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SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-43- Scratches on pipe during


MECH Renly Silvestre 10-00060-4529
SK-95 bending

OMPP-NA2-M-42-
MECH Edison Cusi 10-01032-5850 Support of valve damage
SK-94

OMPP-NA2-M-28- External FBE coat damaged


MECH Edison Cusi 10-01032-5846
SK-62 due to improper handling

Page 1 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-47-
MECH Edison Cusi 10-01032-5846 PRESERVATION
SK-103

Page 2 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-55- Wrong sequence of bolt


MECH Muhammad Sufyan 10-00791-3530
SK-132 torquing @ trunkline 280/283

Page 3 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-32- Mismatch of MTO, SAP No. and


MECH Edison Cusi 10-00791-3530
SK-70 Outbound No.

OMPP-NA2-E-23-SK- Materials Installed not follow


ELECT JOSE BAUTISTA 10-00791-3530
86 Library Drawing

Page 4 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-C-10- Pipe Support (TPS) foundation


CIVIL Soaib Khan 10-00791-3530
SK-108 without Surface preparation

OMPP-NA2-E-24-SK- Material Installed without


ELECT JOSE BAUTISTA 10-00791-3530
88 Receiving Inspection

OMPP-NA2-W-17- Safwa ETHANE line high


WELDING Vivek 10-01032-5846
SK-92 rejection rate

Page 5 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-48-
MECH Hassan Alkhuwaildi 10-00060-4529 End CAP missing
SK-109

OMPP-NA2-C-12- BERRI-881 / 00-01032- Poor storage of coated steel


CIVIL Shoaib Khan
SK-117 5850 bars

OMPP-NA2-E-39-SK- Insufficient proper accescover


ELECT JOSE BAUTISTA 10-00791-3530
134 from installation of instrument

Page 6 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-49- Pipes in yard with excessive


MECH Muhammad Shakeel 10-00060-4529
SK-113 corrosion)

OMPP-NA2-M-59- Damage plug valve hand


MECH Muhammad Sufyan 10-01032-5842
SK-146 wheel

Page 7 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-50- Improper Calibration of Relief


MECH Junaid Farooq 10-00791-3515
SK-114 valve

OMPP-NA2-E-27-SK-
ELECT JOSE BAUTISTA 10-00791-3530 Material in the site
96

OMPP-NA2-W-21- ABU-ALI welding consumable


WELDING Ibrahim Syed 10-00791-3530
SK-140 store condition

Page 8 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During Cold bending of 16" pipe 0.844"wt, API5L, SMLS Gr. X-60,SAP# 4504741031
ITEM# 00001 P#031, HN# 243587 EXT,COATED PIPE@ QTIF P21A SITE AREA w/c
was performed by Mizat Company on 10 March 2016.1t was found that the
Externally Coating of Pipe suffered deep scratches due to sudden rotation of pipe 3/13/2016 4/14/2016
while bending. This violates the SAES-H-200
section 5.1.1 that states coated pipe is handled at all times in a manner that
prevent damage to the pipe wall,bevelled ends and to the coating.

During internal receiving inspection to BER-882 Bl-10-01032-5850 on 12-March-


2016 @ OMPP-NA-2 LAYDOWN@ JUAYMAH PMT YARD by QC-Mech/Piping it was
3/12/2016 4/16/2016
found out that the 12" CL 300 FLANGE, RF, CS, ASTM A105/ A350 LF2 WITH SN-
1418509 BALL VALVE (QTY-1)the STAND SUPPORT was bended.

During internal receiving inspection to NTI# QTFTL-61/160-009 & NTI# QTFTL-


61/160-011 raised by Material Group@ QATIF 61/160
SITE on 14-Jan-2016 by QC-Mech/Piping & QC-Coating Inspector it was found out
that the PIPE 8" X 0.562" WT GR X60 X 12.2M EXTERNALLY COATED (QTY=126 Nos) 1/14/2016 4/17/2016
received from ARAMCO YARD and almost 70% has scratches I excessive damaged
in externally FBE Coated.

Page 9 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site visit on 19-March-2016@ QATIF-61/160 Bl-10-01032-5842, it was found


out that there was a pipe laying on the ground and with an open end and also
continue of fit-up and welding without conduct of airblowing. Where in as per Saudi
Aramco Standards SAES-L-450
SECTION 11.2 Each length of pipe shall be examined to make sure it is free from
internal obstructions. Any obstructions shall be removed before the pipe is welded
3/19/2016 4/20/2016
into a string. Each joint shall also be air blown to remove dust and sand
immediately prior to welding into a string. 11.3 Pipe strings shall be supported and
laterally restrained by an approved pipeline support methods such as pig pen
pipeline support, air bag or earth pillar methods.11.4 Open ends of pipeline strings
shall be capped to prevent entry of debris or animals and birds.

Page 10 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 19th Apri12016 Well Trunk line 280/283 FJ No 821t has been observed that
Construction Raised NTI for Stud Bolt assembly and bolt tightening. During site
activity Inspection it was found bolt tightening crew is not properly following the
sequence of the bolt as it is mentioned in SAEP-351. Hence it is clear violation of
SAEP-351 Para 9.1
Root Cause: It was found as construction made a change in bolt tightening crew
and added one more person in crew. The new crew member was not well aware of
Saudi Aramco Bolt tightening procedure SAEP-351and he was failed to fallow bolt
numbering properly.
Corrective Action: 4/19/2016 4/21/2016
1-Lose all Stud bolts from FJ # 82 and Readjust all stud bolls again and start
tightening as per SAEP 351 and complete it as same procedure
2-Toolbox meeting with the bolt tightening crew and explain the bolt tightening
procedure 351
3-Meeting with Crew Supervisor and advise him to make sure compliance with bolt
tightening procedure SAEP-351
4-Quallity inspector will verify bolt lightning of every flange
Preventive Action: Meeting with Supervisor and explain them the importance of
bolt tightening by complying the proper bolt tightening procedure SAEP-351.

Page 11 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During internal receiving inspection to NTI# BER283-0048 Bl-10-00791-3530 on 28-


Jan-2016@ OMPP-NA-2 LAYDOWN YARD by QC- Mech/Piping it was found out that
the material received by MATERIAL GROUP SAP# 1000030388 SPECTACLE PLATE
12" CL 1500
FLANGE, RING JOINT, CS, ASTM A36(QTY-1) does not match the material description 1/30/2016 4/29/2016
on OUTBOUND & IFC MTO SAP# 1000030388
SPECTACLE PLATE 12" CL 1500 FLANGE, RING JOINT, CS, ASTM A516 GR. 70 the
requirement.

During site inspection around 1:30pm,at WellHead 345 Area the Ground ln1)ection
Pit,Installed the Pipe only 460mm as per Standard Drawing shown 450 + 450 mm =
900mm totallength of the Pipe,the material should be Pipe; Fibergal ss 250mm
dia.as per standard,and the material still not received for inspection. Which is
2/27/2016 4/29/2016
violated under the Standard Drawing DD-950022, Sh.1of 12 and schedule Q
attachment 4 section 3.3 (Traceability shall be maintained on materials as specified
in Saudi Aramco Standards and manufacturer's specifications.Documents and
records shall enable the materials to be traced and used in installaton.

Page 12 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During daily routine surveillance last March 29,2016@ BERRI280,283 & 345.STA#
( 2+152, 5+022) Loop# 01 . QC Civil Inspector obseorved that the construction
have installed the TPS Steel Support on the foundation without roughened the top
surface of foundation. This is the clear violation with SAIS-Q-010 Sec- 3.2 which 3/29/2016 4/29/2016
refers to PIP ST03600, Sec. 6020101 that states Laitance,oil-soaked or damaged
concrete shell be removed down to sound concrete fractured aggregate or to a
minimum of the top 1 inch 25mm of the concrete.

It was been already 2 weeks when the Switch Rack was InstalledIn the Site with the
khowledge of SAPMT,with the agreement the Construction will not Install do
anything In the SWitchrack until it will received for Inspection the material, the
construction received the Switch Rack is not the one they install in the site the
documents is not match in the installed Switch Rack.Which Is violated under 2/29/2016 4/30/2016
Schedule Q attachment 4 section 3.3 (Traceability shall be maintained on materials
as specified in SaudiAramco Standards and manufacturer's specifications.
Documents and records shall enable the materials to be traced and used in
installation.)

