140730

SUMMARY OF LBE
As of July 30, 2014

Nos. % Nos. % Nos. %
1 AMANA 3 18% 16 12% 19
13%
2 ARCC 1 6% 5 4% 6
4%
3 ASYAD 1 6% 3 2% 4
3%
4 FCN 0 0% 1 1% 1
1%
5 GACC 0 0% 4 3% 4
3%
6 IKK 0 0% 3 2% 3
2%
7 KCC 2 12% 10 8% 12
8%
8 PSCL 0 0% 1 1% 1
1%
9 PCMC 0 0% 2 2% 2
1%
10 SENDAN 0 0% 7 5% 7
5%
11 SENDAN/DAELIM 0 0% 1 1% 1
1%
12 TCC 1 6% 12 9% 13
9%
Subtotal 8 47% 65 50% 73
50%
DAELIM
1. Engineering:
- Eng. 6 35% 14 11% 20 14%
- Inst. 0 0% 1 1% 1 1%
- Mech. 0 0% 8 6% 8 5%
2. Construction:
- Civil 0 0% 1 1% 1
1%
- Elect 1 6% 3 2% 4
3%
- Mech. 1 6% 13 10% 14
10%
3. Procurement:
- Mat'ls 0 0% 14 11% 14
10%
- Mech. 0 0% 5 4% 5
3%
4. Mat. Deprt.:
- Mat'ls 0 0% 1 1% 1
1%
- Mech. 1 6% 0 0% 1
1%
- Preservation 0 0% 2 2% 2
1%
5. Preservation
- Telecom 0 0% 1 1% 1
1%
6. Mat & Pro. Dept
- Mat'ls/Pro. 0 0% 1 1% 1
1%
Subtotal 9 53% 64 50% 73
50%
17
100%
129
100%
146
100%
13
GRAND TOTAL
TOTAL
(PN & VAF) S/N
Proactive Notification
(PN)
Violation After Fact
(VAF)
Contractor/
Subcontractor
LOG BOOK ENTRY (LBE) SUMMARY
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
LBE-AMA-ELECT-
001
AMA VAF ELECT Electrical 23-Mar-12 26-Mar-12 06-Apr-12 07-May-12 Closed
LBE-AMA-ELECT-
002
AMA VAF ELECT Electrical 23-Mar-12 26-Mar-12 06-Apr-12 07-May-12 Closed
LBE-AMA-CIVIL-001 AMA VAF CIVIL Civil 24-Mar-12 27-Mar-12 07-Apr-12 05-May-12 Closed
LBE-AMA-CIVIL-002 AMA VAF CIVIL Civil 24-Mar-12 27-Mar-12 07-Apr-12 16-Jun-12 Closed
LBE-AMA-CIVIL-003 AMA VAF CIVIL Civil 24-Mar-12 27-Mar-12 07-Apr-12 12-May-12 Closed
LBE-AMA-CIVIL-004 AMA VAF CIVIL Quality Management 24-Mar-12 27-Mar-12 07-Apr-12 04-Apr-12 Closed
LBE-AMA-CIVIL-005 AMA VAF CIVIL Civil 26-Mar-12 29-Mar-12 09-Apr-12 04-Apr-12 Closed
LBE-AMA-CIVIL-006 AMA VAF CIVIL Civil 29-Mar-12 01-Apr-12 12-Apr-12 15-Apr-12 Closed
LBE-AMA-CIVIL-007 AMA PN CIVIL Civil 02-Apr-12 05-Apr-12 16-Apr-12 10-Apr-12 Closed
LBE-AMA-CIVIL-008 AMA VAF CIVIL Civil 03-Apr-12 06-Apr-12 17-Apr-12 07-Apr-12 Closed
LBE-AMA-CIVIL-015 AMA VAF CIVIL Civil 17-Apr-12 20-Apr-12 01-May-12 22-Apr-12 Closed
LBE-DLM-CIVIL-016 DAELIM VAF CIVIL Quality Records 24-Apr-12 27-Apr-12 08-May-12 08-May-12 Closed
LBE-AMA-CIVIL-017 AMA VAF CIVIL Civil 25-Apr-12 28-Apr-12 09-May-12 07-Jul-12 Closed
LBE-AMA-CIVIL-018 AMA PN CIVIL Civil 25-Apr-12 28-Apr-12 09-May-12 20-May-12 Closed
LBE-AMA-CIVIL-019 AMA VAF CIVIL Civil 01-May-12 04-May-12 15-May-12 20-May-12 Closed
LBE-AMA-CIVIL-021 AMA PN CIVIL Civil 01-May-12 04-May-12 15-May-12 09-May-12 Closed
During surveillance inspection at the Concreted Gas Furnace foundation F1170, at 0840 hrs., 17/04/12,
it was observed that the surface of the newly & concreted foundation is dry without plastic sheeting or
burlap covering. The water truck delivering curing water was just arriving at the time. Concrete pouring
was completed around 2200 hrs. on 16/04/12. This is in violation of RT25-3001-01 Section 9.
Batch Plant QC Inspector from Contractor Daelim & Sub-contractors are not issuing RFIs to SADARA
for Batch Plant Management at Qanbar RMC during scheduled hours. This is in violation of Inspection &
Test Plan and concrete specifications. No RFIs were issued on 23/04/12, 22/04/12.
PN: Due to the onset of summer hot days, concreting should be scheduled by the rise in ambient
temperature. Today, measured ambient temperature exceeds 43C at 1400hours, while rebar
temperatures exceeds 50C. Contractor to follow section 5.2 of RT2S-3001-01.
During surveillance inspection, it was found out that the Contractor has carried out concrete repairs at
Liquid Furnace FDNs F-1250. There was no submission yet of concrete repair procedure to Company
which requires approval. This is in violation of section 11 of RT2S-3001-01.
PN: It was observed that there are numerous surface defects on the completed Liquid Furnace FDN F-
1250 after removal of formworks. Contractor to submit concrete repair procedure with Materials to be
used for approval.
Inadequate water covering at the Gas Furnace FDNs F1130, F1160 and Liquid FDNs F1240, which are
less than 7 days old concrete. These are gaps in the plastic sheet and are blown by wind. For F1240,
the side forms have been removed and sides of the concrete FDN are totally exploded without any form
of concrete curing. Violations to Section 9 of RT25-3001-01.
During material receiving for FBE coated reinforcing bars, bundles of 25 mm bars were found with
excessive uncoated lugs on the rebar exceeding the 2% max. allowed for coating damages. As advised
to the QC Inspectors of both Contractor & Sub-contractor, the rejected bars are required to be
quarantined and separated from the accepted bars.
Reference to Site Quality Deficiency Report (SQDR-AMA-CI-008) the test frequencies as stipulated in
the Concrete Specification have not been complied with for the concrete ingredients per sections 2.4.7
and 2.2.15. These are repeated violations of these sections. The SQDR-AMA-CI-008 has been closed
without valid documents to prove closure.
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
The contractor has started concreting activities (Lean Concrete pouring) however, an approved
Concrete Quality Control Engineer (CQCE) is not available. This is in violation of RT25-3001-01
Concrete Specification section 1.5.2 The quality control program which shall be prepared by the CQCE
is also not available. (Required by RT25-3001-01 section 1.5.3.
The contractor has no approved batch plant QC Inspector as required by Schedules of attachment 1,
during the batching of lean concrete for liquid furnace FDN.
During inspection at site, it was found out that there are two revision drawings in circulation at the site.
Drawing nos. A554-E-103-CV-DWG-C30-331 to 343 Rev. 1 are being used by the construction team.
Violation to schedule Q section 3.2
The contractor has issued RFIs which includes concrete pouring of lean concrete. The contractor
however has no approved (ITP) Inspection & Test Plans and Checklist. The work activities require ITPs
for Earthwork Concrete and Earthing. A violation of schedule Q, section 3.3.
The contractor has proceeded with the Lean Concreting of Liquid Furnace FDN without approved Mix
Design. RT25-3001-01 Concrete Specification section 3.5.3 specifies that No concrete pouring shall
commence before trial mixes, 28 days compression test and all other test in this specifications are
completed and approved by Owner.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Daelim/Subcontractor Response / Reason
Company
comment
Approved Close
LBE by Company
STATUS
During preliminary inspection of reinforcing bars installation for FDN F-1250, Liquid Furnace area, it was
found out that the concrete cover along the perimeter of the foundation are less than the minimum
requirements reveal readings of down to 30mm only. Violation to IFC drawing # A554-E-103-CV-DWG-
C30-334 Rev. 2.
During inspection the vertical S. No. 14 (LH) for pedestals P7 at Liquid Furnace do not comply with IFC
DWG # A554-E-103-CV-DWG-C30-315 rev. 2. The bar bending schedule & details DWG # AMA-
SMFCP-CV-001 shows different bending detail for s.no. 14 than that is required in the IFC drawing.
During inspection of M30 & M36 anchor bolts for furnace, no measuring tool for checking diameter of
bolts. The nuts for M36 bolts are grade 105, ASTM A563, while DWG A554-E-103-CV-DWG-599-402
requires grade DH ASTM A563.
PN: Contractor has to provide sufficient curing water meeting the requirements of concrete mixing water
at site for curing of concrete structures. It is recommended that records of that test maintained at site.
During receiving of reinforcing bars for gas furnace FDN, tags are only found on one end of the bundles
and are not traceable to the mill certificate batch numbers. RT25-3001-01 section 2.5.4.3 requires tags
at each end of bundles.
During surveillance, it was observed that newly delivered inspection reinforcing bars without receiving
inspection are being installed at gas furnace FDN F1140. The mill test certificates are not yet available
for review & verification relative to the reinforcing bar deliveries. Violation to ITP & RT25-3001-01
section 2.5.
Contractor has started installing reinforcing bars at Liquid Furnace Area FDN L17-L20 while the tests for
tensile/elongated and bend/re-bend tests have not yet been done as required by RT25-3001-01 section
2.5
PN: Reinforcing bars installation at Gas Furnace area tooting F1170 were observed with inclined
position of some bars and irregular spacing. Contractor to rectify to comply with placement as shown on
IFC drawings and as per section 7.1.1/7.1.2 RT25-3001-01.
During inspection for receiving, storage and presentation of reinforcing bars, it was observed that some
bundles were laid directly on the concrete slab, in violation of section 2.5.4.4 RT25-3001-01. Unbundled
bars were also observed scattered on the concrete slab.
CONTRACTOR'S CORRECTIVE ACTION PLAN
Page 2 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-023 AMA VAF CIVIL Quality Records 05-May-12 08-May-12 19-May-12 08-May-12 Closed
LBE-KCC-CIVIL-024 KCC VAF CIVIL Quality Management 08-May-12 11-May-12 22-May-12 20-May-12 Closed
LBE-DLM-CIVIL-025 DAELIM VAF CIVIL Civil 09-May-12 12-May-12 23-May-12 20-May-12 Closed
LBE-KCC-CIVIL-026 KCC VAF CIVIL Civil 09-May-12 12-May-12 23-May-12 07-Jun-12 Closed
LBE-AMA-CIVIL-027 AMA VAF CIVIL Civil 10-May-12 13-May-12 24-May-12 17-Jun-12 Closed
LBE-DLM-CIVIL-031 AMA VAF CIVIL Quality Management 14-May-12 17-May-12 28-May-12 26-May-12 Closed
LBE-AMA-CIVIL-032 AMA VAF CIVIL Civil 17-May-12 20-May-12 31-May-12 16-Jul-12 Closed
LBE-AMA-CIVIL-033 AMA PN CIVIL Civil 20-May-12 23-May-12 03-Jun-12 23-May-12 Closed
LBE-AMA-CIVIL-034 AMA VAF CIVIL Civil 20-May-12 23-May-12 03-Jun-12 16-Jul-12 Closed
LBE-AMA-CIVIL-035 AMA VAF CIVIL Civil 22-May-12 25-May-12 05-Jun-12 26-May-12 Closed
LBE-AMA-ELECT-
003
AMA VAF ELECT Electrical 24-May-12 27-May-12 07-Jun-12 03-Jun-12 Closed
LBE-KCC-CIVIL-036 KCC VAF CIVIL Civil 04-Jun-12 07-Jun-12 18-Jun-12 09-Jun-12 Closed
LBE-KCC-CIVIL-037 KCC VAF CIVIL Civil 06-Jun-12 09-Jun-12 20-Jun-12 09-Jun-12 Closed
LBE-AMA-CIVIL-038 AMA VAF CIVIL Civil 06-Jun-12 09-Jun-12 20-Jun-12 17-Jul-12 Closed
LBE-AMA-ELECT-
004
AMA VAF ELECT Electrical 10-Jun-12 13-Jun-12 24-Jun-12 13-Jun-12 Closed
LBE-AMA-ELECT-
005
AMA VAF ELECT Electrical 21-Jun-12 24-Jun-12 05-Jul-12 25-Jun-12 Closed
LBE-KCC-CIVIL-039 KCC VAF CIVIL Civil 23-Jun-12 26-Jun-12 07-Jul-12 07-Jul-12 Closed
LBE-AMA-CIVIL-040 MR. YAP AMA VAF CIVIL Civil 27-Jun-12 30-Jun-12 11-Jul-12 01-Oct-13 Closed
LBE-AMA-CIVIL-041 AMA VAF CIVIL Civil 27-Jun-12 30-Jun-12 11-Jul-12 24-Jul-12 Closed
PN: During surveillance inspection, it was observed that the bottom bent bars of E-W pipe rack A FDN
F3 at gridline GL 21-23 GL 18-20 and GL 24-26 (Amana) have less than 75 mm concrete cover with
some bars touching the lean concrete along the slopes. Violates section 7.1.8 RT2S-3001-01.
Surveillance inspection at Gas Furnace FDN F-1170 Pedestals, it was found out that anchor bolts at
Pedestal F3 at GL 26/GF and P18 at GL GL/GH exceeded the 1:100 plumbness tolerance limit in
violation of section 8.1 RT2S-3001-01 (Random Measurement 15mm: 295 mm)
During review of calibrations, it was found out that Calibration Certificates of Batch Plant (Qanbar
Satorp) ice, water, cement and admixtures weighing/batching equipment have already expired. Last
calibration was on March 30, 2012. Per RT2S-3001-01, section 4.1.3.i required frequency of calibration
is 6 weeks.
The applied bituminous coating at Liquid Furnace FDNs F-1250 and F-1240 do not comply with
Document No. A554-K-PRG-PI-SPC-VIA-150 Protective Coatings for Industrial Concrete Structures,
Section 5.1 where RTAPCS-3, Coal Tar Epoxy System and RTAPCS-3, High Build Liquid Epoxy System
for Buried Concrete and Steel, are the required coating systems. This is also subject of LBE No. 028
with Nitoproof 100 bitominous coating used; in violation of standard A554-K-PRG-PI-SPC-VIA-150
requirements.
Due to the day & night schedules of work for concrete as a result of high temperature (ambient) in the
daytime, Daelim has insufficient QC Inspector for FDN/concrete works. At present only one QC
Inspector for FDN/Concrete is available to cover day & night concrete works. Violation of schedule Q,
section 3.2.
During surveillance inspection at Liquid Furnace F-1250 pedestals, it was observed that anchor bolts on
pedestals P6 at L6/L18; P5 at LA/L18; P19 at GL/PS2 and P4 at La/L19, (2 each on P6, P5 and P19 and
1 pc on P4) have exceeded the plumbness tolerance; In violation of RT2S-3001-01 section 8.1 where
limit is 1:100.
Foundation F1170 Gas Furnace pedestal P7 (2 units) were concreted on 09 May 2012. The block-out
shown on DWG # A554-E-103-DWG-C30-341 Rev. 1 with dimension of 550W X 300L X 150# clashes
with the standard hooks reimbursements as shown on section drawing A-554-103-DWG-C30-335 Rev.
1. This should be resolved with the designer and drawings revised prior to concreting.
During surveillance inspection, it was found out that the Contractor has started concrete coating on the
east side vertical faces of Liquid Furnace foundations F-1250 and F1240. There were no approved
repair procedures, there was no repair performed and there was no approved ITP for concrete coating.
Likewise, the applicators have no training as the Coating was applied without surface preparations.
Violation to schedule Q, section 3.2.
During surveillance inspection, TPER joints were found damaged at Gas Furnace foundations F-1130 (2
pcs) and F-1140 (1 pc). The damages were at the joints of the factory prepared T-joints.
During Surveillance, it was found out that the Column ties for the on-going fabrication of reinforcing bars
for columns at the N-S Main Pipe Rack are not as per IFC Drawings, A554-E-103-CV-DWG-C40-002, CI
Column detail. Hoop bars and DH bars do not have hooks and are being installed.
During Surveillance inspection at 1100-1130 hours, 24/06/12, it was observed that the finishing works
on E-W Pipe Rack B FDN F-7 is still on-going with visible cracks on surfaces that had already dried-out.
Per records of Concrete delivery, the last truck mixer delivered on site at 23:40 hours 26 June 12 and
had completed pouring at around 01:00 hours, 27/06/12. Workers were observed adding water (re-
tempering) to the concrete surface to facilitate finishing, as the concrete had already hardened due to
more than 10 hours elapsed after deposition. There are violations to Sections 9.14.2 and 5.4.17 of RT2S-
3001-01.
Subcon: Work Cannot proceed due to TCC activities Surface preparation shall be undertaken by
Contractor/ Subcontractor upon completion of the on-going installation of pipe rack super
structure by TCC.
Reinforcing bars 10mm for stirrups and ties do not have bar bending schedule and were delivered
near pipe rack B foundation F8 covered by RFI # CI-529. Violation to Section 2.5.5.1 RT2S-3001-01. It
also noted that the bars bent were without hooks on ends. The rebar are recommended to be
quarantined.
During Surveillance inspection at the Gas Furnace F-1150 Pedestals, it was found out that curing was
inadequate as the surfaces of the pedestals were dry, without burlaps and plastic covering. Repeated
violation of Section 9, RT2S-3001-01 (F1150 poured on 04 June 12).
The Contractor has issued RFIs without at least 24 hours notification to the Company as standard
procedure which violated schedule Q, attachment IV, section 1.1.3.
On June 20, Wednesday afternoon, it was found out that Amana has prepared grounding cable
installation for the eye shower in furnace pipe rack A (F6) without informing the Company for final
inspection. The work done is not complying on the approved IFC drawing E-016103-AFOOZ-EL-EHZ-
001. There was a concrete pouring on site on that day and we cannot find the presence of Mr. Nabil
Mr. Nabil, Amana Electrical QC Inspector was observed and found out the he has not been always on
site and only been seen where there is an inspection. His job must be 100% dedicated to SADARA
project only. This is in violation of Schedule Q Sec. 5.9/5.10.
During surveillance, it was found out that bituminous coating was applied at the N-S pipe rack
foundations F7 and F6 (GL AA-CA/53A-58A) without RFI issued for the coating application inspection
which is a "hold point" for contractor and full inspection by Subcontractor QC. This is in violation of ITP
and schedule Q, section 3.2. Note: Application was done during sandstorm.
Test reports of concrete compressive strength tests are not available for KCC area pipe rack
foundations. With the first concreting done on 5th May 2012, until today, no records of concrete
compressive strength tests are available. As of May 27, 2012 nine foundations for the N-S Pipe rack
were concreted. Violation to Schedule Q, section 3.2.
Mr. Jere Asas, KCC QC Supervisor has not been seen on the site for the past one-week. As per
information from KCC acting Site QC Manager, he is on emergency leave, however, there was no
notification to Company of his leave. This is in violation of Schedule Q section 5.14
Mr. Roger Lopez, Daelim Batch Plant Inspector was observed and found not attending to his duties as
Batch Plant Inspector. He has not attended inspection at the Qanbar Batch Plant at SATORP where the
current concrete is supplied from for major concrete pouring since April 30, 2012, Violation to Schedule
Q sections 5.9/5.10.
During concrete pouring at KCC N-S pipe rack foundation F-5, there were delays in the delivery of
concrete and long gaps in arrivals of truck mixers at site recorded as from 12:26 to 13:30 hours and
from 14:34 to 16:02 hours. At the middle North to South section, the first layer has hardened due to
more than 3-hour time elapsed before the next layer is poured. Cracks in the first layer have already
appeared on the hardened concrete. The next layer poured was more than 150mm thick and initial
vibrations were observed hitting the hardened concrete of first layer. Violation to section 5.4 of RT2S-
3001-01.
During attendance of inspection at site for receiving of reinforcing bars, the QC inspectors from
Contractor (Amana) Sub-contractor do not have a copy of the approved bar bending schedule for use as
reference, despite reminders to ensure that this small be available during inspection for rebar receiving
violation to schedule Q section 3.2.
Page 3 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
001
DAELIM VAF MECH Structural 03-Jul-12 06-Jul-12 17-Jul-12 6-Nov-12 Closed
LBE-DLM-MECH-
002
DAELIM VAF MECH Structural 04-Jul-12 07-Jul-12 18-Jul-12 11-Feb-13 Closed
LBE-KCC-CIVIL-042 KCC VAF CIVIL Civil 07-Jul-12 10-Jul-12 21-Jul-12 25-Jul-12 Closed
LBE-DLM-MECH-
003
DAELIM PN MECH Structural 12-Jul-12 15-Jul-12 26-Jul-12 25-Jul-12 Closed
LBE-KCC-MECH-
004
MR. NOOR KCC VAF MECH Structural 23-Jul-12 26-Jul-12 06-Aug-12 26-Jul-12 Closed
LBE-AMA-CIVIL-043 AMA VAF CIVIL Civil 29-Jul-12 01-Aug-12 12-Aug-12 04-Sep-12 Closed
LBE-KCC-CIVIL-044 KCC PN CIVIL Civil 29-Jul-12 01-Aug-12 12-Aug-12 08-Aug-12 Closed
LBE-KCC-CIVIL-045 KCC PN CIVIL Civil 31-Jul-12 03-Aug-12 14-Aug-12 11-Oct-12 Closed
LBE-DLM-MECH-
005
DAELIM VAF MECH Structural 31-Jul-12 03-Aug-12 14-Aug-12 6-Aug-12 Closed
LBE-DLM-MECH-
006
DAELIM VAF MECH Structural 01-Aug-12 04-Aug-12 15-Aug-12 6-Aug-12 Closed
LBE-KCC-MECH-
007
MR. NOOR KCC VAF MECH UG-RTR 05-Aug-12 08-Aug-12 19-Aug-12 15-Aug-12 Closed
LBE-DLM-MECH-
008
DAELIM VAF MECH Structural 11-Aug-12 14-Aug-12 25-Aug-12 15-Aug-12 Closed
LBE-KCC-CIVIL-046 KCC VAF CIVIL Civil 12-Aug-12 15-Aug-12 26-Aug-12 08-Aug-12 Closed
LBE-KCC-MECH-
009
LBE-KCC-CIVIL-047 KCC VAF CIVIL Civil 20-Aug-12 23-Aug-12 03-Sep-12 04-Sep-12 Closed
LBE-ARCC-MECH-
010
ARCC VAF MECH Structural 21-Aug-12 24-Aug-12 04-Sep-12 20-Sep-12 Closed
LBE-KCC-MECH-
011
MR. NOOR KCC VAF MECH UG-RTR 30-Aug-12 02-Sep-12 13-Sep-12 3-Sep-12 Closed
LBE-KCC-MECH-
012
MR. NOOR KCC VAF MECH UG-RTR 02-Sep-12 05-Sep-12 16-Sep-12 3-Sep-12 Closed
LBE-AMA-ELECT-
006
AMA VAF ELECT Electrical 03-Sep-12 06-Sep-12 17-Sep-12 09-Sep-12 Closed
LBE-DLM-MECH-
013
DAELIM PN MECH Structural 03-Sep-12 06-Sep-12 17-Sep-12 15-Sep-12 Closed
LBE-KCC-MECH-
014
LBE-KCC-CIVIL-048 KCC VAF CIVIL Civil 04-Sep-12 07-Sep-12 18-Sep-12 11-Oct-12 Closed
LBE-KCC-CIVIL-049 KCC VAF CIVIL Civil 05-Sep-12 08-Sep-12 19-Sep-12 17-Sep-12 Closed
LBE-KCC-MECH-
015
PN: During surveillance inspection at 1530 hours, 28 July 2012, it was observed that the formworks for
column including support for the beams of N-S Main Pipe rack F7 and F6 were anchored to (connected)
to the scaffold system. It is recommended that the contractor to verify the stability/capability of the
supports to the structures to be connected as per section 6.1.2 RT2S-3001-01.
PN: It was noted during the inspection of N-S Main Pipe rack at 6/LBA/54A-58A CI & 61, the plates on
top of beam do not have weep holes which is required as per the requirement of RT2S-3001-01 Para.
8.2.4. Ensure that all succeeding installation of these plates, weep holes are already provided.
F-1160. Radiant Box section installed without receiving inspection. All other Radiant Box sections
arranged for receiving inspection at the trailer prior to erection.'
PN: Plan to install HT Mastic for Furnace Joints; Provide a Method Statement to detail the application
that has to be strictly controlled. E.g. 1.Schedule a mock-up joint to ensure effectiveness. 2. Provide
proper tools, spatulas, wet film gauge. 3. Record/document each joint completed, etc.
RFI-MFCM-KCC-Mech-001. Embedded shear connectors were manually welded without qualified WPS
and JCC, and components were hot dipped galvanized. Violation of IFC drawing specifically A554-E-103-
DO:C2080 and section 2.30 FRT8S-65001.
During surveillance inspection 28/07/12 at Column rebar fabrication near E-W pipe rack B, F1, it was
observed that the column reinforcement are being fabricated in a Metal frame (scaffolds and 32mm
rebar). The frame, however, was not provided with padding for the protection of the FBE Coating despite
reminders. Violation of ACI 301 Section 3.1.2.2.
Radiant Panel F-1250: Fire Damage. Evaluation in progress. 1
st
step: Hardness checks complete 15
points; Report awaiting Company evaluation. 2
nd
step: Metallurgy Replication, 3
rd
STEP: party to be
scheduled ASAP prior to re-locating to site.
Radiant Panel F-1250: Pre-receiving inspection of unit shows numerous locations of weld discrepancies
for example: incomplete welds, poor finish/worm holes, members missing welds, etc. Contactor to
provide to Company a) Corrective Action Plan, b) Root Cause Analysis and c) Preventive Action Plan to
improve and eliminate repeating same defects on all other sections released from Vendor.
During surveillance inspection at KCC site, it was observed that bar bending on improvised bending
assembly is being done by workers. The DH 10 bars (10mm) were being bent to produce the hooks on
16mm mandrel using metal pipe. The mandrel was not provided with pads to protect the coating of
rebar from damage. Violation to ASTM-775 & ASTMC 615.
CWR-093031-02 Joint No. FW-04. During the inspection of the lamination, there were air bubbles found
which is unacceptable. Contractor to ensure that repair grind and eliminate that air bubbles area.
During surveillance inspection at the Southside of E-W Pipe rack for Liquid Furnace near F2 & F3
Foundations, the Contractor stores the fabricated reinforcing bars for columns without sufficient
protection and some portions directly to the ground. This violates ASTM-A-775 Para. 15.4 which states
that Coated Steel reinforcing bars shall be stored off at the ground on protective cribbing. Also no
padding on contact areas per Para. 15.1.
During the inspection of FRP/RTR Line in Cooling Water and B2 area (Sub-station), some debris and
sand were found inside of pipe during the bonding of lamination. As per standard, the Contractor has to
ensure that the assembly of the installation of FRP/RTR should be cleaned prior to laying in the trench.
During inspection of columns and beams at N-S Main Pipe rack at GL BA,57A-58A, CA 57A-58A (CI) &
AA-CA/57A-58A (65), it was noticed that safe access to the working platforms were not provided. Some
planks were not secured from movements. Several obstructions are hazardous to workers along the
way. Contractor to ensure safe access is provided for safety of workers and inspection personnel while
performing their jobs.
F-1160 2nd section of Radiant Panel. Box on to structural member (east side) 2 locations were
damaged (as marked on site) during transportation/installation time. Required rectification as per
approved procedure and re-schedule final inspection/acceptance before start installation of 3rd section.
Poor housekeeping in Cooling Tower main header beside of trench.
Materials were released (FMIR NO. 0071) RFI0AKF-SS-0019 to site without prior to inspection/approval.
Violated schedule "Q" attachment IV, sec. 2.31.
ARCC has installed the Furnace Radiant Panel Module of F-1250 (Completed), F-1240 - three (3)
sections. F-1170 - two (2) sections and F-1160 - one (1) section; all of which are without proper Method
of installation as mentioned in the SADARA approved Procedure. It is clear violation of A554-E-103-QA-
GEN-PRO-017, Para. 7.3.5 and 7.3.6.
On August 30, 2012, KCC's FRP lamination crew has started the work at 3:00 PM until 4:00 PM which
during this production time there was no QC Inspector. Said Inspector came only at 4:00 PM. A clear
violation as per schedule "Q".
Received test report for aggregates base coarse for structural backfill for upper C3 splitter & upper C3
splitter reboiler and lower C3 splitter & lower C3 splitter reboiler but there is no test report for CBR.
Contractor to submit test report as a requirement for aggregate base coarse designation.
It was noticed during surveillance at the N-S Main Pipe rack that the proper curing method was not
implemented on the top of the girder at GL. AA-CA -56-57. This violates RT2S-300-01 regarding the use
of Poly-Othylene sheets with burlap. The Contractor utilized burlap only and some portions were
exposed and dry during the inspection. Subcontractor has to be advised to comply accordingly.
It was observed that the material of FRP in cooling water area shelter inside without average boxes as
SADRA document no A554-E-103-QA-GEN-PRO-008, and Para. 9.4.4 as SADRA Procedure.
On Sept. 2, 2012, it was observed that the presence of Mr. Nabil (Amana Electrical QC Inspector) was
again not on site. There is an urgent inspection to be raised on that day but his presence to perform his
duties and responsibilities as a subcontractor's quality personnel is not performed. This is a repeated
violation of Schedule "Q", sec. 5.9 and 5.10.
PN: Violation of RT-5S-1821: All flanges face. Nozzle shall be protected from damage. Install Radiant
Module Flanges nozzles to be protected immediately by contractor (F-1250, F-1240, F-1170 & F-1160).
It was observed that the Contractor did not cover the end protection of FRP Pipes at the completion,
installation and of the workday. All openings shall be sealed to protect from all foreign matter including
dust, dirt, water, etc. as per G85-6015-04, Para 3.3.1
Page 4 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-ELECT-
007
AMA VAF ELECT Electrical 10-Sep-12 13-Sep-12 24-Sep-12 06-Oct-12 Closed
LBE-KCC-CIVIL-050 KCC VAF CIVIL Civil 17-Sep-12 20-Sep-12 01-Oct-12 10-Oct-12 Closed
LBE-AMA-MECH-
016
AMA VAF MECH Preservation 19-Sep-12 22-Sep-12 03-Oct-12 25-Sep-12 Closed
LBE-AMA-MECH-
017
AMA VAF MECH Plumbing 19-Sep-12 22-Sep-12 03-Oct-12 16-Oct-12 Closed
LBE-KCC-MECH-
018
MR. NOOR KCC VAF MECH UG-RTR 20-Sep-12 23-Sep-12 04-Oct-12 25-Sep-12 Closed
LBE-KCC-CIVIL-051 KCC VAF CIVIL Civil 25-Sep-12 28-Sep-12 09-Oct-12 11-Oct-12 Closed
LBE-AMA-CIVIL-052 AMA VAF CIVIL Civil 25-Sep-12 28-Sep-12 09-Oct-12 20-Oct-12 Closed
LBE-KCC-ELECT-
009
KCC VAF ELECT Electrical 25-Sep-12 28-Sep-12 09-Oct-12 07-Nov-12 Closed
LBE-AMA/KCC-
CIVIL-053
AMA/KCC PN CIVIL Civil 26-Sep-12 29-Sep-12 10-Oct-12 20-Nov-12 Closed
LBE-AMA/KCC-
CIVIL-054
AMA/KCC PN CIVIL Civil 30-Sep-12 03-Oct-12 14-Oct-12 20-Nov-12 Closed
LBE-AMA/KCC-
CIVIL-055
AMA/KCC VAF CIVIL Civil 30-Sep-12 03-Oct-12 14-Oct-12 20-Nov-12 Closed
LBE-KCC-CIVIL-056 KCC VAF CIVIL Civil 01-Oct-12 04-Oct-12 15-Oct-12 14-Oct-12 Closed
LBE-AMA-ELECT-
008
AMA VAF ELECT Electrical 01-Oct-12 04-Oct-12 15-Oct-12 06-Oct-12 Closed
LBE-ARCC-MECH-
019
ARCC VAF MECH Structural 06-Oct-12 09-Oct-12 20-Oct-12 7-Oct-12 Closed
LBE-DLM-MECH-
020
DAELIM VAF MECH Structural 07-Oct-12 10-Oct-12 21-Oct-12 30-Apr-13 Closed
LBE-KCC-CIVIL-057 KCC VAF CIVIL Civil 11-Oct-12 14-Oct-12 25-Oct-12 20-Nov-12 Closed
LBE-AMA/KCC-
CIVIL-058
AMA/KCC PN CIVIL Civil 11-Oct-12 14-Oct-12 25-Oct-12 20-Nov-12 Closed
LBE-KCC-MECH-
021
MR. NOOR KCC VAF MECH UG-RTR 13-Oct-12 16-Oct-12 27-Oct-12 16-Oct-12 Closed
LBE-KCC-MECH-
022
MR. NOOR KCC VAF MECH UG-RTR 14-Oct-12 17-Oct-12 28-Oct-12 16-Oct-12 Closed
LBE-AMA/KCC-
CIVIL-059
AMA/KCC VAF CIVIL Civil 20-Oct-12 23-Oct-12 03-Nov-12 20-Nov-12 Closed
LBE-KCC-CIVIL-060 KCC VAF CIVIL Civil 20-Oct-12 23-Oct-12 03-Nov-12 18-Nov-12 Closed
LBE-AMA/KCC-
CIVIL-061
AMA/KCC VAF CIVIL Civil 21-Oct-12 24-Oct-12 04-Nov-12 12-Apr-12 Closed
During site surveillance and inspection at 8:30 AM on September 10, 2012, again it was found out that
Amana's QC Electrical Inspector (Mr. Nabil) has not been on site. His presence and responsibilities to
perform his duties are again not performed. This is another repeated violation of Schedule "Q", sec. 5.9
and 5.10.
It was observed in several occasions that during inspection of columns, the nelson stud of angular
embedded items were not fully embedded in the inside of the column ties. There is a tendency that
these angular embedment will be removed from the column during the installation f connectors once the
member connection is subject to tension. Advice QC personnel to ensure full embedment of this type of
embedded items.
Observed that Contractor Amana has stored embedded material (galvanized) directly to the ground
without proper wooden supports. Shall be taken special precautions to avoid damage any steel structure
by wood support or alternative method. Violation of SADARA Doc. A554-E-103-QA-GEN-PRO-012.
PN: Please verify it is not required to have the activity in the battery problems of substation G 1120 & G
1121 the painted with acid resistant paint. In the finish schedule only the walls are required to be painted
with acid resistant paint.
It was noticed during inspection at substation building G 1121, that the drain pipe for AHU G 1121 -AHU
001A and G 1121-AHU-001B are located away from the foundation there is a tendency that the pipe
going to the drain from both units will be trip hazards and will be safety item punch list in the future
MCC. please evaluate location of this drain in the future installation of substation G 1120
Ref. RFI # MCF-DLM-KCC-CI-861. Schedule Q for inspection at 1800H on Sept. 30, 2012 for
Foundation of T-2210, T-2220 & C2 Splitter Equipment Structure is hereby rejected due to major finding.
28 25mm reinforcing bars (14 at bottom and 14 at top) were not installed, which require to remove
forms and already installed reinforcing bars. Concrete placement as scheduled was postponed.
It was noticed that the embedded plate with least dimension greater than 300 mm installed at the corner
of beams & columns have no sufficient weep holes located at the E-W pipe rack. This violates the
requirement of RT2S-3001-01, Para. 8.2.4.
It was learned that Mr. Jayson Tabilisima electrical QC inspector has already on vacation leave without
informing or giving notification to company at least 30days in advance on KCC annual Leave plan his
vacation is on dec.10.2012 but the contractor did not advise the company and changes of personnel for
qualify coverage .a violation of "SCHED-Q, Attachment Q-4,SEC.5.14"
PN: Please verify the requirements of floor drain and eye wash in the battery rooms of substation G
1120 & G 1121. The drawing for both substations do not reflect that it should be provided. The
reinforcing bars installation in substation G 1121 is almost complete and this requirement shall be
resolved before concreting.
Observed that Contractor Amana was done plumbing (drainage system sub-station no. G-1121)
activities and done the gravity test without approved ITP, Plumbing Inspector and not approved drawing
(IFC), not approved work procedure bonders/personnel without compaction and survey report, not
approved gravity test procedure which have been doing for more than 50 joints for gravity test.
During inspection of RFI no. MFC-DLM-KCC-UG-PIPING-002 and Hydro test package no. 1481HT017,
the test manifold was not tested as per schedule "Q" requirements. The Contractor should comply with
the standard as per document no. A554-E-103-QA-GEN-PRO-009, Para. 1 (General).
With reference to Log Book Entry #050, it was again noted that some nelson stands were not properly
embedded in the concrete columns during the inspection at N-S main pipe rack at several locations
although subcontractors has repaired these deficiencies some locations way have been missed and this
could lead to removal of embedment (angular plate) in the future during installation of connection please
advise the subcontractor to properly rectify method of embedment installation
It was observed that KCC FRP/GRP installers are grinding and shaving without JCC, which in violation
to SADARA Standard (G8S-6010-00).
During site visit at the Liquid furnace area below furnace F-1250 the contractor did not were the newly
grouted foundation utilized as mock up for grouting this violates G25-3050-01 Para 3.4.1 which requires
concrete to be required for minimum of 5 days.
During Inspection after the repair of all leaks at sump fit #0636. some leak were still not repaired in two
locations it was also observed that there are deposits of water just below the wall on the east side of the
foundation/wall leak investigate the water if where is the origin since the leaks are required on the wall
There is a possibility that there wafers leaks from the bottom slab.
It was noticed that the contractor filled the two sump pits (S-0636 & S-0642) with water for leak test
without submitting RFI. Several leaks were observed during the time the sump pits were already filled.
Later on the leaks disappeared, no information was received from the contractor to know these leaks
were required as per Document A554-E-103-PA-GEN-PRO-011 this stages of work shall be inspected.
PN: It was noted that some girder/beams curing were not properly undertaken due to removal of
polyethylene sheet are wrapped all over the members of the subject structure by using tape or tie wires
to secure polyethylene sheets on the surface.
It was observed that the Contractor did not cover the end protection of FRP Pipes at the completion,
installation and of the workday. All openings shall be sealed to protect from all foreign matter including
dust, dirt, water, etc. as per G85-6015-04, Para. 3.3.1
During the Surveillance of monitoring at site, it has been Found out that one PVC Conduit(4" D/A)of the
communication duct bank at G-1121 S/STN area were damaged and this Damaged may cause the
accumulation of water & dirt inside the conduit .This is violates design and standards G7C-0311-03 &
G7C-0305-04.
During the surveillance inspection at F-1250, it was observed that ARCC was installing Handrail at site
which the material (Hand Rails) was not inspected by SADARA. Violation of Schedule "Q", attachment
A, IV, section: 2.31.
During Material Receiving Inspection we have found damage paint require touch up paint as per SMITP-
M-001-01 item No. 4.12 touch up Coating & Painting
Daelim: Contractor shall repair the damaged paint as per approved procedure and in accordance
to the Touch-up Coating and Painting SMIC-H-2032.
The Contractor does not submit test results for compressive strength of concrete this violates schedule
Q attachment N Para 3.3 which states contractor must submit its test reports and review and submit the
test reports of its sub contractors to the company representative as specified by the applicable standard.
Page 5 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-062 AMA/KCC PN CIVIL Civil 21-Oct-12 24-Oct-12 04-Nov-12 02-Oct-13 Closed
LBE-AMA/KCC-
CIVIL-063
AMA/KCC VAF CIVIL Civil 30-Oct-12 02-Nov-12 13-Nov-12 28-Nov-12 Closed
LBE-DLM-MECH-
023
DAELIM VAF MECH Structural 30-Oct-12 02-Nov-12 13-Nov-12 10-Nov-12 Closed
LBE-ARCC-MECH-
024
ARCC VAF MECH Structural 30-Oct-12 02-Nov-12 13-Nov-12 8-Nov-12 Closed
LBE-ARCC-MECH-
025
ARCC VAF MECH Structural 01-Nov-12 04-Nov-12 15-Nov-12 28-Apr-13 Closed
LBE-KCC-CIVIL-064 KCC VAF CIVIL Civil 03-Nov-12 06-Nov-12 17-Nov-12 28-Nov-12 Closed
LBE-CTS-ELECT-
010
CTS VAF ELECT Electrical 05-Nov-12 08-Nov-12 19-Nov-12 07-Nov-12 Closed
LBE-ARCC-MECH-
026
ARCC VAF MECH Structural 05-Nov-12 08-Nov-12 19-Nov-12 10-Nov-12 Closed
LBE-DLM-CIVIL-065 DAELIM VAF CIVIL Civil 06-Nov-12 09-Nov-12 20-Nov-12 28-Nov-12 Closed
LBE-ARCC-MECH-
027
ARCC PN MECH Structural 11-Nov-12 14-Nov-12 25-Nov-12 11-Feb-13 Closed
LBE-PSCL-MECH-
028
PSCL PN MECH Tank 11-Nov-12 14-Nov-12 25-Nov-12 11-Dec-12 Closed
LBE-KCC-CIVIL-066 KCC VAF CIVIL Civil 17-Nov-12 20-Nov-12 01-Dec-12 28-Nov-12 Closed
LBE-KCC-ELECT-
011
KCC VAF ELECT Electrical 17-Nov-12 20-Nov-12 01-Dec-12 28-Nov-12 Closed
LBE-AMA-CIVIL-067 AMA VAF CIVIL Civil 20-Nov-12 23-Nov-12 04-Dec-12 02-Dec-12 Closed
LBE-KCC-CIVIL-068 KCC VAF CIVIL Civil 20-Nov-12 23-Nov-12 04-Dec-12 28-Nov-12 Closed
LBE-AMA-CIVIL-069 AMA VAF CIVIL Civil 21-Nov-12 24-Nov-12 05-Dec-12 Closed 04-Dec-12 Closed
LBE-AMA-CIVIL-070 AMA VAF CIVIL Civil 25-Nov-12 28-Nov-12 09-Dec-12 12-Apr-12 Closed
LBE-AMA/KCC-
ELECT-012
AMA/KCC PN ELECT Electrical 26-Nov-12 29-Nov-12 10-Dec-12 01-Dec-12 Closed
LBE-DLM-ELECT-
013
DAELIM PN ELECT Electrical 27-Nov-12 30-Nov-12 11-Dec-12 05-Dec-12 Closed
LBE-DLM-MECH-
029
DAELIM PN MECH Structural 27-Nov-12 30-Nov-12 11-Dec-12 4-Dec-12 Closed
On Nov 1.2012 as per requested RFI for Formworks, Embedment and rebar inspection prior to concrete
placement it was found out that two(2)numbers Q25 mm re Enforcing bars were missing located at the
bottom of girder type G5 at GC AB-37/38.This missing reinforcing bars could effect the structure stability
of the girder. Contractor shall effort more effort in their inspective process and reply to this log book
entry shall include preventive action this a respected violence.
Regarding The Inspection today(Nov.5.2012)RFI # CTS-EL-001,The Representative from corrpro Arabia
Cathodic production co was not able to attend the visual inspection for the HDPE Secondary
containment liner @ Spent caustic storage tank,V-0500A due to sickness and not sending anybody for
the substitute a violation of "SCHED-Q,ATTACH.IV.SEC.3.4/3.7
During Material inspection at ARCC laydown yard, it was found out that the Contractor has started Hot
dipped galvanized structural members (Furnace) were kept on contaminated steel support and rest of
the members were laid on the ground. ARCC has to store galvanized material free from dirt and other
foreign materials. A violation of RT-2S-2120-01.
F-1130 at Radiant Box section was installed without Material Receiving Inspection. Repeated violation
on previous logbook entry no. 005.
During surveillance inspection at F-1130 area, it was found out that ARCC welder (W-AR-2045) was
welding on plate washer without baked electrode. It is clear violation to RT-8-S-65000-1, section 5.3.
During Material Receiving Inspection on Furnace Radiant Box (F-1110), some defects were observed.
*Worm hole porosity on weld at difference area (as marked on site) (RFI for 1120). *Deep grinding on
(Material lose) Main Structure (1 beam). *Base column lashed with chain without proper protection. *
Coating damaged during handling of Transportation time.
Subcontractor: Hauling group of ARCC provided softeners (used cut to size nylon) to prevent
scratches on steel structures, photos attached. ARCC QC Conducted orientation on material
handling & preservation to the person involves in hauling & warehousing, attached attendance
sheet. Final inspection shall be conducted prior to final acceptance. RFI shall be raised upon
released from welding repair when it is completed.
PN: Please advise all sub contractors that prior to removed of water sump pits being tested for leak test
or similar structures approved by Sadara quality group shall be obtained and down enter as required by
ITP, removal of water without documentation shall be considered retest and another RFI shall be
submitted.
Please be informed that a logbook entry was made in OSAIMI LAB, MFC site regarding the following in
accordance with ASTMC 39M-12 Para 7.3 all test specimens for a given test age shall be broken within
the permissible time tolerance Prescribed as follows.7 days -6h or 3.6%,28 days -20h or 3%..the
following as cylinder sample were not broken in accordance with the above requirement. Sample #268
to 276-Amana, sample # 185-KCC,The above samples were note Crushed on OCT 27 and 28 for 28-day
compressor strength test requirement for 7 (Seven) days crushing of Samples .Sample #303-For
Amana, Sample # 229 to 232-For KCC. Please advise Third Party of the above Violation.
Rejected RFI No. MFC-DLM-KCC-CI-1224, as per RFI requested, at E-W C3 Splitter Pipe Rack @ GL-
AD-CD/22D-29D the following comments were noted during inspection. 1. The column ties located at the
Girder side were not tied on all columns. 2. Some of the angle bolts nelson studs were not fully
embedded on the concrete and supported by reinforcing bars (repeated violation). 3. Toe boards on
some plat bars were not installed.
During monitoring of activities at spent caustic tank area, the contractor mixes the sand cement mix
ratio of 1:33 with wet sand from stock piles which had been wet during the rain. This is a violation of the
requirement shown on DWG. # A554-103-CV-DWG-C30-295 Note 9 (d) which require sand to have not
more than 2% free-moisture content by weight of dry soil. It was also observed that the workers are
directly mixing the sand-cement-mix without the proper proportion as mentioned in the approved
procedure.
Please investigate the sand-cement mixture at Tank (Spent Caustic Tanks, Process Holding Tank and
Pad Water Tank) due to rain which maybe had contaminated with water yesterday. These tanks are
covered with polyethylene sheets but water may sip at joints since it had been raining heavily.
During the leak testing of sump 0635, it was noticed that the portion at the bottom of the north side of
sump where the transition of slab to sump have been damped. This location shall be dry and Contractor
shall investigate the damped area and shall be repaired prior to final acceptance. All the three sides of
the pit have been inspected and all leaks were repaired and accepted.
It has been noted that the subcontractor (KCC) continued with their Electrical activities without Electrical
QC Inspector and continuously concrete pouring on various locations without RFI and electrical
clearance from electrical QC dept. in spite of receiving two (2) NCR from the Contractor (DAELIM),
again, continued their violation for the third time. A repeated violation of "Schedule Q, attachment Q-1,
sec. 1.6".
As per RT2S-3050-01 Sec. 3.7.5. water for grouting shall be checked for chloride and sulfate weekly.
Subcontractor should be advised to submit report as specified in the standard.
As per the requirement of RT2S-3001-01 Rev. 4, Table 7, Total chlorides per sulfates per BS 1881, Part
124 Method 10.2 and total method 10.3 shall be performed every month for the first 3 months and every
3 months thereafter. Contractor to advise the subcontractor/batching plant to comply with the
requirement and submit report.
PN: Material Inspection (Receiving) of Transition Duct Lower part (TM-1120, to TM-1170 Gaff) and TM-
1210, To 1250 Gaff) shown several locations weld discrepancies on duct, example: Crack, bend,
incomplete weld, worm holes, members cracked, etc. Vendor to provide: *Corrective action plan *Root
cause analysis & preventive action *Extension of damage report with repair procedure for rectification.
PN: During witness inspection of material and qualification of Coating & Blasting personnel at Petro
Steel Facility, the following were observed: *Blasting Equip. And associated attachment were not
adequately earthed to avoid electrical static discharge. *Dead-Man shot-off coated were arrested with to
prevent the control system. *Air hose were damaged and broken. *Missing calibrated pressure R/valves
and pressure gauges on Air receiver Tank. * The Contractor to advise Petro Steel to take necessary
safety precaution and project requirement as per Sadara procedure RT-16-0101-xy and Schedule "Q"
requirements.
PN: Contractor shall perform continuity testing (point-to-point test) between installed main grounding
system to all grounding riser prior to the final backfilling and concreting to confirm that there are no
damages in the grounding cable during backfilling and consequently, to avoid re-work in the future.
PN: During routine site visit, it was found out that there are 18 MV motors arrived at DAELIM warehouse,
In connection with this, Contractor shall provide preservation plan and shall preserve the motors as per
manufacturer's recommendation, i.e. energization of the motors space heater to prevent accumulation of
moisture inside the motor.
PN: During Inspection at Furnace Radiant Box and Open Structural for Transition and Convention
Module, it was found out that Elevation variance in all column J+ was above the Tolerance allowable
limit. *Daelim Engineering Team has to verify the subject issue and submit the rectification Method to
Sadara for review and approval.
Page 6 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
030
DAELIM PN MECH Mechanical 28-Nov-12 01-Dec-12 12-Dec-12 11-Dec-12 Closed
LBE-KCC-MECH-
031
MR. NOOR KCC VAF MECH UG-RTR 28-Nov-12 01-Dec-12 12-Dec-12 3-Dec-12 Closed
LBE-KCC-MECH-
032
LBE-KCC-MECH-
033
LBE-DLM-CIVIL-071 DAELIM PN CIVIL Civil 04-Dec-12 07-Dec-12 18-Dec-12 22-Jan-13 Closed
LBE-DLM-CIVIL-072 DAELIM PN CIVIL Civil 04-Dec-12 07-Dec-12 18-Dec-12 22-Jan-13 Closed
LBE-DLM-CIVIL-073 DAELIM PN CIVIL Civil 05-Dec-12 08-Dec-12 19-Dec-12 12-Dec-02 Closed
LBE-DLM-CIVIL-074 MR. GERALD DAELIM PN CIVIL Civil 05-Dec-12 08-Dec-12 19-Dec-12 15-Sep-13 Closed
LBE-DLM-ELECT-
014
DAELIM VAF ELECT Electrical 05-Dec-12 08-Dec-12 19-Dec-12 22-Jan-13 Closed
LBE-DLM-MECH-
034
DAELIM PN MECH Material 05-Dec-12 08-Dec-12 19-Dec-12 6-Jun-13 Closed
LBE-PSCL-MECH-
035
PSCL PN MECH Tank 05-Dec-12 08-Dec-12 19-Dec-12 27-Jul-13 Closed
LBE-DLM-MECH-
036
DAELIM VAF MECH Mechanical 05-Dec-12 08-Dec-12 19-Dec-12 25-Apr-13 Closed
LBE-DLM-MECH-
037
DAELIM VAF MECH Structural 08-Dec-12 11-Dec-12 22-Dec-12 9-Dec-12 Closed
LBE-DLM-MECH-
038
DAELIM VAF MECH Quality Records 08-Dec-12 11-Dec-12 22-Dec-12 9-Dec-12 Closed
LBE-DLM-MECH-
039
DAELIM VAF MECH Structural 10-Dec-12 13-Dec-12 24-Dec-12 11-Dec-12 Closed
LBE-ARCC-MECH-
040
ARCC VAF MECH Structural 11-Dec-12 14-Dec-12 25-Dec-12 25-Apr-13 Closed
LBE-KCC-MECH-
041
MR. NOOR KCC VAF MECH UG-RTR 11-Dec-12 14-Dec-12 25-Dec-12 16-Dec-12 Closed
LBE-AMA-CIVIL-075 AMA VAF CIVIL Civil 13-Dec-12 16-Dec-12 27-Dec-12 31-Dec-12 Closed
LBE-AMA-CIVIL-076 MR. JERRY AMA VAF CIVIL Civil 13-Dec-12 16-Dec-12 27-Dec-12 02-Oct-13 Closed
During the surveillance inspection, KCC RTR/FRP crown did not provide end protection of FRP Pipe in
cooling water area and some areas at package no. 14, 04, etc. Violation as per standard G8S-6010-00 &
G8S-6015-04 and as per Procedure Para. No. 3.3.1.
PN: It was observed that the cold season has started and the temperature has gone down this morning
at 8'C. Contractor/Subcontractor is informed that the Batch Plant will be reduced the amount of
admixtures to compensate the retardation time of concrete. Contractor/Subcontractor to ensure that the
reduced amount of admixture is reflected in the concrete delivery ticket and water is not increased or
added and the water cement ratio is not affected. Batch Plant Inspector has to be aware of the
requirement.
PN: It was observed that some testing requirements for concrete were not submitted since they are not
included in the ITP and/or checklist. These requirements mentioned in RT2S-3001-01 such as Rebar
mechanical testing Para 2.5.6.1 Compressive strength test, table 7 total chlorides table 7, total sulfates
table 7, reactive silica table 6 shall be included in the ITP/Checklist to ensure requirements of
specification are complied. Revise ITP and checklist for SMIC-Q-1001 and SMITP-Q-001-01 to reflect
said requirements.
PN: Daelim Painting and Refractory Teams to verify the Coating requirements (appropriate) prior to
apply Refractory on Transition Module (Lower part). Coating QA/QC Inspector shall make action to
prevent inorganic zinc from coming in contact with stainless steel anchor.
It was observed that KCC did not follow the SADARA standard G85-6015-04 Para 3.1.4 & procedure
handling and storage. Daelim/KCC, FRP/Pipes fittings are placed through directly on the ground in
various locations: package #04, 15, 19 and near the cooling water line. Contractor/subcontractor should
not store FRP Pipe and fittings directly on the ground and avoid rough handling of FRP Pipes and
During inspection, it was observed that KCC's certified laminator Mr. Sher Khan, with RTR ID No.011,
has allowed his helpers to do lamination job without JCC in his presence and keeps an eye on foxiness,
keep under surveillance knowing that his supervisor is also on the site. This is a standard violation as
per G85-6010-00 and G85-6115-01 Para 1.3.2, a repeated violation and as per ISO 14692-4, annex D.
During Material Receiving Inspection of Fabricated steel structural members manufactured by Yoong
Hwa at Daelim Laydown Yard, some were observed: * Material were damaged due to improper bonding;
*Galvanized surface were scratched, peeled, etc. Daelim, Material receiving team has to take extra care
on handling and storing of galvanized material. Violation of RT-2S-2120-01) Sadara procedure. Weld
discrepancies: On structural member, Daelim QA/QC Team has to prepare necessary rectification
method to control weld defects prior to start installation on site.
During Material Receiving inspection of storage tank (V.0500A/B) Annular Plate at site: It was observed
that Petrol steel had failed to submit proper document as per material receiving procedure and also
violated the Proactive Notification requirement: (PR:Entex-35). Daelim QA/QC Team to verify all
required documents if they are available prior to offer RFI to SQI.
TCC started the erection of Pipe Rack Column at N-S Pipe Rack area without Structural QC Inspector.
The Mech. Supervisor is monitoring the activity at site. TCC should comply with Sadara Quality
requirement as per schedule "Q" and Daelim to advise KCC to follow quality requirement as per
schedule "Q" and specifications.
PN: Combustion Air Duct (Vendor Metaphil) observed that following defects on subject Material
Receiving Inspection: 1 Coated externals showing poor application, excess thickness and scratched
surface. 2. Air Control System (Dumper) not working properly due to improper alignment. 3. Uncoated
internal areas exhibiting serious oxidization. Daelim QA/QC Team to rectify all damaged coating.
Alignment of bumpers and working properly prior to delivery to site. Daelim should take Material
Clearance prior to install duct on site.
Daelim: As per request of SQIT/SPMT greasing of damper mechanism was performed including
those with damage are segregated with corresponding marks/tags. Further mechanism "open" &
"close "marking started stencil printing as per proper location of damper opening & closing. Spray
paint was used for stencil marking. On-going.
PN: During the Focus assessment on Petrol Steel Fab. Shop in regards to 7 tanks will be erected at site,
the following discrepancies were recorded: 1. No release not "ARN" from steel plate and flanges
manufacturer for level "2" Inspection material were presented. 2. The ITP utilized did not have any
Company involvement. Daelim to ensure all documentations are complete and contact the QR to
ensure/confirm the proper involvement of the Company in all the P.O.'s placed by Petrol Steel.
Subcon: 1.) IRN's are prepared and attached with the materials that are shipped from shop to
site. 2.) The ITP has been revised fro Company involvement and also it has been approved.
Contractor Inspector is in charge for the activities in the shop. PSCL confirms that all the
documents for the materials that are being released to site will be required.
During witness inspection for surface preparation prior to application on the Radiant Box internal floor
(bottom) F-1250 were found that the Mechanical cleaned area even exceeded (100 sq.) as allowable
acceptance limit as per Sadara Painting procedure: G-163-0101-54
Daelim: The issue was addressed to Mr. Gerald F. and replied that the affected area is just small
& impractical to do blasting, in which he didn't find any major issue with power brushing to remove
the rust, mill scale & any grease. Just that it has to be ensured after repair is completed, the area
must be cleaned and bitumastic coating must be applied.
PN: During surveillance inspection @ cooling tower basin @ GL: 1D-6D, some prepared area for lean
concrete applications were not conforming to 50mm thickness requirement as shown in the IFC drawing.
The actual thickness is ranging only from 30mm up to 35mm. Contractor/Subcontractor is advised to
rectify the deficiencies prior to final inspection.
PN: It was observed that RFI'S execution or implementation of Contractor/Subcontractor, some are
already been inspected and the structure had been poured. But, more than one (1) week time slot, the
said RFI's with attachments are not yet submitted for signature & comment. Contractor is therefore
advised to submit RFI's on time for proper documentation.
Subcon: RFI's are now prepared and given to inspectors to be available on site during inspection
with SQIT.
Despite of the Proactive Notification (LBE-E-013) done last November 27, 2012, the Contractor is still
not energizing the Space Heater of the 18 MV Motors arrived at Daelim Warehouse last Nov. 25, 2012,
which is a violation as per RT7D-0665-00, section 13.1.2.
It was observed that the TPER located at the southern most portion of the Spent Caustic Tank Pipe rack
was severely damaged. Contractor/subcontractor to provide method of statement and include sketch
how to repair the damaged TPER and the affected FND to maintain the required sealant on each joint.
Subcon: Access road, repair will proceed after cleared by Contractor. M/S was submitted for
repair of TPER's & it was decided in quality meeting (MOM-54) that each Subcon required to
protect TPER with steel plate.
During surveillance inspection at ARCC yard for inspecting Transition Duct (Lower), it was observed that
GIWI (Blasting painting contractor) has started blasting activities on transition duct without informing the
QA/QC Team of Daelim and Sadara. Also found the following: *Coating inspection/Crew Supervisor was
not available at site. *Wet garnet was using at site.*Failed to conduct climatic condition, *Failed to
conduct moisture % at air supply (battery test). Daelim QA/QC Team has to closely monitor KCC if
activities are meeting the Sadara specification and Schedule. Violation of Schedule "Q" and RT-168-01
and 54.
Subcon: Coating inspector & crew supervisor (ARCC) are warned to be present on site always.
Wet garnet was replaced with new garnet QA/QC personnel is advised to strictly monitor and keep
log of all ambient readings and conduct readings and conduct blotter test during cash shift.
During inspection, it was observed that subcontractors KCC & PTS workers are doing bonding &
lamination of FRP without JCC: Drawing no. Five Water Line:FW:071004-02, Joint No. 46, Drawing No.
Fire Water Line: FW:017111-01, Joint: 22,23,24; and they are using contaminated and rusted material of
FRP lamination with woven roving and boal tape. This is a standard violation as per G8S-6115-01 &
G8S-6010-00 & ISO 14692-04 Annex-D.
