visits PID found that contractor procured Stainless Steel Pipes and flanges with out the involvement of VID and with out any inspection. The same has been discussed in yesterdays weekly meeting. Today during our regular site visits we found that FIT UP of pipes and flanges are being done by contractor with out even clearance of earlier issue which is a violation. Contractor shall follow all the requirements of Aramco Standards. During our regular Site Visits, PID found that Contractor is welding Stainless Steel Spools with out receiving Inspection. Already Vendor Inspection Division has issued a NCR as these material was procured with out involvement of VID.Contractor is advised strongly to adhere to the requirements of ARAMCO Standards for Smooth & Safe running of the Project.
SATIP-W-011-01
SAIC-W-2008
Mechanical
SAEP
SAEP-1160
Section 6
978
1/1/2009 2:39:46 PM
SATIP-H-100-01
SAIC-H-2023
Mechanical
ScheduleQ
Schedule Q
1.3
979
4/26/2009 7:33:46 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-A-206
Schedule Q
A IV Para 3.4
980
7/25/2009 1:25:01 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
981
10/9/2008 1:18:51 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
3.1
982
6/29/2009 2:31:13 PM
ViolationAfter The Fact ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.4
983
6/29/2009 2:31:13 PM
SATIP-L-350-08
SAIC-L-2005
Mechanical
SAES
SAES-L-350
6.2
984
7/4/2009 1:28:58 PM
SATIP-L-350-08
SAIC-L-2005
Mechanical
SAES
SAES-L-350
6.2
Schedule Q
A IV Para 3.4
985
10/13/2009 2:59:29 PM
Mech
During the focus assessment on the recently received three RO Skids, many welding repairs and welding patches been observed on different locations of the RO skids spools, without the submittal and approval of repair procedures and without the involvement of SAPID. Contractor fails to use the right methodology and steps in resolving this welding issue, in violation of article 18 of SAES-W-011. Contractor shall submit corrective action to resolve above issue During the focus assessment on the recently received three RO Skids, many welding repairs and welding patches been observed on different locations of the RO skids spools, without the submittal and approval of repair procedures and without the involvement of SAPID. Contractor fails to use the right methodology and steps in resolving this welding issue, in violation of article 18 of SAES-W-011. Contractor shall submit corrective action to resolve above issue During the focus assessment on the recently received three RO Skids, many welding repairs and welding patches been observed on different locations of the RO skids spools, without the submittal and approval of repair procedures and without the involvement of SAPID. Contractor fails to use the right methodology and steps in resolving this welding issue, in violation of article 18 of SAES-W-011. Contractor shall submit corrective action to resolve above issue
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
18
986
10/13/2009 2:59:40 PM
Mech
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
18
987
10/13/2009 2:59:51 PM
Mech
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
18
Schedule Q
Attach III par 3
988
7/28/2007 1:59:30 PM
hnrp trape area
1" x3000 THREDOLET IS COMING 3" OVER THE F/E SLEEV @ S/L 701 of SRB jump over near shop weld # 7 spool # 3( SEE CONSTRUCTION ViolationNOTE 7), SRB req to make 1 opening in to the sleeve so as to fix this Prevented field problem, to correct this and to create the exact match for this Installation ,PID/PLIU request an FCN (field change note) and a change in IFC WITH REFLECTION OF THIS CHANGE WITHIN AS BUILT DWG PID observed plentys of spectacle plate , spacer and blind installed at G-26 area are not complying saudi aramco standard drawing . The contractor is recieving materials at their laydown yard but this is not being recorded in the two week look ahead schedules which are being submitted at the weekly QC meetings. Advise the contractor he is in violation of schedule Q, Q-8, para 7.1 & must take immediate corrective actions to rectify this serious deficiency. During the weekly quality meeting held on 07/21/07 the contractor failed to submit the weekly QC organization chart for review which is in violation of schedule Q Q-6 para 5.9. In addition the 2 week look ahead schedule for review which is in violation of Schedule Q, Q-8 para 7.1. it was also noted that the recently approved welding inspector nor the QC manager where on site The contractor has failed to conduct his 60% procurement audit even though the project status for procurement is 76.44. This is in violation of Schedule "Q" , Q-8 para 7.2.2 It has been noted by inspection that the contractor is sending inspectors to other work sites, even though our project is coming to its peak. This is in violation of Schedule "Q" Q-6 para 5.6 "Contractors Quality personnel shall be dedicated to the work" If the contractor continues with these actions then APIU will be left with no option but to issue an NCR. In addittion these actions cancels their approved QP & should be resubmitted. APIU have note that SAACO have now demobilized three inspectors, Juanito Quitlong Civil Insp, Andres D. Maghanoy Equip Insp & R B. Rejas Jr Electrical Insp with out any replacements or approval from Aramco. This is in violation of Schedule "Q" Q-6 para 5.6 & Q-7 para 5.10. Please advise the contractor to take immediate rectification action. APIU have note that the contractors top management has not submitted its six monthly quality management review for review. This is in violation of Schedule "Q" Q-4 para 4.1. Have the contractor take immediate neccessary corrective action.
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-L-350-01
SAIC-L-2018
Mechanical
Drawing
Schedule Q
1.3
989
5/5/2009 2:52:28 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-350
6.2
990
6/24/2007 6:42:43 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.5
991 992 993 994
7/22/2007 7:14:58 AM 7/22/2007 7:14:58 AM 7/22/2007 7:14:58 AM 2/10/2008 6:51:46 AM
NA NA NA NA
NA
Mechanical Mechanical Mechanical Mechanical
ScheduleQ ScheduleQ ScheduleQ ScheduleQ
Schedule Q
5.12 A IV Para 1.5 5.1 7.3.2
NA NA
NA
Schedule Q
995
2/26/2008 1:11:15 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.9
996
3/1/2008 3:24:55 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.11 & 5.12
997
3/1/2008 3:30:07 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
4.1 & 4.2
998
5/25/2008 7:02:57 AM
SAACO conducted an internal audit on their third party NDT contractor AMYSCO at the beginning of April 08. The audit report was scheduled for submittal to the company representative on the 19th April 08. To date 05/25/08 the audit report has not been submitted. This is in violation of Schedule "Q" Q-9 para 7.2.5. SAPMT have the contractor takew immediate action to rectify this defeciency. It has been note that the dedicated QC manager has not been on site for a number of days. Advise SAACO that this is in violation of Schedule Q and the QC manager shall always be available at site. APIU have noted with concern that the contractor has still not had their Quality Plan approved although it was submitted twice. This is in violation of Schedule "Q" Q-2 para 1.7. The raised face of 2 x 6" x 150 # rated R/F flanges where grit blasted by the contractor in violation of 02-SAMSS-011 para 7. Advise the contractor not to use these flanges and put into quarantine immediately. however the contractor been notified through a proactive notifications to have thier QCpersonnels on the work site full time APIU found During a routine site visit that contractor is performed a welding activities without a Quality inspector moniotoring . The activity is AHOLD POINT and the QC Inspector Mr.Michel was absent which is arepeated violation to Sch"Q" . During my morning site visit for SACCO(BI-10-00170), to witness Hydrotest and after we reach the Hydrotest pressure, a leakage been noticed on the valve flange although The contractor strike the pipes to stop the leakage while the system under pressure and this is unsafe practice and in violation of GI.2.102.
NA
NA
Mechanical
ScheduleQ
Schedule Q
7.3.5
999
7/2/2008 10:18:44 AM 2/17/2007 2:29:02 PM 12/12/2007 2:37:20 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
1000
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.2
1001
D-0301
SATIP-L-350-01
SAIC-L-2006
Mechanical
other
02-SAMSS011
13.2
1002
10/2/2007 8:29:28 AM
D-305
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
1003
11/1/2008 11:55:12 AM
E-004
SATIP-A-004-02
SAIC-A-2013
Mechanical
SAES
SAES-A-004
5.1
1004
11/11/2008 8:56:37 AM
During witnessed of hydro test of piping spools at ABQ GOSP-3,it has been noticed that contractor was preparing a non-standard blind ViolationAfter The flange fabricated form plat materials without any details such class, Fact materials thickness ,materials type, this violation accordance to SAES-A004 ,SAES-L-109 . Pipes stored in the yard shall be properly covered from both ends to Violationprevent accumulation of dust and forein materials. this violates SAES-L- After The Fact 350 para. 7.4. Plz advise the contractor to cover all pipes properly. It has been noticed frequently that the Mechanical QC Inspector is not available in site. As per Schedule Q, the QC personnel should be in the site and notification should be sent to APIU when any individual is planning to be absent. Tie-in of the new fire water line to the existing line is rejected and will not be signed off by APIU. 1- Hydrotest package is not approved yet. 2NDT was not conducted RFI was not raised by the contractor These actions violate Schedule Q. SAPMT is requested to take action with the contractor to resolve this serious descripency. APIU have noted that the contractor is changing / demobilizing QC personnel around without the correct notification as per schedule "Q" niether has the updated QA/QC organization chart been submitted for review / approval. This is in violation of Schedule "Q" Q-6, paras 5.9 & Q-7 para 5.11. These actions by the contractor are unacceptable. It has been noted that the contractor is continuing welding activities on 20" dia piping line # 20-RL-81211 Drwg BB-577289-1CS9P without their approved welding insp being present on site. This is in violation of Schedule "Q" Q-2 para 1.4 & their approved QP which states welding as a hold point for the contractor. APIU will not accept the welding carried out on the line & require that the joint be cut out. Radiography of the joint is unacceptable as an alternative as it does not provide the mechanical properities of the joint.
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
8.3
1005
5/20/2008 3:56:08 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
1006
4/22/2008 12:47:28 PM 2/6/2008 3:22:22 PM 2/6/2008 3:22:22 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1 A IV Para 3.7
1007
SATIP-L-350-02
SAIC-L-2025
Mechanical
other
Best Practice
NA
Schedule Q
1008
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
1009
10/20/2007 1:11:47 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.11 & 5.12
1010
10/20/2007 1:24:58 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
1011
3/13/2008 8:30:58 AM
E/W PS
The Contractor has proposed that a QC Welding Inspector only visits the installation to conduct inspection after the welding is completed.This is unacceptable to SAPID. The QC Welding Inspector shall be in attendance to conduct all welding inspection activities, before, during, and after the welding operations. This comment was highlighted on PIDs responses to the submittals of Welding Procedure Specification and issue of Job Clearancer Cards.The Contractor is required to source a qualified Welding Inspector and submit his CV to SAPID for approval prior to starting the welding activities. PID observed that EPC, the contractor have proceeded to welding activities in area-3,PS-10 without raising RFI to PID.This is violation to Sch. "Q". Having post-welding inspection for blast-proof door frame, PID found a welding defect (arc strike) in weldment. Defect has been marked. This defect shall be rectified. Having post-welding inspection for blast-proof doorframe, PID found a welding defect.Defect has been marked on the surface. This defect shall be rectified.
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
1012
11/22/2008 8:20:49 AM 12/14/2008 6:09:12 PM 12/14/2008 6:12:35 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
1013
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1014
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1015
11/9/2009 10:49:15 AM
During design review for the hot tap piping detail VA-205823-001 48AY & VA-205826-001 FOR 56-AY I noticed that the branch connection for the all hot tap (total 150 branch connections) will be according to Violationdrawings weld out without reinforcement pad this is a violation Prevented according to SAES-L-110 chart 1 which show that if the header size is Engineering 48 or 56 and the branch size is 2 the branch type will be in region 4 (weld outlet weld with reinforcing pad) PMT is kindly requested to rectified this issue before starting the constructions. Having post-welding inspection for blast-proof door frame, PID found welding defects ( surface porosity) in weldments.Defects have been marked.These defects shall be rectified. The QA/QC Manager vacation schedule reflected in Contractors monthly Quality Management Report was dated Feb. 20 to march 20, 2010. The Contractor failed to notify PID through letter at least 30 calendar days before the scheduled vacation in violation of Schedule "Q" paragraph 5.14. Contractor should provide the letter and the proposed Aramco approved replacement. Tie-in of the new fire water line to the existing line is rejected and will not be signed off by APIU. 1- Hydrotest package is not approved yet. 2NDT was not conducted RFI was not raised by the contractor These actions violate Schedule Q. SAPMT is requested to take action with the contractor to resolve this serious descripency. APIU have noted that the contractor is changing / demobilizing QC personnel around without the correct notification as per schedule "Q" niether has the updated QA/QC organization chart been submitted for review / approval. This is in violation of Schedule "Q" Q-6, paras 5.9 & Q-7 para 5.11. These actions by the contractor are unacceptable. It has been noted that the contractor is continuing welding activities on 20" dia piping line # 20-RL-81211 Drwg BB-577289-1CS9P without their approved welding insp being present on site. This is in violation of Schedule "Q" Q-2 para 1.4 & their approved QP which states welding as a hold point for the contractor. APIU will not accept the welding carried out on the line & require that the joint be cut out. Radiography of the joint is unacceptable as an alternative as it does not provide the mechanical properities of the joint.
NA
NA
Mechanical
SAES
SAES-L-110
chart 1
1016
12/14/2008 6:05:04 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1017
2/22/2010 2:06:16 PM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
1018
2/6/2008 3:22:22 PM 2/6/2008 3:22:22 PM
SATIP-L-350-02
SAIC-L-2025
Mechanical
other
Best Practice
NA
1019
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
1020
10/20/2007 1:11:47 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.11 & 5.12
1021
10/20/2007 1:24:58 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
1022
3/13/2008 8:30:58 AM
E/W PS
The Contractor has proposed that a QC Welding Inspector only visits the installation to conduct inspection after the welding is completed.This is unacceptable to SAPID. The QC Welding Inspector shall be in attendance to conduct all welding inspection activities, before, during, and after the welding operations. This comment was highlighted on PIDs responses to the submittals of Welding Procedure Specification and issue of Job Clearancer Cards.The Contractor is required to source a qualified Welding Inspector and submit his CV to SAPID for approval prior to starting the welding activities. PID observed that EPC, the contractor have proceeded to welding activities in area-3,PS-10 without raising RFI to PID.This is violation to Sch. "Q". Having post-welding inspection for blast-proof door frame, PID found a welding defect (arc strike) in weldment. Defect has been marked. This defect shall be rectified. Having post-welding inspection for blast-proof doorframe, PID found a welding defect.Defect has been marked on the surface. This defect shall be rectified.
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
1023
11/22/2008 8:20:49 AM 12/14/2008 6:09:12 PM 12/14/2008 6:12:35 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
1024
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1025
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1026
11/9/2009 10:49:15 AM
During design review for the hot tap piping detail VA-205823-001 48AY & VA-205826-001 FOR 56-AY I noticed that the branch connection for the all hot tap (total 150 branch connections) will be according to Violationdrawings weld out without reinforcement pad this is a violation Prevented according to SAES-L-110 chart 1 which show that if the header size is Engineering 48 or 56 and the branch size is 2 the branch type will be in region 4 (weld outlet weld with reinforcing pad) PMT is kindly requested to rectified this issue before starting the constructions. Having post-welding inspection for blast-proof door frame, PID found welding defects ( surface porosity) in weldments.Defects have been marked.These defects shall be rectified. The QA/QC Manager vacation schedule reflected in Contractors monthly Quality Management Report was dated Feb. 20 to march 20, 2010. The Contractor failed to notify PID through letter at least 30 calendar days before the scheduled vacation in violation of Schedule "Q" paragraph 5.14. Contractor should provide the letter and the proposed Aramco approved replacement. PID found out that CAT QA/QC Manager Mr. Bahaa Maarouf was assigned in two project BIs # 00179 & 00433 in violation of Schedule Q paragraph 5.1, 5.2, 5.3 & as per attachment VI which required that the QA & QC Manager should be full time at site through project completion. The Contractor QA/QC Manager should either be dedicated full time for this project or appoint other Saudi Aramco approved QC Manager full time in this project. The Contractor failed to respond to the e-log book entry # 84 (Violation after the Fact regarding QA/QC Manager), the date of e-Log entry dated February 2 was not responded for more than 24 hours in violation of Schedule Attachment VI of "Q" paragraph 5.9. The Contractor need to comply with this Schedule "Q" requirement. The Contrcator failed to submit their 60% quality system audit report for their procurement phase in violation of Schedule "Q" paragraph 7.3.2. No Request for Inspection (RFI) was raised prior to installation of the oily water maximum flow pumps @ Plant R74. Pre installation verification of equipment support structure/foundation is required by SATIP-G-005-01 using checklist SAIC-M-2006 - Violation to Schedule Q Sections 1.5 & 3.1 Surveillance at SIS coating fabshop PID has noticed runs or sags and embedded foreign matters and flies on top coat 24" diameter carbon steel pipes reference spool numbers 054-7D1, 054-7A1,054-7A2,0547B1,-054-7B2,054-7B2,054-7C1 and C2. QC contractor already informed to repair the coating imperfection.
NA
NA
Mechanical
SAES
SAES-L-110
chart 1
1027
12/14/2008 6:05:04 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1028
2/22/2010 2:06:16 PM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
1029
2/2/2010 10:31:03 AM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1, 5.2 & 5.3
1030
2/6/2010 7:55:07 AM
Standards Violation
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Para 4.7
1031
12/20/2009 1:26:46 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
7.3.5
1032
2/14/2010 3:13:14 PM
SATIP-G-005-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
1033
9/23/2009 2:06:05 PM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6
1034
8/11/2009 1:23:37 PM
PID found blistering and bittiness coating imperfection in spool 923Violation2D1 24" diameter and spool 923-2D3. QC contractor already inform on Prevented the said defects and required to repair prior to start -up the final Installation coating application. Routine site inspection at coating fabrication yard a 16" diameter C.S pipe with spool numbers 878-2H, 878-2E, 878-2D are applied completely with the intermmidiate coat, some defects and bitteness, embeded foriegn objects and insects are found . SAPMT/contractor recommend to repair the defects prior to proced the final coat. During focus assessment inspection PID found out the contractor committing many technical and safety violation: Contractors coating QC inspector is falsifying pipes surface preparation and DTF reading to a bear within acceptance criteria. Contractor shall immediately correct all the violation and provide the safety means to the coating shop prior to resume any coating activities Contractors QC manager to propose a corrective action for the pipes already coated PID is revoking the contractors coating QC inspector for his very poor performance Material safety data sheet and safety sheet are not mad available at site, violation to SAES-H-102, Para. 4.3.7 Open coating containers kept for days in the adverse weather violation to SAES-H-100 Para. 6.2
SATIP-H-100-01
SAIC-H-2029
Mechanical
SAES
SAES-H-100
8.1.6
1035
10/31/2009 4:38:04 PM
SATIP-H-100-01
SAIC-H-2030
Mechanical
SAES
SAES-H-100
8.1.6
1036
1/24/2010 2:03:42 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
1037 1038 1039
1/24/2010 2:03:42 PM 1/24/2010 2:03:42 PM 1/24/2010 2:03:42 PM
1040
8/26/2009 2:20:54 PM
Coating equipments measuring instruments are expired since Nov. 2009, violation of Sch. Q attachment IV - Para. 6.1 These are violation of Sch. Q Para. 1.3: During surveillance at SIS fabshop PID has found damange coating and bittiness imperfection on spool 3H 24" diameter AREA 369 Violationreference DWG-RB. 743923 sheet-3,/DWG-RB744351 sheet 2 spool Prevented 351-2I 4" diameter and DWG-RB 744352 sheet 3/2 spool 352-3D 6" Installation diameter.PID required SAPMT to take corrective action on these issues. SS Spools/materials received for Aluminium Dozing Plant without any proper documents/reports. During surveillance inspection, PID found out many pipes and fabricated spools at fabrication Shop and materials yard are without pipes end protections, this is a violation of SAES-L-450 Para. 8.5 Inspection requesting contractor to immediately comply with standards and provide proper pipe ends protection as required During witnessing RFI#2213 at SIS YARD for final inspection of piping spool prior to release for site,PID found metal debris & weld spatters inside the spool#054-7E2 DWG#RB-744054 sht 7 which is voilation as specified in 01-SAMSS-010 Para 10.2 During visit to the SIS Fabshop to attend the RFIS#2354 & 2355,PID found that no concern Inpector available at location with the documents required at mentioned time even after lunch also, which is violation as specified in SCH Q SEC 1.4 & 1.8.This RFIS has been Rejected.Contractor QC Manager should advise to the concern Inpsector to adhere with Project Sch Q and Re-issue the RFIs. Routine surveillance at SIS fabshop NAPID observed that the mechanical QC is allowing the welders to fit-up the 6" diameter C.S 90 degrees elbow without performing the material recieving inspection. in addition the tack weld size is not sufficient and not meeting the recommended length which is 12.5 to 25.4 mm. Routine surveillance at SIS fabshop PID observed that there were various sizes of weld neck flanges not properly stored it was directly exposed to dusty area without cover protection. In addition some flanges connected to pipe spools are not provided by end protectors, violation in SAES L-350 para 7.4
SATIP-H-100-01 SATIP-H-100-01 NA
NA SAIC-H-2025
SAES SAES ScheduleQ
SAES-H-102 SAES-H-100 Schedule Q
4.3.7 6.2 7.1 of Attachment IV 1.3
NA
Schedule Q
SATIP-H-100-01
SAIC-H-2030
Mechanical
SAES
SAES-H-100
8.1.6
1041
3/18/2010 7:57:15 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A III Para 3.22
Schedule Q
A IV Para 3.3
1042
1/25/2010 1:11:49 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
SAES-L-450
8.4
1043
2/9/2010 5:19:48 PM
SATIP-L-350-08
SAIC-L-2038
Mechanical
other
01-SAMSS010
10.2
1044
2/20/2010 8:19:57 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.4, 1.8 & 5.1
1045
11/16/2009 4:28:16 PM 11/16/2009 4:28:16 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
1046
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.3
1047
11/25/2009 3:17:34 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
1048
7/11/2009 2:27:00 PM 7/12/2009 3:42:47 PM
1049
Site surveillance at SIS fabrication shop Safaniya PID noticed that pipe Violationspools with flange connected at the end are not protected with Prevented wooden cover bolted to the flange. this a violation per SAIC L-2038 Installation item B5. PID observed at SIS fabshop that numerous pipe spools are stored ViolationPrevented directly on the ground and clashing each other, violation per SAIC LInstallation 2034 Project Inspection found that Contractor not using approved IFC drawing for fabrication of structural columns , accessories and also making alterations in the drawing in terms of addition of structural supporting plates and dimension changes, without any design authority approval, which is violation against SCH Q Para 1.4 & 6.1.1. Contractor shall plan, organize, control & execute all work in accordance with contractors Approved Quality Plans & documented Procedure. Location: Safaniyah, Tanajeeb, Abu Ali During PID follow up investigation of the contractors QC personnel compliance, PID found out that contractor has been lacking the following QC personnel: Contractor is lacking (2 QC supervisors) (2 electrical QC inspectors) (4 civil QC inspector) (1 mechanical QC inspector) (1 welding QC inspector) These are Violation of Sch Q. Para 5.11; these violations have been previously noted to contractors and SAPMT and have been documented during the weekly QC meeting without and compliance from the contractors side. Inspection requires: Contractors QC manager to assure the adherence with the project Sch. Q quality personnel requirements and Contractor shall provide a qualified candidates to S. Aramco for interview as soon as possible to avoid work obstacles Contractors QC manager shall provide a preventative action to assure the nonoccurrence of this violation in the future Location: Safaniyah During PID auditing activities of the contractors QC personnel compliance, PID found out that contractor released QC supervisor Arnel Predas: for his annual leave without providing a qualified replacement, this is a violation of Sch. Q Para. 5.11 Inspection requires: Contractors QC manager to investigate the root cause of this violation. Contractors QC manager to immediately provide a replacement. Contractors QC manager shall provide a preventative action to assure the nonoccurrence of this violation in the future During document verification, inspection found out the contractor has been working without providing an approved RTFI to evaluate and accept the subcontractors RT results and already these are a total of 215 butt welded joints contractor accepted without the evaluation of an RFTI, this is a violation of Sch. Q Attachment IV Para. 7.3 Inspection requires: Contractor to investigate this violation root causes Contractor shall immediately provide a qualified RTFI to fulfill the requirements of Sch. Q Contractor shall provide a corrective action to assure the integrity of the 215 but welded joints Contractors QC manager to provide a preventative action to assure the nonoccurrence of similar violation in the future Location: Fabrication shop Surveillance inspection found contractor is pre-heating joints # JT 37 & TJ 23 for welding prior to clean the joint metal from rust and other foreign matters; this is a violation of SAESW-011 Para. 11.3.1 Furthermore, PID already highlighted these violation two days earlier to contractors welding QC inspector Rajeev, but no action is taking to enhance the quality work. Inspection requires: Contractors QC manager to investigate the root cause for this violation. Contractor shall cut out these weld fitted rusted joints and re-work as per quality procedure. Contractor shall issue RFI for PID to inspection the re-fit up for these joints. Contractors QC manager to provide preventative action to assure the nonoccurrence of similar violations
SATIP-L-350-08
SAIC-L- 2038
Mechanical
SAES
SAES-L-350
7.1 & 7.4
01-SAMSS010
10.4.1
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
1050
3/11/2010 11:02:53 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3 & 6.1.1
1051
1/11/2010 2:10:46 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1 & 5.11
1052
1/11/2010 2:13:49 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
1053
1/17/2010 8:29:22 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
1054
1/19/2010 7:57:22 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.1
1055
7/18/2009 2:08:19 PM
Recieving inspection of Oil skimmer at SIS fabshop PID noticed that the flange delivered at site is not SS 316 violation per project specification. Site surveillance at G-26 area, PID observed that in process welding of joint number 24,25 &26 carbon steel pipe 24 inches diameter is on going without using the welding blanket adjacent on the joint sleeve a violation per SAES W-011 para 11.11 and SAES H-200 para 6.2. In addtion coated pipes laying on the ground at the same area supported with hard wooden blocks without padding or any soft materials that can prevent from damage the topcoat During surveillance, Project Inspection verified that the Welding QC Mr.Javed assigned for coverage in plant R74 Safaniya is absent at site on 17th March 2010 & conformed that the subject QC personnel already transferred to Abu Ali area,without providing a qualified replacement & any information,which is a Violation as specified in Sch Q Para 5.11. Inspection requires contractor QC Manager to investigate the root cause of this violation & immediately provide a replacement & shall provide a preventative action to assure the non-occurrence of this violation in future. SS weld for 1"-C-0247-1SDOP, RB-7440247, FW-25(Flange),AREA M18, RB-744683-001, 1 of 4, FW-52, 3/4" Sockolet with Nipple Area F31 were found severe distortion due to excess heat input.
Standards Violation ViolationAfter The Fact ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
1056
12/8/2009 4:39:18 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.11
SAES-H-200
6.2
1057
12/8/2009 4:39:18 PM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-002
5.3
1058
3/18/2010 4:27:50 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
1059
3/18/2010 8:20:48 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.4
1060
3/3/2010 8:00:29 AM
During surveillance Inspection, the Welder with ID# S2174 found ViolationTacking using GTAW Process for the joint no 10 for DWG# RB-744053After The 4C without adequate windshields in Open yard Environment which is a Fact violation against SAES-W-011 Para 11.2.1 & 11.2.3 LBE No-08 PMI procedure needs to be reviewed and approved prior to raise a RFI. PMI shall be done during incoming material inspection and or prior to fabrication. SATIP-W-011-01 SAIC-L-2004) LBE NO -06 WPS shall be reviewed by PID prior to welding activities. Hence contactor to comply the requirements. SAES-W-011-01 (SAIC W-2001) LBE No -04 Contractor QC Welding is not having Tools and Equipments to assess weld Fit-ups and weldments. SCH. Q ATT.IV Para. 6 LBE No-09 QC has to raise RFI`s for on going activities. LBE NO-10 QC Welding shall not proceed for welding & installation activities without shop weld details(Weld History, NDT, Weld Map & Spool Identification. LBE NO-07 Fillet welds found to be lesser in size on some of the sleeve joints , needs to be rectified for the line No 6-OW-45110-12LCOU. SAES-W-011-01 and WPS (SAIC-W-2004) Surveillance at SIS fabshop Safaniya PID noticed that a 12" dia. C.S pipe with spool number 610-13A, it has been observed that a tack weld length size is not meeting the minimum requirement specified in SAES -W-011 para 11.5.3 which is 12.5 mm to 25 mm. LBE NO -011 SS fit-ups shall be done by keeping tack-welds inside the groove not by bridge tacks to avoid further surface grinding and PT test) SAES-W-011-01 (SAIC-W-2005) SS fittings were mixed up with CS material and improper coverage for SS Welding activities. PID received RFI # SAF-006 by fax for selection of NDE (MPI) for structural steel no other information which project BI # missing (RFI attached). When we reached the shop we found as follows:- 1) Shop has no approval.
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationPrevented Installation ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011 11.2.1 & 11.2.3 Project Documents & Specification s. SAES-W-011
1061
1/28/2010 11:20:26 AM 1/28/2010 11:17:05 AM 1/28/2010 11:37:02 AM 1/28/2010 11:37:02 AM 1/28/2010 11:37:02 AM 1/28/2010 11:23:35 AM 11/7/2009 3:56:19 PM 1/28/2010 11:27:16 AM 3/3/2010 6:16:46 PM 3/3/2010 6:16:46 PM 1/2/2010 7:47:39 AM
SATIP-L-350-01
SAIC-L-2004
Mechanical
Scope
NA
1062
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
7.1.5 & 7.1.8
1063 1064 1065
NA NA SATIP-L-350-08
NA
ScheduleQ ScheduleQ ScheduleQ
Schedule Q
5.5 1.7
A IV Para 3
NA
Schedule Q
SAIC-L-2038
Schedule Q
1066
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011 17.5.1 & 17.5.2
1067
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.3
1068 1069 1070
SATIP-W-011-01 NA NA
SAIC-W-2005
SAES ScheduleQ ScheduleQ
SAES-W-011
11 & 12 A IV Para 6
A IV Para 3.2
NA NA
Schedule Q Schedule Q As listed in SAIC
1071
SATIP-L-350-08
SAIC-L-2031
Mechanical
other
NA
1072 1073
1/2/2010 7:47:39 AM 1/2/2010 7:47:39 AM 1/28/2010 11:14:20 AM
2) Welders has no JCC. 3) Material fabricated without receiving inspection LBE NO-05 Weld Modifications is not matching with the actual in the ISO Dwg`s. ISo Dwg`s to be updated and revised by Engineering( stamped, initial with revision No), QC shall use the approved DWgs, accordingly. SAES-W-011-01 (SAIC-W-2036) Site surveillance at SIS fabrication shop PID observed that visual inspection of three completely weld joints # 11, spool 924-7A , joint # 13 spool # 924-4B and fillet weld joint # 27 spool # 351-9F are not acceptable due to incomplete filling or undercut . and PID found that QC contractor does not have fillet weld gauges to measure the leg of fillets weld as well as convex and concave welds. Site surveillance at SIS fabrication shop PID observed that electrode container for 7018 H4R is opened for long time and not stored in a proper place. Welding machine # 149 at SIS fabrication shop has been reset and the amperage reading is set to different value which is not in compliance with applicable WPS requirement . Reference RFI M-34 was issued for receiving inspection of argon gas 14 cylinders at fabrication shop are not acceptable because it does not passed SAIC W-2010 item B6 & B7 which means conforming Compressed Gas Association CGA-11.1 grade A and shall be CSD approved. Preservation of and 1 diameter SS pipes is not satisfactory. Some of the Pipes Severely rusted, which were kept barely in the site. This violates SATIP-W-011-01, para 2.1 The Main Oven(Baking/Holding)is having Gauge to measure temperature is not functioning properly. Routine surveillance at plant G-26 PID noticed that the 24" diameter carbon steel pipe already installed on the pipe sleepers and the clearance between bottom of the pipe and finish grade has not complying the minimum requirement of SAES L-310 Para 12.3.I Project inspection has issued already a pro-active logbook entry on this issue but it seems that no corrective action has been taken. addition PID has observed that the pipes installed on the sleepers were not internally clean by air blowing a violation specified in SAES L-350 Para 15.2.1. In process welding of Spool# 877-2D, 24", joint# 07,08. Spool# 8772E, 24", joint# 8& 8A is not acceptable contractor did not performed the pre heat and interpass temperature as mandatory required in the WPS MSAS-81 QW-406.and no available QC at jobsite while the welding activities in progress at plant G26 a vioaltion per schedule Q.in addtion 24" carbon steel pipe laying at the same area not covered and it was contanimated with sand. no available QC at jobsite while the welding activities in progress at plant G26 a vioaltion per schedule Q.in addtion 24" carbon steel pipe laying at the same area not covered and it was contanimated with sand. in addtion 24" carbon steel pipe laying at the same area not covered and it was contanimated with sand. During surveillance at fabshop project inspection observed that were two welding machines no. WM 010 and WM 240 current range reading are not complying the WPS requirement. The current selector was adjusted into 200 amperes to 240 amperes instead of 100 to 130 amperes for root pass (GTAW process) as specified in WPS 81. The contractor was raised RFI for the installation of buried piping at oily fit on ABQ. 2 prior for backfilling. During inspection it was found out that there is no available drawings on site and no checklist SAIC-L2019 a very impoprtant tools for inspection for verification. The contractor was advise to provide and prefer aproved drawings on site during inspection and installation
SATIP-W-011-01 NA
SAIC-W-2005 NA
SAEP ScheduleQ
SAEP-324 Schedule Q
5
A IV Para 3.3
1074
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAEP
SAEP-1160
1075
7/5/2009 3:26:04 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011 17.1.7 & 17.1.8
1076
7/6/2009 4:21:10 PM 7/6/2009 4:21:10 PM 5/19/2009 11:23:50 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1077
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
1078
SATIP-W-011-01
SAIC-W-2010
Mechanical
SAES
SAES-W-011
6.7
1079 1080
2/16/2010 5:17:54 PM 3/3/2010 6:22:05 PM
SATIP-L-350-01 SATIP-W-011-01
SAES SAES
SAES-L-350 SAES-W-011
7 6.1
1081
12/14/2009 2:40:03 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.3
1082
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.2.1
1083
12/17/2009 10:46:54 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.1
1084
Mechanical
ScheduleQ
Schedule Q
5.1
1085
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
1086
12/26/2009 1:40:08 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1087
10/29/2009 8:02:22 AM
SATIP-L-350-01
SAIC-L-2019
Mechanical
ScheduleQ
Schedule Q
1.3
1088
1/4/2009 7:24:21 AM
In my site visit I noticed that in Abqaiq GOSP5 the tie in activity is going on by AL-BADAR.While we earlier reject tthere tie in procedure and ask them to re-submit again.But the contractor is doing the tie in without informing us.This is serious voilation of aramco standard. Surveillance conducted as part of Focussed Assessment on Piping Installation and found out that burried piping was backfilled without holiday testing.This is a clear violation on SAES-H-200 and SAIC-L2019 that pipe shall be 100% holiday tested before backfilling.The contractor was advise to expose the pipe and conduct holiday testing as a corrective action as per SAES-H-201. During survielance conducted on Aindar Gosp 1 it was found out that there was misalignment on the flange connected to the pumps. As per SAIC -L-2014 flange tilt should be 1.6 mm maximun. The Contractor was advise to rectify the spool on and align as per required. RFI to be raise for flange alignment. Focuss assestment was done for internal coating and found out that the contractor was internaly painted the spools that was rectified and burned internal coating due to cutting and welding. Painting was done internally without cleaning the damage area as per surface preparation requirements SAES-H-201 section 7 para 7.2 Focuss assestment was done for internal coating and found out that the contractor was internaly painted the spools that was rectified and burned internal coating due to cutting and welding. Painting was done internally without cleaning the damage area as per surface preparation requirements SAES-H-201 section 7 para 7.2 During surveillance at fabrication shop found the following, 1)Welder stamp # BT was being done filling pass with E6010. . References) Drawing # BB155250 Spool no. 43 - SW#111 - WPS#AB-10 Recommended Root pass in WPS is with E6010. And Recommended Fill & Capping pass in WPS with E7018. 2) Many joints have been found without welder identity mark. 3) Many pipe spools were lying on dirty floor
SATIP-L-450-04
SAIC-L-2115
Mechanical
ScheduleQ
Schedule Q
1.7
1089
10/22/2009 9:34:26 AM
SATIP-L-350-01
SAIC-L-2019
Mechanical
SAES
SAES-H-002
5.1.3
1090
9/17/2009 9:38:16 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
1091
11/25/2009 9:09:15 AM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
7.2
1092
11/25/2009 9:16:20 AM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
7.2
1093
2/4/2010 12:18:42 PM
Oily Water System
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1094 1095 1096

10/18/2009 7:30:58 AM
SATIP-W-011-01 SATIP-L-350-01
SAIC-W-2006 SAIC-L-2012 SAIC-L-2003
SAES SAES ScheduleQ
SAES-W-011 SAES-L-350 Schedule Q
16.1 7 A IV Para 3
There was no evidence of piping material traceability which is in violation with Schedule-Q, Attachment-IV, Section 3.0 Permanent approval of Quality Control Inspectors were not avaliable for the following inspectors, Mr. Alexander Marcos, Mr. Ver San Miguel, George Abescoro which is violating SCHE Q ATTACHMENT I. During the focuss assessment on welding I noticed that the contractor was doing the repair welding without the approval of repair welding procedure and sending any RFI to NGPIU. During site surveillance at RR substation# 27&28 PID has found the following: 1. The contractor didnt submit RFI for structural welding activity which is violate schedule Q. 2. The contractor continue welding activities without the presence of welding QC inspector, As per SATIP-W-011-01, pre-welding and post welding inspector is Hold point for contractor QC welding inspector. As per the surveillance inspection at Substation # 27, Contractor Welder having symbol PBT was engaged to continue welding of Blast doors with any welding procedure, RFI and no presence of the Contractor QC welding inspector. This is the violation of SAES-W-011 Para 7.1.8 that All WPSs, PQRs, and Weld Table shall be available at the work site for verification at any time by the authorized Saudi Aramco inspector. Also it violates the schedule Q attachment VI, AS well as SATIP W-011 that contractor Welding Inspector has missed the hold point and work has been started. The welded portion shall be inspected THROUGH NDT. The welder JCC card has been revoked for a while
SATIP-L-350-01
1097
10/18/2009 8:00:05 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
A1
1098
2/24/2009 3:58:38 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.3
1099
12/9/2009 1:02:08 PM
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
1100
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
1101
2/15/2010 9:23:56 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.8
1102
2/15/2010 9:29:35 AM
As per the surveillance inspection at Substation # 27, Contractor Welder having symbol PBT was engaged to continue welding of Blast doors without any welding procedure, RFI and no presence of the Contractor QC welding inspector. This is the violation of SAES-W-011 Para 7.1.8 that All WPSs, PQRs, and Weld Table shall be available at the work site for verification at any time by the authorized Saudi Aramco inspector. Also it violates the schedule Q attachment VI, AS well as SATIP W-011 that contractor Welding Inspector has missed the hold point and work has been started. The welded portion shall be inspected THROUGH NDT. The welder JCC card has been revoked for a while. APIU where unable to continue with the weekly site QA/QC meeting on 09/26/06 @ 08.30am due to non-attendance of the contractor QC manager. This is in violation of Schedule "Q" Q-5 para 5.1 & Q-6 para 5.6 The contractor presented radiographed to be reviewed to APIU for assessment.It was noted that the contractor did not have an independent RTFI to review AMYSCO radiographs prior to submitting to APIU for final approval. This was highlighted at the quality meeting held on the 12/05/06 and at previous quality meetings. The contractor had to date not sourced and independent RTFI which is in violation of Schedule "Q" QIV-5 para 7.2 & 7.3. Ref: SANITARY SEWER LINE GRAVITY TEST & MANHOLE LEAK TEST: RFI 819 & 854 ARCC has raised RFIs without having the prior approval of Hydro Test Packages. This is in violation as per the requirements of Sch. Q Attach. IV Sec 3.7 Contractor is advised, through SAPMT, strictly adhere to the Project Quality Requirements. During surveillance, it is noticed at GOSP-5, that the flange faces of the spools are not covered by wood or plastic or metal covers to protect from the mechanical damages. These spools are transported from ARCC fabrication Yard to the work site. This is in violation to: 02SAMSS-011, para 10.4 SAPMT is adviced to remind the construction contractor of the above standard & to avoid further reoccurrence of the violation. Ref: Field Hydro Testing of Valves: RFI # 1605 ARCC has raised RFIs without having prior approval of Valves Field Hydro Testing Procedure which comes under the Special Process category. This is in violation as per the requirements of Sch. Q Attach. IV Sec 2.1 Contractor is advised, through SAPMT, strictly adhere to the Project Quality Requirements. NGPIU have noted that ARCC have released the approved Mech Inspector (Equipment)Mr. C F. Baco (NGP)without justification or advanced notification to SA. This is in violation of Schedule "Q" Para 5.11, Q-7. During Focuss assessment NGPIU found that contractor are not including in the Pressure Test Diagram the limits of piping (including test manifold) and equipment included in each pressure test, high points and low points (drain), locations of pressure gauges, test pressures, test temperature, test fluid, line flushing requirements, and safety precautions NGPIU has rejected hydro tests, Test pack no: TP-U56-5830-006 & Test pack no: TP-U56-5830-008 due to Radiography results not being made available before test & not included in the test package. This is in violation of SAES-A-004 & GI 002.102 requirements. Entire length of 3"x0.216WT SS TP 316L pipes, coated externally with hand applied tapes. As per SAES-H-002,para 5.1.7, this is violation.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.8
1103
9/26/2006 9:25:07 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.1 and 5.6
1104
12/6/2006 7:48:36 AM
SATIP-NDE-RT-01
SAIC-RT-2002
Mechanical
ScheduleQ
Schedule Q
7.2 and 7.3
1105
2/24/2009 9:35:03 AM
SATIP-A-004-02
SAIC-A-2001
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.21
1106
12/29/2008 4:18:04 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
other
02-SAMSS011
13.2
1107
5/6/2009 10:40:15 AM
SATIP-A-004-02
SAIC-A-2001
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
1108
2/18/2009 7:30:01 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1109
10/27/2009 9:21:30 AM
SATIP-A-004-02
SAIC-A-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1110
3/17/2009 8:08:19 AM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAEP
SAEP-1160
1111
11/27/2008 8:42:34 AM
SATIP-H-002-02
SAIC-H-2015
Mechanical
SAES
SAES-H-002
5.1.7
1112
4/22/2009 10:08:20 AM
Observed at SHD GOSP 4, during shut down, Flare System Area. Following 3 field Joints of 1 SS pipe lines found not in compliance with the standard requirements: Drg. BA-936009-Sht 003 Rev. 0C : FW 018 (HTP# TP-U59-5983-006) No axial gap. Drg. BA-936009-Sht 004 Rev. 0D : FW 018 (HTP# TP-U59-5983-007) Axial gap found 6 7mm. Drg. BA-936009-Sht 005 Rev. 0C : FW 018 (HTP# TP-U59-5983008) Axial gap found 6 - 7mm. The required axial gap minimum 1.5 mm & the maximum being 3.0 mm. The burs are also not removed from the cut pipe end. This is in violation as per the requirements of SAES-L-110 para 5.2.4 Contractor ARCC is advised, through SAPMT, to strictly adhere to the quality requirements at all times. During the verification of Test Preperation & Test Equipment for Pressure Testing, at Shudgam GOSP 5- Flare System Area, found that the piping system is connected with Pressure Gauges of range 0 300 PSI, to conduct the Hydro Test at 45 PSIG. This is in violation as per SAES-A-004 para 7.1.5 which states: All gauges have a range such that the test pressure is with in 30% to 80% of the full range The contractor ARCC is advised, through SAPMT, to comply with the standard requirements & then conduct the hydro test. During the surveillance at SHD GOSP 5, following points are observed & noted. Welding activities of some structural supports near cold tapped area: 1) Electrodes are not baked. 2) Electrodes are not stored in the portable ovens. 3) 7016 Electrodes are used directly from carton box. 4) Welder is not aware of his immediate superiors. 5) Welding Inspector / Welding Supervisor are not monitoring at the job site. 6) This is in violation as per the requirements of SAES-W-011 The contractor ARCC is advised, through SAPMT, to comply with the standard quality requirements. Professional approach towards the work will be appreciated. Perform a pneumatic pressure testing with only one none calibrated gage which in viloation with SAES-A-04 par. 7.1.5 a & c during a routine visit, PID inspector detect the two main baking ovens temperature exceeds the limits addressed in SAES-W-011, hence the contrctor QC was advised that he should pay more attension to this matter the workers are still handling the material with careless, irresponsible, and in rapid approche during lefting the spools and moving it from place to place and when prepare it to be mobilized to the yard, the contractor QC was informed and directed to push the labur more for better handling the materials PID request ENPPI/PETROJET to comply with SAES-L-350 & SAES-W011 regarding the spools storaging & flange covering in their yard, if this situation didnt rectified within 6 working days PID will issue NCR during valve testing, one valve failed in seat test (10", 150 lb, S. No. 93120)hence the contractor were adviced to send this valve for repair into aramco approved repair shop It was observed that while the project construction on the peak, there is no enough coverage from ENPPIs side regarding the QC personnel, the assigned welding inspector have went on leave w/o a replacement and they have only one inspector to cover all mechanical activities, hydrotesting, NDT, coating, welding, Tie-Ins...etc However this is a violation to sch. Q attachment VI and SATIP-W-011 requirements, SAPMT are requested to advise the contractor to rectify this matter reference to FRI logbook entry No. 1914 regarding two rejected Stainless Steel Pipes because of PMI test, PID have ask ENPPI to force Petroject to hire a 3rd party contractor to perform PMI test on stainless steel pipes that have the same heat numbers of 61009 & 58652 to validate their PMI readings done by their QC
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.4
1113
4/9/2009 2:07:46 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
7.1.5
1114
7/27/2009 7:57:44 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1115
6/16/2009 2:06:28 PM
SATIP-A-004-01
SAIC-A-2021
Mechanical
SAES
SAES-A-004
7.1.5
1116
9/15/2007 7:50:17 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1117
12/30/2007 11:02:39 AM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
1118
3/19/2008 8:36:27 AM
SATIP-L-108-01
SAIC-L-2042
Mechanical
ScheduleQ
Schedule Q
1.3
1119
8/27/2008 9:15:48 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
1120
12/30/2007 9:20:23 AM
SATIP-W-011-01
SAIC-L-2010
Mechanical
ScheduleQ
Schedule Q
1.3
1121
5/19/2008 1:35:07 PM
1122
6/26/2008 3:03:59 PM
It is observed that wrong flange rating has been welded on V-084-D0976 (Refrigerant Flash Drum) Nozzle # N4 ,the required FLANGE rating was 4" # 300 Sch 120 while the actual installed flange rating is # 150.This is violation of approved drawing No MISA-0814-004-V Rev 4. As per SAEP-351 Para 4.4 "Proper lubricant for bolts and nuts shall be used". Lubricant for bolts and nuts shall be Jet-Lube SS-30 or other acceptable lubricants listed in Table-SAEP-351-01 while contractor is not using approved lubricant, moreover this matter has been communicated several times to contractor but no action has been taken and contractor is continuing this activity .Contractor is notified that all stud bolts are tightened without approved lubricant are not acceptable De-ethanizer column Inspection has been performed and observed followings. 1) Three anchor bolts are removed and two anchor bolts thickness were reduced 10mm to 15 mm at lower base plate during flame cutting. 2) Due to clearance between the base plate holes diameter and the anchor bolts diameter, nine numbers anchor bolts are bonded with bottom side of compression ring base plate are under stress condition, 3) Flame cut locations are not ground smooth and twenty seven anchor bolts threads are damaged at lower and upper side of compression ring. 4) Coating has been damaged at compression ring on different locations. 5) Compression ring bottom plate is cut on two locations after installation of column. CSD concurrence is required for all design changes has been made against approved drawing, moreover prior to grouting of de-ethanizer column, rectification is required for under stress anchor bolts, repairs of damaged coating, smooth grinding of flame cut locations. During hydro testing 16 x 12 two reducing tees Material (ASTMA234 WPB) leaked due to crack for Line 16-S-5114-6CS9P-HC/16-S5117-6CS9P-HC. The leakage occurred 50 mm from intersection point between the branch outlet of reduced section and the main run, moreover the leakage occurred in same heat number. Hydro testing is rejected for loop no 62B, 62D. Contractor is advised to establish root cause of this failure and submit report to Saudi Aramco and moreover all reducing tees has been delivered against this heat number and welded or hydrostatically passed the test shall be examined per CSD recommendation. During hydro testing 16 x 12 two reducing tees Material (ASTMA234 WPB) leaked due to crack for Line 16-S-5114-6CS9P-HC/16-S5117-6CS9P-HC. The leakage occurred 50 mm from intersection point between the branch outlet of reduced section and the main run, moreover the leakage occurred in same heat number. Hydro testing is rejected for loop no 62B, 62D. Contractor is advised to establish root cause of this failure and submit report to Saudi Aramco and moreover all reducing tees has been delivered against this heat number and welded or hydrostatically passed the test shall be examined per CSD recommendation. The C2+Feed Surge 16 dia pipe line class 9CS9P 45 degree welded elbows UT Thickness reading has been done and found that 45 degree elbows WT is 17.6 mm while per approved drawings the required WT is 22.2 mm.The 45 degree elbows WT is 4.6 mm less which is violation to approved drawing.Contractor is instructed to measure WT of all welded elbows and submit UT thickness reports to Saudi Aramco review and acceptance. In fabrication shop, pipe spools were stored directly on concreate floor.This is violation of SAES-L-350 Para 7.1.Contractor is instructed do not put flange face side on concreate floor because flange face will be damaged due to this wrong practice..
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
Schedule Q
1.3
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAES
SAEP-351
4.4
1123
6/21/2008 11:48:01 AM
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.8.1
1124
8/14/2008 1:40:14 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
7.3.4
1125
8/14/2008 1:40:37 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
7.3.4
1126
1/6/2008 8:35:32 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
1.3
1127
1/28/2008 3:41:29 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.1
1128
3/23/2008 4:07:59 PM
Per SAES-L-310 Para 14.7.2 .A 6 mm weep hole shall be drilled for all dummy supports. The weep hole shall be located near the base plate for all vertical dummy supports, and near the run pipe at 6 oclock position for all horizontal dummy supports but several dummy supports weep hole has not been provided. Contractor is instructed to ensure the standard requirements for all dummy supports. It was observed that in feed surge area valves and piping spools were stored directly on grond.This violation to SAES-L-350 Para 7.1& 7.3.This violation has been repetitive since several months and contractor is not complying to Saudi Aramco Engineering Standards. As per SAES-L-105 Line class 1CS9P 1 and under Socket weld RF flanges to be used and moreover approved isometrics requires to use socket weld flanges while contractor is using threaded reducing flanges which is violation of SAES-L-105 and approved Isometrics drawings. Contractor is advised to replace threaded flanges with Socket weld RF flanges as required by isometrics and Saudi Aramco specifications. As per 01-SAMSS-035 Para 1.2 all API-5L pipes shall be manufactured to product spoecifecation level PSL-2 but contractor have procured pipes manufactured product specifecation level is PSL-1.This is violation to 01-SAMSS-035 and approved P.O.No 3123-400-01-58.To use manufactured product specifecation level PSL-1 pipes at project CSD concorence is required. Enppi has started welding acitivites in Fabrication Shop but welding Inspector has not been assigned to cover full time Welding work.This is incompliance to Schedule Q attachement VI Para 4G which clearly states that approved quality personnels shall be be avaliable on site 7days ahead of the acitivity start. The contractor has demobilezed QC Supervisor/Welding Inspector without prior information or approval form Saudi Aramco.This is violation of Schedule Q Para 5.9.5 5.10,5.11. during a routine site visit, one 30" welded joint was rejected due to a misalignment of 9 mm which is more than the allowed limit of 1.5 mm as per the approved WPS No. 13/07 which is a clear violation the SAESW-011. the contractor is advised to rectify this situation immediately noting that a previous recommendation from CSD (dated on March the 10th) that the maximum allowable misalignment in a joint (if there is an ovalness in the pipe or fitting) is 1/4 of the pipe thickness During a routine site visit it was observed that several pipe supports delivered to site which have a poor quality welds such as uneven caps, irregular shapes, and corners were not fully welded...etc the contractor was instructed to rectify all defected supports and raise RFI against these supports. It is observed on LTCS lines welding that welders are using E-1818 C1 3.25 mm dia electrode with weave bead techenique and also weaved bead width was more than three times diamater of electrode, while this matter was verbally discussed with Enppi/Petrojet QC personnels that 3.25 mm dia electrodes shall not be used because LTCS Welding procedures was qualified with 2.5 mm dia electrode and practically it is very dificult to meet the heatinput requirment by using the large dia mater electrodes with weave bead techenique.This is violation of approved WPS.Contractor is instructed that do not use 3.25 mm dia electrodes with weave bead techenique.The log book entry is reloged again in system because system showes that log book entry is closed while log book has not been closed. During Surveillance observed that one unqualified welder was doing tack welding on 1 dia line fillet joints. This is violation of SAES-W-011 Para 8.1 which clearly states that all welders, shall be qualified in accordance with the ASME SEC IX ,for all welding ,including tack ,temporary ,and repair welds.Contractor is instructed to cut all joints that tack welded by un qualified welder.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
14.7.2
1129
4/15/2008 9:40:48 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.1 and 7.3
1130
6/28/2008 11:11:08 AM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-105
1131
9/6/2007 4:50:19 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
other
01-SAMSS035
1.2
1132
7/25/2007 9:43:27 AM
SATIP-L-350-08
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
1133
2/12/2009 11:41:15 AM
SATIP-L-350-08
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.11
1134
8/23/2008 2:44:59 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.3
1135
3/31/2008 7:10:16 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1
1136
11/3/2007 9:40:58 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1137
11/12/2008 10:47:45 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
1138
1/29/2009 3:32:48 PM
1139
3/13/2008 2:31:42 PM
It is obsrved that Contractor is not issuing RFIs for welding acitiviets which is violation of SATIP-W-011-01 Item 3.6,3.8.Contractor is advised to issue RFI against welding acitivites as per requirment of SATIP-W-011-01. It is observed that Drawing Number VD-118962 Rev 0 30 Inch dia Stainless Steel Pipes weld no W3, W4, W13, W14, W15 has been welded with 3 to 4mm internal misalignment, CSD was consulted for this issue and as per their recommendations joints internal misalignment were measured again along with SAPMT representative and contractor QC Manager and due to internal misalignment these joints were rejected. Contractor was instructed to cut out these welds and moreover if Enppi have any technical solution which meets the CSD acceptable criteria for joint internal misalignment, these joints can be re welded. The following violations has been observed on completed welds for Drawing No VD-112650 and VD-112651 (SK# 1843 /1844) Moreover visual Inspection was performed and accepted by PTJ/Enppi QC and spools were released for coating. 1) Electrode weaving is done more then three times diameter of electrode which violates to approved WPS. 2) Careless workman ship and uneven weld profile observed, violation to SAES-W-011 Para 11.6. Contractor is instructed to rectify these welds prior to do the coating. the contractor is not sending any request or RFI for NDT (MT and RT) activities at site since long time ago which violates the requirement of SATIP W-011, this issue was discussed to SAPMT to make a the necessary corrective action to resolve this matter two gate valves ( 8", 300 lb, S. No. 93451 & 93449) were rejected because it was discovered that the seat failed to be in closed position due to a manufacturing error ( some excess metal in the path of the seat closing groove was not removed after casting of the valve which prevent the seat to be 100% closed) the contractor was recommended to contact PV company representative in kingdom to clarify this issue De-ethanizer column Inspection has been performed and observed followings 1) Three anchor bolts are removed and two anchor bolts thickness were reduced 10mm to 15 mm at lower base plate during flame cutting. 2) Due to clearance between the base plate holes diameter and the anchor bolts diameter, nine numbers anchor bolts are bonded with bottom side of compression ring base plate are under stress condition, 3) Flame cut locations are not ground smooth. 4)Twenty seven anchor bolts threads are damaged at lower side of compression ring. 5) Coating has been damaged at compression ring on different locations. The all design changes has been made against approved drawing, should be concur by CSD, moreover prior to grouting of de-ethanizer column, rectification is required for under stress anchor bolts, repairs of damaged coating, smooth grinding of flame cut locations. ist is observed that Drum # V84-D-974 is installed on foundation without perfroming material receiving inspection and issueing RFI per SATIP-D-001-01 item 2.2 and Schedule Q Attachement IV para 7.1. the contractor brought coating reports to be signed while PID didnt received RFI since mid of May 2008 and the coating activities were ongoing, which violates SATIP-H-100 and SAEP 1150 Despite internal NCR from ENPPI two weeks back, the newly painted pipes are still draged @ pipe rack, which cause damage of painting. It is observed that Internal FBE coated 12 dia pipes welding was in progress at 2G Horizental position and due to welding spatters/arc internal FBE coating has damaged.Advised contractor to prevent internal FBE coating damages of fire water system piping, perform welding at Flat position.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.7
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.3
1140
4/5/2008 5:24:17 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
Schedule Q
1.3
1141
5/6/2008 2:59:29 PM
SATIP-W-011-01
SAIC-W-2015
Mechanical
ScheduleQ
Schedule Q
1.7
1142
3/19/2008 10:52:51 AM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
1143
6/19/2008 3:41:02 PM
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.8.1
1144
12/25/2007 8:08:58 AM
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1145
7/27/2008 11:54:29 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
ScheduleQ
Schedule Q
1.7
1146
11/25/2007 3:40:54 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
1147
9/23/2007 2:42:04 PM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.5.2
1148
8/28/2008 2:13:10 PM
during a routine site visit, it was observed that a lot of spool flanges were directly laying on the ground which is a repeated violation and also a Saudi Aramco NCR was processed on SAP and closed earlier this month. this is the 5th 6th time PID detect this violation, now SAPMT are kindly requested to urge the contractor to rectify this standard violation and prevent reoccurrence The following valves were rejected before and sent to repair to the vendor. When it come back it retest again and discovered that it have leakage on the both seats by the same rate was rejected for before. And these valves are: 1- 12 CL 300 # RF Ball Split Body Type, TAG No 50-ZV-020. 2- 12 CL 300 # RF Ball Split Body Type, TAG No 32-ZV202. 3- 12 CL 300 # RF Ball Split Body Type, TAG No 42-ZV-202. 412 CL 300 # RF Ball Split Body Type, TAG No 52-ZV-202. It has been observed that after installation of Spiral Wounded Gasket, the contractor intent to performed painting by manual brush into the installed gasket at flanges which is violation to approval procedure PTJQCP-12 section 4 and SAES-L-109 Para. 11.3.1. Recommended corrective action: This is in related inspection to be performed on the gasket verification according to line class and bolt tightening as per SAIC-L-2014. Item A & B shall be inspected one at time accordingly: 1. A random bolts tightening and clarifications of gasket according to class and color code shall be inspected as per SAIC-L-2014. 2. with responds to violation on the gasket manual painting due to safety, shall be inspected, and if found there were still some gasket not replaced, the gasket shall be removed to quarantined area and shall be replaced with the approval one with no exception (applicable on class 300 and class 600). During a routine visit observed a broken gasket after installation in place. Ref. in between Loop 1A drawing VA-112842 Sht. 1/1 and Loop 7 drawing VA-112845 Sht. 2/2 Recommended corrective action: 1. The gasket shall be removed and replace with new one. 2. The contractor should advise PID upon rectification. It has been observed that Drawing Number VD-112650 Rev 0 (Line No 6-RL-5841-1CS9P N) One inch branch connection has been welded on 90 degree elbow, which violates to SAES-L-110 Para 12.3.which states that branch connection ,such as those for drain and vent connections, on tees elbows and reducers are not permitted. When not avoidable, the piping design should be reviewed and approved by the chairman of piping committee.Contractor is instructed to comply the standard requirments. It has been observed that on 30 dia blow down line, pipe supports are welded directly with pipe while pads are not provided. This is violation of SAES-L-310 Para 16.2.4 which states that Saddle-type supports with pads shall be provided for piping 30-inch NPS and larger.In case saddle pipe support cannot be installed, the line shall be analyzed for localized stresses. The analysis shall be submitted to the Piping Specialist of CSD for review and approval. Contractor is advised comply Saudi Aramco engineering standard requirement. During RTFI review manufacturing defects has been observed on Equal & Reducing tees for LT lines for material (ASTM-A350-LF2) of drawings No- -VD-118905 (FW19) ,VD 118802 (FW01) ,VD 118801 (FW13) ,VD 112284 (FW13) .Contractor has been advised to perform UT for defective Equal & Reducing tees from Saudi Aramco approved third part subcontractor. Moreover update for total numbers of tees procured against each heat number along with MTC copy for defective tees. Kindly Note UT activities shall be hold point for Project Inspection.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.1
1149
2/9/2009 6:21:59 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
1150
12/17/2008 5:26:55 PM
SATIP-L-350-02
SAIC-L-2014
Mechanical
SAES
SAES-L-109
11.3.1
1151
12/17/2008 5:32:14 PM
SATIP-L-350-02
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.1
1152
4/6/2008 5:51:17 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12.3
1153
6/3/2008 5:34:16 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
16.2.4
1154
6/5/2008 10:52:36 AM
SATIP-L-350-01
SAIC-L-2006
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
1155
9/23/2007 2:22:21 PM
Pipe spools stored directly on ground and careless spools handling has been observed during routine site visit at Petrojet fabrication and Enppi lay down yard .This is violation of SEAS-L-350 para. 7.1 & 8.1.Enppi welding inspector has already issued internal NCR for same issue but no action has been taken from Petrojet side. Contractor is advised to avoid any flanges face damages comply Saudi Aramco Engineering standard requirments. There are total 3 POs material (CS pipes, RTR pipes and Electrical pannel) received @ site but receiving inspection not yet perfromed by Contractor which is violation to 3123-SMCP-001 Para 6.7. It is observed that several pipes recived by contractor, are pitted and rusted on inside and outside.Advised contractor to ensure these pipes minimum design wall thickness by followings steps. -Segregate all rusted pipes. -Clean worst pitted pipes on inside and outside. -Measure pipes wall thickness for worst pitted pipes by UT thickness method. Saudi Aramco shall select the UT Thickness location. -Submit UT thickness report to Saudi Aramco review. During a routine visit to the lay down area found that the rejected pipe section of Rockwell insulation material is not removed from the site to quarantined area as agreement to avoid messing with during installation. This material should scrape out of site immediately. Moreover we find some of remaining material pages is not covered all the material to ensure dryness of the material. The contractor recommended to re-segregate it and remove any material indicates contact with moisture. As per SATIP-N-001-02, SAIC-N-2005 & SAES-N001, Section 3.2 which state (All materials are stored in a manner that prevents contamination by water, process chemicals or physical damage.) During routine visit to the site it is observed there is some weather proof damaged (Aluminum Cover) on the Deethanizer column on the second platform from the top please fix that damaged part and raise RFI for inspection. It is observed that Petrojet approved welding Inspectors are not performing the Joint fit up Inspections and moreover rejected Mechenical Inspector is performing the joint fit up Inspections.This is violation of Schedule Q attachment IV Para 2.1.Contractor is instructed, in future only approved welding inspectors shall perform joint fitup inspections. Construction phase sixty percent (60%) internal audit has not been scheduled and performed while (62.6%) construction progress completed .This is violation of Schedule Q Para 7.2.2 &7.2.6 as a minimum fully quality internal audit shall be carried out on fifteen percent (15%) and sixty percent (60%) of completion stage for design, procurement, and construction work phases. During Pneumatic testing Inspection of Loop -20 Blow Down 30 dia Line, observed that after release of test package from Saudi Aramco one Socket Weld was repaired for I 1CS9P line and no MT was done on this weld. This is violation of SAIC-A-2010 Item BI and moreover No QC Inspector has attended the test from Enppi side which is violation of SATIP A-004-002 Item 3.5.Contractor is advised to comply the Saudi Aramco requirements. During a routine visit to the site found that condensate compressors loop 79A is under rectifying actions (06 weld joints were ground off the capping and filling and recapped on the lines 6-SC-5283-1CS9p & 12-SC-5289-1CS9P) while this loop have been hydro tested and accepted.Contractor has been instructed to re do the hydro test again and moreover in future any modification shall not be done without prior information to Saudi Aramco.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.1 and 8.1
1156
5/8/2007 10:30:54 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
1.3
1157
8/12/2007 11:15:33 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
1.3
1158
12/2/2008 5:14:34 PM
SATIP-N-001-02
SAIC-N-2005
Mechanical
SAES
SAES-N-001
3.2
1159
2/3/2009 2:22:25 PM
SATIP-N-001-02
SAIC-N-2010
Mechanical
SAES
SAES-N-001
8.1.1
1160
10/2/2007 9:27:19 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
1161
4/1/2008 5:29:27 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.2.2 and 7.2.6
1162
10/15/2008 3:41:05 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
1163
11/25/2008 6:33:36 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18.5
1164
12/31/2007 9:13:40 AM
during a routine check on daily welding report and electrodes issuance and return log, it was observed that one welder have welded two joints while the issuance report didnt shown that he had electrodes issued to him, the QC was advised that he should exert more effort on consumables controll During a routine inspection it has been observed that some of electrode for SMAW welding is not stored in portable ovens continuously at 65C.This is a violation of SAES-W-011, 6.1 which states (The exposure may be extended to 8 hours if the electrodes are continuously stored in a portable electrode oven heated to 65C minimum.). The electrode was just warmed so we can handle it which means it is not stored continuously at 65C. It is observed on LTCS lines welding that welders are using E-1818 C1 3.25 mm dia electrode with weave bead techenique and also weaved bead width was more than three times diamater of electrode, while this matter was verbally discussed with Enppi/Petrojet QC personnels that 3.25 mm dia electrodes shall not be used because LTCS Welding procedures was qualified with 2.5 mm dia electrode and practically it is very dificult to meet the heatinput requirment by using the large dia mater electrodes with weave bead techenique.This is violation of approved WPS.Contractor is instructed that do not use 3.25 mm dia electrodes with weave bead techenique. It is observed on LTCS lines welding that welders are using E-8018 C1 3.25 mm dia electrode with weave bead techenique and also weaved bead width was more than three times diamater of electrode, while this matter was verbally discussed with Enppi/Petrojet QC personnels that 3.25 mm dia electrodes shall not be used because LTCS Welding procedures was qualified with 2.5 mm dia electrode and practically it is very dificult to meet the heatinput requirment by using the large dia mater electrodes with weave bead techenique.This is violation of approved WPS.Contractor is instructed that do not use 3.25 mm dia electrodes with weave bead techenique. The submitted reports from last six weeks shown that welds rejection rate is 12.6% on joint basis .The high welds rejection rate matter was discussed with Enppi/Petrojet management and advised to take serious steps to reduce the welds rejection rate but untill repair rejection has not been reduced upto acceptable limits.Project inspection has focussed the high welds rejection rate and monitored all techenical aspects but in our openion Petrojet welders workmaship is quastionable.As per SAES-W-011 Para 17.5.2 requirments,contractor is instructed to perform 10% addationl RT for completed production welds by excluding the all tracer welds,moreover if welds rejection rate will not reduced below 5% acceptable limits project inspection may instruct contractor for addational RT.Please note that addational 10% welds for RT shall be selected by project inspection. During Surveillance observed that 2 dia line five butt joints were welded and there is no identification was found such as weld number. Drawing number which is violation of SAES-W-011 Para 16.1 and moreover no fit up inspection was performed from PTJ/Enppi for these joints, which is violation of SATIP-W-011-01 Item 3.6. Contractor is instructed to perform 100% RT for these five joint or cut and re -weld these joints. Contractor has commenced welding activities for low temp lines without CSD and Project Inspection approval .This is violation of SAESW-011 Para 7.1.5.Contractor is instructed not to precede welding work for low temp lines until CSD/Project Inspection shall approve low tem lines WPS.Moreover all low temp lines welding work has been done is not accptable untill required procedure qualifecation mechenical tests destractive testing results shall accepted by CSD for these Welding Procedures.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1165
6/14/2008 2:07:48 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1166
10/24/2007 5:07:59 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.3
1167
10/24/2007 5:08:46 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.3
1168
10/24/2007 6:25:18 PM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
17.5.2
1169
11/12/2008 10:52:16 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1
1170
9/12/2007 10:27:23 AM
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
7.1.5
1171
9/12/2007 11:05:20 AM
Welders Job Cleareance Cards (JCC) has not been submitted to Project Inspection for low temp meterial welding work while welding work has commenced.This is violation to SAEP-1150 Para A.10.3.2.Contractor is instructed for issuance of JCC submitt welders procedure qualifecation record to project Inspection. It is observed that during production welding, contractor is not recording the heat input for LTCS piping welds for each weld.This is violation of SAES-W-011 Para 19.4 which clearly states that heat input (HI) of each production weld must be calculated, if notch-toughness tests are specified, and then confirmed not to exceed the heat input limits listed in the welding procedure specifications.Advised contractor to comply the Saudi Aramco engineering Standard requirments. During routine site visit observed that Welder stamped No-R-09&R-028 was doing welding on LTCS lines while these welders JCC were revoked due to poor workmanship.This is violation of Saudi Aramco Engeering Standards& Saudi Aramco Engineering Procedures.Contractor is instructed to perform 100% RT for all production welds welded by these two welders and submitt RT reports copy to Project Inspection for information and record. Welder Stamp No C-08 & C-67 first three production welds has been inspected and visually rejected these joint due to poor workman ship and welding defects.JCC has been revoked and instructed contractor to send these two welders for two week training session and stop these welders for any production welding. the contractor have Proceeds for the next activity of valve hydrotesting W/O a prior acceptance from PID inspector for the material receiving inspection (RFI No. 110 valve receiving inspection) for the 8" and 4" ball valves (MTC is not availble) which is a clear violation as per SAEP1150 The gauges used during hydrotesting for Hot Tap Tie-In V83-013 stickers was not meeting to the requirments of SAES-A-004 Para 7.1.5.The gauges should have a range such that the test pressure is within 30% to 80% but used gauges full range was morethen 200%.Advised contractor to arrange proper range gauges for future hydrotesting. Observed that Potable electrode Oven was not heated 65 degree c while contractor was transfering the elctrodes in portable electrode oven in cold condation.Contracor was advised to heat portale electrode oven upto required level tempracture per requirment of SAES-W-011 6.1 and then transfer electrode in portable oven for use. Calibration documents were reviewed for welding machines,electrode baking oven and found that no calibration certificates avaliable with contractor for newly purchased welding machines and moreover electrode baking oven was calibrated from anapproved aramco agency.Contractor to advise provide welding machines calibration certeficates copy and calibrate the electrode baking oven from aramco approved agency. It was observed that AHC does not have a coating inspector on the site while they doing a painting activities. This is a violation of Schedule Q and SAEP 1150 Para. 8.14.5.. The Welding activity on bearing palte for Boiler stack has been started without avaiability of Welding QC, which violates Schedule Q. the contractor welding activities is ongoing at site without having a welding inspector at site which is a violation to schedule Q attachment 6 and to article 5.10, SAPMT is notified that the contractor must provide a welding inspector at site otherwise 100% RT is required from now on.
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAEP
SAEP-1150
10.3.2
1172
10/2/2007 9:38:08 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.4
1173
10/4/2007 12:11:19 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
1174
7/29/2007 2:46:07 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1175
5/10/2007 8:16:13 AM
V83-004
SATIP-L-108-01
SAIC-L-2040
Mechanical
SAES
SAES-L-108
8.3
1176
4/18/2007 11:13:53 AM
V83-013
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
7.1.5
1177
6/12/2007 11:49:32 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1178
3/1/2007 1:25:51 PM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
6.1
SAES-W-011
19.2
1179
2/5/2009 12:07:46 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-1150
8.14.5
Schedule Q
5.1
1180
12/30/2007 2:58:53 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAEP
SAEP-1150
8.14.5
Schedule Q
5.1
1181
10/29/2008 1:15:43 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAEP
SAEP-1150
8.14.5
Schedule Q
5.1
1182
11/22/2008 6:23:17 PM
Contractor have started the Welding for Steam line piping without approved WPS .This is violation of SAES-W-011 Para 7.1.5 which clearly states that Welding shall not commence until the welding package has been approved for application by Saudi Aramco Inspector and returned to the fabricator. Any welding prior to the approval of the welding package is subject to rejection at the sole option of Saudi Aramco Inspector Any rework required as a result of this rejection shall be at the fabricators expense The boiler stack one bracket damaged during transportation and crack is visable from both sides of plate..Vender to submit repair procedure for saudi aramco review and approval prior to any rectifecation of damaged bracket. Location: AKM - 42 On Jan. 17, 2010, inspection found out the contractors coating QC inspector (Michael Matavas) has been falsifying pipes surface profile (Testex) reading,. This is a violation of Sch. Q Para. 1.3 & 1.4 & SAIC-H-2006 All of these investigations were done with the presence of SAPMT. Inspection requires: Contractors QC manager to conduct a root cause for this violation Contractors Shall proposed a corrective action to solve this violation Contractors QC manager to provide a preventative action to assure the nonoccurrence of similar violations in the future CSD approved procedure for FBE coating for girth welds of piping below 4" has not been submitted for review. It has been informed to Bonnati in weekly qc meetings and the action is not yet taken.The CSD approved procedure is required prior to start of FBE coating for girth welds of pipes. Bonnati is requested take appropriate action on the issue to avoid re-work at a later stage. According to the requirement stated in para 4 of schedule Q ,Contractors top management shall review the project specific quality system every six months to ensure that the system is suitable ,adequate and effective. Evidence of such review is not found with the contractor since start of the project, Nov 2007. Contractor shall make root cause analysis and corrective actions for the violation. It was observed that various pipe spools do not have both end protection/cover(1 no. 374-24"-P-4025-06,BB-205306-001; 1 no.34712"-P-4022-03,BB-205307-001;1 no.374-24"-P-4025-02,BB-24"-P4025-02),1 no. check valve 12"x 600# & 2 nos. reducer 90 elbow 34712"-P-4022-07,BB-205307-001. This violates SAES-L-350 ITEM 7.4 During site survey at UGOSP-7, Bolt tightening was running for spool 418-20"-SW-9114-08 class 1500 and tightening pressure was 8800 psig. While there was no RFI issue so QC inspector no available. During site survey at UGOSP-1 observe that no RFI issue so No QC inspector available during installation valve and spool.which violattion to Sch. Q. Valve has been Installing without send RFI then Contractor Inspector did not do inspection as per SAIC-L-2043; Valve Installation Inspection and Valve Stroking. It was observed that pipe spools, 2" globe valves(2 nos.) are directly laying on the ground & without end covers for the spools.This violates SAES-L-350 Item 7. Violation-after-the fact(No insulating gaskets for dissimilar metals flange joints-SS valves & piping)in accordance with SAIC-L-2014(E4 gasket verification) & SAES-L-109 para. 12.6 insulating gasket 1.It has been observed that external coating of the modified pressure sewer line spools is damaged near to base metal due to mishandling of the coated spools violating the requirement of SAES-H-200,5.1. 2.Coating of the pipe spools including flange edge in trasported truck from shop to GOSP-7 has been damaged due to insufficent padding requirements violating the requirements of SAES-H-200,5.2.4.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.5
Schedule Q
1.3
1183
5/8/2008 12:43:34 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1184
1/25/2010 1:43:50 PM
SATIP-H-100-01
SAIC-H-2006
Mechanical
ScheduleQ
Schedule Q
1.3 and 1.4
1185
1/9/2010 10:46:06 AM
SATIP-H-002-08
SAIC-H-2057
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
1186
2/1/2010 2:59:59 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
1187
10/18/2009 8:29:56 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
7.4
1188
8/31/2009 2:00:02 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
1.3
1189
8/31/2009 1:50:51 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
ScheduleQ
Schedule Q
1.3
1190
9/27/2009 1:01:41 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
ScheduleQ
Schedule Q
1.3
1191
10/15/2009 3:45:27 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
1192
10/15/2009 10:36:34 AM
SATIP-L-350-02
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.6
1193
3/9/2010 3:37:40 PM
418
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
1194 1195 1196
5/10/2009 1:23:21 PM 7/18/2009 2:46:27 PM 7/18/2009 3:24:41 PM
LBE # 448: Painting should not be made prior to Hydrotesting has been completed unless prior approval from Inspection Agency is obtained as per para. 21.2 of SAES-L-350. pipe spools are stored directly on the ground and without end covers. this violates SAES-L-350 item-7. The contractor did not provide Insulating dissimilar metal flanged joints (between SS valve and DC flange piping) as per SAIC-L-2014 and SAES-L-109 Para. 12.6 Insulating Gaskets. 1)During the reviewing of welding consumables storing and handling documents,it has been observed that no documents is maintaning about the elctrode storing in storing oven violating the requirements of SAES-W-11,6.2& Table 1.and no record is maintaning for the electrode return by the welders and there furthur storing activities. 2)Bonatti store have no separate electorde baking oven in case if any electorde baking requirement come up. Violation-after-the-fact is issued to the contractor for failure to address the following violations noted during the inspection of hydrostatic testing activity at UGOSP-8. (1) There was no mechanical inspector present at the site during the scheduled time of activity . Violation was raised in reference to Schedule Q Para. 1.4, SAES-L-350 and SAES-A004 Para. 5.6.1 / Para. 7.1.1 (2) There was no duly approved test package available the site (3) Piping internal cleanliness or flushing inspection was not raised to PID inspector
Violation-After The Fact Violation-After The Fact Violation-After The Fact
SATIP-A-004-02 SATIP-L-350-01 SATIP-L-350-02
SAIC-A-2015 SAIC-L-2012 SAIC-L-2014
SAES SAES SAES
SAES-L-150 SAES-L-350 SAES-L-109
7.3 7 12.6
SAES-L-350
21.2
1197
2/1/2010 8:06:22 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1198
9/30/2009 2:26:11 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
5.1
1199 1200
10/7/2009 9:10:00 AM
SATIP-A-004-02 SATIP-L-350-01
SAIC-A-2001 SAIC-L-2017
SAES ScheduleQ
SAES-A-004 Schedule Q
5.6.1 1.7
Schedule Q
A VI Para 2.21
1201
RFI #2033 was being REJECTED due to said Hydrotest Package#TPG1-G8-24-03 is still under review with SGPIU. Re-issue an RFI after receiving the approved review response together with the package. It has been noted from the weekly welding reporth that the rejection rate is increasing sharply this week please trece the the welders and findout the higher repair the report it to UPIU. LBE # 66 Oct. 12, 2008 RFI # 281(Mech) Hyde. Test of fire waterline (RTR) partial test at UGOSP-8. Test personnel are not safety trained/ experienced to doing the test as per SAES-A-004 par. 5.1 & SAIC-A2011 item # A17. A focus assessment has been conducted to verify the performance of Quality activities. No evidence is found on the approval for work procedures; socket Joint Gap control, Field Engineering change control, Coating and, Gasket Installation and Bolt Torque. It is required to obtain review/approval of Saudi Aramco for the work procedures of special processes prior to 30 days start of work as per Para 2, Attachment IV, Schedule Q. Contractor is required to provide the root cause for the violation and take to necessary action to comply with the requirement. SPIU performed STG document review and spot checking of tools or measuring and testing devices to be used for controlling quality. It was found out that the calibration of the holiday detector is overdue (it was already nine months). This is not acceptable as per the quality requirements of schedule "Q" attachment IV. Please advice contractor to send this equipments for re-calibration. Thank you. During the hydro-testing of 30" ball valve at STG lay-down yard Sabkah-40. SPIU observed that only one (1) gauge using that during the pressure testing. This is in a violation of SAES-A-004 sec.7 para.7.1.5 (c)that states a minimum of two (2) pressure gaguges are required for the test system. One pressure gauge shall be on the test manifold and the other on the test system. Their accuracy shall be within 5% of one another. Please advice STG contractor to comply this requirements. Thank you.
SATIP-A-004-02
SAIC-A-2001
Mechanical
SAES
SAES-A-004
5.6.1
Schedule Q
A VI Para 2.21
1202
10/11/2008 3:28:54 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
7.5.3
1203
10/22/2008 12:35:28 PM
SATIP-A-004-02
SAIC-A-2011
Mechanical
SAES
SAES-A-004
5.1
1204
2/14/2010 12:35:34 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
A IV Para 2
1205
8/26/2008 5:58:10 PM
SATIP-L-350-01
SAIC-L-2031
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1206
9/11/2008 7:50:15 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
1207
11/16/2008 7:43:01 AM
1208
10/9/2007 12:05:27 PM
Routine visit at site to verify and check the line prior to hydro-testing and found out some irregularities hereunder: 1) No relief valves calibrated yet. 2) No pressure gauges installed on the designated locations. 3) No documentations & verifications of equipments such as SAICs/SATIPs. 4) The water on the line not stabilized yet. Noticed that the line is not ready for the hydro-testing due to these findings. Please SAPMT/STG to rectify these findings accordingly prior to hydro-testing. Thanks. Performed Focused Assessment - Verification and inspection of RT films and Isotope Radiation Monitoring Devices. Noticed that the Isotope Monitoring Devices observed is very weak because the activity in curies is only 13.1 and this is not sufficient. SPIU recommend to provide sufficient or appropriate source as required. Please advised VETCO accordingly. Thanks. Performed Focused Assessment - Verified and checked that the VETCO co. utilizing portable cabin at Sabkah-40 with NDE technicians/crew, NDE/NDT procedures i.e. RT, MT, PT and equipments with approval and initiated by Aramco. But noticed that the crew & source is only one (1)and available at site. Therefore SPIU recommends VETCO must have two (2)crews & source if the welding activities are fully blast to avoid RT backlog to monitor immediately the welders performances & control weld repair rate (WRR). Please advised them accordingly as required. During my routine visit and inspection at site as well as documents review, it was found out that the STG has twenty joints RT backlog and this is not acceptable by SPIU. So please advice STG QA/QC personnel to eliminate this backlog ASAP. Thank you. During my routine visit at site sabkah-40 to monitor and check the ongoing fabrication and welding of spools.It was found out that the baking oven with contain a large number E8018 welding Electrodes had been switched off as well as the numerous welding quivers were also found un-plugged. This is violation of SAES-W-012 Table-1 that states all low hydrogen electrodes must be dry to perform welding properly. Unopened can shall hermitically sealed container and provide an excellent protection or in good storage conditions, opened cans shoul be stored in a cabinet @ 250 to 300 degree fahrenheit. For future reference and stict compliance such as conditioning, reconditioning, drying, re-drying esposure and storage of low hydrogen electrodes shall be refer to SAES-W-012 Table-1. Please advice Contractor to comply. Thanks. STG Failed to maintain WRR 5% maximum as per SAEP-1150 para.A10.5. RT backlog should be radiograph immediately to monitor the rejection rate properly of each welder. Please advise STG accordingly. Thanks. During my routine visit at STG warehouse at sabkah-40 lay-down yard. It was observed that there was no quality documentation or no welding consumables issuance records. This violates of SAES-W-012 table-1 and para.6.2. Please advice QA/QC welding supervisor/inspector to sort this issue out and SPIU recommend to use SATR-W-2010 form as required. Thank you. It has been observed that the QC personnel assigned to this project could not perform their functions to Monitor, to Check & Inspect the Equipment item which the contractor has been doing from day to day because of No Car Vehicle was issued to their QC Inspectors to conduct the required activities. Besides the Contstruction management side of the contractor will not probably inform their respective QC for the specific construction activities just to keep them away or Hide from the issue of what they are doing at site that might contradict with the ARAMCO standards. This is Violation against SCHEDULE "Q" section 5.1 of ARAMCO.
SATIP-A-004-02
SAIC-A-2011
Mechanical
SAES
SAES-A-004
7.1.5 & 5.5.1
Schedule Q
1.3
SATIP-NDE-RT-01
SAIC-RT-2004
Mechanical
ScheduleQ
Schedule Q
1.3
1209
10/9/2007 12:16:56 PM
SATIP-NDE-RT-01
SAIC-RT-2007
Mechanical
ScheduleQ
Schedule Q
5.1
1210
8/26/2008 5:34:50 PM
SATIP-NDE-RT-01
SAIC-RT-2007
Mechanical
ScheduleQ
Schedule Q
5.1
1211
11/2/2008 4:50:34 PM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
A1
1212
1/13/2008 2:08:37 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1150
10.5
1213
9/6/2008 5:43:02 PM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.2
1214
4/6/2009 2:55:22 PM
SATIP-L-450-03
SAIC-L-2113
Mechanical
ScheduleQ
Schedule Q
5.1
1215
1/30/2008 8:56:54 AM
At that time of Holiday Inspection it is observed that, the inspection is carried out at two locations with one STG Coating Inspector. STG is advised to increase the coating inspector. The Record is not available for Coating repairs like Type, Numbers & Location. It is to be recorded as per the requirement of SAES-H-200 Para 7.5.1, SAIC-H-2016. The same is to be recorded in SATR-H-2008. It is observed that, the Coating repairs attended were not inspected again. The same is required for 100% holiday inspection and record. PMT / STG to take action and Implement. During the Site visit on 27 April 2008 SPIU observed that, In Km 41 the Coating Activity is going on without Coating Inspector Presence. The same as discussed in the Weekly quality meeting on 29 April 2008 and STG agreed to take action about the same. But the same as absorbed on 01 May 2008 the Coating activity is going on at KM 42 without any JCC. Hence STG is advised through PMT to take immediate action. And also observed that the Blasting Operators and the Coating Applicators (Except One Applicator Mr. Mabra Thaba ID No. I 2237241845) are not having the qualifications (JCC Card) as per Aramco Requirement SAEP 316. It is observed that, The Temperature Tie-In Welding is going on in the Pipeline Cleaned Sections without doing Gauging. (The Joint Nos. are KM00/FW26T, KM02/FW34T, KM04/FW10T & KM05/FW37T etc.,) As per Aramco Standard / STG working Procedures, the Pipeline Cleaned Sections were Gauging Plate inspection is required before Temperature Tie-in. Please refer Saudi Aramco Standards SAES-L-450 Para 450 and STG Cleaning Procedure S1PCE-STG-PR-061 Rev A Para 5 for more details. Hence STG is advised through PMT to take corrective action immediately. During the Site Visit SPIU is observed that, in the Scraper Launcher / Receiver (GOSP 4) Area the Anchor Flange was made a fit up with main Pipeline for welding. The Sleeve length of Anchor is found 30 long. As per drawing no. BA-213540, the length of sleeve should be 6000 mm and the sleeve should be visible 500mm on either side after Concreting. Also please refer SAES-L-450 Para 7 Anchor Attachments for some additional information. Hence STG / PMT are requested to clarify the same before start of progress. As per SAES-L-450, Para 11.7 & SAIC-L-2132 each Pipe String Shall be Gauged by passing an internal gauging plate with a diameter not less than 93% of the Inside Diameter. But it is observed that no Gauging activity is going on in the field. PMT / STG to take action and implementation immediately. STG submitted the Procedure for Internal Pipeline Cleaning (SIPCESTG-PR-022) to Saudi Aramco and the same is Reviewed and Accepted by SEPD PMT / PID and informed the same to the Contractor. During the site visit SPIU observed that, the Contractor is not followed the Procedure requirement. After so many discussions had with the Contractor regarding the Cleaning procedures since they are not complying the Procedure Requirements. Hence STG is advised through PMT to follow the Saudi Aramco Standard SAES-L-450 Para 11 for Pipeline Stringing pre cleaning (For String Length, Cleaning and internal Gauging etc.,) before implementing the same. During the site visit SPIU observed that at KM 66 (Manual welding) & KM 159 (CRC Automatic Welding) the Contractor STG is not following the Cleaning procedure as per Saudi Aramco Standard SAES-L-450 Para 11 Requirement. And also they are not following the Strings Cleaning before welding of Temperature Tie-ins. After so many discussions had with the Contractor regarding the Cleaning procedures since they are not complying the Procedure Requirements. Hence PMT is to take necessary action of the same.
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
7.5.1
Schedule Q
5.1
1216
5/2/2008 9:30:12 AM
SATIP-H-100-01
SAIC-H-2010
Mechanical
ScheduleQ
Schedule Q
5.1
1217
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAEP
SAEP-316
3.1
1218
6/1/2008 8:43:52 AM
SATIP-L-450-04
SAIC-L-2017
Mechanical
SAES
SAES-L-450
11.7
1219
5/8/2008 11:40:26 AM
SATIP-L-450-04
SAIC-L-2130
Mechanical
ScheduleQ
Schedule Q
1.3
1220
1/30/2008 8:32:38 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.7
1221
2/27/2008 2:10:08 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11
1222
4/6/2008 3:36:01 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11
1223
5/3/2008 4:02:31 PM
The Pipeline Section KM05/FW37 KM06/FW05, for lowering RFI is raised on today (03 May 2008) for Tomorrow Inspection (04 May 2008). But during the Site visit today it is observed that the same section lowering activity is going on without any information and also without STG Mechanical Inspector. The STG Mechanical Inspector was reached during middle of the Lowering. And also observed that, the section was lowered using 2 Side booms with Belt. This is violating the STG Approved Procedure No. S1PCE-STG-P-012 Rev 01 Dated 16 Jan, 2008 Para 7.1 & 7.1.1. Hence STG is advised through PMT to take corrective Action. The Surge Relief skid (structural Frame) has been set for erection and found not in a proper level elevation against the Concrete foundation thus this poor quality of foundation preparation and SKID Fabrication was contradicting to SAIC-M-1024 & SAIC-M-1025 for Civil works, and PIP STS05130 Section 6.7.4 of ARAMCO standard requirements. Ref: Hydro Testing of Relief Header RFI # 3309 STG has raised RFIs without having prior approval from NGPIU for Hydro Test Package. This is in violation as per the requirements of Sch. Q Attach. IV Sec 2.1 Contractor is advised, through SAPMT, strictly adhere to the Project Quality Requirements. Follow-up for the previous log book entry RFI no.14 Contractor reference no.016 and this entry has been closed without any action from the SAPMT due to some technical problems (QMIS problems on the system). This is regarding the receiving of 4", 6" & 16" bare pipes received @ sabkah-40 without proper identifications or traceability. Please SAPMT to take a course of action and advised STG to contact the material coordinator to provide us a copy of CMTRs as required prior for SPIU review and acceptance. Thanks. SPIU Conducted the Surveillance Visit at Dark Room (Sabka 40) on 04 April 2008 for Verification of Radiographer / Technician Qualifications. During the SPIU Visit and observed that, there are some RT films (Km 55, 56 & 59 Taken by Internal crawler) available on their Table after interpretation of Vetco RTFI and found mostly as Repair. The same is not yet submitted to Saudi Aramco RTFI for Assessment. Hence STG / Vetco required to clarify the same and also submit the below films to SA RTFI for Assessment. The Joints are : KM 55 Repair : FW 27, 28, 17, 12, 31, 33, 18, 15, 19, 39, 34, 32, 38, 42, 44, 43, 40 Acc : FW 36 & 18 No Result : FW 30, 35, 03 & 04 KM 56 Repair : FW 08 Acc : FW 05 No Result : FW 02, 09 & 06 KM 59 No Result : FW 29 SPIU advised to STG / Vetco, whatever Radiography (Internal & External Crawler) films taking in the Saudi Aramco Project should be reported to Saudi Aramco for Assessment and should not repeat the same in future. During the document review of STG, it is observed that the Management Review Meeting is not conducted and SPIU is not receiving any document /any information related to the same. As per Sch Q Para 4.1 that states In accordance with ISO 9001, CONTRACTORs top management shall review the project specific Quality System every six months to ensure that the system is suitable, adequate and effective (Also Please refer Para 7.2 of Sch Q for more details). Hence STG is advised through PMT to take immediate action. Stroytransgaz yet to hire replacement for the rejected Quality assurance Manager. This is a violation to Schedule Q general requirement paragraph 5.3. PMT to advice the contractor to comply with schedule Q requirments as well as Saudi Aramco standards. Stroytransgaz yet to hire replacement for the rejected Quality assurance Manager. This is a violation to Schedule Q general requirement paragraph 5.3. This is repeated violation with reference to survielance entery # 8 dated 8/15/2007.
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
1.7
1224
4/6/2009 5:29:29 PM
SATIP-M-001-01
SAIC-M-1024
Mechanical
other
PIPSTS05130
6.7.4
1225
5/16/2009 4:17:20 PM
SATIP-A-004-02
SAIC-A-2001
Mechanical
ScheduleQ
Schedule Q
2.1
1226
2/6/2008 4:51:12 PM
SATIP-L-350-01
SAIC-L-2205
Mechanical
SAES
SAES-A-206
14.2.9
Schedule Q
A IV Para 3.3
1227
4/14/2008 9:40:14 AM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.3
1228
5/5/2008 2:13:25 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
4.1
1229
8/15/2007 5:20:09 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.3
1230
9/12/2007 1:29:05 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.3
1231
3/20/2008 5:00:43 PM
SPIU Conducted the Focus Assessment for Radiography Selection of welded joints. Found that STG not having the copy of RT request and they are not ready to submit to SPIU for review. STG is advised through PMT to submit the Same for review and Approval. And STG is advised to Mark the joints Selected for Radiography in the SATR 2007 for better information. SPIU conducted the document review for NDT Requirement in following section and found that Radiography coverage is not meeting the requirement of Saudi Aramco Standard SAES-W-012. The sections are a). KM00/FW27 KM02/FW33 b). KM02/FW35 KM04/FW09. c) KM04/FW11 KM05/FW36 The above sections were already lowered. Hence STG is advised to take the Balance Radiography before backfilling the same. SPIU conducted the document review for NDT Requirement in Lowered sections and found the following as of 17 Feb 2008. There are 14 sections were lowered. Out of 14 sections 2 sections found not meeting the NDT (Radiography) requirement of the Saudi Aramco Standard SAES-W-012. The sections are a). KM18FW40 to KM19FW26 & b). KM19FW26 to KM21FW36. The two sections were lowered and buried without fulfilling the requirement of SAES-W-012. SPIU has conducted a Focused Assessment Dated 17 Feb 2008 related to NDT requirements as per SAES-W-012.Consequently, we found that the contractor didnt perform NDT (Radiography) requirements as follows: 1.Para 16.6.1.1 for Onshore Pipeline the radiography is required a minimum of 10% of the welds made each day. 2.An Increase to 50% RAD is required when the repair rate exceeds 30%. This increase shall be required for both the same days (i.e., additional joints must be radiographed to increase to RAD for that day to 50%) and the next days production. 3.An Increase to 100% RAD is required when the repair rate exceeds 50%. This increase shall be required for both the days (i.e., all joints for that day must be radiographed) and the next days production Based on the above requirement SPIU found that, the backlog for Radiography is approximately 503 Joints (as of 13 Feb 2008) and contractor to take immediate action for covering the Backlog. SPIU will submit detail status to PMT SPIU is observed that, the NDT backlog of CRC Automated Welding is become very high (KM 188 Onwards) because of the AUT Machine Breakdown. And also found that the welding is still under progress. As per SAES-W-012 Para 16.3.3 When a Computerized AUT is used, this is to insure the number of joints completed prior to inspection is as small as possible so that repetitive defects do not occur for a large number of consecutive welds. For normal jobs, it is expected that the UT system will be within approximately 10 joints of the last completed weld. Hence STG is advised through PMT to take necessary action. The contractor STG has welded several joints using external clamp in the interface with GOSP-4. This is clear violation to SAES-W-012 paragraph 10.4.2. Contractor is requested to adhere to Saudi Aramco standards and requirements. It is observed that at KM 30 the Free Tie-In Welding is going on without any Welding Inspectors Supervision. (The Joints Numbers KM30 FW34, FW35 & FW36 are for your ready reference.) It is deviating as per Schedule Q Para 1.3 and STG advised to keep the Welding Inspectors at the Welding Progression sites.
SATIP-W-012-01
SAIC-W-2054
Mechanical
ScheduleQ
Schedule Q
1.5
1232
3/20/2008 5:26:01 PM
SATIP-W-012-01
SAIC-W-2054
Mechanical
ScheduleQ
Schedule Q
1.3
1233
2/18/2008 8:00:23 AM
SATIP-W-012-01
SAIC-W-2051
Mechanical
ScheduleQ
Schedule Q
1.3
1234
2/18/2008 9:50:38 AM
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
16.7
1235
5/6/2008 5:15:49 PM
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAES
SAES-W-012
16.3.3
1236
12/3/2007 2:53:09 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.4.2
1237
2/7/2008 12:51:00 PM
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
1.3
1238
3/8/2008 7:43:57 AM
The CRC Automated welding is going on without any Information to PID and there is no RFI raised till date for doing the Inspection activities. If any new activity is started, the first three incidents of each Inspection or testing activity listed require 100 % participation by Saudi Aramco Site Inspection Personnel. But till that date SAPID is not received any RFI or any Information from STG. This is violating the Saudi Aramco Standard SAES 1150 and the STG Project Quality Plan (S1PCE-STG-PL-001). STG / PMT to take immediate action on this type of behavioral situation. verified and checked that the production welds repair rates and welders performances weekly for four (4) welders, welder Symbol Stamp no. CSR, GCA, KPL and SAE violated as per SAEP-1150 para.A.10.5. That states the target for maximum project repair rate (calculated on joint basis) should normally not exceed 5%. Those welders were having higher repair rates should stoped welding and more training are required prior for re-qualifications. Please advised STG Contractor to comply the requirements. Thanks. Initial insulation installation work done by Contractor on the 12" & 10" air lines at specified locations on RFI 29288 confirmed that the insulating/finishing cement does not conform to ASTM C449 - hence violation to SAES-N-001/PIP INSH1000 requirements. during my routine site to the fabrication shop contractor has started the hyrotest of package number.HTP-SR-0021,0022,,0023,0024 AND 0025. Found there is no record of test manifold pressure test report.it violates SAES-A-004.Para5.5.4. During inspection of storage, handling & preservation of equipment; SPIU have found that manufacturer recommended preservation procedures are not available for most of equipment. Contractor has to submit the manufacturer recommended procedures for preservation to meet the schedule Q requirement for all the equipment which are required to be preserved. Refer our previous surveillance log book entry number 18556 & 18273. It has noted & observed plenty of equipments of all disciplines have arrived and installed at site. But preservation requirement as per the Schedule Q has not been implemented for individual items. Contractor also failed to do the preservation as per his schedule declared. Contractor has not initiated RFIs for preservation as per the applicable SATIP for the major equipment. Refer SPIU response No. ID/PID/SPIU/LOG No. 1435/08 dtd May 20, 2008 about SPIU comments for equipment preservation. Equipment tag number B22-D-0031 had nitrogen filled before installation. But after installation it was found that nitrogen was not there (Positive pressure). Refer drawing number 4266-M03-01 Rev 1 General notes #19 says to preserve the internals. Contractor is advised to follow the requirement of drawing. SPIU would like to inform the contractor that the installation of the Water Oil Separator (WOSEP) B22-D-0006A will be on hold due to its damages on the way coming to Shaybah, until the following exercises are completed successfully: 1- Damages are evaluated, reported and rectification of the equipment will principally be agreed by the vendor/designer/CSD.2- Approval of the corrective action plan and method of rectification will be agreed by the vendor & CSD. 3Rectification shall be made by the approved personnel under quality controlled supervision. 4- Acceptance of the rectification shall be reevaluated and accepted by the vendor & CSD. 5- The Safety Instruction Sheets (SIS) to be modified & approved as per SAES-A-005 Att. D-1 as required. Contractor will also require maintaining traceability of the rectification through the quality controlled documentation.
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7
1239
11/4/2007 8:54:58 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1150
10.5
1240
2/23/2009 10:12:50 AM
SATIP-N-001-02
SAIC-N-2014
Mechanical
ScheduleQ
Schedule Q
1.3
1241
4/2/2008 5:55:49 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
5.5.4
1242
10/13/2008 12:50:02 PM
SATIP-D-001-01
SAIC-D-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1243
8/12/2008 9:39:02 AM
SATIP-D-001-01
SAIC-D-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1244
8/17/2008 5:30:15 PM
SATIP-D-001-01
SAIC-D-2005
Mechanical
ScheduleQ
Schedule Q
1.7
1245
2/5/2008 4:28:23 PM
SATIP-D-001-01
SAIC-D-2005
Mechanical
ScheduleQ
Schedule Q
1.3
1246
5/17/2008 2:05:33 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 4
1247
12/13/2007 9:38:10 AM
During Preliminary receiving Inspection of tank tag number B22 D0031. SPIU noticed that slot holes of anchor chair have ferrous contamination. This may be inherited due to usage of improper tools. Corrective action needs to be initiated to remove the ferrous contamination. Please refer SAES W-017 Para 10.4.3 It was observed that sleeves for pump B22-G-0002 A/B/C was being blasted and coated with APCS 3 internally. CSD specified to coat with APCS 113A. CSD communicated through its email to all concerned. SPIU has observed at pipe spur rack # 7 welding of 48-P-001 run pipe & 24 branch pipe with reinforced pad done (B22-666055-0010A1) Spool-A. Dimension of the reinforce pad width is shorter (65 mm) against the requirement of SAES-L-110 (Para 12.1.1 & 12.1.2). Geometry of reinforce pad cut at the end to avoid welding encroachment does not meet also the requirement of full encirclement. Contractor has to propose the corrective actions. Stress Identification Factor (SIF) shall be evaluated & accepted as per the standard. Gaskets (e.g. Metallic Ring Gaskets) were ordered without Saudi Aramco representative approval/review. Prior to bolt tightening for the E-W pipe rack, the torque value for each size of bolt shall be furnished. Contractor started tightening of bolts without furnishing the torque values. This is observed that contractor start the work for fabrication & Installation of the RTR pipe work with out submitting / approval of the Special Process for the RTR pipe work. This is violation of the Schedule Q Attachment VI-table 2. During Inspection of pipe support coating SPIU found that this support have a lot of defect like mechanical damage and welding defect (Spatter, lack side of fusion, porosity) and these support pass the receiving inspection and send to coating shop without notice from SNC or NESMA During check fit-up foe Tee TAG SP 192 16" 1.1"Wt XS WPHY 60 Body heat# 16848 Bar heat# 34872 with pipe 16" 1.1"Wt, SPIU notice that there is 30 mm thickness different because the thickness of the Tee is 2.2 " During hydro-testing of 12 spools at 3350psi package no. HTP 711, the spools were being tested while the isolation valve connecting to the pressure relief valve was not sealed open and this is a violation to SAEP-1160 bullet item 3 and G.I.-2.102 paragraph 5.5 SPIU would like to inform the contractor that the installation of the Injection Gas Compressor Suction KO drum B23-D-0013A will be in hold untill the following is successfully completed: 1- internal and external access is provided for further inspection to evaluate all areas (e.g. internals, contact area with the ground, etc). 2- further investigation / correction / corrective action by the contractor 3- send the agreed data to Consulting CSD for further evaluation and advice. 4take the correction / corrective action as per CSD recommendations During routine site visit it has been observed that one of the cooler B23-E-0049 pressure gauge is showing zero pressure which violates the requirement of preservation as per 32-SAMSS-011 Para 11.3.3. Vendor representative stated in the hard copy of RFI# 19662,19663,19664 that " Nitrogen filling/blanketing to a required range (pressure reading) should be made after shaft alignment only". The preliminary alignment was conducted and the Nitrogen was not introduced yet. This is in vioaltion to Schdule Q attachment IV paragraph 5. Contractor is requested to adhere. it is noticed that during hydro-testing of 30" ball valve class 150 that the isolation valve connecting to the pressure relief valve was sealed closed and this is a violation to SAEP-1160 bullet item 3 and G.I.-2.102 paragraph 5.5
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
SAES-W-017
10.4.3
Schedule Q
A IV Para 4
1248
1/7/2008 5:13:14 PM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-001
7 & 10
SAES-H-002
5&6
1249
9/26/2008 11:09:43 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12.1
1250
5/21/2008 1:07:50 PM
SATIP-L-350-01
SAIC-L-2007
Mechanical
ScheduleQ
Schedule Q
1.3
1251
8/19/2007 11:53:42 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
12.4
1252
5/3/2007 3:40:48 PM
SATIP-L-350-05
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
AIII para 3.6
1253
3/23/2008 3:00:07 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.4.2 & 11.6
1254
8/20/2008 10:55:05 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
9.3
1255
11/8/2008 4:20:51 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAEP
SAEP-1160
GI.2.102
5.5
1256
3/17/2008 3:03:15 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1257
7/21/2008 8:54:11 AM
SATIP-E-007-01
SAIC-E-2005
Mechanical
other
32-SAMSS011
11.3.3
1258
10/18/2008 5:49:17 PM
SATIP-K-402-01
SAIC-K-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1259
11/3/2008 5:53:22 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAEP
SAEP-1160
GI.2.102
5.5
1260
11/3/2008 6:48:20 PM
A check valve piston type class 150 was seat-tested at 315psi. The pressure relief valve used for this test is set to pressure 330.75psi and it was calibrated one day before the test. The pressure for that test reached 370psi and the pressure relief valve did not open. The other test was a check valve class 150 body-test at 450psi and the pressure relief valve was set at pressure 472.5psi. It was over pressurized up to 500psi and the pressure relief valve did not open while it was also calibrated one day before the test. Then we tried to perform a test randomly for any one of the pressure relief valves to see if it opens or not. We picked pressure relief valve with serial number K-7 which is set to a pressure of 330.75psi and tested up to 500psi and did not open while it was also calibrated one day before the test. The attachment is the certificates of all 3 pressure relief valves. This is a violation for the standard SAES-A-004 paragraph 5.5.1 On Sunday 11/16/2008, two gate valves 4" class 300 were hydrotested while the isolation valve of the relief valve was sealed closed. it is a violation to SAEP-1160, Bullet Item # 3 Tank Tag number B25-D-0029 (Bulk Lube Oil/Seal Oil Tank) was installed on the foundation with out inspection as per the requirements of SATIP-D-109-1. No receiving and pre installation inspection was carried out. This repeat violation of Log book entry 3802 No RFI for receiving Inspection has been issued. Violating requirements of SATIP-D-109-01 Item 2.1 and 2.2 PACKAGE NO.1 of 11, 2 of 11, 3 of 11, 4 of 11, and 5 of 11 was inspected upon receiving. It was found that the most of the flare stack need blasting and repainting. Ladder brackets are twisted during transportation. Please provide documentation for NDT and painting done at vendor place. Please confirm weather windbreakers are required for this flare stack (Item No A8 of SAIC F- 2031). Scaling was observed inside the stack which is required to be cleaned before installation. Number of spools were found laying directlty on the ground which is direct vilation to SAES-L-350 paragraph 7.1 "pipes should not be stored on the ground" and SAES-H-200 paragraph 5.1.1 "The coated pipe shall be handled at all times in a manner that prevents damage to the pipe walls, beveled ends, and to the coating(including internal coatings, if applied)". During site inspection in area B25, CPF-GOSP 4 project, Project Inspection found that orifice tapping connection for 6 IA -206 was not yet installed as per Isometric Drawing # BB-876137-004. This orifice flange was included in the test limit as indicated in hydrotest diagram. Orifice flange assembly including the orifice tapping connection and flush grinding requirement have to be verified and inspected by contractor if completed in site before submitting the Test Package for ARAMCO punchlisting. During site inspection prior to spool installation, PID found that the intermittent welding been done for pipe shoe to pipe weld for line 6 SR-904-ILE2P BB-212310 Spool A & 6 W-040-1LE2U BB-714135 Spool D. This violates the SAES-L-310 par.16.1.4 requirements which states that all weld to pipe shall be continuous weld. PMT and Contractor been reminded to follow the standard requirement to avoid violations. The stem of 14" valve in 14"-B25-FG-070-015 has a clearance of only 24mm to the cable tray above it. This violates SAES-L-310 paragraph 12.4 that states "A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe".
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
5.51
1261
11/16/2008 9:14:46 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAEP
SAEP-1160
GI.2.102
5.5
1262
1/9/2008 2:48:36 PM
SATIP-D-109-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.3.2
1263
12/9/2007 3:18:48 PM
SATIP-D-109-01
SAIC-D-2015
Mechanical
ScheduleQ
Schedule Q
1.7
1264
12/24/2007 6:10:41 AM
SATIP-F-007-01
SAIC-F-2031
Mechanical
ScheduleQ
Schedule Q
A IV Para 7
1265
10/27/2008 9:18:28 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
7.1
SAES-H-200
5.1.1
1266
10/12/2008 11:06:07 AM
SATIP-L-350-01
SAIC-L-2016
Mechanical
ScheduleQ
Schedule Q
1.3
1267
10/18/2008 4:33:24 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-L-310
16.1.4
1268
11/1/2008 10:18:25 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
1269
9/27/2008 12:39:19 PM
During site inspection in area B25, CPF-GOSP 4 project, Project Inspection found that line stopper (support) was not completely welded to pipe for 12 A-662 air line prior to pressure testing of the line. The contractor had been instructed to complete the welding of support prior to testing. The Subcontractor QC (NESMA) and Main contractor QC (SNC Lavalin Inc.) have failed to carry out thorough inspection and verification of all welds including support especially direct welded to pipe which is a violation against SAES W-011 PARA. 17.1.2, which state that written reports and evaluation of all inspection performed by contractor shall be made. For this case the line stopper have to be verified and inspected by contractor if completed in site before entering the data in the Weld Summary Record. Reference made to the SNC letter # tr-sa-2560-SNC-SA-S-L-508 / sepdt-154-09 subject to annual vacations of the QC Personnel. This is observed that contractor failed to provide 30 calendar days in advance notification for proceeding of the annual vacation of the following three QC Personnel (Piping), Mr. Kaneti Raju, Johan Audie Renacia and Flaviano Facultad. This is a violation of the Schedule Q section 5.11. Matter is being recorded and highlighted to the contractor to prevent from further / repeated procedural violations. Contractor used insufficient bolt lengths (all bolts have no full thread &/or complete engagement with the nuts) in the installation of blind non metallic flanges for the RTR oily water future pipe connections at Area B23 - OWMH No. 37. This non conforming installation is typical to all other manholes with future connections & violated provisions of SAES-L-109 Section 3/ASME B31.3 Para 335.2.3. Contractor started pipe insulation work @ Area B22 & B25 without complying with the following mandatory quality control requirements: 1. RFI for material receiving for the pipe insulation materials & accessories was not conducted with SA Inspection therefore insulation material certificates were not verified if conforming to SAES-N-001 Para 1.2 (PIP INSH 1000) & specific ASTM requirements. 2. No insulation procedures &/or specifications are approved PRIOR to start of work Violation to Schedule Q Section 3.1. It has observed that for CGT # 1, 2 & 3 turbine & accessory module some fabrication & welding of the auxiliary piping is done at Shaybah field. These field fabricated/welded auxiliary piping require to be hydrostatic tested as per the 01-SAMSS-017 Para 9.4 & SAES-L-150 Para 5.8. Please note that any fabrication/welding of auxiliary piping at field shall be subjected to hydrostatic tested. For pneumatic pressure test contractor is using household detergent & which is not acceptable as per the SAES-A-004 Para 5.6.1 & ASME Sec V Article 10 para I-1032b & I-1072. It has observed that instrument air rack piping is installed without complying the slope requirement as per the SAES-J-901 Para 4.8.1.2 1. CS & SS pipe spools were found damaged. 2. SS pipe spools found damaged/dented (Sch Q Para 7.3.7). 3. CS pipe spools found damaged/dented & external coating also damaged (Sch Q Para 7.3.7) Contractor (HHI) has completed Pneumatic tests of some High Pressure systems. SPIU would like to inform SAPMT to request contractor to comply with the requirements of SAES-A-004, para. 5.2.1, which stats pneumatic testing is not permitted without written approval of the Manager, Inspection Department before doing any more High Pressure Pneumatic tests. As the PMI (Positive Material Identification) of all weld joints of SS & DSS spools fabricated in OOK is done; hence contractor is reminded to do the PMI of same for Shaybah field welded joints as per the SAES-A206.
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.2
1270
5/13/2009 2:47:58 PM
SATIP-L-350-02
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.11
1271
8/25/2008 3:28:22 PM
SATIP-L-350-02
SAIC-L-2014
Mechanical
SAES
SAES-L-109
ASME B31.3
335.2.3
1272
2/12/2009 4:54:05 PM
SATIP-N-001-02
SAIC-N-2004
Mechanical
SAES
SAES-N-001
1.2
1273
1/2/2008 11:31:27 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
5.8
01-SAMSS017
9.4
1274
2/13/2008 5:33:33 PM
SATIP-A-004-02
SAIC-A-2021
Mechanical
SAES
SAES-A-004
5.6.1
ASME SEC V
Article 10
1275
12/10/2007 3:53:41 PM
SATIP-J-901-02
SAIC-J-2015
Mechanical
SAES
SAES-J-901
4.8.1.2
1276
9/6/2007 5:48:21 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
7.3.7
1277
3/10/2008 1:46:01 PM
SATIP-A-004-02
SAIC-A-2021
Mechanical
SAES
SAES-A-004
5.2.1
1278
1/3/2008 6:35:15 AM
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
6&7
1279
9/4/2007 4:08:16 PM
Today it has been seen that in substation bulilding # 50 the welding work of cable tray support was ongoing. Following violations were noted after the fact: 1. There was no RFI for the said activity. 2. There was no WPS. 3. Welder doing welding not approved & no JCC. 4. No calibration record of welding equipments submitted to SPIU. 5. No receiving inspection of electrodes done which is being used for the welding. 6. There is no approved welding / QC inspector.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.7
1280 1281 1282 1283 1284