On 1st March,the RTFI result was received for ethane line and it was found 13 joints
were rejected among 67 joints shooted. This number of rejections made the 3/6/2016 4/30/2016
cumulative rejection rate of ethane line as 20.8%.

Page 13 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

DURING SITE VISITE ON 31-MARCH-2016 @ QATIF 7 OPS Bl-10-00060-4529, IT WAS


FOUND OUT THAT THERE WAS APIPEAND SPOOLS WITH OPEN END. WHERE PER
SAUDI ARAMCO STANDARD SAES-L-450 SECTION 11.4 OPEN ENDS OF PIPELINE 3/31/2016 4/30/2016
STRINGS
During daily
SHALL
routine
BE CAPPED
Surveillance
TO PREVENT
lastApril12,
ENTRY
2016@
OF DEBRIS
BERRI.881.STA#
OR ANIMALS(0+500)
AND .QC
BIRDS.
Civil Inspector Observed that the Construction Group Use Small Cribbing for storage
of Steel Reinforcing Bars as QC observe Steel Reinforcing Bars are touching to the
surface of Ground . This is the clear violation with09-SAMMS-106 Sec -III.B. Which
refers to (ASTM A775/A 775--7b, Sec.15.3) that states Coating Steel Reinforcing
Bars Shell be Stored off the Ground on Protective Cribbing.
Root Cause: Saudi kad civil construction group did not Store Coating Steel 4/13/2016 5/1/2016
Reinforcing Bars properly.
Corrective Action: Civil construction group shall be stored the Coaling Steel Bars
on the protective cribbing to protect the Coating Steel Reinforcing Bars from
touching ground surface.
Preventive Action: Saudi Kad civil construction group shall comply I adhere with
the 09-SAMMS-106 Sec -111.8.
During routine site inspection it was observed that the PVC conduit installed near
well doesnt have proper cover for preparation of installation of instrument such as
UFM cable insertion prior to cable pulling activity, as per NEC article 501.15 seals in
conduit & cable systems shall comply with this standards.
Root Cause: No NTI from construction prior to PVC coated installation of conduit. 4/20/2016 5/5/2016
Corrective Action: Advised construction to always issue NTI before installation to
avoid future violation. Rectify the conduit installation to fix cable pulling activity.
Preventive Action: Construction group shall raise the NTI & follow the sequence
of work.

Page 14 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 07-04-2016 it was observed during internalinspection at Juaymah Laydown


Yard,Material Department brought 10" NPS,0.438" WT,CS,API5L,GR X60 INT FBE
Coated Pipes received (15 PCS) for 10" Test Line Header Ext. @ P21A DWG # RB-
4/7/2016 5/6/2016
873472-001 have Strong Pitting and Corrosion on the Pipe Surface. The Line Class
being 9CS1P02,The Corrosion Allownce Max Allowed is 1.6mm where as the pipe
corrosion and rust is more than permitted. 1

DURING THE HYDROTESTING OF 8" PLUG VALVES, CL900, RJ, CS, ASTM A216 WCB
BODY, SS AISI410 TRIM,. ONE VALVE (SN# L9515) OF SAME DISCREPTION LOST
BALANCE RESULTING TO DAMAGE OF IT'S HANDWHEEL. THIS VALVE NOT SCHEDULE
FOR HYDROTEST AS PER RFI. THE GROUP IS PREPARING THIS VALVE FOR THE NEXT
HYDROTEST SCHEDULE.
Root Cause: LACK OF SUPERVISION OF IN-CHARGE PERSON IN THE TESTING AREA
DURING PREPARATION AND PERFORMING OF VALVE HYDROTESTING.
4/28/2016 5/7/2016
Corrective Action: THE DAMAGE VALVE SHALL BE TRANFERED TO QUARANTINE
AREA AND PROPER PRESERVATION SHALL BE OBSERVED WHILE WATING FOR THE
DISPOSITION FOR THE DAMAGE HANDLWHELL.
Preventive Action: A COMPETENT AND REPONSIBLE IN-CHARGE SHALL BE
ASSIGNED TO SUPERVISE THE VALVE HYDROTEST AREA. ALL HEAVY VALVES SHALL
BE PROVIDED WITH SUFFIECIENT TEMPORARY SUPPORT IN EVERY STAGING OF TEST
UP TO RELEASE TO SITE.

Page 15 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 10-April-2016, during the hydrotesting of 1" line at QW-42, the relief valve
popped up at 4500psi. The test pressure was also 4500 psi.
Root Cause: Calibration of the relief valve was not proper.
4/10/2016 5/9/2016
Corrective Action: The relief valve to calibrate again and hydro test to be done.
Preventive Action: Tool Box Meeting with the construction people regarding the
relief vavl e calibration.

It was been observe that the Corrosion Inhibitor System and Battery Charger
Rectifier received and bring to the site without materialreceiving inspection. The
Construction bring to the site and Install the materials, which is clearly violation in
Schedule Q. Attachment 4 Section 3.3 . Traceabllity shall be maintained on
3/13/2016 5/13/2016
equipment,materials, and parts components, as specified on Saudi Aramco
standards and Manufacturer's specifications.Documents and records shall enable an
item to traced throughout fabrication,erection, installation,repair, modification and
use of the item.

Upon routine surveillance in abu ali welding store on 23-april, 2016 @ 8:00am, I
observed that the store is full of mess with other equipment apart from welding
consumables and oven, which is not acceptable. As per project quality plan (level III
& IV) para 4.1.1
Root Cause: Lack of space to store other equipment. 4/23/2016 5/15/2016
Corrective Action: Apart from welding consumables and oven all other equipment
should be remove from the store.
Preventive : Welding Consumables should be stored in a separate designated
place in a proper organized manner.

Page 16 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

entende to May 20,


open
2016

open

Page 17 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 18 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 19 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

ACD EXTENDED open

Page 20 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

ACD EXTENDED open

open

Page 21 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

open

open

Page 22 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

open

Page 23 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

extended 1 month open

open

Page 24 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

External FBE coat


OMPP-NA2-M-
MECH Edison Cusi 10-01032-5846 damaged due to
28-SK-62
improper handling

OMPP-NA2-M- Mismatch of MTO, SAP


MECH Edison Cusi 10-00791-3530
32-SK-70 No. and Outbound No.

Page 25 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E- Materials Installed not


ELECT JOSE BAUTISTA 10-00791-3530
23-SK-86 follow Library Drawing

Page 26 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

Material Installed
OMPP-NA2-E-
ELECT JOSE BAUTISTA 10-00791-3530 without Receiving
24-SK-88
Inspection

Page 27 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-W- Safwa ETHANE line high


WELDING Vivek 10-01032-5846
17-SK-92 rejection rate

OMPP-NA2-M- Support of valve


MECH Edison Cusi 10-01032-5850
42-SK-94 damage

OMPP-NA2-M- Scratches on pipe


MECH Renly Silvestre 10-00060-4529
43-SK-95 during bending

Page 28 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-
ELECT JOSE BAUTISTA 10-00791-3530 Material in the site
27-SK-96

Page 29 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-
MECH Edison Cusi 10-01032-5846 PRESERVATION
47-SK-103

Page 30 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

Pipe Support (TPS)


OMPP-NA2-C-
CIVIL Soaib Khan 10-00791-3530 foundation without
10-SK-108
Surface preparation

OMPP-NA2-M-
MECH Hassan Alkhuwaildi 10-00060-4529 End CAP missing
48-SK-109

Page 31 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M- Pipes in yard with


MECH Muhammad Shakeel 10-00060-4529
49-SK-113 excessive corrosion)

OMPP-NA2-M- Improper Calibration of


MECH Junaid Farooq 10-00791-3515
50-SK-114 Relief valve

Page 32 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-C- BERRI-881 / 00- Poor storage of coated


CIVIL Shoaib Khan
12-SK-117 01032-5850 steel bars

Page 33 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-H- No painting Crew


Painting/Coating Iftikhar Ahmed 10-00060-4529
06-SK-119 Supervisor

Page 34 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E- Damaged coating of


ELECT JOSE BAUTISTA 10-00791-3530
34-SK-125 Conduit stub-up.

Page 35 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M- Received fabricated


MECH Muhammad Shakeel 10-00060-4529
53-SK-126 jack screw.