The Contractor/Subcontractor did not install the schedule 80, 40 mm dia. Pipe for leak detection as
shown on drawing # A554-E-103-CV-DWG-C-30-295, rev. 3 and other drawings for Spent Caustic Tank
storage tanks V-0500 A/B, Pad Water Tank and Process Holding tank. This requirement was discussed
two weeks ago with Contractor QC Supervisor and Amana QC Supervisor. Contractor/Subcontractor is
advised to comply with this requirement prior to install tanks.
Subcontractor: Subcontractor Already Installed The Schedule 80 Pipes in all the tanks in
compliance with IFC Drawings.
Page 7 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-PSCL-MECH-
042
PSCL VAF MECH Tank 13-Dec-12 16-Dec-12 27-Dec-12 20-Apr-13 Closed
LBE-DLM-MECH-
043
DAELIM VAF MECH Structural 13-Dec-12 16-Dec-12 27-Dec-12 24-Apr-13 Closed
LBE-AMA-CIVIL-077 AMA VAF CIVIL Quality Management 16-Dec-12 19-Dec-12 30-Dec-12 01-Jan-13 Closed
LBE-SEN-ELECT-
015
SENDAN VAF ELECT Electrical 17-Dec-12 20-Dec-12 31-Dec-12 23-Jan-13 Closed
LBE-DLM-ELECT-
016
DAELIM VAF ELECT Electrical 23-Dec-12 26-Dec-12 06-Jan-13 22-Jan-13 Closed
LBE-ARCC-MECH-
044
ARCC VAF MECH Structural 23-Dec-12 26-Dec-12 06-Jan-13 5-Jan-13 Closed
LBE-ASYAD-INST-
017
MR. SHABIRUL ASYAD VAF INST Instrumentation 25-Dec-12 28-Dec-12 08-Jan-13 22-Jan-13 Closed
LBE-ARCC-MECH-
045
ARCC VAF MECH Structural 25-Dec-12 28-Dec-12 08-Jan-13 28-Apr-13 Closed
LBE-DLM-MECH-
046
DAELIM VAF MECH Mechanical 26-Dec-12 29-Dec-12 09-Jan-13 12-Jan-13 Closed
LBE-AMA-CIVIL-078 AMA VAF CIVIL Civil 27-Dec-12 30-Dec-12 10-Jan-13 08-Jan-13 Closed
LBE-DLM-MECH-
047
DAELIM VAF MECH Preservation 29-Dec-12 01-Jan-13 12-Jan-13 2-Jan-13 Closed
LBE-AMA-CIVIL-079 AMA VAF CIVIL Civil 01-Jan-13 04-Jan-13 15-Jan-13 07-Jan-13 Closed
LBE-AMA-CIVIL-080 AMA PN CIVIL Civil 02-Jan-13 05-Jan-13 16-Jan-13 28-Jan-13 Closed
LBE-KCC-CIVIL-081 KCC PN CIVIL Civil 02-Jan-13 05-Jan-13 16-Jan-13 21-Jan-13 Closed
LBE-DLM-ELECT-
018
DAELIM PN ELECT Electrical 03-Jan-13 06-Jan-13 17-Jan-13 08-Jan-13 Closed
LBE-KCC-ELECT-
019
KCC VAF ELECT Electrical 05-Jan-13 08-Jan-13 19-Jan-13 08-Jan-13 Closed
LBE-ARCC-MECH-
048
ARCC VAF MECH Quality Management 05-Jan-13 08-Jan-13 19-Jan-13 26-Jan-13 Closed
LBE-KCC-ELECT-
020
KCC VAF ELECT Electrical 06-Jan-13 09-Jan-13 20-Jan-13 10-Jan-13 Closed
LBE-KCC-ELECT-
021
KCC VAF ELECT Electrical 06-Jan-13 09-Jan-13 20-Jan-13 12-Mar-13 Closed
LBE-ARCC-MECH-
049
ARCC VAF MECH Structural 06-Jan-13 09-Jan-13 20-Jan-13 21-Apr-13 Closed
It was observed that the QC Manager of Amana has not been available for the past several days. During
the quality meeting he was also not present. It was also heard from Contractor's QC Personnel that the
QC Manager has left the project. Contractor to verify the authenticity of the report. As per requirement of
Schedule Q, Para. 5.14 regarding quality personnel charges.
Subcontractor (SENDAN) for Electrical works is still not submitting their quality documents, i.e. )PQP,
ITP, Method Statement, CV's of QC personnel) to the Company for review and approval more than 30
days from now since the kick-off meeting in Nov. 4, 2012. A violation of Schedule "Q", attach. Q-2,
para.3.
Focus assessment was conducted for the Preservation of 18 MV motors at Daelim Warehouse and
found out that the Contractor has not taken any action regarding the Energization of Space Heaters for
these MV motors despite of the Pro-active Notification and standard Violation issued by the Company.
During surveillance inspection at Field Erected Tank area, Petrol Steel were installing the Annular and
Bottom plate at site and observed the following violations: *Welders were tacking alignment clip on
annular/Bottom plate without JCC for conducting the activities at site. Violation of Sched. "Q" and
SADARA Spec:RT2S-600-1. * The electrode used by welder was not dried and not properly conditioned
for use at job. *Electrode/Filler Material was not inspected and approved as per Sch. "Q" requirement
and approved welding consumable handling flow chart. * Petrol Steel QC, Welding and Mech Inspectors
have to take more care on the aforementioned violations and shall meet the Company Quality
requirements.
The Subcontractor GIWI had been started structural erection activities at site prior to obtaining approval
of quality plan and quality requirements as per Sadara Specs. It is clear violation of schedule "Q", Para.
1.6 and Para. 3.
During surveillance inspection at base slab cooling tower basin (Part C), it has been observed that
curing of newly casted base slab, only polyethylene sheet & water without burlap or hessian. This is a
violation to RT2S-300-01 (Rev.3) Para. 9.1.4. Contractor to advise Amana to comply.
PN: During surveillance inspection at cooling tower basin (base slab) part-A & part C, it has been
observed that south portion of (part A & North portion of part C) they are using as a stored area for
shutter and form works materials, wherein can cause or resulted to damage for the newly poured
structure. Said structure has been casted last (29 & 31 Dec. '12) respectively. Contractor/subcontractor
to ensure that concretes are sufficient enough to carry the load of shuttering materials. Subcontractor
must be advised to make immediate action on the issue.
PN: It was noticed that the backfilling of vertical car pump (P2571) was undertaken without consideration
of removal of support and backfilling of the adjacent ground. There is a tendency that the ground
backfilled will collapse when the support is removed and it not removed the support will be very hard to
remove. Contractor to advise subcontractor to reconsider that condition while the adjacent ground is still
not backfilled.
Perforated plates of combustion air duct are exposed to the open atmosphere & rusted in Daelim yard.
Duct frame & duct inlet openings are not properly closed in Daelim yard. Some metallic materials are
directly in contact with the ground like galvanized studs & structural items, etc. in the Daelim yard.
Contractor shall submit method statement for rust cleaning & offer for the SADARA inspection,
necessary actions required ASAP.
During surveillance inspection at substation G1121, it was observed that partial delivery of concrete
masonry unit (CMU) at north side of substation G1121, were not properly stored & rest on the ground
without proper protection. This is a violation to G25-4300-01, Para. 3.1.1. Contractor to advise the
subcontractor to comply the violation.
During the Material Receiving Inspection for Radiant Coil-F-1170, following violations of Material
Preservation: Stainless steel alloy on radiant coil were directly stored on row woods. There is a chance
to collect dew point condensation on subject material. There is a chance to contact with soil, potential
corrosive blowing sand and etc. Violation of Material & Equipment Protection & Preservation Plan: RTG-
OCS, Para. 2.15.
During surveillance Inspection at Furnace area, it was observed that ARCC has used Fastener (High
Strength Bolt) by different manufacturer which were not informed or conduct Material Receiving
Inspection. Repeated violation of schedule "Q" and RT25-5210. Daelim QA/QC Team has to
investigate the discrepancy occurred at site; Take necessary rectification action on subject matter.
Subcontractor (ASYAD) for Instrumentation works is still not submitting their Quality Documents such as
PQP, ITP, Method Statement, CV's of QC Personnel to Company for review & approval. It has been
more than 30 days since the kick-off meeting was held in Aug. 5, 2012 and until now the Company has
not received any of its QC documents which is violation of Schedule "Q", attachment Q-2, Para. 3.
It was observed that ARCC has installed the Transition Duct (Lower Part) at F-1250 after rectification of
column Elevation variance. The activities were conducted without final inspection of plumbness
alignment & elevation which is violation of Repair Procedure inspection sequence: Document # A554-E-
103-MECH-GE-008, Para. 5.3.
It was observed that the grounding Pad installed in deethanizer structure (D-2055) and D-2152 off gas
compensation suction are not complying with a minimum distance of 150mm above the ground level. A
violation with IFC DWG. # A554-E-103-EL-DWG-EHA-499, sht. no. 34, rev. 2.
During routine visit, it was found out that the grounding cable and grounding rod at the east side of C2
splitter equipment structure area was damaged during excavation as per schedule Q, attachment IV,
sec. 3.2.
During the surveillance inspection at Furnaces area: F-1170, it was observed that ARCC was installing
Radiant coil on F-1170. The crew members were handling the Radiant coil with improper method and
carelessly done. Company & Daelim had conducted a workshop regarding handling and preservation on
SS & SS Alloy material at ARCC yard. ARCC team to re-evaluate the material preservation
implementation plan according to site condition. Violation of material preservation procedure: RT-6-ICS.
PN: Contractor shall verify the installation of grounding cable from power transformers to the grounding
grid as per the requirement of G7-104-00 sec. 6.5.2. As of now, there is only one connection of
grounding cable to the local ground grid.
During site surveillance on Jan. 3, it was found out that one PVC stub-up in cold box structure
foundation was damaged, and also not complying as per project specifications and standards. A
violation of equipment specs. 67D-0311-03 Para. 2.2.3/4.4.1/4.4.2.
During surveillance inspection, it was observed that Contractor's subcontractor (ARCC) has started the
refractory works without its QA/QC Refractory Inspector. A standard violation as per schedule "Q".
Page 8 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-ELECT-
022
AMA VAF ELECT Electrical 09-Jan-13 12-Jan-13 23-Jan-13 14-Jan-13 Closed
LBE-DLM-MECH-
051
DAELIM VAF MECH Structural 09-Jan-13 12-Jan-13 23-Jan-13 30-Apr-13 Closed
LBE-ARCC-MECH-
068
ARCC PN MECH Refractory 09-Jan-13 12-Jan-13 23-Jan-13 20-Apr-13 Closed
LBE-KCC-CIVIL-082 KCC VAF CIVIL Civil 10-Jan-13 13-Jan-13 24-Jan-13 21-Jan-13 Closed
LBE-AMA-CIVIL-083 AMA VAF CIVIL Civil 10-Jan-13 13-Jan-13 24-Jan-13 08-Jul-13 Closed
LBE-PSCL-MECH-
052
PSCL PN MECH Tank 10-Jan-13 13-Jan-13 24-Jan-13 17-Jan-13 Closed
LBE-AMA-CIVIL-084 AMA PN CIVIL Civil 12-Jan-13 15-Jan-13 26-Jan-13 26-Mar-13 Closed
LBE-AMA-CIVIL-085 AMA VAF CIVIL Civil 13-Jan-13 16-Jan-13 27-Jan-13 20-Jan-13 Closed
LBE-ARCC-MECH-
050
ARCC PN MECH Structural 13-Jan-13 16-Jan-13 27-Jan-13 21-Apr-13 Closed
LBE-ARCC-MECH-
053
ARCC VAF MECH Material 14-Jan-13 17-Jan-13 28-Jan-13 11-Feb-13 Closed
LBE-PSCL-MECH-
054
PSCL PN MECH Tank 15-Jan-13 18-Jan-13 29-Jan-13 17-Jan-13 Closed
LBE-DLM-MECH-
055
DAELIM PN MECH Refractory 16-Jan-13 19-Jan-13 30-Jan-13 10-Jun-13 Closed
LBE-AMA-CIVIL-086 AMA VAF CIVIL Civil 19-Jan-13 22-Jan-13 02-Feb-13 05-Feb-13 Closed
LBE-AMA-CIVIL-087 AMA PN CIVIL Civil 20-Jan-13 23-Jan-13 03-Feb-13 28-Jan-13 Closed
LBE-DLM-CIVIL-088 DAELIM VAF CIVIL Civil 21-Jan-13 24-Jan-13 04-Feb-13 Closed 29-Apr-13 Closed
LBE-KCC-CIVIL-089 KCC VAF CIVIL Civil 21-Jan-13 24-Jan-13 04-Feb-13 Closed 18-Feb-13 Closed
LBE-AMA-ELECT-
023
AMA VAF ELECT Electrical 21-Jan-13 24-Jan-13 04-Feb-13 27-Feb-13 Closed
It was observed that the grounding cable installed in substation G-1120 transformer yard for grounding
bus bar is 70 mm instead of 120mm as per the IFC drawing. A violation in IFC DWG. No. E-016103-AA-
00Z-EL-EHZ-001 Rev. 4.
During the inspection for Bolt Tightening at open structure at F-1220, following violations were observed:
The Lower Transition Duct was installed at position without conducting Final Bolt tightening verification
by Daelim & Company (SADARA), violation of procedure: A554-E-QA-GEN-PRO-012 sec. 7.3. The
Installed open structure members Piece Marks are not matching as per IFC drawing of F-1220. Violation
to Sched. "Q" , attachment IV, sec. 4.2 & RT-25-5120, Para. 4.1.3 & 4.1.4. Contractor to verify the
discrepancy and forward the remedy action to SADARA.
PN: It is observed at site F-1140 Gas Furnace that the left portions of temporary angles after cutting are
still not yet grinded up to smooth surface in the Lower Transition Duct. Contractor is advised to grind all
of these left portions of angles up to smooth surface of the Trans. Duct as per RT SAES-N-110 Para.
No. 8.1, A554-T-103-MB5-827, Para. No. 7.1.4.
During Material Receiving inspection of welding consumable at ARCC yard, the following Filler materials
were rejected; The subject brand Filler Materials are not meeting the requirement of SADARA specs:
RT:8S-6500-3., Sect: 3.3. A Flag Tag indication as per AWS0-ASME Specs shall be affixed to both
ends of all SS and All nickel-chromium based and titanium alloy cut-length filler material. The Materials
brand & classifications are *ER-309L.2.4 mm BD-CN-231-21G24 *ER-308L.2.4mm BD-EAS2IG2,4
(BOHLER Brand).
PN: During inspection of the tank, it is observed that jigs and fixtures for temporary attachments are not
properly handled by Petrol Steel. A. Storage at tank bottom shall not be in direct contact to the bottom
plates to avoid mechanical damages. B. Wedges and channels surfaces must be smooth grounded t
avoid mechanical damages on the tank bottom and shell plates. C. Direct hammering on the plates must
be averted to avoid the mechanical damages.
PN: During surveillance inspection, it was found out that air set mortar dry 50 lbs. bags for refractory
application stored in the Daelim laydown yard (warehouse) inside have been expired on Dec. 4, 2012.
As per SADARA Standard, expired materials must be shifted to the quarantine area to ensure that it will
not be used,RTSAES-N-110, Point 7.3.
PN: During Surveillance inspection at cooling tower basin (RC-Wall), it has been observed that
presence of Laitance for the rebar @ RC-Walls & some portion of water stopper need to be aligned and
proper cleaning is needed. Contractor is advise to take action concerning the issue prior to second lift
execution or implementation for the structure.
During surveillance inspection at roof slab for substation G-1120, it was found out that water curing
application & protection for the newly casted slab was insufficient enough. Please note that this structure
was casted last 9 Jan. '13 which means only 5 days after casting. This is a violation to RT2S-3001-01,
Para. 9.1.1 and 9.1.4.1. Contractor has to advise Amana to comply on the issue.
PN: It was observed that Radiant Coil installation at F-1170 in progress, Contractor and ARCC to take
more care on following work sequence at Furnace. Application of Castable at Bottom (Radiant Box) and
corbel part (side) by Gunning which will produce heavy dust and water spray. There will be a chance to
be contaminated the Radiant Coil. ARCC to take extra care for SS & SS Alloy Material as per procedure
& take more attention to protect the SS Alloy material by using alternative method as agreed in the
meeting by polyethylene sheet/or equivalent.
During the surveillance at East-West Dryer Pipe Rack GL 10,9.7/DC, it was found out that these
locations have honey combs on the columns of the newly removed formworks. These locations shall be
checked prior to repair. Since other columns formworks were not yet removed, ensure that other
locations with typical concrete defects shall be inspected prior to repair.
The Contractor cut the main reinforcing bars of N-S cable tray rack at location near G-1121/Foundation
type F1 in three locations. The Contractor shall provide method statement and sketch of the existing
pedestal and location of the newly revised location as shown in the IFC drawing.
Subcon: Work in progress, completion date will be on 07 June 2013.
PN: For inspection of 2nd shell course vertical fit-up joints of Tank V-500 A,B provided access was only
monkey ladder and below that the scaffolding platform was also unsafe. Instead to provide the proper
access for inspection one more RFI raised for the other tank with the same type of access. Ref. RFI nos.
are MFC-DLM-PS-ME-215-055, 066 which are rejected. SADARA Safety officer Mr. Joseph also
rejected the scaffolding and the monkey ladder for the use of inspection. Ref. FAR No. 02.
During site surveillance at dry flare super heater drum (D-0307) structure & dry flare drum (D-0301) at
North side of dryer pipe rack, it has been observed that installation of filler board are using nail in which
can damage some portions of birimen coating. This is a violation to RT2S-3001-01 Para. 11.1.1.
Contractor is advised to take immediate action concerning the issue in order not to repeat the same in
other structures.
During site surveillance on Jan. 21, it was found out that the grounding pad damaged & grounding cable
were cut after the installation of equipment no. V-0955 at the cooling tower area. A violation of
Equipment specs, G7D-0104-00 Para. 5.13.2.1, 5.13.3.2 and 5.13.3.
During site surveillance at V-0955 & sump 0906 areas, it was noticed that the end cuts of delivered
reinforcing bars located between these structures were not coated with epoxy paint patch up materials.
Some of the reinforcing bars might have been installed and since the cut ends are facing downward,
cannot be seen anymore. Contractor to advise the Contractor to repair cut ends and other damages on
epoxy coating prior to delivery on site to avoid rejection for violation of ASTM A-775, Para. 11.
PN: During surveillance inspection at substation G1121 GL A/1-11 at newly installed CMU. It was found
out some vertical rebar in some locations were not properly fixed or tied- up to the existing dowel bars
(12mm). Note that SADARA has a standard for splicing at vertical rebar, and mock-up sequence has
to be followed and implemented. Contractor is advised to take remedial action & proper supervision in
order not to be repeated in other areas.
During site surveillance at substation G1121 GL A/1-11, for on-going concrete masonry unit (civil)
installation & execution, it has been observed the following: 1. Contractor shall assign a permanent QC
Inspector to control & monitor the work to assure proper implementation of standard and IFC drawing. 2.
Contractor should submit testing of aggregates for mortar & grout in accordance to ASTM C-33 (REF.
G25-4300-01 Para 2.6.1) 3. Contractor should provide mixing boards at site in order that mortar & grout
mixing are not contaminated. 4. Subcontractor is not using measuring box for proper mix proportion as
per SADARA Standard.
Page 9 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
056
ARCC VAF MECH Structural 22-Jan-13 25-Jan-13 05-Feb-13 13-Jul-13 Closed
LBE-ARCC-MECH-
057
ARCC VAF MECH Structural 22-Jan-13 25-Jan-13 05-Feb-13 27-Feb-13 Closed
LBE-ARCC-MECH-
058
ARCC PN MECH Structural 22-Jan-13 25-Jan-13 05-Feb-13 21-Apr-13 Closed
LBE-PSCL-MECH-
059
PSCL PN MECH Tank 23-Jan-13 26-Jan-13 06-Feb-13 27-Jul-13 Closed
LBE-AMA/KCC-
ELECT-024
AMA/KCC PN ELECT Electrical 24-Jan-13 27-Jan-13 07-Feb-13 04-Feb-13 Closed
LBE-DLM-MECH-
061
DAELIM PN MECH Preservation 24-Jan-13 27-Jan-13 07-Feb-13 27-Jul-13 Closed
LBE-PSCL-MECH-
062
PSCL PN MECH Tank 24-Jan-13 27-Jan-13 07-Feb-13 Closed 1-Jun-13 Closed
LBE-DLM-MECH-
060
MR. HARIKUMAR DAELIM PN MECH UG-RTR 26-Jan-13 29-Jan-13 09-Feb-13 Closed 23-Oct-13 Closed
LBE-ARCC-MECH-
063
ARCC PN MECH Refractory 26-Jan-13 29-Jan-13 09-Feb-13 Closed 25-Apr-13 Closed
LBE-PSCL-MECH-
064
PSCL VAF MECH Tank 26-Jan-13 29-Jan-13 09-Feb-13 Closed 14-May-13 Closed
LBE-DLM-MECH-
065
DAELIM PN MECH Refractory 26-Jan-13 29-Jan-13 09-Feb-13 Closed 25-Apr-13 Closed
LBE-DLM-ELECT-
025
MR. MARK DAELIM PN ELECT Electrical 28-Jan-13 31-Jan-13 11-Feb-13 06-Oct-13 Closed
LBE-DLM-MECH-
066
DAELIM PN MECH Refractory 28-Jan-13 31-Jan-13 11-Feb-13 25-Apr-13 Closed
LBE-ARCC-MECH-
067
ARCC PN MECH Structural 28-Jan-13 31-Jan-13 11-Feb-13 6-Jun-13 Closed
LBE-ARCC-MECH-
069
MR. AMIN ARCC PN 2 MECH Quality Records 29-Jan-13 01-Feb-13 12-Feb-13
Incomplete
response
(130201)
Make sure
cylinder
regulators
10-Feb-14 Closed
LBE-DLM-MECH-
070
DAELIM PN MECH Quality Management 29-Jan-13 01-Feb-13 12-Feb-13 2-Apr-13 Closed
LBE-KCC-MECH-
071
MR. NOOR KCC PN MECH UG-RTR 29-Jan-13 01-Feb-13 12-Feb-13 7-Feb-13 Closed
LBE-DLM-ELECT-
026
DAELIM VAF ELECT Electrical 30-Jan-13 02-Feb-13 13-Feb-13 17-Feb-13 Closed
During surveillance inspection at Furnace are observed that: F-1220. *Stair case open structural was
installed at site without conducting elevation verification at site. Violation to RT2S-51200-01.
PN: Observed that Transition Duct upper part installation at F-1170 is on progress. Daelim and ARCC to
take more care on following work sequence. *The erection joint flange face of LTD were uneven at
radiant box side. *The LTD erection flange surface were rested and conducted-need cleaning prior to
apply mastic. *Scallop hole rectified are end plated welded area need flush grinding. *L/T duct flanges
face is not matching with radiant section' flanges.
PN: It is observed in Tank area of shell Daelim/Petrol Steel that the welding of 2nd shell course of Tank
V-500A, V-500B, V-1425, V-0615 and its horizontal joint of tank V-500B has been completed but
Contractor/Subcontractor is willing to collect more joints welded and then they will get its RT. Due to this
strategy, RT back log may increase and welders may not be judged parallel to the production. So it is
advised to get RT for all the Tanks parallel to the production.
Subcon: Petrol Steel has noted the proactive notification, and will to be steps to submit the RT
Report to submit ASAP to Company. RT computed as mentioned.
During surveillance inspection at Furnace observed that the following dimensional discrepancies at site:
F-1250, F-1240. *Duct alignment, centering & leveling are deviated by more that allowable tolerance
limit. *The elevation joints flanges of UTD were not rested on end plates and gap bet.UTD & LTD more
than allowable tolerance limit. *Misalignment on duct wall with UTD/LTD. *The erection joint bolt hole are
not matching. *Shim plate requirement (installed at site) at erection joints of side plate are not
mentioned on IFC drawing. *ARCC was started rectification activities without approved method of
statement by Company.
Subcon: ARCC put shims to make level the both sides of upper transition module & lower
transition module, refer to RFI #MFC-ARCC-MECH-0062 & 0063. F-1250 & F-1240 Erection from
Radiant Box up to Convection Breech are already done. Continuous monitoring for the alignment,
plumbness and other quality issues shall be implemented.
Daelim: F-1250 &F-120 erection from radiant box up to convection breach are already done.
Alignment (Final) shall be raised upon the other repair such as welding and bolt tightening is
done. Continuous monitoring for the alignment, plumbness and other quality issues shall be
implemented.
PN: It is observed that Contractor QC Representatives are not submitting the RFI's on time for closing
and final acceptance. After the inspection, RFI's must be submitted to Company as per Schedule "Q".
Attachment IVV, Para. No. 1.1.3.
PN: Contractor shall verify the installation of the Transformer. As of now, the foundation of the
transformer is already approximately 1.3 meters in height. And the auxiliary cabinet for the transformer
will be approximately 1 meter above the foundation as per G7D-0920-00 which means that the auxiliary
cabinet will be located approximately 2.3 meters above the floor which very high.
As per Electrical design philosophy A554-K-PRG-EL-GEN-PHL-005, Sec. 23.16 Pedestal
PN: During surveillance inspection at site on F-1250 Liquid Furnace area, it is observed that the
Refractory mixing activities are in-process but in morning time and the temperature measurement
comes below 10c. But Contractor/Subcontractor Quality Team must be aware that the temperature
should be maintained from 10c to 32c or as per manufacturer's recommendation and/or SADARA
Standard: RTSAES-n-110, Para. 9.1.12.
PN: It was observed that Daelim laydown area, the piping materials were stocked in an improper method
and mixed with carbon steel & LTC. It is not acceptable as per Sadara procedure and specifications.
Daelim Material handling team has to segregate the piping materials based on class, type specs. QC
Material Receiving and Piping team to follow approved material preservation plan.
Contractor: All the material was segregated and placed as per approved procedure. Warehouse
department was instructed and actions shall be taken accordingly.
PN: It is observed that expansion joints around the Burner tiles and doors are on-going. Therefore,
Contractor/Subcontractor's RB Hilton QC representatives must ensure that these joints are meeting the
requirements of SADARA Standard (G58-1805-01) Para. No. 5.15.9 & RT-SAES-N-130 Para. No. 6.1.
It is observed that during cutting of temporary attachments from the 2nd shell of Tank V-500B, grinder
cut marks are made by poor practice of grinder crew. After removal of temporary attachments, grinding
on the shell plates is not smooth and uniform. Some point also show that temporary attachments are
removed by hammer without proper grinder cutting. It is a violation as per API.650 Para. No. 5.8.1.1 &
7.1.6.
Subcon: The temporary attachment removed areas were built-up and ground smooth as to the
requirement as per API 650, Para 5.8.1.2 , 7.1.6 and the same was inspected by the
Contractor/Company inspector and found acceptable at the time of inspection against RFI no.
MFC-DLM-PS-ME-215-142. Petrol Steel construction team was also advised regarding the
discrepancy to avoid the recurrence of the same in the future.
PN: The Contractor shall educate / remind their subcontractors' workers who are doing chipping works at
the foundations to take care and not to damage the insulation of the grounding cables during chipping
works.
PN: During Surveillance inspection at Daelim MFC warehouse, it was observed that RESIN (Epoxy Vinyl
Ester 411-45) material was stocked at Laydown facility which will be expiring on Jan. 28, 2013. As per
manufacturing data sheet, it was manufactured on June 28, 2012 and self-life is 6 months only. Daelim
is advised to shift the subject materials to quarantine area after expiration date. This proactive
notification is issued to avoid the usage of expired material.
Daelim: Vinyl ester and epoxy resin which we are using at site, it will be used before its expiry
date, some of the resin drums expire 28/01/13 and some drums expire date 29/01/13. Expired
resin will not be used at site. Necessary action are taken to ensure the material which we are
using at site for lamination is within its expiry date. Expired resin already transferred to the
quarantine area.
PN: It is observed that the welding of vertical and horizontal joints is on-going on the Tanks (V-500A, V-
500B, V-142, V-0615) and their welding sequence needed a strong monitoring by Daelim & Petrol Steel
Quality team at each shell stage to ensure the following: A. Alignment of the vertical and horizontal
joints is meeting the requirements of API-650 Para. No. 7.2.3.1, 7.2.3.2 respectively. B. Plumbness of
the top of the shell shall not exceed 1/200 of the total tank height as per API-650 Para. No. 7.5.2. C.
Peaking of vertical joints and banding of horizontal joints shall not exceed 13mm as per API-650 Para.
No. 7.5.4.
PN: During the surveillance inspection, it was observed that Contractor/Subcontractor's workers are
doing the shaving and lamination on FRP line in cooling water area without JCC. Contractor Quality
Team must ensure and advise Subcontractors that all FRP fabricators/installers have their JCC with
them whenever an activity is carried out.
During site surveillance on Jan. 29, it was found out in Substation G-1120 near transformer yard that the
lighting protection cable (120mm bare copper) were not properly protected from physical damages and
dirt. A violation of checklist no. SMIC-P-3756.
PN: During Inspection at Furnace area, observed that ARCC team were installing Burner Assembly at F-
1250 without conducting Final Alignment Inspection and the Refractory contractor also installed and
fixed the Burner tile stream (Balcony side): The Bolt activities shall be synchronized and fixed the final
alignment between burner and burner tile assembly. Violation of ITP-A554-E-103-QA-GEN-PLN-039.
DAELIM QC team to coordinate with ARCC activities and fix the final alignment accordingly.
Subcon: ARCC aware on alignment of burners. ARCC will raised RFI once it is ready for
inspection (aligned).
PN: Daelim & ARCC is advised to display WPS always near the welding job site and that WPS must be
approved. Cylinder pressure gauges must be calibrated and heating torchers & cylinders must have
flash back arrester.
Subcon: ARCC advised welding department that WPS always available at welding area and be
displayed. Calibration of gauge at argon cylinder is not required Company to provide which
standard/reference requirements to calibrate the pressure/level gauge of gas cylinder. Flash back
arrestor was provided.
PN: It is observed that sometimes Daelim inspector raising RFI without proper and complete
information, required for that inspection like location, ITP no, etc. Contractor QC Inspectors must ensure
that RFI's have a complete information and activity no of ITP is perfectly referenced on the RFI and
checklist.
Page 10 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
072
TCC PN MECH Piping 31-Jan-13 03-Feb-13 14-Feb-13 8-Jun-13 Closed
LBE-ARCC-MECH-
073
ARCC PN MECH Refractory 31-Jan-13 03-Feb-13 14-Feb-13 20-Feb-13 Closed
LBE-AMA/KCC-
CIVIL-090
AMA/KCC PN CIVIL Civil 02-Feb-13 05-Feb-13 16-Feb-13 06-May-13 Closed
LBE-AMA-CIVIL-091 AMA VAF CIVIL Civil 02-Feb-13 05-Feb-13 16-Feb-13 26-Mar-13 Closed
LBE-AMA-CIVIL-092 AMA PN CIVIL Civil 02-Feb-13 05-Feb-13 16-Feb-13 26-Mar-13 Closed
LBE-PSCL-MECH-
074
PSCL PN MECH Tank 02-Feb-13 05-Feb-13 16-Feb-13 1-Jun-13 Closed
LBE-AMA-CIVIL-093 AMA VAF CIVIL Civil 03-Feb-13 06-Feb-13 17-Feb-13 12-Feb-13 Closed
LBE-AMA-CIVIL-094 AMA VAF CIVIL Civil 04-Feb-13 07-Feb-13 18-Feb-13 06-May-13 Closed
LBE-DLM-ELECT-
027
DAELIM VAF ELECT Electrical 04-Feb-13 07-Feb-13 18-Feb-13 06-Feb-13 Closed
LBE-KCC-CIVIL-095 KCC VAF CIVIL Civil 06-Feb-13 09-Feb-13 20-Feb-13 08-Apr-13 Closed
LBE-AMA-ELECT-
028
AMA PN ELECT Electrical 06-Feb-13 09-Feb-13 20-Feb-13 12-Mar-13 Closed
LBE-DLM-MECH-
076
MR. HARIKUMAR DAELIM PN MECH Structural 06-Feb-13 09-Feb-13 20-Feb-13 23-Oct-13 Closed
LBE-ARCC-MECH-
077
ARCC PN MECH Structural 06-Feb-13 09-Feb-13 20-Feb-13 6-Jun-13 Closed
LBE-ARCC-MECH-
078
ARCC PN MECH Structural 06-Feb-13 09-Feb-13 20-Feb-13 20-Apr-13 Closed
LBE-DLM-MECH-
075
MR. AMIN DAELIM PN MECH Quality Records 07-Feb-13 10-Feb-13 21-Feb-13 10-Oct-13 Closed
LBE-ARCC-MECH-
079
ARCC PN MECH Refractory 07-Feb-13 10-Feb-13 21-Feb-13 25-Apr-13 Closed
LBE-ARCC-MECH-
080
MR. NOOR ARCC PN MECH Refractory 09-Feb-13 12-Feb-13 23-Feb-13 12-Sep-13 Closed
LBE-ARCC/TCC-
MECH-081
ARCC/TCC PN MECH Piping 12-Feb-13 15-Feb-13 26-Feb-13 27-Mar-13 Closed
PN: During surveillance, it was observed that second layer of Castable Refractory on Lower Transition
duct F-1140 was on-going during rain and was not properly covered which may affect the density &
strength of refractory. Contractor/Subcontractor has to ensure to take preventive measures during
adverse weather condition.
PN: It was noticed that during inspection by SADARA Quality Group, some major items that affects the
structural integrity of the structure were missed by Contractor/Subcontractors' inspectors.
Contractor/Subcontractors shall inspect specially the items that are critical to the structural integrity of
the structure keenly to avoid recurrence.
During site surveillance at substation G-1120 transformer yard, it was found out that newly casted
concrete was not properly protected; without burlap & polyethylene sheet, and insufficient water curing
application. This is a violation to T2S-3001-01, Para. 9.1.1 & 9.1.4.1. Contractor was advised to take
remedial action on the issue.
PN: During the inspection of TCC's first activity at their Fab. Shop, it was observed that TCC has to
improve their preservation of piping materials. Especially in rainy environment, all piping materials must
be properly handled with suitable covering. Contractor/Subcontractor's QC inspection team must ensure
that proper inspection tools are available at the time of inspection. Ensure that large bare pipe spools
have proper clamps for fit-up, proper spool stands and proper lifting equipment which will be involved in
inspection.
Subcon: Inspections tools are available spools properly covered during rain. Further during
inspections spools are on stands. TCC inspector must be with all inspective tools. Agreed and
action has been taken.
PN: Contractor/Subcontractor shall provide protection for the underground PVC conduit for
communication duct bank at operator building G-1122 as these conduits were exposed to mechanical
damage.
PN: During Material Receiving Inspection, it is observed that (Convection Module: Sec.1) Convection
Tube weld joint was rested on the support. Daelim Engineering Team has to verify the strained impact
on convection tube during operation.
Contractor: Already informed DAELIM Engineering team. Necessary action has been taken cared
of.
PN: After inspection of convection module (part-3), it was observed that several Elevation & plumbness
variance on site: Daelim Engr. & QC Teams have to verify the variance and fix the elevation variance
according to approved recommendation method by SME of SADARA.
During site surveillance at Transformer FDN (Substation G1120), it was found out that three (2) span of
RC wall FDN were already removed the burlap & polyethylene sheet without proper water curing
application. Note that the structure was only four (4) days after the concrete was casted. This is a
violation to RT2S-3001-01 Para. 9.1.2, Contractor is advised to take remedial & immediate action on the
issue.
During routine site visit , it was found out that the contractor is shutting-off the power supply for the
space heater of the MV induction motors at laydown yard which is a violation as per manufacturer's
instruction and G7D-0665-00, section 13.1.2.
With reference to RFI Nos. 2014 & 2016, Contractor/Subcontractor was not able to complete the
concreting of girder at 6L BB/18-BL/18 and Conditional beam at 6L BL19-18 and columns at 6L 18 BB &
18 BC. The location of the construction joints were not in accordance with requirements of RT2S-3001-
01 section 5.4.7 which requires to be at the bottom of the element supported for columns and at mid-
span for girders & beams. Anchor bolts and other embedded items were spattered with concrete
including the reinforcing bars. Contractor/Subcontractor to provide method statement for Company
approval prior to proceed with succeeding activity including root cause and preservative actions.
PN: During site surveillance at cooling tower RC wall (Part-A) along north & east sides, it has been
observed that the Tie-Rod lock and some horizontal & vertical bracings were removed which can affect
the newly casted RC wall. Note that the structure was casted last 31 Jan. '13 at around 5 pm. Contractor
is advised to take remedial action concerning the issue.
PN: It is observed that R.T. is on-going on Daelim/Petrol Steel MFC Tanks & welders are repairing the
four welds (W-985, W-816, W-046, W-333) which are still pending, and Contractor/Subcontractor Quality
Teams must ensure the following: A. All repairs must be done as soon as possible & RFI must be raised
for its inspection as per SMITP-M-001-02 Rev.02, activity no. 6.7. B. Repair rate must be controlled for
During surveillance inspection at cooling tower basin along east side, it was observed that backfilling
works did not conformed to the standard of (200mm,thk) layer by layer as stated on RT2S-2200-01,
Para. 3.4.9. But Subcontractor has backfilled the area at 400mm thk. at one time.
PN: During surveillance, it is observed at F-1240 Convection Breech Module prior to installation
inspection activities, it was found out that the Refractory was damaged in some locations and broken
near the flange. Daelim/ARCC quality team must ensure that the repair activities is perform as per
manufacturer's recommendation, RTSAE-N-110. Para. Nos. 9.1.8 & 11.5.
Daelim: Contractor raised an internal logbook (LBE (54) pertaining this issues. Further portions
have been marked as well. These defects shall be repaired with PID presence as soon as
possible.
Subcontractor: ARCC to repair the damaged refractory as per issued site instruction.
During surveillance inspection at substation G1120 along transformer yard, it was found out that partial
delivery of concrete masonry units (CMU) 250mm thk. re not properly protected, without cover and some
are rested on the ground. This is a violation to G2S-4300-01 Para. 3.1.1.
PN: It is observed that during welding ARCC/TCC welders are needed to be monitored more closely by
the TCC/ARCC/DAELIM QC Team for the following: Only qualified welders will tack & weld the joint.
Welder will not weld the joint without Fit-up inspection acceptance. Weld shielding must be proper to
avoid air entrapment during welding. Welder will not weave the welding lead more that 3 times the
electrode diameter during filling and capping. Welder will not exceed the limit of weld deposition from his
qualified thickness for the relevant welding process. Final weld cap reinforcement profile must be
smoothed and with proper each weld layer overlapping avoiding all visual defects as per ASME B313.
Ensure the welder shall not proceed the welding if Fit-up tack is already cracked during his root pass
welding. Ensure that all welders have passed the 1st three production welds by RT prior to proceed for
continuous welding.
PN: It was observed that sealing plate of convection module, section 03 at header box was damaged
and the part was dismantled. Daelim QA/QC Team has to closely monitor the repair activities and
carried-out in accordance with the approved procedure and method.
PN: All WPS, PQR, Weld maps and Weld line description matrix should be available at each work site
any time for verification by the Company Inspector. Contractor Inspection team has to provide these
documents at site and off-site Sadara Jobs. Ref. TR8S-6500-01.
Contractor: Situation complying with the requirement.
PN: It was found out that the Subcontractor R.B Hilton has been fixing the ceramic board (50mm) in
corbel area F-1250 Liquid Furnace prior to summing application. But still there were gaps around the tile
clip extension and gusset plates. These gaps should be filled with ceramic blanket prior to installation of
C-clip, tile anchor.
Page 11 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-PSCL-MECH-
082
MR. AMIN PSCL PN 2 MECH Tank 12-Feb-13 15-Feb-13 26-Feb-13 19-Feb-14 Closed
LBE-ARCC/TCC-
MECH-083
ARCC/TCC PN MECH Preservation 12-Feb-13 15-Feb-13 26-Feb-13 27-Feb-13 Closed
LBE-ARCC-MECH-
084
ARCC VAF MECH Refractory 13-Feb-13 16-Feb-13 27-Feb-13 2-Jun-13 Closed
LBE-ARCC-MECH-
085
ARCC VAF MECH Structural 13-Feb-13 16-Feb-13 27-Feb-13 22-Apr-13 Closed
LBE-KCC-CIVIL-099 KCC VAF CIVIL Civil 14-Feb-13 17-Feb-13 28-Feb-13 08-Apr-13 Closed
LBE-TCC-MECH-
086
TCC PN MECH Mechanical 14-Feb-13 17-Feb-13 28-Feb-13 28-Apr-13 Closed
LBE-AMA-CIVIL-101 AMA PN CIVIL Civil 16-Feb-13 19-Feb-13 02-Mar-13 01-May-13 Closed
LBE-ARCC-MECH-
087
ARCC PN MECH Piping 17-Feb-13 20-Feb-13 03-Mar-13 3-Mar-13 Closed
LBE-DLM-MECH-
088
DAELIM PN MECH Refractory 18-Feb-13 21-Feb-13 04-Mar-13 16-Jun-13 Closed
LBE-AMA-CIVIL-102 AMA PN CIVIL Civil 23-Feb-13 26-Feb-13 09-Mar-13 18-Aug-13 Closed
LBE-AMA-CIVIL-103 MR. GERALD AMA PN CIVIL Civil 25-Feb-13 28-Feb-13 11-Mar-13 16-Oct-13 Closed
LBE-KCC-MECH-
089
KCC VAF MECH Mechanical 25-Feb-13 28-Feb-13 11-Mar-13 9-Mar-13 Closed
LBE-AMA-ELECT-
029
AMA VAF ELECT Electrical 26-Feb-13 01-Mar-13 12-Mar-13 03-Mar-13 Closed
LBE-PSCL-MECH-
090
PSCL PN MECH Tank 27-Feb-13 02-Mar-13 13-Mar-13 2-Jun-13 Closed
LBE-PSCL-MECH-
091
PSCL PN MECH Tank 27-Feb-13 02-Mar-13 24-Oct-13 4-Mar-14 Closed
LBE-AMA-CIVIL-104 AMA PN CIVIL Civil 28-Feb-13 03-Mar-13 14-Mar-13 22-May-13 Closed
PN: It observed that distortion control on Petrol Steel Tanks is needed close concentration for vertical
and horizontal shell weld joints. Petrol Steel/Daelim needed to submit a separate distortion control
welding sequence procedure for SADARA approval. It is advised to Daelim/Petrol Steel QC team to
monitor closely for peaking , banding and weld joints misalignment, etc. as per API-650 requirements.
Subcon: The proactive notification has been noted, the welding sequence for vertical and
horizontal joints are already mentioned in the approved general erection procedure. Petrol Steel is
working closely to avoid this violation in the on-going progress.
PN: DAELIM/ARCC/TCC QC team to ensure that welding electrodes are color coded with high
temperature heat resistant paint prior to re-baking to avoid re-baking the electrode twice. Dont allow any
kind of paint material for this purpose which is flammable at the oven temperature.
During material receiving inspection, it was observed that Refractory Lining was damaged at splice joint
between Convection Module and Breech Module. Daelim & ARCC teams have installed the modules on
position without correcting the repair activities. Daelim/ARCC team to propose rectification method to
Company and take this concern seriously in order to avoid further interruption during operation. Violation
of pro-active notification log #80 and RTSAES-N-110 & RT-6-ICS.
Daelim: F-1250 Convection Breech Module has been repaired with Sadara witness. Rectification
& repair for the refractory lining defects are already done.
PN: Contractor submitted RFI # AMA-CI-1856, dated 18/12/12 & RFI # AMA-CI-1860 dated 18/12/12
concerning concrete sampling testing & placement insp. (CI.C2 & MGI) its lift (Substation G1120), the
required strength for this structure is 4000 PSI with micro silica. But the attachment is only 2000PSI/type
1, as per submitted RFI. And also, it has conflict with location & structure. Contractor should investigate
& check the attachment & explain to SADARA QC personnel on what to the said RFI's.
PN: It is observed that Piping work is on-going for different line classes and ASME standards at off-site
Fabrication of ARCC. Daelim/ARCC QC team is advised to ensure the following: Proper material &
spool segregation as per line class, B31.1, B31.3 & approved drawings. Fittings are used as per latest
approved drawings. Color coding system is implemented. Proper identification for SADARA MFC
designated areas.
PN: During Material Receiving Inspection on Convection Module, it was observed that Refractory Lining
was severely damaged at F-1160 & F-1170. At F-1160 the north flange area & F-1170 the west side:
Brazing location. Daelim/Subcontractor shall rectify the defects with proper Refractory rectification
method approved by SADARA prior to start further installation at site. RT-SAES-N-110 & RT-6-ICS.
Subcon: As per SME, damages happened to refractory surface would be a big concerned (as per
attached photos of SME for verification) AS this damages are happened mainly in the flange area
which was already covered with mastic and thick ceramic fiber blanket , no leakage or not spot is
expected. Leakage is not expected since enough and thick patching material of C. F Blanket was
provided to between CM-1240-2 and 3. Then Subcontractor would like to close this issue.
With reference to today's RFI # MFC-DLM-KCC-CI-2204-0A and RFI # MFC-DLM-KCC-CI-2205-0A, the
following are observed: GL 65, 66, 67, 68/AB - column ties were bent and hooks not properly embedded.
No pouring access of concrete pump hose to columns below the beams at first lift at GL 66/13B & GL
67/BB. This is a violation to RT2S-3001-01 Section 5.6.10 which states "Concrete shall not be allowed to
fall free from a height more than 1.0m. Heights greater than 1.0m shall require approved down pipe
tremie or chute" Bolt offset of more that 3mm at GL 65/BC and 68/BB.
PN: During site surveillance at substation G1120, it has been observed that some portions for CMU
installation are not using fish tail for proper anchoring at columns and also chipping at columns are not
properly implemented prior to CMU installation. Contractor is advised to take immediate action
concerning the issue & also properly monitored as per IFC drawing.
PN: During surveillance of TCC fabrication, it has been observed that there is no 24 hours power supply
for electrode holding oven. TCC has been advised to maintain 24 hours supply to sustain temperature in
the holding oven.
It is observed that ARCC Fabrication team was fabricating shim plate on gratings at Furnace area
(ELC:3S.4). The area was contaminated, spread grinding debris around & occurred corrosion on
adjacent structure and gratings. ARCC team to rectify the surface of immediately and control the
corrosion where it occurred. ARCC QA/QC team is advised to use proper protection during rectification
or fabrication at site.
PN: The Contractor submitted RFI # AMA-CI-1645 dated 22/11/2012 regarding leak testing for unit sump
# 4 (Sump 634) already signed by sub-contractor and Contractor QC personnel. This Sump is still
pending and needs further leak test due to non-completion of the repair at the West-Side portion of the
wall. Contractor shall review RFI's prior to sending for approval and ensure activities are in compliance
with SADARA specification and the ITP.
During site surveillance at substation G1120, it has been observed that mixing of mortar & grout
intended for CMU installation. AMANA is not using measuring box for proper proportioning or ratio of
comment & sand. This is a violation to G2S-4300-01 Para. 2.4.2 & 3.2.14.1. Contractor was advised to
control & monitor properly not to repeat the issue.
PN: During inspection at Mid-Wall 3, 4, 5, & 6 at Cooling Tower (Part-B), it was found out that
construction joints were provided but such does not follow IFC drawings. The Contractor was advised to
justify this const. joints by confirmation from the engineering of Daelim and to submit shop drawing for
proper documentation.
Subcontractor: Drawing Confirmed & Signed by Daelim
It was observed that the stub-up grounding cable in area are now in bad shape and some of the cable
are already damaged because of no protection and not secured from physical damage. A violation of
schedule 'Q', attachment Q-1, sec. 1.2.
PN: Petrol Steel has erected the last shell course of 2 tanks V-500A & V-500B and its maximum
inspection like weld visual, NDE, Peaking, Banding & Plumbness inspections are still balance. Also
many inspections are still remaining for lower shell courses and bottom as well. Daelim inspection team
must ensure that all required inspections are completed prior to roof or compression plate erection on
the last upper shell course.
PN: Daelim drawings for Tanks are showing the weld joint of compression plate to tank roof overlapped
instead of under lap as per design calculation don no. V-1425-103-9004-01-215. Its joint design is under
lapped which may be a more stringent. Daelim QC team is advised to ensure the final joint design from
engineering prior to activity start-up.
PN: During site surveillance at Cooling Tower (Part-B) base slab, it was observed that some portions of
slab are having hairline cracks. Contractor/Subcontractor has to investigate the said cracks prior to
repair works.
Subcon: Hairline cracks to be repaired using approval repair material. A method statement was
submitted for repair of cracks.
PN: During site surveillance at substation G1121 along (CMU) perimeter wall, it was observed that the
installation of CMU wall's IFC drawing was not followed where there is no installed weep holes.
Contractor is advised to take immediate action concerning the issue that proper monitoring of the works
must be observed.
Subcon: Weed holes already installed. Contractor QC will be conducting internal inspection prior
to Company inspection. RFI will be raised.
During surveillance, it was found out that Daelim/KCC started "PIV" valves installation on-going without
Testing the 5 water lines, packages no. 04,05,15,18,20 and valves no. 0708, 0709, 0706, 0702, 0705,
0707. As per A554-0-PRG-IC-GEN-DOC-001, Daelim/KCC QA/QC Team must ensure that the valve
installation activities as per Company document as above.
Page 12 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
092
ARCC VAF MECH Refractory 28-Feb-13 03-Mar-13 14-Mar-13 20-Apr-13 Closed
LBE-AMA-CIVIL-105 AMA PN CIVIL Civil 03-Mar-13 06-Mar-13 17-Mar-13 05-May-13 Closed
LBE-TCC-MECH-
093
TCC PN MECH Mechanical 03-Mar-13 06-Mar-13 17-Mar-13 5-Jun-13 Closed
LBE-ARCC-MECH-
094
ARCC VAF MECH Structural 03-Mar-13 06-Mar-13 17-Mar-13 13-Jul-13 Closed
LBE-AMA-CIVIL-106 AMA PN CIVIL Civil 04-Mar-13 07-Mar-13 18-Mar-13 21-Mar-13 Closed
LBE-ARCC-MECH-
095
ARCC VAF MECH Piping 05-Mar-13 08-Mar-13 19-Mar-13 13-Jul-13 Closed
LBE-DLM-MECH-
096
DAELIM VAF MECH Quality Records 05-Mar-13 08-Mar-13 19-Mar-13 08-Jun-13 Closed
LBE-KCC-MECH-
097
MR. NOOR KCC VAF MECH UG-RTR 05-Mar-13 08-Mar-13 19-Mar-13 Closed 19-Mar-13 Closed
LBE-KCC-MECH-
098
MR. NOOR KCC VAF MECH UG-RTR 05-Mar-13 08-Mar-13 19-Mar-13 01-Jan-14 Closed
LBE-TCC-MECH-
099
TCC VAF MECH Piping 07-Mar-13 10-Mar-13 21-Mar-13 Closed 22-Apr-13 Closed
LBE-TCC-MECH-
100
MR. NASSAR TCC PN MECH
Coating/
Painting
07-Mar-13 10-Mar-13 21-Mar-13 Closed 22-Apr-13 Closed
LBE-PSCL-MECH-
101
MR. AMIN PSCL VAF MECH Tank 07-Mar-13 10-Mar-13 21-Mar-13 22-Oct-13 Closed
LBE-KCC-CIVIL-107 KCC VAF CIVIL Civil 10-Mar-13 13-Mar-13 24-Mar-13 09-Apr-13 Closed
LBE-AMA-CIVIL-108 AMA PN CIVIL Civil 10-Mar-13 13-Mar-13 24-Mar-13 08-May-13 Closed
LBE-AMA-CIVIL-109 AMA PN CIVIL Civil 10-Mar-13 13-Mar-13 24-Mar-13 09-Apr-13 Closed
LBE-TCC-MECH-
102
MR. NASSAR TCC VAF MECH Quality Management 10-Mar-13 13-Mar-13 24-Mar-13 22-May-13 Closed
LBE-ARCC-MECH-
103
ARCC VAF MECH Mechanical 10-Mar-13 13-Mar-13 24-Mar-13 22-Jun-13 Closed
LBE-DLM-MECH-
104
MR. NASSAR DAELIM VAF 2 MECH
Coating/
Painting
11-Mar-13 14-Mar-13 25-Mar-13 17-Feb-14 Closed
It was observed that ARCC Construction team has installed the Burner Assembly at F-1250 in improper
way and no proper protection on Burner tip. Burner tips are open Refractory material & all debars were
occurred on Burner tip. Delay to install Burner tress. Tips were damaged and bended. Daelim QA/QC
team to closely monitor the installation of sensitive part of the equipment at Furnace and coordinate with
the Subcontractor's activities as per approved procedure and specification. Violation of Proactive
Notification #67 ITP-A554-GE-PLA-039.
PN: It was observed that the area to be epoxy grouted at the Compressor shelter at the compressor
shelter are wide enough that may crack due to expansion of the epoxy grout. It is recommended that the
manufacturer of the epoxy grout shall be consulted to advise location of expansion joints on adjacent
area of the sole plates to avoid cracking of the epoxy grout.
During inspection of valve installation of fire water line: FW-071206-09-02 area no B1 valve # PIV-0720
on site. It is observed that the Contractor/Subcontractor is using nut, bolts and gaskets in fire water line
without material receiving inspection. As per relevant ITP, SMITP-M-350-01 activity no. 2.3, 2.4 its
inspection level is witness for Company and this is a violation of schedule "Q", Para. 1.6.
Subcon: KCC Construction was instructed to ensure proper documentation on supplied materials
before using on site. Daelim: The activity
at the site on hold the material receiving RFI for bolt and nuts on hold due to dishwashing's are
not done as per the ASTM F436 and this issue was already informed to Daelim Material
Department to solve said problem as soon as possible and we are not giving to use this washer
until this issue is solved and packed already and further inspected by SADARA Inspectors.
During surveillance, it was observed that TCC welder (TCC-001) was found welding in an open
atmosphere. In spite of the tool box meeting conducted by TCC QC and Daelim QC to all TCC welders,
said welder is still welding in an open atmosphere. Contractor/Subcontractor is advised to welding a
controlled atmosphere to avoid weld discrepancies.
PN: It is observed that the weather conditions are severe which can cause problem for sand blasting
and coating. Therefore, Contractor/Subcontractor is advised to ensure that sand blasting & coating
activities are carried out in a controlled environment.
Subcon: No any blasting and coating activity allowed in sandy weather.
Crew supervisor and Painting inspector are ensure it regularly basis.
Daelim:
It is observed that during WQT qualification at site, 6 welders has started the WQT but DAELIM, ARCC
& Third party were not having any measuring device for Pre-Heat, Inter-pass temp. measurement and
Clamp meter for heat input measurement and clamp meter for heat input measurement as per relevant
WPS. This has been a repeated violation that welders are doing welding without ensuring the WPS
parameters.
Subcon: The WPQT-009 cancelled on that day 5 March 2013, only this day 12 May 2013
conducting WPQT for 14 welders, while the third party inspection (AMSYCO) have been provided
his instrument for measuring temperature & every now & then, AMSYCO aware on Sadara's
requirement. Daelim:
The RFI for WPQT is cancelled by Daelim. Action have been already taken by raising Logbook
Entry to ARCC/AMSYCO.
During ITP review, Daelim inspection team doesnt have proper document tracking system, and ITP
preparing personnel also not caring to edit a reference document number in ITP for quality procedure
reference. Daelim inspection team must ensure the proper corrective action and Preventive measures in
the future.
During inspection of bolts torqueing prior to pressurization of fire water line FRP, test bolts were over
Torqued for the "PIV" valve and blind flanges by spanner instead of using calibration torque wrench
which is violation to SADARA Standard (G85-8010-47) for over torqueing the FRP, which may damage
or leave potential defect in the flange material.
Daelim: All the Bolts of the blind flanges in package no.:20 & 21 are removed after completion of
the hydro test of both "pkg" after hydro test "PIV" bolts are also loosed and when we will do bolt
tightening for "PIV" Contractor will issue RFI for SQIT witness.
PN: TCC has started welding activities (Tack Weld) on structure at site without notification. The following
violations are observed: 1. Welder was welding without proper tools (oven, etc.) 2. Welding
consumables were not inspected or approved for site. 3. Welding Inspector was not available at site.
Daelim QA/QC team shall closely monitor the TCC welding activities at site.
Subcon: One welding inspector for TCC site welding activities had been already approved by
Company. Safety orientation and get pass in process. After getting SADARA gate pass said
Inspector will be available at TCC site. Mr. Imran taking care for MFC Project site welding
activities. Action has been taken and welding Inspector is present at site.
The following violations were observed on the installation of grating and stairway at Furnace area:
Stairways were released for construction activities without final Bolt tightening. Gratings were laid on the
platform in improper way and not fixed/aligned properly. Grating panels are provided with a minimum of
2 fasteners at each support with minimum of 4 fasteners per panel. ARCC/Daelim shall follow the
minimum requirement as specified on RT2S-5120 and construction drawing for installation of platforms
and stairways.
Subcon: ARCC installed bolts/fasteners on structural members, grating clips and pictures were
taken as proof of the actions were undertaken..(photos sent to DAELIM)
PN: During site surveillance at substation G1121 (Soffit Slab Structure) along switch gear area, it was
found out that Contractor/Subcontractor has started application of primer paint without Material
Receiving Inspection done on the paint material and an approved Method of Statement for Interior
Painting (Building) submitted to Company for review and approval. Contractor/Subcontractor is advised
to submit first RFI for material receiving inspection with its valid supporting documents for proper
documentations.
During surveillance on fire water valves, it has been observed that delamination (adhesion failure &
flaking, coating damage and blasting application) or dirt inclusions of paint surface was noted in the
bonnet flange. The post indicator valve was manufactured by waters. Daelim shall conduct root cause
analysis including corrective action. These valves affected and implications of a continued coating
breakdown. Contractor need to ensure the effective implementation of preservation requirements for all
equipment and materials during storage installation.
Daelim: Daelim Material Team shall feedback the item to the vendor and shall obtain the repair
procedure for the item. Daelim Coating team shall repair the item with Company approved
procedure and applicable standards.
PN: During inspection at (slab & Haunch) portion at Cooling tower "East of Pump Sump", it was found
out that the location of water stopper was adjusted and did not follow the IFC drawing. Contractor is
advised to submit shop drawing showing the actual location of water stopper with the confirmation of
Daelim Engineering team.
During surveillance, it was noticed that the Contractor/Subcontractor carried out the job without
informing SADARA SQIT. When visited the site, there was no Contractor QC Inspector but surface
preparation and painting application were going-on during sand storm and intermittent rain. The crew
members who applied the coating did not hold JCC with them. A violation to the Standard and as per
schedule "Q" attachment IV section 2 & work procedure A554-E-103-QA-GEN-PRO-041, Para. 5.2.1.2 &
5.2.1.3. Photos were provided.
Subcon: Performance test was done on 23 Feb. 2013, waiting for
JCC to come out.
Daelim:
It is observed that the weld repair rate of Daelim/ARCC has increased, violating the Sched. "Q" Attach.
IV, Para. 3.9 at ARCC off-site Fabrication. Daelim & ARCC quality team to provide root cause analysis,
corrective action and preventive measures as soon as possible. Sch. "Q" weld rejection rate
requirement is up to <5% only but ARCC's actual weld reject is 11.764%.
Subcon: ARCC conducted electrodes test/verification & found out that some porosities were
visible for "GEKA" brand. ARCC fabrication shop are utilizing Bohler brand. ARCC submitted
corrective & preventive action plan via email & officially transmitted.
Daelim:
Misalignment is observed at third horizontal weld joint at 03 locations. Actual measurement .07
misalignment is 1.7-3mm which is not acceptable as per API-650 Para. 7.2.3.2. Additional RT might be
required for assurance of the weld joint integrity. Proper corrective action is required from Daelim/Petrol
Steel.
Subcon: The misalignment area has been rectified and the weld integrity has been assured by
taking additional RT spots in the rectified misalignment area. (Ref. RT report no. J28323, J28324,
& J28520 & J28521). The rectified area was also offered for Contractor/Company inspection and
it was found acceptable.
After removal of formworks at Pipe rack A, it was noticed that excessive honeycombs are prominent on
the West side portion of the column at first level 9+ 6L 6/AB. The honeycombs at the surface of the
column is about 3.45 m high. Contractor/Subcontractor is advised to provide Method Statement of how
to repair the excessive honeycombs and preventive action so that it will not happen again.
