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

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

2

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

3

6/22/2008 11:12:02 AM


Mechanical

SAES

SAES-L-110

8.1

4

11/18/2008 7:54:34 AM


SATIP-A-004-02

SAIC-A-2010

Mechanical

SAES

SAES-L-150

7.1

5

5/27/2008 9:48:05 AM


SATIP-L-450-04

SAIC-L-2112

Mechanical

SAES

SAES-L-450

8

6

1/31/2010 4:16:58 PM


SATIP-H-002-02

SAIC-H-2016

Mechanical

SAES

SAES-H-200

7

7

4/8/2009 1:52:02 PM

ViolationPrevented Installation

SATIP-H-002-02

SAIC-H-2011

Mechanical

SAES

SAES-H-201

7.2.5

8

2/9/2010 8:06:11 AM


SATIP-L-450-03

SAIC-L-2017

Mechanical

SAES

SAES-L-450

18.2

9

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

7


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

6

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

8

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

8

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

7

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

7

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

3

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

3

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

3

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 1427/12/2007 5:55:44 PM

SATIP-W-011-01 SATIP-W-011-01Violation-After The Fact

SAIC-W-2005 SAIC-W-2006 SAIC-W-2032

Mechanical Mechanical Mechanical

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 WELDI

qmis lbe rev mech final old

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