Page 36 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

UPS battery without


OMPP-NA2-E-
ELECT JOSE BAUTISTA 10-00791-3530 materila receiving
36-SK-128
inspection

Page 37 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

Not installed post


OMPP-NA2-E-
ELECT JOSE BAUTISTA 10-00791-3530 marker for burried
37-SK-129
cabvles.

Page 38 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M- 3-1/18" Ball valve


MECH Renly Silvestre 10-00060-4529
54-SK-131 leaking during seat test

Page 39 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

Wrong sequence of bolt


OMPP-NA2-M-
MECH Muhammad Sufyan 10-00791-3530 torquing @ trunkline
55-SK-132
280/283

Page 40 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

Insufficient proper
OMPP-NA2-E- accescover from
ELECT JOSE BAUTISTA 10-00791-3530
39-SK-134 installation of
instrument

OMPP-NA2-M- 8" plug valves failed in


MECH ADIL AYAZ 10-00060-4529
58-SK-138 seat test
Page 41 SK-QAF-057 NCR LOG.docx.xlsx
G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During internal receiving inspection to NTI# QTFTL-61/160-009 &


NTI# QTFTL-61/160-011 raised by Material Group@ QATIF 61/160
SITE on 14-Jan-2016 by QC-Mech/Piping & QC-Coating Inspector it
was found out that the PIPE 8" X 0.562" WT GR X60 X 12.2M 1/14/2016 4/17/2016
EXTERNALLY COATED (QTY=126 Nos) received from ARAMCO
YARD and almost 70% has scratches I excessive damaged in
externally FBE Coated.

During internal receiving inspection to NTI# BER283-0048 Bl-10-


00791-3530 on 28-Jan-2016@ OMPP-NA-2 LAYDOWN YARD by
QC- Mech/Piping it was found out that the material received by
MATERIAL GROUP SAP# 1000030388 SPECTACLE PLATE 12" CL
1500 1/30/2016 4/29/2016
FLANGE, RING JOINT, CS, ASTM A36(QTY-1) does not match the
material description on OUTBOUND & IFC MTO SAP# 1000030388
SPECTACLE PLATE 12" CL 1500 FLANGE, RING JOINT, CS, ASTM
A516 GR. 70 the requirement.

Page 42 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site inspection around 1:30pm,at WellHead 345 Area the


Ground ln1)ection Pit,Installed the Pipe only 460mm as per
Standard Drawing shown 450 + 450 mm = 900mm totallength of
the Pipe,the material should be Pipe; Fibergal ss 250mm dia.as
per standard,and the material still not received for inspection.
2/27/2016 4/29/2016
Which is violated under the Standard Drawing DD-950022, Sh.1of
12 and schedule Q attachment 4 section 3.3 (Traceability shall be
maintained on materials as specified in Saudi Aramco Standards
and manufacturer's specifications.Documents and records shall
enable the materials to be traced and used in installaton.

Page 43 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

It was been already 2 weeks when the Switch Rack was


InstalledIn the Site with the khowledge of SAPMT,with the
agreement the Construction will not Install do anything In the
SWitchrack until it will received for Inspection the material, the
construction received the Switch Rack is not the one they install
in the site the documents is not match in the installed Switch 2/29/2016 4/30/2016
Rack.Which Is violated under Schedule Q attachment 4 section
3.3 (Traceability shall be maintained on materials as specified in
SaudiAramco Standards and manufacturer's specifications.
Documents and records shall enable the materials to be traced
and used in installation.)

Page 44 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 1st March,the RTFI result was received for ethane line and it
was found 13 joints were rejected among 67 joints shooted. This
3/6/2016 4/30/2016
number of rejections made the cumulative rejection rate of
ethane line as 20.8%.

During internal receiving inspection to BER-882 Bl-10-01032-5850


on 12-March-2016 @ OMPP-NA-2 LAYDOWN@ JUAYMAH PMT YARD
by QC-Mech/Piping it was found out that the 12" CL 300 FLANGE, 3/12/2016 4/16/2016
RF, CS, ASTM A105/ A350 LF2 WITH SN-1418509 BALL VALVE
(QTY-1)the STAND SUPPORT was bended.

During Cold bending of 16" pipe 0.844"wt, API5L, SMLS Gr. X-


60,SAP# 4504741031 ITEM# 00001 P#031, HN# 243587
EXT,COATED PIPE@ QTIF P21A SITE AREA w/c was performed by
Mizat Company on 10 March 2016.1t was found that the
Externally Coating of Pipe suffered deep scratches due to sudden 3/13/2016 4/14/2016
rotation of pipe while bending. This violates the SAES-H-200
section 5.1.1 that states coated pipe is handled at all times in a
manner that prevent damage to the pipe wall,bevelled ends and
to the coating.

Page 45 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

It was been observe that the Corrosion Inhibitor System and


Battery Charger Rectifier received and bring to the site without
materialreceiving inspection. The Construction bring to the site
and Install the materials, which is clearly violation in Schedule Q.
Attachment 4 Section 3.3 . Traceabllity shall be maintained on
3/13/2016 5/13/2016
equipment,materials, and parts components, as specified on
Saudi Aramco standards and Manufacturer's
specifications.Documents and records shall enable an item to
traced throughout fabrication,erection, installation,repair,
modification and use of the item.

Page 46 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site visit on 19-March-2016@ QATIF-61/160 Bl-10-01032-


5842, it was found out that there was a pipe laying on the ground
and with an open end and also continue of fit-up and welding
without conduct of airblowing. Where in as per Saudi Aramco
Standards SAES-L-450
SECTION 11.2 Each length of pipe shall be examined to make
sure it is free from internal obstructions. Any obstructions shall be
3/19/2016 4/20/2016
removed before the pipe is welded into a string. Each joint shall
also be air blown to remove dust and sand immediately prior to
welding into a string. 11.3 Pipe strings shall be supported and
laterally restrained by an approved pipeline support methods
such as pig pen pipeline support, air bag or earth pillar
methods.11.4 Open ends of pipeline strings shall be capped to
prevent entry of debris or animals and birds.

Page 47 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During daily routine surveillance last March 29,2016@


BERRI280,283 & 345.STA# ( 2+152, 5+022) Loop# 01 . QC Civil
Inspector obseorved that the construction have installed the TPS
Steel Support on the foundation without roughened the top
surface of foundation. This is the clear violation with SAIS-Q-010 3/29/2016 4/29/2016
Sec- 3.2 which refers to PIP ST03600, Sec. 6020101 that states
Laitance,oil-soaked or damaged concrete shell be removed down
to sound concrete fractured aggregate or to a minimum of the
top 1 inch 25mm of the concrete.

DURING SITE VISITE ON 31-MARCH-2016 @ QATIF 7 OPS Bl-10-


00060-4529, IT WAS FOUND OUT THAT THERE WAS APIPEAND
SPOOLS WITH OPEN END. WHERE PER SAUDI ARAMCO STANDARD
3/31/2016 4/30/2016
SAES-L-450 SECTION 11.4 OPEN ENDS OF PIPELINE STRINGS
SHALL BE CAPPED TO PREVENT ENTRY OF DEBRIS OR ANIMALS
AND BIRDS.

Page 48 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD


On 07-04-2016 it was observed during internalinspection at
Juaymah Laydown Yard,Material Department brought 10"
NPS,0.438" WT,CS,API5L,GR X60 INT FBE Coated Pipes received
(15 PCS) for 10" Test Line Header Ext. @ P21A DWG # RB-
4/7/2016 5/6/2016
873472-001 have Strong Pitting and Corrosion on the Pipe
Surface. The Line Class being 9CS1P02,The Corrosion Allownce
Max Allowed is 1.6mm where as the pipe corrosion and rust is
more than permitted. 1
On 10-April-2016, during the hydrotesting of 1" line at QW-42, the
relief valve popped up at 4500psi. The test pressure was also
4500 psi.
Root Cause: Calibration of the relief valve was not proper.
4/10/2016 5/9/2016
Corrective Action: The relief valve to calibrate again and hydro
test to be done.
Preventive Action: Tool Box Meeting with the construction
people regarding the relief vavl e calibration.