PN: It was observed that repetitive inspection has been undertaken at Floor Pipe rack area due to
conflict in between details in the drawing. DWG. No. A554-E-104-CV-DWG-C40-383, rev. 2B has 2
conflicting details. One detail shows: Top of grout to be 155mm while the other shows 155mm Top of
concrete projection. Contractor shall verify first with Engineering prior to finalize setting out of anchor
Page 13 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
105
TCC VAF MECH Piping 16-Mar-13 19-Mar-13 30-Mar-13 22-Apr-13 Closed
LBE-ARCC-MECH-
106
MR. NASSAR ARCC VAF MECH Quality Management 16-Mar-13 19-Mar-13 30-Mar-13 22-May-13 Closed
LBE-ARCC-MECH-
107
MR. NASSAR ARCC PN MECH
Coating/
Painting
16-Mar-13 19-Mar-13 30-Mar-13 23-May-13 Closed
LBE-TCC-MECH-
108
Coating/
Painting
16-Mar-13 19-Mar-13 30-Mar-13 22-May-13 Closed
LBE-ARCC-MECH-
109
ARCC VAF MECH Piping 16-Mar-13 19-Mar-13 30-Mar-13 18-May-13 Closed
LBE-AMA-CIVIL-110 AMA PN CIVIL Civil 17-Mar-13 20-Mar-13 31-Mar-13 15-Apr-13 Closed
LBE-DLM-MECH-
110
MR. NOOR DAELIM VAF 2 MECH Material 17-Mar-13 20-Mar-13 31-Mar-13 12-Feb-14 Closed
LBE-AMA-CIVIL-111 AMA PN CIVIL Civil 18-Mar-13 21-Mar-13 01-Apr-13 18-Aug-13 Closed
LBE-DLM-MECH-
111
MR. AMIN DAELIM VAF 2 MECH Quality Records 18-Mar-13 21-Mar-13 01-Apr-13 10-Feb-14 Closed
LBE-ARCC-MECH-
112
ARCC VAF MECH Quality Records 18-Mar-13 21-Mar-13 01-Apr-13 18-May-13 Closed
LBE-TCC-MECH-
113
MR. NASSAR TCC VAF MECH
Coating/
Painting
18-Mar-13 21-Mar-13 01-Apr-13 22-May-13 Closed
LBE-DLM-MECH-
114
MR. NOOR DAELIM VAF MECH Preservation 18-Mar-13 21-Mar-13 01-Apr-13 01-Jan-14 Closed
LBE-PSCL-MECH-
115
MR. AMIN PSCL VAF MECH Tank 19-Mar-13 22-Mar-13 02-Apr-13 27-Oct-13 Closed
LBE-ARCC-MECH-
116
MR. NASSAR ARCC VAF MECH
Coating/
Painting
LBE-TCC-MECH-
117
TCC VAF MECH Quality Records 20-Mar-13 23-Mar-13 03-Apr-13 22-Apr-13 Closed
LBE-AMA-CIVIL-112 AMA PN CIVIL Civil 23-Mar-13 26-Mar-13 06-Apr-13 18-Aug-13 Closed
LBE-KCC-MECH-
118
MR. NOOR KCC VAF MECH UG-RTR 23-Mar-13 26-Mar-13 06-Apr-13 9-May-13 Closed
LBE-KCC-CIVIL-113 KCC VAF CIVIL Civil 24-Mar-13 27-Mar-13 07-Apr-13 08-May-13 Closed
During routine inspection at TCC off-site fabrication facility, it is observed that 2 LTCS 36" pipe of
random length are found stored with normal CS material which is a violation against Sadara
Preservation Plan RT-6-ICS. TCC & Daelim QC have not been notified regarding the arrival of LTCS at
TCC facility, moreover on factory.
During routine inspection on Furnace 1250; RFI #MFC-DLM-ARCC-H-0192 it has been observed that
the responsible coating Inspector of ARCC Mr. Christopher Ofiaza was doing the job without approval
from Sadara. This is violating the Standard as per schedule "Q" attachment I, Para. 5.6.
Subcon: ARCC submitted CV of Mr. JJ Buendia Painting Inspector, interviewed and approved
conditionally.Mr. Bundia is raising RFI & conducting inspection. Chris Ofiaza is assist on Painting
Inspection activities under supervision of JJ Buendia.
It is observed that Daelim Quality team is not reviewing and approving the subcontractor welder's
certification & submitting to Company directly. It is violation of Sadara procedure A554-O-PRG-QA-GEN-
PRO-012, Rev.2 Para. No. 5.0. Daelim quality team needs to comply with the Sadara requirements.
Subcon:
Daelim: Contractor apologizes for the clerical errors found in the welder qualification records with
mentioned transmittal, Contractor is not doing any violation against the as per standard and
specifications of the Company. Further, after Company approved third party certification.
Contractor reviewing and if there is any errors found after rectification only we submit to the
Company. However Contractor will give more attention to avoid this will happen again in the
future.
WQT done at off-site ARCC welding academy without approved WPS (WPS No. 1148/09A, rev.1)
against the RFI No. ARCC-PIP-WE-0057 dated 12th March 2013, WPS was stamped on the additional
top page only by Mr. J.H. An but Daelim QC representative told that it is approved by Sadara Welding
Specialist Mr. Adnan but actually that is not approved by him. This is a violation of Schedule Q, Atta. IV,
Para. 2.1. Daelim Quality needs to comply with the Sadara requirements.
During routine inspection on the external coating touch-up/repair for pipes & spools as per RFI No. TCC-
H-046, it has been observed that painters applied touch-up on the defected area by roller in front of
Company Inspector. This is violation of the Standard as per GI6S-0202-02, section 4, Para. 4.2.
Subcon:TCC Painting Inspector will make sure to follow any repair in painting surface as per
approved Procedure and Sadara specifications. Initial application of Prime shall not be allowed
with roller, only brush shall be used & subsequent coats shall follow manufacturer's
PN: During witness crushing of cubes at site laboratory (third party) for cement mortar intended for
substation G1121 GL-1G/A, 1/A-B, it was found out that at 28 days compressive test result the average
is 2487.5psi in which as per requirement is 2500psi. Contractor is advised to take corrective action on
the issue.
During Material Receiving inspection found that material identification on washers are missing which is
violation against schedule "Q" attachment IV Para. 4.2. Contractor must ensure that the materials
should be complied as per project specification's requirements before installation of PIV valve for
underground system.
Subcon:
Daelim: Regarding the material identification on washing, Contractor informed to material
distributor to solve this issue and Contractor will take care that such type of actions will be
repeated again. All the washers were conducted by Third Testing party. Only 4 packet were found
rejected. All other found accepted. The rejected washers were segregated and will be replaced.
PN: During inspection at cooling tower "Wall 9a", it was found out the splicing from starter bar for
vertical rebar 2.5mm is not in accordance with Sadara' s standard. Note that the actual splicing
dimension is only 1500mm, and as per standard requirement dimension at 1650mm. Contractor is
advised to submit shop drawing & confirm by Daelim's Engineering team for proper documentation.
Subcon: Daelim reviewed the drawing and found acceptable. Please see attached drawing
signed by Daelim.
PN: During routine inspection at inside Furnace-1110, it has been observed that uniform pock marked
appearance in particular of spray applied coating in which the surface of the paint film resembles the
skin of an orange (orange peel). The probable cause - failure of the paint film to flow-out, usually caused
by poor application techniques, by incorrect solvent blend or too high ahrotropy. Other defect is bubbles
without paint film appear as small blisters.
PN: During routine inspection for external primer Coating for pipes and spools at TCC facilities, it has
been observed that mechanical damage for pipe no. N016103C2A-CUR; the depth of this damage is
1mm.
Subcon:TCC Piping inspector will make sure for no damage on receiving materials. Before final
spool release RFI piping inspector is responsible to rectified any mechanical damage.
Daelim:
It is observed that some welders at off-site ARCC fabrication are violating the allowable weld bead width
by GTAW & SMAW Processes more than 03 times the core wire or filler wire dia. It is notified 2nd time
to Daelim welding inspector but told that he allowed the welders himself.
Subcon: ARCC QC Inspector conducted orientation tool box meeting on welders and welding
staff with regards to wide bead. Daelim has already taken action by raising log-book entry to
ARCC and subcontractor has taken also corrective action by conducting tool box meeting to the
welders.
During the review of RFI's submitted for Sadara Quality Group's signature, it was noticed that RFI No.
MFC-DLM-KCC-CI-2531 (3/18/13) has attachment with laboratory test report without reference number.
The contents of the test report are also in conflict with the requirements. The specification requirements
for relative density is 75% while the result of 71.3% & 70.7% were marked as pass. Computation of %
density is also wrong. Contractor/Subcontractor to investigate root cause and corrective action.
Subcon: Osaimi technician admitted his lapses and asked for consideration on the matter,
promised not to repeat the same mistake in the future. Contractor/Subcontractor QC will be more
careful in double checking 3rd party's reports. Compaction testing shall then be HOLD point
inspection for Contractor. Lean concrete, however, was removed & conducted re-testing on the
affected area. Compaction testing passed and poured lean concrete again.
During routine inspection at White Nile fabrication, it is observed that incorrect & irrelevant WPS(WN-
WPS-A-03, Rev. 0 & WN--WPS-A-02, Rev.1 was displayed at the facility area, violating Sadara
specification RT8S-6500-01. Pro-active notification was also logged as LBE No. 75 on 7 Feb. 2013.
Subcon: All Rev. WPS was removed from the site & approval of WPS was there . All job location
only. Approved WPS will be their. Daelim:
PN: During surveillance inspection at cooling tower "Perimeter Wall" part A,B,&C internal portion, it was
found out some portion of walls have presence of hairline cracks in several locations. Contractor is
advised to check and investigate said hairline cracks and take corrective & preventive action on the
issue.
Subcon: Subcontractor had been submitted method statement for repair of hairline cracks at the
perimeter walls of the cooling tower.
A violation has been noted for over-torqueing of valves which exceeded more than 345N-M for 10" &
20" and 150-210 N-M for 6" dia pipes but as per Sadara specification G8S-810-47, maximum torque
limit for 10" is 105 N-M, for 20" maximum 185 N-M and for 6" maximum torque limit is 70 N-M. Daelim
quality team must take corrective action and preventive measures.
Subcon: The over Torque Flange was already removed after the Hydro test.
Succeeding Torqueing shall be closely monitored by Inspectors to ensure correct torqueing.
Found that Nuts, Bolts and Washers stored in Daelim Laydown yard in open atmosphere. As per
Company Material Preservation plan & Project requirement as per "RT-6-1CS" states that Nuts, Bolts &
washers should be kept in sealed water tight containers if stored outside.
Daelim: All the Nuts, Bolts, and washers were packed back in wooden boxes. All stored properly.
After inspection it is found satisfactory.
During inspection of 5th horizontal & vertical weld joints found the following standard violations:
Misalignment violations on weld joint # TV5BH5=2.1, 2.8mm, # TV5DH5=2.1mm & TV6DH5=2.0mm.
Banding violations between V5C and V6C at horizontal weld joint = -14 mm & between V6C & V5D at
horizontal weld joint = 14.6mm. These violations are as per API.650 Para. 7. Sadara LBE no. 101
logged for same type of violations. PN #62,82.
Subcon: The Misalignment areas TV5BH4, TV5DH, TV6DH5, were rectified according to the
requirement in API 650 para 7.2.3.2 and Banding discrepancy between V5C and V6C,, and V5D
was also been rectified according to the requirement in API 650 para 7.5. (b). As assurance for
the weld integrity, additional RT spots has been taken in selected areas (Ref. RT report no.
J27194 & J27193). The same was offered for inspections to the Contractor/ Company Inspector
and was found acceptable. Daelim:
During routine inspection on the external coating touch-up/repair for weld joints of F-1250 as per RFI No.
H-0201, it has been observed that too many defects on the coating and weld joints. ARCC coating
Inspector, started, welding department has been released weld joints for coating. This is violating the
standard as per Doc. No. A554-E-103-QA-GEN-PRO-043, Rev. 1, Para. 6.2.7 & 6.2.8.
Subcon:ARCC raised RFI for weld defects prior to painting activities,
then ARCC painting group raised RFI for surface preparation & primer,
but other areas are under Daelim Scope. (Painting at Shop).
Daelim:
Page 14 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-KCC-CIVIL-114 KCC VAF CIVIL Civil 24-Mar-13 27-Mar-13 07-Apr-13 09-Jul-13 Closed
LBE-TCC-MECH-
119
TCC PN MECH Piping 24-Mar-13 27-Mar-13 07-Apr-13 22-Apr-13 Closed
LBE-DLM-ELECT-
030
DAELIM PN ELECT Electrical 25-Mar-13 28-Mar-13 08-Apr-13 25-Mar-13 Closed
LBE-PSCL-MECH-
120
MR. AMIN PSCL VAF MECH Tank 25-Mar-13 28-Mar-13 08-Apr-13 27-Jul-13 Closed
LBE-PSCL-MECH-
121
PSCL VAF MECH Tank 25-Mar-13 28-Mar-13 08-Apr-13 14-May-13 Closed
LBE-PSCL-MECH-
122
PSCL VAF MECH Tank 25-Mar-13 28-Mar-13 08-Apr-13 14-May-13 Closed
LBE-PSCL-MECH-
123
MR. NASSAR PSCL PN MECH
Coating/
Painting
LBE-PSCL-MECH-
124
MR. NASSAR PSCL VAF MECH
Coating/
Painting
LBE-ARCC-MECH-
125
Coating/
Painting
LBE-TCC-MECH-
126
TCC VAF MECH Quality Management 25-Mar-13 28-Mar-13 08-Apr-13 22-Apr-13 Closed
LBE-DLM-MECH-
127
MR. HARIKUMAR DAELIM VAF MECH Preservation 26-Mar-13 29-Mar-13 09-Apr-13 24-Oct-13 Closed
LBE-TCC-MECH-
128
TCC PN MECH Piping 28-Mar-13 31-Mar-13 11-Apr-13 21-Apr-13 Closed
LBE-TCC-MECH-
129
Coating/
Painting
LBE-TCC-MECH-
130
MR. NASSAR TCC VAF MECH Preservation 30-Mar-13 02-Apr-13 13-Apr-13 23-May-13 Closed
LBE-PSCL-MECH-
131
PSCL VAF MECH Tank 30-Mar-13 02-Apr-13 13-Apr-13 14-May-13 Closed
LBE-PSCL-MECH-
132
PSCL VAF MECH Tank 30-Mar-13 02-Apr-13 13-Apr-13 14-May-13 Closed
LBE-KCC-CIVIL-115 KCC VAF CIVIL Civil 01-Apr-13 04-Apr-13 15-Apr-13 13-May-13 Closed
LBE-PSCL-MECH-
133
PSCL VAF MECH Tank 01-Apr-13 04-Apr-13 15-Apr-13 14-May-13 Closed
LBE-ARCC-MECH-
134
ARCC VAF MECH Piping 01-Apr-13 04-Apr-13 15-Apr-13 8-Jun-13 Closed
LBE-PSCL-MECH-
135
PSCL VAF MECH Tank 01-Apr-13 04-Apr-13 15-Apr-13 14-May-13 Closed
LBE-AMA-CIVIL-116 MR. GERALD AMA VAF CIVIL Civil 02-Apr-13 05-Apr-13 16-Apr-13 15-Aug-13 Closed
During the review of RFI Nol. 2690 (KCC), the following items were noticed. 1.Request was for sump pit
#9 (SUM 0639) dated 03/03/13. 2. Attachment is sum 0906-dwg. No. A554-E-103-CV-DWG-C30-204.
Rev. 2A. 3. Attachment for Test report is Sum 0632 dated 28/02/13. These conflicts in attachment were
signed by sub-contractor and Contractor QC. To review all RFI including attachment prior to submission
to Company QC group.
Subcon: Correct attachment and test report to be submitted.
PN: During routine inspection at TCC off-site fabrication facility, it was observed that fit-up and
inspection of joints were completed 1 month before and still have no welding were performed on the
pipes spools welding in common. Contractor must ensure prior to welding surplus to be welded &
adjacent surplus, both inside & outside diameter of the pipe, for
It was observed that during routine inspection on furnace F-1140, ARCC has been advised to bring DFI
gauge during inspection phase but ARCC was performing the job without complying the procedure. It is
violation against A554-E-103-CPA-GEN=PRO-036.
Subcon: The DFI is not possible to check for applied mastic due to very thick 300mm. Just only
WFT which was using by ARCC.
During routine inspection at TCC off-site fabrication facility, it is observed that TCC quality personnel are
not monitoring and implementing traveler's remark for fabricated spools. Violating spec. A554-E-103-QA-
GEN-PRO-042., Para. 6.4.2.
During Material Receiving of pipe spool at laydown yard observed that numerous pipe spools were
exhibiting severe oxidation on internal area due to improper preservation, violation to RT6-ICS, Para.
2.19.3 & 5. Implement remedy action on subject matter.
Daelim: Action has been taken. All pipes on wooden support. All ends were covered. It is found
that acceptable and satisfactory.
It is observed that roof plate to compression plate calculation for tank V-1425 and drawing # V-1425-103-
9004-01-215 rev.2. as per reply of Petrol Steel against the Sadara LBE #091 (of dated 27-2-13) reply of
Engineering shall be followed but activity has been proceeded without engineering response. Fit-up of
joints is not acceptable due to 12mm gap between compression plates and roof plates and due to
conflict mentioned above. Daelim quality team must ensure the corrective action and preventive
measures to avoid the discrepancies and delay in job.
PN: During surveillance, it was noticed that Petrol Steel has kept the coated angles on the ground
without wooden skids which caused damage to the coated tank anchor chairs stored in a very bad
condition.
Subcontractor: Corrective action was taken. Angles are keeping on the wooden skids.
Daelim:
During surveillance, it has been noticed that coated sumps for spent caustic storage tank, pad water
tank & process condensate holding tank have been damaged due to poor handling and lifting execution.
And coating defects (orange peels, pinholes & dirt inclusions) on the parent coating due to improper
Subcon: Handling damages was rectified. Once completed before installation
raise RFI for inspection. For tank 0500A already inspection done by Company Inspector. Another
3 tanks on process for RFI. Ref. RFI-MFC-DLM-PS-H-012,13,14
PN: Focus assessment was conducted for the installation of grounding pad for the transformer
foundation at substation G-1121 and found out to be in compliance with project specification and
standard.
It is noted that Daelim & Petrol Steel inspectors are not doing inspection prior to Company which is a
violation of Sched. "Q" Atta. IV, Para.#3. It is observed during inspection of material receiving of anchor
chairs at tank V-1425 (RFI # MFC-DLM-PS-ME-215-329). This material released from workshop to site
with post weld inspection acceptance but actually anchor chairs are only tack welded. Welding for them
is already started at site but Daelim & Petrol Steel inspectors raised RFI with closed eyes. Daelim &
Petrol Steel quality teams must perform inspections prior to Company and after their satisfaction they
can raise RFI for Company inspection.
Subcontractor: The anchor chair material has been offered for Contractor/Company inspection
again by raising new RFI (RFI no. 136) and the same was found and acceptable. The rectification
was carried out at the site by welding the anchor chair with required alignments. Preventive
measures have been taken to avoid the recurrence of these kinds of discrepancies in the future.
Daelim:
During Fit-up inspection of Tank's anchor chairs for RFI No. MFC-DLM-PS-215-330 found the following
discrepancies: Anchor chairs don't have part no. identification reflecting the cross reference of material
release inspection reports. Some dimensions are not as per approved drawings and inspection report
prepared by workshop inspectors. Anchor plate hole is not as per drawing. Pad plates & Rib plates are
not prepared as per drawing no. V-1425-103-9003-18-215, Rev.3.
It is noticed that Petrol Steel quality team is violating the inspection requirements and not raising RFI's
for material receiving which are already arrived at site since 2 days before during surveillance at site, it
was informed and suggested to Petrol Steel to raise RFI for (Tank V-500B) anchor chair material
receiving prior to erect on shell but next day it has seen that they already fitted and tack welded with the
tank shell without material inspection. Violation to schedule Q and ITP.
It is observed that ARCC material (pipe spools) segregation and traceability in spool staging & RT area,
is not proper and spools are mixed with some other project spools & materials. This is a violation of
schedule Q Para. 4.2. Daelim quality needs to ensure proper segregation and traceability for Sadara
pipe spools.
Subcon: Spools/Materials were segregated and separate area and proper signage's were
provided to avoid mixed up with other materials. (photos sent to DAELIM)
It is found out that Petrol Steel welded the angles between the roof rafters of Tank V-1425 without
material receiving and fit-up inspection. This is a repeated violation as per schedule Q & ITP. Daelim
quality needs to ensure the quality requirements with corrective action and preventive measures.
It is observed that Daelim & Petrol Steel quality team have a lack of interest for inspection
responsibilities as repeated violations are in routine. Anchor chairs of tank V-500A are fitted with tank
shell without material receiving inspection. This is a violation of schedule Q, att. IV, Para. no. 3. Daelim
quality team needs t take corrective action & preventive measures.
It is observed that Daelim & Petrol inspectors are raising RFI's without their inspection and at the time of
Company inspection oftentimes job is not ready to inspect. Examples are RFI # MFC-DLM-PS-ME-215,
237, 238, 239, 352 & 353. This is a violation of schedule "Q" Attach. IV, Para. 1 & 3. Daelim Quality
team needs to take corrective action and preventive measures.
During inspection observed that on top of embedded plate of concrete girder beam of east-west pipe
rack, El : 25200, 31-35A, A/AB, BB (Inspected 5 location) were showing inclination, level variation and
improper installation of embedded top plate as per ISO drawing. A554-E-103-CV-DWG-S10-248 Rev.3
the elevation variance exceeded up to 23mm, this will cause uneven surface levels during installation of
platform/gratings. Violation RT2S-5120-01. Daelim QA and engineering team shall verify and establish
a remedy action with appropriate approved method in order to avoid any further discrepancy.
Subcon: Joint survey by DAELIM, KCC and TCC surveyors was conducted and witnessed by its
QC Inspectors respectively. Gathered AS-Built elevations of elevations of embedded plates is
now under review of DAELIM Construction/Engineering team to establish corrective action.
PN: Observed that TCC has installed pipe spools in an uncompleted structure at NS column:48 area.
Daelim shall comply Sadara specs & requirements as per RT25-5120-01, Para. 3.4.2.
PN: During routine inspection, it was noticed that TCC's storage coated pipes & spools after coating
activities without proper protection between it. This caused damaged to the coating during lifting &
transportation.
Subcon: TCC Coating inspector will make sure that all painted pipes/spools are in a proper
storage.
Daelim:
During surveillance, it has noticed that galvanized structure materials (T-section, Beams, U-channels &
Angles) keeping in very poor storage without proper protection and left them in the ground without
wooden skids, this cause coating damage. These materials located in East West pipe rack. It is violation
against materials & equipment protection and preservation plan (RT-G-1CS).
During surveillance inspection at substation G1120 & G1121, found out some materials are not properly
protected, such as cement, CMU, etc. This is a violation to 625-4300-01, Para 3.1.1 and also observed
that some CMU are scattered on some locations of building. Contractor was advised to backload some
extra materials in order to maintain good housekeeping at site. And also needs provide proper
protection & handling of the said materials.
Subcon: Work in progress, completion date will be on 07 June 2013. The scattered materials
shall be removed from the site.
Page 15 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-117 AMA PN CIVIL Civil 03-Apr-13 06-Apr-13 17-Apr-13 14-May-13 Closed
LBE-AMA-CIVIL-118 AMA VAF CIVIL Civil 03-Apr-13 06-Apr-13 17-Apr-13 05-May-13 Closed
LBE-AMA-CIVIL-119 AMA VAF CIVIL Civil 03-Apr-13 06-Apr-13 17-Apr-13 23-Jun-13 Closed
LBE-AMA-CIVIL-120 AMA VAF CIVIL Civil 03-Apr-13 06-Apr-13 17-Apr-13 28-May-13 Closed
LBE-DLM-ELECT-
031
DAELIM PN ELECT Electrical 03-Apr-13 06-Apr-13 17-Apr-13 20-Apr-13 Closed
LBE-ARCC-MECH-
136
ARCC VAF MECH Structural 04-Apr-13 07-Apr-13 18-Apr-13 21-Apr-13 Closed
1
LBE-AMA-MECH-
137
AMA VAF MECH Hvac 04-Apr-13 07-Apr-13 18-Apr-13 9-May-13 Closed
LBE-DLM-MECH-
138
DAELIM VAF MECH Material 07-Apr-13 10-Apr-13 21-Apr-13 20-Apr-13 Closed
LBE-TCC-MECH-
139
TCC VAF MECH Piping 08-Apr-13 11-Apr-13 22-Apr-13 22-Apr-13 Closed
LBE-DLM-MECH-
140
DAELIM VAF MECH Quality Management 10-Apr-13 13-Apr-13 24-Apr-13 22-Apr-13 Closed
LBE-DLM-ELECT-
032
DAELIM VAF ELECT Electrical 11-Apr-13 14-Apr-13 25-Apr-13 28-Apr-13 Closed
LBE-DLM-ELECT-
033
LBE-DLM-MECH-
141
DAELIM VAF MECH Quality Records 13-Apr-13 16-Apr-13 27-Apr-13 18-May-13 Closed
LBE-TCC-MECH-
142
TCC PN MECH Preservation 13-Apr-13 16-Apr-13 27-Apr-13 13-Jul-13 Closed
LBE-TCC-MECH-
143
Coating/
Painting
13-Apr-13 16-Apr-13 27-Apr-13 23-May-13 Closed
LBE-TCC-MECH-
144
MR. NASSAR TCC PN MECH Preservation 14-Apr-13 17-Apr-13 28-Apr-13 23-May-13 Closed
LBE-ARCC-MECH-
146
ARCC VAF MECH Mechanical 14-Apr-13 17-Apr-13 28-Apr-13 13-Jul-13 Closed
LBE-KCC-CIVIL-122 KCC PN CIVIL Civil 15-Apr-13 18-Apr-13 29-Apr-13 26-May-13 Closed
LBE-DLM-ELECT-
034
Observed at Furnace area F-1250, ARCC structural team was assembling open structure members at
site without proper protection. The hot dip galvanized materials were handled with improper method and
kept directly to the. Most of the materials were damaged (coating) due to improper handling. ARCC shall
store/handle the galvanized material properly and reduce the damage during erection and assembling at
site.
It is noticed that Daelim/Amana inspectors are not doing inspection prior to Company which is a violation
of schedule Q, attachment IV, Para. 3., It is observed during inspection of HVAC galvanized dusts
installation and volume damper inspection at switch gear room; G-1121, RFI # MFC-DLM-AMA-HV-
0013, 0014. Daelim & Amana Quality team must perform inspection prior to Company and after their
satisfaction, Contractor/Subcontractor can raise RFI for the activity.
During Material Inspection based on RFI-MFC-DLM-JNK-003 dated 4 April 2013 for Convection
Crossover Pipe & Manifold at Lay down yard, observed that Daelim/ARCC Team were shifted in Material
to site and partially installed/positioned at site. Daelim/ARCC material team has been repeating the
same violation & challenging the Company quality programs, schedule Q and approved procedure.
Violation of A554-E-103-QA-GEN-PRO-055, Para. 6, Sch. Q, sec. 3 Para. 3, sec 4, LBE 05, 23 & 84.
During routine inspection/monitoring at ground flare area, it was noticed that the inside walls of sump
0380 has honeycombs at several locations. This deficiency shall be re-inspected after all the loose
portion of aggregate has been removed by SADARA QC using the approved repair material.
Subcon: Work in progress, completion date will be on 07 June 2013. The Honeycombs to be
repaired and inspection to be conducted after repair.
It was noticed during site monitoring that the two columns at 1st lift of the dilution structure being
supported by a girder has congested rebar which made concrete not positive to enter the center of the
columns. The reinforcing bars are all over the top and the 4 sides of the columns. Contractor to discuss
with its Engineering team to revise the bar arrangement for constructability and will give better strength
to the columns.
Subcon: Congested rebar to be rectified to acceptable spacing
PN: Contractor shall re-seal the cable ends of the cables after the on-reel cable testing with heat
shrinkable, self sealing end caps to prevent the entrance of moisture into the cable as per 67D-0404-00,
sec. 7.3.
PN: During inspection @ Operator building, it was noticed that Contractor wanted to concrete the roof
slab, girder & beams, including the wall & column one time only. Contractor was advised to submit
Method Statement for concrete pouring of operator building simultaneously for Company revise &
comment.
During inspection at ground flare area for leak test for sump 0380, it was noticed that the bottom slab
area has no more leaks. Upon further inspection, it was found out that there is no water inside the sump.
The three sides have been previously inspected and the remaining water to check the bottom slab as
agreed was not maintained. Contractor shall undertake proper preparation prior to inviting QG as
required by ITP.
Subcon: The leak test to be conducted again once the sump repaired
During routine inspection on TCC facilities for pipe spools, it has been observed an incorrect coating
thickness. The dry film thickness measurements for the final coat; average is 520 microns and the
maximum dry film thickness, as per standard requirement shall be 325+ 20% microns. Reference: A554-
E-103-QA-GEN-PRO-041 & G16S-0201-10.
Subcon: As per paint manufacturer, there no problem with DFT
average 520 microns for epoxy paint.
Daelim:
PN: During routine Inspection imitating XT end portion of cooling tower pumps (P09016& P0901 H).That
newly casted lean concrete was already stamped for rubber installation in which only one day after
casting and also no paper caring application had run done (as per construction standard)Construction
was advised to take remedies arias concerning this issue.
PN: During Surveillance at site on spent caustic storage tanks manholes flanges it has been observed
that weld spotted stuck on the flange serrated surface due to inappropriate protection during welding
activities. This is for information ,root cause & corrective action.
Subcon: PSCL taken corrective action on that issue and also inform
construction team to protect all manholes, flanges and serration area
need to covered.
Daelim:
Referenced to LBE-E-032, the Contractor did not report the damage of the cable trays to the Company
in timely manner which is a violation as per schedule G, attachment 11, section 14.3.16.
Daelim: Overage, shortage, incorrectness, damage report (OSID) was initiated by Contractor
Material department as part of Sched. "G". Report will issue to Company for closure of this LBE.
It is found that Daelim welding inspector (Mr. C. Viswanathan) is not raising RFI's for Pre-welding & In-
process welding inspections as per relevant ITP (SMITP-M-001-02) rev. 3 for tank's job at MFC
Daelim/Petrol Steel tank area. Also, the welding on tank V-1425 roof rafter to roof started without fit-up &
in-process welding inspection RFI. It is a violation as per schedule "Q" attach. IV, Para. 3. Daelim quality
team must ensure the implementation of approved ITP. Company comments are still not incorporated in
ITP, rev. 3.
PN: It is observed that TCC (White Nile) Quality team needs to ensure the proper storage and handling
of Pipe flanges and fittings with more concentration to void damages. Flange faces must be covered
with suitable non-metallic blinds or covers during all the activities of fabrication, welding and
transportation.
Subcon: Noted all flange face protective with plywood will be provided new material receiving
time. Inspector will make sure that all flange faces protected and place in proper way. All pipe
spools which from transport NDT must be end closed and flange face cover with plywood.
During routine inspection at TCC (White Nile) fabrication facility, porosity has been observed at fit-up
joint for 12" pipe due to inadequate protection to weld area from wind & dust, violating Sadara specs. RT-
-8S-6500-01, Para. 12.1 & A554-E-103-QA-GEN-PRO-056, Para. 16.1.
During surveillance, it is found that Daelim Welding Inspector (Mr. Satish) was not available at off-site
TCC (White Nile) fabrication since morning to 10:30 AM while the inspection time was 9:30 AM. It is
violation per Sched. "Q" attach. IV, Para. 3. Daelim Quality team must ensure the availability of
inspectors is full time at off-site fabrication facilities during on-going activities.
During routine site visit, it was observed that some cable trays were damaged at the laydown yard due to
an accident. These cable trays were hit by a vehicle, causing a physical damaged to these cable trays.
This is a violation as per schedule G, attachment 11, sec. 14.2.5.
Daelim: Contractor shall comply as per 67D-0404-00, section 7.3
After several periodic instructions it is observed that cylinders gauges and flow meters are not calibrated
at off-site ARCC Fabrication WQT & Procedure qualification testing shops. It is a violation as per "Q"
attach. If Para # 7.DAELIM and ARCC quality team must ensure the corrective action with preventive
measures.
Subcon: Calibration of cylinder gauges and flow meters are not possible. (ARCC already inquire
to 3rd party laboratory)
PN: During Concrete placement of vertical pump are the compressor are the inner casing hole where
concrete was started to vibrated. It was noticed laser or that there is no support for the inner casing to
placement floatation. This practice of fixing the support has been practice in the past painting of the
same structure. But forget at this time. Contractors shall always repetitive work of this kind shall be
treated as first time always to avoid repetition as first time always to avoid repetition of work (proactive).
It was Found out During material Receiving and Cable Testing that the cables on cable drum nos.
30276544 and 30276544 and 30276799 were damaged on it's cable jackets. And cable drum
nos.30276812 and 30276880 were also received without end cap. A repeated violation of Sched. G,
Attach. II , sec.14.3.16 (SEE LBE # 033) on which contractor should report any damage to company
without delay and in timely manner. The contractor should implement remedy action as per Sched. G
attach. II, Sec.14.3.5.
Daelim: For the damage cable, the OSID was already issued to Company by Contractor Material
Department as part of Sched. "G"'s concerns and the disposition for repair will be by Vendor
Supplier & Procurement.
Page 16 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
145
ARCC PN MECH Piping 15-Apr-13 18-Apr-13 29-Apr-13 6-Jun-13 Closed
LBE-TCC-MECH-
147
Coating/
Painting
15-Apr-13 18-Apr-13 29-Apr-13 23-May-13 Closed
LBE-ARCC-MECH-
148
MR. NOOR ARCC PN MECH Refractory 16-Apr-13 19-Apr-13 30-Apr-13 12-Sep-13 Closed
LBE-ARCC-MECH-
149
ARCC VAF MECH Material 16-Apr-13 19-Apr-13 30-Apr-13 28-May-13 Closed
LBE-ARCC-MECH-
150
MR. NASSAR ARCC VAF MECH Quality Management 17-Apr-13 20-Apr-13 01-May-13 Closed 25-May-13 Closed
LBE-DLM-MECH-
151
DAELIM VAF MECH Piping 17-Apr-13 20-Apr-13 01-May-13 Closed 1-Jun-13 Closed
LBE-PSCL-MECH-
152
MR. NASSAR PSCL PN MECH
Coating/
Painting
17-Apr-13 20-Apr-13 01-May-13 23-May-13 Closed
LBE-PSCL-MECH-
153
PSCL VAF MECH Tank 18-Apr-13 21-Apr-13 02-May-13 14-May-13 Closed
LBE-TCC-MECH-
154
Coating/
Painting
18-Apr-13 21-Apr-13 02-May-13 25-May-13 Closed
LBE-TCC-MECH-
155
MR. NASSAR TCC VAF MECH Preservation 18-Apr-13 21-Apr-13 02-May-13 25-May-13 Closed
LBE-DLM-ELECT-
035
DAELIM VAF ELECT Electrical 20-Apr-13 23-Apr-13 04-May-13 13-May-13 Closed
LBE-DLM-ELECT-
036
DAELIM PN ELECT Electrical 20-Apr-13 23-Apr-13 04-May-13 14-May-13 Closed
LBE-ARCC/TCC-
MECH-156
MR. AMIN ARCC/TCC VAF 2 MECH Mechanical 21-Apr-13 24-Apr-13 05-May-13 20-Jan-14 Closed
LBE-TCC-MECH-
157
TCC VAF MECH Piping 22-Apr-13 25-Apr-13 06-May-13 25-May-13 Closed
LBE-TCC-MECH-
158
TCC VAF MECH Preservation 22-Apr-13 25-Apr-13 06-May-13 13-Jul-13 Closed
LBE-DLM-ELECT-
037
DAELIM PN ELECT Electrical 25-Apr-13 28-Apr-13 09-May-13 28-Apr-13 Closed
LBE-DLM-INST-038 DAELIM PN INST Preservation 25-Apr-13 28-Apr-13 09-May-13 13-May-13 Closed
During Material Inspection of convection module F.1220-1 observed that numerous serious weld defect
occurred on Module: i.e. : worm hole, porosity, incomplete fusion, slag inclusion, spatters etcand
placed on position: Daelim Eng.: & QC Team shall verify the root cause of discrepancies and take
remedy action on subject matter.
Subcon: Contractor already forwarded and addressed the issue to the Construction team to send
the report to the Vendor/Manufacturer (JNK) with photos. (By DAELIM)
During notice inspection at F# 1250; RFI # MFC-DLM-ARCC-H-0242 it has been noted that there was no
ARCC QC inspector in prior to SQIT.As per SMITP-H-100-032 the level of inspection for sub contractor
QC Inspector in hold point (H). Standard violation # 106 was entered before related this practices.
Reference # A554-E-103-QA-GEN-PLN-033
Subcon: ARCC raised new RFI (RFI# MFC-DLM-ARCC-H-0246) Final inspection was conducted
by ARCC approved painting inspector and witness &
accepted by contractor & company inspector.
During Fit up Inspection of :(IP: 241502.24"HCF) process line for T.2410.observed that 24"dia 4 EA of
end spools were welded with end cap for Hydro Test purpose. The activities were conducted without
inspections performed by Daelim and company Quality team. Contractor must perform Inspections and
test in accordance with the approved ITP identifies test and Inspections. Violation of Sched.: 'Q' Sec. IV:
3.7 and ITP - A554 - E103 - QA - GEN - PLN - 046.
Daelim: The end Caps of 24" dia pipe were cut. After proper surface preparation. The end caps
were fit-up and welded as per approved procedure. The line was Hydro tested. It found
acceptable, after hydro test. The end caps were cut and line were installed properly.
PN: During pre- Cleaning Inspection (Prior to Installation of Pipe spools of Pipe Rack) observed the
exhibiting sever oxidation on internal aria of pipe spools. Daelim,TCC & ARCC shall establish a
appropriate method for internal cleaning and Make sure any forging substances dropped on spods Refer
SADARA specification.G4S-0210-1
Subcon: If required, TCC will provide foam dump for internal cleaning of pipe spools. ARCC to
provide a dry air filter to make sure that the air to be use for internal cleaning is dry & clean.
During routine inspection on TCC facilities for pipe spools, it has been observed that dust inclusions
defect on the finished coat(silicon coat) due to blowing the dust during vehicles and fork lift movement
and wind during coating activities since the aria close to painting workshop. This is for information &
Corrective action. Reference .A554-E-103CPA-GEN-PRO-041 & RT16S-0203-06.
Subcon: The pipes & spools were re-blasted on 09 May 2013 and repainted.
To prevent dust in future, the entire area is sprayed by water and
aggregates are poured.
Daelim:
PN: During Surveillance it is found that following refractor. Material are expiring room stored @ the
Daelim laydown and ARCC laydown yard.(I) - Refractory material cost *L-135 shipment no.MFC - 19 will
be expired on 24th April 2013. (II) - Refractory material cost F-50 G3 Shipment no MFC - 19 WILL BE
EXPIRED ON 23 rd. April 2013. (III) - Refractory material cost M / W -144 Shipment no MFC - 19 will be
expired on 07 'the' May 2013.Daelim and Subcontractor Quality must ensure to avoid the use of expired
material and to shift it in Quarantine area upon expiry.
Contractor: During Castable application, Subcontractor are maintain a log sheet in which material
expiry date is also getting noted and recorded. Further any expiry material during pre-application
inspection shall be segregated. So far, all materials have been used which where shelf life.
Subcontractor: ARCC will monitor the expiration of the refractory materials & will not be used.
PN: As discussed last weekly Quality meeting, The contractor shall store are 96 cable trays to
quarantine aria as these cable trays were already subjected to mechanical stress and lost its integrity to
hold the load requirement as per C7D-0322-00
PN: During surveillance inspection at operator building for concreting of RC wall & columns, it was
noticed that some presence of laitance along perimeter beam and some portions of perimeter RC beam
the concrete level up to the bottom portion of beam in which not in accordance with M/S & preservation
conducted by Amana. Contractor was advised to do chipping some excess concretes and remove of
laitance no to apply paint to rebar with laitance, ensure all cements must be properly implemented by the
Contractor prior to submit RFI.
It is found that weld rejection sate of ARCC (of welders) and TCC (03 welders) has been exceeded than
5% while is a violation as per Sched. "Q" all.iv,para # 3.9 & A554-E-103-GEN-PRO-056 Para
19.2.Daelim quality team must ensure the corrective action and preventive measures.
Subcon: ARCC Quality & Welding Team to conduct presentation to SADARA and DAELIM
QA/QC Team for root cause of High rejection, corrective action and preventive measures.
Implementation already done at fabrication shop and rejection rate is slowly going down. TCC
Tool box and Presentation training program with welders done. Rejection rate slowed down and
continue training program with welders is on-going.
During Surveillance it has been noticed TCC contractor keeping coated pipes & spools carelessly
without proper protection (padding) this cause coating damage. It is violation against motionless &
equipment protection & preservation plan (RT-6-ICS).
Subcon: Corrective action has been taken and conducted tool box meeting regarding the proper
handling of materials using proper padding on contact point.
Daelim:
PN: During surveillance/monitoring inspection at roof slab of substation G1121, concerning installation
of 8 plywood prior to installation of EPDM for water proofing works. It was observed that some installed
plywood are uneven and some portions are with gaps. Contractor was advised to take corrective action
on the issue prior to submit RFI.
Display of the Proactive Notification, Given by the company last weekly meeting for quality
(Apr.14.2013), That the damaged cable trays shall be stored in the quarantine area. The contractor did
not follow and they just serrated the damaged cable trays bot still lying the same aria watch is a violation
as per RT-4-105 Sec 2.2.11.
Daelim: As agreed in construction meeting between Company & Contractor, the proposal for the
damaged materials shall be surrounded by warning tape and provide with Tag "Do not Used" for
awareness of issuing/releasing the damaged material.
PN: During Surveillance at roof for spent caustic Storage Tanks ( V-0540 A & V-0500 B) it has been
noted that u beam / u-shopped of umbrella roof type was fitted without blast & coating for
coiners,bolts,riverts & roofter side. This is for information & corrective action.
Subcon: U-beams & channels are using for roof lifting purpose only.
Once lift the roof, temporary materials are removed by grinding.
Daelim:
It is found that petrol steel welder (ice# 315, w# 759 was welding on the tank V-500 B without shielding
which is a violation of RT8S-66500-01 PARA # 1201 and A554-E-103-QA-GEN-PRO-056 Para #
16.1,Also find that Daelim inspectors was not available at site and petrol steel welding inspector was
sitting in their site office. Daelim quality team must ensure the proper shielding availability of inspectors
at site.
During routine inspection of TCC blasting & coating facilities for pipes & spools, it has been observed
that dart & dust inclusion defect are found on the finished coat of 80" pipes due to stored very close to
ground during coating activities result in adhered dirt & dist. on srfoce.This is for information root cause
analysis and corrective action. Reference :-A554-E-103-QA-GEN-PRO-041& G16S-0202-10.
Subcon: Corrective action has been taken and Pipes was inspected and released. RFI# MFC-
DLM-TCC-H-097
Daelim:
PN: Contractor shall provide for the base copper grounding cable at cooling tower area exposed to
mechanical damage. Provide to wooden box to cover all grounding cable.
During routine inspection at gate no. 18 for fit-up & post-weld inspection of 36" LTU pipe, it was
observed that portable oven used for storing LTCS electrodes were not maintained at minimum
temperature of 65c, violating SADARA Specs. A554-K-PRG-CE-SPC-DES-009, att. 1
Subcon: Electrode are disregard and welding inspector will make sure required temperature for
portable oven.
During surveillance at TCC fabrication facilities it has been noticed that TCC contractor keeping
galvanized structure materials carelessly on the ground without proper protection and sand rocked up it.
It is violation against materials & equipment protection & preservation plan (RT-6-1CS).
Subcon: Noted, action will be taken. All galvanized structure materials preserved properly.
PN: During material receiving inspection of materials and equipment, all found damaged materials must
be isolated and quarantined immediately until corrective action is applied. Ref. Doc. No. RT-6-1CS, sec.
2.2.11.
Page 17 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
159
DAELIM VAF MECH Quality Management 27-Apr-13 30-Apr-13 11-May-13 18-May-13 Closed
LBE-DLM-MECH-
160
MR. AMIN DAELIM PN MECH Quality Records 27-Apr-13 30-Apr-13 11-May-13 13-Oct-13 Closed
LBE-TCC-MECH-
161
TCC VAF MECH Quality Management 27-Apr-13 30-Apr-13 11-May-13 25-May-13 Closed
LBE-TCC-MECH-
162
TCC VAF MECH Mechanical 27-Apr-13 30-Apr-13 11-May-13 25-May-13 Closed
LBE-DLM-MECH-
163
DAELIM VAF MECH Refractory 27-Apr-13 30-Apr-13 11-May-13 2-May-13 Closed
LBE-AMA-CIVIL-125 MR. GERALD AMA PN CIVIL Civil 28-Apr-13 01-May-13 12-May-13 16-Oct-13 Closed
LBE-ARCC-MECH-
164
ARCC VAF MECH Piping 29-Apr-13 02-May-13 13-May-13 13-Jul-13 Closed
LBE-DLM-MECH-
165
DAELIM VAF MECH Quality Management 29-Apr-13 02-May-13 13-May-13 Closed 12-Jun-13 Closed
LBE-DLM-MECH-
166
DAELIM VAF MECH Piping 29-Apr-13 02-May-13 13-May-13 18-May-13 Closed
LBE-DLM-MECH-
167
DAELIM VAF MECH Piping 29-Apr-13 02-May-13 13-May-13 6-Jun-13 Closed
LBE-DLM-MECH-
168
MR. AMIN DAELIM VAF MECH Mechanical 29-Apr-13 02-May-13 13-May-13 13-Oct-13 Closed
LBE-PSCL-MECH-
169
PSCL VAF MECH Preservation 30-Apr-13 03-May-13 14-May-13 14-May-13 Closed
LBE-AMA-MECH-
170
AMA VAF MECH Quality Management 30-Apr-13 03-May-13 14-May-13 13-May-13 Closed
LBE-ARCC-MECH-
171
ARCC VAF MECH Refractory 30-Apr-13 03-May-13 14-May-13 19-May-13 Closed
LBE-TCC-MECH-
172
TCC VAF MECH Quality Records 03-May-13 06-May-13 17-May-13 25-May-13 Closed
LBE-TCC-MECH-
173
Coating/
Painting
04-May-13 07-May-13 18-May-13 25-May-13 Closed
LBE-TCC-MECH-
174
MR. NASSAR TCC VAF MECH Preservation 04-May-13 07-May-13 18-May-13 Closed 9-Jun-13 Closed
LBE-DLM-CIVIL-126 MR. JERRY DAELIM PN CIVIL Civil 06-May-13 09-May-13 20-May-13 06-Oct-13 Closed
LBE-DLM-CIVIL-127 MR. JERRY DAELIM VAF CIVIL Civil 06-May-13 09-May-13 20-May-13 01-Oct-13 Closed
During routine inspection at TCC-2 Fabrication facility, it is observed that only one TCC Welding
inspector is deputed for welding inspection & activities of 24 welders of TCC-2 Fabrication which is a
violation against Sched. "Q", attach. VI, table VI-1.
During routine inspection at TCC NASCO Fabrication facility, it is observed that rebake oven used for
electrodes do not have temperature gauge to continuously monitor the temperature, which is a violation
against SADARA specs. A554-K-PRG-CE-SPC-DES-009, Para. 3.
During surveillance, found that the Refractory Material missing the ambient temperature was 34c and
found that during mixing material, the water temperature was up to 34c instead of 10c to 32c as per
SADARA project specification RTSAES-N-110 and G8S-1540-01. Daelim Quality team must ensure that
the Sadara requirements are implemented.
It is noticed that Daelim quality team released a welding inspector without notifying the Company in
advance. It is violation as per Sched. "Q", section 5.14. Contractor must advise the Company
representative at least 30 days in advance of scheduled absences or changes to personnel and quality
coverage or within 72 hours. Daelim quality must ensure the corrective action and preventive measures.
Subcon: Noted action will be undertaken. All galvanized structure materials preserved properly.
PN: In a format acceptable to the Company representative, Contractor must have a records retention
system which enables the identification, retention and retrieval of all construction phase inspection
records at all times. Daelim quality needs to ensure for all records of Daelim & subcontractors.
Contractor: Noted and all related information will be collected and keeping with tracking system.
Found that Petro Steel Tank's area welding consumables' control is improper and electrode holding
oven temperature was 80C instead of 120. Another consumable store at same site was having holding
oven & some portable quivers with some have Hydrogen electrodes inside there without power
connection. It is a violation as per RT85-6500-03. Attach.1 corrective action with preventive measures is
required.
Found that AMANA HVAC Inspector not available at site during HVAC Duct and damper installation
activities and inspection time since last month 25 April-2013. Corrective action with Preventive
measures are required. Schedule "Q" AH IV para #3.
During Surveillance inspection at MFC ARCC Laydown yard and Furnace area found that the Refractory
Castable material "Cast F 50 G3" was stocked at Furnace area. As per Manufacturing Data Sheet. It was
manufactured on April 30, 2012 and self-life is 06 months only. Daelim is advised to shift the subject
material to Quarantine area after expiration date. Daelim advised to Subcontractor ARCC/R.B. Hilton to
avoid the usage of expired material.
It is noticed that I.T.P. for Welding of on plot Piping Transmittal #IK-MFC-T-DJ-CJ-QM-0500, was
rejected on 14th Feb.2013 but welding activities and inspection are in routine. It has been reminded
several times to Daelim Quality but still it is not revised and resubmitted for Company review and
approval. Daelim Quality team must ensure that all ITP's and procedures being used approval by
Company. Ref. ITP # SMITP-W-011-01 Rev.0. Company Transmittal Ref. IK-MFC-CJ-DJ-CM-0708.
SCH. "Q" Attached !V Section 1.
During pre-cleaning Inspection of Pipe Spools at N-S Pipe Rack CL-3 area observed that following
discrepancy's. *
Wooden planks stocked on 20" spools.
* Spools Beveled were dent and damaged.
* Daelim and Subcontractor Q/C Personnel shall be verify and accepted all scheduled Inspection
activities provide to offer RFI to Company violation of Schedule "Q" IV: 3.7 and cleaning procedure.
Daelim: Proper cleaning is done by TCC and damaged pipe has been rectified. Inspection had
been done and accepted. (Ref. RFI # TCC-PIP-0042 at 02 may 2013). Proper Inspection shall be
carried out prior to Company Inspection.
Found repeated violation that Daelim Welding Inspector not available at off-site ARCC Fabrication shop
during welding activities and inspection time since morning 06:00 a.m. to 10:30 a.m. Corrective action
with preventive measures are required. Ref. Violation : Schedule "Q" attached IV para #3. RFI-#MFC-
DLM-ARRCC-PIP-WE-0127 (Rejected)
Daelim: After the long shift of Daelim QC not available only at 6:00AM to 10:00AM. In this regard,
Subcontractor SADARA approved QC available at shop. However, Contractor will change to
Daelim QC available time. In addition, Contractor will assign one (1) QC Welding Inspector as
soon as earlier time.
PN: During surveillance/monitoring inspections at roof slab of Substation G-1121, regarding installation
of EPDM Membrane. It was observed that some installed EPDM Membrane are not properly paste to
plywood and cause some irregular/plot of surface. Contractor was advised to take corrective action
concerning this issue, prior to proceed to other areas.
Subcon: The portion of EPDM which is irregular/plot of the surface was not accepted has been
rectified/repaired. The repair activity has not been accepted by Company but re-work shall be
started rectify repairs on 15.nov.2013.
It is found that ARCC Pipe Spools Preservation, Segregation & Traceability in RT areas is not proper
and SADARA Pipe Spools are mixed with some others Project spools. This is a repeated violation like
SADARA WBE #134. Some Pipe Spools and their Flanges were also directly placed on the ground. Also
found that a heavy duty 36'' Flange is damaged a little on its edge of circumference due to improper
staging of Pipe Spools with each other. Relevant Daelim or ARCC Piping Inspector might be revoked
due to repeated violations. Proper corrective action and preventive measures are required. Location -
ARCC Offsite Fabrication Shop Ref. Schedule Q attached # IV para #4, RT-6-ICS-Rev.3, Para #
2.19.17, 2.16
Subcon: 1. Presently ARCC RT Area was divided into two areas to separate SADARA pipe
spools to pipe spools from other project (photos sent to DAELIM)
2. Tag/mark with the respective drawing & spool number was provided on all SADARA spools to
serve as identification. Currently all SADARA spools are properly stored at ARCC-SADARA
staging area with end cover and every flanges face are protected with wood cover. (photos sent to
DAELIM)
3. For the 36 inches flange the damage is minor/acceptable which is outside or not on the
serration area.
It is found that Contractor Welding Inspectors was not available at ARCC Fabrication shop during
welding activities from morning 06:00 a.m. to 10:00 a.m. Similarly it is also found that Piping Inspectors
of Daelim was not available at inspection time at Daelim laydown TCC Facility even I have been waiting
their 40 minutes. These are violations of Schedule "Q" Attached IV Para #3 Corrective Action &
Preventive measures are required.
Daelim: Daelim has been taken corrective action against this issue, currently one (1) assigned
QA Welding Inspector for each shift at the ARCC Fabrication shop. Furthermore, Daelim QC will
be available for every activity in accordance with ITP. QC will not allowed to absent prior to inform
concern SADARA Inspector.
PN: During inspection of Dilution Structure on 24/04/13, two sets of anchor bolts at GL 2 & 3 E at DL
25.63 had wrong orientation. Contractor shall ensure that survey has been done accurately and
verification of the Subcontractor's surveying activities are undertaken independently to avoid
recurrence.
Daelim: Daelim surveyor to check and submit survey report to ensure correction of the
Subcontractor report.
Despite discussion and on-going verbal instruction to provide protection to all exposed TPER,
Contractor still has not provided sufficient and acceptable protection to avoid damage TPER. This is a
violation of Document No. A554-K-PRG-CV-SPC-C20-047 Rev.a that states "suitable guards shall be
provided to protect exposed projecting edges and end of partially embedded water stops when concrete
has been discounted.
Daelim: Attachment will show protective action being undertaken by the Contractor for exposed
TPER to prevent from damage. Wooden box installed as protection to damage. Further protective
action is continuously being done for exposed TPER. Concerned subcontractors in areas with
exposed TPER has also been advised to undertake proper protective measures for the TPER.
During Inspection of TCC NASCO fabrication facility, it was observed that pre-heat requirements are not
being followed respect to WPS, violating RT85-6500-01, para 6 & A554-E-103-QA-GEN-PRO-056 para
12.1 requirements. Moreover NASCO facility do not have source for pre-heat prior to welding.
TCC has been started installation of grinder beam on main column at N-S Pipe Rack area without
surface preparation and coating of Gusset plate welded area. TCC shall carried out proper cleaning and
coating of for damaged Hot dip Galvanized embedded plate and gusset plate welded area with
approved coating repair procedure prior to commence further installation activities. Violation of RT-25-
2120 and procedure of A554-E-103-QA-GEN-PRO-0021.
Subcon: During installation of gusset plate welding will be grinded properly by removing the
galvanized material damaged galvanized and welded area will be touched up with approved
Coating repair procedure.
Daelim: Touch-up repair procedure for galvanized structure materials should be submitted to the
Company for review and approval.
It has been noted that too many locations on the shell and pipelines of Splitter # T-2410 has been
damaged due to transportations and handling. This is for information & corrective action. It is violation
against materials & equipments & protect preservation plan (RT-6-ICS).
Subcon: Noted, tool box meeting will be arranged with rigger for proper handling of painted pipe
spools. TCC Coating/Painting Inspector will submit minutes of tool box. Damage area will be
rectified as per approved Touch-up and repair procedure.
Daelim: Damage area will be rectified as per approved touch-up and repair procedure.
Page 18 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-128 MR. GERALD AMA PN CIVIL Civil 06-May-13 09-May-13 20-May-13 24-Sep-13 Closed
LBE-TCC-MECH-
175
TCC VAF MECH Piping 06-May-13 09-May-13 20-May-13 25-May-13 Closed
LBE-ARCC-MECH-
176
Coating/
Painting
06-May-13 09-May-13 20-May-13 9-Jun-13 Closed
LBE-DLM-MECH-
177
DAELIM VAF MECH Quality Management 06-May-13 09-May-13 20-May-13 01-Jun-13 Closed
LBE-TCC-MECH-
178
TCC PN MECH Quality Records 08-May-13 11-May-13 22-May-13 8-Jun-13 Closed
LBE-ARCC-MECH-
179
ARCC VAF MECH Quality Management 11-May-13 14-May-13 25-May-13 13-Jul-13 Closed
LBE-AMA-ELECT-
039
AMA PN ELECT Electrical 13-May-13 16-May-13 27-May-13 04-Jun-13 Closed
LBE-TCC-MECH-
180
MR. AMIN TCC VAF 2 MECH Piping 13-May-13 16-May-13 27-May-13
Disagreed
(23/05/13)
lack of skill,
action not
acceptable
(25/05/13)
14-Mar-14 Closed
LBE-ARCC-MECH-
181
ARCC VAF MECH Refractory 13-May-13 16-May-13 27-May-13 18-May-13 Closed
LBE-KCC-MECH-
182
MR. NOOR KCC VAF MECH UG-RTR 13-May-13 16-May-13 27-May-13 Closed 1-Jun-13 Closed
LBE-DLM-MECH-
183
MR. HARIKUMAR DAELIM PN MECH Piping 13-May-13 16-May-13 27-May-13 Closed 23-Oct-13 Closed
LBE-ARCC-MECH-
184
ARCC PN MECH Structural 13-May-13 16-May-13 27-May-13 Closed 10-Jun-13 Closed
LBE-ARCC-MECH-
185
ARCC VAF MECH Mechanical 13-May-13 16-May-13 27-May-13 Closed 13-Jul-13 Closed
LBE-TCC-MECH -
186
TCC VAF MECH Piping 13-May-13 16-May-13 27-May-13 Closed 1-Jun-13 Closed
LBE-KCC-CIVIL-129 KCC VAF CIVIL Civil 15-May-13 18-May-13 29-May-13 24-Jun-13 Closed
LBE-DLM-INST-040 MR. SHABIRUL DAELIM PN INST Material 15-May-13 18-May-13 29-May-13 15-Sep-13 Closed
LBE-DLM-ELECT-
041
DAELIM PN ELECT Electrical 15-May-13 18-May-13 29-May-13 02-Jun-13 Closed
LBE-KCC-MECH-
187
MR. NOOR KCC VAF MECH UG-RTR 15-May-13 18-May-13 29-May-13 2-Jun-13 Closed
LBE-TCC-MECH-
188
Coating/
Painting
15-May-13 18-May-13 29-May-13 28-May-13 Closed
During routine Inspection at TCC NASCO Fabrication facility, it was observed that flange facing on all
piping or not protected at all times during fabrication & construction activities, violating SADARA
Specification RT-6-ICS Para 2.16 & 2.19.6
During inspection at painting fabrication equipment at ARCC Fabrication shop prior to close-out NCR-
ARCC-MECH-008, it has been observed that equipment's used for blasting of pipes & spools were not
calibrated. Violating SADARA Specification A554-E-103-QA-GEN-PRO-041. Contractor advised to
verify & attached calibration certificates prior to Company inspection.
Subcon: Equipment used at ARCC Fabrication shop were sent to Calibration Laboratory currently
all Equipment are Calibrated and certificates were provided. Final Inspection for ARCC Painting
shop facilities was done and accepted (Refer to RFIT # MFC-DLM-ARC-H-0293)
Found that Daelim Welding Inspector not available at MFC Daelim Laydown TCC activates. Corrective
action with preventive measures are required. Reference Sch. Q Attach. IV Para # 3.
PN: During surveillance/monitoring inspections at roof beam of Substation G-1120, some locations of
anchorage are not yet installed as per IFC Drawing, in this regards please check properly the detailed
drawing for the said anchorage. Contractor was advised to take corrective action concerning this issue,
prior to re-inspection.
Subcon: Anchorage installed and inspected by SADARA.
PN: During Material Receiving Inspection observed that numerous Quality of defective Pipe Fitting
(A420/420A) 2" 90 Shedule:40 Elbow found at Laydown Yard. Those Material are to be placed on hold
and placed to Quarantine area for further evaluation by Third Party (HDE) to asses to Eastern of
damage. Daelim shall be released the subject Materials for Fabrication until get final acceptance by
Company/Third Party.
Contractor: All the damage materials were shifted to quarantine area. A list has been provided.
