LESSONS LEARNED
EGA2 Project
Sr. No Observation or
Comment
Process
Walkdowns done by QC
1 personnel without Construction
prior check
Lack of expeditor for
procurement of materials and
2 P
preparation of LPO.
1. Super duplex and SS Piping
Materials mix up. (NCR)
2. Lack of Traceability of
3 materials according to the
Material groups, types and PO.
3. Uncontrolled Electrodes
storage and distribution (NCR)
4 270 structure misalignment for
not following the ITP. (NCR)
Installation of slip critical
5 structural connections
To be Encouraged (E) or Project End Date
Problem to Avoided (P)? Affected? (Y/N)
P Y
Y other 2 days in HO
P N
P N
P Y
Narrative Suggested Action
The full project was dependant on Quality Punch lists
which costed lot of manhours, disputes and delay in the
completion of construction cause the construction was 1. Construction shall do walkdown prior to QC walkdown.
depending upon the punch list to complete the actual 2. The line responsible construction personnel (Supervisor/Foreman) shall always be
balance scope of works rather than completing the job and with QC during walkdwon to clear the balance items to achieve better quality in
offering it and Each line was walked down by QC 2-3 times constrcution and to reduce the amount of rework.
for hydro and 2-3 times for reinstatement.
It took lot of efforts from different people from different
departments to work upon different MRF's due to the Procurement Engineer shall be mobilized to site for atleast 3 days a week and the
unavaialbility of this personnel in the site.
1. There was lot of Mix-up between duplex to super duplex
mateial (Like bolts, pipe, etc.) resulted in Project NCR and
additional work. 1. PMI shall be carried out on SS and duplex, CS and LTCS material items in case of
2. The materials upon delivery to site were found ambiguity, prior to release to site.
2. Quarantined materials rack/area shall be maintained to identify and detain the
untraceable and unsegregated or unstacked which lead to unacceptable materials.
issuance of wrong materials to site than the required. 3. Consumable control check sheet to be followed by store personnel under the
3. The electrode issuer was not aware about the monitoring of QC.
elctode baking & heating requirements, no of times to be 4. Regular training from QC to educate the people with the project specs is
made hot, the distribution of electrodes was unorganised. mandatory.
The action required from Quality team to eradicate this had
leaks in delivering in right time.
The ITP requirements were overridden by the construction 1. Construction team be aware of the minimum std. tolerances atleast from Engineer
Team, by not doing the proper survey and without level and to be strictly followed.
following the sequence for grout release which lead to 2. Periodical training to the engineers, Supervisor and Surveyors required from QC
serious complications in the alignment of the main grids 2. The columns/grids shall not be relased to grouting or for the next level with out
and columns and lead to consequences. alignment by QC and Surveyor and Bolt tightening inspections (AS per ITP)
The slip critical connections were installed in painted
condition rather than with removed paint condition. The slip critical joints are to be identified in the beginning of the project, to be made
Though this was mistake from BPJV and Target, the aware which one is a slip critical to the site supervisor and Inspector level and
proper training to be conducted by QA/QC personnel to eradicate this error in future
consequences were to be faced by Target by welding the
projects.
connections.

Uncontrolled documents and
6 drawings in the site and offices
The distribution matrix was not followed.
Controlled copy numbers were not followed.
Old revision drawings are not marked as superseded
P N Lack of exposure to site teams about the control copy
requirements.
Few drawings were issued by BPJV through email and also
to site without being transmitted to DC.
Document control procedure has to be established and to be made followed by the
full project under the guidance and monitoring of QA Engineer.
Internal Surveillance and sudden Audits shall be carried out by QA Engineer to avoid
the procudure implementing failure.
Registers of Master, Control, Superseded documents and drawings are to be
maintained by DC under the as per the documented procedure.
QA shall educate the control copy, superseded and Numbering purpose to the site
level.
A separate test packs team has to be considered establised either from Quality or
from Technical for this sort of SMP projects.

Lack of Quality Inductions to the
7 required personnel and
awareness of the project quality
requirements
1. It shall be made mandatory to have a project quality Inductions just like safety for
every personnel prior (Relevant) to joining the project. Right from the Project
Though there were some Quality Inductions and sessions Manager through Workers.
on Fit-up and welding, Flange management, Hydro Testing, 2. A quality Induction plan to be developed by the QA Engineer covering all the
P Y grouting, etc. The required trainings/Inductions and daily different group of personnel in the project. This training/ induction to be done
tool box talks were not sufficinet enough to cover large periodically (Every 3 months or low) covering all the groups in the project with
amount of scope of works. changes occurring at site.
3. One dedicated QA Engineer with an associate QA (If required) shall be made avail
from the beginning of the project.

Quality Management

Under estimation of QC man-
1 power required and their role in
the project
The amount of QC Manpower required was verily
underestimated which lead to the hiring of Manpower and
caused an impact on budget as it was unplanned.
P Y The need for inspectors in different areas of site, covering
the different disciplines of the project, no of walkdowns,
etc. was not taken into consideration from the beginning of
the project.
The Site quality Manager/Lead shall be noimnated from the beginning of the project
to understand the actual project scope of works, to study the contract and for
preparation PQP.
Project quality Manpower shall be planned and prepared by the Division Quality
Manager & Project Quality Manager during the initial histogram/ plan preparation
stage according to the project requirements, to make sure that the required
personnel for the project are identified and mobilized in the right time.
Manpower plan to be reviewed by Site QC Manager every month to meet the
project requirements.

Lack of; Periodical trainings and audits were not carried out to
2 Periodical Internal Audits P Y required extent convering the project manpower and with Internal sudits shall be carried out at perdiodic intervals as per the Project Quality
Internal Observations/NCR's. different trades. Plan and QA Engineer shall carry out unplanned Audits to raise NCR's.