Page 49 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During daily routine Surveillance lastApril12, 2016@


BERRI.881.STA# (0+500) .QC Civil Inspector Observed that the
Construction Group Use Small Cribbing for storage of Steel
Reinforcing Bars as QC observe Steel Reinforcing Bars are
touching to the surface of Ground . This is the clear violation
with09-SAMMS-106 Sec -III.B. Which refers to (ASTM A775/A 775--
7b, Sec.15.3) that states Coating Steel Reinforcing Bars Shell be
Stored off the Ground on Protective Cribbing. 4/13/2016 5/1/2016
Root Cause: Saudi kad civil construction group did not Store
Coating Steel Reinforcing Bars properly.
Corrective Action: Civil construction group shall be stored the
Coaling Steel Bars on the protective cribbing to protect the
Coating Steel Reinforcing Bars from touching ground surface.
Preventive Action: Saudi Kad civil construction group shall
comply I adhere with the 09-SAMMS-106 Sec -111.8.

Page 50 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

In Qatif 7 OPS site the coating activities are carried out without
any approved painting crew supervisor, which is clearly violation
of SAEP-316, para 3.1 and Schedule Q Attachment IV para 2.1
Root Cause: SK management could not get the approved crew
supervisor yet. 4/14/2016 5/21/2016
Corrective Action: Painting crew supervisor immediately to be
arranged
Preventive Action: The management should assign all staff
according to Schedule Q.

Page 51 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During Site inspection it was found out the stub-up installed in


Analog and Digital Junction Box, found out the coated conduit the
Construction fabricated the conduit (threading) some of them
damage the coated parts of the conduit, this is a violation as per
SAES-P-104 Para.8.3 Conduits above ground in severe corrosive
environments shall be as specified in Paragraph 8.2 and, in
addition, shall be factory PVC coated (minimum thickness of
PVC:40 mils (1mm) per NEMARN1. 4/17/2016 5/17/2016
Root Cause: The Construction E and I Fabricate the conduit
without taking care of the materials.
Corrective Action: The Construction E and I shall apply PVC
touch to cover the open coated conduit upon installation.
Preventive Action: The Construction E and I is advice to comply
with all the activities and requirements as per approved
procedure and SAES P-104

Page 52 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

Material Department received Fabricated Jack Screw Bolts from


Vendor at Juaymah Laydown Yard UNC Series Class 2A FIT1" X 7"
long (24 Pcs) & 3/4" X 5-112"1ong (12 PCS) for 70PS without
marking & Identification on the head of bolt. Material must have
Clear Identification and Marking according to the Schedule Q 3.2
and 3.3.
Root Cause: Vendor is not aware with the Material Requirement 4/17/2016 5/16/2016
as per Purchase Order.
Corrective Action: Return those Jack Screw Bolts to Vendor and
Bring New Bolts with Marking g of Material Identification.
Preventive Action: Procurement Department must ensure that
Material Order form Vendor are Correct as per Project
Requirement.

Page 53 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During routine surveillance it was observed that UPS battery was


installed already in RTU area, this UPS battery ws not yet
received by QC organization & didnt received internal noticed to
inspect from construction organization.
Root Cause: No receiving of installed UPS battery.
4/19/2016 5/17/2016
Corrective Action: Advised construction to issued NTI before
they proceed with instruction to avoid future violation.
Preventive Action: Tool box meeting / Warehouse must be
aware & should not issue the material without receiving
acceptance.

Page 54 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site inspection it was found that post marker was not
installed after final back filling in BERRi-280 & BERRI-345 or any
temporary post marker for direct buried cables. These
requirements of SAES-P-104 PAR.10.8 which state the location of
undergrouding cable, duct bank or conduit marked in accordance
with standard drawing AB-036273 or AB-036326.
4/18/2016 5/17/2016
Root Cause: Post marker installed after back filling.
Corrective Action: Advised construction to provide temporary
post marker for easy identification of direct buried cable in
BERRI-280 & BERII-345.
Preventive Action: Construction to always refer & follow IFC
drawing and standard drawing to avoid future violation.

Page 55 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 17-Apri-l 2016, During Valve testing activity at Juaymah Pre-


cast Area/ Valve testing area, Mechanical Inspector found that a
Ball Valve 3-1/18", with Serial No.150360010131 was found
leaking during the seat testing activity due to mechanical defect
internally; also the ball was not closed although the indicator
was showing Closed. Violation of SAES-L-108 Par.4.7.5
requirement 4/19/2016 5/19/2016
Root Cause: Manufacturing Defect
Corrective Action: The defective Ball Valve to be returned to
SaudiAramco warehouse.
Preventive Action: Warehouse to Ensure that the material
received/delivered to Saudi Kad are in proper
condition/functional.

Page 56 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 19th Apri12016 Well Trunk line 280/283 FJ No 821t has been


observed that Construction Raised NTI for Stud Bolt assembly
and bolt tightening. During site activity Inspection it was found
bolt tightening crew is not properly following the sequence of the
bolt as it is mentioned in SAEP-351. Hence it is clear violation of
SAEP-351 Para 9.1
Root Cause: It was found as construction made a change in bolt
tightening crew and added one more person in crew. The new
crew member was not well aware of Saudi Aramco Bolt tightening
procedure SAEP-351and he was failed to fallow bolt numbering
properly.
Corrective Action: 4/19/2016 4/21/2016
1-Lose all Stud bolts from FJ # 82 and Readjust all stud bolls
again and start tightening as per SAEP 351 and complete it as
same procedure
2-Toolbox meeting with the bolt tightening crew and explain the
bolt tightening procedure 351
3-Meeting with Crew Supervisor and advise him to make sure
compliance with bolt tightening procedure SAEP-351
4-Quallity inspector will verify bolt lightning of every flange
Preventive Action: Meeting with Supervisor and explain them
the importance of bolt tightening by complying the proper bolt
tightening procedure SAEP-351.
Page 57 SK-QAF-057 NCR LOG.docx.xlsx
G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During routine site inspection it was observed that the PVC


conduit installed near well doesnt have proper cover for
preparation of installation of instrument such as UFM cable
insertion prior to cable pulling activity, as per NEC article 501.15
seals in conduit & cable systems shall comply with this
standards.
Root Cause: No NTI from construction prior to PVC coated 4/20/2016 5/5/2016
installation of conduit.
Corrective Action: Advised construction to always issue NTI
before installation to avoid future violation. Rectify the conduit
installation to fix cable pulling activity.
Preventive Action: Construction group shall raise the NTI &
follow the sequence of work.

On 19-April-2016, during the hydrotesting of size 8" plug valves,


class 900# ( L-9517, L-9499, L-9510, L-9507, L-9491, L-9494, L-
9476). The valves are found leakage when performing seat test
pressure at 2440 PSI. As per standard there shall be no leakage
for the minimum specified test duration (see table 4) . As per
4/19/2016 5/18/2016
SAES-L-108 PARA 4.7.5 & API598.
Root Cause: Poor preservation @ Saudi Aramco Facilities.
Page 58 SK-QAF-057 NCR LOG.docx.xlsx
AS PER:MAY 2016

CLOSING DATE REMARKS

open

open

Page 59 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

ACD EXTENDED open

Page 60 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

ACD EXTENDED open

Page 61 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

entende to May
open
20, 2016

open

Page 62 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

extended 1 month open

Page 63 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 64 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

open

Page 65 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

open

Page 66 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 67 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 68 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 69 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 70 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 71 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 72 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 73 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

Page 74 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:MAY 2016

CLOSING DATE REMARKS

open

open

Page 75 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-43- Scratches on pipe during


MECH Renly Silvestre 10-00060-4529
SK-95 bending

OMPP-NA2-M-42-
MECH Edison Cusi 10-01032-5850 Support of valve damage
SK-94

OMPP-NA2-M-28- External FBE coat damaged


MECH Edison Cusi 10-01032-5846
SK-62 due to improper handling

Page 76 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-47-
MECH Edison Cusi 10-01032-5846 PRESERVATION
SK-103

Page 77 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-52- Preservation of 12" FBE


MECH Vivek Sukumaran 10-030071-1011
SK-122 Coated pipe / Directly sunlight.

Page 78 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-55- Wrong sequence of bolt


MECH Muhammad Sufyan 10-00791-3530
SK-132 torquing @ trunkline 280/283

OMPP-NA2-C-09- Poor presrvation of coated


CIVIL Benidect Asuncion 10-00060-4529
SK-102 bars.