OSI & D was issued to the Vendor. The subjected material will be replaced.
PN: During surveillance at Furnace #1250 it has been observed spot corrosion in different locations of
galvanized structure. This is for information, root cause analysis & corrective action.
Subcon: ARCC QC & DAELIM QC conduct investigation on installed packer plates with corrosion
and the initial agreement for correction is to clean the affected areas and apply touch up paint
using applicable painting system (RFI to be endorsed to DAELIM)
During surveillance at Furnaces it has been observed that all galvanized guide plate of concrete
pedestal has been rusted, therefore SQIT is request to touch-up and repair all rusted areas before
installation. This is for information, root cause analysis & corrective action.
Subcon: Surface preparation inspection was completed and accepted with RFI # MFC-DLM-
ARCC-H-370-A. Primer coat for final inspection tomorrow 19 June 2013. LBE 185. to be closed
tomorrow after final inspection of primer coat.
Found entirely wrong Fabrication at TCC facility #1 for 48" Flange to pipe, instead to resolve the ovality
problem, two helpers grinding the 10mm thickness of the pipe from one side of the joint. Two joints were
observed with the same condition. Pipe spools were also not having any identification for Drawing or
joint numbers. Daelim Inspection team must ensure the quick corrective action with preventive
measures. Violation Reference TRS-6500-01 Para # 5.3 (a) Sch. "Q" Attach. IV Para #4.
Subcon: 48'' pipe sch. Xcs thickness is 12.7'' only. After fit-up inspection accepted by TCC Piping
Inspector RFI will be for Daelim/Company. During fit-up of large dial pipe ovality measured and
divided equally to all around dia-inch.
As per SADARA/Daelim/TCC Tool Box meeting in work shop 1, all Fabricators, Fitters and
Supervisors were advised regarding the mismatch/HI-LO fit-up.
During surveillance inspection at MFC F-1140 Gas Furnace area found that Refractory Castable
Material (F-50-G3) was stocked in area. As per manufacturing data sheet. It was manufactured on April
30, 2012, Self-;if is one year only. Daelim is advised to shift the subject material to Quarantine area.
Daelim advised to Subcontractor R. B. Hilton to avoid the usage of expired material.
During surveillance, it is noted that the Daelim Subcontractor (PTS) carried out U/G five water FRP
joints preparation and fit up without informing Company inspection team. Found that above activity was
on-going without presence of any Contractor & Subcontractor QC Inspectors. Found that FRP (eights
joints were already completed and further fit-up was ongoing also. It is violation as per Schedule "Q"
attachment IV section 3 and A-554-E-103-QA-GEN-PRO-008. Reference pictures are also attached.
Daelim: The Contractor Daelim issued RFI to the Company Inspection Department for all fit-up
joints which is KCC done fit-up on the site. And strictly inform to Subcontractor that before they
start any kind of activity they must be inform Daelim/Sadara Inspection which joints is already
done laminations. Contractor will be issue RFI>
PN: found that Sprit levels are not calibrated at all the Fabrication facilities under the Daelim
Subcontractors. Some are giving false readings and not matching with each other's measurements. It is
observed during Flange to pipe Fit-up inspection at TCC Fabrication Facility # 01. One Sprit level was
showing misalignment while the other shown acceptable alignment. So Daelim have to ensure that all
measuring and testing equipments or tools are calibrated.
Subcon: Noted, all measuring tools will be calibrated soon.
During surveillance inspection at Furnace area observed that following serious quality violation is on-
going at Construction site. 1) ARCC is carried out Pipe Fabrication installation and welding activities at
site without Piping Quality Inspector at site. 2) One (1) Mechanical Inspector is not sufficient to control
this on-going activities as per Manpower ratio as specified in Schedule "Q" Requirement. 3) Quality
Supervisor not yet assigned at site. A minimum of one (1) QC Supervisor shall be assigned for each
position if is number of workers/QC Personnel performing the activities is specified in Sched. Q. A clear
violation of Sched. Q attachment IV.
Subcon: For Item (1) Mr. Albert Bumal-o (ARCC Approved Piping & Welding Inspector) was
utilized as piping inspector and currently performing site piping inspection activities. Item ((2)
Presently our mechanical inspector is still sufficient base on schedule Q requirements Ratio 1:25
actual manpower at site for mechanical works is 19 workers including foreman, 1 additional
mechanical inspector will be mobilized @ site on June 8, 2013 in preparation with rotating
equipments works. Item (3) Currently ARCC have 2 approved supervisors 1 for Structural and 1
for Mech./Piping for welding QC supervisor already requested CV to be submitted.
PN: During routine site visit, it was noticed that the expansion bolt installed for the 2.5 MVA
Transformers at Substation G-1120 were only four (4) expansion bolt each while it shows in the vendor
drawing that six (6) expansion bolt shall be clarify with the vendor if this installation is acceptable.
PN: During routine site visit at Furnace area, it was noticed that the Contractor is installing support for
the Expansion Splice Plate on one side only. The Contractor shall follow the installation of support for
the expansion Splice Plates as per NEMA VE-2 Sec. 4.3.2 and figure 4.12.
Daelim: During the last meeting dated 28 May 2013, it was discussed that Supports will be
provided per standard, 2 feet distance from the splice plates as well as from the joint expansion
plate. Subcon has already been informed regarding the issue.
During inspection, it was noticed that the Daelim Contractor (KCC) carried out the Hydro Test of UG/ fire
water system 1401 Area-A-Unit-S2- (Hydro Test Package #0720). After 24 hour pressure holding found
that pressure has been dropped and caused the test failure. Test must be carried out again ensuring
that SADARA requirements are fulfilled. Violation reference: A554-E-103-QA-GEN-PRO-008 and G45-
6423-01
It has been noticed that, TCC subcontractor has been applied the primer coat on weld joints for 20 pipes
& spools without RFV from the company (Sadara), this is violation against Sadara General
Requirements for Pressure Testing (A554-O-PRG-QA-GEN-PRO-014 Sect.6.1). This is for information,
root cause & corrective action.
Subcon: Subcontractor assured that no more painting on weld area. TCC get reply MFC-T-DJ-TC-
CM-0591.
During routine Inspection at TCC NASCO Fabrication facility, it was observed that all fabricated pipe
spools &assemblies are kept directly on ground & pipe openings or not protected from entry of sand &
foreign matter, violating SADARA Spec. TR-6-ICS para 2.19.17.
Subcon: Noted and one group assigned. All pipe end covers and flange face protection.
During surveillance/monitoring inspection at E-2070 Pedestals north side of common compressor, it was
observed that concreting works for this structure has no slump & temperature testing has been done by
third party. The transit mixer used are the following : (TM #204, 206, & 210) This is a violation to RT25-
3001-01 Para 3.6.2 (Table 7) & schedule "Q" Quality requirements para 1.3. In this regards, Contractor
was advised to take corrective action concerning this issue, in order not happen again in other areas.
Subcon: Anchorage installed and inspected by SADARA.
Daelim: Contractor will send letter to third party regarding the issue and will advise that slump and
temperature testing shall be limited to provisions stated in concrete specification RT25-3001-01
para 3.6.2 (table 7) but also maybe required anytime during concreting works by any contractor
QC personnel or by SDARA SQIT.
PN: During material receiving of Skid package compressor C-1601 AB cracked Gas Compressor CR-
2301 CR2 missing serial numbers Purchase Order numbers on the data sheets. Contractor provide
revised data sheets during pre-commissioning.
Daelim: Compress packages C-1601 & C-2301 was already coordinated to Vendor regarding the
incomplete SN on data sheet. Contractor will inform Company once the Vendor response.
Page 19 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-ELECT-
042
DAELIM VAF ELECT Electrical 19-May-13 22-May-13 02-Jun-13 27-Jul-13 Closed
LBE-DLM-MECH-
189
DAELIM PN MECH Piping 19-May-13 22-May-13 02-Jun-13 8-Jun-13 Closed
LBE-ARCC-MECH-
190
ARCC VAF MECH Refractory 19-May-13 22-May-13 02-Jun-13 23-May-13 Closed
LBE-DLM-MECH-
191
DAELIM PN MECH mechanical 20-May-13 23-May-13 03-Jun-13 24-Jun-13 Closed
LBE-AMA-CIVIL-130 MR. GERALD AMA VAF 1 CIVIL Civil 21-May-13 24-May-13 04-Jun-13 24-Apr-14 Closed
LBE-AMA-CIVIL-131 AMA VAF CIVIL Civil 21-May-13 24-May-13 04-Jun-13 06-Jun-13 Closed
LBE-AMA-CIVIL-133 AMA PN CIVIL Civil 21-May-13 24-May-13 04-Jun-13 18-Aug-13 Closed
LBE-DLM-ELECT-
043
DAELIM VAF ELECT Electrical 21-May-13 24-May-13 04-Jun-13 02-Jun-13 Closed
LBE-DLM-MECH-
192
MR. HARIKUMAR DAELIM VAF MECH Material 21-May-13 24-May-13 04-Jun-13 23-Oct-13 Closed
LBE-DLM-MECH-
193
MR. AMIN DAELIM VAF MECH Quality Management 21-May-13 24-May-13 04-Jun-13 05-Oct-13 Closed
LBE-KCC-MECH-
194
MR. NOOR KCC VAF MECH UG-RTR 21-May-13 24-May-13 04-Jun-13 7-Jun-13 Closed
LBE-DLM-CIVIL-135 DAELIM VAF CIVIL Civil 22-May-13 25-May-13 05-Jun-13 23-Jun-13 Closed
LBE-TCC-MECH-
195
TCC VAF MECH Piping 22-May-13 25-May-13 05-Jun-13 6-Jun-13 Closed
During routine site visit at Daelim Laydown yard, it was observed that the Contractor still not energizing
the space heater for the fourteen (14) Electric motors for fan skid arrived at site last May 08, 2013 which
is a violation as per RTYD-0665 sec 13.1.2.
Daelim: Contractor has coordinated to Vendor regarding the Preservation of Motor unfortunately
no response received yet. Contractor shall notify Company once the Vendor responded.
PN: Contractor must submit pressure test packages for piping, pipeline and equipment including limiting
factor, for Company review and approval at least 72 hours prior to the planned conduct of the pressure
tests. The pressure test must comply with all Company requirements. All pending items from pre-
pressure test line punch list must be clear and verified by SQIT. Ref. Sch. Q IV para 3.13.
Occasionally observation about he Temperature requirements of Castable refractory are as under F-
1120. 1) Observed that the weather temperature Castable refractory during mixing and application was
40 C instead of 32C. 2) Observed that the water Temperature during mixing of Castable refractory was
above 33C instead of 27C. 3) Observed that temperature of the backing surface during Castable lining
application was also above 34 instead of 32C.Daelim Quality Team need to ensure that requirements
meet SADARA Specification and cod & ITP as per SADARA SP A554-E-103-QH-GEN-PRO-047 para
4.2.7, A554-T-103-MB--SPC-MB-B27 (SP-0-0127) API 936 Para 4.4.2 and RTSAES-N-110-para 9.17.
Subcon: Additional Fan/Blower was provided on Castable mixing and application area to maintain
acceptable ambient temperature. Water with ice was used for mixing of Castable refractory to
maintain acceptable temperature. Closed monitoring and daily checking of ambient,
metal/backing surface and Castable mixing temperature were conducted to ensure conformance
with the requirement.
During routine visit, it was noticed that the Contractor was using a 316 stainless steel spline bolt for the
installation of splice plate and expansion splice plate for cable tray which is a violation as per G70-0322-
00 sec 4.1 in which, hot dipped galvanized fasteners shall be used.
During Material receiving Inspection, It was observed the following quantity of defect of pipes such as
PIPE, BE, EFW, ASTM, A671-CC70 CL.12 S2, etc. as per attached in LBE 192. Daelim shall shift
above listed material to quarantine area.
Contractor: All the damaged materials were shifted to quarantine area. A list was provided to
Company. All the damage items will be repaired as per approved M.O.S. after inspection the
materials will be accepted.
Found that Daelim Welding Inspector not available at MFC tanks area since few days and Tank
Inspector is raising RFI's for welding inspections. RFI's might be rejected due to violation of Sch. "Q"
attachment IV para #3, corrective action with preventive measures is required.
Daelim: Corrective action has been taken, assigned approved Daelim welding inspector to Petrol
Steel tank area, hence, the situation presently -Complying with the quality requirement.
It was noticed that curing of flare pipe rack pedestal is not continuously under taken. The pedestal was
poured on May 16, 2013 and at 5:30 pm (19/05/13), the pedestal was delay, the formwork has been
loosened from the structure. There is no schedule of concrete curing on all structures poured and
without advise of the engineer in charge, the curving truck did not come to cure those structures in this
location. A violation of RTS25-3001-01 section 9.
Subcon: Provided drawing to support at flare area.
PN: During surveillance/monitoring inspection at cooling tower (RC wall) along S/E corner, it has been
observed that piece of wood was inside RC wall, in which prior to concreting works, must see to it that
proper cleaning and all debris must be remove, and also con container slab along west portion near
expansion joint. Found out that hairline crack on soffit slab. Contractor was advised to the corrective and
preventive action, in order not to happen again on others structure.
Subcon: Method Statement was submitted for the repair of cooling tower surface defects.
With reference to LBE #132, some pedestals were exposed open without burlap and poly ethylene
sheet. In accordance with the Project Engineer his workers left the pedestal open since it is time for
them to go. S, at 5pm till the next day, the Subcontractor did not undertake curing of these pedestals.
Contractor shall reply to what action to take since this is already a repeated violation. Contractor QC and
Subcontractor QC Inspectors are witnesses of this violation.
Subcon: Subcontractor will assigned curing team to be responsible for the curing of concrete
structures and to monitor curing.
PN: During alignment verification of Oil Quench Tower T-1310, it has been observed the following
discrepancy, 1) Washer plate for anchor bolt were not matching due to hold down bolt hole are not
centered, which is insufficient to distribute the bolt damping force to equipment foot, cause of deflection
on yielding on washer. 2) Columns of shim plate were installed on several location to control alignment
and leveling. 3) Daelim shall follow project specification and code and rectify no occurred discrepancy
with proper Engineering support. AP-1686, A554-E-103-QA-GEN-PLN-056, A554-E-103-QA-GEN-PRO-
035.
Subcontractor: Fabricated new square washers were replaced for the oil quench tower T-1310,
anchor bolt's location were required. The equipment base anchor bolt opening locations are fully
covered with square washer without any issue. After installation of new washers, temporary bolt
tightening (anchor bolt) completed.
During surveillance and monitoring inspection at switchgear/MCC room and transformer yard C substation G1120
& G1121. It has been observed the following items to be repair or rectify A) transformer yard a.1) All chamber
columns, firewalls, and beams shall be minimize 25x25mm to the true line and dimension as per IFC drawing a.2)
Removal of loose concrete or laitance on floor slab & repair damage of WS even surfaces. a.3) All joint groove
between columns and cmu wall shall be out & filled uniformly depth and width as per IFC drawing. a.4) Complete
installation of weed holes on cmu walls as per detailed drawings, and ensure are not blocked of loose concrete or
laitance.a.5) some portions of exterior cmu cement textured finished should be rectify & removal of loose plaster
prior to repaint. a.6) Rectify some portion's of firewall with bulging and apply putty prior to repaint. a.7) Complete
finishing provision for HVAC & Electrical openings on substation cmu wall, as per IFC drawing. a.8) All exterior
surface of all columns c1 should be flush & straight to roof beam as per IFC drawing. a.9) Ensure painting works
after all repair are finished or completed. a.10) Trim excess concrete at expansion joint on flour (TPER) & removal
of loose concrete or laitance on TPER. a.11) ALl faded paint on exterior columns, beams, and wall should be
repainted. B) ) Switchgear/MCC Room b.1) ALl joint groove between column, beams, and cmu walls shall be cut &
filled uniformly depth & width as per IFC drawing. b.2) Repair uniformly all internal corners of columns & beams to
the dimension as per IFC drawing. b.3) Ensure flatness of floor slab, provide sample for approval prior proceed with
repair as per the approved method statement. b.4) Roof beams and soffit slab exposed to view shall be chipped
and grounded of excess concrete to form an even and smooth surface finished as per paint schedule. b.4) Ensure
all uneven form joints of all columns should be grinded & repair to attain smooth & straight surface finished. b.5) All
faded paint on columns, beams, walls soffit should be repainted. b.6) All CMU wall with pinholes should be repair &
apply paint (as per approved sample). b.7) Internal CMU wall at 6L 8/B-C along ducting level up to roof beam.
should be repair prior to painting. b.8) Repair uneven surface of CMU wall & columns. b.9) All chip ends & uneven
surface around CMU wall openings shall be properly repaired.b.10) Ensure painting works after all repair are
finished/completed. b.11) Installed door tabs as detailed on the drawing. Provide method statement on how to fill
door tabs with grout. In this regard, Contractor was advised to rectify all items above prior to installation of electrical
equipments and other discipline involved.
Subcon: Work in progress, completion date will be on 30 June 2013. Assigned a group of
workers to close punch lists in the substations. The
first target schedule does not meet due to huge numbers of punch items. in this regards
contractor need to increase manpower to close the punch lists in order to meet the 2nd
contraction schedule on 30.Jan.2014.
It was noticed that spent caustic train A & B, some of the top bars (25mm) of the foundation was cut due
to intersection with anchor bolts. Please provide justification to resume concrete placement after the
anchor bolts are installed on the anchor box.
Subcon: Daelim to provide new drawing showing modifications.
FRP UG fire water line found damage elbow from shaving during joint fit-up & assembly inspection. It is
observed that Daelim and KCC Quality team have a lack of interest for inspection responsibilities as
repeated violation are in routine. It is observed that Daelim/KCC Inspectors are raising RFI's without
their inspection. An example is RFI no. MFC-DLM-KCC-UG-RTR-1218. Drawing No. FW-7100-5-3. This
is a violation of Schedule "Q" Atch. IV para 3. Daelim/KCC Quality must perform Inspection prior to
Company and after their satisfaction/ Contractor/Subcontractor can raise RFI for the activity. Daelim
Quality team need to take corrective action and preventive measures is required.
Daelim: Total insertion depth of the elbow is 130mm and the damaged area due to impact during
transportation is less than 25mm in dept. and it is about 3 inches in width. As the affected are was
small so the Contractor/Subcontractor Inspector have allowed that elbow for fit-up. But when
SADARA Inspector come for fit-up inspection he said that the affected elbow will not be accepted.
There was another elbow available in spare and was replaced with the damage elbow and fit-up
inspection was accepted. Contractor/Subcontractor Inspectors are doing inspection of each item
before issuing RFI to Company.
Contractor QC Civil Supervisor left the project without a written notification and approval replacement.
This is a violation to Schedule Q para 5.14 which require quality personnel changes required coverage
notice 30 days in advance or 72 hours for
Daelim: Contractor has given late notification on the absence of its Contractor QC Civil
Supervisor. Contractor has submitted MR. J. H. Lee as temporarily replacement and was
approved as evidenced via transmitted Company letter # IK-MFC-L-CJ-DJ-0093. Contractor shall
propose a candidate for the position. Contractor shall also make proper notification to Company
for any future QC personnel absence.
During routine inspection at TCC-2 fabrication facility, found that only one welder is welding 36" butt joint
instead of two welders, violating A554-E-103-QA-GEN-PRO-056 para # 17.1.4 Spec. TCC & Daelim
Inspectors must ensure the corrective action with preventive measures.
Subcon: Tic Welding Inspector will make sure all 12'' above welds assign tow welder.
Page 20 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
196
TCC VAF MECH Quality Management 22-May-13 25-May-13 05-Jun-13 1-Jun-13 Closed
LBE-PSCL-MECH-
197
PSCL VAF MECH Preservation 22-May-13 25-May-13 05-Jun-13 Closed 27-Jul-13 Closed
LBE-TCC-MECH-
198
LBE-DLM-MECH-
199
MR. HARIKUMAR DAELIM VAF MECH Quality Records 25-May-13 28-May-13 08-Jun-13 13-Oct-13 Closed
LBE-DLM-INST-044 MR. SHABIRUL DAELIM PN 1 INST Instrumentation 27-May-13 30-May-13 10-Jun-13 27-Jul-13 Closed
LBE-ARCC-MECH-
200
ARCC VAF MECH Piping 27-May-13 30-May-13 10-Jun-13 6-Jun-13 Closed
LBE-TCC-MECH-
201
LBE-TCC-MECH-
202
Coating/
Painting
27-May-13 30-May-13 10-Jun-13 Closed 9-Jun-13 Closed
LBE-AMA-CIVIL-138 MR. GERALD AMA PN CIVIL Civil 28-May-13 31-May-13 11-Jun-13 02-Oct-13 Closed
LBE-DLM-ELECT-
045
MR. MARK DAELIM VAF ELECT Electrical 28-May-13 31-May-13 11-Jun-13 29-Aug-13 Closed
LBE-DLM-MECH-
203
MR. AMIN DAELIM PN MECH Quality Records 28-May-13 31-May-13 11-Jun-13 13-Oct-13 Closed
LBE-TCC-MECH-
204
TCC PN MECH Mechanical 29-May-13 01-Jun-13 12-Jun-13 18-Aug-13 Closed
LBE-AMA-CIVIL-139 AMA VAF CIVIL Civil 30-May-13 02-Jun-13 13-Jun-13 02-Oct-13 Closed
LBE-DLM-MECH-
205
MR. AMIN DAELIM VAF MECH Piping 01-Jun-13 04-Jun-13 15-Jun-13 8-Oct-13 Closed
LBE-DLM-MECH-
206
MR. AMIN DAELIM VAF 2 MECH Piping 01-Jun-13 04-Jun-13 15-Jun-13
Disagreed
(06/06/13)
Provide
corrective action
(12/2/14)
04-Mar-14 Closed
LBE-DLM-MECH-
207
MR. AMIN DAELIM VAF MECH Piping 01-Jun-13 04-Jun-13 15-Jun-13 29-Sep-13 Closed
Observed that Civil drawing and structural drawing is conflicting on EW and NS pipe rack area.
Embedded plot locations were not matching with structural drawing were showing inclination, level
variance dimensions discrepancy location and etc. Guest plate installation and welding activities on hold
at several location. 1) Daelim Civil structural, Quality and Engineering team shall verify and propose a
remedy method with engineering for final acceptance. 2) Daelim Quality team shall move vigilant on
subject matter and avoid further discrepancy on platform erection.
Subcon: Noted. Activities will be taken. The issue was informed to Engineering team.
During routine monitoring activities at spent caustic area, it was noticed that the steel attachments to the
anchor bolt to hold the anchor bolts in a correct bolt and to be embedded in the concrete is rusty without
casting. This is a violation of RTS-3001-01 para 8.2.7 which anchors these items to the concrete shall
be similarly galvanized.
Subcon: Anchor bolts & embedded steel supplied by Contractor.
During routine inspection at N-S pipe rack, the curving of pump foundation G-1311 C and G-1321 were
not properly undertaken. Only polyethylene sheet without burlap covers the foundation and since part of
the foundations are dry. This is a violation of RT25-3001-01 para 9.1.4.2
Subcon: Assigned curing team to be responsible for the curing of concrete structures.
During Inspection at TCC NASCO fabrication facility , it has been observed that no approved QC
(Welding & Piping) Inspectors are available at their facility, two RFI's have been raised for the
inspections of fit-up and post welding which is Hold point for TCC QC Inspector as per relevant I.T.P.
Subcon: Piping Inspector for NASCO interview was accepted and approve dry Company. After
required documentation Piping Inspector assigned fulltime. Two Welding Inspector assigned for
Construction activates.
Found that welding electrodes E-7018 (2.6mm not #3998 7 packet each 20kg), (3.2mm lot #2850, 21
pkts each 20kg), (4mm lot #3542, 18pkts each 20kg) are stored in high humidity 66.5% instead of below
40% at Petrol Steel Tanks consumable store. Available A/C in the store was out of order and switch-off.
High humidity causes moisture in electrode coatings. It is a violation as per QCP PSC_103-1008-07-21-
Rev.0 Atch. 1 para # 1.1. Corrective action and preventive measures are required.
Subcon: The electrode storage area has been rectified, the air conditioner which was not working
has been replaced by another air conditioner. It was also inspected by the Contractor/Company
Inspector and the same was found acceptable.. The electrodes were stored inside a plastic
sealed base, which reduce the effect of moisture and also
During routine inspection at TCC-2 fabrication facility. It is observed that flange forcing on all piping or
not protected at all times during fabrication & construction activities, violating SADARA Spec RT-6-ICS-
para 2.16 & 19.4
Subcon: TCC QA/QC Manager give instruction to TCC QC Piping Inspector to ensure that all
flange face protected during fabrication activity, flange face protected with duct tape/masking
tape.
PN: Daelim quality needs to ensure that the date tracking system(s) shall be maintained and kept
current and available for MFC project Quality Group's review at all times. The data shall be available on
a daily basis for both current and cumulative data. Data shall be retrievable by date for any given day
from commencement of the work trough project completion. Ref. A554-O-PRG-QA-GEN-PRO-013
Rev.2 Para # 5.2.
Contractor: Noted and follow as per procedure and requirements.
PN: TCC had started pad plates preparation of Rotating and static equipment. Observed the following
violation; a.) Improper preparation of ground material (pre-installation activities.) b.) Lack of caring after
pouring of grouting material. C.) Crack observed after installations of equipment. d.) Daelim/TCC shall
follow manufacture instructions for grout/padding plat proportion. e.) Verify the root cause of cracked
pad plate and remedy action to repair subject pad. T-2410,1310.
Subcon: NCR-TCC-MECH-012 received from Contractor. After action taken and closure of NCT
copy will be attached.
It has noticed that the slab of Cooling Tower located at North side span 1 & 2 have chipping marks in
preparation for the installation of cooling tower superstructure/equipment. Contractor shall inform the
Company of such activities. If there is a deviation on the IFC drawing or the Contractor shall issue NCR
to record the violation. Please investigate and provide corrective action.
During routine inspection at TCC-1 it has been noticed that blasting and coating activities are on-going
without qualified crew painting supervisor. This is a violation against Schedule Q.
Subcon: One (1) crew supervisor interviewed by Daelim, waiting for Company interview. TCC
painting and coating inspector available in work shop 1 laydown.
PN: During routine inspection activities at operator building (external RC wall), found out some portions
of RC wall have presence of hairline crack and waily walls, also some uneven surface of RC wall due to
exceeded used of formworks. Contractor was advised to investigate and take corrective action
concerning this issue.
Subcon: All minor surface defects in the operator building shall be repaired with approved repair
material. All formworks to be replaced to improve the concrete surface finishes.
During material receiving, it has been noticed that the bolts used for the fiber glass cable tray fittings
were 316 stainless steel bolts which is a violation as per G7D-0323-00 sec. 4.1.5. Also, it has been
noticed that the hold down clamp was made of 316 stainless steel which is a violation as per G7D-0323-
00 sec. 4.14.
Contractor: It has been confirmed from the vendor regarding the replacement of exiting stainless
bolts/nuts on the reducer fitting delivered on site. Vendor to replace with silicon bronze equivalent
of the fitting assembly hardware and will advise Company upon the arrival of replacement
hardware. (email received from vendor dated 12 June 2013).
PN: During surveillance to the Daelim Laydown yard it was found that the Contractor is fixing the lifting
seeing at wrong place and it might be cause the damage of the cable. Contractor is advise do not repeat
the same mistake during the lifting & transportation. Manufacturer's to be mandatory.
Daelim: Notified and informed Subcontractor (ASYAD) personnel who unloaded the instrument
cable that they were not following the proper procedure as per schedule Q of sec.6 on handling of
materials and equipments that may result in damaging the materials and equipments. Contractor
already instructed not to repeat the improper handling of materials and equipments. They agreed
to follow and comply with proper procedure to prevent damages and violation in the future.
During routine inspection at ARCC fabrication shop. It has been observed that all fabricated pipe spools
& mumbles are filed up and not maintained in shipping properly to prevent mechanical damages.
Violating SADARA Spec. RT-G-ICS para 2.19.17 C.
During routine inspection at TCC NASCO fabrication facility. It has been observed that no tagging
system for fabricated pipe spools memblast has been implemented for traceability, violating Schedule Q
para 6.29 & A554-E-103-QA-GEN-PRO-042 para 6.51.3 & 6.51.6 requirements.
Subcon: Spool trucking systems implementation travel sheet equipment in W.N. work shop will
ensure by TCC Piping Inspector before shifting spools from W.N. to the work shop. All tags,
flange face protection end caps will be verified by TCC piping Inspector.
It is found that pipe spools and flanges preservation and handling in TCC facility #1 is not proper, some
pipe spools found in direct contact with ground and flanges barrier in the sand. Some flange faces are
observed with lot of scratches welding one intense scratched flange. Relevant piping inspector (Mr.
Rico) of Daelim might be revoked due to his lack of responsibilities to avoid huge loss of project.
Preservation problems were highlighted to him several times before but he is not capable to handle the
job. Corrective action and preventive measures are required Ref. RT-6-ICS para 2.16, 2.19.17, 2.19.12.
PFI-ES-31-para 2.3.
Daelim: With respect to the SADARA PID Mr. AMIN, this LBE #205 is already being highlighted
by DAELIM QC Piping Inspector (Mr. Rico) through NC issued to TCC (NCR-TCC-MECH-008)
dated May 22, 2013. As to date June 06, 2013 this NCR is still open & TCC is still solving this
issues, the material handling and preservation.
During surveillance at TCC #1 it has been found that TCC have utilized one pipe spool which was hold
due to over grinding and ovality problem. Two pipe spools were hold against the ovality and grinding
issues and SADARA LBE #180 was also logged for this. After Company enquiry it is observed Daelim
Piping Inspector (Mr. Rico) is not aware about that spools location or condition. Ref. LBE-180,. RT8S-
6500-01 para # 5. 3(a).
Daelim: The spool that was mentioned in this LBE 206 was not being utilized. I t was mistakenly
welded by the welding group without the signature and release from TCC piping inspector as well
as the Daelim QC Piping Inspector assigned (MR. Raja). Nevertheless, Mr. Rico knows about that
issue and instructed TCC to recover that spool from their yard to replace the pipe which has been
hold for welding due to excessive grinding.
During surveillance at TCC #1 it has been fond that Daelim Piping Inspector (Mr. Rico) is passing the
pipes joints fit-up with 4mm and 5mm high-low. Three joints of 42'', 48'' dia found already welded with
above mentioned discrepancy passed by him. Post weld usual inspection still not carried out by Daelim
and TCC Inspectors. As highlighted before also that Daelim Piping Inspector is not capable to handle
the job. So now it is recommended to revoke his approval. Daelim Quality needs to ensure the
corrective action with preventive measures.
Daelim: This issue about the HI-LO of 4-5mm is due to the contraction of the welding process.
Daelim QC advised the welder to be careful on removing tack welds or distortion control to avoid
this kind of problems. This 4-5mm HI-LO one side is not tolerated. We are also assuring that the
HI-LO was divided along the pipes' circumference.
Page 21 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
208
Coating/
Painting
01-Jun-13 04-Jun-13 15-Jun-13 15-Jun-13 Closed
LBE-ARCC-MECH-
209
Coating/
Painting
01-Jun-13 04-Jun-13 15-Jun-13 Closed 15-Jun-13 Closed
LBE-KCC-CIVIL-140 KCC PN CIVIL Civil 02-Jun-13 05-Jun-13 16-Jun-13 Closed 23-Jun-13 Closed
LBE-DLM-CIVIL-141 DAELIM PN CIVIL Civil 02-Jun-13 05-Jun-13 16-Jun-13 27-Jul-13 Closed
LBE-DLM-CIVIL-142 DAELIM VAF CIVIL Civil 03-Jun-13 06-Jun-13 17-Jun-13 Closed 25-Jun-13 Closed
LBE-DLM-MECH-
210
MR. AMIN DAELIM PN MECH Quality Records 03-Jun-13 06-Jun-13 17-Jun-13 06-Oct-13 Closed
LBE-AMA-MECH-
211
AMA VAF MECH
Coating/
Painting
03-Jun-13 06-Jun-13 17-Jun-13 27-Jul-13 Closed
LBE-DLM-INST-046 MR. SHABIRUL DAELIM PN INST Instrumentation 04-Jun-13 07-Jun-13 18-Jun-13 08-Oct-13 Closed
LBE-DLM-MECH-
212
DAELIM VAF MECH UG-RTR 04-Jun-13 07-Jun-13 18-Jun-13 27-Jul-13 Closed
LBE-DLM-MECH-
213
MR. AMIN DAELIM VAF MECH Piping 05-Jun-13 08-Jun-13 19-Jun-13 11-Oct-13 Closed
LBE-DLM-MECH-
214
DAELIM VAF MECH Piping 05-Jun-13 08-Jun-13 19-Jun-13 30-Jun-13 Closed
LBE-ASYAD-MECH-
215
MR. HARIKUMAR ASYAD VAF MECH Mechanical 05-Jun-13 08-Jun-13 19-Jun-13 06-Jan-14 Closed
LBE-SEN-MECH-
216
MR. HARIKUMAR SENDAN PN MECH Quality Management 05-Jun-13 08-Jun-13 19-Jun-13 31-Oct-13 Closed
LBE-TCC-MECH-
219
TCC VAF MECH Preservation 05-Jun-13 08-Jun-13 19-Jun-13 25-Jun-13 Closed
LBE-DLM-MECH-
217
DAELIM PN MECH Refractory 06-Jun-13 09-Jun-13 20-Jun-13 11-Jun-13 Closed
LBE-TCC-MECH-
218
TCC VAF MECH Mechanical 06-Jun-13 09-Jun-13 20-Jun-13 25-Jun-13 Closed
LBE-DLM-MECH-
220
MR. NOOR DAELIM VAF MECH Quality Records 06-Jun-13 09-Jun-13 20-Jun-13 6-Aug-13 Closed
LBE-DLM/KCC-
MECH-221
MR. NOOR DAELIM/KCC VAF MECH UG-RTR 06-Jun-13 09-Jun-13 20-Jun-13 11-Jul-13 Closed
PN: It has been observed that starting June 01, 2013. All concrete cylinder & cubes sampled at MFC
site by Third Party (OSAIMI) they are bringing the sample at OSAIMI (Jubail Branch), for crushing the
said specimen, in which no info or proper documentation and approval from the Company. Contractor
was advised to take corrective action concerning this issue. and to ensure that all
documentation/approval was properly done.
Contractor: Company already approved the third party laboratory (Al-Osaimi) Jubail branch
During the inspection of pump foundation P4215 A/B, near splitter the 4 NDS-RSB-Q12mm which are
supposed to be embedded in the pump foundation. During installation of reinforcing beams are drilled to
the pump foundation as shown on the drawing.
Subcon: The FDN P-2415 A/B at pedestal.
PN: Daelim Quality needs to ensure that the Contractor/Subcontractors shall track welding activities on
a daily basis and submit to QR each week a weld for tracking and welder performance report for that
weeks work. Cut-off date for submitting weekly performance report shall be agreed to by Contractor and
QR. Output for cumulative weld data and welder data required by this document is to be reported weekly
in the weld tracking and welder performance report. Shop and field and welder data may be included on
the same report. Ref. A554-O-PRG-QA-GEN-PRO-13-Rev.2 para # 5.3
Contractor: Will provide the required data as per the sample format.
During routine inspection at ARCC/OTC blasting painting facility. It has been noticed that empty paint
cans has been stored in the paint storage. This is violation against A554-E-103-QA-GEN-PRO-041.
Subcon: Empty paints cans removed on OTC paint storage area, ARCC to continuous monitor on
painting facilities of OTC to avoid re-occurrence violation.
It has been noticed that yellowing defect on the phenolic epoxy top coat at ARCC blasting/coating facility
due to improper protect from sunlight. This is violation against A554-E-103-QA-GEN-PRO-041.
Subcon: International protective coating's representative confirmed that the changes of interthem
228 color to yellow is normal as stated on product date sheet & clarification of Mr. James
Donoghue (IPC Representative) during visit at ARCC painting shop. See attached letter.
PN: During surveillance/monitoring inspection at compressor C-2301 & C-2001 along pedestal E-2370 &
E-2070), found out some portion surface of pedestals having honeycomb/voids after removal of
formworks. Contractor w3as advised to investigate the cause of honeycomb void and take corrective
action. Please advice the Company Representative to check whether the surface preparation is ready to
received repair materials with approval.
Honey comb (voids are repaired as per approved method statement). See attached photos
PN: Daelim subcontractor M/S Sendan conducted WQT for structural welding with 4 conductor.
Observed that third party inspector has rejected all test coupon due to discrepancy founded. Daelim
Quality (welding team) shall instruct to subcontractor welder have got Engr. training prior to perform
qualification test.
Subcontractor: Noted. Daelim Welding QC team discussed with Sendan Welding QC inspector
and agreed before that WPQT will arrange good training as for all welders.
During inspection at TCC-2 fabrication facility, it has been observed that 24" dia fabricated flanges were
rolled with foot. Contractor must ensure proper handling and storages at the fabrication facilities as per
SADARA RT-6-ICS.
Daelim: On the spot that works was on-hold. It has been giving warning that all TCC QA/QC
Inspectors are more vigilant at site now. In future if it is found that the person will be removed
from site.
PN: Found that Daelim Refractory Inspector not available at site during casting and gunning activities
and inspection time since May 25th 2013. Corrective actions are required.Ref. violation Schedule"
attachment IV para #3.
Daelim: Because of emergency vacation I could not attend some of the inspections. On 10th
June 2013 I have been rejoined for the inspections.
It is found that Daelim Inspector (Mr. Rico) is irresponsible for the following I.) Fit-up inspection
accepting 3-5mm high-low. II.) Pipes openly in direct contact with ground. III.) Flanges mixed with lot of
debris and scrap materials. IV.) Handling of measuring pools is very poor. V.)Damaged pipes mixed with
the fabricated spools. CNB3130K328.4.3, Fig.K328.4.3), RT8S-6500-01 RT-6-ICS, (SMIC-W-2005
(820).
Subcontractor: ARCC already segregated the spool found with 3mm & 2 mm HI-LO. During daily
inspection on TCC, ARCC found that TCC piping group is carefully preserving the piping
materials. Further during daily fit-up inspection, ARCC check all the accurateness of each
measuring tools upon inspection.
Crossover pipe were damaged at header nozzle area of #(HTC-4). At F-1170: CM-1170-3 (HTC-2 IN
LET-PASS-3) Daelim shall propose repair procedure with approved recommendation of SME for further
action.
Contractor: After discussion with Company SQIT, Daelim agreed to repair/rectify work at F-1170
CM-03 HTC-2 Inlet Pass-3. Pipe damaged shall be carried-out with approved procedure/method
the repair work activities will be informed to the Company through RFI.
It has been observed that Daelim subcontractor ASYAD started pre-fabrication and welding activities
without proper information to quality team. Daelim shall instruct to subcontractor to follow Schedule Q
requirement and Daelim Quality team shall closely monitor all related activities and meet the schedule Q
requirements.
Subcontractor: ARCC will be immediately stopped, then submit resume for Welding Inspector
(ASYAD) and be interviewed by Contractor, CV of said Inspector was forwarded to SADARA for
final interviewed and approval. Once Inspector approved by Company, ASYAD Welding
Inspector will closely monitor and communicate to Daelim Welding Inspector. Further, materials
receiving for consumables will be raised, when comply the requirements Fabrication will resume
with the final instruction from the client.
During routine inspection it has been observed that anchor support proms of spent caustic crystal has
been applied the coating on the rusted surface without surface preparation & installed it. This lead must
crack defect for all frames. This is for information, root cause analysis and corrective action.
Contractor: Duplication of item No. 136 Civil LBE, work completed and closed
PN: During material receiving inspection, it has been observe that Instrument cable drum # 13-0079E
size 24Px20 AWG has damage insulation jacket around 24 inches from the end cap. Contractor is
advised to coordinate with the vendor's to replace the damage cable drum.
Daelim: Cable drum # 13-0079E 24 P X 20 AWG shall be tested on reel once the cable passed
the IR test & Contractor will offer this PN to Company for closure.
During witness inspection of FRP U/G line street reinforcement lamination joint. It is found that Daelim
Inspector (S. Khalid Basha) did not inspect the joint prior to Company Inspection. It has been found that
he has accepted the joint and reported without his inspection which has lot of visual defects such as
voids, air bullies from down side of the tee. Daelim Quality team needs to take corrective action
preventive measures. Ref. RTI # MFC-DLM-KCC-UG-RTR-1233 and drawing joint #No16103 AAB=FW-
071004-04-02 joint #960. This is a violation of Schedule "Q" attachment IV para #3 and G85-6115-01
para # 39.
Subcontractor: Daelim FRP U/G inspector Mr. S.K. Basha resigned from Daelim Company.
Daelim assigned Mr. Raja as FRP/RTR UG inspector, approved by Sadara as per schedule "Q",
Att. I, Para 2.2.3. Daelim Quality team make sure that Pre-inspection will be done prior to
Company inspection.
During routine inspection at TCC fabrication facility, it has been observed that open SAW floor were not
stored continuously in ovens at 65C minimum temperature, violating SADARA Spec. RT85-6500-03 AH
# 2 & A554--E-103-QA-GEN-PRO-056- para 15.5.1.6 requirements. Contractor must insure that open
SAW flu shall be stored continuously in ovens at 65 C at all time.
Daelim: The flux was discovered and further a tool box conducted with welders and welding
inspectors. TCC welding inspector will monitor all kind of flux storage for smooth and defect free
weld.
Repeated violation found that the Daelim Refractory Inspector is not submitting the RFI's timely to
Company after the inspection. Approximately 400 RFI's are still awaiting for which inspection has been
done already. This is a violation as per schedule "Q" attachment IV para #3.
Daelim: All pending RFI's have been submitted except those RFIs need sample test results from
third party laboratory. And those RFIs shall be submitted as soon as the result arrived.
During Inspection. It was noticed that the Daelim and Subcontractor (KCC) carried out Hydro Test of U/G
fire water system 1481 area-A-Unit-SI (hydro Test Package #0714). After 24 hours pressure holding
found that pressure has been dropped. Daelim Quality team needs to take corrective action with
preventive measures and provide root cause analysis for that test failure. Test must be carried out again
ensuring that SADARA requirements are fulfilled. Violation reference : A554-E-103-QA-GEN-PRO-008
and GAS-6423-01. para #65.
Daelim: Re-Hydrotest has been carried out on 9 June 2013 and accepted. RFI # MFC-DLM-KCC-
UG-RTR-1241 (Package # 1481-HT-0714)
Page 22 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
222
TCC VAF MECH Mechanical 06-Jun-13 09-Jun-13 20-Jun-13 30-Jun-13 Closed
LBE-AMA-CIVIL-143 AMA PN CIVIL Civil 08-Jun-13 11-Jun-13 22-Jun-13 22-Jul-13 Closed
LBE-DLM-ELECT-
047
DAELIM VAF ELECT Electrical 10-Jun-13 13-Jun-13 24-Jun-13 29-Aug-13 Closed
2
LBE-AMA-MECH-
223
MR. NOOR AMA VAF 2 MECH Hvac 10-Jun-13 13-Jun-13 24-Jun-13 16-Mar-14 Closed
LBE-DLM/TCC-
MECH-224
MR. HARIKUMAR DAELIM PN 2 MECH
Mechanical
(Equipment)
10-Jun-13 13-Jun-13 15-Jun-13 25-Feb-14 Closed
LBE-AMA-CIVIL-144 MR. JERRY AMA VAF CIVIL Civil 11-Jun-13 14-Jun-13 25-Jun-13 15-Sep-13 Closed
LBE-AMA-CIVIL-145 AMA VAF CIVIL Civil 11-Jun-13 14-Jun-13 25-Jun-13 25-Jul-13 Closed
LBE-TCC-MECH-
225
Coating/
Painting
11-Jun-13 14-Jun-13 25-Jun-13 13-Jul-13 Closed
LBE-ARCC-MECH-
226
ARCC VAF MECH Refractory 11-Jun-13 14-Jun-13 25-Jun-13 13-Jul-13 Closed
LBE-KCC-MECH-
227
MR. NOOR KCC VAF 2 MECH UG-RTR 11-Jun-13 14-Jun-13 25-Jun-13 12-Feb-14 Closed
LBE-SEN-MECH-
228
MR. HARIKUMAR SENDAN VAF MECH Quality Management 11-Jun-13 14-Jun-13 25-Jun-13 31-Oct-13 Closed
LBE-DLM-MECH-
229
MR. AMIN DAELIM PN MECH Preservation 11-Jun-13 14-Jun-13 25-Jun-13 05-Oct-13 Closed
LBE-DLM-MECH-
230
MR. AMIN DAELIM PN MECH Piping 11-Jun-13 14-Jun-13 25-Jun-13 06-Oct-13 Closed
LBE-DLM-MECH-
231
MR. AMIN DAELIM VAF MECH Quality Management 15-Jun-13 18-Jun-13 29-Jun-13 8-Oct-13 Closed
LBE-DLM-MECH-
232
MR. AMIN DAELIM PN MECH Quality Management 15-Jun-13 18-Jun-13 29-Jun-13 08-Oct-13 Closed
LBE-DLM-CIVIL-146 DAELIM PN CIVIL Civil 17-Jun-13 20-Jun-13 01-Jul-13 28-Jul-13 Closed
LBE-TCC-MECH-
233
TCC VAF MECH Preservation 17-Jun-13 20-Jun-13 01-Jul-13 30-Jun-13 Closed
During material receiving inspection (RFI #AMA-HV-0022) found that fire pumpers don't have "UL Label
Fire Rating" Identification marking to demonstrate fire rating. It is a violation against " RT-LPP-10.18
and document # A554-K-PRG-AR-SPC-LPP-064 para#2. Corrective action and preventive measures
are required.
Contractor: Contractor QC informed Amana regarding the highlighted issue. Amana decided to
replace the material (Fire, smoke damper) that was delivered on the site without requirements of
"UL listed and re-submitted the new specification of (Fire smoke damper with required "UL" listed
as per standard specification of Sadara.
PN: TCC/Daelim installed PSA drum (absorber vessels) D-2611 to D2616, it has been observed that
during lifting time Construction team depressurized preserved N2 and Equipment end nozzle aged as
lifting device, presently no N2 level is showing zero. The N2 level as recommended by vendor in order
to avoid any further corrosion internal shell and accessories.
Subcontractor: TCC noted and further to check with Equipment Inspector pertaining this issue.
During concrete placement of Pump Foundation (P-1321 B), the forms collapsed. It was noticed that the
concrete is almost full at the time of collapsed. Contractor shall investigate and provide corrective action
to avoid recurrence. There are still 2 remaining foundations which require concrete placement and
contractor shall ensure that the remaining foundation will not suffer the same consequence.
Subcon: During concrete pouring of pump foundation (P-1321B) was collapsed, it was totally
removed and cleaned. Amana has already installed new rebar and formwork and the work has
been done, photos are attached.
During surveillance found that TCC helper (Mr. Liu Chaoyang Badge # 037038) was doing the track
welding on the pipe joint with GTAW welding process. Also found that welders are tack welding in
atmosphere without any wind & sand protection during high velocity sand storm. Daelim Quality notified
about above violations. Ref. RT85-6500--01 para #5.5,12.1. Corrective action with preventive measures,
are required.
Subcontractor: TCC to checked with TCC QC Welding Inspector concerning on this issues.
PN: During surveillance/monitoring activities at Sub-station G-1120 along mechanical room, it was found
that some partial deliveries of Timber were defective (not solid wood), intended to be used for Roof Slab
System. Contractor is advised to remove immediately and quarantine said defective timbers for proper
material disposition, and replace with solid wood.
Subcon: All defective black timber has been removed from mechanical room. Pictures attached.
PN: During routine site visit at Daelim's Laydown yard, it was noticed that some of the cable trays and
fittings were already stuck in sand as a result of the sandstorm. The Contractor shall remove the sand
and make sure that the cable trays were stored off the ground.
Daelim: Cable trays & fittings will be cleaned and transferred to an elevated area.
PN: Based on the violations already logged (LBE#180, 2016, 207, 213) it is advised that Quality Team
must ensure that II joints weld joints of excess of High-Low and 02 flanges of deep scratched has been
segregated for corrective action. Fit-up inspection and preservation should be monitored more closely to
avoid above-mentioned discrepancies. Daelim Inspector have detailed list of above-mentioned rejected
joints and flanges.
Contractor: Noted and will follow the activities only as per the procedure.
It is found that Daelim Quality team don't have Inspector for Material Receiving inspection at MFC
Daelim Laydown. Piping Inspector (Mr. Melchor) was raising RFI's since many days on temporary
permission but he is also involved in different activities at site for piping inspection. It is observed that
he is not capable to handle the material receiving inspections. Furthermore, Company had been
observed that many mechanical material damages and deep grinded spots on different large bore pipe
fittings which were accepted by him. As per Schedule Q Att. VI table VI-I Mechanical and Piping material
receiving inspector requirement is 1 per work at site. Daelim Quality team needs to fulfill the Sch. Q
requirements. Also prepare and submit the detail report of imperfections on the large bore pipe fittings.
Contractor: Daelim got the approved piping material inspector. All the material receiving activity
is done by approved QC Inspector Mr. Ludiveco.
PN: Daelim quality team must provide heat treatment (PWHT) Inspector prior to start of any heat
treatment activity. As per Schedule Q Attach. IV Table VI-1 requirement, for Contractor is 1 inspector per
4 localized heat treatment machines or 2 furnaces and 1 for 5 Subcontractors inspectors.
Contractor: Daelim provided PWHT Inspector for the PWHT activities and future more inspectors
will be provided.
Found that during removal of the collapsed concrete with excavator from pump foundation (P-1321B)
FRP Schedule Q fire water line FW-071053-02 broken while removing the concrete. The line was
already visually inspected and hydro tested against the test package # HT-004 activity was performed
by Subcontractor AMANA under supervision of Daelim. Daelim Quality team needs to care corrective
action with preventive measures.
Subcontractor: Fire water line (FW-071053-02) damaged pipe has been removed and fabricate
with new spool and fit-up & pipe laying is completed, dated July 9, 2013, reference RFI #MFC-
DLM-KCC-VG-RTR-1281.
Subcontractor SENDAN started welding activities (Tack Welding on cable tray support) at site & it has
been observed that welding inspectors was not available at site.
Subcontractor: Sendan welding inspector entry pass was not ready, within 3 days will arrange
the gate pass and then started the welding activities.
The corrective action has been taken, Sendan's welding QC Inspector has been interviewed,
approved and mobilized at site.
PN: Based on the violations already logged (LBE#180, 206, 207 & 213) it observed that Daelim Quality
team must ensure that 11 joints weld joints of excess High - Low and 02 Flanges of deep scratched has
been segregated for corrective action. Fit-Up inspection and preservation should be monitored more
closely to avoid above mentioned discrepancies. Daelim inspector already had detailed list of above
mentioned rejected joints and flanges.
Subcontractor: Noted and will be taken care to avoid recurrence in the future.
During surveillance/monitoring activities at operator building on June 10, 2013 (inside portion) found out
that installation of CMU "First Layer" had been done without submitting first "RFI" for surface preparation
& proper layout. Contractor is advised to remove the said CMU instn. And to ensure proper
documentation, and also repair
Subcon: Surface preparation done by chipping the area before laying of CMU. Raise RFI to close
LBE-145
During routine inspection at TCC-02 offsite blasting & coating facility, it has been observed that coating
activities carried out during sand storm, violating SADARA Spec. A554-E-103-QA-GEN-PRO-041, para
5.21.
Subcontractor: TCC Painting Inspector already informed Construction group that weather
condition especially sand storm is not allowed to undergone work for painting, otherwise work will
be stopped during sand storm. TCC to check with painting inspector assigned on that area or
regarding this issues.
During surveillance Inspection at MFC ARCC Furnace Area found that Refractory material cast (F50-G3)
was stocked in area as manufacturing data sheet. It was manufactured on June 11, 2012 and self life
only year. Daelim is advised to shift the material to Quarantine area. Daelim Quality team need to take
corrective action and preventive measure are require.
Daelim: Material has been shifted to quarantine area and said material are not used for
application. A log sheet is being maintained for verification for gunning & blasting activities.
PN: During surveillance and monitoring inspection at MFC site Laboratory, it has been noticed that
Laboratory Technician in-charge will be leaving this coming 20 June 2013 (last working days) for final
exit in his company. In this regard, Contractor was advised to have a replacement for said technician,
for proper hand-over and documentation concerning our site MFC Laboratory status.
Contractor: Contractor already advised third party (Al-Osaimi) the replacement of site laboratory
technician and Company already approved by third party laboratory Jubail-1 branch
During routine at TCC-2 Fabrication facility, it has been observed that LTCS Material is not segregated
from normal material during storage. Violating SADARA Specification RT-6-ICS, para 2.19.8b
TCC Piping Inspector assigned for LTCS workshop and he will make sure that all
precaution will be taken cared of regarding LTCS materials
Page 23 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
234
TCC VAF MECH Piping 17-Jun-13 20-Jun-13 01-Jul-13 30-Jun-13 Closed
LBE-DLM-MECH-
235
MR. NOOR DAELIM PN MECH UG-RTR 18-Jun-13 21-Jun-13 02-Jul-13 21-Aug-13 Closed
LBE-DLM-MECH-
236
DAELIM PN MECH Quality Records 18-Jun-13 21-Jun-13 02-Jul-13 21-Jul-13 Closed
LBE-DLM-MECH-
237
MR. NOOR DAELIM VAF 2 MECH Quality Management 18-Jun-13 21-Jun-13 02-Jul-13 12-Feb-14 Closed
LBE-DLM-MECH-
238
MR. NOOR DAELIM VAF MECH Refractory 18-Jun-13 21-Jun-13 02-Jul-13 22-Jul-13 Closed
LBE-DLM-CIVIL-147 MR. GERALD DAELIM PN CIVIL Civil 19-Jun-13 22-Jun-13 03-Jul-13 28-Jul-13 Closed
LBE-TCC-MECH-
239
Coating/
Painting
21-Jun-13 24-Jun-13 05-Jul-13 27-Jul-13 Closed
LBE-TCC-MECH-
240
TCC VAF MECH Piping 22-Jun-13 25-Jun-13 06-Jul-13 18-Aug-13 Closed
LBE-ARCC-MECH-
241
ARCC VAF MECH Piping 22-Jun-13 25-Jun-13 06-Jul-13 16-Jul-13 Closed
LBE-DLM-ELECT-
048
MR. MARK DAELIM PN 1 ELECT Electrical 23-Jun-13 26-Jun-13 07-Jul-13 09-Mar-14 Closed
LBE-TCC-MECH-
242
TCC VAF MECH Piping 23-Jun-13 26-Jun-13 07-Jul-13 18-Aug-13 Closed
LBE-TCC-MECH-
243
TCC VAF MECH Quality Management 23-Jun-13 26-Jun-13 07-Jul-13 Closed 27-Jul-13 Closed
LBE-DLM-MECH-
244
MR. HARIKUMAR DAELIM VAF MECH Preservation 23-Jun-13 26-Jun-13 07-Jul-13 Closed 24-Oct-13 Closed
LBE-TCC-MECH-
245
TCC VAF MECH Piping 23-Jun-13 26-Jun-13 07-Jul-13 Closed 30-Jun-13 Closed
LBE-AMA-CIVIL-148 MR. GERALD AMA PN CIVIL Civil 24-Jun-13 27-Jun-13 08-Jul-13 Closed 10-Oct-13 Closed
LBE-DLM-MECH-
246
MR. KHAN DAELIM VAF MECH Quality Management 24-Jun-13 27-Jun-13 08-Jul-13 Closed 19-Oct-13 Closed
LBE-DLM-MECH-
247
MR. KHAN DAELIM VAF MECH Quality Management 24-Jun-13 27-Jun-13 08-Jul-13 19-Oct-13 Closed
LBE-TCC-MECH-
248
Coating/
Painting
25-Jun-13 28-Jun-13 09-Jul-13 6-Jul-13 Closed
LBE-DLM-ELECT-
049
DAELIM PN ELECT Electrical 25-Jun-13 28-Jun-13 09-Jul-13 27-Jul-13 Closed
LBE-AMA-CIVIL-149 MR. GERALD AMA PN CIVIL Civil 26-Jun-13 29-Jun-13 10-Jul-13 30-Jul-13 Closed
During inspection, it has been found that the Contractor & Subcontractor not following the drawing (KCC-
108-1084-07-137) for refractory brick lining in F-1170 gas furnace. Daelim quality team must ensure that
work is carried for Construction drawings. Corrective action & preventive measures are required.
Contractor: As per SME (Mr. Jerald), the lining is acceptable as per his verification upon his visit
at the site. This variation was happened due to the extra tie-back plate provided on the side walls
of F-1170 which will eventually give more support for the brick lining. This would happen in F-
1250 & F-1160 also.
PN: It has been noticed that testing of total chlorides and total sulfates conducted by our third party
laboratory (OSAIMI), found out that there is no updated test records submitted to Company. In this
regard, Contractor was advised to updates all records that frequencies of the various test has been
comply wit RT-25-3001-01 para 3.6.2 for proper documentation.
Contractor: The testing of total chlorides and total sulfates, the updated test reports are already
submitted by Contractor, see updated test report. Weekly reports submitted to the Company
based on the results released by Third Party Lab. Test frequencies as per RT2S-3001-01 is being
complied by concrete supplier.
During routine inspection, it has been noticed that TCC-01 offsite coating & blasting facility doing the job
without crew supervisor. This is violating the SADARA standard & schedule.
Subcontractor: Crew Supervisor CV submitted to Daelim & waiting for Sadara Interview. Crew
supervisor was approved by company. NCR #20 closed.
PN: Contractor must submit pressure test packages for piping under ground and above ground line
including limiting factor, for Company review and approval at least "72" hours prior to the planned
conduct of pressure test. The pressure test must comply with all Company requirements. All pending
items from pre pressure test line punch list must be clear and verified by Company Inspector as per
Sch. "Q" Att. IV para # 3.13.
Subcontractor: Noted and will be taken care of in order to Comply the project specs.
Requirement.
PN: Contractor must submit each week to the Company representative a fourteen (14) day loo-ahead
schedule of all planned Quality activities during Construction phase and pre-commissioning. The
schedule must be sent electronically in a format acceptable to Company. Daelim Quality team needs to
take corrective action with preventive measures as per schedule "Q".
2-weeks look ahead inspection schedule has already been sent to PID and shall be followed
up in the future.
It is noticed that Daelim Quality Team released HVAC Inspector Mr. Shaik Khalid Basha without
Company advised or information. It is violation as Sch. "Q" section 5.14. Contractor must advise the
Company Representative at least thirty (30) days in advance of scheduled absences or changes to
personnel and Quality coverage or within seventy (72) hours for unscheduled leave. Daelim quality team
must ensure the corrective actin and preventive measures.
Contractor: New HVAC Inspector Mr. Ruperto Vermug is already approved. All activities of
HVAC has been conducted as per ITP.
During routine inspection at TCC-2 fabrication facility shop, it has been observed that invite fabricated
spools & assembly, pipe opening are not copped or covered, violating SADARA Specs. RT-6-ICS, para
2.19.4 & 2.19.5
TCC Piping Inspector will make sure all welded spool, proper preservation as per Sadara
specs.
Found that welders are welding more than 24mm, violating the WPS (PI-PI-04) and SADARA
Specifications at White Nile TCC fabrication shop. Also there is no welder identification on large bore
pipe joints weld by two different welders. Noted on DWG # C016103VIA-SH-011342-03A joint # SW.11
daily 24" Schedule 60. Corrective action with preventive measures are required.
Subcontractor: Warning was issued to welder and 2 days deductions for the violation done.
PN: During surveillance & monitoring inspection at base slab, around pump foundation along east side
portion of cooling tower. Found out that some portions of base slab (finished) are not properly done
especially perimeter of pump foundation and comments between old and new slab concrete. In this
regards, Contractor was advised to take corrective action concerning this issue. Please note that this
area needs guiding and touch-up for proper finishing work.
Subcontractor: finish work between new concrete and old concrete has been grinded to make
both concrete in same level(please see attached picture) repair work will be done as per approved
method statement or recommended by third party.
Daelim did not submit table lifting each joint requiring heat treatment, prior to start of PWHT activities at
ARCC Office Fabrication shop, violating RT8S-6500-01 para 8 and ITP checklist SMIC-W-2006
requirement.
Contractor: Daelim has submitted PWHT Table request on 25/06/13 prior to start the work 7
coordinates submitted to Company.