1/24/2008 12:12:01 PM
SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01

SAIC-W-2005 SAIC-W-2005 SAIC-W-2011 SAIC-W-2010 SAIC-W-2005
Mechanical Mechanical Mechanical Mechanical Mechanical
SAES SAES SAES ScheduleQ ScheduleQ
SAES-W-011 SAES-W-011 SAES-W-011 Schedule Q Schedule Q
7.1.8 8.1 19.2 A IV Para 3.3 5.1
1285
1286
11/28/2007 2:11:47 PM
RBE
1287
2/18/2008 12:43:00 PM
1288
3/10/2008 10:09:04 AM
1289
2/18/2008 12:38:29 PM
1290
7/31/2007 3:07:51 PM
TAPO-1001
Contractor started hot insulation work for the 6" diameter Fuel Gas Line between FG Skid & Metering Equipment @ CGT 2 without an approved procedure. This violates Schedule Q Section 3.1 requirement. Contractor shall initiate RFI for welding consumables, installation of pumps and strucutral steel prior to installation work. Contractor used non conforming fasteners (stud bolts, nuts & washers)in the installation of underground buried valves & CS riser connections to hydrants/fire monitors. Material type & coating of buried fasteners shall comply to SAES-L-105 Section 12 ( Line Class Tables - 12FEOU) Stud bolts & nuts used for bolted flange joint assembly & duty pumps auxiliary piping connections for the 6" CS Piping @ the mechanical room do not conform to SA standard requirements. Stud bolts/nuts shall be ASTM A193 Gr B7/A194 Gr 2H conforming to SAES-L-109 Section 12. Contractor used non conforming fasteners (stud bolts, nuts & washers)in the installation of underground buried valves & CS riser connections to hydrants/fire monitors. Material type & coating of buried fasteners shall comply to SAES-L-105 Section 12 ( Line Class Tables - 12FEOU) To prevent any possible delay, please submit Bolt tightening Procedures as per Schedule Q. Attachment IV paragraph 2.1 Fin Fan Coolers was mounted and set-up in the site location and it was observed that a violation was occurred against ARAMCO Standard as mentioned in Schedule Q attachment IV- 3 of 4 for the storage and preservation requirement as reflected in Paragraph 6, when the contractor does not maintain the inhibitor gas inside the Equipment and letting those inhibitor gas to goes all through-out from the internally condition as it was preserved the equipment item since they install those associated SUS piping around. One dent observed on 30 main line pipe at KM50+400 near Weld No FW1912, The dent depth is more than 5mm and length 125 mm which is not acceptable per API5L .Contractor is advised to cutout the defective section and add a new pipe. During site surveillance PID notice that SRB have two 18x900 orifice flanges the angle between the drilled tap holes is 45 degree in both flanges. The angle between tap holes must be 180 degree according to SA standard drawing AD-03004 sheet- 1. PMT kindly requested to verified this issue before the installation. The FIN FAN COOLERS was installed and mounted by the Contractor in the location with the following observation & comments. 1. Not complying with the SCHEDULE Q attachment 1V -3 of 4 Par. 7 PRESERVATION. 2.It was observed that the preservation gas in the FIN TUBES was released. 3. It was observed that ARAMCO standard SAES -A-004 edition 2005 of March 30, were not been followed and complied as mentioned in the Paragraph 1.3 and 6.4.5
SATIP-N-001-02
SAIC-N-2006
Mechanical
ScheduleQ
Schedule Q
3.1
Schedule Q
1.3
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.7
SATIP-L-350-05
SAIC-L-2007
Mechanical
SAES
SAES-L-105
12
SATIP-L-350-05
SAIC-L-2007
Mechanical
SAES
SAES-L-109
12
SATIP-L-350-05
SAIC-L-2007
Mechanical
SAES
SAES-L-105
12
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
Schedule Q
2.1
1291
1/19/2010 4:31:31 PM
N/A
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1292
12/16/2009 7:28:08 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
16.1.8
1293
1/10/2010 2:21:32 PM
n/a
SATIP-L-350-01
SAIC-L-2016
Mechanical
ScheduleQ
Schedule Q
1.3
1294
1/18/2010 8:42:24 AM
n/a
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1295
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1296
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-A-004
7.4.5
1297
1298 1299
4. SUS Associated Piping around the unit were installed with temporary Bolts & Nut which is not acceptable to standard of PIP SUS material preservation and associated CS supports were not isolated with the UNS or SUS pipes which is not complying with the ARAMCO standard 01 SAMSS-046 section 18. 5. Valves and hand wheels where installed and mounted with constricted location thus adequate space to serve for maintenance services is inconvenient . 6. PZV has no 3rd party approved calibration, MFR data sheet, Calculation sheet (SIS) with Insptn. form 3099A 1. The spool valve manifold for VB-77-114479-001-00 along km 1135 valve station was cut at the end portion since last week 9th of February living behind with-out any temporary cover that a violation was committed against the SAES-L-350 section 15.2.3 to 15.2.4 and 15.3 of ARAMCO respectively. This is also a violation against Schedule "Q" section 6 (Preservation after Hydro test and Lay-up in Hawiyah fabricaation shop of SRB, which is mention also on SAIC-L-2011 item A15 for SAES-L-350 Sec. 7 & section 14 for storage care. It is observed that contractor have made the tie-in of the two pipeline strings together in normal temperature of the day and did not consider the tie-in as temperature tie-in of two pipeline strings which is the violation of the SAES-L- 450 Para 15.1 that says A temperature tie-in weld is a weld that connects one of the following ; Two pipeline strings together During site surveillance PID was notified of the manufacturing defect noted on one of 28 X 1500# weld neck flanges bolt holes. This item is located at the spools lay down yard inside PS#6 and is intended for use on pump (v72-G-0300D) discharge header. This violates schedule Q paragraph 7.3.1 which states that contractor shall control contractor and subcontractor supplied materials and fabricated assemblies that do not conform to requirements as indicated in 7.3.2, 7.3.5 & 7.3.6 also of above schedule. Control to restrict processing or installation of non-conforming or defective items pending decision on disposition shall be established and maintained. This item shall be put on hold and segregated until the time that the issue is resolve by concern parties. There are three crews are working for LINE welding. Two crews of them are engaged for line welding which comprise each about 18 welding operators. One crew is engaged for tie-ins. These three crew are controlled by two welding inspectors at site which is not in the compliance of schedule Q. They should have one more welding inspector for covering the tie-in activities During site visit today PID noticed re welding activities for 18 pipe. (Cutting, re beveling, NDT for bevel (MT) & fit up) all these activities were done without any notification to PID which violated schedule Q and SAES-W-011. PID noticed the below issues during site surveillance 1-Two welding machine were used with expired calibration certificate, 2-QC didnt use voltmeter to check the voltage 3-Welding Machine SRB 915-265 was working without Ground All these issues are violated SAES-W-011 Most of the pipe sections from KM 315 TO KM 428 have been observed without night caps. As per SAES-L-450 Para 11.4 Open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds. It is noted at km 410, the pup piece cut from pipe and welded to the pipe line without transferring the vendor marking and information which violates the SAES-L- 450 Para 8.8 that says that When a length of pipe is cut from a longer joint of pipe, all vendor markings and other identifying information shall be transferred to each length of pipe. The immediate action shall be taken to rectify this nonconformity
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
SAES ScheduleQ
SAES-J-700 Schedule Q
8.2 1.3
1300
3/8/2010 9:50:41 AM
n/a
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15 & 7
1301
5/23/2009 1:50:28 PM
n/a
SATIP-L-450-03
SAIC-L-2108
Mechanical
SAES
SAES-L-450
15.1
1302
2/3/2010 9:19:22 AM
n/a
SATIP-L-350-01
SAIC-L-2008
Mechanical
SAEP
SAEP-351
4.2
Schedule Q
1303
5/23/2009 1:54:00 PM
n/a
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A VI Para Table 2
1304
1/10/2010 1:46:23 PM
n/a
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
1305
1/10/2010 1:57:31 PM
n/a
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
1306
5/23/2009 1:47:34 PM
n/a
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
1307
6/27/2009 9:34:11 AM
n/a
SATIP-L-450-03
SAIC-L-2110
Mechanical
SAES
SAES-L-450
8.8
1308
3/11/2010 2:15:29 PM
- During site surveillance PID noted 1 vent (gate) valve (1500#A105N) already installed to spool B of V72-4519-002 blow down line. Based on drawing VB-114519-002 rev.00 and corresponding MTO (Material Take Off) list showed that installed valve is correct. However, the above spool falls under 1CA9P line class. SAESL-105 table for this class specifies 800# (A350-LF2) for sizes 1&1/2 and under for gate valve; therefore the one installed is not in compliance with above standard. The contractor is advised to have it confirmed by the designer and a revised copy of the MTO to be made available at site prior modification. Once confirmed remove the weld, do the MPI on affected items and MPI report to be generated for this joint. provide end covers for the strings we found without end covers, locations close to valve station-997 & close to the PS-3. pipe lowering,trench back filling and berm making shall comply with the Aramco relevant standards regarding stones etc, PID wants srb quality organization to read and digest the attached highlighted stuff of saes-l-450- specially the section 14.8.2,14.8.3 and 14.8.4,,pid also requires the assigned civil qc to be onsite during all such type of the sensative activities , the assigned Forman and construction staff shall be checked for thier competence regarding thier due diligence in this regards a document prove of their Re training is being suggested for ,so as to correct their irresponsible attitude at site keeping in view this sensitive activity(sand paddin has to be as per aramco req,stones shall not be tolerated and all non avoid able stones shall comply with the aramco req,pipe shall be lower,trench shall be back filled,and berm shall be made and stabilized as per aramco standards req, satip ,saicand satr shall be followed accordingly) The string has been lowered in the trench after holiday testing without backfilling or spot backfilling. The pipe section shall be buried immediately after conducted the holiday testing as required by the SAES-H-200 Para section 7, says that The coated pipeline shall be 100% inspected with a pulse-type DC holiday detector employing an audible signaling device immediately prior to burial, i.e., after the last boom. During surveillance, PID observed mechanical damage on 30 weldneck flange having 900 class rating and that is welded with Scraper Trap Receiver holding tag number V78-D-0002. Scraper trap is transported to site at KM-220 for installation. This damage is appeared as indentation groove mark across the outer surface of the flange rim. The protective coating is damaged as well. The SAPMT is requested to advice the contractor QC to investigate the root cause of the damage and initiate a corrective action in this regard. From KM 324 to KM329, PID observed incorrect color-coding for grade65 material pipe lengths provided by the pipe manufacturer. Green color 50mm wide stripe found which reflects pipe material identification API grade 52 not API grade 65 per standard API 5L, table-27. SHY-1, LOOP-2 requires API grade 65 pipes. SAPMT and the contractor QC are requested to ensure API grade 65 for these pipe lengths providing all test reports, prior to welding of these pipe lengths. Despite of proactive notification, the contractor QC is failed to provide RTFI report for the first batch of the welds that has been RT tested on Feb.12, 2009. It is a violation to SAEP-1160. PID is SRB balance joint(BACKLOG) to be submitted to PID and also SRB SAEP-1160 sect.5.1, 5.2, and 6.3.
SATIP-L-108-01
SAIC-L-2040
Mechanical
SAES
SAES-L-108
8.3
1309
1/18/2009 3:04:08 PM
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
1310
1/26/2009 4:19:27 PM
SATIP-L-450-03
SAIC-L-1004
Mechanical
SAES
SAES-L-450
14.8
1311
5/23/2009 1:44:41 PM
SATIP-L-450-03
SAIC-L-1004
Mechanical
SAES
SAES-H-200
1312
10/10/2009 4:18:51 PM
SATIP-L-450-03
SAIC-L-2002
Mechanical
SAEP
SAEP-351
4.3
1313
2/10/2009 6:50:33 AM
SATIP-L-450-03
SAIC-L-2113
Mechanical
ScheduleQ
Schedule Q
1.3
1314
2/22/2009 9:19:45 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1315
3/9/2009 5:54:52 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1316
2/2/2009 6:47:45 AM
Since the last 02 weeks 518 weld joints have been completed at an average of 50 joints per day. No Radiographic Testing was scheduled so far. This daily weld production can lead to a big RT BACKLOG. Despite of proactive notification and violation (after the fact) made by PID earlier, the contractor QC is failed to manage the Radiographic Testing of the daily weld production and to evaluate weekly weld status and welders performance that based on the RT results. It is a repeated violation per SAEP-1160. Radiogarphic Testing was carried out by the NDT sub-contractor from Feb 12 to Feb 16 without RFI and without contractors inspection coverage.This is a violation to Sch."Q".The contractor QC is advised to comply Sch. "Q" and Saudi Aramco Standards. 03 e-log entries are made by PID at PS-10 dated 12/14/2008. The contractor QC, so far, failed to respond all of these e-log entries. This is a violation to Sch."Q" attacment IV, para 4.9. The contractor QC is requested to respond. PID noticed piping activities on going without the presents of the piping QC which violated schedule Q. This issue was discussed & logged it in the QA/QC minutes of meeting last week. The Contractor shall carry out his obligations toward project quality PID observed that one of the NDT crews deployed for Radiographic Testing left the site without informing PID. This is a violation to Sch."Q". During installation of the 28x1500# flange in BI 10-00295, it has been revealed that the flange was defective in the inner surface of one of the bolt hole. The flange was released from the manufacturer premises (Melesi) without final inspection nor a notification sent to the assigned SAIR. The UT readings was performed and revealed a casting of deep metal loss with approximately 20-35 mm deep, 25 mm wide & 50 mm long. An EDR (400009511) & SA VID-NCR (500003832) were issued recommending replacing the flange with same material & grade. And as a result of waiving the final inspection, the assigned Procurement QC supervisor (Nino Sawal, SAP# 700009467) has been disqualified by VID. And therefore, SRB shall look for immediate & dedicated replacement for Nino. PID observed that o4 number of welds, FW-X-23,FW-X-82,FW-X-112 & FW-X-152, have been RT exposed by the NDT sub-contractor. Their RT films have not been submitted for RTFI by the the subcontractor.Why it was happened ? The contractor welding QC was not able to answer. this is a violation to SCH."Q",para7.2. Welding production is in progress @ LOOP-2 since Jan 19, 2009. 222 weld joints have been completed and visual inspected. So far, no Radiographic Testing have been started. This is a violation to SAEP1160.SAPMT and the contractor QC is requested to mobilize RT crew on site to conduct Radiograpy ASAP. The contractor QC is failed to provide PID weekly weld summary, SATRW-2008 for the week ending FEB.13, 2009. The welding have been started since Feb. 10, 2009 from KM-288 onward to PS-09. This is a violation to SAEP-1160,para 5.3. The contractor QC is failed to provide PID weekly weld summary, SATRW-2008 for the week ending Feb.20, 2009. The welding have been started since Feb.10, 2009 from KM-288 onward to PS-09. This is a violation to SAEP-1160,para 5.3. The contractor QC is failed to provide PID weekly weld summary, SATRW-2008 for the week ending Feb.27,2009. The welding have been started since Feb.10, 2009 from KM-288 onward to PS-09. This is a violation to SAEP-1160,para 5.3. PID observed that welds,FW-X-23,FW-X-82,FW-X-112 and FW-X-152 have been RT exposed and weld markings have been placed for RT process.However,these welds have not reflected in the RTFI assessment report, dated Feb.24,2009 submitted to PID. This is a violation to SAEP-1160.
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1317
2/17/2009 7:36:02 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
1.7
1318
12/25/2008 3:22:55 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para 4.5
1319
3/2/2010 11:17:21 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1
1320
4/12/2009 4:53:27 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
5.1
1321
2/23/2010 10:24:39 AM
SATIP-L-350-01
SAIC-L-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1322
3/1/2009 7:14:56 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.3
1323
1/26/2009 8:32:13 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1324
3/1/2009 6:32:00 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1325
3/1/2009 6:34:17 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1326
3/1/2009 6:36:45 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1327
3/1/2009 6:53:44 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1328 1329
4/22/2009 9:51:25 AM 4/22/2009 9:52:59 AM
Internal NCR No. C-0010M not documented and provided to PID within 48 hours. It is a violation to Schedule Q. NCR originator for NCR No. C-0010M did not identify the weld numbers those are found questionable. It is a violation to Schedule Q, Para 5.6. Proposed Corrective Action advised in NCR No. C-0010M is not per SAES-W-012, Para 16.6.1.It is a violation to Schedule Q, Para 5.6. Proposed corrective Action to stop welding, not implemented immediately. 77 welds have been completed after signing of NCR. It is a violation to NCR No. C-0010M. First 05 joints have been visually accepted on April 05, 2009. Their RTFI assessment report not provided to PID so far. It is a violation to Schedule Q, attachment VI, Para 2.8. All of the questionable welds due to poor workmanship of SINOPEC welding crew, not selected for NDT. It is a violation to SAES-W-012, Para 16.6.1. PID observed that during inspection of SINOPEC production welding, contractor QC did not use inspection checklists and did not update the performance & inspection results of the sub-contractor to PID. It is a violation to Schedule Q, attachment VI, Para 2.7. During site visit at KM-220 Scraper Trap Receiver area, PID observed damaged bevel preparation for 24" erected pipe spool-D drawing No. V78-VB-114381-001.SAPMT is requested to advise the contractor to investigate the cause of occurence and make a corrective action accordingly. During site surveillance PID noted one container (opened) and 3 portable ovens filled with low hydrogen electrode left unplugged inside site storage room and it is keep exposed more than the maximum permitted time. This is a violation to SAES-W-011 paragraph 6.2 and 6.1 which specifies that low hydrogen electrode from newly opened hermetically sealed container or drying oven or storage oven is only be allowed 4 hours maximum time of exposure and prior expiry this shall be put back on storage oven continuously heated to 120 degree Celsius minimum temperature and after expiry this shall be put back to drying oven. It is recommended that this batch of exposed electrode be discarded. During our Regular Site Visits we found that Shear Stud Welding Activities are being carried out with out Welding Inspector.In this regard an Aramco NCR also been Issued afterwhich contractor proposed a Welding Inspector and has been interviewed and Approved also.But the same has not yet been Mobilized to site.Contractor shall meet all the requirements of Schedule "Q" and assign required Quality Inspectors before actual work starts. Sub Contractor has fabricated an 11.5 degree Elbow from a 90 degree standard elbow in their workshop without getting approval from CSD or even without informing any Saudi Aramco representative. After cutting from elbow, sub-contractor welded this cut piece of elbow with another piece of pipe using butt joint design. Which is a violation of SAIC-L-2075 (attachment 1, STD. DWG. AB-036090)type 3 joint for Cement Lined Pipe. This type of joint is allowed only for the pipe larger than 24". focuss assessment was performed and found thatPressure Test Diagram contractor are not including the limits of piping (including test manifold) and equipment included in each pressure test, high points and low points (drain), locations of pressure gauges, test pressures, test temperature, test fluid, line flushing requirements, and safety precautions Projection of the anchor bolts are found excessive high as Equipment can not be hold down using the same anchor bolts. Eqpt Drw# P-7454PM-GAV-C0922-001 Rev F and Civil Drw# BA-143517-001 Rev 00.
SATIP-L-350-01 SATIP-W-011-01
SAIC-L-2011 SAIC-W-2036
ScheduleQ ScheduleQ
7.3.3 5.6
1330
4/22/2009 9:54:17 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.6
1331
4/22/2009 9:55:42 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.3
1332
4/22/2009 9:57:25 AM
SATIP-W-011-01
SAIC-W-2015
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.8
1333
4/22/2009 10:00:02 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
16.6
1334
4/22/2009 10:01:28 AM
SATIP-W-011-01
SAIC-W-2015
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.6
1335
2/6/2010 2:37:42 PM
SATIP-L-450-04
SAIC-L-2112
Mechanical
SAES
SAES-L-350
1336
2/6/2010 4:36:30 PM
SATIP-W-011-01
SAIC-L-2032
Mechanical
SAES
SAES-W-011
6.1 & 6.1
1337
5/9/2009 9:24:53 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
1338
3/15/2010 3:35:20 PM
Plumb
SATIP-L-350-07
SAIC-L-2075
Mechanical
ScheduleQ
Schedule Q
1.3
1339
10/27/2009 9:33:11 AM
SATIP-A-004-02
SAIC-A-2003
Mechanical
SAEP
SAEP-1160
1340
12/23/2009 12:21:47 PM
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.8.1
1341
5/4/2009 10:19:07 AM
During site visit found that flash drum been arrived to the site and was erected without any receiving inspection and without attendance of their QC Equipment Inspector. Also MFH failed to raise RFI to Saudi Armco for inspection and been noticed that MFH fixed the external cladding without also RFI. MFH shall mobilize their approved equipment inspector to the site and raise RFI for receiving inspection. Equipment has been installed on foundation, perhaps according to Mech Drw#40031-M02-01 Rev 8 and Civil Drw# BA-143516-001 Rev0, typical Plates of 25mm thick are not installed under the saddle support of the vessel. (Equipments Recieving Inspection is not yet carried out). During site surveillance found that, the still column installed / placed over the reboiler (reboiler nozzle# 9), dont have all the bolts installed and complete Joint has been left fully loosen. Most of the studs are without nuts. (Ref Frame Drw# P7454-PM-GAV-C0923-E-0937-001 Rev-D). Equipment installation inspection was done on June23, 09 through RFI #1446 and was signed off. During the site surveillance found that, the preservation Oil is spilled on the deck of Pump; investigation proved that during the discharge line modification the constant oil leveler was tilted down thus causing drain of Oil from bearing casing. (QC was called at site and advised to fill the Oil and properly tight the leveler fittings. In addition piping crew was also advice to avoid such Violation). 1-Leveling is not done using / following the standard and manufacturer recommendations. 2- No test reports in record. 3-Preliminary alingment is not done and 1st stage (Epxoy) grouting is Over. 4Suction End of the pumps are with cocentric reducers (suppose to be ecentric ones). Recommending that, verification of leveling and to perform the preliminary alignment prior to 2nd stage (Non shrink) grouting. 462-G-955 A/B and 462-G-950 A/B, pumps found with out preservation oil in bearing casing. IT IS NOTED THAT THE MAIN DISCHARGE VALVE & NRV ARE INSTALLED IN LINE WITH OUT EVEN TEMPORARY GASKETS. During the surveillance found a 4 piping spool directly welded (Tacked) with transverse beam to restrain on pipe rack. SAES-L-350 Para 8, 11, and Sch Q Att IV. During surveillance found that the Contractor has welded the (4) four clamps in But Weld Joint base with the Shoe Support causing Damage of External and Internal coating of the Pipe spool "as the pipe was resting in the shoe". For Ref Drw #s BB-143310-001-00 , BC-143425060-00 , BC-10-143425=-28-00FI , BA-391475-001-0IA ,. Location has been seen to QC of welding and coating, the matter has been brought to QC Supervisor / manager too. Contractor has painted the effected location to hide this. (Line # 10"-BD-1045-ILE0PI - CS-Pipe Sch 40, API 5L GR-B (NACE). During routine visiting of MFH yard it has been noticed that 1- RTR piping and fittings are not stored properly accordance to SAES.S-070. 2. It has been noticed that all carbon steel valves not stored accordance to SAES-L-108. 3-The yard not clean from unnecessary materials such wood. Found mechanical damage (Dent of 4.5mm deep) on Internaly coated Pipe. Ref Drw #s, BB-143310-001-00 , BA-391475-001-01A, BC143425-028-00F1. Line 10"BD-1045-ILE0PI (Sch 40 - Thickness 9.27mm). During the inprocess welding inspection (of 24"-P-0826-0827 / 11443CS2P2) found that, the weave width of the weld is 30mm during filling, which is a Clear violation of the Approved WPS (MFH/018 and 019).(the Joint is not yet fully welded).
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS020
15.1
1342
12/24/2009 2:48:07 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
1343
1/31/2010 12:14:34 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
1344
2/17/2010 7:34:38 AM
SATIP-G-005-01
SAIC-G-2003
Mechanical
other
31-SAMSS004
Schedule Q
A IV Para 5
1345
12/20/2009 7:09:51 AM
SATIP-G-005-01
SAIC-G-2021
Mechanical
other
API 686
3.9
1346
12/19/2009 7:48:24 AM
Violation-After The Fact ViolationPrevented Installation Violation-After The Fact
SATIP-G-005-01
SAIC-G-2003
Mechanical
other
31-SAMSS004 SAEP-351
Schedule Q
A IV Para 5
1347
12/30/2009 10:21:17 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
4.1
1348
1/11/2010 12:38:42 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
11
1349
2/3/2010 8:03:11 PM
SATIP-H-002-02
SAIC-H-2015
Mechanical
ScheduleQ
Schedule Q
1.7
1350
3/2/2009 2:43:26 PM
SATIP-L-350-05
SAIC-L-2054
Mechanical
SAES
SAES-S-070
5.5
1351
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
7.3
1352
2/3/2010 7:46:39 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
1353
2/16/2010 4:08:57 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1354
2/17/2010 7:53:27 AM
During response to RFI#2173, found that a Pup piece welded with the piping spool got dogleg in unacceptable angle. QC was called at site and Contractor has taken an immediate action to perform remedy. During routine site visit to job site (ABQ plant)it has been noticed that some coated spools got coating defect due to transportation of pipe spools from yard to site .more over it has been noticed that some spools transported before curing time . Please be sure that all defects have to re blast and recoat.This as peer SAES-H-200 During routine site visit to MFH YARD it has been noticed that pipes and flange have been stored without End protectors on pipes, flange s,this is violation of SAES-L-350 para 7.4 . Please make sure that End protectors on pipes, flanges shall be firmly attached . During routine site visit to MFH sit it has been noticed that pipes and flange have been stored without End protectors on pipes, flange s,this is violation of SAES-L-350 para 7.4 . Please make sure that End protectors on pipes, flanges shall be firmly attached . During welding inspection it has been noticed that welding ongoing for pipe spools using E 7018 without oven or portable oven this violation has been done by sub-contractor of MFH ,this is violation of SAES-W011 . During routine site visit it has been noticed that contractor not following the approved procedure of welding consumables, please make sure that welding QC shall be responsible of this procedure. It was found that the contractor had held back 182 radiographed joints between 11/03/08 & 12/14/08 for final verification by the NGPIU RTFI. This is in violation of SAEP-1160. Please advise the contractor to submit radiographs for verification no later that the end of each business week. NGPIU have noted that MFH are not completing radiography within a reasonable time frame but waiting till a large number of welded joints are ready before initiating the RT contractor, last number was 96 with 19 still outstanding. This is in direct violation of SAEP-1160 Tracking & Reporting of Welding NDT. This ia a repeat violation by MFH. The contractor must cease this practice immediately to ensure weld & NDT continuity. During toutine site visit to MFH yard it hasbeen noticed that blasting ongoing without using The Operational remote control valve (Deadman).This is violation of SAES-H-100 prar 5.4.2. During routine site visite to MFH YARD it has been noticed that the surface profile (Roughness)not conforms with the profile specified for the applied coating system which required surface profile is 40 micrometer .this as SAES-H 100 para 5.1.1 . Para 5.1.1 During routine site visit it has been noticed that blasting and coating ongoing for Funnel spools, the violations noted are. 1-No RFI sent to inspection. 2-NO SAIC prepared for blasting or coating. 3-Contractor coating QC not informed regarding this activates. This is violation as SAEP-1150 and contractor approved quality plan Recommendations. 1Reblast and repaint shall be done. 2-Inspection shall be informed. 3SAIC shall be utilize During routine site visit to MFH YARD it has been noticed that pipes and flange have been stored without End protectors on pipes, flange s,this is violation of SAES-L-350 para 7.4 . Please make sure that End protectors on pipes, flanges shall be firmly attached . During routine site visit to MFH YARD it has been noticed that the coated structural has been stored without protection .This is can cause damage to coating .This is accordance to 12-SAMSS-008,
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
9.3
1355
10/12/2008 3:38:41 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-450
1356
10/21/2009 10:55:22 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
7.4
1357
7/5/2009 3:03:04 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
7.4
1358
11/8/2009 7:57:21 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1359
7/14/2009 2:54:07 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1360
12/14/2008 10:51:21 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1361
2/2/2009 6:50:57 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
1362
3/22/2008 3:42:23 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.4.2
1363
6/23/2009 3:02:39 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.1.1
1364
7/7/2009 3:11:14 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
1.7
1365
7/12/2008 8:14:43 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
7.4
1366
4/29/2008 3:05:06 PM
SATIP-M-001-01
SAIC-M-2005
Mechanical
other
12-SAMSS008
Section 1
PIPSTS05130
1367
12/25/2008 8:36:07 AM
RFI# 770 was initiated 1:51pm of 12/24/2008, inspection date and time is 11.44am of 12/25/2008. RFI# 773 was initiated 2:06pm of 12/24/2008, inspection date and time is 8:00am of Nil date. RFI# 774 was initiated 2:13pm of 12/24/2008, inspection date and time is 8:30am of 12/25/2008 RFI# 775 was initiated 2:17pm of 12/24/2008, inspection date and time is 10:13am of 12/25/2008. Please be reminded that as per Schedule Q, Attachment 1V, sec 1.2.3 , the notification requirements for Request for Inspections (RFI) should be a minimum of 24 hours for site work and 48 hrs for weekend inspection. Also refer to SAEP-1150 sec 8.9.2. Contractor has violated the above stated standard and SAPMT is adviced to remind the construction contractor of NGPIUs concerned, to avoid any more recurrence in the future. APIU have raised serious concerns about the current high repair rates for welders (I.143, 144,157,177&211) this is violation of SAEP-1150 A10-5. failure of MFH to control the welder performance will result in removal of the welders JCC . During routine site visit to MFH welding shop it has been noticed that welder (I-157) welding root pass with electrode (ER705-2) while he is not qualified for this type of electrode as peer his JCC .This is violation accordance to SAEP-324 SEC 5. Recommendations. 1-All joints that welded by (I-157) shall be cut and re weld. 2-All welders shall weld according to their qualification. During shop surveillance found that, fabricated structure items are kept in paint shop for painting (even some are primer coated)and some finals, with a lot of un acceptable welding defects and fabrication mistakes. (for Ref Snaps are available). APIU have noted that MFH welders I-211, BD-086 & BD-011 are having high weekjly repair rates in excess of 5% which is in violation of SAEP-1160 & SAES-W-011. APIU have revoked these welders JCC & to return them to APIU through SAPMT for cancellation. APIU have noted that MFH are using bridge tack welds with incompatible material. The MFH WI was unable to identify the material used for the bridge tacks. This is in violation of SAES-W-011. The contractor shall remove these bridge tacks and reset the fit-up using approved compatible material. It has been noted that the contractor is not using a drying & re-drying electrode oven. This is in violation of SAES-W-011 Attachment & MFH approved special process. Due to the high weekly repair rate above 5% JCC for welders BD 099 & I 177 have been revoked in accordance with SAEP- 324 para 6.5.4 APIU have noted that MFH are using bridge tack welds with incompatible and corroded material on PIPE SPOOL 24"-p-1001-3 C.S Sch 40 API 5L. The MFH WI was unable to identify the material used for the bridge tacks. This is in violation of SAES-W-011. The contractor shall remove these bridge tacks and reset the fit-up using approved compatible material. this is a repeated log book entry and APIU will issue an immediate NCR and the Contractor QC Welding inspector will be revoked if this bad construction practice repeated again. During visual inspection of ongoing welding at fab shop,it has been noticed that the welders not clean weld surface at least 25mm of adjacent base metal. more over it has been noticed that there is poor cleaning between inter pass . this violation accordance to SAES-W-011 para 11.3
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAEP
SAEP-1150
8.9.2
Schedule Q
A IV Para 1.2.3
1368
6/15/2008 1:52:17 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1150
10.5
1369
7/19/2009 12:50:33 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAEP
SAEP-324
Section 5
SAES-W-011
8.1
1370
2/13/2010 11:23:42 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1
1371
10/7/2008 10:51:01 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
SAEP-1150
10.5
1372
10/7/2008 10:53:25 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.6
1373
10/7/2008 10:56:03 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1374
10/26/2008 2:30:25 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-324
6.5.4
1375
11/5/2008 1:36:09 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.6
1376
11/5/2008 2:43:19 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3
1377
4/8/2009 1:54:50 PM
Responding to RFI # 1177 & 1178 for the fit up welding of the incoloy piping which have now been rejected. NGPIU initial findings where 1.The documents mill certs for pipe, flanges, GTAW wire, or SMAW electrodes where not immediately available for review. Re-inspection found the flange to pipe had been set with bridge tacks of incompatible material. These are all in violation of SAES-W-014.
SATIP-W-014-01
SAIC-W-2064
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.4
1378 1379 1380 1381