Page 79 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-33-SK- Cable pulling without


ELECT JOSE BAUTISTA 10-00791-3530
121 inspection of RTU panel.

OMPP-NA2-M-32- Mismatch of MTO, SAP No. and


MECH Edison Cusi 10-00791-3530
SK-70 Outbound No.

Page 80 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-23-SK- Materials Installed not follow


ELECT JOSE BAUTISTA 10-00791-3530
86 Library Drawing

OMPP-NA2-C-10- Pipe Support (TPS) foundation


CIVIL Soaib Khan 10-00791-3530
SK-108 without Surface preparation

Page 81 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-24-SK- Material Installed without


ELECT JOSE BAUTISTA 10-00791-3530
88 Receiving Inspection

OMPP-NA2-W-17- Safwa ETHANE line high


WELDING Vivek 10-01032-5846
SK-92 rejection rate

OMPP-NA2-M-48-
MECH Hassan Alkhuwaildi 10-00060-4529 End CAP missing
SK-109

Page 82 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-C-12- BERRI-881 / 00-01032- Poor storage of coated steel


CIVIL Shoaib Khan
SK-117 5850 bars

Page 83 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-56- 12" FBE coated pipe cut


MECH Vivek Sukumaran 10-03007-1011
SK-133 without transfer traceability

OMPP-NA2-E-39-SK- Insufficient proper accescover


ELECT JOSE BAUTISTA 10-00791-3530
134 from installation of instrument

Page 84 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During Cold bending of 16" pipe 0.844"wt, API5L, SMLS Gr. X-60,SAP# 4504741031
ITEM# 00001 P#031, HN# 243587 EXT,COATED PIPE@ QTIF P21A SITE AREA w/c
was performed by Mizat Company on 10 March 2016.1t was found that the
Externally Coating of Pipe suffered deep scratches due to sudden rotation of pipe 3/13/2016 4/14/2016
while bending. This violates the SAES-H-200
section 5.1.1 that states coated pipe is handled at all times in a manner that
prevent damage to the pipe wall,bevelled ends and to the coating.

During internal receiving inspection to BER-882 Bl-10-01032-5850 on 12-March-


2016 @ OMPP-NA-2 LAYDOWN@ JUAYMAH PMT YARD by QC-Mech/Piping it was
3/12/2016 4/16/2016
found out that the 12" CL 300 FLANGE, RF, CS, ASTM A105/ A350 LF2 WITH SN-
1418509 BALL VALVE (QTY-1)the STAND SUPPORT was bended.

During internal receiving inspection to NTI# QTFTL-61/160-009 & NTI# QTFTL-


61/160-011 raised by Material Group@ QATIF 61/160
SITE on 14-Jan-2016 by QC-Mech/Piping & QC-Coating Inspector it was found out
that the PIPE 8" X 0.562" WT GR X60 X 12.2M EXTERNALLY COATED (QTY=126 Nos) 1/14/2016 4/17/2016
received from ARAMCO YARD and almost 70% has scratches I excessive damaged
in externally FBE Coated.

Page 85 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site visit on 19-March-2016@ QATIF-61/160 Bl-10-01032-5842, it was found


out that there was a pipe laying on the ground and with an open end and also
continue of fit-up and welding without conduct of airblowing. Where in as per Saudi
Aramco Standards SAES-L-450
SECTION 11.2 Each length of pipe shall be examined to make sure it is free from
internal obstructions. Any obstructions shall be removed before the pipe is welded
3/19/2016 4/20/2016
into a string. Each joint shall also be air blown to remove dust and sand
immediately prior to welding into a string. 11.3 Pipe strings shall be supported and
laterally restrained by an approved pipeline support methods such as pig pen
pipeline support, air bag or earth pillar methods.11.4 Open ends of pipeline strings
shall be capped to prevent entry of debris or animals and birds.

Page 86 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During Survelliance of SaudiKad laydown Yard NA2 of Berri Abu All,it was found out
that 12" FBE coated pipe API5L Gr X60 ,0.375" thk,CI300 are stored under direct
sunlight with no seperation by full encirclement with non compressibel rubber
4/16/2016 4/20/2016
padding or equivalent of atleast 10mm thk which vilolates Saudi Aramco
Engineering Standard SAES-H-
200,Section 5,Para 5.2.2 & 5.2.2.4

Page 87 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 19th Apri12016 Well Trunk line 280/283 FJ No 821t has been observed that
Construction Raised NTI for Stud Bolt assembly and bolt tightening. During site
activity Inspection it was found bolt tightening crew is not properly following the
sequence of the bolt as it is mentioned in SAEP-351. Hence it is clear violation of
SAEP-351 Para 9.1
Root Cause: It was found as construction made a change in bolt tightening crew
and added one more person in crew. The new crew member was not well aware of
Saudi Aramco Bolt tightening procedure SAEP-351and he was failed to fallow bolt
numbering properly.
Corrective Action: 4/19/2016 4/21/2016
1-Lose all Stud bolts from FJ # 82 and Readjust all stud bolls again and start
tightening as per SAEP 351 and complete it as same procedure
2-Toolbox meeting with the bolt tightening crew and explain the bolt tightening
procedure 351
3-Meeting with Crew Supervisor and advise him to make sure compliance with bolt
tightening procedure SAEP-351
4-Quallity inspector will verify bolt lightning of every flange
Preventive Action: Meeting with Supervisor and explain them the importance of
bolt tightening by complying the proper bolt tightening procedure SAEP-351.

ON 21 OF MARCH 2016 ,DURING SURVEILLANCE IN THE SITE.WE FOUND OUT THAT


THE EPOXY COATED STEEL BARS WAS FOUND LAYING IN THE GROUND AND
SCATERRED IN THE WORKING AREAS,THIS WAS ACLEAR VIOLATION OF SAIC-Q- 3/22/2016 4/22/2016
10081TEM NO.B4 THAT THE COATED STEEL SHALL BE STORED OFF THE GROUND
ON PROTECTIVE CRIBBLING.

Page 88 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

The RTU installed in the site, the Construction E and I pull the Instrument cable
inside the RTU Panel, the panel stil not raise inspection for the RTU Installation, The
Construction need to prepare the red mark drawing for the RTU, Battery Rectifier
and Battery Bank IFC Drawing to be sign by the Construction and PMT as a
reference drawing and this sign red mark IFC drawing need to attach in the RFI to
4/16/2016 4/26/2016
proceed for Inspection RTU Panel Installation . Which violation the Schedule B.
Section 5.1. Contractor shall update and revise construction package to renect the
current as-built status of the facilities during performance of the work. Additions wil
be marked in red with deletions marked out in green, all drawings willbe dated,
signed and have the Contractor's complete company name..

During internal receiving inspection to NTI# BER283-0048 Bl-10-00791-3530 on 28-


Jan-2016@ OMPP-NA-2 LAYDOWN YARD by QC- Mech/Piping it was found out that
the material received by MATERIAL GROUP SAP# 1000030388 SPECTACLE PLATE
12" CL 1500
FLANGE, RING JOINT, CS, ASTM A36(QTY-1) does not match the material description 1/30/2016 4/29/2016
on OUTBOUND & IFC MTO SAP# 1000030388
SPECTACLE PLATE 12" CL 1500 FLANGE, RING JOINT, CS, ASTM A516 GR. 70 the
requirement.

Page 89 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site inspection around 1:30pm,at WellHead 345 Area the Ground ln1)ection
Pit,Installed the Pipe only 460mm as per Standard Drawing shown 450 + 450 mm =
900mm totallength of the Pipe,the material should be Pipe; Fibergal ss 250mm
dia.as per standard,and the material still not received for inspection. Which is
2/27/2016 4/29/2016
violated under the Standard Drawing DD-950022, Sh.1of 12 and schedule Q
attachment 4 section 3.3 (Traceability shall be maintained on materials as specified
in Saudi Aramco Standards and manufacturer's specifications.Documents and
records shall enable the materials to be traced and used in installaton.