During material inspection, it has been observed that Subcontractor TCC were installed PSA unit (Valve
skid PU-2610) at site. Pressure transmitter manifold and piping system ( PT-261059 & 58) were
damaged during handling on lifting time. A.) Daelim shall investigate with extents of damage occurred
on piping and instrument system and establish vendor recommended remedy action in order to avoid
and further action of discrepancy on system. b.) Daelim shall re-instate the preservation (N2 purging)
system immediately to avoid corrosion on valve skid.
Subcon: Noted Activities will be taken. N2 has been purged. MOM-68. 11/7/13 Closed
During inspection at TCC-2 fabrication facility, it has been observed that there is no Piping Inspector has
been deployed for Hold point inspection for the fit-up and spools release inspection. Violation ITP
(SMITP-F-001-009) & Schedule Q.
Daelim: TCC workshop 2 assigned 4 Piping Inspectors and all inspection done as per approved
ITP. 4 pipe inspectors are all available in TCC workshop-2
During Material Receiving Inspection for loose part of PSA unit (FU-2610) it has been observed the
following a.) SS and SS alloy material and butterfly valve were directly stored on row wooden box, those
material had contacted with potential corrosive blowing sand. b.) Fitter Element (Cellulose) protection
cover were destroyed and had open position. c.) Daelim Material and preservation Dept., shall
implement a corrective action and take more care to preserve the sensitive material parts at Daelim
facility. Violation of equipment protection and preservation plan: RT6-ICS para 215.
Contractor: All the inspected valves are put back in the wooden carton. All required preservation
protection has been taken.
It is found that Pipe spools at TCC-1 are almost completely buried under the sand. Some pipe spools
might be already burred and hidden in the sand. Preservation is entirely failed even violations are
repeated several times with same problem and always highlighted by Company Inspector. Also found
pipes with direct contact with ground with out heat no transferring while cutting into pieces. Relevant
Piping Inspector (Mr. Rico) again recommended for revoke. Corrective action with preventive measures
are required.
Subcontractor: Activities taken. Activity on-going after completion will be informed and pictures
will be attached.
During fit-up inspection at Furnace F-1160 area, it has been observed that a.) Dimensional discrepancy
between vendor fabricated pipe spools. (FPH, economized and conventional coil nozzle. b.) Tack weld
were cracked due to over stress and improper fabrication method. c.) ARCC shall verify the orientation
and dimensional verification prior to install vendor fabricated pipe spools at site.
Subcontractor: ARCC will cut & adjust the Vendor pipe for fit-up alignment and welding as per SI
# MFC-SI-DJ-AR-134.
PN: During routine site vest, it has been noticed that one of the fastener at radiator isolation valve of
transformer TR-103H202A was not fully tighten. Contractor shall re-tighten the fastener prior for the final
installation of the transformer.
Daelim: Contractor will check the said fastener at the radiator isolation valve if it can be easily
tightened but if it's not possible, Vendor shall be contacted and addressed this issue.
PN: During surveillance & monitoring activities at Operator Building, it was found out that Subcontractor
is not using "measuring box" for proper proportioning of sand & cement mixtures "mortar" but in stead
has used shovel only.
Subcontractor: Strictly advised to Engineer and Foreman to follow the approved method.
Construction has removed the person from site. Advised to Building QC to check time to time and
reminded its men.
Contractor & Subcontractor did not have heat treatment inspector for ongoing PWHT activities at ARCC
office fabrication shop. Violating Sch. Q Attach. VI & ITP (SMITP-W-011-01) requirements. Proactive-
Notification was already raised by Company Inspector prior to start of activity
Contractor: Both Contractor & Subcon have been assigned PWHT Inspectors in the specified
work locations.
It has been noticed that coated pipes & spools at TCC-01 off-site coating & blasting facility are almost
completely buried under the sand, some pipe spools are contacted with ground without any protection.
This is violation against SADARA preservation plan. Root cause analysis & corrective action shall be
taken.
Subcontractor: One crane is mobilized with rigger crew assigned for the activity after all pipe
spools come out from sand and properly preserved, inspection will be offered.
PN: Contractor shall verify the Chemical properties of the cable tray splice plates, expansion splice
plates and other cable tray accessories of these fittings were alloy 3105 which does not met the
requirement as per G7D-0322-00, section 4.3.2.
Daelim: Alloy 3105 already accepted by Dow Company
Page 24 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
249
TCC VAF MECH Piping 29-Jun-13 02-Jul-13 13-Jul-13 18-Aug-13 Closed
LBE-TCC-MECH-
250
MR. NASSAR TCC VAF MECH Preservation 29-Jun-13 02-Jul-13 13-Jul-13 4-Aug-13 Closed
LBE-TCC-MECH-
251
MR. AMIN TCC VAF 2 MECH Piping 30-Jun-13 03-Jul-13 14-Jul-13 17-Mar-14 Closed
LBE-KCC-CIVIL-150 MR. JERRY KCC VAF CIVIL Civil 01-Jul-13 04-Jul-13 15-Jul-13 01-Oct-13 Closed
LBE-KCC-CIVIL-151 KCC VAF CIVIL Civil 01-Jul-13 04-Jul-13 15-Jul-13 27-Jul-13 Closed
LBE-TCC-MECH-
252
TCC VAF MECH Piping 01-Jul-13 04-Jul-13 15-Jul-13 6-Jul-13 Closed
LBE-TCC-MECH-
253
TCC PN MECH Quality Records 01-Jul-13 04-Jul-13 15-Jul-13 14-Jul-13 Closed
LBE-TCC-MECH-
254
Coating/
Painting
01-Jul-13 04-Jul-13 15-Jul-13 04-Dec-13 Closed
LBE-TCC-MECH-
255
MR. HARIKUMAR TCC PN MECH Material 02-Jul-13 05-Jul-13 16-Jul-13 24-Oct-13 Closed
1 LBE-TCC-INST-050 MR. SHABIRUL TCC PN 1 INST Instrumentation 03-Jul-13 06-Jul-13 17-Jul-13 16-Jul-14 Closed
LBE-AMA-ELECT-
051
AMA PN ELECT Electrical 03-Jul-13 06-Jul-13 17-Jul-13 27-Jul-13 Closed
LBE-TCC-MECH-
256
Coating/
Painting
05-Jul-13 08-Jul-13 19-Jul-13 4-Aug-13 Closed
LBE-DLM-MECH-
257
DAELIM PN MECH Preservation 05-Jul-13 08-Jul-13 19-Jul-13 1-Sep-13 Closed
LBE-KCC-CIVIL-152 KCC PN CIVIL Civil 06-Jul-13 09-Jul-13 20-Jul-13 02-Sep-13 Closed
LBE-TCC-MECH-
258
TCC PN MECH Piping 06-Jul-13 09-Jul-13 20-Jul-13 27-Jul-13 Closed
LBE-TCC-MECH-
259
MR. AMIN TCC PN MECH Piping 06-Jul-13 09-Jul-13 20-Jul-13 10-Nov-13 Closed
LBE-TCC-MECH-
260
MR. AMIN TCC VAF MECH Piping 06-Jul-13 09-Jul-13 20-Jul-13 08-Nov-13 Closed
LBE-AMA-CIVIL-153 AMA VAF CIVIL Civil 08-Jul-13 11-Jul-13 22-Jul-13 05-Sep-13 Closed
It is found that activity fit-up being performed by TCC team at TCC facility #1 is inadequate especially for
large bore pipes & fittings. In stead to rectify the ovality, equally dividing the HI-LO, tampering the
excess thickness as per requirements & using proper clamps or jacks, fabricators and fitters are just
grinding and reducing the thickness of loose metal.
Subcontractor: On-going. TQ with Daelim. Piping QC Supervisor. Excessive grinded pipe has
already replaced. High-Low TQ is on-going.
With reference clarification from SME (Subject Matter Expert), Bed Color above paving of U/G electrical
cables is required per RT2S-3001-01, section 2.6.7. Please advise and discuss with your Construction
group this requirement. One slab is already poured north of Flare pipe racks where this situation
occurred despite of previous discussion.
Contractor: Drawing was already issued to Subcontractor (A554-E-103-CV-SPC-C99-001, REV.
3)
It was noticed during monitoring that the installed HDPE liner for containment slab of Equipment V-1690
area has punctured. The HDPE liner shall be checked and tested again to ensure no damage has been
done on the membrane prior to install R & B.
Contractor: The installed HDPE liner that was damaged was already rectified. Welding and
vacuum tests were done, pictures attached.
During routine inspection at TCC-2 off-site fabrication facility for Stainless Steel (SS) pipes, it was
observed that oxygen analyses are not used to verify purging in the SS pipe around the joints, violating
project procedure A554-E-103-QA-GEN-PRO-056, Para. 14.3.11 & WPS requirements.
Subcontractor: TCC QC team has informed Construction group and will be provided soon. O2
analyzer is available at workshop-2
During inspection at site (T-1910) observed that following Coating damages on 6" HC-35 (P-
19140505C). Coating adhesion is doubtful, several damaged observed due to improper
handling/transportation. Advised for adhesion test prior to install subject pipe spools on T-1910,
Equipment. Verify remaining coated spools for conforming in-adhesion with same coating system.
Subcon: Noted. Test - on-going. After getting report, copy will be provided or attached. Test was
failed. All pipe related with this LBE will be re-blasted.
It has been noticed that TCC subcontractor has applied coating on the damaged area for T-1910 by
another manufacturer's product (interthem) instead of original manufacturer's product (Amer coat91).
This is violating Sadara specs. #G16S-0201-11.
Subcon: Noted. Action will be taken. next time all touch-up and repair will be carried out with
same manufacture.
PN: During Material Receiving inspection of splash deck trays for F-1410 (Internal Parts). *SS & SS
alloy materials were stored on broken/damaged wooden box. Those SS Materials have had conducted
with potential corrosive blowing sand. * Daelim Quality & Preservation Team to take necessary
corrective action and more care of sensitive material handling.
Contractor: Sand has been removed inside the affected wooden bozes and tarpaulin are placed
to cover the damaged wooden boxes to avoid sand entry
PN: With regards to surface preparation of internal or sumps prior to painting with RT-APCS-2B waiting
system, please be aware of the requirements of document no. A554-K-PRG-PI-SPC-VIA-142 (RT-APCS-
2B) Para. 3 "Surface Preparation requirements".
Contractor: As per SAES-H-003, Para. 7.2.1.1 for surface preparation requirements for concrete,
scouring the surface to remove any protrusions and sharp edges by using an abrasive bricks
(carborundum), power grinding or power brushing. For old concrete surface preparation, as per
SAES-H-003, Para. 7.3.1, remove all loose concrete, surface contaminations, sealants & old
coatings by abrasive blistering (or other mechanical means) and or hot water with pressure
washing as appropriate, prior to making concrete repairs and coating application, pictures
attached. RTAPCS-2B.
PN: During material receiving inspection of acetylene reactors (R-2025, R-2030 & R-2035) observed the
following discrepancies: CJ2 Procedure Lose observed on R-2035. (Pressure level is showing zero); An
open punch item was not yet closed during orientation of Heck nozzle; for R-2030 and R-2035);
Daelim/TCC shall provide corrective action for Re-orientation of nozzle spools as per GA/IFC drawing
and re-establish the original purging state for all Equipment to comply with the project preservation
requirements (SP:RT-6-ICS).
Subcon: Noted. Action will be taken.
PN: During surveillance at TCC site, installed PSA unit valve skid PU-2610 A/B observed that Pressure
Transmitter Manifold and Piping system PT-261059 & PT-261079 and solenoid valve air exhaust filter
were damaged due to improper handling & lifting. Daelim shall investigate the extents of damage
occurred on piping & instrument system with Vendor recommended method in order to avoid any further
functional discrepancy.
Daelim: Contractor has already issued NCR and Company will be notified regarding the
corrective action and response of Vendor's recommendation for the said damaged.
PN: During surveillance, it was noticed that Installed Grounding cable is damaged at several locations
under E/W Furnace Pipe rack. Forklift was continuously passing through grounding cable . Column #43,
44 provide wooden box for grounding cable protection and avoid any damaged grounding cable.
Daelim: Subcontractor already notified regarding the cable (grounding) that needs protection
which will be provided by them.
During surveillance at TCC-2 off-site fabrication facility, it was observed that pipe spools are not welded
as per IFC drawing No. N016103L4A-CA-280101-01 & 02 the material grade given in IFC & fabricated
spools do not match. As per IFC drawing method of pipe is 106-hv.B where fabricated spool is A106.hv
& NACE. The color coding & IFC has not been followed during fabrication.
Daelim: This issue was noted and made a log in Contractor Internal Logbook, LBE # TCC-FS-2-
28, on 26/6/2013, as a corrective action from Contractor all the joints will be cut out and re-
fabricated as per approved ITP and IFC drawing.
PN: During review for welding RFI (MFC-DLM-TCC-WE-453) It was observed that unauthorized Daelim
Contraction personnel is making changes in IFC approved drawing (016103A-PR-250601-01, Rev.1)
without involvement of Daelim Engineering for red marking of modification of changes to the drawing.
Subcon: For revise the ISO drawing. Sadara approved procedure will be followed. Construction
group already informed.
During routine inspection at TCC-1 Off-site blasting & coating facility, it has been observed that blowing
dust during vehicles & forklift movement and wind since the area close to priority to painting workshop.
Therefore, SQIT representative requested from Subcontractor to put concrete or aggregate on the floor
to avoid blowing the dust.
Subcon: Construction group has been informed and action will be taken. Small stone are already
layer on main entrance of workshop T-1 painting works.
During inspection of foundation for FL-1423 A/B for Formworks, rebar and embedment's, the installed
Anchor Bolts cannot be explained by both Amana & Daelim surveyors with regards to the Orientation as
shown in Dwg. # A554-E-103-CV-DWG-C30-159, Rev. 1B. The filter foundation schedule shows various
orientation in degrees of all anchor bolt as detailed in various types.
Contractor: With regards to this issue, Daelim & Amana surveyors counter-check the Anchor bolt
orientation.
PN: It is found that fabrication team @ TCC-1 has started the fabrication for NACE piping, therefore,
Daelim quality needs to make sure that different materials are segregated and identified separately in all
stages to avoid mishandling & measure of NACE materials with CS or LTCS materials.
Subcontractor: Noted. TCC all piping and welding inspectors are informed about new activity in
workshop 1, all required precautions will be taken.
PN: It is found that Fabrication team @ TCC-1 has started the fabrication for SS Piping, therefore,
Daelim quality team needs to ensure that following activities are being performed as per Sadara &
relevant standards and specs: 1. Preservation before, during and after fabrication; 2. Cutting works; 3.
Fab. and Fit-up under tolerance; 4. Welding, interpass temperature, Heat input; 5. Purging + O2
monitoring by calibrated oxygen analyzers inside the SS joints; 6. Marking by Low Chloride markers; 7.
Piping, Fittings and Spools staging, etc.
Subcontractor: Noted and one tool box meeting was held in TCC workshop #1 regarding S.S.
Pipe work starts. All required precautions will be taken during and after fabrication of S.S. pipe
materials and spools.
During surveillance at TCC Fab. Facility-2 found following violations: 1. Welder (TCC-ISS/JCC#489) was
using the portable quiver without power cable for low hydrogen electrodes; 2. 36" dia. Flange to pipe
joint found welded joints having 6.5mm & 3mm high-lo in different two locations and accepted by TCC &
Daelim Quality inspectors.
Subcontractor: Noted. Working given to the welder. TCC welding inspector will improve their
surveillance and make sure all welders make their portable ovens, plug-in wind protection. This
point will be discussed in the coming tool box meeting with welding supervisor and welders in
TCC workshop 2.
Page 25 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-GLOBAL-
MECHL-261
MR. NASSAR GLOBAL VAF 2 MECH Quality Management 08-Jul-13 11-Jul-13 22-Jul-13 23-Feb-14 Closed
LBE-KCC-MECH-
262
MR. NOOR KCC VAF MECH UG-RTR 08-Jul-13 11-Jul-13 22-Jul-13 27-Jul-13 Closed
LBE-PSCL-MECH-
263
MR. AMIN PSCL VAF MECH Mechanical 08-Jul-13 11-Jul-13 22-Jul-13 8-Oct-13 Closed
LBE-PSCL-MECH-
264
MR. AMIN PSCL PN MECH Quality Records 08-Jul-13 11-Jul-13 22-Jul-13 8-Oct-13 Closed
LBE-TCC-MECH-
265
TCC VAF MECH Mechanical 10-Jul-13 13-Jul-13 24-Jul-13 27-Jul-13 Closed
LBE-TCC-MECH-
266
TCC VAF MECH Mechanical 10-Jul-13 13-Jul-13 24-Jul-13 27-Jul-13 Closed
LBE-TCC-MECH-
267
MR. KURIAN TCC PN 2 MECH
Mechanical
(Equipment)
10-Jul-13 13-Jul-13 17-May-13 20-Jul-13 Closed
LBE-AMA-CIVIL-154 AMA PN CIVIL Civil 11-Jul-13 14-Jul-13 25-Jul-13 05-Aug-13 Closed
LBE-KCC-CIVIL-155 KCC VAF CIVIL Civil 13-Jul-13 16-Jul-13 27-Jul-13 01-Aug-13 Closed
LBE-TCC-MECH-
268
TCC VAF MECH Piping 14-Jul-13 17-Jul-13 28-Jul-13 27-Jul-13 Closed
LBE-AMA-CIVIL-156 AMA VAF CIVIL Civil 16-Jul-13 19-Jul-13 30-Jul-13 29-Jul-13 Closed
LBE-ASYAD-MECH-
269
MR. KURIAN ASYAD VAF MECH Instrumentation 16-Jul-13 19-Jul-13 30-Jul-13 06-Jan-14 Closed
LBE-ASYAD-MECH-
270
MR. KURIAN ASYAD PN MECH Quality Records 16-Jul-13 19-Jul-13 30-Jul-13 06-Jan-14 Closed
LBE-TCC/ARCC-
MECH-271
TCC VAF MECH
Coating/
Painting
17-Jul-13 20-Jul-13 31-Jul-13 4-Aug-13 Closed
LBE-ARCC-MECH-
272
MR. NASSAR ARCC VAF 2 MECH Preservation 17-Jul-13 20-Jul-13 31-Jul-13 16-Feb-14 Closed
LBE-ARCC-MECH-
273
MR. NASSAR ARCC VAF MECH Preservation 17-Jul-13 20-Jul-13 31-Jul-13 29-Sep-13 Closed
LBE-TCC-MECH-
274
MR. AMIN TCC VAF MECH Piping 18-Jul-13 21-Jul-13 01-Aug-13 Closed 28-Aug-13 Closed
LBE-KCC-CIVIL-157 MR. GERALD KCC VAF CIVIL Civil 21-Jul-13 24-Jul-13 04-Aug-13 27-Jul-13 Closed
LBE-ASYAD-INST-
275
MR. KURIAN ASYAD VAF 2 INST Instrumentation 22-Jul-13 25-Jul-13 22-Feb-14 Closed
LBE-AMA-CIVIL-158 MR. GERALD AMA PN CIVIL Civil 22-Jul-13 25-Jul-13 05-Aug-13 24-Sep-13 Closed
LBE-ARCC-MECH-
276
Coating/
Painting
22-Jul-13 25-Jul-13 05-Aug-13 29-Sep-13 Closed
During witness inspection of Plumbness found that some temporary curvature plate attachments are not
removed prior to inspection & found a buckle at 2nd horizontal joint near temporary attachments. Also
measured Banding at buckle area is more than the acceptance criteria of API-650. Buckle/distorted area
to be checked for plumbness, flatness and banding measurements.
Subcontractor: Company representative has witnessed and inspected the buckle area of Tank
V0500A. The reports are submitted to Company for approval.
PN: It is advised to Daelim & Petrol Steel to close all the lob book entries logged by Quality team of
Subcontractor, Contractors and Company about MFC Tanks prior to Hydrotest to avoid any discrepancy
and delay in job. Also recommended to complete all the quality documents and their data status of all
the inspection and NDE requirements as per applicable standards and specification making sure that
none of the activity or inspection is overlooked.
Subcontractor: Noted. Petrol Steel has submitted prior to Hydrotest all the documents for review.
During routine inspection at TCC-2 fabrication facility, it was observed that low chloride are not used for
heat number & other data transfer on NACE or LTCS pipes. This is a clear violation against Sadara
procedure A554-E-103-QA-PRO-056.
Subcontractor: Noted and one tool box meeting was held with Piping Group in workshop 2
relative to the issue. Piping Supervisor and TCC Piping Inspectors will make sure use proper
marker for transferring data on LTCs and NACE's pipes.
During routine inspection, it was observed that insulation Crew Supervisor is not available at site during
insulation activities at T-1910 Debutanizer, violating Schedule "Q" requirements.
During witness inspection of FRP-U/G Line stress reinforcement lamination defects on items such as
voids, air bubbles and improper lamination at T intersection point for up and down side. Found that
Contractor/Subcontractor have accepted the joints and raised RFI's without inspection. Corrective action
with preventive measures is required.
Subcontractor: The defects that was found were re-grinding and re-shaving to remove the air
bubbles & voids and do the proper lamination. RFI was raised and accepted by the Company.
KCC QC inspector was informed to check & inspect the area before raising the RFI.
During the surveillance at PIB Building, ASYAD welders (no. W#3160, 2268) were found using quivers
without calibration and not heated to 65c with welding rods in it. Violation as per A554-E-103-QA-GEN-
PRO-056, Para. 9.2.
Subcontractor: Asyad Welder is welding with calibrated quiver and maintain minimum
temperature of 65c as per A554-E-103-QA-GEN-PRO-056.
PN: During inspection at PIB structural support for cable tray were found modified without AS-Built which
can be done with proper technical query. Drawing E-016103-DB-00A-IC-135-001, revision 2.
Subcontractor: In PIB Structural support for cable tray, Asyad is using modified with As-Built
drawing No. DRW-E-016103-DBOOA-IC-135-001.
During surveillance at site, it has been observed too many coating damages for pipes & spools due to
poor handling & internal transpiration of pipes & spools done by truck without proper protection such
rubber pads.
Subcontractor: TCC Construction group has been informed. More precautions will be taken
curing painting the pipe spools shifted at site.
ARCC Construction group had been advised & will do some precaution to avoid damage on
painted spools.
During inspection of D-2190 (Perimeter Wall) as west side of N-s Pipe rack, it was found out that anchor
bolt length was not shown on the detailed drawing, wherein the diameter & projection are reflected on
the plan. Contractor is advised to clarify the anchor bolt length for the Engineering point of view and tale
corrective action prior to place/pouring of concrete for the said structure.
Subcontractor: In the drawing of D-21090 (Perimeter wall) the Anchor Bolt projection, size & type
were shown. The length of Bolt can be found in drawing # A554-E-103-CV-599-402 Rev. 2
(Standard details of Anchor Bolts schedule).
During inspection at TCC-2 fabrication facility, it was observed that damaged pipe was used for fit-up
without Company notification. Moreover, damaged pipe was not kept in quarantine area or separated
from other non-damaged pipes 35" damaged pipe was used for fir-up without following approved
procedure.
Subcontractor: Noted. All damaged pipes will be transferred in quarantine area. Piping Inspector
will make sure during Fit-Up inspection, all pipe lengths and fittings should be free from any
damage. All inspectors will be informed by TCC QC Manager.
During monitoring & surveillance inspection at air compressor shelter (pedestals), found but newly
casted pedestal & removal renewal of formworks are insufficient. Concrete curing application. This is a
violation to RT2S-3001-01, Para. 9.1.2. Contractor is advised to take corrective action on this issue.
Contractor shall provide drum for stock of water for easy curing application.
Subcontractor: Monitoring of curing for newly casted concrete , Amana has assigned a person to
monitor all concrete which is under curing period. Advised Construction to provide empty drums to
have small structure cured by this drum water. Also, extended the during period from 7 days to 9
days.
During the Material Receiving inspection for tail Gas silencer (SL:2610) water found collected waste the
equipment also the nitrogen pressure found (0.01) both are violation as per RT-6-ICS and A554-E-103-
QA-GEN-PRO-035
Subcontractor: Noted. Action will be taken accordingly.
PN: Heat Exchange installed on anchor bolt whose thread not extended to the base plate of support
(leg) which have a standard washer 3mm only. Clarification required for rectification.
PN: During inspection of Pedestal at Liquid Furnace area F-1240, F-1250 and Gas Furnace area F-1140
3 nos. small pedestals, found out that some pedestals have insufficient spacing prior to ground works.
Contractor is advised to take corrective action concerning this issue. Contractor is reminded that prior to
inspection, materials should be prepared the same like ice & others prior to execute the works.
Subcontractor: Advised Grouting group to monitor sealing properly prior to inspection and
grouting.
It has been noticed that ARCC/OTC blasting/coating facility stored blasting activity without approval of
blasting facilities. Ref RFI No. MFC-DLM-ARCC-H-0551.
Subcontractor: The issue has been elevated/escalated to NCR-ARCC-MECH-012, issued by
Contractor to ARCC.
During surveillance and monitoring inspection at G-1123 Expander Building along Roof sub-station, it
was found out that newly casted "Screening" has no sufficient water curing application and also burlap &
polyethylene sheet are not properly arranged.
Contractor: Burlap and plastic sheet were arranged together with container full of water. Mason
crew was assigned to do the curing continuously. Curing period was extended for 2 more days.
During surveillance at SENDAN & ASYAD consumable control room is found without humidity
measuring instrument. This is violation as per 15.8.1 of A554-E-103-QA-GEN-PRO-056. Corrective
action is required as per the Standard's requirements.
Subcontractor: ASYAD has to arrange the digital temperature with calibration properly.
PN: During inspection at foundation for ground flare (FS-0353) row 16 to 19 (SP-4 & SP-15) 12 nos. has
been observed that some formworks being used are not in good quality "Old Formworks". In oder to
maintain good quality of concrete surface, Contractor/Subcon needs to use new and good quality of
formworks.
Subcontractor: Damage formwork being used are replaced with good plywood. Work has been
done and inspected against RFI No.
During routine inspection at ARCC/OTC blasting/Coating facility for pipes & spools, it has been
observed that inadequate dust management or protection during vehicles & forklift movement operation
and strong wind condition.
Contractor to ARCC.
It has observed that OTC blasting/coating facility mixed with coating materials of MFC Project with some
other project. This is violation against schedule "Q".
Contractor to ARCC.
It is observed that TCC-1 welding SS joints without proper monitoring of purging and heat input. TCC do
not have O2 analyzer and heat input measuring tools. It is a violation as per A554-E-103-QA-GEN-PRO-
056 Para. 14.3.11 and WPS requirements. Corrective action with [preventive measures are required.
Page 26 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
277
MR. AMIN TCC VAF MECH Piping 23-Jul-13 26-Jul-13 06-Aug-13 8-Oct-13 Closed
LBE-DLM-MECH-
278
MR. NOOR DAELIM VAF MECH Preservation 26-Jul-13 29-Jul-13 09-Aug-13 24-Aug-13 Closed
LBE-DLM-MECH-
003
MR. IMTIYAZ DAELIM VAF 1 MECH Preservation 21-Jul-13 24-Jul-13 04-Aug-13 Closed 12-Jan-14 Closed
LBE-ARCC-MECH-
004
MR. IMTIYAZ ARCC VAF 1 MECH Preservation 21-Jul-13 24-Jul-13 04-Aug-13 Closed 12-Jan-14 Closed
LBE-DLM-ELEC-
001
MR. MARK DAELIM VAF 1 ELECT Preservation 27-Jul-13 30-Jul-13 10-Aug-13 Closed 11-Nov-13 Closed
LBE-DLM-MECH-
279
MR. AMIN DAELIM VAF MECH Preservation 28-Jul-13 31-Jul-13 11-Aug-13 8-Oct-13 Closed
LBE-ARCC-MECH-
280
Coating/
Painting
28-Jul-13 31-Jul-13 11-Aug-13 29-Sep-13 Closed
1
LBE-DLM-
MECH-281
MR. KURIAN
DAELIM
(Procurement)
VAF 2 MECH Material 28-Jul-13 31-Jul-13 11-Aug-13 Open
LBE-AMA-CIVIL-159 AMA PN CIVIL Civil 29-Jul-13 01-Aug-13 12-Aug-13 07-Aug-13 Closed
LBE-KCC-CIVIL-160 MR. GERALD KCC PN CIVIL Civil 29-Jul-13 01-Aug-13 12-Aug-13 15-Aug-13 Closed
LBE-TCC-INST-052 MR. SHABIRUL TCC VAF INST Instrumentation 31-Jul-13 03-Aug-13 14-Aug-13 15-Sep-13 Closed
2
LBE-DLM-
MECH-283
MR. KURIAN
DAELIM
(Procurement)
VAF 2 MECH Material 01-Aug-13 04-Aug-13 20-Jul-14 Open
LBE-GLOBAL-
MECH-282
MR. NASSAR GLOBAL VAF 2 MECH Insulation 02-Aug-13 05-Aug-13 16-Aug-13 23-Feb-14 Closed
LBE-KCC-CIVIL-161 MR. GERALD KCC PN CIVIL Civil 05-Aug-13 08-Aug-13 19-Aug-13 21-Aug-13 Closed
LBE-SEN-ELECT-
053
MR. MARK SENDAN PN ELECT Electrical 05-Aug-13 08-Aug-13 19-Aug-13 10-Nov-13 Closed
LBE-ARCC-MECH-
284
MR. NASSAR ARCC VAF MECH Quality Records 05-Aug-13 08-Aug-13 19-Aug-13 29-Sep-13 Closed
LBE-AYTB-MECH-
285
MR. KHAN AYTB VAF MECH Piping 05-Aug-13 08-Aug-13 19-Aug-13 19-Oct-13 Closed
LBE-AMA/KCC-
CIVIL-162
MR. GERALD AMA/KCC PN CIVIL Civil 06-Aug-13 09-Aug-13 20-Aug-13 01-Oct-13 Closed
Discoloration is ovserved on SS weld joints at TCC-1 Fab. Facility which is a violation to AWS C5.5,
D10.4 and D18.2 corrective action with preventive measures are required.
Subcontractor: Preservation will be provided prior to spool release for Blasting & Painting.
During surveillance inspection at Daelim MFC warehouse observed that Resin (Total 64 drums of epoxy
vinyl ester 411-45) material was stock piled at MFC Laydown Facility in open area under direct sunlight
@ 44c. As per manufacturer data sheet, Resin shall be stored indoor in dry place away from direct
sunlight between the temperatures 10c to 25c.
Contractor: Noted. All the epoxy resin drums are stored inside the A/C room andd also
lamination kits stored inside the A/C room. Room temperature is monitored and noted. The
wearehouse people are advised to take care the materials.
PN: During inspection at transformer foundation prior to grouting at substation G1121 along four
locations, it was found out that (4) installaed anchor bolt were imporperly installed, touching the upper
portion.
Subcontractor: Subcontractor has already rectify the anchor bolt for the transformer pad.
PN: During inspectionfor rebar & formworks at lightning pole footing at KCC pre-cast area, it was found
out that some formwork materials used are not in good quality and/or condition where an old formwork
was re-utilized which has resulted to poor workmanship.
Contractor: Overused form works were segregated and sent to KCC central warehouse for
dumping. Good & still usable forms were installed & applied form oil.
During site surveillance, it has been noticed during pipe erection of TCC at north/south pipe rack,
columns #33, 34, 36, 37, installed Instrument cable tray was damaged by TCC. A violation as per
Schedule "Q", Para. 3.6, attachment IV.
Daelim: SQDR has been issued by Contractor and under discussion with the concerned party
who damaged the cable trays as well as the replacement. Company will be notified on the action,
sonnest.
Several violations observed at Daelim Laydown yard. 1. Daelim does not have material receiving
inspector, 2. Some SS Pipe Fittings are kept in open atmosphere without protection from cross-
contamination. 3. Some CS Pipe Fittings are not elevated above the ground and above the max water
run-off. 4. Some pipe ends are not covered and protected from entry of rain and foriegn matters. 5. Few
shipping containers are damaged under the other over layered containers. After removal from downside,
detail inspection shall be required for any kind of damage.
Contractor: Material Inspection is approved and already doing the work. All the SS materials
were kept properly. Maximum were issued to Fab.Shops. Wooden piece were provided with all
pipes at ground. All pipe ends were covered. Damaged pipes shifted to quarantine area.
During routine inspection at ARCC/OTC blasting/coating facility, it has been observed that said facility is
using recycled garnet for blasting. This is violating Sadara Standard and Q.C workshop procedure.
Subcontractor: OTC removed the contaminated & used garnet in blasting . ARCC raised RFI for
the cleanliness of blasting pot. Escalated/elevated to Daelims NCR-ARCC-MECH-014
Material receiving inspection at Daelim laydown yard revealed cooling
tower accessories supplied bt SPIG (internal & external plates) were found
damaged. Square tubes were stocked improperly. All these accessories
are made of FRP materials without proper maintainance.
Contractor: These items were verified with Sadara Inspector in the
presence of SPIG of personnel that external/Internal plates material
with damaged parts shall be repaired as per procedure. SPIG will
submit the work procedure to Daelim and Sadara prior to start the
repair work. Target date: 3 weeks.
The following Equipment are lacking the preservation requirements from the TCC scope in site.
The N2 level is "zero", Daelim Construction/TCC has to take immediate necessary corrective
action for these lacking equipment. The tag nos. are D-1530, D-1607, E-1606, FL-0905 A/C/D,
D-0627 & D-2509.
Contractor: Equipment have been verified and confirmed by Vendor/manufacturer that
N2 is only for shipping and long storage, once the equipment installed at site, N2 are no
longer required as per Vendor recommendation.
The Steam Drum D-1210 and D-1230 are found with "zero" N2. This is a preservation violation.
ARCC has to take immediate corrective action for filling the N2 to meet the preservation
requirements.
Contractor: Furnace SME Mr. Frederick Gerald verified and confirmed that all Steam
Drums, TLE's and other Static Equipment installed at site were no longer required N2 as
per email converstaion/query.
During routine site visit at Daelim's warehouse, it was noticed that the Contractor has not yet energized
the space heater of the motor control center that arrived last July 23, 2013 which is a violation as per RT-
6-1CS, section 2.9.1c in which the equipment with furnished space heater shall be connected to a
continuous power source upon arrival at site.
Contractor: Not required. MCC has no space heater.
PN: During surveillance & monitoring activities at site, it has been observed that some newly casted
structures have no "marking or signboards" wherein can easily monitor or check proper curing
application for the said structure.Contractor is advised to take corrective action in this issue and must
provide signage with structure name if when it was casted date and when is the 7 days finish for proper
curing application or implementation at site.
Subcontractor: Curing tags were present for the newly casted areas.
PN: During inspection at substation G-1121 transformer yard, it was found out during the bolt tightening
that once of the bolts for transformer anchorage was loose thread. RFI was rejected and Contractor was
advised to replace the bolt and raise new RFI for the final acceptance for the installation of transformer
TR-103H201A.
Daelim: Anchor bolts will be replaced and Company will be notified again thru RFI.
It has been repeatedly observed that ARCC is not paying attention in preparing reports with reference to
NCR No. 15 & 16 issued by Contractor and it has come to notice that ARCC painted 75 spools during
adverse weather condition and un-acceptable temperatures. ARCC is advised to submit immediate
corrective action on the issue.
Subcontractor: ARCC corrected the wrong data & used the approved format & resubmitted the
report to Daelim. Escalated/elevated to NCR-ARCC-MECH-016.
During inspection at AYTB fabrication shop, it was observed that damaged pipes are used for fit-up
without notifying Company Inspector. LBE-268 was already looged for the same issue.
Contractor: NCR was issued by Daelim to Material department . Corrective action has been
taken by Daelim warehouse group. TQ has been issued by Engineering and will response some
time in Nov. 2013.
During material receiving inspection at site revealed that plates with plates
secondary transfer live exchanger (E1122) supplied by ALSTDM having
distorted nameplate occurred due to improper lifting or transportation
violation as per A555-E-103-QA-GEN-PRO-0353, para 8.2.1.
Contractor: Regarding ladder rung which has corroded at sump pit
#645, Company has already issued NCR to Contractor. As per advice
by Sadara Inspector, Amana has started the cleaning/grinding work of
ladder rung of sump-0645. Amana will rectify the coating as per
recommendation od Company.
During routine inspection at T-1510 Process Condensate Stripper has been observed that Insulation
activities are going-on during sandstorm.
PN: During inspection for formworks at (Center & West side wall) open ditch (0635-D1500-014) at south
side of sump pit # 0636, it has been observed that some forworks installed are not in good quality "old
formworks". Contractor is advised to take corrective action to make sure that after removal of
formworks, the surface of concrete is acceptable or good quality & properly implemented.
Subcontractor: Overused forms were segregated so that it can not be used anymore. Forms that
are still usable were applied by form releasing agent.
Page 27 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
3
LBE-DLM-
MECH-286
MR. KURIAN
DAELIM
(Procurement)
VAF 2 MECH Material 06-Aug-13 09-Aug-13 20-Aug-13 Open
LBE-DLM-MECH-
287
MR. KURIAN DAELIM VAF 2 MECH
Mechanical
(Equipment)
06-Aug-13 09-Aug-13 20-Aug-13 31-Mar-14 Closed
LBE-SEN-ELECT-
054
SENDAN VAF ELECT Electrical 07-Aug-13 10-Aug-13 21-Aug-13 29-Aug-13 Closed
LBE-ARCC-MECH-
288
MR. KURIAN ARCC VAF MECH Structural 07-Aug-13 10-Aug-13 21-Aug-13 31-Oct-13 Closed
LBE-DLM-MECH-
289
DAELIM VAF MECH Material 07-Aug-13 10-Aug-13 21-Aug-13 11-Aug-13 Closed
LBE-TCC-MECH-
290
MR. KURIAN TCC PN 2 MECH Structural 07-Aug-13 10-Aug-13 21-Aug-13 18-Feb-14 Closed
LBE-TCC-MECH-
291
MR. KURIAN TCC PN 2 MECH Structural 07-Aug-13 10-Aug-13 21-Aug-13 23-Mar-14 Closed
LBE-TCC-MECH-
292
MR. KURIAN TCC PN 2 MECH Piping 07-Aug-13 10-Aug-13 21-Aug-13 18-Feb-14 Closed
LBE-KCC-MECH-
293
LBE-DLM-CIVIL-163 MR. GERALD DAELIM PN CIVIL Civil 11-Aug-13 14-Aug-13 25-Aug-13 02-Oct-13 Closed
LBE-DLM-CIVIL-164 MR. GERALD DAELIM PN CIVIL Civil 13-Aug-13 16-Aug-13 27-Aug-13 15-Sep-13 Closed
LBE-SEN-ELECT-
055
MR. MARK SENDAN PN ELECT Electrical 13-Aug-13 16-Aug-13 27-Aug-13 11-Sep-13 Closed
LBE-SEN-ELECT-
056
MR. MARK SENDAN VAF ELECT Electrical 14-Aug-13 17-Aug-13 28-Aug-13 11-Sep-13 Closed
LBE-TCC-MECH-
294
MR. AMIN TCC VAF 2 MECH Piping 14-Aug-13 17-Aug-13 28-Aug-13
Send spool
storage plan
through Daelim.
(29/09/13)
23-Mar-14 Closed
LBE-AMA/KCC-
CIVIL-165
MR. GERALD KCC VAF CIVIL Civil 15-Aug-13 18-Aug-13 29-Aug-13 09-Sep-13 Closed
LBE-DLM-MECH-
295
MR. KURIAN DAELIM VAF 2 MECH Material 15-Aug-13 18-Aug-13 29-Aug-13 17-Feb-14 Closed
4
LBE-DLM-
MECH-296
MR. KURIAN
DAELIM
(Mat. Dept)
PN 2 MECH
Mechanical
(Equipment)
17-Aug-13 20-Aug-13 15-Jul-14 Info
LBE-DLM-MECH-
297
MR. KURIAN DAELIM PN MECH Preservation 17-Aug-13 20-Aug-13 31-Aug-13 14-Sep-13 Closed
LBE-SEN-ELECT-
057
MR. MARK SENDAN VAF ELECT Electrical 17-Aug-13 20-Aug-13 31-Aug-13 11-Sep-13 Closed
LBE-AMA-CIVIL-166 MR. GERALD AMA PN CIVIL Civil 18-Aug-13 21-Aug-13 01-Sep-13 24-Sep-13 Closed
During Material receiving inspection of C3R 4th stage suction drum
(D2508) supplied by DOOSAN found corroded in the skill portion of the
equipment which require better preservation to avoid further degradation as
per A554-E-103-QA-GEN-PRO-035, Para. 8.2.5. Corrective action
required.
Contractor: Noted. Action shall be taken and as per Construction
Plan for the corrosion, painting touch-up repair shall be
commenced/implemented. Target Date: 25 Nov. 2013.
Most of the equipment foundation at MFC site found with achor bolt threads not covered with duct tapes
or suitable means to keep them clean and to prevent any damage. Violation as per A554-E-103-QA-
GEN-PRO-035 Para. 10.1.5. Corrective action is required.
Subcontractor: Noted. Actions will be taken. Anchor bolt for the equipment foundation shall be
covered with duct tape and plastic for protection to dirt and damage. Target date: 25th of October
2013.
Site container storage for FRP Materials found following violations:
*External shaded: NHO Bitumastic Drum open. The storage temp req. is 5C to 30C unopenned.
*Internal container storage: No power
*Temp gauge reading 117F = 47-22C. Derakane Resin storage req. 10C to 25C
*Log, not maintained.
*Housekeeping poor potential fire hazard, reference Sadara Spec RT-6-ICS, Para. 2.9.10 and manual
Recomemended storage req.
Subcontractor: Nitoproof 100 & BASF materials are already transferred to other container van
with air-conditioning.
PN: During inspection of foundation E-1602 at south side of C, G compressor, it was found out that No
Contractor Surveyor to double check or counter check the survey data from subcontractor if it does
comply with IFC drawing.
Subcontractor: Contractor surveyor I s absent, during the inspection but the IFC drawing
reference used was corrent as per contractors record. On the following afternoon contractor
surveyors had cross checking .
PN: During surveillance and monitoring activities at site, it was noticed that from Aug. 8 - 13, 2013, no
one from Contractor represetative witnessed the crushing/breaking of concrete cylinder & cube samples
at Osaimi, Jubail branch as confirmed by Osaimi staff and its assigned Technicians.
Contractor: QCI for Batch Plant, Mr. Ronald, has been assigned to witness daily compressive
strength testing at Al-Osaimi, Jubail 1 Satellite Lab.
PN: During surveillance at E-W pipe rack structural welder (TCC-60) found using quiver without
calibration sticker on it.
Subcontractor: Noted. TCC welding inspector will monitor continuously for all calibration stickers
which may be old or unable to recharge.
PN: Mismatching of the dimension between embeded and gusset plate structural causing extended
point of the gusset plate outside embeded plate without welding at E-W pipe rack near CU compressor.
Engineering clarification required.
PN: Pipe spool welded for T-1820 were found with joints without welder no. (identification). Subcontractor: Noted and area inspectors will make sure for all weld's uniform action.
During routine site inspection of installation of EMT conduits inside substation G-1120, it was noticed
that the EMT conduits were not reamed-off by the Contractor during cutting of conduits which is violation
as per NEC 358.28(A).
Daelim: Subcontractor already informed to ream the edge of EMT conduit. Once the activity is
done, RFI will be raised to Company for the closure of the LBE.
Angle piece provided between lower transition duct and upper tansition duct to prevent mis-alignment
between bottom flange of upper transition duct nd upper and lower erection joint. F-1120 are found tack
welded without sanblasting and aluminum painting (for high temp). Corrective action required.
Subcontractor: Angle piece installed transmission duct F-1120 was removed and sent to painting
shop for sand blasting & painting. Sand blasting & painting of angle piece were completed (refer
to painting RFI # MFC-DLM-ARCC-H-1112 & 1131).
3004 Gasket Kam profile, SS 316L with loose locating ring and flexible graphite filler on both sides
found damage material receiving these gaskets where equipment are D-1095 supplied by MISA- the
damage may have been occurred due to improperly handled by poor material supplied by manufacturer.
Damaged materials (Gasket) to be moved to quarantine area.
Contractor: Gaskets will be replaced by supplier with a newly made gaskets. OSID report has
already been prepared by Material Department for the replacement of gaskets, reference OSID
No.: OSID-0358
PN: Preservation and storage of FRG material for cooling tower in the west side is not proper, it is
violation as per A554-E-103-MY-DOF-MUG-48, erection manual, para. 3.0.
Contractor: Preservation and storage of cooling tower FRP materials (square tube, channel &
FRP plate) are re-arranged properly and stored all FRP items above the ground level with proper
supports.
During routine site visit, it was noticed that there isno QC personnel monitoring the Electrical activities of
SENDAN which is a violation as per schedule "Q", section 3.2 & 5.9. A repeated violation of LBE-EL-
056.
Subcontractor: The correction action has been taken cared that the one new QC Inspector has
been approved and already mobilized at site and another inspector who is on vacation will be at
site on 5 Sept. '13 to meet the Sch. "Q" requirements.
PN: During surveilance & monitoring activities at Dilution steam generation structure along GL:2
El+18,700, it was found out that some embedded plates are incorporated for repair works of column &
rebar while in IFC drawing it shows that the embedded plated are exposed to beam/column for some
structural supports attachment.
Subcontractor: Amana has already scrapped and cleaned all repair materials, all embedded
plates were already grinded and cleaned.
During inspection of formworks and surface preparation for (18) columns and (2) stair pedestals at E-W
furnace area "B" at GL:BB-CB/69B-77B and GL:AO/65-66 prior to grouting works, it was found out the
some chipping preparations of some columns did not meet the required thickness and some column
squareness of formworks are not properly alligned to the edge of base plates.
Subcontractor: Additional chipping was already done in areas that did not meet the required
depth. As for the squareness of plate to the column, KCC already discussed to Contractor
mechanical/structural discipline and advised to proceed grouting for it was already released for
grouting & accepted by Company.
During the material receiving inspection for Turbo expander ECM 2.5 (Exp 2151/C2151), it is found that
the consumable kit has several items were noted.
Contractor: Expired loctite threaded lacker 421, loctite primer T-7471 & Bostik NEVERSEEZ fro
turbo expander ECM 2.5 will be replaced with a new one. RFI will be raised for another inspection
when the newly material arrives.
PN: During the Material Receiving inspection for Turbo expander: Unit
counter panel (21392-3) box with the indicator with showing red color.
(Showing shock occurrence due to handling improperly) hence inspection
for damages require as per manufacturer advice if damaged imidiate
inspection request from carrier within 15 days of delivery. 2. Spare rotating
assembly is N2 purged container with O reading in the gauge and red light
indication piece no. (21392-1)
Contractor: It was completed for inspection works with Mr. Kurian and
already installed at site few months ageo. Daelim already closed the
issue. 2 spare rotating containers had been changedN2 in container
and already been installed at the rotor storage area.
PN: During routine site visit inside substation G-1121, the Contractor has already installing cable tray
and it was noticed that the supports for the cable tray fittings and straight runs did not meet the
requirements of Sadara specs 67C-0324-05 & 67C-0324-06.
Subcontractor: The correction action has already been started as per Sadara specification 067C-
A324-05EI67C-0324-06 & NEMA VE2, RFI will follow upon the completion of work.
During routine site visit, it was noticed that there is no QC personnel for subcontractor Sendan to monito
the activities at site which is a violation as per schedule "Q" section 3.2 & 5.9.
Subcontractor: The correction action has been taken cared that the one new QC Inspector has
been approved and already mobilized at site and another inspector who is on vacation will be at
site on 5 Sept. '13 to meet the Sch. "Q" requirements.
Found that pipes and pipes spools are not properly traceably stored, segregated and identified at TCC
facility #1. Spools are not traceable that which lot came from which Fab Facility and whoch not NDT is
remaining. Some spools found without identification tags and some spools were incomplete inside the
completed spools.
Subcontractor: During spool releasing for blasting and painting every spool detail attched with
RFIs. Spool stored is in workshop 1 as per provided spool storage plan. NASCO & white nile have
been closed two months back. NCR No. 8 is closed.
Page 28 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
298
Coating/
Painting
18-Aug-13 21-Aug-13 01-Sep-13 29-Sep-13 Closed
LBE-PSCL-MECH-
299
MR. AMIN PSCL VAF MECH Tank 18-Aug-13 21-Aug-13 01-Sep-13 8-Oct-13 Closed
LBE-PSCL-MECH-
300
MR. AMIN PSCL VAF MECH Tank 18-Aug-13 21-Aug-13 01-Sep-13 8-Oct-13 Closed
LBE-AYTB-MECH-
301
MR. KHAN AYTB VAF MECH Piping 24-Aug-13 27-Aug-13 07-Sep-13 8-Oct-13 Closed
LBE-ARCC-MECH-
303
MR. KURIAN ARCC VAF 2 MECH Piping 24-Aug-13 27-Aug-13 07-Sep-13 24-Mar-14 Closed
LBE-PSCL-MECH-
304
MR. AMIN PSCL PN MECH Tank 24-Aug-13 27-Aug-13 07-Sep-13 8-Oct-13 Closed
LBE-DLM-MECH-
305
MR. KHAN
DAELIM
(Construction)
VAF 2 MECH Piping 24-Aug-13 27-Aug-13 09-May-14 10-May-14 Closed
LBE-ARCC-MECH-
302
MR. KHAN ARCC VAF MECH Piping 25-Aug-13 28-Aug-13 08-Sep-13 19-Oct-13 Closed
LBE-DLM-MECH-
306
MR. HARIKUMAR DAELIM VAF 2 MECH
Mechanical
(Equipment)
26-Aug-13 29-Aug-13 09-Sep-13 31-Mar-14 Closed
LBE-DLM-MECH-
308
MR. KURIAN DAELIM VAF MECH Material 27-Aug-13 30-Aug-13 10-Sep-13 06-Nov-13 Closed
LBE-ASYAD-INST-
058
MR. SHABIRUL ASYAD VAF INST Quality Management 27-Aug-13 30-Aug-13 10-Sep-13 15-Sep-13 Closed
LBE-AMA-CIVIL-167 MR. JERRY AMA VAF CIVIL Civil 27-Aug-13 30-Aug-13 10-Sep-13 31-Aug-13 Closed
LBE-AMA-CIVIL-168 MR. GERALD AMA PN CIVIL Civil 27-Aug-13 30-Aug-13 10-Sep-13 01-Oct-13 Closed
LBE-ARCC-MECH-
307
MR. HARIKUMAR ARCC PN MECH Mechanical 28-Aug-13 31-Aug-13 11-Sep-13 27-Oct-13 Closed
LBE-DLM-MECH-
309
MR. KURIAN DAELIM VAF MECH Material 28-Aug-13 31-Aug-13 11-Sep-13 29-Sep-13 Closed
LBE-TCC-MECH-
310
MR. KURIAN TCC VAF 2 MECH Piping 28-Aug-13 31-Aug-13 11-Sep-13 23-Mar-14 Closed
LBE-TCC-MECH-
313
MR. KURIAN TCC VAF 2 MECH Mechanical 28-Aug-13 31-Aug-13 11-Sep-13 19-Feb-14 Closed
LBE-DLM-ELECT-
059
MR. MARK DAELIM VAF ELECT Electrical 29-Aug-13 01-Sep-13 12-Sep-13 10-Nov-13 Closed
Observed that Contractor/Subcontractor carried out fabrication and welding activities at their respective
sites/facilities without conducting project specified PMI Test requirements for welding filler materials and
electrode. Violating project PMI procedure A554-E-103-QA-GEN-PRO-075 and Sadara project
specifications RT8S-4001-61 Para. 4.1. and 4.2 (Each batch has lot of filler metal shall be tested in
accordance with Table 4.1 of RT8S-4001-61.) Contractor's Welding & Piping team shall investigate the
discrepancies and implement the remedy action to Subcontractors all facility and site.
Contractor: The issue was noted and all the consumables were PMI tested for each NDT and
found accepted. Contractor will monitor all incoming High and Low alloy consumable and mae
sure all are PMI tested prior to start (each NDT). Please the copy of RFI and close this LBE.
During routine inspection at ARCC fabrication shop, poor preservation for pipes, fittings, fabricated
spools were observed, violating Sadra Specs, RT-6-ICS, Sec. 2.19.16 & 2.19.117.
Contractor: All the spools were placed properly. Action has been taken.
Observed that Contractor/Subcontractor teams (TCC) are installing an incoming Equipment/Material (E-
2119 & E-2222) directly on place/location without conducting Material receiving Inspection released by
Contractor and Company Quality teams. Repeated violation of Sch. "Q" attachment IV, Para. 3.2.33 &
project procedure A554-E-103-QA-GEN-PRO-035 and ITP A554-E-103-QA-GEN-PLN-056.
Subcontractor: Noted. TCC will check with Construction group. All equipment required RFI as
per ITP. TCC equipment inspector will be made.
During inspection at AYTB fabrication shop, it was observed that Joint 2 & 4 for spool nos. N016103V3A-
TW-250249-02-08 & N016103V3A-TW-250312-02-08 are misalligned up to 6mm after completion of full
welding. Damaged out of roundness pipes beyond acceptance criteria from quarantine have been used.
Also refer to LBE No. 285. Violation ref. ASME B31.3.
Contractor: A technical memorandum (MFC-TM-QA-0005) has been issued to the Company for
approval. Action will be taken as per approved TQ in Nov. 2013.
During fir-up inspection at F-1250, F-1240 & F-1230 the HPSSH-1 outlet and HPSSH-2 inlet (both
having parent material grade SA234 WP91) connecting with elbow of parentmaterial SA234PB22 (10")
having a ID mismatch of 25mm and this loop is not in alignment with the outlet and inlet of convection
module. Joint no. J17 & J18. Reference O-A554-E-103-MEC-GEN-006
Subcontractor: Rectification and re-inspection of Fit-Up on affected joints were done and
accepted (refere to ARCC-FW-FUR-0188 & ARCC-FW-FUR-0174).
PN: During surveillance, two locations observed representing distortion on east (near V3A & west side -
on 4D- of the Tank V-0500B which shall be measured separately as per API-650 requirements for
plumbness, flatness, peaking and banding inspections whichever is applicable. Locations have been
shown to Contractor/Subcontractor quality and construction group.
Subcontractor: Noted. Company representatives have witnessed the discrepancy and reports
are submitted to Company for approval.
During routine inspection at ARCC/OTC blasting/coating faciity, it has been observed that the facility is
using recycled garnet for blasting second time within two weeks.
Subcontractor: Contaminated garnetwas removed in blasting pot & new garnet was placed in
blasting pot. The removal & replacement of garnet were verified by ARCC, Daelim & Sadara QC
Inspectors, RFI No. MFC-DLM-ARCC-H-0692.
Distortion out of tolerance as per API-620, ASTM A20/20m in-between the 145-215 different locations of
third shell course at Tank-V-0500A. It shall be inspected again after recitification. A suitable metod
statement might be required for its proper rectification to avoid more complications.
Subcontractor: Company representative has witnessed and inspected Dent area and reports are
submitted to Company for review & approval.
Found following violations at Tank site under Daelim/Petrol Steel.
1. Low hydrogen electrodes in a portable quiver without power connction inside the Tank-V-0500A.
Violation Ref. RT8S--6500-03
2. Tank area do not have welding inspector from Daelim which may result to lot of problems. Schedule
"Q" attachment IV.
Subcontractor: After investigation against this LBE, welder brought electrode from store & kept
on down side the tank & went top side at the tank to lift the oven by using rope. The same time it
was noticed by Sadara Inspector.Welders are advised to follow the requirementw without any
discrepancies.
During visual inspection on N-S pipe rack 2" pipes welded together is out of alignment with each other
(see line no. NH 041802-2) the subcontractor/contractor are not checking the alignment of the pipe
during and before in zig-zag position over the pipe rack as it is to be fitted and welded in a straight way.
Subcontractor: TCC welding inspector will make sure that all weld visual inspection will be
completed prior to RFI. Spatters, slag misalignment underfell ext. Rectification done.
During surveillance at southern end of the N-S pipe reack found Subcontractor using welding machines
without calibration sticker out of 5 welding machines & two of them were without calibration sticker. A554-
E-103-QA-GEN-PRO-056, Para. 9.
Subcontractor: Welding equipment has calibration certificates in office. Sticker maybe removed
due to heat, new sticker will be provided.
Despite of the Proactive Notification issued by the Company, the Contractor did no action to remove all
the sand that was stacked in the cable trays that were stored at Daelim's Laydown yard which is a
violation as per NEMA VE-2, Section 3.
Daelim: Removal of cable tray that was stacked in sand due to sandstorm is on-going. Contractor
will notify Company once the activity is finished.
PN: During surveillance & monitoring activities at cooling tower RC Wall (interior portion) along south
side, it was observed that some preparation works done by Amana are not acceptable. Contractor is
advised to supervise properly the activitiesand must take corrective action concerning the issue.
Subcontractor:Already assign one QC inspector to monitor surface preparing of cooling tower to
avoid any mistake again. South side interfrior wall already inspected and appear to start repairing
work
PN: During RT film interpreatation on weld joint for Radiant Coil to Crossover /Piping, NDT level III Mr.
Troller reported that following comments:
*weld joints were rejected due to surface indication on base metal
*debris are entrapped on weld joints
*evidence of mismatch & misalignment
*third party RT reports are not clear and not specified in defect (reason for rejection). Daelim and ARCC
Subcontractor: Action has been taken. NET coordination and NCT Third Party will do proper
precautions.
During material receiving inspection at Laydown yard (Daelim) for FD fan for the furnace (B-1174) found
with shaft connecting bearing and fan part rusted which is a cause for poor preservation, cleaning of the
rusted part is required. Ref: RT-6-ICS, 2.6.C.2. & Appendex 1-5, 19.
Subcontractor: Rusted portion of the shaft has been cleaned and removed. Continous
preservation will be done on the equipment in order to prevent such non-conforming condition.
Also, inspection has been carried-out with Sadara Inspection.
Material receiving inspection shown F.D. fan for liquid furnace (B-1244) with damaged expansion
chambers part no.(63) in drawing no. 974.03. (Assembly drawing with parts list) It is supplied by
bolorachi, the damage may have caused due to poor handling/transportation. This is a violation as per
A554-E-103-QA-GEN-PRO-034, Oara. 8.1.3.
Contractor: Damaged expansion chamber/breather for F.D (B-1244) will be replaced by Vendor.
Bold Rochi when the new material arrived another RFI will be raised for inspection. Target date of
deilivery: Two months.
During site surveillance, it was noticed that there is no QC personnel monitoring the Instrumentation
Activities of Contractor/Subcontractor (ASYAD) which is a violation as per schedule "Q", section 3.2 &
5.9.
Daelim: Due to miscommunication, QC Personnel of Contractor & Subcontractor were not seen
by Company but Contractor assures that the monitoring & attendance of QC Personnel at site is
within the schedule "Q". QC Inspector shall be given respective area in the on-going activities as
of present.
During inspection of LFU stripper (T1330) foundation prior to grouting, it was noticed that the drain is not
in accordance with the drawing. Contractor to clarify with designer (Engineering) if the location is
acceptable and As-Built the location if accepted.
Daelim: Drawing has already been revised.