1/30/2008 2:44:33 PM 2/10/2010 7:16:39 PM
1382
4/14/2009 2:05:52 PM
2.The pipe to flange the welding bevels had not been cleaned of foreign matter. 3. GTAW welding wire in found in unmarked / broken cardboard boxes with no identification. It has been noticed that no material control -tock control (first in ,first out and issuance for welding consumable . MTC of electrodes E316L Lot # 851W was available during inspection. RFI # 2141 During visual inspection it has been noticed that spool #3A got Arc strike which can cause crack to the pipe and not permitted according to SAES-W-011 para 11.6. Recommendations. 1-MPI shall be done for the location of Arc strike. 2-Remove Arc strike. During visual inspection it has been noticed that the height of reinforcement for spool#1045 joint #73 (10") more than acceptance criteria of weld according to ASME-B-31.3 table K341.3.2. During witnessing Verify Test Equipment (Safety Assessment) per SAIC-A-2009 and pre test walkthrough for test package TP-D74-P-001A, Line Class 9CS2P06 with 3350 Test Pressure ,following unsafe practice & violation related to test was observed by SAPID. 1. Temporary gasket was being utilized for connection between manifold & line. 2. There was a fabricated spool with 300# class rating flange used with 900 class # scope. 3. The fabricated spool weld detail is not traceable and examined. 4. Blind flange provided with outlet for installing gauge needs the weld quality examined visually & MPI/DPI done. 5. The BOLT torque needs to be performed & report available for review. The above all violate GI 2.102 (PRESSURE TESTING SAFELY) requirements stated at Para.4 & 5 5.1.2.5 , The use of properly rated gaskets. The verification of compliance with the manufacturers rating specifications (e.g., quality, service use, pressure rating) for all gaskets used. During review of Tie-in Hydro test package for TP-74-023, it is observed even after repeated rejection of test package the contractor is not complying with requirements related to completion of package prior commencing any hydro test activity. Following comments are made for rejection of the TP-74-004, TP74-023. Refer to SATIP-A-004-02 the following stages of inspection needs to be completed prior any hydro testing of plant piping. 1. Verification of Testing equipment (including safety reqmts) SAIC-A-2009. It is request contractor shall prepare a test package meeting all requirements with flow chart indicating acceptance of test package by individual responsible department of SIS, PMT,PID & PROPONENT. At assigned stages prior commencing any hydrotesting. 2. Internal Cleanliness and/or Flushing performed and reported (SAIC-L-2017).
Violation-After The Fact ViolationPrevented Engineering
SAIC-W-2021 SAIC-W-2066 SAIC-W-2066 SAIC-W-2010
SAES SAES SAES
SAES-W-014 SAES-W-010 SAES-W-010 Schedule Q
6.2 A2 A2 A IV Para 2.1
Mechanical
ScheduleQ
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
1383
7/12/2009 11:26:22 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.1.7 & 17.1.8
1384
2/2/2010 1:45:16 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
G.I.2.102
4&5
1385
2/10/2010 3:32:26 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
G.I.2.102
1386
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3
1387
12/22/2009 8:05:24 AM
Surveillance of site activity at Harad Gas plant its observed the project scope equipments (Air Receiver,D-0703/0704) & other static / rotary equipments installed has no preservation done which violates requirements of schedule Q Attachment-IV, Para5, there shall be a procedure established with a log book showning all activities carried out for same. Refer Schedule-Q Attachment-IV Para -5, CONTRACTOR shall include procedures for handling, storage, and preservation of material as specified in all applicable specifications, manufacturer recommendations and SAUDI ARAMCOs standards. The procedure shall list all inspection schedules for maintaining the quality of the material or equipment as well as provide for documentation that the required activities have been performed Sample witnessing of calibration of pressure relief valve using the new calibration equipment (Digital Pressure Indicator) as proposed replacement of Dead Weight Tester was conducted at SIS calibration shop. It was found out that relief valve being used to verify the suitability of the propose calibration equipment is defective/passing. Schedule-Q Para. 1.4 was apparently not observed. The said calibration equipment is therefore not acceptable. SIS shall make sure that all equipments are all ready before any inspection is requested and conducted. On site inspection was conducted for the on-going piping installation inside Haradh Gas Plant and found out that some piping that were subjected for PWHT are now at the site ready for installation and some are already installed. Further checking shows that non-pressure containing attachments (shoe support, dummy extensions ans legs)are not yet welded in all the spools that has been subjected to PWHT. This is a violation to SAES-L350 Para. 10.3 which states that "If post-weld heat treatment (PWHT) of pipe spools is required (refer to SAES-W-011), nonpressure containing welded attachments such as shoe support for insulated lines, dummy extensions and legs, and wear pads shall be welded to the pipe spools before stress relieving. PWHT of piping spools with flanged joints shall be done before flange assembly". Contractor is required to rectify this violation. During surveillance of site fabrication yard & site stock yard of SIS its observed the material identification and traceability related to piping & fittings are not being implemented as required per schedule-Q Attachment-IV , Para. 3.2, and SAES-A206 (Positive Material Identification ) AS per schedule Q CONTRACTOR shall implement an identification procedure for all materials, parts and components, including partially fabricated assemblies. Identification of an item shall be addressed either by using tags, stamps, color coding, stencils or labels, and as per SAES-A-206 Para, 14.2 Color Coding, The color coding system for material identification described herein is intended to help prevent fabricators from using incorrect alloy material. The principal purpose of color coding is visual identification during storage and after the components have been cut for fabrication. Its request the contractor meet this requirements of standard and provide traceability for all material.
SATIP-D-001-01
SAIC-D-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1388
9/28/2009 2:48:57 PM
SATIP-J-600-01
SAIC-J-2008
Mechanical
ScheduleQ
Schedule Q
1.4
1389
11/2/2009 2:43:54 PM
SATIP-L-350-02
SAIC-W-2004
Mechanical
SAES
SAES-L-350
10.3
1390
1/31/2010 11:29:47 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
SAES-A-206
14.2
Schedule Q
A IV Para 3.2
1391
2/10/2010 10:26:14 AM
A focus assessments was performed by Projection inspection on site NDT coverage and inspection requirements based on Saudi Aramco Standard requirements per Schedule Q , SAEP-1160, SAEP- 1141 (Industrial Radiation Safety),1142( Qualification of Non SA NDT Personnel, 1143(RT),1144(MT) and 1145(LPT). Following below mentioned missing requirements needs a urgent address by the contractor. 1. A NDT coordinator as required per schedule Q needs to be approved by PID and positioned in organization chart , this person can be a QC person with Knowledge in welding processes & NDT tech. Refer Schedule Q Attach-VI- Para. 2.18. 4. Prime Contractor 2. A NDT Check list for MT & PT site requirements verification & compliance is not been maintained on regular basis for current NDT activity, this is required per Inspection and Test Plan, Refer Schedule- Q- Attachment- VI- Para. 2.12. 3. The status and vacation schedule for approved NDT personnel needs to be current & active available with SIS. During focus assessment of welding activity & documentation its observed the scope of NDT coverage for below mentioned line class material is reported/covered wrongly with 10% Radiography coverage instead 100% as stated per SAES-W-11 Para. 17.5.2.1 . a. 1SV0P02 (Super Austenitic SS) B. 3SV0P01 C. 9SV0P01 It is requested the contractor shall comply with this requirements of RT coverage as required per SAES-W-11 Para.17.5.2.1, & following information shall be corrected/ reported to project inspection, & not limiting to this. a. The exact number of joints back log for the above line class. b. All QC documented reported shall be corrected accordingly. Refer: SAESW-011 (Welding Requirements for On-Plot Piping) 1. All stainless steels (except type 304 and 316) and nickel alloys require 100% radiography. Interpretation shall be to "normal" service except there shall be no lack of root penetration or root fusion. During Focus assessment of Welding Quality control documentation. Inspection noted the 10% hardness testing requirement for line class(1CS4P06,CS2P06,3CS4P06,6CS4P06) for sour service is not being covered for the project scope. It was observed the piping class in sour Service, Material Carbon steel (P-1), rating class 150 to 600 # were fabricated and installed without covering the scope with 10% Hardness testing requirement in accordance with SAES-W-011 Para. 14.3. A 10% weld shall be sample hardness tested for all welds in P-No 1 material and the maximum allowed hardness shall be 200BHN. It is requested the scope welds under above catagory shall be identified and necessary hardness testing carried out prior to hydrotesting. D-73-L-300838 sht 1 SW # 19. No RFI was issued/raised for Fitup, In-Process and Final Welding Inspection During Fit-up inspection of Split Tee 24" x 8" x 1" SS at D81-025 Mar 23, 2009 it was identified that SIS Construction incorrectly selected WPS # MSAS-159 Rev. 0. The selected WPS was in fact only qualified to weld wall thickness up to 11mm as were the welders JCCs deployed to do the welding.
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.18
1392
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.12
1393
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
5.11
1394
12/29/2009 12:59:30 PM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
17.5.2.1
1395
1/2/2010 1:48:02 PM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
14.3
1396
1/26/2009 1:07:14 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.7
1397
3/24/2009 9:54:48 AM
SATIP-L-052-01
SAIC-W-2094
Mechanical
SAEP
SAEP-311
5.4.6
1398
10/13/2008 5:37:20 PM
CONTRACTOR has failed to submit the following documentation. Sch. Q, Para. 5.9.1, specifies: "CONTRACTOR shall provide organization chart(s) clearly showing assignments of personnel including: all planned quality personnel for the project in accordance with Attachment VI of this schedule Q. Repeated Violation: During the routine site visit, it was noticed at 303 Corridor (near to 302A casual waiting area) 3rd floor UPDC Bldg. tack welding for the glass supports was performed by the welder without approval and Job Clearance Card. This activity does not comply with SAEP-323 clause # 6.4, SAEP-324 clause # 6.2 and 6.5 & SAEP - 1150 clause # A.10.3. SAPMT advice the contractor to strictly follow all SA standards: SAEP-323 clause # 6.4, SAEP-324 clause # 6.2 and 6.5 & SAEP - 1150 clause # A.10.3. During the routine site visit it was noticed at UPDC Building, 3rd floor - 329A Corridor- tack welding for the structural joints was done by the welder without JCC. This activity does not comply with SAEP-324 Clause # 6.2 and 6.5. The contractor QC to be ensures that all welders shall have JCC prior to all type of welding including tack, repair and temporary welding. SAPMT advice the contractor to strictly follow SA standards : SAEP-324 Clause # 6.2 and 6.5. During the Site survillance of SRG-2 Pipeline(CAT),The contractor pressurizing the Pipeline for Hydro testing (Now 998PSIG), the Strength test Pressure is 1202PSIG.Still the contractor has not been submitted Approved calibration certificates of Relief Valve and Pressure gauges. This is the violation against SAES-A-004 Para5.5.1,SAIC-A-2009 and GI-A-0002-102 During job site survillance at Uthmaniya PCV 441A/B manifold, SAPLU observed the contractor has been welded with existing piping (DWG-HB-158855), prior to Hydro testing of new piping. This is violation against SAEP -310 Para 10.1 and Approved design Drawing. During the site survillance and Document review,SAPLU observed,the contractor was painted(APCS-113A)field girth weld of Blow down line at KM-27,53 and 56 without Approved Procedure.This is violation against SAEs-H-002 Para.5.1.6 SAESH-002 states that, 5.1.6 Liquid coating systems shall not be used on new projects as the primary external coating on buried pipelines For field girth welds consult with the coating RSA to use liquid coating if other systems given in item 5.4.2 deemed impractical . 1.In the Coated area, the Sand blaster is doing blasting the pipe without Aramco approval JCC. 2.Wooden pallets and wooden wastages are nearby painting yard. Painting yard should be free from hazardous materials and Good housekeeping is required the Painted Area During the survillance of BI-00433-002 at KM # 0 (Scraper Launcher).It was observed the sub contractor (HydroTight)has been tightened the Bolt of 56" MOV without Using the Proper Lubricant for Bolts and Nuts.This is violation against SAEP-351 para 4.4. Hence the contractor should be used Proper Lubricant for bolt and nut prior to Torquing. CAT is not following the VALVEs manufacturer recomendations for the Valves Preservation.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.9.1
1399
3/14/2010 1:43:38 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAEP
SAEP-324
6.2
SAEP-1150
10.3
1400
1/17/2010 3:47:13 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAEP
SAEP-324
6.2
SAEP-1150
10.3
1401
8/20/2009 11:33:31 AM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
5.5.1
1402
3/16/2010 9:59:23 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAEP
SAEP-310
10.1
1403
9/6/2009 8:51:17 AM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.1.6
1404
9/7/2009 8:11:12 AM
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAEP
SAEP-316
3.1
1405
SATIP-H-100-01
SAIC-H-2025
Mechanical
ScheduleQ
Schedule Q
1.3
1406
1/31/2010 2:59:38 PM
SATIP-L-450-03
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.4
1407
6/20/2009 11:30:24 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
1408
10/14/2009 2:10:50 PM
SAPID found that CAT is not performing well the activity of Dewatering and Preservation after the Valve Hydrotest, it was noticed when we passed a compressed air form the valve vent by keeping the vlave drain open. There was plenty of water left over in the valve cavity. CAT should submit a detailed Valve Preservation Procedure, specially for the big valves how they are going to get the proper drying of the valve cavities. During the Job site survillance at Ghazlan PP2, SAPID observed, the contractor has been welded the 4 BD line with existing line prior to Hydrotest of new constructed BD line. This is violation against SAES-L- 150 Para 5.2,5.3 Approved P&ID and SAEP -310 Para 10.1 Hence the contractor to cut the existing joint and carried out the Hydro test as per Hydrotest Diagram. During the Documents Review of a 12" dia. 0.375" WT SMLS Pipes lot, its found that the Desing requirements(SAW Pipes) are different than the material(SMLS Pipes) received, the MTC is not showing the correct item number as per the placed PO and finally there is no vendor inspection/release reports for this particular item number. During the site visit observed the pipe support structural compared with the Drawing No HA-166694 this structural material Angle iron used for non standard material As project Mechanical QC activity is going on in Northern Area for three location 1. Berry Jn, 2. Al-wusta, and 3. Ghazlan PP-2, At present two area is covering by contractor Mech QCs remaining one area is no QC personnal available in the site. As per required in Sch "Q" Attachement VI, Table VI-2.(Required more Mechanical QC for Northern Area). During surveillance visit at Berri Jn # Appx 6 mm & 8 mm gap found at the Beam to Beam connecting area at Level EL+ 14291 Meter, contractor did not properly use Bolt Tightening Procedure. These discrepancies found at the following Beams:- B-164 (02 Nos) , B=165 (02 Nos), B-166 (02 Nos), B-261 , B-233 (02 Nos), B-247, B-262, B-272 & B273 (02 Nos). The above mentioned areas should be rectified as per their own procedure in Para 6.6. During Surveillance visit SAPID found that in Al-Wusta area Structural and piping Installation is going on but QC Mechanical inspector is not available. It is violation to Sch Q. Two 56 Scrapper Launcher & Receiver No. D-37-D-0001 & 0002 received form Martime Industrial Services Arabia Co. LTD (MISA)at the job site at Shedgum Km 0 and E/W Pump Station-1 of BI 10-00433-0002 (MGS EASTERN REGION EXPANSION with the following deficiencies: 1-The drop plate at the scrapper Launcher & Receiver has a shortage of 100mm in length, as per MISA IFC Drawing No. 2000000450-000 Sheet 1 of 1 that the total ling of the plate is 2425 mm where it is the actual calculation is 2350 (see attached Drawing), so the total difference is 105 mm. 2-As per Saudi Aramco IFC drawing No. HB-158771 Sheet 1 the 1 welded drain valve shall be welded and provided along with the Scraper and Launcher; however, it has been received without welded valve. SAPID observed that CAT Document Control Unit at Dammam and Shedgum offices is not distributing the revised drawings to SAPMT and SAPID. CAT-Dammam Fab Shop welding: CAT is not putting the right tacks, its a violation under SAES-W-012, Para: 10.9.6.
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-A-004
9.3
04-samss035
12.1
1409
3/17/2010 7:06:49 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAEP
SAEP-310
10.1
SAES-L-150
5.3
1410
11/1/2009 11:39:27 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
AIII Para3.22
1411
9/13/2009 5:24:34 PM
SATIP-L-350-08
SAIC-M-2011
Mechanical
ScheduleQ
Schedule Q
1.3
1412
1/21/2010 4:41:22 PM
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
5.1
1413
2/27/2010 7:28:54 AM
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1414
1/19/2010 8:20:00 AM
SATIP-M-001-01
SAIC-M-2010
Mechanical
ScheduleQ
Schedule Q
5.1
1415
2/17/2010 7:17:36 AM
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
5.1
1416
11/8/2009 1:56:41 PM
Violation-After The Fact ViolationPrevented Installation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.7
1417
12/15/2009 8:21:45 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.9.6
1418
10/31/2009 5:04:11 PM
Today morning CAT was doing one 6" dia. weld joint (pipe to elbow) FW-13 of drawing HB-158764. PMT found that the contractor was not maintaining the root gap as per the approved WPS and finaly CAT completely welded this joint with a root gap of around 6mm which is a big violation. Its observed that contractor welding QC is not checking the joints fit-up before the welders starts welding the joint. The contractor CAT should cut and re-weld this particular weld joint (FW-13). Thanks. SAPID observed that at CAT Fabrication Shop-Dammam, the construction group is fabricating some GUARD RAILS using 6" dia. pipe, but there is no IFC drawing available for this fabrication, on checking with the construction/fabrication crew they are telling that this fabrication is for guarding the perimeter fence and it is on the instructions of site people from Shedgum. During the site visit at Al-Wusta FW # 09 & 10, 16" dia pipe spool welding was going on without proper wind shield. This is violation as per W-12 Para 10.2.1 During the site visit at Berry Junction Field weld No:2, 42" dia pipe spool welding was going on without proper wind shield. This is violation as per W-12 para 10.2.1 During Receiving Inspection of Valves ast CAT Dammam Fabrication Shop Area, the item equipment of numerous valves were found non compliance to ARAMCO standards and Specification with 04 SAMSS-005; SAES-H-002. Valves paint/ coating is not acceptable and not suitable for outdoor exposures. Inside of the valves were dirty and not complying with the SAESL-350 Sec. 15.1 The contractor backfilled the location description without reholiday testing. As per our agreement of Contractor QC Coating Inspector (Mr. Alex Manaoat) that they should re-holiday test the said location prior to back filling. During the valve receiving inspection in MGS-BI-10-00433-0002, CAT co @ Dammam Fabrication shop, SAPID/SAPLU has found that the Aramco Supplied MOV 0001 ball valve 56 #600 , has mismatch between the valve body & Ball seating during 100% open condition. Vendor Inspection documents are not available for Aramco Supplied valves. During the Valve receiving inspection @ CAT fabrication shop , Dammam for BI-00433-0002 MGS,SRG2 Pipeline, Upgradation of PCVs and Filter-stations, it was found that some pin holes and seat ring impression mark on the seat of the 56 # 600 class Ball valve-MOV 0009, SL # 1083100 which was supplied by the Aramco. It was witnessed by Contractor & SAPID. It was visual rejected and has to be rectified. During site visit surveillance at PP9. PID observed that welding activities going on without monitoring by welding QC this violate Schedule Q. All joint product in that day required for NDT. During site visit surveillance at PP7 PID found contractor install and weld vent at 24temporary By-pass line without inform PID by sending RFI to conduct visual examined for root pass. This violate SAES-W-011 Para 16.8.1. PID request contractor to investigate status provide feedback ASAP
n/a
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
1419
12/30/2009 3:33:16 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.3
1420
3/18/2010 4:05:40 PM
ViolationPrevented Installation ViolationPrevented Installation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.2.1
1421
11/14/2009 7:36:36 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.2.1
1422
1/12/2010 1:34:12 PM
n/a
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15.1
1423
6/1/2009 3:54:02 PM
SATIP-H-002-02
SAIC-H-2018
Mechanical
SAES
SAES-H-200
1424
8/24/2009 1:58:02 PM
SATIP-J-700-01
SAIC-J-6072
Mechanical
ScheduleQ
Schedule Q
1.3
1425
8/20/2009 9:26:19 AM
SATIP-J-700-01
SAIC-J-6702
Mechanical
ScheduleQ
Schedule Q
1.3
1426
11/22/2009 11:39:54 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
1427
12/8/2009 9:04:15 AM
SATIP-W-012-01
SAIC-W-2057
Mechanical
SAES
SAES-W-012
16.8.1
1428
2/21/2010 4:13:29 PM
The assigned QA/QC manager Mr. Anand Job of CAT has been absent for 2 weeks with out any detail as per Schedule "Q" Section 5.9 up to 5.14 of ARAMCO.
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
5.11
1429
3/7/2010 2:35:05 PM
1430
7/19/2009 5:32:38 PM
1431
11/23/2009 5:05:25 PM
Violations were observed during todays inspection for the welding of split tees at Berri Junction. 1. No approved HOT TAP Package at site. 2. There was NO APPROVAL of WPS for welding of split tees. 3. NO RFI received for the Pre-welding & weld joint fit up inspection. Please refer to SATIP-W-012-01 for inspection requirements. Contractor is advised to comply with all the requirements before start any activities at site. During the site surveillance visit in UBTG 4 @ KM 76 rail roads crossing and observed that the carrier pipe insertion into the casing pipe has been performed prior to install 2 vents in both ends of the casing pipe as per the Drawing HA I59505-001 rev 00. 4 pipe guard barrier shall be installed after the berm construction @ the vent locations. During the inspection visit in UBTG 4 (MGS) @ KM 96 & 152, it was found that the STOPAQ coating of the MLW 3859, FW 3859A & MLW 6196 & 6197 have damaged due to the pipeline string touching the ground directly and trench collapsed respectively. It is violation against the SAES H 002V para 4.6. Backfilling can be performed immediately after the applied coating system has been checked, inspected, and approved by the inspector. SAES H 002V Para. 4.6 (g) During the site surveillance visit in UBTG 4 @ KM 61, it was found that MLW 6291, 6292 & 6299 STOPAQ and FBE coating have been damaged due to mishandling of pipe section during welding. It is violation against the SAES H-002V Para. 5.1. Damaged portion of the STOPAQ and FBE shall be repaired with the compatible coating procedure. Care shall be taken to avoid such coating damage during welding activities. During the inspection visit in UBTG 4 at KM 132+315 & 133+550, it was found that previously holiday tested portion of the lowered pipeline string still exposed and no backfilling has been done. MLW 5211, MLW 5212,FW 5212A,B,C, MLW 5213 & 5214 @ KM 133+550 & MLW 5168,5169,5170,FW 5170A,B MLW 5171 & 5172 @ KM 132+315 to be re holiday tested prior to backfilling. It is violation against the SAES-H-002V APCS-113C Para 4.6. During the surveillance visit in UBTG 4 @ Km 68 and found that previously backfilled of the pipeline has been exposed in few areas due to the wind. This areas shall be re holiday tested and backfilled immediately as per SAES-H-002V APCS-113C Para 4.6 During the surveillance visit in the UBTG 4 , 56 MGS line @ Km 128, it was found that the coating inspector is not available in the coating application (APCS 113C STOPAQ) area to monitor the coating activities. It is violation against the Schedule Q Attachment VI table 2. During the surveillance visit in the UBTG 4 coating shop in AinNakhil fabrication yard it was noticed that the 6 spool s, SPL 415E, F, G, H, SPL 447E, F, SPL 460 E & F have been coated with APCS 113A. As per the IFC drawing it is required to coat with APCS 104 (FBE coating). It is violation against the Approved drawing and SAES H-002 paragraph 5.1.14. 5.1.14 For new construction, buried carbon steel piping in diameters 4 inches and smaller shall be coated with APCS-113A, APCS-113C, or other systems with prior approval from RSA.
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.7 & attachment IV- 2.1
SATIP-L-450-04
SAIC-L-2120
Mechanical
SAES
SAES-L-460
8.1
Schedule Q
1.3
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
4.6(g)
1432
12/12/2009 5:35:57 PM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
5.1
1433
11/21/2009 5:35:26 PM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
4.6
1434
3/4/2010 10:33:57 AM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
4.6
1435
10/13/2009 7:00:33 AM
SATIP-H-002-11
SAIC-H-2082
Mechanical
ScheduleQ
Schedule Q
5.1
1436
7/4/2009 6:39:02 AM
SATIP-H-002-02
SAIC-H-2009
Mechanical
ScheduleQ
Schedule Q
5.1
1437
1/27/2010 1:35:51 PM
During the site visit in UBTG4, 56 Mainline @ KM 69 to 71, it was found that girth weld coating (STOPAQ APPLICATION) for MLW 6807,6848,6853,6856,6859,6867,6949 & FW 005 have been damaged due to the thermal expansion of the pipeline. Coating repair shall be performed as per the SAES H-002V Para. 5 During the site visit @ UBTG 4, Main line KM 161+, it was noticed that a 56 pipeline string is lying on the ROW without the effectively padded clean sand. Exactly the Stopaq coating is touching the ground and stones. It shall be visual inspected and Holiday tested with high voltage holiday detector and repaired if any holidays found prior to lowering into the trench. Some string pipes have not been end capped. Recommendation:Externally coated pipe strung along the right-of-way is supported on rock free sand, sand bags, rubber tires, or similar compressible material to prevent damage. SAES-H-200 Para. 5.3 & Open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds. Keeping sand alone will be blown away from the sand storm. Wooden skids with tire shall be kept under the string pipe to prevent the coating damage. Location: @ From KM 161-176.(MLW404,410,441,521 to 532,623,626,628-648,663671. During the surveillance visit in 56-UBTG 4 @ KM 70+750, it was noticed that a pipe 56 Pipe # 08-11620, HT # 751219 has been rolled from the support and damaged the near by Pipe bevel, Pipe # 08-14085, HT # 814231. These two pipes bevel shall be re beveled and magnetic particle inspection shall be carried out on those bevel to check the pipe integrity. Coating damage shall be repaired. It is clear violation against the Standard SAES-H200, Para. 5.1.3. Contractor has to check the strung pipes on the ROW periodically to avoid such rolling the pipe off the supports. During the surveillance visit in UBTG 4 MGS line & BJBFG 3 @ KM 56, 152,212, 0 & 6, it was found that 36 flanges have being kept on the valve supports in MOV 186,187,200,201,205,206,214,215,0004,0005,0009 & 0010 locations. It is clear violation against the SAES 350 Para 12.5. Issue Date: 22 April 2009 During the surveillance visit in UBTG 4 @ KM 56 (Scraper launcher area) it was found that the piping end of the 48 lateral line (48-P-0146-6CS1P1) has been opened for long time and it is clear violation against the SAES L-350 Para. 15.2.1 to 15.2.4. Piping ends shall be covered to prevent the entry of debris, rain water and other foreign material etc. During the inspection visit in UBTG 4 @ KM 56 (Scraper launcher area), it was found that the 6 plug valve SL # 4QKH130 one side of flange has been kept open and preservation has not been taken properly as per the 04-SAMSS-035, Paragraph 12 & SAIC-L2041. It violates the Aramco standards and this practice will prone to corrode the material & dust entrapment inside the body. Contractor has to take the necessary action to comply the Aramco standards. Contractor has to follow the SATIP-L-108-01 for valve testing and preservation During the site visit in UBTG 4 pipeline @ KM 147-149, it was found that strings #190,191,192,193,194 & 195 which were lowered into the trench have been uncapped. Open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds. It is violation against the SAES-L-450, Para. 11.4.
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
5.1
1438
1/5/2009 5:53:05 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.3
1439
3/31/2009 5:43:30 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1.3
1440
11/16/2009 7:04:55 AM
SATIP-L-350-02
SAIC-L-2014
Mechanical
SAES
SAES-L-350
12.5
1441
12/12/2009 8:13:25 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
1442
1/24/2010 5:53:55 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12
1443
12/16/2009 6:00:32 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
1444
8/11/2009 6:46:02 AM
During the routine site visit @ UBTG 4, KM 138-148, it was found that the welded strings from KM 138-148 has no pipe end caps installed to protect the entry of the debris and animal. It is violation against SAES-L-450, Para. 11.4. Some Externally coated pipe section strung along the right-of-way is supported on stone contained sand. Stones shall be removed from the sand support wherever it contains from KM 113 to 148. Contractor QC shall monitor the whole section periodically and take necessary action to prevent the violation. This same practice is continuing. During the surveillance visit in UBTG 4 @ KM 134 to KM 145, it was found that pipeline strings 142,143,149,156,158,159,160, 162, 164,169,171 & 173 are touching ground directly where FBE coating could be damaged due the stones and the bare girth weld areas could be corroded. Among these strings string # 143 and 149 have rolled from the tire. This is violation against SAESH-200 Para. 5.3,,5.1.3 During the site visit @ UBTG 4, Main line from KM 125-13.2, it was noticed that a 56 pipeline string is lying on the ROW without the effectively padded clean sand and some strings rolled down from the tire support. External FBE coating shall be damaged due to the string touching the ground directly and the Contractor QC has to check all the string periodically and take the necessary action against that. Recommendation: Externally coated pipe strung along the right-of-way is supported on rock free sand, sand bags, rubber tires, or similar compressible material to prevent damage. SAES-H-200 Para. 5.3 During the site visit in 56-MGS-UBTG 4 project @ KM 136+800, it was noticed that the 56 UBTG 4 pipeline has been crossed over the existing 16 gas line without any approved document. It is clear violation against the drawing HA-159307 sheet 051 Rev 00 note 8 & 9, SAES L 450, Para. 10.3.3 & SAES B 064 Para. 7.9. During the surveillance visit in UBTG4 @ KM 129, it was observed that 6 (BD-0217-6CS1P1) External FBE coated pipes had been mishandled and kept on the wooden skids directly. It violates the SAES H-200, Para. 5.3. Damaged coating shall be repaired as per SAES H-200, Para. 6.3. And it was observed in Km 152 that the 6 Blow down line flange (BD-0224-6CS1P1)) has been kept without the end cover and it is clear violation against the SAES L-350 Para. 15.2.1 to 15.2.4. Piping ends shall be covered to prevent the entry of debris, rain water and other foreign material etc. During the surveillance visit @ UBTG 4 Km 212 Juaymah area and found that flange tightening has being take place without RFI to the PID and RFI shall be given to PID for permanent gasket verification and bolt tightening. Also it was noted that the insulating gasket has been installed prior to the hydro test. During the hydro test temporary gasket shall be installed and replace with the new one after the test. Contractor has to evaluate their stocks of sufficient gaskets for permanent installation. Installation of insulating gasket prior to the hydro test is violation against the Saudi Aramco standards and the project IFC drawings.
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
1445
10/29/2009 1:46:30 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
1446
7/11/2009 5:33:48 PM
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-H-200
5.3
1447
12/1/2009 10:37:27 AM
SATIP-L-450-04
SAIC-L-2131
Mechanical
SAES
SAES-B-064
7.9
1448
2/15/2010 6:09:52 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.3
1449
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
1450
9/29/2009 10:01:25 AM
SATIP-L-450-04
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
1.7
1451
12/13/2009 5:35:34 PM
During the surveillance visit in UBTG 4 @ KM 152, it was found that the fabricated piping system (48 and 6) have been transported and kept in the site without the end caps. It violates the SAES L 450- Para. 8.9. and it states that for pipelines in sales gas piping systems, each joint shall be cleaned and capped with durable plastic sheet prior to transportation to the field. During the surveillance visit in UBTG4 @ KM 152, 174, 175 and 212, it was found that some piping spools at Km 152,174 & 212 have been kept without the end cap. It is clear violation against the SAES L-350 Para. 15.2.1 to 15.2.4. And 2" plug valve has been installed without the end cover in the 40 lateral line @ KM 212. It violates the Aramco standards and this practice will prone to corrode the material & dust entrapment inside the body. Contractor has to take the necessary action to comply the Aramco standards. Contractor has to follow the SATIP-L-108-01 for valve testing and preservation. During the surveillance visit @ UBTG 4 Km 152 and found that Material preservation has not been done in the proper way as mentioned in the Standard & UBTG 4-QUAL-PQMP-002, Parapraph 4.3.2.1 & 4.3.2.4, Schedule Q attachment IV, Paragraph 5 & SAES L 450 paragraph 8. For Example: Valves, Stopaq material, piping spools and stud bolts kept exposed to the atmosphere. Piping spools are lying on the ground and full of sand covered. Contractor has to take the necessary action to make proper storage and preservation. During the focused assessment in BI-00433-0003 (UBTG4 & BJBFG3) SAIPEM Ain nakhil Quality control office, it was found that the controlled copy (DCN # 22F3) of the engineering design drawing has no revised index sheets. All issued controlled copies of the engineering drawings to PMT and PID have old revision and new revision drawings together. Document controller shall put the stamp on the old revision as SUPERSEDED as per the UBTG 4-QUAL-PQMP-001 Paragraph 5.5 and ISO 9001-2000 clause 4.2.3. Verified sample document: HD-159271 8/21 Rev 00 VS HA-432843-001-F2 & HA-432843-002-F1 This is violation against the Quality plan and ISO 9001-2000 During the inspection visit in UBTG 4 @ Km 56,152 and 212, it was found that XPI & XT have been installed as per the Isometric drawings of HB-159411-001-00,HB-159442-001-00, HB159457-001-00 & HB-159478-001-00 but not per the IFC of P&IDs ( HA-159274-001,004,005,& 006) in the trapper areas. Contractor has to verify it and correct if any changes made in the drawing or in the fields. There is a conflict between the P & ID and Isometric drawings. It has to be rectified. During the site surveillance in UBTG 4 @ KM 175, FW 822A, it was found that the electrode holding oven temperature gauge is not working properly and the calibration of the temperature gauge has no calibration sticker. Contractor is using that oven for holding purpose. Contractor shall use the calibrated and good working condition of the oven and temperature gauges. This practice will lead to poor welding performance and rejection of the weld. Calibration cycle of devices shall not exceed 6 months. Reference Schedule Q IV paragraph 6. It is violation against the schedule Q IV paragraph 6, SAES-W-012, Table 1
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4 & 8.9
1452
3/18/2010 3:22:43 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4 & 8.9
1453
9/29/2009 9:44:21 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
Schedule Q
A IV Para 5
1454
10/27/2009 8:11:16 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
3.7
1455
3/8/2010 9:28:37 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
1.3
1456
10/6/2009 7:23:38 AM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
Schedule Q
A IV Para 6.1
1457
1/29/2009 5:02:01 PM
During the routine visit in the SAIPEM fabrication shop UBTG 4 MGS, it was observed that the welder has used the E8018 C3 electrode instead of E7018 which was mentioned in the approved WPS 105/93. Initial production had been made by E7018 only. Records also showing the same electrode E8018C3 had been used for more production. This is the procedure violation and approved WPS is not available to use this electrode. WPS shall be revised to use this electrode. For further details CSD has been contacted and waiting for the result. During the site surveillance in UBTG 4 @ KM 122+200, FW 4820A, it was found that the electrode holding oven temperature gauge is not available in the system. Some E 8018 C3 electrode have been kept inside the holding oven for holding purpose. Contractor shall use the calibrated and good working condition of the oven and temperature gauges. This practice will lead to poor welding performance and rejection of the weld. Calibration cycle of devices shall not exceed 6 months. Reference Schedule Q IV paragraph 6. It is violation against the schedule Q IV paragraph 6, SAES-W-012, Table 1. During the routine surveillance visit, it was found that the base metal of some steel structure columns of the platform was damaged / removed during some cutting operation. In those areas primer / paint has also been applied. Contractor needs to remove paint at all such areas, clean the surfaces and carry out the build up. Smooth contour and appearance is required after repair welding. Contractor to raise the RFI for this remedial activity. During Surveillance it was found that the Latest Revision of the drawing (40" dia P/L) is Not Available at the site. Working crew / QC inspector was not aware of the installation of 3/4" vent. This violates Schedule Q. During routine surveillance visit, it was found that the backfilling was incomplete at the mentioned locations of UBTG-4 Pipeline. FBE coating at the upper part of pipe was not covered with sand. Also some stones were present in the sand touching the pipe. Contractor is required to perform re-holiday test of these uncovered/poorly backfilled areas and remove the stones. Proper and timely backfilling to be assured after the holiday test. During the inspection visit @ UBTG 4, 56-MGS-KM 116, it was found that the holiday tested and lowered pipeline string # 99 which was lowered on September 13, 2009 was not yet backfilled. Exposed portion of the pipeline string has to be reholiday tested prior to backfill. Weld joints or sections of pipelines left open for some time after holiday test was performed are re-holiday tested before backfilling. SAES-H200,Sec. 7. During the site visit @ UBTG 4, 56-MGS pipeline, KM 115, it was found that the APCS 113C has being applied without the pipeline clearance from the ground to the bottom of the pipe. It is violation against the SAES H-002V paragraph 4.4. SAES H-002V, APCS 113C paragraph 4.4: Allow proper accessibility to the pipeline from all directions for free movement of labor during the application.
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
7.1.1
1458
10/8/2009 10:18:59 AM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
Schedule Q
A IV Para 6.1
1459
2/9/2010 6:02:13 PM
SATIP-M-001-01
SAIC-M-2012
Mechanical
other
AWS D1.1
5.18
1460
11/23/2009 7:04:16 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
3.7
1461
1/24/2010 7:42:15 PM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
apcs 113c paragaraph 4.4
1462
9/15/2009 8:21:09 AM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
1463
9/13/2009 7:45:08 AM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
1464
3/15/2010 9:45:48 AM
During surveillance visit and observing the welding reports, it was found that at Km 212 Juaymah, 6 diameter Blowdown line Joint nos. 482/33, 482/34, 482/35, 482/36 & 482/37 have been welded while the pipe thickness is lesser than the required as per IFC drawing. Thickness of welded pipe is 0.280 but the required id 0.312 according to IFC drawing No. HB-159482 Sheet 001, Rev. 00. Prior to welding, contractor did not obtain the Design Approval from the designer. 12.4 The fire pipelines are coming into direct contact with HVAC ducting and electrical conduits. A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement resulting from hammering, expansion, vibration of fire water piping according to SAES-L-310. A corrective action shall be established to resolve above matter. During the recieving inspection of the refrigeration unit SKid R290,the following deficiencies are noted and these needs to be corrected. 1.There is no drain or vent valve between PZV and inlet or outlet block valve for all PZVs on the skid. Violating 34SAMSS-831 para. 8.1.1.3.1 2.All block valve for PZV not painted orange 3.The drain piping connected to equipments (Z28-D0205,Z28-E-0103, Z28-D-0204,Z28-E-0102,Z-E-0101,Z28-D0201,Z28-E-0104/0105) is dead leg. 4.There is no drain install on the pocket suction of line 4" connected to Z28-E-0101and HV193. Violating 01-SAMSS-17 para. 6.7. 5.No equipment number marked on the Name plate for equipments (Z28-D-0205,Z28-E0103, Z28-D-0204,Z28-E-0102,Z-E-0101,Z28-D-0201,Z28-E0104/0105). 6.There is no enough welding (fillet weld) for the connection of " nipple of Level glass near HV-136. 7.There is no Name plate for Z28-D-0202 & 0203. All block valve for PZV not painted orange No equipment number marked on the Name plate for equipments (Z28-D-0205,Z28-E-0103, Z28-D-0204,Z28-E-0102,ZE-0101,Z28-D-0201,Z28-E-0104/0105). As per routine site visit, it is noted in the AL-SUWIADI Fabrication shop a 4 x 300 lb inch blind flange has been drilled for drain purpose in newly fabricated instrument air header which is not complying with SAES-L-109-(cut off date 9 March 2008) Para 6.6 that Blind flanges shall not be drilled for connections such as drains, flushing, etc., unless a stress calculation per ASME SEC VIII D1, Appendix 2 shows that the flanges will not be over stressed. The header side flange has been used as WN with raising face while as per the line class 12CG0U it supposed to be 150LB FF with 1.6 mm Synthetic fiber gasket. The above concerns shall be corrected to comply the requirements of SAES-L-109-(cut off date 9 March 2008) Para 6.6 and SAES-L-105 line class 12CG0U. Contractor will start to do the cold insulation activities for the skids and related pipes @ area H , The Skids & related pipes are coated with APCS-26T & APCS-2A, APCS-26T is not accepted to be covered by cold insulation. APCS-26T is designed for atmospheric environment. During site visit surveillance PID observed that relief valve at air receiver tank out of expired date this violate SAES-H-102 Para 4.4.1.5 .
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.3
1465
12/5/2009 4:59:34 PM
MWW
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
Section 12
1466
12/7/2009 8:52:08 AM
Mechanical
other
34-SAMSS831
8.1.1.3.1
1467 1468
Mechanical
other
34-SAMSS831 34-SAMSS831
8.1.1.3.2 11
Mechanical
other
1469
2/4/2010 11:04:59 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-109
6.9
1470
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-105 Line class 12CGOU
1471
2/10/2010 10:47:57 AM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
1472
10/21/2009 2:23:12 PM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-102
4.4.1.5
1473
8/4/2009 2:37:16 PM
The Contractor has submitted third party welder qualification records containing numerous errors in the certificates. The Contractor is required to establish the root cause, and establish the required corrective actions, and obtain correct qualification certificates showing conformance to ASME IX. As explained to SIS Welding QC Inspector,the linear percentage repair rate stated on the weld status reports is incorrect. This is due to the RTFI not giving the actual length of the defect. This situation emphasises the requirement for SIS to deploy a qualified RTFI to review the films and reports of the NDT contractor. Please advise PID of the status of the deployment of the Suwaidi RTFI. When he has reviewed the films and measured and reported the actual defect length, the correct linear repair rate can be calculated. During review of the submitted welding reports,it is noted that the Contractor is not using the correct reporting formats to record the welder repair rates. The Weekly Welder Repair Rates shall be calculated and reported via Saudi Aramco Test Report SATR-W-013. Please review the reporting requirements as stated in SAEP 1160 Section 5, and ensure all reports are in accordance with SAEP 1160. The Contractor continues welding despite no NDT having been conducted on the welds completed to date. Welds shall be considered as " backlog" if more than 7 days elapses between the welds being visually accepted and the NDT being completed. The Contractor is requested to inform PID of the amount of joints currently in excess of this 7 day requirement. During the assessment conducted by PID representatives, the welding repair rates of welders utilized during the shutdown was reviewed and found to be excessive. The Contractor is requested to submit the repair rates for the shutdown phase of the project, as this is the only Radiographic Testing conducted to date. The Job Clearance Cards of welders whose repair rates exceed the requirements of SAES-W-011 section 8.4. shall be returned to PID 1-Poor handling of Fabricated structure Laying on soil / sand Ref (SAES-L-350, Para 8). 2-Poor handling of Valves (lined valves without covers) laying on soil / sand Ref (SAES-L-350, Para 8). Welding machine grounding / earthing connected to hard barricaded scaffold tube (Safety Hazard). Poor handling of Fabricated Spools (flange faces are on rough surface) causing damages on sealing surfaces, RTR / CPVC material, fittings are left without covers kept on soil / floor, Ref SAES-S-070 Para 5.3 & SAES-L-350, Para 8. During the site visit found that, many of the piping work / construction activities are in progress, perhaps Contractor did not raise any RFI, which is violation of the Sch Q, and SATIPs.
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
1474
8/12/2009 2:18:25 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.3
1475
8/12/2009 2:46:41 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
Schedule Q
A IV Para 7.3
1476
7/28/2009 8:04:58 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5&6
Schedule Q
A IV Para 7.3
1477
8/4/2009 10:13:00 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAES
SAES-W-011
8.4
1478
1/7/2010 3:12:54 PM
HYPOCHLORITE GENERAT
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
1479
2/22/2010 3:21:57 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
SAES-S-070
5.3
1480
3/10/2010 2:18:50 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
1.7
1481
1/7/2010 2:58:48 PM
1482
1/7/2010 3:02:47 PM
1483 1484
1/7/2010 3:06:07 PM 1/7/2010 3:09:27 PM
HYPOCHLORITE GENERAT HYPOCHLORITE GENERAT
1485
12/31/2009 8:23:54 AM
1486
1/31/2010 11:55:19 AM
1. Installed 4 columns of structure have incomplete welding for 1 stiffener plate. 2. Installed 8 columns of structure missing 1 stiffener plate from 3. 3. Installed 6 columns of structure have 3 stiffener plates tack welded only but coated. 4. Installed 1 columns of structure 2-D have 1 clit plate (used temporary for fit up) left tack welded as final product as it is coated / painted too. Ref SAES-W-011, Para. 11 (For above Ref Drw# BA-527292Sheet1,2,3 Rev 00) 5. Installed few columns have weld defects like, under cut, under fill, spatters, arc strikes, coated without removal of slag. Ref SAES-W-011, Para. 11 & 12-SAMSS-007 Para 5.2, 6.1, 7 Fabrication / paint Completed Rafter beams at site shop / yard were having many fabrication and welding defects like, incomplete welding, welded without removal of galvanizing, ark strikes, spatters, poor weld bead, under cut, under fill and under size. (12-SAMSS-007 Para 5.2, 6.1, 7 and SAES-W-011, Para. 11). Welder (Trieu Van Dang) does not have J C C for this BI. For Ref SAEP-324 Para 5 and 6 No SA approved welding Inspector at site (Sch Q Att-1 Para 3.3.1). During site visit following has been found, welding activity without RFI, No continuity record of Welders, Qualification Cards are Expired, No Baking / Storage Oven at all for Electrodes, Portable Ovens without power connection, Low hydrogen (A5.1 E7018) Electrodes are kept in Open Tin can, Welding machines are not calibrated (SAES-W-011 Para 19). Contractor QC has been advised to complete the required items per SAES-W-011 att1 4th time repeated violation Same Welder (Trieu Van Dang ) without Qualification found at initial stage of welding work at site Last QMIS entry # 5,34,80 . (Contractor has raised their NCR after my finding, even in QMIS reply it was mentioned from Contractor that the Welder has been gone for WQT). 5th time repeated violation, without Qualification of welder found fabricated Material arrived at site, Last QMIS entry # 5,34,80,121 . (Contractor has raised their NCR after my finding, even in QMIS reply it was mentioned from Contractor that the Welder has been gone for WQT).Contractor has mentioned in the rectification Plan that, RFI will be raised after obtaining the JCC for welder and Joining of welding inspector. but the said material has been fabricated without any Official information / RFI even without internal RFI of Contractor construction to QC. 5th time repeated violation without Qualification for welding and assigned welding inspector, found fabricated structure main items at material yard beside the site office.Contractor had issued their internal NCRs after the fact entries by PID in QMIS and contractor committed in rectification Plan (submitted to PID earlier) also in reply to QMIS entries stating that no welding work will be done without prior approval of welders and welding inspector. Ref Last QMIS entries # 5,34,79,80,121 . Even in QMIS reply it was mentioned from Contractor that the Welder has been gone for WQT) and during activity RFI will be raised. Received material involves many type of violation all together such as "major Weld defects, Galvanizing with out cleaning of welded area,Fabricateion faults etc Non galvanized material has been used for fabrication of structure. (Base plates and other structural attachments were Painted to hide their actual appearance of metal). (For above Ref Drw# BA-527292-Sheet1,2,3 Rev 00)
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-W-011
11 & 12
12-SAMSS007
5.2 & 6.1 & 7
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-W-011
11 & 12
12-SAMSS007
5.2 & 6.1 & 7
SAEP ScheduleQ
SAEP-324 Schedule Q
5&6 5.1
SAES-W-011
8.1
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
1.7
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-324
5&6
SAES-W-011
8.1
1487
2/3/2010 1:58:17 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-324
5&6
SAES-W-011
8.1
1488
2/3/2010 7:15:37 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-324
5&6
Schedule Q
5.1
1489
1/17/2010 11:14:02 AM
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
12-SAMSS007
5.2
1490
1/17/2010 11:27:51 AM
Repeated violation (Previous QMIS entry # 36) , No SA approved welding Inspector at site (Sch Q Att-1 Para 3.3.1). Poor handling of Fabricated structure Laying on soil / sand Ref (SAES-L-350, Para 8). Poor handling of Valves (lined valves without covers) laying on soil / sand Ref (SAES-L-350, Para 8). Repeated Violation, Welder does not have JCC. For Ref SAEP324 Para 5 and 6. Welding work carried out without RFI, or closing the NCR # M-01 on 06-Jan-10 issued by contractor, this reflects unsatisfactory corrective actions taken by contractor. During yesterdays inspection, It was noticed that welders were fabricating the temporary by pass line for IBN SINA along Hadeed Area and observed that NO QC Inspector available at site. This is a violation to Contractors Sch. Q para. 5.1 & 5.6. SGPIU have noted that the QC manager failed to attend the QC meeting in addittion his failure to attend the SGPIU audit assessment held on 2/15/2010. This is in violation of Schedule Q. para 5.3 "The QC manager shall be assigned to the work through project completion" Failure of the contractor ROBAYA to impliment this requirement shall lead to an NCR. The QC manager informed SGPIU at the weekly quality meeting that he is not dedicated to the project & his company are using him on other projects. This is in violation of Schedule Q. para 5.3 "The QC manager shall be assigned to the work through project completion" Failure of the contractor ROBAYA to impliment this requirement shall lead to an NCR. This is repeated violation & if continuation of the violation by the cotractor will result in this being raised to NCR status. The contractor has failed to submit his Monthly Quality Management reports from the start of the project. This is in violation of Schedule Q Para 7.7. SAPMT to advise the contractor to comply with the requirements of Schedule Q SGPIU have revoked the provisonal approval of the QC manager Mr. Edwin Enriquez SAP # 70002289 due to his poor field performance, found not to be technicaly competent to perform the role of QC manager,low PQI score, violation after the fact notifications in QMIS & SA initiated NCR. These are all in volation of Schedule Q requirements. The contractor has failed to have his quality plan approved prior to start of construction This is in violation of Schedule Q para 3.2 & V which states that PQP shall be submitted & approved within 30 days of the effective date of the contract. Failure of the contractor to have an approved PQP will result in the issuance of an NCR. It has been through email that the contractor provisionally QC manager mr. Edwin M. Enriquez has proceeded out on emergencey leave. No notification has been forwarded through SAPMT in this respect including his tentative return date. This is in violation of Schedule Q Para 5.14. If the QC manager fails to return within a reasonable period of time then SGPIU will provoke his provisional approval. Please note that emails are not classified as offical documents. 1) Pipes are having Blisters, fish eyes & pin holes.this is the standard voilation of 09-SAMSS-089, PARA 7.6 2) Pipes are having damages due to transportation(loading/un-loading). This is the stanard violation of SAES-H-200, Para 5.1.1 & SAES-L450.
SATIP-M-001-01
SAIC-M-2010
Mechanical
ScheduleQ
Schedule Q
5.1
1491
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-L-350
1492
1/17/2010 11:22:05 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAEP
SAEP-324
5&6
SAES-W-011
8.1
1493
2/21/2010 7:57:09 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
1494
2/17/2010 12:53:40 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.3
1495
3/3/2010 7:06:45 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.3
1496
11/18/2009 2:11:32 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.5
1497
11/25/2009 8:09:29 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.6
1498
11/9/2009 1:28:58 PM
Standards Violation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.2
1499
11/11/2009 7:24:01 AM
Standards Violation
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1500
2/28/2010 5:10:57 PM
Standards Violation
SATIP-L-450-04
SAIC-L-2112
Mechanical
SAES
SAES-H-200
09-SAMSS089
7.6.
1501
2/8/2010 11:51:23 AM
During inspection activities for the Material receiving inspection for the 8 Gate valve at the contractor yard in RTR, it has been found that the 8 Gate valve does not have a marking identification on the body or on the identification plate. This violates Saudi Aramco Checklist SAIC-L-2040 Item No. B and Saudi Aramco Standard SAES-L-108. This valve has to be rejected or the identification is corrected from the manufacturer. During inspection activities for Material receiving inspection of RTR pipes and fittings, it has been found that the contractor QC failed to identify the correct material for the pipes and fittings when he filled the Saudi aramco checklist SAIC-S-4055 Item No. A7. The pipes and fittings material manufacturer is not listed in Saudi aramco standard SAES-L-101. The contractor was asked to verify and correct this issue. During my visit to the fab. yard for valves testing inspection, following violations were found: 1- Blasting activity was on going without an RFI issued which is a violation of Sch.Q. 2- The blater doing the work was not certified per SAEP-316.
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
Section 11
1502
2/2/2010 10:08:50 AM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-101
1.2
1503
3/16/2010 2:05:38 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
1.7
1504 1505
2/17/2010 12:25:33 PM
SATIP-H-100-01
SAIC-H-2010 SAIC-W-2006
Mechanical
SAEP
SAEP-316 Schedule Q
3.2 5.1
1506
2/14/2010 6:08:54 PM
welding activities were going on in the fabrication shop (Ain Nakhel) without the presence of welding inspector. This is violation as per Sch Q, During tighten of pipe with Elbow and flange, clamp marks have been observed on 1 " pipe spool. *Remedy and offer through RFI for verification. During witnessing the MPI test at SAACO open field fabrication area (Riyadh) PID review the document for the technician and we find he can not perform MPI. The contractor should comply with SA requirements and provide certified technician. During site surveillance at SAACO open field fabrication area (Riyadh) PID found that there are material of structural steel shapes and plates with no material receiving inspection and this is violation according to schedule Q. All material should be inspected before used. During site surveillance at SAACO open field fabrication area (Riyadh) PID found the following: 1. The contractor continue welding activities without the presence of welding QC inspector, As per SATIP-W-011-01, pre-welding and post welding inspector is Hold point for contractor QC welding inspector. . 2. The contractor continues welding activities with not qualified welders 3. Contractor used 7018 electrodes for structure welding without Portable ovens. All welding consumables including 7018 electrodes shall be stored, preserved and handled as per SAESW-011, 6.1. Those items are violating SA standard according to SAES-W-011 6.1. The contractor should comply with SA requirements. Contractor has bring 2" & 16" piping material to site with unacceptable coating defects. Contractor is proceding with welding while he is not compling with requirment of SAEP-323 Para:6.2.1 The first three (3) production pressure retaining butt welds welded by each new contract welder shall be 100% radiographed. This a clear violation and RT shall be done ASAP for first 3 joints and another 3 joints more as a penalty. During surveillance inspection piping material were not segregated properly, This is a violation to contractor quality plan and Schedule Q requirement.
SATIP-W-011-01
Mechanical
ScheduleQ
SATIP-W-011-01
SAIC-W-2037
Mechanical
ScheduleQ
Schedule Q
1.3
1507
1/26/2010 10:46:09 AM
SATIP-NDE-MPT-01
SAIC-MPT-2002
Mechanical
SAEP
SAEP-1142
4.4
1508
12/7/2009 9:51:24 AM
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1509
2/21/2010 1:21:28 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
1510
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
1511
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
1512
1/30/2010 4:39:56 PM
Standards Violation
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
1513
3/4/2010 9:10:31 AM
Standards Violation
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-323
6.2.1
1514
3/4/2010 2:24:52 PM
Standards Violation
SATIP-L-350-02
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
7.3.7
1515
8/2/2009 2:02:41 PM
1516
12/2/2009 8:25:37 AM
1517
2/22/2010 2:23:48 PM
The original design scope of work was to provide centrifugal pumps in oily water lift station (OWLS), which was changed at a later stage by submersible pumps. The lift station remains classified as Zone 0. This is a violation to SAES-B-068 which is currently classifies OWLS interiors as Class 1 Zone 0, so submersible pumps are not allowed to be used. See also SAER6168 Para:9.2.1, Page:21. One 8" spool (928-1B) damaged by MSC during the transportation from AQPCT-Dammam to MSC-Dhahran yard, contractor has to prepare a damage report and should come up with the required corrective action. During Pre-commissioning of Surge Skid Pilot valve, it was observed that inlet Gate valves were leaking. This is a clear violation and those valves shall not be leaking. PID performed surveillance @ NESMA Fab.Shop and witnessed inprocees welding of two joints having 69mm wall thickness,without availability of an approved welding procedure at the site. This is a violation as per SAES-W-011,para.7.1.8 - During site surveillance inspection in PS6 at piperack the PMT and contractor been advised that the ends of the spool for line no.12 P-0226 and 10RL -0260 to be covered so as to protect the line from entry of debris or sand prior to fit-up and welding. This practice will eliminate entry of foreign matter and ensure cleanliness of line and avoid any unnecessary RT reshoot due to debris inside when the joint will be welded later on, thus additional cost for reshoot will be save as experienced in previous project The welding for 28" P 0216 line SB-07 was started without PID WPS project approval as required in SAEP -352 appendix II which states that Inspection Department will review the WPS for project approval before the WPS can be use. The WPS NESMA 46PS -06HT rev.0 was approved with comment by CSD. The contractor been instructed to use Lincoln L61,EM12K wire LOT NO. BRE-27 and Lincoln flux L860 LOT NO. KSC 20 as stated in CSD review sheet prior to SAW welding of 28"P-0216 line SB 07. During routine site visit, PID has observed that water injected for filling and pressurizing for hydro testing of HTP-012 is not from the lowest point as required by the Aramco standard SAES-A-004 para 8.1.1. NESMA is advised to follow the procedure before proceeding further. During routine surveillance, PID has observed that NESMA has painted welded joints SB26, SB27, FP27A & FB28 of drawing number HB-316240-001, prior to hydrotesting, which is a violation of SAES-L-150 Para 7.3. PID has observed that NESMA has not made any arrangement for the lay up of already hydrotested lines even after 30 days time period. This is a violation as per SAES-A-007 Clause 5.2.1. NESMA is advised to verify all such occurrences and take remedial action as early as possible. During routine site visit, PID has observed that NESMA has heated the 16 NB X 30mm pipe of discharge line to align it with the nozzle of pump A. This is a violation as per SAES-L-150 Para 5.8 as the pipe is already hydrotested and the uncontrolled heating and the subsequent deformation does not guarantee the integrity of the pipe material.
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
1.3
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
1518
11/29/2006 2:46:38 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
7.1.8
1519
11/12/2006 5:01:37 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
1520
10/21/2006 9:39:43 AM
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
7.1.1
SAEP-352
APPENDIX II
1521
10/21/2006 10:04:36 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11
1522
5/3/2007 10:17:33 AM
SATIP-A-004-02
SAIC-A-2013
Mechanical
SAES
SAES-A-004
9.1.1
1523
5/20/2007 7:42:58 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.3
1524
6/27/2007 2:13:30 PM
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.1
1525
5/28/2007 1:49:09 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-L-150
5.8
1526
3/7/2007 4:52:18 PM
1527
6/10/2007 9:50:03 AM
1528
5/21/2007 10:55:16 AM
During routine surveillance, PID has observed that the 18 spool SP-I of line No.18-P-0212-15CS9P and ISO No. HB-316241-001 has been erected without any internal cleaning. This is a violation as per SAES-L-350 para 15.2. More than that, improper handling caused the unprotected flange face of the said spool collided three times with another spool and support during erection. This is a violation as per SAES-L-350 para 7.4. During routine surveillance, PID has observed that NESMA has used ASTM A 105 6NPS SCH 160 900# flange in place of ASTM A 350 LF2 6NPS SCH 120 900# for joint FB136 of drawing HB316251-002. This is against the design requirement and Aramco requirement of SAES-L-109 Table 3. NESMA is advised to investigate further for similar occurrences and take remedial actions. During routine site visit, PID has observed that NESMA has made 02Nos. of 1NB branch connections (for drain & vent) on a 2NB header of drawing number HB-316255-001. This is a violation as per SAES-L-110 Para 12.1.1 and Chart 1. During surveillance, PID has observed some bad damage on the flange face of joint SB 86 of drawing HB-316252-002. This was caused by improper handling during installation and is a violation as per SAEP-L-350 Para 4.3. NESMA is advised to investigate further for any such occurrences. During routine surveillance, PID has observed that the groove dimension of 6" SCH 120 ring joint flange installed for joint FB113 of drawing HB-316252-002 is not conforming to the requirements of ASME B16.5. NESMA is advised to investigate further for any such occurrences and take corrective action. Prior to ARAMCO RT film review, the contractor been reminded and instructed to provide their certified RTFI,as per the requirements of Schedule Q attachment I and attachment IV. During surveillance, PID has observed that NESMA Mechanical QC Inspector is absent from the site frequently to another temporary assignment at some other place. There were no replacement for this inspector and PID has not been informed in advance. This is a violation of Schedule "Q" Para 5.10 & 5.11. As a part of routine random physical verification, PID has observed that the heat number of 06 Nos. of flanges and 02 Nos. of Thread O Lets of drawing HB-316251-002 were not matching with the contractors records. This is a violation as per Para 3.3 of Attachment IV to schedule Q as there is no traceability for the said materials. More than that, NESMA has used two numbers of SCH XXS Tee fittings in place of SCH 120 Tee fittings for the same spools as against the requirements of material take off. During surveillance, PID has observed that NESMA is using electrode baking oven EG-4-706 for heating the coupling for Pump C prior to installation. Calibration for this oven is expired on 25th March 2007 and the temperature gauge of this oven is showing an erroneous 75C instead of the required 180C. PID has informed one day in advance to the concerned QC Inspector to use only the properly calibrated instruments. This is a violation as per Attachment IV Schedule Q Clause 6.1.
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-109
Table 3
Schedule Q
1.3
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
12
1529
6/11/2007 1:46:05 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
4.3
1530
6/15/2007 8:55:45 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
1.3
1531
8/30/2006 2:19:12 PM
SATIP-NDE-RT-01
SAIC-RT-2002
Mechanical
ScheduleQ
Schedule Q
5.1
1532
4/24/2007 4:13:13 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1 & 5.11
1533
6/7/2007 5:47:40 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-350
6.2
1534
6/27/2007 5:48:22 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1535
5/3/2007 5:09:10 PM
During routine site visit, PID has observed that NESMA has carried out repair on the acceptable area of joint FB 04 (28NB X 45 mm thk) of drawing HB-316246-002. This repair has been carried out under the direct supervision of NESMA QC Manager without the knowledge of the concerned welding inspector. This is a violation as per SAES-W-11 para 18.4 and the Aramco approved method statement DOC.M.S.04. NESMA is advised to follow the correct procedure for attending repair. During routine surveillance, PID has observed that, three Nos. of 2 sch40 SS joints (SB16, SB17 of pump A and a similar joint in pump C) connecting pump to working oil cooler found to be welded without approved welding procedure. This is a violation as per SAES-W-011 Para 7.1.5 and Para 7.1.8. NESMA QC to ensure that there is no more joints welded like this and take action to reject all such joints, if there is any. During routine site visit, PID observed that 08Nos. of joints for SA335 Gr. P9 material were welded and the following violations observed. 1. The WPS is not yet approved for this welding and it is a violation as per SAES-W-011 Para 7.1.5 and Para 7.1.8. This violation is repeated a second time, refer E-log entry 3065. 2. No high frequency unit used for this welding violating SAES-W011 Para 5.2.1. 3. No RFI issued and neither NESMA QC nor PID informed about this activity which is a hold point for contractor and a witness point for PID as per SATIP W-011-01, item 3.6 and hence is a violation. 4. There is no JCC issued for welder for welding these particular joints and is a violation as per SAES-W-011 Para 6.2.5. During routine site visit, PID has observed that NESMA has done tack welding and fit-up of elbow to pipe joint FB 04RW (28 X 70MM THK) of HB-316247-003, which were once welded and again cut and re-beveled by flame cutting and grinding. NESMA has not carried out any NDT for checking the lamination before fit-up violating SAES-W-11 para 11.3.3. NESMA is advised to take action to rectify the same. Site surveillance performed and found weld joint#FG-15(69mm thickness)having a 20mm weave width during filling that is more than 3 times core diameter of the electrodes used.This is a violation to NESMA WPS#28PS-A-06HT Rev.0. The contractor QC is advised to ensure that all WPS(s) parameters are applied within the limits. In addition, all the block valves installed on the inlets to PZVs shall be painted orange color. IT IS OBSERVED THAT SUBMITION OF RFI REQUIRES MINIMUM 24HRS FOR INSPECTION AS PER SCH Q PARA 1.2.3. THE RFI REF# SP-COT-A3-011 & IPC-COT-A3-011 DT17-10-06 TIMED 6AM WITH INSP TIME 10 AM AND 1 PM RESPECTIVELY. THIS IS VIOLATION. OID / NDT Unit have reviewed submitted RT films and reports. Report NDT-AIR-A2-044 shows that OID NDT Unit have observed a "crack like indication" on 56" FW 633 T1-011. Contractor is requested to propose their remedial actions to assess the "crack like indication". If the indication proves to be a crack, Contractor shall submit a repair procedure for CSD approval prior to commencing the welding repair activities.
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
18
1536
3/12/2007 1:19:15 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
7.1.5
1537
6/3/2007 11:30:52 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
7.1.5
1538
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
5.2.1
1539
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.7
1540
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
8.1
SAEP-324
6.4.1
1541
5/3/2007 5:36:30 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.3
1542
1/16/2007 4:15:33 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
1543
Mechanical
other
34-SAMSS831
8.1.1.3.2
1544
10/17/2006 8:22:31 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
1545
11/18/2007 8:25:30 AM
SATIP-NDE-RT-01
SAIC-W-2007
Mechanical
ScheduleQ
SAEP-1143
11.2
Schedule Q
A IV Para 7.3
1546
10/8/2007 6:45:56 AM
PL
10/07/07, Area 4, Yanbu: The contractor has failed to conduct hydrostatic testing of the 30 Bypass piping associated with the new MLIV site located at KM 125, 121 and 108 at the required strength test pressure. During review of TP-HYT-A4-02 for KM 101, PID realized that the M.O.C. used for the 30 Bypass lines was actually 0.612, X70 not 0.500, X60 as indicated in the IFC dwgs. IFC, Hydrostatic Test Diagram VA-291640, Test 5 indicates a strength test pressure for these line of 1800 psi limited by the 0.500, X60 pipe, but after re-calculating the strength test pressure required based on actual M.O.C., the strength test pressure required for the pipe is now 2265 psi which is > than the 2250 psi permitted for the 600# flanges, therefore the required strength test pressure shall be 2250 psi limited by the 600# flanges. All the affected IFC dwgs must be redlined and the 30 bypass line re-tested in accordance with the actual required strength test pressure. Concerning the disassembly of the 12 bypass lines at each of the 56 MLV locations for the purpose of further cleaning of the 56 valve cavity and the bypass piping itself. ASME B31.8, Chapter 1, 817; Condition for Reuse of Pipe states: Removal of a portion of an existing steel line and reuse of the pipe in the same line or in a line operating at the same or lower pressure is permitted and is subject to the restrictions of paragraphs 817.13 (a), (f) and (i). These paragraphs require (a) Inspections to discover any defects that might impair the strength or tightness, (f) Inspection for surface defects which shall then be qualified in accordance with B31.8 paragraph 841.24 and (i) Hydrostatic Test. In addition, the 12 valves which have been removed shall be field tested prior to re-installation and all flanged connection shall be made in accordance with SAEP-351 and documented in the appropriate SATR-L-2001. Despite requests, Contractor has not submitted a revised Quality Organization Chart to PID. The Contractor has recently demobilized many QC Inspectors at short notice. The revised Organization Chart is required to prove to PID that Contractor has adequate QC Inspectors to cover the remaining Scope of Work activities on BI 0194 and BI 3094. The Radiographic test report SATR-NDE-2004 shall be completed by the film interpreter (RTFI Level II) he shall register his legible Signature and his full name and Saudi aramco badge number on it. 3 6" AOVs require to be field tested. The Contractor is proposing to pressure test the 6" valves manually, independendent of the actuator. SAES-L-108 sect. 4.7.5 states that the test procedures, pressures, durations etc shall be equal to those that the valves were originally purchased to. 04-SAMMS-048 is the "Valve Inspection and Testing Requirements" applicable to the Purchased material. Sect.5 "Pressure Tests" para 5.4 states that "when a valve is ordered with an actuator, the valve/actuator assembly shall be tested as a unit" Therefore the contractors proposed valve pressure test is not acceptable. The valve / actuator assembly shall be field pressure tested as a unit in accordance with 04-SAMSS-048, sect.5.4
SATIP-A-004-03
SAIC-L-2139
Mechanical
SAEP
SAEP-1160
6&8
1547
8/14/2006 3:06:50 PM
PL
SATIP-L-450-03
SAIC-L-2113
Mechanical
other
ASME B31.8
Chapter 1, 8.17
1548
11/28/2007 1:28:12 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.9
1549
7/27/2006 8:16:36 AM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
SAEP
SAEP-1143
12.1
1550
8/15/2007 12:05:30 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
other
04-SAMSS048
5.4
SAES-L-108
4.7.5
1551
9/24/2007 8:29:50 AM
0194
During surveillance inspection in PS 10 scraper receiver area, the gearbox assembly of MOV 0095 was trouble shooted to determine the cause of abnormal sound in the gearbox assembly and they found out that there are damage in the pinion bearing and spur gears. The contractor has to submit report to identify what is the root cause, the action to be taken, and the prevention plan to avoid similar case to happen. In spite of PIDs Proactive Notifications (L-1128) and clear advise to the Contractor regarding the preparation and submission of complete documents required for valve receiving inspections prior to installation and welding in Area 3, still the contractor has not offered for material receiving inspection for 56 GOV for km 287 and 284 due to incomplete documents like Inspection release certificate, Inspection reports, and other documents. During surveillance inspection the above mentioned GOV had been welded/installed without material receiving inspection offered to PID, which is in violation with Schedule Q Attachment III para. 3.14 and SATIP-L-108-01(Valve Installation), which form a part of the Quality Plan which requires 100% witness inspection by PID with regards to valve inspection and verification prior to installation and welding. It has been observed a deep damages on both ends of pipe bevel. This is due to mishandling of the pipes during loading and unloading. This is violation. The contractor is advised to take care of the pipes during loading and unloading. They have to take a step for the remedial steps in order to rectify the bevel damage. During surveillance inspection in PS 10, the SGS NDT subcontractor was conducting Radiography in the fabrication shop within the SAIPEM Camp with incomplete safety measures, like barricade tape which is in violation with SAEP 1141 PAR 12.3 which states that the controlled area must be clearly identified to provide adequate notification to the general public (Non radiation worker) of the presence of work involving ionization radiation by radiation warning signs and barricade with approved warning barrier tape or orange rope with radiation warning pennants. The Contractor been instructed to act on this matter to prevent similar situations to happen. Permit for temporary isotope storage facility @ PS-10 Saipem camp has been expired on November 18,2007.It violates Saudi Aramco Engineering Procedure SAEP-1141,Para 9.2.5. The contractor coating & painting QC inspector left the site without 30 days notice in advance.It is a violation to Schedule"Q";Para 5.11. During the site visit in order to witness the tie in joint at KM241, it was observed that the job was not ready and the cut end of the pipes in the trench kept opened. It has to be closed as per the SPEC SAES-L-450 PARA 11.4. This is violation REVIEW OF TEST PACKAGE TP-HYT-A3-002 WAS CLEARED FOR REVALIDATION TEST AND THE TEST HAS PASSED BUT IN REGARDS OF THE WET LAYUP AS PER THE SAES-A-007 ( 22 FEB 2006) PARA 5.2.2.2 WATER SAMPLE TO BE ANALYSED FOR RESIDUAL LEVELS OF OXYGEN SCAVENGER AND DISSOLVED OXYGEN CONCENTRATION. THIS WAS NOT DONE WHICH IS AGAINST THE STANDARDS ( VIOLATION). PLS CLARIFY
SATIP-J-700-01
SAIC-J-6702
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1552
7/7/2007 1:17:10 PM
0194
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS048
Schedule Q A III Para 3.15
1553
10/4/2006 8:14:59 AM
0194
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
7.4 & 8.1
1554
6/23/2007 7:45:51 AM
0194
SATIP-NDE-RT-01
SAIC-RT-2003
Mechanical
SAEP
SAEP-1141
12
1555
8/19/2007 6:54:53 AM
0194
SATIP-NDE-RT-01
SAIC-RT-2003
Mechanical
SAEP
SAEP-1141
1556
8/26/2007 11:54:03 AM
0194
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.11
1557
9/18/2006 9:54:44 AM
0194
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
1558
12/20/2006 3:32:56 PM
0194
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.2.2
1559
11/29/2007 10:31:54 AM
0194
1560
6/28/2007 9:00:26 AM
0194
PID note that the gas filling line from AY-1 to EWG-1 at PS 3 is sceduled for hydrostatic testing today Nov 29. While acknowleding that this activity may come under the commissioning phase, and the test may be witnessed by Operations Dept, PID express the following concerns: Some of the material used has existing welds. There is no test certificates/ documentation related to this material. There are no welding records available for the pipe fabrication activities conducted at PS 4. No NDT has been conducted on the joints welded at PS 4. The Welding / NDT requirements of SAES-W-012 were confirmed with Contractor QC Manager, but to date no Check lists, weld summaries, or NDT reports have been prepared. PID state that all Project activities shall be conducted in accordance with Saudi Aramco Standards. Contractor has installed 36"x36"x600lb rated split tee fitting on existing line # 36"-P-929-6CS1P2 to facilitate the hot tapping operation at Tie in no. K06-001 [P&ID Dwg no. VA-437763 Sheet 001 Rev.01A] The split tee thickness at the longitudinal seam locations is approximately 50mms. The Contractor has only welded approximately 50% of the 50mms groove thickness, i.e leaving approximately 25mms of the groove not filled by weld deposit. Contractor has used WPS SAS 169 Rev.0 which shows that the longitudinal groove joint should be a full thickness groove weld. Saudi Aramco Standard Dwg AB 036719 also shows a full thickness weld joint is required at the longitudinal groove. The split tee installation has already been hydrotested satisfactorily, witnessed by Operations Dept. SAPMT/Contractor are requested to contact CSD / Proponent for a resolution to the situation. Contractor has failed to complete the joint within 24 hours in pump station # 3 of 56 riser launcher area as required by SAESW-012 para 10.7.6 which says that the weld joint shall be completed within 24 hours of starting, now it has over 48 hours and still the joint is uncompleted. Contractor shall perform NDT examination (MPI) with proper preheating prior to start the remaining passes and100% radiography shall be carried out after completion of weld joint by using slow speed film Contractor has started welding at KM 956 of received 10xsch 40 ASTM A333 GR 6 for blow down line by using their WPS SAS190/02, rev-0 which is not suitable WPS for this pipe as the pipes are designed for low temperature from minus 46 C to Minus 18 C while the WPS SAS-190/02, rev-0 is from ambient to 77 C . Contractor shall develop and provide the welding procedure specification and PQR to reflect these material requirements. Currently contractor has no WPS and PQR which cover the chemistry of 10x sch 40 ASTM A333 GR 6 pipes. WPS and PQR together with line designation table shall be submitted to CSD for approval prior to submit to SAPID. Contractor also find the criteria of acceptance of the welded joints. As per the routine site visit at PS-3 MBR area PID found the paints not install in control environment and directly exposed to the sun and the store is on the bad situation. Moreover conduct is not covered at the site which not matching the mentioned checklist . Contractor has been carried out hydro test of PVC irrigation piping at PS--3 without out submitting a complete hydro static package for these piping sections, it is several times reminded to the quality department to produce such package for conducting the hydro static test but still not complied.
SATIP-A-004-02
SAIC-L-2139
Mechanical
SAES
SAES-W-012
16
SATIP-L-052-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.6
Schedule Q
1.3
1561
11/27/2006 3:51:36 PM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7.6
1562
2/6/2007 10:49:47 AM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.3
1563
11/18/2007 1:54:23 PM
3094
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
1564
11/8/2006 8:40:57 AM
3094
SATIP-A-004-03
SAIC-L-2139
Mechanical
SAEP
SAEP-1160
5&6
SAES-A-004
5& 7.1.1
1565
4/9/2007 4:58:48 PM
0194
1566
4/9/2007 4:30:23 PM
0194
1567
5/17/2007 5:24:51 PM
0194
During the routine site visit the contractor was performing the coating activities on strong dusty and windy weather which is not matching with SAES-H-100 Para 8.1.1 The storage of the Abrasive material shall be stored in dry and clean area, during the site visit to the area PID found the storage of that is not matching S.Aramco standard SAES-H-100, Para. 5.2.1. PID has found during the routine Surveillance @ the painting and Coating Area, around 20 numbers of Spectacle Blind of different diameter has been Abrasive blasted without even masking the gasket seating surface (Raised face and flat face)and also preparing to coat the spec. blinds, which violates SAES L-109 and B16.5 requirements. Saipem has to take the suitable & correctgive action for the blasted spec. blinds to satisfy the Inspection. During routin site visit at the storage facility in PS #4, a thinner container shows signs of leackage. Violation of SAES-H-100 Para 6.3 ( containers showing signs of leackage should be discarded). Contractor has been carried out hydro test of the re-used valves of the different sizes; the following valves are failed during test. One 2x 600 lb gate valve is failed due to seat passing. Four (4) of 8x 600 lb and two12x 600 lb gate valves are failed due to seat passing Keeping this records of failures of the valves in notice, contractor shall be instructed to test all existing Valves from sizes 2 and above of if they are intended to be re- used in place in different locations in order to prove that these existing valves are properly working and prevent failures of the valves during operation.This is a quality issue and this testing of the valves shall be carried out without the discussion of scope of the contract. As per the surveillance inspection at pump station # 4 and focused to inspect the bending of 56 pipe to be used at launcher area, contractor has failed to established a bending quality procedure or method statement as required by Schedule Q attachment IV Para 1.1 which says that Unless submitted with the Project Quality Plan in accordance with paragraph 3.2 of Schedule Q, one month prior to the start of the applicable WORK, CONTRACTOR shall submit for review and approval a detailed Inspection and Test Plan (ITP) along with related procedures/work instructions for all construction processes to be executed by CONTRACTOR or subcontractors Contractor shall be instructed to establish a quality procedure for bending activities as this process is not included in their Quality Plan; there shall be a separate procedure to describe the bending activity in complying with safety, standard and personnel responsibility to be involved. Contractor has received WT shapes beam ASTM 572 (Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel) of different sizes which do not satisfy the requirements of IFC drawing VA-294630 Para 2 of Notes, which shall be ASTM 992/992M (Standard Specification for Steel for Structural / Shapes for Use in Building Framing. contractor shall be instructed to approach the designe contractor for concurrence of the ASTM 572 rather than ASTM 992.
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-100
8.1.1
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
5.2.1
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-L-109
SAES-L-350
1568
11/2/2006 2:03:08 PM
0194
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.3
1569
3/19/2007 8:19:03 AM
0194
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
Schedule Q
1.3
1570
8/27/2006 9:48:41 AM
0194
SATIP-L-450-03
SAIC-L-2112
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.1
1571
11/27/2006 3:41:05 PM
0194
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1572
7/16/2007 8:49:57 AM
0194
As per the contractor submitted weekly record /reports of welding status, which reveal that there 422 joints are backlog and be expecting by the production of welding in different locations/areas that backlog may increase. These joints look like that are not shot yet and not completed RTFI by prime contractor and & OID. Contractor shall be instructed to provide extra NDT crew to cover this backlog. The continuation of this backlog may affect the milestone of the project completion. Contractor has no calibration status about the vernier caliper as it is under the use of QC department to chck the thickness of the fittings and pipes. this is tool is using as quality tool and need to be calibrated as per requirments of schedule "Q" Para 6.1 attachment IV Which says "The CONTRACTOR shall identify, maintain, control, adjust, and calibrate all tools, gauges, instruments and other measuring and testing devices used for controlling quality". contractor shall be instructed to calibrate their vernier caliper as they are using it for controlling of quality. During calibration of the gauges at contractor shop at PS-4, the calibration room have no temperature reader and humidity recorder which shall confirm the temperature 23 C 2 as required by the ASME/ANSI PTC 19.2 and SATR-A-2002. Contractor shall be instructed to provide the a temperature gauge to comply the above standard and SATR A-2002 requirements. Pipe10" Dia.X Sch40 API 5L X52 have been mobilized without completing the receiving documents to job site and have started the welding. It was mentioned in the receiving inspection stage that contractor shall provide the approved vendor information for piping materials and mill test reports to confirm and verify the chemistry and heat number of the pipe. It was requested in the response of RFI Number 6473 but no action has been taken. Contractor has submitted a RFI for "REFURBISHED 56" Dia, GATE VALVE 600#." which is to be done at NASECO Jubial.This short notice is given to PID in limited time WITH sudden change the test location with no proper information and guidance. contractor did not mention this activity and place in their two week look ahead schedule. As per the surveillance inspection at launcher area of pump station # 4, the tie-in weld to full thrust anchor has been visually checked and Contractor QC welding inspector has been instructed to check and verify the reinforcement (cap) that shall be as per the approved WPS and API-1104 which says that reinforcement shall be 1/32 to 1/16as given in API-1104 FIGURE -1. Saudi Aramco RTFI has reviewed the weld # SW-968/07 RI 20P-003 PS-3 and found that the repaired area is not matching with the original area in the RT film. Contractor shall investigate the root cause of omitting the original area of repair to be radiographed. The weld # SW-968/07 RI shall be proved that it matches with original film. Saudi Aramco RTFI has reviewed the weld # FW-178/13 10-BD0237 KM-833 and found some spatters from 16-18. Contractor shall inspect the weld try to remove the spatters from the weld in order to eliminate the chances of crack hiding beneath the spatters and re-shoot for confirmation.
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
1573
2/3/2007 2:14:18 PM
0194
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
A IV Para 6.1
1574
1/13/2007 9:06:15 AM
0194
SATIP-A-004-02
SAIC-A-2001
Mechanical
SAEP
SAEP-1160
Schedule Q
1.3
1575
1/27/2007 2:19:27 PM
0194
SATIP-L-450-03
SAIC-L-2112
Mechanical
other
01-SAMSS038
Schedule Q
1.3
1576
3/6/2007 1:46:02 PM
0194
SATIP-L-108-01
SAIC-L-2043
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
1577
9/10/2006 11:55:31 AM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.1
Schedule Q
1.3
1578
7/2/2007 4:46:24 PM
0194
SATIP-NDE-RT-01
SAIC-RT-2007
Mechanical
SAEP
SAEP-1143
8.3.1
1579
7/2/2007 4:50:54 PM
0194
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
SAEP
SAEP-1143
11
1580
7/24/2007 10:04:30 AM
3094
A receiving inspection has been performed for the 4x 150 lbs gate valves (148). During physical verification it is found that the valve end flanges are not fitted with plywood covers and a lot of sand accumulation inside the valves found. This is the violation of the 04-SAMSS-035 Para 12.2 which says that Flanged valves NPS 2 and smaller shall be fitted with UV resistant plastic covers. Other sizes, valves end flanges shall be fitted with plywood covers. Contractor shall investigate and generate a internal NCR to supplier or vendor. Contractor was in the process of using a non approved abrasive material. documents submitted did not have a stock No. Contractor advised to remove the material from site ASAP. During site visit to the Painting store, contractor was transferred Heat Shrink Sleeve materials HTL-P80 285X30 from Yanbu Area to PS-4 area, After inspection of that material PID found all the packages of that materials are opened and sands found inside, which is not matching SAIC-H-2075 Para A5 and B3. Coating for the pipe supports was not uniformed. Paint runs were found in two pipe supports. Violation of SAES-H-100 Para 8.1.6 & 8.1.6C. During site visit to the coating yard. Coating for the spool found defective contractor is informed that the finished coating must have a uniform appearance. Violation of SAES-H-100. Site visit to pump station # 5, during the visit it is observed that the civil crew have removed the cap of 56 pipe section at full thrust anchor end, due to that a lot of dust/debris and sand has been entered in the pipe section . Any how contractor will go for final cleaning but the crew shall be discouraged of removing caps or plastic sheets from the end of pipes or sections. In a case where it is required to remove the caps for some reasons, responsibility to be given to the crew to place back in position as required by SAES-L-450 Para 11.4 which says that Open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds. October 8, 2006. PID has observed that SAIPEM has welded two numbers of A234 GR WPB elbows in place of A420 GR WPL6 as against the design requirement. This violation was observed on joints FW 031/19 of drawing VB-292031-001 and joint FW 028/19 of drawing VB292028-001. SAIPEM is advised to investigate further for any such occurrences and take remedial actions. modification done to line 2"-P-0042-6CS1P2 without any notification to PID this line was hdrotest on 11,Oct and must be rehydrotested. during the prepration to perform rehydrotest for modified 2" line PID notice that the insrument air tubing is conected to the hydrotest system this is not acceptable according to SAES-L-150 prar 5.12 modification done to line 2"-P-0046-6CS1P2 without any notification to PID this line was hdrotest on 11,Oct and must be rehydrotested
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.3
1581
3/15/2007 8:45:48 AM
SATIP-H-100-01
SAIC-H-2024
Mechanical
SAES
SAES-H-100
3.1
1582
6/17/2007 3:43:00 PM
SATIP-H-002-10
SAIC-H-2075
Mechanical
SAES
1583
1/30/2007 3:48:38 PM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6C
1584
5/15/2007 5:20:47 PM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6C
1585
10/8/2006 2:40:46 PM
0194
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
1586
7/18/2007 11:09:13 AM
0194
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
1.3
1587
11/10/2007 10:52:11 AM
0194
SATIP-A-004-02
SAIC-A-2001
Mechanical
SAES
SAES-L-150
5.8
1588
11/13/2007 11:09:56 AM
0194
SATIP-A-004-02
SAIC-A-2011
Mechanical
SAES
SAES-L-150
5.12
1589
11/10/2007 10:54:53 AM
0194
SATIP-A-004-02
SAIC-A-2001
Mechanical
SAES
SAES-L-150
5.8
1590
12/21/2006 3:34:39 PM
0194
Based on the information confirmed by CSD through SAPMT shows that the hydro-tested Pipeline Section-1 at KM 586-578 is under wet lay-up providing the specified chemicals were actually applied in the required concentration as per SAES-A007(2005).However,the residual concentration of the specific chemicals used have not been verified and documented by the contractor for further reference so far. This is a violation to SAESA-007(2005). The contractor is intended to perform 100% RT of welded joints for 56" underground pipeline to 56" GOVs at all EIV stations in area -2. Therefore, a waiver request for NDT in lieu of hydrostatic tests for all these joints is required per SAES-A-004. Mud cracking found over 04 numbers of 56x30 inch Barred Tees coated with APCS-113A.These tees are intended to use for EIV stations at KM578 and KM586.The contractor QC is advised to understand the cracking cause and rectify the whole affected area.The SAPMT is informed. as per drg. vb 292196 pipe wall thickness of 56" dia pipe reqd is .688" to match with the barred tee wall thickness .but used on site is pipe wall thickness of .812" PID observed that flow direction of 2"globe valve installed at line# 2"-P-0056-6CS1P2(PS7) does not follow the process flow direction. The contractor QC is instructed to re-install the globe valve in correct direction. As per site visit to PS-7 Pipeline Section-1 at KM 586-578, the pipeline section has pressure tested for revalidation and now the system is under wet lay up, the following findings are found (1)The system is kept under wet lay-up position at beginning of hydro test as the contractor has provided combined product champion blacksmith O-3670R which is not mentioned as lay up activity in the contractor hydro test procedure EWG-1CONS-024 Para 5.20, but only mentioned in Para 5.12 water filling and venting. (3) Contractor Hydro Test Procedure EWG-1CONS-024 Para 5.20 does not specify the wet lay up. It states the requirements of SAES-A-007 Para 5.2.3.2 which specify the requirements of dry-lay up. It means contractor did not follow their procedure. (2) Analyze water data is not recorded and reported in the hydro test report as required by SAES-007-2006 Para 5.2.2.1 As per site visit to PS-7 Pipeline Section-1 at KM 586-578, the pipeline section has pressure tested for revalidation and now the system is under wet lay up, the following violation are found. No gauges are provided to confirm that the system is under wet lay up and maintained under positive pressure 30 to 50 PSI as required by SAES-A-007 PARA 5.2.2.3 which says "Use gauges with a scale range not exceeding three times the target pressure to monitor the positive pressure in the system during lay-up" PID come to know that the NDT sub-contractor performed some NDT job at PS#7.In this regard,however,the main contractor(Saipem)QC failed to generate any RFI. Therefore the PID was not able to verify in-process techniques and procedures as per relevant SATIPs. PID observed a temporary weld in-process without any weld identification and welder symbol.Although it is a temporary weld yet its identification is required per SAES-W-012 para 10.9.2.
SATIP-A-004-03
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.2.2
1591
6/28/2007 3:33:58 PM
0194
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAES
SAES-A-004
1592
7/26/2007 2:59:35 PM
0194
SATIP-H-002-06
SAIC-H-2050
Mechanical
SAES
SAES-H-100
8.1.6
1593
2/27/2007 8:44:57 AM
0194
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
1.3
1594
8/5/2007 7:28:42 AM
0194
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-J-700
8.8.1
1595
12/24/2006 2:14:51 PM
0194
SATIP-A-004-03
SAIC-A-2018
Mechanical
SAEP
SAES-A-004
9.2
Schedule Q
1.3
1596
SATIP-A-004-03
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.2.1
1597
12/24/2006 2:21:47 PM
0194
SATIP-A-004-03
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.2.4
1598
10/29/2006 4:17:06 PM
0194
SATIP-W-012-01
SAIC-W-2054
Mechanical
ScheduleQ
Schedule Q
1.7
1599
5/13/2007 2:46:56 PM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.9.2
1600
1/31/2007 9:11:15 AM
0194
WELDING ELECTRODES TINS 2 NOS WERE OBSERVED TO BE KEPT OPEN IN THE FEILD AND NO PERSONNEL ARE WORKING THERE. THIS HAS BEEN LEFT OVERNIGHT IN THE OPEN CONDITION WITH NO PROTECTION FROM RAIN OR HUMIDITY.THIS PARTICULAR TINS TO BE IDENTIFIED AND SHOULD NOT BE USED IN THE PRODUCTION WELDING. it is observed that low hydrogen welding rods, 8018, tin is lying open in the site.the rods, if to be used should be either kept in the quivers or the storage oven. PLEASE NOTE THE FOLLOWING WITH RESPECT TO THE MATERIAL STORAGE YARD. 1)THE PVC PIPES AND CONDUITS ARE UNPROTECTED FROM THE SUNLIGHT. 2)PLEASE STORE THE FUEL GAS AND OXYGEN GAS CYLINDERS SEPERATELY IN ANOTHER ENCLOSURE AS REQUIRED AS PER ARAMCO CONSTRUCTION MANUAL.CURRENTLY THEY ARE BEING STORED IN THE SAME ENCLOSURE. Contractor failed to mention "Coating activity" in the two weeks look ahead schedule.Violation of schedule "Q" attachement V "Quality system deliverables" Inspection Schedules: Paragraph 7.1. contractor should submit activities to SARAMCO fourteen (14) calendar days before the start of any related activities. IT IS OBSERVED THAT THE WELDING ACTIVITY IS IN PROGRESS IN PS#7 LAUNCHER AREA. WELDING FIT IS BEING DONT WITH EXTERNAL CLAMP IN SPITE OF USING INTERNAL CLAMP AS PER THE REQUIREMENT. THIS VIOLATION. THE CONTRACTOR IS ADVISED TO USE INTERNAL CLAMP FOR THE FIT UP
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
1601
2/28/2007 2:43:57 PM
0194
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
1602
2/5/2007 9:00:57 AM
3094
SATIP-S-070-03
SAIC-S-4056
Mechanical
SAES
SAES-S-070
5.2a
1603
9/12/2006 3:01:53 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.5
1604
9/11/2006 10:18:11 AM
SATIP-L-450-03
SAIC-L-2115
Mechanical
SAES
SAES-W-012
10.4
1605
10/17/2006 8:06:36 AM
0194
Ref WELD-FW-PIP-A3-035/036, REVEALS DURING INSPECTION OF THE WELD HAD NOT CARRIED OUT NDT( MPI OR DPI) BEFORE DOING BACK WELD AFTER GRINDING. THIS IS VIOLATION. REFER SAES-W-012 PARA 10.3.4
PID has conducted review and subsequently rejected the submitted Hydrostatic Test Procedure EWG-1-CONS-054 related to testing of the Scraper Trap Areas and Pressure Reducing Stations. PIDs comments include: The proposed tests deviate from the IFC hydrotest Diagram and the approved Technical Query [TQ 45].The test pressures and test limits are changed. The Procedure does not address internal / cleaning or flushing of the lines prior to the hydrotest. Contractor is required to address all comments in PID response and resubmit the procedure for further review. 4 NOS VALVES HAVE BEEN REMOVED FROM KM 95 AND BROUGHT TO YANBU CAMP TO FORWARD FOR RFURBISHMENT TO DAMMAM. PLEASE ARRANGE TO PROTECT THE VALVES END WITH A RIGID MATERIAL SUCH AS A PLYWOOD IN PLACE OF THE POLYTHENE SHEET WHICH IS ALREADY ON THE VERGE OF COMING OUT. Concerning welding 09/27/06; MLW-227 thru 242 were welded for a total of six (6) welds. The report indicates capping by (4) welders, EHO/MUH and NBR/EPO. Only MLW-239, EHO/MUH received (RT). The contractor shall complete (RT) of MLW-242, NBR/EPO. Concerning welding 09/28/06; MLW-243 thru 252 were welded for a total of ten (10) welds. The report indicates capping by (6) welders, EHO/MUH, NBR/EPO and ALM/EPO. Only MLW-243, EHO/MUH received (RT). The contractor shall complete (RT) of MLW-246, NBR/EPO AND MLW-252, ALM/EPO.
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.3.4
1606
8/9/2007 2:52:31 PM
SATIP-A-004-02
SAIC-A-2001
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
1607
11/12/2006 2:23:33 PM
0194
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.2
1608
10/1/2006 9:59:45 AM
0194
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAEP
SAEP-1160
1609
1/11/2007 7:09:46 AM
0194
Concerning Contractor letter no. SAS/EWG-1/PS4/SA/L-1258/07 dated 03 January, 2007; QC Supervisors Leave of Absence; the letter informs Saudi Aramco that Mr. Syed Masood Ali, Welding Inspector assigned to Area 4, Yanbu will be in charge during the absence of the assigned QC Supervisor Mr. Ravichandran Thaigarajan. PID advises the Contractor of the following: Schedule Q, Section 5.11 states, the Contractor shall advise the Company Representative of personnel changes at least thirty (30) calendar days in advance of scheduled absences. Mr. Ravichandran Thaigarajan is scheduled to depart on 12 January, 2007, the letter was stamped received by the SAIPEM Yanbu site office on the 5 January, 2007 therefore, the contractor is in violation of Schedule Q. Review of SATR-W-2008; Weld Summary, Welder Performance and Non-Destructive (NDT) Tracking System was completed and PID (Mechanical) has the following comments: Concerning MLW-167; completed on 09/18/06, (RT) was requested on 09/18/06 and the weld rejected in Report No. RT-A4-014. Contractor shall (RT) the succeeding joint MLW-168 as required by SAES-W-012, para. 16.6.1.1.3. Concerning welding 09/19/06; MLW-169 thru 178 were welded for a total of ten (10) welds. The report indicates capping of these (10) welds by a combination of six (6) welders EHO/MUH, NBR/DWE and NBR/EPO. Only MLW-172, NBR/DWE is indicated as having received (RT) on this date. SAES-W-012, para. 16.6.1 states those joints to be radiographed shall be selected to include a representative selection from all welders. The contractor shall complete (RT) of MLW-169, EHO/ MUH and MLW-178, NBR/EPO. Concerning welding 09/20/06, MLW-179 thru 184 and MLW-186 thru 189 were welded for a total of ten (10) welds. Concerning welding 09/21/06; MLW-190 thru 199 were welded for a total of ten (10) welds. The report indicates capping by (4) welders, EHO/MUH and NBR/EPO. Only MLW-192, EHO/MUH received (RT). The contractor shall complete (RT) of MLW-197, NBR/EPO. Concerning welding 09/22/06; MLW-200 thru 207 were welded for a total of eight (8) welds. The report indicates capping by (4) welders, EHO/MUH and NBR/EPO. Only MLW-203, NBR/EPO received (RT). The contractor shall complete (RT) of MLW-200, EHO/MUH. Concerning welding 09/23/06; MLW-208 thru 215 were welded for a total of eight (8) welds. The report indicates capping by (4) welders, EHO/MUH and NBR/EPO. Only MLW-203, EHO/MUH received (RT). The contractor shall complete (RT) of MLW-213, NBR/EPO. Concerning welding 09/24/06; MLW-216 thru 223 were welded for a total of eight (8) welds. The report indicates capping by (6) welders, EHO/MUH, NBR/EPO and ALM/EPO. Only MLW-219, NBR/EPO received (RT). The contractor shall complete (RT) of MLW-216, EHO/MUH and MLW-223, ALM/EPO. Concerning welding 09/25/06; MLW-224 thru 230 were welded for a total of seven (7) welds. The report indicates capping by (6) welders, EHO/MUH, NBR/EPO and DWE/EPO. Only MLW-228, EHO/MUH received (RT). The contractor shall complete (RT) of MLW-225, NBR/EPO and MLW-230, DWE/EPO. Concerning welding 09/26/06; MLW-231 thru 236 were welded for a total of five (5) welds. The report indicates capping by (6) welders, EHO/MUH, NBR/EPO and DWE/EPO. Only MLW-231, EHO/MUH received (RT). The contractor shall complete (RT) of MLW-232, NBR/EPO and MLW-234, DWE/EPO.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.11
1610
10/1/2006 9:40:58 AM
0194
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAES
SAES-W-012
16.7.1.6
1611
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAEP
SAEP-1160
1612
10/1/2006 9:55:15 AM
0194
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAEP
SAEP-1160
1613
10/1/2006 9:57:40 AM
0194
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAEP
SAEP-1160
1614
6/12/2007 9:23:04 AM
0194
11 June, 07; Flange bolt tensioning of 36" valve K34-MOV-011 (Hot Tap). Tensioning is being completed employing hydraulic torque wrench (hydratight)method. Contractor has failed to provide calibration certificates for the equipment which is a violation of Sch. Q, Att. IV, Para 6.1. Also, no evidence has been provided to establish that the contractors personnel executing the installtion have been properly trained in the use of the equipment or Saudi Aramco requirements concerning gasket installation and bolt tensioning. This is a violation of SAEP-351; Bolted Flange Joint Assembly, Para 3.2.2. In addition, Contractor procedure no. EWG-1-QUAL-PCP-707 which was previously approved by another PID inspector as "Acceptable w/ comments" is no longer acceptable because the PID comments were never addressed i.e. the procedure does not address the tools, calibration requirements and methods of torque to be employed during the project. This procedure requires revision and resubmittal for review. The assigned Mechanical Inspector area for has departed on vacation and to date no Aramco approved replacement has been provided. Contractor has failed to provide QC replacement for their assigned QC Supervisor Mr. Mohammad Uz-Zaman during his emergency leave. Contractor shall make quality personnel changes due to vacations, illness, temporary assignments, emergency leaves, resignations or other reasons as necessary to maintain the required quality coverage. Schedule Q, 5.11. 09/20/06 BI-10-0194, Yanbu, Area 4: Surveillance visit conducted along E/W pipeline during welding of 42. Note; the current rejection rate for Area 4 is 27%.This visit revealed the following: No temperature-indicating crayons or contact pyrometers were available enabling the contractors QC welding personnel to verify the required pre-heat of 100C and to monitor the maximum interpass temperature during welding. This is a violation of SAES-W-012; Welding Requirements for Pipelines, para. 11.4. 09/20/06 BI-10-0194, Yanbu, Area 4: Surveillance visit conducted along E/W pipeline during welding of 42and during visual inspections completed by PID mechanical after cleaning of the root passes, hot passes, fill passes and covers passes it was noted that more often than not each weld pass was not being thoroughly cleaned and all slag as required before the next pass was deposited. In particular, wagon tracks were observed and failures to remove these areas of trapped slag are contributing greatly to the current rejection rate. This is a violation of SAES-W-012; para. 10.6.1. Area 4, Yanbu; Surveillance visit, during welding of 42 pipe. The following was observed: the contractor is failing to maintain the minimum pre-heat temperature of (100C) as required by the Saudi Aramco approved WPS No. SAS-197/06 Rev. 0. The contractor shall ensure that before welding commences the required minimum preheat has been achieved. The base metal temperature shall be monitored during welding to assure that the maximum interpass temperature (315) is not exceeded and the minimum required still exist. The contractors QC personnel shall complete regular monitoring of the joints being welded with pyrometers and ensure that the two assigned welders who make each pass are operating simultaneously in the opposite quadrants (SAES-W-012, para. 10.7.1). In addition, QC personnel shall ensure that the second or hot pass is added as soon as possible after the completion of the root pass. In no case shall the period between the root and hot pass exceed 15 minute 10/09/06 BI-10-0194, Yanbu, Area 4; Surveillance visit conducted along E/W pipeline at road crossing during fit-up and welding of 42 pipe. This visit revealed the following: Contractor failed to keep the bridge tacks made during fit-up completely within in the weld groove as required by SAES-W-012, para10.9.6.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
3.2.2
Schedule Q
A IV Para 6.1
1615
6/16/2007 9:18:03 AM
0194
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1616
9/9/2006 4:11:13 PM
0194
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1617
9/20/2006 2:33:46 PM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
11.4
1618
9/20/2006 2:44:41 PM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.6.1
1619
10/8/2006 2:10:19 PM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7.1
1620
10/10/2006 7:31:44 AM
0194
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.9.6
1621
10/10/2006 7:47:41 AM
0194
10/09/06 BI-10-0194, Yanbu, Area 4; Surveillance visit conducted along E/W pipeline at road crossing during fit-up and welding of 42 pipe. This visit revealed the following: The contractor failed to complete 50% of the root bead prior to removing the external clamp which is a violation of SAES-W-012, para. 10.4.2. During my routine visit site (twice) @ sabkah-54. It was observed that the Positive Seal Coupling Installation is on-going without the presence of Mechanical QA/QC Inspector (Mr. Warlito Daguro). This is in aviolation of approved QA/QC Plan and schedule "Q" general requirements. Please advised contractor accordingly. I would like to seek your utmost attention and immediate action regarding this negative findings. Thanking you in anticipation. During my routine visit @ site sabkah-77 scraper area this afternoon dated February 2, 2008 at 1:30 pm. It was observed that the hydrotesting of 20" pipes for G3ST4 mainline (Lateral Line)is on-going without approved hydro-test package. Noticed that this hydro-test package was submited to SPIU/PID last 29, January 2008, this package is still under process for review prior to hydro-testing and this is not acceptable by Shaybah Project Inspection Unit. Please advised contractor accordingly. During my routine visit @ site sabkah-77 scraper area this afternoon dated 2 February 2008 at 1:30pm. It was observed that the hydrotesting of 20" pipes for G3ST4 mainline (Lateral Line) is on-going without approved hydro-test package. Noticed that the hydro-test package was submited and forwarded to SPIU/PID last 29 January 2008 and this package is still under process for review prior to any hydro-testing. Therefore the hydro-testing are not acceptable by SPIU. Please advised contractor accordingly. During my site visit @ sabkah-21 it was found out that the storage/stacking of internally coated pipes, fittings and vallves violated as per the requirements of SAES-H-200 sec.5 para.5.1 thru para.5.4. Noted the following deficiencies: 1) Pipes stored directly on the ground. 2) Fittings and valves were not stored in shipping crates or on racks. 3) End protectors on internally coated pipes, flanges & weld bevels not firmly attached. If the RHM Contractors does not intent this non conformity SPIU will proceed to issue an NCR (Non conformance Report). Please advised them to comply the standrads. Thanks. Absence of QA/QC Supervisor at site - Dedicated QA/QC supervisor at site is mandatory required as per QA/QC plan and as per the schedule "Q" General requirements. In addition SPIU will not accept any Resume submittal prior to review & approval without the presence of QA/QC supervisor at site respectively. Moreover if the contractor does not intent this non conformity PID will proceed to issue an NCR. Please SAPMT to sort this out ASAP. Routine visit @ site - During my routine visit verified and checked that since 12 July 2007 till now 15 July 2007 there was no QA/QC coating inspector @ site. SPIU investigated this issue and found out that the QA/QC coating inspector leaving @ site/shaybah without proper notification to SAPMT and inspection. This is in a violation of shedule "Q" general requirements para.1.3., para.1.4. and para.5.11. Could you please advice QA/QC supervisor or Contractor to take a course of action regarding this issue. If the QA/QC supervisor or Contractor does not intent this non conformity SPIU will proceed to issue an NCR and therefore starting today 15 July 2007 all coating activities will not be accepted by SPIU. Please discuss to the contractor about this issue accordingly. Thanks.
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.4.2
1622
8/21/2007 10:20:43 AM
001
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.1
1623
2/2/2008 2:28:40 PM
001
SATIP-A-004-02
SAIC-A-2011
Mechanical
SAEP
SAEP-1160
1624
2/2/2008 4:01:41 PM
001
SATIP-A-004-02
SAIC-A-2011
Mechanical
SAEP
SAEP-1160
1625
5/20/2007 10:30:31 AM
001
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-H-200
1626
4/27/2009 4:09:22 PM
001
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1
1627
7/15/2007 1:51:30 PM
001
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
1.3 and 5.11
1628
8/13/2008 3:53:48 PM
001
During my routine visit and inspection at site (On various Sabkahs) observed the Contractor RHM QA/QC Mechanical Inspector Mr. Arnold Garcia was not available at site since 9th August 2008. Verified that the Mechanical inspector leaving at shaybah and RHM did not notice SPIU & SAPMT team in this aspects and this is unacceptable. This is in violation of schedule "Q" para. 5.1.1 general requirements. Therefor please advice Contractor to provide the reliever as necessary to maintain required Quality coverage. No Adequate supports of Coated Pipes - During my site visit @ sabkah20 scraper area near GOSP-2. Noticed that the coated pipes (Scraper Piping Spools)violated of SAES-H-200 sec.5 para.5.1 & 5.2 that states the coated pipes shall be handled at all times in a manner to prevents damage to the pipe walls, beveled end & to the coating & shall not be dragged onto the ground. Please advised contractor to comply the standard requirements and therefore if this non conformity does not intent SPIU will proceed to issue an NCR. During my routine visit @ site it was observed that the 16" mainline/lateral line including scraper pipings @ sabkah-20. Noticed that the lines has been water filled without the approval of hydro-test package as required. This activity is designated as "Best Practice" to guide the project in the process of implementing and tracking of all pressure testing. Violated as per SAIC-A-2003 and Quality plan. Please comply the specific requirements. Thanks. During my site @ sabkah-57 to monitor and check the on-going welding of externally FBE coated pipes 20" dia.G2ST4 T/L replacement. Verified that the welding is temporarily stopped due to the internal line-up clamp is not working properly, the internal clamp is subject for repair and maintenance. Contractor Mech. QA/QC is aware of this situation. During my site visit & documents reviewed, it has been observed that the contractors RHM were having a lot of backlog joints for RT. Apparently, Mr. Reynaldo Sebastian, QA/QC supervisor has not been informing SAPMT since Dec.01,2007 & also no any action taken about this issue, thats why this has resulted that the no.of joints increasing for RT, hereunder: For 16 sets, 1)2"-18jts. 2)4"-6jts. 3)6"-2jts. 4)10"10jts. 5)16-36jts. 6)20"-32jts. For 700 Gas line, 1)2"-37jts. 2)4"125jts. 3)6"-13jts. Please advise and obliging Contractor to sort this out immediately. Your utmost support and quick action regarding this matter is very necessary. Thanks. PID has observed that one unqualified welder was doing tack welding of I-Beam connected to the base support. This violates SAES W-012 para 8.1 & 10.9.1 During the weld there was excavation so that the air blow sand and the welding area is not cover with tent this is violation in SAES W-012 prg 10.2.3 During the weld, the 6010 consumable was store in gloves in the ground this violate SAES W-012 Parg 6.2 During the welding, the coating near the joint welded was damage The apparatus of the welding is not use; ground clamp has to be used not welded clam in the coating. This clam is damage the coating near it During my routine visit @ site it was observed that the AMSYCO Radiation or Monitoring Devices is very weak (11 curie only. This is insufficient and not acceptable by inspection. SPIU/PID recommend AMSYCO to provide an appropriate source as required to cope-up the number joints backlog. Please take an action ASAP. Thanks. Verified and checked the manifold system to be used for the hydrotesting. Noticed that the manifold system calibration date is overdue and this is violated as per the schedule "Q" sec.6 para.6.1 of the attachment IV that states the calibration cycle shall not exceeds six months. Please advised contractor accordingly.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1
1629
8/19/2007 4:30:27 PM
001
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-H-200
1630
5/4/2008 1:17:59 PM
001
SATIP-A-004-03
SAIC-A-2003
Mechanical
SAEP
SAEP-1160
1631
1/21/2007 8:46:08 AM
001
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.4
1632
1/12/2008 1:47:15 PM
001
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
1633
12/5/2007 1:51:31 PM
001
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
8.1 and 10.9.1
1634 1635 1636 1637
12/6/2007 4:54:36 PM 12/6/2007 5:03:57 PM 12/8/2007 6:46:45 AM 12/8/2007 6:52:13 AM
001
Violation-After The Fact Violation-After The Fact Violation-After The Fact Violation-After The Fact
SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01
SAES SAES SAES SAES
SAES-W-012 SAES-W-012 SAES-W-012 SAES-W-012
10.2.3 6.1 10.15 10.15
001 001
001
1638
3/12/2008 4:53:11 PM
SATIP-NDE-RT-01
SAIC-RT-2004
Mechanical
SAEP
SAEP-1143
12.1.3
1639
5/19/2008 11:29:01 AM
SATIP-A-004-02
SAIC-A-2011
Mechanical
ScheduleQ
Schedule Q
A IV Para 6.1
1640
1/20/2008 3:47:51 PM
1641
2/20/2008 12:43:12 PM
Verified and checked that the QA/QC supervisor Mr. Vicente A. Marande leaving @ shaybah without notification to SAPMT and to Project inspection division as necessary. This is in violation of schedule "Q" general requirements para.5.11. Noticed that if the contractor does not intent this non conformity or does not adhere the quality requirements SPIU/PID will proceed to revoke his qualification. Please advised contractor accordingly. Thanks. Contractor work continuation without performing the internal quality auditing at the stage of 60% compilation of the project. This is in a violation of the schedule "Q" section 7.2 para.7.2.2. Contractor shall adhere the requirements and please advised them to perform internal audit ASAP. The String Pipe spool (Joint Nos FW-217 to FW-221 at Maint Road Crossing)was lowered without Holiday test witnessed by PID. Coating applicator/Blaster blasting without earthed/grounded Pressure gauge available on the blasting machine can not be readable The String Pipe spool (Joint Nos FW-217 to FW-221 at Maint Road Crossing)was having major visual defects(sags, Lumps, and deep depressions) were not attended prior to Holiday testing/Lowering in the trench. Sand and foreign materials were contaminated the repair area after coating application without drying and curing .The String Pipe spool (Joint Nos FW-217 to FW-221 at Maint Road Crossing)was Lowered without drying and curing. Coating QC is not available inside Abu Ali Plant to witness Surface Preparation and measurement prior to welding contractor has coated several Pipes in open condition(SABKHA and Slat Contamination)and Spools found with severe rusting and peel off on the coated Pipes. Coating works(Surface Preparation and paint Application) were not inspected for two months, for the coated spools and Pipes at AME Yard near Well Heads. Abrasives- Deccan Garnet, Batch No.1109, not identified and verified, was being used for Pipes & Spools for the trunk Lines. Most 10" Spools/Pipes found without end cap Coated Pipes were received and erected without material receiving and traceability. No document found for received materials. Bolt tightening was observed with hard hammer blows on the manual spanner with insert rod/Pipe at Well head Piping for most of the Flange Joints assembly. No Shop Weld documents for the modified joints for the shop welds, after weld acceptance. PID found that FW390C, SW390C and FW61C, SW61C were identified as Joints are violation as per standard. Contractor QC is hiding the reporting systems and Weld status. Joints modified for the shop welds after weld acceptance. Weld Joints Found without Welder Symbol and date Spool AD was cut out after the spool has been shop fabricated and different rating of flanges found with the same spool(900# and 1500#) Weld Fit-ups were made with less bevel angle and QC was not available. Weld Beads found starts from same location and ends on the top with the same location, during welding. Field Joints, FW-279, FW-340, FW-321D, FW-321C, FW-307, FW-309 and FW-01A were repaired last week. PID requested contaracor QC for Penalty joints and documents Last Week. Contractor has not complied.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.2
1642 1643 1644
2/25/2010 6:07:45 PM 2/22/2010 5:50:37 PM 2/22/2010 5:54:04 PM
SAES SAES SAES
SAES-H-200 SAES-H-102 SAES-H-102 01-SAMSS035
7 4.4.1.1 4.4.1.5
1645
2/25/2010 6:18:35 PM
Standards Violation
SATIP-L-450-04
SAIC-L-2112
Mechanical
SAES
Annex H
1646
2/25/2010 6:24:16 PM
Standards Violation
SATIP-H-002-02
SAIC-H-2015
Mechanical
SAES
SAES-H-201
8.2.4
1647 1648
2/22/2010 5:58:27 PM 2/22/2010 5:46:28 PM
ScheduleQ SAES
Schedule Q SAES-H-100
5.1 8.1.1
1649 1650 1651 1652
2/21/2010 3:53:07 PM 2/21/2010 3:35:46 PM 2/22/2010 5:08:52 PM 2/22/2010 6:03:56 PM
SATIP-H-100-01 SATIP-H-100-01 SATIP-L-350-01 SATIP-L-410-01
SAIC-H-2027 SAIC-H-2024 SAIC-L-2011 SAIC-L-2083
ScheduleQ SAES SAES ScheduleQ
Schedule Q SAES-H-100 SAES-L-350 Schedule Q
5.1 3.1 7.4 A IV Para 3.3
1653 1654 1655 1656 1657 1658 1659 1660
2/25/2010 5:43:31 PM 2/21/2010 2:22:40 PM 2/26/2010 1:21:38 PM 2/21/2010 4:23:03 PM 2/21/2010 5:10:39 PM 2/22/2010 5:37:16 PM 2/22/2010 5:40:25 PM 2/21/2010 5:18:05 PM
Standards Violation Standards Violation Standards Violation Standards Violation Standards Violation Standards Violation Standards Violation Standards Violation
SATIP-L-410-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01
SAIC-L-2014 SAIC-W-2051 SAIC-W-2051 SAIC-W-2051 SAIC-W-2048 SAIC-W-2051 SAIC-W-2048 SAIC-W-2048
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical
SAES SAEP SAEP SAEP SAES SAEP ScheduleQ SAES
SAES-L-350 SAEP-1160 SAEP-1160 SAEP-1160 SAES-W-012 SAEP-1160 Schedule Q SAES-W-012
12.4 6 6 6 15.1 6 5.1 10.17
1661
2/26/2010 1:43:41 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAEP
SAEP-1160
1662 1663 1664 1665 1666
2/26/2010 1:34:18 PM 2/21/2010 2:53:36 PM 2/22/2010 5:27:08 PM 2/25/2010 5:32:11 PM
Contractor is not following the RT selection for daily welding coverage, and failing to submit the weld summary reports.PID has requested several times. Damaged Electrodes-7018 being used for Structural Welding by welder AJC(Inside Abu Ali). MIG Spools during STT welding found contamination and without cover(Mounting Cover) Fit-up made for Joint FW-433(Abu Ali Plant) with less gap and without surface preparation(rust and contamination) and Welding inspector is not available at site to monitor the Fit-up which was ready for welding. Joint FW-433(Abu Ali Plant) was welded without gap and this was noted by PID when half portion of the weld was completed. PID raised this issue for wrong Fit-up and cleanliness prior to welding. QC welding is not available at the work site to cover fit-up and welding activities. Re used Flange 900#(Fittings) under fit-up is ready for welding without NDT for lamination Check for the rebevel or recut edges, for FW421A. WPS is not available at site with the contractor for Structural welding. PID comments that the proposed modifaction details to use additional flanges, is not Best Industry Practice for the following reasons:- 1) SAES-L-110, Para.8.1: "Flanged connections shall be avoided when butt-welded joints can be used in services and locations where leaks are likely to occur." 2)PIP PNE00001. Para. 8.3.1: "Flange connections shall be used minimally." The Blaster/Coating Applicator has Blasted Several pipes without being inspected by QC Coating Most of the Welds found with Structural Welds are having severe U/C, Weld leftouts, Uneven weld profile and Slag(improper Cleaning) and Poor workmanship. Thorough Inspection to be required before, during and after welding since major arc strikes and pinholes were found, on and adjacent to the welds. Field Weld Joints FW-09B,FW-181,FW-192H,FW-209,FW-226C,FW283,FW-285,FW-288,FW-307,FW-309,FW-354 are having slag, spatters, electrode inclusions, excess penetration and severe rusting which were found before internal coating. Most of the Pipe support structures found with Ragged,irregular edges and severe gouging. As per RFI # 415, initiated on 17 October 2007, an inspection was required on 18 October at 3:00 PM. When Project Inspection arrived at site at 2:50 PM, for witnessing the activity, the pipeline was already lowered two third of the total string with out the presence of Project Inspection and even contractor Inspection representative. As per SATIP, that inspection point is a H1 (100% Hold Point for QC Inspection or Test) for project inspection and as well as for contractor QC. It is a serious violation, so strongly recommended to go back to arrange the Holiday Test and make sure the presence of Project Inspection. During site visit, the following FMQ Employ has founded performing STOPIC (APCS-113C) at TL-7, FW-757, and failed to show the Coating Applicator Certification Cards. The employs are 1- Ibrahim Mohammad Salah, FMQ Badge # 800190 2- Saeed Mohammaf Ahamad, FMQ Badge # 800342 Performing coating with out certification is a serious violation of Saudi Aramco Engineering Procedure SAEP-316, Para 4.4 and Supplement 1, Para 5 sub Para 5.1. RECOMMENDATIONS: 1Remove the coating done by above-mentioned employs and re-coat with certified coating applicators. 2- Instruct to QC Inspector to insure that coating work shall be performed with certified coating applicators On 3/2/08, at 9:50 blaster without certification
SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01 SATIP-W-012-01
SAIC-W-2054 SAIC-W-2044 SAIC-W-2044 SAIC-W-2048 SAIC-W-2048
SAEP SAES SAES SAES ScheduleQ
SAEP-1160 SAES-W-012 SAES-W-012 SAES-W-012 Schedule Q
6 6.1 6.1 10.3.1 5.1
1667
2/26/2010 1:14:23 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
9 & 10.3.1
1668 1669 1670
2/22/2010 5:18:11 PM 2/22/2010 4:07:15 PM 2/21/2010 5:40:20 PM
ScheduleQ SAES SAES
5.1 10.3.3 7.1.6
1671
3/3/2010 11:20:57 AM
Dwg.#F07-L-RB301882
Standards Violation
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-110
8.1
1672 1673
3/17/2010 11:47:15 AM 3/6/2010 7:00:29 PM
SATIP-H-100-01 SATIP-W-012-01
SAIC-H-2027 SAIC-W-2048
ScheduleQ SAES
5.1 10.6.2
1674
3/17/2010 11:11:48 AM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.6.2
1675
3/17/2010 5:29:46 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.6.2
1676
3/6/2010 6:49:32 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.3.2
1677
10/19/2007 7:21:54 AM
SATIP-H-002-02
SAIC-H-2018
Mechanical
SAES
SAES-H-200
Schedule Q
1.8
1678
11/14/2007 7:03:55 AM
SATIP-H-002-02
SAIC-H-2010
Mechanical
SAEP
SAEP-316
4.4
1679
3/3/2008 8:11:02 AM
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAEP
SAEP-316
4.4
1680
and no QC available at the site Coating work is on going at Abu-Jifan Water well # 621, with out any QC presence. This matter already highlight with Contractor QC from last three weeks but all in vain. Coating work without QC presence is a serious violation of Schedule Q and it is H1 100% Hold point for contractor QC. It strongly recommended that re-blast and re-coat all the work on Water well # 641 & 621 that performed with out coating QC. During surveillance dated Feb. 5 and Feb. 7, it observed that coating work is ongoing with out coating QC at well # 142 & 60 for T/L-1. The weather condition is very bad and sand storm is there. Saudi Aramco Inspection as well as contractor QC manager instructed the crew supervisor to follow the Saudi Aramco Engineering standard but all in vain. The contactor Lead coating QC is also working as construction supervisor due to that supervisor pay all his attention towards the progress not at all for quality. It is strongly recommended to go back to re-blast and re-coat the both well and take the serious action against inspector/coating supervisor. Pare carbon steel pipes and spools of different sizes are directly lying down on ground at both shop and store area A serious damage found during surveillance due to which deformation occured in the string#29 violatiing Aramco standard SAES-L-450 Construction of On-Land and Near-Shore Pipelines 8.3 Pipe stacking shall be made in a manner which will not damage the pipe or the coating. It is, therefore, advised to handle the material with extreme care by following the Aramco procedures & standards. Several Coated pipes with different size scatter all over the shop and yard is stuck on pare lay on bar steel or in top of each other no insulation to protect the coating. Several different size pipes and spools lay on the ground During surveillance of FMQ yard for material traceability, it is observed the contractor is not having the traceability of material like plate, pipes and fitting used for fabrication being properly maintained. It was found the reinforcement pads, drag anchor being manufactured does not have identification done for traceability. It is also observed that the pipe & plates cut has no material heat number/ other information transferred to the left material. The welding record sheet SATR W2007 has no proper entry made at the material heat number Colum. The electrode (E-7018) used has no proper drying record available for traceability of the electrode batch number being used for fabrication. The above all is violation of schedule Q- Attachment IV-Para 3.2 CONTRACTOR shall implement an identification procedure for all materials, parts and components, including partially fabricated assemblies Welding crow were spotted welding at two locations Fw 510 & 513 of TL 8 at 8:45 AM 5/12/08. They were welding without the following items RFI, QC,MPI and welding procedure weld fit-up in progress without present of QC and RFI It noticed that Contractor FMQ welded a Temperature Tie-In weld, on Trunk Line-2, weld # FW-625A, at less than 5 0C. As per Data Sheet the minimum Tie-In Temperature is 70 0F (21.11 0C). The Contractor violate the Saudi Aramco Engineering Standard SAES-L-450, Para 15.2, 15.3, 15.4, 15.5 and Contractor approved Quality Work InstructionMechanical, for Temperature Tie-In, Para C & D. The contractor violates all this even Saudi Aramco Inspector explains the concerned inspector about Temperature Tie-In welding as well as request for not violating the spec. & standards but all in-vain. These serious violations have the impact on material (Pipeline) contraction and expansion behavior.
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
1681
1/29/2009 7:15:54 AM
SATIP-H-002-06
SAIC-H-2048
Mechanical
ScheduleQ
Schedule Q
5.1
1682
2/9/2009 9:37:24 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
1683
5/13/2008 8:17:48 AM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1
1684
12/14/2008 7:17:56 AM
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
8.3
1685
4/27/2008 3:39:15 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1
1686
10/14/2008 2:28:46 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1
1687 1688
5/12/2008 10:26:53 AM 3/4/2008 3:42:27 PM
SAIC-W-2006
ScheduleQ ScheduleQ
1.3, 5.1, 1.7, attachment IV 7.3 5.1 and 1.7
SAIC-W-2048
1689
1/16/2008 5:53:35 PM
SATIP-W-012-01
SAIC-W-2057
Mechanical
SAES
SAES-L-450
15.2
1690
1/26/2008 7:33:54 AM
During the site visit, it noticed that welding of a Temperature Tie-In in on going on Trunk Line-2, weld # FW-784A, at 7:30 AM, with out contractor welding Inspector as well as with out any RFI. As per Data Sheet, the minimum Tie-In Temperature is 70 degree Fahrenheit (21.11 degree Celsius), and this is a Hold point for Contractor Inspection and 100% witness for Saudi Aramco Inspection. This is the violation of Saudi Aramco Engineering Standard SAES-L-450, Para 15.2, 15.3, 15.4, 15.5 and Contractor approved Quality Work Instruction-Mechanical, for Temperature Tie-In, Para C & D and Saudi Aramco SATIP-W-012, Item No. 3.6. These serious violations have the impact on material (Pipeline) contraction and expansion behavior. It noticed that Contractor FMQ welded a Temperature Tie-In weld, on Trunk Line-4, weld # FW-11, at less than 4 degree Celsius at 8:20 AM, with out contractor welding Inspector as well as with out any RFI. As per Data Sheet, the minimum Tie-In Temperature is 70 degree Fahrenheit (21.11 degree Celsius), and this is a Hold point for Contractor Inspection and 100% witness for Saudi Aramco Inspection. This is the violation of Saudi Aramco Engineering Standard SAES-L450, Para 15.2, 15.3, 15.4, 15.5 and Contractor approved Quality Work Instruction-Mechanical, for Temperature Tie-In, Para C & D and Saudi Aramco SATIP-W-012, Item No. 3.6. These serious violations have the impact on material (Pipeline) contraction and expansion behavior. with out contractor welding Inspector as well as with out any RFI. During the site visit it noticed that welding of a Temperature Tie-In in on going on Trunk Line-4, weld # FW-221, with out contractor welding Inspector as well as with out any RFI. Welding of Temperature Tie-In is a Hold point for Contractor Inspection and 100% witness for Saudi Aramco Inspection. This is a violation of Saudi Aramco SATIP-W-012, Item No. 3.6. During site visit, it is noticed that repair work was on going on T/L-11, FW-1210, with out any Weld Repair Procedure, RFI and presence of Welding Inspector. As requested by Project Inspection to FMQ QC department to provide the RT report dually signed by all three RTFI,S (NDT company RTFI, VETCO that is reviewing the film on the behalf of FMQ and Saudi Aramco RTFI) that can show the repair/rejected area of the weld. FMQ QC department failed to provide the RT report. It also noticed that welding work wasd ongoing under the strong wind bellowing. This is serious violation of Saudi Aramco Engineering Procedure SAES-W-012, Para 17, Para 10.2 and Saudi Aramco Test and Inspection Plan SATIP-W-012-01. with out any Weld Repair Procedure, RFI and presence of Welding Inspector. As requested by Project Inspection to FMQ QC department to provide the RT report dually signed by all three RTFI,S (NDT company RTFI, VETCO that is reviewing the film on the behalf of FMQ and Saudi Aramco RTFI) that can show the repair/rejected area of the weld. FMQ QC department failed to provide the RT report. It also noticed that welding work wasd ongoing under the strong wind bellowing. This is serious violation of Saudi Aramco Engineering Procedure SAES-W-012, Para 17, Para 10.2 and Saudi Aramco Test and Inspection Plan SATIP-W-012-01. During site visit, it noticed that welding work is on going on T/L-5, FW670 & 671 with out RFI and presence of Welding Inspector. It also noticed that welders have tack welding the ground lead with the base metal that will cause the ARC Strike and damage the base metal. It is bade practice for welding work and violation of Schedule Q requirements. During site visit, it noticed that repair work is on going on T/L-12, FW2356 and T/L- 1, FW-1161 & FW-1169, with out any Weld Repair Procedure, with out RFI and presence of Welding Inspector. This is serious violation of Saudi Aramco Engineering Procedure SAES-W-012, Para 17, Para 10.2 and Saudi Aramco Test and Inspection Plan SATIPW-012-01.
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1691
1/19/2008 6:32:31 AM
SATIP-W-012-01
SAIC-W-2057
Mechanical
SAES
SAES-L-450
15.2
1692
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1693
1/21/2008 8:22:22 AM
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1694
1/26/2008 5:37:51 PM
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
17.3
1695
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1696
4/18/2008 8:12:14 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1697
1/28/2008 6:09:55 PM
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
17.3
Schedule Q
5.1 and 1.7
1698
2/11/2008 5:53:14 PM
1699
2/12/2008 2:15:51 PM
1700
weld rapier is on going without shielding, weld repair procedure, MPI, and welding is carried out with 7010 electrode instead of using correct welding procedure Weld rapier is on going without shielding, weld repair procedure, MPI, no QC inspector and welding is carried out with 7010 electrode instead of using correct welding procedure Weld rapier is on going without shielding, weld repair procedure, MPI, no QC inspector and welding is carried out with 7010 electrode instead of using correct welding procedure During site visit dated 01 April 2008 at 1700 Hrs, it noticed that repair work is on going on T/L-12, FW-1105 with out RFI and presence of Welding Inspector. Weld Repair Verification is 100% HOLD POINT for contractor QC. This is serious violation of Saudi Aramco Engineering Procedure SAES-W-012, Para 17, Para 10.2 and Saudi Aramco Test and Inspection Plan SATIP-W-012-01. During surveillance dated 19 Nov. and 24 Nov. 2007, it has been observed, that welding crew on TL-8 is not fulfilling the WPS requirements for pre-heat. As per welding procedure FMQ-W-91, the minimum pre-heat temperature shall be 34 degree centigrade. This is a serious violation as per SAES-W-012 and FMQ Welding Procedure FMQ-W-91. On 4/14/08 welding progress on Fw 1203A without RFI and QC Welding fit up for flange of flow line at T/N 41 without present of QC and no RFI more over four open electrodes can in the compartment of the truck. I have waited for half hour but the QC did not show up On Monday around 10 AM 2/11/08, FMQ Welding on TL/11 FW 1032 without RFI and QC Inspector welding fit-up progress wiouth QC Welding fit-up in progress without QC and using cold welding electrode During surveillance dated 24 Nov. 2007, it has been observed that during welding at TL-8, production joint exceed the specified time lapse between root pass and hot pass that is 15 minutes maximum. Saudi Aramco Inspector as well as contractor Inspector instructed the crew supervisor to follow the Saudi Aramco Engineering standard, conduct the MPI of the root pass, and pre-heat the joint up to 60 degree centigrade prior to start welding for hot pass but crew supervisor did not follow. This is a serious violation as per SAES-W012, Para 10.7, Sub Para 10.7.2 It is strongly recommended that the second shift production (FW-904 to FW-934) shall be 100 % RT. During the site visit, it noticed that welding on Trunk Lines 3, 5 and 7 in interface area is in progress with out any RFI. As per Schedule Q, Attachment IV, Sub Para 1.2.3, RFI shall be issued 48 Hours in advance for weekend inspections. This is a violations of Schedule Q as well as ITP. During the site visit, it noticed that welding on Trunk Lines 3, 5 and 7 in interface area is in progress with out any Welding Inspector/Inspection. As per Schedule Q, Para 2.1, Table VI-2, one welding inspector per crew is required for pipeline welding. This is a violation of Schedule Q as well as ITP. On 3/6/08 at 9:15, at sit connection & saddle welding is in progress without present of QC and welding electrode of 7018 was opened on truck comportment no oven available to store electrode at this site. On 3/6/08 at 9:15, at sit connection & saddle welding is in progress without present of QC and welding electrode of 7018 was opened on truck comportment no oven available to store electrode at this site.
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
17.3 and 10.2
Schedule Q
5.1 and 1.7
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
17.3 and 10.2
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1701
4/1/2008 6:36:57 PM
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
17.3 and 10.2
Schedule Q
5.1 and 1.7
1702
11/25/2007 10:32:27 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
11.1
1703
4/15/2008 6:43:09 AM
ViolationPrevented Installation ViolationPrevented Installation ViolationPrevented Installation ViolationPrevented Installation ViolationPrevented Installation
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1704
4/7/2008 2:14:44 PM
SATIP-W-012-01
SAIC-W-2044
Mechanical
SAES
SAES-W-012
6.1
Schedule Q
5.1 and 1.7
1705 1706 1707
2/11/2008 5:44:07 PM 3/3/2008 5:35:49 PM 3/3/2008 5:42:33 PM
ScheduleQ ScheduleQ SAES
Schedule Q Schedule Q SAES-W-012
5.1 and 1.7 5.1 6.1 Schedule Q 5.1
1708
11/25/2007 11:11:52 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7 and 10.7.2
1709
1/26/2008 7:22:57 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7 and attachment IV para 1.2.3
1710
1/26/2008 7:25:06 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
1711
6/4/2008 7:58:59 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
ScheduleQ
Schedule Q
5.1
1712
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-012
A1
1713
10/14/2008 3:47:06 PM
During surveillance of FMQ fabrication shop it is observed the alloying welding involved for fabrication of well head spools is being carried with no requirements of positive material identification being followed, this is violation of Aramco standard requirements per SAES A-206 Please refer below standard requirements for PMI. 7.2 One hundred percent PMI testing shall be performed on all pressure components and welds of alloy materials. 7.7.2 PMI Testing of Welding Consumables One consumable from each lot shall be PMI-tested. The remainder of the lot shall be compared to the identified consumable to verify that the markings of the electrodes/wires are correct. 8.1 The Equipment Manufacturer or the Fabricator, as applicable, shall implement a written PMI Procedure, covering testing and reporting, which shall be made available to the Saudi Aramco Inspector for review, acceptance, and verification of implementation. During surveillance of FMQ fabrication shop it is observed fitting (3elbow) used for fabrication of spool for oil well -121 well head piping is being cut & re beveled for fabrication is not examined for lamination prior to welding, as per SAES W-12 this is violating the standard requirement. Refer SAES W-12 Para. 10.3.3 Fittings that are re-cut or re-beveled shall have the cut surface examined for laminations before welding. The NDT method to be used shall be determined by Saudi Aramco Inspection Discrepancies have been noted on radiographs and multiple marking of spools indicating a loss of QC control in the FMQ Fabrication Shop, as evidenced by -Spool 709 T SW-73A & Spool 674 SW 58A indicate Radiographs matching and SW 58A indicates joint shot on April 2008 with a LOF defect, new joint for SW 58A shot on 16th May does not match with original shot and no Indication of repair. -Spool 668A & Spool 1015 SW are matching. -Failure to produce requested radiographs for Spool 664A, 673A,612D,643D -Spools marked with multiple spool numbers. 646-694D,724D, 708,970,6730,740,694J,610C,662B,686E,700,610U,693K,685K,752,62 4M,612R,79 6M,725M,701A,704S,709U,622J,712J,698L,624B,662D,626B,633, 646 ncr # 500003078 It has been noticed that FMQ have only two welding Inspector for BI10-03004. The Inspectors are assigned as under. 1- G. Chanliongco Line Welding 1st Shift 2- R. Caballero Line Welding 2nd Shift There is no welding inspector for Tie-In welding crew as well as for fabrication shop both shift (day & night). It is a serious violation of Schedule Q, Para 2.1, Table VI-2. Please arrange minimum three experienced welding inspectors to fulfill the Schedule Q requirements. Refer to Surveillance Number 1018, in addition to all that two more TieIn welding Crew were added. It observed that, there is no more approved Welding Inspector to inspect the welding work of Tie-In and Temperature Tie-In. As per Schedule Q, Table VI-2, One Welding Inspector per crew for Tie-In welding including Temperature Tie-In is required. This is a serious violation of the contact agreement. It is strongly recommended that please arrange the Welding Inspectors to fulfill the Schedule Q requirements.
SATIP-W-012-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
7.2
1714
10/14/2008 3:19:19 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.3.3
1715
5/27/2008 8:57:22 AM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.3
1716
12/3/2007 5:19:55 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
1717
12/5/2007 3:22:32 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
1718
12/7/2007 7:18:04 AM
It observed that FMQ not follow the inspection notifications period. Few RFIs are as under: RFI # ISSUE DATE\ISSUE TIME INSPECTION DATE\INSP.TIME 1052 12/6/2007 11:13:02 AM 12/6/2007 02:00:00 PM 1048 12/5/2007 09:05:47 PM 12/6/2007 11:00:00 AM 1047 12/5/2007 08:56:47 PM 12/6/2007 08:00:00 AM 1039 12/5/2007 03:15:12 PM 12/6/2007 07:30:00 AM 1034 12/4/2007 09:13:50 PM 12/5/2007 09:00:00 AM 1033 12/4/2007 09:08:03 PM 12/5/2007 07:00:00 AM 1032 12/4/2007 06:57:29 PM 12/5/2007 10:00:00 AM 1028 12/4/2007 11:21:44 PM 12/4/2007 01:00:00 PM 1027 12/4/2007 11:12:50 PM 12/4/2007 01:00:00 PM As indicated above some RFIS have only less than two hours time between RFIs initiated and Inspecti On 3/11/08 8:45 and 10AM weld repair progress without presence of QC, shield from air , no MPI and no welding procedure. In addition to that one type of electrode used from root to cap which is 7010. on 3/2208 welding repair on T/L 1 without RFI, QC, and MPI During routine site visit to Trunk line 7 (Khurais Village back road crossing) on 20 Oct 2008, It was found there is welding activity being carried out violating following welding requirements. a. There is no RFI raised for the above activity. 2. Further visit to manifold area (trunk line -1) there is similar requirements being violated. a. There is no welding inspector available at site. b. The potable oven being used is defective. c. Cool electrode (7018) being used for welding pipe joints. d. Spools accepted at shop is being modified with out any RFI raised for the same. e. New spools are fabricated at site (05 Joints) with out clearance from QC b. The holding oven being used has defective temperature gauge, broken thermo couple, calibration expired since 27 March 2008. The electrode store in the oven was cold. c. The electrode being used has no issuance and drying record available. d. There is no welding inspector available for monitoring above activities.
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2
1719
3/11/2008 2:49:07 PM
SATIP-W-012-01
SAIC-W-2051
Mechanical
ScheduleQ
Schedule Q
5.1
1720
3/23/2008 6:51:07 AM
SATIP-W-012-01
SAIC-W-2051
Mechanical
ScheduleQ
Schedule Q
5.1 and 1.7
1721
10/21/2008 9:44:35 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7
1722 1723 1724
SAES SAES ScheduleQ
SAES-W-012 SAES-W-012 Schedule Q
6.1 6.1 5.1
1725
8/6/2009 3:28:12 PM
During my holiday RFI for flow lines of TR.L # 14 it was observed that flow lines are being damaged at different location during trench excavation. FMQ Inspection is raising RFI with out rectifying damaged portion. The matter was discussed in weekly meeting & decided rectification & reporting procedure but actual at site the damaged pipes of flow lines are replaced with out FMQ Welding inspector presence. Weld nos. are not available on those joints. There is not even single inspection repot submitted against rework. This is violation of Aramco SATIP-W-12-01 & Standards L-450& Sch. Q Att. VI Tables (SAIC-W -2036) Therefore it is advised welding inspector should stay at work location monitor work execution, perform relevant NDE, Tie-in inspections, submit Inspection documents & offer RFI for INSPECTION. Damaged Flow lines # MZJ 08,14,16,19,23,182.183,185,241,243. During site visit in Mazalij area for trunk line # 14 & relevant flow lines, it is observed that welding have been completed at flow line # Mzlj-15 tie-in LOCATION but inspection is not being performed. The Elbow between Anchor block & riser fitted up & welded pathetically i.e. fit up high low, uneven capping, under bead capping, surface u/cut. Elbow joints to be cut & re-fitup prewelding / post welding inspection to be carried out. Inspection RFI to be raised for PID inspection
SATIP-W-012-01
SAIC-W-2051
Mechanical
ScheduleQ
Schedule Q
5.1
1726
7/25/2009 2:22:42 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
1727
4/11/2009 7:15:31 AM
During surveillance dated April 9, it observed that coating work is ongoing at T/L-12 after Riyadh-Hufoof highway. The weather condition is very bad and sand storm is there. Contractor QC coating inspector instructed to the crew supervisor to follow the Saudi Aramco Engineering standard but all in vain. It is strongly recommended to go back to re-blast and re-do the work and take the serious action against inspector/coating supervisor. During the site visit, it noticed that Bolt Tightening was on going on Trunk Line-8, manifold area with out any QC inspector. Flange Joint inspection (Gasket verification & Bolt Tightening) is a 100% witness point for Contractor Inspection and RFI for such activities required. As per Schedule Q Table IV-2, prim contactor QC personnel requirement for Flange Assembly one inspector per 15 workers is required. This is a serious violation of Schedule Q as well as the inspection and Test plane. During Site Visit it noticed that Weld # 2157 B is welding with out any inspection. This joint is a Temperature Tie-in Weld. SAPID call to welding supervisor and requst that this is joint is temperature tie-in weld and as per SATIP-W-012, Temperature Tie-in weld is a HOLD POINT for contractor QC but all in vain. No inspector reach at site. This sis a voilation of SA SATIP. During site vist it noticed that welding of Temperature Tie-in is ongoing with out any QC inspector Presence. This is HOLD POINT for contractor QC and 100 witness point for SAPID. Contractor have not raised any RFI as well as not informed to SAPID. SAPID call to contractor welding supervisor but all in vain. This is a serious violation of SATIP. During the site visit, it noticed that welding of a Temperature TieIn/Tie-In was on going on Trunk Line-8 Mainline (FW-617, 618), Tie-in @ Oil well # 425 Tie-in area, Temperature Tie-In @ oil well # 517, Flow line 64, Temperature Tie-In @ Flow line 65, FW96 and Temperature Tie-in @ Flow line # 520. All above noted areas, no inspection coverage from contractor QC have noticed. Tie-In and Temperature Tie-in welding is a 100% Hold point for Contractor Inspection and 100% witness for Saudi Aramco Inspection. As per Schedule Q Table IV-2, prim contactor QC personnel requirement for Tie-In and Temperature Tie-in welding one inspector for each crew are required. As well as for Pipeline welding minimum one inspector is required within 5 Km radius. These serious violations have the impact on welding quality as well as NDE requirement. During the site visit, it noticed that the main line crew proceeding welding on Trunk Lines 13, in Abu Jafan area is in progress with out any RFI, As per Schedule Q, Attachment IV, Sub Para 1.2.3, RFI shall be issued 24 Hours for normal days and 48 Hours in advance for weekend inspections. This is a violations of Schedule Q as well as ITP. with out the presence of welding inspector.
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
APCS 113C 4.1 and Section 6
1728
4/4/2009 1:44:22 PM
SATIP-L-450-03
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
5.1
1729
6/26/2009 9:28:12 AM
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
5.1
1730
6/26/2009 9:35:53 AM
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
5.1
1731
4/4/2009 1:30:05 PM
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
5.1
1732
2/9/2009 9:08:04 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
1733
7/4/2009 7:55:08 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
1734
During site visit it noticed that welding of temperature Tie-In weld was on going with out any RFI . This is serious violation of SATIP that indicate the 100% Hold point for contractor QC. as well as the cotractor QC presence
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
1.7
1735
SATIP-W-012-01
SAIC-W-2057
Mechanical
ScheduleQ
Schedule Q
5.1
1736
12/21/2009 10:38:07 AM
1737
11/8/2008 4:06:41 PM
During my hydro test witnesses of drain lines at well head it is observed that many open ends of drain lines inside drain pit which were temporary blinded with welding still not removed at different trunk lines well heads. (Half water drained through the plug at centre of end blinds) it is against the Aramco standard SPEC. SAES A-004, GI-002-102. It is discussed in meeting then removal of blind started with flame cutting which is not acceptable however it is advised to visit all well heads insure removal all end blinds, grind / paint the ends & raised RFI for verification Focused Assessment was carried out on RT Joint Selection, Request to NDT contractor, Report writing and Assessment reports for first 12 Oil Well Head Piping and found only one joint for Oil Well # 107, SW-15, was shooted as a Re-Shoot but the area of intrust is not the correct. It is recommended that contractor shall go back to re-shoot the correct area and pay more attention on repair/reshoot marking. During the site visit, it noticed that the welding crew proceeding the welding on Trunk Lines 7 oil well # 312 & 29. Welding was progress with out any RFI, . The wind speed was too high. The shop welded joints cut and re-welded at site. Also joints shall be coated internally but it noticed that without coating spool was installed (Spool E) As per Schedule Q, Attachment IV, Sub Para 1.2.3, RFI shall be issued 24 Hours for normal days and 48 Hours in advance for weekend inspections. Welding cannot be proceed with out inspection and with out welder JCC. It also strongly recommended that open all spool E for drain line and check coating with out the presence of welding inspector as well as welder has no JCC Pipe Spool A of wellhead# khurs.4 is being installed. The shop weld joints SW.5, 6 & 7 are cut at site for adjustment of spool. WPS is not followed for proper fit up of weld joint (bevel angle & root gap) advised for proper bevel & root gap before welding. Gama graphic shots of weld joints shall be reported It noticed that 120 joints of 8 and 10 Dia pipe for oil wells were rejected in AUT and sum joints was repaired. Repair welds were examined by RT that is a clear violation of SAEP-W-012, Para 17.4. All repaired welds shall, as a minimum, be inspected using the original testing method that is AUT. As we achieved a concurrence, that recommended cutting and re-welding the all welds have to be repairs. Repaired joints shall have a different number and can be examined by RT. A separate assessment sheet shall be prepare and submit for SA assessment. SAPID shall closely monitor all cutting, repairing and RT processes. During Routine site visit to water injection well (733,732,731 etc), it is observed there is no isolation being done for flanged joint involving bi-metallic joint (SS # CS), this is violation of Saudi Aramco standard requirement. As per SAES-L-109 Para 11.5 The PIKOTEK gaskets, or approved equal, with isolating sleeves and washers Shall be used for isolating dissimilar metal flanged joints (i.e., electrical Isolation), and insulting joints for cathodic protection
SATIP-A-004-03
SAIC-A-2017
Mechanical
SAES
SAES-A-004
10.4
SATIP-NDE-RT-01
SATR-NDE-2008
Mechanical
ScheduleQ
Schedule Q
A IV Para 4.3
1738
4/4/2009 7:08:00 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7
1739 1740
ScheduleQ SAES
5.1 8.1
1741
3/13/2009 11:00:17 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
1742
11/17/2008 2:09:33 PM
SATIP-W-012-01
SAIC-W-2051
Mechanical
SAES
SAES-W-012
17.4
1743
10/15/2008 6:38:35 AM
SATIP-L-450-04
SAIC-L-2014
Mechanical
SAES
SAES-L-109
11.5
1744
10/11/2008 9:49:26 AM
During routine site visit to FMQ Fabrication shop it has been observed that welding of vent assembly of the well head piping for installing on the same is carried with under mentioned discrepancies which violate construction drawing & SA Engineering standard. Refer drawing number- BB-147991-00100. 1. The vent assembly has a 1 x 6 SS nipple (Item No.6126), which as per the above drawing needs to be inserted through the blind flange (Item No. 6602) and have a stub projecting out though the other side by 3mm & with seal welding done all-round. It is requested that all the assemblies fabricated with such wrong fabrication shall be corrected. 2. It is also observed that there was no fit-up or welding record available for fabrication of these assemblies, violating Schedule Q attachment VI Para. 8, SATIP-W-11-01 ITEM No. 3. The above mentioned assemblies has SS welding performed, which as per SAES A 206 Para 7.2 states One hundred percent PMI testing shall be performed It is also observed that there was no fit-up or welding record available for fabrication of these assemblies, violating Schedule Q attachment VI Para. 8, SATIP-W-11-01 ITEM No. 3. The above mentioned assemblies has SS welding performed, which as per SAES A 206 Para 7.2 states One hundred percent PMI testing shall be performed Refer to our weekly quality / exception item meeting the shortage of FMQ QC inspector manpower were many time discussed. At last shortage of FMQ QC manpower were asked through PMT Transmittal # KHUPD/T-1605/2009 dated 15th Nov.2009. the required shortage of manpower were transmitted to PMT through PID Trans.# KHUPD/1611/2009 dated 23rd Nov.2009 but till to date action is not been taken. One mechanical inspector is working at all exception items of 14trunk lines & more than 400 water & oil wells till to date. Activity of Dain line installation, hydro testing, holiday, painting, civil work under progress parallel with closing of exception items. However it was advised to increase QC manpower as per Sch. Q. keeping in view scattered pipe lines area. Required inspector as under. 1Two additional Mechanical inspectors for exception items at site & one for test packs in work shop 2 - Two additional inspectors for painting. 3- Three additional inspectors for civil During site visit surveillance at W.I.Header PID has found the powder materials cans that ALQHTANI using in girth weld coating was keeping exposed to direct sunlight also cans not have manufacture name ,product identifications number, batch number ,date of manufactures and shelf life or the expiry date this violations to SAES-H-201 Para .5 During site visit surveillance at W.I.Header PID has found welder keep electrodes at the ground and pick it up to start welding this violation as per SAES-12 table 1.PID request 100% RT for welding production on 04/21 During site visit, surveillance at 24 W.I.line PID has observed follows: 1. Contractor do not use full protection blanket to avoid pipe coating damage during welding activates this violate SAES12 Para 10.15 2. Welders has symbol SA was welding with bad technique .PID request welding QC to evaluate him for 3 Joints production this week. It was observed that the contractor S.A.S failed to submitt and performed the internal audits for the full quality system audits at fifteen percent (15%) of the construction work phases. Violated as per schedule requirements sec.7 para.7.2.2. Please advise contractor to comply. Thanks.
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.3
1745
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
1746
Mechanical
SAES
1747
12/13/2009 11:31:12 AM
SATIP-L-450-03
SAIC-L-2113
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
1748
4/20/2008 10:27:48 AM
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-201
1749
4/21/2008 4:18:21 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
6.1
1750
4/27/2008 2:21:37 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.15
1751
6/17/2008 1:12:07 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.2.2
1752
9/23/2008 2:31:01 PM
Internal Quality Auditing - Due to the non availability of the approved third party lead auditor, the Contractor S.A.S fails to performed the "Internal Quality Auditing on September 21, 2008 at stage of 60% compilation of the projects. Please SAPMT to advice Contractor to submit the alternative lead auditor to SPIU for review and approval. So that the 60% internal audit can be performed ASAP and to satisfy the Saudi Aramcos Procedures as mentioned in the schedule "Q" general requirements under sec.7 para.7.2.2. This is strict compliance. Thanks. Insufficient monitoring and inspection coverage of on-going activities (Mechanical & Welding) at site sabkah-24 and at sabkah-27. The QA/QC inspectors violated of the schedule "Q" General Requirements under section-1 para.1.3 & para.1.4. Please contractor to comply the requirements. Thanks. hydrotest was done to valves at fab shop using maifold that not have tagged certificaton or number which viloated SAES-A-004 all SA standard and procedure must implemented to the job at any stage. Based on RFI PID find that Air receiver, gage, and valve are not certified also Blasting equipments are not work probable. During site surveillance PID find at PWI 512 and PWI 502 flange not covered and this is violation according SAES. The flange face should be covered at all the time. During site surveillance PID find at PWI (512),(503),(502),(511) valves installing without RFI and this is violation according to SAEP-1150. We observe AL-BARGHASH install 8 valves without present of QC this is violate schedule Q. 1-Mr, Rommel Vicame QA/QC supervisor went for vicaation without one month notification. 2-contractor assing Mr,Marc Yamit Mech/Welding Inspector to cover his duites with out any notification or approval from PID. these 2 issues violated schdual Q. the contractor failed to reduce the RT back log the total joints RT 670 RT back log 236 according to the laetest weekly weld statuse report. rebar was tacked to spools # SP-01 & SP-02 BB-367139 which violated SAES-W-011 all tack rebar shall be removed and NDT is requiered. visual inspection must be done when these spools arraived to site. Contractor has commenced welding activities of structural attachments at Pump Station 10 without approved QC welding Inspector on site, or RFI to inform PID of the activity. There is no documented evidence of the correct WPS being used or any pre or in process inspection being conducted. This violates Schedule Q, and Saudi Aramco Typical Inspection Plans which show the hold and witness points for Contractor QC Inspectoprs. During The routine site visite PID found the Paint sotre is not matching S.Aramco reqirments at SAES-H-100: 1-Paints and thinners are stored in well-ventilated buildings at the recommended storage temperatures given in Saudi Aramco Paint data sheet, SAES-H-101V. Note: Shelter storage temperature is normally @ 35C maximum unless stated otherwise in the Paint Data Sheet. 2-Temperature sensitive and self polymerization Paints materials are stored in air conditioned storage area at the temperature recommended in the Saudi Aramco Paint data sheet SAES-H-101V. 3-Temporary storage of paint materials covered with canvas, tarpaulins has not exceeded the specified 14 days period.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.2.2
1753
10/26/2008 7:31:31 AM
SATIP-L-450-03
SAIC-L-2113
Mechanical
ScheduleQ
Schedule Q
1.3 and 1.4
1754
4/6/2008 1:55:28 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
G.I.2.102
5.1.5.5
1755
5/21/2008 2:30:06 PM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-102
1756
4/27/2008 4:42:44 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-350
7.4
1757 1758
4/28/2008 10:52:13 AM 4/28/2008 10:58:39 AM
Mechanical
ScheduleQ
1.7 5.1
SAEP-1150
8.9
Mechanical
ScheduleQ
1759
5/13/2008 3:32:21 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.11
1760
3/19/2008 9:02:26 AM
SATIP-W-012-01
SAIC-W-2056
Mechanical
SAEP
SAEP-1160
5 and 6
1761
4/6/2008 1:51:24 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
9.5
1762
3/20/2008 11:35:20 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
1763
5/11/2008 4:45:37 PM
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
1764
12/30/2007 1:34:09 PM
1765
9/4/2007 11:18:23 AM
HB-111-166001
1766
4/13/2008 3:36:15 PM
1767
7/22/2008 1:36:37 PM
1768
8/12/2008 2:26:03 PM
It has been obseved that the revised Quality Plan was not yet submitted to inspection since the provisional approval of the Contractors Quality Plan. It must be clearly understood that full approval of Quality Plan should be secured upon commmencement of all activities. Inspection is urging the contractor to respond all the comments in the Final Review of the Quality Plan and submit corresponding revised copy. Imad QC manager Mr. Joey V has left the projerct for an emergency leave and Imad faild to have a qualified replacment for him.The project is runing without Qc manager which will affect the overeall project Quality and also this is a violation to Sch"Q" Table VI-2. PLEASE advice the contractor to have a replacment immediatly otherwise APIU will elevate this log-book to an NCR level. Visual Inspection has been done for structural that have been galvanized and it has been noticed that. The structural coating (galvanized) has (dull grey coating) which is acceptable accordance to ASTM A 123 .but it has been noticed that there are some defects due to handling and storage. Contractor has to prepare procedure for handling and repairing the defects. APIU have noted that the QC manager Mr Roberto R. Miranda did not return of his emegency leave on 07/17/08 as specified in IMADs letter to SAPMT. This is in violation of Schedule Q. Please have the contractor correct this violation urgently either by specifying the actual return date to site or a replacement QC manager. APIU have noted that the contractors (IMAD) QC supervisor Mr A Khan. Jadoon has departed the project several days ago without any formal notification to the Company representative. This is in violation of Schedule "Q" Q-7 para 5.11 The contractor must submit a replacement. After many requests for IMAD to mobilize their welding inspector to site in accordance with Schedule Q they have failed to comply. This is in violation of Schedule Q Para 5.10, Q-7 & Table VI-2 Construction Phase Quality Personnel Requirements. IMAD have failed to mobilize their QA Manager to date with the procument phase at 78.44% completed. This is totally unacceptable and is in violation of Schedule "Q" Q-5 para 5.1. IMAD must source a QA manager imediately, have him approved by PID & mobilize to site. IMAD have failed to mobilize their internal auditor to site to complete the 15% internal construction audit. Construction progress is now running at 28.26%. This is unacceptable and is in violation of Schedule "Q" Q-8 para 7.2.3. It has been noted that the contractor IMAD has let his approved Mech inspector (Sharif Ansari) go out on vacation schedule without notification or submitted a replacement. This is in violation of Schedule Q para 5.11 Q-7. The contractor has repeated this violation in the past and continues to ignore the requirements of Schedule Q. Continuation of this practice by the contractor APIU will issue an immediate woorksheet. SAPMT please ensure the contractor is aware of this serious violation and to take immediate corrective action.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.2
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
SATIP-M-001-01
SAIC-M-2005
Mechanical
other
12-SAMSS007
6.3.2.2
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1769
1/28/2009 11:26:04 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1
1770
8/8/2007 7:42:25 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1
1771
8/8/2007 7:47:29 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.2.2
1772
12/2/2008 2:21:28 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1773
12/21/2009 5:25:39 PM
Found, two weld+ end couplings tie-in joints employed by the Contractor on New MLV installation at QA10-Km65 (2 couplings) and at UA4-Km 99.7 (1 coupling) pipeline sections. These were violation against specified drawings (HB-265908-001-00 Tie-In Joints #271-901 and HA-266001-00 Tie-In Joint #282-216) which shall be Butt Welds. During Aramco Audit in GCC-BI 03096 project, Ain Nahkil pre fab yard, auditor found that Drawing # HB 265942, Spool # A, I SW 29 & SW 57 has no daily welding report and visual inspection report. RFI has not been issued for welding inspection to PID. CONTRACTOR (MSC)IS BEING ADVICED TO clear all out standing repair or reshoot for the radio graphed joints prior to the hydro test, PID has noted that the following joints needs reshoot as per your rtfi and aramco assessment report 1-FW1-23 2-FWI-17 3-FWi-07 4-FW1-39 5-FW1-13(16 LATERAL) MSC QUALITY ORGANIZATION AGAIN BEING REMINDED OF THIER LAPSES IN REPROTING PROPERLY,PID NEEDS ALL HYDROTEST PACKAGES TO BE THOROUGHLY REVIEWED AND ALL REQUAIREMENTS SHALL BE MET AS PER ARAMCO STANDARDS AND CHECK LIST PRIOR TO THE SUBMISSION TO PID AND ALL CONSTRUCTABILITY SHALL BE CLEARD BY THE PMT FOR ANY DISCRIPENCY AND SHORT COMINGS ETC. contractor dont have any air reciever to provide the req pressure of minimum 90 psig@the nozzel(for surface blasting) for the air coming via compressor to staisfy the req of SAES-H-100, ARTICLE 5.4.2 IT HAS BEEN OBSERVED THAT THE ABOVE SUBJECT VALVE IS NOT PROPERLY CENTERE TO THE VALVE SUPPORT # 400,CONTRATOR HAS BEEN ADVICE TO CORRECT THIS BY ISSUE A FIELD CHANGE NOTICE FOR THE EXTRA SUPPORT THROUGH PMT AND REFLECT THE CHANGE TO THE AS BUILT DRWAING it has been observed that MSC onsite mechanical inspector Mr tahseen jaffar is offsite( because of his mother illness etc) since more than one week and msc is failed to provide the replacement and further failed to reflect the transation in to the vacation scheduale or organization chart even after repeated reminders by sapid/plpiu ,it is violation of the agreed contratc and will result in the issuance of the possible NCR. The contractor MSC was ongoing joint welding of 38" dia. main pipeline without 100% monitor by QC Welding Inspector, as per Contractor Schedule Q, paragraph 5.6, Contractor Quality personnel should be dedicate to the work and should no other function on this contract. Ongoing Welding on 38"X0.375 by Automatic Welding process @ mainline P/L. @ Km.132+500 with un-attended Welding QC @ site for production joint welds, this is a violation of Shedule Q, paragraph 5.1 pid has oobserved that the contrator is using APCS-113-A COATING SYSTEM FOR THE COATING REPAIR OF THE ALL FIELD GIRTH WELDS WITHOUT ANY EXCEPTION IN VIOLATION OF SAES-H-002WHER AS THE STANDARD requires APCS-104 or APCS-113C on external girth welds of new pipelines.
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.3
1774
11/27/2008 7:12:25 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7
1775
3/6/2009 8:23:39 AM
SATIP-NDE-RT-01
SAIC-RT-2010
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.3
1776
2/20/2008 5:44:41 PM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-100
5.4.2
1777
4/22/2008 4:07:22 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-J-700
9.2.2
1778
4/22/2008 10:52:59 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
1779
4/14/2008 8:14:19 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.6
1780
5/28/2008 7:42:44 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
1781
2/25/2008 2:21:30 PM
SATIP-H-002-06
SAIC-H-2049
Mechanical
SAES
SAES-H-002
5.4.2
1782
3/1/2008 7:47:11 AM
1783
1/18/2010 12:22:39 PM
1784
3/14/2010 3:14:26 PM
contrator is carraying out the high pressure hydro testing of the valve@ thier khurais yard where as no document has been submitted to PID( so as to make sure that the test blind are safe and test worthy) REGARDING THE PROVE OF THE ASME certification of the test blinds and NDE of the inlet nipple/bossess welde to the blind,CONTRACTOR IS CONTINUE WITH THIS ACTVITY AT HIS OWN INSPITE OF THE REPEATED INSTRUCTION OF PID TO AVOID THIS UNSAFE PRACTICE,PID IS NOT WITNESSING ANY TEST. During Welding activities for 16" pipeline @ KM 15, it has been found that the contractor is using some equipments without a valid calibration certificate (e,g: Digital thermometer). This is violation to Saudi Aramco Standard. The contractor was asked to send any equipment to an approved third party company for calibration. During surveillance inspection for coating activities for 16 pipeline at Km 6, it has been found that the testing equipment used for measuring the dew point and relative humidity is not working properly and does not give an accurate reading. This violates Saudi Aramco Checklist SAIC-H-2081 Section C & Saudi Aramco Standard SAES-H-002V Para 6. The contractor was asked to stop the coating activities until they provide accurate and calibrated equipment During surveillance inspection for pipeline stringing and laying for 16 pipeline at Km 13-16, it has been found that during lowering the pipeline inside the trench, the pipe has unsupported length of more than 3 meter. This violates Saudi Aramco Checklist SAIC-L-2132 Section A20 & Saudi Aramco Standard SAES-L-450 Para 14.5. The contractor was asked to correct this issue before continuing this activity During surveillance inspection for bending activities for 16 pipeline at the contractor fabrication yard, it has been found that the contractor is performing some bending activities without informing ARAMCO PID by RFI notification and without an inspection coverage by the contractor mechanical QC. This violates the inspection requirements as per SAEP-1150 and schedule Q (Inspection coverage in projects During surveillance inspection for coating activities for 16 pipeline at Km 6, it has been found that there is a 24 meter coated pipe has a physical damage for around 1 meter on the pipe surface. The damage is near joint No.: AP-34-W-050-51-02. This violates Saudi Aramco Checklist SAIC-L-2112 Section C10. The physical damage needs to be investigated to see if the pipe material is affected or not During Surveillance inspection for the 16" pipeline material @ Km 9, it has been found that some 16" pipes are touching the ground and there are no sufficient protection. This is violation to Saudi Aramco Standard SAES-H-200 Para 5.2.1 and SAES-L 450 Para 14.10.4. The contractor was asked to elevate the pipes from the ground at least 150 mm During surveillance inspection for 16 pipeline @ Km 5, it has been found the contractor welding QC does not have Temperature-indicating crayons, thermocouples, or contact pyrometers Which must be used to measure the preheat and interpass temperatures. This violates Saudi Aramco standard SAES-W-12 Para 11.3. The contractor was asked to stop welding activities at that area until they provide one
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A IV Para 6.1
Standards Violation
SATIP-H-002-02
SAIC-H-2082
Mechanical
ScheduleQ
Schedule Q
A IV Para 6.1
1785
3/15/2010 10:51:11 AM
Standards Violation
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
14.5
1786
2/7/2010 3:56:24 PM
Standards Violation
SATIP-L-450-04
SAIC-L-2114
Mechanical
ScheduleQ
Schedule Q
1.7 and 5.1
1787
3/14/2010 2:53:51 PM
Standards Violation
SATIP-L-450-04
SAIC-L-2112
Mechanical
SAES
SAES-H-200
5.1.1
1788
1/18/2010 4:05:14 PM
Standards Violation
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
14.10.4
SAES-H-200
5.2.1
1789
2/22/2010 11:10:00 AM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
11.3
1790
2/27/2010 8:19:49 AM
During surveillance inspection for welding activities for 16 Pipeline @ Km 12, it has been found that the contractor starts welding a Transition Joint No. AP-38-W-34-SI-01 between ends of unequal thickness of 16" Pipeline which require special fit-up preparation as per Saudi Aramco Checklist SAIC-W-2048 Attachment 2 without informing the welding QC and Saudi Aramco PID. This violate Saudi Aramco Schedule Q requirements and Saudi Aramco Checklist SAIC-W-2048. The contractor was asked to cut Joint No. AP-38-W-34-SI-01 and re-weld it in present of the welding QC and Saudi Aramco PID During welding activities for 16" pipeline @ Km 14-15, it has been found that the contractor failed to use wind shields or tents during welding with strong wind. This is violation to Saudi Aramco Standard SAES-W-12 Paragraph 10.2. The contractor was asked to put the tents in these weather conditions. During surveillance Inspection on welding activities for 16" Pipeline @ Km 14-15, it has been found that the contractor is using External clamp on welding 16 pipeline. As per Saudi Aramco Standard SAES-W-12 Paragraph 10.4, this is a violation except for Tie-In welds and Cement line pipe. For other conditions there must be an approval from Aramco CSD Welding Engineer and 100% radiography is performed to the production welds. The contractor was asked to remove the External clamp after the hot pass and start using Internal Clamp for the next joints. 100% NDT will be performed to the Joint No. AP-W-25. And if there is any defect in that joint, it shall be cut and re-weld again During surveillance inspection for welding activities for 16 pipeline @ Km 6-9, it has been found that there is no sand control in the right of way and the soft marl sand will affect the quality of welding and will increase the welding rejection rate. The tent shield is not enough to protect the welding. Reference Standard SAES-W-12 Paragraph 10.2 During welding activities of the 16" pipeline @ KM 14 to KM 15, it has been found that the contractor moved the sideboom that was supporting the partially welded joint. This caused the pipe to move before completing the joint. This is violation to Saudi Aramco Standard SAES-W-12 Para 10.7 which states that the pipe shall not be lifted or moved during welding. During surveillance inspection for welding activities for 16 Pipeline @ Km 5, it has been found that the contractor cut a completed weld joint no. AP-31-W02-SI-02 without informing the Saudi Aramco PID due to a stuck internal clamp inside the pipe. This violate Saudi Aramco Schedule Q requirements 1) As a minimum, full quality system audits shall be carried out at fifteen percent (15%) of completion stage for the Construction WORK Phase. Construction Progress Completion is now 26.57%. 2) Audit notifications and agenda shall be submitted to the Company Representative fourteen (14) calendar days in advance. 3) Quality System Auditors: CV shall be submitted to PID for review and approval, as per Sch. Q-Att. 1, Para. 1.2. Welding inspectors Should have and use all the required Tools For Checking the Welding Fit-up (high-low gage, bevel gage, digital contact pyrometer)
