LESSONS LEARNED EGA2 Project Sr. No Observation or Comment To be Encouraged (E) or Project End Date Problem to Avoided (P)? Affected? (Y/N) Narrative Suggested Action 1. Construction shall do walkdown prior to QC walkdown. 2. The line responsible construction personnel (Supervisor/Foreman) shall always be with QC during walkdwon to clear the balance items to achieve better quality in constrcution and to reduce the amount of rework. Procurement Engineer shall be mobilized to site for atleast 3 days a week and the other 2 days in HO Process 1 Walkdowns done by QC personnel without Construction prior check P Y 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 depending upon the punch list to complete the actual balance scope of works rather than completing the job and offering it and Each line was walked down by QC 2-3 times for hydro and 2-3 times for reinstatement. 2 Lack of expeditor for procurement of materials and preparation of LPO. P Y It took lot of efforts from different people from different departments to work upon different MRF's due to the unavaialbility of this personnel in the site. 3 1. Super duplex and SS Piping Materials mix up. (NCR) 2. Lack of Traceability of materials according to the Material groups, types and PO. 3. Uncontrolled Electrodes storage and distribution (NCR) P N 1. There was lot of Mix-up between duplex to super duplex mateial (Like bolts, pipe, etc.) resulted in Project NCR and 1. PMI shall be carried out on SS and duplex, CS and LTCS material items in case of additional work. ambiguity, prior to release to site. 2. The materials upon delivery to site were found 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. 4 270 structure misalignment for not following the ITP. (NCR) P N The ITP requirements were overridden by the construction Team, by not doing the proper survey and without following the sequence for grout release which lead to serious complications in the alignment of the main grids and columns and lead to consequences. 1. Construction team be aware of the minimum std. tolerances atleast from Engineer level and to be strictly followed. 2. Periodical training to the engineers, Supervisor and Surveyors required from QC 2. The columns/grids shall not be relased to grouting or for the next level with out alignment by QC and Surveyor and Bolt tightening inspections (AS per ITP) 5 Installation of slip critical structural connections P Y The slip critical connections were installed in painted condition rather than with removed paint condition. Though this was mistake from BPJV and Target, the consequences were to be faced by Target by welding the connections. The slip critical joints are to be identified in the beginning of the project, to be made 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 projects. 6 7 Uncontrolled documents and drawings in the site and offices Lack of Quality Inductions to the required personnel and awareness of the project quality requirements P P 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. N The distribution matrix was not followed. Controlled copy numbers were not followed. Old revision drawings are not marked as superseded 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. Y 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 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 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. 1 Under estimation of QC manpower required and their role in the project P Y 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. 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. 2 Lack of; Periodical Internal Audits Internal Observations/NCR's. P Y Periodical trainings and audits were not carried out to required extent convering the project manpower and with Internal sudits shall be carried out at perdiodic intervals as per the Project Quality Plan and QA Engineer shall carry out unplanned Audits to raise NCR's. different trades. P Y The shortfall of QA engineer can be clearely identified; 1. The Quality logs were found to be unupdated like (System handover, PTR, Calibation, etc.) 2. 3 Lack of; Timely Quality Logs for systems, Unupdated existing logs The required logs are to be prepared according to project requirements and shall be under QA monitoring and to be mainstained BY QC DCC. QA Walkdowns are to be conduted at required frequency suiting the project to identify and Highlight the observations. 4 5 High weld repair % Inconsistent Material Inspections. P P Y 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 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. Y There was delay in inspection from Quality Team on Target procured materials in Steel and Piping. One full lot of ASTM A 493 bolts were rejected as the quality requirements were 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 inspected the QC personnel within 3 days or earlier (Depending upon need) upon missing to be issued to Target. receipt of materials. N 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. 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. N There were no trained mapower to carry out the preservation of Space heaters/Equipment. 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. Construction 1 Debris and Foreign materials insde the pipe and damaged steel 2 Lack of Resources for Preservation of Equipment (Space heaters) P P 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. Y Improper Mixing is one of the Major reason and setback in the process of grouting Epoxy as well as Cementatious. Ofcourse the materials supplied by Sika itself was having a problem and the full batch of materials were taken back by Sika and replaced with another Batch. Proper and suffiencent amount of Mixing tools to be procured or to be made avail depending upon the scope of grouting works in the project. The manpower shall be skilled enough or to trained before to get rid of this sort of problems. Demo from Manufacturer (Depending upon the batch quantity) is recommended/suggested. The manufacturer requirements shall not be violated. P Y Lack of pressure grouting tools for tank grouting in time, resulted in Underfill of grout in the Tank COD area and minor gaps. Proper and suffiencent amount of tools to be procured or to be made avail depending upon the scope of grouting works in the project. The manpower shall be skilled enough or to be trained before to get rid of this sort of problems. P Y There was no plan for the calibration of testing equipment A centralised Calibration log monitoring the in and out of the instruments, due date for calibration per project requirements is required to to be maintained by Materials as the requirement from BPJV was very stringent. with Qaulity DC. 3 Bubble formation while on grouting with Sika 42 MP Slow Expoxy grout product while grouting pumps P 4 Underfill of cementatious grout in the COD area of tanks in all the areas of the site. 5 Uncontrolled calibration cycle of the hydro Instruments to meet the project requirements. 6 General 1 Monthly incentives in the form of Etisalat/Du Cards for the encouragement of welders E Y Appreciation certificates along with 2 PBQ (People based Quality) E Y 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. 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. 3 QC coverage for the Procument process of material Vendor Packages. E Y Site Quality Personnel shall be involved in the process of procurement process right from the MRF review, till the final handover of the systems Welders shall be encouraged enough for better quality in an unbiased and professional approach Vendor site visits and Audits to be considered in the budget for the Target manufacured/Procured materials as per the contract.