Page 29 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
311
MR. HARIKUMAR ARCC PN MECH Mechanical 31-Aug-13 03-Sep-13 14-Sep-13 24-Oct-13 Closed
LBE-TCC-MECH-
312
MR. AMIN TCC VAF MECH Piping 31-Aug-13 03-Sep-13 14-Sep-13 9-Oct-13 Closed
LBE-TCC-MECH-
314
MR. KURIAN TCC PN MECH Piping 31-Aug-13 03-Sep-13 14-Sep-13 28-Sep-13 Closed
LBE-TCC-MECH-
315
MR. KURIAN TCC VAF MECH Piping 31-Aug-13 03-Sep-13 14-Sep-13 28-Sep-13 Closed
LBE-DLM-MECH-
316
MR. KURIAN DAELIM VAF MECH
Mechanical
(Equipment)
01-Sep-13 04-Sep-13 15-Sep-13 15-Sep-13 Closed
LBE-ARCC-MECH-
317
Coating/
Painting
01-Sep-13 04-Sep-13 15-Sep-13 20-Nov-13 Closed
LBE-DLM-ELECT-
060
MR. MARK DAELIM VAF ELECT Electrical 01-Sep-13 04-Sep-13 15-Sep-13 06-Oct-13 Closed
LBE-DLM-ELECT-
061
MR. MARK DAELIM VAF ELECT Electrical 01-Sep-13 04-Sep-13 15-Sep-13 06-Oct-13 Closed
LBE-AMA-CIVIL-169 MR. GERALD AMA PN CIVIL Civil 01-Sep-13 04-Sep-13 15-Sep-13 14-Oct-13 Closed
LBE-DLM-MECH-
318
MR. AMIN DAELIM VAF 2 MECH Tank 03-Sep-13 06-Sep-13 17-Sep-13 18-Feb-14 Closed
LBE-DLM/PSCL-
MECH-319
MR. AMIN DAELIM/ PSCL VAF 2 MECH Tank 04-Sep-13 07-Sep-13 18-Sep-13 18-Feb-14 Closed
LBE-KCC-CIVIL-170 MR. JERRY KCC VAF CIVIL Civil 05-Sep-13 08-Sep-13 19-Sep-13 10-Sep-13 Closed
5
LBE-DLM-
INST-062
MR. PERVEZ
DAELIM
(Procurement)
VAF 1 INST Material 05-Sep-13 08-Sep-13 17-Sep-13 24-Jul-14 Open
LBE-TCC-MECH-
320
MR. KURIAN TCC VAF 2 MECH Piping 07-Sep-13 10-Sep-13 21-Sep-13 23-Mar-14 Closed
LBE-AMA-CIVIL-171 MR. GERALD AMA PN CIVIL Civil 08-Sep-13 11-Sep-13 22-Sep-13 24-Sep-13 Closed
6
LBE-DLM-
MECH-321
MR. KURIAN
DAELIM
(Construction)
VAF 2 MECH
Mechanical
(Equipment)
09-Sep-13 12-Sep-13 23-Sep-13 Open
LBE-GLOBAL-
MECH-322
MR. NASSAR GLOBAL VAF 2 MECH Preservation 09-Sep-13 12-Sep-13 23-Sep-13 16-Feb-14 Closed
During Material Receiving Inspection of Hot Dipped Galvanized channel cable tray and fittings at
Daelim's Laydown yard, it was noticed that the zinc coating for the HDG channel cable tray and fittings
were grinded in some protions causing the metal to corrode, It also resuces the thickness of the zinc
layer coating which is a violation as per G165-0205-03, Section 3.1 and ASTM A 123, Table 1.
Daelim: HDG channel tray & filltings shall be quarantined; and Company will be informed for
further soclutions.
During Material Receiving Inspection of Hot dipped galvanized channel cable tray and fittings at
Daelim's Laydown yart, it was noticed that the manufacturer is Wahah Electrical Supply Co.,
(WESCOSA) was not included in the RTIP project supply plan, A554-K-PRG-PU-LIS-DOC-009.
Contractor: Contractor submitted FMAR for HDG channel tray where WESCOSA is the proposed
manufacturer. FMAR was approved by Company.
PN: During surveillance & monitoring inspections along East side of substation 1121 & cooling tower, it
was found out some door frames are already deformed cue to mishandling and without proper protection
at site. Contractor is advised to take coorective & presventive action.
Subcontractor:deformed door frame already removed from site and send it to suppiler for
rectfication. Amana will resubmit RFI for inspection once door frame will arrive at site.
During welding in-process inspection, welders were found using permanent markers for Identification on
the SS pipe/spools which is prohibited on SS as low chloride Sulfur markers are required for SS & LTCS
spool/pipe marking.
During inspection of equipment foundation pads leveling of equipment there was an excess building of
the concrete surface below the pad plate, also with excess projecting rebars the distance between the
concrete surface and pad plate should be 25mm. Further, chipping required to maintain the distance.
Ref: A554-E-103-QA-GEN-PRO-034/035, Rev.4, Para. 10.2.2.4.
Subcontractor: Additional chipping was done & reinforcing bars were bend to meet the concrete
covering requirement, damaged coating of rebars were touched-up.
It has been observed that during the past eight days, the rejection rate for pipes & spools at ARCC/OTC
blasting & coating facility has increased due to coating defects resulting from bad performance & follow-
up from ARCC/OTC quality team.
Subcontractor: Problem on painting defects were settled during ARCC meeting with Contractor
QC ^ Construction Team and presently production quality was improved and defects on painted
spools were controlled.
PN: Daelim & ARCC quality team shall plan to conduct Ferrite Testing for Completed Weld joint for
304H 308H classified lines (HC-68) as per requirement of line class and project spec: G4S-7600-1.
Daelim/ARCC shall confirm the Ferrite Content of weld metal shall be controlled, and content of all as
deposited weld metal shall be within the range of 2FN to 6FN at individual measurements.
Contractor: Action will be taken. Noted.
During surveillance at TCC-1 found that welder was using high amperage (145 amps instead of max. of
113 amps) for SS welding even instructed several times. Discoloration (Dark Blue) also deserved on the
subject weld joints and notified to Daelim & TCC inspectors. Also WPS parameters must be followed.
Corrective action with preventive measures is required.
Subcontractor: Noted. Action will be taken accordingly. TCC welding inspector give instruction to
all SS welders that WPS. Parameters should be followed. TCC welding inspector has 02 analyzer,
Amps motor with him in SS workshop 1.
PN: During surveillance at N-S pipe (TCC) rack SS welding were carried-out without high frequency
welding machine as it is required. For GTAW welding of Pno. 5A/5B/5C base material for a quick start.
Confirmation of high frequency welding which is using ate site is required. Ref. RT8S-6500-02, para.
3.1.
During Material Receiving at site for inspection of Ground Flare Auxiliary
and spare parts. Supports found with bolts welded to the support, have
threads exposed without proteection. It is a violation as per RT-^-ICS,
2.19A4C.
Subcontractor: Noted. Action will be taken.
During routine inspection at E/W Piperack (Dryer area), it has been noticed that insulation materials
kept in a very poor storage without proper protection & kept some materials on the ground without
wooden skids. This behaviour cause accummulate sand on it & insulation mnaterials damage.
During Material Receiving inspection of Compressor, it was observed that
compressor instrument & Junction Box (JB) are not as per Standard.
Compressor C-02501 documents are not available such as FAT Report,
MTR, Calibration report. Grounding is not connected to JB Instrument and
not completed. This violates G06A-0003-17 & G06A-41-00.
Contractor: Contractor will provide the documents; and RFI shall be
resubmitted to Company for review and approval. Related to NCR.
NCR-ARCC-INST-001, ARCC requested Daelim to provide MOV then
ARCC shall install.
Inspection of Fit-up at North-south pipe rack shown tack weld made outside the weld groove bridge tack
shall be above the root area but within the groove area and shall be completely removed prior to
completion. Ref. A554-E-103.QA-GEN-PRO-056, Rev.1, Para 17.4.5. Line OW-064002-4" PU35.
Subcontractor: TCC welding and piping inspectors conducted tool box meeting with Piping group
and taught them regarding tacking requiements. TCC welding and piping inspectors will make
sure for proper tacking as per Sadara Specifications.
Company informed Contractor/Subcontractors concerning GROUT TEMPERATURE USING
MASTERFLOW 524L intended for Substation G-1121 transient UPS System-Equipment/Concrete Pad
where during inspection prior to grouting the materials were already exposed to sunlight and without
proper protection/handling resulting to increase of temperature after mixing to water with cube ice.
Contractor to take corrective and preventive action in order not to reject the grouting activities and to
ensure that grout temperatures are complying with the manufacturers recommendation.
Subcontractor:All grouting material shifted the shade area to avoid delary of inspection/rejection
It is observed that Contractor's Tank QC Inspector has shown poor performance on his assigned
discipline. Some of his shortcomings are the followings:
Tank ITP, Rev.3 not revised and resubmitted since 7th March 2013; Accepting Tank distortions which
are not acceptable as looged in LBE #299 and repairing is on going; Raised RFI for V-500B distortion
measurements after half inspection and after three days did not offer inspection for the remaining half to
Company final inspection. Reference: Sch. "Q", A20M & LBE.
Violations are found at Tank MFC Area:
*Petrol Steel has fixed some temporary curvature plates and channels to rectify the distortion on the last
shell of Tank V-0615 at 225 degre around a nozzle.
*After Company enquired from Contractor QC Tank Inspector about the issue, said Inspector has not
initiated an inspection due to Subcontractor did not offer for inspecttion.
*Different Welders found welding on Tanks V-0500B, V-0615 without any wind shielding. Contractor QC
Welding inspector also not at site. Contractor Quality team needs to take necessary actions for the
above violations. Ref: RT8S-6500-1, Sch. "Q" & A554-E-103-QA-GEN-PRO-056.
It was noticed that some of the equipment structures have exposed top bars after the chippings for
grouting were completed by the equipment installer. These portion of te top of the foundation shall be
chipped more deeply to lower down the reinforcing bars to meet the cover requirements of the stardards
or as shown on the drawing.
Subcontractor:Additional chipping was done & reinforecing bars were band to meet the concrete
covering requirement, damaged coating of rebars were touched up
Page 30 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
323
MR. KHAN ARCC VAF MECH Quality Records 10-Sep-13 13-Sep-13 24-Sep-13 19-Oct-13 Closed
LBE-ARCC-MECH-
324
MR. KHAN ARCC VAF MECH Piping 10-Sep-13 13-Sep-13 24-Sep-13 19-Oct-13 Closed
LBE-ARCC-MECH-
325
MR. KHAN ARCC VAF MECH Piping 10-Sep-13 13-Sep-13 24-Sep-13 27-Oct-13 Closed
LBE-AMA-CIVIL-172 MR. GERALD AMA PN CIVIL Civil 10-Sep-13 13-Sep-13 24-Sep-13 14-Oct-13 Closed
LBE-DLM-MECH-
326
MR. AMIN DAELIM PN MECH Quality Records 11-Sep-13 14-Sep-13 25-Sep-13 19-Oct-13 Closed
LBE-PSCL-MECH-
327
MR. AMIN PSCL PN MECH Tank 11-Sep-13 14-Sep-13 25-Sep-13 09-Dec-13 Closed
LBE-DLM-MECH-
328
MR. AMIN DAELIM VAF MECH Piping 11-Sep-13 14-Sep-13 25-Sep-13 10-Oct-13 Closed
LBE-DLM-MECH-
329
MR. KURIAN DAELIM VAF MECH Mechanical 11-Sep-13 14-Sep-13 25-Sep-13 06-Oct-13 Closed
LBE-TCC-MECH-
331
MR. KURIAN TCC VAF 2 MECH
Mechanical
(Equipment)
11-Sep-13 14-Sep-13 25-Sep-13 03-Apr-14 Closed
LBE-DLM-ELECT-
063
MR. MARK DAELIM VAF 1 ELECT Electrical 11-Sep-13 14-Sep-13 25-Sep-13 13-Feb-14 Closed
7
LBE-DLM-
MECH-330
MR. KURIAN
DAELIM
(Procurement)
VAF 2 MECH Material 11-Sep-13 14-Sep-13 25-Sep-13 Open
LBE-DLM-MECH-
332
MR. SAYED DAELIM PN 2 MECH Material 14-Sep-13 17-Sep-13 29-Sep-13 25-Feb-13 Closed
LBE-DLM-ELECT-
064
MR. MARK DAELIM PN 1 ELECT Electrical 16-Sep-13 19-Sep-13 30-Sep-13 13-Feb-14 Closed
LBE-AMA-CIVIL-173 MR. JERRY AMA VAF CIVIL Civil 16-Sep-13 19-Sep-13 30-Sep-13 27-Oct-13 Closed
LBE-AMA-CIVIL-174 MR. JERRY AMA VAF 1 CIVIL Civil 16-Sep-13 19-Sep-13 30-Sep-13 10-May-14 Closed
LBE-AYTB-MECH-
333
MR. KHAN AYTB VAF MECH Piping 17-Sep-13 20-Sep-13 01-Oct-13 19-Oct-13 Closed
During routine inspection of ARCC fab.shop, it was observed that material of material SS spools are not
matching with the materials of the pipe listed in the BOM of the IFC drawing, materials of the pipe
observed at the shop is 3062 whereas the requested material as per IFC drawing is 304H.
Contractor: Daelim shall perform the PMI for SS material especially for pipe. The PMI report was
304H, based on the PMI report
During material receiving inspection at Laydown for C3R first stage suction drum. (D2505) accessories
liner plates and companion flanges found corroded. No galvanizing was found on the liner plates to
resist the corrosion. Galvanizing is required as per the drawing D-2505-103-9003-03-205 (Res) the
accessories are supplied by DOOSAN. Ref: A554-E-103-QA-GEN-PRO-035, Para. 8.2.1, 8.1.11, 8.1.12,
RT-6-ICS, 2.19.3.
Contractor: As we discussed with Construction team, corroded diner plates for D-2505 will not be
used by TCC for equipment erection and these materials were shifted in the quarantine area. In
the case of Companion Flange corrossion will be cleaned and it shall be done as per prevention
team schedule. Target date of completion: 2 weekds.
During Equipment Installation Alignment and plumbness inspection for T-2220 TEC found placed shim
under the equipment with a total of five nos. ofshims exceeding total stalk height of 12mm in which more
than one shim is greater than 3mm. This alignment shim used on centerline or near centerline support,
extend beyond the support pads.
Subcontractor: Activities taken. Plumbness inspected and accepted. Alignment inspected and
accepted.
During routine site inspection at substation G-1121, it was found out that the Contractor installed EMT
Conduits for Fire Alarm System inside the battery room which is a violation as per G7C-0311-06,
Section 3.3.
Subcontractor: We discussed the issue with DAELIM Engineering and they will raise the RFC to
SADARA upon the approval we follow accordingly.
It is found that subcontractors replying SADARA LBEs sometimes incorrectly and Daelim Quality is not
acknowledging the replies for agreement o disagreement. After Daelim quality is satisfied for the closure
of any LBEs, Company inspector must be informed immediately for final acceptance without any delay.
PN: Observed following at Tank V-500A,B:
1.Roof nozzle's flange faces are getting rusty and needs proper cleaning and protection.
2. Galvanized roof walkway gratings are needed some rectifications by cutting and welding. Proper
coating shall be required.
RFI's MFC-DLM-SOSTA-PIP-018, SEAH-PIP-064, BASSI-PIP-008, BASSI-PIP-009 & BASSI-PIP-010
are submitted to Company after acceptance of Daelim QC and Company found following discrepancies:
1. Wrong Heat number marking on pipes
2. Wrong size marking on pipes
3. RT, Hydro Test reports attached are of A516-70 instead of A234 Fittings MTC.
4. MTCs of Materials A335, A182 submitted instead of A234 CS Fittings. Approval of RFV and PMI and
PMI is required for all of above.
Contractor: NCR is issued to the Vendor SOSTA by Company. All the pipes were conducted
PMI. The test result is satisfactory.
During routine inspection at ARCC fabrication shop, discoloration is observed on the weld disposition &
HAZ. As per AWS (5.5, D10.6 & D12.2), this discoloration is not acceptable & will affect the condition
resistance.
Contractor: ARCC Welding inspector had been taken immediate action regarding the highlighted
issue; before started the welding, Contractor checks the purging level and during the welding also,
checking the heat input and inter-pass temperature.
During inspection for Post Welding of SS joints, it was observed that some joints are partially welded
which is not allowed as per approved WPS at ARCC fab.shop.
Contractor: Naction has been taken. Tool box meeting given to welders to follow the WPS.
It has been noticed that some RFI's had been submitted late by Contractor/Subcontractors for more that
two months back are still pending. Contractor/Subcontractor has to expedite submission to Company all
pending RFI's to ensure that proper documentations are secured.
Subcontractor: Amana is ongoing doing all pending RFI and make sure that by end of October
2013 already submitted to Daelim QC Office.
The Contractor repaired the corner bottom slab of Sump 0906 (near the Cooling Tower) without chipping
or removing the honeycombs and other loose concrete. Repair should not be undertaken without
approval of Company as required by RT2S-3001-01 Sec. 11.
Subcontractor: Amana is ongoing chipping and removing the repaired materials after all chip,
Amana will raise RFI prior to start repair.
Spent Caustis Foundation V500A & B have circumferential non-uniform finish with regards to
circumferential plate of the tank above the sloop portion of the foundation. Please advise the
subcontractor to follow the detail shown in the drawing after the tank settlement activities.
Subcontractor: Amana is waiting to release spent caustic foundation from Petro steel to start
repairing work as per IFC drawing slope
During routine inspection at AYTB fabrication shop, it was observed that specified material of 2" pipe in
BOM of IFC drawing is ASTM A312-TP304/304 L SMIS but the materials used for fabrication is ASTM
A312-TP 304/306L welded, violating design requirements.
Contractor: The pipes were shifted to AYTB by mistake. Corrective action has been taken. All the
welded pipes were removed. All the joints made on welded joints were rejected.
During Material Receiving inspection for Equipment (W1720) & (W1721) at
site, the Equipment W1720 found with flanges corroded, external surface
of the equipment especially place were saddle was attached and other
surface of the equipment, some internal pipes connection to the flange
were also also found corroeded. Equipment W1721 found with corroded
flanges. The equipment is also found errected without proper preservation
for corrotion deterioration. This is a violation as per A554-E-103-QA-GEN-
PRO-035, Para 8.2.1, 8.1.11, 8.1.12, RT--6-ICS, 2.19.3. These equipment
are supplied by DOOSAN Engineering.
Subcontractor: Noted. Action shall be taken and as per construction
plan for the corrossion, painting touch up repair will be implemented.
Target date: 25 Nov. 2013.
PN: During Material Receiving Inspection for CS Pips ASTM A53B, it was found out that 23 nos. of
pipes of different sizes are not matching with MTC. (P.O. No. 100532-42-P02-005 AO1, Manufacturer -
Seah Steel, Korea):
1. In the MTC of 12" pipe, heat no. SB76608 is not matching with MTC (Total 19)
2. IN the MTC of 20" pipe, heat no. SB74629 were physically on 4 nos. of pipes heat no SB72061, as
per Sched. "Q", att. II, para.2.3.
Contractor: All the pipe without proper tag were shifted to quarantine area.
PN: During routine site visit inside operator building G-1122, it was noticed that the Contractor was
about to install EMT conduits embedded in concrete which is a violation as per G7C-0311-06 Sec. 3.5.
Subcontractor: The issue already under discussion with SADARA PID and DAELIM. We will
follow the result of final discussion.
Page 31 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
334
MR. AMIN DAELIM PN MECH Piping 17-Sep-13 20-Sep-13 01-Oct-13 12-Oct-13 Closed
LBE-AMA-CIVIL-175 MR. GERALD AMA VAF CIVIL Civil 17-Sep-13 20-Sep-13 01-Oct-13 31-Dec-13 Closed
LBE-SDN-ELECT-
002
MR. PERVEZ SENDAN VAF 1 ELECT Preservation 18-Sep-13 21-Sep-13 02-Oct-13 Closed 19-Sep-13 Closed
LBE-AYTB/TCC-
MECH-335
MR. AMIN AYTB/TCC VAF MECH Piping 18-Sep-13 21-Sep-13 02-Oct-13 8-Oct-13 Closed
8
LBE-DLM-
MECH-338
MR. KURIAN
DAELIM
(Procurement)
VAF 2 MECH Material 18-Sep-13 21-Sep-13 22-Jul-14 Open
LBE-DLM-MECH-
339
MR. KURIAN DAELIM VAF 2 MECH Piping 18-Sep-13 21-Sep-13 02-Oct-13 19-Feb-14 Closed
LBE-AMA-CIVIL-176 MR. JERRY AMA VAF CIVIL Civil 18-Sep-13 21-Sep-13 02-Oct-13 Closed 27-Oct-13 Closed
LBE-GLOBAL-
MECH-336
MR. NASSAR GLOBAL VAF 2 MECH Quality Management 19-Sep-13 22-Sep-13 03-Oct-13 Closed 16-Feb-14 Closed
LBE-DLM-MECH-
340
MR. KURIAN DAELIM PN 2 MECH Piping 20-Sep-13 23-Sep-13 29-Sep-13 29-Sep-13 Closed
LBE-DLM-MECH-
337
LBE-DLM-MECH-
341
MR. SAYED DAELIM PN 2 MECH Material 22-Sep-13 25-Sep-13 08-Oct-13 04-Mar-14 Closed
LBE-AMA-CIVIL-177 MR. JERRY AMA VAF 1 CIVIL Civil 23-Sep-13 26-Sep-13 07-Oct-13 Closed 30-Jan-14 Closed
9
LBE-DLM-
MECH-342
MR.
HARIKUMAR
DAELIM
(Construction)
VAF 2 MECH
Mechanical
(Equipment)
23-Sep-13 26-Sep-13 Open
PN: Daelim has started the PWHT since 12th September 2013 at TCC fab. facility #1 but until now
Hardness Testing has not been started yet. Contractor needs to arrange Hardness testing as soon as
possible to ensure that PWHT result is satisfactory.
Contractor: Noted. Action will be taken accordingly.
During inspection & monitoring activities at Operator Building, we found out the following: A) At
monitoring area and permit issue area, installation of electrical piping / electrical boxes are already
started, wherein the repair works for the perimeter RC wall are not yet finished. In this regards, please
expedite the repair works for the said structure, including touch-up for soffit beam and slab; B) at
sample preparation room and corridor, it has been observed that after cutting of concrete prior to
installation of electrical piping/junction bixes, we found out that some "block mesh" truss type was
affected due to preparation works done by the electrical discipline. COntractor was advised to take
corrective and prventive action concerning this issue, in which proper coordination between other
discipline involved and not to encounter problems for the future.
Subcontractor: This LBE is for Sendan. Amana will repair all damaged block mesh and will install
wire mesh along connection of two blocks but Amana will claim additional payment. Amana is
waiting to get the handing over from sendan to start repair work. Once sendan wil hand over the
building amana will start rectification work. Amana can rectify work on 28 OCT.2013.
During routine site visit at Substation G-1121, it was observed that Contractor installed panel
without information of Company and building was not ready and panel not reserved. Air
conditioner not on, room temperature not maintained, building full of dust. These violates project
specification A554-E-103-CM-GEN-PLN-002.
Subcontractor: The action has been taken. Sendan is maintaining the room temperature
as per project Standard requirements, temperature gauge is already requested for
continuous monitoring the temperature. Vaccume cleaner already provided to control the
accumulation of dust.
Contractor: Panels are now installed as per procedure and preservation are now
maintained such as temperature and humidity requirements.
PN: Prior to PWHT, Contractor/Subcontractor shall ensure the following:
1. All welding and repairs shall be performed before PWHT. 2. PWHT shall be performed prior to
Hydrotest. 3. Ensure that all rusted paints are removed and proper supports are provided. 4. PWHT
charts should be marked prior to PWHT with identification number of welds and start time. 5. All
machined surfaces such as flange faces, threaded bolts, threads, etc. shall be protected from oxidation
during the Heat Treatment bu coating with deoxaliminate or other suitable material. 6. PWHT shall be
perfromed before NDE is conducted. 7. After PWHT, all TCs shall be removed and attachment area
shall be ground smooth to clean and sound metal.
PN: During the material receiving inspection for Lateral Reducing Tee 14" x 10" Sch XS x Sch 20 ASTM
358 304 43 (Tag No. EPI-205 RFI No. DLM-MFC-BASSI-PIP-011) it was found that material offered for
inspection without MTC. Ref. (per Sch. "Q" Att. III Para. 2.3 )
Contractor: Noted and action will be taken. All the materials will be offered for inspection after
MTC.
The anchor bolt at flare area pipe rack with 36mm diameters (M36) was cut since it was hit by the
equipment. The 2nd anchor bolt was also hit but was not cut. The 2nd anchor bolt shall be verified if still
fit to be used since it tilted from its original position. Contractor shall provide method statement for repair
as removal of the foundation and the replacement.
Subcontractor: Amana submitted Method Statement of repair and waiting for approval before
starting of repair.
It was observed that during finishing stage of concrete foundation slabs and paving, the Contractor do
not comply with the requirements of SMIC-Q-1015-A2 regarding planeness of surface with a 3000mm
straight edge applied at not less than two different angles. This requirement prior to apply broom finish
shall be monitored by COntractor QC. Please check usual concrete surface finish.
Subcontractor: Advised to construction & concrete pouring team to use always 3000mm straight
aluninum bar and two different angles. Qc inspector and surveyor to recheck slope level and
finishing,
During routine inspection for insulation activities at Debutanizer Reboiler (D-1977) reactor (R-2025) &
primary demethanizer (T-2110), it has been noticed that the insulation Inspector of Globar Suhaimi is not
available at site during insulation activities. This is violation against Schedule "Q".
Subcontractor: Global Suhaimi removed the previous QC Inspector from site and replaced with
new QC Inspector.
PN: During weld visual inspection of welded joints (FW1) for line CP-151123-10 HC 87 welder ID was
missing from the weld information box written on the pipe shall write there IDs or welder no. on the
respective joint they have welded. Ref. A554-E-103-QA-GEN-PRO-056, 8.8 (In-Process Weld
Inspection).
Contractor: Noted. Action will be taken.
Found that SS pipe spools of line class HC-61, HC-70, transferred from AYTB Fab.shop to TCC #1 and
are painted already without RFI and Inspection. It is hold point activity for Contractor and Witness for
Company. Corrective action & Preventive measures are required. Ref. SMITP-F-001-04, Rev. 4 activity
#4.7. PMI of above mentioned painted spools is also balance.
Contractor: PMI has been conducted as per RFI. All the spools were documented. RFI was
issued for spools release for blasting. Strict actions have been taken.
Material Receiving inspection of the flare runner at laydown yard shown the
supports welded to the runners for attaching heat shield found bended.
This can damage the welded portion and also may have taken place during
transportation mishandled the equipment. The supplier of this equipment is
ZEECO Industries, Korea. P.O. No. is 100532-14-216-001- A01, violation
as per Ref. A554-E-103-QA-GEN-PRO-035, Para. 8.2.1, 8.1.11, 8.1.12.
Contractor: The bended material already repaired and installed at
site.
During surveillance in the North-south pipe rack beveled ends of the joints and fittings found exposed to
the atmosphere for long days, as no grinded bevel or open pipes and fittings to be exposed to the
atmosphere without covering which can corrode or damage it, hence, to be covered. Ref. A554-E-103-
QA-GEN-PRO-059, rev.0, para. 9.3, 7.3, A554-E-103-QA-GEN-PRO-056, para. 10.7.8, 11.1.1, 16.1,
17.1.2.
Subcontractor: Noted. Action will be taken.End opening of the pipes at pipe rack, all pipe spools
and flange faces protection have been done. TCC piping inspectors are checking on daily basis
and reporting to QC Supervisor.
During surveillance inspection at furnace F-1160, Radiant crossover piping
installed on position observed that numerous discrepancies on pass 1 and
2 header lines. Example: Inclination of levelness, plumbness, dimensional
discrepancy on pipe supports and sidtoration due to improper fabrication
method etc. by Vendor JNK, Korea. Daelim/ARCC shall verify occured
discrepancy and propose corrective action in accordance with appropriate
Engineering Method.
Page 32 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
343
MR. AMIN DAELIM PN MECH Piping 24-Sep-13 27-Sep-13 08-Oct-13 29-Sep-13 Closed
LBE-DLM-MECH-
344
LBE-ARCC-MECH-
345
MR. NOOR ARCC VAF MECH Refractory 24-Sep-13 27-Sep-13 08-Oct-13 13-Oct-13 Closed
10
LBE-DLM-
MECH-346
MR.
HARIKUMAR
DAELIM
(Enginnering)
VAF 2 MECH
Mechanical
(Equipment)
25-Sep-13 28-Sep-13 09-Oct-13 Open
LBE-DLM-INST-065 MR. SHABIRUL DAELIM PN INST Instrumentation 26-Sep-13 29-Sep-13 10-Oct-13 08-Oct-13 Closed
11
LBE-DLM-
MECH-347
MR. SAYED
DAELIM
(Procurement)
VAF 2 MECH Material 28-Sep-13 01-Oct-13 12-Oct-13 Verified 20-Jul-14 Closed
LBE-TCC-MECH-
348
MR. AMIN TCC VAF MECH Preservation 29-Sep-13 02-Oct-13 13-Oct-13 11-Oct-13 Closed
LBE-DLM-MECH-
349
MR. AMIN DAELIM VAF MECH Quality Records 29-Sep-13 02-Oct-13 13-Oct-13 29-Sep-13 Closed
LBE-TCC-MECH-
350
MR. AMIN TCC VAF MECH Piping 30-Sep-13 03-Oct-13 14-Oct-13 Closed 10-Oct-13 Closed
LBE-AMA-CIVIL-178 MR. JERRY AMA VAF 1 CIVIL Civil 01-Oct-13 04-Oct-13 15-Oct-13
On-going.
27/10/13
28-Apr-14 Closed
LBE-AMA-CIVIL-179 MR. JERRY AMA VAF 1 CIVIL Civil 01-Oct-13 04-Oct-13 15-Oct-13 28-Apr-14 Closed
LBE-DLM-MECH-
351
MR. AMIN DAELIM VAF MECH Piping 01-Oct-13 04-Oct-13 15-Oct-13 10-Oct-13 Closed
LBE-KCC-CIVIL-180 MR. JERRY KCC VAF CIVIL Civil 02-Oct-13 05-Oct-13 16-Oct-13 7-Oct-13 Closed
LBE-AMA-CIVIL-181 MR. GERALD AMA PN CIVIL Civil 02-Oct-13 05-Oct-13 16-Oct-13 12-Oct-13 Closed
Observed several locations Anchor bolt holes were extended during
equipment installation due to misalignment/dimensional discrepancy with
fabrication/GA drawing and trimmed hole are extended as specifying
tolerance limit by Vendor. The anchor bolts hole shall not be
extended/reduced in diameter nor offset to facilitate modification of the
mounting plate to facilitiate alignment is not permitted unless authorized by
designated vendor. Violation of A554-E-103-QA-GEN-PLN-056. Trimmed
area shall be coated with paints material.specifications.
Contractor: As per discussion with Construction Mech.
Superintendent Mr. E.M. Choi, Engineering Query shall be released in
support for the bolt hole enlargement. (Field Engineering Personnel
Mr. Chan Ho Park will be available on the 2nd of November 2013)
Target date: 1st week of November.
-> Received approval from Company on Daelim's corrective action. So
this shall be closed.
During material receiving inspection at Daelim yard, it is observed that 285
nos. of CS pipe ASTM A103 Gr. B Galvanized (1 1/2 x Sch. 80 size)
received with no marking of material specification on the pipe. RFI no. MFC-
DLM-GERAB-PIP-003, P.O. No. 100532-42-P01-008-A01, Supplier: Gerab
National Enterprise. This is violation of schedule "Q" Attachment 4, Para.
4.4, which stated that traceability shall be maintained on equipment,
materials, part and components, as specified in the Company Standard and
Manufacturer's specification.
Contractor: All the materials without tag were rejected. It was shifted
to quarantine area. It will be returned and will be replaced soon.
Preservation, storage & handling of SS Piping material at Fab. Facility-1 (TCC) may cause damages on
Elbows and Flanges. Also found some SS material which does not belonged to MFC project at the same
location. Material shall be re-inspected for mechanical damages after corrective action. Corrective
action with Preventive measures is required. Violation Ref: RT6-1GS Para. 2.15, 2.16, 2.19.
Contractor: Some materials found at Laydown shop #1 was removed from the location. All SS
piping materials were segregated; proper protection has been provided. Preservation corrective
action were taken at shop #1. No damage found during re-inspection.
Found that Daelim doesn't have proper control of weld map/number changing on IFC drawings.
Subcontractor/Contractor Construction team is overwriting on the approved IFC drawings without getting
signed by Daelim Engineering. Although found that JCR (Joint Change Request) format being used is
not a part of Daelim internal quality system. Construction representative is making changes in JCR, IFC
Drawings whenever they like. Some JCRs showing signature place for Daelim Field Engineering and
from some have been deleted. Quick corrective action with preventive measures is required.
Contractor: Weld joints are indicated in spool drawing generated in Daelim's own program. If
there is a joint change request from Contractor or subcon, the joint change request to be
confirmed/signed by Daelim Construction representative. Weld joint is not related to Engineering
works so Daelim's field engineering does not involve weld joint change.
Found discrepancy (Dull Sound) at bullnose area during final hammer test inspection of applicant of
Castable/Gunning Refractory as per RTSAES-N-110-01 at F-1170. Marked and identified area shall be
rectified and offered for re-inspection by Company.
Contractor: Dull sound area has been chipped and applied new refractory and was accepted by
Sadara as per RTSAES-N-110-01
PN: During surveillance at Daelim's laydown yard, it was found out that Subcontractor is lifting at the
wrong place at drum and it might cause the damage of the Instrument cable. Contractor is advised not to
repeat the same mistake during the cable drum lifting and transportation. This has been a repeated
violation on LBE-044.
Subcontractor: Asyad material in-charge was reprimanded. Written final warning has been
issued and received by Asyad material-in-charge. Both agreed that if repeated , appropriate
disciplinary action will be undertatken. The written final warning was also served to the "Rigger"
who facilitated the lifting.
PN: It is advised to Daelim Quality team to ensure that thirdt parties coming for MFC, NDE, PMI, PWHT
and Hardness testing are using only calibrated tools and quipment including calibration blocks with their
certification.
PN: Found that some sort of Daelim piping materials are quarantined at Daelim lay-down yard due to
mechanical damages and ovality. Company Construction approved Mecthod Statement only for removal
of damaged parts from the entire length at least about Quarantined Fittings and Oval Pipes still there is
no action plan from Daelim. However, quality Daelim needs to make sure that after removal of damaged
portion, rejected or quarantined material shall be used only after acceptance of material receiving
inspection by Company.
During JCC review found welder JCC #1513 (TCC-384) approved by third party and Daelim QC for
dia. CS Pipe qualification without meeting the standard requirements of ASME IX Para. No. QW-302.2.
For dia qualification minimum 4 test coupons or (min. 6" weld length) are required to be tested
coupon accepted by Daelim and third party (NDTCCS). RT report for said welder shows 3 test coupons
acceptance instead of one welded by him. Also WQT RF Films are not being reviewed by Daelim and
Sadara NDT Level III. Daelim must provide justification and corrective action for above discrepancies
with preventive measures.
Contractor: A violation may be recorded when there is any findings of deviation from the code or
specification but TCC has conducted WQT with Sadara approved Third party in accordance with
code and standard (ASME sec IX) required for minimum of 150mm weld made by each welders.
Here, is it attained with 1/2" 60X5 Sch. 3 test coupon and its WQT & RT report has been
submitted to Company. Therefore, this WQT is complying with the application code and standard.
Moreover, in the WQT visual inspection report showing the welder is visually accept or not,
hence, Contractor emphasizes to Company that this shall not be considered as a violation.
With reference to RFI No. MFC-DLM-KCC-CI-4638, the slope of the requested area does not comply
with the requirements of Civil Project Instructions document no. A554-T-103-CV-SPC-BOD-001, clause
3.2, the RFI was rejected.
Subcontractor:with reference to the RFI no #MFC-DLM-KCC-CL-4638-0A, all ready accepted
PN: During surveillance inspection at Cooling Tower Basin along "RC Wall", found out some locations or
portions are ready for injection but the materials intended for the area were not available at site suc as
"Packer" for injection, concresive 2020. Contractor is advised to expedite delivery of said materials in
order not to dealy the schedule of repair works. Corrective actions should be taken by Contractor.
Subcontractor: Amana already issued Purchased Order but unfortunately Supplier has no
available materials.
TCC reply on Sadara LBE #277 and commented on RFIs to perform passivation on Heat sensitized
discolored (bluish) joints. Instead to perform passivation as agreed, TCC grinded some SS weld joints
inside the area around the root by inappropriate stone grinder and hide the discoloration band. The
grinded portion can get rust easily like Heat sensitized joints. Daelim quality team must ensure proper
corrective action with preventive measures.
Contractor: The discoloration of the SS spool joints were removed by buffing and wire brushed.
The joint inspections by Company Welding Engineer along with Company Inspector is done and
found satisfactory.
In addition to LBE No. 040 (clsoed) to reflect on this Logbook, there are several locations where the top
surfaces of concrete foundations and pavings have footmarks and the finish is not in accordance with
the requirements. Contractor/Subcontractor to provide schedule of repair and mock-up to meet the
requirements mentioned in the logbook entry no. 176.
Subcontractor: Amana proposed to chip 5 cm for whole area and re-concrete by 4000 Psi
concrete to attain same color and same finish of existing paving.
With reference to LBE # 127, there are several locations at site where the TPER's protection has not
been completed. Contractor shall ensure that protection of TPER is undertaken in accordance with doc.
no. A554-E-PRG-CV-SPC-E20-047, Rev.1.
Subcontractor: Amana & KCC is ongoing making protection board for all exposed TPER.
Page 33 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
352
MR. KHAN DAELIM VAF 2 MECH Engineering 02-Oct-13 05-Oct-13 31-Oct-13 04-Mar-14 Closed
LBE-ARCC-MECH-
353
MR. KHAN ARCC VAF MECH Material 02-Oct-13 05-Oct-13 16-Oct-13 27-Oct-13 Closed
LBE-ARCC-MECH-
354
MR. HARIKUMAR ARCC VAF 2 MECH Piping 05-Oct-13 08-Oct-13 19-Oct-13 23-Mar-14 Closed
LBE-ARCC-MECH-
355
MR. KHAN ARCC VAF 2 MECH Piping 06-Oct-13 09-Oct-13 13-Oct-13 04-Mar-14 Closed
LBE-DLM-MECH-
005
MR. SAYED DAELIM VAF 1 MECH Preservation 06-Oct-13 09-Oct-13 30-Mar-14 19-Apr-14 Closed
LBE-SEN-ELECT-
066
MR. MARK SENDAN VAF 1 ELECT Electrical 07-Oct-13 10-Oct-13 21-Oct-13 26-Jan-14 Closed
LBE-KCC-MECH-
356
MR. NOOR KCC VAF 2 MECH UG-RTR 07-Oct-13 10-Oct-13 21-Oct-13 12-Feb-14 Closed
LBE-PCMC-MECH-
357
MR. NASSAR PCMC VAF 2 MECH
Coating/
Painting
07-Oct-13 10-Oct-13 21-Oct-13 16-Feb-14 Closed
LBE-GLOBAL-
MECH-358
MR. NASSAR GLOBAL VAF 2 MECH Insulation 08-Oct-13 11-Oct-13 22-Oct-13 23-Feb-14 Closed
11
LBE-DLM-
MECH-359
MR. AMIN
DAELIM
(Enginnering)
VAF 2 MECH Engineering 09-Oct-13 12-Oct-13 17-May-14
Company
still awaits
reply from
Constractor
Mar.2, 2014
Open
LBE-DLM-MECH-
360
MR. AMIN DAELIM VAF 2 MECH Piping 09-Oct-13 12-Oct-13 26-Oct-13
Submit the
welder
performance
report & return
the revoked
20-Apr-14 Closed
LBE-GLOBAL-
MECH-361
MR. NASSAR GLOBAL VAF 2 MECH Quality Management 10-Oct-13 13-Oct-13 24-Oct-13 18-Feb-14 Closed
LBE-DLM-INST-067 MR. PERVEZ DAELIM PN INST Material 13-Oct-13 16-Oct-13 27-Oct-13 14-Dec-13 Closed
LBE-TCC-MECH-
363
Mechanical
(Equipment)
13-Oct-13 16-Oct-13 27-Oct-13 23-Mar-14 Closed
PN: During surveillance and monitoring inspection at Operator Building, it was noticed that some
materials scattered such as block mesh, CMU & cement located near at the north & west area which
these materials are spare used. Contractor/Subcontractor is advised to remove/transfer to the
warehouse for proper housekeeping and handling.
Subcontractor: Amana already start removing and housekeeping the said area.
Amana already removing material(14/Oct/2013)
During routine inspection at ARCC fab.shop, it was observed that the listed reference drawing for
fabricated lateral fitting in the BOM of IFC drawing (1016103BEA-P-124315-01) is not available with
Daelim Engineering. Daelim provided another drawing for fabricated lateral fitting which is not approved
and the material given is not matching with control material stamped. The material given in the drawing
is ASTM A240 GR304H whereas control material is ASTM A358 304H.
Contractor: During material receiving inspection, it was made clear that SS ASTMA 358 GR
304H cl3 were equivalent to A240TP304H. The materials were inspected and after acceptance, it
was issued.
During routine inspection at ARCC fab.shop, it was observed that SS material for MFC project is stored
along with CS material for other project. This is a clear violation against RT-6-ICS & Project requirement.
Subcontractor: Re-arrangement of stainless steel spools was carried out on staging/storage area
of Sadara MFC spools with proper distance from storage area of other materials.
During surveillance, it has been noticed that cold insulation activity has been carried out for Dryer Feed
KO Drum (D-1718) during bad weather (Sand storm). Also QC Inspector & crew Supervisor not available
at that time. This is clear violation against Sadara Standard & Schedule "Q".
Found that Isometric IFC Drawings of Daelim are showing one of the notes
in the left bottom corner for "FFW" (indicates Field Fir Weld, Pipe at this
joint shall be fabricated 150mm longer) but actually on drawings it is not
marked on any required locations. Discrepancy also enquired from Daelim
Quality & Engineering Departments and Contractor also acknowledged. It
is a violation of G4D-0140-10. Daelim Quality must ensure FFW markings
on IFC drawings to avoid any discrepancy while connecting pipe joints to
the rotating equipment. Some Ref. Dwg. Nos. are 054703-02, 051703-02 &
131109-01.
Contractor: Daelim applies the following method to field welding
around rotating equipment. 1. The tack weld requirement in G4D-0140-
10 at flange adjacent to rotary equipment nozzle is applied for both
suction and discharge nozzle. 2. In case the fabricated spool length is
not enough according to site condition, then Daelim judges whether it
can be managed with specified FW or not. If it is judged that could not
be managed then the pipe is to be cut and welded with additional
longer pipe piece. 3. To make sure not to cause strain on the flange
conncetion to rotary equipment nuzzle, Daelim checks the flange
position and parallel condition nozzle without bolting after pipe piece
installation is completed. 4. Daelim ensures the pipe strain on the
rotating equipment nozzle does not exceed the limit of coupling
movement specified in G4D-0140-10 and G5S-5321-02. 5. If any
heating repair is conducted without prior written approval, Daelim re-
fabricates the certain spool.
Found that weld repair rates of ARCC, TCC, AYTB & PCMC have been increased more than 5% joint
basis, violating Scheduule "Q" Attch. IV, Para. 3.9. Daelim Quality must provide the root cause analysis,
corrective action and preventive measures as soon as possible. Rejection rate weekly & cumulative
found excessive between 6% to 13%.
Contractor: The welder whoever uses the limit of the allowable repair rate had been revoked and
more precautions will be taken to control the weld repair.
During routine site inspection, it was noticed that the Contractor installed type DB-120 PVC sleeve at
Operator Building which is a violation as per G7D-0311-03 section 2.2, in which, type EB shall be used
to be encased in concrete.
Subcontractor: It is investigated and Construction agree to replace the conduit sleeve DB-120 to
EB type sleeve as project per standard requirements.
During inspection, it is found that the Contractor/Subcontractor carried out U/G Fire Water Line joint Fit-
up and assembly. Contractor did not follow follow the drawing. Contractor Quality team must ensure that
work is carried out as per approved & issued for construction drawings. Corrective action & preventive
measure are required. Reference: Drawing No. FW-071005-03, Rev. 02, RFI No. MFC-DLM-KCC-UG-
RTR-1815.
Subcontractor: AS-Built drawing was already provided. In case and in order to carry out
inspection, Subcontractor shall sue RED line drawing for Company inspection prior to As-
Build drawing.
It has been obsereved during bad weather (high wind & sand storm), liquid Coating activities has carried
out at PCMC blasting/coating facility for Pipes & spools.
Subcontractor: Work was stopped immidiately and affected areas were rectified and inspection
was done and accepted against RFI No. PCMC-M-0109.
Observed that ARCC welder W-AR-1828 performed Welding (Tacking) activities on Furnace F-1240.
Radiant coil to primer TLE without appropriate qualification. On subject materials (35-45 Ni-Cu),
violation: Sch. "Q" and Project Specification recommendation or RT8S-6500-1. Contrcator shall
investigate the root cause of the subject descripancy and implement appropriate corrective action.
Subcontractor: Qualification/JCC of Welder W-AR-1828 was revoked and presently was
removed from Sadara MFC project.
During routine inspection at ARCC fabrication shop, two welders were found welding more than the
maximum allowable weld bead width for welds made with GTAW process (3 times (3x) the core wire or
filler metal dia) as per RT-85-6500-01 & approved WPS. MOreover, one of the welder ACRR-613 was
along two filler wire during production welding instead of one.
Contractor: Action shall be taken regarding the issue of excess weaving: Weld layer. ARCC QC
shall remove the weld layer and again re-weld it in accordance with the approved WPS. *613
welder should be removed from Sadara project.
During surveillance inspection at Daelim laydown, it was observed that FRP Spool and fittings
store without protection of end cores due to this sand accumulate inside the spool and fittings.
This is violation of G85-6015-04 requirement stated in 3.2.1.
Pipe Material at laydown such as FRP Spools, Carbon Steel and Fittings
During routine inspection at Equipment D-1827, D-1917, E-2026, R-2025, R-2030 & R-2035, it has been
noticed that the insulation Inspector of Global Suhaimi is not available at site during inspection
activities. This is violation against schedule "Q".
Subcontractor: The former QC Inspector assigned in the site/area has been removed from
site and placed new QC to continue the work assignment.
PN: During Material Receiving inspection of cable tray, it was found that Contractor released few 90
horizontal bend without inspection of material receiving of tray, this violates Schedule "Q".
Thru misccommunication of material inspector and material department the said cable tray
was released and it was noticed also that FMIR not yet signed. Contractor shall raise RFI
and rest assured that cable trays are ingood condition.
PN: During the pre-welding inspection at the Equipment C2 Splitter (12220), the square washer at the
Anchor Bolts found grinded/removed of cap to 10mm length which were projection out of the bottom
compression . Any deviation or modification, shall be approved by Engineering department of SME of
both Contractor and Sadara (client). Ref: RFI-WE-0273 DRawing No. 72220-103-90003-44-230.
Subcontractor: Noted. Construction group was informed regarding the issue.
Page 34 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
364
MR. KURIAN TCC PN 2 MECH Engineering 13-Oct-13 16-Oct-13 27-Oct-13 19-Feb-14 Closed
LBE-TCC-MECH-
365
MR. KURIAN TCC VAF 2 MECH Structural 13-Oct-13 16-Oct-13 27-Oct-13
Engineering
clarification note
to be attached. 26-May-14 Closed
12
LBE-DLM-
MECH-367
MR.
HARIKUMAR
DAELIM
(Construction)
VAF 2 MECH
Mechanical
(Equipment)
14-Oct-13 17-Oct-13 22-Oct-13 Open
LBE-AMA-CIVIL-183 MR. JERRY AMA VAF CIVIL Civil 14-Oct-13 17-Oct-13 28-Oct-13 31-Dec-13 Closed
14
LBE-DLM-
MECH-366
MR. SAYED
DAELIM
(Procurement)
VAF 2 MECH Material 14-Oct-13 17-Oct-13 20-Jul-14 Verified 20-Jul-14 Closed
LBE-SEN-ELECT-
068
MR. MARK SENDAN VAF ELECT Electrical 16-Oct-13 19-Oct-13 30-Oct-13 10-Nov-13 Closed
LBE-TCC-MECH-
368
MR. SAYED TCC VAF 2 MECH Mechanical 20-Oct-13 23-Oct-13 03-Nov-13 20-Feb-14 Closed
LBE-AMA-CIVIL-185 MR. JERRY AMA VAF 1 CIVIL Civil 20-Oct-13 23-Oct-13 03-Nov-13
On-going., to be
closed upon
implementation.
27/10/13.
26-Mar-14 Closed
LBE-AMA-CIVIL-186 MR. GERALD AMA PN CIVIL Civil 20-Oct-13 23-Oct-13 03-Nov-13 24-Oct-13 Closed
13
LBE-DLM-
MECH-369
MR. KURIAN
DAELIM
(Procurement)
VAF 2 MECH
Mechanical
(Equipment)
21-Oct-13 24-Oct-13 04-Nov-13 Open
LBE-DLM-MECH-
370
MR. KURIAN DAELIM VAF MECH
Mechanical
(Equipment)
21-Oct-13 24-Oct-13 04-Nov-13 17-Nov-13 Closed
LBE-TCC-MECH-
371
MR. SAYED TCC VAF 2 MECH Piping 21-Oct-13 24-Oct-13 04-Nov-13 20-Feb-14 Closed
LBE-AYTB/PCMC-
MECH-372
MR. KHAN AYTB/PCMC VAF MECH Quality Management 21-Oct-13 24-Oct-13 04-Nov-13 06-Jan-14 Closed
LBE-AYTB-MECH-
373
MR. AMIN AYTB PN MECH Piping 21-Oct-13 24-Oct-13 04-Nov-13 27-Nov-13 Closed
LBE-DLM-ELECT-
069
MR. MARK DAELIM VAF ELECT Electrical 22-Oct-13 25-Oct-13 05-Nov-13 10-Nov-13 Closed
LBE-ASYAD-INST-
070
MR. PERVEZ ASYAD VAF 1 INST Mechanical 22-Oct-13 25-Oct-13 05-Nov-13 25-Jan-14 Closed
During surveillance work at Flare Area Pipe rack, it was discovered that two anchor bolts were cut in one
foundation due to equipment working in the area doing backfilling works hit the foundation. This is a
second incident where anchor bolts were cut due to equipment being near the foundation . It was
previously discussed during the QC meeting that heavy equipment should not work near foundation to
avoid damage to foundation. This is a recurring incident and Contractor shall implement proactive action
to avoid recurrence, see LBE # 177.
Subcontractor: Advised to Contruction to use or install hard barricade to avoid accident in the
future. Amana will submit Method of Statement for approval and will start repairing work as per
approved method statement.
PN: During inspection at diesel generator building along column C & C2 (2nd lift) and beam. We found
out that some installed formworks are not acceptable "old formworks". In this regards, Contractor was
advised to remove & replace with new one for good surface finish after concerning was done or
implemented.
Subcontractor: Advised to Constrruction and Civil QC Inspector to check formworks condition,
used plywood are acceptable or not if any damage plywood used, immediately replace with new
one.(see attched picture)
During Material Receiving inspection, it was again found that 1/2" CS
ASTM A106 GR Galvanized pipes without material identification mark on
the pipe or tag on the bundle. RFI No. GERAB-PIP-004 P.O. No. LPO-
100532-42-POI-008-A01, Supplier GERAB National Enterprises. This is
violation of Sch. "Q", attachment 4 Para. 4.4.
Verfied.
PN: A gap of 20mm and 25mm found on horizontal beams at C13 8 C10, Rf. Dwg. (2676-083)
Structural) Engineering solution is required.
During Fit-up inspection for Structural Steel Air Cooler support near N-S cable rack Suuper (G013) was
tack welded to the embedded plate with a gap of 15mm, the embedded plate was not positioned in
"Straight" to the beam which cause the gap. There should not be gap in between filled weld member
(plate). Ref. B31-3,3288.5.2, 328.5.2A fig.) Ref. Dwg. A554-E-103-CV-DWG-S20-641, Rev. 3.
Observed that Surface Condensater (CG Compressor #2301) pressure
parts. (Vendor clossed part) were open for easy installation which is not
designed for Contractor activities. Daelim/TCC team is not authorized to
open/relocate the PCE without proper approval, elsewhere it has be to be
designed for further Constraction. Violation of Sch. "Q" and ITP and
required corrective action.
Contractor: Noted: Contractor Engineering Dept. will issue
documents to primarily support this aactivity. Target date: 1st week of
Nov. 2013.
During surviellance inspection at TCC site area, it was found that Welders (ID Nos. 213 & 394) were
performing Welding of 36" pipe joint with cold low hydrogen eleectrodes. This is violation of Sadara
Specification RT8S-6500-03, Att.1. Submit warning letter to Company.
Subcontractor: Tool box meeting was conducted to welders on 22nd October 2013, regarding
the issue. Welder Nos. 213 & 394 were issued with warning letter for said violation.
RT was carried out at AYTB & PCMC fabrication shops during Eid Holidays by NDT Service provider
"RAWABI" non of the procedures & NDT technicians are approved by Company. Also, prior to start of
any activity, Contractor shall initiate Kick-Off Meeting as per Sch. "Q" requirement.
PN: Found that SS pipe spools are not preserved/covered properly at AYTB Fab. shop and getting
environmental effects shich may cause corrossion. Also AYTB needs to improve storage arrangements
to avoid cross contamination. Contractor QC team must ensure quick correctve action with Preventive
measures. Ref. RT-6-1CS, Rev. 3, Para. 2.15, 2.19.9, 2.19.2.
Contractor: AYTB QCs & its Construction team were advised that all the SS Spools must be
protected. Action will be taken.
PN: During inspection at Cooling tower sum-pump area "external wall" (North side) along wall 6 & 8,
found out that filler board is already installed without conducting first DFT (second coat application) by
Third party. Contractor is advised to remove first the installed filler board and conduct DFT prior to re-
install said filler board.
Subcontractor: Advised to Construction that before starting installation of filler board,
coordination with QC Inspector has to be confirmed that coating thickness checking is done or
not. (see attached picture)
At surveillance, it is observed that Equipment E-2303 bottom side of the
supporting leg is not painted as per the required painting specs. Also this
part is corroded which may damage the metal support. This is the improper
following of painting spec. The equipment is supplied by Doosan
Engineering with P.O. No. 100532-13-231-001.
During surveillance, it's being observed that Equipment E2110 (Demethanizer reboiler) with incorrect
paint (different specs) on the equipment body which is wrong as per the drawing. Equipment is supplied
by Dossan Engineering.
During routine inspection, it was found out that the Contractor installed Fastener for expansion splice
plates without a Flat Washer and Self-Locking Nut which is a violation as per G7C-0324-01, Note 4.
During surveillance inspection at TCC site (near Dryer pipe rack), it was noticed that pipe spool
connected to Equipment (FL-2041, FL-1723 & E-2026) prior to Mechanical clearance (like flange face
inspection, etc.) This is violation against Company Procedure A554-E-103-QA-GEN-PRO-059, Rev. 3,
Para. 9.3.3.3.
Subcontractor: Noted. Action will be taken accordingly. RFI will be raised for flange face
inspection.
It was noticed that the backfilling of foundations at flare area is goin on without proper compaction and
moisture content of soil is not in accordance with RT2S-2200-01, Rev. 4, Para. 3.4.9. The subcontractor
is backfilling the area without compaction record of each foundation layer by layer since the foundations
were excavated individually. Contractor to provide record of compaction testing for each foundation
layer by layer.
Subcontractor: Advised to Construction that before preparing subgrade, remove 200mm top
loose soil and recompact below soil before layinf next layer. Amana will raise RFI for final layer
inspection prior to start gravel bedding.
During routine site inspection, it was found out that the Contractor already pulled and laid a cable to the
cable tray without final acceptance of the cable tray from the Company inspector which is a violation as
per approved ITP and schedule Q. Also, it was found out, in the inspection of the said cable tray,
several standard violations occured. First, the vertical interval support was measured with 3,000mm and
the maximum shall be 2440 mm as per 67C-0324-04 note 4. Secondly, there is no support before and
after vertical elbow fitting which is a violation as per 67C-0.24-04. And lastly, at expansion splice plate
During site surveillance, it was noticed that Contractor/Subcontractor installed Junction box on column
and not as per standard, instead of Bolt connector but was welded on beam. This is standard violation
of G-07C, 0326-64.
Contractor submit RFC to Company for clarification.
Company answered thru transmittal no. MFC-T-CJ-DS-IC-0560.
Page 35 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-INST-071 MR. PERVEZ DAELIM PN 1 INST Instrumentation 22-Oct-13 25-Oct-13 05-Nov-13 25-Jan-14 Closed
LBE-DLM-MECH-
374
MR. AMIN DAELIM PN MECH Preservation 22-Oct-13 25-Oct-13 05-Nov-13 27-Nov-13 Closed
LBE-SEN-
TELE-001
MR. RODNEY SENDAN VAF 1 TELECOM Telecomunication 22-Oct-13 25-Oct-13 05-Nov-13 20-Jan-14 Closed
LBE-SEN-
TELE-002
MR. RODNEY SENDAN VAF 1 TELECOM Telecomunication 22-Oct-13 25-Oct-13 05-Nov-13 20-Jan-14 Closed
LBE-SEN-TELE-003 MR. RODNEY SENDAN VAF 1 TELECOM Telecomunication 22-Oct-13 25-Oct-13 05-Nov-13 01-Feb-14 Closed
16
LBE-DLM-
TELE-004
MR. RODNEY
DAELIM
(Enginnering)
PN 1 TELECOM
Telecommunica
tion
22-Oct-13 25-Oct-13 20-Feb-14 20-Jul-14 Closed
LBE-AMA-
TELE-005
MR. RODNEY AMA VAF 1 TELECOM Telecomunication 23-Oct-13 26-Oct-13 06-Nov-13 13-May-14 Closed
LBE-ARCC-MECH-
375
MR. KHAN ARCC VAF 2 MECH Piping 24-Oct-13 27-Oct-13 31-Jan-14 04-Mar-14 Closed
LBE-DLM-MECH-
376
MR. SAYED DAELIM PN 2 MECH Material 26-Oct-13 29-Oct-13 15-Feb-14 28-Feb-14 Closed
LBE-TCC-MECH-
377
MR. AMIN TCC PN MECH Piping 26-Oct-13 29-Oct-13 09-Nov-13 06-Jan-14 Closed
LBE-KCC-CIVIL-187 MR. JERRY KCC VAF CIVIL Civil 26-Oct-13 29-Oct-13 09-Nov-13 17-Nov-13 Closed
LBE-AMA-CIVIL-188 MR. GERALD AMA VAF CIVIL Civil 26-Oct-13 29-Oct-13 09-Nov-13 04-Nov-13 Closed
17
LBE-TCC-
MECH-378
MR. SAYED TCC VAF 2 MECH Piping 27-Oct-13 30-Oct-13 10-Nov-13 20-Jul-14 Verified 20-Jul-14 Closed
18
LBE-DLM-
MECH-379
MR. SAYED
DAELIM
(Procurement)
PN 2 MECH Material 27-Oct-13 30-Oct-13 03-Mar-14 Verified 20-Jul-14 Closed
LBE-PCMC-MECH-
380
MR. KURIAN PCMC PN 2 MECH Piping 27-Oct-13 30-Oct-13 10-Nov-13
Still Company
waiting for reply
Mar.2, 2014 21-Oct-13 Closed
LBE-TCC-MECH-
381
MR. NASSAR TCC VAF 2 MECH Preservation 27-Oct-13 30-Oct-13 10-Nov-13 16-Feb-14 Closed
LBE-GLOBAL-
MECH-382
MR. NASSAR GLOBAL VAF 2 MECH Preservation 27-Oct-13 30-Oct-13 10-Nov-13 16-Feb-14 Closed
At Bdlg. G-1122 Operator building the Contractor uses the outlet box as a oullbox. This in violation of RT-
SAES-T-916 Para. 4.8.18.2 states that in commentary note, the outlet box shall not sevre as a pull point.
Contractor shall comply as per specifications.
PN: At the TER of Bldg # G-1121, no enough space to install the 3/4"
backboard. And no 38mm clearance in between the conduits inside the
TER.
Contractor: Backboard was rectified to accommodate the sub-duct.
At building # G-1120 adjacent to pipe rack, communication conduits not using inproper end plugs. Advised to construction to replace the end cap with correct material. AMANA has already
replaced trge conduits end caps and work has been done and approved.
PN: Found that alloy & LTCS pipes are shifted to PCMC Fab. Shop which needs proper identification
and segregation arrangements to avoid mix-up and misuse of different materials. Ref. TR-6-1CS Para.
2.19.8.
Contractor: QC & Construction team were informed. Proper corrective action will be taken.
Observation noted.
Contractor installed different types of cable tray to be used to distribution system. Contractor is advised
to change rge cable tray with perforated tyoe and must be capable enough to house the numbers of IWA
for Buildings requirements. See IFC details for cable tray for telecoms. G1122 MFC/Daelim
Contractor shall replace the cable tray as per specifications and Company will be informed thru
RFI. Contractor already removed the installed cable ladder type tray. Once the aactivity started,
Company will be notified and also for the compliance of materials and installation. Contractor offer
the LBE to company for closure.
In building (G1122 Operator Bldg.) Contractor installed cable tray at the height of almost 4m and it is not
accessible because it will be on top of the HVAC ducting. This in violation of Sadara standard SAES-T-
916 stating that the cable tray must be accessible for maintenance and operation work force RT-SAES-T-
916 Para. 4.3.5.1 The cable tary height is should be 30cm from the ceiling as per RT-SAES-T-916
4.3.5.1
Contractor shall replace the cable tray as per specifications and Company will be informed thru
RFI. Contractor already removed the installed cable ladder type tray. Once the aactivity started,
Company will be notified and also for the compliance of materials and installation. Contractor offer
the LBE to company for closure.