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7 and 5.1
1791
1/18/2010 9:07:03 AM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.2
1792
1/20/2010 2:19:26 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.4
1793
2/9/2010 11:53:29 AM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.2
1794
1/9/2010 3:41:26 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7
1795
2/21/2010 1:55:21 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2051
Mechanical
ScheduleQ
Schedule Q
1.7
1796
3/2/2010 1:54:20 PM
Standards Violation
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
7.2.2, 7.2.6 and Schedule Q attachment 1 para 1.2
1797
7/12/2006 10:55:05 AM
N/A
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
12.4
Schedule Q
A IV Para 6.1
1798
7/11/2006 9:53:00 AM
Reference to isometric piping detail drawing # RD-582977 SHT 001 . 12"-R84-P-9535-75-3CS9P1 . a turbulence free minimum distance of 12" checkvalve downstream less than 2 pipe diameter.violate SAES L-108Para 6.3.4 For all sizes NPS 4 inch and above, a turbulence-free minimum distance of 5 pipe diameters upstream and 2 pipe diameters downstream of every check valve shall be maintained. No pipe fittings such as elbows, reducers, tees, etc., or flow restricting devices such as orifices, control valves, etc., shall be installed in these zones. contractor shall provide corrective action before fabrication. During document (isometric) reviewing 8 line R 84-P-9173 drawing # RD-583349 SHT 002-013 we found there is no vent at high point for hydro test activities this is violate SAES A-004 Para 7.4.1 vent shall be provided at all high point . On routine inspection, N18A nozzle WNRF flange 20" X 150# (downcomer) of the storage vessel was noted with scratch radially across the raised face, about 1mm wide x 40mm long and went deeper than the serration. As per ASME B16.5 Table F3 and MSS SP-44 Table 11, permissible facing imperfections for this flange NPS is allowed up to 0.25" or 6mm radial projection only. Contractor is advised to resolve above prior to final installation. On external inspection of R81-D-103D, it was found that : 1]the nameplate for both the deaerator (heater) and storage tank have the same equipment no. R81-D-0103D, in non conformance to ASME BPVC VIII Div. 1 Ed. 2004 par. UG-116(j) and 32-SAMSS-004 par. 17.1. 2]the Dwg. CAD-1659-01 sht. 8 Rev. 7 indicates initial test pressure of 1082 Kpa & periodic test of 923 Kpa for the deaerator (heater) while the actual nameplate indicates 1031 and 924 Kpa respectively in non conformance to ASME BPVC VIII Div. 1 ed. 2004 par. UG-119(d) and UG90(b)(17). Contractor to provide corrective action. On internal inspection of R81-D-103D, it was found that the internal tray enclosure assemblys 5 support channels were welded to the structural support against manufacturer Sterling Deaerator Co. Dwg. # D-5824-2 requirement that specify welding both ends of center channel only, in non conformance to Contract Sched. B par. 1.4 & 3.7 . Contractor to provide corrective action. Noted Nozzle N10C - 2" x 150# (level instrument service) next to sliding saddle has its flange in contact with the structural support, offering no gap allowance to compensate for vessel expansion. Contractor should take appropriate corrective action before vessel is put into service. This was noted during vessel alignment & elevation check. During our surveillance at Utility R81-E-158 after cooler area we found outlet line of PZV#116 ( 3 RL-10667-1CS9P ) without Drain valves violating SAES J-600 Para.9.7.6 (d). Please provide us corrective action
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.4
1799
7/6/2006 11:52:39 AM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-A-004
8.4.1
1800
7/8/2007 8:19:55 AM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
ASME B16.5
Table F3
1801
3/3/2008 1:47:15 AM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
17.1
1802
3/3/2008 1:35:03 AM
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1803
7/14/2007 7:58:19 AM
SATIP-D-001-01
SAIC-D-2007
Mechanical
ScheduleQ
Schedule Q
1.3
1804
3/19/2008 2:58:59 PM
SATIP-J-600-01
SAIC-J-2009
Mechanical
SAES
SAES-J-600
9.7.5
1805
4/12/2008 4:40:34 PM
During surveillance at Caustic drum D-130 it was observed that the following things 1) Line 2 C-10360-1CA9C4, RB-598040-00100 Normal carbon steel pipes and fittings, valve were used for this line .It is violating against the piping line class 1CA9C4 and Piping specification RE-585599 sheet 09 of 99. It is required the Impact tested carbon steel materials. 2) Also found that there is conflicts in materials specification used for the level indicators LG651-to 654 and the stand pipe connection. Ref. RB-597955-002003. Materials used for the stand pipe connection is low temperature materials but connecting the level gages fitting and valves are normal carbon steel materials. Please provide us the corrective action. While doing surveillance at utility area it was noticed that the line 24-DFW-10405-1CS9P ,Drawing # R81-L-RB-597987-0020A3 Girth weld SW29 was covered by the saddle support reinforcement pad refer Support # PSW12 and it was welded with the A234 Gr WPB 90 degree elbow fitting which is violating our standard SAES-L-350 Para 10.6 .requirements. Its states that the Branch connections and their reinforcement shall not cover the girth welds. Please provide us corrective action. During our surveillance at utlity area and found the Stainless Steel thermowells eg(TW-468,469,470,471,475,and TGs,etc) installed at all the equipments and piping without isolation kids violating SAES L-109 Para.11.5 (SAIC-L-2020 item # A9 ),please provide us corrective action. During site surveillance at utility site it was noticed that the line 16-CWS-10388-12CGOU ,RB-597971-001-003 and completed welds FW24,FW29 were modified without Engineering approved instructions and notification to Quality control Department. It is violating with the approved Project Method statement MS-D-044, Para 4.1,SATIP-W-011,item 3.17 and SAEA-W-011. From the above results the following activities are not performed. 1) Nonperformance of fit up inspection 2) No verification of welding procedure and welder qualifications 3) No verification of materials traceability esp. on addition of pup pieces 4) Nonperformance of the required NDT. During site surveillance at utility site it was noticed that the line 8-CWS-10390-12CGOU ,RB-597973-001-00 and completed weld SW19 was modified without Engineering approved instructions and notification to Quality control Department. It is violating with the approved Project Method statement MS-D-044, Para 4.1,SATIP-W-011,item 3.17 and SAEA-W-011. From the above results the following activities are not performed. 1) Nonperformance of fit up inspection 2) No verification of welding procedure and welder qualifications 3) No verification of materials traceability esp. on addition of pup pieces 4) Nonperformance of the required NDT. It is repeated voilation .please refer ARAMCO NCR#B1-3193 NCR-018. During test package walk through at feed and surge area, it was observed that the test pack R83-F9-1262 found water droplets from the stainless steel line drain point. After our verification of this line package,it was hydro tested on 29-06-08 and layup not yet completed.It may cause for internal pitting corrosion and Microbiological induced corrosion. It is violating Saudi Aramco standard SAES-A-007 Para 6.3 and 7.5.1 which states that the maximum hydrostatic water contact time is maximum 4 days. It is advice the contractor to investigate the line condition and provide us the corrective action.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
1.3
1806
3/20/2008 9:10:26 AM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-350
10.6
1807
3/19/2008 3:06:54 PM
SATIP-L-350-01
SAIC-L-2020
Mechanical
SAES
SAES-L-109
12
1808
3/3/2008 1:09:16 PM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
5.1
1809
3/25/2008 7:45:53 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
5.1
1810
7/23/2008 11:23:05 AM
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
6.3 & 7.5.1
1811
3/31/2007 10:08:19 AM
On surveillance inspection, heavily pitted 42 in. dia. pipe is used for the pump casings of subject pumps now for installation at the location. Drawing specifies for 42 in. casing pipe with Sch-XS (1/2 in wall thk) and 1/4 in. deep pits were found on it. This is in violation of Sched. Q para. 7 related to non conformance on drawing requirements. Also requirements for materials to be free from defects under SAIC L 2005 and SAIC L 2006. Besides the reported severe pitting corrosion (QMIS Item#4730) on the subject pump casing, the delivered pipes to the site noticed with the following non-conformities: As per the IFC design drawing R83-0-RA-370847.001.00A, the required material of the casing pipes is CS 42/40 DIA. with SCH-XS thickness which is 0.500. In addition, the welded reducer plate should be made from 0.500 plate. However, the delivered pipes actual thickness is lower than STD schedule of having an average thickness of 0.320 which was measured using UT measurement. On the other hand, the welded reducer plate actual measured thickness was found about 0.300. Summing up, these casings were found with the following nonconformities: 1.Severe pitting corrosion covering about 25% of the external surface. 2.The sub standard wall thickness versus the design drawing RA-370847.001.00A that was designed based on vendor drawing G205392MZ.001 dated on 04/04/06. While doing our surveillance at utility and 200 feet pipe way the following things are notified 1) Drawing # RB-598021 -001-0C1 the trunion was welded with welding sleeve also the welding was covered by the trunion support joint welding which is violating SAES-L-350 Para 10.6 and SAES-L-150 Para7.3 . 2) Drawing #RB520853 -001 and RB-520848-004-0B1 the spacers and blinds were installed with out any productive coating which is in direct contact with sea water. Please clarify the requirements with engineering and provide us the corrective action. During our site surveillance at 100 feet area,the line RB-620741sheet 001 rev-01, 2 BD-10193-1SDOP the following points were observed 1)Dead legs found the FW7& 8 joints 2)Between the joints FW4&6 line was permanently deformed also this line found rusted condition due to improper handling and installation.It is violating the SAES-L-350 Para 8.1 which states that all materials shall be handled with care during fabrication and installation to prevent damage. It is advice the contractor to replace the damaged piping spools. During site surveillance it was noticed that the following lines 20600S-10462-6CS9P and 20-600S-10463-6CS9P the end of installed insulation with cladding were note protected from rain, other form of atmospheric conditions,(fog, Humidity,Chemicals,Corrosive dust and sand). It is violating as per SAES-N-001 para1.2, INSH200, section 4.1 and 5.10, which states that the Installed insulation has the required permanent protection or temporary protection applied before the conclusion of that days work. Protection is planned ahead. (INSH2000, Section 5.10) and SAES-N-001, Section 1.2, INSH2000, para 4.1 states that Installed insulation is protected from the elements (rain, other moisture, chemicals, corrosive dust, sand, etc
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1812
4/3/2007 7:35:38 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1813
3/23/2008 2:58:24 PM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-350
10.6
SAES-L-150
7.3
1814
12/30/2007 1:06:17 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
11.4
1815
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
1816
8/13/2007 5:20:42 PM
SATIP-N-001-02
SAIC-N-2015
Mechanical
SAES
SAES-N-001
1.2
1817
1/13/2008 10:12:07 AM
From the recent inclement weather conditions, it is reminded that additional pre-heating equipments are needed for removing the moisture and preheating the joints that are normally not heated in summer, also adequate (wet) weather protection is required for the joints to be welded especially for heavy wall welds that take 12 to 24 hours to complete. Also noted that the end of installed insulation with cladding are not covered with polyethylene sheet which results all insulation materials are in wet condition at off site area which is violation of SAIC N-2014. It is advice the contractor to replace the wet condition insulation materials and to prevent the part of the insulation which was not covered by cladding until the insulation completed for the rest part of the pipe. Such earlier anticipation would eliminate delays in work that would significantly save cost and time. On an inspection round around at C2+ 100 south pipeway area, 4:30 p.m. 01Mar2008, it was found that Line-8-10323-3CS9P, Dwg. RB-520826-002-00, Spl-P6-0826-02D, weld jt. # FW22 was found left unfinished with its root pass in about near half of the total weld length (pipe circumference). This is in violation of SAES-W-012 par. 10.7.2 that says The second or hot pass shall be added as soon as possible after the completion of the root pass, but shall not exceed 5 minutes for vertical down welding with cellulosic 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 60C minimum or the preheat specified in the procedure, whichever is greater, prior to making the hot pass. Contractor to please provide corrective action, and steps to prevent recurrence. On an inspection round around at C2+ 100 south pipeway area, 4:30 p.m. 01Mar2008, it was found that Line-8-10323-3CS9P, Dwg. RB-520826-002-00, Spl-P6-0826-02D, FW22 has been inserted with an 8" pup piece that has no heat # or ID for traceabiliy in non conformance to Sched. Q Att. IV par. 3.2 and 3.3 . Contractor to provide corrective action.
A
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
12
1818
SATIP-N-001-02
SAIC-N-2005
Mechanical
SAES
SAES-N-001
Section 3
1819
3/2/2008 1:31:01 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7.2
1820
3/2/2008 2:00:46 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
3.2 and 3.3
1821
3/12/2008 9:06:01 AM
PZV# R84-42-200A (bellow type) was installed in the place of the PZV# R84-44-409A (Conv. type) During a walkthrough for punch listing the test package TP-R84A4-0361 line number 8-R84-P-9328-15-3CS1P3 and drawing number RD-583597 we found the following violations: 1) drains were found very close to structure support. 2) Missing bracing on drains. 3) Misalignment was noticed on flange joints. Violation Prevented Installation On routine inspection of R84-C0471 A, with internals installation works on-going for catalyst support grid, it was noted support grid panels (1G, 1E, 1C) with wire screen (3 x 3 mesh-2.2 mm wire dia) slotted holes (22 x 40 mm) are mismatched/offset with vessel support rings holes (22 mm). Grid panels cannot thence be fixed/attached to vessel support rings with its M20 x 110 bolt. The support ring holes need to be redrilled to align it with the grid panels slotted holes. Contractor need to submit proposal/method statement on remedial measures to be considered before taking further actions. Reference is Costacurta Drawing No. B.M6.723. Note that vessel has already been PWHTd, hot works need to be verified/confirmed first if applicable if being opted.
SATIP-J-600-01
SAIC-J-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1822
3/13/2008 11:31:39 AM
SATIP-A-004-02
SAIC-A-2010
Mechanical
ScheduleQ
Schedule Q
1.3
1823
4/9/2007 1:00:24 PM
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1824
11/29/2007 6:03:38 AM
(1)Pressure Relief Valves were already installed at N8, N9, and N10 without supports in violation of API RP 520 part II par. 4.3.1 Pressure relief devices should be isolated from piping stresses through proper support, anchoring or flexibility of the discharge piping (see fig. 1 typical PRV installation with vent pipe with atmospheric discharge and fig. 7-typical PRV installation with vent pipe). (2)Also violates par. 12.3 Valves should be tested before installation to confirm the set pressure. Contractor advised to remove the PRV for testing before installation and install proper supports. Internal inspection of R84-D-0467 revealed following: 1]The Anthracite Coal Baffle has its welded grating 44x5mm plate item 138/138b tack welds with the 19x5mm banding bar item 88/88b not uniformly spaced and staggered, and there are areas not welded. Vendor Schwartz Hautmont Dwg. 747a06-203 Rev. 9 do not provide the detail on the spacing and location of the welds, hence, clarification is needed. 2]Some welds were found unfused and incomplete, needs to be rewelded. 3]The stack connection F in Dwg. 747a06-200 Rev. 12 is now bolted with carbon steel bolts, need to be replaced with stud bolt item 25 and nut item 26 as per Dwg. 747a06-201 Rev. 6. These are both UNS 31254 as per Dwg. 747a06-204 Materials List. 4]Stack connection F is with dissimilar metals joint (carbon steel flange to SS flange and bolt), isolation kits should be provided as per SAES-L-109 par. 11.5. Above items are for action by Contractor. On internal inspection, it was noted that tack welds for the 44x5mm plate item 138/138b to 19x5mm banding bar item 88/88b were staggered, not uniform in spacing. Vendor Schwartz Hautmont Dwg. 747a06-203 do not clearly specify this detail. Also, some welds were poorly done. Vendor to please clarify and offer corrective action. On external inspection of R81-D-103D, it was found that : 1]the nameplate for both the deaerator heater and water storage tank have the same equipment no. R81-D-0103D, in non conformance to ASME BPVC VIII Div. 1 Ed. 2004 par. UG-116(j) and 32-SAMSS-004 par. 17.1. 2] Mismatched information between Dwg. No. CAD-1659-01 Sht. 8 Rev. 7 and actual client nameplate for detail for deaerator heater that indicate 1082 Kpa for initial test while actual vessel nameplate indicate 1031 Kpa., 13211 kg. for empty weight while actual is 9995 kg., and 25.8 m for capacity while actual is 25.05 m in non conformance to ASME BPVC VIII Div. 1 ed. 2004 par. UG-119(d) and UG90(b)(17). This referenced to closed surv. # 13946 to correct the informations therein. 1) Noted demister pads were loose and not fitted tightly in nozzle N2 of the vessel, not in accordance to the General Note # 36 of the IFC Drwg. # J-Y2K5-216-091 Demister Pad will be oversized suitably for tight fit in the vessel, for clarification/verification with engineering and vendor. 2) Internal coating at about 3 x 0.4 mtrs area from bottom head tangency line upwards, oriented North East, near internal ladder found with rust spots, need to be repaired. Contractor to submit method statement.
SATIP-D-001-01
SAIC-D-2008
Mechanical
other
API PR 520 part II
4.3.1
1825
3/26/2008 7:10:54 AM
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1826
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.6
1827
3/23/2008 6:37:59 PM
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1828
3/10/2008 5:49:35 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
17.1
1829
12/12/2007 3:21:39 AM
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
1830
3/1/2008 3:09:54 PM
1831
2/25/2008 1:58:32 PM
1) Noted demister pads were loose and not fitted tightly in nozzle N2 of the vessel, not in accordance to the General Note # 36 of the IFC Drwg. # J-Y2K5-216-091 Demister Pad will be oversized suitably for tight fit in the vessel, for clarification/verification with engineering and vendor. 2) Internal coating at about 3 x 0.4 mtrs area from bottom head tangency line upwards, oriented North East, near internal ladder found with rust spots, need to be repaired. Contractor to submit method statement. This is to reopen Surv. # 12252 issue that was earlier closed. Following found on internal inspection: 1]Support grating panels for sand filter have clearances between panels (60mm max.) bigger than specified in the As-Built Drwg. R84-D-J-Y2K5-215048 Rev. 1. 2]Support grating panels have actual widths (435mm) different from specified (289mm) in the As-Built Drwg. R84-D-J-Y2K5-215-048 Rev. 1 . 3] As-Built Drwg. R84-D-J-Y2K5215-048 Rev. 1 is mismatched with the actual grating dimensions in non conformance to Sched. B par. 1.4. and 3.7 . Contractor to provide corrective action. On inernal inspection of R84-D-0405B following were found: Item 1]Incomplete weld penetration at entire length of stilling baffle plate in non conformance to ASME Sec. VIII Div. 1 sec. UW-36 and UW-37(d). Item 2]Deep gouge more than 1mm at the shell plate behind the stilling baffle plate in non conformance to ASME Sec. VIII Div. 1 sec. UW-35 par. (b)(1) and (b)(2). Both are in non conformance to 32-SAMSS-004 par. 1.2 and 11.1.2, and SAES-W-010 par. 11.6 and 11.8. Please provide corrective action. This is entered for closure of RFI #s 15503 and 15629 (Vessel Closure Inspection), to be entered to SATR-A-2011 Final Insp/Reinst. Checklist if not done by that time. Conferred with A. Al-Somali JGPE Insp., A. Al-Hamdan JGPE Opns. Proj. Engr., A. Al-Solaili JGPE Opns. Maint. 04Jul2008 for confirming acceptance of the piping installation re N5 connected to inlet line while vessel drawing assigns this with PI (Press. Ind.) & N1 for inlet but was installed with PI of this entry. All agreed that there is no problem with this and only revision of As-Built Dwg. R84-D-JY2K5-240-031 Rev. is needed. Emailed to PMT S. Mahmood for follow up with TRG Engg. On surveillance inspection with Mr. Osman (PID), 2" and 1" PP pall rings were found stocked exposed to sunlight. Internals manufacturer recommends these plastic materials to be shaded (preferrably indoors) from sunlight and open atmospheric conditions to protect from damage and embrittlement. Feed Pipe @ N1 found without drain holes for 20", 14" and 12" and @ N8 for 20", 14" and 8" internal piping (for draining off fluids to dry up pipe internal after testing works per 32-SAMSS-004 par. 16.3.13) Feed pipe @ N1 found without drain holes for 20", 14", and 12", also @ N8 for 20", 14", and 8" internal piping. Please clarify with vendor, for corrective action as necessary. Pipes need to be drained off for future maintenance/repair works.
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
1.3
Sch B
1.4 and 3.7
1832
2/16/2008 11:20:32 AM
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-W-010
11.6 and 11.8
32-SAMSS004
11.1.2
1833
7/7/2008 10:47:32 AM
SATIP-D-001-01
SAIC-D-2012
Mechanical
ScheduleQ
Schedule Q
1.3
1834
9/3/2007 7:05:38 AM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
A IV Para 5
1835
9/26/2007 8:03:39 AM
SATIP-D-001-01
SAIC-D-2009
Mechanical
other
32-SAMSS004
16.3.13
1836
9/26/2007 9:25:02 AM
SATIP-D-001-01
SAIC-D-2009
Mechanical
other
32-SAMSS004
16.3.13
1837
4/13/2007 11:13:44 PM
Violation Prevented Installation On routine inspection, following discrepancies were found at R84-C-0431: 1) False Downcomer Stiffener (part # B135) above Tray #53 has only 2 pcs. available and as indicated in the parts list also. But actual required as per Kotsch Glitsch Drwg. # C03-12372-D658 Sht. 5 Rev. 3 is 6 pcs., hence, shortage of 4 pcs. 2)M24 SS U-bolts holding 14 distributor pipes above the False Downcomers are obstructing installation of the False Downcomer Beams. 3) 14 distributor pipes have no drain holes, Kotsch Glitsch Drwg. # C03-12372-D659 Sht. 1 Rev. 2 says it should have. These items should be clarified with the vessel and tray manufacturer for resolution On inspection of installation works for tray no. 25, found: 1)Bolt holes of downcomer plates mismatch with joint plates, needs redrilling. 2)Wear plate at middle downcomer per drawing has skirt at 120deg and 85mm from tray no. 24, but actual installation do not have. 3)Part RB-116 downcomer plate according to drawing should be in the installation, but actual materials and parts list do not have this. Please clarify with manufacture and rectify as necessary. Trays were completed and inspected except the center downcomers pending resolution. On inspection of installation works for tray no. 25, found: 1)Bolt holes of downcomer plates mismatch with joint plates, needs redrilling. 2)Wear plate at middle downcomer per drawing has skirt at 120deg and 85mm from tray no. 24, but actual installation do not have. 3)Part RB-116 downcomer plate according to drawing should be in the installation, but actual materials and parts list do not have this. Please clarify with manufacture and rectify as necessary. Trays were completed and inspected except the center downcomers pending resolution. Vessel has been installed on its structural platform with its west end hemispherical head straddled by the horizontal beam of steel walkway platform causing the beam to be bent and deformed, and also the walkway vertical column to be buckled by 8mm deflection. Contractor need to verify/check vessel head at point of impact/contact for damages to ensure its integrity, and initiate corrective action if necessary. On routine inspection, discrepancies were found at R84-C-0441 Adip Extractor: 1) 8 clips welded to vessel shell for 4 internal anodes obstructs installation of RPB Bedlimiters. These clips are indicated in vessel manufacturer Bilfal Dwg. # DA-7495-01-001 Rev. 3, but not in the Internals Arrangement Drawing no. 1106.403.845 by Sulzer. 2) Internal ladder rung under Nozzle A1 Manway also obstructs installation of the RPB Bedlimiter. 3) Distributor N2 header (20 ) installed in vessel is carbon steel while Sulzer Distributor N2 Dwg. No. 2-106.403.853 specifies for 316L Stainless Steel. 4)The symmetrical half of segments 1-8 has no attachment to part 002 (Beam), only at the tank support ring through the Universal Clamp. 5)Hex bolts M20 x 100 for item 011 flange joints (40 sets)cannot be tightened as their ends are in already contact with the 20 distributor pipe. These items are to be clarified with the vessel and tray manufacturer for resolution.
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1838
3/16/2007 8:25:53 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1839
3/16/2007 8:25:58 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1840
8/30/2007 12:14:56 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
ScheduleQ
Schedule Q
1.3
1841
4/13/2007 11:37:59 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1842
4/23/2007 1:10:26 PM
Violation Prevented Installation: On routine inspection following were found: 1)Item 100 Beam 6x150x3000mm is to be installed 15mm away from internal clip to get the correct centering distances of redispenser plates per Dwg. No. 1106.403.851. Temporary washer spacers were inserted to install the assembly. The gap and use of spacers is not as per drawing. 2)Distributor Nozzle N3 has no vent holes but Dwg. No. 1106.403.850 has this required. 3)Item 001 Beam (2 pcs.) that supports Distributor Nozzle N3 pipe item nos. 003, 004, & 005 per Dwg. No. 1-106.403.850 has drilled holes for the clamps offset by 80mm with the pipes and cannot be clamped down. 4)Pipe item no. 005 (centermost pipe straddling 0 as per Dwg. No. 1-106.403.850) for Distributor Nozzle N3 is off by 80mm from vessel center line. These items shall be resolved with the concerned vessel or tray manufacturer for corrections, submit method statement for the actions to be undertaken, and subject to reinspection once done. On an inspection with proponent, we found: 1)Missing 48 stainless washers for joint 24/9500R 2)Missing 1/2in. bottom drain holes per drawing 3)Holes per drawing for center distributor pipe unclear whether top vent or bottom drain, existing has top drains only 4)Flange bolts need retightening and plate flanges has flat gaskets, should be spiral wound? 5)Tapped 10mm holes at 16" and 18" flanges of distributor pipes? Please clarify with manufacturer and rectify as necessary. On an inspection with proponent, we found: 1)Missing 48 stainless washers for joint 24/9500R 2)Missing 1/2in. bottom drain holes per drawing 3)Holes per drawing for center distributor pipe unclear whether top vent or bottom drain, existing has top drains only 4)Flange bolts need retightening and plate flanges has flat gaskets, should be spiral wound? 5)Tapped 10mm holes at 16" and 18" flanges of distributor pipes? Please clarify with manufacturer and rectify as necessary. Violation-Prevented Installation Following items found during routine inspection round: 1)Tray panel #24 & #25 were missing for Tray # 3 to 10 2)Tray panel# 24 & 25 were the ones only available for Tray #1 3)Tray #2 panels missing 4)Tray beams for Tray # 11 were missing 5)Steel plates 3mm thk x 110mm x 140mm stenciled A516 Gr. 60 were among materials received but not indicated in drawings 6)As laid out, tray panels adjacent to downcomer plates and at junction with tray beam will have opening of 50mm x 60mm which is not in detail drawings 6)Tray panels will be welded to vessel support rings, panel to panel, and panel to beams, except manway to be bolted and neoprene gasketed. Method statement/welding procedure, vendor/manufacturer approval needed to proceed as vessel is post weld heat treated already. After inspecting the first tray on R84-C-0401, we found the following items: 1. Mismatch holes on B-875 shear clips and downcomer beam 4 typical location. See details on drawing C0312372-D648 SHT.3. 2. Two slotted holes 15mm*20mm of the adjacent side of angular shear clip B-873 are missing. See details on drawing C03-12372-D648 SHT.3. These items are to be resolved by PMT with the vessel and tray manufacturer and it will be subject to re-inspection when correction is done.
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1843
3/16/2007 8:07:42 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1844
3/16/2007 8:07:54 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1845
4/29/2007 8:04:06 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1846
5/29/2007 8:15:52 AM
SATIP-D-001-01
SAIC-D-2009
Mechanical
ScheduleQ
Schedule Q
1.3
1847
7/17/2007 6:05:24 PM
1848
5/13/2008 1:32:58 PM
On routine surveillance, nozzle N2, 20" x 300# WNRF flange was found with scratch 3mm wide x 25mm long x 1mm deep at 20mm radial distance originating from inside diameter of raised face. Raised face width = 54mm. This defect is not acceptable per MSS SP 44 allowable imperfection of 6mm radial lenght for this flange size. Contractor is adviced to correct the defect accordingly. On review of NMR as required by 32-SAMSS-004 par. 20.1 for R84-D-, following items were found missing: 1] Ultrasonic thickness readings of vessel shell section, heads, nozzles as per 32-SAMSS-004 par. 20.3 . 2] Alloy verification of all materials except carbon steel as per 32-SAMSS-004 par. 12.1.6 . Final Disposition Reports submitted by vendor was used for the NMR verification. Contractor to provide resolution for compliance as required. On review of Radiographic Test Reports included in Final Disposition Report (Quality Dossier) Nr. 10 Rev. 0 for Item R84D-0453 under PO # BNIK-R84-32-A166-DA, it was found that radiography or alternative ultrasonic examination was not done on welds at CS1 location 120-150 and 270-0 (top head to shell circumferential weld jt.) and on CS3 location 120-130 and 240270 (bottom head to shell circumferential weld jt.) due to obstruction by lifting lug attached on these areas. This is in violation of 04-SAMSS-004 par. 14.2.3, ASME VIII Div. 1 Sec. UW-11 par. (a)(5)(a) and par. (a)(7). It is also violating SIS Dwg. # RE-578429-001 and Data Sheet Dwg. # RD-578319-001 requirement for joint eff. 1.00 and 100% radiography. Please provide corrective action or waiver. Violation-Prevented Installation: On routine inspection, vessels R84-D-0481, 0465, 0462, 0431 were using temporary A193 B7 stud bolts and A194 2H nuts in violation of 32-SAMSS-004 para. 10.4.4 that requires A307 Gr. B bolts. Vessels need to be fixed on permanent bolts before final alignment and succeeding works. The following vessels were noticed with carbon steel grounding lugs and not Austenitic Stainless Steel: D-466A/B, D-462 east side, D-463A/B both sides, D-454A/B, D-465, E-446, and E-421. This is violating 32-SAMSS-004 para 11.4 and PIP VEFV-1100 drawing # VEFV1103 requirements. Contractor has to verify this requirement and list all vessels that have the same nonconformity and act accordingly. On receiving inspection and review of final disposition reports of vessel R84-D-0487 (Jacket Condensate Drum), following were found: 1.Manhole was not provided in non-conformance with ASME Sec. VIII Div. 1, Par. UG-46(f)(3) and SAES-D-001 par. 7.3.4. These requires vessels to be provided with a minimum of 18 inch diameter manway. 2.Head to shell circumferential (category B) and shell longitudinal (category A) weld joints were not subjected to 100% radiography in non conformance to 32SAMSS-004 par. 14.2.3 (refer to RT Report Nos. 0920, 1058, 1210) : a.Top Head to Shell joint CS1 (Loc. 0-30) and CS1-T (loc. 0-6) b.Bottom Head to Shell joint CS2 (Loc. 0-30) and CS2-T (loc. 0-6) c.Shell longitudinal weld joint LS1-LC3 (Loc. 0-7) and LS1-LC2 (Loc. 0-7). Contractor to provide resolution.
SATIP-D-001-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
SATIP-D-001-01
SAIC-D-2022
Mechanical
other
32-SAMSS004
20.1 and 20.3
1849
2/21/2008 11:36:10 AM
SATIP-D-001-01
SAIC-D-2022
Mechanical
other
32-SAMSS004
14.2.3
1850
4/27/2007 5:53:35 PM
SATIP-D-001-01
SAIC-L-2007
Mechanical
other
32-SAMSS004
10.4.4
1851
8/27/2007 9:14:20 AM
SATIP-D-001-01
SAIC-L-2002
Mechanical
other
32-SAMSS004
11.4
1852
5/7/2008 2:21:47 AM
SATIP-D-001-01
SAIC-D-2022
Mechanical
other
32-SAMSS004
14.2.3
Schedule Q
1.3
1853
10/16/2007 6:58:39 AM
1854
5/10/2007 1:33:19 PM
Lay-up has not been done yet in violation of SAES-A-007 par. 5.2.1 (Lay-up shall be required for heat exchangers unless startup is ensured within 14 days of commencing hydrostatic test). Required lay-up is dry lay-up as per 32-SAMSS-011 par. 9.3.10 (After testing, exchangers shall be completely drained and thoroughly dried with dry air to an exit dew point of less than 1C). Violation-Prevented Installation. This is for information only. On routine inspection round, R84-E-0445 A was found having one item 214 (7/8 in. x 10 1/2 in. stud bolt) broken. Four nearby nuts and small portion of item 204 (cover) were found with coating scratches. Extent of damage assessment and corrective actions to be undertaken by Contractor to be informed to SAPMT. This is in violation of Sched. Q Att. IV Para. 7.1 cited by item B1 of SAIC-E-2002 (Received heat exchangers are free of physical damage on its mechanical components). External inspection revealed some damages to the insulation supports and holding rings of E-403D. This creates some cracks to the attachment welds to the shell of those supports. this physical damage on the mechanical components of this exchanger is violating item B of SAIC-E-2002 and violating Scheduel"Q" Att. IV, Para 7.1. Contractor is requested to assure that no propagation of the cracks into the bare metal of the shell. In addition, they should provide us with their corrective action to this issue ASAP. Insulation shall not be done to this exchanger until this item is clarified. R84 E-403A was noticed with the following non-conformities to SAIC-E-2002 at the stage of external inspection: 1.FDR not provided to PID at this stage of material receiving. 2.Damaged insulation supports due to poor lifting. 3.Severe coating failures were noticed on the external shell. 4.Nozzles N5, N6, and N9 were noticed in conflict with the design drawings 6059651 sheet D101 Rev D. 5.Equipment was noticed with waters and oils in the channel head and shell side indicating insufficient drying at the vendor shop. 6.N10 was noticed with threaded plug. As per SAES-L-110 para 8.1, threaded plug that might posses plant to risk shall be seal welded. R84 E-403B was noticed with the following non-conformities to SAIC-E-2002 at the stage of external inspection: 1. FDR not provided to PID at this stage of material receiving. 2. Damaged insulation supports due to poor lifting. 3. Severe coating failures were noticed on the external shell. 4. Nozzles N5, N6, and N9 were noticed in conflict with the design drawings 6059651 sheet D101 Rev D. 5. Equipment was noticed with waters and oils in the channel head and shell side indicating insufficient drying at the vendor shop. 6. N10 was noticed with threaded plug. As per SAES-L-110 para 8.1, threaded plug that might posses plant to risk shall be seal welded. R84 E-403C was noticed with the following non-conformities to SAIC-E-2002 at the stage of external inspection: 1. FDR not provided to PID at this stage of material receiving. 2. Damaged insulation supports due to poor lifting. 3. Severe coating failures were noticed on the external shell. 4. Nozzles N5, N6, and N9 were noticed in conflict with the design drawings 6059651 sheet D101 Rev D. 5. Equipment was noticed with waters and oils in the channel head and shell side indicating insufficient drying at the vendor shop. 6. N10 was noticed with threaded plug. As per SAES-L-110 para 8.1, threaded plug that might posses plant to risk shall be seal welded.
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.1 and 5.3
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1855
8/27/2007 9:03:51 AM
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1856
10/1/2007 1:12:33 PM
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1857
10/1/2007 1:20:55 PM
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1858
10/1/2007 1:24:47 PM
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1859
10/1/2007 1:28:05 PM
R84 E-403D was noticed with the following non-conformities to SAIC-E-2002 at the stage of external inspection: 1. FDR not provided to PID at this stage of material receiving. 2. Damaged insulation supports due to poor lifting. 3. Severe coating failures were noticed on the external shell. 4. Nozzles N5, N6, and N9 were noticed in conflict with the design drawings 6059651 sheet D101 Rev D. 5. Equipment was noticed with waters and oils in the channel head and shell side indicating insufficient drying at the vendor shop. 6. N10 was noticed with threaded plug. As per SAES-L-110 para 8.1, threaded plug that might posses plant to risk shall be seal welded. For info and action. Noted scratched and pressed points at shell of the heat exchanger at south side, one with 20mm lght at 1080mm from sliding saddle on upper shell, one with 50mm lght at 2000mm from fixed saddle on both upper and lower shell. Apparently caused by hard contact with metal handling tools/equipments and not soft/resilient material/slings. Suggest to do NDE to confirm affected areas are of cracks. Violation-Prevented Installation: Heat Exchanger R84-E-0431 A & B installed with temporary anchor bolts against 32-SAMSS-004 para. 10.4.4 requiring A307 Gr. B bolts. This was noted on respective SAIC-D-2007 for installation, alignment, elevation works, and need to be replaced with the final bolt as required. During surveillance inspection it was observed that the pump G0431 B casing pipe was found 48 inch diameter and 0.4 inch thickness. It is Violating against the reference drawing R84 RA578695 Sheet 001 Revision A requirements which states that 48 inch diameter, Schedule XS is Ref.ASME B36.10 12.70mm thick. On routine inspection, it was noted that thickness of 40"/42" dia. carbon steel casing pipe is at 8 mm measured at the open end. This is in violation of Drawing RA-370847.001.00A that indicates it should be sch-XS (12.7 mm) and sched. Q para. 7 (non conformance to drawing requirements). For corresponding corrective action by the Contractor. On an inspection round, casing pipe intended for R84-G-0401 A & B were found with 10mm thickness against IFC Drwg. RA578686-001 specified sch-XS (1/2" thk = 12.5mm). This is in violation of Sched. Q para. 7 related to non conformance on drawing requirements. Following violations found: 1)Suction piping being installed with pipe eccentric reducer 12" x 8" located immediately after pump suction nozzle, no provision for 5 times diameter length of straight run (SAES-G-005 par. 5.2.3) 2) The eccentric reducer 12" x 8" is being installed with flat at the bottom (SAES-G-005 par. 5.2.4) 3) The eccentric reducer 12" x 8" being installed with taper angle exceeding 12 degress. 4) P & ID Drwg. No. R81-ARA-230446-002-00A indicates "RTJ 900# Flange" for suction and discharge flange connections of the pump. Pump Gen. Arrangement Drwg. #05-016704 indicates pump suction and discharge flanges of raised face, verified by physical inspection. Iso. Drwg. #R81-L-RB-597877-001-00A & Piping matl. classification Dwg. #R84-L-RE-585599 sht. 83 Rev. B do not include RTJ Flanges. (SAEP 110 par. 3.1, Sched. Q para. 1.4, 3.7, Att. 3 par. 3.1) Please correct fabrication, verify other pump instn. and correct drawings.
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1860
9/27/2007 8:27:08 AM
SATIP-E-004-01
SAIC-E-2002
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
1861
7/2/2007 11:38:04 AM
SATIP-E-004-01
SAIC-D-2007
Mechanical
other
32-SAMSS004
10.4.4
1862
5/6/2007 3:06:20 PM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1863
7/3/2007 10:47:30 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1864
5/6/2007 9:18:01 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
1.3
1865
9/14/2007 7:31:55 AM
SATIP-G-005-01
SAIC-G-2005
Mechanical
SAES
SAES-L-310
11.7
Schedule Q
1.3
1866
4/30/2008 6:51:46 AM
1867
12/19/2006 6:59:11 AM
1868
3/7/2008 11:12:43 AM
1869
7/22/2007 6:00:57 PM
The 6in.-BD-8223-38-04B suction line for pump R84-G-0482B suction nozzle and line 6in.-BD-8223-37-03B for pump R84-G0482A suction nozzle have the same case of flanges being fitted on forced alignment, bolts were strained on misaligned flange holes, stuck and are not free. Contractor should correct the alignment as per SAEP-351 par. 7 step 3 that require studs to pass freely through the flange holes. Reference to line designation information for coating Mod 4 there are many mistakes example line # P-9173 & P-9541 required coating as per standard SAES H-002 Para.5.1.3 & scope of work section 3 Para.3.9.3 but as per line designation coating information N/A JEPIU advice the contractor to review all coating, insulation information to avoid missing coating or coating at pipe rack. During our inspection at Mod.4 pipe rack we found the contractor applying different coating system 11A for condensate lines violating SAES H-002 Para.5.6.5 and approved ISOs, as per ISO and standard paint shall be 1A. PLEASE PROVIDE US CORRECTIVE ACTION During our surveillance at Mod. 4 at pipe rack we found 36" 150C -9670-75 coated with tow type of coating APCS 1A and APCS 11A as per SAES H-001 Para.5.1 B operating temp.(below 150C) coating shall be APCS 1A . During my routine inspection; R84 E-0472 A/B were noticed to have wrong coating system on their skirts. The skirts of these dehydrators will be fireproofed. The skirt should be painted with APCS-1B while actually they were painted as per APCS-17A. After verifying the standard requirements and the design data, this is a violation to SAES-H-001 para 7.1.E which states to use APCS1B under fireproofing. In addition, the existing type of coating on the skirt is not meeting the designed painting system as per the design data 746a05-100DWG. Rev.5. The contractor should apply the required coating system to meet the requirements. 14-150C-10395/10397-1CS9P at 200 pipeway was noticed with some unpainted spools which is violating SEAS-H-002 para 5.1.4. The spotted spools are: 150C-0869-01O, 150C-0869-0RL1, 150C0869-01G and 150C-0869-01F. On the other hand, the line identification tag was found printed with P.S.11A while the line was painted with APCS-1A. The contractor is requested to identify the proper painting system for such service and act accordingly to apply it to all spools. Bear pipe is not accepted. The correct P.S. should be reflected in the tags attached to the pipe spools and contractor shall correct the misleading information. During our surveillance at Mod.4 ADIP area we found (5) outlet lines of PZVs without Drain valves violating SAES J-600 Para.9.7.6 (d) PZVs # as follows:- PZV # 501 A/B for D-452B, PZV # 476 A/B for D 452A, PZV # 477 for D-495. Please provide us corrective action On inspection of AHU 1 & 2 Installation using SAIC-K-4005, item A6 requiring raw water hose bib per SAES-K-001 para. 5.1.9 and item A11 requiring equipment nameplate per SAES-K-001 para. 4.8.1.2.3 were found not complied. Contractor is advised to resolve mentioned deficiencies.
SATIP-G-005-01
SAIC-G-2005
Mechanical
SAEP
SAEP-351
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-002
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-001
1870
3/20/2007 7:41:10 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-001
1871
3/26/2007 1:06:04 PM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.1.4
1872
1/28/2008 4:12:47 PM
SATIP-J-600-01
SAIC-J-2009
Mechanical
SAES
SAES-J-600
9.7.6 D
1873
7/7/2007 1:50:49 PM
SATIP-K-001-02
SAIC-K-4005
Mechanical
SAES
SAES-K-001
5.1.9 and 4.8.1.2.3
1874
6/18/2007 1:40:15 PM
During the visual inspection of the valves prior to the valves field testing, the following concern was highlighted with regard to the valves hand wheels: 7 valves 6X300 were reported with improper hand wheels which are not fit to the pushing of the valve stems. These valves are not operable with the current received hand wheels. Contractor shall verify this with the vendor as all of them are Orion valves. These valves are considered rejected valves. Contractor shall report all valves with same deficiency and log them out in the rejection log sheet. On inspection thru RFI QR # PIPE-VI-710, it was noted that 10" BUTTERFLY VALVE rubber lined has tag VC-1439. As per SA Form 2616 ENG, tag VC-1439 is for GATE VALVE and under 12LC0U class. The correct tag should be VM 18A7 as per the line class. This is in violation of SAES-L-105 specification for 12CG0U line in accordance to SA Form 2616 ENG Piping Matl. Specs. Contractor should provide SA approval for change of tag. During our surveillance at Mod.4 we found all utility lines at utility stations pointed 90 degree violating SAES L-310 Para.18.5 as per standard they shall be pointing 45 degree downward. .please provides us corrective action. Following need action from Contractor: 1]For R84-E-0402A 24 piping for line no. 36-R84-P-9092-45-3CS9P spool no. P0-453294-01F nozzle N5A, line no. R84-P-9092-45-3CS9P spool no. PO-45-3294-01H nozzle N5C, line no. 36-R84-P-9092-45-3CS9P spool no. PO-45-3294-01E nozzle N5D, ends were open and without covers in non conformance to SAES-A-004 par. 7.1.2.b & c. and SAES-L-350 par. 15.2.2 & 3. Pipes already have debris, cutting, weld slags and dirt inside, and marked with Air blowing 28-11-7, pipes have been inspected for internal cleanliness already. Perform internal cleanliness and inspection again and install cover. 2]Nozzle 5D has been installed with flat gasket strips only instead of the full face gasket which is insufficient protection against entry of foreign materials or water/moisture inside the reboiler in non conformance to API 660 par. 11.1.3. Replace gasket strips with full face flat gasket and check/do with other nozzles of the equipment. Poor workmanship in maintaining verticality and horizontality of piping resulting to mis-matches of flanges, force fitting of flanges at flange connections, in non-conformance with ASME B31.3, Par. 335.1.1 (Piping Distortions) noted within the Vicinity of vessel R84-D-476: a. piping and by-pass line of PCV-651, were all bolted up with vertical lines not plumbed, horizontal line not level and with a 90 bend not square in one elbow. b. Miter joint noted on FW-12 of 10 line upstream of PZV-652A/B (Top of R84D-0467). c. 3 line for Test Pack #A7-0583 being prepared for hydrotest on the same platform of PZV-652A was found to have 3 line clamped to the supports but have the horizontal section sloping back to the middle horizontal elbow. d. Small bore piping between R84-D-0467 and E-462 are out of plumb and 90 bends are not square. e. Piping assembly around LCV-661(east side of R84-D-469) have by-pass out of horizontal level.
SATIP-L-108-01
SAIC-L-2040
Mechanical
ScheduleQ
Schedule Q
1.3
1875
2/10/2008 3:18:12 AM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
11
1876
3/17/2008 10:19:49 AM
SATIP-L-350-06
SAIC-L-2068
Mechanical
SAES
SAES-L-310
18.5
1877
2/23/2008 5:55:55 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
SAES-A-004
8.1.2
1878
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
API 660
11.1.3
1879
3/26/2008 1:24:08 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
other
ASME-B-31.3
335.1.1
Schedule Q
1.3
1880
2/28/2007 5:32:30 PM
During my surveillance to the lay down yard I have noticed the following: 1.Some of the valves were not dried out and cleaned as per SAIC-L-2041. For ex. valve serial No.05/335/190/4 was not drained and dried from the test fluid for two days. 2.The preservation plans were not followed for the valves that were tested up to this moment which are more than 50 valves. 3.SAICL-2041 was filled out and entered into the system. Hard copy is with the originator for reference. The following deficiencies were observed during the routine site visit on 06/17/07 with the valves preservation after field testing: 1.3X300 globe valve tested on 06/11/07 and not removed to the quarantine area. 2.Three valves were tested on 06/11/07 and not covered with end protector and not removed to the accepted valves area. 3.About 5 valves were tested on 06/14/07 while they observed not dried out against the test fluid. Furthermore, most of the tarpaulin covers for the accepted valves were found damaged, worn out, and or blown out due to windy weather. Valves were not protected well against dust. during our serveillance at Mod.4 we found 2 line 16"-R84-P-9156 & 9157 -45-3CS9P the clearance between the bottom of the pipes and grade is less than 300 mm which is violating SAES L310 Para.12.3 (Above-grade piping shall be supported to provide a minimum of 300 mm clearance between bottom of the pipe and the finished grade) during our surveillance at Mod.4 we found line 30"-R84-P-9104 51-3CS9P the clearance between the line and cement line is less than 50 mm before insulation which is violating SAES L-310 Para.12.4 (12.4 A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe) during our surveillance at Mod.4 we found line 20"-R84-P-9190 40-3CS9P1 discharge of pump # G 421 A, the clearance between the the pipes and column is less than 50 mm which is violating SAES L-310 Para.12.4 (A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe ) and the column is subject to fire proofing . During our surveillance at Mod.4 we found line # 28"-R 84- P9108 -55 touch the foundation of E 405 B and the line is subject for cold insulation violating SAES L 310 Para.12.4 A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe. please provide us corrective action. During our surveillance at Mod.4 compressor Area line # 48-P9172 -3CA9P we found at south side the flanges resting on the beam and this line shall be cold insulation there is no space for insulation .please provide us corrective action .
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1
1881
6/17/2007 3:10:39 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
ScheduleQ
Schedule Q
7.3.7
1882
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1
1883
12/8/2007 4:40:52 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.3
1884
12/10/2007 11:22:04 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
1885
12/10/2007 11:35:55 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
1886
12/12/2007 4:35:30 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
1887
3/16/2008 11:13:18 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
1888
9/2/2007 3:04:48 PM
The piping spools at E-403A/B/C and D platforms were noticed installed on incomplete structure steel members with missing bolts, bolts not finally tightened, and some bolts only hand tightened. This is unsafe action and violates 12-SAMSS-008 and PIP STS-05130 requirements. In addition, it is violating SAIC-L2011 item C3. The following two lines are examples of this highlight: 1.36-P-9196-50-3CA9P/SPL-P1-50-3567-01H. 2.24-P9197-50-3CA9P/SPL-P1-50-3523-01E. Contractor should adhere to erection procedures and to piping installation and inspection checklists such as SAIC-L-2011 requirements. Contractor QC is held countable for controlling such activities and assures coinciding with Aramco requirements. The piping spools at E-403A/B/C and D platforms were noticed installed on incomplete structure steel members with missing bolts, bolts not finally tightened, and some bolts only hand tightened. This is unsafe action and violates 12-SAMSS-008 and PIP STS-05130 requirements. In addition, it is violating SAIC-L2011 item C3. The following two lines are examples of this highlight: 1.36-P-9196-50-3CA9P/SPL-P1-50-3567-01H. 2.24-P9197-50-3CA9P/SPL-P1-50-3523-01E. Contractor should adhere to erection procedures and to piping installation and inspection checklists such as SAIC-L-2011 requirements. Contractor QC is held countable for controlling such activities and assures coinciding with Aramco requirements. The 12-SW-8634-16-12C0U/ SPL-02A job sited east of C-441 was observed with the following deficiencies: 1.The spool was not labeled and the tag is hard to be read. 2.The reinforcement pad of the 4 branch connection was cut out improperly and the radius of the reinforcement pad was reduced to unacceptable level. This is just to match the installation of the 12 pup peace to the 12 line. This indicates poor fabrication and measurements on early stages to prevent such deficiency. The contractor is requested not to install this spool until this deficiency is rectified to meet the requirements of our codes and standards. For ex. 01-SAMSS-010 para6.1.2 asks for minimum outer radius of 51mm for the reinforcement pad. This is violating SAIC-L-2013 requirements. This is referred to QMIS Surv.#s 5600, 5643, 9151 and 9152 which are being closed with all issues therein covered in this entry for follow up and further action/resolution. All mentioned nozzles are connected with spools in violation of SAES-L-310 sec. 4, 11.3, and 11.4 (R84-D449 nozzle N5 with 3" x 2.6 m. spool, C441 nozzle N5 with 4" x 18 in. spool, C421 nozzle N4 with 6" x 4.5 m. spool, E443 nozzle N7 with 2" x 6.8 m. spool). Reference Iso Dwg. #s R84-RD-583999-001, 583302-001, 583048-001, & 584155-001. Contractor is advised to address these items asap. Following are dead legs: 1] 3-DSW-7468-15-3CS1P3 for R84-D449, Dwg R84-RD-583999-001, ref. Surv. # 5600. 2] 4-BD-808415-3CS9P for R84-C-441, Dwg R84-RD-583302-001, ref. Surv. # 5643. 3] 6-BD-8048-40-3CS9P for R84-C-421, Dwg R84-RD583048-001, ref. Surv. # 9151. 4] 2-SR-7925-10-1CS9P for R84E-443, Dwg R84-RD-584155-001, ref. Surv. # 9152. These are violating SAES-L-310 sec. 4, 11.3, 11.4.
SATIP-L-350-01
SAIC-L-2011
Mechanical
other
12-SAMSS008
Section 1
1889
9/2/2007 3:11:05 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
other
12-SAMSS008
Section 1
1890
6/18/2007 2:13:59 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
other
01-SAMSS010
6.1.5
1891
2/10/2008 3:39:02 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.3 and 11.4
1892
2/10/2008 4:11:14 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.3 and 11.4
1893
12/3/2007 4:41:22 AM
Installed TE 101, TG 107, TW 116 2 x 300# SS Flanges on 2 x 300# carbon steel nozzle flanges of line 20-BFW-10613-1CS9P (refer to Dwg. # R81-L-RB-597901-001) have no isolation kits in violation of SAES-L-109 par. 11.5 (The PIKOTEK gaskets, or approved equal, with isolating sleeves and washers shall be used for isolating dissimilar metal flanged joints (i.e. electrical isolation), and insulting joints for cathodic protection). Contractor is advised to comply with the standard requirement. Following were noted on site round for for spool BD-41-297302D. 1)Isometric drwg. R84-L-RD-582973-002-00 do not match P & ID drwg. R84-A-NA-B44995-231-00A. 2)Material used is not for low temp. e.g. A106 Gr B for A333 Gr 6 pipe, A105N for A350 LF2 flange 3)The size of 1/2" dia. for the spool is against SAES-L310 par. 10.2 saying pipe smaller than 3/4" shall not be used for hazardous services. Contractor to correct above deficiencies asap. 2-DSW-7479-10-1CS2P2/SPL-DSW-10-3128-01E that is connected to the 8-P-9414-10-1CS2P2/SPL-P-10-3607-01C was observed with the following non conformities: 1.The CS portion of that spool was not painted and marked as NA for the painting requirements. This spool is not meeting the criteria of 90% of the time in operation. It is cold distilled water supply to D-451 which is used during cleaning purposes only. It shall be painted as per APCS-1A requirements. 2.This spool is creating a dead leg with length of about 1990mm in reference to the current lay out and to ISO metric drawing RD583128-001 rev.00A. Contractor to check and act accordingly to meet SAES-L-310 section 11 requirements. 3.The SS portion of spool 01D of that 2 DSW line was observed touching the nearest platform structure with 0 clearances. Contractor shall maintain the required minimum clearance of 50mm from any fixed structure to meet SAES-L-310 para12.4. The 4-BD-8084-15-3CS9P B/D line out of R84 C-441 was observed with a dead leg of having a spool with about 18 in length which is not self draining. This violates SEAS-L-310 para. 11 requirements and SAIC-L-2013. The ISO drawing and the actual field installation reflect this concern. Furthermore, contractor has to avoid all dead legs in all equipments especially in the treating section where the chemical fluids (ADIP and NAOH) presence is there (corrosion media). The 3-DSW-7468-15-3CS1P3 that is connecting to R84 D-449 observed with a dead leg of having a spool with about 2.6 meters in length which is not self draining. This violates SEAS-L310 para. 11 requirements and SAIC-L-2013. Furthermore, contractor has to avoid all dead legs in all equipments especially in the treating section where the chemical fluids (ADIP and NAOH) presence is there (corrosion media). Contractor is notified not to use purchased and presently stocked SS 316 swaged fittings (item nos. 15, 16, 17 under MRR-OOK No. TRG-007)intended for line class 1SD0P (SAES-L-105) w/c strictly requires SS 316L, and to other applications w/ SS 316L requirement also. Strict compliance/adherence to referenced SATIP/SAIC required as request for acceptance to use denied.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.5 and 12.6
1894
2/6/2008 6:46:17 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-310
10.2
1895
9/2/2007 11:26:30 AM
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.1.4
1896
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
1897
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
1898
4/29/2007 3:08:57 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
1899
4/28/2007 1:23:23 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
1900
9/27/2006 4:08:55 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-105
1SD0P
1901
10/4/2007 10:16:10 AM
During our surveillance at Mod.IV we found many ZVs valves installed without high pressure test ZV # 406, 702, 701, 657, 201, 200 and this is violating SCH. B Para 3.31.4 as stated in this Paragraph .all MOVs and ZVs and there bypass valves subject to high pressure closure test. these ZVs numbers only samples contractor shall remove and test all valves as per Sch.B. Yesterday, I have noticed the following deficiencies in piping storage and handling at the job site. The highlighted concerns found violating SAES-L-350 storage requirements and SAIC-L2011 and QC procedure. They were summarized as follows: 1.Many pipe spools were found touching the ground without proper protection. The list of these spools is at the hard copy of the surveillance report. Here are examples of the spotted spools: 24-P-9108-50-3CS9P/SPL-4069-01D, 6-P-150S-9888-361CS9P/SPL-4019-02A and 2-DSW-7491-60-1SD0P/SPL-3277-01A two spools. 2.Some cut out spools(loose material) and/or fabricated were found not marked, for ex. 20 spools with about 5meters long east of the B/L and one 12 spool west of column 11D. 3.Many fittings and valves not stored in the shipment craters and/or on racks as per SAES-L-350 para 7 requirements. 4.South of C-401, large stock of 1 galvanized piping was put over each other and south of D-468 as well. During site surveillance inspection at module 4 area top elevation, it was noticed that fin fan cooler header lines spools are loaded with the fin fan nozzles. Also fin fan header line R84P-86-3348 -01A/B/C was used as a support for lifting of the pipe spools and 3R84-3728-01a/b/c was hanged by using sling rope with above said line header. It is violating against the SAES-L350 Para 11.2. requirements which states that the pipe shall not be used to support other pipes and structures. Its results the fin fan headers &nozzles may be get damage (bend) and fin fan tubes location in the header can be get leakage. It is advised to the contractor to provide necessary temporary supports for the headers immediately. This spool was observed with concrete spilled over the external coated service. This indicates poor preservation and communication between subcontractors. Poor preservation is violating schedule Q attachment IV para 5 requirements. Contractor is requested to inspect this spool and check the coating efficiency. I recommend grit blasting and painting the spool as per APCS-1A specifications. During our surveillance at Mod.4 C 471 A/B and C 472 A/B we found 8 Drains located very near to the beams at lines # 10"-R 84-P-9523 , 10"-R 84-P-9528 , 10-R 84-P-9576 , 10-R 84-P-9546 and 10-R 84-P-9551 Violating SAES L- 310 Para 12.5 (12.5 Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of all sizes, shall be located at a minimum horizontal distance of 610 mm (24 inches) from any fixed obstruction. This requirement does not apply to that part of the support which is attached directly to the piping, such as horizontal and vertical dummy extensions. Exception: When the above requirement cannot be met, the following criteria should be applied: a) Thermal piping stress analysis shall determine if branch clearance with obstruction is acceptable. b) If the thermal growth direction will result in a movement of the branch connection away from the obstruction, a minimum of 300 mm spacing will be acceptable).Please provide us corrective action.
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.2
1902
4/1/2007 8:48:49 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
1903
5/30/2007 9:39:58 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
11.1
1904
9/2/2007 9:39:24 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-H-200
5.1.1
Schedule Q
A IV Para 5
1905
12/12/2007 4:19:20 PM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
1906
2/6/2008 7:02:13 AM
1907
9/2/2007 10:27:52 AM
During our surveillance at Mod.4 ADIP area we found 8 line P9421 connected in Y lateral configuration to header line # 8-P9417 -65 without reinforcement violating to SAES L-110 Para.12 Please provide us corrective action. The 6-BD-8048-40-3CS9P B/D/Spl-BD-40-3048-01B out of R84 C421 was observed with a dead leg. This violates SEAS-L-310 para.11 requirements and SAIC-L-2013. The ISO drawing and the actual field installation is reflecting this concern. Contractor should inspect the line and act accordingly to avoid the dead leg presence. Furthermore, contractor has to survey the unit and avoid all dead legs in all equipments. The 2-SR-7925-10-1CS9P/SPL-SR-10-4155-01A out of R84 E443 shell side to the ADIP Sump was observed with a dead leg with a length of 6796mm. This violates SEAS-L-310 para.11 requirements and SAIC-L-2013. The ISO drawing and the actual field installation is reflecting this concern. Contractor should inspect the line and act accordingly to avoid the dead leg presence. Furthermore, contractor has to survey the unit and avoid all dead legs in all equipments. 8 -line R84-CA-7404-20-1CC9C4 used to support 3 line R84PA-7707 -20-1CC9C4 by welding support on the 8 line violating SAES L-310 Para.16.1.2 the pipe shall not be used to support other pipes and structures without appropriate analysis . Please provide us corrective action. During our surveillance at Mod.4 we found line 20"-R84-P-9107 52 ,there is no space for insulation at 2 location the coated pipes touch the fire proof beams which is violating SAES L-310 Para.12.4 (A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe ) . During our site surveillance at rerun area and observed the following : 1)10SW-8602-12LCOU,Drg # .R84-RB-585540-001 Rev00B Sea water to 4 way Valves of D-783 C were noticed inadequate pipe supports .. 2) R84-RB-585590-002-00A ,12-5522-02B line was noticed obstructing with structural pipe supports assembly near E717C.Both of the above required Engineering clarification. 3) The weep hole not provided with the Dummy/ Trunnion supports welded nearer the E717C exchanger area .It is violating the SAES L-310 para14.7.2 which stated that A 6 mm weep hole shall be drilled for all dummy supports. The weep hole shall be located near the base plate for all vertical dummy supports, and near the run pipe at 6 oclock position for all horizontal dummy supports. On surveillance 14Mar2008, it was noted that piping for nozzle N1 (18in. x 300#) steam inlet of R84-E-0403B was being fitted with force by a crew. The foreman was told of the violation and chain blocks used were removed, but a number of bolts were left stuck in the joint and were already bent. This is in violation of SAES-L-350 par. 3.2 and ASME B31.3 par. 335.1(a). Contractor should be advised to stop immediately this wrong practice of installing piping to vessels and equipments.
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.2.3
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
1908
9/2/2007 11:20:07 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
1909
1/15/2008 2:21:30 PM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
16.1.2
1910
4/29/2008 7:32:33 AM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
12.4
1911
10/22/2007 2:34:50 PM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
12
1912
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
12.4 and 12.5
1913
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
14.7.2
1914
3/15/2008 11:53:40 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.5
1915
5/11/2008 6:30:54 AM
On laying up works after hydrotesting (TP-R84-BI-1082) of line 12"-P-9139-1CS9P Spl. P-5517-04B under Dwg. RB-585517-004A2, it was noted that 12in. x 150# flange of FW11MW is not parallel with the existing 12in. x 150# valve flange, the tilt is measured at 5/16in. from the square position (one side measured 1 5/16 in. gap and other side 1 5/8 in. at free position) which is over the 1.6mm tilt tolerance given by SAES-L350 par. 9.4d. Contractor to provide correction for this violation. Following need action from Contractor: 1]R84-D-401 nozzle N9 Line 6-R84-BD-7976-50-1SD0P stainless steel valve 6 x 300# bolted with line 6-R84-BD-7986-50-3CS9P using carbon steel bolts, nuts, and spiral wound gaskets, without isolating sleeves and washers in non-conformance to SAES-L-109 par. 11.5. 2]Suction line 6 for R84-G-0482 A & B carbon steel flange bolted with 6 stainless steel valve using carbon steel bolts, nuts, spiral wound gaskets without isolating sleeves and washers in non-conformance to SAES-L-109 par. 11.5. Contractor to provide corrective action. The 1 drain valves on 6-R84-P-16322-3CS9P and 6-R84-P16333-30-3CS9P1 were observed with socket end valves not NPT valves as requested in the bill of material printed on the isometric drawings RD-583123 and RD-583244 respectively. On the other hand, contractor decided to install caps to close the open ends of the drain and vent valves to atmosphere. This is violating SEAS-L-110 para 10.7 requirements and to SAIC-L-2015 item A5 where solid pipe plugs are required. In addition, it is violating the standard drawing AC-036045 sheet 001 rev.12. These reported non conformities were noticed applicable to most of the vent and drain valves that the contractor is working on this time. The designated valves and drawings above are just examples of this non-conformity. During our surveillance at Mod. 4 we inspect check valve installation we found as follows: 1) 8-60 S -8949-15 (8 check valve). 2) 16-P-9521 (16check valve). 3) 8-FG-7629-40 (8300 check valve). 4) 16-P-9220-40 (16-300 check valve). 5) 20P-9186-40 (20-300 check valve). 6) 20-P-9188-40 (20300check valve). Installation of these 6 check valves violating SAES L-108 Para.6.3.4 for maintaining a turbulence free minimum distance as stated in the standard shall be 5 pipe diameters upstream and 2 pipe downstream and no pipe fittings such as elbows , reducers , tees , etc or flow restricting devices such as orifices , control valves etc .shall be installed in these zones. Contractor shall provide corrective actions. E log book # 251 violation prevented installation issued before dated 7/11/2006 for 12 check valve installation, During our continuous surveillance at Mod. 4 we inspect check valve installation second batch we found as follows: 1) 16-P9453-75 (16x300 check valve). 2) 16-P-9531-30 (16x300 check valve). 3) 8-P-9526-30 ( 8-300 check valve). 4) 16-P9534-75 (16x300 check valve). 5) 10-P-9572-76 (10x300 check valve). Installation of these 5 check valves violating SAES L-108 Para.6.3.4 for maintaining a turbulence free minimum distance as stated in the standard shall be 5 pipe diameters upstream and 2 pipe downstream and no pipe fittings such as elbows , reducers , tees , etc or flow restricting devices such as orifices , control valves etc .shall be installed in these zones. Contractor shall provide corrective actions.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
9.4
1916
2/24/2008 6:02:06 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.6
1917
5/12/2007 11:12:07 AM
SATIP-L-350-01
SAIC-L-2015
Mechanical
SAES
SAES-L-110
11.7
Schedule Q
1.3
1918
7/11/2007 11:28:45 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.4
1919
7/12/2007 10:49:20 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.4
1920
8/7/2007 1:10:18 PM
1921
2/8/2008 10:45:45 AM
During our surveillance at Mod.4 we found the contractor installed two 1 drain at reducers for line # R84-FG-7633-60 at top of pipe rack this is violate SAES L-110 Para, 12.3 Branch connections, such as those for drain and vent connections, on tees, elbows and reducers are not permitted .when it is not avoidable review and approval by the chairman of piping standards committee required. During our surveillance at Mod.4 we found 2 lines copper nickel welded with carbon steel flange 1) 2-R 84 RL-7804 -35 spool # 1A / 1B 2) 2-R 84 RL-7807-35 3) 2-R84-SW-8670 as per SAES L-105 Para.12 carbon steel below 4shall not used for SW and we have no approval of WPS for DMW . Please provide us corrective action during our review of piping materials specification documents we found line class 12CGOU 4 inch and above galvanized carbon steel this violate saudi aramco standard SAES L 105 Para 11 table 1 state that line class 12CGOU 3 inch and smaller. It was noticed that contractor is using inadequate pipe guides for the insulated pipes 2-24 crossing on the pipe racks. They are fabricated from plates with 10mm thickness in triangular shapes welded to the structural beams at the pipe rack. These pipe guides are not meeting any of the detailed designs provided in PIP-PNFS0001 pipe supports details. In all types, the proposed height was noticed below the center line of the pipe where the industrial practice and existing plant design requires. This was indicted in the drawing RB-585598 sheet 64 Rev.00 pipe supports T-G-2 types 1-4. Inspection noticed that the rquired thickness for pump casing#R84-G-431B,R84-G-401A and R84-G-401B were less than the required thickness. the rquired thickness according to the drawing #RA-578686 sheet(1) Rev.0 is XS which equal to 0.50"according to American Standard B36.10.Contractor to verify.Inspection is still waiting for corrective action to be taken. Daily walk through to the job site at R84 revealed low preservation levels for the piping spools delivered to the site. This nonconformance violates schedule Q attachment IV para 5 requirements. Here are two examples: 1.10-P-9546-753CS9P1/SPL-P5-75-3217-01C was observed with open end and sand accumulates inside the spools. It is west of E-431. 2.1RW8522-40-12CG0U/SPL-RW-40-3976-01D east of north analyzer house. This spool observed laying at ground level and being covered with sand from the nearest excavation. This results in atmospheric corrosion to the union of that threaded piping spool. Contractor is requested to: 1.Provide corrective action for the reported items. 2.Survey the area and adhere to the requirements of the preservation for all delivered spools
It has been noticed that LSTK contractor provided many valves made of SS body materials equipped with CS (B7) bolting assembly and the gland nuts as well. This is a non conformity to 04-SAMSS-035 para 7.6. 7.6 The corrosion resistance of Body-Bonnet and packing gland bolting, and gasket materials shall be at least equal to the material of the body, bonnet and yoke. The following SS valves (manufactured by ORION) with their serial numbers are as examples of this highlight: 2X150 gate valve serial No. 05/333/012/18 3X150 gate valve serial No. 05/333/008/37 Also, CSD has stated in their e-mail dated 09/17/2007 to this issue that using such CS bolts with SS valves will lead to galvanic corrosion. Actually, not all received SS valves are violating the above requirement. Thus, it is the contractor responsibility to list all valves with this non-conformity and highlight to Company. After that, Contractor is requested to act immediately and provide a corrective action.
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.3
SATIP-L-350-07
SAIC-L-2073
Mechanical
SAES
SAES-L-105
12.2
1922
6/28/2006 4:09:16 PM
SATIP-L-350-09
SAIC-L-2078
Mechanical
SAES
SAES-L-105
12.1
1923
5/21/2007 4:37:45 PM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
15.2.3
1924
4/15/2007 1:29:31 PM
SATIP-G-005-01
SAIC-G-2002
Mechanical
SAES
SAES-G-005
4.7.1
1925
9/2/2007 10:05:32 AM
SATIP-L-350-01
SAIC-W-2011
Mechanical
SAES
SAES-L-350
Schedule Q
A IV Para 5
1926
10/8/2007 9:49:51 AM
SATIP-L-108-01
SAIC-L-2040
Mechanical
SAES
SAES-L-108
8.3
1927
4/21/2007 5:15:07 PM
The received butterfly valves under P.O. #8396-LT-016 were observed with t he following non-conformities versus the P.O. specifications in addition to those listed in SAIC-L-2040: 1.The internal lining is rubber not epoxy versus the purchase order specifications. 2.16 and 20 valves disc screws are made Violationof ferromagnetic material looks like CS and not SS as specified in the valve Prevented drawing #119-629 to 119-636. 3.The plugs of the valve bottoms were noticed Installation to be CS as mentioned in the valve drawing. In addition, the valves complete documentation still not received yet. Therefore, these equipments shall not be released for installation unless otherwise approved by SAPID. During our surveillance at Mod.4 we found Stainless Steel thermowells installed at all the equipments and piping without isolation kids violating SAES L-109 Para.11.5 (SAIC-L-2020 item # A9 ), please provide us corrective action. ViolationAfter The Fact
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS048
1928
7/23/2007 10:01:26 AM 6/18/2007 11:25:22 AM 11/21/2007 10:10:00 AM
SATIP-L-350-01
SAIC-L-2020
Mechanical
SAES
SAES-L-109
12.5
1929
16-P-9341-15-3CS1P3 connected to D-449 was noticed with two dummy supports with open ends. These dummy supports are attached to the vessel Violationshell at east side. Per SAIC-M-2010, this is violating 12-SAMSS-007, para 6.1.4 Prevented all open ends shall be sealed to prevent internal corrosion. Contractor needs to Installation close and seal weld the end of these pipe supports. during our surveillance at Mod.4 D 450 we found tow vertical spacing of ladder rungs near first platform are not uniform this is violating SAES B -054 Section 8 item # D9 at SAIC M-2010 please provid us corrective action. ViolationAfter The Fact
SATIP-M-001-01
SAIC-M-2010
Mechanical
other
12-SAMSS007
6.1.4
1930
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-B-054
1931
11/25/2007 9:38:21 AM
1932
11/26/2007 4:40:05 PM
1933
11/25/2007 10:52:27 AM
1934
2/27/2007 6:06:56 PM
1935
6/18/2007 11:01:27 AM
1936
3/22/2007 3:45:25 AM
1937
4/4/2007 1:42:50 PM
During our surveillance at Mod.4 we found cages of fixed ladders at platforms does not comply with the standard SAES B-054 section 8 checklist SAIC M Violation2010 item # D26 and PIP STF-05501 violation is extended vertical bars not After The installed between cages and top rail while the dimensions is less than 4 feet. Fact Locations: - C 463 and C 462 last elevation and D 463 A/B , C 466 A/B and C 461 . Please provide us corrective action for these equipment ladders and others During our surveillance at Mod.4 top handrail of platforms mitered constructed and this is violating SAES B 054 section 7 Para.6.18 and PIP # STF 05520 , top Violationhandrail shall be 190 mm radius (Bending ) location platforms of equipments After The as follows :- C 431 , C421 , C 401 , C 471 A/B , C 472 A/B ,C 441 , C442 , C Fact 461 , C 463 , C 469 , D 402 , D 403 , D 404 , D406 , D 483 and some location at pipe rack (bridge between tow pipe rack and at top stair ladders.) Please provide us corrective action. During our surveillance at Mod.4 we found connector plates for diagonal Violationbracings found not properly installed due to unequal thickness of gusset After The plates. As per detailed drawing 25 mm thickness is required, actual thickness Fact is only 20mm at bracing side plates. Location main pipe rack tubular columns .drawing # R84-M-RA -585621 SHEET 50 , 53 and 54. During my surveillance I have noticed that contractor performed the following: Some of the cantilever supports for the expansion loops connected to the galvanized structural pipe supports were made with an angular splice which violating 12-SAMSS-007, Para. 6.2; Connections: (All connections shall be either engineer-designed, fabricator-selected, or fabricator-designed. Unless otherwise noted on the design drawings, all connections not fully detailed on Violationthe design drawings shall be fabricator-designed.) However, at the time of After The observing this practice there was neither engineering design, nor approved Fact WPS and/or clear NDT requirements. Furthermore, as per PIP STS05130 para6.6.3: Field welding shall not be used except as shown on the shop drawings or erection drawings. (Approved drawings are not available. I think, such welding practice is conflicting with 12-SAMMS-007, 12-SAMMS-008, and PIP STS05130 and may need waiver if to be done) The structural holders of the lights that were connected to D-450 platform Violationnoticed without complete weld. This will cause crevice corrosion. Contractor Prevented need to seal weld all sides of the structural supports to prevent crevice Installation corrosion in the future. Violation-Prevented Installation On routine inspection, it was noted scaffolding supports were pressing on the jacketed areas of R84-C-0431. As this flattens the corrugated jackets of the completed insulation system (and could crush Violationthe calcium silicate under it) and is against SAIC-N-2014 item C13 - All Prevented insulation is smooth & free form cracks, voids & depressions greater than 3 Installation mm. Cracks, voids & derpressions in insulation greater than 3 mm is to be refitted., Contractor should repair all affected portions and subject to reinspection/acceptance. The subject valve was brought to site by MMG while it was rejected due to Violationseat test failure on both sides of the seat. This valve was tested and rejected Prevented on March 26, 2007 as per the SATR-A-2001A mechanical report 07-215. Having such rejected item job sited is an alarming indication of a weakness in Installation contractor QA/QC system.
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-B-054
SATIP-M-001-01
SAIC-M-2010
Mechanical
SAES
SAES-B-054
SATIP-M-001-01
SAIC-M-2004
Mechanical
Drawing
Schedule Q
1.3
NA
NA
Mechanical
other
12-SAMSS007
6.2
NA
NA
Mechanical
other
12-SAMSS007
6.2.6.6
SATIP-N-001-02
SAIC-N-2014
Mechanical
SAES
SAES-N-001
1.2
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.2
1938
2/27/2008 6:10:46 PM
Modification work for SW1 and SW3 was carried out without following SATIPW-011-01 item 3.17 (Weld modification or re-work after weld acceptance), no RFI was issued and no approved revised drawing from engineering before work was started. Contractor should follow the responsibility assignments for the job per SATIP and MS-D-044. Following modifications were found on-going : 1.For line 6-R84-60C-8887-201CS9P on Dwg. RD-583221-001-00B. 2.For line 30-P84-P-9104-50-3CS9P on Dwg. RD-584068-001-00A, FW#4A and FW#4B (Sht. 1) and FW#13A and FW#13B (Sht. 2). This activity is a HOLD POINT inspection for both Contractor & PID Inspectors, but works are carried out without RFI and without Contractor QC involved the contractor are not fallowing there mothed statement MS-D-044. please provide us corrective action . Performed Focus Assessment to determine root cause of high weld rejection rates for first 2 weeks of pipe shop fabrication works. Common defect is porosity. Using SATIP-W-011-01, following are recommendations : 1) Installation of end covers on the shop. 2) Use Argon (shielding gas) to CGA G11.1 Grade "A" instead of Grade "C". 3) Provide end covers during root pass of pipes being welded. 4) Not to use portable electric fans in the shop floor. Performed Focus Assessment to determine root cause of high weld rejection rates for first 2 weeks of pipe shop fabrication works. Common defect is porosity. Using SATIP-W-011-01, following are recommendations : 1) Installation of end covers on the shop. 2) Use Argon (shielding gas) to CGA G11.1 Grade "A" instead of Grade "C". 3) Provide end covers during root pass of pipes being welded. 4) Not to use portable electric fans in the shop floor. Document Review of Post weld heat treatment (PWHT) charts HT-3542, it was noticed that 1) As required by Chart report, PWHT SATR-W-2004, 2005, 4 Thermocouples need to be used. It is advice the contractor to revisit the reports and provide the required thermocouples as mentioned the report. Please provide us the corrective action. Focussed Assessment was done to ensure contractors compliance and implementation of quality requirements regarding Hardness Testing activity. Procedure No. PROC-L-009 is reviewed and accepted. On inspection round yesterday afternoon, following were found at the worksite in violation of SAES-W-017 and SAES-D-108 par. 9.1 : 1. Welding works of the 20 in. slip on flange with tank nozzle started without compliance of inspection requirements as per SATIP-W-017-01. Welding rods used were not pre-conditioned. Welding oven has no temperature gauge and not calibrated. Contractor should address above violations and correct. during site routine visit to dammam fabrication shop, random inspection on welding machines was held and some of the machines had expired calibration and required to be calibrated again. contractor should follow the calibration requirements and the watch the due date of calibration continuously, machines for example: 1- U1060607921 (expired on 01 March 2007) 2KF867723 (expired on 06 May 2007) 3- KF894176 (expired on 03 May 2007) Spool piece 150-60-3548-01G under Dwg. R84-L-RD-583548-001-0A for R84-D432A N3 condensate outlet line no. 12-R84-150C-9636-60-1SD0P was found with dissimilar metal weld joint at SW#22 between stainless steel 6 x 4 eccentric reducer with heat # S12529 Sch. 40S 316/316L and carbon steel 4 x 300# flange with heat # ALA in non conformance to SAES-W-011 par. 7.1.8 and par. 7.1.1. (there is no approved WPS for this dissimilar metal joint). Contractor should correct the material and drawing. During our surveillance at Mod. Area 40 equipment E 422-B we found the contractor Using heavy wall thickness reducers for SCH 40 pipe line # R 8436-P-9215-40-3CS9P tapering with grinder and not as per standard this is violating SAES W-011 Para. 9.5 Internal misalignment of butt joints shall not exceed 1.5 mm. Internal tapering in accordance with ASME B31.3 by machining, back welding, or a combination may be used to correct the misalignment. Please provide us corrective action for all heavy wall thickness reducers used For other lines. During our surveillance at Mod.4 we found 6 discharge line of pump # G 0482 A/B one spool each line carbon steel welded with SS flanges and same case for 8 150 C outlet lines of D 405 A/B this is violation as per SAES W-011 Para.6.4.2 and we have no approval of WPS for DMW of pressure containing . Please provide us corrective action.
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
Schedule Q
1.7
1939
2/25/2008 9:49:27 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
SAES
SAES-W-011
18
Schedule Q
1.7
1940
7/31/2006 10:00:23 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.7
1941
7/31/2006 10:14:17 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.7
1942
6/11/2008 7:03:49 AM
ViolationAfter The Fact ViolationPrevented Procurement ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-W-011-01
SAIC-W-2004
Mechanical
SAES
SAES-W-011
13.13
1943
10/30/2006 3:40:10 PM
SATIP-W-011-01
SAIC-W-2014
Mechanical
SAES
SAES-W-011
14
1944
5/14/2008 12:03:44 PM 5/14/2008 12:03:44 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
1945
SATIP-W-017-01
SAIC-W-2083
Mechanical
SAES
SAES-W-017
6.2
1946
5/13/2007 5:20:18 PM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAES
SAES-W-011
19.2
1947
3/28/2008 7:27:47 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
6.4.2 & 7.1.1 & 7.1.8
1948
2/3/2008 3:00:10 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
9.3
1949
2/6/2008 1:37:36 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
6.4.2 & 7.1.1 & 7.1.8
1950
2/26/2008 5:48:11 AM
Modification work for line 4-R84-P-9124-50-3CA90 under Dwg. R84-L-RD584450-001-00 is done with following violations: 1]FW#28 is jointed with a 2 x 300mm lght pup piece that is without heat no. ID in non conformance to Sched. Q Att. IV par. 3.2 and 3.3 (verification and identification of materials traceable to manufacturers specification ensuring compliance to SAramco specifications). Weld joint has no identification markings , weld no. is not marked adjacent to weld joint in non conformance to SAES-W-011 par. 16.1 (welds to be marked for identification with weld no. & welder symbol) and par. 16.2 (identification shall uniquely identify each member and weld joint). This is for the standpipe of R84-E-403 B. Contractor to please provide corrective action.
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
4.2 & 4.3
1951
2/26/2008 5:48:11 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
16.1 & 16.1
1952
3/27/2007 9:32:51 AM
1953
3/4/2010 2:18:59 PM 3/4/2010 2:18:59 PM
1954
During my surveillance, I have the following two concerns on the subject line @ FW-15: 1.The welder was welding and light rain was there at the area of welding by the time of inspection. Wind shield tents requirements were not Violationdone properly to protect the weld joint against inclement weather. 2.This line After The was supported on a ready concrete foundation of G-472A which is a repetitive Fact failure by the contractor and had been highlighted before. In addition, at the side of welding this line was supported on a fabricated spool 8-BD-8001-561CS9P/SPL-4097-02A. During surveillance inspection for welding of steel structure, the fit up was not Violationaccording to IFC drawing. This is a violation to IFC drawing. In addition, the Prevented drawing which was on the site was not stamped as controlled copy which is Installation violation to contractor quality plan. ViolationIn addition, the drawing which was on the site was not stamped as controlled Prevented copy which is violation to contractor quality plan. Installation As a minimum, full quality system audits shall be carried out at fifteen percent (15%) of completion stage for the, Procurement, and Construction WORK Phases. CONTRACTORs audits may be rescheduled only with the concurrence of the Company Representative while 19% construction and 38% procurement work is completed and no request has been sent to company for rescheduling of 15% internal audits . This violation of Schedule Q Para 7.3.2.Contractor is advised to arrange 15% Quality Audits at earliest. It has been noticed that the contractor QC Mechanical Inspector Mr. Tony Lagda was not regularly available at site. This is violation of schedule Q Sec; 5.1 and attachment VI. Approved quality personnel shall be full time on site. PID has learned that he is still working in Yanbu project. Surge Drum D-7110 has been installed without foundation inspection. Wrong size dia M22 foundation bolts are installed but required size is M27 as per drawing. NCC & SNEPM inspectors are not involved for inspection as investigated. This is a violation against installation procedure & ITP witness. Arrange inspection witness of vessel closure. Immediate action required. refrance to approved procedure for installation of column internals (PCP-M011)Para 4.0.3 Accessibility & scaffolding, Stated that all out side steel structure platform/ladders shell be installed & inspected prior to start of internals. but at site installation of steel structure & internals are parllally in progress. it was highlited to area supervisor as well sas snepm inspection deptt. to close issue. but no responce. During my verifying visit to close my yes item against exception list for PZV. 8112 of shipping pump8101.Wrong PZV.8112 of air accumulator have been installed. Set pressures of both are different. Root cause found that the installed PZV.8112 is same no. Air instrument PI&D # BA-863795. REPLACE PZV. & revise the PI&D with different valve no HOLIDAY TEST LINE # 496-01-TW-9600/90 IS BURRIED WIThOUT holiday test. this is third time that lines were burried without test at different location. this is a hold point as per SATIP. No rfi raised.
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.1 & 11.2.2
NA
NA
Mechanical
Drawing
Drawing#
NA
NA
NA
Mechanical
ScheduleQ
Schedule Q
6.1.1
1955
2/4/2010 11:20:50 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
7.3.2
1956
3/16/2010 3:34:17 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
1957
11/15/2008 8:45:08 AM
10
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
4.8.5
1958
3/10/2008 1:37:42 PM
10
NA
NA
Mechanical
other
PCP-M-01
4.0.3
1959
9/15/2008 11:56:17 AM 4/16/2008 1:16:17 PM 4/16/2008 1:16:17 PM
10
SATIP-G-005-01
SAIC-G-2004
Mechanical
other
P&ID#BA863795
NA
1960 1961
10
SATIP-H-002-02 NA
SAIC-H-2016
Mechanical
SAES
SAES-H-200
NA
Mechanical
ScheduleQ
Schedule Q
1.7
1962
10/28/2008 10:48:17 AM
10
This reference to routine site visit it was observed that new painting colour of hand rail is different than colour on existing handrails. It was investigated Violationthrough STANDERED & PHYSICALLY stock available at NCC painting store. As per standard required paint RAL.1018 but available stock is RAL.1003 which is Prevented Engineering violation of standard SAES-H-001 There is no check on material used by subcontractor. SNEMP shall Raise NCR for answering for action plan & route cause
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-001
1963
5/27/2008 3:32:17 PM
10
LINE # 496-IA-9179 IS BEING PAINTED WITH OUT DPT EXAMINATION OF SOCKET WELD JOINTS. DURING DFT & HOLIDAY TEST IT WAS QUSTIONED TO NCC & SNEMP INSPECTOR, DO THEY HAVE ANY CLEARANCE FOR PAINTING BY NDT DEPTT. IT WAS ALSO DISCUSSED WITH NDT COORDINATOR.ACCORDING TO HIM LINE IS NOT YET COMPLETED. IT LOOKS THERE IS NO COORDINATION TO AVOID THIS KIND OF SITUATION. REMOVE PAINTS FROM ALL SOCKET JOINTS FOR DPT EXAMINATION THIS IS REFRENCE TO MY TIME TO TIME FOLLOW UP ABOUT CRTS PAINTING INSPECTION REPORTS FOR & LIQUED COATING & HOLYDAY TEST OF UNDER GRUOND PIPING INSPECTION. SNAMP IS STILL NOT SUBMITTED RELEVENT REPORTS FOR REVIEW & VERIFICATION. HOWEVER LINES ARE PHYSICALLY WITNESS & TESTED. IT IS AGAIN ADVISED TO SUBMIT RELEVENT REPORTS. SNAMP SHOULD SHOW HIS INTENSION TO CLOSE THE ISSUE. After inspection witness of lube oil flushing i was just turnd to towards new erected by pass line @ 20" on pump discharge to see inside cleaning was done or not. then it was abseved that inside coating was damaged due to welding of dummy pipe support. remove the line from position re-blast inside surface & re-coat damaged area. Above mentioned 4 shop weld joints are cut at site for erection adjustment .during cutting NCC supervisor was advised to take care to avoid damaging of FBE coating other than weld joint area Dated, August 29, 2008.Joints are verified for coating & found damage coating beside the weld joints. Weld joints are rejected against damaged coating due to cutting by the fabricator. Joints shall be re-blast & coat. Arrange new RFI for inspection. manholes fillters module 20 are being touched up without surface preparation ( sand paper/ wire brush) basically the particular worker was not qualified painter. he had not JCC with him. Ncc inspector is advised to remove paint.prepare suface & then paint Hydro test pack IS forward as urgent work. No physically walk through done by NCC & SNEMP inspector. Two gaskets are found 150 rating instead of 300rating during filled water. REMOVE WRONG GASKIT IMMIDAITLY & INSTALLED NEW GASKIT. SNEMP TO RIASE NCR and report on root cause an proposed corrective action. There are no inspectors at site to check physically. This is not first time. Snemp inspector is BASICALLY a hydro test coordinator, thats whey he is signing test pack flow chart on behalf of NCC. It was observed during internal holiday testing that the following violations were found, Holes prepared for branch connections for AE and PIT instruments were not properly dressed and incomplete penetration was found on all weld-o-lets. This violates SAES-W-011 para 11.3.2.1 and 11.3.2.2 for thermally irregular shaped holes. And violates AD-036643 001 for incomplete penetration of the joints. Reference PI&D # BA-863782 Line # 56-TW-96073LEOP This demonstrated the poor inspection and workmanship of contractor. Please rectify immediately and issue FRI for re-inspection. Weld joint nos. 35 of both chemical lines # 496-01-C-9061& 9062/90 are fabricated & welded with miter cut. According to NCC piping superintendent lines are fitted at 13 to 15 degree miter cut. Miter bends are not permitted Snemp to request for approval PROCEDURE by PMT As per SAES-L-110 11.4 Miter elbows are not permitted. In case miter bends have to be used prior approval by the Chairman of the Piping Standards Committee is required.
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
17.5.3.1
1964
11/23/2008 10:00:49 AM
10
SATIP-H-100-01
SAIC-H-2034
Mechanical
other
GI.2.710
4.1.1.2
1965
5/31/2008 10:26:00 AM
10
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.2.4 & 8.2.5
1966
8/29/2008 2:14:06 PM
10
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.2.4 & 8.2.5
1967
4/8/2008 5:16:10 PM
10
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAEP
SAEP-316
3.1
1968
8/5/2008 1:45:51 PM 8/5/2008 1:45:51 PM
10
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-L-450
9.4
1969
10
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1 & 5.9
1970
8/5/2008 6:14:26 PM
10
SATIP-L-350-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.2.1 & 11.3.2.2
SA standard Drawing# AD036643
NA
1971
7/9/2008 3:24:55 PM
10
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-110
12.4
Schedule Q
A IV Para 3.3
1972
7/30/2008 3:32:14 PM
10
Two SS pipe spools are IMROPER store & handled at site near shipping pump. ViolationSpools are lay directly at ground & almost 25% buried. This un acceptable. Prevented Remove pipe spools from the sand /clean inside / out side put end cap & stack Installation at proper manner stariner conical. During routine visit it was abserved that conical strainer was installed in wrong direction at module 22. with feed water pump. issue was discused with NCC PIPING SUPERVISOR & asked for erection drawing. the drawing was not avaiable at site. after conformation that wrong orientation. no body by snemp & NCC QC IS VERIFING these hidden items.it is still wrong but the further worked is proceeded Now it is advisable that all strainers shell be verified & recorded. de-asseble the pipe assambly & correct orentation During my bolt tightened inspection of dearators column steel structures it was observed that pipe supports # 211(S18) of sea water line # 496-SW110/25&26 are not welded completely. Welding work shall be commenced on priority bases otherwise there will be no access for rectification. Pipe supports at same location module 27&28 to be checked by SNEPM QC before offer reinstatement verification Remove paint & weld the support properly.
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.1 & 7.4
1973
4/11/2008 10:19:51 AM
10
SATIP-L-350-01
SAIC-L-2022
Mechanical
Drawing
Drawing#
NA
Schedule Q
1.3
1974
10/14/2008 4:26:32 PM
10
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAES
SAES-L-350
11.3
1975
10/14/2008 9:17:43 AM
10
1976
10/7/2008 7:35:06 AM
10
1977
9/21/2008 10:44:16 AM
10
1978
3/12/2008 12:59:53 PM
10
1979
3/17/2008 9:33:09 AM
10
1980
3/17/2008 9:33:31 AM
10
1981
7/16/2008 4:39:03 PM
1982
7/16/2008 4:39:03 PM
Considerable distortion found in the erected structural steel bracing of pipe rack in Module-26 and one bracing has not yet been installed. This distortion may have been occurred either during receiving or during erection or may be failing to install adjacent bracing causing greater load. Repair or replacement of such bracing is recommended and installation of adjacent bracing is to be carried out immediately. 12-SAMSS-008 - Erection of Structural and Miscellaneous Steel STS05130 - Erection of Structural and Miscellaneous Steel Specification Para-6.2.3 Any damage caused during erection shall be reported to the buyer. Corrective measures shall be completed as directed by the buyer at no cost to the buyer. Para-6.10.2 The erector shall repair all sags, deformations, holes, and other irregularities This is reference to my focused assessment it was observed that pipe fabricator are not taking care during pipe fit up of SS weld joints in area 17 inside the plant the thickness of the pipes are Sch.10S. the misalignment of joints are not in acceptable limit. Joint No. FW11 of line no. 496-01-C-9072/17 & FW 12 of line no. 496-01-C-9115/17 are to be cut & re-weld with proper fit up. This is reference to my observation that radio graphic of the field weld joints are not done inside the plant. The extent of radiography is demonstrated in SAES-11 Para 17.5.2 that for Saudi Aramco projects where less than 100% radiography is coverage required, random selection shall be based on the weekly weld production. Checks the last radiographic test done based on production & arrange RT crew for evaluation of production weld joints inside plant as per SAES Penalty shots Against weld joint repair. it was advised three weeks ago in a meeting that SP would provide status of Penalty shots attempted against repair so it will not effect the schedule during pressure test activity. but after doc. review it is abserved that NCC/SNAMP did not prepare status. it will unable to approve final test pack for pressure testing. pls take immidaite action. DURING MY VISIT AT NCC WORK SHOP, IT IS ABSERVED THAT ONE PIPE SPOOL OF LINE NO.49601-TW-9616-32. THE PIPE JOINT (Without Weld no.marking)HAVING LESS DISTANCE BETWEEN TWO WELD SEAM.LONGITUDNAL SEAM OF THE WELDED PIPE ARE CLOSER 12 MM. AS PER ARAMCO ENGG.STANDERED W-011 THE DISTANCE BETWEEN THE WELDS SHALL BE THREE TIME OF WALL THICKNESS. RE-FITUP REQURED. LITTLE ROTATE. AND THEN TACK. DURING MY VISIT AT NCC WORK SHOP, IT IS ABSERVED THAT ONE PIPE SPOOL OF LINE NO.49601-TW-9616-32. THE PIPE JOINT (Without Weld no.marking)HAVING LESS DISTANCE BETWEEN TWO WELD SEAM.LONGITUDNAL SEAM OF THE WELDED PIPE ARE CLOSER 12 MM. AS PER ARAMCO ENGG.STANDERED W-011 THE DISTANCE BETWEEN THE WELDS SHALL BE THREE TIME OF WALL THICKNESS. RE-FITUP REQURED. LITTLE ROTATE. AND THEN TACK. In attending RFI to check the preparation for grouting of PLT near lube oil at shipping pump 8001, 8002, and 8101, SAPID noticed that the pedestal (PLT) have already partially grouted at the bottom of its base plate without inspection. The violations of the contractor are as follows: 1). No RFI to checked verticality and alignment. Structure shall be plumbed, leveled, and brace before any final bolted or welded connections are made PIP STS05130, Par. 6.3.2. 2) Columns or structures with attached base plate are temporarily supported on leveling nuts, shims, and other leveling devices and plumb before grouting. STS 05130, Par. 6.2.1. 3) Partial grouting All grout shall be placed in only one direction to prevent trapping air. Grouting shall be quick and continuous to avoid segregation, bleeding, or premature initial set. PIP STS 03600 Par, 6.3.3. 4) Anchor bolts was over projected from top of concrete violates SAIC-Q-1013 item B10. During surveillance At SO2 Tank Platform, SAPID noticed that structural member at the top layer of the platform had been cut and modified to give way of passing of pipe riser without clearance from Civil Inspection Groups. No documents and approval was submitted prior to modification and installation. Violations to 12-SAMMS-007 are as follows: Paragraph 6.1.7-Shop splices, changes in details or dimension shall not be permitted without written authorization from Structures Standards Committee. Paragraph 6.2.1.3 Request to deviate from specific details of any Eng- designed connection by the fabricator must be in writing with written approval from SA. Paragraph 6.2.3.5 Calculation should be sealed and signed by responsible Structural Engineer and submit to SA representative.
SATIP-M-001-01
SAIC-M-2011
Mechanical
other
12-SAMSS008
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
9.3
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
17.5.2
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
2.8
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.16.1
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.16.1
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
SATIP-M-001-01
SAIC-M-2007
Mechanical
other
12-SAMSS008
Section 1
1983
7/16/2008 4:39:03 PM
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.8.1
1984
11/18/2008 1:40:52 PM
SATIP-M-001-01
SAIC-M-2008
Mechanical
other
12-SAMSS007
1985
11/18/2008 1:40:59 PM
During surveillance At SO2 Tank Platform, SAPID noticed that structural member at the top layer of the platform had been cut and modified to give way of passing of pipe riser without clearance from Civil Inspection Groups. No documents and approval was submitted prior to modification and installation. Violations to 12-SAMMS-007 are as follows: Paragraph 6.1.7-Shop splices, changes in details or dimension shall not be permitted without written authorization from Structures Standards Committee. Paragraph 6.2.1.3 Request to deviate from specific details of any Eng- designed connection by the fabricator must be in writing with written approval from SA. Paragraph 6.2.3.5 Calculation should be sealed and signed by responsible Structural Engineer and submit to SA representative. During surveillance At SO2 Tank Platform, SAPID noticed that structural member at the top layer of the platform had been cut and modified to give way of passing of pipe riser without clearance from Civil Inspection Groups. No documents and approval was submitted prior to modification and installation. Violations to 12-SAMMS-007 are as follows: Paragraph 6.1.7-Shop splices, changes in details or dimension shall not be permitted without written authorization from Structures Standards Committee. Paragraph 6.2.1.3 Request to deviate from specific details of any Eng- designed connection by the fabricator must be in writing with written approval from SA. Paragraph 6.2.3.5 Calculation should be sealed and signed by responsible Structural Engineer and submit to SA representative. Routine site visit to module 20 area and found the contractor is ready to install the 4 butterfly valves that were rejected during the hydrotesting at SAECO workshop according to the manufacure test procedure.QSWPIU is requesting the contractor to get any documents from the manufacture to clarify the rejection of this valves. The duct bank installation at SS-2 covered almost half of the 6" fire water line (FW-9772). Later, during compaction of base course and ground cover it will be imminent that RTR fire water line will be damaged when it got pressed on the duct bank. Contractor is requested to rectify this matter (duct bank or FW line) to comply with the requirements of the Standard (SAES-B-064, SAES-P104, SAES-T-911) prior to backfilling and the Tie-In of Fire Water Line to avoid any consequential delay. Despite the Proactive Surveillance (SUR-7553), and numerous verbal discussions with Contractor RTR QC Inspector, the Contractor continued to connect the new Fire Water line FW-9403 to the existing lines without hydrostatic testing of the new lines (Tie-in 171/ 172). This is a violation the Saudi Aramco Standards SAES-A-004, SAES-B-017 para.12.6 and SAES-S-070 para. 18. Saudi Aramco reiterates that all new pipe lines shall be subjected to hydrotesting prior to be put into service. The fire water line (FW-9403/9773) serving Fire Monitor (FM-23) has a 6" RTR elbow which was not provided with a thrust block. Contractor claimed that the pipe was temporarily backfilled for car/ truck access but until now it was not re-excavated for the provision of thrust block. Note that the area is now being prepared for finished grading. Contractor is required to immediately install the thrust block (while there is still excavation on the area for the transformer drain manhole installation) prior to the final grading. Post Indicator Valves on Fire Water Lines (FW-9416/ 7856/ 9403/ 7857) were installed without the required coated Machine Bolts and Washers. Despite the Proactive Surveillance (SUR-7318) the flanges for post indicator valves were backfilled without replacing the bolts. Saudi Aramco reiterates that the Contractor shall comply with the requirements regarding the type of bolts to be used for underground installation as defined in SAES-L-105 p.190- Material Specification; and GA-E-60051- Project Specification. The Fire Monitor FM-23 located at SS-10 was installed in such manner that the flange connection is below the finished grade level, despite the previous Proactive Surveillance (SUR-8199) reminding that flange connection between fire hydrants/ fire monitors and the pipe riser mating flange shall have a minimum distance of 125mm from the finished grade. Please refer to SAES-B017 Figure 1 and 5 for Fire Hydrant and Monitor installation detail. Please rectify the installation of riser so that hydrant and fire monitor flanges will not be below finished grade. (pls refer to attached picture on email) A Kick off meeting was held with SP NCC SAPMT and SAPID to discuss the field fabrication of two API 650 Storage Tanks. API-650,32-SAMSS-005, SAESW-017 SATIP no.s SATIP-100-01 and SATIP-W-017-01 and Contractor ITP were discussed. WPS to be submitted to CSD for approval, Contractor said it would be done today.
SATIP-M-001-01
SAIC-M-2008
Mechanical
other
12-SAMSS007
1986
11/18/2008 1:41:05 PM
SATIP-M-001-01
SAIC-M-2008
Mechanical
other
12-SAMSS007
1987
11/10/2007 11:32:44 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 4.3
1988
7/6/2008 6:56:22 PM
NA
NA
Mechanical
SAES
SAES-B-064
7.8.2
1989
11/7/2007 5:40:45 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-B-017
12.6
SAES-S-070
18
1990
11/9/2007 11:50:35 AM
NA
NA
Mechanical
SAES
SAES-S-070
17
1991
11/9/2007 2:14:22 PM
NA
NA
Mechanical
other
GA-E-60051Project Specification
NA
1992
2/5/2008 2:12:24 PM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-B-017
7.2.2
1993
12/31/2007 12:19:14 PM
NA
NA
Mechanical
Scope
Schedule Q
1994
12/4/2007 11:09:38 AM
A routine site inspection was done for the seawater filters at module 22 and it was found the cotractor already install the concrete inside the filters without performing a holiday testing for the coating to ensure no damages for the coating as per SAIC-D-2003 which refer to SEAS-H-100 para 8.2.6.The contractor shall clarify this issue to prevent it in rest of the filters. A routine site inspection was done for the seawater filters at module 22 and it was found that the contractor already install the concrete inside the filters without performing a holiday testing for the internal coating to ensure no physical damages for the coating as per SAIC-D-2003 which refer to SEAS-H100 para 8.2.6.The contractor shall clarify this issue to prevent it in the rest of the filters. RFI # 16281 & 16293 Equipment and Foundation elevation checked for Sea Water Filters in Module 27. Base in actual survey results, it was revealed that the four (4) equipment elevations were not complying for the given tolerance which required only 3/16 (4.76mm) as per PIP (VEFV1102) specification. The maximum difference in equipment from which we measured was 34mm. Required elevation is 2634 and actual elevation in site was 2600.Therefore the contractor shall be advice to submit for their corrective action on the above matter. As pointed out all deaerators have internal tray issues namely; downcomer clamps are off center, overlap is required. Longer clamp seal plate are not installed sandwich gasket damaged are required 4 rather then 3. Inform PID when Sulzer are on site to rectify the problems. Routine site visit to perform the internal inspection for the seawater filter and it was notised that the bolting for the internal pipe support is violating SAES-L109 para 11.5 regarding the isolation between dissimilar metal.The contractor shall use isolating washer to have a cathodic protection as stated in SAES-L109. Material receiving inspection of sea water filter vessel(496-D-2204) was done and found unacceptable because the external coating has physical damage which is violating SAIC-D-2002 Item A44.The contractor shall repair that damage according to the requirements of SAES-H-100. During visit at site it is observed that column bottom pump of module #27 has had the initial grouting done (pocket grout with anchor bolts) without any RFI. Initial alignment of pump must be done with the deaerator outlet flange. There is no Deaerator installed yet. Please submit the inital alignment inspection report to verify you are within project tolerances. Routine site visit was done for all the feed pumps and the bottom column pumps and it was noticed the following: 1- The outboard shaft and the stud bolts of the Motor fastened to base plate for the bottom column pump at Module 24 (GM 2402) were generally corroded. 2- The outboard shafts and the stud bolts of the Motor fastened to base plate for the bottom column pump and feed pumps at all modules (GM 2001, GM 2101, GM 2301, GM 2302, GM 2201, GM 2401, GM 2502, GM 2501, GM 2601, GM 2701 and GM 2801) were rusted. The contractor shall clarify this according to 31-SAMSS004 and API 610. During inspection of top coat RFI#14951 it was noticed that SPC-P-1066 support was already taken and bring to the site with out any final inspection.This is a violation of schedule Q par.6.3 to comply the construction quality requirements. During routine inspection it was observed in module 27 & 28 that contractor installed supports without applying final coat and some supports no even primer coat. SP contractor have no control of releasing the supports on this time were construction people can get anytime in lay down yard without any permission if the inspection of the coating is done. SP should make immediate action of controlling and releasing the supports after final inspection and remove all supports without coat which already installed on site. Routine site visit for the coating of the girth welds on the discharge line 60" flange to pipe FW#7 L-496-01-TW-9565/90 at module 28 area.The external FBE coating for the flange was inspected and found some damage to the coating.In same time, it was obseved a second layer underneath.The external FBE coating(APCS-104)is one layer system as per SAES-H-002 para 6.6 (APCS104). This issue shall be clarified by the contractor and the coating vendor proir to complete the welding of this line. During routine site visit, it was noticed that in the south west corner outside of SS#20 there is a newly installed air line 1 dia which is flanged and is 316L material - stub up, which is buried. The externally coated line appears to be hand wrapped; this is in violation of SAES-H-002 para. 5.1.11 Buried stainless steel lines shall be externally coated with APCS-105, APCS-113A, APCS-113B Provide engineering solution to this situation.
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-H-100
8.2.6
1995
12/4/2007 11:16:17 AM
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-H-100
8.2.6
1996
4/13/2008 5:12:29 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
Drawing
IFC drawings
NA
1997
2/6/2008 3:14:44 PM
SATIP-D-001-01
SAIC-D-2009
Mechanical
other
32-SAMSS020
9.1.4
1998
11/20/2007 4:02:07 PM
SATIP-D-001-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.5
1999
1/27/2008 4:42:24 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
SAES
SAES-H-100
8.1.6
2000
2/6/2008 2:49:24 PM
SATIP-G-005-01
SAIC-G-2021
Mechanical
other
31-SAMMS004
6.3.14
2001
11/10/2007 11:18:22 AM
SATIP-G-005-01
SAIC-G-2003
Mechanical
other
31-SAMMS004
1 (Scope)
2002
3/15/2008 5:28:38 PM
SATIP-H-100-01
SAIC-H-2031
Mechanical
ScheduleQ
Schedule Q
6.3
2003
10/6/2008 9:50:27 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6
2004
1/24/2008 10:20:55 AM
SATIP-H-002-08
SAIC-H-2015
Mechanical
SAES
SAES-H-201
8.2.4
SAES-H-002
6.6
2005
1/27/2008 1:39:28 PM
SATIP-H-002-06
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.1.11
2006
3/7/2008 11:36:28 AM
Despite not having complied yet to the proactive surveillance (SUR-13735 reminding the contractor to apply the required coating for repaired/extended pipe riser), the contractor poured the concrete anchor on uncoated pipe. Contractor is requested to comply with the requirements of SAES-H-002 and SAES-B-017 and apply internal and external coating on the Fire Monitor/ Hydrant pipe riser. (picture will be attached on email) During my surveillance this afternoon dated 01.06.2008 I found three NCC helpers doing painting in sleeper way area applying final coat without blasting or cleaning and primer coat in biocide line supports. Due to no painting SPQC available in project NCC continuing using the helpers to do the job without following the proper procedure. Therefore PID advised to remove all applied paint in biocide supports and offer RFI for inspection before applying primer coat. The hydrotesting of 30" x600 gate valve(Tag NO.496-MOV-8144) manufactured by ORION was done and found unacceptable (heavy leakage observed through the upstream seat due to a crack on the gate seat area.This violate API 598 Para 4.4.3 and schedule Q Para 7.3.7.The contractor shall follow up with is issue and notify the manufacturer for repair or replacement. Job site survailance was done and found the contractor installed 36"x150 gate valve Tag No.496-MOV-7934 at tie-in#90 which is falied in downstream saet test during the hydrotest at SAECO.This violate API 598 Para 4.4 (Table 5) and schedule Q Para7.3.7.The contractor shall clarify this issue. The hydrotesting of 30" x600 gate valve(Tag NO.496-MOV-8244) manufactured by ORION was done and found unacceptable (heavy leakage observed through the upstream seat due to a crack on the gate seat area.This violate API 598 Para 4.4.3 and schedule Q Para 7.3.7.The contractor shall follow up with is issue and notify the manufacturer for repair or replacement During reviewing the package Tie-in # 004 it was found out that FJ-21 and FJ31 in Line No.496-01-56-TW-9573/00-1LEOP, the Radiographic Test report (RT) showing that each joint have re-shoots. On this matter the contractor will arrange a re-shoot before hydrotest. This is an A punch list item. During my routine site visit this morning 9:30am i noticed that the package Tie-in #004 was already pressurized since yesterday without any approve package and RFI submitted. The Line was uncontrolled, external painting job on the joint is on going on this line at the same time hydrotesting is also on going.Poor practices in our safety procedure can create injuries. To avoid this problem contractor safety officers must be present on this activities. Package No. 308,309,310,311,358,359,360,361 were schedule for hydro test today 27.03.2008 and found that the contractor did not follow the safety requirements as per SAIC-A-2009 that relief valve shall be installed during the test. The line was pressurizing with 150psi with out pressure relief valve connected to the manifold. To eliminate risk, contractor should advise or remind of their hydro test workers about safety rules and practices. RFI # 15896 witnessed hydro test package #207 dated on 01.04.2008, it was observed that the line no.20-SW-0104/20 sht 2 have two (2) different class of materials the 1FEOP (RTR) and 1LEOP (SMO). Both class included during hydro test. Therefore the contractor is required to submit laboratory result of the chloride content of the water used during the test. SMO or type 300-series stainless steel as per SAES-A-007 required low chloride content with a maximum of 50 ppm in order to avoid pitting and stress corrosion cracking. Hydro test of package # 1462/1463 were scheduled at 1:30pm dated 05.04.2008. The test was cancelled due to contractor have using two (2) gauges with expired calibration certificates and no traceability number for the manifold to verify the calibration certificate. Again the contractor should advice to their hydro test workers to follow as per SAIC-A- 2009 to eliminate risk in future. Hydro test of the package # 306 cancelled due to the Line No. 14-UW0150/22 constructed not as per drawing. Contractor failed to submit the modification drawing as requested before the test. Contractor should be aware that the above mentioned line which typical from module 22 to 28 erected with the same as in module 22. For this reason the cut the line in module 22 to follow as per drawing requirements.
SATIP-H-002-06
SAIC-H-2023
Mechanical
SAES
SAES-H-002
5.1.5
2007
1/6/2009 3:03:56 PM
SATIP-H-100-01
SAIC-H-2029
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
2008
4/22/2008 12:57:53 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
API 598
4.4.3
2009
3/29/2008 3:12:02 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
API 598
4.4
2010
4/29/2008 2:45:13 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
API 598
4.4.3
2011
3/11/2008 4:03:49 PM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAEP
SAEP-1160
2012
3/14/2008 10:55:28 AM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAEP
SAEP-1160
2013
3/27/2008 4:55:47 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
G.I.2.102
5.1.5
2014
4/4/2008 10:19:39 AM
SATIP-A-004-02
SAIC-A-2008
Mechanical
SAES
SAES-A-007
6.1
2015
4/5/2008 5:23:38 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
7.1.5
GI.2.102
5.1.5
2016
4/12/2008 12:59:56 PM
SATIP-A-004-02
SAIC-A-2003
Mechanical
SAEP
SAEP-1160
2017
5/5/2008 5:42:59 PM
After completion of successful hydrotest dated 05.05.2008 in Package # 302, I was observed that one of the contractor hydrotest team did not know the safety requirements and procedure as per SAES-A-004 para 9.1 how to depressurizing the system. Without any instruction he loosens the bolts in 2diameter flange to release the pressure of 150 psi. To eliminate the risk in the future, contractor shall arrange a tool box meeting regarding the procedure and the above issued specially in hydrotest team. RFI # 20084 hydro test for package # 326, it was revealed that the hydro test was rejected due to the leak from the elbow and Tee. After evaluating, the leak was found in the material it self not in the joint. The contractor advised to conduct further investigation of this SO2 line since we encounter leak from module 20 to 22. We have now total five elbows and one Tee rejected due to leak on this line. RFI # 20961 Hydro Test of package # 781(30 dia RTR). Leak was observed after 2 hours and 40 minutes of holding the pressure, schedule for 4 hours test with 150psi in Line 496-01-UW-9508/29 sht 5 joint # 48. Visual inspection was carried out and crack was noted in the joint at 5 to 7 oclock position. Repair the joint and offer for inspection and re-hydro test the line. Several pipe spools are being installed without a controlled means of verifying that cleaning of the internal surfaces have been accomplished. Spools are also being stored without end caps. Some workers are using the inside of the piping to store there safety helmet, gloves & tools. The lack of Contractor or Sub Contractor QC piping personnel at site is a function of this proble. Implement SAIC-L-2017 (Piping / Equipment Internal Cleaning Inspection)Implement the use of a report to document that the pipe segments have been cleaned just prior to bolt up. Every site supervisor shall arrange & dedicate one worker in his area to be responsible for pipe cleanliness and end capping. Piping Inspector presence to be increased at site, for monitor and witnessing spool cleanliness & erection activities. All pipe installers shall do a better job of keeping the pipe clean inside. Conduct regular Tool Box meetings with pipe fitters and formans. As per my surveillance dated 07.04.2008 I noticed in module 20 to 28 that they are using ASTM A193 Grade B7 stud bolt between RTR to stainless steel flanges connection, as per drawing ASTM A 307 Grade B stud bolt shall be used. Austenitic materials such 300 series stainless steel shall be using the same type of bolt material to prevent contamination. I believed that the two type of bolt mentioned above is all carbon steel. During my site surveillance dated 24.03.2008, RTR flanges 36 at the back of module 20 to 28 were found a surface crack at the corner of the flange to pipe connection. It was also observed during installation of valve, that the contractor were not following the bolt tightening procedures and maximum torque for bolting on non metallic flanges as per SAES-L-610 par.4.3.1.C. They are manually tightening the bolt by hammering. In this matter as per 01SAMSS-034 Table 3 surface crack is not permitted. Therefore the contractor will issue a corrective action and offer for inspection on the following line: 49620-SW-0101/20 SHT5; 496-21-SW-0101/21 SHT5; 496-22-SW-0101/00 SHT1; 496-23-SW-0101/00 SHT1; 496-24-SW-0101/00 SHT1; 496-25-SW-0101/00 SHT1; 496-26-SW-0101/26 SHT1; 496-27-SW-0101/27 SHT1; 496-28-SW0101/28 SHT1. Contractor requested on 24.06.2008 for internal cleanliness verification of the line No. 496-01-TW-9602/90 and 496-01-TW-9616/32, 56diameter line before conducting hydro test. It was observed a bunch of sand and found 2 X 3 X 24 wood inside of the pipe. To avoid repetition of the above violation, contractor QC will conduct inspection before requesting PID for final verification. During my routine surveillance dated 01.11.09 @ 5:00PM it was observed in nitrogen area that NCC workers installing RTR line without qualification. As per SAES-S-070 para 8, Qualified personnel or installer shall be trained in proper handling and usage of applicable materials. PID informed SP QC supervisor and NCC manager site in-charge to stop working until qualified RTR installer were available at site but still they continued their job and they completed 9 joints 4 dia. and 3 joints 8 dia. Therefore PID advised to cut all the joints and raise RFI for inspection after completing the job.
SATIP-A-004-02
SAIC-A-2017
Mechanical
other
G.I.2.102
5.2.6
2018
6/24/2008 8:05:05 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.3
2019
7/12/2008 5:18:25 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.3
2020
2/24/2008 11:25:28 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3
Schedule Q
5.1
2021
4/8/2008 5:21:16 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
13
2022
3/25/2008 9:16:42 AM
SATIP-S-020-01
SAIC-L-2014
Mechanical
SAES
SAES-L-610
4.3.1
01-SAMSS034
Table 3
2023
6/24/2008 7:47:22 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3.2
2024
1/12/2009 8:12:03 AM
SATIP-S-070-01
SAIC-S-4054
Mechanical
SAES
SAES-S-070
2025
7/7/2008 8:38:07 AM
Instrument Air Installation Violations SAES-J-901: 1.Contractor requested for service test (Test Pac # 1206) for their instrument air line from existing (TIEIN beside Module 28) to QUAD 2. It was observed that line # 3-IA-92731SDOU was buried approximately 300 meters. Base in our standards SAES-J901 para 4.8.1.7 Instrument Air piping shall not be installed underground. However in exceptions, instrument air may be buried however they shall have low point drains. This exception item is documented in Test Pac # 1206, item # 5, it is an A item. 2. There is another Log Book entry on this matter at SS 20, IA 1 line for the diesel oil fuel tank. - Surveillance 12403. So far this is the only Test Pac (1206) that has this violation and no MCC has been signed. Service Test has been done on 1.5" .A.9011.CG0U air line Package#1311/1 , and leakage found in several joints. After that, PID notified to come again and check these joints after repairing and inspecting by the QC, but the PID found that the line was de-pressurized and the QC was making the test while there was no air(pressure) in the line. After pressurizing the line and inspected by the PID a leakage has been found again in the same line. this is a clear violation of SCHEDULE Q-1.3 1.3.that is CONTRACTOR shall be totally responsible for the quality of WORK required by this Contract. During routine inspection, it was noticed that the installation of suction piping for hypochlorite pumps have used a concentric reducer instead of eccentric type as shown on isometric drawing (496-L-BC-871430/ 871435/ 871447). This is a violation to the requirements of the standard to use eccentric reducer (with the flat on top) on the suction line (refer to SAES-G-005 para. 5.2.4) and also mentioned on Process Industry Practice PIP REEP004. Contractor is requested to rectify the installation and comply with the requirements of the Standards. PID has rejected the material receiving for the vinylester adhesive (ref. RFI26877)citing that there is no identification label and no batch certificate. However, it was learned that the Contractor continued to use the adhesive on the SO2 lines. Contractor is requested to clear the items prior to installation/ application. It has been found that the electrical conduit is supported by the instrument air line of 2 diameter which is the violation of SAES-L-350. Contractor is advised to rectify it as per Aramco Standard. Below is the relevant reference. SAES-L350 Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008 11.1 Welded attachment to the piping systems which irrelevant to the piping systems, such as those for electrical conduits, shall not be installed without prior permission by SAPMT in consultation the Chairman of the Piping Standards Committee. 11.2 The pipe shall not be used to support other pipes and structures without detailed calculations and prior approvals by SAPMT in consultation the Chairman of the Piping Standards Committee. During inspection at NCC Fabrication Shop, it was observed that some of the weld neck flanges sealing face lay directly on the ground. This violates 10.4 of 02-SAMSS-011 which states all flanges shall be protected from mechanical damage. Welding ends and sealing faces shall be protected with suitable wood or plastic or metal covers. Flanges shall be packaged in steel-banded wooden crates or secured to skids. Reference to Manufacturers recommendation of the Plastic Pipe Cement and based on Standard installation of PVC, a primer shall be applied on the PVC prior to the application of Pipe Cement. The purpose of the primer is to soften the contact surface of the material prior to the application of the pipe cement, to have a proper adhesion along the surface of the joint. The Raw Water line (496-01-RW-9695/90 and RW-9696/90) as per RFI-6403/ 6404, was installed in such a way that only a Pipe Cleaner was applied(no Primer) and direct application of cement. It clearly showed on several joints that there is no proper adhesion since there are gaps and bubbles visible between the joints. The installation (RFI 6403/6404) was rejected for failing to follow the standard installation of PVC. It is also noticed that the workers assigned are not skilled to handle the installation. Contractor has to rectify the installation and provide skilled workers to do the installation to avoid rework.
SATIP-L-350-09
SAIC-L-2080
Mechanical
SAES
SAES-J-901
4.8.1.7
2026
8/9/2008 4:08:44 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
2027
8/20/2008 7:39:00 PM
SATIP-G-005-01
SAIC-G-2005
Mechanical
SAES
SAES-G-005
5.2
2028
1/14/2009 9:05:49 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2029
3/29/2009 9:20:14 AM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-350
11.1
2030
9/8/2007 3:12:11 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
other
02-SAMSS011
13.2
2031
9/27/2007 6:41:13 PM
SATIP-S-070-01
SAIC-S-4054
Mechanical
SAES
SAES-S-070
2032
10/11/2007 1:09:02 PM
2033
11/9/2007 3:33:01 PM
2034
12/9/2007 12:21:39 PM
2035
2/2/2008 8:31:13 AM
2036
2/9/2008 4:17:41 PM
Despite the Proactive Surveillance (SUR-6652), the required 12mm thick x 150mm width neoprene tape was not provided on RTR trust block installation. PID has clearly defined in the Proactive Surveillance that the Contractor is required to comply with the recommendation of the PM Lessons Learned. The Contractor acknowledged the surveillance, however they did not prevent the pouring of concrete on the thrust block. Some elbows were wrapped with plastic sheets and others were covered with cement. This is a violation to SAES-S-070 para. 17.5, and it is a total neglect of the Standard Requirement. Project Management Lessons Learned issued regarding thrust block installation includes the following: INSP-094(Ensure Neoprene Tape Wrapping on RTR Pipe Joints at Thrust Block Locations) and NAPD-097(RTR Pipe Installation Considerations). Please refer to Saudi Aramco Library Drawing No. DB-950078 for Thrust Block installations. For Neoprene Tape,refer to SAMSS Stock Numbers 09-966-251/254/257. The FBE coated carbon steel riser for Fire Hydrants (H-23/ 24/ H-25) and Fire Monitors (FM-20/ 21/ 22/ 23) were connected to the RTR Fire Water Line using an uncoated stud bolts and washers. This is a violation to the requirements of SAES-L-105 p.190- Material Specification; and GA-E-60051Project Specification. Also, non metallic flanges shall be provided with matching coated washers. It was found out during surveillance 12/9/2007 that all coated (APCS 4) carbon steel pipe fittings such as Tees and Elbows has lost all traceability during coating. And this is violation of the following standard. SAES S- L-350 Para. 6..1 All pipe and fittings shall have the material specification and grade stamped, stenciled, or otherwise clearly marked with permanent marking method. And 01-SAMMSS-01 Fabricated Carbon Steel Piping. Paragraph 5. Material requirements. All materials supplied by vendors for piping elements or structural attachments shall conform to the applicable code and shall be traceable to mill Certificates. Material selection may further limit in this specification or in the Purchased Order. Used or Unclaimed materials of unknown specification are not permitted. Despite the Proactive Surveillance and verbal information. The contractor continued to install bolts/ nuts on flange connection without using the required washers (pictures attached on email). This is a violation to SAES S070 and SAES L-610 requirements. SAES S-070 Paragraph 10.7 states "Flat washer shall be used under nuts and bolt heads on non-metallic flanges". It was clearly specified also on SAES L-610 Item 4.3.1d "Washer shall be used for bolting non-metallic flanges". It has been observed that the Contractor have been installing/ pouring concrete pavement on module area without providing block out on installed underground pipe routes. The underground piping at Module Area have not been tested. Gravity test was initially done at Module 27 & 28 (RFI-12940) and the test failed due to considerable amount of water leakage. Contractor is requested to provide block out on underground pipe route (GS/ FW/ TW/ SW)before pouring concrete to avoid consequential problems later (like concrete cutting) should there be leaks on underground piping during testing. During Routine Site Inspection, PID noticed that a mitered fittings (elbows and tee) were field fabricated and have been connected to RTR spool. This is a violation to the requirements of the standard SAES-S-070 para. 11.6 "Field fabricated mitered fittings shall not be used". Contractor is requested to comply with the standard and use the required factory standard RTR fittings. Pressure testing at Module 21 SO2 piping (Line No. 496-21-C-0203/21 1FE0U5 Vinylester) reveals a leak on the fitting itself (2" and 1-1/2" elbow). It appeared to have a crazing (surface crack) on the elbow. The Subcontractor tried to repair the 1-1/2" elbow by lamination and subjected it to pressure testing the following day but still there is evidence of weeping/ leaking. PID rejects the pressure testing. Contractor is requested to replace the defective elbows and was informed that pressure testing of the above mentioned SO2 line will push through only if the defective elbows were replaced. During the hydrostatic test against the Test Pack No. QSWP/NCC/ HT-161 /TN 355, it was found that the due to increase in atmospheric temperature, pressure increased beyond the limit of set pressure of Relief Valve but it did not pop which is fatal for sfety of Aramco assets & it means that relief valve was out of calibration. Calibration certificate for such valve was verified which was done only a day before. Clarification is needed that how the calibration certificate had been issued by SAECO or it got out of calibration due to mishandling at site. Pls. investigate and acknowledge PID the reason & take the necessary action to over come this problem which must not be repeated.
NA
NA
Mechanical
SAES
SAES-S-070
17
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.5
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
6.1 & 6.2
SATIP-S-020-01
SAIC-L-2014
Mechanical
SAES
SAES-L-610
4.3.1
01-SAMSS034
Table 3
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
2037
6/2/2008 9:51:50 AM
SATIP-S-070-01
SAIC-S-4054
Mechanical
SAES
SAES-S-070
11.6
2038
6/4/2008 3:50:03 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.3
2039
6/5/2008 5:24:40 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
5.5.1
2040
7/9/2008 1:59:36 PM
Project inspection found out that no Mechanical Inspector for RTR piping on this date July 09, 2008. Inspector had left in site for vacation with out any replacement as required in Schedule Q Para. 5.11. The contractor shall advise the SA of such personnel who will be in vacation at least 30 calendar days in advance. It was confirmed and verified yesterday that the Contractor had used an expired adhesive/ catalyst (WELDFAST CL-200) in joining Vinylester Pipes. The adhesive Manufacturer clearly stated on their product label not to use the product after the specified expiry date. The Contractor warehouse was checked for the adhesive stock and found out that most adhesive for Vinylester pipe were expired. The issue was raised by PID and a meeting was held together with PMT and Contractor to discuss the issue. During inspection to NCC Fabrication Shop, it was observed that pipe supports are being coated and there is no QC qualified for coating, and as per Schedule Q, attachment IV, paragraph2.1 this is a violation. During the material recieving visual inspection of stainless steel fitting NPS 10x6 Ecc Red ASME B 16.9 ASTM A403W316L, It was noticed that the drawing shows 10x8 Ecc reducer and not showing 10x6 which the right because the tiein will be to 6" Existing pipe.The contractor shall revise the drawing no.Bc871362 to have 10x6 reduser instead of 10x8. Violation of dimensional roundness requirements specified in the following. 02SAMSS-005 para. 9.2 Visual Examination and Dimensional Check ,... Dimensions of the fitting shall be checked against ASME B16.9, The ovality was measured at one end of the 48 run and is out of round and exceeds the tolerance specified in Table 2 of ASME B31.9. Max tolerance 4.8 mm actual measurement was 21 mm this violates the max out-of roundness spec. The hydrotesting of 30" x600 gate valve(Tag NO.496-MOV-8830) manufactured by ORION was done and found unacceptable (heavy leakage observed through the upstream seat due to a crack on the gate seat area.This violate API 598 Para 4.4.3 and schedule Q Para 7.3.7.The contractor shall follow up with is issue and notify the manufacturer for repair or replacement. The hydrotesting of 24" x600 gate valve(Tag NO.496-MOV-8830) manufactured by ORION was done and found unacceptable (heavy leakage observed through the upstream seat due to a crack on the gate seat area.This violate API 598 Para 4.4.3 and schedule Q Para 7.3.7.The contractor shall follow up with is issue and notify the manufacturer for repair or replacement. It was noted during hydrotesting of Gate Valve, 8"-150 S/N 496-ZV-61455 failed the seat test. Continual leakage was observed in both directions. The Mfg is Orion from Italy also see failed valve entries from the same Mfg QMIS Surv-15704 and Surv-15699 56" Gate Valve failed seat test, linear indication in gate seat noted. Valve ID 496-MOV-8736 PO21724 Item # 1. See SAECO Cert No 70721170/223. SP to inform SA of any status updates. Biocide Pipe Spools Incorrect Line Class has been designated on the 316L pipe spools that were tested in the shop. 6SDOU was listed however 3SDOU should have been listed. Correct hydro test package and resubmit. RFI 15896 submitted yesterday (01.04.2008) witnessing the hydro test of package # 207, PID did not attend on this activities due to the package still not approve and review and walk through is required in order to check if the line constructed as per the drawing, reference SAIC-A-2010. Therefore the hydro test last night is rejected. It was noticed during routine inspection in the warehouse that 4 - 2 and 4 24 Class 150 metallic spiral wound gaskets did not have the designated color code on them, as per your Procedure PCP-M-03 Rev 01. This is a violation of your procedure PCP-M-03 Rev 01, Project Specification 496-L-BE-866653 Section 7, and Schedule Q-IV-3 para 3.2. 1. 12-SAMMS-007 par. 5.2.3.2 the Fabricator shall remove weld slag before galvanizing.Contractor to correct. Contractor shall provide assurance from galvanising sub-contractor by means of certificate of compliance, material specification is as specified in Purchase Order. 3. Provide detailed fabrication drawings specifying dimesions in order to do materials inspection dimension checking. Contrator installs baseplates at in his own risk, and they may be subject to removal. Contractor to provide corrective action for above items and notify SA upon completion for re-inspection. 2. 12-SAMMS- 005 par. 4.2 and 5.0 Material Markings. Metal products ordered to ASTM or equivalent other specification shall, as a minimum, be marked in accordance with such specification.
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
2041
7/9/2008 3:08:48 PM
SATIP-H-100-01
SAIC-H-2024
Mechanical
SAES
SAES-H-100
6.4
2042
8/28/2007 3:43:52 PM 11/25/2007 1:24:50 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2043
SATIP-L-350-01
SAIC-L-2006
Mechanical
SAES
SAES-L-350
2044
8/8/2007 11:11:35 AM
SATIP-L-350-01
SAIC-L-2006
Mechanical
other
02-SAMSS005
9.2
2045
4/22/2008 12:55:33 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
API 578
4.4.3
2046
3/29/2008 3:30:19 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
API 578
4.4.3
2047
3/30/2008 6:00:30 PM 4/1/2008 5:56:29 PM 11/10/2007 12:21:47 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
API 578
4.4.3
2048
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
API 578
4.4.3
2049
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-A-004
5.6.1
2050
4/2/2008 9:59:28 AM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-A-004
5.6.1
2051
3/4/2008 3:32:31 PM
SATIP-L-350-01
SAIC-L-2007
Mechanical
SAES
SAES-A-206
14.2.8
Contactor proc No PCPM-03, Rev 01
NA
2052
1/24/2007 4:04:27 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
other
12-SAMSS007
5.2.3.2
SAES-W-011
11.4.2
2053
1/24/2007 4:04:27 PM
SATIP-L-350-01
SAIC-L-2006
Mechanical
other
12-SAMSS005
4&5
2054
3/14/2008 8:08:03 AM
2055
9/21/2008 2:05:07 PM
2056
8/29/2008 11:40:37 AM
During final review of the package tie-in-004 i was found out that there were (4) four weld joints with Radiographic test reports were not mentioned in the history sheet attached in the package.The contractor did not showing this report for the reason was the result were all re-shoot due to high density and with porosity defect.This is a violation of our engineering procedure SAEP1160 and SAIC-A-2003 implementation of quality system on this project.This is an "A" punch list item. Package #604 in module 28 submitted on 20.09.08. Package reviewed and found line # 496-28-TW-0144/28 joint # 39 has a radiographic report RT32779 dated 09 April 2008. After my initial investigation the contractor did not mentioned this report in their history sheet for the reason that this joint 39 was radiograph in another joint not in actual joint (weldolet to flange joint). This is the second time that contractor providing radiographic report shooted in another joint not in the actual. SP shall make urgent investigation and submit to PID immediately. Package TP-759 suction header in 496-G-8201 line # 496-01-TW-9582/31 sht 3 rev 1 joint 23; As per submitted package the above joint was a radiograph report (RT-41929) with a reshoot status. I made an investigation of this joint with regards to the report which I noticed that elliptical shoot is not possible for the weldolet to flange joint. When i reviewed the radiographic film it was revealed that the are shooting in flange to pipe joint which is contradict in the actual joint. Contractor shall make urgent investigation on this matter and report to SAPID immediately. Piping: SP/NCC to provide record of weld repair, penalty, and re-shoot summary status. And provide schedule to rectify. During attending RFI # 4824 as per SAIC M-2006 Verification of Equipment Support Structure and Foundation @ 9:00AM as stated on RFI inspection date found out that Feed Pump already in foundation. The foundation is not acceptable and violates SAIC M-2006 item A7 which specified that the Top of concrete has been roughened (Std. Dwg. AA-036322-001) or chipped with hammer to remove laitance, oil-soaked or damaged concrete to the level of sound concrete or to a minimum of the top 1 inch (25 mm) of concrete. (PIP STS-03600, Para. 6.2.1.1 for Non-Shrink cement grout, and STS-03600, Para. 6.2.1.1 for epoxy grout). Sharp concrete edges are ground down (proper bearing) as per SAES Q 010 Sec 1V No notification given for cancellation of the weekly QC meeting. Start preparation for lamination, Grind the surface joint area, remove the top coating and V cut pipe end without JCC of personnel and not yet approved procedure and not issue RFI for that joints. Contractor have initiated a pressure testing for DW/ RW line serving Substation-06. The test was not able to hold pressure due to leakage. During re-excavation, the exact location of leak was discovered on the branch pipe riser of DW line. PID have noticed that the RTR branch pipe ground cover was only 300mm. This is a violation to the requirement of the Standard to have a minimum of 600mm ground cover (refer to SAES-S-070 para. 9.5/ Table2). Further checking revealed that the Contractor revised the drawing to have a branch riser near the main pipe instead of the original drawing were the riser goes up only near the valve box. Original drawing could have attained the minimum ground cover. Contractor is requested to rectify immediately the installation of DW/ RW branch pipe and comply with the "ground cover" requirement to avoid delay on asphalt works and other activities. Also, please give priory to the pressure testing of all underground DW/ RW lines for Substations. During surveillance @ 3:00PM 15/04/2007 pipe #0643S10009 GRP 54" connected to Joint # 16 line 496-01-SW-9303/90 RFI # 1134 lowered 160mm below Compacted level this will removed the compacted bedding requirement as per SAES S-070. A bedding layer of sand 150mm in depth is required for all trenches. The sand shall free of debris and rocks and compacted to at least 70 percent relative density in accordance with ASTM D4253 and ASTM D4254. During surveillance @ 3:00PM 15/04/2007 pipe # 0643S1031 connected to Joint # 16 pipe line designation 496-01-SW-9303/90 lowered 160mm to compacted level, this removed the compacted requirement of SAES S-070. A bedding layer of clean sand 150mm in depth is required for all trenches. The sand shall be free of debris and rocks and comppacted to at least 70% relative density in accordance with ASTM D4253 and ASTMD4254
SATIP-A-004-02
SAIC-RT-2010
Mechanical
SAEP
SAEP-1160
SATIP-A-004-02
SAIC-RT-2010
Mechanical
SAEP
SAEP-1160
SATIP-A-004-02
SAIC-RT-2010
Mechanical
SAEP
SAEP-1160
2057
3/24/2008 10:23:49 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
2058
8/22/2007 9:33:39 AM
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-010
2059 2060
4/13/2008 10:05:51 AM 3/18/2007 9:59:32 AM
NA SATIP-S-070-03
NA SAIC-S-4058
ScheduleQ SAES
Schedule Q SAES-S-070
1.2 8
2061
7/20/2008 9:33:55 AM
SATIP-S-070-03
SAIC-A-2015
Mechanical
SAES
SAES-S-070
9.5
2062
4/15/2007 4:27:35 PM
SATIP-S-070-01
SAIC-S-1005
Mechanical
SAES
SAES-S-070
9.14
2063
4/15/2007 4:50:49 PM
SATIP-S-070-01
SAIC-S-1005
Mechanical
SAES
SAES-S-070
9.14
2064
4/15/2007 5:30:20 PM
During my surveillance @ 4:00 PM 15/04/2007 2 NCC/PTS personnel Pumping Hetron 22 GRP resin in an storage with containing 3 drum of Hetron 22 to small container to be dilivered to intake. Storage manufacturing requirement for Hetron Stored to storage below 35 deg. Centegrade and This violates SAES S-70 section 5 para 5.4 and or 5.6 it shall be stored in enclosure where temperature do not exceed 38 deg. Centegrade Despite verbal communication with Contractor QC personnel to monitor and check RTR site installation with respect to raised RFI, there were several lapses being observed. To date there were 7 questionable RFIs (6400, 6312, 6399, 6863, 6861, 6908 & 6402) where some have curing/ heating result even the pipe field joints were not yet installed. When PID requested to monitor one critical field joint installation, the Contractor RTR QC personnel claimed he will inspect only at site if the subcontractor raised an RFI. This is a violation to Schedule Q Attachment I, IV and VI. Contractor is requested to investigate and review the scope work of your QC personnel. Saudi Aramco demands the normal presence/ visibility of Contractors Quality personnel to monitor Site installation and they shall be dedicated to their respective work assignment. The Contractoer is in violation of Sch Q para 5.11. He has failed to provide vacation relief for the Welding Supervisor Elango. The CONTRACTOR shall make quality personnel changes required due to vacations, illness, temporary assignments, emergency leave, resignations or other reasons as necessary to maintain required Quality coverage. CONTRACTOR shall advise the Company Representative of such personnel and quality coverage at least thirty (30) calendar days in advance of scheduled absences or changes and as soon as possible for other changes. During surveillance @ 11/29/2007 10:00AM to 11:30AM near Substation 30 QSWP pipe welding of 490-01-TW-9590/90 FJ 27 ; 56 diameter pipe 28.60mm thick found that pipe internal misalignment of more that 3mm 10 o clock to 2 0clock location and trim portion of misalignment that reduced the thickness of the pipe. This is violation of the following standard. SAES-W-011 9.3 Internal misalignment of butt joints shall not exceed 1.5 mm. Internal tapering in accordance with ASME B31.3 by machining, back welding, or a combination may be used to correct the misalignment. ASME B. 31.3 328.4.2 End Preparation (b) Circumferential Welds (1) If component ends are trimmed as shown in Fig. 328.3.2 sketch (a) or (b) to fit backing rings or consumable inserts, or as shown in Fig. 328.4.3 sketch (a) or (b) to correct internal misalignment, such trimming shall not reduce the finished wall thickness below the required minimum wall thickness, tm. routine site visit was done to NCC fabrication yard to inspect the welding process of the pipe supports.During the inspection of the welding consumables storage it has been noticed that the calibration for the temprature gauges attached to the welding rod ovens were expired.As per schedule Q attachment IV para 6.1,SAEP-1154 para 5.7.6.3 and SAES-W-011 tale A note 1 the calibration cycle shall not exceed six months.The contractor shall have all the gauges calibrated to maintain proper storage for the welding rods. SP shall submit SAFMI welding procedure plus weld table and SAFMI welders for approval. Also submit the assigned mechanical inspector/piping inspectors resume who is assigned to SAFMI. Aramco also requires RFIs for ongoing shop work. SAFMI job specific NDT procedures must be listed with the technicians job specific approvals. Undersize Welds on Pipe Supports;It was noted that some pipe supports installed at Module 20 appeared to have undersized fillet welds. It is requested that SP/NCC check these welds and itemize each deficient weld during punch listing/walk down and take corrective measures to rectify. At around 6:00 pm (29/06/08) SAPID was informed by the SLSA construction that the instrument line with the test package no. TP-066 (Instrument Air Line) was already pressurized and ready for inspection. During inspection on testing loacation, it was found that the hydrotest is not available on site and not approve due to the outstanding punch item in category A. this is a violation of GI 2.102 section 5.2 which stated that the test package shall be available to site and approved. In addition the contractor was not issued RFI pertaining to the hydrotest inspection activity.
SATIP-S-070-03
SAIC-S-4056
Mechanical
SAES
SAES-S-070
5.4
2065
10/18/2007 5:32:36 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3, Attachment IV & VI
2066
4/13/2008 8:04:26 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
2067
11/29/2007 1:13:09 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
9.3
2068
7/14/2007 1:13:20 PM
SATIP-W-011-01
SAIC-W-2011
Mechanical
SAEP
SAEP-1154
5.7.6.3
SAES-W-011
Table A, Note 1
2069
12/8/2007 3:24:47 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7 & 3
2070
3/26/2008 12:01:03 PM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1
2071
6/29/2008 7:15:20 PM
SATIP-A-004-02
SAIC-A-2013
Mechanical
other
G.I.2.102
5.2
SAES-A-004
5.6.1
2072
6/29/2008 7:15:20 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
2073
3/3/2008 11:22:49 AM
SAPID found out that structural steel members were already installed at modified cable tray pedestal (CT E17A E19A) without compressive test reports submitted while the curing is on process. The pedestal was poured only last February 28, 2008 which is a clear violation to SAES-Q-001 paragraph 10.3 and SAIC-M-2006 item A3 which states that concrete foundation has reach the curing period up until the compressive strength has reach 70% of the specified strength, but not less than 7 days after placement, also no RFI submitted for inspection of support foundation prior to structural installation which is a violation to SATIP-M-001-01. The QC manager of SLSA Mr. Ben Hamida Sadok has gone for emergency leave on the 3rd of February with out advance notice with the Saudi Aramco representative on site. He is temporarily replaced by Mr. Mariappan to act as QC manager, however he is also working as a mechanical inspector at the same time which is creating a vacuum on the position of QC manager. This is in violation of schedule Q. para 5.11 requiring the contractor to advise the company representative 30 days in advance in case of vacation or emergency leave and etc. Moreover the QC personnel who will take over the vacated position shall be dedicated to the work and shall perform no other function on the present contract as require by schedule Q para 5.6. During Construction surveillance @ 3:15 PM 22 March 2008 found contractor continue hydro test of Test Block 327-105-014 Test Package TP 026-A (4 FG Vent) & Test Block 327-105-013 Test package TP-025-A (Vent Stack System) even there is Pro-active violation in QMIS with # 15439 that as per SAES A004 Para. (7.1.5.b) All gauges shall have a range such that the pressure test is within 30% to 80% of the full range. Pressure test with 450 psig, use gauge with # 08068049 Ref # M40-001 (3092000141-054) has 0-10,000 psig & 2nd gauge with # 08086054Ref # M40-001 Z-M-GPE 0735-94 has range from 01600 psig. Construction continues hydro testing activities without participation of SAPID. During attending RFI # 15432 & RFI # 15430 found that 4 150# Gate Valve2 units installed in 4-BD-1002 Line found no ID/Tag for field hydro test accepted as per SATIP L- 108-01 Item 2 develop list is tracked for all valves (field test or not) is given a unique ID # (Examine & Accept) & tracked through construction process. Pro-active violation with this requirements e-log in QMIS # 15168 & 4-BD line including this two valves hydro tested with another violation e- log in QMIS # 15439 During SAPID routine site visit it was found out that sun shade parking shelter structural members were already installed without any information/RFI given to SAPID which violates the schedule Q, attachment IV para. 1.2.3, SATIP-M001-01 & SAIC-M-2006. Furthermore, the installed structural members do not have a materials receiving inspection which violates the SAIC-M-2004 & 12-SAMSS-007 para. 7.6. During SAPID routine site visit it was found out that sun shade parking shelter structural members were already installed without any information/RFI given to SAPID which violates the schedule Q, attachment IV para. 1.2.3, SATIP-M001-01 & SAIC-M-2006. Furthermore, the installed structural members do not have a materials receiving inspection which violates the SAIC-M-2004 & 12-SAMSS-007 para. 7.6. This violation was previously entered on the system last August 20, 2008 but due to system problem the entry was disappeared. During SAPID routine site visit it was found out that sun shade parking shelter structural members were already installed without any information/RFI given to SAPID which violates the schedule Q, attachment IV para. 1.2.3, SATIP-M001-01 & SAIC-M-2006. Furthermore, the installed structural members do not have a materials receiving inspection which violates the SAIC-M-2004 & 12-SAMSS-007 para. 7.6. This violation was previously entered on the system last August 20, 2008 but due to system problem the entry was disappeared. During SAPID routine site visit it was found out that sun shade parking shelter structural members were already installed without any information/RFI given to SAPID which violates the schedule Q, attachment IV para. 1.2.3, SATIP-M001-01 & SAIC-M-2006. Furthermore, the installed structural members do not have a materials receiving inspection which violates the SAIC-M-2004 & 12-SAMSS-007 para. 7.6. This violation was previously entered on the system last August 20, 2008 but due to system problem the entry was disappeared.
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-001
10.3
2074
2/5/2008 11:38:58 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.14
2075
3/22/2008 4:53:11 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
8.1.5.3
2076
3/22/2008 5:30:32 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7
2077
8/20/2008 4:47:51 PM 8/20/2008 4:47:51 PM 8/24/2008 11:40:37 AM 8/24/2008 11:40:37 AM 8/24/2008 11:49:08 AM 8/24/2008 11:49:08 AM 8/24/2008 11:51:45 AM 8/24/2008 11:51:45 AM
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2078
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2079
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2080
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2081
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2082
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2083
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2084
SATIP-M-001-01
SAIC-M-2003
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2085
2/17/2008 8:57:12 AM
During receiving inspection of Dosing Skids for Aindar, it was noted a crack on the mounting lug on dosing tank (327-D-1000-B). SAIC-D-2015 item A3 for receiving inspection of tank requiring that the tank shell and its appurtenances Violationhas no signs of physical damage such as dents, gouge, cracks, etc. This Prevented concern was entered in QMIS to prevent the installation of the Dosing skid Installation and to issue a OSD (Over, Short, Damage) report by the contractor to be submitted to equipment vendor for proper disposition and corrective action. SAPID has noticed that a modification has been done on one of the anchoring base plate of the potable water tank (327-D-4002) with out any approve technical query or change order from SAPMT. The contractor was modified the base plate by enlarging the hole to fit with the coordinates of the anchor bolts, moreover a two square washer was placed on top of the base plate as clip. This is a violation of approved construction drawing for the potable water tank. SAPID noted that the Air reciever drum D-0100 and the Knock out drum D0717 was emptied of nitrogen gas preservative. This is violartion of schedule Q para 5.0. Contractor shall immediately restore the nitroge preservation on these two tanks. Contractor SLSA and MMG was carried out a modification on mounting bracket of Pump 327-G-311 (cut and reweld) reducing the height by almost 40mm without any approval from the vendor or technical query approved. The said modification is also consist of different documnetation such as welding procedure, repair procedure and coating materials needed to restore rust protection of the skids requiring a SAPID approval which is the contractor failed to provide. This is a violation of vendor (Sulzer) drawing 1-104.430.2983/3 and scchedule Q attachement IV para. 4. Contractor shall secure vendor and Aramco Enginnering approval and all necessary related quality documents as earlier mentioned before to resume the modification. Lube Oil flushing has been completed on CGT-6001 with out any inspection offered to SAPID. Refering to SATIP-G-115-01 item 4.3, the flushing activity is a hold point for both in contractor and SAPID. Contractor shall comply with the stage wise inspection requirement of applicable SATIP for Gasturbine and Pumps erection (CGT-6001/5001/311). During surveillance inspection on pipe sleeper area at Aindar WIPS, it was found that all the bearing plate weld surface area has already been touched up by paint with out inspection from SAPID. The RFI has been initially raised, however it was rejected since the subcontractor (ICC) could not able to provide the calibrated instrument (hygrometer) Contractors SLSA and ICC violated the project schedule Q attachment IV section 6.1 requiring the contractor shall calibrate all measuring devices used for controlling quality. Without calibrated hygrometer, the contractor failed to provide the accurate environment condition as required by SAES-H-100 paragraph 8.1.1. not even a material certificate of the paint The contractor also violated SAES-H101 paragraph 4.2 requiring the material data sheet or batch certificate of the coating materials for verification. nor having a QC to check the activity. It was found out that during attending RFI # 6236 @ 10:30 AM 10/7/2007 MMG Abrasive blaster has no Job Clearance Card and not approved by Saudi Aramco and this is violation of SCHEDULE Q ATTACHMENT IV PARA. 2.1 The following special processes (Coating) require Saudi Aramco approval of personnel qualification (as per special process Table Personnel Qualification Approval required (YES). It was found out that during attending RFI # 6236 @ 10:30 AM 10/7/2007 MMG start sandblasting for liquid painting preparation on fabricated items without Approved Coating Procedure and this is violation of SCHEDULE Q ATTACHMENT IV PARA. 2.1 The following special processes (Coating) require Saudi Aramco review and or approval of work procedures. (Work Procedure Approval)(A). The contractor (SLSA) and Sub-contractor (MMG) was started the repair of the spots burn on internal FBE coating (nearby girth weld) on fabricated spools for WIPS at MMG yard without any repair approved procedure nor a qualified repair crew. This is a violation of schedule Q attachment IV which is stated the coating as special process shall require the review and approval of both procedure and personnel involving on the job.
SATIP-D-109-01
SAIC-D-2015
Mechanical
other
32-SAMSS030
3.8.1
2086
2/13/2008 3:08:36 PM
NA
NA
Mechanical
Drawing
Drawing#
Not available
2087
6/2/2008 1:21:40 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2088
9/20/2008 1:12:10 PM
NA
NA
Mechanical
Drawing
Drawing#1104.430.2983/3
NA
2089
6/27/2008 11:53:34 AM 1/15/2008 3:19:25 PM
SATIP-G-115-01
SAIC-G-2015
Mechanical
SAES
SAES-G-116
2090
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
2091
1/15/2008 3:19:25 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
7.1 of Attachment IV
2092 2093
1/15/2008 3:19:25 PM 1/15/2008 3:19:25 PM
SATIP-H-100-01 NA
SAIC-H-2024 NA
SAES ScheduleQ
SAES-H-100
3.1 5.1
Schedule Q
2094
10/7/2007 1:30:27 PM
SATIP-H-100-01
SAIC-H-2010
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2095
10/7/2007 1:46:21 PM
SATIP-H-100-01
SAIC-H-2023
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2096
2/6/2008 8:27:43 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2097
10/21/2007 1:38:37 PM
It was found out that during attending RFI last October 20, 2007 with the following RFI number RFI # 6786, RFI #6787, RFI #6791, RFI# 6796; @ 10:00AM that Painting jobs are on going on fabricated pipe support structures and pipes without approved Coating procedure at site and this is violation of SCHEDULE Q Attachment IV Para 2.1 and Attachment VI section 5 modification of Schedule Q for Attachment IV table Para. 2.1. This violation second and replaced SUR 6276 wherein painting jobs stop due to another welding violation It was found out that during attending RFI # 6236 @ 10:30 AM 10/7/2007 MMG start sandblasting for liquid painting preparation on fabricated items without Abrasive material receiving inspection as per SATIP H-100-01 & SAIC H-2024 Receiving Inspection of Abrasive materials. During surveillance inspection at Aindar site (Feb. 13 08), it has been noticed that the 2 blow down external FBE coated spools connected to CGT-6001 is already backfilled without any inspection done. The last inspection raised to SAPID regarding this spool was the post weld inspection of girth welds, this only means that the girth welds are not yet coated nor holiday tested prior to burial. This is a clear violation with our project specification referring to isometric drawing requiring for the 2 BD-1894-1CS9-N shall be fully FBE externally coated. Contractor shall expose the entire backfilled pipes and follow the SATIP-H-002-02 for coating inspection requirements. This is also a violation to SAES-H-200 section 7 requiring the externally coated pipes to be 100% holiday tested prior to burial. Contractor SLSA and MMG was carried out painting on modified mounting bracket of Pump skid 327-G-311 by overcoating the existing paint without any raising RFI for inspection required. This is a violation of schedule Q para 1.8 and SATIP-H-100-01. The opposite side of the brackets (internal side of the skid beam) is also required to be painted since it will be embedded to grout. The paint to be use for the restoration of skid protection shall be same brand as the origanal coating as required by SAES-H-100 para 7.5 which also the contractor failed to comply with. Contractor shall follow the inspection required by SATIP-H-10001. Piping spools in which the girth welds are being internally coated by ARC coating system was released to site from MMG fabrication without a final holiday testing witnessed by SAPID. With reference to SAES-L-100 para. 8.2.6 requiring all the structures for immersion service to be holiday tested.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2098
10/7/2007 1:57:34 PM
SATIP-H-100-01
SAIC-H-2024
Mechanical
other
09-SAMSS060
5.1 & 5.2
Schedule Q
A IV Para 3.3
2099
2/13/2008 1:42:01 PM
SATIP-H-002-02
SAIC-H-2018
Mechanical
SAES
SAES-H-200
2100
2/13/2008 1:42:01 PM 10/25/2008 4:45:18 PM
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
2101
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
2102
10/25/2008 4:45:18 PM
SATIP-H-100-01
SAIC-H-2032
Mechanical
SAES
SAES-H-101
4.2
SAES-H-100
7.5
2103
1/21/2008 4:33:17 PM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.2.6
2104
1/21/2008 4:33:17 PM
2105
2/27/2008 7:46:42 AM
2106
3/22/2008 5:43:51 PM
In addition, the spools were also not inspected prior to release which is also violated the Aramco project schedule Q attachment III para. 3.14 requiring the contractor to submit all the manufacturing test reports. Contractor is advised to return all the spools to MMG Dammam for inspection. List of the spools; BBViolation918267-5 TW-10481-D, BB-706468-9 TW-10440-B, BB-706467-6 TW-10439-D, After The BB-918267-7 TW-10481-A, BB-700468-9 TW-10440-C, BB-918267-7 TWFact 10481-B, BB-706468-9 TW-10440-A, BB-706467-3 TW-10439-B, BB-918267-3 TW-10481-G, BB-918550-3 TW-1259-E, BB-706468-8 TW-10440-B, BB-7064675 TW-10439-C, BB-706467-3 TW-10439-D, BB-706467-6 TW-10439-B, BB706468-4 TW-10440-B, BB706467-5 TW-10439-D. It was found out that during Document review of Positive Material Identification (PMI) result with REPORT Number AV-SF-864 ,JOINT Number SW-01 BM2 Pipe, BB-706412 -006-A as per SATR-A-2012 requirement, the ViolationCarbon content exceed the acceptable ranges at specified range of values as After The per SAES-A-206, Para. 10.1. Contractor and Sub-contractor QC accepted and Fact sign the report. This is violation of SCHEDULE Q Para. 5.5 & 5.6 Contractor must be technically competent to perform their duties and shall be dedicated to the work. It was found out that during Document review of Positive Material Identification (PMI) result with REPORT Number AV-SF-961 , JOINT Number PSW-03 WM Pipe, BB-706411-001-RL2 as per SATR-A-2012 requirement, the Carbon content exceed the acceptable ranges at specified range of values as Violationper SAES-A-206, Para. 10.1. Contractor and Sub-contractor QC accepted and After The sign the report. This is violation of SCHEDULE Q Para. 5.5 & 5.6 Contractor Fact must be technically competent to perform their duties and shall be dedicated to the work. This is the second time violation as per QMIS # 14233 which corrected by re-shoot the spool involve but QC personnel liable to this violation the contractor has failed to action. SAPID noticed that no prepared hydro test package by the MMG and SLSA for the valve testing at SAECO test shop at Al-Khobar. Moreover the QC inspector assigned by MMG for the testing is not having approval from SLSA and SAPID. ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
A III Para 3.22
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
10.1
Schedule Q
5.5 & 5.6
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
10.1
Schedule Q
5.5 & 5.6
2107
4/24/2008 5:55:33 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
2108
4/24/2008 5:55:33 PM
This is a violation of schedule Q attachment VI para U which stated that the hydro test package shall be submitted prior to the test. Contractor and subcontractor shall comply with the requirement of schedule Q SAPID noted that some of the thrteaded connection joints for the instrument air network lines are having more than 3 externally exposed threads which is giving a doubt on the lackness of the internal thread engagement . This is a violation of ASME B1.20.1 table 2 which is the exposed threads shall be limited only to 3.5 and internal threads minimum engagement of 8 threads for 3 & 2.5 NPS. To verify the compliance of the inside thread engagement, the 100% RT shall be implemented. Surveillance inspection has been made at MMG stainless steel fabrication in Nov. 21 07. Fittings such as elbows, flanges and wear pads were seen placed indiscriminately around the area and some are placed directly on the concrete floor, some are mixed with consumable items such as used abrasive wheel, rugs & etc. A 4 elbow was noticed clamped using carbon steel tool. This is a violation of SAES-L-350 para. 7.3 & para. 8.1. and SAES-W-016 para 4.3. SAPID noted that the 6 Lube oil piping were already bolted with the inlet and outlet flanges of Lube oil cooler both for GT-6001 and 5001 which is caused to released the nitrogen preservation inside the bundle tubes. This is a violation of schedule Q attachment IV section 5. Contractor shall restore the nitrogen preservation on Lube oil bundle tubes and conduct a preservation schedule inspection as per approved contractor procedure. SAPID noticed that bolt torquing has been started on 60 treated water header line without raising RFI to PID. Furthermore the subcontractor is using a tensioning machine (Hi-Force) which is not approved by SAEP-351 nor having a conversion table to verify the required torque (from SAP-351) to the actual machine pressure setting. Contractor shall comply with the requirements of SAEP-351 and SATIP-L-35001 item 3.10. It has been observed during the assembly of discharge pipes and its instrument connection valves at CGT-6001 & 5001 that a contractor(SLSA) and Subcontractor (MMG) is not conducting cleaning on the flanges faces prior to installation and insertion of the gasket. The protective coatings are still visible on the seating surface of the flanges that may cause poor sealing capability. This is violated SAEP-351 para 4.3 stated the cleaning of the flanges faces and shall be free from coating material for sealing purpose. Contractor shall conduct a full close monitoring on this activity and shall also raise RFI to SAPID for cleaning verification prior to installation of gasket to all flanges connection. It was found out that during attending RFI # 6202 @ 9:30 AM 10/7/2007 MMG using Positive Material Identification Control Procedure # QCD -3-028 approved by SLSA with reference # 084255-SLS-MMg-DRR-039 without Approval of Saudi Aramco and this is violation of SCHEDULE Q ATTACHMENT IV PARA. 2.1 The following special processes (Alloy Verification PMI) require Saudi Aramco review and or approval of work procedures. (Work Procedure Approval)(A). It was found out that during attending RFI # 6202 @ 9:30 AM 10/7/2007 MMG using Positive Material Identification Control Procedure # QCD -3-028 approved by SLSA with reference # 084255-SLS-MMg-DRR-039 without Approval of Saudi Aramco and this is violation of SCHEDULE Q ATTACHMENT IV PARA. 2.1 The following special processes (Alloy Verification PMI) require Saudi Aramco review and or approval of personnel qualification (as per special process Table Personnel Qualification procedure Approval required (YES), Personnel Qualification Approval required (YES During surveillance inspection at site (April 17 08), it is observed that there is no available welding inspector on site as well as the piping inspector for both contractor (SLSA) and subcontractor (MMG). There are present one (1) approved welding and one (1) piping inspector from MMG, however they were being utilized for the preparation of hydrotest packages. The contractor SLSA doesnt have also approved piping inspector. This is violation of schedule Q attachment VI section 2. Contractor (SLSA) and subcontractor (MMG) shall comply with the requirements of inspectors as required by schedule Q. section 5 para 5.1 and 5.2.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Para 4.13
2109
6/29/2008 7:17:16 PM
NA
NA
Mechanical
ASME B1.20.1
Table 2
2110
11/22/2007 1:21:20 PM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.3 & 7.5
SAES-W-016
4.3
2111
4/29/2008 11:30:07 AM 4/29/2008 1:19:23 PM 4/29/2008 1:19:23 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2112
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
2113
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4, 5, 6 & 7
2114
5/22/2008 10:55:08 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
2115
10/7/2007 1:08:22 PM
SATIP-L-350-01
SAIC-L-2004
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2116
10/7/2007 1:11:15 PM
SATIP-L-350-01
SAIC-L-2004
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2117
4/17/2008 5:04:36 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
Schedule Q
A VI Para 2
2118
5/17/2008 1:09:38 PM
Surveillance inspection noted that the 1 socket joint (swage to flange) was welded without providing space for thermal expansion (Dwg. # BB-653218001 rev. 00E, 2-LO-1222-001A). This is a violation to SAES-L-110 para 5.2.3 which is requiring the axial gap between male an female component prior to welding shall be 1.5 to 3.0 mm as shown in ASME B31.3 figure 328.5.2C. This is the second time to highlight this problem in which the first occurrence having surveillance no. 17322. To ensure the compliance of socket welded joint with the requirements of aforementioned standard, the contractor shall conduct a 10% radiography (including interconnecting piping on CGTs) on the basis of welders daily production output. Radiography result will be submitted to PID for verification. SAPID noted the blow down line 2-BD-14894 (transition section) was fixed by poured concrete pavement on CGT-6001. This is violation of SAES-L-350 which stated that the transition of metallic piping from the above ground to under ground shall not be encompassed by concrete or asphalt. A minimum of 1 foot annuals of sweet sand capped with aggregates shall be surrounded the transition section. SLSA shall proceed with the corrective action. RFI 23266 & 23269 has been raised to SAPID for the inspection of locally purchased 30 Octagonal gasket with LMRR-590-1 & 603. Further verification was carried out by SAPID and revealed that our project specification (doc. # 017239-0000-ES-4600-06) material requirement for the gasket for line class 15LE0P, 15LE0P6, 15LE0P7, 15LE0P8 is stainless AISI316. This is violated the above mentioned project specification and schedule Q attach. III Para 3.14. These gaskets under LMRR-590 & 603 (38 nos.) shall be rejected and quarantine for proper disposition. Upon inspection and document verification, it was found that the material S321 (stainless) is not having a PMI report and material disposition report prior to release for shipping. January 03 2008; During surveillance inspection for fabrication of underground piping spool for WIPS at MMG, it was noticed that the externally FBE coated fittings and pipes were not having a material specification stamp on it or no traceability of the material at all during the fabrication. This is a violation from schedule Q attachment 4 para 3.2 & 3.3 requiring that any materials as specified in Saudi Aramco standard shall be traceable throughout the fabrication. SAES-L-350 para 6.1 and 09-SAMSS-89 para 12.1 also specified that Pipes shall have the material specification and grade stamped, stenciled, or clearly marked with a permanent marking method. Further verification also found that the coated materials were issued and fabricated as spool without receiving inspection when received from Al-Qahtani pipe coating. SAPID has noted a 56 x WT. 0.750 and 42 x 0.562 elbows with heat number 686663 and 603629 respectively are having pittings in different location on the internal surface. This is a violation of schedule Q attachment 4 paragraph 2.4 requiring all incoming materials for visual inspection to ensure free of any defects upon received. Contractor is requested to segregate the two rejected elbows for further investigation and disposition. Piping spools which was fabricated at MMG has been shifted to Uthmaniya and Aindar WIPS with out any inspection nor RFI offered to SAPID prior to release. Shipment of spools from MMG fabrication shop to sites without inspection is a violation of Saudi Aramco project schedule Q attachment III para. 3.14 and SATIP-L-350-08 item 4.1 which requiring the contractor and subcontractor to submit the manufacturing test reports as specified on each form SA-175. The contractor shall review and indicate its acceptance of these inspection records prior to issuing the inspection release (or shipping). RFI number 17142 has been raised to SAPID for inspection of Support Foundation prior to erection for 327-GT-111 lube oil cooler. Inspection noted that there are no anchor bolts installed which is violated the IFC drawing (BA579371-012 rev. 00F) and applicable SAIC-L-M-2006 requiring the inspection of anchor bolts alignments. This is also a violation for contractor mechanical inspector (Marriapan) from schedule Q para1.3 and 1.4 stating that it is his responsibility to inspect test and accept any work in compliance to IFC drawings, specification or standards. RFI shall only be raised to PID if the inspection points is ready after verification by the contractor QC and SAPMT as stated in SAEP-1150 para 8.9.1. Surveillance inspection found that uncoated shim plates were used for the vertical elevation alignment of exhaust stack for CGT-6001 and 5001. This is violated PIP-REIE686 para 3.9.1.1 stated that mounting plate shall be blasted to near white metal and then to be immediately coated with a grout compatible coating. Contractor shall comply with this requirement.
SATIP-W-011-01
SAIC-W-2037
Mechanical
SAES
SAES-L-110
5.2.3
2119
7/11/2008 11:08:30 AM
SATIP-L-350-01
SAIC-L-2019
Mechanical
SAES
SAES-L-350
16.4.1
2120
8/1/2008 10:50:20 AM
NA
NA
Mechanical
Scope
Proj spec # 017239-0000ES-4600-06
NA
2121
8/1/2008 10:50:20 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A III Para 3.23
2122
1/3/2008 4:23:42 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 4
2123
1/3/2008 4:23:42 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.2 & 3.3 of Attachment IV
2124
2/13/2008 2:52:05 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2125
1/20/2008 11:20:37 AM
SATIP-L-350-08
SAIC-L-2038
Mechanical
ScheduleQ
Schedule Q
A III Para 3.22 & 3.23
2126
4/20/2008 1:25:25 PM
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.8
2127
4/29/2008 11:10:49 AM
SATIP-M-001-01
SAIC-M-2007
Mechanical
other
PIP-REIE686
3.9.1.1
2128
8/20/2007 11:45:50 AM