Lack of; The shortfall of QA engineer can be clearely identified; The required logs are to be prepared according to project requirements and shall be
Timely Quality Logs for systems, 1. The Quality logs were found to be unupdated like under QA monitoring and to be mainstained BY QC DCC.
3 Unupdated existing logs P Y (System handover, PTR, Calibation, etc.) QA Walkdowns are to be conduted at required frequency suiting the project to
2. identify and Highlight the observations.

4 High weld repair %
The repair % of the welders went upto 24 % in the project.
Firstly, RT on the welds from BPJV started 6 months after
the welding commenced in the site and no one knew what
was the quality of the welds from the beginning of project.
The repair % Caluculation was not according the B 31.3 and
the same was not conisdered by Target Quality Team.
Lack of QC coverage for the welding activities in different
areas of the site was one of the big setback as the required
P Y Inspectors was a serious setback.
Unacceptable; Fit-up, consuambales usage and lack of
resurces like Wind protection Tent, Welder tools,
Continuous breakdown of the Mother Oven played a major
role in the welds failure.
There were huge porosity problems with E7018-1 Adhor
eloectrodes which resulted in RT repairs.
1. This % of repair shall be monitored from Day 1 of the project per welder. The first
two production welds by any welder shall be Radiogrphed and the quality of weld
has to examined. If the quality is found low, then the welder has to be sent for
further training and repeat the same.
2. In order to acheive the above, the NDE contractor has to be finalised before the
beginning of the project, gate pass, safety inductions, and all approval need to be
done and the crews to be made ready for the same. The LPO for NDE contractor
shall be reviewed and accepted site Quality Lead as weel.
3. The client spec requirements shall be well read and understood by Site Quality
Manager to agree and document the % caulucations in the beginning of the prject.
4. The QC inspectors, with previous experience and necessary certifications shall be
made avail in site in right time.
5. Demo and testing of the welds done with Adhor E7018-1 electrodes shall be
carried out prior to use of these electrodes in prouction from next projects.

There was delay in inspection from Quality Team on Target

5 Inconsistent Material Inspections.
procured materials in Steel and Piping. One full lot of ASTM
A 493 bolts were rejected as the quality requirements were
P Y DMR shall be issued immediately upon the receiving of the materials.
not met.
It was also observed that the some of the DMR were found QA engineer shall make sure that te inspections of the materials received shall be
missing to be issued to Target. inspected the QC personnel within 3 days or earlier (Depending upon need) upon
receipt of materials.

Construction

Debris and Foreign materials
1 insde the pipe and damaged
steel
The materials upon receiving, were not stacked and The material receiving procedure has clear instruction of storage/stacking of
preserved properly which resulted in damage to the project materials. Materials and Construction teams shall be trained by QA/QC.
P N materials and debris went inside the pipe. This resulted in Pipes prior to installation shall be checked for debris.
Addditional boroscopic inspection under Heavy some Pipes if procured by us, then the order shall uinclude End caps with Bevel protectors
unplanned budget and Causing delay in Project schedule. for the protection of bevels from mechanical damage.

There were no trained mapower to carry out the

Lack of Resources for
2 Preservation of Equipment
(Space heaters)
preservation of Space heaters/Equipment.
P N The required Grease, cable, oil etc. were not avail in site.
There was no Generator and Power cables to make sure
that the preservation is carried in the right time without
Moisture forming in the equipment.
Dedicated and trianed Manpower to be categorised from the beginning.
The resources required for the preservation of equipment as per the scope to be
studied and made avail to avoid NCR's or warranty issues.
DG to be considered in the scope for preservation of equipment as required for
project.

Bubble formation while on
3 grouting with Sika 42 MP Slow
Expoxy grout product while
grouting pumps
Underfill of cementatious grout
4 in the COD area of tanks in all
the areas of the site.
Uncontrolled calibration cycle of
5 the hydro Instruments to meet
the project requirements.
General
Monthly incentives in the form
1 of Etisalat/Du Cards for the
encouragement of welders
2 PBQ (People based Quality)
QC coverage for the Procument
3 process of material Vendor
Packages.
Proper and suffiencent amount of Mixing tools to be procured or to be made avail
Improper Mixing is one of the Major reason and setback in depending upon the scope of grouting works in the project.
the process of grouting Epoxy as well as Cementatious. The manpower shall be skilled enough or to trained before to get rid of this sort of
P Y Ofcourse the materials supplied by Sika itself was having a problems.
problem and the full batch of materials were taken back by Demo from Manufacturer (Depending upon the batch quantity) is
Sika and replaced with another Batch. recommended/suggested.
The manufacturer requirements shall not be violated.
Proper and suffiencent amount of tools to be procured or to be made avail
Lack of pressure grouting tools for tank grouting in time, depending upon the scope of grouting works in the project.
P Y resulted in Underfill of grout in the Tank COD area and The manpower shall be skilled enough or to be trained before to get rid of this sort
minor gaps. of problems.
There was no plan for the calibration of testing equipment A centralised Calibration log monitoring the in and out of the instruments, due date
P Y as the requirement from BPJV was very stringent. for calibration per project requirements is required to to be maintained by Materials
with Qaulity DC.
Welders shall be encouraged enough for better quality in an unbiased and
E Y Appreciation certificates along with
professional approach
PBQ is one good process which can adapted in the future Upon screeing, workers to be selected and to be trained to work Quality in PBQ.
E Y projects for the betterment of the Quality in the works and This can be utilized in unprofessional manner as well if not monitored properly.
make the people work more enthusiastic towards quality.
Site Quality Personnel shall be involved in the process of Vendor site visits and Audits to be considered in the budget for the Target
E Y procurement process right from the MRF review, till the manufacured/Procured materials as per the contract.
final handover of the systems