PN: During line inspection for Material Receiving at Daelim Laydown yard, it was observed that Tray was
not preserved but kept together without separation. This violates NGM- VA2, & Schdule "Q".
Contractor QC informed already and coordinated as well to material department regarding
this PN. Company will be informed for action.
PN: During Material Receiving inspection at Daelim laydown, it was
observed that ASTM A106 GR B Pipe of different sizes received without
performing Hydrotest at Manufacturer and no marking of Hydrotest on
pipes. RFI No. MFC-DLM-TEN-PIP-021, Shipment No. MFC-05-1, P.O.
No. 100532-42-P01-006-A01. This is violation of ASTM A106, Para. 13.1 &
Para. 25, Table 4.
Contractor: Hydrotest reports were provided by Vendor. It was
submitted to Company.
PN: During Surveillance at PCMC (East-West) pipe rack pipes were found with open ends. This is a
violation as per A554-E-103-QA-GEN-PRO-059, Rev.2, Para. 7.3.5 G4S-4210-01, Para. 3.1.4.
Subcontractor: Noted, and PCMC shall take the preventive action, all the pipe ends are closed
and it is on-going.
It has been noticed that at Blasting/Painting facility (TCC-1), Spools are released to blasting/painting
facility before RT examination & PWHT on the welded joints. Those spools already blasted and painted.
Contractor: Noted and action will be taken. Four spools were shifted to painting workshop without
spool relaeasing inspection prior to blasting and painting. Painted spool was returned ti PWHT
area for complete balance activity. After completing PWHT, RFI will be attached. Daelim NCR #
040 for same issue.
With reference to RFI # MFC-DLM-KCC-CI-4770, the attached weekly materials test report is the same
as the weekly materials test report of the previous week. This is a violation of RT2S-3001-01 Table 1
regarding weekly testing if raw materials for concrete for the specified test. Contractor/Subcontractor to
review all materials test report prior to submission. Said RFI is rejected.
Contractor: Due to the delayed release of weekly test results from Third party laboratory,
subcontractor KCC attached same results from the previous week which was overlooked by
Contractor QC Inspector. RFI will be resubmitted with the Third party. Contractor asks for
Company consideration and assure the same will not happen again in the future.
During surveillance inspection at diesel generator building G1124 along newly casted concrete on roof
slab, it was noticed that insufficient water curing applciation has been done by subcontractor which
violates RT2S-3001-01, Section 9, Para. 9.1.2. Contractor is advised to take corrective action
concerning the issue.
Subcontractor: Already advised to Constructiona and already implemented that Amana had
extended the curing of water up to 8 days. Also make sure that curing of water on structure at 3
times per day to control the abrupt evaporation of water.
During Surveillance inspection at TCC site area, it was noticed that 19 nos.
of Fabricated pipes of 2", 3" & 4" found distorted after welding. (e.g. 3" -
N016103N2A-SSLD-075303-01 joint No. 2 & 4" -NO16103N2A-NL-041202-
01 joint no. 03). This is violation of ASME B31.3 Para. 321.1.1 which states
that "The design of piping and its supporting elements shall be directed
towards preventing excessive distribution or sag in the pipe.
Noted and action will be taken. Some of deffective weld joints are
rectified and found acceptable. Work is on-going.
During routine inspection at ARCC Fab. Shop, it was observed that PMI has not been performed on weld
joints for line class PU74 prior to PWHT, 12 joints have been not treated without performing PMI. As per
Sadara requirement (RT8S-4001-61) PMI shall be conducted before any PWHT.
Contractor: Issue has been notified to ARCC and PMI will be contacted before PWHT.
PN: During Material Receiving inspection at Daelim laydown, it was found that the Gasket offered for
inspection without color code. Approximately 30,000 Metallic Gasket without color code. This is violation
against Sadara Specs G4S-3240-60 and Contractor Procedure. A554-E-103-QA-GEN-PRO-059.
PN: Found mishandled released pipe spools for site at TCC Fabrication Facility #1. Pain is damaged on
different locations of the spools by rigging team and transferring spools to site without involvement of
TCC & Daelim Quality. It is also happened because spools were not transferred to site on the same date
when inspected. Also trailer driver was not having any kind of document to handover to site people like
spool release report signed by Quality.
Noted and action will be taken. Tool box meeting has been conducted with riggers for
proper use of lifting tools and wood packing on trailer during shifting of pipe spools to MFC
site.
During normal inspection at MFC site, it was noticed that Insulation on daddle supports for Equipment T-
1910, T-1510 & T-1820 have not been completed yet and those areas did not protect properly against
weather condition (sandstorm, rain, humidity, fog, etc) which leads to insulation damage.
Subcontractor: Subcontractor already covered all saddle support by venture clad and complete
it.
Page 36 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
383
MR. AMIN DAELIM PN 2 MECH Quality Records 27-Oct-13 30-Oct-13 23-Mar-14 Closed
20
LBE-ARCC-MECH-
384
MR. HARIKUMAR ARCC VAF 2 MECH Piping 27-Oct-13 30-Oct-13 10-Nov-13 14-Jul-14 Closed
LBE-TCC-MECH-
385
MR. AMIN TCC VAF MECH Piping 27-Oct-13 30-Oct-13 10-Nov-13 06-Jan-14 Closed
LBE-DLM-ELECT-
006
MR. PERVEZ DAELIM VAF 1 ELECT Preservation 30-Oct-13 02-Nov-13 13-Nov-13
Company:
According to
Contractor
response, it's not
clear regarding
Preservation
Plan, Contractor
has to follow as
per LBE or has to
provide
19-Nov-13 Closed
LBE-DLM/KCC-
MECH-386
MR. NOOR DAELIM/KCC VAF MECH UG-RTR 03-Nov-13 06-Nov-13 17-Nov-13 25-Nov-13 Closed
LBE-DLM-MECH-
387
MR. AMIN DAELIM VAF MECH Quality Records 03-Nov-13 06-Nov-13 17-Nov-13 06-Jan-14 Closed
LBE-AMA-CIVIL-189 MR. JERRY AMA VAF CIVIL Quality Management 03-Nov-13 06-Nov-13 17-Nov-13 16-Dec-13 Closed
LBE-DLM-ELECT-
007
MR. MARK DAELIM PN 1 ELECT Preservation 03-Nov-13 06-Nov-13 17-Nov-13 Closed 19-Nov-13 Closed
LBE-DLM-MECH-
388
MR. AMIN DAELIM VAF MECH Preservation 04-Nov-13 07-Nov-13 18-Nov-13 28-Nov-13 Closed
LBE-AMA-CIVIL-190 MR. JERRY AMA VAF 1 CIVIL Civil 04-Nov-13 07-Nov-13 18-Nov-13 Closed
LBE-DLM-CIVIL-191 MR. JERRY DAELIM VAF CIVIL Civil 04-Nov-13 07-Nov-13 18-Nov-13 14-Dec-13 Closed
19
LBE-ARCC-
INST-072
MR. PERVEZ ARCC VAF 1 INST Instrumentation 05-Nov-13 08-Nov-13 19-Nov-13 16-Jul-14 Closed
LBE-PCMC-
MECH-389
MR. KHAN PCMC VAF MECH Piping 06-Nov-13 09-Nov-13 20-Nov-13 02-Jan-13 Closed
LBE-ASYAD-INST-
073
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 07-Nov-13 10-Nov-13 11-Nov-13 31-Mar-14 Closed
LBE-ASYAD-INST-
074
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 07-Nov-13 10-Nov-13 11-Nov-13 31-Mar-14 Closed
LBE-ASYAD-INST-
075
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 07-Nov-13 10-Nov-13 17-Nov-13 08-Apr-14 Closed
LBE-TCC-
MECH-390
MR. KURIAN TCC VAF 2 MECH Piping 07-Nov-13 10-Nov-13 21-Nov-13 28-May-14 Closed
Found that Daelim Quality not revising and resubmitting the qulaity documents like QCP of welding
activities and consumable control procedure & ITP for Welding of On Plot Piping whose dates are
overdue since March, May 2013. Severally instructed but still noaction carried out. It is a violation of
Sched. Q Para. 3.5
Also found that joint identification numbering for repairs and rewelds by CIMS is conflicting with DAELIM
QCP and Company Procedure A554-O-PRG-QA-GEN-PRO-013. Corrective action with preventive
measure is required.
Contractor: QCP for Welding and Consumable Quality Control ProcedureRev. 2 and ITP for
Welding On-Plot Piping Rev. 2 have been submitted to Company on 6 Nov. 2013. Weld
identification numbering also revised as per CIMS requirements in Rev. 2 of Welding and
Consumable Quality Control Procedure, also procedure for Welding Repair (A554-E-103-QA-GEN-
PRO-119) Rev. 1 submitted to Company on 11 Nov. 2013. All due date ITP and QCP already
submitted to Company.
It was observed that during the concrete placement of paving south of E-W pipe rack/ air cooling area,
there are no QC inspectors for the subcontractor and Contractor monitoring the testing of concrete and
concrete placement of the paving. This is a violation to SMITP-Q-001-02 which is a witness point for the
Contractor.
Contractor: The Contractor has arranged with the QC Civil Inspectors to make sure that one
Inspector will be present at the Concrete testing checkpoint and one inspector in the concreting
location area.
PN: During routine site surveillance at Daelim laydown yard, it was noticed that new variable frequency
diliveries arrived at site. These control equipment shall be store inddors as per RT-6-1CS, section 2.9.1.
Contractor: VFDs are now transferred to site and already inside of each substation to comply on
its Preservation requiremetns.
Found that TCC fabrication team did some lettering (60mm wide & > 12mm thick) around the CS80" dia.
pipe branch connection to fire the wrong (short or distorted radios) RF pad on it. RF pad internal and
external edges were not able to fit on the main pipe due to approx. 2" gap. TCC was also using an
unapproved and wrong drawing sketch for branch connection & RF pad Fit-up detail. Above violations
shall be avoided to repeat. Daelim Quality must ensure the corrective action with preventive measures.
Noted and action will be taken. DPT has been done and found acceptable.
During Surveillance at laydown yard, it was observed that 7 nos. of Analyzer shelter have arrived and
kept outside the warehouse without airconditioned and temperature not maintained as per IEC-60079
part II. The door of Shelter is open and inside temperature is hot and humid. These violate IEC-60079
part II.
Contractor: Daelim is waiting for the documents/manual of the Analyzer which include the
specific/Applicable preservation requirements on the shelter unit. As per Project specific
requirement RT-6-ICS Rev.3, section 2.12.4: Analyzer shelters and complex analyzer shall be
stored as per the recommendations of the suppliers.
During inspection, it is found that the Contractor/Subcontractor (KCC) performed joint assenbly butt and
wrap instead of bell and spigot joint of UG fire water line 8" dia, violating the IFC isometric drawing # FW-
071065-01-02. Three (3) joints no. (FW-06, FW-07 and FW-11) found with the same discrepancy by
Company. Preventive measures are required. Ref: ES17, Para. 3, P,PSES1701.
Noted: Contractor received approval from the Daelim Engineer on the line drawing for Butt-
wrap joints instead of Bell & Spifot joint. The joint has been made as per FRI receive and
infomed CIMS for the As-Built drawing.
PN: Contractor shall forward records of all non-conformances to Company within 48 hours of issue.
Contractor shall provide the Company representative with an explaination for non-conformances that will
require more that 14 days to resolve. Contractor shall respond in writing, including proposed corrective
action, to all non-conformance issued by Company within three (3) business days of receiving
notification of the non-conformance. Ref. Sch. Q, Para No. 7.3.3, 7.3.4 & 7.3.6.
Subcontractor: Action will be taken informed to all concern and will comply with the given
notification to the company.
During surveillance inspection at ARCC area (Furnace and East-West pipe rack area observed the
following discrepancy. (Ref: HC-35 3"). Distortion occurred on weld joints due to improper method of
fabrication and lack of temporary supports. Random spools were inclining/uneven or sag in position
during Fit-up and welding . Alignment, leveling and strengthness were not followed during Fit-uop and
welding time. Daelim shall take necessary action to control the implemented method at site. Distoration
occured spools shall be rectified with approved repair method.
Subcontractor: ARCC construction group to be rectified the distorted joints, will provide proper
supports prior to full welding to avoid distortion. Cut & weld.
During site surveillance at furncae pipe rack, it was observed that cable pulled in improper way not in a
good engineering practice cable layed in scaffolding pipe and ibstruct with support. This is project
standard violation of NEC-70 Article 110.12, Method of statement & Schedule Q.
Subcontractor : Cable will be supported properly with a wooden flanks with softener above, to
protect the cable from stressed. Also, obstructions will be removed.
During time of site surveillance, it was observed that cable tray has been damage after inspection of
cable tray at furnace pipe rack & wrong bolt used in vertical drop of tray support. This is standard
violation of Schedule Q, G-7C-3024-04, G-07-0321-01 & NEMV-V2
Subcontractor : Cable tray (damaged) has been replaced including the bolts from hexagonal to
mushroom type.
During surveillance SHOW sub-contractor TCC lifting spool to attach flange nozzle of equipment E2020
in a wrong way, which can damage the equipment. Also, the equipment is position to the correct
alignment tolerance previously which can be effected due to this way of lifting by putting full load or
stress than fall on the equipment.
Realignment of the equipment is to be scheduled with new RFI to re-assure the centering, elevation and
plumbness.
Contractor: Noted and action will be taken. Tool Box meeting has been completed with
Equipment group regarding the issue. Next time it will be taken cared properly.
During site surveillance, it was observed that Actuator dial damage for 36"
MOV D.D.B. valve during the installation of F-1170. This is standard
violation of Schedule Q. Contractor requested to take preventive action.
Contractor: Contractor has issued NCR to ARCC for corrective
action. ARCC requested to Daelim Construction for the replacement.
Daelim escalated to NCR, No. NCR-ARCC-INST-001. ARCC
requested Daelim to provide MOV in which ARCC shall install.
During routine inspection at PCMC fabrication shop it was observed that SS pipes are stored along with
CS pipes, violation of SADARA specs. RT-6-1CS.
During inspection of cable tray, it was observed that on furnace pipe rack cable tray support was not as
per standard support installed on more than 3 meters and hold down clamp missing. This is standard
violation of G7C-0324-04
Subcontractor : Additional support will be installed in order to mee the 3m. Maximum distance
between supports. Complete accessories will be installed.
Found that preservation and storage of SS, LTCS & Alloy Piping material is improper even in the rainy
environment. Pipes and fittings are in non-drainable positions without end covers having little water
stagnant in them with improper storage. Company instructed severally and also logged LBE#373 but still
no action taken. Daelim quality must ensure the corrective action and preventive measures. Ref. RT-6-
1CS. Rev. 3 Para. 2.15, 2.19.9, 2.19.12, 2.19.4, 2.19.16.
Contractor: Noted. Action will be taken. Action has been taken. Pictures were send by
email. The LBE # 373 was also closed.
During inspection of paving at substation G-1120 area, it was noticed that some of the joints of TPER
were not welded properly Welding of TPER joints shall be performed by trained personnel as required by
Manufacturer's Recommendation/Instructions.
Subcontractor: Persons who did not undergo the proper training of installation and welding of
TPER were already removed from the group. Only trained personnel are allowed to conduct the
said activity.
During inspection of paving front of Expander Building, the Contractor cut the TPER at the ramp.
Contractor shall submit revise drawing and/or method Statement to provide continuity of TPER as
recommended by the Manufacturer.
Subcontractor : Daelim Engineering will issue drawing regarding the TPER that has been cut at
Expander Building. Method of Statement shall follow upon the issuance of the drawing.
Page 37 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-
MECH-391
MR. AMIN TCC VAF 2 MECH Piping 07-Nov-13 10-Nov-13 21-Nov-13 10-Feb-14 Closed
LBE-AMA-CIVIL-192 MR. GERALD AMA PN CIVIL Civil 09-Nov-13 12-Nov-13 23-Nov-13 31-Dec-13 Closed
LBE-AMA-
MECH-392
MR. SAYED AMA VAF 2 MECH Hvac 10-Nov-13 13-Nov-13 24-Nov-13 24-Apr-14 Closed
LBE-AMA-CIVIL-193 MR. JERRY AMA VAF 1 CIVIL Civil 11-Nov-13 14-Nov-13 10-Mar-14 06-May-14 Closed
LBE-SEN-ELECT-
076
MR. MARK SENDAN VAF ELECT Electrical 11-Nov-13 14-Nov-13 25-Nov-13 27-Nov-13 Closed
LBE-GLOBAL-
MECH-393
MR. HARIKUMAR GLOBAL PN 2 MECH
Mechanical
(Equipment)
11-Nov-13 14-Nov-13 25-Nov-13 23-Mar-14 Closed
LBE-ARCC-MECH-
394
MR. HARIKUMAR ARCC PN 2 MECH
Mechanical
(Equipment)
11-Nov-13 14-Nov-13 25-Nov-13 23-Mar-14 Closed
LBE-ASYAD-INST-
008
MR. PERVEZ ASYAD VAF 1 INST Preservation 11-Nov-13 14-Nov-13 25-Nov-13 Closed 01-Feb-14 Closed
LBE-SEN-ELECT-
077
MR. MARK SENDAN PN ELECT Electrical 12-Nov-13 15-Nov-13 26-Nov-13 28-Nov-13 Closed
14
LBE-DLM-
MECH-395
MR.
HARIKUMAR
DAELIM
(Enginnering)
VAF 2 MECH
Mechanical
(Equipment)
12-Nov-13 15-Nov-13 17-May-14 Open
LBE-ASYAD-INST-
078
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 14-Nov-13 17-Nov-13 28-Nov-13 25-Jan-14 Closed
LBE-AMA-
MECH-396
MR. GLENN AMA VAF 2 MECH Mechanical 14-Nov-13 17-Nov-13 28-Nov-13 26-Jan-14 Closed
LBE-ASYAD-INST-
079
PN: Equipment are releasing to construction activities. Daelim advised to implement appropriate action
to control debris, grinding and welding particles etc. . . Are entrap in the exchanger tube and other
accessories.
* Implement cleaning method prior and after hydrotest for pipe circute directly connected to equipment.
Implement cleaning Method for Furnace Radiant Tube and cross over piping system and liner
exchanger. It shall be got prior approval from Company SME.
Subcontractor: ARCC Construction group will provide proper protection on equipment, tubes and
other structures around the area with grinding and welding activities.
During site surveillance, it was observed that at G-1121 area Contractor kept all Instrument
Panel without information of Company and not preserved. No airconditioned and kept outside in
Sun without proper preservation. This violates project specification A554-E-103-CM-GEN-PLN-
002.
Contractor: Installed instrument panel are now preserved and temperature and humidity
are maintained as per approved Preservation Plan.
PN: During routine site inspection, it was observed that the installation of cable tray at the transformer
yard going to substation (G-1120 & G-1121) may not meet the required bending radius of the cables.
The Contractor shall verify and confirm that the installation of cable in this area shall meet the bending
radius requirement of the cable.
Contractor : Based on design aid of Sadara installation of Cable tray at substation G-1121 &
1120 will accommodate the bending radius of power cables.
It was noticed that the slope of the open ditch south of Sump 0906 Open ditch 0636-D750-026 is not in
accordance with the drawing. Water/drainage will not flow on the east portion of the branch of the ditch
because it is lower than the adjacent elevation. Contractor shall rectify elevation.
Contractor: Regarding open ditch 0635-D750-026, Amana already started the chipping of ditch
slab to maintain the slope as per IFC drawing. Once chipping finish, Amana will submit RFI to
start grouting.
During routine site inspection, it was noticed that the Contractor already puled a cable in a cable tray
that was not yet inspected and accepted by Company inspector which is a violation as per approved ITP
and Schedule Q Attachment IV Section 3.7.
Contractor : There was a miscommunication between the Contractor & Subcontractor regarding
the installed cable tray. This resulted to the not inclusion of the said cable tray installation activity
in previously raised RFIs.
- Contractor raised RFI to Company and was accepted.
PN:Observed that Daelim and Subcontractor started insulation activities for static equipment (tower,
Column, exchanger drum, etc.) at ground level prior to position on foundation.
Daelin shall advised to implement appropriate option for alignment and plumbness verification for
vertical and horizontal equipment according to Sadara Specification : G9G-1000-01,k G9G-1000-02 and
ITP A554-E-103-QA-GEN-PLN-056.
Contractor: Noted. Action will be taken. TCC Equipment Inspector will be making sure all works
as per approved ITP & Procedure
Found that two rejected elbows (102" dia.) transferred to inside the sandblasting area of TCC # 1. As per
Daelim M/S of Repair for Damaged Fittings Doc. # A554-E-103-CM-GEN-PI-006, these elbows were
supposed ti be shifted in the segregated quarantine area for buildup by welding rectification but TCC still
dont have specified any quarantine area. Corrective action with preventive measures are required.
Ref. Sched. Q Attch. IV Para. # 3, 4 & RT-6-1CS Para. # 2.2.11, 2.1.9.2
Contractor: Noted and action will be taken. After Built-up activity complete accepted report will be
attached.
PN: During surveillance inspection at Cooling Tower Basin "internal portion" for repair works, it has been
observed that no proper curing compound application using "Masterkure: for the newly repair areas or
portion. In this regards, Contractor was advised to take corrective action concerning this issue. In order
to comply with the repair procedure.
Subcontractor: Advised to Site Engineer and QC Inspector to monitor curing compound
application properly to avoid any problem in future.
In substation G1121, AMANA had completed blarzing of 60 joints without isometric drawing and brazing
activity was carried out in the absence of HVAC inspector.
This violates Sched. Q Item 1.2 & 5.9
On the specific issue an NCR (NCR-AMA-HVAC-002 dated 2/11/13) was issued to AMANA. Still
waiting to close the NCR from subcontractor. NCR was closed and accepted.
During site surveillance, it was noticed that Contractor installed MCt at substation without approved
Method Statement & ITP & QCP. This is violation of Schedule Q.
Subcontractor: Method staement & ITP have been prepared and submitted and waiting for its
approval.
Installation process of Incinerator at spent caustic area noted the following
discrepancy:
* Alignment process of smelt dissolver and incinerator sole and filler plate
height exceed up to 70: as recommended by gvendor it shall be 20mm.
*Incinerator holding structure (secondary girder beam @ 23050) are
showing inclination level variance and gusset plate are slightly bend.
* Bolt length are not sufficient to engage lock nut as per vendor design.
* Daelim shall advised to re-evaluate the structural integrity and fix the
discrepancy with prior approved Method by Company.
Contractor: This item already have been solved. Please note as
below description. Although the alignment height is approx. 20mm as
per vendor print, Contractor will adjust the alignment through inserting
the more filler plate at site. Hence, Contractor eill request vendor to
confirm whether 70mm height for alignment is suitable; and receive
the confirmation letter. Also, Daelim will officially receive the revised
drawing as per site adjustment. The exact slightly in AISC Code,
Flange-tilt tolerance are allowed to 8mm, in case depth exceeds
300mm. The depth of W12x40 is 303 mm, which means the tilt
tolerances could be approved by 8mm. So the case of support beam
for IN-0510 is no problem.
During Site surveillance it was observed rgar rge installation of cable tray at C3 Splitter pipe rack not as
per standard, cable tray supports under the expansion splice plate required 200mm wide as per
approved RFC Document No. A554-RFC-PRG-060.
Subcontractor: Already discussed with Mr. Lee/Daelim with Asyad Construction and both agreed
and conformed to follow as per A554-RFC-PRG-060.
Non-compliant Duct Insulation : It was observed that duct board insulation installed in MCC/PIB G-1121
Mechanical room and other use rooms per IFC drawing A554-E-103-HV-DWG-A30-003 with
specification 24kg/cu.m x 25mm thick and K value of 0.035 W/m-deg. C (0.24 Btu-in / Sq. Ft-hr-deg. F)
with thermal resistance value less than R-5 is not meeting the following Company requirements:
- RT5S-5051-01 para. 3.8.1.1 unless otherwise specified, external insulation shall be a minimum of
0.024 g/cu.m (1.5 lb/cu. ft.), a minimum of 40mm (1 1/2 inich) thickness of flexible fiberglass duct wrap
insulation with aluminum foil scrim kraft (FSK) facing. All supply & return ducts and plenums shall be
insulated with a minimum of R-5 insulation when located in unconditional spaces and with a minimum of
R-8 insulation when located outside the building.
-RT5S-5051-01 para. 3.8.2.1 All ducts specified to be insulated and exposed in equipment room shall be
insulated with 0.032 g/cu.m. (2.0 lb/cu.ft.) minimum of 25mm (1inch) thickness fiberglass rigid board, All
supply and return ducts and plenums shall be insulated with a minimum of R-5 insulation when located
in unconditioned spaces and with a minimum of R-8 insulation when located outside the building.
Contractor: Contractor submitted the RFV (Request for Variance) to Sadara to close the
highlighted issue regarding the duct insulation used in substation G-1120 & G-1121. Sadara
responded on RFV and approved.
Page 38 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ASYAD-INST-
080
LBE-SEN-ELECT-
081
MR. FELOMINO SENDAN VAF 1 ELECT Electrical 17-Nov-13 20-Nov-13 01-Dec-13 30-Mar-14 Closed
LBE-AMA-CIVIL-194 MR. GERALD AMA VAF 1 CIVIL Civil 17-Nov-13 20-Nov-13 01-Dec-13 20-Feb-14 23-Feb-14 Closed
LBE-AMA-CIVIL-195 MR. JERRY AMA VAF CIVIL Civil 17-Nov-13 20-Nov-13 01-Dec-13 31-Dec-13 Closed
LBE-AMA-CIVIL-196 MR. GERALD AMA VAF CIVIL Civil 17-Nov-13 20-Nov-13 01-Dec-13 31-Dec-13 Closed
LBE-AMA-CIVIL-197 MR. GERALD AMA VAF 1 CIVIL Civil 18-Nov-13 21-Nov-13 02-Dec-13 01-Apr-14 Closed
LBE-DLM-MECH-
397
MR. AMIN DAELIM PN 2 MECH Piping 18-Nov-13 21-Nov-13 02-Dec-13 10-Feb-14 Closed
LBE-TCC-MECH-
398
MR. KURIAN TCC VAF 2 MECH Piping 19-Nov-13 22-Nov-13 03-Dec-13 02-Mar-14 Closed
15
LBE-DLM-
MECH-399
MR. KURIAN
DAELIM
(Enginnering)
VAF 2 MECH Structural 19-Nov-13 22-Nov-13 03-Dec-13 Open
16
LBE-DLM-
MECH-400
MR. KURIAN
DAELIM
(Enginnering)
VAF 2 MECH Structural 19-Nov-13 22-Nov-13 03-Dec-13 28-Jul-14 Closed-
22
LBE-DLM-
MECH-401
MR. SAYED
DAELIM
(Procurement)
VAF 2 MECH Material 19-Nov-13 22-Nov-13 20-Jul-14 20-Jul-14 Closed
LBE-DLM-
MECH-402
MR. AMIN DAELIM PN 2 MECH Piping 21-Nov-13 24-Nov-13 05-Dec-13 10-Feb-14 Closed
LBE-DLM-ELECT-
082
MR. MARK DAELIM VAF 1 ELECT Electrical 21-Nov-13 24-Nov-13 05-Dec-13 26-Jan-14 Closed
During surveillance inspection at Cooling Tower pump sump @ "wall-5" along GL : BD/10, concerning
water stop installation does not conform to IFC drawing wherein half portion should be embedded to
existing concrete. In this regards, Contractor was advised to submit Method Statement concerning this
issue, prior to continue for RC wall formworks.
Contractor: As per Daelim Engineering concern that no need to install water stop at stated area
and it is not mentioned on IFC drawing.
Depsite several verbal instruction to provide burlap on the surface of the completed paving near the
cooling tower area, the Contractor still did not comply. The pavement was poured on 12 Nov. 2013 and
as of this writing still there is no burlap. It was observed that the polyethylene sheet covering the top
surface has been blown by the wind leaving the surface open and dry several times and the attention of
the QC inspectors were called to comply with the requirements. This is violation to RT2S-3001-01 Para
9.1.4. Contractor shall provide evidence that the concrete is the same as the compressive strength of
the laboratory test result.
Contractor : Subcontractor (Amana) already secured burlaps and polythylene sheets for the
newly casted concrete will be strictly implemented , newlt poured areas will be closely monitored.
During Material Receiving inspection at AMANA Laydown area/warehouse, it was noticed that some
repair materials intended for cooling tower was not properly stored on container, instead put only outside
the container. In this regards, Contractor violates ITP checklist (SMIC-R-1001) "Material Handling &
Storage" and manufacturer recommendation. Contractor was advised to take corrective action
concerning this issue & comply with Manufacturer's instruction.
Contractor : Subcontractor (Amana) alreadyremoved the materials and transferred to a close
container, proper material handling & storage is done.
During inspection at site of JB - installation it was observed that Contractor installed JB without proper
use of rubber clamp between supports and JB bolt. This may caused galvanic corrosion. This violates
NEC. Art. 342.14
Contractor/Subcontractor: installed rubber or equivalent material between JB and Supports to
avoid Gavanic reaction. Contractor raised RFI and accepted with regards of this violation.
During site surveillance, it was observed that Contractor pulled the cable on tray at Furnace pipe rack
sub tray 1240, without inspection of tray. This is not the first time repeated violation done by Contractor.
This violates Schedule Q, Para 3.7. and approved ITP.
Contractor : Contractor issued NCR to sub-contractor for this violation, 17 Nov. 2013. Contractor
raised RFI to close the NCR. RFI was inspected and accepted by Company.
PN:
1. Daelim must ensure that only SADARA approved NDT service providers are being utilized.
2. RTFI must review the NDT Assessment reports properly to avoid mistakes like welding process and
RT report number etc.
3. RTFI must interpret the WQT films 100% to avoid any overlook from weld defects.
4. Contractor Quality must follow-up closely for getting the WQT results timely.
5. Any JCC shall not be submitted without RT interpretation of SADARA NDT Level III.
6. JCC having any disagreement in RT assessment report for film or weld quality shall not be submitted
without SADARA NDT Level III final review.
7. Daelim must inform all NDT companies for write down the location and size of defects on the RT &
assessment reports for WQT and Production welds.
Ref.: ARCC-AMY-RT-WQT-001, AYTB-FURO-WQTAR-01, TCC-NDTCCS-DAR-002 (Assessment
reports)
Subcontractor: Action has been taken accordingly.
During routine site visit at Daelim's Laydown yard, it was noticed that some of the cables stored do not
have an approved end cap at cable ends which is a violation as per G7D-0404-00, Section 7.3.
Contractor : Scontractor will provide the approved end caps and Company will be notified for the
action will be taken.
During surveillance above the 2nd lyre of the EW pipe rack of the east side
from column 10 onwards were found in inclined position ladder fixed as it is
fauling with the beams.
Contractor: TQ raised for approval from Daelim Engineering
department.
During surveillance, pipe rack in between liquid furnace and G1120
MCE/PIB were found with structure have vertical blogging positioning
diagonally with ladder fixed to it without toe clearanc. The clearance there
found is 40mmm and 11mm but the required is 225mm. It is a violation as
per ref: RT2G-5515-01 drawing.
Subcontractor: Noted. Action shall be taken. Engineering issue.
Engineering issue. This item already been solved. The orientation of
vertical brace has been rotated 180 degree which means the
clearance of ladder has been retained.
During material receiving jnspection, it was found that CS welded pipe 42"
x 12.70 (XS) ASTM A672 CL70-CI-22 with H.No.: LK669412 is not comply
as per the purchase order PO-100532042-PO2-005-A01. The requirement
as per PO was NACE MR-0103 pipe BE ASTM 672-CL-20 but the actual
material received and the MTC was not compliance with NACE-MR-0103.
This violates Sched. "Q" Para. 1.3 which states that "All materials and
equipment meet the requirement of the Contract and the applicable
purchase order.
Verified.
During surveillance inspection at substation G1121, it has been observed that some steel door frames
are installled without issuing first "RFI" request for inspection, and some are grouted already. This is in
violation to Schedule "Q" attachment IV section 1 para. 1.1.3 and also as per G2S-4300-01 Section 2.4
Para. 2.4.1 "Grout shall have a minimum strength of 3750psi." In this regards, Contractor was advised to
take corrective action and remedial action concerning this matter, And also Contractor are required to
submit proof of compressive testing that the grout being used for the steel door frames are comply with
our specification requirements.
Subcontractor: Subcontractor shall submit RFI for final inspection after installation of all
accessories regarding grouting. Report on crushing is attached.
PN: Because of raining and start of cold seasons, Daelim Quality must ensure that:
1 - Piping materials are properly preserved and stored in drainable positions.
2 - SS material are properly covered by water repllent sheet.
3 - End covers are in place and proper space is maintained from the ground.
4 - Welding consumables are stored in controlled temperature and humidity.
5 - Pre-heating and metal surface temperatures are monitored closely to avoid welding on moistened
base metals.
6 - Relevant inspectors and welders are using a suitable temperature measuring sticks or pyrometers.
Contractor: Noted and action will be taken. NCR #41 is related to this issue and now closed.
During inspection of flange face of P4 2131 Nozzle with below type connection (G vent) on the cold box
north side found bented and the top of the south side of the cold box nozzle were connected to the
piping with no proper piping support (temporary) as it can cause an extra load on these nozzle than the
specified tolerance limit by the manufacturer. It is a violation as per A554-E-103-QA-GEN-PRO-034 para
8.1.3 & A554-E-103-QA-GEN-PRO-035 para 8.2.1
Subcontractor: Noted. Action shall be taken. All piping connection has been complied
Page 39 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-ELECT-
083
MR. FELOMINO AMA PN 1 ELECT Electrical 21-Nov-13 24-Nov-13 05-Dec-13 28-Jun-14 Closed
24
LBE-DLM-
INST-084
MR.
SHABIRUL
DAELIM
(Procurement)
PN 1 INST Instrumentation 23-Nov-13 26-Nov-13 07-Dec-13 16-Jul-14 Closed
16
LBE-DLM-
MECH-403
MR. SAYED
DAELIM
(Procurement)
VAF 2 MECH Material 24-Nov-13 27-Nov-13 14-Jul-14 Open
LBE-AMA-MECH-
404
MR. GLENN AMA VAF MECH Hvac 24-Nov-13 27-Nov-13 08-Dec-13 18-Dec-13 Closed
LBE-AMA-MECH-
405
MR. GLENN AMA VAF MECH Hvac 25-Nov-13 28-Nov-13 09-Dec-13 18-Dec-13 Closed
17
LBE-DLM-
ELECT-085
MR.
FELOMINO
DAELIM
(Mat. Dept &
Procurement)
VAF 1 ELECT
Material
(Procurement)
26-Nov-13 29-Nov-13 10-Dec-13 Open
LBE-DLM-ELECT-
086
MR. FELOMINO DAELIM VAF 1 ELECT Electrical 26-Nov-13 29-Nov-13 10-Dec-13 23-Feb-14 Closed
LBE-DLM-MECH-
406
Mechanical
(Equipment)
28-Nov-13 01-Dec-13 23-Mar-14 Closed
LBE-AMA-CIVIL-198 MR. JERRY AMA VAF CIVIL Civil 28-Nov-13 01-Dec-13 12-Dec-13 16-Dec-13 Closed
LBE-AMA-CIVIL-199 MR. GERALD AMA PN CIVIL Civil 28-Nov-13 01-Dec-13 12-Dec-13 31-Dec-13 Closed
6
LBE-AMA-MECH-
407
MR. GLENN AMA PN 2 MECH Hvac 02-Dec-13 05-Dec-13 12-Feb-14 22-Apr-14 Closed
LBE-DLM-MECH-
408
MR. AMIN DAELIM PN 2 MECH Quality Management 03-Dec-13 06-Dec-13 17-Dec-13 10-Feb-14 Closed
19
LBE-DLM-
MECH-409
MR.
HARIKUMAR
DAELIM
(Enginnering)
VAF 2 MECH
Mechanical
(Equipment)
04-Dec-13 07-Dec-13 17-May-14 22-Jul-14 Closed
LBE-SEN-ELECT-
087
MR. FELOMINO SENDAN PN 1 ELECT Electrical 05-Dec-13 08-Dec-13 19-Dec-13 23-Feb-14 Closed
PN: During site surveillance at G-1120 & G-1121 substations, it was observed that the metal door frame
of substation building don't have provision for grounding connection. This violates as per G7C-0104-00,
section 6.12.2.
Contractor : As per construction coordination, cable grounding will be from the top and exposed
for metal door frame. According to 67C-0114-16 note 9, that the PVC along the wall to a
substation ground bos is Acceptable instead of the cable through the concrete foundation.
Observed that Mechanical Inspector is not available at site Daelim and Subcontractor shall be fully
responsible for the performance and control of the on-going activities and work process violation of
Schedule "Q" attachment 3 and ITP-A554-E-103-QA-GEN-PLAN-022.
According to the schedule Daelim will provide more inspectors as soon as possible
It was noticed that the reinforcing bars of the pedestal near cold structure area was bent to provide
access to equipment of the other subcontrcator working on the same area. Contractor/Subcontractor to
provide protection to all exposed reinforcing bars of all pedestals to avoid recurrence of the incident.
Also to provide corrective action on the Ben reinforcing bars of the pedestal. This is a violation to the
minimum bending readiness required by AC1318 and 315.
Subcontractor: Rebars were rebend and returned to its plumbness. Damaged coating has been
touched-up.
PN: During Surveillance inspection & monitoring activities at cooling tower sturcture, Sump pump area &
basin have been observed that after raining in few days, it was found out the presence of the water.
Contractor advised to make dewatering the said structure in oder to continue the repair work especially
the Internal portion of the RC wall.
Subcontractor: Amana has already removed the water from sump pump area and repairing work
is on-going.
Supply air elevation higher than requirement. It was observed in MCC/PIB G-1120 (Typical to G-1121)
that 2 nos. supply air outlets are located around 7.2m above floor in Battery room. This violates RT52-
500-01 section 6.11.4.3 Supply air 150mm above floor or lower and exhausr at ceiling or at high point of
any flammable gas pocket.
Contractor: As per the comments, during start of any activities or work for HVAC, Construction
MFC Daelim they have submitted shop drawing to Sadara for review or approval. This is the one
of Sadara comments to provide at least one air device above and that was complied by Daelim
MFC Engineering as the revised drawing.
During material receiving inspection of RFI # CCHINDS-EL-024 at Daelim
Laydwon area, it was observed that the 2" Hot dip galvanized PVC coated
conduit and 2" X 3/4" reducer fittings has no labeled and not listed. This
violates as per G7C-0311-01, Para 1.2.
Contractor: Daelim will provide certificate from Vendor for proof.
Contractor will not use anymore these materials as per construction
and it was already quarantined at the laydown yard.
During Inspection at East West main piperack, it was observed that the cable tray was installed using
temporary support and cable pulling activities were on-going. This violates G7C-0321-01, Para. 4.1.
Construction: Subcontractor's Construction team was aware of this issue, as Daelim
Construction team avised them to provide temporary support due to structural issues. Company
to be notified during the weekly quality meeting as soon as Contractor receives the schedule from
structural to provide structures at the E-W main pipe rack.
PN: During site surveillance, it was observed that the Gear box of MOV
103-EBV 116417 has been damaged during lifting time. Contractor to
report Vendor or replace part of the damage gear box of MOV-30.
Contractor : Contractor will issue OSID to notify the Vendor regarding
the damage neither inoformation nor notification will be given by
Contractor to Company for the action.
During material receiving inspection of Valves, it has been noticed that
failure of paint bwtween prime coat and top coat. P.O. No. U31-002-A02-
42, Vendor: NEWMANS, RFI No. MFC-DLM-NEWMAN-PIP-001. No of
Valve approximately 54 nos. This violates Sadara Specification G16S-0202-
04 which mandates "each coat shall be of the correct colour, free of defects
such as but not limited to pinholes, blisters, dry spray, detrimental runs and
sags, excessive or inadequate film built, improper recoat times, foriegn
inclussion and adhesion between Coat and to the substrate shall equal the
manufacturer's limit. Contractor shall verify occured discrepancy and
propose Corrective action.
Contractor: Daelim Material Dept. already completed the repair works
at the painting shop.
Incorrect duct support- It is observed in MCC/PIB G-1120 & G-1121 that angle bars are used to support
ducts in mechanical room. This violates RT5S-5052-01, Para. 4.41.1. In Equipment room use 42mm (1
5/8") Unistrut with M12 (1/2") threaded rod. Hanger spacing not to exceed 1.5m. Purpose of this hanger
type is to allow other disciplines a place to hanger attachment. (Ypical to G-1120).
Contractor: Daelim designed and installed the type 2 duct hanger supporting arrangement as per
"RT5G-5051-10 Typical duct hanger (Refer to attachment #1). Specification RT5S-5051-01, Para.
4.14.1 describes "Purpose of Unitrust hanger type is to allow other disciplines a place for hanger
attachment. In general HVAC practice, the ducting needs in individual hangers support.
Therefore, Type 2 hangers arrangement is installed to support the individual application like
ducting and not to be paired with any other disciplines. Hence, the Unistrut type hanger supports
are not envisaged for equipment room.
PN: During surveillance at all area of main piperack for installation of cable tray expansion splice plate,
it was observed that the length of splicing bolt was insufficient length tha actual length is 16mm. Some
of the bolts are loosen and if the bolts are fully tighened the splicing plate were fixed permanently to the
side rail of cable tray.
Contractor: Splicing Bolt used for splicing plate was changed from 16mm to 19mm from the day
the Contractor received the comment.
PN: It was observed in MCC/PIB G-1120 inspection for Electric Duct Heater installtion that no access
door provided and airflow sensor not installed. This violates RT5S-5051-01 Para. 4.9, All ductwork
enclosed equipment to have access door installed on up-stream and down-stream with respect to air
flow and section 1.5.6.1.4 Airflow switch sensor provided by manufacturer to be installed.
Contractor: Daelim already informed to Amana regarding the issue raised by Company and
Subcontractor shall provide access door for every duct work enclosed equipment that allowing
maintenance work.
PN: Found that Daelim Piping and Welding inspectors duputed at offsite fabrication shops (AYTB &
PCMC) are not reaching there in time. Shift starts at 06:00 AM but Daelim inspectors are reaching at
8:00 AM. This schedule is entirely unacceptable and needs immediate correction action. Cold season
has been started and mornig activities are much important now than hot season. During High rejection
rate full time close monitoring is very important.
Contractor: Contractor inspectors are going to Daelim office the morning time for the purpose of
completing the documents of the daily activities. However, Contractor Inspectors will try to reach
and join with subcontractors QC in the off-site as early as possible.
Dimentional and Elevation discrepancy observed at Debutinizer area on E-
1920 A and E 1920. Grinder Beams are conflicting with Equipment Nozzle
and limited space for piping installation. Daelim Engineering team to re-
evaluate the connection and implement the appropriatee corrective action
in accordance with Engineering approval by Company E-1920AB-103-9002-
01 - 209.
Contractor: Company inquiry already been solved. The clashed girder
has been cut 25mm at site to install the pipe in accordance with "E-
1920AB-103-9002-01 - 209". The structural calculation considering
25mm cutting on girder has been also done, whos result is no
problem.
Page 40 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-ARCC-MECH-
410
MR. HARIKUMAR ARCC VAF 2 MECH Piping 07-Dec-13 10-Dec-13 26-Feb-14 28-Mar-14 Closed
LBE-TCC-MECH-
411
MR. NASSAR TCC VAF 2 MECH
Coating/
Painting
07-Dec-13 10-Dec-13 21-Dec-13 Closed
LBE-PCMC-MECH-
412
Coating/
Painting
07-Dec-13 10-Dec-13 21-Dec-13 16-Feb-14 Closed
LBE-AMA-CIVIL-200 MR. JERRY AMA VAF 1 CIVIL Civil 09-Dec-13 12-Dec-13 23-Dec-13 08-Apr-14 Closed
LBE-PCMC-MECH-
413
MR. NASSAR PCMC VAF 2 MECH Preservation 09-Dec-13 12-Dec-13 23-Dec-13 16-Feb-14 Closed
8
LBE-DLM-
MECH-417
MR. KURIAN
DAELIM
(Enginnering)
VAF 2 MECH
Mechanical
(Equipment)
09-Dec-13 12-Dec-13 17-May-14 23-Jul-14 Closed
LBE-GLOBAL-
MECH-414
MR. NASSAR GLOBAL VAF 2 MECH
Coating/
Painting
10-Dec-13 13-Dec-13 24-Dec-13 16-Feb-14 Closed
18
LBE-DLM-
MECH-418
MR. KURIAN
DAELIM
(Enginnering)
VAF 2 MECH
Mechanical
(Equipment)
10-Dec-13 13-Dec-13 17-May-14 Open
LBE-SEN-ELECT-
088
MR. FELOMINO SENDAN VAF 1 ELECT Electrical 10-Dec-13 13-Dec-13 24-Dec-13 04-Mar-14 Closed
LBE-DLM-ELECT-
089
MR. FELOMINO DAELIM VAF 1 ELECT Electrical 10-Dec-13 13-Dec-13 24-Dec-13 30-Mar-14 Closed
LBE-AMA-MECH-
415
MR. GLENN
DAELIM
(Enginnering)
PN 2 MECH Hvac 11-Dec-13 14-Dec-13 25-Dec-13
Engineering
response id for
exhaust fan only,
bleed fan in
equipment room
is not responded.
10-May-14 Closed
LBE-AMA-MECH-
416
MR. GLENN AMA PN 2 MECH Hvac 11-Dec-13 14-Dec-13 25-Dec-13 12-Feb-14 Closed
LBE-SEN-MECH-
419
MR. KURIAN SENDAN VAF 2 MECH Mechanical 11-Dec-13 14-Dec-13 25-Dec-13 07-Mar-14 Closed
LBE-ASYAD-INST-
090
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 11-Dec-13 14-Dec-13 01-Jan-14 04-May-14 Closed
During routine inspection at PCMC blasting & coating facility, it has observed that dust inclusions and
dry spray due to applying the paint during high wind.
Subcontractor: Action was taken and all area where over spry was rectified and inspected and
accepted through RFI PCMC-M-0269
With reference to RFI # MCF-DLM-AMA-CI-5428 located at Ground Flare Area for gravel 1 1/2 inch, the
Contractor shall provide test results that the materials comply with the requirements of RT2S-2200-01
Para. 2.7. Sadara QG shall be involved during taking of samples of this materials.
Subcontractor: Regarding Grand Flare area gravel, Amana has already submitted RFI for
sample collection and Test result already submitted which sill send back to supplier to replace
with new material.
During surveillance, it was observed during transportation and handling the pipes and spools, some
pipes & spools have been damaged due to pipe poor transportation and handling. Those pipes and
spools found at MFC site (E/W pipe rack) Tank Farm # V-500B.
Subcontractor: Noted. PCMC advice the spool release team for the proper caring of the spools
and following proper preservation.
ARCC has ignored to implement Welding parameter as per WPS-1400-WMS-PSA-005A for line class
HpssH-1, the provision version was followed until oct. 26 and as per production data sheet. 8 joints were
welded at site after 2nd revision of subjected WPS (G4N-HM-001. G5N-HM-001, G6H-HM-0001 and
G7N-HM-001). which is showing significant variance to addition of extra requirement for maintenance
intermediate pout heat and sok time. Violation of project specification RT8S-G500-1 and WPS-1400-
WMS-PSA-005A. Daelim Welding Engineering Team shall investigate and propose corrective action in
accordance with SME approval.
Subcontractor: A change of pre-heat maintenance is a non-essential variable as per OW-406.2.
Therefore, it does not affect the mechanical properties of the weldment.
During routine inspection at TCC-01 blasting & coating facility, it has observed that dust inclusions and
pinholes due to applying the paint during blasting progress.
Subcontractor: Noted. Action shall be taken.
PN: Air intake elevation not meeting erquirement. During surveillance in MCC/PIB G-1121 (typical to G-
1120), it was observed that bottom of outside air intake is 7m above grade. (0.5m short to requirement).
This violates RT52-5000-01, Para. 6.7.4 The air intake of a pressurized building shall be located in a
non-classified area 4.5m minimum above any classified area and 7.5m above grade.
Contractor: As per Proactive Notification which is clearly mentioned in SADARA Standard, RT5Z-
5000-01, additional section 6.3.1.3 "Fresh Air intakes shall be located a minimum of 2.4 m (7Ft-
10in) above grade, with sand trap louver, birs screen, manual volume damper and internal dust
filter. An intake stack may be necessary but not required to achieve intake minimum height above
grade. No need to provide RFC again to close the LBE M-416 since this is already mentioned in
this section of Sadara Standard. With respect to the PN regarding the Height of outside air intake,
Contractor's Construction and QC teams had verified the issue with below finidngs:
Building on the top of concrete = EL. 24400 (high point)
GR.FL.=+14700(T.O.C), Size of building beam = 800mm
Height of opening: 1500, Weight of opening: 1800
BOL EL: 21700 Intake sand trap louver; Therefore, 24400-14700=9700mm
(Height of building), 9700-800=8900mm, 8900-1500=7400mm.
Which means the elevations are 7000mm only, we still have clearance from the beam to upper
opening. In this case, we cannot reach 7500mm as per required standard grabe because the
building is less in height. Reference IFC drawings:
*A554-E-G1121-DWG-A02-206
*A554-E-G1121-DWG-A03-243
*A554-E-103-HV-DWG-A30-032
During regular visit to SENDAN Fabrication shop found the holiday oven is not maintaining the required
Temperature of 120C and the Welders were found not using quiver. This is violation as per RT-8S-6500-
03, Para. 2 (Storage & Reconditioning), (Note 2) A554-E-103-QA-GEN-PRO-050, Para. 9
Recalibration/Replacement of holding oven and quiver is required as per the Sadara specification.
Subcontractor: The holding oven maintaining the temperature at 120c as well as every welders
using quiver.
During inspection of cable tray, it was observed that Contractor installed splice plate on supports +-
300mm. This violates G7C-0324-03. According to Standard, Contractor shall install heavy duty splice
plate +-300 on support.
Contractor: Subcontractor's and Daelim Construction team were informed about this violation
and advised to rectify the same. After receiving the comments from Company, immediately
informed concerned parties to follow typical installation details, maximazing the distance of the
splice plate and support to 600mm.
During Surveillance at operator building G-1122 for lightning conduit installation, it was observed that
the flexible conduit was installed directly to junction box plate cover. This violates NEC article 300.15
(A).
Contractor: Subcontractor's QC department and Daelim's Construction team were already
informed regarding the violation of the NEC standard pertaining to the installation of the flexible
conduit directly to the JB plate cover and advised to rectify the same.
During Inspection at Gas Furnace area F-1160 for cabnle tray installation, ir was observed that vertical
outside ao elbow cable tray fitting is not installed. This violates G7C 0321-01, Para. 6.1.2.
Contractor: This issue was already addressed to Daelim Engineering Team for review and
necessary action.
PN: Missing motorized damper. During verification of IFC drawing for MCC/PIB G-1121 (Typical to G-
1120) it was observed that backdraft damages are provided in battery room exhaust outlet and bleed or
outlet. This violates RT52-50001-01 Para. 8.2.8 Motorized dampers that closed when the system is not
operating shall be provided for outdoor air intakes and exhaust openings to eliminate infiltration. Use of
gravity damper is not recommended due to their short life and reliability.
Contractor: Mottorized damper is not required in battery EF outlet, since the fan is continuously
running whole year round. In case the duty fails, the back-up fan will operate. Thus, infiltration is
imposible. In the event of system shutdown, it will only occur in very short span of time. During
emergency cases only. So BDD can serve its purpose by eliminating ingress of outside air.
Surveillance show P-2320-B (Ethylene product pump) with damaged 0.75"
pipe (Vent connection) connected to the discharge nozzle flange. The
pump is from vendor Flowserve, the damage may have happened during
installation at site as there was no damage physically during material
receiving inspection. This is violation as per A554-E-103-QM-GEN-PRO-
034, Para. 8.1.3 & A554-E-103-QA-GEN-PRO-035, Para. 8.2.1.8.1.11 &
8.1.1.
Contractor: P2320 was already sent to Supplier's repair shop. After
repair of damaged nozzle, Contractor will inspect and erect P-2320-B.
-> P-2320 was repaired at vendor shop after inspection. It is
reinstalled at site
During routine inspection at Global Suhaimi, blasting/coating facility has been noticed that pinholes
defect on the top coat surface. Applied paint code is G16S-0203-03 (P2-2). The number of valves are 8
24" Dia.
Subcontractor: All the items having the pin holes are already repaired and accepted by QC of
Daelim and SADARA.
Surveillance shown the equipment P42131 (Cold box) the nozzle "GVENTI"
found bended due to mishandling or may be during installation at site, this
is a violation as per A554-E-103-QA-GEN-PRO-034, Para. 8.1.3. and A554-
E-103-QA-GEN-PRO-035, Para. 8.2.1. & 8.1.11.8.1.1.
Contractor: Contractor cannot recognize this issue for Cold Box (PU
2131). Please expalin or provide the picture for bended nozzle to us.
Page 41 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-201 MR. JERRY AMA VAF 1 CIVIL Civil 14-Dec-13 17-Dec-13 28-Dec-13 08-Apr-14 Closed
LBE-AMA-CIVIL-202 MR. JERRY AMA VAF CIVIL Civil 14-Dec-13 17-Dec-13 28-Dec-13 31-Dec-13 Closed
LBE-AMA-CIVIL-203 MR. JERRY AMA VAF CIVIL Civil 15-Dec-13 18-Dec-13 29-Dec-13 31-Dec-13 Closed
LBE-AMA-CIVIL-204 MR. JERRY AMA VAF 1 CIVIL Civil 15-Dec-13 18-Dec-13 29-Dec-13 02-Feb-14 Closed
20
LBE-AMA-
CIVIL-205
MR. JERRY AMA VAF 1 CIVIL Civil 16-Dec-13 19-Dec-13 11-Feb-14 19-Jul-14 16-Jul-14 Closed-
LBE-DLM-MECH-
420
MR. KURIAN
DAELIM
(Construction)
PN 2 MECH
Mechanical
(Equipment)
17-Dec-13 20-Dec-13 31-Dec-13 03-Jun-14 Closed
LBE-GLOBAL-
MECH-421
Coating/
Painting
17-Dec-13 20-Dec-13 31-Dec-13 12-Apr-14 Closed
LBE-GLOBAL-
MECH-422
Coating/
Painting
17-Dec-13 20-Dec-13 25-Feb-14 12-Apr-14 Closed
LBE-KAF-MECH-
423
MR. NASSAR KAEFER VAF 3 MECH Fireproofing 17-Dec-13 20-Dec-13 12-Apr-14 12-Apr-14 Closed
LBE-AMA-CIVIL-206 MR. JERRY AMA VAF 1 CIVIL Civil 18-Dec-13 21-Dec-13 01-Jan-14 07-Jan-14 Closed
LBE-DLM-CIVIL-207 MR. JERRY DAELIM VAF 1 CIVIL Civil 19-Dec-13 22-Dec-13 22-Apr-14 22-Apr-14 Closed
LBE-DLM-ELECT-
091
MR. FELOMINO DAELIM VAF 1 ELECT Electrical 19-Dec-13 22-Dec-13 02-Jan-14 30-Mar-14 Closed
LBE-GLOBAL-
MECH-424
MR. NASSAR GLOBAL VAF 3 MECH Quality Management 19-Dec-13 22-Dec-13 02-Jan-14 23-Feb-14 Closed
19
LBE-AMA-
CIVIL-208
MR. JERRY AMA VAF 1 CIVIL Civil 20-Dec-13 23-Dec-13 19-Jul-14 Open
LBE-DLM-MECH-
425
MR. AMIN DAELIM PN 3 MECH Quality Records 21-Dec-13 24-Dec-13 04-Jan-14 10-Feb-14 Closed
During normal inspection at Global Sujami workshop, it has been noted no subcontrcator coating
inspector is assigned at the time of inspection. Inspection has been verified in presence of Daelim
inspector. Logbook entry will be escalated to NCR when lack of action by Daelim to provide the required
project ITP.
Subcontractor: QC Inspector is already informed to be present at site and if repeated, he will be
removed from approval.
At Global Suhaimi workshop, it was noticed more than 128 gate valves 2" dia already coated with wrong
paint code (G16S-0203-03) Silicon Aluminum Finish and as per tag (P-1) which is installed the paint
code required in G16S-0201-11 (Epoxy Phepolic). This is violation against coating procedure for field
application on valves *CM-2029).
Subcontractor: Painted and changed the paint code system as per Daelim advice through email
on Dec. 24, 2013.
It has been noticed that existing coating (HB surface tolerant epoxy of uninsulated parts and Equipment
tag has been damaged due to overspray of zinc phosphate (Primer color) and Fireproofing intumescent
coating. The cause of damages was poor protection for un-insulated parts prior to coating application.
Contractor: Item Closed as per NCR-KFR-MECH-001
Balst resistance doors delievered shall be inspected during installation as per Company comments in
Contractor transmittal nos. IK-MFC-T-CJ-DJ-CM-0529 and Company reply IK-MFC-T-DJ-CJ-QM-0403
dated 22 Dec. 2012.
Subcontractor: Delivered Blast Door has been Installed and Inspected (See Attached Photos)
The repaired concrete surface of the Cooling Tower External Walls have
different color compared to the existing concrete surfaces. The color of the
concrete surfaces around the external walls shall be repaired as required
by RT2S-3001-01, Section 11, Para 11.1.1 including color of the repaired
materials.
Subcontractor: Advised to Construction to discuss with Daelim
Construction and finalize which material to be used for external well.
Waiting from Daelim to get approval to start painting works.
PN: EQ106 (Primary demethanizer feed/secondary demethanizer bottom exchanger) is found with no
painting after welding of sole plate at left plate at sole plate with base plate of the saddle support.
Subcontractor: As per PN 420 already took action regarding the sole plate welding.
It was noticed during monitoring activities that the reinforcing bars of Open Ditch wall sout-east of
substation G-1120 has been exposed and there is no more bar cover. There are about 11 nos. where
cover did not comply with specification. This is a violation of RT2S-3001-01, Para. 6.1.10.
Subcontractor: Advised to Construction to make shop drawing to adjust rebar where they have
spacing problem. Daelim approved the shop drawing.
The curing of foundation at Flare area is not being done properly. The contractor provided burlap and
poleyethylene sheets at the sides of the foundation but left the pedestal area without burlap and
poleyethylene sheet. The area inside the reinforcing bars of pedestal is wider and larger than the side of
foundation.
Subcontractor: Subcontractor already placed the burlap and polyethylene sheet on pedestal area
and curing has been placed.
The alignment of open ditch, east of substation G-1120, to the sump pit southeast of substation G-1120
is not straight. Please verify which of the two structures is misaligned (sum0644 or ditch) prior to pour
concrete wall of the ditch submit shop drawing for approval.
Subcontrctor: Subcontractor Already Make the shop drawing and Approved by Daelim
Engineering team. Work has been Inspected and approved. IFC Revised.
No subcontractor coating inspector is assigned at the time of inspection. As per project ITP, inspection
sctivities for subcontractor inspector is Hol point. Daelim should raised NCR and take positive action
with Subcontractors to maintain the quality prior to, during and after activities without any defects.
Subcontractor: The QC inspector has been changed.
The Conrractor started to erect equipment/structural support without
submitting RFI at Air Cooler Structures area and Fresh Ethane Structure
area. Some deficiencies noted on the structures are the following: No
chamfer on exposed corners, chamfers were not uniformly trimmed,
blowholes and small honeycombs were not repaired, beams have irregular
shapes, some color of the repaired structures were not uniform, the top
portion of the beams were not properly cleaned prior to repair. Contractor
did not submit RFI to cover Item 3.6 of ITP SMITP-Q-001-02.
PN: It is observed that Daelim RFI's submission process as per Sadara RFI guideline QA-F-001-R1,
transmittal # IK-MFC-T-CJ-DJ-CM-1899. Also, the Rfis shall be filled completely and properly with all
required attachments as per latest approved ITPs.
Contractor: All QC inspectors are informed.
It was noticed that the reinforcimng bars at the sumps area of the cooling tower, has been submerged
under water for a long time (near the screen) and rust has been developing on the open coats of the re-
bars. The water on the surface shall be removed and rebars shall be inspected prior to apply repair
materials.