During surveillance @ 10:00AM 8/20/2007 found out that Air cooler Heat exchanger for CGT 6001 already installed and grouted the foundation without RFI for the following installation requirement as per SATIP M-001-01. 1.0 SAIC M-2006, Inspection of support foundation prior to structural or equipment installation. 2.0 SAIC M-2007 Structural Alignment prior to grouting. During surveillance inspection on site SAPID noted that the length of the installed anchor bolts on Fuel Gas Skid 327-D-6010 is only having a 150mm length. This is violated the equipment vendor IFC drawing 05.274-AM-ME-409 sheet 001 requiring the embedded bolt length of 230mm from the top of concrete. Contractor is requested for immediate corrective action regarding on this matter. RFI # 5833 request 9:35:12 AM dated September 30, 2007 and Inspection time is 1:30 PM of the same date, this is violation of SAEP 1150 Para 8.9.2.1 (RFI Timing); At least 24 hours for week days or 48 hours for week ends/holidays prior to the required for inspection. It was also found out that during material receiving inspection of RFI # 5833 @ 1:30 PM 9/30/2007, the anchor bolt does not as per Saudi Aramco Standard drawing AB-036322 Sheet No. 001 (Rev. No. 7) and this is violation with 12 SAMSS -007 Para 4.8 & 4.9 states that Anchor Bolt Assemblies shall be in accordance with Standard Drawing AB-036322 Sht. No. 001 (Rev. No. 7 or later) The drawing they are using is not approve IFC drawing and most of the bolts already installed. During surveillance @ 7:30 AM 8/22/2007 found that foundation for Air cooled heat exchanger altready grouted and this is violation of Saudi Aramco Standard as per 12 SAMSS-008 Erection of Structural and Miscellaneous Steel Section 1 specified that the Process Industry Practice PIP STS05130 in its entirety except as modified by this standard shall constitute the basis of this standard. The procedure of setting base plates is not as per PIPSTS05130 Section 6.4 para. 6.4.1 Specified that The erector shall clean the top of bearing surface and the bottom of the base plates. The erector shall set and shim column base plates to correct positions, elevations and locations as shown on the erection drawing. Shims or wedges may be used and shall provide by the erector. If setting nuts are used, they shall be loosened before grouting. High welders rejection rate of 2.19 percent by linear basis as well as the project weld rejection rate of 10 percent by joint basis on field welds has been recorded on weld rejection report dated April 5 to 8 in all WIPS sites. This is violation of SAES-W-11 para 8.4 and SAEP-1140 para A.10.5 states that the welders should not exceed with 2 percent rejection by linear and the project weld rejection rate shall not exceed to 5 percent respectively. Contractor shall implement the 50% coverage on radiography to all sites (Aindar, Uthmaniya, Hawiya, Haradh) including MMG fabrication shop as per the provision of SAESW-11 para 17.5.2. It was noticed that the piping materials such as elbows, pipes, flanges are just place on the concrete flooring during spools fit-up. Furthermore, some of the tacked spools as well as welded with flanges were stored facing directly on the concrete floor without any protection which is violated SAES-L-350 sec 7. & 8 and 01-SAMSS-10 sec 10.4. The QC responsible at MMG fabrication was already informed verbally in this matter previously and still no action has been taken. The contractor (SLSA) and subcontractor (MMG) has started the welding of 60 dia, pipe with wall thickness of 1.312 on spool 423-TW-10480-05-A (BB918266-05) and 327-TW-10480-004-A (BB-918260-004) joint # 009 and 002 respectively with out approved welding procedure. This is a violation to SAESW-012 para 7.1.5 stating that welding shall not commence until the welding package has been approved for application by Saudi Aramco inspector and returned to the fabricator. Contractor is immediately advised to hold further welding activity on the said pipes until the procedure and welders get the approval. The two welded joints shall be 100% x-rayed and the result shall be submitted to Aramco RTFI for assessment. Furthermore, the welders are not qualified for the said thickness. With reference to drawing # BB-918338 sheet 01, the joint SW-4 was requested for radiography in Nov, 12 07, however there was no available report from MMG file. The spool was inspected and found the joint (SW-4) is having arrow mark, which means NDT has already done. This is violated SAICW-2016 item B1, Schd. Q attach. VI para. 2.7. SLSA shall investigate all requested joints if completed the NDT from the start of fabrication. Missing NDT reports and films shall be submitted to PID for verification.
SATIP-M-001-01
SAIC-M-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2129
7/1/2008 5:25:50 PM
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.8
IFC drawing 05.274-AMME-409 sheet 001
NA
2130
10/1/2007 7:33:54 AM
NA
NA
Mechanical
SAEP
SAEP-1150
8.9.2
2131
10/1/2007 7:33:54 AM
SATIP-M-001-01
SAIC-M-2021
Mechanical
other
12-SAMSS007
4.8 7 4.9
2132
8/22/2007 9:56:17 AM
SATIP-M-001-01
SAIC-M-2021
Mechanical
other
12-SAMSS007
Section 1
2133
4/14/2008 4:03:15 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1140
A.10.5
SAES-W-011
8.4
2134
11/12/2007 8:13:55 AM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
7.3 & 7.5
01-SAMSS010
10.4
2135
1/13/2008 9:52:10 AM
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-012
7.1.5
2136
1/13/2008 9:52:10 AM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-012
2137
11/24/2007 4:21:42 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
A VI para 2.7
2138
11/24/2007 5:03:55 PM
Two welders with symbol L-109 & O-041 were found performing welding and tacking at structural and stainless steel materials respectively without Job Clearance Card. This is violation of sched. Q attach. VI para 2.1 which requires welding personnel an approval from Aramco prior to start the work. Welds made by L-109 shall do 100% MPI and all joints tacked by welder O-041 shall be re-fit up by qualified welders. Last September 6, 2007 MMG Start welding activity at MMG Fabrication Shop. Contractor has no approved RTFI Technician, as per Schedule Q Attachment I Para 3.3.15.2 As per Schedule Q Attachment IV Section 2 Special processes such as welding & NDE require work procedure approval and personnel qualification approval. Schedule Q Attachment IV para. 7.3 Contractor shall review/witness and accept result of all NDT performed by subcontractor and submit the test result to company and RTFI Technician is required. It was found out @ 10:00 AM 10/01/2007 that Welding activities are continue done in MMG Fabrication shop at Dammam even there is existing violation as per SUR # 4656 & SUR # 4779, There is violation against SCHEDULE B Para 3.30.7.1. & Saudi Aramco SATIP W-011-01 General Notes is not followed; it is stated that the first three of each inspection or testing activity listed require 100% participation of Saudi Aramco Site Inspection personnel. After this period, Saudi Aramco inspection may adjust the levels of Saudi Aramco participation based upon the Contractor performance.
SATIP-W-011-01
SAIC-W-2035
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2139
9/8/2007 6:04:11 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.3.15.2 of Attachment I
2140
10/1/2007 5:13:06 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
other
Schedule B
3.30.7.1
2141
2142
2143
2144
2145
2146
It was found out that during attending RFI 6236 @ MMG Steel FactoryDammam that Fabrication of Steel Structures already started and completed some structures for pipe support and delivered to Sand blasting and Painting; as per SATIP M-001-01 AWS D1.1 Pre-welding Inspection, In process welding inspection, and Post welding inspection is required using SAIC M2012. With reference to drawing # BB-653245 sheet 003 rev. A, the Positive Material 11/21/2007 Identification result of (Mo=1.27 Molybdenum for joint SW-1 does not met the 11:41:18 requirement criteria of SAES-A-206 para 10.1 which is (1.8 to 3.3). The AM contractor shall investigate and comply with the requirement of SAES-L-206 para 11.1 to 11.3. During routine site visit to UWSS, it is observed the installation of fin fan cooler for CGT 6006 is carried out with no receiving inspection performed, on 10/9/2007 enquiring about any inspection performed by SLSA or any documentation 423-115-001 2:16:52 PM available for this, it is found there is no such inspection even performed by SLSA or MMG, violating Schedule Q Attachment VI Para 2.4 & 2.7 requirements. During routine site visit to above location it is observed installation of Air filter house is carried out for CGT 6006 on the structural steel support which is not completed & cleared by inspection. As per SATIP M-001-01 there is following 12/1/2007 works are balance. Item 3.4(Grouting), 3.5 ,3.9, 3.10, 4.1 & 4.2(final punch 423-115-001 5:42:08 PM listing). As per SATIP K-402-01 for installation of equipment please refer item no. 3.2 (inspection of support structure for release for equipment installation per SAIC-M-2006) The above all is violation of sehedule Q Attachment VI Para 4. During attending FRI for raw water tank & site surveillance at UWSS-1, 11/6/2007 following discrepancies observed: a. The foundation bolt of the tank (423-D2:10:09 PM 2000) is damaged at one location(bend) during installation & at other location there is insufficient gap for putting nut on the bolt found. b. Coating of the ventilation & silencer Duct received for GT-6006 is found to 11/6/2007 be peeling off at various locations (there is no inspection release note 2:10:09 PM available). 10/15/2007 2:53:55 PM c. Grating mesh 22 x 76 Bearin plates 30 x 3 FE360B H.D.G. is received in damaged condition (GT-6006 SUPPORT STRUCTURE). d. Column HEB300 is found to have dent at the base, this may cause problem if not corrected prior to installation (GT-6006 SUPPORT STRUCTURE). e. Vertical Ladder Protection Cage Damaged during transportation (GT-6006 SUPPORT STRUCTURE) It is requested all above discrepancies may be addressed. It is observed the spool received from MMG Dammam Fabrication Yard are being installed with out having the inspection completed per SAIC L2011(Piping Pre-Installation Inspection (Prior to On-Plot Work)SATIP-L0350-1 Item No. 3.1. this is violation of Schedule Q Attachment-VI Para 4. There is a proactive notification also in this regard pending for contractor to adhere to this requirement. The Dry lay up inspections are not been carried out for lines that are hydro tested which requires drying the system to a dew point of -1 degree Celsius, immediately after dewatering. This is a violation of SAES-A-007 paragraph 5.2.3.2, and as specified on SAIC-A-2018/SAIC-A-2007, also it violates the requirements as per Schedule Q Attachment IV paragraph 1.2. Re-flushing shall be done and dry lay up inspection to be performed.
SATIP-M-001-01
SAIC-M-2012
Mechanical
AWS D1.1
SATIP-W-011-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
10.1
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
SATIP-M-001-01
SAIC-M-2011
Mechanical
ScheduleQ
Schedule Q
A VI Para 4
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.8.1
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6
2147
11/6/2007 2:10:09 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2148
3/1/2008 8:36:38 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
A VI Para 4
2149
8/5/2008 1:12:49 PM
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.3
2150
7/28/2008 10:41:03 AM
It was noticed that at the given period of time, Shutdown spools which are hydrotested are not properly covered and sealed preventing enrty of debris. it violates the requirements specified in SAES-A-004 para. 7.1.2 in accordance with SAES - L- 350. Internal cleaning shall be done prior installations. During site surveillance it was noticed that pipes/spool are not properly stored/handled and preserved as. it violates the standards SAES-L-350 PARA 7 for construction of plant piping as well as schedule Q Attachment IV Para 5 , the said requirements shall apply to storage areas relevant to the particular project which includes, but not limited to, layout yards, receiving areas, warehouses, etc It is observed installation of above structure is done with out having the Material receiving inspection & Inspection of support foundation prior to structure installation stage mention in SATIP, the embedded plate used for installation is corroded & no traceability available. above all is violation of schedule Q Attachment VI Para 4 & Attachment III Para 1 (Quality requirement for contractor supply material).It is requested the embedded plate shall be replaced or coated as recommended per drawing requirements which is hot dip galvanized or coated with zinc rich epoxy primer per APCS-1C or SAES-H-101 and required stages of inspection performed. Surveillance inspection found that exhaust stack of CGT-6006 was adjusted and correcrted the vertical elevation using a metal wedge. This is a violation of PIP-STS05130 para. 6.7.4. prohibiting the use of wedge for structural faulty correction of works with out prior approval of the procedure. Contractor shall submit a corrective action in this matter. At Given period of time and with the current phase of the project, up to now there is no available Equipment/Mechanical Inspector from the primary contractor. This is a violation of the requirements state on Project Specific Quality Requirements Schedule Q Attachement VI Table VI-2 Construction Phase Personnel Requirements. SAPID noticed that a portable quiver containing low hydrogen electrode E7018 was placed on site unplugged which is violation of SAES-W-11 6.1 for low hydrogen electrode storage requiring continuous heating by 65deg C. (inside quiver) to extend its exposure time. The exposed electrode has immediately been discarded. The quiver is belong to welder W#B-240 which shall be issued with a warning letter regarding on this matter. The contractor QC inspector shall conduct a regular toolbox meeting on welders once a week to improve their quality awareness. The welding activity carried out by MMG at UWSS site is violating following requirements. 1. There is no proper record related to electrode stored in baking oven is available. 2. There is no pyrometer available for ascertaining the welding temperatures. Looking at present climate condition were the steel temperature shall be below 10 deg. centigrade this may lead to cracking of joints. The integrity of the weld made during this period is suspected. Carrying out welding with above deficiencies is violation of Saudi Aramco standard. SAES-W-11 12.4 Temperature-indicating crayons, thermocouples, or calibrated contact pyrometers shall be used to measure preheat and interpass temperatures. Temperature-indicating crayons shall not be used for any weld joint that is to be coated 3. The is no weld gauge available at site for measuring the weld profile, while inspection of a joint with suspect weld profile below parent material there was no weld gauge available at site. Currently no available Welding Inspector to monitor the daily welding activities. As per Schedule Q , paragraph 5.11 Contractor shall make quality personnel changes reuqired due to vacations, illness , temporary assignments, emergency leave, resignations or other reasons as necessary to maintain required Quality coverage. It is observed welding activity of CGT interconnecting piping has commenced with out knowing the material grade, as there is no MTC available for having the identification done.It would be reminded selection of WPS is based on grade of material to be welded. Please see below attached Para of Section IX & W-11. Contractor has commencing welding with out material tractability, which is violation as per Schedule-Q Attach VI Para. 2.4. Any welding made without tractability of material shall not be acceptable. i.e (FW-07 & FW-09 CGT of Drg no: N.SM09924665/3 and line no: 10-MOV-120-10A31.47). QW401.1 Essential Variable (Procedure). A change in a welding condition which will affect the mechanical properties of the weldment (e.g.change in PNumber) W-11 Para 7.4 1) The assigned inspector and the contractor welding engineer/representative must verify that the welding procedure is within the welding parameters qualification range (e.g., diameter, thickness, material grade)
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15
SAES-A-004
8.1.2
2151
7/10/2008 1:55:21 PM
SATIP-L-350-07
SAIC-L-2074
Mechanical
SAES
SAES-L-350
Schedule Q
A IV Para 6
2152
12/5/2007 7:28:46 AM
SATIP-M-001-01
SAIC-M-2004
Mechanical
other
12-SAMSS007
6.3.2.1
Schedule Q
A VI Para 4
2153
4/29/2008 11:06:53 AM
NA
NA
Mechanical
other
PIP-STS05130
6.7.4
2154
8/13/2008 2:45:06 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
2155
4/17/2008 11:41:56 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2156
1/26/2008 3:27:47 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2157
1/26/2008 3:27:47 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
12.4
2158
1/26/2008 3:27:47 PM 7/2/2008 10:23:35 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
5.10
2159
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1 & 5.14
2160
3/31/2008 5:50:28 PM
SATIP-W-011-01
SAIC-W-2001
Mechanical
other
ASME Sec IX
QW 401.1
Schedule Q
A IV Para 4
2161
5/11/2008 7:13:22 AM
During conducting of hydro testing for 30 Treated water spool at Hawiyah WIPS, during process of filling water in the spool the concern piping inspector of SLSA conducting the Hydro test was moved out of jobs which is violating Schedule Q Attachment VI Para 2 (Table VI-2 Construction Phase Quality Personnel Requirements), during the balance stage of pressurizing, draining etc there was no QC inspector available which is of a concern related to safety also. The Project Inspection would like to bring to the notice of SLSA that in feature there shall be no Hydro test witnessed by inspection without discipline QC inspector. It is also requested the inspector approved for the site shall be position immediately.
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
Schedule Q
A VI Table VI2
2162
7/17/2008 1:07:06 PM
2163
6/2/2008 7:00:56 AM
2164
3/7/2008 11:55:08 AM
2165
3/7/2008 11:55:08 AM
It has been observed during routine inspection that paints and thinners were stored next to the Smoking Area near ICC Warehouse (see picture on email). ViolationContractor is requested to comply with the requirement of proper storage of After The paint as per SAES-H-100 and related Safety Standards. Also provide Fact extinguishers, Safety Signage, and the Paint Storage Area shall be separate from other structure. Please comply immediately. During site visit to above location it is observed the preservation for instrument air receiver (H01-D-0021) is at zero pressure violating requirements mentioned by manufacturer (35kpa) & as per SALSA Approved Violationpreservation procedure (Schedule Q Attachment IV Para 5 ). The weekly Prevented preservation schedule says the equipment preservation was checked & found satisfactory. This is repeated violation & further not adhering to preservation Engineering requirements shall call for raising of NCR by Project inspection. Contractor is also requested to kindly investigate why there is a wrong reporting being submitted on preservation. It is observed there is violation of schedule Q requirements in construction activity being done by SLSA. The spools received at site are not having the receiving inspection completed & are being modified without information. The Violationspool received from MMG Dammam Fabrication Yard since 02months are not After The having the inspection completed, violating Schedule Q Attac-VI Para 1.9 Fact CONTRACTOR shall ensure the Inspection/Shipping release is available with the equipment and materials at time of receipt at job site. Copies of inspection/shipping release shall be submitted to Company within 48 hours of issue. 2. There was modification on the above spools performed with out having the Violationreceiving Inspection done which is violating the schedule Q Attachment VIAfter The Para 2.7, CONTRACTOR shall review/witness in accordance with the SATIPs Fact and Checklists and accept all work and tests performed by subcontractors & submit results to the SAUDI ARAMCO. During routine inspection for RTR pipe installation, it was noticed that there are underground blind flanges installed on Raw Water line and Blow Down RTR pipes where the bolts and washers are not coated. This is a violation to the requirements of SAES-L-105 p.190- Material Specification. Corrosion protection is required for bolting underground installation. During routine site visit to above location it is observed steel structure for above location is Erected without having any stages of inspection completed like receiving inspection,inspection of foundation prior to installation. Even the SLSA inspector is also unaware about the installation of this structure. The above is violation of schedule Q attachement VI Para 4.requirements. During routine site visit to above location it is observed Steel structure received for pipe rack is installed with out having the receiving inspection cleared. The steel structure does not have the inspection release note available. installation of structure with out having cleared by Third party/ Vendor Inspection is violation receiving inspection requirements.REFER SECHEDULE Q ATTACHMENT -IV PARA7.1 (7.1. CONTRACTOR shall visually inspect all incoming equipment for damage and for conformance to all applicable requirements, including the supplier inspection release with verified Material Test Reports (MTR). ) Contractor used 10mm fabricated spacer not coated in between flanges @ Flanged joint # 20 in between Globe Valve CL 600 RF and spool # H14-TW4964-004-B Treated Water Line with reference drawing # BB-650679-005W0E, This is violation of SAES-L-109 item 4.4. Use of components which requires special analysis or proof testing (e.g. ASME B31.3 paragraph 304.7.2) shall be subject to review and approval by the Chairman of the Piping Standards Committee in CSD. During construction surveillance @ CGT 4001 Pipe with Line # 2-LO-4803-003 touch gearbox of 6 Ball Valve (CL 150 RFFP 0 line # 6-LO-4805 in CGT 4001.This is violation of SAES L-310 Paragraph 12.4 A minimum of 50mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure. ViolationAfter The Fact
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.1
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
2166
5/26/2008 7:40:29 PM
SATIP-S-070-03
SAIC-S-4057
Mechanical
SAES
SAES-L-105
page 190
2167
1/2/2008 12:05:15 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
Schedule Q
A IV Para 4
2168
12/13/2007 11:55:55 AM
SATIP-M-001-01
SAIC-M-2004
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2169
8/27/2008 8:45:24 AM
H14-105002
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-L-450
9.4
SAES-L-109
5.1 & 5.2
2170
9/3/2008 4:47:25 PM
H14-105002
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
2171
9/6/2008 10:54:57 AM
H14-105002
During construction surveillance @ CGT 4001 Pipe with Line # 6-LO-4801-002B near reinforcement pads S4 as per BB-65074-002-00F touch Stairs guide Violationand less than 50 mm distance from Vertical Stairs post. This is violation of After The SAES L-310 Paragraph 12.4 a minimum of 50mm shall be provided for Fact inspection and freedom of pipe movement between above ground piping crossing with any structure. I was found out that horizontal distance of drain for 2 FG -4813 with Drawing # BB-650526-016 near KO Drum from concrete wall is violation of SAES-L-310 Para. 12.5 Branch connections, 4 and smaller, including drain and vents valve and drip leg of all sizes, shall be located at a minimum horizontal distance of 610mm (24) from any fixed obstruction. During attending RFI for shut down at Harad GOSP-II, there is following violation of standard observed while performing the shut down activity. 1. Gasket used is of different thickness (1.6 &3mm) & some are not full faced, receiving inspection of all gasket used is not performed or any document available to verify, Violating Schedule Q-Attach III Para 1.1 & SAES L-105 table-12CGOU Note -4 (for flat face flange use full face gasket). 2. 3 Nipple used for the line is old used one & non galvanized, Violating SAES L-105, Para 11 & SAES L-132 Table-1 3. The stud & bolts used are not galvanized. The existing line has all galvanized stud bolt used. 4. The ball valve used has no receiving inspection details for verification, Violating Schedule Q-Attach III Para 1.1. 5. The piping material & fitting has no receiving inspection performed or any record available for support, Violating Schedule Q-Attach III Para 1.1 Contractor is conducting Hydrostatic testing activities & pressurized the system in HARADH GOSP 2- WIPS Expansion without Saudi Aramco Inspection Representative for TP-59&60 @ 3:00PM 18 September, 2008. RFI issued at the same time and at the same date. This is violation of Schedule & Q. GI.002.102. It was found out that Some Welded joints Positive Material Identification (PMI) is not yet conducted & this is violation Of SAES-W-011 Paragraph 17.6. During routine site visit to SALSA Store yard of Harad, it is observed the KO drum received by the contractor is not internally preserved with Nitrogen, which as required drawing (600147-dwg-021.Sht-001.R2). Para.13 needs to be protected with nitrogen pressurized at 35KPA. Presently the equipment & accessories received at SALSA site store yard are not following proper preservation schedule. A. The material received does not follow proper maintenance as required per SLSA - Doc.No.o84255-0000-PC 6000-002-0A Material & Equipment, ware housing, preservation & delivery. Presently there is no such document available ensuring preservation being carried out. c. Equipment issue to site are not properly staged & covered protecting from atmospheric condition, equipment at the site are not regularly cleaned or preserved.( Harad : Silencer Duct has insulation(fine fiber)cover with sand. The above all violate. Schedule Q Attachment IV Para 5. ViolationAfter The Fact
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
2172
9/6/2008 10:59:52 AM
H14-105002
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
12.5
2173
9/11/2007 6:31:12 PM
H14-130001
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2174
9/19/2008 7:50:41 AM 9/19/2008 7:50:41 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
2175
SATIP-W-011-01
SAIC-L-2010
Mechanical
SAES
SAES-W-011
17.6
2176
11/25/2007 8:05:31 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2177
12/16/2007 2:55:02 PM
During routine site visit to above location it observed the 25 mm mounting plate used for above pump is corroded. Please refer 31-SAMSS-004,Para. 1.1.1 Violationwhich calls for coating of the plate.(Unless otherwise specified, the vendor Prevented shall commercially sand blast, in accordance with SSPC SP 6, all grout contact Installation surfaces of the base plate, and coat those surfaces with inorganic zinc silicate in preparation for epoxy grouting, (API 610 Para. 3.31.7) It is observed that the section joining seam of CGT Stag after completetion of girth welding is coated with silver colour paint used for asthetic coating .This is violation per schedule Q Attachment IV, paragraph 2.1 (procedure approval) state the coating shall be as per approved aramco liquid paint scheme standard SAES-H -001. During routine site visit to harad Wips on 16 Feb 2008, it is observed the Material kept at work site of MMG is not preserved & there is deterioration of items found. a. In the Exhaust panel of CGT , there is water & Sand found to have entered the insulation & panel. b. Dust collector drum of CGT is found with water & rust developed on the internal surface. c. The steel structures for pipe rack is found to be lying scattered in the mud & water. The above all is violation of Schedule Q Attachment IV Para 5 & SLSA preservation procedure 084255-0000-pc-7000-010-pc. ViolationAfter The Fact
SATIP-G-005-01
SAIC-G-2021
Mechanical
other
31-SAMSS001
1st para
2178
7/14/2008 3:24:59 PM
SATIP-H-100-01
SAIC-H-2023
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2179
1/16/2008 2:01:49 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2180
7/13/2008 4:17:32 PM
During site visit to above location it is observed the preservation for CGT 4001 & 5001 fin fan cooler is found with zero preservation pressure inside, the cooler is at zero pressure since 01week & there is no action initated by contractor SLSA, This is violation of manufacturer requirements for having the Violationcooler filled with positive nigrogen pressure, SALSA Approved preservation Prevented procedure (Schedule Q Attachment IV Para 5 ). The weekly preservation Engineering schedule says the equipment preservation was checked & found satisfactory. This is repeated violation and needs to be addressed correctly with preventive & corrective action taken. Exhaust duct structure for 4001 & 5001 is installed on shim plate which is violating standard requirements, the plate used is not stain less steel & not Violationtraceable. as per API 617 Para 3.3.1.2.2 Equipment supports shall be provided Prevented with stainless steel (AISI Standard Type 300) shim packs, 3 millimeters to 13 Engineering millimeters thick. Refer : (API 617 Para 3.3.1.2.2) 31-SAMSS-001 Site visit to above location it is observed instrument air line spool (of DrgNo. BB650570) is being welded without having tracability of the reducer available, there is no receiving inspection done or MTC available. The above is violation per schedule Q attachment VI Para. 2.4 CONTRACTOR shall visually inspect all incoming material for damage and for conformance to all applicable requirements, including the supplier inspection release with verified Material Test Reports (MTR). During routine site visit above location ,it is observed the steel structure received for CGT 4001 & 5001 WALKWAYS is being installed with having the requirements of receiving inspection being completed. 2. The Nuts, bolts & washer received per drawing(BA -569341/001 ) does not have any MTC available & the items is installed with having correct tracability. Above all is violation of schedule Q Attachment-VI Para 2.4 ATTACHMENT- VI PARA 2.4 CONTRACTOR shall visually inspect all incoming equipment for damage and for conformance to all applicable requirements, including the supplier inspection release with verified Material Test Reports (MTR). If the equipment does not have the required inspection release and MTR, CONTRACTOR shall verify and document the compliance of the equipment with applicable standards and specifications prior to release to be used as part of the WORK. Conducting focus assessment of available QC manpower of SLSA & Sub Contractor at Harad, hawiyah & uthaminayah site, it is found there is shortage of supervisor & inspector found at this site. In some sites there is shortage of inspector & other site UN approved personnel are employed for inspection activities .violating Schedule Q- Attachment-VI Para 2.1 & Schedule Q Attachment -I (Contractor & Sub Contractor Quality personnel requirements) a. Harad : SLSA :QC Supervisor, piping, coating inspector. c.Uthamaniyah: SLSA Piping Inspector. MMG: Welding, Mechanical, &Piping Conducting focus assessment of QC manpower employed at Harad Wips expansion site, it is observed there is violation of schedule Q Attachment VI Para 2 (table VI-2) for assigning QC manpower for various discipline. There is no approved welding Inspector, piping inspector & QC supervisor available at site. Presently the piping & welding work is at peak phase of the project & not employing the discipline inspector is effecting the QC requirements. The quality documentation required to be maintained is lacking, during the last internal Audit of SLSA the lack of this was also pointed out by the members but still there is no correct initiative taken by SLSA. It was observed during inspection that RTR pipe riser near H14-GT-4001 was in direct contact with concrete (see picture attached on email). SAES-S-070 para. 17.4 requires thermoplastic pipes shall be protected from contact with concrete by tape wrapping. Or Contractor may have the option of providing sleeve on the riser prior to concreting, then a sealant will be applied later on the space between RTR riser and the sleeve. Contractor is requested to comply with requirement During routine site visit to above location it is observed the Sub-contractor MMG is carring out welding with following violation of standard & electrode manufacturer requirement. 1. low hydrogen electrode is not having any record of issuance or baking/conditioning. 2. The electorde used is cool not per the mfg recommendation. 3. The welding partable oven used is not warking. Above all is violation of AWS D1.1 Section 5.24,Section 5.18 & 12-SAMSS007Para. 7.5 4. The profile & the weld made is not meeting AWS D1.1 Requirements. 5. The welder employed is not having JCC OR WPS per which welding is performed.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2181
7/14/2008 9:56:01 AM
SATIP-G-005-01
SAIC-G-2021
Mechanical
other
31-SAMSS001
1st para
2182
3/31/2008 6:49:44 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2183
2/28/2008 8:55:01 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2184
11/21/2007 7:37:25 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
2185
4/12/2008 4:13:37 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
2186
7/4/2008 5:45:50 PM
SATIP-S-070-03
SAIC-S-4058
Mechanical
SAES
SAES-S-070
17.4
2187
2/28/2008 3:56:18 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
AWS D1.1
5.18 & 5.24
2188 2189
2/28/2008 3:56:18 PM 2/28/2008 3:56:18 PM
NA SATIP-W-011-01
NA SAIC-W-2035
international Standard other
AWS D1.1
12-SAMSS007
Sec 5.18 & 5.24 7.5
2190
7/14/2008 5:20:43 PM
During surveillance at Harad wips facility it is observed welding of CGT exhaust stag (joint between two sections of stag) is carried out violating various requirements per schedule-Q. 1. Welding is performed with out approved or any welding procedure specification. per schedule -Q attachment VI Para 4E, 2.7 (Inspection & accepting of job per SATIP). Attachment IV Para 2.1 (welding procedure approval) 2. There is no RFI raised for the above construction activity and so no record of inspection available with SLSA QC.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2191 2192
7/14/2008 5:20:43 PM
NA NA
NA NA
ScheduleQ ScheduleQ
1.7 A VI Para 6.2
2193
2194
2195
2196
3. SLSA is not aware of construction code for installation /erection & welding 7/14/2008 of the stag. The above all is violation of welding requirements & inspection 5:20:43 PM requirements During surveillance 7 May 2008 found that no Holiday testing done during lowering. A large scratch damages covering area of four square inch found 15 5/8/2008 meter from the last side boom before pipe touch the sand pads. And this is 7:31:51 AM violation of SAES-H-200 Paragraph 7 Inspection & Quality assurance. The coated pipeline shall be 100% inspected with pulse-type DC holiday detector immediately prior t burial. There is no Coating QC on site during lowering. This is violation of SCHEDULE 5/8/2008 Q Section 1.3 Contractor shall be totally responsible for the quality of work 7:31:51 AM required by this contract. & 1.4 Contractor shall inspect, test and accept all parts of work. During surveillance @ 10:30AM 9/03/2007 found that bended pipes P/N 5080/5018;5070/5118;5021/5067;5098;0148 are damages due to worn out Plastic padding in clamp of bending machine. This is violation of SAES-H-200 9/3/2007 ADKH-1 (60` para. 5.1.2 All equipment, including field bending machines and pipe cradles, 4:47:40 PM DIA) that contact the coated surface of the pipe shall be padded. and SAES H-200 para5.1.1 The coated pipe shall be handled at all times in a manner that prevents damage to the pipe walls, beveled ends, and to the coating (including internal coatings, if applied). It has been noticed that the QC inspector Mr. Danny Rafoels from Al-Qatahni is not having any approval from Saudi Aramco. This is a violation with the 11/22/2007 ADKH-1 (60` requirements of schedule Q para 3.3.7 and para 2.1. Al-Qahtani shall submit 5:38:06 PM DIA) the resume of their prospective candidates for review and to be scheduled for interview if his qualification found satisfactory. During the review of video CDs, A defect detected called orange peel and then verified visually on the actual job at site by PID. The violation is being raised ADKH-1 (60` as the CDs are reviewed by the subcontractor, contractor inspector and DIA) contractor supervisor too before submitting to PID. SAES-H-201 8.2.4 the finished coating shall have a uniform, glossy appearance and be free of defects such as holidays, fish eyes, lumps, dry spray, sags and runs. Bending Activities in ADKH 1A & 1B already completed and upon verification of Construction Quality Activities found that for all Reported Damages during bending there is no Quality Report for Repair either external or external damages. This is violation of SAES H-201 Paragraph 8.5.5 Contractor shall keep daily records of the work progress and result of all inspection activities in a form suitable for Saudi Aramco Inspector surveillance and approval.
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-200
5.1.1 & 5.1.2
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
2197
4/2/2008 8:46:00 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6
SAES-H-201
8.2.4
2198
5/11/2008 3:49:29 PM
ADKH-1 (60` DIA)
SATIP-G-002-02
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.5.5
2199
6/20/2008 6:32:50 AM
2200
6/20/2008 9:52:00 AM
During Document Review of Isometric piping details for Hydrotest preparation found that contractor are using 3/4" valves welded to nipple. This is violation ADKH-1 (60` of Saudi Aramco standard as per 04-SAMSS-035 General requirements for DIA) Valves item 6.2 b) Valves 2 and below with soft seals or seats shall have factory-installed extension nipples or extended bodies to prevent damages due to welding heat. During Verification of Hydrostatic Test package found that contractor are using ADKH-1 (60` 3/3" nipple ASTM 182 F 44 conformed by FUGRO-SUHAIMI LTD PMI test DIA) report and this is not conform to Material specs requirements as per KSPE-SASMR-015 Line # 1.5 which is ASTM A 312 GR F 44 It was noticed that the sand skids placed on pipe section 108 & 115 at Km 31+600 & 33+700 respectively are having stones that could damage the external coating of the pipe which violated SAES-H-200 para 5.3. Externally coated pipe strung along the right of way is supported on rock free sand, sand bags, rubber tires or similar compressible materials to prevent damage.
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
04-SAMSS035
6.2 b
NA
NA
Mechanical
Drawing
Drawing # KSPE-SASAMR-015
Line # 1.5
2201
11/23/2007 ADKH-1 (60` 12:11:48 PM DIA)
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.3
2202
8/13/2007 5:16:26 PM
During surveillance inspection today (08.13.07), it has been noticed there are no end caps for the following pipe strings between kilometer 000 to 004 which ADKH-1 (60` violate SAES-L-450 para. 11.3. String start from MLW 13 ( end cap not DIA) available both ends) String : MLW54 to 58 ( Both ends) String : MLW63 to 65 ( +ve end) String : MLW 68 to 70 ( +ve end) String : MLW 73 to 76 ( +ve end) Hence end cap shall be provided for all open strings.
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
2203
8/18/2007 2:39:28 PM
During surveillance of Cold Field Bending at KM 000 of ADKH-01 today, it was observed that the Out of Roundness of bent pipe is beyond the acceptable limit of Saudi Armco and International standard. The out of roundness measured at the end of the pipe # 5145, Heat # 2-435764 & DJ # 0064 , 8 Sag bend, after the bending and found 55mm out of roundness which is greater than 1 % of Pipe(60 API X70, w.t0.679mm) diameter. As per 01ADKH-1 (60` SAMSS-035, para 7.2.2,C , it is a clear violation. Further the internal diameter DIA) of pipe was measured at middle of the double joint pipe at 2 locations and noted the internal minimum diameter is 1440mm. As per ASME B31.4 Para 434.7.1.b, the pipe diameter shall not be reduced at any point by more than 2.5% of the nominal diameter. So the ovality at middle of the pipe, violates above standard as well. Hence this Cold Field bend pipe is rejected. Further Saipem is advised here by to fabricate and arrange a template as per 01SAMSS-035, para7.2.3, to check . Slected bedding material being used for sand bedding was containing stones of size unacceptable per ARAMCO Standard. SAES -L-450 Para14.9.3c Selected bedding material shall be placed in the bottom of the trench and made level. ADKH-1 (60` The bedding material shall be clean sand or soil and shall not contain stones DIA) larger than 12 mm size that would cause damage to the pipe or pipe coating. Use the sweet sand and replace the bedding made by the questionable sand and conduct re-hliday test for the areas covered by the stoney sand. It was found that the pipeline at such area has been lowered and no backfilling was made so far. The sand used for spot back filling is also not sweet. It is the violation of SAES-H-200, Sec. 7. 7 Inspection and Quality ADKH-1 (60` Assurance The coated pipeline shall be 100% inspected with a pulse-type DC DIA) holiday detector employing an audible signaling device immediately prior to burial, i.e. after the last boom. Rejeeping and sweet sand backfilling is recommended to be carried out.
SATIP-L-350-08
SAIC-L-2036
Mechanical
other
01-SAMSS010
2204
4/6/2008 8:50:31 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
14.9.3
2205
4/8/2008 9:16:22 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
2206
4/8/2008 10:22:17 AM
IT HAS BEEN NOTICED THAT THE END CAPS OF THE LINE ARE NOT PLACED BACK ONCE THESE ARE REMOVED FOR ANY WORK. MANY AREAS ALONG THE ViolationADKH-1 (60` LINE, STRINGS ARE WITHOUT END CAPS WHICH IS THE VIOLATION OF SAESAfter The DIA) L-450, PARA 11.4. Open ends of pipeline strings shall be capped to prevent Fact entry of debris or animals and birds. IT IS RECOMMENDED FOR ALL THE OPEN ENDS TO BE CAPPED IMMEDIATELY. THE STRINGS AND PIPES ARE PUT OVER THE STONEY SAND BERMS VIOLATING SAES-H-200 During storage the coated pipes shall be placed at least 150 mm off the ground on either rock-free sand berms covered with polyethylene sheeting or on padded skids spaced and leveled so that the pipes are supported without damaging the coating. THE LENGTH OF PIPE HAS BEEN LOWERED BUT NO BACK FILLING WAS CARRIED OUT SO FAR VIOLATING SAES-H-200, Sec. 7. 7 Inspection and ADKH-1 (60` Quality Assurance The coated pipeline shall be 100% inspected with a pulseDIA) type DC holiday detector employing an audible signaling device immediately prior to burial, i.e. after the last boom. REJEEPING AND BACKFILL WITH SWEET SAND SHALL BE CARRIED OUT. It was found during the sureillance that the length of pipeline mentioned above had been lowered after jeeping but no back filling was done violating SAES-H-200, Sec. 7. Inspection and Quality Assurance The coated pipeline shall be 100% inspected with a pulse-type DC holiday detector employing an audible signaling device immediately prior to burial, i.e. after the last boom. The electrode used for locating holidays shall be in direct contact with the ADKH-1 (60` coating (with no visible gaps) and provide complete coverage of the whole DIA) coated surface. All holidays shall be repaired and the repairs shall all be checked with a holiday detector to verify that they are adequate. This final inspection procedure shall be monitored by a Saudi Aramco Inspector. An email through Mr. Nuwaiser was sent on 29/03/08 recommending the rejeeping and immediate backfilling. Just ensure that this practice will never be repeated. During the VALVE INSPECTION and TESTING, cracks, porosities, SPATTERS ADKH-1 (60` and other welding defects found in the differnt areas of intermitent fillet welds DIA) between the stiffners and the valve body. Rectification of all the defects and removal of spatters and then touch ups of coating is recommended. ADKH-1 (60` DIA) ADKH-1 (60` DIA) VISUAL CRACKS FOUND IN THE WELDS BETWEEN THE STIFNERS AND THE VALVE BODY. ViolationAfter The Fact
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
2207
4/8/2008 10:47:22 AM
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-H-200
5.1
2208
4/8/2008 10:57:25 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
2209
4/14/2008 8:13:47 AM
SATIP-L-450-04
SAIC-L-2114
Mechanical
SAES
SAES-H-200
2210
4/5/2008 11:43:14 AM 4/27/2008 11:57:25 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.4.2
2211
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.4.2
2212
It was found out during surveillance @ 2:30 PM 10/24/2007 that sandblasting equipment removed in KM 30+000 10/23/2007@ 3:30 PM as per construction manager directives. Finished joints are 12 in which 9 joints are without sandblasting, this is not as per agreed construction procedure and approved 10/25/2007 ADKH-1 (60` by Saudi Aramco work procedure. As per AQPCT-WP-379 Paragraph 7.6 The 9:31:09 AM DIA) Client (main contractor-SEIPEM) shall use steel grit or garnet blast clean the pipe ends prior to welding as per ISO 8501-01 to get the Sa 3 white metal cleanliness with profile of 1.5 to 3.5 mils. The interior of the joint shall be cleaned before welding it to the mainline pipe string. Client shall check and record the cleanliness and profile of each pipe ends. 4/8/2008 8:40:01 AM During the surveillance, preheat temperature was asked to check. It was ADKH-1 (60` found lower than the recommended value. 100 degree centigrade is the DIA) preheat temperature but it was found 60 to 70 degree only It is the violation of Aramco approved WPS- SAS-202.
NA
NA
Mechanical
other
Work Proc#AQPCTWP-379
7.6
2213
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
12
WPS-SAS-202
NA
2214
2215
2216
During lowering and during final holiday test of mainline String# 69 on 08.24.07 , the external coating of MLW 863 & MLW 870 were rejected due to more number of holidays and major damages and violates SAES-H-201, para 8.5.1 . Hence the external coating shall be completely blasted off and to be 9/16/2007 QUAD-2 (56` recoated as per above SAES-H-201 clause. But these joints are backfilled 12:28:23 PM DIA) without rectification and SAPID inspection. Hence above joints to be opened and external coating shall be rectified and to be re-offered to SAPID for inspection and final holiday test witness. There were another two joints, MLW 1236 & 1240 (String # 98) rejected for the same above reason on 09.09.07 and to be rectified and re-offered to SAPID. During the review of coating final inspection video for tie-in 520A & 1221A at Km 14+850 & 33+600 respectively, it was found that scores of spent abrasive materials was left un removed nearby the girth weld. Al-Qahtani work 10/17/2007 QUAD-2 (56` procedure AQPCT-WP-379 rev. 6 para 8.1.3 stated that the spent abrasive 8:41:37 AM DIA) shall be removed by robotic crawler vacuum. Contractor shall clean the two mentioned tie-in before proceed to weld the next joint. This entry shall also be applied to all succeeding tie-ins throughout and till the completion of the project. Final coating inspection video for FW-468A, Km 13+450 was submitted to PID and found that the footage for visual inspection, holiday testing, dry film thickness was not matching with the footage of surface preparation. Further investigation reveals that the submitted video was altered with some of the 10/8/2007 QUAD-2 (56` inspection footage was taken from different joints. This is a non compliance 3:34:12 PM DIA) with project schedule Q para 1.3, 1.4, 1.5. The contractor shall take footage on the original joint and submit to PID for review and acceptance. Upon the submission of the video, it shall be identified by project name, pipe size and tiein weld number or field weld as specified in AQPCT-WT-379 rev.6 and this is applicable for all incoming submittal.
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-201
8.5.1
NA
NA
Mechanical
other
8.1.3
NA
NA
Mechanical
other
NA
Schedule Q 1.3, 1.4 & 1.5
2217
4/9/2007 7:01:08 AM
2218
1/13/2007 3:28:46 PM
2219
7/16/2007 5:20:03 PM
During surveillance of bend pipes, SAPID found cracks and damages on below pipes between KM 4.5 to KM 10.00 of QUAD-2 (56) on 08-April-07. Pipe # 1481(DJ-950) 2 Cracks Pip # 0144(DJ-1066) 3 cracks Pipe # 804 (DJ-058) 3 cracks Pipe # 1376/1214( DJ859) 1 Crack Pipe # 836 (DJ-803) - 1 Crack ViolationQUAD-2 (56` Pipe # 5322/0562 3 damages Pipe # 370/1374 - 2 damages All above pipes Prevented DIA) are bend pipes and the coating had been damaged during bending. Your Installation immediate corrective action is required. It is a clear violation of SAES H-200 para 5.1.1 5.1.1 The coated pipe shall be handled at all times in a manner that prevents damage to the pipe walls, beveled ends, and to the coating (including internal coatings, if applied). During routine site Surveillance at KM -52 on 12 Jan 07 . 1.It was observed contractor had carried out coating of girth weld with out having received RT Violationresult.On confirming about the result it was known there is a repair on the QUAD-2 (56` joint and was requiring the complete coating removed for making repair. 2.The After The DIA) Fact coating of the above joint was under taken with out filling any Pre blasting & coating checklist filled. The all above violate SCHEDULE Q Para- 6.3 and Attachment VI Para 2.7. During attending Holiday test Per SAIC H-2018 Final Inspection of External FBE Coated Field Girth Welds before Backfill @ KM 2+100 (String 6), KM 2+100 FW 53A, KM 2+400 FW 65A from 10:00 AM to 4:00 PM July 16, 2007 ViolationThere is no Contractor QC at site. This is a hold point to Contractor & Saudi QUAD-2 (56` After The Aramco, this is violation of SCHEDULE Q. section 5.6 Quality personnel shall DIA) Fact be dedicated to the work described in this schedule Q and shall performed no other function on this contract. And SCHEDULE Q Attachment VI item 2.7 Contractor shall review/witness in accordance with the SATIPS and checklist and accept all work and test.
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-200
5.1.1 & 5.1.2
NA
NA
Mechanical
ScheduleQ
Schedule Q
6.3
Schedule Q
A VI Para 2.7 4.2
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
Schedule Q A VI Para 4.2
2220
7/17/2007 3:36:40 PM
QUAD-2 (56` DIA)
2221
7/19/2007 5:26:26 PM
QUAD-2 (56` DIA)
2222
7/21/2007 5:19:04 PM
QUAD-2 (56` DIA)
2223
9/20/2007 2:14:53 PM
QUAD-2 (56` DIA)
During attending Holiday test Per SAIC H-2018 Final Inspection of External FBE Coated Field Girth Welds before Backfill @ KM 3+100 (String 7), from 8:00 AM to 11:00 AM July 16, 2007 There is no Contractor QC at site. This is a hold point to Contractor & Saudi Aramco, this is violation of SCHEDULE Q. section 5.6 Quality personnel shall be dedicated to the work described in this schedule Q and shall performed no other function on this contract. And SCHEDULE Q Attachment VI item 2.7 Contractor shall review/witness in accordance with the SATIPS and checklist and accept all work and test. During attending Holiday test Per SAIC H-2018 Final Inspection of External FBE Coated Field Girth Welds before Backfill @ KM 3+680 (String 9) & KM 4+350 String 11, from 1:00 PM to 4:00 PM July 19, 2007 There is no Contractor QC at site. This is a hold point to Contractor & Saudi Aramco, this is violation of SCHEDULE Q. section 5.6 Quality personnel shall be dedicated to the work described in this schedule Q and shall performed no other function on this contract. And SCHEDULE Q Attachment VI item 2.7 Contractor shall review/witness in accordance with the SATIPS and checklist and accept all work and test. During attending Holiday test Per SAIC H-2018 Final Inspection of External FBE Coated Field Girth Welds before Backfill @ KM 2+750Tie-in FW 66A,KM 3+00 Tie-in FW 78A; KM 6+000 String 13, & String 14 from 9:00 AM to 4:00 PM July 21, 2007 There is no Contractor QC Coating at site. This is a hold point to Contractor & Saudi Aramco, this is violation of SCHEDULE Q. section 5.6 Quality personnel shall be dedicated to the work described in this schedule Q and shall performed no other function on this contract. And SCHEDULE Q Attachment VI item 2.7 Contractor shall review/witness in accordance with the SATIPS and checklist and accept all work and test. At Km 36+000, a pup piece welded to buried pipe string with weld joint no. FW-1325A is noticed with burnt on internal coating. The burnt probably caused by a molten metal spew during cutting of the pipe into pup piece. This violate SAES-H-200 para 5.1.1 and SAES-W-012 para 10.15. The mentioned damaged internal coating shall be repaired prior to the tie-in of the pup piece to succeeding string.
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.15
2224
9/3/2007 8:16:10 AM
During reviewing Pre Coat (surface preparation of internal girth weld area) CD for Tie-In welds FW-235A on 08.29.07 and FW274B on 09.03.07, it was observed that the surface preparation was not meeting following Suadi QUAD-2 (56` Aramco requirements as per SAES-H-201, Para 7.2.3 and SAES-H-002 Para DIA) III.b for APCS 102 . The surface cleanliness is not equal to SA 2 or SA 3 and not near white metal or white metal cleanliness and found rust on many places. Hence internal coating of above joints is rejected. Further FW-235A was rejected on 08.29.07 but no action taken by saipem to repair the coating.
SATIP-H-002-08
SAIC-H-2059
Mechanical
SAES
SAES-H-201
7.2.3
2225
1/16/2007 11:38:27 AM
2226
5/20/2007 11:49:05 AM
During routine site Surveillance at KM 0+385, it was observed a 56 Dia pipe with below details was bend with buckling observed at 9mtrs from the end. The standard calls for Bending of spiral wound line pipe shall be conducted with proper tools and performed with skilled operators because spiral wound ViolationQUAD-2 (56` pipe is more prone to buckling. For example, a hydraulic bending mandrel and Prevented DIA) polyurethane-lined bending dies should be used for spiral-welded pipe. RFI No. Installation 002. Pipe Grade & dia. API 5L X65, 56 Pipe No. 0214 Heat No. 624032 DJ No. 918 Saipem Report No.Mech-008 The above violates SAES-L-450 Para 10.7.1 (Appendix-B .1.3) Upon conducting routine inspection on bended pipes at Km. 56+450, it was discovered a buckle on pipe no. 2957 with heat no. 631073/631029 and bend no. 777. Prior to this pipe at Km 49+900 had also discovered with buckle, pipe ViolationQUAD-2 (56` no. 3515 and bend no. 699. This is a repeated occurrence of buckling despite After The DIA) that violation (surveillance no. 240) had been issued earlier regarding dents on Fact pipes which also related with bending. With reference to SAIC- L-2114, the bends shall be free from buckles, dents, wrinkles, cracks, any mechanical damage or indention. With reference to proactive notification no. 162 raised dated April 15, 2007, the contractor was failed to do corrective action in the issue of rampant QUAD-2 (56` coating damage on external coating of pipes during bending. Close monitoring DIA) has been made by PID on bending till this date (May 6, 2007) and visual inspection record shows that no changes with the defects rate. This is repeated violation with SAES-H-200 para 5.1.1 and 5.1.2. Pipe Buckled during bending : During inspection of Cold field bend pipes on 15.03.07 , it was observed that the below pipe was buckled during bending operation in one location, in the size of 300mm length X 150mm width X QUAD-2 (56` 15mm deep, near spiral seam and 3.5mtr from girth weld (double joint) at KM DIA) 23+790. Pipe # 5745, Heat # 627123 & 626115, DJ# 0406, Bend LT 630 . As per SAIC-L-2114, A9 Field Bends are free from Buckles, other mechanical damages. Hence it is clear violation. ViolationAfter The Fact
SATIP-L-450-04
SAIC-L-2114
Mechanical
SAES
SAES-L-450
10.7.1
SATIP-L-450-04
SAIC-L-2114
Mechanical
SAES
SAES-L-450
Appendix B
2227
5/6/2007 3:31:56 PM
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-200
5.1.1 & 5.1.2
2228
3/18/2007 4:59:12 PM
SATIP-L-450-04
SAIC-L-2114
Mechanical
other
01-SAMSS010
7.1.1
2229
During routine surveillance of Main Line welding at Quad-2 pipeline, there is a buckled bend pipe discovered at KM 44 on 23.May.07. The details of bend is as follows. Pipe no. 6424, Heat no. 626130/629099 & DJ No. 1608 6 RT+SAG. The bend pipe is already welded at Main line welding MLW 1591.The Violation5/25/2007 QUAD-2 (56` buckle is found about 5mtr from MLW 1591 negative side. As per SAIC LPrevented 12:08:50 PM DIA) 2114 Rev2 , Field Bends are free from of buckles, dents, cracks, wrinkles, Installation other mechanical damage, or indentations. As per ASME B31.4,( 434.5(7) & 437.1(b) Bends shall be free from buckling and buckled pipe shall be replaced as a cylinder. Hence above buckled bend pipes to be replaced. During surveillance inspection (22 July 07) at Km. 49 +400, it was found that bended pipe with no. 2464 is already made into string welded with other pipes. The mentioned pipe was previously rejected due to having number of dents along its length. It also came to my attention that it was been repaired without securing repair procedure from CSD. Please be reminded that the QMIS entry no. 240 still open giving violation for the said pipe including five more with related issue. The contractor action violates project schedule Q para. 7.3.1, para. 7.3.5, para. 7.3.6, para. 7.3.7. During surveillance on site in May 17, 2007, it has been discovered that the contractor was started to do some repair on the pipes having dents which was rejected previously with reference to surveillance no. 240. The contractor is trying to eliminate the dents by their own way, although it has already been concluded in the recent Quality Meeting last May 13, 2007 that the dents on the said pipes can only be repaired provided that the contractor shall submit a written repair procedure and get approval from CSD. Contractor has violated Schedule Q para. 7.3.6. It is observed during surveillance of Cold Field Bending at KM58+000 to Km60+000 of 56" QUAD-2 P/L that found hydraulic oil inside surface of all the bend pipes in whole length due to oil leakage in the bending machine. We unable to inspect internal surface of bend pipes for internal coating damages and mechanical damages due to the oil. Hence contractor is advised here by to stop oil leakage in bending machine immediately and clean thoroughly all the bends where there is oil inside. Further following cleaning to be done before mainline welding and blasting as per SAES-H-201. 7.2 Surface Preparation: 7.2.1 Prior to blast cleaning, Oil within a 500 mm wide band centered over the weld shall be removed from the pipe by solvent cleaning per SSPC SP-1. Kerosene, diesel, or similar degreasers that leave an oily film shall not be used. Acceptable degreasers are Saudi Aramco solvents SAP# 1000186759 and SAP# 01000198575. During surveillance inspection, it has been noticed that numerous pipe strings were un capped from kilometer 40 to 49 which violate SAES-L-450 para. 11.3. End cap shall be placed next to the following weld join numbers 1469, 1481, 1520, 1565, 1567, 1578, 1592, 1603, 1604, 1614, 1615, 1630, 1642, 1655, 1681, 1693, 1694, 1709, 1719, 1720, 1745, 1746, 1758, 1771, 1772, 1779, 1782. There will be two strings having weld joint number 1639 ~1641 and 1615~1617 at kilometer 44+500 to 44+600 respectively are resting directly on the ground. Another three strings having weld joint number 2289 ~2290, 2334 ~2346, 2347 ~2359 are fell of from the wooden skids and resting on the ground at kilometer 65+400 to 67+000. This violates SAES-H-200 para. 5.2.2.
SATIP-L-450-04
SAIC-L-2114
Mechanical
SAES
SAES-L-450
Appendix B
2230
7/23/2007 7:21:01 AM
QUAD-2 (56` DIA)
SATIP-L-450-04
SAIC-L-2114
Mechanical
SAES
SAES-L-450
Appendix B
2231
5/17/2007 2:58:45 PM
QUAD-2 (56` DIA)
NA
NA
Mechanical
ScheduleQ
Schedule Q
3.1
2232
6/8/2007 11:15:53 AM
QUAD-2 (56` DIA)
SATIP-H-002-08
SAIC-H-2059
Mechanical
SAES
SAES-H-201
7.2.3
2233
7/8/2007 1:07:30 PM
QUAD-2 (56` DIA)
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
2234
7/8/2007 1:30:32 PM
QUAD-2 (56` DIA)
SATIP-L-450-03
SAIC-L-2112
Mechanical
SAES
SAES-H-200
5.2.1
SAES-L-450
14.10.4
2235
4/4/2008 2:04:06 PM
During the VALVE INSPECTION and TESTING, cracks, porosities, L.O.F, QUAD-2 (56` spatters and under cutting found in the differnt areas of intermitent fillet DIA) welds between the stiffners and the valve body. Rectification of all the defects and removal of spatters and then touch ups of coating is recommended.
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.4.2
2236
During routine surveillance visit at Ainakhel fabrication shop, it was observed that the fabricated 42 piping spool, Drg # H15-L-BB-573140 Sht01, Rev 3 is 11/26/2007 QUAD-2 (56` released and sent to Al-qhatani coating yard without completing NDT (MPI)of 4:47:40 PM DIA) 2 welds, weld # 32 & 38. And found there is no spool control sheet/NDT summary available and approved for release. It is clear violation of SAIC L2038 (Final Inspection for Release of Fabricated Piping) Item no A9. During post weld inpsection of completed welds ( process Auto GMAW Passo) at mainline on 07 -May-07 , it was observed that the Cap height/ external reinforcement at 6 Oclock position found 3 - 4mm for weld joints MLW -1070, 1071 & 1072. Since it is not meeting the requirement of SAIC -WQUAD-2 (56` 2048 , attachment5 & SAES-H-201, para7.2.2 which required 1.5mm, it was DIA) informed to Saipem QC Inspector to rectify the same. But saipem QC inspector denied / refused to rectify the welds. It is a clear violation of Suadi aramco standards SAES-W-12 & SAES-H-201. Hence Saipem is advised to rectify the above welds and advised to strictly follow the saudi Aramco standard requirements which supersedes all Saipem work procedures requirements.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3
2237
5/7/2007 5:58:07 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
15 & Attach 5 of SAIC-W-2048
2238
7/16/2007 4:47:53 PM
During attending Holiday test of External Girth weld coating in KM 2+100 FW53A @ 2:30PM & 2+400 FW 65A 7/16/2007 found out that there are many damage coating near girth weld one meter from girth weld on both side. This QUAD-2 (56` is violation of the following Saudi Aramco Engineering Standard 1. SAES WDIA) 012 item 10.15 Coated and clad or overlaid surfaces shall be protected from the welding arc, associated weld spatter, and damage from ground clamps or other associated equipment (external line clamp). 2. SAES H-200 item 6.2.1 Protective sleeves made from welding blankets or QUAD-2 (56` similar nonflammable material at least 0.5 m wide shall be wrapped snugly DIA) around the coated ends of the pipes adjacent to the girth weld area while field welding is taking place. 3. SAES H-200 item 7.5.2 If the coating defect rate is higher adjacent to the QUAD-2 (56` field girth weld area than elsewhere along the pipe length, the Contractor shall DIA) improve the means used to protect the girth weld area coating during welding. During holiday test before backfilling of string 7 @ 8:00 AM to 11:00 AM 7/17/2007 Pipe lifted to allow Holiday ring to cover the whole area of the pipe. QUAD-2 (56` Weld tie-in joints FW 66A between string 6 and string 7 a welding proccess in DIA) on going during holiday testing . This is a violation of SAES W-012 Para 10.7.4 The pipe shall not lifted or moved during welding During internal manual coating inspection on FW-001D Km 44+900, it was noticed a broken pieces of glass inside the pipe. It was believed that glass was used by welders in their welding mask and left inside the pipe after welding. This is a violation of SAES-L-450 para. 11.5 states that each string of the pipe line shall be cleaned to removed all debris.
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.15
2239
7/16/2007 4:47:53 PM 7/16/2007 4:47:53 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-H-200
6.2.1
2240
SATIP-H-002-02
SAIC-L-2009
Mechanical
SAES
SAES-H-200
7.5.2
2241
7/18/2007 6:59:08 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7.4
2242
7/18/2007 5:40:14 PM
QUAD-2 (56` DIA)
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.5
2243
During focas assessmnet on electrode controlling at Tie-In weld sections at KM 26 & KM 38 on 11/28/07, it was observed that the low hydrogen electrodes E8018 C3 (the balance electrodes those are not used after open the electrode 11/29/2007 QUAD-2 (56` container) are being used for next day production without Re-drying and 3:59:22 PM DIA) without holding continuously (storage)at 120C temperature. Actually after open the electrode pack, some electrodes are used to weld a tie-in joint and the balance electrodes are neither re-dried nor continuously keep at 120C. This is a clear violation of SAES-W-12 , Table 1, page 41. During surveillance on 24.June.07 at mainline welding , the following Violations noted: 1)The surface preparation of internal pipe ends is not being QUAD-2 (56` inspected/monitored and the profile is not being recorded by Saipem QC due DIA) to unavailability of saipem QC at mainline since last 3 days. This is not complying Al-Qahtani procedure AQPCT-WP-379 Rev 8 , para 7.6 & 7.7. 2) Oil observed on internal surface of all bend pipe ends (due to hydraulic oil leakage in bending machine) but the abrasive blasting is under progress without removal of Oil using solvent. Which is violating SAES-H-201, para 7.2.1. Please refer QMIS entry # 398. 3) During checking of preheat temperature on MLW 2428, found both QUAD-2 (56` pyrometers (two) are not working condition. 4) The induction heating system DIA) is under break down. To achieve uniform preheat all around the joint (56 dia pipe), the induction heating system to be used. QUAD-2 (56` DIA) During Surveillance @ 9:30 AM 17-06-2007 Contractor are using Temperature Crayons in checking Pre-heat temperature this is violation of SAES-H-201 paragraph 7.3.4 Preheating temperatures shall be measured with contact pyrometers. Temperature crayons shall not be used. Coating materials Karumel EX 4413 drum at the job site exposed and direct sunlight this is not as per manufacturer requirement handling and storage procedure listed on drum to be stored in controlled temperature of 27 degree Centegrade. It was noted from MYN that during his inspection @ 1:30PM 10/23/2007 there is no QC-Coating on site. This is violation as per Schedule Q Para 5.1 Contractor shall provide resources to implement Quality System as set forth in this contract. For all... Construction activities, sufficient saudi aramco approved quality personnel identified in Attachment IV of this schedule Q shall be on site prior to the start of applicable work. and there is No blasting is done before welding It was noted from MYN that during his surveillance 1:30 AM 10/23/2007 found that Externally coated line pipe strung along the right-of-way supported by sand with hard rock it violate SAES H-200 Sec 5.3 Stringing Requirements it shall be supported on rock-free sand, sand bags, rubber tires, or similar compressible material to prevent coating damage. (See also the general handling requirements in Para. 5.1.)although externally coated pipe supported by rubber tires still the rock sand cover large portion of the pipe and it also violates SAES H-200 para 5.1 This is Secodary violation as per SUR # 963 which was noted that contractor will take proper action but not taken.
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
2244
6/24/2007 4:16:03 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
7.6 & 7.7
2245
6/24/2007 4:16:03 PM 6/24/2007 4:16:03 PM
SATIP-H-002-08
SAIC-H-2059
Mechanical
SAES
SAES-H-201
7.2.1
2246
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
11
2247
6/17/2007 2:20:34 PM
SATIP-H-002-02
SAIC-W-2015
Mechanical
SAES
SAES-H-201
7.3.4
2248
6/17/2007 2:20:34 PM
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-201
2249
10/23/2007 3:01:05 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
2250
10/23/2007 3:17:32 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1 & 5.3
2251
4/25/2008 9:44:12 AM
2252
4/26/2008 4:44:34 PM
2253
10/23/2007 2:55:26 PM
During the surviellance, it has been noted that the part of the pipe line is exposed to atmosphere although the backfilling has been done. It is due to unsufficeint backfilling or low depth of trench. Take the necessary action to correct it. During the welding of spool#232-B for UHW-2C, the hood cover(used for the air prtection) caught fire. The whole cover got burnt. Fire was any way extinguished by the help of the fire extinguishers. If the worker had not escaped well in time from inside the hood, it would have been very fatal. Contractor is required to refresh the awareness of the safe working conditions and habits to all the workers by time to time & some extra safety precautions are needed to be measured. It was noted from MYN that during his inspection @ 1:30PM there is no QCWelding on site. This is violation as per Schedule Q Para 5.1 Contractor shall provide resources to implement Quality System as set forth in this contract. For all... Construction activities, sufficient saudi aramco approved quality personnel identified in Attachment IV of this schedule Q shall be on site prior to the start of applicable work.
SATIP-L-450-02
SAIC-H-2016
Mechanical
SAES
SAES-L-450
14.3
NA
NA
Mechanical
SAES
SAES-W-012
19
NA
NA
Mechanical
ScheduleQ
Schedule Q
5.1
2254
10/23/2007 3:30:28 PM
It was noted from MYN that during his surveillance 1:30 AM 10/23/2007 found Violationthat Externally coated line pipe finished string mainline weld strung along the Prevented right-of-way removed ends cover as per SAES H-200 Bevel protector when Engineering used shall be firmly attached to the pipe. During surveillance inspection PID has found 36"KHAJ-1 pipeline string along Violationthe right of way was supported on rock sand which causing external coating After The damage and violating SAES-H-200.Contractor has been instructed to support Fact on rock free sand,sand bags,rubber tires or similar compressible material to prevent coating damage. Observed a violation of Saudi Aramco Engineering Standard SAES-W-12, Para Violation10.4.2 and 16.6.1.1.3i), 100% RT of Welded Joints using External Clamps and Prevented all Tie-In joints shall be conducted. Installation BALL VALVES LEAKED DURING THE BODY HYDROTEST: 2 Class 600 LBS Violation(SN# 227101003 and SN # 227101006),manufactured by Della Foglia,Italy, Prevented failed during the body Hydro test, these valves shall stand 2225 PSI however, Installation started leaking at 500 PSI. During routine site visit to above location it is observed ,the external surface ViolationQUU-4 (60` of of the pipe is coated manually violating AQPCT -WP-378 R-2 Para 7.0 & After The DIA) 8.2.3 which calls for using external FBE coating unit. Fact During survillance of KM 0+200, it was observed contractor has received 60 ViolationQUU-4 (60` FBE coated pipe with following descripinces 1. There is no Heat No mentioned Prevented DIA) on the pipe or any supporting document to have traceabilty of the pipes, Installation violating the PQP-PQMP Para 4.4.2 . QUU-4 (60` DIA) 2. Off the 56 Nos of pipe received at site, there is damage observed on 44 No pipes with blister formed all around the girth weld area. Violating 09 SAMSS Violation091 Para.8.4 The color and gloss of the cured coating shall be within the Prevented approved range and the cured coating shall be free of blisters and fish eyes as Installation defined in SSPC Vol. 1. Refer: PQP-PQMP Para 4.4.2 09 SAMSS 091 Para.8.4 ViolationAfter The Fact
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
2255
12/12/2007 10:56:46 AM 8/5/2007 4:30:34 PM 5/26/2008 11:12:26 AM 5/28/2007 12:16:16 PM 1/23/2007 2:22:05 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1 & 5.3
2256
SATIP-W-012-01
SAIC-W-2054
Mechanical
SAES
SAES-W-012
10.4.2
2257
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108 Work Proc#AQPCTWP-378 PQP-PQMP
4.7.5
2258
SATIP-H-002-02
SAIC-H-2009
Mechanical
other
7.0 & 8.2.3
2259
NA
NA
Mechanical
other
4.4.2
2260
1/23/2007 2:22:05 PM
SATIP-H-002-02
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.2.4 & 8.2.5
2261
9/30/2007 6:26:31 AM
2262
10/23/2007 1:43:56 PM
2263
10/23/2007 2:53:02 PM
2264
9/16/2007 1:13:34 PM
At Km 75+500 some pipes were noticed with internal coating scratch due to beveling machine shoe clamp is unpadded and directly touching the coating. This is violation with SAES-H-200 para 5.1.2. The contractor shall conduct inspection to find out all the affected pipes and shall do the necessary repair as per SAES-H-200 para 6.3.2. A bended double joint pipe with number 3549/6521 which placed at Km 91+000 was found with cracks on internal coating of the seam weld. The said pipe was coated by Al Qahtani and usually prone to cracking after bending as QUU-4 (60` observed in our projects. Found cracks could be interpreted using a holiday DIA) tester as a holidays which violated 09-SAMMS-091 para 10.6.4. The pipes shall be repaired by the contractor as per the requirements 09-SAMSS-091 para 10.6.6.1 prior to welding. This entry will be applied to all bended pipes and to be bended. Pipes having number 5729/5668 and 9292/10199 were found strung (22Oct.07)at Km 90+000 with scores of cluster external coating scratches. These pipes are fell off the truck along Saudi Cement highway during QUU-4 (60` transportation and the coating was rejected with reference to 09-SAMSS-089 DIA) para 11.1.1. The pipe shall be remove from being strung and quarantine. The contractors shall asses the extent of coating damage and propose a corrective action. It has been noticed that the FBE powder which is being used during manual coating of tie-in welded joints are being brought to work location in daily basis QUU-4 (60` by Al Qahtani crew from Dammam. This is violated the requirement of SATIPDIA) H-002-08 & 002-2 item 2.1 which requires the verification of FBE powder material for both internal and external prior to use on site. SAIC-H-2058 & 2011 listed all inspection items. QUU-4 (60` DIA)
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-200
5.1.1 & 5.1.2
SATIP-H-002-02
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.5
09-SAMSS091
10.6.4
SATIP-H-002-02
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.5
09-SAMSS089
11.1.1
SATIP-H-002-08
SAIC-H-2058
Mechanical
SAES
SAES-H-201
6.1
2265
9/30/2007 6:12:55 AM
QUU-4 (60` DIA)
The welded pipe strungs in 60 QUU 4/C from Km 71+250 onwards are not being capped. This violated SAES-L-450 para. 11.4. which states that open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds.
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
2266
9/20/2007 2:23:27 PM 5/10/2008 4:01:14 PM
2267
2268
5/10/2008 2:57:49 PM
It was observed that welded pipe strings in 60 QUU 4/C from Km 62+500 onwards are not being capped. This violated SAES-L-450 para. 11.4. which states that open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds. Please notify that pipe insulating sleeves shall be installed between the saddle QUU-4 (60` support and the pipes as per IFC BA574289-002. please checked the following DIA) locations. SL/124,SL/125, SL/126 , SL/127, SL/128, SL/129, SL/130 , SL/131. thanks. It was inspected that gaskets installed where not having proper identifications as per the approved procedure(KGSSP-QUAL-PCP-707 REV. B pages 6 and 13)paragraph 5.2.2 says that permanent marker paint shall be located @ four QUU-4 (60` equal sides of the gasket 90degree apart. Following flange connections are to DIA) be rectified: REF. DWG. No. BB-573131-001-0F2, BB-573131-002-0. Spool 131P-1, Spool 131-N-1, MOV 10708, Spool 131-J-1 , Spool 131-F-2, MOV 10709 , Spool 131-A-2. QUU-4 (60` DIA) It has been found that excess weld penetration and burrs are present with all the Passo internal welded joint at 60 QUU 4/C pipeline package C. This violated SAES-H-201 para. 7.2.2 which states that All weld joints including adjacent areas to be FBE coated either internal or external shall be ground to smooth and free from burrs, weld spatter, sharp edges. Weld toes shall be merged smoothly and rounded with no sharp undercuts.
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450 IFC Drawing# BA-574289002
11.4
NA
NA
Mechanical
Drawing
NA
SATIP-L-450-04
SAIC-L-2014
Mechanical
other
Work Proc# KGSSP-QUAL- Page 6 & 13, Para PCP-707, Rev 5.2.2 B
2269
9/12/2007 6:07:05 PM
QUU-4 (60` DIA)
SATIP-H-002-02
SAIC-H-2014
Mechanical
SAES
SAES-H-201
7.2.2
2270
11/2/2007 11:06:36 AM
2271
10/27/2007 4:19:58 PM
During routine site visit & document review it is observed contractor is not blasting joints prior to welding, which as per AQPCT-WP-379 Paragraph 7.6 is violating the procedure,as per prodedure the Client esc.(main contractorSEIPEM) shall use steel grit or garnet blast clean the pipe ends prior to UHW-2 (60` welding as per ISO 8501-01 to get the Sa 3 white metal cleanliness with DIA) profile of 1.5 to 3.5 mils. The interior of the joint shall be cleaned before welding it to the mainline pipe string. Client shall check and record the cleanliness and profile of each pipe ends. This violations are observed for joint No. MLW 15A,16A,76A,76B,76C,76D. The application of coating for more than a joint is not as per procedure AQPCT UHW-2 (60` -WP-378 R-2 Para 8.2.3 & 7 which calls for coating of the external surface DIA) with a machine applicator. During routine site visit to above line following discrepancies observed with robotic crawler coating. d. There is coating of 27th string being done with no joint cleared till to date, the video of 05 strings submitted has poor image, UHW-2 (60` problems with holiday detection, surface finish cannot be assessed because of DIA) the poor video quality etc. In spite of repeated request made there is no improvement achieved & Al- Qahtani is carrying out coating of joints with all above discrepancies. Refer Al-Quathani procedure 379 Rev-6 SAES-H-201 UHW-2 (60` a. The Robotic Holiday testing machine is not detecting holidays. (String No. 1 DIA) was manually holiday tested & found be with holidays) UHW-2 (60` DIA) UHW-2 (60` DIA) b. The Quality of Surface cleanliness found prior to coating is very poor with complete rust mark. (Photos attached), the Qahtani blasting machine cannot achieve any more cleaning. c. There is sagging of paints observed on external surface of coating (MLW192,213,228,239,241,261,266,267,268,270 etc)
SATIP-H-002-08
SAIC-H-2059
Mechanical
other
7.6
SATIP-H-002-02
SAIC-H-2015
Mechanical
other
8.2.3 & 7
2272
10/21/2007 3:00:21 PM
NA
NA
Mechanical
other
Al-Quathani procedure
Proc 379, Rev 6
2273 2274 2275
10/21/2007 3:00:21 PM 10/21/2007 3:00:21 PM 10/21/2007 3:00:21 PM
NA SATIP-H-002-02 SATIP-H-002-02
NA SAIC-H-2014 SAIC-H-2015
ScheduleQ SAES SAES
Schedule Q
SAES-H-201 SAES-H-201
7.1 of Attachment IV 7.2 8.2.4
2276
5/5/2007 4:09:30 PM
2277
5/13/2007 5:00:26 PM
RECEIVING OF PIPES WITH INTERNAL COATING CRACK. During routine site visit to above location, it is observed contractor is receiving 60 pipes with internal coating cracks. 1. This violates the schedule Q Attachment IV Para 4 UHW-2 (60` and 2. KGSSP-QUAL-PQMP-002, Para 4.1.2. Which says, saipem representative DIA) shall inspect the physical status of pipe before they are loaded on the trucks? SAPMT shall be notified immediately of any shortage, damage or other materials deficiency. Suspect material discovered before trucks are loaded shall be left at the storehouse or pipe yard until the discrepancy is resolved. During routine inspection of pipe bending activity at above location, it is observed the field bend made on Pipe DJ NO. 359, 1387 & 1307 has buckled. As per below standard, this violates the requirements. Refer: SAIC- L-2114 UHW-2 (60` Para A-9 & 01 SAMMS-010-Fabricated Carbon Steel Piping (cold bending). 01DIA) SAMMS-010 Para. 7.1.1. : Bends shall be completely free of buckles, dents, cracks, wrinkles, other mechanical damage, or indentations such as caused by the grips of the bending machine.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
Work Proc# KGSSP-QUALPQMP-002
4.1.2
SATIP-L-450-03
SAIC-L-2114
Mechanical
other
01-SAMSS010
7.1.1
2278
11/6/2007 5:53:22 PM
2279
9/19/2007 4:27:07 PM
2280
9/19/2007 4:27:07 PM
During routine site visit & attending RFI for back filling, it is observed back filling at above location is carried out without civil inspector available at site UHW-2 (60` which is violation of Schedule Q Attachment-VI Para 2.1CONSTRUCTION DIA) SPECIFIC QUALITY REQUIREMENTS 2.1. As a minimum, CONTRACTOR shall assign, or require its subcontractor to assign SAUDI ARAMCO approved quality personnel to the WORK During focus assessment of pipe stringing after completion of welding. It is observed the pipe string are rested on sand padding which have stones(20UHW-2 (60` 50mm) mixed with sand. Refer SAES-L450 Para 14.9.3 (shall not contain DIA) stones larger than 12 mm size that would cause damage to the pipe or pipe coating.) II. The pipe string of HWHD line are found with no end caps on, on inspecting UHW-2 (60` the pipe from inside it is found with Derbies & sand. Refer para 11.4 (Open DIA) ends of pipeline strings shall be capped to prevent entry of debris or animals and birds).
SATIP-L-450-03
SAIC-L-1004
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
14.9.3
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
2281
4/16/2008 3:26:29 PM
HARAD HP (16 DIA)
During surveillance of 16 line inside the Harad Gosp-II, it is observed MOV 202 installed on 16 line has no coating done on external surface. I had discussed this with Mr. Haja who told me this shall be coated after Hydro test. Firstly, the valve needs to have coating completed prior to delivery at site & Violationsecondly on receipt at site this shall have receiving inspection completed prior Prevented to installation. The surface condition of the valve is bad and it will be difficult Installation of achieve surface preparation made (SA2.5 Minimum) after fitment of bolts, it is there fore requested the valve shall be blasted & coated prior to installing on line. If the valve has to be accepted with such surface preparation & coating it calls for a waver. During routine site visit to above location, it is observed Hydro for the above line spool (151) is carried out with violation of Saudi Aramco standard requirements. 1. There is no proper RFI issued for conduction the pressure test, the timing of the pressure test was for 12Nov at 2130hrs, which was not conducted & no further proper time was scheduled for another inspection. The above all violate SAES A-004 Para 7, safety requirements per SAIC A2009, Schedule Q Attachment VI Para.4 U 2. On reaching the site it was found the test was completed with no procedure available. 3. There is no manifold used for pressurizing the spool.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2282
11/13/2007 HARADH 4:04:21 PM HP(20` DIA)
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.7
2283 2284 2285 2286
11/13/2007 HARADH 4:04:21 PM HP(20` DIA) 11/13/2007 HARADH 4:04:21 PM HP(20` DIA) 11/13/2007 HARADH 4:04:21 PM HP(20` DIA) 11/13/2007 HARADH 4:04:21 PM HP(20` DIA)
4. There is no second pressure gauge used as required by standard. 5. The nipple used has no rating available or mentioned on it.
2287
5/23/2007 11:14:39 AM
2288
5/14/2007 6:25:14 PM
2289 2290
5/14/2007 6:25:14 PM 5/14/2007 6:25:14 PM 5/14/2007 6:25:14 PM
During routine site visit to above location, it is observed contractor is performing coating of the above line with violation of procedure AQPCT-WP300-260. 1.The joints are coated with no record submitted or maintained at site. Presently there is coating of string No.14 being carried out with no proper record submitted as per the procedure. 2.The submitted record for string 1-4 is not as per the requirement of AQPCT-WP-300-260 Para: 8.2.3 Final HARADH Inspection. There was a joint video inspection done with Saipem Coating HP(20` DIA) Inspector & following deficiencies agreed which does not comply with the procedure. a. The Video camera picture is not clear for review. b. There is no evidence or video showing the holiday testing brush probe is making contact with surface. c. There is no Calibration test video or calibration witnessed record available for asserting the recorded reading is correct or holiday test performed is detecting know defects. violates Schedule Q Atth. VI Para. 2.5, 2.6 2.7 During Routine site visit to 20line(MLW-88 to 93) , it was observed the coating application for the line was carried out with following Violations. 1. HARADH - There is No QC Inspector from the contractor / Sub Contractor available at site HP(20` DIA) for ensuring the work is performed per the requirement of Standard/ Approved procedure. Refer Schedule Q. Attachment VI Para 2.7 & AQPCT-WP-378 (R2) 2. The joints for coating is preheated & coated without confirming the required HARADH temperature is reached (there is no contact pyrometer available with HP(20` DIA) contractor at site) Refer AQPCT-WP-378. (R-2) Para 8.2.2 HARADH HP(20` DIA) 3. The coating of the external joint is applied manually. Violating procedure AQPCT-WP-378. (R-2) Para 8.2.3.
SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02
SAIC-A-2011 SAIC-A-2009
SAES other
SAES-A-004
GI.2.102
5.6.1 5.1
SAES other
SAES-A-004
GI.2.102
8.1.5 5.1
SATIP-H-002-08
SAIC-H-2060
Mechanical
other
Work Proc#AQPCTWP-300-260
8.2.3
SATIP-H-002-02
SAIC-H-2015
Mechanical
other
AQPCT-WP378. (R-2)
Not specified
other other
AQPCT-WP378. (R-2) AQPCT-WP378. (R-2) SAES-H-201
8.2.2 8.2.3
2291
4. The existing factory applied coating is not abraded/ feathered. Refer SAESHARADH - H-201 Para: 7.2.4. The gloss shall be removed from the shop-applied FBE pipe HP(20` DIA) coating that will be overlapped by the field coating by light abrasive (sweep) blasting or sanding.
SATIP-H-002-02
SAIC-H-2014
Mechanical
SAES
7.2.4
2292
4/16/2008 3:42:08 PM 2/6/2007 7:30:35 PM
2293
2294
2/6/2007 7:30:35 PM
2295 2296
2/6/2007 7:30:35 PM 2/6/2007 7:30:35 PM
2297
2/15/2007 10:45:05 AM
BALL VALVES LEAKED DURING THE BODY HYDROTEST:20 Class 1500 LBS Violation(SN# 2225020001), TAG NO. H14-HOV-0207,manufactured by Della Foglia, Prevented Marnate,Italy, failed during the body Hydrotest, these valves shall stand 5575 Installation PSI however, started leaking at 4700 PSI. During attending for RFI for welding ( 20-NW Branch Header )Mainline KMViolationHARADH - 10+500 to 07+000.There are following violations of standard observed. 1. The After The HP(20` DIA) electrode used for GMAW (STT) ER 70S-3 has no receiving inspection done Fact prior use for production(SAIC-W-2044), there is no issuance record available with site QC Inspector (SATR-W2010),Violating PQP PCP-701 002.Para 5.2.2 (Delivery of electrode to store & ViolationHandling and issuance of electrode) and Schedule Q Attachment VI ,Para HARADH After The 2.4. 2. Electrode E-8018 C3 (Low hydrogen electrode) being used has no HP(20` DIA) Fact issuance detail available ( SATR-W-2010). There is no record available showing time of issuance,Violating PQP PCP-701 Para 5.2.2 (Handling and issuance of electrode) 3. Saipem Welder PVR is employed on production welding with out Job ViolationHARADH Clearance Card issued by inspection per SAEP-324,Violating PQP PCP-701 After The HP(20` DIA) Para 5.4 (possession of JCC). Fact ViolationHARADH - 4. Welding of pipe is carried out with out proper record of inspection(SATR-WAfter The HP(20` DIA) 2006). Fact Reviewing the weekly welder repair rate and weekly weld status, it is observed the welder IFA is found to a have alarming high weld repair rate, exceeding 15% joint basis, there is no action initiated by contractor on the welder till date and he is continuing with the production weld with WPS 204/07 Rev-0 (STT). On inquiring the current weld repair rate status with the contractor on ViolationHARADH 14 Feb 07, it is found to be alarming (13) 22% for the 58 field joint Prevented HP(20` DIA) radiographed. There is no action initiated by contractor per PCP-701 Para 5.3, Engineering with drawing the welder from the production welding. The QSWPIU is left with no option but to revoke the approval of said welder IFA, he shall be not allowed to under take any production weld with WPS-204/07 Rev-0 (STT) and shall be re-qualified for the same process. Refer Saipem PCP-701 Para 5.3 HARADH HP(20` DIA) During routine site visit to above location it is observed the line pressure of the above line is zero, as per SAES-A-007 Para 5.2.2.3 Maintain the system under a positive pressure between 210 to 350 kPa (30 to 50 psig) hydraulic pressure of the treated water. Install thermal relief for systems that are to be laid up with hydraulic pressure. For wet lay-up, establish and maintain throughout the system a minimum residual oxygen scavenger concentration of 20 ppm in the water and a maximum oxygen concentration of 10 ppb. Refer: SAES-A-007 Para.5 (Hydrostatic Testing Fluids and Lay-Up Procedures)
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7
SATIP-W-011-01
SAIC-W-2044
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
NA
NA
Mechanical
other
PQP-PCP-701002
5.2.2
SAIC-W-2005
Mechanical
SAES
PQP-PCP-701002
5.1
SAEP-324
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
PCP-701
5.3
2298
5/13/2008 9:00:48 AM
HWHDSWL(42` DIA)
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.1
2299
8/20/2007 4:17:35 PM
HWHDSWL(42` DIA)
2300
4/1/2007 3:38:24 PM
HWHDSWL(42` DIA)
2301
7/7/2007 4:18:46 PM
HWHDSWL(42` DIA)
During review of CD for String No. 076-077 & 077-078 (KM 23+480 (FW793B) & KM23+703 (FW-797-A) there are indication of defective coating observed at girth weld location, there are similar indications of this type found Violationon string No. 136, however having a visual inspection conducted at site for After The string No. 136 joints, it is clear the indication found for above joints (FW-793B Fact & 797-A) are not of defects, however on inspecting the other joints of string 136, it is found MLW-1230 & 1225 are having blisters & lumps, which as per SAES-H 201 Para 8.2.4 & AQPCT-WP-300-291 Para A8.2.1 are not accepted. During attending RFI for coating & holiday inspection at KM 0+000 ,42 HWHD SWL for Full thrust anchor, it is observed the internal repaired area of Violationcoating has small bubbles,Dry spray formation on the coating, which is not Prevented accepted per SAES-H 201, relevant Para of SAES is attached below for Engineering reference. H-201 Para. 8.2.4 The finished coating shall have a uniform, glossy appearance and be free of defects such as holidays, fish eyes, lumps, dry spray, sags and runs. During surveillance of coating activity on 5th Jul 07, following violation of standard observed. 1. The joints blasted during the day is being coated during the complete night shift Violating the SAES H-201 Para 7.3.2,As soon as surface preparation by blast cleaning operation is completed to specified standard & required profile is achieved and within a maximum period of 4 hours, the coating of the area to be completed. 2. There is no QC available Violationduring the coating operation. 3. There is no record for blasted surface After The available with QC or any evidence coating inspector witnessing the blasting Fact activity (related SAIC, time blasting commenced/finished, grit used & it related test certificate etc. 4. There is no temperature record (induction coil heating) prior coating available. 5. Calibration on Pup piece prior to coating / inspection not informed, violating inspection & test plan. Refer: SAES: Para. 7.3.2 AQPCTWP-378 R-2 Para 8.2.2, 8.1.4
SATIP-H-002-02
SAIC-H-2015
Mechanical
SAES
SAES-H-201
8.2.4
AQPCT-WP300-291
A8.2.1
SATIP-H-002-02
SAIC-H-2015
Mechanical
SAES
SAES-H-201
8.2.4
SATIP-H-002-02
SAIC-H-2014
Mechanical
SAES
SAES-H-201
7.3.2
AQPCT-WP378
8.2.2 & 8.1.4
2302
5/2/2007 4:50:27 PM
HWHDSWL(42` DIA)
During routine site visit to above loaction, It is observed Robotic Crawler FBE Coating of above line is made with Higher DFT observed on all the joints (average reading 35-40 Microns. as per SAES H-201 & field coating procedure, The machine shall apply powder to a uniform rate, to a correct width centered on the girth weld, to a minimum dry film thickness of 325 microns minimum up to 625 microns maximum for Internal, in the least number of passes possible. Refer H-201- Para 7.3.5.1 & Coating procedure AQPCT-WP-379 (R6)Para 8.2.1 During routine site visit to above location it is noticed major coating crack observed while bending 42 Dia pipe (22 degree) at Km 48, HWHD SWL, there is intermittent & continues cracks of length, varying from 0.9 to 1.5 long (approx) at 10 location along the spiral weld seam & between the Pipe,(No. 6538/1786). Looking at the extend of crack & no related repair procedure available this pipe is rejected per 09-SAMSS-091 Para 10.6.4 &12.4. During review of Video for above line, it is observed there is no video submitted for review for precoating inspection. refer to Al-quathani procedure 300-291-R 5 Para A7.2.7. 2. The Quality of the picture for above line is dark & not adequate for visual inspection Refer para A8.2.1. 3. The DFT reading for 42" Dia pipe needs to be 6 reading per joint. 4. There is no DSC Analysis check performed Refer para A8.6. 5. There is a log needs to be recored for temperature & RH to be maintained for FBE powder storage facility. During execution of holiday testing on string no. 40 and 41 it was noticed that the electrode travel speed is exceeding 300mm/sec inspite of often reminder with contractor QC not to exceed with the requirements. This violate SAES-H200 para 7.1. Furthermore the QC is not also conducting witness on the actual excecution of holiday testing. With reference to SATIP-H-002-02 item no. 3.7 (Only available SATIP) the level of inspection for the contractor is H1 which means inspection or test shall not be carried out without the contractor QA/QC representative in attendance. During visit to above site for witnessing inspection & Quality assurance performed to verify integrity of the pipe coating after bending operation, it is observed there is a cracking of FBE coating observed on Pipe no. 4116/4106. DJ No. 1298, at above location. Cracking of coating during bending is of great concern& violate SAES-H 200 , Para 5.1.2 & SAES L-450 ,Appendix B Preformed Cold Bending of Line Pipe. Refer SAES 200-H-200 Para 5.1.2: All equipment, including field bending machines and pipe cradles, that contact the coated surface of the pipe shall be padded. Slings shall be nylon or equivalent; steel cables shall not be used. SAES L 450 Appendix-B B.1.4 For internally coated pipe, the bend angle per bite may be reduced to minimize damage to the coating. (As a minimum, the internal coatings shall withstand the bends described in B.2). A corrective & prevent action to this may be immediately initiated During routine site visit to above location it was observed contractor is carring out spool fabrication for hydro test with violating following standards requirements. 1. Work not notified as per SATIP (SCHEDULE Q) 2. No quality requirements followed fit up,weldvisual etc. 3. No welding inspector available. 4. weld Joints found with off set, porosity etc. 5. Corroded pipe joints not cleaned prior to welding. 6. Material tracability not available. 7. Electrode control not followed (cold electrode being used) The Above all is violation SAES W-12 & Schedule Q Requirements. Upon completing the internal coating repair and holiday testing on 42 HWHD pipeline in June 19, 2007. PID has requested to have the accomplishment report to further check as per the actual accomplishment and at the same time to have as advance copy for information. However, the SAIPEM QC (Mr. Veerrakhavan) has denied the PID to acces the report to which they used to give a copy after putting their signature in previous days. This is a violation with reference to Shedule Q para. 1.6 which states that Contractor shall not refuse access to technical or other data which contractor consider prorietary or confidential, and which is reasonably required to inspect contractors performance of the work. During routine site visit to above location it is observed the Surge Relief Skid (H15-3 Run Surge relief Skid 12 Class 600) supplied by M&J Valve Company USA, has 03 Nos. Danflo Valve material 316-L connected to Carbon steel line without having isolating kit installed, Accordance to SAES-L-109 Para 11.5. a isolating sleeves and washers shall be used for isolating dissimilar material metal flanged joints (i.e., electrical isolation),and insulating joints for cathodic protection 1. Complete test package is to be approved for the hydro test of the 42" HWHD-SWL PIPELINE before the commencing of any hydro test activity (water Flushing, Filling, Venting).
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
7.3.5.1
AQPCT-WP378
8.2.1
2303
7/26/2007 11:44:17 AM
HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA)
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
8.2.4 & 8.2.5
09-SAMSS091
10.6.4 & 12.4
2304 2305 2306
8/24/2007 9:29:09 AM 8/24/2007 9:29:09 AM 8/24/2007 9:29:09 AM 6/25/2007 7:19:05 AM
SAIC-H-2060
Mechanical
other
Al-Quathani procedure Al-Quathani procedure Al-Quathani procedure SAES-H-200
Proc300-291-R 5 Para A7.2.7 300-291-R 5 Para A8.2.1 300-291-R 5 Para A8.6 7.1
other other
2307
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
2308
6/25/2007 7:19:05 AM
SATIP-H-002-02
SAIC-H-2016
Mechanical
ScheduleQ
Schedule Q
5.1
2309
4/10/2007 8:50:40 AM
HWHDSWL(42` DIA)
SATIP-H-002-02
SAIC-H-2011
Mechanical
SAES
SAES-H-200
5.1.1 & 5.1.2
SAES-L-450
Appendix B
2310
2/18/2008 2:17:42 PM
HWHDSWL(42` DIA)
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
1.7
2311
6/19/2007 7:00:57 AM
HWHDSWL(42` DIA)
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.6
2312
1/12/2008 6:16:17 PM
HWHDSWL(42` DIA) HWHDSWL(42` DIA)
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.5
2313
2/26/2008 10:31:56 AM
SATIP-A-004-02
SAIC-A-2003
Mechanical
ScheduleQ
Schedule Q
4.13
2314 2315 2316 2317 2318
2/26/2008 10:31:56 AM 2/26/2008 10:31:56 AM 2/26/2008 10:31:56 AM 2/29/2008 11:26:59 AM 2/29/2008 11:26:59 AM
HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA) HWHDSWL(42` DIA)
2. Work not notified as per SCHEDULE Q 3. Internal cleaning report per KGSSP-QUAL-MECH-004 was not prepared before commencing of the cleaning, this form is to be used to insure the Number and the condition of scraper send and received. 4. Water was not disposed properly. 1. The installation of the launcher and the two scrapers was done without inspection by any of SIPEM Quality department, SAPMT, SAPID. 2. The installation was not notified as per SCHEDULE Q. 3. Internal cleaning report per KGSSP-QUAL-MECH-004 was not prepared before commencing of the cleaning, this form is to be used to insure the Number and the condition of scraper sent and received.
NA SATIP-A-004-02 SATIP-A-004-02 NA SATIP-A-004-02
NA SAIC-A-2017 SAIC-A-2017 NA SAIC-A-2017
ScheduleQ SAES SAES ScheduleQ SAES
Schedule Q
1.7 8.1.2 10.2 1.7 8.1.2
SAES-A-004 SAES-A-004
Schedule Q
SAES-A-004
2319
3/26/2007 5:57:50 PM
HWHDSWL(42` DIA)
During site surveillance 42 HWHD SWL at 0900 hrs on 26 Mar 07, It is observed AUT scanning of MLW. No. 388 onward to 397 is being under taken with out, prior manual UT examination for lamination checks. This is violation of Procedure UT-06566 (General), Para 9, which calls for Pipe ends should be Violationexamined for lamination at the pipe mill / by manual UT method prior to AUT. Prevented The AUT carried out on 26 Mar 07 shall be noted as violation of procedure & Engineering needs to be re performed as required by procedure. Refer: Para 9.Scanning Preparation & Surface Condition Number : UT-06566 GENERAL Revision : E AUTOMATED ULTRASONIC TESTING Welder performance has not been properly controlled and COMPANY requests adherence to WPC Procedure and cites violations to agreement for control of Welding Quality. See e-mail to Danilo Sabio on June 10, 2008 (11:15 AM) requesting corrective action ASAP. Those informed will be ccd in the e-mail. ViolationAfter The Fact
NA
NA
Mechanical
other
UT-06566
2320
6/10/2008 11:12:48 AM 7/7/2008 5:26:24 PM 7/7/2008 5:34:20 PM 12/23/2008 6:39:11 PM
NA
NA
Mechanical
other
WPC Procedures
Not specified
2321
2322
2323
2324
3/30/2009 6:14:22 PM
In the stainless steel shop the Welds number & Welders symbol for the Violationwelded joints were marked on top of a masking tap taped to the pipe, where it After The should be marked properly direct on the welded joint with a low chloride Fact permanent marker. These violate SAES-W-011,Para. 16.1. In the stainless steel shop the Welds number & Welders symbol for the Violationwelded joints were marked on top of a masking tap taped to the pipe, where it After The should be marked properly direct on the welded joint with a low chloride Fact permanent marker. These violate SAES-W-011,Para. 16.1. In the Inlet/Outlet (B37) area internal coating has been started for 16 Violationdiameter line with APCS-2G system by OTC. The coated joints have not been Prevented inspected visually nor the DFT has been measured. This violates OTC Installation approved coating control procedure. Taki During surveillance inspection, PID noticed that there was a dead leg located at the portion of line 2-P-1998 at inlet/outlet area which is a potential for Violationinternal corrosion due to flow stagnation. This is violation of SAES-L-310 which After The the finding is in compliance with the criteria specified in section 11.4. Fact Contractor is advised to initiate the needed and proper corrective action to eliminate the flow stagnation. B32-2"-SR0660 Drain line (B32-2"-SR-0660) attached to the header line (B32-12"-P-1556) is 14.6" in length. This length of the 2 drain line forms a dead leg as per SAES-L- Violation310 Item 11-4-2. This condition is on all the similar pipes connected to the After The heat exchangers at Gosp-1 and all other GOSPs. Contractor shall review the Fact drawings and make necessary correction to comply with ARAMCO standards. Vent line (B32-2"-P-1386)attached to the header line (B32-12"-P-1386) is 31.7" in length. This length of the 2"vent line forms a dead leg as per SAES-L310 item 11-4-2.This condition is on all the similar inlet and outlet pipes connected to the heat exchangers at GOSP-1 and all other GOSPs. Contractor shall review the drawings and make necessary corrections to comply with ARAMCO standards. Numerous deficiencies were found on internal receipt inspection of B32-D0212 Desalter Vessel. No Data Dossier review was performed and no drawings were available for inspection. Deficiencies were photographed and forwarded to Bassam Ugaily & George Moldovan for their awareness and action by e-mail (April 26, 2008 @ 4:50 PM). Vessel was fabricated "out of tolerance" ... 32-SAMSS-004, Para. 3.1, VEFV1000, VEFV1002 Item # 26. See e-mail & photos attached. NCR & EDR is required ASAP. Major welding repairs and Method Statement to prevent welding distortion is required for Corrective Action. EDR & NCR should prevent any additional vessels from reaching site without proper elevation surveys. Tolerance of around 6mm has gaps up to 40 mm at site. See Photos and email to Bassam Ugaily dated May 19, 2008 ViolationAfter The Fact
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
2325
11/10/2008 9:36:05 AM
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
2326
12/22/2008 9:40:10 AM
B32-P-1386
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4
2327
4/26/2008 4:50:43 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
All cl refered in SAIC-D-2002 & 2003
2328
5/19/2008 2:28:30 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
3.1
2329
5/19/2008 7:02:52 PM
Contractor failed to acknowledge & incorporate adequate Corrosion and Cracking Control Measures during design phase for (8) Desalter & Dehydrator Vessels. In particular, internal critical piping components of this separation process include: Carbon Steel (CS) Piping components CS Flanges (not of code construction = SAES-D-001 & SAES-L-109 violation) Copper Alloy jet nozzles (Sour Service requires a Corrrosion resistant alloy) improperly tack welded / threaded directly to CS pipe (Galvanic/dissimilar weld metal corrosion and cracking will result) Welds in piping were not designed for prevention of SCC Bolting & bar stocks incl. use of zinc plate (Prohibited per SAES-A-301, Section 8) Numerous violations exist and references are as follows: 1. SAES-L133 (Para. 1.0, Sections 6, 7 & Para 7.2.4) 2. 34-SAMSS-004 (Para 3.1 & SAESA-301) 3. SAES-A-301, Sect 5 (CS matls piping, etc) & 8 (Bolting)
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
3.1
SAES-L-133
6&7
2330
9/28/2008 2:01:50 PM
During inspection the alignment of installed chemical drums in GOSP-1, I noticed some discrepancies on B32-D-0222 Corrosion Inhibitor Storage Drum as following: 1. Coating damage and grinding used enlarge base hole . ViolationInspection recommend to recoat damaged location which caused by wrench or Prevented grinder. 2. One of drum bolts highly attracted to be fitted to drum base hole. Installation Inspection recommended engineering to evaluate the findings. 3. One of drum bolts found without Polythene sheet and only protected with type wrap. Inspection recommended engineering to evaluate the findings. See E-mail dated June 2, 2008 to G. Moldovan describing poor practices by Al- ViolationSuwaidi group regarding "Correction of errors" due to mislocated bolt holes Prevented during erection of LPPT Vessel in Train # 1 Installation The horizontal vessel, B33-D-0215, erected in GOSP-2 has damaged Teflon tape and base plate has been slightly bowed on the sliding slide. Damage of Teflon probably due to the wrong use of plastic (CPVC) adhesive applied between Teflon and stainless steel plate which is a violation of standard Violationdrawing # DD-950008, Sheet#1, Note 2 says, TFE Pad shall be chemically After The etched and bonded using a hot setting epoxy resin adhesive. Contractor is Fact advised to take corrective action for the above said damaged Teflon pad. In addition to this contactor is also advised to take corrective action for the bow of base plate if it is above the acceptable limit. During surveillance it was noted that, contractor is violating storage and preservation of vessel by kept opening the inlet nozzles and manways during Violationthese rainy days thereby rainy water and other debris would go inside and Prevented lead to corrosion as well as would damage the internal coating. So the contractor is recommended to adhere to preservation procedure and cover the Installation inlet nozzles and manways during rainy days and close these nozzles when there is no activity as well. SAPID surveillance noticed that installed vessels D-0218,0223,0060,0222,0221 in all GOSP especially those having Austenitic materials for is not preserve as required by Schedule Q-IV-3 para 5. This is also a violation of 32-SAMSS-004 para 19.2.5 requiring nitrogen blanket with pressure of 5psig shall be provided during construction till prior to commissioning of the said vessels. Contractor shall make a provision to comply with this requirement. ViolationAfter The Fact
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-H-100
8.1.6
2331
6/2/2008 7:48:48 AM
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
2332
10/15/2008 2:16:30 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
Drawing
Drawing # DD950008, Sheet#1
Note 2
2333
11/9/2008 8:24:16 AM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2334
2/28/2009 6:55:11 AM
NA
NA
Mechanical
other
32-SAMSS004
19.2.5
Schedule Q
A IV Para 6
2335
10/19/2008 5:05:23 PM
In wet/dry heat exchanger in GOSP2, deposited water was observed when temporary blind was removed to connect the piping with the equipment which shows that heat exchanger was not drained and dried properly after testing by the manufacturer. Rust on the blind is consequence of deposited water for Violationlong time. Heat exchanger was supposed to come in purged with Nitrogen Prevented state which is not maintained for this heat exchanger. Contractors early action Installation on this is requested. It is advised to check the heat exchanger thoroughly from the inside and re-clean it properly if required. Equipments from same manufacturer shall be checked properly before connecting piping. Shipment to site of fin fan coolers did not utilize correct equipment and provide proper support of fin fan frame. See photo attached & sent to George Moldovan. Trucks need to be longer or modified with temporary support for these fin fan coolers It is observed SNAMPROGETTI has commenced final coating of APCS-1B at GOSP-1 & the procedure used for application of coating is violating manufacturer application procedure mentioned Per SAES H-101V for APCS- 1B. The contractor is using roller application for final coating of complete line, as per standard this needs to be spray applied. aS PER SAES- H 101V , APCS-1B Para 3.7 and SAIC-H 2028 C-1 : Brush/roller are used when allowed by the paint manufacturer or as indicated in the paint manufacturers data sheet in Item A1. ViolationAfter The Fact
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.1
2336
7/7/2008 5:16:08 PM
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2337
3/7/2009 5:22:55 PM
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-100
8.2.1
2338
10/26/2008 9:55:49 AM
During site surveillance of blasting & coating facility at Saipem coating yard on 25th Oct 2008, it is observed there is activities performed which violates Saudi Aramco coating & safety standards. The list of such violation is mentioned below & it is requested the contractor shall corrects this violation immediately & take necessary action to avoid repetition of such violation. a. Saipem sub contractor OTC is found employing unapproved blaster & coating inspector, this is violation of Schedule Q Attachment II Sl.No.8 SAEP-316 (Performance Qualification of Coating Personnel) b. It is observed blasting activities is performed without dead Man handle fitted on the nozzle ,this is violation of safety requirement per SAES-H-102 (Safety Requirements for Coating Applications) Para 4.4.2.1 Blasting shall be equipped with a remote control shut-off "dead man". c. It is observed the contractor is reusing the abrasive which is expandable type, this is violation per SAES H-100 Para 5.2.2 During surveillance of Al- Qahtani Coating activity at Snamprogetti coating yard it is observed that 2 and 3 spools including welded branch connection below 4 are being coated without approved coating procedure. This is violation of Schedule Q Attachment VI Para 5.2, list of special processes requiring Saudi Aramcos review and/or approval of work procedures. Contractor is requested to take corrective action at the earliest. Some examples are as below: a. Line B32-SR-0425, Spool No. S5A,3 Dia. shop weld No. 18 & 19. b. Line B32-SR-0377, Spool No. SQ1, 2 Dia shop weld No. 5. c. Line B32-RW-2285, Spool No. SQ1, 3 Dia. Shop weld No. 34.
SATIP-H-100-01
SAIC-H-2010
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2339
10/26/2008 9:55:49 AM 10/26/2008 9:55:49 AM
SATIP-H-100-01
SAIC-H-2026
Mechanical
SAES
SAES-H-100
4.4.2.1
2340
SATIP-H-100-01
SAIC-H-2024
Mechanical
SAES
SAES-H-100
5.2.2
2341
11/1/2008 5:43:39 PM
SATIP-H-002-08
SAIC-H-2057
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2342
4/20/2009 3:45:52 PM
Inspection was carried out on suction screen for LP and HP compressor in GOSP 1 and found that mesh wire was welded to the downstream of the reinforcing structure. The weld is found also to be insufficient to hold the wire mesh overtime that if been collapsed could cause severe damage to the Violationcompressor. This is violated the requirement of Aramco Standard drawing AB- Prevented 036764-001-01 that the screen shall be a perforated plates with a back up Installation screen at the upstream side. The contractor is requested to remove the installed screen in GOSP1/ 2 and consider the re-design the suction strainer in compliance with Aramco Standard drawing requirement. During attending RFI for Buried Vent Gas line No. B-32-VG-0308 (Externally coated with APCS 113A), there are discrepancies observed which does not meets requirements of SAES L-310 Para 13.3.2. 1. The line needs to be Violationprovided with Cathodic protection per L-310 Para 13.3.2(see below). SAES- L Prevented 310 1. 13.3.2 The buried piping (including appurtenances) shall be cathodically Engineering protected with impressed-current or galvanic anodes system to meet the requirements of SAES-X-400 or SAES-X-600. Serial # 3035, 3031, & 3032 of P.O. 23820 (8"-150-Gate Valve) were opened and photos taken of valve fouling at flange serrations and body sealing surfaces. Valve seat lubricant was filled with foreign matter, texture = sand blasting medium with "gritty" texture (photos taken and Snamprogetti ordered ViolationAfter The to file claims report. Valve internals require solvent cleaning to remove these Fact residues and fouling materials that could result in seat damage. Snamprogetti is requested to inform Vendor ASAP relative to Warranty and directions to proceed with Field Testing, and cleaning of valves. COMPANY REJECTS THESE VALVES ON RECEIPT Contractor SAECOs test manifolds (Rated at 6,500 psi) are improperly constructed with tapped holes and threaded nipples of 3000# construction with only 4 of nine threads engaged. This serious Safety threat was forwarded ViolationPrevented for weekly highlight consideration. SAECO safety was questioned on the job, Installation and their engineering department must provide a skecth of test manifolds. Snamprogetti must insure all Safety issues are addressed before WORK begins. SAPID noticed that externally coated piping spools and supports are just placed on the concrete flooring and ground scattered all around the area of GOSP1, 2, 3 & 4. There are some cases that the flange faces are just facing Violationthe concrete flooring without any protection. This is clear violation of SAES-LAfter The 350 section 7 requiring the storage of the coated pipes to be placed on Fact mounds or sleeper and not touching the ground. Contractor shall comply with the requirement of this standard and QC shall monitor and be proactive in this matter.
NA
NA
Mechanical
Drawing
Aramco Standard drawing AB036764-00101
NA
2343
2/28/2009 4:44:05 PM
SATIP-L-350-01
SAIC-L-2019
Mechanical
SAES
SAES-L-310
13.3.2
2344
8/6/2008 6:07:04 PM
SATIP-L-108-01
SAIC-L-2040
Mechanical
SAES
SAES-L-108
8.3
2345
8/6/2008 5:50:57 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
GI.2.102
5.1.5.5
2346
1/21/2009 10:20:19 AM
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
2347
3/19/2009 10:33:20 AM
PID observed that many piping spools being erected and stored on site are not having end covers nor protected from any ingress of foreign materials such as lumber, dust and animals. Salt water pump B32-G-0214A/B/C suction and discharge in GOSP1 were seen as the immediate example of this findings which is violated SAES-L-350 section 5.1 specially para 5.1.3 stated that the piping ends shall be covered after inspection to prevent unauthorized removal of the end cover prior to making the joint to the succeeding section of the piping. Contractor shall strongly implement the requirement of the mentioned standard to prevent any damage on any equipment or Aramco properties during startup or initial operation of the plant. During surveillance inspection, PID noticed that the platform gratings are clashing with pipe stand on vessel B32-D-0050A as well on line B32-6-RL0924. This is violated the SAES-L-310 para. 12.4 stated that a minimum clearance of 50mm shall be provided for inspection and freedom of pipe movement and to avoid contamination of stainless pipe stand by the carbon steel gratings materials. Contractor shall rectify the said findings as well as to verify other areas (GOSP-1/2/3/4) for possible having the same condition. PID noticed that installed relief valves at GOSP1 are having incomplete information on TAG which the calibration due or re-test date is not indicated. The relief valves having this problem are those calibrated in Al-Shuwayer. This is violated SAEP-318 section 9 which specify the requirements of relief valve tagging. In addition to this the Tag shall be firmly fixed with gage 16 stainless steel wire. Contractor shall identify all the calibrated valves having this non compliance and immediately rectify and comply with the requirement of mentioned standard. List of affected valves shall be submitted to PID for monitoring and inspection reference. The locknut provided for the heat exchangers installed in GOSP-1 is not fully engaged with the bolt which is a violation of PIP-STE05121, para: 5.6.6 & SAIC-M-2009, Item#A11, which states Bolts have full thread engagement with the nut. The bolt length used shall be such that the end of the bolt extends beyond or is at least flush with the outer face of the nut when properly installed. Contractor is recommened to take corrective action at the earliest. During surveillance of insulation activity for above vessel it is observed welding of pipe support on the vessel is carried being carried out, after the vessel is released for insulation, & even completion of the inner layer of rock wool insulation blanket. Above is violation of OTC insulation procedure, release for insulation inspection report.-MDT.CB.CDQ.0102, SAES-N-001 (Basic Criteria, Industrial Insulation) Para. 7.5.2 All equipment, vessels, and piping shall have been tested and inspected as required by the relevant specification prior to the installation of insulation. Project Scope: DOC.NO.00GA-E-60703 . Para 2. Insulation shall not be applied to piping or equipment until required pressure testing, & seal welding is completed. PIP INSH2000Installation of Hot Service Insulation Systems Para 5.1.3 It is observed OTC is utilizing the Carbon steel floating ring which is supplied with the vessel (B32-D-0202A &B), as per project scope (DOC.NO.00GA-E60703, Para 7.2.3, specification for hot insulation) this ring shall be of stainless steel material. Requirements of this floating ring & its material was discussed with the contractor prior commencement of the work, but still it is observed wrong material is being used. PID observed during surveillance inspection on installation of hot insulation on Crude Stabilizer B32-C-0202, that OTC is installing Aluminum Jacket without a vapor barrier. This is violated the contractor installation procedure MST-OTCKCC-384 rev. 0 section 4.4 which stated that the jacketing material shall be Aluminum 3003 or 3005 with factory applied polycraft moisture barrier. Prime contractor is advised to conduct immediate investigation on this regard and submit a concrete corrective action to PID. Contractor shall also verify the extent of the installed metal jacket without vapor barrier in all GOSP areas. It was observed that Some GCC welders kept their portable ovens unplugged. Cold electrodes were found in three ovens. This violates SAES-W-011, Para. 6.2. Contractor was informed. He promised to take action. Any action against portable oven custodians shall be communicated to PID. This is repeated violation and toolbox meeting shall be conducted with intimation to PID. All portable ovens shall have some sort of identification numbers for tracking purpose.
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
2348
4/4/2009 5:42:26 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
2349
4/7/2009 8:02:45 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAEP
SAEP-318
2350
9/11/2008 1:26:06 PM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
PIP-STE05121
5.6.6
12-SAMSS008
Sec I
2351
12/14/2008 11:20:08 AM
SATIP-N-001-02
SAIC-N-2006
Mechanical
SAES
SAES-N-001
7.5.2
Project Scope: DOC.NO.00G A-E-60703
2352
12/23/2008 5:21:51 PM
SATIP-N-001-02
SAIC-N-2006
Mechanical
other
project scope DOC.NO.00GAE-60703
7.2.3
2353
1/29/2009 1:53:48 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
1.3
2354
10/16/2008 10:15:19 AM
SATIP-W-011-01
SAIC-W-2010
Mechanical
SAES
SAES-W-011
6.1
2355
2/2/2009 8:07:11 AM
2356
7/15/2008 2:02:31 PM
2357
6/25/2008 10:12:57 AM
The repair activity on Fin Fan cooler B32-E-0054A was started in Gosp1 and one nozzle has been welded, however there was no single RFI has been raised to any activity. This is in violation of schedule Q attachment IV-1 closure 1.2.3 that RFI shall be raised within 24 hrs prior to the activity. On call basis during the activity inspection is allowing by PID but the RFI still needed to be raised for documentation record purposes. Contractor shall comply with project schedule Q. Welding preceded approval of package, and preheating was not accomplished resulting in tack pass cracking. CSD was consulted and preheat values were passed to Snamprogetti and INMA. Letter was issued documenting the deficiencies of repair packages and Welding practices by INMA. E-mail also covered repair package deficiencies regarding unacceptable condition (welding distortion) at the expansion end saddle base plate, 15 mm maximum distortion noted. The survey was randomly conducted to field weld work of process piping on all GOSPs revealed as following: 1. Arc strikes on some of completed joints. Arc strikes may result in hardening or fatigue cracking, and serve as potential sites for fracture initiation. 2. Poor grinding and cleaning after welding completion. 3. No QC inspectors around the jobs to clear these findings and no QC mark on weld joints;in addition, I was looking for them but no one appears. 4. Welders carelessly work and not dealing safely around work location such sleeping inside the weld shield laying over the pipe, throwing welding electrode around the welding location without using basket to collect used electrodes and the welder are not make any awareness to welding machine wires under their feet during welding which may slip or lose their balance. These discrepancies are conflicting of Saudi Aramco Standard SAES-W-011. NOTICED PERMANENT REPAIRS OF ANCHOR BOLTS TO ALL CRUDE TOWERS BY CONTRACTOR WITH UNAPPROVED REPAIR PROCEDURE, INSPECTION AND UNAPPROVED MECHANICAL COUPLINGS DESIGN AND MATERIAL. EVEN GALVANIZING AND COATING REPAIRS TO TOWER BASEPLATES ARE YET NOT ATTENDED EVEN AFTER PROACTIVELY NOTIFYING CONTRACTOR BY LBE#21768; "ALSO SEE THAT AFTER ATTENDING ERRORS THESE OBLONG HOLES SHOULD BE PAINTED & DRIED TO AVOID CORROSION.". The location of vent pipes installed in Oily Water Lift Station for all GOSPs including Inlet/Outlet Area violates SAES-S-020 para. 4.12.4. Horizontal distance of vent shall not be closer than 15meters horizontally from a source of ignition.Pump motors and electrical outlets are considered a source of ignition. Contractor is advised to evaluate the requirement and rectify the location of vent pipe to comply to the standard.
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
18.2
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11
2358
6/24/2008 6:32:30 AM
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
2359
5/24/2009 10:37:05 AM
SATIP-S-020-01
SAIC-S-2001
Mechanical
SAES
SAES-S-020
4.12.4
2360
3/21/2009 5:52:48 PM
2361
4/13/2009 7:10:58 AM
2362
11/3/2008 9:20:45 AM
2363
7/7/2008 7:35:12 PM 11/13/2008 10:24:15 AM
A focus assessment and investigation has been carried out on March 17-18, 09 for KCC equipments cleaning (4 GOSPs). The investigation covered 139 mechanical equipments, some piping and vessels (with different sizes). Two pumps were found uncovered from suction side. Pumps impellers were visible and dust was there (B32-G-0203B,B32-G-0026A). Many pumps were found Violationconnected to an open ends pipes. Dust and other objects can reach inside the Prevented pumps through these openings(B35-G-0231B,B34-G-0201B,B33-G-0201C,B34- Installation G0026A). A welding cleaning brush was found inside one of the piping systems. This is totally not acceptable because the brush may not come out even with air blowing (B35-FG-0261). All plant piping shall be cleaned per SAES-L-350 para. 15. NOTICED LACK OF PIPE CLEARANCE FOR SEAL FLUSH WATER SYSTEM IN ViolationGOSP-1 & RAW WATER SYSTEM IN INLET-OUTLET. THIS FINAL PIPE TO After The PIPE/STRUCTURAL SPACING IS IN VIOLATION WITH SAIC-L-2012 ITEM A3 & Fact SAES-L-310 PARA 12.4 During routine site surveillance it was observed that nozzles # N18 of LP Gas Compressor Suction Drum (D-0052) at GOSP-2 is very close to structure (platform). It is a violation of P&ID # BA-653603 SHT. # 021. Purpose of Violationnozzle 18 is to install a dummy spool when steaming out vessel (Note 5) in After The future. Platform will obstruct the dummy spool installation during steaming. Fact Contractor should take corrective action by modifying the platform. It is worth mentioning that many other nozzles in different areas are having same problems. Anchors and underside baseplate were damaged by SAIPEM supervision who Violationperformed an improper repair and bent anchors. Photos attached to e-mail After The sent to G. Moldovan Fact For the HP 2nd stage discharge drum (B33-D-0051), contractor has placed 0.5mm thickness CS plate between SS plate and Teflon which is violation of equipment drawing number B33-RC-B-20810. Contractor is advised to follow the drawing and remove this CS plate before it is too late. ViolationAfter The Fact
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.3
Schedule Q
5.1
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
SATIP-D-001-01
SAIC-D-2002
Mechanical
Drawing
P&ID # BA653603 SHT. # 021
Note 5
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005 Equipment drawing number B33RC-B-20810
4.8
2364
NA
NA
Mechanical
Drawing
NA
2365
11/15/2008 8:14:58 AM
2366
3/4/2009 2:45:37 PM
2367
12/30/2008 10:40:38 AM
2368
11/22/2008 7:27:02 AM
Horizontal vessel, B33-D-0205, has been erected in GOSP-2 without pre installation inspection of the foundation which is a violation of SAIC-D-2006. ViolationAramco inspection did not inspect and release equipment and foundation After The retainers as well as Teflon bondage. It was noted that Teflon they provided Fact has been detached already due to wrong adhesive which is REPEATED VIOLATION of entry#38747. Contractor is recommended to take corrective action as early as possible. Internal inspection of Wash Water Surge Tank B33-D-0215 at GOSP2 revealed the installation of the two blind flanges of water jetting piping is clashing with the north end side of the vessel shell which is coated. Moreover, loose and Violationmisaligned flange connection is also observed with visible gap which is sign of After The un-tightened bolts. This is violated the vendor issued for construction drawing Fact 40015-M03-02 rev. 4 which is showing a proper installation. Contractor shall coordinate this violation with the vendor for immediate corrective action on this issue. The same vessel in GOSP-1/3/4 shall be rectified as required in GOSP-2. During routine survillance of the facaility at GOSP-II its observed MAC ViolationKettaneh is using Silica sand as a abrasive material for blasting Concrete After The structure & foundation. use of sand per SAES-H-001 Para 6.3.2 Silica Sand as Fact abrasive material is prohibited in Saudi Aramco as per GI-0006.021 requirements. During pre-punch listing of line (B33-P-1334) prior to hydro-test, wrong bolting material was noted at flanged joint connection FJ-3 & FJ-2. Final flanged joint inspection had been completed & accepted by contractor QC. B7 bolts & 2H nuts were used against B7M & 2HM bolts as mentioned in IFC Violationdrawing (Line No. B33-12-P-1334-1CS2P1-PP). This is violation of SAES LPrevented 109 Para. 12.4 and Contractors Piping Specification (GA-E-60001 & Drawing). Installation Contractor is requested to replace all the fasteners as per above requirements & re-offer the same for final flanged joint inspection, it is also requested that all previously accepted joints with above discrepancies shall be identified & corrective action shall be taken Check valve installed vertical position in line No. 3"P-1342 sheet 1, is a violation in SAES-L-108 para 6.3.5. Contractor shall revised the location of the check valve or approval from the chairman is required. During re-instatement in GOSP-2 dated 05.05.2009, it was observed in TP0018 (High Pressure Line) line number SR-0459 and SR-0460 that isometric drawing were not match in P&ID. By verifying P&ID downstream of MOV-3025 A/B spectacle blind of the drain line after the valve should be in closed position contradicting in ISO drawing operating in open position. Therefore engineering shall issue a revise drawing to construction department in GOSP-2, 3 & 4 to correct the installation of spectacle blind. During the hydro testing of 600 lbs class piping system (line 2-P-1510) in GOSP-2, it was noticed that lesser thickness of Stainless steel test blind flange 300lbs is being installed connecting the manifold and the system under pressure. Stainless steel x 300 lbs is only rated for 900lbs test pressure (with reference to ASME B16.5) and the system is under pressure of 2.225 psig which might explode anytime and imposed a potential hazard with the people around and nearby areas. The hydro test crew foreman that time was immediately instructed to depressurize the system to avoid catastrophic results to human life and properties. This is a violation of SAES-A-004 para 7.3. With regards on this, contractor shall strictly implement SAIC-A-2009 and submit a concrete solution to prevent the re-occurrence of this near miss. SAPID inspection noticed the installation of 3 check valve is in vertical position on line 3-P-1546 in GOSP-2 nearby vessel D-0051. This is in violation of SAES-L-108 Para 6.3.5 stated that check valves in sizes NPS 3 and above shall not be installed in vertical lines. This is in typical situation with all GOSP. Contractor is advice to comply with the proper installation of the check valve. During my routine inspection I was observed that in line B33-SR-0758 check valve and gate valve installed not as per drawing. Contractor advised to install the check valve in up-stream and gate valve shall be in down-stream location as per isometric drawing. After completion of the above mentioned PID will check and verify the installation. During my routine surveillance in GOSP-2 dated 23.04.2009 it was observed that in line B33-SR-0813; B33-SR-0370; B33-SR-0700 check valve installed in wrong flow direction. Therefore contractor advised to install the check valve in correct flow direction and offer for PID verification. During my routine surveillance in GOSP-2 dated 23.04.2009 it was observed that in line B33-UW-1262; B33-UW-2703; B33-UW-1266 globe valve installed in wrong flow direction. Therefore contractor advised to install the globe valve in correct flow direction and offer for PID verification. ViolationAfter The Fact
SATIP-D-001-01
SAIC-D-2006
Mechanical
SAES
SAES-Q-005
SATIP-D-001-01
SAIC-D-2003
Mechanical
Drawing
Drawing 40015-M0302 rev. 4
NA
SATIP-H-100-01
SAIC-H-2024
Mechanical
SAES
SAES-H-100
5.2
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-350
12.4
IFC drawing (Line No. B3312-P-13341CS2P1-PP)
NA
2369
4/23/2009 1:39:11 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.5
2370
5/5/2009 5:45:14 PM
SATIP-L-350-01
SAIC-L-2022
Mechanical
Drawing
P&ID # & ISO Drawing # line number SRnot 0459 and SR-0460 mentioned.
2371
2/24/2009 7:54:07 AM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
8.3
2372
3/11/2009 2:23:28 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.5
2373
4/26/2009 9:55:53 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
Drawing
P&ID # & ISO Drawing # line B33-SR-0758 not mentioned. P&ID # & ISO line B33-SR-0813; Drawing # B33-SR-0370; B33not SR-0700 mentioned. P&ID # & ISO line B33-UW-1262; Drawing # B33-UW-2703; not B33-UW-1266 mentioned.
2374
4/24/2009 1:44:24 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
Drawing
2375
4/24/2009 1:46:24 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
Drawing
2376
3/1/2009 4:04:08 PM
During performing survillance of Hydrotest activity for above line , It is observed the water analysis report submitted by MMG is not meeting hydro testing requirements for testing 300 series SS lines, as per SAES-A-007 the chloride content shall be less then 50PPM,but the report submitted by MMG has chloride content 70ppm. The contractor is requested to have the corrective action per SAES-A-007 Para 6 shall be followed to clean the spool and verify the surface choloride of spools is less then 50ppm. SEAS-A-007 , Para 6.1 Type 300-series stainless steels shall be tested only with water that has very low chloride content in order to avoid pitting and stress corrosion cracking. The maximum allowable chloride concentration is 50 ppm. Verify the quality of the water following the requirements of Paragraph 4.2. Site surveillance & walk through of line prior hydro testing, its observed MMG is utilizing ungraded blind flange. There is no design calculation or inspection being performed for acceptance of blind flange prior to use. As per SAIC- A2009 Fabricated test components (blinds, spools, welded couplings, etc) are of proper code construction, receive inspection and are properly identification/marked for their pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never allow uninspected non-code test component use. Components found unfit for testing (non-code, under thickness or schedule & without calculations, deteriorated, damaged, corroded) are reported and removed ASAP from Company Projects. Please see attached photographs of fabricated blind, which violates the above SAIC A-2009 requirements During attending RFI for hydrotesting of fin fan cooler after completion of damage repair, it was observed contractor is not adhering to the below required mentioned in G.I.-2.102, Para 5.5 ,Relief valve is located in the system under test and near the test pump with Isolation valves on the inlet and outlet of the relief valve sealed open during the test. (SAEP-1160, Bullet Item # 3). The test was rejected and contractor was requested to comply with above requirement. Internal inspection of B34-D-0212 Desalter performed and revealed the followings: 1. External metal pitting defect visible under the coating layer along the 3-5 oclock positions on the third shield from the west side of the vessel. Inspection recommended to gritblast 2X2 feet the third shield for farther inspection an. 2. External metal pitting defect visible under the coating layer and improper coating application along one of 8 inlet header spools from the west side of the vessel. Inspection recommended removing this spool to the shop for gritblasting and farther inspection. (This spool was marked on the vessel). 3. All marked coating damage locations should be repaired. Snamprogetti Quality Group allowed installation and covering (induced draft fan shroud / guard) of fin fans coolers WITHOUT performing Receipt Inspection. Numerous damages to erected fin fans exist (bent nozzles, damaged tube fins, frame damage, etc). No RFI has been presented in accordance with 00-ZA-E-09622 (Quality Plan violation). As damages may now be covered up (due to shroud installation), COMPANY must invoke "inspection access" clause of Sch Q, and requests immediate issuance of RFI and full inspection of erected air coolers. In the future, the upper layer of fins must be inspected, cleaned, debris removed, bent fins "combed" and straightened as per checklists. Conducting surveillance at GOSP-3 its observed the spools cut for correcting the parallelism of the pump 0231 has cause alignment/level of the pump suction line displaced, its requested contractor may assess the alignment of suction line for this pump (0231A,B&C) and carry out necessary corrective action to have the suction line aligned/leveled as per IFC drawing. As we know misalignment of this line can cause starving of the pump & which may lead to formation of cavitations during suction. Please see below attached photos of the pump suction line, which clearly shows the line is misaligned, A log book entry for the same is made in QMIS for having this corrective action initated by contractor. It is also observed the interconnecting pipings of the pump (0204A & 0231 AB&C) installed has various deficiencies, there are location missing orifice plate & loose flange connection found, it requested this shall be completed with part of PUMP Mechanical package. surveillance conducted and found out that the Structural contractor are doing painting on new welded structures without proper cleaning/surface preparation on damage area and done by unqualified painting personnel.The contractor was advised to comply the requirements on APCS and SAES-H-101
SATIP-A-004-02
SAIC-A-2008
Mechanical
SAES
SAES-A-007
6.1
2377
2/10/2009 5:12:00 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
8.3
2378
3/13/2009 1:51:21 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
GI.2.102
5.5
2379
9/28/2008 1:53:39 PM
SATIP-D-001-01
SAIC-D-2003
Mechanical
SAES
SAES-H-100
8.1.6
2380
7/29/2008 12:09:56 PM
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2381
6/13/2009 9:53:43 AM
SATIP-G-005-01
SAIC-G-2005
Mechanical
SAES
SAES-G-005
5.2
2382
9/15/2008 3:18:38 PM
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAEP
SAEP-316
3.1
2383
1/12/2009 1:40:31 PM
2384
5/19/2008 11:25:37 AM
2385
4/16/2009 2:15:54 PM
2386
3/31/2009 8:10:48 AM
2387
12/3/2008 11:03:29 AM
2388
5/8/2009 10:24:25 AM
During site surveillance of OTC yard coating activity, its observed 2 Spool is being internally coated with pouring & hand rolling the spool. There is no such approved procedure available with OTC, the only approved procedure is with machine rolling, which is calculate based on quantity of paint & with sufficient RPM for rolling on special approved rig roller. Please refer :OTC Method of statement, OTCS/315900/C-03PRR,Rev 0 scope, internal coating of 2 to 6 spools using pipe rolling rig method.. There is 10 such spool found violating the scope requirements.( B-34-SW-1136-S7, B-34-SW-1139-S7, B-35-SW-1136S7). Above is violation & it is requested the spools may only be coated with approved work procedure from SAPID. It is also requested spools with complicated fabrication shall be only coated with proper demonstration of quality requirements done prior to coating. The second production weld by Al-Qahtani was visually examined in all three phases (weld root exam, post-clean/blast, post-coating repair). Deficiencies were found as identifed by photos & e-mail (D. Sabio 5-19-2008 11:30AM) See attached e-mail for proposed action to correct deficiencies and ensure COMPANY acceptance on future joints Its observed OTC & APQCT is carrying out internal coating of line without having proper arrangements for cleaning the leftover abrasive from spools, which is violation of their procedure to clean the spools before & after each blasting operation. Today during surveillance at GOSP-3 &4 (Line no. B-3410RW-2269) over a 100mtrs lengths on main pipe rack was being blasted without having proper provision available to internal clean the line. On enquiring regarding this from there site representative, its was know they are planning to clean the line prior to hydro testing with pneumatic blow through, which is of a great concern because the abrasive after each operation shall accumulate and be difficult to be removed prior to hydro testing by air blow through, also there are chances that this shall clough the various equipment like valve fitted on the line. A proactive is submitted to remind contractor the requirements of internal cleaning of line. Its observed the coating scheme applied on line 20" P-1505 at GOSP-3 & 4 is APCS-1B, were as, as per line requirement for PP insulation this shall be 17A( refer coating schedule). Also as per SAES-H-001 the compact ability over coating on 1B with 17A is not permitted , contractor may be requested to blast & recoat the line with APCS-17A. The operating temperature of the line is 285 degree F and if PP insulation is applied with present condition the coating shall fail. Surveillance of above area it is observed the quality of painted spool (APCS17A) released from Saipem Open shelter coating yard is very poor & of real concern, there is holidays of more them one Sq.ft and rust formed on it. The details of few such spools is as follow. (B-34-S-0047, Spool 10. BFW-1277-S-2) It is requested all such defective coated spool shall be removed re-blasted & coated. During checking reinstatement of TP-148,its found the check valve installed in the line is found without flapper, this is second instance a check valve is found installed without flapper & been offered for reinstatement inspection. I would like to bring this to your notice because, 100% checking of each valves during reinstatements is not possible & feasible during reinstatement, this shall be not appropriate for construction as well for PID, Presently there is a joint inspection being offered and so the QC cannot be made responsible for this. I request the contractor may be advised to complete the reinstatement and have the line accepted by there QC, thereby making a person responsible & account for such incidence. TP- 148 , LINE 2 B34-0418 While performing surveillance of pipe laying activity ,it is observed on pressure server line & at various other line that the check valve has a gate valve installed next to the same(see line SR0493) without any distance kept between, which is violating the Aramco standard SAES-L-108, Para 6.3.4 i.e. For all sizes NPS 4 inch and above, a turbulence-free minimum distance of 5 pipe diameters upstream and 2 pipe diameters downstream of every check valve shall be maintained. No pipe fittings such as elbows, reducers, tees, etc., or flow restricting devices such as orifices, control valves, etc., shall be installed in these zones unless specifically approved by the Chairman of the Valves Standards Committee. It is requested the contractor shall comply with the above standard requirements and modify all the line which does not meet above Aramco standard requirements.
SATIP-H-100-01
SAIC-H-2023
Mechanical
Scope
Method of statement, OTCS/315900 /C-03PRR,Rev 0
Scope
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
7&8
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.4.4
Contractor Coating procedure
Not specified
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-001
7 & 10
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
SAES-H-100
8.1.6
SATIP-L-350-01
SAIC-L-2022
Mechanical
Drawing
P&ID# / TP148
LINE 2 B340418
2389
4/20/2009 6:25:00 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.4
2390
3/13/2009 11:49:59 AM
During witnessing gasket installation for line B-34-SW-1130, Class 15LEOP in GOSP-3, it was observed contractor is installing gasket (pikotech) on the joints without removing the FBE coating from the flange face. As per ASME B 16.5 the flange face shall be clean & have required serration. ASME B 16.5 PIPE FLANGES AND FLANGED FITTINGS 6.4.5.3 Other Flange Facings. Either a serrated concentric or serrated spiral finish having a resultant surface finish from 3.2 to 6.3 _m (125 to 250 _in.) average roughness shall be furnished. The cutting tool employed should have an approximate 1.5 mm (0.06 in.) or larger radius, and there should be from 1.8 grooves/mm through 2.2 grooves/mm (45 grooves/in. through 55 grooves/in.). It is requested contractor comply with above standard requirements.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.3
SAES-L-109
12.10
2391
5/5/2009 1:28:59 PM
2392
5/27/2009 8:48:05 AM
2393
6/13/2009 4:37:54 PM
2394
3/9/2009 5:45:39 PM
2395
5/10/2009 7:12:56 AM
2396
5/20/2009 4:58:22 PM
Its observed during reinstatement, the below shown half repair weld joint is not having any weld summary reflected in the mentioned Test package, as per the attached weld summary this joint was shop welded and internally & externally coated. It is requested contractor may be advice to Re-hydro test Violationthe modified repaired joint spool and also confirm whether this is internally After The coated, as there is no internal coating report attached in TP. The Contractor is Fact also requested to submit internal coating report during reinstatement of line, the above package is also rejected for no internal coating report. (GOSP-3, TP520, Line number,SR-466, Joint number-20(shop weld) During my re-instatement in GOSP-3 dated 26.05.2009 in package TP-010 it was observed that the flow orifice (B34-FO-0022) installed in the line P-1496 Violationwas found site fabricated. In order to accept the item contractor engineering After The shall submit the proposal to ARAMCO and approval is required before making Fact site fabrication. The package is in hold until the contractor provides the acceptable FO-0022. During survillance at GOSP-3 its observed the Saddle type support (SPS-X2751,2753 etc) there is a need for providing additional bracket welded between beam flanges. It is requested contractor shall identify this location & provide an additional plate brackets at all such structural support location at GOSP-3. Some few location are mentioned below for information. P-1509 ViolationSUPPORTS NUMBERS (S-17,607&S12,621), P-1498 SUPPORTS NUMBERS(SPrevented 13,620), P-1467 SUPPORTS NUMBERS (S-23,451,18,452), P-1468 SUPPORTS Engineering NUMBERS(S-23,451,19,452), P-1471 SUPPORTS NUMBERS(S17,452,456,454,455,17), P-1500 SUPPORTS NUMBERS(S23,622,611,609,620,674), .The above supports belong to Test package 81,82,83,10A,001 & 002 It is observed 30 ball installed on line B-34-30 P-1364 (ICS2P1-P) Tag No. ZV3011C is found to be having one of the grease nipple broken during handling, this improper handling is violation SAES- L- 350 Par-8, All materials shall be handled with care during fabrication and installation to prevent damage It is requested the valve repair and testing shall be carried out with approved procedure accordance to applicable Aramco standard. Please also refer below ViolationSAMSS. 04-SAMSS-048 (Valve Inspection and Testing Requirements) 4.3 After The Repairs of valve components with unacceptable defects shall be in accordance Fact with the governing material specification for the component. Proposed weld repairs that are not covered by the applicable material specification shall require the approval of Saudi Aramcos Engineer prior to the performance of repair work. All pressure tests shall be repeated on valves after any weld repair to the pressure retaining components. During routine surveillance of the site at GOSP-3 ,Pipe rack-2, its observed 10 Globe valve installed on line SW-1145 is damaged while moving a Violationcompressor , the cap provided at the hand wheel with manipulating lever is After The broken. This is violation of below standard requirement and the contractor is Fact requested to take necessary action replacing the damaged part. Document Responsibility: Piping SAES-L-350, Construction of Plant Piping Issue Date: 30 September, 2003 Its observed the nitrogen line installed at GOSP-3 & 4 is not provided with Drain & Vent provision at all location as per P&ID drawing (see below line Violationnumber for location), this is violation of IFC drawing requirement and the After The contractor is requested to comply with the approved drawing. P&ID No: BAFact 653736-001(Nitrogen Distribution line Gosp-3) Line Number: 2N-1784(Pipe rack-3) : 2N-1795(Pipe rack-7) Without raising SAIC-D-2006 (pre-installation inspection for equipment foundation), Contractor has installed another vessel, B34-D-0205 at GOSP-3, which is violating company procedure and standard. Aramco inspection is not sure about what type of plate has welded to equipment saddle and foundation base plate since contractor did not raise any RFI for the same. Contractor shall be advised to adhere to company procedure and to avoid this type of practice which leads to unnecessary delay of the project.
SATIP-L-350-01
SAIC-L-2022
Mechanical
SAES
SAES-L-350
21
SATIP-L-350-01
SAIC-L-2022
Mechanical
Drawing
P&ID # not Orifice No B34-FOspecified. Line 0022 no P-1496
SATIP-L-350-01
SAIC-L-2022
Mechanical
Drawing
Pipe support SPS-X-2751,2753 drawing (AFC)
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
SATIP-L-350-08
SAIC-L-2034
Mechanical
SAES
SAES-L-350
SATIP-L-350-01
SAIC-L-2012
Mechanical
Drawing
Line Number: 2NP&ID No: BA- 1784(Pipe rack-3) 653736-001 : 2N-1795(Pipe rack-7)
2397
11/17/2008 7:10:52 AM
SATIP-D-001-01
SAIC-D-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2398
6/15/2009 2:35:31 PM
2399
2/7/2009 1:56:04 PM
During surveillance & inspecting the joint for internal coating its observed the fit-up made for weld o let (branch connection) is not as per SAES-W-11 requirements, the cut made on header is under sized by more than 8mm in diameter, as per W-11 Para 11.3.2.1, all holes cut for set-on nozzles, bosses, or branch connections shall be ground smooth and the diameter of the hole shall be 1.6 mm of the inside diameter of the set-on member. It is requested the contractor shall rectify the above finding. Line Number: SW1171 Field Weld number-145 A, GOSP-3 Surveillance conducted on GOSP 4 and found out that the spools with line no. P-1346 TP-138,P-1340 TP-135 and P-1317 TP-142 was cut and reweld because of misalignment found during installation of PZV. The spolls was hydrotested and accepted. The contractor was advise to conduct re-test on that test packages. The vessel, Water-Oil-Separator, in all the four GOSPs, for eg: B35-D-0213 in GOSP-4 has been PWHTed as per the name plate and data sheet. But PWHT caution sign is missing on the vessel which is a violation of 32-SAMSS-004, para: 15.6 which states, A sign shall be painted on a postweld heat treated vessel and located such that it is clearly visible from grade reading: "CautionVessel Has Been Postweld Heat Treated-Do Not Weld". Without raising RFI, SAIC-D-2006, Contractor erected another vessel, D-0051 in GOSP-4 which is a violation of Aramco standard and damaged the foundation. Same adhesive which is used for carpet and rubber is being used. This is a repeated violation of entry #42220 on usage of wrong adhesive. Now the contractor has started erecting structural around the vessel without taking corrective action on above above issues. Contractor is requested to take necessary steps in order to avoid delay in the project. Contractor raise RFI for Holiday Testing of fire water line with line no.B35-FW1891,FW-1910 and FW-1953 at GOSP no. 4 and found out that the line was backfilled without holiday inspection and tape wrapping. The contractor advised to excavate and expose the whole line prior for inspection. Inspection of Holiday Testing to be conducted at B35 GOSP 4 at Fire Water Line with Line no. FW-1891,FW-1910 and FW-1953 and found out that the line was backfilled by the civil contractor without holiday test and tapewrap. The contractor was advised to excavate and expose the line for inspection.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.2.1
SATIP-A-004-02
SAIC-A-2001
Mechanical
SAES
SAES-L-150
5.4
2400
9/6/2008 9:43:02 AM
SATIP-D-001-01
SAIC-D-2002
Mechanical
other
32-SAMSS004
15.6
2401
11/26/2008 5:23:39 PM
SATIP-D-001-01
SAIC-D-2006
Mechanical
ScheduleQ
Schedule Q
1.7
2402
9/13/2008 9:28:46 AM
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
2403
9/14/2008 6:57:56 AM
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
2404
4/7/2009 6:24:57 AM
2405
1/26/2009 7:57:28 AM
2406
9/14/2008 5:12:46 PM
2407
9/17/2008 2:10:51 PM
2408
9/17/2008 2:22:42 PM
It is observed the branch line from 10-SW-1139 leading to pressure and gravity sever line 2-SR-0462 and 2 inch-SR-0450 is having only 50-100mm clearance to ground, the flange connection joints are found touching the ground, this violate SAES-310 requirements to maintain 300mm ground clearance, Also because of not having this clearance the gravity sever requirement per SAES-S-020 Para,4.8.3 is also been violated, The lip of a drain Violationfunnel shall be elevated 80 mm above the ground to prevent surface drainage After The from entering the drain. The contractor is requested to rectify the above line Fact and maintain the required ground clearance as required per standard. Refer: SAES-L-310 (Design of Plant Piping) 12.3 Above-grade piping shall be supported to provide a minimum of 300 mm clearance between bottom of the pipe and the finished grade.SAES-S-020 Para,4.8.3, The lip of a drain funnel shall be elevated 80 mm above the ground to prevent surface drainage from entering the drain. Surviellance conducted on GOSP 4 and noticed that the electrical cable tray Violationwas rested on pipe line no.B35-SW-1168 at pipe rack 6. The contractor was Prevented advise to review the location of the cable tray before cable pulling to avoid rework and violation of standard SAES-L-310 para. 12.4 a minimum of 50 mm Installation clearance from structures. Surveillance conducted on MMG site fabrication and found out that the Violationcontractor are using rebar as spacer and tacked on pipes. This is a violation of After The the standards SAES-W-011 section 11 para 11.10 and the contractor was Fact advised not to use rebar. During focus assessment on Consumable Control, it has been noted that some Violationof the portable oven were not maintaining minimum 65 degree which is a After The clear violation of SAES-W-011. Contractor is recommended to repair all the Fact faulty portable ovens and welding QCs are requested to check the temperature of portable ovens randomly on daily basis. During surveillance in the fabrication shop around 6pm, it was noted that welders are not returning the unused electrodes leaving all the electrodes in Violationtheir unplugged portable oven which is violating Aramco standard and After The Contractor QCP. Contractor Welding QCs are recommended to ensure that all Fact the unused electrodes are to be returned to store in order to make color coding for the traceability and also to minimize weld rejection due to poor control of consumables.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.3
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.1
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Contractor QCP #
Not specified
2409
9/17/2008 2:50:06 PM
During surveillance in the fabrication shop around 6pm, it was noted that welders are not returning the unused electrodes leaving all the electrodes in their unplugged portable oven which is violating Aramco standard and Contractor QCP. Contractor Welding QCs are recommended to ensure that all the unused electrodes are to be returned to store in order to make color coding for the traceability and also to minimize weld rejection due to poor control of consumables. During surveillance it was noted that some of the portable ovens were not maintaining minimum 65degree temperature which is a clear violation of SAESW-011. Contractor is recommended to repair all the faulty portable ovens and welding QCs are requested to ensure the temperature of the ovens with digital pyrometer randomly on daily basis. During surveillance it was noted that some of the portable ovens were not maintaining minimum 65degree temperature which is a clear violation of SAESW-011. Contractor is recommended to repair all the faulty portable ovens and welding QCs are requested to ensure the temperature of the ovens with digital pyrometer randomly on daily basis. Surveillance conducted for a focussed assessment and found out debris inside the pipe spool,no air blowing conducted prior for installation and no inspection conducted and SAIC-L-2017 are not utilize by the contractor which is HOLD POINT as per SATIP-L-350. The contractor was advised to used SAIC-L-2017 Piping System Internal Cleanliness Surveillance conducted as a routine site visit and found out that spools connected to the equipment are temporarily installed for joining spools and alignment purposes. The contractor was advised to complete the requirement of SAES-L-350 for the flanges connection with spacer, special blind,orifice plate and strainer should have jackscrew prior for final installation and testing. It was observed that the location of Fire Monitor FM-20 at Inlet/Outlet Area is very close to AHU & ACCU serving B700. Reposition of FM-20 is required to be located away from HVAC equpments to avoid obstruction. Please refer to SAESB-017 para 9.7.3 for the standard requirement. Snamprogetti Quality has failed to perform a proper receipt inspection and detail the extensive damages to these 48 items, and several have been moved out and erected at Train # 4, in violation of Quality Plan (See QR # E-9). COMPANY has proceeded with a detailed receipt inspection before the arrival of VENDOR rep from BTT (France). Company notes failure of Quality Manager Mr. George Moldovan to follow the detailed request from SATIP-E-007-01 (Lessons Learned) & request due diligence for shipment handling and photo evidence of all exchangers on receipt (SAIC-E-2005, Att. 3) Additionally, this item has been identified in a recent audit (CAR issued) and damages noted by Snamprogetti Materials Receipt do not cover the Qulaity Plan requirements, which have been ignored by Quality Group. This LBE is the basis for COMPANY NCR to follow.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Contractor QCP #
Not specified
2410
9/17/2008 2:58:15 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2411
9/17/2008 3:05:27 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2412
10/26/2008 2:57:08 PM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15
2413
11/3/2008 7:22:29 AM
ViolationPrevented Installation ViolationAfter The Fact
SATIP-L-350-01
SAIC-L-2016
Mechanical
SAES
SAES-L-350
14
2414
5/24/2009 11:08:44 AM
SATIP-L-350-05
SAIC-L-2057
Mechanical
SAES
SAES-B-017
9.7
2415
7/29/2008 12:21:00 PM
SATIP-E-007-01
SAIC-E-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2416
8/29/2007 9:21:29 AM
2417
1/13/2008 10:57:54 AM
1)Stud welding symbol is not shown on IFCs, a 6mm fillet weld is shown in the welding detail. (Welding Engineering Evaluation, IFC drawing issue on receipt) 2)Stud welds do not exhibit a full 360 degree flash where stud welded in numerous locations. Welding Repairs will be required. See photos. 3)Bent studs are visible in numerous locations. These need to be straightened Violationand inspected. See Photos. 4)Imbed plates exhibit welding/galvanize process Prevented distortion & warpage in excess of tolerances in SAIC-M-2012, Attachment 4. (6 Installation mm maximum, 1/8 per 10 feet or 1mm/meter rule) 5)Cold zinc repairs per SAIC-M-2012 procedure are required in numerous areas where mechanical damage, flux and small bare spots are visible. Evaluate galvanized items per checklist & document repairs Actual projection / thread length does no allow for thread engagement after considering the thickness of grout & base plate. (An approximate of 40 mm gap exists after considering grout & base plate elevation). This design problem Violationviolates 12-SAMSS-007, SAES-Q-005 and SAIC-M-2006, requirements. Hyundai After The Fact to rectify (propose a rectification method/procedure)this issue and take necessary measures to prevent re-occurrence of such problem in other locations. During equipment receiving inspection of the Condensate stripper feed drum B38-D-0203. The nameplate was supported to the name plate mounting bracket by tag welding only. This is violates Clause 17.3 of 32-SAMSS-004. and PIP VEFV1100 requiring continuous welding of the name plate to the mounting bracket. Hyundai to do the necessary corrective action. ViolationAfter The Fact
SATIP-M-001-01
SAIC-M-2012
Mechanical
other
12-SAMSS007
6.4.1 & 7.10
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.8.1
2418
9/6/2008 3:30:53 PM
SATIP-D-001-01
SAIC-D-2003
Mechanical
other
32-SAMSS004
17.4
2419
2/27/2008 10:16:37 AM 8/29/2007 9:02:49 AM
During surveillance it was noticed that the damage primer coated spools were not repaired by certified coating applicator. Enquired, and came to know that repairs were done by construction group. A clear violation of SAEP-316. These repairs are not acceptable and shall be re-blasted and re-coated. Contractor shall comply with the requirement. PMT and contractor QC were informed. Contractor did not properly apply a minimum of 4 steel shim packs (approx 4 or 100mm wide) set equally near each of the 4 edges of the base plates as per AISC Design Guide 1.
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAEP
SAEP-316
3.1
2420
SATIP-M-001-01
SAIC-M-2006
Mechanical
SAES
SAES-Q-005
4.3.2 C
2421
11/2/2007 5:23:54 PM
Welding was started on precast roof/wal anchor plates & roof connecting plates (permanent installation) with RFI/notification to SAPID. the following violations were noted: 1 No approved AWS D1.1 Structural Welding procedure Violation(SATIP-M-001 SAIC-M-2012 item A1 2 Welders HD/BS-43 & HDBS-49 not Prevented qualified per AWS D1.1 (SATIP-M-001) 6 Unacceptable base metal Installation preparation. Galvanizing was not removed prior to welding (SAIC-M-2012 item B1) 8 Use of an uncalibrated welding machine no. W-59 9 No welding QC onsite during welding 10 No RFI sent to SAPID for start of structural welding 3 Use 0f E-6013 Electrode instead of the required E-7018 (SAIC-M-20120 4 No Violationwelding consumable control or issuance records (SAIC-W-2009) 5 No welding Prevented environmental controls i.e. wind shielding (SAIC-M-2012 item B3) Installation 7 Unacceptable welds (slag inclusions, porosity, lack of fusion, unacceptable Violationweld profiles) welds do not meet acceptance criteria in SAIC-M-2012 Prevented attachment 3 & AWS D1.1 Installation 1)Structural steel column is being erected even backfilling is onViolationgoing/incomplete and required testing not done. 2)Support foundation is not Prevented released for structural installation Installation During routine visit to GT-1 to check RTR pipes assembly, it was noticed that QA/QC RTR piping is not paying full attention on his responsibilities, and his performance is not satisfactory. Following are some violations: - Many bonded joints were found without joint number, Installer number, and Line number. One joint was not cured, and the installer doing another joint on the same Violationsection, violation of FPI procedure. Do not disturb the curing of the adhesive After The by moving or vibrating the joint. - In fabrication yard all pipes and spools are Fact exposed to the sun. RTR pipe shall be stored out of direct sunlight in a building or under a cover that allows free air circulation. SAES-S-070 Para 5.2 (a) and 5.3 - Spools were found on the ground. - QC is not taking care of the heating, and nobody is rotating the heating blanket. Due to that some burning effect noticed (de-colored). Contractor shall comply with the requirement. During material recieving inspection it was noted that 08 nos of pumps (GViolation0664A/B,G-0684A/B & G-0602A,B,C&D) their drain points were located direct After The to the anchor bolts to be re routed to avoid the corrosion and to get the Fact clearance between anchor bolt and drain points. During Hydro test witnessed certain flange joints were found leakage with different line classes because of improper bolt torquing & gasket installation, Tests were rejected and after proper torquing re tests were confirmed. Contractor shall have trained personnel and proper training and skill to conduct this type of critical activity as per SAEP- 351. Each joint stud/ bolt size more than 1-1/2" shall be hydra tighten by trained Tig Tesco third party and certificate shall verified by inspection and attach with hydro test packeges. Every joint shall have tag after confirmation of the bolt torquing.Inline flanges shall have the verified certificates during construction activities. Witnessed the on going coating & blasting activities at Tekfen Yard, found no QC Coating Inspector for this Area and no QC represent Snam in the current time, this is clear violation to Schedule Q Table VI-2.Snam has to comply with Schedule Q and provide Coating Inspector for the Area. Surveillance was made to Saipem Blasting Yard,found Mr.Chai Roman and Ansar were doing blasting without JCC.This is clear violation to SAEP-316 Para.3.1.SP to clarify. Surveillance was made to Saipem Blasting Yard,found Mr.Ganga Ram Mathur Badge #ROB0060 was doing blasting and has invalid card on 15/10/08 and show different employer in his card (Al-Hammam).This is clear violation to SAEP-316 Para.3.1.SP to clarify. Routine visit was made to Tekfen shop, found uncertified applicator was painting on 28 pipe at Tek. Shop, this is clear violation of SAEP-316 Para.3.1 .Contractor has to comply with Aramco procedure and all applicator personnel shall be qualified and certified prior to start of work. Surveillance was made to Tekfen Yard, observed three persons two applicator and one crew supervisor (S.Rajendran, Karunakaran & S.Hameed) were working on site with expired card, this is violation as per SAEP-316 Para.3.4.1 .Contractor has to renew their cards.
SATIP-M-001-01
SAIC-M-2012
Mechanical
other
12-SAMSS007
7.5
2422
11/2/2007 5:23:54 PM 11/2/2007 5:23:54 PM 8/16/2007 7:55:23 AM
SATIP-M-001-01
SAIC-M-2012
Mechanical
international Standard international Standard other
AWS D1.1
5.3
2423 2424
SATIP-M-001-01 SATIP-M-001-01
SAIC-M-2012 SAIC-M-2006
AWS D1.1
12-SAMSS008
5.18 Section 1
2425
3/16/2008 11:20:33 AM
SATIP-S-070-03
SAIC-S-4056
Mechanical
SAES
SAES-S-070
5.2 & 5.3
2426
3/30/2008 2:47:25 PM
SATIP-G-005-01
SAIC-G-2002
Mechanical
SAES
SAES-G-005
4.7 & 4.11
2427
11/4/2008 7:45:35 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
2428
12/15/2007 5:27:30 PM 7/20/2008 3:38:25 PM 11/2/2008 11:29:11 AM 2/11/2008 5:24:36 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
2429
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
3.1
2430
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
3.1
2431
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
3.1
2432
12/17/2007 8:40:23 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
3.1
2433
11/2/2008 2:04:42 PM
Responding to RFI 50860, APCS 113C is applied to uncoated after blasting of 8 spools(spool list # 742), it violates the requirements specified on Para. 5.4.3 Buried fittings, appurtenances and spool pieces of SAESH-002 that APCS 113C is acceptable only for maintenance to replace old tape wrapped. Refer SAES-H-101 for approved protective coating system. It has been observed during MOV testing for 36" Dia, Blind Flange ia without any supporting Documents & Stress Calculations has not been provided for the strength of the weld of the Boss welded to the Flange . It is a safety issue & need to be solved at the earlist. Also Water Quality need to be tested for SRB (Ref: SAIC-L-2042 Para :A7)at intervals .
ViolationPrevented Installation ViolationAfter The Fact ViolationAfter The Fact
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002
5.4.3
2434
9/28/2008 9:16:12 AM 9/28/2008 9:16:12 AM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
7.3
2435
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-A-004
2436
3/11/2009 9:31:49 AM
2437
12/16/2008 1:18:14 PM
For Austenitic stainless Steel Insulated lines, Materials being used shall be as per the requirements. Contractor is requested to please provide Test Certificates of insulation Materials for Austenitic Stainless Steel service that are qualified in accordance per ASTM C795, Chemical Analysis of production lot tested as per ASTM C692 and per ASTM C871 for leachable chloride content Violationand shall comply with ASTM C 929-80.Reference Standards; SAES-N-001, SAIC- After The N-004, Project Specs 00-GA-E-60703 Para 4.1.5, PIP INSH1000 Para. 4.2.6, Fact Para. 4.2.10. To minimize the risk of external chloride, SAES-H-002 Para. 5.6.3 Insulated (Hot System) for Stainless Steel Pipe, Consult the RSA for coating material selections, See Approved Materials mentioned as per Project Specs 00ZA-E-09633 for austenitic stainless steel under insulations. It was noted that underground copper nickel pipes for fire water mains are Violationbackfilled without the approved corrosion protection in accordance with SAESAfter The S-050 Para 4-14.4.2.4 where steel pipe is underground, the pipe shall be Fact coated in accordance with SAES-H-002, and shall be cathodically protected if required by SAES-X-400. It was noted during surveillance at Switchyard Area that none of the 12 OWS vent lines has rise to grade over the asphalt paving. This is not in compliance with IFC drawing BA-666719. Ensure that vent pipes are provided in accordance to IFC drawing and SAES-S-020 Section 4.12 requirements. During Inspection it was noted that joints shall be Bell & Spigot ends as per attached drawingS # BE-672718-1/2-3 Line # FW-0412 & BE-672704-1/6-1Line # & FW-0400-J8 but actual at site contractor was performing Rubber Seal Key Lock Joints those were acceptable as per 01-SAMSS-034 Para- 7.8 b but contractor does not have the revised drawings that is clear violation to the Sch Q. Kindly ask to the contractor to provide revised drawings for the whole system AEAP. Surveillance was made to SAIPEM shop found Mr.Nazard Mohammed was doing tacking for 42 pipe behind the shop (open area) without JCC, This repeated violation to SAES-W-011 Para.8.1.Also, no wind shield or tent was provided to avoid strong wind, this is another violation to SAES-W-011 Section 11.2.SP to clarify. Surveillance was made to SAIPEM shop found Mr.Emmanuel Montevola Bongo was doing the welding without JCC, This is repeated violation to SAES-W-011 Para.8.1.SP to clarify. It has been observed that line 3-FO-0383 has been cut & reweld at 2 locations. The line is already Hydro Tested under TP-195.This violates SAES-L150. Also Welder ID has not been indicated on the joint, SAIC-W-2036 has not been raised. SP needs to carry re-hydro for the subject line. Weld Map to be revised. Also 2 new Girth joints to be recoated with APCS-1A Site surveillance was conducted and confirmed the sub-contractor has installed I-Beams (Rails) on the columns for bridge crane @ GIS building. The violations are as follows: a) The vendor for I-Beams was not approved by Aramco. b) The weld Procedure Specification (WPS) and welders qualification were not available to their approval. c) Astaldis Method of statement for installation of Crane and Structures were not approved. The above mentioned, are the violations of Schedule "Q" Attachment IV Para 2.1. Surveillance was made to MS3, found 7 welders (from Astaldi Arabia ltd) were welding channel floor to rebar had no JCC,s; this is clear violation to SAEP 324 Para. 6.2.5. Contractor has to comply with Aramco requirement. ViolationAfter The Fact
SATIP-N-001-01
SAIC-N-2004
Mechanical
SAES
SAES-N-001
Project Specs 00-GA-E60703
4.1.5
SATIP-S-050-01
SAIC-S-4023
Mechanical
SAES
SAES-S-050
4-14.4.2.4
2438
12/29/2008 3:33:41 PM
SATIP-S-020-01
SAIC-S-2001
Mechanical
Drawing
IFC drawing BA-666719
NA
SAES-S-020
4.12
2439
12/4/2007 5:56:12 PM
NA
NA
Mechanical
Drawing
drawingS # BE-6727181/2-3 & BE672704-1/6-1
NA
Schedule Q
1.3
2440
5/26/2008 3:10:39 PM 6/2/2008 11:04:19 AM 6/3/2009 4:51:29 PM 6/3/2009 4:51:29 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
2441 2442 2443
SATIP-W-011-01 SATIP-A-004-02 SATIP-W-011-01
SAIC-W-2005 SAIC-A-2001 SAIC-W-2036
SAES SAES SAES
SAES-W-011
SAES-L-150
8 5.4 18
SAES-W-011
2444
10/30/2007 11:36:25 AM
Na
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2445
11/21/2007 10:36:23 AM
SATIP-M-001-01
SAIC-M-2012
Mechanical
SAEP
SAEP-324
6.2.5
2446
4/12/2009 7:19:14 AM
To highlight the issue pertaining to Clearance required as mentioned in the approved method of statements and project specifications with regards to Hot ViolationInsulation installation. Aside from the mentioned approved procedures and Prevented specifications SAES-L-310 Para 12.4 50mm clearance shall be maintained for Engineering pipe freedom of movement adjacent to any pipings, structures. Please make necessary corrective action to rectify such obstructions.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
12.4
2447
3/17/2009 1:21:00 PM
During Routine site visit, following observation was noticed; AREA of Locations J2 pipe rack. North Utilities, Boiler Area. 1. Receiving inspection was not offered for the new batch of materials to verify the compliance as per ViolationSpecifications as a hold point for Contractor. 2. Surface preparation shall be Prevented carried out thoroughly to remove the presence of oil, grease, dirt, etc. 3. To Installation keep edges of material under compression, all cracks, voids and gaps greater than 3mm shall be refitted not filled. 4. For the current number of Insulations/Paintings/Coating Crews, requirements of Schedule Q are violated for the required Numbers of ViolationSP/Subcontractor Inspectors. Thus, increasing QC manpower will control the Prevented inspections from receiving , in process and finished products. Please adhere to Installation the requirements of SAES-N-001, SATIP-N-001, Approved Method of Statement and Schedule Q General Requirements and Attachment. Surveillance was made to Tekfen coating yard, found Mr. Sellasamy Balu was doing painting whereas he is approved for Abrasive Blaster only.This is clear violation to SAEP-316 Para.3.1.SP to clarify. ViolationAfter The Fact
NA
NA
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2448
3/17/2009 1:21:00 PM
NA
NA
Mechanical
ScheduleQ
Schedule Q
A VI Table 2
2449
6/23/2008 4:54:51 PM 4/21/2009 9:13:00 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
3.1
2450
At a given period of time,4 OWS- 1428/1429 that descends/immersed into Violationthe sump and having contact with the liquid to be coated with APCS-102 Prevented internally and externally with APCS 104 as per revised drawings and SAES-HInstallation 001 Please make necessary actions prior the sumps put in service. It has been observed that Reinforcing pad being installed do not have VENT HOLES and noted welded in the full encirclement saddle plates. Refer to Std. Drwg AD-036990/001 in conjuction with ASME B31.3 para 382.5.4 ViolationAfter The Fact
SATIP-H-100-01
SAIC-H-2023
Mechanical
SAES
SAES-H-001
7 & 10
Revised Drawing #
Not specified
2451
12/31/2008 9:47:18 AM 12/12/2008 11:16:17 AM
SATIP-L-350-01
SAIC-L-2011
Mechanical
Drawing
Drwg AD036990/001 Schedule Q
NA
ASME B31.3
382.5.4
2452
2453
3/11/2009 2:11:38 PM
2454 2455 2456 2457 2458
8/31/2008 11:25:59 AM 8/31/2008 11:25:59 AM 8/31/2008 11:33:39 AM 8/31/2008 11:33:39 AM 12/15/2008 10:46:34 AM 8/16/2008 11:28:20 AM 8/16/2008 11:39:31 AM 8/16/2008 11:40:29 AM 8/16/2008 1:19:47 PM
2459
2460
2461
2462
It was noted during inspecction of RFI #s 43287 (GS-1049) and 43210 (GS1043) that drainage line are connected directly to the OWS line without passing through a catch basin which is violation of SAES-S-020 Para 4.2.22. Please comply this requirement It was noted during inspecction of RFI #s 43287 (GS-1049) and 43210 (GS1043) that drainage line are connected directly to the OWS line without passing through a catch basin which is violation of SAES-S-020 Para 4.2.22. Please comply this requirement It was noted during inspection of RFI #s 43287 (GS-1049) & 43210 (GS-1043) that funnels for the drinking water tanks drains are connected OWS lines without a passing though a catch basin which is in violation to SAES-S-020 Para 4.2.22 . Pleasse comply requirements. It was noted during inspection of RFI #s 43287 (GS-1049) & 43210 (GS-1043) That funnels for are directly connected to the OWS main without a water seal through a catch basin. It is in violation with SAES-S-020 Para 4.2.22 since it is over 50M beyond the allowabale 15M. Please comply requirements.
It has been observed that contractor do not have an approved method of Violationstatement for Hot Insulation. Contractor is advise to expidite the approval as After The required Fact During Routine Site Inspection, Due to bad weather condition yesterday, Spoil/Damage insulated materials are to be replaced prior weather cladding. ViolationContractor violates the requirements as per SAES-N-001 and procedure on proper installation, handling and storage of materials from delivery to installed Prevented finished products. Contractor is advised to replaced, Temporary protection is Installation to be applied before the conclusion of the days of work, Isolate/disposed all damage materials. ViolationContractor EPC was doing fit-up & welding activity without raising RFI is a After The violation as per SAEP-Q-1150,para.8.9, and Fact Violationno available approved welding Inspector at site is a violation as per ScheduleAfter The Q Fact ViolationContractor was doing fit-up & welding without raising RFI is a violation as per After The SAEP-1150 para 8.9, and Fact Violationno approved welding Inspector available at site is a violation as per ScheduleAfter The Q Fact Contractor tested the lines without complying comments being delivered to Violationthe package. No weld summary attached and no RT results to be shown to After The clear if the line is ready for pressure testing. Fact During inspection of RFI #43210 & 43287 for lines GS-1049 & 1043, it was Violationnoted that installation was done as per IFC drawing but it is violation of SAESAfter The S-020 Para 4.2.22 where the drains do not pass through a catch basin. Please Fact comply requirements. ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-N-001-02
SAIC-N-2012
Mechanical
ScheduleQ
A IV Para 2.1
SATIP-N-001-02
SAIC-N-2006
Mechanical
SAES
SAES-N-001
NA NA NA NA SATIP-A-004-02
NA
Mechanical
SAEP
SAEP-1150
8.9
NA NA NA SAIC-A-2003
ScheduleQ SAEP ScheduleQ ScheduleQ
Schedule Q SAEP-1150 Schedule Q Schedule Q
5.1 8.9 5.1 A VI Para 4.13
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
2463
8/17/2008 6:13:28 AM
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
2464
8/17/2008 6:14:48 AM
It was noted during inspection of RFI #s 43287 (GS-1049) & 43210 (GS-1043) That funnels for are directly connected to the OWS main without a water seal through a catch basin. It is in violation with SAES-S-020 Para 4.2.22 since it is over 50M beyond the allowabale 15M. Please comply requirements. It was noted during inspection of RFI #s 43287 (GS-1049) and 43210 (GS1043) that OWS drains are directly connected to OWS main without a water seal through a catch basin. This is in violation to SAES-S-020 Para 4.2.22 since the length is over 50M that exceeded the allowable 15M from the manhole. Please comply requirements During inspection of leakage for chemical lines 2702, 3076, 480, 1570, 3075, 1566 & 2693 to sump pit S-0601 an acceptable drop in water level was observed. This is in violation to SAES-S-070 Para 19.4 as stated the piping shall be satisfactorily if there is no evidence of leakage or pressure loss after the specified test period. Excavate backfilled lines to find the source of leakage. It was noted during inspection of RFI #s 43287 (GS-1049) & 43210 (GS-1043) that funnels are directly connectly connected to the OWS main without a water seal through a catch basin. This is in violation to SAES-S-020 Para 4.2.22. It does not comply also to the exception since it is more than 50M away from the manhole. Please comply requirements. Contractor EPC conducting fit-up and welding noted prepared joint no weld Identity and line number being marked. Welder did not carry his JCC on his possession is a violation as per SAES-W-011 sec.16, and sec. 8. Contractor EPC found no approved documents prior to welding nor, and is a violation as per SAES-W-011, sec.7, sec.8, sec.11, para.11.3.1 and para.11.5.1. Contractor is advise to submit the necessary requirements prior to welding activity. qualified welders to utilise, no approved welding Inspector to monitor the area. It has been noted that the contractor did not perform pre-heat before welding. No digital pyrometer as calibrated to check the pipe temperature. This is a Violation as per SAES-W-011, sec. 12 Surveillance was made to SAIPEM Fab shop, found Mr. Noor Alam was tacking 4 pipe and has no JCC, this clear violation to SAES-W-011, Para.8.1.Saipem has to remove the tacking and offer it for inspection. Surveillance was made to Tekfen Shop found unqualified welder (without JCC) has welded 3joints (SBW-17, 18 & 19) of 2 pipe (Mr. Umit Demirag. Badge#2371), this is clear violation to SAES-W-011 Para.8.1.Tekfen has to cut the 3 joints and offer fit-up for PID inspection. Contractor Hidada doing welding without raising RFI, , is a violation as per SAES-W-011, sec.7, para. 7.1.8, and sec.16 para.16.1 No WPS available at site No weld ID being marked adjacent to weld During my Inspection. contractor EPC found no Welding Inspector is a violation as per Schedule Q, No RFI being raised is a violation as per SAEP 1150, sec 8, para 8.9.2, Completed weld found unsatisfactory is a violation as per SAES-W-011, sec.11, para 11.4,and 11.6; Still the Contractor do not developed a drawing, joints being welded were not identified, a violation as per SAES-W-011 sec 16; and, Welding machines noted are not calibrated nor validated, a violation as per SAES-W-011 sec.19,para19.2 It has been observed that the welder who performing tig welding(GTAW), did not have a JCC in his possession.This is a violation as per SAES-w-011, sec.8, WPS not available at working area, is a violation as per SAES-W-011, sec.7.. No welding Inspector available at site, is a violation of Schedule-Q.
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
2465
8/17/2008 6:37:42 AM
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
2466
10/27/2008 3:17:03 PM
SATIP-S-070-02
SAIC-A-2015
Mechanical
SAES
SAES-S-070
19.4
2467
8/16/2008 5:20:58 PM
ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact ViolationAfter The Fact
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.1
2468
8/31/2008 12:01:40 PM 8/30/2008 11:09:30 AM 8/30/2008 11:09:30 AM 8/30/2008 11:09:30 AM 10/20/2008 2:02:33 PM 5/18/2008 11:03:53 AM 5/6/2008 1:58:00 PM 8/27/2008 10:47:41 AM 8/27/2008 10:47:41 AM 8/27/2008 10:47:41 AM 9/6/2008 10:25:10 AM 9/6/2008 10:25:10 AM 9/6/2008 10:25:10 AM 9/6/2008 10:25:10 AM 9/21/2008 10:18:11 AM 9/21/2008 10:18:11 AM 9/21/2008 10:18:11 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
16
2469
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
2470 2471 2472 2473
SATIP-W-011-01 NA SATIP-W-011-01 SATIP-W-011-01
SAIC-W-2005 NA SAIC-W-2005
SAES ScheduleQ SAES
SAES-W-011
Schedule Q
8 5.1 12
SAIC-W-2005
Mechanical
SAES
2474
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
2475 2476 2477 2478 2479 2480 2481 2482 2483 2484
NA SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 SATIP-W-011-01 NA
NA SAIC-W-2001 SAIC-W-2007 SAIC-W-2007
ScheduleQ SAES SAES SAEP
Schedule Q
1.7 7 16 8
SAEP-1150
SAIC-W-2007 SAIC-W-2007 SAIC-W-2011 SAIC-W-2005 SAIC-W-2001 NA
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical
SAES SAES SAES SAES SAES ScheduleQ
SAES-W-011 SAES-W-011 SAES-W-011 SAES-W-011 SAES-W-011