During daily routine surveillance last March 29,2016@ BERRI280,283 & 345.STA#
( 2+152, 5+022) Loop# 01 . QC Civil Inspector obseorved that the construction
have installed the TPS Steel Support on the foundation without roughened the top
surface of foundation. This is the clear violation with SAIS-Q-010 Sec- 3.2 which 3/29/2016 4/29/2016
refers to PIP ST03600, Sec. 6020101 that states Laitance,oil-soaked or damaged
concrete shell be removed down to sound concrete fractured aggregate or to a
minimum of the top 1 inch 25mm of the concrete.

Page 90 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

It was been already 2 weeks when the Switch Rack was InstalledIn the Site with the
khowledge of SAPMT,with the agreement the Construction will not Install do
anything In the SWitchrack until it will received for Inspection the material, the
construction received the Switch Rack is not the one they install in the site the
documents is not match in the installed Switch Rack.Which Is violated under 2/29/2016 4/30/2016
Schedule Q attachment 4 section 3.3 (Traceability shall be maintained on materials
as specified in SaudiAramco Standards and manufacturer's specifications.
Documents and records shall enable the materials to be traced and used in
installation.)

On 1st March,the RTFI result was received for ethane line and it was found 13 joints
were rejected among 67 joints shooted. This number of rejections made the 3/6/2016 4/30/2016
cumulative rejection rate of ethane line as 20.8%.

DURING SITE VISITE ON 31-MARCH-2016 @ QATIF 7 OPS Bl-10-00060-4529, IT WAS


FOUND OUT THAT THERE WAS APIPEAND SPOOLS WITH OPEN END. WHERE PER
SAUDI ARAMCO STANDARD SAES-L-450 SECTION 11.4 OPEN ENDS OF PIPELINE 3/31/2016 4/30/2016
STRINGS SHALL BE CAPPED TO PREVENT ENTRY OF DEBRIS OR ANIMALS AND
BIRDS.

Page 91 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During daily routine Surveillance lastApril12, 2016@ BERRI.881.STA# (0+500) .QC


Civil Inspector Observed that the Construction Group Use Small Cribbing for storage
of Steel Reinforcing Bars as QC observe Steel Reinforcing Bars are touching to the
surface of Ground . This is the clear violation with09-SAMMS-106 Sec -III.B. Which
refers to (ASTM A775/A 775--7b, Sec.15.3) that states Coating Steel Reinforcing
Bars Shell be Stored off the Ground on Protective Cribbing.
Root Cause: Saudi kad civil construction group did not Store Coating Steel 4/13/2016 5/1/2016
Reinforcing Bars properly.
Corrective Action: Civil construction group shall be stored the Coaling Steel Bars
on the protective cribbing to protect the Coating Steel Reinforcing Bars from
touching ground surface.
Preventive Action: Saudi Kad civil construction group shall comply I adhere with
the 09-SAMMS-106 Sec -111.8.

Page 92 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During Surveillance on 19 Apri12016 of Saudi Kad Laydown YardNA2 of Berri Abu


Ali,in the materials storage area of 161ateral wells it was found out that 12"
internal FBE coated API5L Gr X60, 0.375" thk, Double random pipe (SAP
no.4501601022) has been cut without Inspection Release from the QC Inspector
and without Transferring the traceability on the other side of the pipe. This is clear
violation as per SK-QAP-091, 0.
Root Cause: Lack of Communication from the construction before carrying out the
cutting activity. 4/19/2016 5/2/2016
Corrective Action:
Construction to provide complete document to conduct material receiving.
Construction is instructed to transfer the pipe traceability such as heat no, pipe no,
and size other material specification on other part of pipe.QC to raise RFI for
inspection and prepare IRC prior to proceed for next step activity.
Preventive Action: Construction is advice to follow the procedure to avoid Re-
occurance of same nature of violation.

During routine site inspection it was observed that the PVC conduit installed near
well doesnt have proper cover for preparation of installation of instrument such as
UFM cable insertion prior to cable pulling activity, as per NEC article 501.15 seals in
conduit & cable systems shall comply with this standards.
Root Cause: No NTI from construction prior to PVC coated installation of conduit. 4/20/2016 5/5/2016
Corrective Action: Advised construction to always issue NTI before installation to
avoid future violation. Rectify the conduit installation to fix cable pulling activity.
Preventive Action: Construction group shall raise the NTI & follow the sequence
of work.

Page 93 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

entende to May 20,


open
2016

open

Page 94 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

Page 95 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

Page 96 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

open

Page 97 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

open

Page 98 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

ACD EXTENDED open

open

Page 99 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

ACD EXTENDED open

open

open

Page 100 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

Page 101 SK-QAF-057 NCR LOG.docx.xlsx


AS PER:APRIL 2016

CLOSING DATE REMARKS JUSTIFICATION OF NEW ACD

open

open

Page 102 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-28- External FBE coat damaged


MECH Edison Cusi 10-01032-5846
SK-62 due to improper handling

OMPP-NA2-M-32- Mismatch of MTO, SAP No. and


MECH Edison Cusi 10-00791-3530
SK-70 Outbound No.

OMPP-NA2-E-23-SK- Materials Installed not follow


ELECT JOSE BAUTISTA 10-00791-3530
86 Library Drawing

Page 103 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-24-SK- Material Installed without


ELECT JOSE BAUTISTA 10-00791-3530
88 Receiving Inspection

Page 104 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-W-17- Safwa ETHANE line high


WELDING Vivek 10-01032-5846
SK-92 rejection rate

OMPP-NA2-M-42-
MECH Edison Cusi 10-01032-5850 Support of valve damage
SK-94

OMPP-NA2-M-43- Scratches on pipe during


MECH Renly Silvestre 10-00060-4529
SK-95 bending

OMPP-NA2-C-09- Poor presrvation of coated


CIVIL Benidect Asuncion 10-00060-4529
SK-102 bars.

Page 105 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-47-
MECH Edison Cusi 10-01032-5846 PRESERVATION
SK-103

OMPP-NA2-C-10- Pipe Support (TPS) foundation


CIVIL Soaib Khan 10-00791-3530
SK-108 without Surface preparation

Page 106 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-48-
MECH Hassan Alkhuwaildi 10-00060-4529 End CAP missing
SK-109

OMPP-NA2-C-11-
CIVIL MOIZUDIN Anchor bolts without marking
SK-110

OMPP-NA2-M-49- Pipes in yard with excessive


MECH Muhammad Shakeel 10-00060-4529
SK-113 corrosion)

Page 107 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-C-12- BERRI-881 / 00-01032- Poor storage of coated steel


CIVIL Shoaib Khan
SK-117 5850 bars

Page 108 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-33-SK- Cable pulling without


ELECT JOSE BAUTISTA 10-00791-3530
121 inspection of RTU panel.

OMPP-NA2-M-52- Preservation of 12" FBE


MECH Vivek Sukumaran 10-030071-1011
SK-122 Coated pipe / Directly sunlight.

Page 109 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-55- Wrong sequence of bolt


MECH Muhammad Sufyan 10-00791-3530
SK-132 torquing @ trunkline 280/283

Page 110 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-M-56- 12" FBE coated pipe cut


MECH Vivek Sukumaran 10-03007-1011
SK-133 without transfer traceability

Page 111 SK-QAF-057 NCR LOG.docx.xlsx


SAUDI KAD CONTRACTING COMPANY

NON-CONFORMANCE REPORT (INTERNAL) LOG


Contract No: 6600033951
Project Title : ONSHORE MAINTAIN POTENTIAL PROGRAM ZONE NA-2

NCR No. DISCIPLINE INSPECTOR LOCATION & BI No. SUBJECT

OMPP-NA2-E-39-SK- Insufficient proper accescover


ELECT JOSE BAUTISTA 10-00791-3530
134 from installation of instrument

OMPP-NA2-M-59- Damage plug valve hand


MECH Muhammad Sufyan 10-01032-5842
SK-146 wheel

Page 112 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During internal receiving inspection to NTI# QTFTL-61/160-009 & NTI# QTFTL-


61/160-011 raised by Material Group@ QATIF 61/160
SITE on 14-Jan-2016 by QC-Mech/Piping & QC-Coating Inspector it was found out
that the PIPE 8" X 0.562" WT GR X60 X 12.2M EXTERNALLY COATED (QTY=126 Nos) 1/14/2016 4/17/2016
received from ARAMCO YARD and almost 70% has scratches I excessive damaged
in externally FBE Coated.