Schedule Q
11 16 19 8 7 5.1
2485
11/28/2007 5:18:10 PM
It was checked during routine inspection that Low Hydrogen electrodes were not storing and conditioning as per the requirement a clear violation of SAESW-011, 6.1. The main storage oven at B40 area was not kept always at 120 deg. C and the same problem accur at B39, where the storage oven has the temperature gauge faulty not calibrated and giving false reading, the welders are also using the exposed electrodes. Welders portable ovens were found defective. Contractor shall comply with SA requirement and follow Standard. The exposed electrodes shall be re-dried at 260 - 430 deg C. Welding activity during night shift have been proceeded without any information from PID, no inspection coverage from the contractor during night shift is a violation as per Schedule Q. During the welding process, a portable oven being observed unplug and low hydrogen electrode has no proper handling. Water came out from one of its headers nozzle during installation of Heat Recovery Steam Generator # E-2000 and water drops were noted at E1000.while both traceability showed that Exchangers were protected by VPCI309. situation was clear violated to the SCH Q Para- 5 attachment 1V-3. & SAES- A-007 Para 7.11. Kindly ask to the contractor/ vendor to provide corrective and preventive actions AEAP.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2486 2487 2488
10/5/2008 1:40:02 PM 10/5/2008 1:40:02 PM 8/2/2008 10:41:34 AM 12/25/2007 3:39:06 PM
ViolationAfter The Fact ViolationAfter The Fact ViolationPrevented Installation ViolationAfter The Fact
NA NA SATIP-W-011-01
NA NA SAIC-W-2032
ScheduleQ ScheduleQ SAES
1.7 5.1 6.1
SAES-W-011
2489
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.1 & 7.11
Schedule Q
A IV Para 6
2490
10/13/2008 2:03:58 PM
After reviewing the CD containing the liquid coating system carried out by CRTS for line # 2167, 2168, 2180, 2181, 2182, 2183, 2164, 2185, 2186, 2187, 2066, 2165, 2161, 2181 & 2179 and we noticed the following: 1- Weld spatter on several joints. ( this is violating SAES-H100 Para.5.3.2). 2- Paint showing gelled on several joints.( this is violating SAES-H-100 Para.7.1 ). 3- Finished coating have bad appearance for most joints.( this is violating SAES-H-100 Para.8.1.6c). 4- Defect such as sags runs & drips on most joints. (this is violating SAES-H-100 Para.8.1.6b). 5- Coating lump on several joints. (As shown on CD). 6- Edges are improperly finished for most joints.( this is violating SAES-H-100 Para.8.1.6c). 7- No video record for pre-blasting & cleaning which both required by procedure. 8- No daily report is submitted to PID for review as per procedure. CRTS has to follow Aramco Standard & procedure and we need SP clarification for all above points. Responding to the following RFI 41827, 49457, 42604, 51034, 51673, 52359, 52846. After reviewing the CDs containing liquid system carried out by CRTS, requirements of SAES-H-100 (SATIP-H-100-01) and approved operational procedure are violated. Following Findings was noticed: Coating defects, Vacuum Cleaning not carried as heavy Dust particle observed (Contamination of Coating with sand & dust) Heavy dust particles embedded in the coating, Feathering of the cutback not done, Sharp edges at overlaps, Bead height seems more than 1.5 mm, not rectified before proceeding further. Some Resolution of the video very poor. Low DFT, No records for holiday & DFT checked for manual coating & inspection, Surface preparations prior coating applications are not recorded for pre blasting & cleaning as required.Corresponding SATR report are not submitted / recorded for PID review. Functional Test (Pup Test) not carried by CRTS when change of Pipe size &Wall thickness. With regard with coating of internal Girth welds with Liquid Epoxy carried by CRTS no inspection report and CD submitted by SP till date for verification .This violation to approved procedure and SATIP 00208,SAIC-H-2060.SP to clarify.
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
2491
12/18/2008 11:29:16 AM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
2492
9/27/2008 1:59:30 PM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
2493
10/28/2008 6:26:46 AM
Responding to the following RFI 47525, 45296,44766,48172,47014,44117,43372,45362. After reviewing the CDs containing liquid system carried out by CRTS, requirements of SAES-H-100 are violated. (SATIP-H-100-01) 1. Most of the coating appearances are not acceptable especially for manual coatings. coating defects such as runs, drips, sags, blisters, coating lump , etc are noticed. 2. Surface preparations prior coating applications are not recorded for pre blasting & cleaning as required. 3. Corresponding SATR report are not submitted / recorded. Also no video recorded for DFT and holiday test for manual coatings. SP shall monitor the coating activities done in night time to verify the processes of applying liquid coatings are being followed. Finished coating have bad appearance for the mentioned above joints, evidence of coating defects are found such as sags,runs,drips.This is violating SAES-H-100 coating requirements. COntractor is instructed to raised NCR. 2" S/S spool is installed at FG/ Filter (GT- 1000 & GT- 2000) not meeting the spacing requirement from bottom of the pipe and finished grade per SAES-L- 310 Para- 12.3 (Minimum clearance shall be 300mm) It was noted in north utilities that 2 compressed air tanks drain lines 2 ea are not coming onto the funnel to the oily water sewer. Please rectify such installation in accordance to correct installation practices. Kindly ask to the contractor to have Tested Relief valves with a tag stamped word TEST",the test pressure and date is checked. Stamp date valadity is a period of one week for project pressure tests. Stickers are legible and valid. A roster is kept for pressure Relief Valves at project. During walk through it was identified by Mr. Jama. Mohammed that 6" lateral branch was welded directly to the 10" headers with out reinforcements that is violated to the standard drawing # AB-036719001-Rev-11. Kindly investigate the concern and provide corective and preventive actions. During surveillance it was noted that soft Plate Washers with out any traceability were provided under nuts of anchor bolts for the Air Filter House Steel Structures, situation is not meeting the requirements of 12SAMSS- 007 Para- 6.2.5.15 & AISC Para 6.1 stated that hardened washers shall be provided under all bolt heads and/ or nuts adjacent to any ply with over sized or slotted holes. For standard holes, a minimum of one hardened washer shall be supplied with each bolt. Ladders step bars were not fabricated as per vendors drawing # SG7276153/3. Bars shall be rounded instead of square.situation violated to the SCH Q Para 1.9 stated that if any inspection or test directed or performed by Saudi Aramco,or by an other party at the direction of Saudi Aramco,reveals any defect in contractor- supplied materials or in the work, contractor shall bear the cost of such inspection and testing and shall promptly correct such defect at contractors expense. All steel structure erected at Khurais producing facility. Please check the requirements as written on general notes drawing # BA-667824001-00A by designer stated that during erection of steel structure sliding conection shall have minimum two nuts, first nut shall be fingure tight to permit expansion and the second nut shall be tightened down as locknut. The use of fully threaded bolts are allowed.But during surviallance it was noted that at PR #01 to PR# 04 Pipe Racks are finalized but their sliding connections are not meeting the requirements of designer as written above and PR# 06A consist of 05 modules and every module have 24 sliding holes, therefore 240 total nuts are required but all connections does not have full threaded long bolts that is why there are no any double nut is installed.Situation is violated to the design requirement. Already it was written as a proactive notification. Kindly check all installed structure and comply the requirement of designer ASAP.
Mechanical
SAES
2494
10/28/2008 1:56:44 PM
SATIP-H-100-01
SAIC-H-2031
Mechanical
SAES
2495
10/14/2008 7:00:37 PM
Mechanical
SAES
2496
3/23/2009 9:32:04 AM
Mechanical
SAES
2497
1/10/2008 5:26:14 PM
Mechanical
2498
9/14/2008 1:06:32 PM
Mechanical
ScheduleQ
2499
12/17/2007 2:48:52 PM
SATIP-M-001-01
SAIC-M-2010
Mechanical
other
12-SAMSS-007
6.2.5.15
2500
12/25/2007 2:49:38 PM
Mechanical
2501
1/19/2008 10:19:36 AM
Mechanical
2502
4/4/2009 5:03:23 PM
At a given period of time, Material receiving inspection was not offered for hot insulations materials of Boiler Stacks A/B/C prior installation. Please adhere the requirements of SAES-N-001, SATIP-N-001-02, and Schedule Q. And it was noticed also that aluminum metal jackets dont have factory applied moisture barrier, as required specified in SAES-N001 Para. 7.7.1.4 and Method of Statement 08-8676-01-MS Para. 6.1.2 Top coat surfaces up to 400C temperature on insulated valves are not required as mentioned on the Appendix A Coating Schedule of Project Specs QCS-00-ZA-E-09633 Rev. 00A Section 1.4.2 as noted on the remarks, APCS 17A Coating System shall be applied as shop primer. It was noted during surveillance that installed u/g sea water line SW2081 with both ends open for number of days now. Sand is already visible coming inside the pipe. Comply SAES-S-070 Para 9.4 Pipe ends shall be capped to prevent egress of foreign materials at the end of every work shift. Please comply this requirement.
SATIP-N-001-02
SAIC-N-2004
Mechanical
2503
3/9/2009 8:09:52 AM
Mechanical
2504
2/28/2008 1:11:03 PM
SATIP-S-070-03
SAIC-S-4058
Mechanical
2505
7/18/2007 5:19:41 PM
It is observed that Shaving operation carried by CCE personnel(2 nos) was not approved Installer .The same was also noticed on (07/16/07)& reported in the QMIS.SP QC shall strictly ensure that for all Assembly operation for RTR only Approved installers shall be utilised It was again noted during inspection that OWS pipe entering manholes 102 & 160 does not meet the required 150mm water seal requirement as per SA Standard Drawing AB-036054 Underground vent lines VG-4907 & 4908 was installed and tested but as noted on RFI. No concrete support was provided on the horizontal-to-vertical transition was provided. It was noted that the line is now backfilled and prepartion for grade slab is in progress. As noted on the surveillance entries and RFIs that Vent lines are not provided with concrete support on the horizontal to vertical transition which is in violation of SAES-S-020 Para 4.12.3. The Contractor has revised its IFC drawing removing the concrete support which is still a violation of the reference standard and Standards drawing AB-036054 As noted during inspection at GT 1000 4000 that adjacent OWS vents were terminated about 200mm separation which is in violation to SAES-S-020 paragraph 4.12.8 as stated terminating points of adjacent vents shall be separated by a horizontal distance of not less than 1.0 meter, unless a prior approval is obtained from the Chief Fire Prevention Engineer. Provide approval as required above. The contractor has proceeded catch basin installation without providing any plasticised sheet below the bottom concrete of the encasement that is not compliance to IFC drawing BA-670335. These violation was done to CB#s 174; 175; 176; 177 & 304 The contractor has already installed the outlet pipe from OWS sump pit B-0830/North Utilities which does not comply SAES-S020 Para 4.14.10 as stated the incoming sewer to a lift station sump shall be provided with a water seal similar to that provided on sealed manholes. The outlet of incoming sewer shall terminate not less than 150mm below the pump shut-off liquid level. Upon verification the one inlet has a zero water seal while the other one that is above the outgoing pipe invert has a 770mm water seal.
SATIP-S-070-03
SAIC-S-4054
Mechanical
SAES
SAES-S-070
8.1
2506
6/18/2008 2:20:58 PM
SATIP-S-020-01
SAIC-L-2138
Mechanical
SAES
SAES-S-020
4.2.21
2507
8/12/2008 1:49:18 PM
SATIP-S-020-01
SAIC-S-2001
Mechanical
SAES
SAES-S-020
4.12.3
2508
8/17/2008 7:25:59 AM
SATIP-S-020-01
SAIC-S-2001
Mechanical
SAES
SAES-S-020
4.12.3
2509
4/25/2009 3:15:18 PM
SATIP-S-020-01
SAIC-S-2001
Mechanical
SAES
SAES-S-020
4.12.5.5
2510
5/23/2008 7:56:05 AM
SATIP-S-020-01
SAIC-S-2002
Mechanical
ScheduleQ
Schedule Q
1.3
2511
10/27/2008 11:25:46 AM
SATIP-S-020-01
SAIC-S-4065
Mechanical
SAES
SAES-S-020
4.14.10
2512
9/16/2007 2:12:12 PM
During Survillance , it was observed for Roof plate welding ,Welder W#496 has carried welding in the overhead position for which he is not qualified.Hence PID has revoked his JCC.Hidada to cut the joints & carry re-fit up & offer the same for PID inspection.SP & Hidada inspectors need to be more vigilant & enure SA req. are strictly followed. Survillance was made to Tank#200B ,PID found one welder (Mohammed hassan)doing tack welding for temporary attachment on bottom plate and the welder is not qualified and has no JCC,This is a violation to SAES-W-017 Para. 10.5.Contractor has to comply to Aramco Standards. During routine visit to Tank#200B,PID found (Nasruddin Hadrat Ali) was welding the attachment to the plates and that man has no JCC.This is clear violation to SAES-W-017 Para-8.1.SP has to investigate and clarify. During inspection following were noted. 1- Dew point meter was not calebrated with contractor. 2- SP/ QA/QC department was not aware about the inspection activity. 3- Calibrated dew point meter was used by SA/OPERATION LAB QUALIFIED PERSONNEL & notified at two samples having dew point - 16.1 while third sample having dew point + 14.1 that is violated to the SAES- A- 007 Para- 5.2.3.1. During Hydro test witness packages were not signed off due to actual joints traceability was not corresponding to the QA/QC documents as ICS and approved weld Maps. Some examples are listed below. 1- B- 37- 197- Line # 2"- 2437/J7 was revised but ICS was not revised as per drawing. Joints cut/ re welded were not reflected on the ICS. TP- B39- 039- Joint was welded at field but attached weld map still reflected as shop weld. TP- B40- 091Joints were cut/ re welded at site were not reflected in the weld maps as well as ICS. TP- B37-048- Joints were marked on the site as RTD but those were not reflected in the ICS. TP-B40- 215Joints were marked at site but those were not reflected in the ICS & cut/ re welded joints were not reflected in the ICS.Welders ID was not reflected on the actual job. Tp- b40-216- cut/ re welded joints were not reflected in the ICS.Welders ID was not reflected on the actual job. During surviellance it was noted that some fuel gas and process lines does not meet the SAES- L- 011 Para 8.2 requirement that stated all thread joints up to the first block valve of hydro carbon lines are seal welded, thread engagement has been verified and accepted.Some example lines are mentioned below. 1- B40- FG1498/J2--- TP- B40- 083 2- B40- FG- 1501/J2--- TP- B40- 008 3B40- FG- 1451/J6--- TP- B40- 037C 4- B40- FG- 1416/J6--- TPB37- 037D 5- B40- P - 2728/J2--- TP- B40- 175 6- B40- P 2730/J2--- TP- B40- 175 Kindly look into your all lines related to the hydro carbon services and meet the highlighted standard requirement prior to start pre commissioning actvity Final inspection reports were signed by SP / sub contractor QC and provided to us for signature along with old revision drawings such as BE-676617-2/2-0,BE-672708- 7/8- 01, BE-672708-6/8-1A etc while RTR pipe lines were modified and modification was not checked as per modified drawings that is clear violation to the Sch Q Para 3.7. Kindly ask to the contractor to re check the all modifications as per latest revised drawings and resubmitt the final documents.
SATIP-W-017-01
SAIC-W-2086
Mechanical
SAES
SAES-W-017
8.1
2513
6/17/2007 10:40:45 AM
SATIP-W-017-01
SAIC-W-2086
Mechanical
SAES
SAES-W-017
10.5.1
2514
9/4/2007 4:08:20 PM
SATIP-W-017-01
SAIC-W-2086
Mechanical
SAES
SAES-W-017
8.1
2515
3/29/2009 11:43:26 AM
SATIP-A-004-02
SAIC-A-2018
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.3
Schedule Q
1.3
2516
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.3.7
2517
1/23/2009 10:02:34 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.3
2518
3/14/2009 7:59:36 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-110
9.2
2519
12/11/2007 11:23:03 AM
SATIP-S-070-03
SAIC-S-4057
Mechanical
ScheduleQ
Schedule Q
3.7
2520
4/23/2008 11:43:51 AM
Piping installation and welding activity was on going and since 20 april to 22 April aprox 70 joints were welded, Some of them on the rack and some at ground floor. SP piping and welding inspectors failed to inform PID for inspection as per SATIP inspection level and their approved Project Quality Plan. Contractor inspection violated to the requirement of Schedule Q attachment-6 para-4D- stated that contractor shall not waive the requirement of any contractor Quality Plan or SATIPS previously accepted by company representative.Kindly ask to the contractor they shall strictly follow the requrement of contractual document SATIPs during all inspection activities. All macinery shall be protected As per SP procedure # SPC.00ZA02010 Para- 3.6. KINDLY ASK TO THE CONTRACTOR TO DEPLOY THE QA/QC RIGHT PERSONS TO THE RIGHT JOB SUCH AS RTR UNDER GROUND PIPING APPROVED QC IS WORKING AT STEEL STRUCTRUE ALIGNMENTS AND STRUCTURE QC WORKING AT QMIS ENTRY CLERK. IT IS ONLY ONE EXAMPLE THAREFORE KINDLY SUBMIT YOUR ALL QA/QC PERSONNEL LIST ALONG WITH THEIR ON GOING QC ACTIVITIES FOR FINAL REVIEW AND CORECTION PREVENTION MEASURES. THIS SITUATION IS VIOLATED TO THE SCHEDULE Q ATTACHMENT 1V PARA 2.1 During Material Receiving Inspection it was noted that major document Final Disposition Report for the equipments were not available at work location that is violated to the Sch Q"Attachment 111 Para 3.11. Kindly ask to the contractor to provide complete documents for the all equipments to meet the requirement of contractual document Sch Q" and to aviod any surprise at the time of pre commissioning. Equipments were installed at site as Gas Turbines GT-1000-- GT5000, Water Injection Pumps G- 1000--- G- 5000, Air Oil Coolers for GT-1000-- GT- 5000 etc and some of them lying at site( work location) but material recieving inspection was not yet done by contractor/ sub contractors QC as per SATIP # G- 006-01, SATIPE-007-01, SATIP- E- 004-01 & SATIP- D-001-01. Situation is not meeting the requirement of Saudi Aramco approved Inspection Test Plans. Kindly ask to the contractor to comply the requirement of Inspection Test Plans as some of them written above to avoid any surprise violation during installation and pre comm phase. Kindly advice to the contractor/ sub contractor that all Pipe spools shall be cleaned visually and their end covers shall be installed as per SAES- L- 350 Para- 15.2.3 NUT BOLTS MATERIAL WAS NOT CONFIRMED WITH THE REQUIREMENTS OF SAES- L-109 PARA 12.4.3 AT THE TIME OF Hydro testing of Wasia Well MAIN line RTR- RW- 18"-1914. KINDLY ASK TO THE SUB CONTRACTOR TO USE THE SUB STANDARAD MATERIAL OF BLINDING DURING HYDRO TESTING. Already instructed to SP management that SAIC- M-2011 fallS under pre commissioning activity while at this moment SP work is on going under construction phase, some activities are not yet completed that is why Pre commissioning SAIC- 2011 shall not be use at this time that is not meeting the requirement of approved SATIP-M-001- 01.
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.7
2521
12/11/2007 2:03:24 PM
SATIP-G-005-01
SAIC-G-2003
Mechanical
other
31-SAMSS004
2522
2/9/2008 6:41:11 AM
SATIP-L-350-05
SAIC-L-2055
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2523
2/23/2008 6:26:10 AM
SATIP-D-001-01
SAIC-D-2002
Mechanical
ScheduleQ
Schedule Q
AIII Para 3.11
2524
1/24/2008 4:09:11 PM
SATIP-K-001-01
SAIC-K-4005
Mechanical
ScheduleQ
Schedule Q
A IV Para 7
2525
5/30/2008 11:36:10 AM
SATIP-L-350-01
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.2
2526
2/7/2008 3:02:31 PM
SATIP-L-350-05
SAIC-L-2014
Mechanical
SAES
SAES-L-109
13
2527
1/24/2008 3:29:17 PM
SATIP-M-001-01
SAIC-M-2011
Mechanical
ScheduleQ
Schedule Q
1.3
2528
5/1/2008 6:14:30 PM
Only 02 joints RT back log for the pre fabricated shop joints were reflected on the weekly weld project status report while it was aprox 50 joints were pending as per the previous RT requests.Situation is not meeting the requirement of SAEP 1160 Para 6.3 (9)stated that actual NDT back log shall be reflected on the tracking weekly weld status report.Already discussed with SP QA/QC manager/ QC supervisor and TEKFEN QC Engineer for corective and preventive action ASAP. Kindly look into the Field welds back log joints status also and correct it if required. During surviellance it was noted that many spools were fabricated and those were rejected and kept in the quartine area due to non availability of latest revised drawings and some of them due to dimentioning check. Situation is violated to the Sch Q"Para-3.7 stated that latest revision of contractors Quality refrence documents shall be available for fabrication and installation or construction locations. Refrence documents include all those contained in drawings, specifications and procedures for the inspection of equipment and materials to be fabricated or constructed at the applicable site.Kindly instruct to the contractor to provide latest revised drawings at TEKFEN SHOP to prevent and correct this situation. Kindly advice to the contractor/sub contractor to provide QA/QC personnel per their current work force related to welding and piping activities on going at site. Current work force at site pipe fitters/ fabricators- 300 Total Qualified welders- 230. As per Sch Q Table VI-2 one piping inspector with sub contractor shall available per 25 pipe fitters and fabricators & one welding Field inspector shall be available per 15 field welders and one shop welding inspoector per 25 shop welders. Kindly review this criteria we have too less QA/QC inspectors with contractor as well as sub contractor to monitor/ execute the quality job at site and at shop. QA/QC man power deployment was already discueed with contractor/ sub contractor but they are not meeting the requirement of Sch Q para- 5.6 stated that contractors Quality personnel shall be dedicated to the work described in the Scq Q and shall perform no other function on this contract. Contractor Quality personnel shall have sufficient and well defined responsibility, Qualifications, authority and organisational freedom to identify Quality problems and area of non conformance and to initiate, recommend and substantiate corrective actions. Kindly instruct to the contractor/ sub contractor to comply our contractual agreement and do not use one QC personnel to any other activity. NUT BOLTS MATERIAL WAS NOT CONFIRMED WITH THE REQUIREMENTS OF SAES- L-109 PARA 12.4.3 AT THE TIME OF Hydro testing of Wasia Well MAIN line RTR- RW- 18"-1914. KINDLY ASK TO THE SUB CONTRACTOR NOT TO USE THE SUB STANDARAD MATERIALS OF BLINDING DURING HYDRO TESTING.
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
6.3 (9)
2529
6/6/2008 2:18:06 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.7
2530
5/18/2008 1:39:00 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A VI Para table 2
2531
6/6/2008 10:32:37 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.6
2532
2/9/2008 6:22:17 AM
SATIP-L-350-05
SAIC-L-2014
Mechanical
SAES
SAES-L-109
13
2533
5/17/2008 7:17:11 AM
During surviallance at E/W Pipe Rack it was notified that Field welds were marked as only word W" that is not denoted by Field Welds. Kindly ask to the contractor/ sub contractor to mark all joints were welded at field as FW & at shop SBW" to differenciate the welds welded at different lacation and to avoid the same discrepancy will reflect on the radiographed Reports,It is also difficult to evaluate the extant of NDE of welded joints at different location.Situation is violated to the SAES- W-011 Para16.1. More over all welders they have their ID denoted by word P only but same word is not reflected on Radio graphed reports and films. Welder ID is reflected with different words like WP, WP,W, etc that is not meeting the requirement of SAEP- 1143. please provide the corrective and preventive action ASAP. Verbal instructed to the SP/ TEKFEN welding inspectors to meet the requirement during Post Weld Inspection but not yet comply the requirement as per SAES- W-011 Para- 11.9 stated that where temporary welds are removed, base metal repairs made or Arc stricks repaired by grinding, examination by MT or LT has been carried out(evidence of NDT performed, marked NDT OK. During Rutine inspection at PR # 03 it was noted that pre heating 100 deg centi was not maintained with same pre heating arrangement for the 48"x39.7 mm thick pipe. Kindly ask to the contractor/ sub contractor to provide bigger size of the pre heating burner to maintain required temperature as per approved WPS or look into an other alternative pre heating method(Pre Heating by coils)to meet the requirement of WPS. All drawings do not follow the weld identification numbering system as per SAEP- 1160 Para 6.2 and SAES- W-011 section 16 stated that welds fabricated in the field shall be prefixed with the letter F" and welds fabricated in a weld shop with the letter S". Contractor shall establish and submit for approval an identification system that shall uniquely identify each number and weld joint.Identification system shall be used to identify all examinations surveys, inspections etc.Excercise shall be carried out by contractors engineering department at early stage of the project but contractor failed to do so. Kindly advice them to provide the corrective and preventive actions to help the piping systems clearance prior to the pre commissioning. Project Inspection recieving Project Weld Status Report weekly basis but following mandatory requirements are not meeting with the report. 1- Report is not contains of three Farmats as SATR- W-2013,SATR- w- 2018 & SATR-W-2019 as per SATIP- W011-01 Section 3.13 2- Contractor is not providing the socket and fillet welds separate database. 3- Pipe welds are not reporting by line class as per SAEP-1160 Para- 6.3. 4- All NDE tests as UT, MPI, PMI, DPT, PWHT and their Back log shall be reported as per SAEP-1160 section 6 Para- 6.3. Kindly ask to the contractor to provide ASAP project weld status report meeting the mandatory requirements as per SAEP-1160 to avoid any surprise during construction prior to the pre commissioning.
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
16
2534
6/6/2008 10:08:13 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.9
2535
4/30/2008 3:06:05 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
12
2536
6/6/2008 7:14:04 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16
SAEP-1160
6.2
2537
6/6/2008 8:01:12 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
6.3
2538
6/6/2008 9:46:27 AM
DURING SURVIELLANCE AT SLEEPER AREA, IT WAS NOTIFIED THAT FOLLOWING JOINTS WERE WELDED AT SHOP BUT THEIR WELDERS IDs ON THE JOINTS WERE NOT CORRESPONDING TO THE DAILY WELD REPORTS EVEN WITH SOME RT REPORTS. 1B40-SW-2067-J6-ISLEOP3-SBW-89I1. WELDER ID P- 723 IS MARKED ON THE JOINT BUT NOT AVAILABLE AT DWR/ RT # 76. 2- B-40-TW-2184-J6-SBW- 83I3- P # 124, 249 AVAILABLE AT SITE BUT NOT FOUND ON DWR/ RT REPORT # 77. 3- - B-40TW-2184-J6-SBW- 81- P # 124, 249 AVAILABLE AT DWR/ RT REPORT # 78 BUT NOT FOUND ON THE JOINT. 4- - B-40-TW2187-J6-SBW- 90- P # 837 AVAILABLE AT DWR BUT NOT FOUND ON THE JOINT. 5- - B-40-TW-2207-J6-SBW- 55- P # 124, 249 AVAILABLE AT DWR/ RT REPORT BUT NOT FOUND ON THE JOINT. 6- - B-40-TW-2207-J6-SBW- 53- P # 124, 249 AVAILABLE AT DWR BUT NOT FOUND ON THE JOINT. 7- - B-40TW-2186-J6-SBW- 65- P # 837 AVAILABLE AT DWR BUT NOT FOUND ON THE JOINT. Kindly ask to contractor to provide correct welders ID traceability to check their weekly performance. At TEKFEN SHOP SULZER PUMP VENDOR VIOLATED TO COMPLY THE REPAIR PROCEDURE AS PER ASME B31.3 PARA- 328.6 AND VENDOR FORM 175. STATED THAT ALL REPAIR SHALL BE MARKED BY WELDING INSPECTOR TO ENSURE ITS DEFECT LOCATION WHILE W-14 SIZE 10" SCH 10 ISO # 985 WAS CUT AND RE WELDED DUE TO WRONG MARKING, JOINT WAS ONLY REPAIR BUT MARKING WAS NOT PERFORMED BY WELDING INSPECTOR AND IT WAS NOT MATCHING WITH THE PREVIOUS RT RESULT THAT IS WHY IT BECAME RE REPAIR.KINDLY ADVICE TO THE CONTRACTOR/ SUB CONTRACTOR ANY WELD REPAIR SHALL BE MARKED BY WELDING INSPECTOR AND ITS EXCAVATION SHALL BE VERIFIED WITH THE PREVIOUS RT RESULT TO AVOID THE REPEATED REPAIR WORK THAT MAY IMPACT TO THE WELD QUALITY AND PROJECT COMPLETION SCHEDULE. Hydrotest was conducted for fire water lines without any welding summary and inspection report submitted nor available during inspection. This is not in compliance to SAIC-A-2003 requirements on QA/QC documentation. The contractor has conducted pneumatic testing to the gas lines in the laboratory building it was test pressure of 150 psig. It was observed that the relief valve was plug thus making it inoperable such practices has been identified as poor practice which may result in incidents as outlined in GI 2.102 Section 4 relief valve inoperable because of a close blocked valve and section 5.1.5 under use appropriate test equipment has specifies that no block valve in relief valve outlet. Installing a plug on the relief valve outlet makes the relief valve useless during the testing and it does not conform to GI 2.102. Partial leakage test was conducted for laboratory building vacuum & compressed air lines, Pressure loss was noted during the test. Investigate source of pressure loss and ensure that systems are leak free. During material receiving inspection and verification of documents the materials delivered manufacturer TA CHEN was not and approved manufacturer. Provide material that is source from SA approved manufacturer.
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
6.2 and 6.3
2539
5/23/2008 10:32:23 AM
SATIP-W-011-01
SAIC-W-2036
Mechanical
other
ASME-B-31.3
328.6
Schedule Q
5.1
2540
6/22/2008 9:00:32 AM
SATIP-A-004-02
SAIC-A-2003
Mechanical
SAEP
SAEP-1160
2541
5/20/2009 5:39:42 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
other
GI-2.102
5.1.5
2542
11/18/2008 7:21:51 AM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
5.2
2543
5/25/2008 10:54:39 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
6.2
2544
1/27/2009 4:23:26 PM
The following were noted during receiving inspection of diesel storage tank 1) there are no clips provided for ground rod attachment to comply SAES-D-109 Section 121; 2) Bolting material are galvanized needs to be coated by fluoropolymer to comply 32-SAMSS-030 Para 2.2.2; 3) Damaged coating due to handling needs to be retouch after installation and after compliance of item no. 1.; 4) Other requirements such as marking & labels to comply SAES-B-067 Para 4.5 and Gauging instrument may be done onsite later. It was noted that control valves from manufactured by Crane & vilan which was Rejected by SAIR due to no approved IAP has been delivered on site. Further it was noted that packaging and shipping does not meet the requirements of 04 SAMSS 035 Paragraphs 12.1 it has no trace of rust inhibiting oil coating on the machined surfaced and 12.2..No plywood covers fitted on valve weld ends thus makes the valves look like not new due to improper packing. It was noted during surveillance at CCR area on the on-going installation of fire hydrants that rubber gasket were used. This is in violation of SAES-L-109 Paragraph 11.3.2 For class 125 and 150 flat face flanges in non-hazardous services up to a maximum temperature of 230 degrees Centigrade, use compressed synthetic fiber with oil resistant binder, 1.6mm thick per ASME B16.21. Contractor is now installing fire hose reel at the MOB area. It was noted galvanized pipe is directly connected to copper nickel pipe and bronze valve. This is not in compliance with project specification Section 15323 Paragraph 3.01.b where required install dielectric flange kits or unions between dissimilar metals tie-in connections in the fire water piping system. Comply SAESL-105 Section 5.7 where dielectric union is required between dissimilar metals. It was observed during inspection at contractor laydown yard that valves 10diameter & larger do not have end protection. This violates the requirements of 04-SAMSS-035 Para.12.2 which states that Valve end flanges shall be fitted with plywood covers. The cover diameter is the same as the outside diameter of the flange and are at least 10mm thick for valves up to NPS 10 and 12mm thick for valves NPS 12 and larger. The cover shall be attached by machine bolts with a nut & washer fitted on the inside of the flange. Same valves 10, 14 & 16 diameters which are not tested on vendors yard shall be tested and witnessed by 3rd party inspection on site as required in 04-SAMSS-037 and IAP. It was observed during inspection at contractor laydown yard that valves 10diameter & larger do not have end protection. These violate the requirements of 04-SAMSS-035 Para.12.2 which states that Valve end flanges shall be fitted with plywood covers. The cover diameter is the same as the outside diameter of the flange and are at least 10mm thick for valves up to NPS 10 and 12mm thick for valves NPS 12 and larger. The cover shall be attached by machine bolts with a nut & washer fitted on the inside of the flange. Same valves 10, 14 & 16 diameters which are not tested on vendors yard shall be tested and witnessed by 3rd party inspection on site as required in 04SAMSS-035 and IAP.
SATIP-D-109-01
SAIC-D-2015
Mechanical
SAES
SAES-D-109
12
32-SAMSS030
2.2
2545
7/6/2008 3:37:03 PM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
12.1 and 12.2
2546
4/30/2009 4:53:23 PM
SATIP-L-350-05
SAIC-L-2057
Mechanical
SAES
SAES-L-109
12.8.2
2547
5/16/2009 6:37:16 AM
SATIP-L-350-05
SAIC-L-2057
Mechanical
SAES
SAES-L-105
5.7
2548
11/22/2008 9:51:02 AM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
12.2
04-SAMSS037
2549
11/22/2008 10:07:04 AM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
12.2
04-SAMSS037
2550
7/26/2008 9:50:21 AM
Focus assessment was made for bolts and nuts with the following observations: 1) Chemical analysis is available for review and comply SAES-L-109 section 12; 2)Bolts & nuts have workmanlike finish with chamfered points and comply SAES-L109 section 12; 3)Material is free from defects and scale; 4) Sand and dust has fouled the material which is not compliant to SAEp-351 Para 4.2. Corrective action is required for this item. The contractor has conducted leakage test of SWS lift station at the Fire Training Area which is already coated with bitumen. This violates SAES-S-070 Para 18.8.f site testing shall take place prior to backfill and/or application of protective coatings. The contractor has to submit a waver concurred by CSD for this noncompliance as this issue has been brought to attention long time ago with surveillance entry from civil and discussed in quality meeting. Focused assessment for the RTR pipe to be used for fire water and potable water lines. 1) Material has been approved as per 01SAMSS-034 requirements. 2) Work procedure and installers were also approved as per schedule Q requirements. 3) Pipe nos. 299068, 299010 & 299098 markings were modified from series 2410 & 20 Bars test pressure to series 2412 & 25 bars test pressures. Available documentations shows the above pipes are series 2410 & tested at 24 bars 7 4 diameter manufactured 12/5/07 & 12/6/07. 4) Bearing boards shall be spaced on 3m maximum center with the first supports 1.5m from end of pipe. This SAES-S-070 Para 5.2.d requirement shall be complied as bended pipes are already noted during inspection and upper bearing boards shall be placed in line with the lower bearing boards to have uniform transmission of load. It was noted for the past two weeks that there is no Mechanical QC present on site. Also on 8/11 & 8/12/08 Mechanical QC is still not on site where RFI was iniated by the site engineer. This is in violation of schedule Q Para 5.1 as stated..Contractor shall provide resources to implement the quality system as set forth in this contract...Sufficient SA approved quality personnel identified in attachment VI of this Schedule "Q" shall be on site prior to the start of the applicable work. During the surveillance it was again noted that pipe storage shall comply SAES-S-070 Para.5.2(d) If pipe is stored on racks or bearing boards, the supports shall be spaced on 3m centers maximum with the first supports 1.5m from the end of the pipe. Contractor should observe preservation requirements to protect bending of pipes. No receiving inspection/document review was raised to PID prior proceeding further for installation for the above mentioned pumps. This is a violation of Schedule Q Section 3 Documentation Requirements and of Attachment III.Contractor is advice to adhere the requirements. During Pre Punch Inspection , it was noticed that contractor is using 2 and 4 fabricated blinds to isolate the test sections for the fire water lines, As per SAES-A-004, Section 7.3 Isolation of test sections, paddle blinds or spectacle blinds shall be used to isolate the test sections. They shall be the same class rating of the system or maybe fabricated based on the appropriate calculations. Provide the calculations for the fabricated blind flanges prior the hydrotest. Please take note that 24hrs testing is required for the lines.
SATIP-L-350-01
SAIC-L-2008
Mechanical
SAEP
SAEP-351
4.2
2551
8/31/2008 3:34:08 PM
SATIP-S-010-02
SATR-S-4002
Mechanical
SAES
SAES-S-070
18.8
2552
1/1/2008 3:23:37 PM
SATIP-S-070-03
SAIC-S-4056
Mechanical
SAES
SAES-S-070
5.2
2553
8/12/2008 7:17:32 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.1
2554
1/1/2008 8:51:51 AM
SATIP-S-070-03
SAIC-S-4056
Mechanical
SAES
SAES-S-070
5.2
2555
9/6/2009 7:22:46 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
2556
10/3/2009 10:26:35 AM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-A-004
8.3
2557
12/12/2009 9:51:24 AM
It was noticed that no approved drawings for ISOTOPE Storage PIT Cylinders, no receiving inspection reports, vendor acceptance. Violation of Schedule Q General requirements. Provide Documents prior internal pipe coatings and approved procedure for field pipe internal coatings.
Civils
SATIP-H-002-08
SAIC-H-2057
Mechanical
ScheduleQ
Schedule Q
2558
1/27/2008 5:51:47 PM
2559
3/23/2009 2:40:52 PM
The Contractor is Welding the Pre-cast panel with the Structure steel using E-7018 low H2 elechody been welded without proper heating and without an oven. that is in violation to Saudi Aramco Standard SAES-W-012. Jet fuel tanks platforms & structure are painted without surface preparation by non qualified workers. This is against the implementation of Project specification & SATIP-H-100-1. Therefore it is advised to remove the paint by blasting, check the surface profile & offer for inspection before painting with qualified painters. The compressed air piping at Bldg 171 was installed not as per Standard and Project requirement. SAES-K-403 para. 6.11 have clearly mentioned that a single non-slam piston type check valve shall be installed in the common discharge header downstream of all compressors. Also, the Project Specification (RE-SK001 Section 15486) and the Material Technical Approval (Ref 019-A dated 01-27-2007) has specified that a refrigerated dryer will be included in the compressed air system. The refrigerated dryer was included during compressor delivery and was already on site but it was not installed by the Contractor. Please note that the designed compressed air system has piping installation along trenches (creates pockets/ traps). If the refrigerated dryers are not installed, condensates will accumulate on the pipes along trenches making the compressed air system inefficient, and the corrosion of piping is imminent. Contractor is requested to comply with the Standard and Project requirements It was noted during inspection that one pc series 2410 RTR pipe was installed along with the correct series 2412A pipes. This is in violation with 01-SAMSS-034 Para 1.3 which requires 12bars rating for fire water service. Remove and replace the material. Take note that the 6 diameter; series 2410 is not usable in scope of work Contractor has started doing fit-up on pipes for fuel lines at underground fuel storage tanks. Please be reminded of the following standard and project requirements: The gasket contact area of the flange shall not be coated as per SAES L-109 para. 12.10, so remove all paints on the flange gasket contact areas. The Project Specification Section 15175 mentioned that pipe work shall be of line class 1CS9P of SAES L-105. Thus, all piping accessories i.e. flange, bolts, gaskets shall be in accordance with the specified line class. Installed rubber gasket on flanges shall be replaced with spiral-wound, 316 windings, flexible graphite filled with carbon steel outer ring, per ASME B16.2. Also, contractor is requested to verify and confirm with the Vendor that the gasket being used on UG Tank Manhole lid to be compatible with petroleum product application. Please comply with the Standard and Project requirements to avoid reworks and delays.
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
6.1
SAES-W-012
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
SAEP-316
3.1
2560
8/12/2009 11:20:20 AM
SATIP-K-403-02
SAIC-K-2026
Mechanical
SAES
SAES-K-403
6.11
2561
5/30/2008 9:40:44 AM
SATIP-L-350-05
SAIC-L-2055
Mechanical
other
01-SAMSS034
1.3
2562
8/13/2009 8:11:50 AM
SATIP-D-109-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.1
2563
11/15/2009 8:59:00 AM
2564
1/2/2010 8:54:23 PM
2565
2/8/2009 7:34:36 PM
It was noticed during inspection that the Contractor used a threaded flange for fuel piping connection. This is a violation to the standard requirement to use only raised face socketweld or weldneck flange for line class 1CS9P (SAES-L-105). Also the Contractor used a flexible hose with clamp on the flexible joint contrary to the designed flanged type flexible connector. Contractor is requested to comply with the requirements of the standard to ensure a safe operation of the fuel line/dispensing system. Despite several reminders, the Contractor continued to backfill the fuel piping without rectifying the reverse slope of the pipe (survey result have shown that the pipe near the tank is higher compared to the pipe near valve box). Also the contractor has been reminded that red tiles shall be provided on the underground fuel piping. To make it more complicated they started preparing the area for concrete pouring for the manhole cover. It has been observed during routine inspection that the installed flanges for chilled water piping are Raised Face. The valves and strainers are Flat Face and suppose to have a mating flange with the same Flat Face and use a full face synthetic rubber gasket. Note that connecting a carbon steel RF flanged to a flat face valve/ strainer (which is normally cast iron) will greatly affect and have the risk of cracking on the mating flange of the valve/ strainer during bolt tightening and during the cyclic continuous operation of the pump. Contractor is requested to rectify or replace the flanges of the chilled water pipes to match the mating flat face flange of the valve/ strainer and comply with the requirements of ASME B16.5. Please find below Surveillance regarding the gasket installation which violates the Standard requirement mentioned in SAES L109 para.11.1 and 11.3.1. At Bldg 230 Mechanical Room, a double gasket was installed on chilled water pipe flanged connection and at Tank FW/ PW Riser, a full face rubber gasket was used for a raised face slip-on flange. Contractor is requested to comply with the requirements of the Standard and use only the gaskets compatible with the flange facing and not more than one gasket shall be installed. During routine site visit it was observed that welding activities for valve support are in progress without availability of welding inspector. This is a violation to Schedule Q requirement. During review of project drawing, contrctor prvided ASTM A36 for Crain Rail. This is a vilation to 12-SAMSS-14, Para:4.12 Crane Rails. Rails 60 lb/yd to 84 lb/yd (30 kg/m to 42 kg/m) ASTM A1 Rails 104 lb/yd to 175 lb/yd (52 kg/m to 88 kg/m) ASTM A759, Also,12-SAMSS-007, Para 6.1.2 All crane rails shall conform to one of the following specifications: ASTM A1 for rails less 104 lb/yd ASTM A759 for rails 104 lb/yd to 175 lb/yd During initial production weld evaluation, PID found all initial welds (SW-7, SW-29 & SW-30 (RB-312485) of welder ET-03 rejected. the welder should removed from the project. cut out all of this welder welded joints including all joints he weld proceeded welding prior initial production weld evaluation ((HB271618) SW-03, SW-13 & SW-14) Contractor has to provide a root cause & preventive action to assure no occurrence in the future. Contractor is reminded seriously that RT Backlog is increasing slowly.RT Back log shall be cleared on weekly basis to enable control of weld rejection rate.
SATIP-D-109-01
SAIC-L-2014
Mechanical
SAES
SAES-L-105
10 1SC9P
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-D-116
5.1
SATIP-K-001-04
SAIC-L-2014
Mechanical
SAES
SAES-L-109
8.5
2566
2/26/2009 7:49:50 AM
SATIP-K-001-04
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.1 and 12.3
2567
3/15/2010 6:40:55 PM
SATIP-M-001-01
SAIC-M-2010
Mechanical
ScheduleQ
Schedule Q
5.1
2568
10/15/2009 3:06:04 PM
SATIP-M-001-01
SAIC-M-2003
Mechanical
other
12-SAMSS014
6.1.2
2569
3/29/2008 9:30:38 AM
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
7.3.4
2570
9/21/2008 10:47:24 AM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAEP
SAEP-1160
6.3(9)
2571
10/15/2009 4:45:43 PM
2572
3/29/2008 3:15:20 PM
The 4schedule 40 pipeline number 6630-1CS1P installed in Tank Farm Gate 7 is in touch with the old existing piping. Non existing of enough gab below the pipe to absorb the vibration and allow for pipe movement violates SAES-S-70 demanding that a ground bed of soft sand below the bottom of the pipe shall be formed of at least 150 mm in depth. Also the depth of the trench shall be dug deep enough to provide a minimum ground cover above the top of the pipe. Contractor the propose a corrective action to resolve this issue. During initial production weld evaluation, PID found all initial welds (SW-10 & SW-21 (HB-312485)) of welder ET-02 rejected. the welder should removed from the project. cut out all of this welder welded joints including all joints he weld proceeded welding prior initial production weld evaluation ((HB-312485) SW04, (HB-271618-003) SW-20, SW-22) Contractor has to provide a root cause & preventive action to assure no occurrence in the future. During Surveillance Inspection on (12-15-2008) PID observed the following, Two Centrifugal Pumps (Tag Number: X17-G-0103 A & B) has been installed inside the Qatif LPG Plant without carrying out the Receiving Inspection. No relevant documents available at the site for verification. No applicable SATIP & SAIC have been followed and filled by the QC Inspector As per SATIP G 005 01 and Sch Q Para 1.3, 1.4, 1.7 & 1.8 it is a violation. Inspection requires, The QC Manager to find the root cause of this violation and carryout immediate corrective action and report to PID The QC Manager to Isolate the equipment & Pumps area for further activity The Contractor to follow the related / applicable SATIPs and SAICs and provide the related documents for these equipments With ref.to the LBE (QMIS G27 & D30) PID attended the weekly meeting at Qatif.At discussion contractor QC Sup (Faheem Malik) provided a document stating thatthe receiving of drum and pumps are in INCR raised by us.While verifying the mail doc from QC Sup it was not highlighted in INCR. From this PID observed the contractor is trying to give false information to Aramco.Ref.NCR # raised by Al-Osais was M 004&M005.As per Sch. Q Para 7.3 and Sch. Q Para 1.3 it is a violation.Insp.Warns the QC Sup not to provide any forge documents to Aramco in the future. If any such violations are been observed in the future by the QC Dept. then the responsible person will be revoked from the project by PID and this will be reflected in the SAP.The QA Manager to investigation, find root cause of this violation & take necessary corrective action & submit a detail report to PID. The QA Manager to provide the exact status of the equipments and provide related documents
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-S-070
9.5
SATIP-W-011-01
SAIC-W-2016
Mechanical
ScheduleQ
Schedule Q
7.3.4
2573
12/24/2008 9:48:17 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
1.3, 7.3.4 and attachment IV 7.1
2574
1/10/2009 10:00:58 AM
SATIP-G-005-01
SAIC-G-2002
Mechanical
ScheduleQ
Schedule Q
7.3.4
2575
12/24/2008 9:36:19 AM
During Surveillance Insp. (12-15-2008) PID observed the following A knock out drum (Tag No: X17-D-0103) has been installed inside the Qatif LPG Plant without carrying out the receiveing. Insp. from PID. No relevant documents available at site for verification. No applicable SATIP, SAIC have been followed&filled by the QC Insp. The major six items in the SATIP D 001 -01 prior to Installation of drum have been waived by the Contractor. As per SATIP D 001 01 and Sch Q Para 1.3, 1.4, 1.7 & 1.8 it is a violation. Inspection requires, The QC Manager to find the root cause of this violation and carryout immediate corrective action and report to PID The QC Manager to Isolate the equipment & Pumps area for further activity The Contractor to follow the related/applicable SATIPs and SAICs and provide related document for these equipments Surveillance was made to SRBP, inspected hydrostatic testing of 8 line from sump D-405 to sump D-401, found leakage at 14 flanges. Test is rejected and contractor has to repeat bolt torque of all joints and sending RFI. As discussed with the Contractor and SAPMT. During disconnection of the flanges for machining, it has been observed that 4" and below piping spools have not been internally coated as required by 12LE0U. The Technical Query approved by SAPMT does not relieve the Contractor of the requirement to ensure that the works meet all aspects of the applicable Standards. This is applicable to all jobsites on BI-03566. When the Contractor sends the spools for internal coating, all Saudi Aramco requirements must be met at the coating subcontractors. Surveillance was made to SRBP , found the contractor installed RTR pipe sleeve 14 for CS pipe 10 for road crossing under SRBP fence and using casing seal 14X12 , which is violation to SAES-L-460 Para 8.1 & 8.3 that state the casing shall be designed to withstand the superimposed loads and the casing pipe shall be at least two nominal pipe sizes larger than the carrier pipe. Contractor to be clarify and confirm. I received NCR#18 on Saturday 23/5/2009 and please submit RFI after the corrective action. During QA assessment and Focused Inspection yesterday ( Nov. 03,08) PID found out that there is no available Mechanical QC at site. The Contractor Violated Schedule Q attachment VI,Table VI2 ( Construction Phase Quality Personnel Requirements) which requires a full time Mechanical QC at site. Contractor was advised to maintain required level of QC personnel at site to attain the desired quality in all phases of work. Investigation conducted by PID has found instances of incorrect material installed on some piping systems. This relates mostly to slip on flanges. For example, the heel recovery system at SRBP, and one 20" flange at NRBP are slip on type. The Oily Water system requires internally FBE coated pipe (2LEOU) These have been fitted with slip on flanges. These seem to meet the requirement of SAES-L-105. However SAES-L-105 requires flat face flanges. PIDs random checks have revealed that some raised face flanges have been installed e.g. NRBP and SRBP. This is despite SAPMT authorizing an approved vendor to machine the raised face flanges to flat face. The Contractor is required to conduct a survey of all the piping systems to examine the extent of the situation. SAPMT should immediately contact CSD to obtain guidance on how to resolve this situation.
SATIP-D-001-01
SAIC-D-2003
Mechanical
ScheduleQ
Schedule Q
7.3.4
2576
3/15/2010 3:11:46 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.2
2577
2/22/2010 1:21:14 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-105
12.2
2578
5/24/2009 9:56:15 AM
SATIP-L-450-04
SAIC-L-2120
Mechanical
SAES
SAES-L-460
8.1 and 8.3
2579
5/24/2009 9:29:35 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
7.3.4
2580
11/4/2008 2:34:44 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
5.1 and 5.11
2581
11/14/2009 2:06:55 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-105
12LE0U
2582
10/14/2008 3:49:38 PM
Numerous pipe lengths and pipe spools are observed without end covers or bevel protectors. This violates SAES-L-350 SECT 7.4.The Contractor must ensure that all prefabrication activities are in accordance with SAES-L-350 Contractor [Al Khodari] has received fabricated welded pipe sleeves from Modern Steel and Exhaust Pipe Factory: Vendor ID 10013225. No welding records or plate material certificates accompanied the shipment. SAPMT are requested to confirm that the vendor / supplier is approved to carry out fabrication and welding activities, and submit a copy off all material, fabrication, welding and Inspection reports to PID. Contractor should submit approved personnel forecast within 60 days including demobilization of the personnel. This change should be reflected also in the organizational chart. Violation of Schedule "Q" 5.1-1&2 and 5.9 and 5.11. The contractor failed to provide the require personnel for the construction phase of the project. An approved 2 mechanical inspectors are required to provide coverage as per schedule "Q". table IV-2 attachment VI. During covering RFI at RR area 27 for holiday test on sewage pipe 24 was rejected due to the following: 1. Holiday test device (electrometer) is not calibrated. 2. There are damages in external coating in pipe. Contractor should calibrate the device and repair the damage and submit RFI. SLS 02 Pressure Gauge Installation: It has been noticed that pressure gauges installed at SLS-02 with G.I fittings. Material shall be 12BD0U (90/10 Copper Nickel) as per construction drawing VB-226412-001 and SAES-L-105, Para 12.2 and line class table of 12 FE0U in SAES-L-105. Another violation is that the pressure gauges not equipped with vent/drain valves as required per SAES-J-902, Para 6.4. On 1/5/2009 during my surveillance inspection at lay down yard I was found two welders without JCC.This is violation to SAEP 324 Para.6.2.7. The contractor required to be sure all the welders have JCC before the start any welding work. Location: RT Airport Date: 10/23/2008 During inspection coverage of (RFI # 106 for Hydrotest of valves) PID found out that this RFI was raised to PID by Plumbing QC and we found him very poor in conducting the hydro-test for valves. He didnt know what the procedure and methods of hydrotest for valves, and he didnt understand what the difference between the hydrotest for valves and pipes. This is a violation of sch Q Para 1.3 &1.4. PID requires: 1- Contractor has to follow the SA procedure and requirements. 2- Contractor has to provide qualified mechanical QC for handling the mechanical activities. 3Contractor has to conduct the hydrotest for all valves at project site. 4- Contractor has to be aware of the quality of the project. Location: RT Airport Date: 10/23/2008 During surveillance inspection @ BI-10-03970, PID found out that there was a worker doing a welding activity on angle structure inside the building and he was not carrying the welder JCC which is a violation of SAEP-324 Para 6.2.4 and through investigation we found also the contractor did not have the WPS for this project approved yet by PID nor by CSD, and while there is no welding QC approved for this project yet. PID requires: 1- Contractor has to follow the SA procedure and requirements.
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
7.4
2583
12/18/2007 11:10:37 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
6.2
2584
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
6.3
2585
2/17/2009 8:14:24 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
5.1, 5.9 and 5.11
2586
5/13/2008 9:19:51 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
5.1 and attachment VI table 2
2587
1/18/2010 10:05:37 AM Coating
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
Schedule Q
A IV Para 7.1
2588
SATIP-L-350-09
SAIC-L-2011
Mechanical
SAES
SAES-L-105
11
Schedule Q
1.3
11/19/2009 8:58:42 AM
2589
1/10/2009 3:10:44 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
8.1
SAEP-324
6.2.7
2590
SATIP-A-004-02
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
1.3 and 5.1
10/25/2008 5:22:10 PM
2591
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
1.3
10/25/2008 4:59:13 PM
2592 2593 2594 2595
2- Contractor has to provide welding QC prior to starting the welding activity. 3- Contractor has to have the WPS approved by CSD & then by PID prior to starting the welding activity. 4- Contractor shall adhere to Sch. Q requirements. 5- Contractor to remove/cut the area in question and invite PID before activity started. Regarding Space frame coating inspection at Bldg. 110 the following are comments raised by PID coating inspector;. . . . 1) Web members are not ready for coating due to improper surface abrading and cleaning. 3) Suppliers representative that recommended this procedure is not present on site. 4) Some section need additional platform, not accessible for workers to do the job. 5) Some workers make use of sand paper grit 100 instead of the recommended grit 80 in abrading old paint. . . . In the next notice to perform this job all of the above comment must be properly addressed, PID coating inspector recommend to conduct a tool box meeting and require all concern personnel to attend. 2) Assigned coating applicators qualification ID is expired. RFI for bolt and nut inspection/verification Testing of Direct Tension Indicator is prepared, Safe access for inspection not been prepared particularly in mezzanine floor. Safety device flat form should be installed in all area of inspection. For safe reason prompt action regarding this matter is highly required. For your compliance Control of Monitoring and Measuring Devises - Verified and checked that the Hydro-test Manifold system has been exceeds six months from the date of actual testing that was on March 19, 2006. This is not acceptable as per the requirements of schedule "Q" para.6.1 prior to be used for the hydro-testing of G3ST7 @ sabkah-80 to 81. Please advised contractor to comply the requirements. During my site visit @ sabkah-76 it was observed and found out the following deficiencies: 1) Pipes and elbows (internally coated) stored directly on the ground. Pipe not placed on mounds or sleepers. 2) Stacking of elbows not be made in a manner to avoid damage to pipes/elbows or coatings. 3) Fittings not stored in shipping crates. 4) End protectors on flanges, weld bevels not firmly attached. This is in violation of SAES-H-200 sec.5 para.5.1 thru 5.4. Noticed that if this non conformity does not intent SPIU will proceed to issue an (NCR) Non Conformance Report. Please advised Contractor to comply. Thanks. Routine visit @ site - During my routine visit verified and checked that since 12 July 2007 till now 15 July 2007 there was no QA/QC coating inspector @ site. SPIU investigated this issue and found out that the QA/QC coating inspector leaving @ site/shaybah without proper notification to SAPMT and inspection. This is in violation of schedule "Q" general requirements para.1.3, para.1.4 and para.5.11. Could you please advice QA/QC supervisor or Contractor to take a course of action regarding this issue. If the QA/QC supervisor or Contractor does not intent this non conformity SPIU will proceed to issue an NCR and therefore starting today 15 July 2007 all coating activities will not be accepted by SPIU. Please discuss to the contractor about this issue accordingly. Thanks.
ScheduleQ SAES ScheduleQ ScheduleQ
Schedule Q SAES-W-011 Schedule Q Schedule Q
5.1 7.1.1 1.3 1.7
2596
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
Schedule Q
1.3
5/9/2007 11:04:23 AM
2597
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAEP
SAEP-316
2598
6/20/2006 3:28:19 PM Q
SATIP-M-001-01
SAIC-M-2009
Mechanical
ScheduleQ
Schedule Q
1.3
2599
5/23/2007 2:37:47 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
HDD
2600
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
SAES-H-200
5/19/2007 4:43:45 PM
HDD
2601
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
1.3 and 5.11
7/15/2007 1:31:46 PM
HDD
2602
8/29/2006 8:50:53 AM HDD
During my site visit @ SABKAH-80 & 81 it was observed that since 19 August 2006 till now 29 August 2006 the approved QA/QC coating inspector is not available @ site. This is in a violation of schedule "Q" General requirements para.1.3 and 1.4. Please advised contractor to comply the requirements. all 2" valves in line 900 class has Rised face flange connected to pipe with RTJ flange J&P use PICKOTEC gasKet. this isseu violated SAES & project Piping Spec for line 9LE2P. J&P need to make corrective action to solve this issue J&P install PICKOTEC Instead of O Ring gasket between CS pipe flange & SS valve both have RTJ flange faces.this voilated SAES & Project Spec. J&P send RFI-14713 for hydro test without any information such as line Number, drawing number & system ID which violated schedule this info are required to avoid confusion between one test and another. Modifications were done to many spools different sizes and classes belong to the remaining 6 HT packages at RIS-A not reported to PID. all RIS-A hydro test Packages will be in hold and it will not be accepted until J&P provide PID with red Mark drawing including to all the require quality documents. during reviwing hydro test package I noticed that there no approved Lay up procedure which violate SAES-L-350 Para 19.1 Piping systems which have been completed as far as cleaning and pressure testing shall be properly laid up and SAES-A-007 Par 5.2 Lay-up Procedures 5.2.1 Equipment must be laid-up after hydro testing unless it can be ensured that it will be returned to service within 30 days from the first introduction of hydro test water to the system. During surveillance inspection PID found the following concerns.. 2" Externally coated Underground valve installed without RFI, which require HT, internal epoxy coating etc.etc. Uncoated stud bolts and nuts were installed, All underground steel studs/bolts to have fluoropolymer coated as per SAES L105 para 5.6.3 All coated vent piping to be holiday tested before back filling PID noticed that inlet pipe 30"-RL-665-1CS2P was erected to the gas gathering drum with out vent for hydro test use which is violated SAES-A-004 Para, 7.4.1. also the isometric drawing BB222916 dose not show the vent location since this line is the highest point in system it shall have vent to install pressure gage during hydro test stage this is a mandatory requirement before starting any hydro test.. J&P need to do corrective action to clear this issue before final installation to prevent any delay in the progress. Contractor J&P has failed to conduct the PMI testing for the SS Materials at GOSP Area while the Production of the welds of SS is fast going.It was scheduled this morning that the subcontractor VECTO will conduct the PMI testing for J&P but when they mobilized to the site it is observed that their machine can not verify the carbon content in the materials together with other segneficant materialS as required by SAES-A-206 Para 7.5 Table 1. Contractor shall organize the PMI testing as soon as possible as the production is keep going with PMI TESTING.
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
2603
8/16/2009 11:21:03 AM RIC-A
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
8.5
2604
8/16/2009 11:41:00 AM
RIC-A
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.2.1
2605
8/17/2009 1:29:22 PM
SATIP-A-004-02
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
1.3
RIS-A
2606
8/17/2009 1:14:55 PM RIS-A
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
7.5.7
2607
SATIP-A-004-02
SAIC-A-2007
Mechanical
SAES
SAES-A-007
5.2
SAES-L-350
19.1
11/30/2008 4:24:13 PM
2608
8/11/2008 5:28:08 PM
SATIP-L-108-01
SAIC-L-2043
Mechanical
ScheduleQ
Schedule Q
1.7
2609 2610
SATIP-L-450-04 SATIP-H-002-02
Mechanical
SAES
SAES-L-105 SAES-H-200
5.6.2 7
Mechanical
SAES
2611
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-A-004
8.4.1
8/31/2008 8:17:55 AM
2612
SATIP-L-350-01
SAIC-L-2010
Mechanical
SAES
SAES-A-206
7.5 (table 1)
10/21/2008 11:11:33 AM
2613
11/26/2008 7:59:54 AM
PID noticed during hydro test for package SK-6 A1 @ TIG Unit that J&P used water as test media but this package is for (instrument air piping) so it shall be tested only by pneumatic test according to SA specifications and requirements. J&P need first to submit A pneumatic procedure and shall be approved by PID manger before doing any air test according to SAES-A-004. PID noticed that there is no draine for line 1"-A-1230-12CG0U which coming down from pipe rack. which violated SAES-A-004 Para,7.4.2 as observed during routine site inspection, Contractor has installed the pressure vessel (Compressor suct drum) without implementing reqd QC tasks as covered by SATIP-D-001-01. Unfortunately, the vessel was installed and bolted "forcibly" to the anchor bolts which has resulted to unacceptable workmanship. Contractor has violated the SAED-D-001, Para. 3.2 and has failed to comply with the checklist(SAIC-D-2007). Contracotr was requted to rectify work and comply with applicable SA standard. as observed during routine site inspection, Contractor had installed the pressure vessel(suct drum) without implementing the reqd QC tasks covered by SATIP-D-001-01 and has failed to issue RFI for the activity. Unfortunately, the vessel was installed "forcibly" to fit with the anchor bolts which has then resulted to unacceptable workmanship. Contractor has viloated SAES-D-001, para. 3.2 and failed to comply with the checklist (SAIC-D-2007). Contractor was requested to rectify observed defects and comply with SA standards. as observed during routine site inspection, contractor has again "forcibly" fit the anchor bolts and/or installation of the portable water tank to its supports which have resulted to unacceptable workmanship. this is a "repeat violation" and is also in violation of SATIP-D-001-01 and SAES-D-001, para. 3.2. Contractor is requested to rectify said installation as reqd. 03/01/08, Nuyyaim Project: Contractor J&P has begun layout and fit-up of the bottom plates for TEG Storage Tank No. H96-D400, reference Dwg. No. 40017-M12-02. This work is a violation for the following reasons: 1) The Olayan Descon Co IFC Dwgs have not been Issued for Construction 2) The required ITP, associated procedures and test reports have not been submitted and approved by Saudi Aramco. 3) There are no approved QC personnel available to monitor the construction activity and 4) Based on instruction from CSD, Olayan Descon shall be employed to and made responsible for the design engineering, supply of materials, and field fabrication of said tank(s). 03/01/08, Nuyyaim Project: Contractor J&P has begun layout and fit-up of the bottom plates for TEG Storage Tank No. H96-D400, reference Dwg. No. 40017-M12-02. This work is a violation for the following reasons: 1) The Olayan Descon Co IFC Dwgs have not been Issued for Construction 2) The required ITP, associated procedures and test reports have not been submitted and approved by Saudi Aramco. 3) There are no approved QC personnel available to monitor the construction activity and 4) Based on instruction from CSD, Olayan Descon shall be employed to and made responsible for the design engineering, supply of materials, and field fabrication of said tank(s).
SATIP-A-004-02
SAIC-A-2001
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2614
12/3/2008 7:25:48 AM
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAES
SAES-A-004
8.4.2
2615
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
6/12/2008 3:02:45 PM
2616
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
6/12/2008 3:13:52 PM
2617
6/19/2008 2:58:41 PM
SATIP-D-001-01
SAIC-D-2007
Mechanical
SAES
SAES-D-001
3.2
2618
SATIP-D-100-01
SAIC-D-2025
Mechanical
other
32-SAMSS005
7.2.1.11
Schedule Q
1.3
3/1/2008 8:10:49 AM
2619
SATIP-D-100-01
SAIC-D-2025
Mechanical
other
32-SAMSS005
7.2.1.11
Schedule Q
1.3
3/9/2008 5:16:43 PM
2620
3/26/2008 9:39:20 AM
03/01/08, Nuyyaim Project: Contractor J&P has begun layout and fit-up of the bottom plates for TEG Storage Tank No. H96-D400, reference Dwg. No. 40017-M12-02. This work is a violation for the following reasons: 1) The Olayan Descon Co IFC Dwgs have not been Issued for Construction 2) The required ITP, associated procedures and test reports have not been submitted and approved by Saudi Aramco. 3) There are no approved QC personnel available to monitor the construction activity and 4) Based on instruction from CSD, Olayan Descon shall be employed to and made responsible for the design engineering, supply of materials, and field fabrication of said tank(s). 05/20/08, Nuyyaim: Regarding the Flexible Membrane Liner for the TEG Storage Tank H96-D-400; see Dwg. No. BA-407843; in accordance with API 650, Appendix I, I.6.3 the contractor is required to complete the following; 1) Submit for approval the procedure to be used (including testing methods) to bond or weld the liner seams. The procedure shall specify all the critical parameters, such as temperature, speed, surface preparation and curing time to achieve liquid tight seams. 2) Proof testing of the flexible membrane liner shall be performed to verify the seam strength, flexibility and the adequacy of bonding. 3) All shop and field seams of the flexible membrane liner shall pass a vacuum box test. 02/28/08, Nuyyaim Project: Contractor J&P has begun layout and fit-up of the bottom plates for Fire/Utility/Wash Water Tank No. H96-D-053, reference Dwg. No. 40017-M11-02. This work is a violation for the following reasons: 1) The Olayan Descon Co IFC Dwgs have not been Issued for Construction 2) The required ITP, associated procedures and test reports have not been submitted and approved by Saudi Aramco. 3) There are no approved QC personnel available to monitor the construction activity and 4) Based on instruction from CSD, Olayan Descon shall be employed to and made responsible for the design engineering, supply of materials, and field fabrication of said tank(s). It is oberved during the surveillance inspection that fin fan cooler heat exchangers H96-E-0126 & E-0146 having no preservation status as the installed gauges showing zero pressure which also reveal that these exchangers are sealed vapour tight for the inhibitor to be effective as required by 32-SAMSS-011 Para 11.4.The other compressors lube oil cooled exchangers have installed the gauges and showing some positive pressure.Please instruct the Contractor to confirm the preservation and the comply the requirements of 32-SAMSS-011 Para 11.4. G-214B, the difference in elevation between point G and H (the pump feet) is 1mm while the distance between these points is 0.7m. Thus, the elevation offset is 1.4mm/m.So G-214B level needs to be corrected before the final alignment As per the review of the pump data sheets for (1) potable water off loading pump H96-G-226 (2) potable water supply pump H96G-227/228 (3) Diesel oil off loading/transfer pump H96-G-57A/B (4) TEG make up pumps H96-G-400 A/B, it is found that all motors have the same serial numbers that is 7461679. This number is written on all motors name plate. Please instruct the contactor to contact the supplier for explanation and corrective action.
SATIP-D-100-01
SAIC-D-2025
Mechanical
other
32-SAMSS005
7.2.1.11
Schedule Q
1.3
2621
SATIP-D-100-01
SAIC-D-2025
Mechanical
other
API 650 appendix 1
1.6.3
5/20/2008 6:50:34 AM
2622
SATIP-D-100-01
SAIC-D-2025
Mechanical
other
32-SAMSS005
7.2.1.11
Schedule Q
1.3
2/28/2008 1:59:26 PM
2623
SATIP-E-007-01
SAIC-E-2005
Mechanical
other
32-SAMSS011
11.4
9/2/2008 10:37:00 AM
2624
7/22/2008 2:07:29 PM
SATIP-G-005-01
SAIC-G-2022
Mechanical
other
31-SAMSS004
1 and 2.5
2625
SATIP-G-005-01
SAIC-G-2002
Mechanical
other
31-SAMSS004
5.13
9/6/2008 2:36:33 PM
2626
10/7/2008 2:44:29 PM
A site visit to verify the leveling records for the new Injection Pump at RIS-C was carried out this afternoon. During the visit, the outboard mechanical seal inlet pipe found to be broken and disconnected. Part of the broken male NPT still engaged inside the seal flange female NPT. The broken pipe was rethreaded for future use which is not acceptable and the seal flush pipe would have to be pulled at least 6 mm to bring the flanges together. The seal flange inlet port was plugged with a napkin. Therefore, the cleanliness of the mechanical seal is questionable. Rethreading the broken pipe indicate that this issue was noticed by J&P but was not addressed. New spool need to be installed in addition to checking the thread integrity for the seal flange inlet port as well as ensuring the seal is free from debris. Contractor J&P QC department shall investigate the this issue as it is noticed after recieving inspection done. During site surveillance PID found the following: 1. two underground oily water sewer lines vent in TEG UNIT area are backfilled without holiday test which violating the Aramco standard SAES-H-002 parg 5.1.1 2. two Underground instrument air piping number (3-3-1128-1CS2U) and (2-N-844-1SD0P) beside to control room wear test the holiday and backfill it and now are excavated again which need to make holiday test before backfilling again to guaranty there is no damage from excavating. PID have visited painting and blasting activities in the night shift at site and following violations have been observed . 1.Found two contractor blasters named: 1-Omran Khan 2- Mohd Aslam using the reclaimed garnet (used garnet) for blasting the structural steels which violates SAES-H-001 para.6.3.4. 2.There is no QC.inspector to monitor and record the blasting requirement. 3.No crew approved supervisor. 4.Omran Khan he is not approve as blaster. 5.Reclaimed garnet material stored beside the blasting yard 6.Based on the attached Contractor letter there is no blasting activities at night shift. PID requested the following: 1-Contrctor to investigate. 2-Mohd Aslam certificate shall be revoked and to be returned back to PID 3-No blasting &painting activities allowed without approved coating QC inspector and crew supervisor. 4-Reclaimed garnet material to be immediately collected and stored a way from the blasting yard During site surveillance in evaporation pond area PID fond that, Al-Qahtani continue works on Fusion Bonded Epoxy coatings on the INTERNAL girth weld areas with no represent for QC which is violation. QC should attend all the contractor work. PID noticed painting activities at WI area and its not done as SAES because of these two issues: 1- the paint was applied by non certified applicator 2- There is no surface preparation before painting supports. These violate SAEP-316 Para 3.1 All protective coatings applicator personnel shall be qualified and certified prior to the start of work. During site surveillance PID fond that, Al-Qahtani continues work on Fusion Bonded Epoxy coatings on the INTERNAL girth weld areas for 2 with no approved procedure which is violation according schedule Q. During site surveillance in GOSP area PID found that five underground hydrant lines are backfilled without holiday test which violating the Aramco standard SAES-H-002 parg 5.1.1. Those hydrant numbers listed below: M-16, HR-17, HR-22, M-10, and M-01.
SATIP-G-005-01
SAIC-G-2004
Mechanical
ScheduleQ
Schedule Q
1.3
2627
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-002
5.1.3
10/22/2008 4:02:58 PM
2628
SATIP-H-100-01
SAIC-H-2024
Mechanical
ScheduleQ
Schedule Q
7.5.4
10/22/2007 7:55:50 AM
2629 2630 2631
SAES ScheduleQ SAES
SAEP-316 Schedule Q SAES-H-001
4.4 5.1 6.3.4
2632
11/7/2008 10:26:41 AM
SATIP-H-002-08
SAIC-H-2060
Mechanical
ScheduleQ
Schedule Q
5.1
2633
11/18/2008 7:06:30 AM
SATIP-H-100-01
SAIC-H-2010
Mechanical
SAES
SAEP-316
4.4
2634
11/18/2008 4:02:54 PM
SATIP-H-002-08
SAIC-H-2057
Mechanical
ScheduleQ
Schedule Q
3.1
2635
12/3/2008 4:31:01 PM
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-002
5.1.3
2636
2/13/2009 9:57:11 AM
During surveillance inspection @ Al-Qahtani yard for final inspection from PID, a 8-RW-0466 belongs to RIC A spool (Spool @# 001-4) has complete linear internal damage (happen because of poor handling and transportation ) on the existing coating which causes holiday during inspection. The entire spool has to be re-blasted and FBE coated internally before final release from PID. During surveillance visit by PID @ south side of the GOSP flare road crossing following violation noted. J & P to take corrective action and issue RFI to close the log book entry A bunch of lines including 30 Flare header has extended the backfilling beyond the specific coating. FBE coating to be extended 1 meter beyond the backfilling as per SAES H-002. Coating and holiday not completed for CAD welding @ the road crossing. Flange joints were not protected before backfilling of flanges. Control has backfilled the coated copper pipe without performing holiday testing as required by SAES-H-200 PARA 7,The coated pipeline shall be 100% inspected with a pulse-type DC holiday detector employing an audible signaling device immediately prior to burial, This final inspection procedure shall be monitored by a Saudi Aramco Inspector. Contractor J&P have painted the 2" and 8" pipes with APCS-1A. This system is assumed to be for corrosive atmosphere exposure and high humidity exposure as per SAES-H-001 para 5.6.5 and SAES-H-002 para 7.1B while such case is not existing in the project. in order to confirm the right painting system , Contractor J&P shall provide a painting schedule for all line designation piping. up to date al QAHTANI Coating crew did not able to stick with their approve work procedure AQPCT-WP-300-291 section A7.1.2 for welds which are not possible for direct visual verification a camera shall be used . Accordingly Saudi Aramco PID need CD record to camera used after shut plasting and coating. As the Contractor J&P mechanical group have open the flanges of compressors and the nitrogen has been removed. As per the KAWASAKI Preservation procedure for compressors F3186-0411 Para 2.1 note, it shall be immediately re-charging N2. While as per API 686 Para 1.12.6 All large compressors, if expected to be in the field in excess of 3 months, shall be purged with nitrogen. When nitrogen is not available, case openings shall be sealed. Vapor phase inhibitor and desiccant shall be used to protect internals from rusting. The equipment shall be tagged indicating the number and location of all vapor phase inhibitor and desiccant bags." Contractor shall be instructed to take action immediately and purge with nitrogen as stated above. It is observed during the site visit that shims under the air compressor H96-K-311 & 312 have been corroded before applying the grouting and in some locations under air compressors used a corbon steel thick plate as a shim which need to be replaced with type-300 series stainless steel shim as required by API-686 Para 3.9.3.7. contractor shall be advised to remove corbon steel thick plate used as a shim and corroded shims before grouting. The elevation and alignment shall also be checked after removing the non-qualified shims.
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-200
5.1.1
2637
SATIP-H-002-02
SAIC-H-2018
Mechanical
SAES
SAES-H-002
5.1.5
3/16/2009 5:38:30 PM
2638
2/13/2008 10:36:15 AM
SATIP-H-002-02
SAIC-H-2016
Mechanical
SAES
SAES-H-200
2639
3/2/2008 8:00:53 AM
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-001
2640
7/28/2008 5:31:40 PM
SATIP-H-002-08
SAIC-H-2060
Mechanical
SAES
SAES-H-201
7.1.5
2641
SATIP-K-402-01
SAIC-K-2001
Mechanical
other
API 686
1.12.6
Schedule Q
A IV Para 6
12/24/2008 11:45:01 AM
2642
SATIP-K-402-01
SAIC-K-2008
Mechanical
other
31-SAMSS001
API 686
3.9.3.7
9/2/2008 10:59:13 AM
2643
4/17/2009 9:25:32 AM
2644
8/24/2008 6:09:27 PM
2645
8/26/2008 9:19:23 AM
2646
10/8/2008 12:52:58 PM
2647
10/22/2008 3:12:34 PM
2648
10/26/2008 5:21:00 PM
2649 2650
11/4/2008 1:59:17 PM
11/4/2008 2:53:24 PM
During routine walk through the following violation were noted on the PZV errection pls. take corrective action to avoid delay MCC signing as some of them are YES item .... * Bellow type relief valve bonnet has been plugged seal, remove the plug on the bonnet and provide a safe vent as per SAEP 318. * All bellow type relief valves bonnet shall be coated green. * All PZV vent to atmosphere shall be provided with a 3/4" vent hole at the low point, to avoid stagnation of water. It is noticed at shop painting area that most of the welded joints are painted prior to Hydro test. As per SAES-L- 150 Para 7.3.All joints including welded shall be left exposed for visual leak detection during the strength test. External coating and priming of such joints are not allowed unless approved by the Manager of Inspection Department and the proponent Organization representative. during site visit I noticed the below: 1- many coated pipes stacked directly on the ground or on pipe. 2-many fittings & flanges not stored shipping crates or on racks. 3- there are no end protectors on pipes, flanges, weld bevels, all these items violated SAES-L-350 Para,7 J&P shall made corrective action to aviode more damage to materials. During site surveillance PID found that two instrument air piping goes to fire water tank which having a pocket witch violating the Aramco standard SAES-J-901 parg 4.8.1.7. line 12"-P-0474-9CS2P were used as support for line 16"-SW2057-9LE2P which violated SAES-L-350 para 11.2 J&P must clear this kind of issue ASAP and make sure that it will not happen again It is noticed in the Contractor IFC drawing that a round bar of 20 mm dia is welded directly on the support SC2.S and pipe spools rest on the bar. This is not complying the requirements of SAESL-310 Para 16.2.1 and SA Standard drawing AD-036555. For the existing situation of the support a query received from the CSD that this type of support is used if there is a potential of corrosion between the pipe and the support. Contractor QC department shall verify the reference for bar welded and purpose included in the IFC. during site visit PID noticed damage due to mishandling on valve flange. NO#7J27-4-1 there are no spacing between line 6"-SR-1735-1LE2P which violated SAES please mange the spacing requirement before final installation. It is observed that during hydro valves seat testing for ( motor operation valves) when the contractor close the flange valve by blind flange to pressurize the water, the air between seat valve and blind flange is trapped because no air vent system used for (MOV) which is violation according API 598 parg 4.1.2. Contractor should solve this problem PID noticed that blind flange class 900 for line 2"-SR-1714-9LE2P was used as reducer and slip-on flange for line 2"-SR-17149LE2P which violated SAES-L-109 Para 6.4 Many Pipes were stored directly on the ground and rust start to build up this violated SAES-L-350 Para 7.1. this issue had been highlighted many time before but there is no improvement. During site surveillance inspection in valves work shop PID has found visual mechanical damage in the disk for valve number 7G21-3-1. J&P requested to investigate and to comply with Vendor and Aramco requirements.
SATIP-J-600-01
SAIC-J-2009
Mechanical
SAEP
SAEP-318
9.5
SATIP-A-004-02
SAIC-A-2015
Mechanical
SAES
SAES-L-150
7.3
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
SATIP-J-901-02
SAIC-J-2015
Mechanical
SAES
SAES-J-901
4.8.1.7
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
11.1
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
16.2.1
Mechanical
other
04-SAMSS035 SAES-L-310
12.2 12.4
Mechanical
SAES
2651
11/8/2008 7:16:40 PM
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
2652
11/10/2008 1:40:56 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
6.2.4
2653
11/10/2008 2:39:26 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
7.1
2654
11/10/2008 6:17:14 PM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
6.2
2655
11/12/2008 3:41:10 PM
PID noticed that valves stem for all 2"drain valves were insalled according to drawing whith The same direction of 20"pipe they will be no accecc between 20" flange and the hand wheels. PID noticed that 2" drain valves 07/186/006/12, 07/186/006/07 & 07/186/006/9 were recived & delivered to site without hand wheel J&P need to investgate this issue During surveillance site visit to J&P fab shop PID found that contractor have drilled again three (4 blind flanges class 900) to be used as slip on flange these blinds were designated for lines P2121-9EL2P & P-2127-9EL2P. This is a design violation according to SAES-L-109 Para6.4 & 6.6. This issue had been high lighted to J&P before by PID & PMT by E-mail and QMIS L-291 but there is no action done by contractor to stop this violation. PID noticed that all the wear pad for dummy supports does not have 6mm weep hole for air test which violate SAES-L-310 Para 14.7.1 The dummy supports shall not create excessive stresses at the attachment welds to the run pipe. This can be accomplished by minimizing the length of the supports and/or increasing the size of the supports. Also NDT (MT or PT) shall be done to welds between pad and pipe J&P use 3" pipe as dummy support and they dirctly welded it to many pipes which will be create stresses to pipes this is a violation according to SAES-L-310 Para 14.7.1 The dummy supports shall not create excessive stresses at the attachment welds to the run pipe. This can be accomplished by minimizing the length of the supports and/or increasing the size of the supports During site visit to WI area PID noticed that many flange SPECTACLE PLATES are not installed as SA standard drawing AC036630 which show that Jack screw must be at 90 degree from spectacle blind nick. During site visit PID found PG crew doing a hydro test preparation for 2 line at TIG unit area without submitting the hydro test package to PID for review and approval this kind of practice not acceptable by SA specification and requirements. J&P shall give justification to PID about this issue. 6.4 Slip-on flanges shall be welded at the front and back of the hub, but not on the sealing face. Slip-on flanges and reducing slip-on flanges shall not be used in: Severe cyclic conditions (see ASME B31.3, paragraph 300.2), Design temperatures above 230C, ASME B16.5 Class 400 or higher rating, Hydrogen services, PID noticed that contractor still used drilled 2blinds flanges as slip in flanges at crude oil manifold area line 36-P-2101-9LE2P. Also the welded the 2pipe to the inside flange face which violated SAES-L-109 6.4 Slip-on flanges shall be welded at the front and back of the hub, but not on the sealing face. Slip-on flanges and reducing slip-on flanges shall not be used in: Severe cyclic conditions (see ASME B31.3, paragraph 300.2), Design temperatures above 230C, ASME B16.5 Class 400 or higher rating, Hydrogen services, During site surveillance inspection in valves work shop PID has found the following: 1. The relief valve that installed in manifold is for instrument air not for water pressure which is violation. 2. The pressure setting for relief valve is 2900psi which higher than what they wrote in the tag 2500psi of the relief valve which is violation.
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-310
11.1
2656
11/12/2008 3:45:39 PM
SATIP-L-108-01
SAIC-L-2040
Mechanical
SAES
SAES-L-108
8.3
2657
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
6.2.4
11/13/2008 1:58:30 PM
2658
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
14.7.2
11/16/2008 10:50:07 AM
2659
11/16/2008 11:01:18 AM
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
14.7.1
2660
11/18/2008 9:57:34 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-310
11
2661
11/18/2008 2:10:29 PM
SATIP-A-004-02
SAIC-A-2003
Mechanical
SAEP
SAEP-1160
2662
11/18/2008 3:17:49 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
6.2.2
2663
11/18/2008 3:20:19 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
6.2.4
2664
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
6.2
2665
11/18/2008 3:20:46 PM
SATIP-A-004-02
SAIC-A-2009
Mechanical
SAES
SAES-A-004
5.5.1
2666
11/18/2008 3:57:29 PM
It is observed that during hydro valves seat testing for 18" control valve they use spool 2.3 meter as reducer from 20" to 18" rather than use blind flange 18", the air between seat valve and blind flange 20" along spool is trapped because no air vent system used, and it is repeat violation according API 598 parg 4.1.2. Contractor should solve this PID noticed that there are no drains between pumps H-95-G-237 A & B discharge nozzles and check valve flange for line 6-P2361-3CS2P & 6-P-2381-3CS2P which violated SAES-L-310. Corrective action shall be done by J&P before hydro test There is no free distance between check valve & MOV for G237A & 237B discharge line. Minimum 2 pipe diameters downstream of every check valve shall be maintained according to SAES-L-108 Para 6.3.4 because of this issue MOVs H95-MOV433 A&B cant be installed As per the surveillance inspection it is found in the water injection area that in the drain connection there 2 x 900 LB Gate Valves are installed having raised face and while the flange piping system is ring joint which is violating the SAES-L-109 Para 8.3 saying that Ring joint flanges for use with ring joint gaskets per ASME B16.20 shall used for Flanges in Class 900 and higher ratings The assembly of raised face to ring joint companion flanges is permissible only in exceptional cases with certain gaskets when approved by the Chairman of Piping Standards committee in CSD as per SAES-L-109 Para 8.4. Please instruct the contractor to provide the correct and suitable valves with ring joint compatible to the piping system or exceptional case approval from CSD. It is observed that contractor J& P have drilled the 4x900 lb blind flange for the Connection of 2-SR-1714- 1LE2P line and did not follow the detail given for the right fabrication which mentioned in their P&ID Drawing BA-40921 Sheet # 3. The isometric drawing for this line is not well explained and detail given in the P&ID Drawing BA-40921 Sheet # 3 is not transferred to isometric drawing. For all measurements of spools and detail of fabrication shall be given in the isometric drawing. Please instruct the contractor to contact their designer to revise the isometric. It is noted that contractor J& P have installed a 30x 150 LB Blind flange at the end relief line 30-RL-661 and drilled 2 hole in the blind flange to connect a 2-P-2213-1CS2P purging line which violating the SAES-L-110 Para 12.1.1 chart-1. As per the chart-1 it requires to have a weldolet or branch weld with reinforcement pad for branch connection when the header size is 30 and branch is 2. Contractor shall be instructed to reconsider this branch connection and act as per the SAES-L-110 Para 12.1.1 chart-1 for all branch connection with designer consultation.
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
API 598
4.1.2
2667
11/25/2008 10:55:17 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
19.3.3
2668
11/25/2008 11:13:03 AM
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.4
2669
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-109
8.4
11/25/2008 6:27:33 PM
2670
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
6.2.4
11/27/2008 11:09:46 AM
2671
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-110
13.1.1
11/27/2008 11:31:16 AM
2672
11/30/2008 11:49:27 AM
It is seen during surveillance that the 3" Drain line of header 16"P-2343 6CS29 at the Launcher area is extended and 3" isolation is located more than one meter which is more than 3 times of pipe diameter due to which a dead leg is created. this arrangement is not in compliance of the SAES-L-310 Para 11.4.2 (c) which states that " When the length is longer than three times its pipe diameter, or 1.22 m (4 ft) whichever is less. The length of the dead leg is the distance measured from the outside diameter of the header (or run) to the near end of the branch valve". Please instruct the contractor to reconsider this and correct as per the SAES-L-310 Para 11.4.2 (c) requirements. It is seen during surveillance inspection that the 3" Drain line of header 16"-P-2343 6CS29 at the Launcher area is extended and 3" isolation valve is located more than one meter which is more than 3 times of pipe diameter due to which a dead leg is created. this arrangement is not in compliance with the SAES-L310 Para 11.4.2 (c) which states that " A section of a piping system meeting the following criteria is considered as a dead leg When the length is longer than three times its pipe diameter, or 1.22 m (4 ft) whichever is less. The length of the dead leg is the distance measured from the outside diameter of the header (or run) to the near end of the branch valve". Please instruct the contractor to reconsider this and correct as per the SAES-L-310 Para 11.4.2 (c) requirements It is noticed by the PID that in the line 4"-SR-1730-1LE2P at HPPT area that check valve 3"x150 LB is installed in vertical line which violates the SAES-L-108 Para 6.3.5 which says that "Check valves in sizes NPS 3 inch and above shall not be installed in vertical lines, unless specifically approved by the Chairman of the Valve Standards Committee".Contractor shall be instructed to rectify the valve installation as per the standard requirement as stated above. Please also requested to check in other location the similar violation. During Surveillance inspection @ water injection area, PID has found orifice plate are being installed on 18"-SW-2076-15LE2P without the following verification by PID as per SAIC L-2016. Internal weld has to be ground smooth and if required NDT inspection required. Minimum straight run pipe Orifice material inspection Orientation of the orifice, cleanliness etc.. J&P is hereby requested to take corrective action and comply with the above requirements. In spite of numerous Hydro test meeting and presentation from PID, J & P is reluctant to comply with the standard requirements. Responding to RFI for the line 3 FO-1CS1U for Hydro test, PID has rejected the test for the following reasons The hydro test package has not been accomplished pre-walk through by PID, and the package not approved for TEST. The hydro test pressure shall be 90% of the Min. yield strength of the section for newly constructed line as per SAES L-150 or as per ASME 16.5 flange rating which ever has the limiting factor. No SIS (Safety instruction sheet) available/attached with the HT package. Contractor QCs A Punch items not completed by the construction prior to test. pack TP-400-08-02 & 400-08-03, no latest revision of ISO drawing attached to the package which create confusion in the field during walk through, J & P requested to use only the latest revision of drawings during package preparation.
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4.2
2673
SATIP-L-350-01
SAIC-L-2013
Mechanical
SAES
SAES-L-310
11.4.2
11/30/2008 1:58:41 PM
2674
SATIP-L-108-01
SAIC-L-2043
Mechanical
SAES
SAES-L-108
6.3.5
12/4/2008 10:18:28 AM
2675
SATIP-L-350-01
SAIC-L-2016
Mechanical
SAES
SAES-J-100
12/4/2008 4:36:49 PM
2676
SATIP-A-004-02
SAIC-A-2003
Mechanical
SAEP
SAEP-1160
12/5/2008 5:29:17 PM
2677
12/8/2008 10:57:50 AM
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
3.7
2678
12/11/2008 8:48:48 AM
All PZVs (Relief valves) to be handled as per SAEP 319 para 6.1 & 6.2. During walk through PID has found the PZV relief valves, ball valves , gate valves were stacked in the field without proper cover, which results in contamination of valve by blasting grits, sands etc, may damage the seats during operation. PID request J & P to flush these mentioned valves with water and re-hydro to follow. H-96-2-PZV - 4122, 4123, 4124, 4125. BALL valves - N-7164/0013,0015, 0018 GATE Valves- 07/134/008/01, 02, 04, 09, 12,13, 22,25.
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAEP
SAEP-319
6.1 and 6.2
2679
12/29/2008 4:02:51 PM
During site surveillance near diesel fuel storage tank area PID found two permanent relief valve # (H96-PZV-3752-1, H96-PZV3752-2) improperly stored inside box without cover and stored with horizontal position. This is clear violation for handling and storage of permanent relief valve as per SAEP-319 para 6. Contractor request to recalibrate these PZV with approved vendor. It is noticed during the surveillance inspection that three 1 instruments lines are resting on the line 12- P-2275-1CS2P between LPPT and booster pump area. As per the SAES-L-310 Para 16.1.2 that the pipe shall not be used as support as saying that The pipe shall not be used to support other pipes and structures without an appropriate analysis. The Contractor shall be instructed to rectify the condition as per the above requirements. During site surveillance inspection in valves work shop PID has found visual mechanical damage in seat disk and hand wheel problem with gear box for Globe valve number 8C8.3.1 . J&P requested to investigate and to comply with Vendor and Aramco requirements.
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAEP
SAEP-319
6.1 and 6.2
2680
SATIP-L-350-01
SAIC-L-2018
Mechanical
SAES
SAES-L-310
16.1.2
12/31/2008 10:08:42 AM
2681
1/11/2009 11:30:21 AM
SATIP-L-108-01
SAIC-L-2040
Mechanical
other
04-SAMSS035
6.2
2682
1/15/2009 5:36:21 PM
Modification has been carried for the HYDRO TESTED line (No 4 4101-1LE2P (TI-3624) below D-340 Knock out drum, without prior information to the Project Inspection, this is a serious violation, that any re-modification (welding or cutting of pressure containing boundaries or dismantling the permanent flanges), J & P has to inform PID well before the start of the activity and hydro tested package to be re-routed (to ensure all damaged Internal coating, NDT fixed) Contractor has to disseminate the above instructions immediately to all construction personnels.
SATIP-W-011-01
SAIC-W-2036
Mechanical
ScheduleQ
Schedule Q
1.7
2683
1/20/2009 6:06:48 PM
During site surveillance inspection in valves work shop PID has found that no cleaning from grease before valves testing which is violation according API 598 parg 4.4.1, the seat sealing surface interface clean and free from oil, grease and sealant. According to SAES-L-310 Para 19.3 the requirement for UtilityProcess Connections doesnt show in P&ID BA-406924-001 in the utility side (bleed valve & spectacle blind) missing. In process side (bleed valve or drain, block valve) required by SAES but missing from drawing.
SATIP-L-108-01
SAIC-L-2042
Mechanical
SAES
SAES-L-108
4.7.5
API 598
4.4.1
2684
1/24/2009 2:59:07 PM
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-310
19.3
2685
1/27/2009 8:53:37 AM
During surveillance inspection @ 2 nos. of manjur water well, the 6 "carbon steel lines has been burried underneath without proper coating of APCS. J & P is requested to excavate the burried line coat with APCS 113A, followed by holiday test before backfilling. During witness Hydro test for the RIS A pipe spools here, PID has found installed a wrong type flange installed on the spec. break intersection. As per drawing on 4"-0465-9LE2P/3LE2P spool # 002/01 ISO drwg # BB-225095/002 shall have 900 RTJ flange instead J & P have installed 900 Raised Face flange. The subject flange to be removed and installed RTJ flange and rehydro tested before before the spool shifted to RIS A.
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-002
5.1.1
2686
SATIP-L-350-01
SAIC-L-2014
Mechanical
ScheduleQ
Schedule Q
1.3
3/13/2009 4:45:46 PM
2687
3/19/2009 3:56:52 PM
During hydro test walk through for the line 3-RL-632-9CA2P, the material take-off list for the bolt & nut were reflecting wrong material, the above line class comes under low temperature service the bolt & nut shall be of ASTM L7, but as per the MTO all installed bolts are B7/2H nuts, J & P is requested to replace all the bolts and nuts as required and revise the MTO.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
13
SAEP-351
4.2
2688
12/15/2007 2:00:00 PM
Contractor J&P have received some jack screws of different sizes from Saudi bea manufacturing co. These jack screws are fabricated by welding nut to stud bolt. the nut is hexagonal type and welded from the top side of the nut like plugging, no fillet welding has been performed between the stud and nut which is required as per the standard drawawing AC-036630 Sheet 15. Contractor J&P shall investigate more about these supplied bolts and verify that these bolts complying as per standard drawawing AC-036630 Sheet 15.
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
13
SAEP-351
4.2
2689
6/10/2008 2:22:29 PM
During the receiving inspection of the H96-K-002 (LP) H96-K001A,B(HP) H96-K-101A,B (P/L) compressors and their lube oil systems, it is noticed that the compressor casing drain piping Provided of Carbon steel which are not in the Compliance of 01SAMSS-017 Auxiliary Piping for Mechanical Equipment, Appendix A, Table A-1 Material Selection and Jointing Methods that drains and vents lines for hydrocarbon and water shall be stainless steel. Contractor J&P shall be instructed to coordinate with their supplier to correct and comply with the above stated requirements of 01-SAMSS-017.
SATIP-K-402-01
SAIC-K-2002
Mechanical
other
01-SAMSS017
appendix A table A-1
2690
4/16/2009 9:11:42 AM
It is found During the site visit that 16 pipe of line 16-P-22351CS2P coming from LPPT to the Crude Booster pump suction and 18" pipe of the line 18-P-341- 1CS2P going to the HP compressor near the ZV-0082 has been suppressed or dented . this may possible with hitting. The pipe need to be cut out and a pup piece to be welded with following of hydro test.
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAES
SAES-L-350
8.1
2691
1/21/2008 8:28:31 AM
It is observed during surveillance inspection of the pipe rack and found that two columns stiffer plates have drilled holes. These drilled holes are not reflected in construction drawing and nor in al-zamil drawing. It looks like that drilled in the site and damaged the welding. Contractor J&P Quality personnel shall investigate the root cause of these drilled holes.
SATIP-M-001-01
SAIC-M-2012
Mechanical
ScheduleQ
Schedule Q
7.5.4
2692
1/26/2008 3:06:17 PM
As per the site visit of the piperack area it is noticed that the stiffner plate is continously welded with colunms and no opening or hole provided as given in the Project drawing BA-407822 Sheet 034 and 35. In two locations contractor have been tried to provide an opening or hole by drilling in welded portion of stiffner plate which is not the actual process followed . Contactor shall provide the root cause and corrective action for their continouse welding of the stiffner plate. During site visit to J&P fabrication facility PID raised comment concerning the placement of the stiffening gussets associated with a pipe support, reference Dwg. No. BE-407701 sht. 130. Further investigation by the contractor QC Manager revealed that the gusset placement was correct, but that the orientation of the vertical leg (I-Beam) on at least one pipe support was incorrect and that it needed to be re-orientated 90 degrees to correct. The Contractors QC Manager has instructed his personnel to reinspect of all structural supports for conformance to appropriate IFC drawings and to generate a report identifying all the supports which require rework and those that are in compliance. Rework is to be completed were required and the QC Manager has reminded all involved personnel of the importance of ensuring that the QC Department remains fully involved at all stages of fabrication during this project. Fillet Weld Assembly: As-Fit-Up assemblies were observed that were in violation of AWS D1.1-2006, paragraph 5.22.1; which states that the parts to be joined shall be brought into as close contact as practicable. The root opening shall not exceed 3/16. Note: When the separation is greater than 1/16 the leg of the fillet weld shall be increased by the amount of the root opening. 3) In addition, the contractors QC Inspectors shall ensure that while conducting post welding visual inspections, all fillet weld profile are in accordance with AWS D1.1-2006, Fig. 5.5 Acceptable and Unacceptable Weld Profiles. Fillet Weld Assembly: As-Fit-Up assemblies were observed that were in violation of AWS D1.1-2006, paragraph 5.22.1; which states that the parts to be joined shall be brought into as close contact as practicable. The root opening shall not exceed 3/16. Note: When the separation is greater than 1/16 the leg of the fillet weld shall be increased by the amount of the root opening. 3) In addition, the contractors QC Inspectors shall ensure that while conducting post welding visual inspections, all fillet weld profile are in accordance with AWS D1.1-2006, Fig. 5.5 Acceptable and Unacceptable Weld Profiles.
SATIP-M-001-01
SAIC-M-2012
Mechanical
ScheduleQ
Schedule Q
7.5.4
2693
SATIP-M-001-01
SAIC-M-2012
Mechanical
ScheduleQ
Schedule Q
1.3
2/29/2008 2:11:34 PM
2694
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5
AWS D1.1
5.22.1
3/2/2008 12:11:02 PM
2695
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5
AWS D1.1
5.22.1
3/26/2008 9:56:28 AM
2696
10/29/2008 4:25:51 PM
During surveillance inspection, PID has found visual cracks on the external surface of the 20/ 600 Plug valve gear box assembly (Serial # ACKC 308, Tag # PL09LE600) the same has also been found passing during testing for valve seat. J & P is requested to investigate and suitable corrective action to be taken. It has been observed that areas beside the manifold have been "open" for equipment/vehicular traffic which have resulted to disturbance/damage of the applied prime coat. Contractor has violated SAES-Q-006, Sec. 5.4.1C. Contractor is requested to rectify prime coat prior to placement of binder course and comply with provisons of SAES-Q-006. Contractor shall develop and implement a color coding system for the indentification and verification of the correct type and rating for gaskets pre-installation as required by the schedule "Q" Para 3.2 attachment IV- and SAEP-351 Para 4.1. As per Sch.Q that Conractor shall implement an identification system for all materials, parts,and components, including partially fabricated assemblies.Identification shall be adressed either by using tags,stamps, color coding, stencils or labels. As per the SAEP351 Para 4.1. requires verification of the gaskets During site surveillance in TEG Unit PID fond that, QC doesnt have measuring tools for welding. During surveillance in Valve Work shop PID found that during lifting of valves, proper procedure to be maintained, PID has found the HT crews lifting the valve through Yoke, which my damage the valve Gland and Bonnet. PID request to lift the valve by using lifting leg provided.
SATIP-L-108-01
SAIC-L-2040
Mechanical
ScheduleQ
Schedule Q
7.5.4
2697
SATIP-Q-006-02
SAIC-Q-1041
Mechanical
1/6/2009 9:21:13 AM
2698
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.1
Schedule Q
4.2
6/22/2008 4:38:24 PM
2699
9/17/2008 11:03:16 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
2700
10/13/2008 5:11:07 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
ScheduleQ
Schedule Q
1.3
2701
It is observed during the surveillance inspection that Contractor J& P has installed carbon steel interconnecting piping between the LP Compressor and dry seal gas panel. These interconnecting piping shall be stainless steel not carbon steel as required by the 32-SAMSS-013 Chapter -4 (self -Acting Gas Seal Support System) Para 2.2 which says that (Exception) All piping and tubing shall be stainless steel irrespective of pressure. And as per the Saudi Aramco standard drawing AA 036537 note # 3 that ALL INTERCONNECTING PIPING SHALL BE STAINLESS STEEL (304, 316, 316L). (for dry seal gas panel) Contractor shall contact the designer and change the pipe materials accordingly.
11/19/2008 11:52:01 AM
SATIP-K-402-01
SAIC-K-2007
Mechanical
other
32-SAMSS013
chapter -4 para 2.2
2702
12/23/2008 3:51:23 PM
During the surveillance inspection at chemical injection area and the following noncompliance of the contractual requirements are noticed. No welding inspector was there to 100% Witness the welding of stainless steel piping which violates the SATIP -W-011 Para 3.6 and 3.7 100% hold and witness point. As per the pipe fitter the welding Inspector was not available for the last three days while welding was in progress. low penetration was observed in one weld of 2" flange to elbow connection and it shall be RTed for close inspection. No welding procedure was available at site area. No check list for the pre-welding and in process welding is used. Contractor shall comply the above stated points and perform Radiographic testing for all three days production welds which are welded without welding inspector inspection at chemical injection area .
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
2703
2/4/2008 10:39:50 AM
A surveillance inspection of the fabrication shop activities has been carried out and it is noted that the Contractor J&P did not take any action to separate the carbon steel and stainless steel fabrication shops as discussed and verbal instructions in quality meetings. As the piping fabrication works of the both materials will commence very soon and the separation of the shops will be significant. In the same shop, both fabrication works together can not be carried out. Contractor shall be instructed immediately to take action to designate a separate fabrication shop for stainless steel piping out of the vicinity of carbon steel . Also the current fabrication shop can not accomodate 25 welders as issued JCCs Contractor J&P has been recieved 30 flanges of 4"x150 lbs RF THREADED. 21 of them have the traceabilty with heat number, manufacturer logo, made by italy while the remaining 9 flanges are locally made without heat number , no manufacturer logo and no documents and no tracibility.these flanges are supplied by saudi pan gulf under one P.O. It is assumed that the 9 flanges are substandard, therefore Contractor Quality department shall investigate the root cause and carry out the corrective and preventive action. 03/22/08, Nuyyaim, J&P Fabrication Facility: During routine site visit, PID observed project materials i.e. pipe, plate and miscellaneous steel which have no heat numbers indicated on them. In addition, these materials were found outside the shop with non-project related materials. This is a violation of Schedule Q, Attachment IV, Paragraph 3.3 and 4.0. PID has requested on numerous occasions in order to avoid this particular violation that all non-project related materials be moved away from the fabrication facility to an area designated specifically for these materials and insisted that the use of such material shall be strictly monitored. As per surevillance inspection of the control building it is found that the fire water piping installation has been started without issuing RFI and Not provided any IFC drawing. Contractor J&P shall provide the proof of monitoring of this activity and the IFC drawings in order to confirm the materials and joint design. The plumbing QC piping shall be present when continuing this activity. During the surveillance inspection of materials yard, it is observed that the diesel fuel storage tank H96-D-055 was loaded to transfer to site for installation. The transportation of this tank was not facilitated with provision of rubber sheet underneeath of the sliding area to protect the tiflone sheet to be damaged.It was noticed that sliding area is directly touching the landing area of the truck. Please Instruct the contractor to upgrade thier transportation means and provide adequate insulation with rubber in order to prevent the coated pipes, equipment as well as insulated areas of equipment to be damaged.
SATIP-L-350-08
SAIC-L-2031
Mechanical
other
PFI-ES-43
3.6
2704
SATIP-L-350-01
SAIC-L-2006
Mechanical
ScheduleQ
Schedule Q
7.5.4
2/18/2008 4:07:20 PM
2705
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3 and 4
3/22/2008 2:30:46 PM
2706
SATIP-L-350-05
SAIC-L-2055
Mechanical
ScheduleQ
Schedule Q
1.7
4/10/2008 9:26:52 AM
2707
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-H-200
5/4/2008 10:27:21 AM
2708
6/1/2008 5:01:43 PM
During the receiving inspection of HP, P/L compressors and lube oil systems, it is found that the actual arangement of dry gas seal piping system is not complying the vendor supplied drawing which as approved by ENOIA.The drawing F-3188-5001-03 R-2 presented at receiving inspection is totally different than the actual system of dry gas seal system. Please instruct the Contractor to provide the actual approved drawing based on what the manufacturing of dry gas seal system carried out. Contractor J&P had been advised with a proactive log book entry # 450 dated 9/24/2007 to designate and identify the storage areas in their yard per their receiving Inspection procedure but no action has been taken to till date.. Now all materials like hold materials and inspected materials are mingled each other and no segregation has been provided, which is the violation of their receiving procedure X41-800-CO-PR-31 section 6. Contractor shall be instructed to act in accordance with their approved receiving procedure in order prevent the nonconformance materials to be used in place of approved materials. Contractor J&P have received some 2, 3, 8 pipes and fittings like elbows 2, 8 etc, and flanges. All of them supplied by Gerab. The marking on the small bore pipes and 8" pipes do not reveal the requirements of 01-SAMSS-038 para 4.7.1 which says that " Pipe purchased to this specification shall be marked "01SAMSS-038" in addition to the markings required by the base specification" and also 4.7.2 says that "Pipe purchased for nonsour service shall be identified by painting a white longitudinal stripe, 50 mm wide by 450 mm minimum length, on the inside surface of both ends. This stripe is intended to provide identification until the pipe is installed. The pipe shall be hard stamped as "Non-Sour" along with the pipe identification details. Contractor J&P shall be advised to investigate the root causeof this of this nonconformance and perform a corrective action as soon as possible. During the recieving inspection of the 4", 3" hot dip galvonized threaded pipes, it is noticed that the pipes are not marked any information given in the mill test certificates to confirm their traceability against the MTCs. The pipes are purchased under 01SAMMS-038 and did not follow the requirements of Para 4.7.2 which says that "The pipe shall be hard stamped as "Non-Sour" along with the pipe identification details". Please instruct the contractor to trace out the pipes against the provided MTCs before installation.
As discussed in weekly progress meeting that Contractor is recieving pipe materials API 5L PSL1. This pipe will only be accepted when there is upgradation report of the pipe from PSL1 to PSL2. This day (april 2, 2008) we conducted the recieving inspection of the pipes and found that some pipes is API 5L grade 42 PSL1 with out upgradation reports.Please instruct the contractor J&P to provide the complete documents which refelcts the upgradation.
SATIP-K-402-01
SAIC-K-2002
Mechanical
other
31-SAMSS001
1.6.1
2709
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
1.3
11/14/2007 7:33:39 AM
2710
SATIP-L-350-01
SAIC-L-2005
Mechanical
other
01-SAMSS038
4.18
12/12/2007 1:42:26 PM
2711
SATIP-L-350-01
SAIC-L-2005
Mechanical
other
01-SAMSS038
4.18
3/22/2008 2:02:55 PM
2712
4/2/2008 4:57:22 PM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
2713
4/17/2008 8:43:56 AM
04/17/08, J&P fabrication Facility, Nuyyaim: During a routine site visit PID requested that the QC Welding Inspector provide a high-low gauge so that the as fit-up condition of a fit-up joint could be verified. The high-low gage provided was not adequate for the intended inspection because the root opening was of limited width therefore the require verification could not be completed. The contractor is required to provide its QC personnel with all the inspection tools necessary to complete their required inspections i.e. wire type high-low gages, mirrors, torches, pyrometers, ect. In addition, only one pyrometer is available with which to verify pre-heat and monitor inter-pass temperatures, therefore if this pyrometer experiences a failure or were its accuracy be brought into question there is no back-up available to permit welding work to continue while a replacement is acquired or re-calibration is completed as required by Schedule Q, Attachment IV, Section 6.1, 04/23/08, J&P Fabrication Facility, Nuyyaim: Routine site visit by PID Supervision was made to fabrication facility and the contractors fit-up personnel were found preparing bullet pieces to be used during bridge tacking of the heavy wall Water Injection line out of re-bar. This is unacceptable and a violation of SAES-W-011, paragraph 11.5.2; which states that all tacks or temporary welds shall be performed with the same care, materials, electrodes, minimum pre-heat and procedures that are used for permanent welds. 06/22/08, GOSP: Visual inspections were carried out on line no. 10-P-3653CS2P, 10x 1 weld-0-let; FW112 (W-13011)and two (2)10"x 2" weld-o-lets, FW ? located @ FW67 (W-13011) and FW62 (W-152). The three (3) welds identified are rejected for lack of penetration. Also the wrong welding process was used on the root pass of each weld. The root pass shall be made using the GTAW process as required by SAES-W-011, paragraph 5.3.2 which states; The GTAW process shall be used for the root pass of butt welds without backing and set-in fittings of 50.8mm (2") nominal pipe size or less. In addition, paragraph 17.5.1.2 states; were accessible, welds shall be visually examined from the root side to ensure that proper penetration and fusion has been achieved. The contractor has failed to provide their QC welding inspectors with the appropriate mirrors with which they can perform the required internal visual inspections. A torch, mirror, wire highlow gage are minimum tools required for Insp. 06/21/08, Nuyyaim GOSP: Visual inspections were carried out on line no. 6SR-1865-1LE1P2, 6x 2 weld bosses; FW18 (W-94), FW26 (W-243), FW14 (W134) and 6SR-1991-1LE2P, 6x 2 weld bosses; FW121 (W-144), FW117 (W94), FW111 (W-13011), FW109 (W-133), FW51 (W-13011) and FW99 (W144). These nine (9) welds were rejected; one (1) for excess penetration, eight (8) for lack of penetration. Of the nine (9), four (4) were found to have already been internally coated. SAES-W-011, paragraph 17.5.1.2 states; were accessible, welds shall be visually examined from the root side to ensure that proper penetration and fusion has been achieved. The contractor has failed to provide their QC welding inspectors with the appropriate sized mirrors with which they can perform the required internal visual inspections. 05/15/08, J&P Fabrication Facility, Nuyyaim: Visual inspections (root side) by PID were completed of the 2 branch connections welds (GTAW) associated with 30-RL-661-1CS2P, Dwg.s BB-222913-001, weld no.s SW-1C [W-135] and SW-1B [W-135], BB-222913-002, weld no.s SW-1G [W-128] and SW-1I [W-128] and BB-222913-7, weld no.s SW-18C [W-135] and SW-18A [SW-135] and the results were unacceptable because the welds failed to exhibit full penetration and 100% fusion as required by SAES-W-011, 17.5.1.2. Note: access to these welds was available due to the 30 size of the header pipe. Such access will not be available on small diameter pipes and the contractor shall limit the length of all branch pups to between 12 to 14 maximum in order to facilitate the VT of all branch welds (root). In addition, the contractor shall provide the appropriate diameter extended reach mirrors to facilitate these inspections. 05/12/08, GOSP Nuyyaim: A QA Assessment of the project weekly report SATRW-2013; Welder Repair Rate Report WE 08 May, 2008 has been completed and the following noted: Welder 13011 has a Rejection Rate of 66.67% for the week and a Project to Date Rejection Rate of 66.67%. Welder 00169 has a Rejection Rate for the week of 35.81% and a Project to Date Rejection Rate of 11.94%. Welder 00144 has a Rejection Rate for the week of 16.67% and a Project to Date Rejection Rate of 11.03%. The contractor shall suspend all welding by these three welders immediately and return their Saudi Aramco issued JCC to PID ASAP.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.1.1
Schedule Q
A IV Para 7.1
2714
4/23/2008 11:29:41 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.2
2715
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
5.3.2
SAES-W-011
17.5.1.2
6/22/2008 8:49:27 AM
2716
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1.2
6/21/2008 3:43:01 PM
2717
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1.2
5/15/2008 1:41:15 PM
2718
5/13/2008 5:42:20 PM
SATIP-W-011-01
SAIC-W-2008
Mechanical
SAEP
SAES-W-011
17.5.1.2
SAEP-1160
5.1
2719
4/29/2008 9:19:45 AM
04/29/08, GOSP, Nuyyaim: A focused assessment of weekly report SATR-W2013; Welder Repair Rate Report has been completed. According to this report no NDT (RT) has been completed for welders 00144, 13011, 13021, 01586 and 01592. According to contractor personnel this is because line no.s 2-P2162-1CS2P and 16-P-2343-6CS2P on which these welders are welding have not yet been permanently placed and therefore weld numbers based on the approved weld maps could not be determined. This is unacceptable and a violation of Schedule Q, Attachment VI-6, Paragraph 2.14 which requires that the first 3 welds made by each welder to receive NDT (RT), SAES-W-011, Paragraph 17.5.2 which requires that selection of welds be based on weekly production and ASME B31.3 341.4.1 (b); which states that the welds to be examined shall be selected to ensure that the work product of each welder doing production welding is included. 11/19/08, J&P Fabrication Facility, Nuyyaim: During routine site visit it was observed that the electrode ovens (Baking and Holding) being used by J&Ps subcontractor (Chinese) are not indicating the appropiate temperatures. In accordance with SAES-W-011, 6.1; prior to use all electrodes shall be dried at between 370 C-430C for 2 hours minimum. This oven shall be identified as the Baking oven. After baking the electrodes shall be stored in a Holding oven. This oven shall be maintained a 120C minimum. Both the Baking and Holding ovens shall operate 24 hours a day. In addition, both of these ovens are required by Schedule Q, Attachment IV, paragraph 6.1 to be calibrated and the calibration cycle shall not exceed six months. The contractor shall maintain records of all calibrations and document regular verification testing of these ovens for compliance and make all such reports available to Saudi Aramco upon request.
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAES
SAES-W-011
17.5.2
Schedule Q
A IV Para 2.14
2720
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
A IV Para 7.1
4/19/2008 8:25:08 AM
2721
4/19/2008 2:14:22 PM
04/19/08, J&P Fabrication Facility and GOSP, Nuyyaim: Consumables Storage. J&P Shop Ovens; Baking temp 263 C (unaccept), Holding temp (accept). J&P GOSP ovens, Baking temp 109 C (unacceptable), Holding temp 99 C (unaccept). Subcontractor (Chinese) apparently transporting electrode from their ovens in the fabrication facility to the field daily, but their Holding oven in the J&P shop is not being left on 24 hours a day as required. The oven was found turned off during lunch today. Again, in accordance with SAES-W-011, 6.1, all Baking ovens must provide a minimum of 370 C and each Holding oven must provide a minimum of 120 C. In addition, the contractor and its subcontractor shall identify each Oven and Portable Oven with a unique number, each shall be calibrated and a sticker affixed indicating the calibration date. The contractor shall maintain accurate records for each oven as required by Schedule Q, Attachment IV, 6.1. 04/23/08, J&P Fabrication Facility, Nuyyaim: During VT of reinforcement pad welding by J&P welder no. 283 it was observed that the welder is still placing stringer beads in the weld groove 2G from the top of the joint to the bottom. The welder was previously instructed by PID Mechanical (MSG) to ensure all stringer beads were placed from the bottom to the top which is the normal placement of stringer beads for joints welded in the 2G position. Welding from top to bottom is unacceptable due to the possibility of slag entrapment and undercut. Undercut was noted this morning. This welder was removed from welding of pipe and or any pressure containing welds weeks ago due to an excessive rejection rate and PID agreed to allow the individual to continue welding structural and or non-pressure containing welds. This arrangement is no longer acceptable; therefore the JJC issued to welder no. 283 shall be return to Saudi Aramco inspection immediately. During site visit to J&P fabrication shop on Friday July 4,PID representive noted the following: Ongoing fitting and tack welding of heavy wall pipe to flange pipe spools [18"-SW-2077-003] without Contractor QC Welding Inspector coverage. . . The Contractor is required to ensure full QC coverage is provided to all pre-welding, in-process, and post weld activities in accordance with SATIP-W-011-01. The welder [ID 1673] making the "bullet" tack welds was not in possession of a Job Clearance Card The E7018 electrodes being used were found to be cold During site visit at GOSP area the following was found: 1-The Welder symbol # 133 found welding 2 weld on line # 2-SR-1801 and he is not qualified to perform TIG welding for 2.PID checked the welding summary and found him already completed 165 welds for 2. For Item # 1 contractor requested to perform 100% RT and qualified the welder. Contractor requested to comply with ARAMCO requirement
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
A IV Para 7.1
2722
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
7.4.7.1
4/23/2008 11:57:07 AM
2723
7/4/2008 3:19:25 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
Schedule Q
5.1
2724 2725
SAES SAES
8.1 6.1
2726
7/17/2008 2:57:06 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1
2727
2-Some welder does not have their welding JCC with them at site.
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
2728
3-Some of the Portable ovens not working or not connected to power.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2729
8/11/2008 6:50:21 AM
During surveillance inspection @ the GOSP site welding consumable storage room, PID has found that from 1st August the consumable Log sheet has not been maintained by the concerned personnel in charge, which naturally jeopardize the quality of the field weld. J & P has to strictly adhere to their internal welding consumable procedure and SAES to maintain welding quality, if not PID may go for additional NDT percentage for the Field Joints. Contractor is in violation of Schedule Q, paragraph 5.1 by failing to provide sufficient resources to implement the Quality System set forth in Schedule Q. Contractor has failed to provide adequate QC Welding coverage as required by Attachment VI of the Schedule. The Schedule states that the Contractor shall provide one (1) QC Welding Inspector for every fifteen (15) shop welders and one (1) QC Welding Inspector for every ten (10) welders working in the field. The contractor is currently working in the fabrication facility on a daily basis and began welding of 8 API 5L pipe today in the field. At present there is only one Saudi Aramco approved Welding Inspector available and therefore welding at both locations is not being adequately covered. It is noticed during the visual inspection of the first three completed welds of 8"-P-2279-1CS2P at GOSP area that one weld # 50 have lack of penetration from root side and some portion of the weld have been tried to back weld which results the root area high than required. The subjected weld is decided to cut out by the contractor QA/QC Manager and QC welding Inspector. a report should be made and submit to PID and make a quality tool box meeting for breafing the welders about standard and WPS requirements. As the Contractor have Completed 6 welds of 8"-P-2279-1CS2P schedule 40. the first three welds for each welder shall be 100% radiographed in order to know their performance. if the RT showing repair then again do the RT for the next three welds shall be RTed. if second time rejected the welder shall be rejected. as per SCH.Q para 2.14 att-VI During site surveillance in TEG Unit PID fond that, welding there are no WPS and PQR in work site which is violation according SAES-W-011 parg 7.1.8. A focused assessment was completed concerning the Control of Welding Consumables and PID has noted the following: 1) The Contractor is in violation of their Company procedure X41-800-CO-PR-036; Section 6.4.3 which states that welding consumables will be issued to the welding SupervisorForman. Currently individual welders are obtaining welding electrodes from the holding oven. 2) In addition, the procedure in Section 7.1; Conditioning , Storage and Exposure under Notes: states that the Storage and Re-bake Ovens shall be equipped with calibrated temperature gauges which enable continuous monitoring of the oven temperatures. To date the ovens are still not equipped as required. 02/28/08, Nuyyaim Project: Contractor J&P has begun layout and fit-up of the bottom plates for Fire/Utility/Wash Water Tank No. H96-D-053, reference Dwg. No. 40017-M11-02. This work is a violation for the following reasons: 1) The Olayan Descon Co IFC Dwgs have not been Issued for Construction. 2) The required ITP, associated procedures and test reports have not been submitted and approved by Saudi Aramco. 3) There are no approved QC personnel available to monitor the construction activit 4) Based on instruction from CSD, Olayan Descon shall be employed to and made responsible for the design engineering, supply of materials, and field fabrication of said tank(s). During site surveillance in water injection pumps PID found that contractor welds conduct support (carbon steel) direct to LUBE OLI RESERVOIRES ( stainless steel) number (H97-D-0742), (H97-D-0752) and (H97-D-0762).. Contractor requested to investigate and to comply with Vendor and Aramco requirements.
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2730
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
3/2/2008 3:07:23 PM
2731
3/5/2008 8:03:01 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1
2732
3/6/2008 9:04:48 AM
SATIP-W-011-01
SAIC-W-2015
Mechanical
SAEP
SAEP-324
6.1.5
2733
9/17/2008 10:50:37 AM
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
7.1.8
2734
3/9/2008 7:32:40 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2735
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2736
3/9/2008 5:08:21 PM
SATIP-D-100-01
SAIC-D-2025
Mechanical
ScheduleQ
Schedule Q
A IV Para 2.1
2737
SATIP-D-100-01
SAIC-D-2025
Mechanical
ScheduleQ
Schedule Q
3.4
2738
SATIP-D-100-01
SAIC-D-2025
Mechanical
ScheduleQ
Schedule Q
5.1
2739
SATIP-D-100-01
SAIC-D-2025
Mechanical
ScheduleQ
Schedule Q
1.3
2740
10/21/2008 8:53:52 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
1.3
2741 2742
Also they used unproper electrode code number (316L) between carbon steel and stainless steel And the welders not qualified. During site visit to J&P fabrication facility PID raised comment concerning the placement of the stiffening gussets associated with a pipe support, reference Dwg. No. BE-407701 sht. 130. Further investigation by the contractor QC Manager revealed that the gusset placement was correct, but that the orientation of the vertical leg (I-Beam) on at least one pipe support was incorrect and that it needed to be re-orientated 90 degrees to correct. The Contractors QC Manager has instructed his personnel to re-inspect of all structural supports for conformance to appropriate IFC drawings and to generate a report identifying all the supports which require rework and those that are in compliance. Rework is to be completed were required and the QC Manager has reminded all involved personnel of the importance of ensuring that the QC Department remains fully involved at all stages of fabrication during this project. It is observed in the fabrication of 2-P-2208-1CS2P near the Booster pump that separation distance between two parallel welds did not keep. Contractor has welded one inch sockolet very closed to the 2 WN Flange. The separation required between two parallel welds is 20 mm or 3 times of weld thickness, whichever is greater as per the SAES-W-011 Para 11. 16. 1 & 2. The distances shall be measured between the edges of the adjacent cap passes. The current distance is about 10 mm. Radiography of the butt welds is required for situations in which the minimum separation is not achieved. For joints other than butt welds, other appropriate inspection methods shall be used, depending on the geometry and material. It is observed during the surveillance inspection that Contractor welding crew at Booster pumps area that a 2 flange and sockolet on 2-P-2208-1CS2P cut out and re-welded without performing any NDT method for examination of lamination before welding which is violating the SAES-W-011 Para 11.3.3. Previously a the log book entry # 9115 created for the same joint that proper separation between two welds was not provided and Contractor did a corrective action that cut out and re-welded without performing any NDT for the fittings. This practice several times repeated and no preventive measures are taken to stop this violation again and again.Contractor shall be instructed to adhere all time to the SAUDI ARAMDO Standard requirements and provide corrective action the above stated violation. As notice during the surviellance inspection that Contractor J&P Wwelding crew is using carbon steel tools for fabrication of stainless steel piping spools which is violating SAES-W-011 Para 11.4.3 which says that "Stainless steel and nonferrous materials shall be cleaned with grinding wheels or stainless steel brushes not previously used on other materials". Contractor have several times notified and advised to use stainless steel tools for piping spools but no action has been taken to rectify the situation. Contractor shall be instructed to have completely stainless steel tools for for fabrication of stainless steel piping spools in order to prevent any chances of galvanic corrosion. As discussed and agreed in QC weekly meeting October 27, 2008 that due to the non-conducting PMI Testing for the Stainless steel piping spools by J&P that further production of these alloy materials need to be stopped but this morning it is noticed that the Contractor J&P continuing welding of SS piping and engaged the welders PH-252, PH-512 and 13013 on lines of category normal 3"-493-P-9SD0P and LO-4259. As 4 joints are welded today, shall be 100% radiographed and JCC cards of stated welders are revoked. PID noticed that the requirements for minimum separation between welds and support shoe was not implemented in lines 12-P-2263, 2262, 2261-3CS2P which violated SAES-W-011 corrective action shall be done by J&P.
SAES SAES
6.4 8.1
2743
SATIP-M-001-01
SAIC-M-2008
Mechanical
ScheduleQ
Schedule Q
1.3
3/9/2008 5:12:35 PM
2744
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.16.1&2
10/23/2008 10:43:02 AM
2745
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.3
Schedule Q
1.3
10/26/2008 9:49:04 AM
2746
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.4.3
10/27/2008 7:13:02 AM
2747
10/28/2008 9:48:42 AM
SATIP-L-350-01
SAIC-A-2010
Mechanical
SAES
SAES-A-206
8.1
Schedule Q
1.3
2748
11/10/2008 2:33:25 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.16.1.1
2749
3/9/2008 5:22:51 PM
Fillet Weld Assembly: As-Fit-Up assemblies were observed that were in violation of AWS D1.1-2006, paragraph 5.22.1; which states that the parts to be joined shall be brought into as close contact as practicable. The root opening shall not exceed 3/16. Note: When the separation is greater than 1/16 the leg of the fillet weld shall be increased by the amount of the root opening. 3) In addition, the contractors QC Inspectors shall ensure that while conducting post welding visual inspections, all fillet weld profile are in accordance with AWS D1.1-2006, Fig. 5.5 Acceptable and Unacceptable Weld Profiles. 3) In addition, the contractors QC Inspectors shall ensure that while conducting post welding visual inspections, all fillet weld profile are in accordance with AWS D1.1-2006, Fig. 5.5 Acceptable and Unacceptable Weld Profiles. Contractor is in violation of Schedule Q, paragraph 5.1 by failing to provide sufficient resources to implement the Quality System set forth in Schedule Q. Contractor has failed to provide adequate QC Welding coverage as required by Attachment VI of the Schedule. The Schedule states that the Contractor shall provide one (1) QC Welding Inspector for every fifteen (15) shop welders and one (1) QC Welding Inspector for every ten (10) welders working in the field. The contractor is currently working in the fabrication facility on a daily basis and began welding of 8 API 5L pipe today in the field. At present there is only one Saudi Aramco approved Welding Inspector available and therefore welding at both locations is not being adequately covered. A focused assessment was completed concerning the Control of Welding Consumables and PID has noted the following: 1) The Contractor is in violation of their Company procedure X41-800-CO-PR-036; Section 6.4.3 which states that welding consumables will be issued to the welding SupervisorForman. Currently individual welders are obtaining welding electrodes from the holding oven. 2) In addition, the procedure in Section 7.1; Conditioning , Storage and Exposure under Notes: states that the Storage and Re-bake Ovens shall be equipped with calibrated temperature gauges which enable continuous monitoring of the oven temperatures. To date the ovens are still not equipped as required. It is observed and noted that Contractor J&P have mobilized a welder 3NQ from subcontractor and engaged him on the production welding without performance qualification and testing. The welder shall be qualified and tested on the Contractor J&P own procedures as required by ASME IX Para QW103.01.More over the welder shall not tested on saudi aramco production welds as saying by SAES-W-011 Para 8.3. welder was working without JCC as No JCC has been issued for this welder on Nuyyam project which also violating the SAEP-324 Para 6.4 "Contractor welders working on field fabrication projects such as BI and JO work, and who are properly certified, shall be registered and issued a Job Clearance Card (Form SA 4758-ENG) by the project inspector prior to the start of work.". No JCC is acceptable reviewed from other projects as stated SAEP-324 Para 6.5.3 " Job Clearance Cards are only valid for the job or project for which they are issued.
SATIP-W-011-01
SAIC-W-2005
Mechanical
other
AWS D1.1
5.22.1
SAES-W-011
7.1.1
2750
SATIP-W-011-01
SAIC-W-2007
Mechanical
other
AWS D1.1
fig. 5.5
SAES-W-011
11.5
2751
SATIP-W-011-01
SAIC-W-2015
Mechanical
ScheduleQ
Schedule Q
A VI Para 5.1
3/9/2008 5:25:25 PM
2752
3/9/2008 5:31:41 PM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2753
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
7.1
2754
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.1&8.3
SAEP-324
6.4&6.5.3
11/29/2008 4:45:56 PM
2755
11/29/2008 6:11:19 PM
It is observed and noted by PID that Contractor J&P have mobilized two welders 3NQ and ICS-204 from subcontractor and engaged them on Saudi Aramco production welds. The follwoing violations are noted. 1.welders are not qualified on J&P welding procedures as required by ASME IX Para 103..01 2. welders have no JCC for the Nuayyam project as violating SAEP-324 Para 6.4 and 6.5.3. 3. welders are not qualified for 2" dia and GTAW as they were engaged to weld for 2" dia pipes in water injection area and HPPT. ASME IX QW-350 4. The welders started production welds without performance qualification which violating SAES-W-011 Para 8.3. Contractor shall be instructed to remove these welders from job site and qualify them on J&P welding procedures and the finished welds shall be 100% xrayed on the contractor cost. AWS D1.1 paragraph 5.15 Preparation of Base Metal states; surfaces on which base metal is to be deposited shall be smooth, uniform and free from fins, tears, cracks and other discontinuities which would adversely affect the quality or strength of the weld. Surface to be welded shall be free of loose or thick scale, slag, rust, moisture, grease and other foreign material that would prevent proper welding or produce objectionable fumes. Mill scale which can withstand vigorous wire brushing may remain except for girders in cyclically loaded structures, in these cases all mill scale shall be removed from the surfaces on which flange-to web welds are to be made. It is noticed during the surrviellance that Contractor J&P welding crew at produced water pump were using a carbon steel grinding disc for stainless steel piping which is the violation of the SAES-W-011 Para 11.4.3 "Stainless steel and nonferrous materials shall be cleaned with grinding wheels or stainless steel brushes not previously used on other materials". Contractor shall be instructed to use stainless steel grinding disc or wheel for cleaning and cutting. Contractor has failed to provide Saudi Aramco Representatives free access to the work (welding) at all time as required by SAES-W-011, paragraph 15.1. Saudi Aramco Inspection personnel are not able to complete required visual inspection monitoring because the scaffold system being employed at site is not Saudi Aramco approved. To date the scaffolds currently being used by construction personnel still have not been inspected by a Saudi Aramco approved Scaffold Supervisor and appropriately tagged (Green, Yellow or Red) permitting access. During site visit to J&P fabrication facility PID raised comment concerning the placement of the stiffening gussets associated with a pipe support, reference Dwg. No. BE-407701 sht. 130. Further investigation by the contractor QC Manager revealed that the gusset placement was correct, but that the orientation of the vertical leg (I-Beam) on at least one pipe support was incorrect and that it needed to be re-orientated 90 degrees to correct. The Contractors QC Manager has instructed his personnel to re-inspect of all structural supports for conformance to appropriate IFC drawings and to generate a report identifying all the supports which require rework and those that are in compliance. Rework is to be completed were required and the QC Manager has reminded all involved personnel of the importance of ensuring that the QC Department remains fully involved at all stages of fabrication during this project. During routine surveillance visit the following was observed: Gouge and Notch Limitations: Steel base plate materials are being thermally cut using the oxyfuel gas process and the cutting is being done free hand (without mechanical guides) which is creating unacceptable finish profiles. AWS D1.1-2006, paragraph 5.15.4.2 states a smooth and regular surface profile free of cracks and notches must be obtained. In addition, paragraph 5.15.4.4 states; that notches and gouges not exceeding more than 3/16 in depth shall be removed by machining or grinding and that those exceeding 3/16 may be repair by grinding if the nominal cross sectional area is not reduced by more than 2%. Note: Thermally cut surfaces which require repair by welding require the approval of the Engineer.
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAES
SAES-W-011
8.3
SAEP-324
6.4
2756
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.4
3/10/2008 9:39:45 AM
2757
12/22/2008 9:41:15 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.4.3
Schedule Q
1.3
2758
3/16/2008 9:46:54 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
15.1
2759
SATIP-M-001-01
SAIC-M-2008
Mechanical
ScheduleQ
Schedule Q
1.3
3/26/2008 9:34:02 AM
2760
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011 11.3.2.1&11.3.2.2
AWS D1.1
5.15.4.2&5.1 5.4.4
3/26/2008 9:46:58 AM
2761
3/26/2008 10:06:26 AM
Contractor has failed to provide Saudi Aramco Representatives free access to the work (welding) at all time as required by SAES-W-011, paragraph 15.1. Saudi Aramco Inspection personnel are not able to complete required visual inspection monitoring because the scaffold system being employed at site is not Saudi Aramco approved. To date the scaffolds currently being used by construction personnel still have not been inspected by a Saudi Aramco approved Scaffold Supervisor and appropriately tagged (Green, Yellow or Red) permitting access. 04/09/08 Nuyyaim: During site visit to the contractors fabrication facility it was observed that repairs were made to the single bevel grooves of heavy wall pipe (50mm) in thickness without the minimum pre-heat temperature required by the contractors approved WPS no. 16, Rev. 1. In accordance with ASME B31.3, paragraph 330.1; Pre-heating, the requirements for pre-heating apply to all types of welding including tack welds, repair welds and seal welds of treaded joints. In addition, paragraph 330.1.3 indicates the means which may be employed to ensure that the temperature required by the approved WPS (98C) is obtained prior to and maintained during welding. During the surveillance inspection of the GOSP it is noticed that pipe fitter and welder have started the fit up and root pass welding of 16-P-2343-6CS2P without the presence of QC Welding inspector. As per the SATIP W-011-01 Item 3.6 Pre-Welding & Weld Joint Fit-Up Inspection is the hold point for the Contractor QC welding inspector and the definition of the hold point that activity can not be started until the QC welding inspector inspect the prewelding and fit up of the joint. As the joint has already started without QC inspector then this particular joint shall be radiographed and the radiography of this joint should not be counted to cover the 10% RT requirement. It is noticed during the RTFI review of RT FILMS by OID that one weld# 14 of STEAM SERVICE 4"-S-4013 have been cut out and rewelded due to the repair or defect but reported as repaired-1 (R1)in place of RW in the RT report.Moreover the weld is between pipe and elbow and the elbow supposed to be MPI after cut out and rebeveling but Contractor did not carry out the MPI.Now it is agreed with QC suppervisor of J&P that HEZ and weld area shall be inspected with UT.And the report shall be corrected with RW in plaace of R1. 04/21/08, GOSP, Nuyyaim, 0830 hrs: Routine site visit made where contractor J&P has erected Line No. 30-P-2156-9LE2P. It was observed that the contractor is erecting 30 pipe and completing bridge tacking of same. This bridge tacking is not being completed completely within the weld groove as required and is therefore a violation of SAES-W-011, paragraph 11.5.6 which states that; Bridge tacks (located above the root area) are acceptable, but such tacks must be made completely within the weld groove and shall be completely removed prior to completion of the weld. A receiving inspection has been carried out for the low hydrogen SMAW electrodes at J&P fabrication shop on October 30, 2007. During the inspection it is found that low hydrogen SMAW electrodes did not supply by the vendor ZULFI WELDING ELECTRODES FACTORY in hermetically sealed metal can, they have supplied these electrodes in hard paper box with plastic sealed which may not comply the requirements of SAES-W-011 Attachment # 1 which says that Prior to use all electrodes shall be dried at 260-430C for 2 hours minimum. The drying step may be deleted if the electrodes are supplied in the dried condition in a hermetically sealed metal can with a positive indication of seal integrity or vacuum sealed package. Electrodes may be redried only once. As the welding will starts may be starts within two months, up that time the electrodes may not be considered in dry condition. Please investigate for further inquiry with vendor. As I routine site visit at Stabilizer Area (Overhead Comprossor & LHR Area), PID found 6 line already Excavated and backfilled without Holiday Test for the painting, which is violated S.Aramco SAES-H-100. Contractor shall do the holiday test before the backfilling. During the routine site visit at PS-3 (Stabilizer Area), The contractor was performing the coating activities on strong dusty and windy weather which is not matching with SAES-H-100 Para 8.1.1 As I routine site visit at Stabilizer Area (Overhead Comprossor & LHR Area), PID found 6 line already Excavated and backfilled without Holiday Test for the painting, which is violated S.Aramco SAES-H-100. Contractor shall do the holiday test before the backfilling.
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
15.1
&
2762
SATIP-W-011-01
SAIC-W-2013
Mechanical
SAES
SAES-W-011
12.1&18.4
4/9/2008 1:12:56 PM
2763
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
4/28/2008 9:13:48 AM
2764
6/2/2008 4:32:09 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.3
2765
4/21/2008 8:30:16 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.5.6
2766
SATIP-W-011-01
SAIC-W-2010
Mechanical
SAES
SAES-W-011
6.1
Schedule Q
A VI Table 2
10/31/2007 9:05:22 AM
2767
11/28/2008 1:40:49 PM 2/15/2009 9:47:21 AM
SATIP-H-002-06
SAIC-H-2016
Mechanical
SAES
SAES-H-200
Section 7
Mech
2768
Mech
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-100
8.1.1D
2769
5/11/2009 10:34:08 AM
SATIP-H-002-06
SAIC-H-2016
Mechanical
SAES
SAES-H-200
Section 7
Mech
2770
11/16/2008 7:50:02 AM
Mech
2771
11/23/2008 3:37:50 PM
Mech
2772
10/10/2008 8:28:12 AM
Mech
2773
7/6/2008 5:26:49 AM Mech
11/15/08, PS3, Overhead Compressor; the contractor has removed the tarp today which had been covering the compressor since its installation in the plant and PID observed the following violation concerning the SS piping. The weld grooves associated with each of the SS fitting have not been completely filled. This is a violation of ASME B31.3/06, paragraph 328.5.4 (d) which states that branch connections, including branch connection fittings, which abut the outside of the run pipe or which are inserted in an opening in the run shall be attached by fully penetrated groove welds which are finished with cover fillet welds. 11/23/08 PS3: in accordance with SAES-L-350; as a minimum and prior to installation and or erection of pipe spools on the pipe racks and pipe supports the following shall be conducted: 15.2.1, all pipes shall be internally cleaned by air blowing. In addition, for larger pipes rag cleaning should be conducted if found practical. 15.2.2, all prefabricated pipe spools shall be visually inspected for cleanliness and shall have all foreign matter removed from the inside. 15.2.3 The piping ends shall be covered after inspection to prevent unauthorized removal of the end cover prior to making the joint to the succeeding section of pipe. Also in accordance with 15.1 of the SAES a detailed procedure for cleaning and flushing of the piping spools and systems shall be established identifying acceptable methods that will be applicable for every individual system category. The procedure shall be agreed upon by PMT, Proponent and the Inspection Agency. To date no such procedure has been submitted. 10/10/08 PS3 NDT (RT) Area; during routine visit PID observed fabricated spools lying directly on the ground including flange gasket surface lying directly in the graveled surface. This is a violation of SAES-L-350 paragraphs 7.1, 7.3, 7.4 and 8.1. During a surveillance inspection at the Coating Yard It is observed that three pipes surface of the 16 API 5L with heat numbers 976770 ( 2 Pipes ) and 32867 ( 1 Pipe ) respectively have a localized pitting and dent on some portion,. This pitting and dent may lead to the pipe failure or reduce the pipe wall thickness. Contractor shall investigate and conduct a corrective action to clear this issue on that pipes prior to installation to determine the propagation of the pitting and dent behavior. 11/28/08, PS 3: A review of the Overhead Compressor Area Dwg # HA430524 was completed in order to determine what type of piping material is to be used for the interconnecting piping between the LP Compressor and the Dry Seal Gas Panel. The material called for is carbon steel; according to Std. Dwg. No. AA 036537 Note 3; all interconnecting piping and tubing shall be stainless steel (304, 316 or 316L). 11/30/08 PS 3: Concerning the OH Compressor Skid; specifically the SS flanges assembled using coated CS nuts and studs. This is a violation of SAESL-109, paragraph 11.5 which states that isolating sleeves and washers shall be used for isolating dissimilar metal flanged joints. 12/07/08 PS3: Concerning line numbers 6-P-2001-1CS2P1 (HB-430325, sht. 001, Rev. 00), 16-P-2000-1CS2P1 (HB-430401, sht. 001, Rev. 00) and 20-P2127-1CS2P1 (HB-430427, sht. 002, Rev. 00), PID has learned that these lines are being fabricated using 300# rated orifice flanges rather than 150# rated orifice flanges required according to the Line Classification Designation System (first field) established for each line number. According to the MTO information provided with each drawing; 300# rated orifices flanges should be used. This is in violation with SAES-L-005, paragraph 7.1.1 which identifies the (first field) in the Line Classification Designation System as the pressure rating and 7.2.1 which identifies the number 1 used in the Line Classification Designation System as 150# Nominal Pressure Rating or Class. 11/28/08 PS 3: Concerning the Stabilizer Pre-Heater H44-E-1C, Dwg HA435997.01; Corrective action is require to correct the following: 1) Portions of the grating is not adequately supported due to excessive spacing of supporting members. 2) The handrails of this structure shall be corrected so that the toe plates are located vertically and horizontally in accordance with the approved SA standard drawing. 3) The as built condition of the hand railing designed to be removable is not acceptable due to the excessive movement built into it. 4) The structures grating will need to be removed in order to facilitate the cleaning and painting of the welds associated with 20mm rebar being attached to accommodate fireproofing (by others).
SATIP-W-011-01
SAIC-W-2007
Mechanical
other
ASME-B-31.3
328.5.4
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
15
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-350
section 7& 8.1
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 3.3
2774
11/28/2008 1:33:45 PM Mech
SATIP-L-350-01
SAIC-L-2012
Mechanical
ScheduleQ
Schedule Q
1.4
2775
11/30/2008 4:53:23 PM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAES
SAES-L-109
12.6.1
Mech
2776
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAES
SAES-L-105
7.1.1
Schedule Q
1.3
12/7/2008 1:22:29 PM
Mech
2777
SATIP-M-001-01
SAIC-M-2010
Mechanical
ScheduleQ
Schedule Q
1.3
11/28/2008 1:43:25 PM
Mech
2778
11/28/2008 1:38:02 PM
Mech
11/28/08 PS 3: Numerous spools have had to be re-worked in the field to address actual field conditions which often involves the removal of fittings (flanges ect.) and the welds associated with these fittings. According to SAESW-011, paragraph 11.3.3; fittings that are re-cut or re-beveled shall have the cut surface examined for laminations before welding. To date the NDT crews still have not been provided with adequate access to the plant enabling the required NDT to be completed. In accordance with Schedule Q, 5.1 the contractor shall provide resources to implement the Quality System set forth in the Contract. 11/28/08, PS 3: The contractor has failed today to provide adequate QC Welding Inspector coverage. In accordance with Schedule Q, 5.1 the contractor shall provide resources to implement the Quality System set forth in the Contract. Based on the number of welders and the numerous areas within the plant where fabrication (welding) is currently ongoing a minimum of three welding inspectors is required. These inspectors must be on site when welding starts and shall remain on site until the welding ends. 08/23/08, PS3 Crude Stabilizer Column; H44-C-1, concerning the Sulzer WPS: SPC1957-001 Rev 0 / Supporting PQR: CTUK 002/05, the WPS is intended to be used for welding the seal pans directly to the column shell and no PWHT will be required. CSD has approved the WPS for non-sour service. PID has learned that the column was designed for sour service and that PWHT was applied as part of the fabrication process. Therefore the contractor shall complete attachments A and B from SAES-W-010, verify the applicability of the above mention WPS with the responsible design group and re-submit all the relevant documents to CSD prior to completing the welding in question for their concurrence. 09/24/08, PS3, Fabrication Facility; PID observed that fabrication of ASTM A333 materials had begun and neither of the two assigned welding inspectors was available. This is a violation of Schedule Q, 5.1 which states; the contractor shall provide the resources required to implement the quality system set forth in the contract. In addition, the QC staffing levels shall comply with Schedule Q, Attachment VI which requires one inspector per 15 welders in the shop and one inspector per 10 welders in the field. 10/21/08, PS3; Feed Pre-Heater Structural; the backing strips provided to facilitate full penetration welding of the beams associated with this structure have been removed. Full penetration welds is indicated in by [FP] on the IFC Dwg. i.e. ZS-734-E03 and Dwg. ZS-734- b6 provides a top and side view of a typical beam as provided by the vendor (Zamil). The contractor will have to completely remove those backing strips which have been cut back and provide a new backing strip in order to complete the required welding. This repair work and all future structural welding is considered a HOLD point by PID. The contractor shall raise the appropriate QMIS notifications. 11/28/08 PS 3: Concerning consumable issuance and control; PID has found welding started at the beginning of work shift with electrodes which are not the appropriate temperature. This is due to several factors: 1) The field storage ovens (baking and re-bake) have both been found cold because the on/off switch supplying the power has been shut off. 2) The ovens are often not properly closed by personnel obtaining electrodes from them. 3) The electrodes are obtained and put into the welders personal quivers which are not heated and then the quivers are taken to the work area only to sit plugged into powerless plug until issuance of the Hot Work permit. Electrodes shall be maintained in accordance with SAES-W-011, 6.1 and issued only by personnel thoroughly trained in the issuance and control of consumables. Their issuance shall be documented and records of same made available to Saudi Aramco upon request. during site visit @ J&P yard I noticed that the welding between heat exchanger sheel and reinforcment pad not acceptable there are a lot of welding defects need to be checked by welding inspector before insallation. this issue is violated 32-SAMSS-007,Para. 7.24.3
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
11.3.3
Schedule Q
5.1
2779
11/28/2008 1:36:02 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
Mech
2780
SATIP-W-010-01
SAIC-W-2058
Mechanical
ScheduleQ
Schedule Q
1.3
8/23/2008 5:05:57 PM
Mech
2781
9/24/2008 11:06:51 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
5.1
Mech
2782
SATIP-M-001-01
SAIC-M-2010
Mechanical
ScheduleQ
Schedule Q
1.3
10/21/2008 2:23:52 PM
Mech
2783
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
11/28/2008 1:50:01 PM
Mech
2784
1/10/2009 10:20:55 AM
SATIP-W-010-01
SAIC-W-2070
Mechanical
SAES
SAES-W-010
11.6
2785
6/21/2007 9:19:28 AM
2786
11/4/2008 8:39:29 AM
2787 2788
10/11/2007 10:52:08 AM 7/5/2008 5:48:06 PM
PID has concerns regarding the contractor using Crane hooks on the pipe ends to lift the pipes from transport trailer and laying on the right of way. This may lead to the following issues. 1. We found a small dent on the Pipe bevel ends and pipes Ovalty. 2. More stress at the welded joint, As two pipes already shop welded and each pipe has a length of more than 80 Feets. This also violates SAES H-200 para 5.1.1 which specifies that only nylon sling to be used for handling FBE coated pipes. Contractor shall stop using any type of hooks as the length of pipe is more than 24 meters, and use nylon slings on the outer surface of pipe for handling and stringing of Pipes. During surveillance inspection PID has found that a 2 - 900 LDS (leak detection system) on 16 Gas pipe line has been coated without the following compliances.. Coating QC nor PID have been informed about the activities. No surface preparation, Which APCS have been used for the coating, what DFT, whether condition etc. APM has to re-blast the existing and recoated according to standard requirement. During routine Survaillance inspection PID has found the Tie-inn Weld # 3/33, 3/33A @ road crossing has been back filled with the holiday testing of the Pipe. it is violation against H-002 and L-450. high pressure test activities where carray out in Fab Shop without useing safety relife valve which violated SIS & SAES-A-004. It is been noticed during a surveillance inspection at km 25 that some part of string has been fall down from the support which touching the ground, which do not complies the requirements of SAES-H-200 Para 5.3 which saying that Externally coated line pipe strung along the right-of-way shall be supported on rock-free sand, sand bags, rubber tires, or similar compressible material to prevent coating damage. (See also the general handling requirements in Paragraph 5.1.). Please instruct the contractor to re-work to bring the string back on support. Contractor also needs to remove the stones from bottom of the pipe string. During Pipe stringing inspection of 20" water injection line, PID has found debris and sand inside the pipe line. which will damage the internal coating during usage of internal clamp used for fit-up of pipes. PID request APM to arrange for internal cleaning of each pipe before fit-up as per SAES L-450 Para 8.9, to avoid damage of internal coating.
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1.1
SATIP-H-002-06
SAIC-H-2049
Mechanical
SAES
SAES-H-100
8.1.1
Schedule Q
1.7
SATIP-H-002-02 SATIP-A-004-05
SAIC-H-2016 SAIC-A-2009
Mechanical
SAES
SAES-H-200 SAES-A-004
7 5.5.1
SAES-L-450
Mechanical
SAES
2789
9/3/2007 11:15:08 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1.&5.3
2790
3/23/2008 11:17:31 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1
SAES-L-450
8.2
2791
3/29/2008 4:16:30 PM
2792
9/8/2007 4:57:35 PM
2793
During surveillance inspection PID has found that, no blasting/surface profile inpection were carried out by the APM Coating QC, its already one Kilometer of pipe has already been blasted and welded without this inspection. APM has to immediatly purchase required Textex Tape, Micro meter, Dew point meter etc. to carryout Coating inpection. It has been observed that Contractor APM has started the application of STOPAC coating on girth weld joints (1) without submitting a request for inspection Contractor shall be instructed to prove the quality of application of STOPAC coating on girth weld joints as not inspected. No method statement has been provided. (2) without an approved coating inspector and coating applicators. Long before PID has verbally requested with the concerned QC regarding the requirements for Coating repairing kits like mechanical file for surface preparation, Portable heating stove (Small) to be used in the site for melting sticks and digital Dew point meter.APM is not in the postion to acquire until now, PMT is requested to take corrective action by APM as early. During site visit at GOSP near to F rack and chemical injection tank it was found that the last joint FW 3 of 20 Water injection line the coating done while the QC was not their which is violation of Schedule Q . It has been noticed during surveillance that Contractor APM is continuing the application of STOPAC coating on girth weld joints without a coating inspector. The coating inspector shall be on site as per the SATIP-H-002-11 3.2 it is hold point for the contractor QC inspector. Contractor shall be instructed to make sure their QC coating inspector is on site to monitor the surface preparation as well as the application of STOPAC coating on girth weld joints.
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
SATIP-H-002-11
SAIC-H-2082
Mechanical
ScheduleQ
Schedule Q
1.7
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAEP
SAEP-316
3.1 & 4.1
2794
10/23/2007 7:40:02 AM
SATIP-H-100-01
SAIC-H-2032
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
2795
8/17/2008 2:22:35 PM
SATIP-H-100-01
SAIC-H- 2031
Mechanical
ScheduleQ
Schedule Q
5.1
2796
SATIP-H-002-11
SAIC-H-2082
Mechanical
ScheduleQ
Schedule Q
5.1
9/11/2007 11:07:24 AM
2797
12/14/2008 1:48:31 PM
2798
12/31/2007 7:13:23 AM
During modification of the 16" Gas pipe line @ the first 500 meter section from GOSP, PID has found the entire section FBE coating exposed outside has been severly damaged including the stopac coating @ girth welds. The excavation have to be widened for access and complete coating shall be carriedout before filling, It is also advised that PMT or PID should witness the Holiday testing. During Holiday inspection at KM 65 and KM 66, PID has found 4 Field weld joints 66/06, 66/07, 66/08 and 67/10 were not wrapped with stoppac coating, it violates H-002 requirements that 100% holiday free before lowering of pipes. this is an repeated violations, this situation also ariased before many times and stern warning were issued to the contractor that no lowering of the string if lacks/non accomplishment of NDT,Repair, Coating, Holiday etc. To avoid NCR, APM has to accomplish the NDT activities within this week for the above joints which has already been lowered. PID has found damage of pipes Coating after been holiday testing and lowering @ KM 100/09 rocky area.APM has to investigate the cause and issue a suitably reply to PID as this is the multiple instance occured in less than one month. During surveillance inspection, PID has found that the coating applicator for the field Stopac coating has been changed without the concent of PID, perhaps the new applicator didnot even approved and have the Applicator JCC. APM to immediatly test the applicator and arrange for the JCC. APM has submitted the hydro test package for the 20" water Injection line and found lot of deficiency in the document, which shows that their internal QA/QC has not been reviewed at all; PID reject the package for the below reason. 1. No traceability for Penalty shots shown. 2. Numerous weld dates Conflict with the NDT dates. Contractor is advised to correct, verify all the Welding Inspection Summary sheet and re-submit the Hydro test package. During routine site visit, we have found that some of the new pipes 8" and 20" are stacked directly on the ground, which violates SAES L-450, whereas shall have a 150 mm stand off distance from the ground. pls. take corrective action immediatly. During surveillance inspection PID found @ KM 81/14, after lowering of the string KM 81/14 it doesnot comply with trench requirements of 50MM clearance from top of the pipe. The pipe still well above the Grade after lowering. This violation of APM standard drawing and SAES L-450. APM has to take coorective action immediatly before backfilling. This is an repeated violation earlier LBE#439. APM does not give RFI to PID, for the fabrication of 20" & 16" sleeve welding/Anchor welding whihc has already been accomplished. The said issue has already been raised, informed to QC department, PID cannot do the detail inpection as called by the APM now. During surveillance inspection PID found all the 20"/16"/18"/ 12" Pipe line string were kept open on both ends, violates SAES W012 and L-450. APM has to take corrective action to close both ends of all string immediatly.
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
APCS 113C Data Sheet Para 5.1
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
APCS 113C Data Sheet Para 6.1
2799
3/1/2008 7:22:52 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.3
2800
3/3/2008 7:29:04 AM
SATIP-H-002-11
SAIC-H-2082
Mechanical
ScheduleQ
Schedule Q
5.11
2801
SATIP-A-004-02
SAIC-A-2010
Mechanical
SAEP
SAEP-1160
9/18/2008 9:54:41 AM
2802
12/11/2007 3:52:29 PM
SATIP-L-450-03
SAIC-L-2112
Mechanical
SAES
SAES-L-350
7.1
2803
1/26/2008 4:32:30 PM
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
14.9.3A
2804
2/10/2008 9:00:02 AM
SATIP-W-012-01
SAIC-L-2048
Mechanical
ScheduleQ
Schedule Q
1.7
2805
2/20/2008 10:56:14 AM
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
11.4
2806
4/20/2008 8:26:54 AM
During Pipe Lowring from KM 1 and 2 near the gosp, PID has found lot of STRESS & STRAIN given the pipe string during lowering at the narrow curvature, PID advised the contractor to use at leat 4 side booms to maitain the S- curve during lowering as per SAES L-450. As the contractor has more experience in the pipe line they should be well prepared and equipped before starting the activities. PID has found the following Violations during Holiday testing and lowering of the Pipes.. 1. Holiday test daily reports have not been submitted routinely, already 3 Kms of pipe have been lowered and not even single reports have been submitted to PID as per SAES H-001 Para 9.2.2. 2. After lowering PID found that people are walking on top of the pipe before back filling to be avoided which may damage the coating. 3. During lowering the pipe shall be handled properly so that no section will comes under stress, pipes to be rested on the padding only not on the surface of the sand and make sure it is centered and have a either side gab of 300mm as per SAES L450. PID has found Tie-Inn 3/18 and 3/18A ( Which comes underneath the existing gas pipe) do not comply with the distance requirement of 600MM, Contractor has to issue an RFI to PID for final acceptance back filling. Responding to RFI, PID has rejected the installation of PIG into the 20" water Injection line for the following reason. 1. PIG installation header not been used, which causes serious damages to the Foam PIG during installation. No pressure gauge used for monitoring the inbuilt pressure. PID has found that APM has installed a Tie-In spool of 10 X 8" have been installed on the existing line drwg # BB 881978/002 without hydro testing, This is violation against Saudi Aramco standard. APM Contractor is therefore advised to do 100% NDT of all girth weld of that spool and raise a waiver as this is already a shut-down job. During the routine surveillance PID has found the post hydro tested Valves 16", 20", 12" were stacked without complete dewatering and internal lay-up. Contractor therefore requested to remove the water completely by flushing compressed Air inside the Valves immediately after hydro test and apply lubricants on the inside surface of ball, seat, disc etc. to avoid corrosion and damages to ball valves. During Survaillance inspection @ the front end production welding, PID has found the following violation. 1. Contractors removing the side boom support for the pipe after completion of the Root pass, As per Standard SAES W-012 para 10.7.3. Side boom support shall be removed only after completion of the Hot pass, to avoid root pass cracking. 2. Time lapse between root pass and hot pass goes much higher than the restricted 5 minutes. Contractor has to take suitable action immediately to comply with the standard, and PID wants to take at least 20% of the days production weld to overcome the concerns on the root pass.
SATIP-L-450-04
SAIC-L-2115
Mechanical
SAES
SAES-L-450
15.5.2
2807
9/28/2007 10:59:43 AM
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-100
9.2.3
2808
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-H-200
5.1.1
2809
SATIP-L-450-04
SAIC-L-2132
Mechanical
SAES
SAES-L-450
14.9.3B
2810
9/29/2007 11:40:21 AM
SATIP-L-450-03
SAIC-L-2115
Mechanical
SAES
SAES-L-450
15.6.1
2811
9/8/2008 9:18:31 AM
SATIP-L-450-04
SAIC-L-2017
Mechanical
SAES
SAES-L-350
Appendix A
2812
9/16/2008 11:15:13 AM
SATIP-A-004-03
SAIC-A-2015
Mechanical
ScheduleQ
Schedule Q
1.3
2813
SATIP-L-108-01
SAIC-L-2041
Mechanical
other
04-SAMSS035
12.1
10/18/2008 8:34:44 AM
2814
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.7.2 & 10.7.3
10/6/2007 11:50:42 AM
2815
10/15/2007 10:55:49 AM
2816
10/29/2007 3:55:43 PM
2817
7/4/2007 9:29:52 AM
During Surveillance inspection PID has found poor workmanship of handling of FBE coated pipe results, the damage of existing stopac wrap coating which has already been tested and lowered @ joint # 8/03. and @ joint # 12/15.This is not the first instance PID has noted. It violates H-002. requirements. All holiday tested joints to be immediately lowered and back filled at least partially. APM has to take corrective action and issue RFi. APM has verbally informed to PID that they are in the process of conducting internal gauging of 16 pipe Line, prior to hydro test. PID has the following concerns 1.There is no approved Procedure/method of statement for internal gauging. 2.PIG launcher shall be Hydro tested and equipped with emergency pressure reliever. 3.Comply with the SAIC-GI-2102 checklist for safety. APM has requested to comply with the above requirments. Contractor APM has already received more than 50 trucks of pipes @ site without following documentation for the PID to verify........... 1. No evidence of final QC release or disposition report before shipment. (to know pending work list if any) 3. No Mill certificate provided. 4. No documentation quality evidence for the circumferential weld done by manufacturer. 6. No coating (External) inspection report. Azher Iqbal has been approved as Procurement Supervisor and not as approved QC inspector for receiving materials. 2. No APM Qc inspector available at Manufacture 5. No Bevel protector or end cap provided for the pipes before transporting. 7. No Material management procedure (Handling, storing, preservation) as per Sch.Q Attc.IV para.5 8. PID has noticed 0.0006% BORON content for the 2" Pipe stock purchased by APM contractor from the ArcelorMittal steel South Africa, As per 01 SAMSS 038 Para 4.3 states that the chemical combination shall not exceed 0.0005%. APM Construction contractor has been advised not to use this pipe for contruction until further notice from PID. APM/petroget has to arrange for the post hydro lay-up for the 16" pipe line, as the first section of the line has already been hydro tested and APM plans to transfer the water from the first completed section, each hydro test completed section should be dry lay up and followed by the nitrogen purging of 30-50 PSi. as per SAES A -007 pARA 5.2.
SATIP-H-002-11
SAIC-H-2082
Mechanical
SAES
SAES-H-002V
5.1
SATIP-L-450-04
SAIC-L-2017
Mechanical
SAES
SAES-L-350
15.1
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
AIII Para 3.22
2818 2819 2820
SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01
SAIC-L-2005 SAIC-L-2005 SAIC-L-2005
ScheduleQ SAES other
Schedule Q SAES-L-350 01-SAMSS038
5.1 7.4 4.14 Schedule Q A IV Para 6
2821
4/22/2008 9:19:16 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
other
01-SAMSS038
4.14
Schedule Q A III Para 3.22
2822
SATIP-A-004-02
SAIC-A-2018
Mechanical
SAES
SAES-A-007
5.2.3.2
5/21/2008 7:46:25 AM
2823
3/30/2008 5:19:43 PM
2824
6/25/2007 2:47:15 PM
APM has already completed more than 40 production weld for the new 20" pipe line, but still there is no intial radiography conducted to know the welder repair/project status these violates Schedule Q requirements. PMT to request APM, to arrange for radiography immediatly. As per the SAES L-450 para 8.4 and 8.9, it specify that pipes for Sales gas shall have a plastic cover @ both ends during transportation and stacking . PID has noted that Contractor violates the above standard, as the pipes arriving without end cover and end bevel protection. PMT to instruct APM to comply with standard requirement, and prepare an Internal cleaning procedure for the pipes already arrived with out end cover.
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
6.3
SATIP-L-350-01
SAIC-L-2112
Mechanical
SAES
SAES-L-450
8.9
2825
8/26/2008 4:09:13 PM
APM has started a new 12" pipe line from RIS Hawta, it has been noticed from our JCC record that all APM welders are entitled to weld only above 12" pipe, No welder has been qualified to weld 12" and below as per API 1104, this has been already informed to the QC manger before, but until now there is no suitable documents submitted to PID for the concerns, Aramco will issue a NCR is APM could not comply with the relevant documents early. During routine visit during welding on Pipe line @ Km 2, PID has found the following concerns......... 1. Improper cleaning of Bevels before fit-up. (Bevel should be cleaned until all traces of Mill Scale removed and bevel shall bright metal before fit-up). 2. All completed weld shall be visually inspected by the approved inspector and accepted. 3. The end each string to be closed with sheet metal cover, temporary plastic cover shall be used 4. QC inspector shall be equiped with there essential tools like Guages, mirrors, permanent marker etc on site. PMT to inform APM to take corrective action immediatly. PID has found shortage of Welding QC personnels @ site, APM has started 20" crude oil line, and about to start 20"/12" water line, 18" oil line. tie-in etc. etc. apart from the main 16" line. APM right now has only one Welding Qc in site @ KM 90, PID request APM to immediatly arrange a Welding Qc to maintain Quality activities for all the wleding areas. During the Surveillance visit @ KM 99/100, PID has found that the welding commences without any preheat of the joint, it violates the project WPS and SAES W-012, where the joint shall be maintained min. 10 degree celsius before start of the welding. APM has to immediatly arrange for the preheating facilities for the weld joints @ site before starting of the weld activities. During PID Surveilliance inspection on the new 18" Oil pipe line following violation noted... * No Quality Control personnel moniteering the welding violation of Schedule Q Requirment. * Prevailling sandstrom welders were not using shadding or tent during welding violation of SAES W-012. * Some of the Pipe bevels were damaged during PID inspection, informed Qc for corrective action. Based on the above discrepancies PID request APM to go for 100% Radiography for the days production weld. During surveillance inspection by PID on the 16"/.500" thick @ the Gosp area the following dviolation were found. * External clamp have been used for the production weld, 100% RT to be covered for all welds used external clamp. * No welds numbers found on the completed field weldd. APM Welding QC shall be well aware of this and take corrctive action immediatly. * Multiple pass to be used for the Capping final pass, weaving of electrode exceeds the 3 times the diameter of Electrode violation of WPS. * No blanket used during welding to avoid damage on the FBE coating. During Surveilliance inspection @ site 20" piple line, PID has found the field production inspector has gone to vacation without any replace rather information to PID. This violation of Schedule Q requirments. APM has to immediatly arrange a inspector on site during production welding.
SATIP-W-012-01
SAIC-W-2039
Mechanical
SAES
SAES-W-012
8.1
SAEP-324
6.2.1
2826
7/22/2007 9:45:40 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.3.1
2827 2828 2829
SATIP-W-012-01 SATIP-L-450-03 SATIP-W-012-01
SAIC-W-2048 SAIC-L-2113 SAIC-W-2048
ScheduleQ SAES
Schedule Q SAES-L-450 Schedule Q
5.1 11.4 A IV Para 7.1
Mechanical
ScheduleQ
2830
12/10/2007 10:35:12 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
A VI Para 2.1
2831
12/26/2007 10:36:37 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
11.1
2832
2/17/2008 1:33:02 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
2833
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.2.3
2834
SATIP-L-450-03
SAIC-L-2112
Mechanical
SAES
SAES-L-450
8.4
SAES-L-350
7.4
2835
3/23/2008 10:14:22 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.4
2836 2837
Mechanical
ScheduleQ
1.3 10.15
Mechanical
SAES
2838
5/6/2008 7:58:37 AM
SATIP-L-450-03
SAIC-L-2113
Mechanical
ScheduleQ
Schedule Q
5.11
2839
6/15/2008 7:28:50 AM
2840
9/11/2007 10:55:16 AM
This concerns have already been raised in our weekly Quality meeting. During surveillance inspection on the 12" water injection line to RIS-C, the internal celeaning of the each pipe is not been carried results in trapped Coating Crawler inside the pipe, Contractor are therefore requested to do cleaning of each pipe as per SAES L-450. It is been noticed during a surveillance inspection at km 38 that the wind breaker (Wind shields or tents) is not properly arranged to protect the welding of filling and capping from the wind and blowing dust. The contractor APM shall be instructed to properly design their Wind shields or tents to protect the welding from the wind and blowing dust. During routine visit during welding on Pipe line @ Km 2, PID has found the following concerns......... 1. Improper cleaning of Bevels before fit-up. (Bevel should be cleaned until all traces of Mill Scale removed and bevel shall be white & bright metal before fit-up). 2. All completed weld shall be visually inspected by the approved inspector and accepted. 3. The end each string to be closed with sheet metal cover, temporary plastic cover shall not be used. 4. QC inspector shall be equiped with there essential tools like Guages, mirrors, permanent marker etc on site. PMT to inform APM to take corrective action immediatly. A surveillance inspection has been carried at welded portion of the 16 line and found that contractor did not mark the welds for identification for weld number and welder symbol which is the violation of the SAES-W-012 Para 15.1 and 15.2 which says that All weld joints shall be marked for identification by a weld number and a welder symbol. These identifications shall be made with a suitable weather-proof marking material. The markings shall be placed in a location such that they will remain visible for a time suitable to the authorized Saudi Aramco inspector. The markings shall be compatible with any subsequent coating or heat-shrink sleeve application. Contractor shall be instructed to provide weld identification for all completed welds and make sure that identification shall be continued close to the weld once it is completed in future. During Welding of Temperature Tie-in Welding, APM is not following SATR-W-2014; it is violation against SAES L-450 and SAES-W-012. APM hereby requested to comply with the above requirements. It is been noticed during a surveillance inspection at km 23 that welding crew has been removed the internal clamp before completion the root pass which is the violation of SAES-W-012 Para 10.4.2 which says that The internal line-up clamp shall not be removed before the completion of the root bead. For external clamps, the root bead must be at least 50% complete prior to removal. The Contractor QC welding Inspector shall request weld # 23/32 for the radiography and shall not be counted as daily production welds selection for RT.
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.5
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.2.3
2841
7/22/2007 9:50:17 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.3.1
2842 2843 2844
SATIP-W-012-01 SATIP-L-450-03 SATIP-W-012-01
SAIC-W-2048 SAIC-L-2113 SAIC-W-2048
ScheduleQ SAES
Schedule Q SAES-L-450 Schedule Q
5.1 11.4 A IV Para 7.1
Mechanical
ScheduleQ
2845
7/31/2007 10:57:12 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
15.1
2846
10/30/2007 7:57:22 AM
Mechanical
SAES
2847
8/22/2007 11:34:33 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
10.4.2
2848
11/9/2008 11:31:47 AM
Hover the contractor has been advise earlyier of the project through a proactive notification APIU found that during survilliance that contractor doing pre-hydrotest without a safety relief valve while the pipes were under pressure which is in violation to SAES-A-004 and GI-2.1 which both stated that All systems (piping and equipment) while being pressure tested shall be protected from being overpressured by Relief valve(s) of adequate capacity set to relieve at 5% above the test pressure shall be installed.The relief valve(s) shall be tested, dated, and tagged within one week prior to the pressure test for new construction projects, and within one month for maintenance operations. if the contractor repeate this unsafe construction practice APIU will left with no option to raise Saudi ARMCO NCR. During routin site visite APIU found that the contractor started structural welding without welding procedure nor approved welders Job Clearance Card(JCC)which is clear violation to schedule"Q" as well as SAES-W-11. Please advise the contractor to submitt the welding procedure and thier welding JCC immediatly to avoide elevating this log book to Saudi Aramco NCR. Absence of an approved Isotope Storage Facilty has meant that no Radiographic Testing has been conducted to date. Over 100 butt joints have been welded, commencing on December 5. This has resulted in a backlog of NDT being created. SAEP 1160 sect 6.3 states that the results of special processes, (Welding / NDT) shall be known within a period, usually 7 days, after visual acceptance. The Contractor is required to ensure that all welding, NDT and reporting is conducted in accordance with SAES-W-012 and SAEP 1160. As on the servillance visit of the site found that the sting already welding was not provided with the end cap.As per SAES-L-450 para 11.4(Open end of pipeline strings shall be capped to prevent entry of debris or animals and birds).This was already informed to the Contractor and still no-action been taken. Anchor blocks locations not shown in the drawing which violated SAES-L-410 & 440 GCC have to check if deflections area on Point B, point B, point C, point D, point E will restrained pipelines still there is no GCC RTFI for review the RT films after the 3rd party RTFI interpatetions. to minimaize the disagrement ratio. SA RTFI disagree with 3rd party RTFI in five welds from 12. The prime cotractor GCC doesnt have their own RTFI. Focus assessment was conducted on welders performance reports for BI-21-02025. There are some issues as below. 1. The total JCCs that issue from PID 31 JCC whoever PID found only 24 welders were working on the site. The explanation I get from GCC that these welders gone for vacation. I made a site investigation and found that some welders didnt report to the site since the start of the project. 2. One welder was logged in welders performance report under anther welder symbol 3. The report shows some welding activities for some welders even they were in vacation according to GCC statement. during site visit at KM 129 PID noticed that the gab for tack weld is below 2.4 mm which violated WPS data and SAES-W-012.
SATIP-A-004-03
SAIC-A-2009
Mechanical
SAES
SAES-A-004
5.5
2849
9/8/2007 10:37:52 AM
SATIP-M-001-01
SAIC-M-2012
Mechanical
other
12-SAMSS007
7.5
2850
12/20/2009 1:04:23 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
6.3
2851
3/9/2010 8:22:10 AM
Standards Violation
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
2852
2/23/2010 7:13:17 PM
Standards Violation
SATIP-L-450-03
SAIC-L-2116
Mechanical
ScheduleQ
Schedule Q
1.3
2853 2854 2855
2/10/2010 8:19:06 AM 1/26/2010 11:59:39 AM
SATIP-NDE-RT-01 SATIP-NDE-RT-01 SATIP-NDE-RT-01
SAIC-RT-2009 SAIC-RT-2009 SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q SAEP-1143 Schedule Q
5.1 11 5.1
SAEP ScheduleQ
2856
3/11/2010 6:33:48 PM
Standards Violation
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
1.3
2857
12/22/2009 3:24:57 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
Schedule Q
1.3
2858
3/2/2010 3:29:40 PM
2859
3/11/2010 6:42:05 PM
2860
3/9/2010 8:29:13 AM
2861
3/2/2010 4:22:25 PM
2862
12/22/2009 3:35:44 PM
2863
1/26/2010 1:39:41 PM
2864
2/9/2010 8:33:30 AM
During my revision to welders performance report I noticed that the data miscalculated for each welder that by the end gives wrong results. GCC need to revised this report and make the require correction. GCC didnt assign replacement for their RTFI during his leave since 1st of March which result in Back log. At the inspection of the tie-in joint as its a hold point.When randomly checked the instrument of the Pipping QC the instrument was not available on the sites.This was already informed to them before to keep the instrument with them on the site . As per the sceheduleQ the contractor should have there RTFI with the third party RTFI to review the FILMS 100%. And if the Contractor RTFI is on leave they should have the sutaible replacement. PID noticed that GCC not ckeck the welding machine voltage which violated SAES-W-012 Para 18 QC shall used voltimeter and recorred the values in SATR-W-2011 GCC didnt submit with weekly welding statuse the Welder performance percentage rejection rate reprot. This shall be calculated and reported on a per joint and linear basis for any welder have repire weld. As per SAES-H-200 para 7 for the coating pipeline.stated that The coated pipeline shall be 100% inspected with a pulse-type DC holiday detector employing an audible signaling device immediately prior to burial, i.e., after the last boom. The electrode used for locating holidays shall be in direct contact with the coating (with no visible gaps) and provide complete coverage of the whole coated surface. All holidays shall be repaired and the repairs shall all be checked with a holiday detector to verify that they are adequate. This final inspection procedure shall be monitored by a Saudi Aramco Inspector. As per procedure prior to backfill a holiday test should be witnessed by SA PID as the inspection level is H1.Which was not performed at km141 to km140+220 for the String#02. As per SAES-H-200 para 7 for the coating pipeline.stated that The coated pipeline shall be 100% inspected with a pulse-type DC holiday detector employing an audible signaling device immediately prior to burial, i.e., after the last boom. The electrode used for locating holidays shall be in direct contact with the coating (with no visible gaps) and provide complete coverage of the whole coated surface. All holidays shall be repaired and the repairs shall all be checked with a holiday detector to verify that they are adequate. This final inspection procedure shall be monitored by a Saudi Aramco Inspector. As per procedure prior to backfill a holiday test should be witnessed by SA PID as the inspection level is H1.Which was not performed at km141 to km140+220 for the String#02. Surface preparation and wrapping of joints for string no 12 joints #368 to #397 is done w/o the presence of qc inspector and crew supervisor to witness and ensure the quality of work.No RFI also is being raised for that certain job, this violation as per required in schedule Q.(Mazher Ahmed, Coating inspector BI 2102025) GCC need to be able to demonstrate that they are meeting the requirements of SAEP 1160 section 5.1 related to tracking welds / welders / NDT repairs / in electronic format. The information must be compiled daily. PID has given GCC an electronic format which is acceptable to Saudi Aramco, and will greatly assist GCC in their tracking capabilities. PID require that GCC use this template for the project, or provide Saudi Aramco with another format which fully meets the requirements of SAEP 1160.
Standards Violation
SATIP-W-012-01
SAIC-W-2039
Mechanical
SAEP
SAEP-324
6.2.3
Standards Violation
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q
5.11
Standards Violation
SATIP-L-450-03
SAIC-L-2115
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
Standards Violation
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
ScheduleQ
Schedule Q
5.1
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
18
Schedule Q
1.3
Standards Violation
SATIP-W-012-01
SAIC-W-2056
Mechanical
SAEP
SAEP-1160
5.3
Standards Violation
SATIP-H-002-06
SAIC-H-2016
Mechanical
SAES
SAES-H-200
Schedule Q
1.7
2865
2/9/2010 8:33:33 AM
Standards Violation
SATIP-H-002-06
SAIC-H-2016
Mechanical
SAES
SAES-H-200
Schedule Q
1.7
2866
3/6/2010 3:27:24 PM
Standards Violation
SATIP-H-002-09
SAIC-H-2066
Mechanical
ScheduleQ
Schedule Q
5.1
2867
1/6/2010 4:08:19 PM
Standards Violation
SATIP-W-012-01
SAIC-W-2056
Mechanical
SAEP
SAEP-1160
5.1
2868
12/19/2009 10:26:03 AM
2869
2/1/2010 3:30:40 PM
2870
8/19/2007 3:59:20 PM
V-84
since the starting of the welding activities GCC didnt submit the weekly weld tracking and welder performance report which violated SAEP-1160 Para 5.3 At the survillance visit of site At KM135+601.The Inspector found their was no Contractor PIPPING QC avialable to check the Fit-Up.Its is a standard violation as per SATIP-W-012-01 the Inspection Responsibility Assign to contractor is H1 that the 100% hold point. During Surviallance it was noted that Sand blasting was carried out by unqualified personnel at SIS Blasting Area that was not meeting the requirement of SAEP- 316 Para 3.1.Kindly instruct to the contractor they shall not start any coating painting/ sand blasting activity until unless operators are qualified/ certified and possessing the valid certification cards. During surveillance inspection it was noted that BOQ was corected as per the changed line class of piping by hand and there was no any revised shop drawings available with contractor documents controller to reflect the all these changes it was the violation of Sch Q Para 3.7 stated that latest revision of refrence documents shall be available for company use at contractors installation and construction locations. During site visit it was noted that pipe spool was conected with Knock out drum nozzle with out proceeding their flange inspection that was not meeting the requirement of SAEP-L-351 Para- 4.3 & SAES- L-350 Para 11.6. As per SATIP-D-001-01 it was hold point for the contractor QC. kindly ask to the contractor to comply the SA std, procedure and ITP requirement. It was noted during surviallance at SIS warehouse that different types of gaskets were recieved but SIS did not follow the requirement of Sch Q Para 3.14 attachment 111. & SAES-L-109 Section 11. stated that manufacturing and testing documents has been submitted and conforms to the applicable SA- 175 Form. and certification documents on all gaskets show acceptable results of material certs, 10% PMI result,winding tests, chamical analysis, mechanical tests and any heat treatment results as applicable(SAES-A-206 Para 5.1.1 & 00-SAIP07 Section 9. First three sample inspection shall be 100% verified by SA/ Project Inspection.Kindly ask to the contractor to comply the SA/ requirements AEAP. It was notified that third party(AMSYCO) executed RT job at site with incomplete traceability(BI#)on 43 nos of joints that was not meeting the requirement of SAEP 1143 Para 8.4.1.Concern was discussed with SAPMT & SA/RTFI. SIS issued internal NCR and requested to rectify this descrepancy by compliance of same procedure Para 8.4.2. During review of the RT reports it was notified that first three production welds for the new welders not yet comleted while they were proceeding the welding activity. Situation was violated to the SAEP- 321 Para 6.3.1.1, 6.3.1.2, 6.3.1.3 and 6.3.1.4. Kindly ask to the contractor to comply the SA Procedure requirement AEAP to verify the welders performance and to control the weld rejection rate.
SATIP-W-012-01
SAIC-W-2056
Mechanical
SAEP
SAEP-1160
5.3
Standards Violation
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAEP
SAEP-316
3.1
2871
8/9/2007 11:38:00 AM
V-84
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.7
2872
8/28/2007 10:28:32 AM
V-84
SATIP-L-350-01
SAIC-L-2012
Mechanical
SAEP
SAEP-351
4.3
Schedule Q
1.3
2873
SATIP-L-350-01
SAIC-L-2007
Mechanical
SAES
SAES-L-109
12
Schedule Q
A III Para 3.15.1
6/23/2007 10:41:04 AM
V-84
2874
6/19/2007 4:09:20 PM V-84
SATIP-NDE-RT-01
SAIC-RT-2007
Mechanical
SAEP
SAEP-1143
8.3.1 & 8.4.1
2875
SATIP-NDE-RT-01
SAIC-RT-2015
Mechanical
SAEP
SAEP-324
6.2.6
8/28/2007 3:14:42 PM
V-84
2876
9/1/2007 5:19:13 PM
V-84
During surprise visit at site on friday it was noted that RT was on going at SIS Fab Yard.RT Crew have 25 nos of RT requests all of them were reviewed and notified that 11 nos of requests were missing their request Nos, QC welding signatures and initiated dates.Such discrepancies lead to the confusion during actual reports to be verified.Please ask to the contractor to provide us all RT requests along with RT Reports to verify the all RT is done and repairs are refcified/ re shooted per line class(10% & 100%)as per SAES- W-011 Para- 17.1.9 & 17.6.1. Kindly ask to the contractor to follow the requirements were writen on SAES-W-011 Para 15.4 stated that all of the rights of Saudi Aramco and their designated representatives for access, documentation, inspection and rejection shall include any work done by contractor, sub contractor or sub vendors. Project Weld Status/ Weekly Welder Repair Rate and Weekly QC Submittals were not submitted to Project Inspection Representative for review and evalute the welders performance through weld rejection rate that is already critical issue for our project.Kindly ask to the contractor to comply the Sch Q attachment V (Summary of Quality System deliverables) & Sch Q Para 7.3. DURING SURVIALLANCE IT WAS NOTED THAT PRE FABRICATED PIPE SPOOLS WERE BEING SHIFTED TO SITE WHILE THEIR NDT WAS NOT COMPLETED SITATION WAS NOT MEETING THE REQUIREMENT OF SAEP-1150 PARA A-12.1 & IMPLIMENTATION OF SIS QA/QC DOCUMENT- SIS/QC/012/01(INSPECTION RELEASE NOTE)SEE BELOW SPOOL NOS 1-VB-420116-002-2"-RL10152,10154 & 10156-1CA1P 2- VB-420128-003- 10- 6"-P-100809CA1P KINDLY ASK TO THE CONTRACTRCTOR TO COMPLY THE SA/ REQUIREMENTS. Radio graphed misidentified can be identified with correction tap or equivalent, only when the Saudi Aramco Film interpreter or field supervispor has determined that it is impractical to re radio graph. Traceability on the RT report # 426 was not corresponding to the RT request # 051 Welder ID was changed on RT report # 425. RT report # 391 SBW-23 S-73 was circled. During surviallance at site and documents review it was noted that WPS # MSAS-75A-Rev-o was reviewed on May 31, 2005 by CSD and handed over to contractor SIS with status-2, (comments to be incorporated and re submitted) but contractor failed to get a revised copy from CSD WHICH IS NOT MEETING THE REQUIREMENT OF Sch Q"Para 3.7 stated that latest revision of ITP, Procedures and all refrence documentation are available at the contractors fabrication and construction locations. Kindly ask to the contractor they shall provide revised WPS at work location ASAP.and provide the preventive action to avoid the re occurance of such potential discrepancies in the whole QA/QC system. It was noted that SIS welders were using wrong size dia 2.4 mm of low hydrogen electrodes (E-8018C3) to weld low temp carbon steel while approved WPS calls for dia 3.2 mm.Situation was violating to the SAES-W-011 Para-7.4.5 stated that filler metal size, type and clasification shall conform with WPS. Kindly ask to the contractor to comply the requirement of approved WPS, if any change/ deviation is required shall be notify and approve by the CSD.
SATIP-NDE-RT-01
SAIC-RT-2007
Mechanical
SAEP
SAEP-1143
8.4.1
Schedule Q
1.3
2877
9/1/2007 5:28:13 PM V-84
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
15.4
2878
9/3/2007 1:28:46 PM
SATIP-W-011-01
SAIC-W-2016
Mechanical
SAEP
SAEP-1160
5.3
V-84
2879
SATIP-L-350-01
SAIC-L-2011
Mechanical
SAEP
SAEP-1150
A12.1
9/5/2007 2:27:35 PM
V-84
2880
9/20/2007 8:57:46 AM
SATIP-NDE-RT-01
SAIC-RT-2009
Mechanical
SAEP
SAEP-1143
8.4.2
V-84
2881
9/23/2007 7:43:18 AM
SATIP-NDE-RT-01
SAIC-RT-2007
Mechanical
SAEP
SAEP-1143
8.4.1
V-84
2882
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
3.7
5/31/2007 5:29:20 PM
V-84
2883
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
7.4.5
5/28/2007 2:04:42 PM
V-84
2884
6/5/2007 9:29:19 AM V-84
2885
5/28/2007 11:35:03 AM
V-84
Tong Tester is not available at site to check the Heat Input for the Low Temp Carbon Steel production welds those shall not exceeded to the Heat Input limits listed on the WPS. Situation is not meeting the requirement of SAES-W-011 Para-19.4. Kindly instruct to the SIS to arrange measuring tool IMMEDIATELY to avoid this situation. QA/QC documents were not retrieve able and readily available at SIS site office to verify the SA/ approved suppliers of low Hydrogen welding electrodes, Filler wires and inert gases were purchased at site.Situation was not meeting the requirements of SAES-W-011 Para- 6.1 and Sch Q- Para- 7.1 6.1V. Cotractor is requested to provide all documents to verify the SA approvals. During routine site visit it was noted that weld # 36 under drawing # VB-420169-001-12"-P-10038-6CA1P was being welded near to complete caping by welder ID # 073.but as per WPS # MSAS 76- QW-406. Interpass temperature- 200 deg cent was not checked by SIS.Kindly instruct to the QA/QC department any welding at site shall not violate to the approved WPS. Qualified welders having ID # 1654, 1656 and 1082 have been demobilized by SIS but JCC (Job Clearance Cards) issued by PID were not yet returned to Inspection Representative at site that is violated to the SAEP-324 Para- 6.5.5. Kindly ask to the contractor to comply the SA Procedure requirement and avoid to re occurance of such discrepancies. Inside PIB building angle iron frame work was being carried out by one of the helper(Alfredo Flanka)and weld quality was very poor. Kindly ask to the contractor to repair all those fillet welds and tacks during mesh installation and frame fabrication and provide us root causes of such potential violations those are not meeting the requirements of SA std SAES- W- 011 Para 11.5.2. During Surviallance inspection it was noted that heavy large bore valves were stored in the uncovered broken crates that is violated to the SA/ std SAES- L-350 section 7.3 stated that fittings and valves shall be stored in shipping crates or on racks off the ground. Kindly ask to the contractor to make sure that penetration(root) and complete fusion have been verified by welding QC for all those welds are accessible. Most of the measuring devices are need to be re calibrated with in this week. Kindly ask to the contractor to take action AEAP to avoid the usage of expired measuring devices. IAP Package- PR-6502-01 Pre Fabricated Steel Structure was reviewed and identified that Steel Structural was fabricated under SIS sub contract with Mechanical Contracting & services company(MCSC)with out having CSD approved WPS/ PQR document in the IAP Package . that is not meeting the requirement of SAES-W-011 Para- 7.1.8 stated that an approved Welding Procedure was available at work location and Welding Procedure request has signed approval by the assigned Saudi Aramco Inspection Agency.Kindly ask to the contractor to provide the CSD approved WPS in their IAP Package. During job site surveillance this is observed that Hygrometer and some other devices have their calibration expired. This is violation to Sch "Q" Para 6.1 and SAES-H-100 Attachemnt "A" requirments.
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
SAES-W-011
19.4
SATIP-W-011-01
SAIC-W-2010
Mechanical
SAES
SAES-W-011
6.1
2886
9/20/2007 10:55:44 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
12.4
V-84
2887
8/27/2007 4:41:36 PM
SATIP-W-011-01
SAIC-W-2035
Mechanical
SAEP
SAEP-324
6.4.4
V-84
2888
9/13/2007 9:27:35 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
11.5.2 & 11.6
V-84
2889
7/10/2007 4:08:26 PM V-84
SATIP-L-108-01
SAIC-L-2041
Mechanical
SAES
SAES-L-350
7.3
2890
8/28/2007 8:24:24 AM
V-84
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-W-011
17.5.1.2
2891
5/19/2007 1:45:27 PM
SATIP-W-011-01
SAIC-W-2005
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
V-84
2892
SATIP-W-011-01
SAIC-W-2001
Mechanical
SAES
SAES-W-011
7.1.8
6/30/2007 7:32:11 AM
V-84
2893
11/17/2008 8:40:45 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
Attachment A
Schedule Q
A IV Para 7.1
V-84-Ethanne
2894
11/27/2008 5:09:20 PM V-84-Ethanne
2895
8/14/2008 2:43:09 PM
V-84-Ethanne
This is observed and even after several reminders and e-mails noticed that coating system applied on subjected line is not in compliance with SA requirmenst. All the 30" flare appreance is not uniform and is violation of SAES-H-100 Para 8.1.6."c" Advice contarctor to rectify the situation. This is observed that SIS had not submimted the Weld map/WPS/PQR for the Falre line structural work. This is Violation to SAES-W-013 Para 7.1.2 The contractor has painted the Barrier Posts without proper surface preparation from some welding defects like spatters & pinholes, that is a violation as per SAES-H-100 Para 5.3.2 During surveillance inspection ,it has been observed that,the DFT readings of primer coating for some Pipes were not as per SAESH-101 ,Para# 4.2 At our mentioned locations this is observed & reminded earlier that coated materials & SS materials are not stacked properly & at many locations they are in direct contact with soil & are getting damaged / contaminated. Already a contractor NCR is generated but no improvement. Advice contractor to take necessary actions immediately and rectify the situation. All these are violations to SAES-L-350 Para 7.1 & SAES-H-200 Para 5.2 Structural steel columns were painted without properly preparation from surface contaminants like spatters for next coating; this is a violation as per SAES-H-100.para 8.1.1. The contractor has painting the structural steel beams without following the specification and procedures requirements of the surface preparation ,since I found that ,the contractor do painting a dirty surface while wind is very strong as well as the surface was not cleaned from spatters ,this is A violation as per SAES-H-100, Para 8.1.1 The contractor has handled coated pipes with badly manner as I found 2 coated pipes laid on the site with damaging coating which may be as a result of dragging or rolled, this is a violation as per SAES-H-200.para# 5.1.3 Coating activities carried out without painting inspection coverage, this is a violation as per schedule Q Para# 2.2.5 During surveillance this is observed that orifice flanges on lines 12"-P-10065-6CA1P, 12"-P-10042-6CA1P & 20-P-10036-3CA1P are not ground Flush. This is a Violation to SAES-L-350 Para 10.4.2 Contractor to be advised to rectify the situation ASAP & avoid this violation in future. During surveillance inspection, it has been observed that, Valves 30 20 were not preserved properly, this is a violation as per schedule Q Attachment (IV) Para# 5 The control valves has been handled without proper preservation, this is a violation as per schedule Q, attachment IV Para# 6 During site visit, it has been observed that, the contractor has installed cut end stud bolts in flange joint connection, this is unacceptable as per Saudi Aramco requirements,Schedule(Q),Attatchment III, contractor advised to replace all damaged bolts by new one.
SATIP-H-100-01
SAIC-H-2031
Mechanical
ScheduleQ
SAES-H-100
8.1.6C
SATIP-M-001-01
SAIC-M-2012
Mechanical
SAES
SAES-W-013
7.1.2
12-SAMSS007
7.5
2896
8/12/2008 11:07:11 AM
SATIP-H-100-01
SAIC-H-2027
Mechanical
SAES
SAES-H-100
5.3.2
2897
3/18/2007 1:44:58 PM
SATIP-H-100-01
SAIC-H-2029
Mechanical
SAES
SAES-H-100
8.1.6A
2898
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
SAES-H-200
5.2
1/5/2008 2:14:15 PM
2899
5/20/2008 1:06:10 PM
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-100
8.1.1
2900
5/27/2008 11:18:15 AM
SATIP-H-100-01
SAIC-H-2028
Mechanical
SAES
SAES-H-100
8.1.1
2901
6/12/2008 8:34:17 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-L-350
SAES-H-200
5.1.3
2902
6/17/2008 12:47:34 PM
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
2903
2/5/2008 11:05:12 AM
SATIP-W-011-01
SAIC-W-2007
Mechanical
SAES
SAES-L-350
10.4.2
2904
5/18/2008 9:34:52 AM
SATIP-L-108-01
SAIC-L-2041
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2905
6/4/2008 3:09:22 PM
SATIP-L-108-01
SAIC-L-2041
Mechanical
ScheduleQ
Schedule Q
A IV Para 6
2906
7/28/2008 8:31:34 AM
SATIP-L-350-01
SAIC-L-2014
Mechanical
SAEP
SAEP-351
4.2
2907
10/23/2007 11:23:49 AM
2908
10/19/2008 10:02:05 AM
2909
6/21/2008 12:59:51 PM
2910
7/21/2008 10:59:27 AM
Manufacturer: INTERFIT Main Supplier: PROMOTE BD LIMITED SA Vendor: Gulf Equipment Co. Ltd. At our site during routine fit up inspection it was observed that one of the 10 90 Elbow have some lamination or cracks marks on surface. The entire surface on subjected area was ground to bright metal and MPI was conducted. During MPI this was observed that indication is going deeper & deeper. Exercise was repeated & same results. All the fittings from same supplier are on hold (Total 23). 11 out of 23 are examined & 04 are fond with problematic. Still remaining (12) are going through the examination (MPI). Final report shall be generated after all the examination will be completed. During site visiting in Butane Pump area, the contractor has weld new pipe support on 4 line that already passed a successful pressure testing , the contractor advised to retest the line as per SAES-L-150,para # 5.8. The contractor starting installation the pipes by hot insulation material without either approved procedures or material receiving inspection by PID ,this is a violation as per schedule Q ,para#3.4,SATIP-N-001-02 During site visit, the contractor using Aluminum cladding materials in fire hazards area; this is a violation as per SAES-N001Para. 7.7.2.2 The contractor still installing damaged hot insulation materials on 4 line that is a violation as per PIP INSH2000, para #5.11.2 The contractor had failed to rectify some data & discrepancies in their submitted Weekly Report despite of the verbal reminders including highlights to the fact, violation of Quality management System Requirement (Schedule Q Para.2). During surveillance inspection, it has been observed that, tow welders leave their portable ovens opened , that will effect to keep a temperature more than 65C, this is violation as per SAESW-011, Table 1 During job site surveillance this is observed that welding grounding cables are being connected far away from weldment. This practice should be stopped immediately especially working near equipments (Compressors, Motors etc) carrying bearing and other precise components. More over it is also a violation to API RP2A Para 12.7. Correct the situation ASAP. During surveillance inspection, it has been observed that, Welding Procedure (WPS) was not available on Site during welding activities, this is a violation as per SAES-W-011, Para. 7.1.8 During site visiting, Pipe rack support for new 30 flare line, the welding activities ongoing without approved welder this is a violation as per SAEP-324, sec 5, and the portable ovens have been kept without power that will effect on the quality of the electrodes and welding, this is a violation as per SAES-W-011 attachment # 1 Line # 8"-P-10069-9CAIP FOR MODIFICATION & NEW WELD ON THESE LINES FOR ALL 03 COMPRESSORS HAVE NOP IDENTIFICATION.This is violation to SAES-W-011 Para 16.1 and 16.2 During rutein visit this is observed that fabricators & fitters are using triangles & files of normal carbom steel for fitup of SS materials. This not acceptable as per material codes & not a good enginering practice. I addition to that this is violation to SAES-W-011 requirments.
SATIP-L-350-01
SAIC-L-2006
Mechanical
ScheduleQ
Schedule Q
1.3
SATIP-A-004-02
SAIC-A-2001
Mechanical
SAES
SAES-L-150
5.8
SATIP-N-001-02
SAIC-N-2014
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.1
SATIP-N-001-01
SAIC-N-2010
Mechanical
SAES
SAES-N-001
7.7.2.2
2911
8/11/2008 4:41:27 PM
SATIP-N-001-02
SAIC-N-2014
Mechanical
SAES
SAES-N-001
Section 3
2912
9/10/2008 2:36:28 PM
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
2.4
2913
5/14/2008 10:48:09 AM
SATIP-W-011-01
SAIC-W-2032
Mechanical
SAES
SAES-W-011
6.1
2914
4/30/2008 7:04:13 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
other
API RP2A
12.7
SAES-W-011
19.3
2915
5/14/2008 11:03:34 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
7.1.8
2916
8/11/2008 11:26:31 AM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
2917
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
6.1
2918
4/26/2008 9:57:12 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
SAES
SAES-W-011
16.1
2919
11/24/2007 7:22:59 AM
SATIP-W-011-01
SAIC-W-2005
Mechanical
other
PFI-ES-43
3.2
2920
12/10/2007 8:32:06 AM
2921
12/26/2007 7:35:26 AM
2922
3/26/2008 11:42:45 AM
2923
6/17/2008 12:53:53 PM
2924
12/12/2006 2:33:48 PM
2925
10/20/2007 9:52:55 AM
2926
3/21/2009 8:45:49 AM
2927
11/18/2009 3:15:22 PM
During surveillance this is observed that contractor is not using any remote control devices to control welding current working on highly elevated pipe racks & equipments. This is violation to SAES-W-011 Para 19.1 More over this non availability of proper accessories is delaying the production & adding cost to the project. In addition to that risk factor is increased for persons working longer working Hrs on high elevated areas & coming for small current changes through monkey ladders up & down several times on high scaffolds. Contractor to be advised to rectify the situation immediatly. Even after SAPMT/SAPID several reminders contractor is not complying to SAES requirements for environmental control during welding works. Most recent Radiographic results are evidence of that (porosity in welds). Now from last three fore environmental situation is getting even worst. Advice contractor to take strict actions to avoid any future repairs, minimize their production welding work during heavy wind as advised in SAESW-011 Para. 11.2 During Surveillance inspection it has been observed that, some of welders making welding activities without JCC, this is a violation as per SAEP-324,Para#6.2.5 of work. Welding activities carried out without welding inspection coverage by approved welding inspector, this is a violation as per schedule Q Para# 2.2.1 It was observed that the coating material REDOX EP-T333 epoxy & SIPCO Redox bituminous HB has stored without sun shade protection. SAPMT/Contractor was informed through preventive notification that the coating material must be covered with appropriate canvas tarpaulins or equipment for temporary storage period not to exceed 14 days as per SAES-H-100; section 6.2.This will avoid any potential violation and costly rework. Routine site inspection discovered that the approved QC Welding Inspector was not on site while his welding crews are performing welding works several weeks ago. Lack of QC coverage during this activity violates the essence of SCHEDULE "Q", Paragraph 5.11. SAPMT is requested to advise the contractor to comply with the requirement. Please be reminded that as per sch.Q attachment IV, sec. 1.2.3 that the notification for request for inspection (RFI) should be at least a minimum of 24 hrs for weekdays work and 48 hrs for weekend inspection. ROUTINE VISIT FOR IN-PROCESS WELDING & FIT-UP INSPECTION, THE FOLLOWING Violations have BEEN OBSERVED. 1) Inspection tools were not available, such as Tong tester for (check the AMP, Voltage, travel speed) as per WPS. temple stick or Pyrometer(For check the Preheat and inter pass temperature during welding) . *Advised the QC to take corrective action immediately, And re-offer for conformity as well as arrange the inspection tools. 2) Portable quiver cap was opened during welding 3) S.S material was lying with C.S material. 4) The width of weaving was too wide on finished weld (capping) The width of weaving should not be exceeded more than 3 time of electrode diameter. Welding Activity in progress with out Qualification (C.S Qualification Vs S.S welding activity). . . . Welding Activity started with out Information (No RFI) Portable Ovan found Non calibrated / out of order
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
19.1
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
8.1
SAEP-324
6.2.5
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
SATIP-H-100-01
SAIC-H-2025
Mechanical
SAES
SAES-H-100
6.2
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
5.1
SATIP-W-011-01
SAIC-W-2007
Mechanical
ScheduleQ
Schedule Q
A IV Para 1.2.3
SATIP-W-011-01
SAIC-W-2006
Mechanical
ScheduleQ
Schedule Q
A IV Para 7.1
2928 2929 2930 2931 2932 2933

12/1/2009 7:59:27 AM

SAIC-W-2006 SAIC-W-2006 SAIC-W-2006 SAIC-W-2048 SAIC-W-2048 SAIC-W-2046
SAES other
SAES-W-011 PFI-ES-43 Schedule Q SAES-W-012 Schedule Q SAES-W-012
6.1 2.4 1.3 7.1.3 1.7 6.1
Mechanical
ScheduleQ
SAES ScheduleQ SAES
2934 2935
Welding consumables were placed in a Steel box instead of a proper portabel Oven. Welding machine not calibrated No Baking oven/ holding oven/ baking record and handling / issuance record. Contractors QC did not comly / and shown Unawareness to welding activities. Remarks: Activity has been stoped untill the requirements are met through SAES-W-012, Appendix 1. DURING SURVELLANCE INSP. IT WAS NOTICED THAT PIPES WELDING WAS DONE AT DUSTY GROUND WITH FREQUENT MOVEMENT OF VEHICHLES AND EQUIPMENTS WITHOUT PROPER USE OF TENTS OR SHILTERS WHICH CONTRIBUTES TO POOR WELD QUALITY. ( CONT NCR 10-UTMN WAS ISSUED ) 1. APCS 113A application on field weld of 8 Flow line has been found sags,and drips on many joints,violating SAIC H-2050, A3. 2. Open end of pipe line strings shall be found uncapped,violating SAIC L-2132,A9. 3. Welding has been carried out without any proper wind shield &inclement weather,violating the requirement of SAIC-W2049,B1,B3. ROUTINE VISIT FOR IN-PROCESS WELDING INSPECTION, THE FOLLOWING VIOLATIONS HAVE BEEN OBSERVED: 1) Baking oven is not available. These have been brought to the attention of PMT as well as contractor for immediate rectificaiton. 2) Baking record for E7018 is not available. 3) Issuance record of electrode is not available 4) A few welding machines were not calibrated. 5) Structure welding was being done without cleanliness of weld surface.
12/1/2009 8:19:03 AM
SAES SAES
6.1 18.2
2936
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
2937
10/31/2009 1:11:29 PM
SATIP-W-011-01
SAIC-W-2006
Mechanical
SAES
SAES-W-011
11.2.3
2938 2939 2940
12/6/2009 1:56:24 PM
SATIP-H-002-06 SATIP-L-450-04 SATIP-W-012-01
SAIC-H-2050 SAIC-L-2132 SAIC-W-2048
Mechanical
SAES
SAES-H-100 SAES-L-450 SAES-W-012
8.1.6 b 11.4 10.2
Mechanical
SAES
Mechanical
SAES
2941
11/18/2009 1:38:45 PM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
2942 2943 2944 2945 2946 2947 2948