During internal receiving inspection to NTI# BER283-0048 Bl-10-00791-3530 on 28-


Jan-2016@ OMPP-NA-2 LAYDOWN YARD by QC- Mech/Piping it was found out that
the material received by MATERIAL GROUP SAP# 1000030388 SPECTACLE PLATE
12" CL 1500
FLANGE, RING JOINT, CS, ASTM A36(QTY-1) does not match the material description 1/30/2016 4/29/2016
on OUTBOUND & IFC MTO SAP# 1000030388
SPECTACLE PLATE 12" CL 1500 FLANGE, RING JOINT, CS, ASTM A516 GR. 70 the
requirement.

During site inspection around 1:30pm,at WellHead 345 Area the Ground ln1)ection
Pit,Installed the Pipe only 460mm as per Standard Drawing shown 450 + 450 mm =
900mm totallength of the Pipe,the material should be Pipe; Fibergal ss 250mm
dia.as per standard,and the material still not received for inspection. Which is
2/27/2016 4/29/2016
violated under the Standard Drawing DD-950022, Sh.1of 12 and schedule Q
attachment 4 section 3.3 (Traceability shall be maintained on materials as specified
in Saudi Aramco Standards and manufacturer's specifications.Documents and
records shall enable the materials to be traced and used in installaton.

Page 113 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

It was been already 2 weeks when the Switch Rack was InstalledIn the Site with the
khowledge of SAPMT,with the agreement the Construction will not Install do
anything In the SWitchrack until it will received for Inspection the material, the
construction received the Switch Rack is not the one they install in the site the
documents is not match in the installed Switch Rack.Which Is violated under 2/29/2016 4/30/2016
Schedule Q attachment 4 section 3.3 (Traceability shall be maintained on materials
as specified in SaudiAramco Standards and manufacturer's specifications.
Documents and records shall enable the materials to be traced and used in
installation.)

Page 114 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 1st March,the RTFI result was received for ethane line and it was found 13 joints
were rejected among 67 joints shooted. This number of rejections made the 3/6/2016 4/30/2016
cumulative rejection rate of ethane line as 20.8%.

During internal receiving inspection to BER-882 Bl-10-01032-5850 on 12-March-


2016 @ OMPP-NA-2 LAYDOWN@ JUAYMAH PMT YARD by QC-Mech/Piping it was
3/12/2016 4/16/2016
found out that the 12" CL 300 FLANGE, RF, CS, ASTM A105/ A350 LF2 WITH SN-
1418509 BALL VALVE (QTY-1)the STAND SUPPORT was bended.

During Cold bending of 16" pipe 0.844"wt, API5L, SMLS Gr. X-60,SAP# 4504741031
ITEM# 00001 P#031, HN# 243587 EXT,COATED PIPE@ QTIF P21A SITE AREA w/c
was performed by Mizat Company on 10 March 2016.1t was found that the
Externally Coating of Pipe suffered deep scratches due to sudden rotation of pipe 3/13/2016 4/14/2016
while bending. This violates the SAES-H-200
section 5.1.1 that states coated pipe is handled at all times in a manner that
prevent damage to the pipe wall,bevelled ends and to the coating.

ON 21 OF MARCH 2016 ,DURING SURVEILLANCE IN THE SITE.WE FOUND OUT THAT


THE EPOXY COATED STEEL BARS WAS FOUND LAYING IN THE GROUND AND
SCATERRED IN THE WORKING AREAS,THIS WAS ACLEAR VIOLATION OF SAIC-Q- 3/22/2016 4/22/2016
10081TEM NO.B4 THAT THE COATED STEEL SHALL BE STORED OFF THE GROUND
ON PROTECTIVE CRIBBLING.

Page 115 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During site visit on 19-March-2016@ QATIF-61/160 Bl-10-01032-5842, it was found


out that there was a pipe laying on the ground and with an open end and also
continue of fit-up and welding without conduct of airblowing. Where in as per Saudi
Aramco Standards SAES-L-450
SECTION 11.2 Each length of pipe shall be examined to make sure it is free from
internal obstructions. Any obstructions shall be removed before the pipe is welded
3/19/2016 4/20/2016
into a string. Each joint shall also be air blown to remove dust and sand
immediately prior to welding into a string. 11.3 Pipe strings shall be supported and
laterally restrained by an approved pipeline support methods such as pig pen
pipeline support, air bag or earth pillar methods.11.4 Open ends of pipeline strings
shall be capped to prevent entry of debris or animals and birds.

During daily routine surveillance last March 29,2016@ BERRI280,283 & 345.STA#
( 2+152, 5+022) Loop# 01 . QC Civil Inspector obseorved that the construction
have installed the TPS Steel Support on the foundation without roughened the top
surface of foundation. This is the clear violation with SAIS-Q-010 Sec- 3.2 which 3/29/2016 4/29/2016
refers to PIP ST03600, Sec. 6020101 that states Laitance,oil-soaked or damaged
concrete shell be removed down to sound concrete fractured aggregate or to a
minimum of the top 1 inch 25mm of the concrete.

Page 116 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

DURING SITE VISITE ON 31-MARCH-2016 @ QATIF 7 OPS Bl-10-00060-4529, IT WAS


FOUND OUT THAT THERE WAS APIPEAND SPOOLS WITH OPEN END. WHERE PER
SAUDI ARAMCO STANDARD SAES-L-450 SECTION 11.4 OPEN ENDS OF PIPELINE 3/31/2016 4/30/2016
STRINGS SHALL BE CAPPED TO PREVENT ENTRY OF DEBRIS OR ANIMALS AND
BIRDS.

During Site Survelence in Juaymah Precast Yard on 05-Apr.2016 it was observed


that Anchor Bolt MatterialArrived without marking on the head of bolt. AnyMaterial
4/6/2016 5/6/2016
Must have Clear Identification and Marking accourding to the Standard12-SAMSS-
007 Para.6.2.5.5.

On 07-04-2016 it was observed during internalinspection at Juaymah Laydown


Yard,Material Department brought 10" NPS,0.438" WT,CS,API5L,GR X60 INT FBE
Coated Pipes received (15 PCS) for 10" Test Line Header Ext. @ P21A DWG # RB-
4/7/2016 5/6/2016
873472-001 have Strong Pitting and Corrosion on the Pipe Surface. The Line Class
being 9CS1P02,The Corrosion Allownce Max Allowed is 1.6mm where as the pipe
corrosion and rust is more than permitted. 1

Page 117 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During daily routine Surveillance lastApril12, 2016@ BERRI.881.STA# (0+500) .QC


Civil Inspector Observed that the Construction Group Use Small Cribbing for storage
of Steel Reinforcing Bars as QC observe Steel Reinforcing Bars are touching to the
surface of Ground . This is the clear violation with09-SAMMS-106 Sec -III.B. Which
refers to (ASTM A775/A 775--7b, Sec.15.3) that states Coating Steel Reinforcing
Bars Shell be Stored off the Ground on Protective Cribbing.
Root Cause: Saudi kad civil construction group did not Store Coating Steel 4/13/2016 5/1/2016
Reinforcing Bars properly.
Corrective Action: Civil construction group shall be stored the Coaling Steel Bars
on the protective cribbing to protect the Coating Steel Reinforcing Bars from
touching ground surface.
Preventive Action: Saudi Kad civil construction group shall comply I adhere with
the 09-SAMMS-106 Sec -111.8.

Page 118 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

The RTU installed in the site, the Construction E and I pull the Instrument cable
inside the RTU Panel, the panel stil not raise inspection for the RTU Installation, The
Construction need to prepare the red mark drawing for the RTU, Battery Rectifier
and Battery Bank IFC Drawing to be sign by the Construction and PMT as a
reference drawing and this sign red mark IFC drawing need to attach in the RFI to
4/16/2016 4/26/2016
proceed for Inspection RTU Panel Installation . Which violation the Schedule B.
Section 5.1. Contractor shall update and revise construction package to renect the
current as-built status of the facilities during performance of the work. Additions wil
be marked in red with deletions marked out in green, all drawings willbe dated,
signed and have the Contractor's complete company name..

During Survelliance of SaudiKad laydown Yard NA2 of Berri Abu All,it was found out
that 12" FBE coated pipe API5L Gr X60 ,0.375" thk,CI300 are stored under direct
sunlight with no seperation by full encirclement with non compressibel rubber
4/16/2016 4/20/2016
padding or equivalent of atleast 10mm thk which vilolates Saudi Aramco
Engineering Standard SAES-H-
200,Section 5,Para 5.2.2 & 5.2.2.4

Page 119 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

On 19th Apri12016 Well Trunk line 280/283 FJ No 821t has been observed that
Construction Raised NTI for Stud Bolt assembly and bolt tightening. During site
activity Inspection it was found bolt tightening crew is not properly following the
sequence of the bolt as it is mentioned in SAEP-351. Hence it is clear violation of
SAEP-351 Para 9.1
Root Cause: It was found as construction made a change in bolt tightening crew
and added one more person in crew. The new crew member was not well aware of
Saudi Aramco Bolt tightening procedure SAEP-351and he was failed to fallow bolt
numbering properly.
Corrective Action: 4/19/2016 4/21/2016
1-Lose all Stud bolts from FJ # 82 and Readjust all stud bolls again and start
tightening as per SAEP 351 and complete it as same procedure
2-Toolbox meeting with the bolt tightening crew and explain the bolt tightening
procedure 351
3-Meeting with Crew Supervisor and advise him to make sure compliance with bolt
tightening procedure SAEP-351
4-Quallity inspector will verify bolt lightning of every flange
Preventive Action: Meeting with Supervisor and explain them the importance of
bolt tightening by complying the proper bolt tightening procedure SAEP-351.

Page 120 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During Surveillance on 19 Apri12016 of Saudi Kad Laydown YardNA2 of Berri Abu


Ali,in the materials storage area of 161ateral wells it was found out that 12"
internal FBE coated API5L Gr X60, 0.375" thk, Double random pipe (SAP
no.4501601022) has been cut without Inspection Release from the QC Inspector
and without Transferring the traceability on the other side of the pipe. This is clear
violation as per SK-QAP-091, 0.
Root Cause: Lack of Communication from the construction before carrying out the
cutting activity. 4/19/2016 5/2/2016
Corrective Action:
Construction to provide complete document to conduct material receiving.
Construction is instructed to transfer the pipe traceability such as heat no, pipe no,
and size other material specification on other part of pipe.QC to raise RFI for
inspection and prepare IRC prior to proceed for next step activity.
Preventive Action: Construction is advice to follow the procedure to avoid Re-
occurance of same nature of violation.

Page 121 SK-QAF-057 NCR LOG.docx.xlsx


G COMPANY

NTERNAL) LOG

DEFICIENCY DESCRIPTION DATE ISSUED ACD

During routine site inspection it was observed that the PVC conduit installed near
well doesnt have proper cover for preparation of installation of instrument such as
UFM cable insertion prior to cable pulling activity, as per NEC article 501.15 seals in
conduit & cable systems shall comply with this standards.
Root Cause: No NTI from construction prior to PVC coated installation of conduit. 4/20/2016 5/5/2016
Corrective Action: Advised construction to always issue NTI before installation to
avoid future violation. Rectify the conduit installation to fix cable pulling activity.
Preventive Action: Construction group shall raise the NTI & follow the sequence
of work.

DURING THE HYDROTESTING OF 8" PLUG VALVES, CL900, RJ, CS, ASTM A216 WCB
BODY, SS AISI410 TRIM,. ONE VALVE (SN# L9515) OF SAME DISCREPTION LOST
BALANCE RESULTING TO DAMAGE OF IT'S HANDWHEEL. THIS VALVE NOT SCHEDULE
FOR HYDROTEST AS PER RFI. THE GROUP IS PREPARING THIS VALVE FOR THE NEXT
HYDROTEST SCHEDULE.
Root Cause: LACK OF SUPERVISION OF IN-CHARGE PERSON IN THE TESTING AREA
DURING PREPARATION AND PERFORMING OF VALVE HYDROTESTING.
4/28/2016 5/7/2016
Corrective Action: THE DAMAGE VALVE SHALL BE TRANFERED TO QUARANTINE
AREA AND PROPER PRESERVATION SHALL BE OBSERVED WHILE WATING FOR THE
DISPOSITION FOR THE DAMAGE HANDLWHELL.
Preventive Action: A COMPETENT AND REPONSIBLE IN-CHARGE SHALL BE
ASSIGNED TO SUPERVISE THE VALVE HYDROTEST AREA. ALL HEAVY VALVES SHALL
BE PROVIDED WITH SUFFIECIENT TEMPORARY SUPPORT IN EVERY STAGING OF TEST
UP TO RELEASE TO SITE.
Page 122 SK-QAF-057 NCR LOG.docx.xlsx
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SAUDI KAD CONTRACTING COMPANY
ONSHORE MAINTAIN POTENTIAL PROGRAM
FOR ZONES NA-2
CONTRACT NO. 6600033951
SK-QOC-01(FAB / SHOP) Rev. 03 QA/QC Organization Chart, Date: 7 January 2017

QA/QC
QA/QCORGANIZATIONAL
ORGANIZATIONALCHART
CHART FAB
FABSHOP
/ SHOP

MOHAMMED ATHAR KHAN


QA/QC MANAGER
OMPP NA-2
(Approval Status 2)
+966506995608

TBA
QC SUPERVISOR

SPOOL RELEASING Valve & Spool MATERIAL WELDING PRECAST PAINTING


RECEIVING NDT Inspections FOUNTATION Fit up Inspections
INSPECTION Testing INSPECTION INSPECTION
INSPECTION INSPECTION

ABDULLAH MOHAMED
MOHAMED JAMAL MOIZUDDIN IFTIKAR
IFTIKAR AHMED
AHMED SUBASH DAAS
ABDULLAH AL-EID
AL-EID SARTHAR WAQAS KHAN MOHAMED VENKATESH JAMAL MOIZUDDIN
QC MOHAMED SHAKEEL
SHAKEEL NDT
NDT Coordinator QC
QC ClVIL
ClVIL INSPECTOR
QC COATING INSPECTOR QC MECH INSPECTOR
QC MECHANICAL
MECHANICAL QC
QC MECH.
MECH. INSPECTOR
INSPECTOR QC MECH. INSPECTOR QC WELDING INSPECTOR Coordinator INSPECTOR
(Approval Status 1) (Approval Status 1) (Approval Status 1) (Approval
(Approval Status
Status 1)
1) (Approval
(Approval Status
Status 1)
1)
(Approval
(Approval Status
Status 1)
1) (Approval Status 1) (Approval
(Approval Status
Status 1)
1)
+966 568596308 +966 540 30 2747 +966 58016 3221 +966
+966 535537293
535537293 +966
+966 593718519
593718519
+ 966580003504 +966
+966 5966
5966 91909
91909 +966
+966 56
56 598
598 9842
9842

HESHAM MARHOON RENLY M SILVESTRE


SUGUMAR
SUGUMAR
QC
QC WELDING
WELDING INSPECTOR
INSPECTOR QC QC
QC MECH
MECH INSPECTOR
INSPECTOR FAHIM
FAHIM MOHAMMED
MOHAMMED
QC WELDING
WELDING INSPECTOR
INSPECTOR
(Approval
(Approval Status
Status 1)
1) (Approval Status 1) (Approval
(Approval Status
Status 1)
1) QC WELDING INSPECTOR
+966 503856159 +966597046639 +966 532554061 (Approval Status 1)
+966597046639

MOHAMMED MUDASSAR
RAJ MOHAN QC Inspector (E&I)
QC
QC WELDING
WELDING INSPECTOR
INSPECTOR MD.
MD. HAMID
HAMID HUSSAIN
HUSSAIN
(Approval
(Approval Status
Status 2)
2)
(Approval
(Approval Status
Status 1)
1) QC WELDING INSPECTOR
+
+ 966540391676
966540391676
+966505805268
+966505805268 (Approval Status 1)
+966
+966 599022732
599022732

RUSTHAM KHAN MD. SALMAN FAROOQUE


QC MECHANICAL QC
QC WELDING
WELDING INSPECTOR
INSPECTOR
(Approval
(Approval Status
Status 2)
2) (Approval
(Approval Status
Status 2)
2)
= Present on site +
+ 966
966 580012240
580012240 + 966 506434398
= Not Present / On Vacation

Prepared By : QA/QC MANAGER


Name : MOHAMED ATHAR KHAN Approved By: PRESIDENT & CEO
Name: KAMAL AZZAM

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