SAIC-W-2046 SAIC-W-2046 SAIC-W-2045 SAIC-W-2046 SAIC-W-2048 SAIC-W-2046 SAIC-W-2048
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical
SAES SAES SAES SAES ScheduleQ SAES ScheduleQ
SAES-W-012 SAES-W-012 SAES-W-012 SAES-W-012 Schedule Q SAES-W-012 Schedule Q
6.1 6.1 18.2 10.3.1 1.7 6.1 5.1
Welding Activity started with out Information (No RFI). Welding consumables were placed in a Steel box instead of a proper portabel Oven. Contractors QC not present at welding activities. DURING SURVELLANCE INSP. IT WAS NOTICED THAT ONE OF THE TWO HOLDING OVEN HAS NO CALIBRATION STICKER ( CONT. NCR # FRM-087 WAS ISSUED ) During site inspection of at SDGM-707 it was observed that welded joints do not contain necessary markings for traceability of weld joints such as welder symbol. This is a violation against SAES-W-012 Para 15.1 which says that "All weld joints shall be marked for identification by a weld number and a welder symbol. These identifications shall be made with a suitable weather-proof marking material. The markings shall be placed in a location such that they will remain visible for a time suitable to the authorized Saudi Aramco inspector. The markings shall be compatible with any subsequent coating or heat-shrink sleeve application.Contractor is required to rectify this violation. Welding Activity started with out Information (No RFI). Portable Ovan found Non calibrated / out of order. Welding was started with out removing the coating from welding area.
2949
10/31/2009 1:15:01 PM
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
2950
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
15.1
1/5/2010 10:40:31 AM
2951 2952 2953
12/1/2009 8:36:08 AM
ScheduleQ SAES SAES
1.7 6.1 10.3.1
2954
Baking record for welding consumables not available. 1 Joint of 8" dia has been done with present circumstances. Welder Identification was not marked on weld joint that is in progress. Welder quited from work location with out disclosing his identity. Contractors QC was absent from working area. During Surveillance inspection on 25th November, 2009 at Metal Service Dhahran Fabrication Shop the following are observed: 1. UTMN 1703 Fabrication of well head spool No.1 Shop weld SW#1, 4" Dia is marked the welder identification is 5138 and the weld inspection report shows welder id is 012, this type of error will directly affect the welder performance. . 2. Both the above welders continuity record are not available 3. Electrode baking and holding oven identification number, calibration sticker and certificates are not available, temperature gauges are missing. This violates the standard requirements: SAES-W-012 1. Open end of pipe line strings shall be found uncapped,violating SAIC L-2113,A9. 2. No proper sign board is provided to reach the work area, safety violation. Unsatisfactory Contractor QC Performance - Execution of jobs without enough qualified QA/QC manpower such as welding inspector and mechanical inspector as well as coating inspector. This is in violation of SAEP-1150 para.8.3 that states if the contractor does not adhere to the quality requirements PID may be required to provide additional support as outlined in schedule "Q" General requirements para.1.3 and para.1.4. Please advice MACE contractor to take a course of action as required. Thank you. During my routine visit at site sabkah-38 near GOSP-4 area it was observed that the lowering was started without an RFIs or SPIU notification inspection. Hence this findings has been broughout to SAPMT and agreed to stopped the lowering and therefore SPIU recommend SAPMT to advice MACE contractor to notify inspection when will be ready with an RFI prior to witness as required. During my routine visit at site sabkah-38 near GOSP-4 area it was observed that the lowering of 30" TR/L-4 was started without an RFI or SPIU inspection notification for Mechanical. Hence this findings has been broughout to SAPMT and agreed to stopped the lowering and therefore SPIU recommend SAPMT to advice contractor MACE to notify inspection when will be ready with an RFI or SAIC-L-2132 prior to witness as required. Internal Quality Auditing - Due to the non availability of the approved third party lead auditor, the Contractor S.A.S fails to performed the "Internal Quality Auditing on September 21, 2008 at stage of 60% compilation of the projects. Please SAPMT to advice Contractor to submit the alternative lead auditor to SPIU for review and approval. So that the 60% internal audit can be performed ASAP and to satisfy the Saudi Aramcos Procedures as mentioned in the schedule "Q" general requirements under sec.7 para.7.2.2. This is strict compliance. Thanks.
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
2955
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
15.1
2956
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
2957
12/1/2009 2:20:37 PM
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAES
SAES-W-012
15.1
Schedule Q
1.3
2958
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAEP
SAEP-324
6.2.3
2959
SATIP-W-012-01
SAIC-W-2046
Mechanical
SAES
SAES-W-012
6.1
2960
10/27/2009 3:02:03 PM
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAES
SAES-L-450
11.4
2961
SATIP-L-450-03
SAIC-L-2113
Mechanical
SAEP
SAEP-1150
8.3
Schedule Q
5.1
6/5/2008 8:59:59 AM
2962
9/1/2008 4:11:11 PM
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
1.3
2963
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
1.3
9/1/2008 4:30:31 PM
2964
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
7.3.2
9/23/2008 2:19:12 PM
2965
3/24/2008 11:41:27 AM
2966
5/27/2008 11:42:10 AM
It was observed that the contractor MACE QC Mechanical inspector was not available @ site since 10 March 2008. Until now MACE did not notice SAPMT & SPIU in this aspects and this is unacceptable. Violated of schedule "Q" sec.1.3 General requirements that states the contractor shall be totally responsible for the quality of works @ site. Please advised contractor to resolved this issue if not their PQIs next coming month will heavily impact. Thank you. Selected joints for NDT and weld control identifications Contractor MACE QA/QC department observed that the tracking and reporting of selected welded joints for the daily production welds subject for RT, noticed that the minimum data requirements such as selected welded joints, weld identification numbering system for RT etc. were not conforms as per the requirements of SAEP-1160 under sec.6. SPIU recommend contractor to be filled-up and used the Saudi Aramco Test Report Forms SATR-NDE-2004 & SATR-W-2007 (Data base) and signed by SAPMT & SPIU prior to submittal to NDT third party for RT as required. Please advice contractor to comply accordingly. Lowering of 10" water system header from Sabkah-40 onwards going to GOSP-4 were not accepted by SPIU. Due to the Contractor QA/QC personnel failed to submitt the appropriate documents & should attached on the RFIs; such as RT results reports on the particular joints; RFTI assesments result reports as well as coatings and holiday testing reports signed and accepted by concerned persons. During my routine at site sabkah-85 it was observed the following deficiency: 1) Internally coated pipes received without material receiving report as per SAIC-L-2005/SATIP-L-350-01. 2) Storage of Internally Coated Pipes - Violates the standard of SAES-H-200 under sec.5.1 General Handling Requirements para.5.1.1 & 5.1.4. Please advise contractor to adhere the requirements. During my routine visit at site sabkah-39 GOSP-4 area found out the following violations: 1) Delivery and receiving of pipes without notifications. This is in violation (item3 1 & 2) per schedule "Q" gen.requirements para.1.3 & 1.4 This is strict compliance and please advice contractor accordingly. 2) Unloading without the knowledge and without the presence of QA/QC mechanical inspector. During my routine visit at site sabkah-39 GOSP-4 area to monitor and check the on-going bending of 24" externally coated pipes and found out the following deficiencies: 1) On-going bending without bending schedule or calculation activity. 3) On-going bending without approved bending procedure or the procedure are not available at site. This is in violation of approved QA/QC Plan and schedule "Q" General Requirements and again this will be heavily impact of their PQI. Please advice MACE contractor to rectify this issues. Thank you. 2) On-going bending without the presence of Mechanical QA/QC inspector. During my auditing verified and checked that the RT Request/Report SA Form-4719 SATR number SATR-NDE-2004 submitted to VETCO NDE/NDT provider and to be filled by the responsible NDE/NDT RTFI do not returned to MACE for their records and proper process control tracking system. Contractor shall comply the proper filing system as per SAEP-1160 sec.6. Please advised contractor to sort this negative findings prior to the Focus Assesment Audit close-out as required. Thanks.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
SATIP-NDE-RT-01
SAIC-RT-2010
Mechanical
SAEP
SAEP-1160
2967
SATIP-L-450-04
SAIC-L-2132
Mechanical
ScheduleQ
Schedule Q
1.3
6/30/2008 1:17:20 PM
2968
10/26/2009 8:55:26 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
A III Para 3.22
2969
SATIP-L-350-01
SAIC-L-2005
Mechanical
SAES
SAES-H-200
5.1.1
2970
7/31/2008 9:43:00 AM
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
1.7
2971
SATIP-L-350-01
SAIC-L-2005
Mechanical
ScheduleQ
Schedule Q
5.1
2972
SATIP-L-450-03
SAIC-L-2114
Mechanical
ScheduleQ
Schedule Q
3.2
7/23/2008 2:20:19 PM
2973
SATIP-L-450-03
SAIC-L-2114
Mechanical
ScheduleQ
Schedule Q
5.1
2974
SATIP-NDE-RT-01
SAIC-RT-2010
Mechanical
SAEP
SAEP-1160
3/5/2008 4:36:05 PM
2975
7/23/2008 7:36:30 AM
During my routine visit at site (Various Sabkahs) it was observed that the contractor MACE QA/QC personnels are used only one (1) vehicle of traveling to all locations where "WORK" is being performed and this is not acceptable as per the QA/QC Plan and Schedule "Q" general Requirements. Noticed that each QA/QC personnel shall be provided with a vehicle for his sole use that it is capable of traveling to all locations where work relating to their contract is being performed. This is strict compliance and please be advised contractor to be resolved this non conformity if not SPIU will proceed to issue an NCR and defenitely their PQI will be heavily impact. Than you No Qualified Coating Inspector at Shaybah Projects -Contractor MACE advised by PID/SAPMT during the kick-off meeting to provide a qualified coating inspector to cover and maintained the quality requirements without any deviations. Noticed that till now the contractor MACE has no any action taken to be done, and this is mandatory as per their QA/QC Program and Schedule "Q" General Requirements. NEGLIGENCE WAS OBSERVED - Mechanical QA/QC Inspector observed lacking of proper care and attention to the standard quality, because PID found out that he is also assigned as a construction supervisor to supervise the on-going construction activities at site. This is in violation of schedule "Q" requirements under Resource Management sec.5 para.5.9 that states the quality personnel shall be dedicated to perform quality functions as described and shall perform no other functions in order to achive the desired level of quality. If this non conformity does not intent PID will proceed to issue an NCR or the approval of the mechanical inspector will be revoked. Please advise them accordingly. Thanks. Noticed that the manifold system was separately tested, dated and tagged with calibration certificate. And verified that the hose are not included during the testing of the manifold system. The hose shall also be tested at 20% above the test pressure or adequate pressure ratings that match or exceed system class/test pressure. Ref. SAIC-A-2009 sec.A1, SAIC-A-2011 sec.C para.C1 thru C7 and G.I-2.102 para.5.1.5.5 so please advise contractor to comply. Quality Personnel Changes - Observed that the RHM Contractor missed to comply the requirements of schedule "Q" under sec.5 Resource Management. That states contractor shall make quality personnel changes required due to vacations, illness, temporary assignments, emergency leave, resignations or other reasons as necessary to maintain required quality coverage. Contractor shall advise the company Representative of such personnel and quality coverage at least thirty (30) calendar days in advance of scheduled absences or changes as soon as possible.This is in compliance to the companys Quality assurance Plan (QAP) Standards & Procedures.Please Contractor to adhere the requirements. Thanks. Absence of Welding QA/QC inspector - During my routine visit at site for couple of days it was observed that the welding is ongoing at sabkah-19 without the presence of welding QA/QC inspector or monitoring is insufficient. This is in violation of schedule "Q" general requirements para.1.2 thru para.1.4. Please advise contractor to adhere the requirements. Thanks.
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.1
2976
SATIP-H-100-01
SAIC-H-2027
Mechanical
ScheduleQ
Schedule Q
5.1
10/26/2009 9:19:43 AM
2977
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.9
11/21/2009 4:44:04 PM
2978
SATIP-A-004-02
SAIC-A-2011
Mechanical
other
G.I.2.102
5.1.5.5
8/4/2009 5:12:39 PM
2979
SATIP-L-350-01
SAIC-L-2011
Mechanical
ScheduleQ
Schedule Q
5.11
10/3/2009 2:53:27 PM
2980
10/1/2009 9:06:11 AM
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
2981
10/1/2009 9:49:59 AM
Absence of QA/QC Welding Inspector - During my routine visit at site to sabkah-76 for a couple of days, it was observed that the welding continously without the presence of QA/QC welding or monitoring is insufficient. This is in a violation of schedule "Q" general requirements under para.1.2 thru para.1.4. Please advise contractor welding QA/QC inspector to adhere the requirements. Thanks. Repeated Violation - During my routine visit at site sabkah-19, it was observed that the construction people still using welders without JCC card. Contractor violates the standard of SAEP-324 para.6.2.1 that states contractor welder shall be tested in accordance with either ASME sec.IX, AWS D1.1 or API-1104 as required for all type of welding includes tack weld and para.6.2.3 the welder JCC shall reviewed by project inspection prior to start of the work. Noticed that if the contractor does not intent of this non conformity SPIG will proceed to issue an NCR and therefore it will heavily impact their PQIs. So please advise contractor to adhere the requirements. Thanks.
SATIP-W-012-01
SAIC-W-2048
Mechanical
ScheduleQ
Schedule Q
5.1
2982
SATIP-W-012-01
SAIC-W-2048
Mechanical
SAEP
SAEP-324
6.2.5
10/19/2009 2:30:56 PM
2983
INSTALLATION-ALIGNMENT & ELEVATION CHECK 0F REFRIGERANT ACCUMULATOR
SATIP-D-001-01
SAIC-D-2007
Drawing
IFC Drawing for Equipment Foundation IFC Drawing for Equipment Foundation
NA
2984
DEMETHANIZER OVERHEAD EXCHANGER
SATIP-E-004-01
SAIC-D-2006
Drawing
NA
2985
WASTE WATER LIFT STATION PUMP(B69-G-0161B)
SATIP-G-005-01
SAIC-G-2021
other
31-SAMSS004
As per SAIC
2986
WASTE WATER LIFT STATION PUMP(B69-G-0161A)
SATIP-G-005-01
SAIC-G-2021
other
31-SAMSS004
As per SAIC
2987
INSPECTION OF AMBIENT LAY-UP OF TEST PACKAGE NO.B64112 (LINE NO.10"-FGH-1329) AND TEST PACKAGE NO.B64155(LINE NO.8"-FGH-1342) INSPECTION OF AMBIENT LAY UP OF TEST PACKAGE NO. B64115(8"-FGL-1357), TP NO.B64-158(3"-FGL-1359), TP NO. B64116(8"-FGL-1358) INSPECTION OF AMBIENT LAYUP OF TEST PACKAGE NO.B64113(LINE NO.16"-FGH-1331-3CS9P) AND TEST PACKAGE NO.B64114(LINE NO.16"-FGH-1333-3CS9P) Inspection of final shaft alignment w/ pipe-off of B64-K-102B (Regeneration Compressor) between gearbox and Compressor prior to commissioning.
SATIP-A-004-02
SAIC-A-2018
SAES
SAES-A-007
5.2.1
2988
SATIP-A-004-02
SAIC-A-2018
SAES
SAES-A-007
5.2.1
2989
SATIP-A-004-02
SAIC-A-2018
SAES
SAES-A-007 31-SAMSS001
5.2.1
2990
SATIP-K-402-01
SAIC-K-2007
other
As per SAIC
2991
INSPECTION OF FINAL COMPRESSOR AND DRIVER ALIGNMENT BETWEEN (COMPRESSOR AND GEAR BOX) ON PIPE PRIOR TO PRE-COMMISSIONING OF B64 AREA / B64-K-102B REGENERATION COMPRESSOR.
SATIP-P-113-02
SAIC-P-3414
SAES
31-SAMSS001
As per SAIC
2992
INSPECTION FOR AIR FLOWING OF SUB SYSTEM B64-FG01HUG GAS FILTERING UNIT WITH LINE NOS.P-1001,P-1002,P1003,P-1012,P-1146.
SATIP-L-350-01
SAIC-L-2022
SAES
SAES-L-310
As per SAIC
As per SAIC
2993
INSPECTION OF DE-PRESSURIZATION AND WATER FOR TEST PACKAGE NO. B65-1-210,36"-P-1010.
SATIP-A-004-02
SAIC-A-2017
SAEP
SAEP-327
As per SAIC
2994
INSPECTION OF AMBIENT LAY-UP FOR TEST PACKAGE NO. B651-210,36"-P-1010. INSPECTION OF THE ACCESS LADDERS, PLATFORMS AND BOLT TORQUING PRIOR TO PRE-COMMISSIONING OF B65 AREA / B65F-104 THERMAL OXIDIZER STACK (PART OF B65-U-109 THERMAL OXIDIZER PACKAGE). INSPECTION OF HYDROTEST PACKAGE NO. B65-2-TPNO. 203A, LINE NO. 4"-P-1017-6SD0P1. INSPECTION OF AMBIENT LAY-UP OF TEST PACKAGE NO. B65-2TPNO. 203A, LINE NO. 4"-P-1017-6SD0P1. INSPECTION OF HYDROTEST PACKAGE NO. B65-2-TPNO. 292, LINE NO. 1"-C-1194-3SD0P. INSPECTION OF DE-PRESSURIZATION AND WATER DISPOSAL OF TEST PACKAGE NO. B65-2-TPNO. 292, LINE NO. 1"-C-11943SD0P. INSPECTION OF AMBIENT LAY-UP OF TEST PACKAGE NO. B65-2TPNO. 292, LINE NO. 1"-C-1194-3SD0P.
SATIP-A-004-02
SAIC-A-2018
SAES
SAES-A-007
5.2.1
2995
SATIP-D-001-01
SAIC-D-2003
SAES
SAES-D-001
As per SAIC
2996 2997 2998 2999 3000
SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02
SAIC-A-2015 SAIC-A-2015 SAIC-A-2015 SAIC-A-2017 SAIC-A-2018
SAES SAES SAES SAEP SAES
SAES-L-150 SAES-L-150 SAES-L-150 SAEP-327 SAES-A-007
7.3 7.3 7.3 As per SAIC 5.2.1
3001
REPORT OF PRESSURE VESSEL FINAL CHECK AND CLOSURE (B65-D-202 DGA STRIPPER REFLUX DRUM)
SATIP-D-001-01
SATR-D-2003
SAES
SAES-D-001
As per SAIC
3002
Materials Inspection of TEEs, SW Ends (pipe fitting) prior to installation, as per P.O. No. 700000/SPSA/497 (items 1, 3 & 5). MTC are attached.
SATIP-L-350-01
SAIC-L-2006
ScheduleQ
Schedule Q
3003
Material Receiving Inspection of PIpe Nipples ,prior to installation, as per P.O. No. 700000/SPSA/497, items 2,4 & 6. Corresponding MTCs are attached.
SATIP-L-350-01
SAIC-L-2005
ScheduleQ
Schedule Q
3004
Receiving inspection of seamless pipes as per P.O. No. 700000/SPSA/500 (item nos. 1 & 21)
SATIP-L-350-01
SAIC-L-2005
ScheduleQ
Schedule Q
3005
Receiving inspection of pipe fittings and flanges as per P.O. no. 700000/SPSA/500 (items 3,4,5,8,9,14). MTCs are also attached.
SATIP-L-350-01
SAIC-L-2006
ScheduleQ
Schedule Q
3006
INSPECTION OF HYDROSTATIC TEST FOR PACKAGE NO.TP-KT101B-098,LINE NO.2"-NL-10-53A31.14 INSPECTION OF PNEUMATIC TEST FOR TEST PACKAGE NO.TPB68-1-328,LINE NO.IA-1567. INSPECTION OF INTERNAL CLEANING OF TEST PACKAGE NO. B68-1-323, LINE NO. TW-2118 (WATER FLUSHING). INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY AND BOLT TORQUE TIGHTENING OF TEST PACKAGE NO. KT-101C-107, LINE NO. 2"-SG-141-52C31.05 / 2"-SG-142-52C31.05 / 2"-SG156-52C31.05 / 2"-SG-157-52C31.05 INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY AND BOLT TORQUE TIGHTENING OF TEST PACKAGE NO. KT-101C-050, LINE NO. 1 1/2"-WWM-044-53A08.03 INSPECTION OF DE-PRESSURIZATION AND WATER DISPOSAL FOR PACKAGE NO.TP-KT-101B-099,LINE NO.2"-NL-11-53A31.14
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-L-150
7.3
3007
SATIP-A-004-01
SAIC-A-2021
SAES
SAES-A-004
3008
SATIP-A-004-02
SAIC-A-2017
SAEP
SAEP-327
As per SAIC
3009
SATIP-L-350-01
SAIC-L-2014
ScheduleQ
Schedule Q
1.3
3010
SATIP-L-350-01
SAIC-L-2014
ScheduleQ
Schedule Q
1.3
3011
SATIP-A-004-02
SAIC-A-2017
SAEP
SAEP-327
As per SAIC
3012
INSPECTION OF DE-PRESSURIZATION AND WATER DISPOSAL FOR TEST PACKAGE NO.TP-KT-101B-100,LINE NO.1"-NL-2053A31.14
SATIP-A-004-02
SAIC-A-2017
SAEP
SAEP-327
As per SAIC
3013
INSPECTION OF HYDROTEST PACKAGE NO. B68-1-603B, LINE NO. P-1297 INSPECTION OF HYDROTEST PACKAGE NO. B68-2-300A, LINE NO. 66"-P-1001-3CS9P2. INSPECTION OF AMBIENT LAY-UP OF TEST PACKAGE NO. KT101D-058, LINE NO. 1 1/2"-WWM-XXX. INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY AND BOLT TORQUE TIGHTENING PRIOR TO HYDROTEST OF TEST PACKAGE NO. B68-2-300A, LINE NO. 66"-P-1001-3CS9P2. INSPECTION FOR AIR BLOWING OF VARIOUS LINES FROM SEAL GAS SYSTEM MCL-1006, BCL-808 TO THE COMPRESSOR IN TURBINE A.
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-L-150
7.3
3014
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-L-150
7.3
3015
SATIP-A-004-02
SAIC-A-2018
SAES
SAES-A-007
5.2.1
3016
SATIP-L-350-01
SAIC-L-2014
SAEP
SAEP-351
4 to 8
3017
SATIP-L-350-01
SAIC-L-2017
SAES
SAES-L-350
15.3.2
3018 3019 3020 3021 3022 3023 3024 3025 3026 3027
INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101A-104, LINE NO. SG-14-52C31.05 INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-096, LINE NO. 2"-SG-013. INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-097 LINE NO. 2"-SG-015 INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-100 LINE NO. 2"-NL-010. INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-092 LINE NO. 2"-SG-004. INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-093 LINE NO. 3"-SG-005. INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-103 LINE NO. 1"-NL-021. INSPECTION OF PIPING AND RE-INSTATEMENT OF TEST PACKAGE NO. KT-101D-101, LINE NO. 2"-NL-011. REPORT OF FLUE GAS DUCT FINAL CHECK AND CLOSURE Materials inspection of pipe fittings and flanges as per item 1,7,11 & 15 of P.O. No. 700000/SPSA/499 and Delivery Note No. 5213. MTCs are also attached. Materials inspection of Pipe Nipples, item DL200, of P.O. 700000/SPSA/582 and as per Delivery Note No. 5210. MTC is also attached.
SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01 SATIP-L-350-01 SATIP-F-001-01 SATIP-L-350-01
SAIC-L-2022 SAIC-L-2022 SAIC-L-2022 SAIC-L-2022 SAIC-L-2022 SAIC-L-2022 SAIC-L-2022 SAIC-L-2022 SAIC-F-2006 SAIC-L-2006
SAES SAES SAES SAES SAES SAES SAES SAES ScheduleQ SAES
SAES-L-310 SAES-L-310 SAES-L-310 SAES-L-310 SAES-L-310 SAES-L-310 SAES-L-310 SAES-L-310 Schedule Q SAES-L-350
As per SAIC As per SAIC As per SAIC As per SAIC As per SAIC As per SAIC As per SAIC As per SAIC 1.3 6
3028
SATIP-L-350-01
SAIC-L-2006
ScheduleQ
Schedule Q
3029
Material Receiving inspection of Spectacle plate and Blind flange as per P.O. nos. 700000/SPSA/711 (item CB 135) and SPSA/623 (Item BB 645)
SATIP-L-350-01
SAIC-L-2006
ScheduleQ
Schedule Q
3030
INSPECTION OF HYDROTEST OF TEST PACKAGE NO.TP-B72008(30"-P-1023-6CS9P)(1915PSI)
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-L-150
7.3
3031
INSPECTION OF HYDROTEST FOR TEST PACKAGE NO.TP901,LINE NO.BD-1298
SATIP-A-004-02
SAIC-A-2015
ScheduleQ
Schedule Q
4.13 of Attachment VI
3032 3033 3034
FIRST PRODUCTION (MONEL INCONNEL). Pre-Application Inspection of Insulation (C-002C) Piping Flange joint inspection for package NO.P-008 to D-607 RECEIVING AND INSPECTION OF SS PIPES UNDER P.O NO:8410LT-002 FOR MRR NO:11052 AND RN-NO:1307. CHECK AS PER CLIENTS REQUIREMENTS. RECEIVING AND INSPECTION OF CS PIPES & FORGED CS FITTINGS UNDER P.O NO:8410-MP-165 (8410-LT-001 & 004) WITH MRR NO:2303. CHECK AS PER CLIENTS REQUIREMENTS.
SATIP-W-011-01 SATIP-N-001-02 SATIP-L-350-01
SAIC-W-2005 SAIC-N-2006 SAIC-L-2014
SAES SAES SAEP
SAES-W-011 SAES-N-001 SAEP-351
As per SAIC 3 4 to 8
3035
SATIP-L-350-01
SAIC-L-2005
ScheduleQ
Schedule Q
3036
SATIP-L-350-01
SAIC-L-2006
ScheduleQ
Schedule Q
3037
RECEIVING AND INSPECTION OF SSTUD BOLTS FULLY THREDED WITH 2 NUTS UNDER P.O NO:8410-ZB-MP-482 FOR MRR NO:2512. CHRCK AS PER CLIENTS REQUIREMENTS. RECEIVING AND INSPECTION OF BUTTERFLY VALVES ACCESSORIES UNDER P.O NO:8410-LT-024 FOR MRR NO:11232. CHECK AS PER CLIENTS REQUIREMENTS. RECEIVING AND INSPECTION OF BW CS FITTINGS UNDER P.O NO:8410-LT-006 FOR MRR NO:11178 & RN-1507. CHECK AS PER CLIENTS REQUIREMENTS. The tested valves already sent to Area B/ Area A are in proper Storage an preservation condition and ready por PID Inspection. RFI for closing LBE 15463 Pipe material verification and visual inspection in accordance with PO 8410-ZB-MP-990K MRR-3089 Visual Inspection and material verification of manual valves inaccordance with: PO 8410-ZB-MP878-K MRR-3101 Visual Inspection and material verification of manual valves inaccordance with: PO 8410-ZB-MP902-K MRR-3023A Visual Inspection OF Pipe fittings in accordance with: PO 8410ZB-MP938-K MRR-3099
SATIP-L-350-01
SAIC-L-2008
ScheduleQ
Schedule Q
3038
SATIP-L-108-01
SAIC-L-2040
ScheduleQ
Schedule Q
3.3 of Attachment IV 3.3 of Attachment IV As per SAIC 3.3 of Attachment IV 3.3 of Attachment IV 3.3 of Attachment IV 3.3 of Attachment IV
3039
SATIP-L-350-01
SAIC-L-2006
ScheduleQ
Schedule Q 32-SAMSS035 Schedule Q
3040
SATIP-L-108-01
SAIC-L-2041
other
3041
SATIP-L-350-01
SAIC-L-2005
ScheduleQ
3042
SATIP-L-108-01
SAIC-L-2040
ScheduleQ
Schedule Q
3043
SATIP-L-108-01
SAIC-L-2040
ScheduleQ
Schedule Q
3044
SATIP-L-350-01
SAIC-L-2005
ScheduleQ
Schedule Q
3045
RECEIVING INSPECTION (EXTERNAL) OF 4TH CONDENSER
SATIP-D-001-01
SAIC-D-2002
ScheduleQ
Schedule Q
6 of Attachment IV
3046
SATIP-D-001-01
SAIC-D-2002
ScheduleQ
Schedule Q
6 of Attachment IV
3047
SATIP-D-001-01
SAIC-D-2002
ScheduleQ
Schedule Q
6 of Attachment IV
3048 3049 3050 3051 3052 3053 3054 3055 3056 3057 3058 3059 3060 3061
Equipment Verification and Visual Inspection for J87-E-0113 SULFUR COOLER Verification of refractory raw matls, Gas Duct of Superheater & Thermal Oxidizer Stack Internal cleanliness inspection.Issued by Jerry Verification of testing equipment inspection.Issued by Jerry Hydrotest inspection of pressure testing.Issued by Jerry Internal cleanliness inspection of testpack (J88-P-066).Issued by Jerry Visual inspection at test pressure for test pack (J88-P066).Issued by Jerry Verification of testing equipment inspection for test pack (J88-P066).Issued by Jerry Internal cleanliness inspection of test pack (J88-TR-003).Issued by Jerry Verification of testing equipment inspection for testpack (J88-TR003).Issued by Jerry Visual inspection at test pressure for testpack (J88-TR003).Issued by Jerry Lay-up Inspection after hydrotest.Issued by Jerry Lay-up inspection after hydrotest for package (J88-TR003).Issued by Jerry IN-PROCESS INSPECTION OF PRIMER APPLICATION FOR TIE-IN JOINT NO, 008 IN TANK FARM AREA. PAINT SYSTEM APCS 11A INSPECTION OF PRIMER APPLICATION FOR TIE-IN JOINT NO, 008 IN TANK FARM AREA. PAINT SYSTEM APCS - 11A INSPECTION OF SURFACE PREPARATION FOR TIE-IN JOINT NO, 20 AT DHT AREA. PAINT SYSTEM APCS - 1E INSPECTION OF TOP COAT APPLICATION FOR TIE-IN JOINT NO, 008 IN TANK FARM AREA. PAINT SYSTEM APCS - 11A INSPECTION OF INSTALLED INSULATION PRIOR TO START CLADDING OR WEATHER PROTECTION FOR J89-150S - 08" HIGH PRESSURE FLARE LINE IN FLARE AREA. VISUAL RECEIVING INSPECTION AND DOCUMENT VERIFICATION OF INSULATION MATERIALS.
SATIP-E-004-01 SATIP-N-110-01 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02 SATIP-H-100-01
SAIC-E-2002 SAIC-N-2020 SAIC-L-2017 SAIC-A-2009 SAIC-A-2015 SAIC-L-2017 SAIC-A-2015 SAIC-A-2009 SAIC-L-2017 SAIC-A-2009 SAIC-A-2015 SAIC-A-2018 SAIC-A-2018 SAIC-H-2028
other SAES ScheduleQ ScheduleQ ScheduleQ ScheduleQ ScheduleQ ScheduleQ ScheduleQ ScheduleQ ScheduleQ ScheduleQ SAEP SAES
32-SAMSS007 SAES-N-100 Schedule Q Schedule Q Schedule Q Schedule Q Schedule Q Schedule Q Schedule Q Schedule Q Schedule Q Schedule Q SAEP-1150 SAES-H-100
As per SAIC As per SAIC 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 8.9.1
3062 3063 3064
SAES SAES SAES
SAES-H-100 SAES-H-100 SAES-H-100
3065
SATIP-N-001-02
SAIC-N-2015
SAES
SAES-N-001
3066
SATIP-N-001-02
SAIC-N-2004
SAES
SAES-N-001
3067
POST WELD JOINT INSPECTION FOR THE FOLLOWING DRAWINGS RB-743924-004-002,6" JOINT# 13,10,11,12 RB743924-007-01,6" JOINT# 21,13,14,15,18,11,12,24 RB-743924006-02,6" JOINT# 32 RB-744488-005-00,6" JOINT# 06,5,4 RB-744552-001-01,6" JOINT# 20,21 RB-744351-009-01,4" JOINT#10 RB-744806-001-001,8" JOINT# 2 rb-743924-004002,6" JOINT# 10,11,12 Visual Inspection and material verification of 4"CL300 - (i)Gate Valves -06 pcs. with Serial#26491-070-6;26491-070-13;26491070-24;26491-070-26;26491-070-40;26491-070-43. (ii)Check Valves -05 pcs. with Serial#26491-290-1;26491-290-2;26491290-9;26491-290-16;26491-290-18. Flushing and internal cleanliness for Loop 46 visual Inspection at Test Pressure for Loop 46 Visual Inspection at Test Pressure for Loop 47 HYDROTESTING OF TIE IN 003A
SATIP-W-011-01
SAIC-W-2007
SAES
SAES-W-011
11.6
3068
SATIP-L-108-01
SAIC-L-2040
SAES
SAES-L-108
8.3
3069 3070 3071 3072
SAIC-L-2017 SAIC-A-2015 SAIC-A-2015 SAIC-A-2015
SAES SAES SAES SAES
SAES-A-004 SAES-A-004 SAES-A-004 SAES-A-004
3073
Visual Inspection at Test Pressure for under ground 12" fire water line FW-5526 section 5 loop 95
SATIP-A-004-03
SAIC-A-2015
SAES
SAES-A-004
3074
Filling and Pressurization of loop no.102,subsystem no.84-FBP1. Visual Inspection at Test Pressure for under ground fire water line 12"-FW-5526 section 1 Loop 95 Visual Inspection at Test Pressure for loop # 92 Internal Cleanliness or Flushing for loop # 092
SATIP-A-004-02
SAIC-A-2013
SAES
SAES-A-004
3075
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3076 3077
SATIP-A-004-02 SATIP-A-004-02
SAIC-A-2021 SAIC-L-2017
SAES SAES
SAES-A-004 SAES-A-004
3078
Visual Inspection at Test Pressure for loops # 62C and 62D
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3079
Visual Inspection at Test Pressure for loops # 62B and 01B
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3080
Visual Inspection at Test Pressure for loops # 62B and 62D
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3081 3082 3083 3084
Visual Inspection at Test Pressure for loop # 03A Visual Inspection at Test Pressure for loop # 52 Visual Inspection at Test Pressure for loop # 106 Internal Cleanliness or Flushing for loop 20.
SAIC-A-2015 SAIC-A-2015 SAIC-A-2015 SAIC-L-2017
SAES SAES SAES SAES
SAES-A-004 SAES-A-004 SAES-A-004 SAES-A-004
3085
Internal Cleanliness and Flushing by air blowing for Loop 20
SATIP-A-004-02
SAIC-L-2017
SAES
SAES-A-004
3086
Internal Cleanliness or Flushing FO LOOP 7
SATIP-A-004-02
SAIC-L-2017
SAES
SAES-A-004
3087
Visual Inspection at Test Pressure for loop 7 Internal Cleanliness and Flushing for Loop No. 098A Pre-Test Punch Listing, Loop No. 102 line No. 2"-S-5193 feed and surge area
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3088
SATIP-A-004-02
SAIC-L-2017
SAES
SAES-A-004
3089
SATIP-A-004-02
SAIC-A-2010
SAES
SAES-A-004
3090
Inspection of Surface Preparation and Prior to Application of liquid coating systems (New Installations)for piping spools system 1B, 11A
SATIP-H-100-01
SAIC-H-2027
SAES
SAES-H-100
3091
Inspection of intermediate coating Inspection of Repair/Touch-up of Coating system APCS-1B 3rd coat for Loop 96A and 2nd/3rd coat for Loop 96B.
SATIP-H-100-01
SAIC-H-2029
SAES
SAES-H-100
3092
SATIP-H-100-01
SAIC-H-2032
SAES
SAES-H-100
3093
Inspection of Surface Preparation and Prior to Application of liquid coating systems
SATIP-H-100-01
SAIC-H-2027
SAES
SAES-H-100
3094 3095 3096
Install the mounted valves 16" on the piping of the metering skid (RTJ flange valves) (Gate) Documents reviewing only of Loop No.096 of sub-system No. 84FBP-2. Valve Installation and flange tighting inspection before backfilling. Field hydrostatic testing of 2 valves RTR 12" #300 body and seat prior to installation at open yard of warehouse of Enppi at site (required for tie in 3A & 42A) 16" 900# gate valve field hydrotest
SATIP-L-108-01 SATIP-L-350-01 SATIP-L-108-01
SAIC-L-2043 SAIC-A-2010 SAIC-L-2043
SAES SAES SAES
SAES-L-108 SAES-L-150 SAES-L-108
3097 3098
SAES SAES
SAES-L-108 SAES-L-108
3099
Field hydrostatic RE-testing of valve seat prior to installation for (1) 8" Carbon Steel (LCB) Globe valve # 150 S No.: 93503. Where the other valves of RFI No. 3316 (serial No 93625, 93624 and 93502 are tested and passed) Field hydrostatic testing of valves prior to installation for (1) 16" Carbon Steel (WCB) Gate valve # 600 S No.: 93566, 93567, 93565, 93562, 93475, 93561, 93476, 93477, 93474, 93564, and 93563. (2)10" Carbon Steel (WCB) Gate valve # 600 S No.: 93472, and 93473. Piping Re-instatement for loops # 112,055,081 and 035
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3100
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3101
SATIP-L-350-01
SAIC-L-2022
SAES
SAES-L-350
3102
Piping Re-instatement for loops # 122,93,78,10
SATIP-L-350-01
SAIC-L-2022
SAES
SAES-L-350
3103
Verification of Insulation Materials - Documentation and Visual Receiving Inspection for HOT INSULATION
SATIP-N-001-02
SAIC-N-2004
SAES
SAES-N-001
3104
Verification of Insulation Materials - Documentation and Visual Receiving Inspection of rockwool pipe section.
SATIP-N-001-02
SAIC-N-2004
SAES
SAES-N-001
3105 3106
To proceed for RT requests # 4, 5, 6, 8 and the relevant balance. to proceed RT for requests 4,5,6,8 and 10 and their balance. Weld visual inspection for CS, LTCS joints "ongoing daily activity"
SATIP-NDE-RT-01 SATIP-NDE-RT-01
SAIC-RT-2007 SAIC-RT-2007
SAEP SAEP
SAEP-1143 SAEP-1143
3107
SATIP-W-011-01
SAIC-W-2007
SAES
SAES-W-011
3108
Weld visual inspection for CS, LTCS joints "ongoing daily activity"
SATIP-W-011-01
SAIC-W-2007
SAES
SAES-W-011
3109
Inspection on fit up joints at site "on going daily activity"
SATIP-W-011-01
SAIC-W-2005
SAES
SAES-W-011
3110
Post-Welding Visual Inspection for site welds "ongoing daily activity" Performing PWHT on line P-5057 material API Gr X60 with thickness 22 mm Performing PWHT on line P-5057 material API Gr X60 with thickness 22 mm Post Weld Heat Treatment Inspection .
SATIP-W-011-01
SAIC-W-2007
SAES
SAES-W-011
3111 3112 3113
SAES SAES SAES
SAES-W-011 SAES-W-011 SAES-W-011
3114
Pre-Welding and Weld Joint Fit-Up Inspection
SATIP-W-011-01
SAIC-W-2005
SAES
SAES-W-011
3115
Post-Welding Visual Inspection for line # 8-W-5905-6CS9P, 2W-5923-1CS9P, 3-W-5922-1CS9P
SATIP-W-011-01
SAIC-W-2007
SAES
SAES-W-011
3116
Pre-Welding and Weld Joint Fit-Up Inspection 0.5" & 3/4" DIA Hot & cold water piping
SATIP-W-011-01
SAIC-W-2005
SAES
SAES-W-011
3117
Pre-Welding and Weld Joint Fit-Up Inspection for line # -VG033,34,35,36-1CS9P
SATIP-W-011-01
SAIC-W-2005
SAES
SAES-W-011
3118
Date: 18th to 20th Aug 2009, Time: 07:00am to 05:00pm, Holiday test for Fire Hydrents and Fire Monitors Nut and Bolts @ UGOSP-08
SATIP-H-002-06
SAIC-H-2016
SAES
SAES-H-200
3119
Date: 10th Sep 2009, Time: 09:10am to 05:30pm, Hydrotest for Plant Piping Preparation @ 418-RL-002,418-P-002 @ GOSP-07
SATIP-A-004-02
SAIC-A-2011
SAES
SAES-A-004
3120
Date: 30th Aug 2009, Time: 07:00am to 05:00pm, Inspection of pressure test preparation @ TP-419-SW-008 at GOSP-08
SATIP-A-004-02
SAIC-A-2011
SAES
SAES-A-004
3121
TO START-TOUCH-UP ACTIVITIES ON WELD JOINTS OF ELECTRICAL CABLE TRAY SUPPORTS @ B-22 PIPE RACK FROM 3MARCH-2008 TO 9-MARCH-2008(ONE WEEK).THIS RFI IS ISSUED FOR INFORMATION ONLY INSPECTION FOR SURFACE PREPARATION/PROFILE CHECK OF PIPE SUPPORTS/GUIDES TO BE PAINTED APCS-26 AS PER ATTACHMENT FINAL INSPECTION FOR COATING/DFT CHECK OF PIPE SUPPORTS/GUIDES PAINTED APSC-26 AS PER ATTACHMENT
SATIP-H-100-01
SAIC-H-2032
SAES
SAES-H-100
3122
SATIP-H-100-01
SAIC-H-2027
SAES
SAES-H-100
3123
SATIP-H-100-01
SAIC-H-2031
SAES
SAES-H-100
3124
(8"-CL300-GATE VALVE- ITEM NO: 149- QTY: 03NOS) (6"-CL150GATE VALVE- ITEM NO: 84- QTY: 07NOS) (6"-CL150-GATE VALVE- ITEM NO: 43- QTY: 01NO) (2"-CL150-GATE VALVEITEM NO: 50- QTY: 01NO)
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3125
20"-CL150-BALL VALVE-ITEM # 32-QTY: 02 NOS.
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3126 3127
INSPECTION OF EQUIPMENT ALIGNMENT AND LEVELING FOR HP FLARE PUMP B25-G-0050. INSPECTION OF EQUIPMENT ALIGNMENT AND LEVELING FOR LP FLARE PUMP B25-G-0021. INSPECTION FOR SURFACE PREPARATION/PROFILE CHECK OF PIPE SUPPORTS/GUIDES TO BE PAINTED APCS-26 AS PER ATTACHMENT FINAL INSPECTION FOR COATING/DFT CHECKING OF PIPE SUPPORTS/GUIDES PAINTED APCS-26 AS PER ATTACHMENT VALVE TESTING INSPECTION OF 30" CLASS 900 M.O.V.(MOTOR OPERATED VALVE).. QTY 1NO...BODY SERIAL NO. G8438...TAG NO. B22-MOV-6462 VALVE TESTING INSPECTION OF 8" CLASS 150, GATE VALVE, QTY 3NOS...ITEM NO. 241..TAG NO. 6521019041
SATIP-G-005-01 SATIP-G-005-01
SAIC-G-2021 SAIC-G-2021
other other
31-SAMSS004 31-SAMSS004 SAES-H-100
3128
SATIP-H-100-01
SAIC-H-2027
SAES
3129
SATIP-H-100-01
SAIC-H-2031
SAES
SAES-H-100
3130
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3131
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3132
VALVE TESTING INSPECTION OF 16", CLASS 900, NON SLAM CHECK VALVE, QTY 1NO....TAG NO. SP-003...ITEM NO. 19...SERIAL NO. A1855
SATIP-L-108-01
SAIC-L-2042
SAES
SAES-L-108
3133
MATERIAL RECEIVING INSPECTION OF ANCHOR BOLTS,NUTS AND WASHER FOR MISC. PIPE SUPPORT FDN AND EQUIPMENT FDN(DIAM.1"-1-1/4")A-36 QTY=188PCS. 1.)1"X130X570-36PCSTPI=8-PO NO. 175151 2.)1"-X120X560-68PCS-TPI=8,PO NO.175143. 3.)1-1/4"X190X1000-84 PCS-TPI=7,PO NO.175225.
SATIP-M-001-01
SAIC-M-2021
other
12-SAMSS007
3134
Inspection of Pressure Test Preparation, for LUBE OIL LINE @ CGT 2 Lube Oil Bulk Tank,(SATIP-A-004-02),(SAIC-A-2011),Test Package No. B24-A-BD-202075-081.
SATIP-A-004-02
SAIC-A-2011
SAES
SAES-A-004
3135
Visual Inspection at Test Pressure,for LUBE OIL LINE @ CGT 2 Lube Oil Bulk Tank,(SATIP-A-004-02),(SAIC-A-2015),Test Package no.B24-A-BD-202075-081.
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3136
Inspection Of Pressure Test Preparation for Fin Fan Cooler @ CGT # 3,(SATIP-A-004-02),(SAIC-A-2011), Test Package NO. B24-A-BD-202075-135. Visual Inspection at Test Pressure for Fin Fan Cooler @ CGT # 3,(SATIP-A-004-02),(SAIC-A-2015),TEST PACKAGE NO.B24-A-BD202075-135. Inspection for Access Structure Installation for Day Fuel Tank Access Structure. Joint preparation of 6" dia CLS pipe connection of 11 degrees elbow
SATIP-A-004-02
SAIC-A-2011
SAES
SAES-A-004
3137
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-A-004
3138
SATIP-M-001-01
SAIC-M-2010
SAES
SAES-M-001
7.1.8.5
3139
SATIP-L-350-07
SAIC-L-2075
SAES
SAES-H-002
APCS 103 para 2e
3140
Final Pump/Driver Alignment FOR SHIPPER PUMP D74-G-401D
SATIP-G-005-01
SAIC-G-2022
other
31-SAMSS004
1 & 2.5
3141
Material Inspection for 2"GT valve at the fabrication yard Dammam.
SATIP-L-108-01
SAIC-L-2040
SAES
SAES-L-108
8.3
3142
PIPE LAYING OF 2" BLOWDOWN LINE ALONG EXISTING PIPEWAY Inspection and close out of item no.73, of SAPID-EIL-Rev.2, for Hydrotesting of drain line 2"-D-0203-1CS9P. Material Receiving Inspection Of Hex Bolt, Nuts & Washers.
SATIP-L-350-01
SAIC-L-2011
SAES
SAES-L-310
3143
SATIP-A-004-02
SAIC-A-2003
SAEP
SAEP-1160
3144
SATIP-M-001-01
SAIC-M-2021
other
12-SAMSS007
4.1.1
3145
Installation Of 5th Shell Course (Surveillance). Note Please: As their is no activity & SAIC available in SATIP-W-017-01. Holiday Testing OF FLOW LINE TO BE BURIED IN WATER WELL HEAD# 674 Holiday Testing FOR FLOW LINE TO BE BURIED IN WATER WELL HEAD # 672 HYDRO TEST OF DRAIN LINE OF WATER WELL HEAD # 644, HAVING DIAMETER 3" HYDRO TEST OF DRAIN LINE OF WATER WELL HEAD # 646, HAVING DIAMETER 3". HYDRO-TEST OF OIL WELL HEAD PIPING # 104 @ 11:00AM AND OIL WELL # 106 @ 3:00PM.
SATIP-W-017-01
SAIC-W-2085
ScheduleQ
Schedule Q
1.3
3146
SATIP-H-002-02
SAIC-H-2016
SAES
SAES-H-200
3147
SATIP-H-002-02
SAIC-H-2016
SAES
SAES-H-200
3148
SATIP-A-004-02
SAIC-A-2015
ScheduleQ
Schedule Q
1.3
3149 3150
SATIP-A-004-02 SATIP-A-004-02
ScheduleQ SAES
Schedule Q SAES-L-150
1.3 7&8
3151
Piping stringing & pipe laying inspettion .The time is 2:30PM. Receiving inspection pipeline materials at worksite and site office yard.
SATIP-L-450-04
SAIC-L-2132
SAES
SAES-H-200 01-SAMSS035
5.3
3152
SATIP-L-450-04
SAIC-L-2112
other
3153
Pre-Punch Listing of On-Plot Piping. Test Package No.TP-R81-C40791
SATIP-A-004-02
SAIC-A-2003
SAEP
SAEP-1160
3154
AIR BLOWING OF THE FOLLOWING SPOOLS. RB-59788603A,03B. TOTAL= 2 SPOOLS.
SATIP-L-350-01
SAIC-L-2017
ScheduleQ
Schedule Q
1.3
3155
AIR BLOWING OF THE FOLLOWING SPOOLS. RB-59791001A,01B,01C RB-597912-01A,01B. TOTAL= 5 SPOOLS
SATIP-L-350-01
SAIC-L-2017
SAES
SAES-L-350
15.3.2
3156
PRE-APPLICATION INSPECTION OF COLD INSULATION. REMARKS: RD-583374-001 & RD-583375-001. EXCLUDING WELD JOINTS AND PIPE SHOE
SATIP-N-001-01
SAIC-N-2006
SAES
SAES-N-001
3157
TESTING OF MANIFOLD TM-01,TM-02,TM-03
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-L-108
4.7.5
3158
INSL-081, RECEIVING INSPECTION OF COLD INSULATION MATERIALS. INSL-134,Verification of Insulation Materials Visual Receiving Inspection.
SATIP-N-001-01
SAIC-N-2004
SAES
SAES-N-001
1.2
3159
SATIP-N-001-01
SAIC-N-2004
SAES
SAES-N-001
1.2
3160
Material Receiving Visual Inspection of Adapter Plates for the Shipping Pump Motors - Revamp. SP Doc # 21625
SATIP-G-005-01
SAIC-G-2002
SAES
SAES-G-005
4.1
3161
HYDROTEST WITNESS FOR TIE-#004 496-01-56"-TW9576/9573/9570/9612/9613/9614/9615/963/9644-6LEOP(BC871510.001.00; BC-871510.002.00A: BC-871509.001&2 0F1/871513.0010F1871514.001.0F1; 871515.001.0F1; 571516.001.0F1871525.001.00; 871526.001.00
SATIP-A-004-02
SAIC-A-2015
SAES
SAES-L-150
7.3
3162
Material Receiving Visual Inspection of Portable Fire Extinguishers - Water Type, 2.5 Gal (9.46 Ltrs) Capacity, UL Rated, Model: WP-61, Make:Badger; CO2 Type 4.5 Kgs Class "C", Model: B-10V, Make: Badger; Dry Chemical Type, 12.2 Kgs Class "A, B, C", Model: I-K-30G, Make: ANSUL USA UL Listed FIRST ALIGNMENT WITH PIPING LOOSEN (COLUMN BOTTUM PUMP AO-DEK-038851R3&496-31-C002-00390-SH-01-0; 496-G2401 FBE GRITH WELD COATING SURFACE PREPARATION AND FINAL INSPECTION 496-01-TW-9565/90 60 FW#01,01A,01B.,04 2 FW # 02A,03A, INT&EXT G/W COATING NEAR SHIPPING PUMP INSPECTION OF DFT MEASUREMENT 1" DIA SS STEEL RANDOM PIPE WELD JOINT FOR INSTRUMENT AIR, L # 496-01A -9171 90; DRW# BC -868810 WELD JOINT NO . 6 , 7, 8,9,10,11,12,13,14, 14A, 15,16,17 ,18,19,20,21
SATIP-B-019-01
SAIC-B-2011
SAES
SAES-B-019
4.1
3163
SATIP-G-005-01
SAIC-G-2004
ScheduleQ
Schedule Q
A VI Table 2
3164
SATIP-H-002-02
SAIC-H-2014
SAES
SAES-H-201
7.2.1
3165
SATIP-W-011-01
SAIC-W-2015
SAEP
SAEP-1160
6.1
3166
Material Receiving Visual Inspection of GASKETS - RED RUBBER, Size 16 & 24 Dia., 50-60 Shore A; SPIRAL WOUND Graphite SS316L Inner/Outer Ring, 3 Dia & SYNTHETIC FIBER/NITRILE Blue, 3 Dia SP Doc #: 23574
SATIP-L-350-01
SAIC-L-2007
SAES
SAES-L-109
12.3.1
3167
HYDRO-TEST WITNESS FOR TEST NO 221; 496-20-2-C-0180/201PUOU HYDRO-TEST WITNESS FOR TEST NO 222; 496-20-2-C-0188/201PUOU . MOUNTING PLATE (BASE PL. & SOLEPL. INSTALLATION & LEVELLING LIFTING PUMP 496-G-3302; H-82435-D
SATIP-A-004-02
SAIC-A-2003
SAEP
SAEP-1160
3168
SATIP-A-004-02
SAIC-A-2003
SAEP
SAEP-1160
3169
SATIP-G-005-01
SAIC-G-2021
ScheduleQ
Schedule Q
1.7
3170
SERVICE TEST WITNESS FOR TEST NO 1150 496-01-A9007/8998/8995/9004-1CGOU (BC-871219.1,2-0F1, 871210.010F2 / 871207.01-0F1A/871216.01-02R-0F1)
SATIP-A-004-02
SAIC-A-2015
ScheduleQ
Schedule Q
1.3
3171
WELD VISUAL INSPECTION 496-D-6101, 496-D-6102 OLAYAN STORE
SATIP-W-011-01
SAIC-W-2007
ScheduleQ
Schedule Q
1.3 and attachment IV 1.2.3
3172
INSPECTION OF SUPPORT FOUNDATION PRIOR TO STRUCTURAL INSTALLATION
SATIP-M-001-01
SAIC-M-2006
other
12-SAMSS008
Sec 1
3173
INSPECTION OF SURFACE PREPARATION AND PAINT APPLICATION FOR PIPE STRUCTURAL SUPPORTS.
SATIP-W-011-01
SAIC-W-2007
ScheduleQ
Schedule Q
5.1
3174
MATERIAL RECEVING INSPECTION OF 30" OCT. RING GASKET AS PER LMRR - 603.
SATIP-L-350-01
SAIC-L-2007
ScheduleQ
Schedule Q
1.3
3175
MATERIAL RECEVING INSPECTION OF 30" OCT. RING GASKET AS PER LMRR-590-1. RECEIVING INSPECTION OF REDUCING FLANGE CLASS 150, A105N 4"X1"; REDUCING FLANGE #150, A105N 4"X2"; WELDING BOSS, #3000 SW, A182 F316L 4"X1". FOR LINE NUMBER 4"-IA-5336-1CG0U-N PRE WELDING INSPECTIONFOR INTER CONNECTING PIPING 3"ACS-130-10A31.07 SHEET # 8/9 (VENDOR SUPPLY-NUOVO PIGNONE) Verification of testing equipment prior to hydro test. RECEIVING INSPECTION OF WALKWAYS AND STAIRS AROUND CGT AND SKID @4001 AS PER THE MMR NO:237 Filling & pressurization inspection of prior to hydro test.
SATIP-L-350-01
SAIC-L-2007
ScheduleQ
Schedule Q
1.3
3176
SATIP-L-350-01
SAIC-L-2006
SAES
SAES-L-350
6.2
3177 3178 3179 3180
SATIP-W-011-01 SATIP-A-004-02 SATIP-M-001-01 SATIP-A-004-02
SAIC-W-2005 SAIC-A-2009 SAIC-M-2004 SAIC-A-2009
ScheduleQ SAES other SAES
Schedule Q SAES-A-004 12-SAMSS007 SAES-A-004
1.3 5.5.1 6.3.2 5.5.1
3181
CHECKING Final bolt tightening inspection for the steel structural of CD 520HIT HAT DRYER
SATIP-M-001-01
SAIC-M-2009
ScheduleQ
Schedule Q
A IV Para 2
3182 3183 3184 3185
RECEIVING INSPECTION OF FABRICATION STEEL AND WALKWAY AND STAIRS AROUND CGT AND SKID @5001 AS PER THE MMR NO:237 Verification of testing equipment prior to hydro test. Filling & pressurization inspection of prior to hydro test. Visual Inspection of hydro test for fire fighting water lines.
SATIP-M-001-01 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02
SAIC-M-2004 SAIC-A-2009 SAIC-A-2009 SAIC-A-2009
other SAES SAES SAES
12-SAMSS007 SAES-A-004 SAES-A-004 SAES-A-004
6.3.2 5.5.1 5.5.1 5.5.1
3186
PRE TEST PUNCH LISTING AND LINE CHECKING FOR PRIOR TO HYDRO TEST OF TP-034&35 & LINE NO-1"-RL4736,4737,4904,4905.
SATIP-A-004-02
SAIC-A-2010
SAEP
SAEP-1160
3187 3188 3189 3190
In-Process & Post-Weld Inspection Of 6"-LO-4805 & 2"-LO-5037 Field Joints BB-650578-001&002 Rev-00F&00G / BB-650582001&002 Rev-00F&00G Internal cleanliness or flushing inspection for prior to hydro test. Visual Inspection of hydro test for fire fighting water lines. Internal cleanliness or flushing for prior to hydro test.
SATIP-W-011-01 SATIP-A-004-02 SATIP-A-004-02 SATIP-A-004-02
SAIC-W-2007 SAIC-A-2009 SAIC-A-2009 SAIC-A-2009
ScheduleQ SAES SAES SAES
Schedule Q SAES-A-004 SAES-A-004 SAES-A-004
5.1 5.5.1 5.5.1 5.5.1
3191
Verification of test preparation and test equipment for pressure testing.
SATIP-A-004-02
SAIC-A-2009
SAEP
SAEP-1160
3192
INSPECTION OF SUPPORT FOUNDATION NEW FUEL GAS K O DRUM PRIOR TO INSTALLATION OF STRUCTURAL STEEL Inspection of Surface Preparation, application of paint and DFT check for relief line 1"-RL-4736-001/002 and 1"-RL-4737001/002. INSPECTION OF SURFACE PREP. & PAINTING OF LIQUID COATING SYS AS PER APCS-26T. HWHD-SWL(42` DIA) KM 13 VALVE STATION IN PROCESS INSPECTION OF FIELD PAINTING/COATING ACTIVITIES BLASTING AND COATING ACTIVITIES FOR PIPESAPCS113,SPOOLS APCS 26T ,APCS-26 & APCS-6 FOR GUARD RAILS AND SUPPORTS Gasket installation and Bolt torquing for surge relief skid.
SATIP-M-001-01
SAIC-M-2006
other
12-SAMSS008 SAES-H-100
3193
SATIP-H-100-01
SAIC-H-2027
SAES
3194
SATIP-H-100-01
SAIC-H-2027
ScheduleQ
Schedule Q
1.3
3195
SATIP-H-100-01
SAIC-H-2028
ScheduleQ
Schedule Q
1.3
3196
SATIP-H-002-11
SAIC-H-2082
ScheduleQ
Schedule Q
1.3
3197
SATIP-L-450-04
SAIC-L-2014
ScheduleQ
Schedule Q
1.3
3198
HYDROTEST FOR 42" AT KM 48+000 FOR SURGE RELIEF SPOOL CLASS # 150
SATIP-A-004-02
SAIC-A-2015
ScheduleQ
Schedule Q
1.3
3199
Replacement Of The Plugs As a Part Of To Close The NCR#049.This RFI On Going Till 23-1-09.
SATIP-E-004-01
SAIC-E-2002
ScheduleQ
Schedule Q
A IV Para 1.2.3
3200
For Final Visual inspection of installation Insulation from ring 01 to ring 04 of crude stabilize columns shell B32-C-0202 Equipment Verification and Visual Inspection of Centrifugal Pumps, B36-G-0004 A/B Pressure Sewer Pump Equipment Verification and Visual Inspection of Centrifugal Pumps. LP 1st Stage Flare Low Point Drain Pump (B37-G-1013 A/B)
SATIP-N-001-02
SAIC-N-2014
ScheduleQ
Schedule Q
1.3
3201 3202
SATIP-G-005-01 SATIP-G-005-01
SAIC-G-2002 SAIC-G-2002
ScheduleQ ScheduleQ
1.3 1.3
3203
Equipment Verification and Visual Inspection of Centrifugal Pumps. LP 2nd Stage Flare Low Point Drain Pump (B37-G-1008 A/B)
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3204
Equipment Verification and Visual Inspection of Centrifugal Pumps; B38-G-0227 A/B HP Flare KO Pot Pump
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3205
Equipment Verification and Visual Inspection of Centrifugal Pumps; B38-G-0205 A/B Methanol Unloading Pump
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3206
Equipment Verification and Visual Inspection of Centrifugal Pumps; B38-G-0226 A/B LP Flare KO Pot Pump
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3207
Equipment Verification and Visual Inspection of Centrifugal Pumps; B38-G-0127 A/B HP Flare KO Pot Pump
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3208
Equipment Verification and Visual Inspection of Centrifugal Pumps; B38-G-0105 A/B Methanol Unloading Pump
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3209
Equipment Verification and Visual Inspection of Centrifugal Pumps; B38-G-0126 A/B LP Flare KO Pot Pump
SATIP-G-005-01
SAIC-G-2002
ScheduleQ
Schedule Q
1.3
3210 3211
Inspection of Support Foundation prior to Equipment Installation / B40-GT-2000 / HRSG-2000 FINAL ALIGNMENT OF STRUCTURAL INSTALLATION--B40,GT3000,GRIDLINE(1-2),ALIGNMENT(A-B"),MODULE,STRUC07A INSPECTION OF BATTERY ROOM BLDG. DRAINAGE&VENT PIPING HYDROTEST--WATER INJECTION FACILITIES B0930 WS1&2 IN PROGRESS WELDING INSPECTION OF BEAM----BOP ABU JIPAN ESPI-----H-BEAM @ GRID LINE 1-4/A-D
SATIP-M-001-01 SATIP-M-001-01
SAIC-M-2006 SAIC-M-2011
other ScheduleQ
12-SAMSS008 Schedule Q
1 1.3
3212
SATIP-S-060-06
SATR-S-4003
ScheduleQ
Schedule Q
1.7
3213
SATIP-M-001-01
SAIC-M-2012
ScheduleQ
Schedule Q
1.3
3214
HYDRSTATIC TEST FOR DRINKING WATER LINE
SATIP-A-004-02
SAIC-A-2015
ScheduleQ
Schedule Q
1.3
3215
GRAVITY TEST INSPECTION FOR 10"DIA RTR DRAIN PIPE LINE MH#01A TO MH#02 JOINT# (FJ-01A TO 14A)10"-D-019780FE0D
SATIP-S-010-01
SATR-S-4001
SAES
SAES-S-070
18.7 and 18.8
3216
IN PROCESS WELDING INSPECTION OF STRUCTURALS(MBR SHELTER ROOF FRAMING) AND PURLINS
SATIP-W-011-01
SAIC-W-2006
ScheduleQ
Schedule Q
1.3
3217
MATERIAL RECEIVING INSPECTION OF CI-CATCH BASIN (TYPE B)WITH 6" OUTLET FOR SEWER DRAIN CONNECTION FOR ALL SITES (X51,X56,X57,X54 & X52)STORED AND LOCATED AT AKS SITE OFFICE LAYDOWN YARD,NRTFF (X56) SURFACE PREPARATION OF INTERNAL PIPE END /JOINTS FOR FIELD FBE INTERNAL COATING PRIOR TO WELDING HOLIDAY TESTING FOR EXTERNAL COATING OF PIPE LINE SPLIT TEE HYDROTEST DFT CHECK ON TOP COAT FOR WORK ACCEPTANCE ON SADDLE SUPPORTS WITH APCS-26T
SATIP-S-030-01
SATR-S-4002
SAES
SAES-S-070
18.8f
3218 3219 3220 3221
SATIP-H-002-08 SATIP-H-002-02 SATIP-A-004-02 SATIP-H-100-01
SAIC-H-2059 SAIC-H-2016 SAIC-A-2015 SAIC-H-2031
SAES SAES SAES SAES
SAES-H-201 SAES-H-200 SAES-L-150 SAES-H-200
sec 1 7 7.3 7
Standard 3
Para3
Is it When it was related to found Design error Construction No
Is it H, W, S
Areas of Concern
Comments on the Logbook
Pipelines
Standard reference is not mentioned
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Hydrotest
Standard para is not mentioned
Material receiving
No
Pipelines
Standard para is not mentioned Standard reference is not mentioned
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Material receiving
No
Pipelines
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NDT
Construction
No
NA
Others
Material receiving
No
Pipelines Coating
Construction Construction Construction
No No No
W H NA
Pipelines Coating No QC Insp
Construction
No
Coating
Construction
No
No RFI
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
Coating
Material receiving Material receiving
No No
W W
Pipelines Pipelines
more than one violations club together
Material receiving
No
NA
Pipelines
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
Welding
Material receiving
No
Hydrotest
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Valves
Construction
No
Welding
Construction
No
No QC Insp
SAES-A-007
4&6
Construction
No
Process Piping
Construction
No
NA
No QC Insp
Construction
No
NA
No QC Insp
Construction
No
NA
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Others
Construction
No
Static Equipment s
Construction
No
Pipelines
Construction
No
Construction
No
Static Equipment s
Construction
No
No RFI
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Hydrotest
Construction
No
Others
Material receiving
No
Valves
Construction
Yes
Hydrotest
Construction
No
Process Piping
Material receiving
No
Valves
Material receiving
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Welding Process Piping
Construction
No
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Hydrotest
Construction
No
No QC Insp
Construction Construction
No No
W W
Welding Welding
Construction
No
Process Piping
Construction
No
Process Piping Process Piping
Standard reference is not mentioned Standard reference is not mentioned
Construction
No
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
NDT
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Valves
Construction
No
No RFI
Construction
No
No RFI
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
NA
Coating
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No RFI
Construction
No
No RFI
Construction
No
No RFI
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
No No No
W W W
No QC Insp Welding Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
No No
W W
Welding Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Rotating Equipment s
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Coating
Construction
No
NA
Others
Construction
Yes
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Static Equipment s
Construction
No
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
No
Valves
Construction
No
Valves
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
NA
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Construction
No
No
Process Piping
No
Welding
Construction
No
Static Equipment s
Construction
No
Welding
Construction
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Hydrotest
No
No QC Insp
Construction
No
Process Piping
Material receiving
No
Process Piping
Material receiving
No
Others
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Construction
No
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
NA
Hydrotest
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
No QC Insp
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Welding
No No
W S
No QC Insp Process Piping Standard reference is not mentioned
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Others
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Material receiving
No
Process Piping
Construction
No
Process Piping
No No
W W
Construction
No
Valves
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
No
Welding
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Valves
Material receiving
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Construction
No
Coating
Material receiving
No
Static Equipment s
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Construction
No
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Others
No
Process Piping
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
No RFI
Construction
No
Others
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Welding
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No RFI
Construction
No
No RFI
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No RFI
Construction
Yes
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Others
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
Yes
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Others
Construction
No
NA
Process Piping
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Material receiving
No
Construction
No
Valves
Construction
No
Process Piping
Construction
No
NA
Process Piping
Construction
No
Welding
Construction
No
Valves
Construction
Yes
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Coating
No No No
H W W
Coating No QC Insp No RFI
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
NA
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
NA
Hydrotest
Construction
Yes
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
328.5.4
Construction
No
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
No No No
W W W
Welding Welding No QC Insp
Construction
No
Hydrotest
Construction
No
Construction
No
Hydrotest
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
No No
W W
Welding No QC Insp Standard reference is not mentioned Standard reference is not mentioned
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
No No
W W
Coating No QC Insp
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
5.1
Construction
No
Coating
Construction
No
No QC Insp
5.1
Construction
No
Coating
5.1
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
No RFI
Construction
No
Valves
Construction
No
Valves
Construction
No
Valves
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Others
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
Welding
No No
W S
Welding No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Static Equipment s
Construction
No
Coating
Construction
Yes
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Others
Construction
No
No QC Insp
Material receiving
No
Others
Material receiving
No
Others
Material receiving
No
Process Piping
Material receiving
No
Others
Construction
No
No QC Insp
Material receiving Material receiving Construction
No
Others
Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
No
Others Process Piping Process Piping Process Piping
No
Construction
No
Construction
No
Construction
No
Process Piping
No No
W W
Process Piping Process Piping Process Piping Others Process Piping Process Piping Process Piping
Standard para is not mentioned Standard para is not mentioned more than one violations club together Standard para is not mentioned more than one violations club together Standard para is not mentioned Standard para is not mentioned
Construction
No
Construction
No
Construction
No
No No
NA W
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
No QC Insp
Material receiving
No
Process Piping
Construction
No
No RFI
Schedule Q
1.7
Construction
No
No RFI
Construction
No
Hydrotest
Construction
No
NA
No QC Insp No QC Insp No QC Insp Standard para is not mentioned Standard para is not mentioned
Construction
No
NA
Construction
No
NA
Construction
No
NA
No QC Insp
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Standard para is not mentioned Standard para is not mentioned
Material receiving
No
No RFI
Construction
No
Others
Construction
No
Hydrotest
Construction
No
Others
Construction
No
Others
Construction
Yes
Others
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
Yes
Process Piping
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Construction
No
Construction
No
Static Equipment s Static Equipment s Static Equipment s Static Equipment s Static Equipment s
Construction
No
Construction
No
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
Yes
Static Equipment s
Construction
No
Static Equipment s Coating
Construction
No
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Material receiving
No
Process Piping
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
Yes
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
Yes
Valves
Material receiving
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Material receiving
No
Coating
Construction
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Material receiving
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Material receiving
No
Static Equipment s
SAES-L350
7.4
Construction
No
Static Equipment s Standard para is not mentioned
Material receiving
No
Others
Construction
No
Coating
Construction
No
Coating
No
Rotating Equipment s Rotating Equipment s
No
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping No QC Insp
Construction
No
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Valves
Construction
Yes
Process Piping
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
Yes
Pipelines
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Welding
No No
W W
Welding No RFI
Construction
No
Coating
Material receiving
No
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
No No No
W S W
Coating Process Piping Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Coating
Construction
No
Coating
Material receiving
No
Static Equipment s
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
No No No
W W W
No QC Insp
more than one violations club together Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
Welding
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Coating
Construction
No
Others
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
8/4/2010
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Others Static Equipment s
Construction
No
Construction
No
Static Equipment s
Construction
No
Valves
Material receiving
No
Valves
Construction
No
Valves
Construction
No
Hydrotest
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Rotating Equipment s Hydrotest
Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
Construction
No
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
Process Piping
Construction
Yes
Process Piping Rotating Equipment s
Construction
No
Construction
No
Welding
Construction
Yes
Process Piping
Construction
No
Static more than one violations club Equipment together s Static Equipment s Welding Standard para is not mentioned Standard para is not mentioned
Construction
No
Construction
No
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Material receiving
No
Pipelines
10/4/2010
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Welding
No
Process Piping
No
Process Piping
Material receiving
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Material receiving
No
Welding
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction Construction Construction Construction
No No No No
NA NA NA NA
Others
more than one violations club together Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
Others No QC Insp
Others
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
NA
Others
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
NA
Others
Construction
No
Process Piping
Construction
No
NA
No QC Insp
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
NA
No QC Insp
Standard para is not mentioned more than one violations club together Standard para is not mentioned
Construction
No
Hydrotest
Construction
No
No RFI
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
NA
No QC Insp
Construction
No
NA
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
Yes
NA
Process Piping
Construction
No
Welding
Construction
No
Others
Construction
No
Hydrotest
more than one violations club together Standard para is not mentioned
Construction
No
No RFI
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
NA
No QC Insp
Construction
No
NA
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
Yes
NA
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
NA
No QC Insp
Construction
No
NA
Others
Construction
No
NA
Others
Construction
No
NA
No RFI
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Others
No No No
S S NA
Coating Coating Standard para is not mentioned
Coating
Construction
No
Coating
Material receiving
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
No QC Insp
Material receiving Construction
No
Others
No
Welding
Construction
No
Process Piping
Construction
No
Construction
No
Construction
Yes
NA
Others
Construction
No
NA
No QC Insp
Construction
No
NA
No QC Insp
13/04/201 0
Construction
No
NA
Others
Construction
No
Welding
Material receiving
No
NA
Others
Construction
No
Welding
Construction
No
Coating
Construction
No
NA
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Others
Construction
No
NA
Welding
Standard para is not mentioned more than one violations club together Standard para is not mentioned Standard para is not mentioned
No No No
NA NA H
Welding
No RFI Process Piping Welding
Construction
No
Construction
No
Welding
No No No
W NA NA
Welding more than one violations club together Standard para is not mentioned
Others No QC Insp
Construction
No
Others
Construction Material receiving Construction
No No
W NA
Welding Others
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
No No
S W
Process Piping Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
No QC Insp
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Welding
No No No
S S W
Welding Process Piping Process Piping No QC Insp
Construction
No
Construction
No
Welding
Standard reference is not mentioned Standard para is not mentioned Standard para is not mentioned
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
NDT
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
No QC Insp
Construction
No
Hydrotest
Construction
No
NDT
Construction
No
Coating
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Process Piping
Standard para is not mentioned Standard reference is not mentioned
Construction
No
Valves
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
NDT
Construction
No
Valves
Construction
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
No RFI
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Welding
Material receiving
No
Process Piping
Construction
No
Process Piping
Material receiving
No
Others
Material receiving
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NDT
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Material receiving
No
Valves
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp Standard reference is not mentioned
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Material receiving
No
Static Equipment s
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
No RFI
Standard reference is not mentioned Standard para is not mentioned Standard reference is not mentioned
Construction
No
No RFI
Construction
No
No RFI Process Piping Process Piping
Construction
No
Construction
No
Construction
No
Coating
No No No
H S W
Hydrotest Process Piping Process Piping
Construction
No
Welding
Construction
No
No QC Insp
No No
H H
Hydrotest No RFI
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
NA
Process Piping
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Pipelines
Construction
No
NA
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Others
Construction
No
NA
Hydrotest
Construction
No
Process Piping
Construction
No
NDT
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
NA
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
NDT
Construction
No
No RFI
Construction
No
Hydrotest
Construction
No
Static Equipment s
Construction
No
Static Equipment s Static Equipment s Static Equipment s
Construction
No
Construction
No
Material receiving
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Static Equipment s Process Piping Process Piping
Construction
No
Construction
No
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Static Equipment s
Material receiving
No
Construction
No
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Static Equipment s Static Equipment s
Construction
No
Material receiving
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping Others
Construction
No
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
Welding
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
Construction Construction Construction Construction Construction
No No No No No
W W S S W
Welding Welding Welding Welding Welding
Construction
No
Others Standard reference is not mentioned
Construction
No
No RFI
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Construction
No
Construction
No
Static Equipment s
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
Static Equipment s Static Equipment s Static Equipment s
Construction
No
Construction
No
Construction
No
Static Equipment s
No No
W W
Valves Valves
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Pipelines
Construction
Yes
Valves
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
No RFI
Construction
No
Others
Construction
No
No QC Insp
Construction
No
NDT
Construction
No
Process Piping
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
Welding
Construction
No
NDT
No No
W H
Others Welding
Construction
No
Welding Standard reference is not mentioned
Construction
No
Others
Construction
No
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
NA
Hydrotest
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Construction
No
Construction
No
Rotating Equipment s Process Piping Process Piping
Construction
No
Construction
No
Construction
No
Coating
Construction
No
Process Piping Valves
Standard para is not mentioned Standard para is not mentioned Standard reference is not mentioned
Construction
No
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
NDT
Construction
No
NDT
Construction
No
Coating
Construction
No
Coating
Construction
No
No RFI
Construction
No
Process Piping
Construction
No
Others
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
No No No No
W S S W
Welding Welding Welding Welding
Standard para is not mentioned Standard para is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
Pipelines
Construction
No
Valves
Construction
No
Valves
Construction
No
Welding
Material receiving
No
Process Piping
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Others
Construction
No
No QC Insp
Material receiving
No
Static Equipment s
Construction
No
Process Piping Welding
Construction
No
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Valves
Construction
No
Valves
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Welding
Construction
No
Process Piping
Material receiving
No
Valves
No No
W W
Valves Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
NA
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
No No
NA W
Welding No QC Insp Standard para is not mentioned
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
NA
Welding
Construction
No
NA
Welding
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Pipelines
Construction
No
Valves
Material receiving
No
Process Piping
Construction
No
No RFI
Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned Standard reference is not mentioned
No No
NA S
Coating No QC Insp
Construction
No
Others
Construction
No
NA
NDT
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
NA
Welding
Material receiving
No
Process Piping
Material receiving
No
Construction
No
Coating
Construction
No
Valves
Construction
No
Welding
Construction
No
Coating
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Material receiving
No
Valves
Construction
No
No RFI
Construction
No
NDT
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
Hydrotest
Construction
No
Others
Construction
No
Valves
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
NA
NDT
Construction
No
No QC Insp
Construction
No
Pipelines
Construction
No
Others
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Valves
Construction
No
Pipelines
Construction
No
Others
Construction
No
Welding
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Pipelines
Construction
No
No RFI
Construction
No
Welding
Construction
No
NDT
Construction
No
NDT
Construction
No
Valves
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Others
Construction
No
NDT
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Others
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Material receiving
No
Others
Construction
No
Coating
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Hydrotest
Construction
No
Valves
Construction
No
NDT
Construction
No
No RFI
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
NDT
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
NDT
Construction
No
Welding
No No No No
W W W W
Welding Welding Welding Welding Standard reference is not mentioned Standard reference is not mentioned
Construction
No
NDT
Construction
No
Hydrotest
Construction
No
No QC Insp
Construction
No
Process Piping
No No No
H W W
Coating Coating Coating
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
Construction
No
Pipelines
Construction
No
Coating
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
No No
W W
Coating Coating
No No No No
W W W W
Coating Coating Process Piping Pipelines
Construction Construction Construction Construction Construction Construction Construction Construction
No No No No No No No No
W W W W W W W W
Pipelines Welding Welding Welding Welding Welding No QC Insp Welding
Construction
No
Welding
No No No No No
W W W W W
Welding Welding Welding Welding No QC Insp
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
Construction
No
Welding
No No No
W W W
No QC Insp Welding Welding
Construction
No
Process Piping
No No
W W
No QC Insp Welding
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
No No
S W
No QC Insp No QC Insp
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
NA
No RFI
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
No QC Insp
No No No
W W W
No QC Insp No QC Insp No QC Insp
Construction
No
Welding
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
NDT
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No RFI
No No No
S S W
Welding Welding No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
No QC Insp
Construction
No
Hydrotest
Construction
No
NA
NDT
Construction
No
No RFI
No No
W W
No QC Insp Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Pipelines
Construction
No
Hydrotest
Standard para is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
Construction
No
Coating Process Piping Valves No QC Insp
Construction
No
No No
W W
Construction
No
No QC Insp
Construction
No
NA
NDT
Standard reference is not mentioned Standard para is not mentioned
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
No RFI
Construction
No
NA
NDT
Construction
No
Coating
Construction
No
Valves
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Coating
Construction
No
Pipelines
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No RFI
Construction
No
Others
Construction
No
Welding
Construction
No
Valves
Construction
No
Hydrotest
Construction
No
Static Equipment s
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Construction
No
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Construction
No
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
NA
NDT
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
Hydrotest
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Construction
No
Construction
No
Construction
No
Construction
No
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
Valves
Construction
No
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Construction
No
Process Piping
Material receiving
No
Valves
Material receiving
No
Valves
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
Yes
Others
Construction
Yes
Others
Construction
No
Others
Construction
No
Valves
MS-D-044
Construction
No
No RFI
MS-D-044
Construction
No
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
Welding
Construction
No
Welding
12/4/2010
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
Yes
NA
Welding
Construction
No
NA
Welding
Construction
No
NA
No QC Insp
Construction
No
Static Equipment s
Construction
No
Static Equipment s
13/04/201 0
Construction
Yes
Valves
Construction
No
Coating Coating
Construction
No
NA
Construction
No
Coating
Construction
No
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Hydrotest
Construction
No
NA
No QC Insp
Construction
No
Welding
14/04/201 0
Material receiving
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
No RFI
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
NA
Valves
Construction
No
Others
Construction
No
Hydrotest
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
NA
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
Static Equipment s
Construction
No
Static Equipment s Static Equipment s Static Equipment s Rotating Equipment s
Construction
No
Material receiving
No
Construction
No
Construction
No
Construction
No
NA
Coating
15/04/201 0
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Valves
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
Valves
Construction
No
Valves
Construction
No
Valves
Construction
No
NDT
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
NA
Hydrotest
Construction
No
Hydrotest
Construction
No
NA
Hydrotest
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Process Piping
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Material receiving
No
NA
Others
Construction
No
Others
Construction
No
Process Piping
Construction
No
NA
Process Piping
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Process Piping
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
NA
Coating
Material receiving
No
Process Piping
Material receiving
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Valves
Construction
No
Valves
Construction
No
Hydrotest
Construction
No
Hydrotest
Proj Spec 496-L-BE866653
Sec 7
Material receiving
No
Process Piping
Material receiving
No
Others
Material receiving
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Others
No No
NA H
Others Others
Construction
No
Hydrotest
22/04/201 0
Construction
No
NA
Others
Construction
No
NA
Others
Construction
No
Others
Construction
No
NA
No QC Insp
Construction
No
NA
No QC Insp
Construction
No
Welding
Schedule Q A IV Para 7.1
Construction
No
Welding
Construction
No
NA
Others
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
NA
Hydrotest
Construction
No
Others
Construction
No
NA
No QC Insp
Construction
No
Hydrotest
Construction
No
Valves
Construction Material receiving Construction
No
NA
Others
more than one violations club together Standard para is not mentioned more than one violations club together Standard para is not mentioned more than one violations club together Standard para is not mentioned more than one violations club together Standard para is not mentioned
No
Others
No
NA
Others
Material receiving
No
Others
Construction
No
NA
Others
Material receiving
No
Others
Construction
No
NA
Others
Material receiving
No
Others
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
Others
Construction
No
Construction
No
NA
No RFI
Construction
No
NA
Coating
No No
W NA
Coating No QC Insp
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating more than one violations club together
25/04/201 0
Construction
No
NA
No RFI
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
No QC Insp
Construction
No
NA
Hydrotest
Construction
No
NA
Process Piping
Construction
No
Process Piping
Construction
No
NA
Others
Construction
No
NA
Construction
No
Construction
No
Process Piping
Construction
No
NA
Others
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
Welding
Construction
No
Process Piping
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Construction
No
NA
Process Piping
Material receiving
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
Static Equipment s
Material receiving
No
NA
No RFI
Material receiving
No
Others
Construction
No
Others
Construction
No
Welding
Construction
No
Process Piping
Construction
No
NA
Welding
Construction
No
NA
Welding
Construction
No
NDT
Construction
No
NA
Welding
Construction
No
NA
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Material receiving
No
Static Equipment s
Material receiving
No
Others
Construction
No
Others
Construction
No
Coating
Material receiving
No
NA
Others
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Pipelines
Material receiving
No
Others
Construction
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
NA
Welding
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
NA
Others
Material receiving
No
NA
Others
Construction
No
NA
Others
Construction
No
NA
Others
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
Yes
Process Piping
27/04/201 0
Material receiving
No
NA
Others
Construction
No
No RFI
Construction
No
Welding
Material receiving
No
NA
Others
Construction
No
Construction
No
NA
Coating
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Construction
No
Material receiving
No
NA
Others
Material receiving
No
NA
Others
Construction
No
NA
No QC Insp
Construction
No
NA
No QC Insp
Construction
No
Others
Construction
No
Welding
No No
Welding Welding
Construction
No
NA
Welding
No No
NA NA
No RFI Others
Construction
No
Coating
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
28/04/201 0
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
NA
Others
Construction
No
Coating
Construction
No
Pipelines
Material receiving
No
Pipelines
Construction
No
Welding
Construction
No
NA
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Coating
29/04/201 0
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Welding
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
No QC Insp
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Welding
Construction
No
NA
No QC Insp
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Welding Standard para is not mentioned
Construction
No
Valves
Construction
No
NA
Coating more than one violations club together
Construction
No
NA
Pipelines
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
NA
Others
Construction
No
Others
Construction
No
Coating
Construction
No
NA
Welding
Construction
No
NA
Coating
Construction
No
NA
Coating
No No No
NA W W
Material receiving
No
NA
Coating
Construction
No
Pipelines
Construction
No
NA
No QC Insp
Construction
No
Pipelines
Construction
No
Pipelines
Material receiving
No
NA
Valves
Construction
No
NA
No RFI
No No
Hydrotest Hydrotest Hydrotest Hydrotest
Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
W
W
No No
Construction
No
Coating
Construction
No
NA
Coating
No No
NA NA
Coating Coating
Construction
No
Coating
Construction
No
Valves
Standard para is not mentioned more than one violations club together
Material receiving
No
NA
Welding
Construction
No
NA
Welding
Construction
No
Welding Welding
Construction
No
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
No No
NA NA
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Pipelines
Construction
No
Welding
Construction
No
NA
Others
Construction
No
Process Piping
Construction
No
NA
Hydrotest
No No No No No
NA W S NA W
No RFI Hydrotest Hydrotest No RFI Hydrotest
Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned more than one violations club together Standard para is not mentioned
Construction
No
NA
NDT
Construction
No
NA
Welding
4/5/2010
Construction
No
Welding
Construction
No
Welding
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Static Equipment s
SAES-A-301
Construction
No
Static Equipment s
Construction
No
Coating
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
NA
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Static Equipment s
Construction
No
Others
Construction
No
NA
Others
5/5/2010
Construction
No
NA
Others
Construction
No
Welding
Construction
No
NA
No RFI
Construction
No
Welding
Construction
No
Welding
Construction
No
Static Equipment s
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Static Equipment s
Construction
No
Construction
No
NA
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Coating
6/5/2010
Construction
No
Process Piping
Construction
No
Valves
Construction
Yes
Process Piping
Construction
No
Hydrotest
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Coating
Material receiving
No
Static Equipment s
Construction
No
Construction
No
NA
Coating
8/5/2010
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Valves
Construction
Yes
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Process Piping
Construction
No
NA
Static Equipment s
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Static Equipment s
Construction
No
NA
Static Equipment s
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
9/5/2010
Construction
No
Process Piping
Construction
No
Others
Construction
No
Static Equipment s
Construction
No
Others
Construction
No
Others
Material receiving
No
Static Equipment s
Construction
No
NA
Coating
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
No No
W W
Welding Others
Construction
No
Others
Material receiving
No
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Hydrotest
Construction
No
Hydrotest
PIP INSH1000
Para. 4.2.6, Para. 4.2.10.
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
NA
Others
Construction
No
Welding
No No No
W H H
Welding Hydrotest Welding more than one violations club together Standard para is not mentioned
Construction
No
NA
Others
Construction
No
NA
Welding
Construction
No
Process Piping
10/5/2010
Material receiving
No
NA
Coating
Construction
No
NA
No QC Insp
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
Process Piping Coating Standard para is not mentioned
Construction
No
NA
Construction
No
Coating
Construction
No
NA
No RFI No QC Insp No RFI No QC Insp Hydrotest
more than one violations club together Standard para is not mentioned more than one violations club together Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned Standard para is not mentioned
No No No No
NA NA NA NA
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Hydrotest
Construction
No
Others
Construction
No
Welding
Construction
No
NA
Welding
No No No
W NA W
Welding Welding Welding Welding Standard para is not mentioned
Construction
No
Construction
No
Welding
No No No No
NA NA W W
No RFI Welding Welding No RFI Welding Welding Welding Welding Welding No QC Insp
Construction Construction Construction Construction Construction Construction
No No No No No No
W W S W NA NA
Construction
No
Welding
No No No
NA NA W
No RFI No QC Insp Welding
more than one violations club together Standard para is not mentioned Standard para is not mentioned
Construction
No
Others
Construction
No
Others
Construction
No
NA
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Others
Construction
No
No RFI
Construction
No
Construction
No
No QC Insp
Material receiving
No
Static Equipment s
Material receiving
No
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
Others
Construction
No
NDT
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
NA
Hydrotest
Construction
No
Others
Construction
No
Hydrotest
Material receiving
No
Process Piping
Material receiving
No
Static Equipment s
Material receiving
No
Valves
Construction
No
Process Piping
Construction
No
Others
Construction
No
Valves
Construction
No
Valves
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Construction
No
Hydrotest
Construction
No
NA
Coating
Construction
No
Welding
Construction
No
Coating
Construction
No
Valves
Construction
No
Others
Construction
No
Coating
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Welding
Construction
No
NDT
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Construction
No
Construction
No
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
No No No No
W W W H
No QC Insp Welding Welding No RFI
Construction
No
Coating
Construction
No
NA
Coating
Construction
No
Others
Construction
No
Hydrotest
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
NA
Hydrotest
Construction
No
No RFI
No No
W H
Pipelines Coating Standard reference is not mentioned
Construction
No
Hydrotest
Construction
No
Others
Construction
No
NA
Others
Construction
No
Hydrotest
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Static Equipment s
Construction
No
Construction
No
Construction
No
Construction
No
Construction
No
Coating
Construction
No
Coating
No No No
NA W W
Coating No QC Insp Coating
Construction
No
No QC Insp
Construction
No
NA
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Construction
No
Construction
No
Valves
Construction
No
Hydrotest
Construction
No
Process Piping
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
No No
W S
Valves Process Piping
Construction
No
Valves
Construction
No
Construction
No
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Welding
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Construction
No
Process Piping
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Others
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Valves
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Process Piping
Material receiving
No
Process Piping
Material receiving
No
Process Piping
Construction
No
Process Piping
Material receiving
No
Coating
Material receiving
No
Material receiving
No
Process Piping
Material receiving
No
Process Piping
Material receiving
No
Process Piping
Material receiving
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NDT
SAEP-1160
Sec 6
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
No No
W W
Welding Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Static Equipment s Static Equipment s Static Equipment s Static Equipment s Welding
Construction
No
Construction
No
Construction
No
Construction
No
No No
W W
Welding Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
NDT
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Standard reference is not mentioned .
Construction
No
Others
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
No QC Insp
No
NDT
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Process Piping
Material receiving
No
Process Piping
Construction
Yes
Process Piping
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Others
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
No RFI
No No
H W
Coating Hydrotest Standard reference is not mentioned
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
Hydrotest
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Hydrotest
Construction
No
Valves
Construction
No
Welding
Construction
No
Coating
Construction
No
Pipelines
Construction
No
Process Piping
No No No
W W W
No QC Insp Process Piping Process Piping
Construction
No
Process Piping
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Pipelines
Construction
No
NA
Welding
Construction
No
Welding
No No No
W S W
No QC Insp Pipelines Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Standard para is not mentioned Standard para is not mentioned Standard reference is not mentioned
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Welding
No No
W W
Welding Welding
Construction
No
No QC Insp
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
No No No
W S W
No QC Insp Pipelines Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Hydrotest
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
Pipelines
Standard para is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
No No No
NA NA NA
NDT NDT NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
NA
NDT
Construction
No
Pipelines
Construction
No
NA
NDT
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
NA
Welding
Construction
No
NA
Welding
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
Pipelines
Construction
No
NDT
Construction
No
Welding
Construction
No
NDT
Construction
No
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
NA
NDT
Construction
No
NDT
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
Welding
Construction
No
Process Piping
Construction
No
Welding
Construction
No
Welding
Construction
No
NA
Welding
Construction
No
Coating
Construction
No
Coating
Construction
No
NA
Others
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
Coating
Construction
No
Coating
Construction
No
Process Piping
Construction
No
No QC Insp
Construction
No
Process Piping
Construction
No
Valves
Construction
No
Valves
Construction
No
Process Piping
Construction
No
Process Piping
Construction
No
NA
Hydrotest
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Others
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
No QC Insp
Construction
No
Coating
Construction
No
No QC Insp
Construction
No
No RFI
Construction
No
Welding
Construction Construction Construction Construction Construction Construction
No No No No No No
S S S W W S
Welding Welding Welding Welding No RFI Welding
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
No No
S W
Welding Welding
Construction
No
Welding
Construction
No
Welding
No No No
H S W
Coating Pipelines Welding
Construction
No
Welding
Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned Standard reference is not mentioned
Construction Construction Construction Construction Construction Construction Construction
No No No No No No No
S S W S W S W
Welding Welding Welding Welding No RFI Welding No QC Insp
Construction
No
Welding
Construction
No
Welding
No No No
W S W
Welding Welding Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Welding
Construction
No
Pipelines
Construction
No
No QC Insp
Construction
No
Pipelines
Construction
No
Pipelines
Construction
No
Process Piping
Construction
No
No QC Insp
No
NDT
Construction
No
Pipelines
Material receiving
No
Process Piping
Material receiving
No
Process Piping
Material receiving
No
No RFI
Material receiving
No
No QC Insp
Construction
No
Others
Construction
No
No QC Insp
No
NDT
Construction
No
Others
Construction
No
No QC Insp
Construction
No
No QC Insp
Construction
No
Hydrotest
Construction
Yes
No QC Insp
Construction
Yes
No QC Insp
Construction
Yes
No QC Insp
Construction
Yes
Welding
Support foundation for this vessel was rejected (RFI# 23029) and the installation of vessel on unreleased foundation is the violation of SATIP-D001-01.This RFI is rejected. This foundation was rejected before and violations (QMIS entry # 31162) still open it. RFI is rejected, please submit RFI after resolution and SAPID approval is required if any modification or rework is to be performed. RFI is rejected, please submit RFI after resolution and SAPID approval is required if any modification or rework is to be performed. W No lay-up conducted hence this RFI is rejected. There is no lay-up conducted after hydro test, hence this RFI is rejected. No lay-up conducted after hydro test, hence this RFI is rejected. The RFI rejected as the job was not ready for Inspection
The piping strain after tightening of the bolts for suction and discharge flanges found to be not in the permissible limits. Hence ,the RFI is rejected Other lines without soft seated valves in line are acceptable. Lines with in line soft seated valves during blowing are violations. No hydrotest was done. Submit new RFI after hydrotest. This RFI is rejected. No hydrotest was done and no lay-up conducted. This RFI is rejected. Submit new RFI when ready.
H H H
rejected due to leakage of two joints rejected due to leakage of two joints rejected due to leakage of 5 socketweld joints rejected due to leakage of 5 socket weld joints
rejected due to leakage of 5 socket weld joints Installation of demister pad for the drum need to be verified for tieing between the segments and internal cleanliness. Hence contractor has to make necessary arrangements to enalbe us to inspect the demister through nozzle of the drum. This RFI considered rejected . Raise another RFI after readiness of the job.
SA NCR No 500002901 was issued for violations observed for materials procurement, NCR was closed after completion of investigations and recomended corrective actions. Unacceptable materials were removed from the stocks.
SA NCR No 500002901 was issued for violations observed for materials procurement, NCR was closed after review of MTC material verification by an approved vendor Inspector and completion of all investigations and recomended corrective actions. Unacceptable materials were removed from the stock, above materials were accepted.
rejected . Rectified and re offered vide RFI : 30985 pneumatic test conducted twice and failed the second time. this RFI was rejected.
This RFI is rejected as the job is not ready rejected as job is not ready rejected .Re-offered vide RFI : 30988 Wrongly selected the category in SAPID reply. In fact the job got rejected. Hence , in closing comments, the category selected as Violation -After the fact
RFI was rejected due to leakage on flange joint. rejected. leak on permanent flange connection The RFI rejected as Hydrotest is not acceptable due to pressure drop rejected. leak on permanent flange connection This general RFI is rejected . Provide another RFI with lines nos
S S S S S S S S
Work rejected . Installed wrong gasket and hence RFI rejected Installed wrong gasket and hence RFI rejected Installed wrong gasket and hence RFI rejected Installed wrong gasket and hence RFI rejected Installed wrong gasket and hence RFI rejected Installed wrong gasket and hence RFI rejected Installed wrong gasket and hence RFI rejected rejected. not ready for Insepction These materials were not approved by SAIR. Hence RFI is rejected. The RFI rejected. Raise another RFI when the replacement for the above materials is received for our Inspection Receving inspection conducted ,Item BB645 of P.O. SPSA/623 found acceptble while Item CB 135 of P.O. SPSA/711 is rejected and to be put in Quarentine area. hydro test was rejected due to leakage on flange connection and pinhole on bonnet of the valve Hydrotesting conducted on Sept. 6, 2007 is rejected. Punch item A of test package is not yet sign off/cleared. This RFI is rejected . This RFI rejected Please send RFI to GT6 SAPID inspector. BT not inspected. this RFI rejected. This RFI is rejected as this material shiped to site without TRG inspection This RFI is rejected as contractor did not provided evidence of approved vendor.
This RFI is rejected. This RFI is rejected - RFI to be resubmitted with the required document as per SAIC
W
This RFI is rejetced This RFI is rejected & LBE will remain open. No response from TRG is noticed so this RFI is rejected. No response from TRG is noticed so this RFI is rejected. No response from TRG is noticed so this RFI is rejected. No response from TRG is noticed so this RFI is rejected. an approved procedure for Storage, Handling & Preservation, is not available with IMAD. This is in violation as per the requirements of Sch. Q Attach. IV Sec 5 & 6. The contractor is advised, through SAPMT, to submit the procedure immediately for approval & preserve these major equipments accordingly.
an approved procedure for Storage, Handling & Preservation, is not available with IMAD. This is in violation as per the requirements of Sch. Q Attach. IV Sec 5 & 6. The contractor is advised, through SAPMT, to submit the procedure immediately for approval & preserve these major equipments accordingly.
an approved procedure for Storage, Handling & Preservation, is not available with IMAD. This is in violation as per the requirements of Sch. Q Attach. IV Sec 5 & 6. The contractor is advised, through SAPMT, to submit the procedure immediately for approval & preserve these major equipments accordingly.
H
W H
H
H W
H
W H
W W
RFI is rejected because job was not ready RFI is rejected because job was not ready RFI is rejected because job was not ready RFI is rejected due to job is not ready RFI is rejected due to job is not ready RFI is rejected due to job is not ready RFI is rejected due to job is not ready RFI is rejected due to job is not ready RFI is rejected due to job is not ready RFI is rejected because job was not ready RFI is rejected due to job is not ready
This RFI is rejected and required to rectify .
Visual Inspection and material for 6 pcs Gate Valves, 5 pcs accepted. One Gate Valve rejected mech damage in seat Serial# 26491-070-26. H
H H
Job was ready ,RFI rejected Job was not ready ,RFI rejected. Job was not ready ,RFI rejected. Acitivity is not done.RFI is rejected. For under ground 12" fire water line FW-5526 section 5 loop 9595 water was filled in line without any information and moreove test package were not released by Saudi Aramco.which is clear violation to Saudi Aramco standards.Test performed after repair on March 8, 2008 and accepted Work not done,RFI rejected. Leakage observed on joint no 20.Test was rejected and after repair retested. rejected due leakage from more than 5 joints, closed not done, rejected the pressure test is rejected, an EDR was proccessed on SAP with reference number 400007913 to find the root cause on this reducing tees and to have a correctve action from the vendor and manufacturer, closed
the pressure test is rejected, an EDR was proccessed on SAP with reference number 400007913 to find the root cause on this reducing tees and to have a correctve action from the vendor and manufacturer, closed all 16"*12" Tees with the same heat number of 9820 shall be subjected to rejection/replacement, closed rejected due to the leak from the socket weld, closed rejected because not ready rejected due to leak on a socket weld, closed Internal cleaning is rejected for Loop 20. Stones and heavy amount of debry found during internal cleaning Inspection for 30 Blow down line .This is violation of approved Cleaning and flushing procedure No- PTJ-QCP20 Rev-2 Para 7.2.1& 7.2.2. Test is not done this is a violation since ENNPI attempt to do the test without releasing the package from review This is a violation that rising RFI without package releasing from review status. Job was not ready,RFI rejected. Package has to be signed off by PJT & ENPPI prior to review by SAPMT/PID as agreed.RFI is rejected. the FRI was rejected due to the absence of the contractor from sie and no work was performed the FRI was rejected due to the absence of the contractor from sie and no work was performed not performed, rejected, closed
H H H
No comments on painting work 1- Rejected and advised to return the following spools due to transportation damage: a1227 Spool B b- 1087 Spool B c- 1128 Spool B 2The angle beam on the I beam column (V84R1-MS06) is not full welded due to that it will be rejected RFI is rejected as activity is not completed yet. Work not done.RFI is rejected. this RFI is rejected due to duplicated request with Mr. Amoudi Seat leakage observed 2 valves RTR 12" #300 were rejected. No acitivity performed RFI is rejected. 8" dia Carbon Steel (LCB) Globe valve # 150 S No.: 93503, Leakage is detected between seat and seat ring due to improper machining of seat.Valve is rejected.
W W W
H H
rejected, not ready The work rejected due to uncompleted job For all loops the painting touch up or insulation activities is general Item 1- Loop # 10 done with comments and rejected. 2- Loop # 78 done with comments and accepted. 3- Loop # 93 done with comments and rejected. 4- Loop # 122 done with comments and rejected. The details provide by PMT on the package. The re-instatement shall be done as per SAIC-L-2022
the material was stored in a bad condition, there were severe damage, and no traceability record from the vendor documents were found, hence its rejected The rejected material is not removed from the site to quarantined area. if we see this material during the progress an NCR will be issue. No activity was done.RFI rejected. RFI is rejected due non avaliabilty of RT crew. the FRI was rejected due to the absence of the contractor from site and no work was performed the FRI was rejected due to the absence of the contractor from site and no work was performed the FRI was rejected due to the absence of the contractor from site and no work was performed the FRI was rejected due to the absence of the contractor from site and no work was performed No activity was done.RFI is rejected. No activity was done.RFI is rejected. Job was not done RFI is rejected. DWG. : VD-118962-001 Spool C W13 rejected due to excessive high-low the advised to cut it and reweld it again. W14 rejected due to excessive high-low the advised to cut it and re-weld it again. W15 reject due to excessive penetration. It is requires only minor repair on the root side and reassessment would be done on it prior to its acceptance.
The inspection has been done and found acceptable. Note: there is no welding inspector at the site and this is violation to Schedule Q clause 5.1 & Attachment VI. The inspection has been done and found acceptable. Note: there is no welding inspector at the site and this is violation to Schedule Q clause 5.1 & Attachment VI. The inspection has been done and found acceptable. Note: there is no welding inspector at the site and this is violation to Schedule Q clause 5.1 & Attachment VI. The work rejected due to not pass the test required to Repair Coating and sends another RFI. Violation-After The Fact, Ref. as per Attach.IV to Schedule"Q" para.1.2.3"Notification requirements for Request For Inspection(RFI)" has been violated. the hydrotest pass( test pressure is 450 psig for line 20"-SW-90931CS2P1) with violation after the fact. Gate valve (vent) 1" class 800 was closed during test time (2 hr.)while plug was fit to this valve and Seat test is 2175 psig as per Valve Date sheet. Touch-up of Coatings is not started so that this RFI is rejected This RFI is rejected because the quality of the weld is not according to standard This RFI is rejected because the quality of the weld is not according to standard
One valve item # 50 rejected due to seat leak One valve # 01 is rejected with the concurrence from the SAPMT & this rejected valve shall be included in the site rejected valve tracking system. work was rejected by SLI QC work was rejected by SLI QC This RFI is rejected because the quality of the weld is not according to standard This RFI is rejected because the quality of the weld is not according to standard Refer to the hard copy for the checklist it was rejected due to leakage during seat test noted a/a..rejecetd a/a/ Refer to the hard copy for the checklist NonSlam Check valve, 16", CL900 quantity 1, Serial No. A1855 wasrejected due to leakage during seat test As this QMIS is older than the one month and no response has been recorded by the contractor. Therefore this RFI is being rejected. The REF is rejected Because the check valve is not dismantle from the lube oil line @ CGT 2 Lube Oil Bulk Tank Fix this and rescheduled the pressure test again The REF is rejected Because the check valve is not dismantle from the lube oil line @ CGT 2 Lube Oil Bulk Tank Fix this and rescheduled the pressure test again
This RFI is rejected due to leakage in one bolt in the fin cooler Try to fix this and rescheduled the RFI This RFI is rejected due to leakage in one bolt in the fin cooler Try to fix this and rescheduled the RFI All the violation items to be transferred to PMCC-2 The fit-up was rejected. See QMIS reference logbook entry no. 5393 QR#L16. The final reading submitted for PID acceptance is rejected because it exceeds the manufacturer acceptance limits These VALVES are rejected by SAPID, and now this RFI is closed as the contractor stated that they sent back these Valves to the manufacturer and inplace they will receive new valves of same number and specs.
W This RFI is rejected because RT report for Tie in joints was not available. This RFI is rejected because document was not ready. This RFI is rejected because, the job was not ready due to not completing of Plumpness inspection. work rejected due to uneven thick saging coating Coating is rejected due to sagging and very thick coating. Blast and recoat damage coating RFI was rejected because line was not redy for test RFI was rejected because job was not ready Package was rejected
H H
The job site inspected and accepted as per the Standards The job site inspected and accepted as per the Standards RFI rejected due to a)Item A4&B1 b)PID have not done Pre-Hydro punchlist prior to pressurizing the line and not following the SATIP-A004-002 and the test flowchart Work not inspected and RFI rejected due to Non availability/No access of the above said pipe spools. RFI rejected due to Reference contractor NCR#S-175,above said spools were installaed with out internal cleaning inspection.It is voilating the SAES-L350 para 15.3.2 and SAIC-L2017.Item# B1,B2 and no access for visual inspection. TEMP. IS 40F low temp.shall be painted with 2A line are rejected. The test manifold was tested but the check valve attached to the manifold was found not holding the pressure. Thus, it was rejected and recommended for replacemnt. this set of material rejected and contractor provide another material already inspected in Jubail and found acceptable material rejected Visual inspection of the above mentioned were rejected.SP not provided the manufacturer data to match the item and type of materials. Hydrotest of the above mentioned was rejected. Contractor are not complying with aramco requirements.
Inspection rejected.
rfi is rejected due to broken dail gauge RFI rejected. No action from the contractor. rejected due to DP test was not conducted on ss socket joints. 1: GASKETS - RED RUBBER, Size 16 & 24 Dia., 50-60 ShoreA are accepted 2: SPIRAL WOUND Graphite SS316L Inner/Outer Ring, 3 Dia SP Doc #: 23574 are rejected because of incomplete material marking identification RFI rejected due to package is not accepted by SA PID RFI rejected due to package is not accepted by SA PID rejected due to not offer for wittness. only raised RFI after installation. Service test was rejected due to leak in the flange to flange connection. SP raise another RFI for re inspection of the line check jiont before my inspection & also give at least 6 hours notification before inspection time rejected work violation against Saudi Aramco standard 12 SAMSS-008 SEC 1, Grouted foundation without laveling and verticality report Stop sand blasting activity due to violation as per surveillance number SUR 6266; SUR 6276 & SUR 6546 which structure has no QC inspection and during inspection found weld defect.
The material is not acceptable. A violation has been raised on this regard. See surveillance # 23725. The material is not acceptable. A violation has been raised on this regard. See surveillance # 23725.
W
The flanges received from un approved manufacturer is rejected. rejected see contractor reply to close rejected for wrong setting of relief valve out standing violation entry pending for reply
W
W
rejected for wrong setting of relief valve rejected, torque values in method of statement is incorrect and there are still issue to be complied in this matter as discussed with SAPMT. out standing violation entry pending for contractor to reply rejected for wrong setting of relief valve rejected for wrong setting of relief valve rejected for wrong setting of relief valve Contractor are conducting Hydrotesting activities without NDE requirements and Hydrotest diagram violation of Schedule Q, SAES A-004 and SAEP 1160 RFI not addressed by inspector. so RFI rejected rejected for wrong setting of relief valve test rejected for wrong setting of relief valve rejected for wrong setting of relief valve
W W W
W
W W W
Please submit hydro test package as required per schedule Q attachment VI para 4 U .Requirements like pressure tesrt gauge, manifold verification is not done by approved Third party agency. please submit check list for mentioning violating clauses.Comply & reoffer. RFI rejected, wrong entry rejection confirm rejected.no activity performed by contractor RFI is rejected for not following the work accordance to SATIP. Please raise inspection accordance to SATIP. RFI rejected, no job description mentined for acceptance. RFI rejected with no responce received by inspector. bolt tightening still pending job details not mentioned for acceptance.RFI rejected. This RFI was raised on January 1409 at 2:05 pm and the inspection schedule was 9:00 am of the same date. This is a violation of Schedule Q attachement IV para 1.2.3. or at least RFI shall be raised at the same date ahead of the inspection schedule and shall be coordinated to PID. Please complete the hot work prior any further insulation work.See violation enrty regading this. Items is rejected. Refer to relevant NCR Pumps rejected by current situation
Pumps / RFI are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed). Pumps are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed). Pumps are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed). Pumps are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed). Pumps are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed). Pumps are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed). Pumps are rejected in the current condition. Corroded parts shall be resolved and agreed by company prior to any further action (Related NCR shall be closed).
QC inspector shall submit RFI when work has been completed to minimize rejection. Resubmit RFI when ready.
This RFI was rejected. Incomplete documents and the issue regarding galvanized pipes and coupling were not yet cleared. Contractor to raise a new RFI as soon as issues are being cleared This RFI is rejected due to error mistake in shop drawing attached to hydrotest package. Contractor correct the drawing and send RFI again. This RFI is rejected due to no approval from CSD for splices. CSD Approved the bolted connection instade of welded connection.
H
H
This RFI is rejected.
Copyright OC Tanner 2007
Project Leader:
Project: Analysis
Project Objective: Determining the causes, the frequency and the nature of viol
Objectives 1 2 3 4 5 6 7 8 9 Major Tasks Identify theTeam Leader (Mechanical) Identify the Team members. Define the objectives Define the Procedure for analysis. Assign the task to team members Review LBE 1- 750 Verify LBE Review LBE 751-1500 Verify LBE Weekly 3 Weekly 2 Week 1
10 Review LBE 1501-2250 11 Verify LBE 12 Review LBE 2251-3000 13 Verify LBE 14 Review LBE 3001-3100 15 Verify LBE 16 Consolidate the Data 17 Formulate the report
Weekly 4
Weekly 5
Identifying typeof violations & relevant information
Prepare for the next phase
improving the knowledge of Inspectors
Major Tasks Target Dates
Objectives
Computer/System access
Log of issues Summary & Forecast
Multi tasks assigned to me
Total LBE 3100 LBE reviewed till 05 May 2010 - 2100 Nos LBE verified till 05 May 2010 - 1050 Backlog due to full time nonavailability of system & LBE review not yet started by Samiuddin.
1-Apr 2-Apr 3-Apr
A B
Owner Primary Owner Secondary
Completed Not Completed Delay activities
Project: Analysis of QMIS violations Mechanical Phase 1
and the nature of violations.
Project Completed By: 3/7/2010
Computer/System access to each members.
Multi tasks assigned to members
d by Samiuddin.
4-Apr 5-Apr 6-Apr 7-Apr 8-Apr 9-Apr 10-Apr 11-Apr 12-Apr 13-Apr 14-Apr 15-Apr 16-Apr 17-Apr 18-Apr 19-Apr 20-Apr 21-Apr 22-Apr 23-Apr 24-Apr 25-Apr 26-Apr 27-Apr 28-Apr 29-Apr 30-Apr 1-May
t Completed By: 3/7/2010
2-May 3-May 4-May 5-May 6-May 7-May

8-May

9-May

10-May

11-May 12-May 13-May 14-May 15-May 16-May 17-May 18-May 19-May 20-May 21-May 22-May 23-May 24-May 25-May 26-May 27-May 28-May
Date: 04/18/10
Owner / Priority A A A A B C B C B C B C B C B C B C C C C C C C C C C C C C C C C C C C C C C C C
29-May 30-May Saud Al Otaibi (Team Mushtaq Mapkar
Ghulam Shabbir Gopi Perumal Muhammad Islam
Asad Azmi
Samiuddin
Labels Other Expenses Capital
Millions Budgeted Expended 0.0 0.0 0.0 0.0 0.0 0.0

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Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

1/7/2010 1:02:43 PM 8/30/2006 1:53:30 PM

SAES SAES SAES SAES ScheduleQ

Mechanical Mechanical Mechanical

SAES-L-450 SAES-H-200 Schedule Q

6/20/2007 1:26:16 PM 2/27/2007 8:12:28 AM

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

A IV Para 4.2 A IV Para 6

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Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact

Violation-After The Fact