Subcontractor: For RFI MFC-DLM-AMA-CI-5504 & 5505, Amana QC will secure the latest
drawings of each area of inspection and other structures adjacent to it. QC will make sure that IFC
drawing is followed before calling for PID inspection. For RFI MFC-DLM-AMA-CI-5542, Missing
rebars were re-installed. All reinforcements shown in IFC drawings were installed correctly. For
RFI MFC-DLM-AMA-CI-5530C, Daelim issued revised IFC drawing to correct the slope of the
paving. Slope of the paving was rectified as per revised IFC drawing. All area are re-inspected
and approved for concrete pouring.
The Contractor is not submitting RFI for final acceptance of concrete structure as per Daelim ITP #
SMITP-Q-001-02 Item 3.6 which is "H" for the Contractor. Some of the structures have surface
deficiencies but the equipment are already installed. This is also a violation of Schedule Q Sec. 3.7
Subcontractor: Subcontractor has stated in the RFI for final Acceptance of Concrete structure
some structure has been checked and accepted.
During inspection at MCC room substation G-1121 for cable tray installation, it was observed that the
vertical spacing os cable tray is not maintained the cable spacing requirement the actual space was
150mm from top to bottom of the tray. This violates G7C-U321-01, Para. 5.2 & G7C-0302-00, Para.
3.7.1.
Contractor: The issue has already been addressed to Daelim Engineering team for review and
necessary action since the 150mm spacing was reflected in the design drawing.
Page 42 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
426
MR. AMIN DAELIM PN 3 MECH Piping 21-Dec-13 24-Dec-13 04-Jan-14 10-Feb-14 Closed
LBE-DLM-MECH-
427
MR. AMIN DAELIM PN 3 MECH Mechanical 22-Dec-13 25-Dec-13 05-Jan-14 10-Feb-14 Closed
LBE-AMA-MECH-
428
MR. GLENN AMA VAF 3 MECH Hvac 23-Dec-13 26-Dec-13 06-Jan-14
LBE will be
closed when
replacement
arrive on site.
17-Mar-14 Closed
LBE-TCC-MECH-
429
Coating/
Painting
23-Dec-13 26-Dec-13 06-Jan-14 23-Feb-14 Closed
LBE-AMA-CIVIL-209 MR. JERRY AMA VAF 1 CIVIL Civil 23-Dec-13 26-Dec-13 29-Mar-14 28-Apr-14 Closed
LBE-DLM-ELECT-
092
MR. FELOMINO DAELIM PN 1 ELECT Electrical 24-Dec-13 27-Dec-13 07-Jan-14 12-Feb-14 Closed
LBE-DLM-ELECT-
093
MR. FELOMINO DAELIM PN 1 ELECT Material 24-Dec-13 27-Dec-13 01-Jan-14 04-Mar-14 Closed
LBE-AMA-CIVIL-210 MR. JERRY AMA VAF 2 CIVIL Civil 24-Dec-13 27-Dec-13 07-Jan-14 01-Apr-14 Closed
LBE-GLOBAL-
MECH-430
MR. NASSAR GLOBAL VAF 3 MECH Quality Management 25-Dec-13 28-Dec-13 08-Jan-14 23-Feb-14 Closed
LBE-TCC-MECH-
431
MR. NASSAR TCC VAF 3 MECH Preservation 25-Dec-13 28-Dec-13 08-Jan-14 17-Feb-14 Closed
LBE-AMA-CIVIL-211 MR. JERRY AMA VAF 2 CIVIL Civil 25-Dec-13 28-Dec-13 08-Jan-14 20-Jan-14 Closed
LBE-TCC-MECH-
432
Coating/
Painting
26-Dec-13 29-Dec-13 09-Jan-14 16-Feb-14 Closed
LBE-KCC-MECH-
433
MR. GLENN KCC VAF 3 MECH Quality Management 26-Dec-13 29-Dec-13 09-Jan-14
QC Inspector
Rafique has
been seen only
once at site
24-Feb-14 Closed
LBE-DLM-MECH-
434
Mechanical
(Equipment)
26-Dec-13 29-Dec-13 03-Apr-14 02-Apr-14 Closed
LBE-DLM-MECH-
435
MR. HARIKUMAR DAELIM VAF 3 MECH Structural 26-Dec-13 29-Dec-13 23-Mar-14 Closed
PN: It is observed that daily RT requested weld joints must be cleaned from outside and inside
especially PWHT joints to avoid RT re-shoots. NDT coordinator or welding inspector shall ensure that
welder and joint identification is present for RT purpose. RT crew must write down the date of RT on
each weld joint to be RT'd. Repair joint should be marked and informed immediately to contractor aqnd
Company quality team. Daily based RT result coming from TRP shall be shared and communicated with
sub-contractor, Contractor and Company inspectors. Repair tracing/amrking shall be done by approved
welding inspector.
Contractor: Noted, action has been taken RAWABI and AMSYCO has been instructed to write
date on joint.
PN: Welder's rejection rate must be monitored closely on daily basis by Daelim Quality team.
Questionable skilled and High rejection rate welders shall be revoked. After revoked, they may be
allowed to resume welding if they received a minimum 8 hours training in the revoked welding process
and take and pass a WQT as specified in the governing codes, statndards or regulations. This training
must be documented and a copy of the documentation shall be submitted to Company. Ref. RT8S-6500-
001, Para. 2.5, 2.5.1, 2.5.2.
Contractor: Agree with proactive notification, Daelim team is monitoring repair rate daily basis.
Contractor revoked few welders and few stopped and sent for training.
Observed that Contractor proceeded with the installation of rejected fire and smoke dampers FSD model
manufactured by SAFID is not UL listed and labeled. This violates RT5S-5051-01/3.11.4 CFSD's shall
be multiple blade type with galvanized steel blacks and frame labelled in accordance with UL standards
555 & 5555 for 1 1/2 hour rating. RT52-5000-01/6.2.4 Provide CFSD in duct penetrations where the
exterior or enterior walls are 2 hours fire rated. Schedule "Q" Para. 7.3.2 Contractor shall establish and
maintain control to restrict further processing or installation of nonconforming or defective items.
Contractor: Noted. The rejected temporary fire/damper shall be replaced by
Contractor/subcontractor as soon as the new materials arrive.
It has been observed at TCC-2 workshop, some spools have been rusted. TCC handled and shifted the
spools to site for installation. This is for information, root cause analysis and corrective action.
Subcontractor: IK-MFC-T-DJ-CJ-QM-1854, DAELIM NCR closed.
RFI No. MFC-DLM-AMA-CI-5643/5645. During the FDT of bottom of foundation of FD-Fan Foundation
and F# Type foundation (North of Liquid Furnace F-1240 & F-1250) the Technician (Osaimi) perform the
test without calibrating the nuclear gauge against the standard block since it was already calibrated.
After the FDT, the backscatter serial number was checked and found to be different from the serial no.
of the nuclear gausge (38778 for nuclear gauge and 32720 for the bacscatter) Also, the serial number of
the bacskcatter is not clear. This is a violation of ASTM-D-6938 regarding calibration as explained in
Annex A1 of this standard. The test performed is not acceptable and a warning shall be given to
Technician and Laboratory.
Contractor: Third party laboratory was notified of the said issue and they have replied as stated
in the attached letter. Contractor and subcontractors shall monitor and follow-up the corrective &
preventive action herein stated by the third party laboratory. Contractor and Subcontractor QC
inspectors shall check reference blocks prior to use.
It has been noticed that during blasting activities, TCC has not installed remote control shut-off "dead-
man" on the blasting hose. This is violation against work procedure and safety requirements during
blasting activities.
Subcontractor: IK-MFC-T-DJ-CJ-QM-1856, DAELIM NCR-046 closed.
PN: During surveillance at substation 1120, it was observed that the MCC panel and VFD panel were
started installation without Material Receiving inspection. This violates as per schedule "Q", Para. 3.2.
Contractor: Subcontractor and Daelim Construction team were advised not to fix/anchor the
panel until material receiving inspection is done. The said panelws inside SS G-1120 were set-up
for positioning and arrangment pusposes to protect and preserve the panels from workers working
and coming in and out of the substation.
There are wood embedment at the top portion of the wall of Cooling Tower located at North-East portion
of Sump. The wood shall be removed and inspected prior to conduct any repair. These woods were
used as spacers.
Subcontractor: Amana Construction has started chipping work to remove embedded wood at top
portion of cooling tower. Once wood is removed, QC will raise RFI for inspection. On-going.
During routine inspection at MFC site for Insulation activities, it has be noticed that Global Suhaimi
Insulation Inspector always not available at site during insulation inspection activities since a month.
Corrective Action shall be taken by Contractor to avoid any mistake during quality process.
Subcontractor: QC Inspector was in emergency vacation due to some family issues. But, it was
informed to QC department and other QC Inspector was already covered in the site all the time.
During surveillance at TCC-2 blasting/coating facility, it has been noted that TCC used contaminated
recycled garnet for surface preparation on spools. This violated Sadara Standards and approved Work
Procedure.
Subcontractor: Recycled garnet third party tent was here.
Again, the surface finish of pavements west of sub-station G-1121 are irregular with light brown finish
and grinded to level with the adjacent surface. The appearance of the grounded portion is not
accpetable as is differs from the adjacent surface finish. Also the edlge of the adjacent scale are not
properly trimmed against the slope and the paving.
Subcontractor: The Affected area mistake done by the site foreman due to misunderstanding
between site engineer and foreman, subcontractor do agreed to rectify effected area. The
corrective action is mentioned below: 1. Effected Area will be Marked and cut/chip the concrete
minimum depth of 50mm deep. 2. once chipping has done, subcontractor to submit RFI for
Inspection. 3. After getting the approval prior to casting concrete we do apply bonding agent and
cast approved concrete.
PN: During surveillance at DAELIM laydown area, it was observed that the MCC Panel was stored
outside. This violates Contractor's Preservation Plan, Para. 2.9.1.
Contractor: MCC panel which was observed stored outside in laydown yard already transverred
to MFC site. New arrival of panels will be coordinated to Material department for proper
preservation as per plan.
No Subcontractor UG-Piping QC Inspector. Observed that KCC has no approved Underground Piping
(RTR) QC Inspector on site for over 2 months. This violates Schedule "Q" atta. VI, section 1.1 As a
minimum Contractor shall assign or require its Subcontractor to assign approved full time Quality
personnel/inspector to the work in accordance with table VI-1. Subcontractor shall provide one U/G
Piping Inspector per 15 installers.
Subcontractor: KCC approved UG-Piping QC Inspector Mr. Rafique will be available on the site
1st week of February 2014.
During pre-assemble verification of internal tray for T-2410 C# splitter observed that numerous tray and
accessories exhibiting severe oxydation, vapor corrosion and the preserved coating were damaged due
to improper preservation method. Contractor must visually inspect all incoming Materials and Equipment
damage and for conformance to all appilcable requirements. Violation of A554-E-103-QA-GEN-PRO-
035. RT-6LCS, Para. 2.19.3.
All Internal Tray Corrosion has been clean and rectified as per company/vendor recommendation
capor phase sorrosion inhibator any internal tray subject for the installation shall be checked first
prior to installation, for preventive measures, all trays shall be covered and protected as per
approved materials such as polytheline sheets and VPCI
Lack of inspection coverage for Structural Inspection: Observed that one QC Inspector. All inspection
activities at Eastern MFC areas. Quality discrepancy is repeated frequently and not enough surveillance
covereage for Subcontractors (ARC, TCC, SENDAN & ASYAD). Daelim shall take necessary corrective
action in order to avoid further adverse effect at site.
Company has revised NCR on the same Corrective action will be taken accordingly as per NCR.
Page 43 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
20
LBE-ARCC-
MECH-436
MR.
HARIKUMAR
ARCC VAF 3 MECH Piping 26-Dec-13 29-Dec-13 09-Jan-14 Open
LBE-ARCC-MECH-
437
MR. NASSAR ARCC VAF 3 MECH
Coating/
Painting
26-Dec-13 29-Dec-13 23-Feb-14 04-Mar-14 Closed
LBE-TCC-MECH-
438
MR. NASSAR TCC VAF 3 MECH Preservation 26-Dec-13 29-Dec-13 09-Jan-14 16-Feb-14 Closed
LBE-AMA/KCC-
CIVIL-214
MR. JERRY AMA VAF 2 CIVIL Civil 26-Dec-13 29-Dec-13 09-Jan-14 26-Mar-14 Closed
LBE-AMA-CIVIL-215 MR. JERRY AMA VAF CIVIL Civil 26-Dec-13 29-Dec-13 09-Jan-14 05-Jan-13 Closed
LBE-DLM-ELECT-
094
MR. FELOMINO DAELIM VAF 1 ELECT Material 28-Dec-13 31-Dec-13 01-Jan-14 26-Mar-14 Closed
LBE-KAF-MECH-
439
MR. NASSAR KAEFER VAF 3 MECH Fireproofing 29-Dec-13 01-Jan-14 12-Apr-14 Closed
21
LBE-DLM-
MECH-440
MR. NASSAR
DAELIM
(Enginnering)
VAF 3 MECH
Mechanical
(Equipment)
29-Dec-13 01-Jan-14 19-Mar-14 Open
LBE-TCC-MECH-
441
MR. AMIN TCC VAF 3 MECH Preservation 31-Dec-13 03-Jan-14 14-Jan-14
Still waiting for
corrective action
15/2/2014
17-Mar-14 Closed
LBE-DLM-MECH-
442
MR. AMIN DAELIM VAF 3 MECH Piping 31-Dec-13 03-Jan-14
Still waiting for
corrective action
Mar. 2, 2014
28-Apr-14 Closed
LBE-DLM-MECH-
443
MR. AMIN
DAELIM
(QA/QC)
VAF 3 MECH Piping 01-Jan-14 04-Jan-14 28-Apr-14
Still waiting for
reply & corective
action, Mar. 2,
2014.
25-Jun-14 Closed
LBE-KCC-CIVIL-216 MR. JERRY KCC VAF 2 CIVIL Civil 02-Jan-14 05-Jan-14 26-Feb-14 14-May-14 Closed
LBE-AMA-CIVIL-217 MR. JERRY AMA VAF 2 CIVIL Civil 02-Jan-14 05-Jan-14 16-Jan-14 04-Mar-14 Closed
It was noticed that the trench/open ditch south-east of Fresh-Ethane structure was backfilled without
completing the seven days cuting period. This is a violation of RT2S-3001-01, Para. 9.1.2. Also, the
Structure was backfilled for access of heavy equipment (Crane). The structure sahll be investigated for
damage during removal of backfilled materials.
Contractor: Open ditch located at south east of fresh ethane structure was backfilled by KCC and
advised by Daelim construction team. Amana has seen the removal of backfilling material to
investigate the structure. Open ditch is totally covered by polythylene sheet.
During site monitoring, the slab of fresh ethane structure was noticed to have irregular surface finish.
Some of the area were roughly finish instead of light brown finish. The Contractor/Subcontractor shall
include this structure in the list of structure to be repaired for top surface finish irregularities. This is a
violation of RT2S-3001-01, Para. 11.1.1.
Subcontractor: Construction is agree to do repair work after completion of TCC work.
Contractor/Subcontractors are advised to utilized forms from sound materials properly made in
accordance with RT2S-3001-01, Para. 6.1. It was noticed that the Subcontractors are utilizing form with
split ends, creating incorrect shapes, lines and dimensions shown in the drawing.
Subcontractor: Advised to Construction team to use sound material and use form oil to maintain
correct shape of structure
Misalignment, distortions, offset at weld joint observed at ARCC field
installaed piping system. Weld joints weredistorted, misaligned and pipe
cocked to one side after welding which is caused by
*Weld joint strength reduction factor *Detrimental strain in Equipment,
piping of components is prohibited. *Excessive piping sag/or desctruction
subject to cause of creep under condition of repeated internal cycle.
Subcontractor: ARCC rectified the distortion joint by cut & reweld.
Refer to attached RFI - 359, 425 & 439.
It has been noted that GIC-ARCC Coating inspector is not assigned during painting activities and
inspection time at GIC workshop. This vioates schedule "Q" attach. VI. Wopkshop has been verified in
the presenece of Daelim inspector and found to be satisfactory. The documented logbook entry will
beescalated to NCR when lack of action by Contractor
During surveilllance at TCC-2 fabrication facilities, it has been noticed that TCC is keeping their stain
less materials and carbon steel materials together and did not segregated. Stainless steel materials
have been kept on ferrous support and have not protected from environtmental conditions. In addition,
stainless shall be stored , segregated from ferrous materials such as carbon steel. This violates Material
and Equipment protection and preservation plan, item 2.15.
Subcontractor: IK-MFC-T-DJ-CJ-QM-1854 DAELIM NCR-046 closed.
It is observed that repairs and penalities RT Backlog has increased since many days of all
subcontractors. In this situation if welder's previous result of backlog appears deffective then welders
cannot be judged at exact time parallel to his production and repair rate cannot be controlled. Daelim
must update and record the pending repairs and penalties of each welder and compare their present RT
Rejection rate to retain or revoke them. Also update the welder's performance report which shows that
how many repairs and penalties are pending for each welder since what date and welder's present
status that he is still working or already revoked. Ref. ASME B31.1 Para # 341.3.4, A554-E103-GEN-
PRO-056 Para # 19.4, p19.5, & RT8S-6500-01 Rev. 03.
Contractor Closely Monitoring all welders in MFC and whenever there is any welder exceeds the
specified limit the welders are susupended for first time as per SADARA site notice and stop all
productions for the welders. Contractor is working on backlog repair and penalty for the welders to
complete as soon as possible. Regarding the corrective action for theabove-mentioned matter,
Daelim is monitoring the welders day by day RT basis by daily RT assessment and if anyone
exceeds the specified R/R, he will be suspended from work/project.
The Contractor/Subcontractor cut the concrete beam of Debutanizer Structure clashing with the pipe.
This reduces the cover of the reinforcing bars and violates RT2S-3001-01, section 7, Para. 7.1.8 where
the cover for exposed to weather for beams is 75mm.
Subcontractor: KCC received site instruction from Daelim to chip/grind portion of beam to give
way for the pipe installation. After the installation and alignment inspection of mechanical piping,
KCC will do the cementitious grouting to cover the exposed rebars. The area was already repaired
and painted with expoxy paint as additional protection for rebars.
It was observed that the top of pedestal of vessel B-2058 has been hit during installation of Vessel
creating a crack on the upper edge of the pedestal. An investigation has to be done.
Contractor: Already inspected and grouted the pedestal.
During routine inspection for insulation activities of Water Quence Towe (T-
1410), it has been noticed that there is no adequate distance between step
ladder of ladder cage and insulation ring (approx. 2"). As per standard
requirement the distance required is 230mm. This is for your information
and corrective action required.
Subcontractor: This isue is related to Daelim Engineering. Reply fom
Daelim Engineeing attached. Contractor: Contractor will modify the
ladder for expanding distance between ladder rung and insulation ring.
For this issue, we already received the confirmation for repair
procedure from Company.
Found that SS pipe spools are not preserved/covered at TCC Fab facility 1 and getting environmental
effects which represents the start of rust on them. Also TCC needs to improve storage arrangements to
avoid cross contamination between CS and SS materials. may pipes ends are open and lying with
ground in direct contact and shown to TCC and Daelim QC inspectors. TCC to provide list of all SS
spools in TCC 1 whch can explain that these spools requires sand blasting and coating or not.
Found that Daelim Piping Inspector doesn't have close monitoring on In-Process Fit-Up activities.
During surveillance, Company found Fit-up joints: 1.Bevels angle of joining components was not
uniform. 2. Bevels were damaged by deep grinder cuts. 3. There was zero root face of the light and
heavy thickness Fit-up joints. 4. Tack Welding performed on heavy thickness (42"dia 22.5mm thick) joint
without preheating as the metal temperature was less than the required temperature as per WPS and
ASME B31.3
The Affected joints was rejected QC Inspector was given strong warning now in future a cross
check and close monitoring will be observed.
AMANA RFI No. 811 (MFC-DLM-AMA-CI-5555-0B). During inspection of the above RFI, the following
deficiencies were noted:
1. Rebars installed at the opening is missing. (16mm - 8 members) only 2 were installed instead of 4 as
shown on the drawing. 2. The location of the puling iron is wrong. The location should be at the opposite
side of the opening. This RFI is rejected.
Contractor: Already rectified and complied the comments and re-inspected. RFI No. MFC-
DLM-AMA-CI-55555-0C
During Material Receiving inspection of RFI No. MFC-DLM-SIEMENS-EL-005 at Daelim laydown area
for FACP, it was observed that the fire alarm control panels color do not comply to Company color
selection desigN aid compared to the actual color of panel are light gray and black. This violates as per
RT16D-0120-01.
Contractor: This issue was already coordinated to Engineering for answered & clarification.
It has been noticed that Kaefer Fireproofing QC Inspector is not assfined during painting activities and
inpsection time at MFC site. This violates Schedule "Q" and ITP. The documented logbook entry will be
escalated to NCR when lack of action by Daelim.
Subcontractor: The assigned QC Inspector for the activity gone for emergency vacation so there
was delay all activities, QC inspector will be available at site during all activities.
Page 44 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
444
MR. AMIN DAELIM VAF 3 MECH Quality Records 02-Jan-14 05-Jan-14 16-Jan-14 02-May-14 Closed
LBE-AMA-CIVIL-218 MR. JERRY AMA VAF 2 CIVIL Civil 04-Jan-14 07-Jan-14 02-Apr-14 15-Apr-14 Closed
LBE-AMA-CIVIL-219 MR. JERRY AMA VAF 2 CIVIL Civil 04-Jan-14 07-Jan-14 18-Jan-14 13-May-14 Closed
LBE-AMA-CIVIL-220 MR. JERRY AMA VAF 2 CIVIL Civil 04-Jan-14 07-Jan-14 18-Jan-14 02-Feb-14 Closed
22
LBE-DLM-
MECH-445
MR. SAYED
DAELIM
(Procurement)
VAF 3 MECH Material 05-Jan-14 08-Jan-14 Open
LBE-TCC-MECH-
446
MR. SAYED TCC VAF 3 MECH Quality Management 05-Jan-14 08-Jan-14 19-Jan-14 10-Mar-14 Closed
LBE-KCC-MECH-
447
MR. GLENN KCC VAF 3 MECH UG-RTR 05-Jan-14 08-Jan-14 19-Jan-14 22-Apr-14 Closed
LBE-KCC-MECH-
448
MR. NASSAR KCC VAF 3 MECH
Coating/
Painting
05-Jan-14 08-Jan-14 12-Apr-14 12-Apr-14 Closed
LBE-DLM-MECH-
449
MR. KURIAN DAELIM VAF 3 MECH
Mechanical
(Equipment)
05-Jan-14 08-Jan-14 19-Jan-14 14-Apr-14 Closed
23
LBE-DLM-
MECH-450
MR. KURIAN
DAELIM
(Mat. Dept)
VAF 3 MECH Preservation 06-Jan-14 09-Jan-14 Open
24
LBE-DLM-
MECH-451
MR. KURIAN
DAELIM
(Construction)
PN 3 MECH
Mechanical
(Equipment)
07-Jan-14 10-Jan-14 Info
LBE-TCC-MECH-
452
Mechanical
(Equipment)
07-Jan-14 10-Jan-14 11-Mar-14 11-Mar-14 Closed
LBE-AMA-CIVIL-221 MR. JERRY AMA VAF 2 CIVIL Civil 07-Jan-14 10-Jan-14 27-Feb-14 15-Apr-14 Closed
Test Fluid not removed at low spot. It was observed that test water at low spots was not removed after
hydrotesting of firewater lines HT-007 conducted on 21 Dec. 2013. This violates Company General
Requirements for Pressure Testing and Lay-up (A554-0-PRG-QA-GEN-PRO-014) section 11.1...No test
fluid shall remain in low spots. Typical to HT-011.
Subcontractor: Test fluid retained at low spots after hydro testing shall be removed during the
pre-commissioning time. KCC will be responsible for the flushing out of water.
It was noticed that KCC did not assigned Coating Inspector for Tape Wrapping activities and Holiday
test examination. This is violation against Sch. "Q", Attachment IV. Daelim needs to comply with
Company relevant standard requirements and need to provide corrective action necessary to rectify this
failure.
Subcontractor: KCC Inspector was on emergency leave vacation & Daelim Inspector was
covering for the activity Holiday test activities were performed by TCC Inspector.
During inspection of orientation, centering and plumbness of the Equipment FL-1304 A/B and FL 1316A,
it is detected that these equipment were installed with a displacement of rear about 10 deg. from
designed orientation in IFD drawing. It is also impacted a vast difference in centering measurement
tolerance contrary to the specification requirement of 3mm. These variations of orientation & centering
can cause mis-match of piping connection with the equipment nozzle also can adversely affect the
equipment with increased stress area and interupted flow during process. Violations as per A554-E-103-
QA-GEN-PRO-035 Para. 12.2.7, 13.8.2, A554-E-103-QA-GEN-PLN-056, SMIC-D-2007-01, 41, A2, A3.
Subcontractor: Noted. Check with equipment group and come up with answer. TCC Construction
is waiting for Engineering reply
At the N-S Cable tray for FIB type foudnation East of substation G-1121 N/W pedestal was chipped after
the installation of structural steel. Contractor shall advise ither Subcontractors to install carefully the
equipment/structural steel to avoid damage on existing foundation or pedestal.
Contractor: already advised to sub-contractor to carefully install the structure/equipment to avoid
damage of pedestal foundation. Already grouted the N-S Cable tray foundation FIB.
During inspectionof Valve leak testing at NASICO, leakage observed at
Seat of a 18 nos of butterfly valves supplied by Zero Engr. And it is beyond
the acceptable limit. Hence, valve is rejected. This violates API S98 para.
3.9.2. The Contractor shall follow up with the issue and notify the supplier
for repair or replacements.
There are shortage of Subcontractor Welding Inspector in TCC site area at present 66 welders are on
site, and only 3 Welding inspectors assigned covering the 66 welders. This is violation against Sch. "Q"
Att. VI, table VI-1 which calls for one inspector per 15 welders.
Subcontractor: The MFC site welding inspector is at 27/1/2014, 4 welding inspectors.
It is observed that Daelim needs to revise the preheat temperature of some WPS which are not meeting
the B31.3 requirements. Two examples ate WPS # TCC-WPS-P1/P1-08 Rev. 0 and TCC-WPS-P1/P1-
04 Rev. 0. Preheat requirement as per B31.3 for P1 CS < 25mm thick is 10 deg. C and for > 25mm is 80
deg. C but above mentioned WPS, are requiring only 21 deg. C or 10 deg.C regardless of the thickness
not meeting.
Contractor: The affected WPSs shall be revised to include B31.3 Preheating requirements.
However, regarding mentioning para no. 6.2.3 (RT8S-6500-01) on WPS, Contractor agrees that
the same can be done on any new WPSs (or on any new revisions). But revising the approved
WPSs solely for that reason will be very tedious and unnecessary.
During inspection/survey of S-wall and paving at north of East-West pipe rack/south of substaion G-
1120, the drawing shows a slope of only .102% (DWG No. E-015103-A0002-CV-C-10-001 Rev. 6B) The
slope is a violation to Technical Memorandum #TM-CV-043 and RT2D-K100-00, 4.1.24. The S-wall must
be redesigned to meet the requirements of this standard. (RFI-MFC-DLM-AMA-CI-5740).
Subcontractor: Regarding the Slope of swale and paving sub-contractor has adjusted the slope
as per requirement, Daelim to revised the IFC drawing work has been executed and approved the
IFC Drawing Already Revised with Drawing No. A554-E-016013-AD00Z-CV-C10-001 Rev. 6B
RFI # MFC-DLM-AMA-CI-5762. During inspection of Cooling Tower Wall at Stop logs area room #4,
BASIN, it was noticed that the adjacent wall connecting the stop logs have a thickness of 450mm while
the design requirement is only 400mm. Contractor shall rectify the wall existing thickness to meet the
design requirements.
Subcontractor: As per Daelim advised, Amana to maintain 400mm thickness after that were wall
thickness above 400nn, Amana agrees to chip those area and repair with repair material.
After the rain, it was noticed that some portion of paving have water of about 1" depth located at 6L-21-
22 west side of N-S piperack and in another location at E-1428/NS pipe rack-west site, at the Cooling
Tower area several construction joints are leaking and some portion of the foundation slab shows
leakage bur there were no marking for the area to be injected. An email was sent with pictures of the
leaking part of the cooling tower and concern regarding patching only of extended side which
cannotcover the leak of the inernal portion of cracks or honeycombs. Contractor is advised to provide
corrective action plan for this concern.
Contractor: Subcontractor advised to QC and Site Engineer to mark those leakage area to start
repairs/ injection. Construction already marked those and started the chipping to find out leak
point. As per meeting with BASF tha all construction joint need to be chipped and inject before
lining work.
During surveillance at MFC laydown yard shown equipment Secondary
demethanizer OUHD condenser (E-2123) were preserved in a wrong way
by keeping the equipment in direct contact with the ground. Outdoor
storage requires separation from sand/mud or areas subjected to pouring
of water. Cross-cut timber with specific dimensions may be used as
recommended in the specification. The equipment is supplied bu vendor
Fives Cryos. This activity is found to be a violation as per A554-E-103-QA-
GEN-PRO-035, para. 8.2.1, 8.2.3, 8.2.4.
PN: Received an equipment D21-24 (Reflex drum) this with three others. T-
2120 (Secondary Demethanizer) E-2121 (Interncondenser) & 2123 will be
installed one over the other vertically with T-2120 at the bottom. E-2121 &
E-2123 are yet to arrive but SME, Engineering and Vendor guidance
instruction required to whether to carry out a combined hydrotest to prove
the integrity of the bolted flange joints of these equipment. The general
arrangement drawing is also mentioning of field hydro test for about 21.047
bar.
Equipment E-2330, E-2331 having washers (16mm) welded with extra some thickness of metal piece in
order to compensate the shortness in length of the threads in anchor bolts for nuts, required hi bolt
tightening. Engineering classification were not provided during bolt tightening. On enquiry, it is found
that the welding was done without the information of welding inspector for witnessing the job, hence
without an RFI rasing.
Subcontractor: After getting Engineering remarks for the use of 32mm thick washer was carried
out and RFI has been served and accepted.
Page 45 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-222 MR. JERRY AMA VAF 2 CIVIL Civil 07-Jan-14 10-Jan-14 04-Mar-14 04-Mar-14 Closed
LBE-DLM-ELECT-
095
MR. FELOMINO
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 12-Jan-14 15-Jan-14 26-Jan-14 12-Jul-14 Closed
LBE-AMA-CIVIL-223 MR. JERRY AMA VAF 2 CIVIL Civil 13-Jan-14 16-Jan-14 27-Jan-14 01-Apr-14 Closed
LBE-KCC-CIVIL-224 MR. JERRY KCC VAF 2 CIVIL Civil 13-Jan-14 16-Jan-14 29-Apr-14 29-Apr-14 Closed
LBE-AMA-MECH-
453
MR. GLENN AMA VAF 3 MECH Hvac 13-Jan-14 16-Jan-14 27-Jan-14 30-Jan-14 Closed
LBE-AMA-MECH-
454
MR. GLENN AMA VAF 3 MECH Hvac 13-Jan-14 16-Jan-14 27-Jan-14 23-Feb-14 Closed
LBE-AMA-MECH-
455
MR. GLENN AMA PN 3 MECH Hvac 13-Jan-14 16-Jan-14 27-Jan-14 23-Feb-14 Closed
LBE-AMA-CIVIL-225 MR. JERRY AMA VAF 2 CIVIL Civil 15-Jan-14 18-Jan-14 29-Jan-14 20-Jan-14 Closed
LBE-AMA-CIVIL-226 MR. JERRY AMA VAF 2 CIVIL Civil 15-Jan-14 18-Jan-14 29-Jan-14 02-Feb-14 Closed
LBE-AMA-CIVIL-227 MR. GERALD AMA VAF 2 CIVIL Civil 15-Jan-14 18-Jan-14 29-Jan-14 21-Jan-14 Closed
LBE-AMA-CIVIL-228 MR. GERALD AMA VAF 2 CIVIL Civil 15-Jan-14 18-Jan-14 02-Apr-14 29-Apr-14 Closed
LBE-AMA-CIVIL-229 MR. GERALD AMA VAF 2 CIVIL Civil 16-Jan-14 19-Jan-14 30-Jan-14 04-Feb-14 Closed
LBE-AMA-MECH-
456
MR. GLENN AMA VAF 3 MECH Hvac 18-Jan-14 21-Jan-14 07-Apr-14 Closed
LBE-AMA-MECH-
457
MR. GLENN AMA PN 3 MECH Hvac 18-Jan-14 21-Jan-14 23-Feb-14 17-Mar-14 Closed
LBE-TCC-MECH-
458
Coating/
Painting
18-Jan-14 21-Jan-14 01-Feb-14 23-Feb-14 Closed
It was noticed during monitoring of Cooling Tower corridor that the honeycomb near the construction
joint/expansion joint (East side) is excessive. There is no more concrete holding the waterstop and the
dowels are exposed. The reinforcing bars are also exposed. The Contractor was advised to seek
recommendation from the manufacturer of the right grout and method to repair this excessive
honeycomb.
Contractor: As per manufacturer recommendation, the excessive honeycomb area should be
filled with micro concrete (Master Emaco Sch33). The surface area to receive the grout is ready
and inspected by the Contractor and Company.
At GL-72/73 of East-West Pipe Rack it was noticed that the beam located at the east side (GL 73) North
has a crack. The crack looks as if the plate was subjected to strain since the area affected is the plate.
Please investigate.
The Cracked area on the beam was already repaired by capping & removing the Loose concrete
& grouted using non-shrink cementitious grout.
Isolation valves without union. During inspection in operator building G-1122, it was observed tjat valves
are installed in PW lines without union. This violates RTSAES-S-060, Para. 605.8.b, a union shall be
installed adjucent to each threaded valve in metallic systems.
Subcontractor: Union will be provided adjacent to the isolation valves for maintenance and
servicing. This will be revised in the drawing accordingly. Union will be installed and Daelim
Construction team and QC Team will ensure the insulation.
It was noticed that during monitoring the effect of heavy rainfall at site yesterday, several excavated
area have eroded such as sump pits, pad water tank foundation and excavated pipe adjacent to the
structures, Air Cooler area and adjacent pipe excavation, Fire monitor and fire hydrant excavated area,
etc. and the eroded soil covered the area. This soil shall be removed and shall be replaced with
approved materials for backfilling since the soil contains mud exceeding the limit of the standard
requirement and these is no record of backfilling and compaction test.
Subcontractor: The mud on the pipe and flange were already removed and cleaned and already
backfilled with the approved backfilling materials. Embeded sand already remobed from sump
area, leak test work on going, once area test is approved, backfilling will be started by approved
backfilling materials.
During inspection of Power Transformer installation tag # TR-103G101A and TR-103G101B at
Substation G-1120, it was observed that the terminal connection pads of primary connection was not tin
plated and secondary connection pads were not properly tin plated coating. This violates as per G7D-
0930-00 Para. 6.3
Contractor: Contractor shall coordinate to procurement & engineering teams on this issue. The
issue was coordinated to Engineering for some clarification so that it will be closed.
With reference to RFI No. AMA-CI-5885-OA & AMA-CI-5886-0A. For roof slab (Concrete Block area) at
generator building G-1124, it was noticed that the area is not ready for inspection and the documents
intended for the RFI are incomplete. In this regards, Contractor is advised to inspect internally first and
see to it the all documents are prepared prior to invite SQG for inspection for proper documentations.
Sub-contractor: It is advised to QC Inspector before going for any inspection to arrange the RFI
and related documents to avoid rejection of inspection. Also, advised to check the area properly
that the area is ready for final inspection or not.
HVAC duct overhead communication room. It was observed in MCC/PIB G-1120 that AC ducts are
routed above communications room. This violates RTSAES-T-916 Sec. 4.4.2 Minimum design
requirements for telecommunications room. Overhead routing of other utilities shall be avoided to
prevent obstruction of telecomms room above ceiling access. Provide SME concurrence. If approved,
both wall penetrations shall have CFSD to maintain fire rating of the calls.
Subcontractor: in regards to HVAC duct Overhead in Communication room which located @ the
duct upper portion and theirs no obstruction that can violates to the RTSAES-T-916 Sec. 4.4.2
PN: Missing FD/CFSD in fresh air duct. It was observed in MCC/PIB E-1120 that FA duct penetrating fire
rated wall between DCS & Mechanical room has no CFSD. This is not compliant to the following
requirements: RT52-5001-01 Sec. 9.16 Provide FD or CFSD at all duct penetration of firerated walls in
accordance with KSA Safety & Fire Protection Directories. IMC or other local code enforced. NFPA 90A
sEC. 4.2.1.3.1 Outside air intakes shall be equipped with an approved fire equipped with an approved
fire damper when not located to meet the requirement of 4.2.1.3. NFPA 90A Sec. 4.2.1.4.1 - Outside
intakes shall be equipped with an approved smoke damper when not located to meet the requirement of
4.2.1.4. Use correct abbreviations to identify FD or CFSD in the IF drawing.
Contractor: Noted. Daelim QC inspector already discussed and informed to Construction group
regarding the issue.
With reference to RFI No. AMA-CI-5853-0A for open ditch near substation bldg. G1120, it was found out
during the witnessing of survey that the actual survey slope is less than the requirement of .123% of the
design and .120% Company minimum requirements. Contractor to ensure that prior survey is conducted
and the requirements of Project Specification and design drawing are met prior to invite SQG for
witnessing. Also, Contractor surveyor shall check first the work by Subcontractor to ensure requirements
with regards to location and elevation are in accordance with the IFC drawing.
Contractor: Already counter-checked both by Daelim and Amana Surveyor. Already rectified the
slope of open ditch (0631-D1100-0005) the requirements of 0.123%.
During surveillance and monitoring activities at Operator building, along corridor area, it was found out
that no proper curing and burlap application on newly grout applied on the floor. In which as of yesterday
only one (1) after grout application. In this regards, Contractor is advised to take corrective action
concerning this issue for proper implementation.
Subcontractor: Subcontractor alreadyplaced the burlap and plastic and proper curing has been
done at same day.
With reference to LBE No. 175 at Operator building along monitoring area and permit issue area. As per
surveillance and monitoring, the remaining repair works/trust up at soffit slab and beams are not
implemented as of date. Since some electrical piping are already installed. In this regards, Contractor is
advised to expedite the repair works for the saind structure.
Subcontractor: regarding soffit slab anf beams subcontractor already remove all loose concrete
and clean the area, subcontractor is going to install false ceiling those area soffit slab and beam
will be covered by false ceiling.
Janitor room without service sink provision. During inspection in operator building G-1122, it was
observed that water and drainage lines are not provided for service sink in Janitor room. This does not
conform to RTSAES-S-060 Sec.1.1 / IPC sec. 403.1 Plumbing fixture shall be provided for the type of
occupancy and in minimum number shown in Table 403.1 nd Feed drawing A554-T-103-AR-DWG-A10-
004. Janitor room has to be provided with service sink for cleaning of janitorial equipment.
Subcontractor: Service sink provision will be provided based on the approved IFC drawing.
PN: Missing water hammer arrestors. During inspection in operator building G-1122, it was observed
that water hammer arrestors (WHA) are not provided nor indicated in IFC drawing. This violates
RTSAES-S-060, sec. 1.1/lpc 604.9 The flow velocity of the water distribution system shall be controlled
to reduce the possibility of water hammer. A water hammer arrestor shall be installed where quick-
closing valves are utilized. The arrestor shall be located within an effective range of the quick closing
valve. WHA shall conform to ASSE 1010. Access shall be provided to WHA.
Subcontractor: Water hammer arrestor will be provided after the approval of IFC Drawing.
Drawing has been submitted to Sadara for approval.
During the torquing of the mechanical coupler for the column extension of P-1321 Piperack, the torque
capacity was checked and it was found out that it is less than the requirement of 185 ft-lbs as required
by the manufacturer. Contractor shall check first the equipment prior to inviting SQ group for witnessing.
Torquing is still pending.
Subcontractor: Already replaced torque and set by 185 ft. lbs
It has been noticed that TCC released too many coated pipes & spools from workshops (TCC-1 & TCC-
2) to MFC site for installation without informing or offering SADARA QIT for inspection. Furthermore, all
those pipes & spools were blasted by recycled garnet which used for blasting without provide Lab tests
certificates (Chlorides & sulfate contamination test, sieve analysis. Water soluble contamination test and
conductivity & oil content test) as per SSPC AB1 & SSPCAB2. This is violation against schedule Q and
work procedure for Garnet recycle system. Note: Blasting & Coating activities have started on 13th Jan.
2014.
Subcontractor: Noted. Test report will be submitted.
Page 46 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-TCC-MECH-
459
Mechanical
(Equipment)
18-Jan-14 21-Jan-14 14-Jan-14 12-May-14 Closed
LBE-TCC-MECH-
460
Mechanical
(Equipment)
18-Jan-14 21-Jan-14 01-Feb-14 03-Apr-14 Closed
25
LBE-TCC-
MECH-461
Mechanical
(Equipment)
19-Jan-14 22-Jan-14 19-Mar-14 Open
LBE-PCMC-MECH-
462
MR. KURIAN PCMC VAF 3 MECH Piping 19-Jan-14 22-Jan-14 24-Mar-14 26-Mar-14 Closed
LBE-TCC-MECH-
463
Mechanical
(Equipment)
19-Jan-14 22-Jan-14 02-Feb-14 23-Mar-14 Closed
LBE-KAF-MECH-
464
MR. KURIAN KAEFER VAF 3 MECH Fireproofing 20-Jan-14 23-Jan-14 23-Jan-14 12-Apr-14 Closed
LBE-SEN-ELECT-
096
MR. MARK SENDAN VAF 1 ELECT Electrical 20-Jan-14 23-Jan-14 03-Feb-14 13-Feb-14 Closed
LBE-DLM-INST-097 MR. PERVEZ
DAELIM
(Procurement)
VAF 1 INST Instrumentation 22-Jan-14 25-Jan-14 05-Feb-14 24-Jun-14 Closed
LBE-AMA-CIVIL-230 MR. GERALD AMA VAF 2 CIVIL Civil 23-Jan-14 26-Jan-14 06-Feb-14 06-Feb-14 Closed
26
LBE-DLM-
MECH-465
MR. SAYED
DAELIM
(Construction)
VAF 3 MECH Piping 23-Jan-14 26-Jan-14 06-Feb-14 Open
27
LBE-AMA-
CIVIL-231
MR. GERALD AMA VAF 2 CIVIL Civil 25-Jan-14 28-Jan-14 20-Jul-14 10-Aug-14 Open
28
LBE-DLM-
INST-098
MR. PERVEZ
DAELIM
(Enginnering)
VAF 1 INST Instrumentation 26-Jan-14 29-Jan-14 09-Feb-14 24-Jul-14 Open
LBE-DLM-INST-099 MR. PERVEZ DAELIM VAF 1 INST Instrumentation 26-Jan-14 29-Jan-14 02-Mar-14
Contractor to
provide full time
QC Inspector 18-Mar-14 Closed
LBE-ASYAD-INST-
100
MR. SHABIRUL ASYAD VAF 1 INST Instrumentation 26-Jan-14 29-Jan-14 02-Mar-14 08-Apr-14 Closed
LBE-DLM-ELECT-
009
MR. MARK
DAELIM
(Mat. Dept)
VAF 1 ELECT Preservation 27-Jan-14 30-Jan-14 15-May-14 02-Jun-14 Closed
29
LBE-AMA-
CIVIL-232
MR. JERRY
DAELIM
(Construction)
VAF 2 CIVIL Civil 28-Jan-14 31-Jan-14 Open
During routine inspection for applied fireproofing (2nd Coat of chartek) at E-W pipe rack, it has been
noticed that poor (eneven) of surface finish, as per Sadara specification, Surface texture of the
fireproofing material shall be "smooth". This is happened due to application of coating by unqualified
personnel. A logbook entry has been made for information, root cause analysis & corrective action.
Note: RFI-DLM-KAF-H-0426.
Subcontractor: JCC and Card Holders were temporary transfer other site, JCC card holders
where brought back at MFC site surface was repaired, shall make sure there is sufficient qualities
manpower at all times.
Contractor performs oil sampling test for transformers at substations G-1120 and G-1121 in which they
will utilize the laboratory of SGS for the testing which is not approved by Sadara. This is a violation as
per schedule "Q", Attachment IV, Section 7.3.
Contractor: Contractor submitted on January 23, 2014 the Company profile that will perform the
testing of oil sampling for power xmer as per transmittal no IK-MFC-T-DJ-CJ-CM-2070, waiting for
approval.
During surveillance at site, it was observed that Contractor installed Analyzer at site 5 nos. at different
locations but all the tray supports have been cracked and with welding defect by vendor.
Contractor: Contractor matrerial department already issued OSID on 05-01-2014 with OSID no.
0677 to notify vendor regarding the damage. Company will notify as soon as vendor give
response.
Contractor at MFC site raised RFI TCC-SS-WE-0608 for the Post welding
inspection Structural Support T--1810 but inspection showed the support
were only tack welded which made the RFI's to cancel. The Structures
attached to this were there never inspected after this and the equipment is
already been erected. The Inspector for pipe welding was on 25/12/2014.
Subcontractor: Supporting drawing was revised. Accepted RFI is
attached,
PCMC is unable to cover the pipe end in the entire E-W pipe rack and unwanted materials were found
inside the pipe. Immediate response is required. This is violation of A554-E-103-QA-GEN-PRO-046,
Para. 7.44.
Subcontractor: We have already taken action special crew is implemented in site for the
preservation of pipe by the PCMC Construction.
During surveillance of E-2210, 2322 A/B, it is noted that almost or several flanges of the Horizontal
exhangers found covered with mere plastic sack and water colleted in it and this damaged sacks may
have caused the water to move through it into the equipment during the rain causing corrosion, hence,
damage to the eqipment. Violation as per G95-8000-08, Para. 3.1.2.1, 4.1.1.1, A554-E-103-QA-GEN-
PRO-035, Para. 8.2.2.
Subcontractor: Corrective action shall be taken. TCC already taken action as per log book, all
have been covered as per recommended plan.
During isntallation at MFC site by TCC, the following descripancies recorded during the erection of
common Shell D-2304 for E-2304 (C2R Condenser) and E-2213 (Dethanizer Condenser), manufactured
and certified by Ellimental for D-2304 and Five Cryons for E-2304, E-2213 bearing P.O. No. 2122351. 1)
290mm lifting trunion of D-2304 were found removed by 85mm with only acetylene gas cutting, ref.
drawing no. D2304-103-9003-01, D2304-103-9003 - Name plate were reverted. These activities were
violations as per 1. G5S-5350-50 Para. 51.1.8, 51.1.9. 2. RT 96.-300-02.
Subcontractor: Noted. Corrective action will be taken. NCR has been closed and/or corrective
action has been done.
MFC site Daelim's Subcontractor found erected equipment (E-2233 & D2304) without undergoing
structural foundation grouting process and getting Civil handover note to proceed mechanical activities.
The structural assembly to be fixed and grouted for the further mechanical construction and inspection
activities to yield precision alignment tolerance as specified in the specification. The once aligned
structural can also be disturbed due to continues construction activities in and around its premises of
not grouted. This is a violation as per A554-E-103-QA-GEN-PRO-035, Para. 9.3.
Subcontractor: Noted. Corrective action will be taken.
During routine site visit, it was noticed that the Contractor shifted MV Motors to the site from the
Laydown yard but did not energized its Space Heater which is a violation as per RT7D-0665-00, section
13.1.2. The Contractor is maintaining the space heater evergization at laydown yard prior to shifting it at
site.
Installed MV Motors at site from laydown yard are now space heater Energized and bi-weekly
preservation is maintained preservation maintenance Log Sheet were provided to record all
activities including shaft rotation and etc.
The Contractor did not continue the grouting of foundation of the inside
portion of the oil quench and water quence structures. Only the outside
portions wre grouted. The Contractor shall ensure that space between
plates shall also be fully filled with grout.
During the time of cable tray inspection, it was observed that Contractor
installed wrong splice plate. Instead of round type connector, installed was
slotted type. This violates NEMA VEZ, project specs G-07C-301.
Subcontractor: Splice plate shall be replaced when the material is
available. Waiting for Daelim supplied material to be available at site.
During routine surviellance and inspection, it was observed the unavailability of Contractor QC presence
at calibration shop. Contractor shall be full-time presence at lab. This violates schedule "Q" and project
approved ITP.
Contractor: The action of this LBE was settled between the contractor & subcontractor by means
of continuing the activity in calibration shop when contractor QC is only available.
During site surveillance, it was observed Contractor doing cable termination at JB side without cable
laying inspection. This is a standard violation of schedule "Q" and project approved ITP.
Contractor: Construction already instructed and be aware of its so thata this violation will not be
repeated. RFI will be submitted to close this LBE.
During Material Receiving inspection at Amana storage area. Concerning metal runner size
(100mmx0.06x3000mm) intended to be used in operator building. It was noticed suring inspection that
this materials are not properly protected or stored. Contractor is advised to arrange these materials with
good storage with proper handling in order not to damage.
Sub-contractor: Contruction has already shifted the material in shaded area (G-1120). Materials
were arranged properly and covered by tarpauline sheet.
During surveillance, it was found that Vendor's Spools (R-2030 & R-2035)
has been cut without providing detail method of statement which WPS and
NDE to be used. This is violation against schedule "Q". Contractor needs
to provide a full detail report on the incident.
During surveillance & monitoring inspection at operator building along blast
type door along north side. It was found out that sub-frame of blast door
was not align properly and squareness of the said sub-frame. Contractor is
advised to submit shop drawing and details on how to rectify or repair the
squareness and alignment of sub-frame.
Contractor: contractor has assigned ARCC welder for welding work
activities and kindly check with Contractor construction group.
Page 47 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-233 MR. JERRY AMA VAF 2 CIVIL Civil 28-Jan-14 31-Jan-14 11-Feb-14 02-Feb-14 Closed
LBE-AMA-CIVIL-234 MR. GERALD AMA VAF 2 CIVIL Civil 28-Jan-14 31-Jan-14 11-Feb-14 03-Feb-14 Closed
LBE-ARCC-MECH-
466
MR. GLENN ARCC VAF 2 MECH Refractory 28-Jan-14 31-Jan-14 11-Feb-14 04-Feb-14 Closed
LBE-KCC-MECH-
467
MR. GLENN KCC VAF 2 MECH UG-RTR 28-Jan-14 31-Jan-14 11-Feb-14 01-Feb-14 Closed
LBE-AMA-CIVIL-235 MR. JERRY AMA VAF 2 CIVIL Civil 29-Jan-14 01-Feb-14 12-Feb-14 30-Jan-14 Closed
LBE-AMA-CIVIL-236 MR. GERALD AMA VAF 2 CIVIL Civil 29-Jan-14 01-Feb-14 12-Feb-14 03-Feb-14 Closed
LBE-AMA-MECH-
468
MR. GLENN AMA VAF 2 MECH Hvac 30-Jan-14 02-Feb-14 07-Apr-14 Closed
32
LBE-DLM-
MECH-469
MR. NASSAR
DAELIM
(Construction)
VAF 2 MECH Insulation 30-Jan-14 02-Feb-14 19-Apr-14 24-Jul-14 Closed-
LBE-SEN-ELECT-
101
MR. MARK SENDAN VAF 1 ELECT Electrical 01-Feb-14 04-Feb-14 15-Feb-14 04-Mar-14 Closed
LBE-KCC-CIVIL-237 MR. JERRY KCC VAF 2 CIVIL Civil 02-Feb-14 05-Feb-14 04-Mar-14 01-Apr-14 Closed
LBE-TCC-MECH-
470
Coating/
Painting
02-Feb-14 05-Feb-14 04-Mar-14 12-Apr-14 Closed
LBE-DLM-ELECT-
010
MR. MARK DAELIM VAF 1 ELECT Preservation 02-Feb-14 05-Feb-14 31-Mar-14 31-Mar-14 Closed
30
LBE-DLM-
MECH-471
MR. SAYED
DAELIM
(Procurement)
VAF 3 MECH Piping 03-Feb-14 06-Feb-14 27-Jul-14 Open
LBE-TCC-MECH-
472
Mechanical
(Equipment)
04-Feb-14 07-Feb-14 19-Mar-14 23-Mar-14 Closed
During inspection of LFO/HFO segregation structure foundation, the dowel bar is contact with concrete
in some locations are already rusted. The Contractor shall check other area to show some rusted dovel
that were painted/touched-up were not corroded and prior to to painting inspection shall be undertaken
to ensure these dowel bars are free of rust and proper type of coating materials shall be applied. RFI
#MFC-DLM-AMA-CI-6050.
Contractor: Construction already clean the rusted rebars by using wire brush and touched-up
paint has been applied.
During surveillance at site for Equipment # W-1720/1721 & W-2040
insulation activities, it has been noticed that there are no adequate
distance to complete cold insulation activities between platform supports (I-
beam) and shell equipment. The actual distance between them
approximately is 70mm and the distance required for insulation is 150mm.
The numbers of I-beams are six (6).
Contractor: LBE-DAELIM-MECH-469: 1.The revised drawing were
issued last february. The modification work will be followed by
construction team.
2. LBE-DAELI<-MECH-440 & LBE-DAELIM-MECH-473 the
modification design is agreed as attached. the further commincation
with sadara QC is being done. once investigation is complete, site
instruction will be issued through constrution team.
During routine site visit, it was noticed that the Contractor is pulling a MV cable from switchgear going to
Transformer at substation G-1121 without the usage of cable rollers which I a violation as per NEMA VE-
2, section 5.4.
Subcontractor: Sendan has been issued internal NCR for the Subject issue. The corrective
action will be taken as per the project requirements.
As discussed and as per the actual survey regarding centerline of pump foundation and for pump P-
2417 A/B where the centerline of the pump is offest by 10cm., the Contractor needs to provide
computation to show dynamic response of foudnation against pump rotation is acceptable. Submit
computation to Sadara MFC structural Engineer for approval.
Subcontractor: KCC is waiting for the design calculation from Daelim.
During attendance of RFI # MFC-DLM-AMA-CI-6080 at Flare area, it was found out that out of 5
foudnations requested for inspection, 3 of the foundations have bolts out of location by 16mm, the
requirement is, 920m between group of Anchor bolts while installed is only .906. RFI was rejected.
Contractor: As per RFI# MFC-DLM-AMA-CI-6080, the achor bolt was rectified and put in the
correct location and re-inspected on the next day by Contractor and Company.
With refe4rence to RFI #MFC-DLM-AMA-CI-6101 at substation G-1121 along (SDG-MECH-ROOM). It
was noticed during inspection that four (4) anchorage at the top portion door frame are incomplete
installation and also one anchor at door frame only by hand it remove not properly fixed. In this regards,
Contractor is advised to counter check the alignment and plumbness and also installation for the said
door prior to final inspection. RFI was rejected.
Sub-Contractor: Advised and instructed to QC Inspector to inspect internally with Daelim
Inspector to confirm inspection acceptance before calling SADARA PID. Work has been rectified
and inspected and approved.
Outdoor air intake motorized damper w/o seals and access doors. During surveillance in MCC/PIB G-
1120 (Typical to G-1121) Hvac duct installation, it was observed that motorized damper in the outside air
intake has no seals and access doors. This violates the following: RT52-50001-01, section 11.6 Gas
detectors, where required in RT-LPP-12.1 & RT-LPP-12.2 shall be installed in the outdoor air intake and
shall be connected to the control room alarm system. A quick closing damper with seals shall be
installed i9n the air intake to prevent the entry of contaminated air into the building. RT52-500-01, sec.
8.2.7. Provide access doors near heating coils, cooling coils, outside air intakes, automatic dampers,
motors, filters, fan wheels, fire dampers and other locations where conditions demand accesibility for
service.
Contractor: Motorized damper with seal was already installed on the outdoor air intake duct
to prevent the entry of contaminated air which is requirements as per RT5Z5000-01 sec.
11.6 in SADARA STD.
During inspection at paving area along sub-station G-1120. It was noticed that the calibration certificates
of the surveyor did not comply or the same to the survey instrument that have been using for the said
paving. Contractor is advised to check the survey instrument at site.
Sub-Contractor: Advised and instructed to Surveyor to keep calibration certificate the instrument
used. Before starting any work at site check properly equipment and calibration certificate.
Incorrect refractory Anchors- During inspection in Furnace F-1240, it was observed that anchors for RCF
Modules were provided at south end wall (radiant bottom) instead of the required anchors for castable
refractory. This violates Vendor drawing no. E-11155, 04-2.
Contractor: Correct Refractory anchors have been welded on south end wall (Radiant bottom) in
order to continue castable application.
Subcontractor: RB Hilton replaced the wrong anchor & used the correct one.
FRP pipe manually tapered- During inspection of UG-Firewater piping installation for HT-006, line nos
FW-071034-8 and FW-071026-6, it was observed that 4 nos. 5 pigots were manually tapered using
grinder instead of the shaving machine per manufacturing procedure. This violates manufacturer
installation procedure section 4, to use shaving machine to obtain the taper angle requirement for Taper-
Taper adhesive bonded joint. J13, 15, 16 & 21 - manually tapered. Manual tapering shall be
disconnected. Use shaving machine to do the taper.
During verification of Internal Tray T-2410 (C-3 Splitter) observed that downcomer pannel holes are
mismatching as per site condition and Vendor GA drawing. TCC/Daelim team has modified some pannel
hole without appropriate approval from vendor and company. Violation of sched. "Q" and approved ITP
(A554-E-103-QA-GEN-PLN-103) Daelim Engineering/Quality team shall verify the discrepancy occured
at site and submit the appropriate rectification method by Vendor to Company.
Subcontractor: This is related to Daelim Engineering. Not for TCC.
During complete absence of Subcontractor Coating Inspector, Coating application activity is on-going at
TCC-1 workshop. As per schedule Q and ITP, this activity is hold point for Subcontractor. For
information and corrective action of Daelim.
Subcontractor: As per request from Sadara communication, TCC QC went to site for urgent
holiday testing from 8:00 - 9:00 AM. At that time, Sadara PID came to TCC shop-1 and noticed
some activities were performed without TCC QC. During that time, Daelim QC was present at
shop-1. Also, holiday inpsection at site, QC immediately came back to shop-1 and resumed the
works.
During routine surveillance at Daelim's laydown yard, it was noticed that there are some MV motors's
space heaters that were not energized which is a violation as per RT7D-0665-00, section 13.1.2.
All MV Motors stored at laydown yard are now energized its space heater, in addition,
preservation maintenance log sheet were attached to record the all preservation activities.
During Material Receiving inspection of pipe fittings under P.O. 100532-42-
K04-005-A01, it was noted that fitting internally coated with rust prevention
paint. This is violation against DOW specification G4S-0210-01 para 2.1.5
which states that "If the piping was coated with a light coating of mineral oil
to prevent corrosion, the coating shall be removed by pulling a swab
saturated in cleaning solution through the piping". Contractor shall
investigate and provide corrective and preventive action.
Contractor: The fittings were internally coated in order to preserved
and to avoid corrosions.Company acknowledged the close the issues.
Page 48 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
31
LBE-DLM-
MECH-473
MR. NASSAR
DAELIM
(Enginnering)
VAF 3 MECH
Mechanical
(Equipment)
04-Feb-14 07-Feb-14 19-Apr-14 Open
LBE-KCC-CIVIL-238 MR. GERALD KCC VAF 2 CIVIL Civil 04-Feb-14 07-Feb-14 18-Feb-14 03-Mar-14 Closed
LBE-SEN-
TELE-006
MR. RODNEY SENDAN PN 1 TELECOM Telecomunication 04-Feb-14 07-Feb-14 05-Apr-14 05-Apr-14 Closed
LBE-ARCC-MECH-
474
MR. HARIKUMAR ARCC VAF 3 MECH Piping 05-Feb-14 08-Feb-14 13-Feb-14 23-Mar-14 Closed
LBE-SEN/DLM-
ELECT-102
MR. FELOMINO
SENDAN/
DAELIM
VAF 1 ELECT Material 06-Feb-14 09-Feb-14 15-Feb-14 26-Apr-14 Closed
LBE-SEN-ELECT-
103
MR. FELOMINO SENDAN VAF 1 ELECT Electrical 06-Feb-14 09-Feb-14 18-Feb-14 03-Jun-14 Closed
LBE-SEN-
TELE-007
MR. RODNEY SENDAN PN 1 TELECOM Telecomunication 06-Feb-14 09-Feb-14 05-Apr-14 05-Apr-14 Closed
LBE-DLM-MECH-
475
Mechanical
(Equipment)
09-Feb-14 12-Feb-14 02-Apr-14 03-Apr-14 Closed
LBE-AMA-CIVIL-239 MR. GERALD AMA VAF 2 CIVIL Civil 09-Feb-14 12-Feb-14 15-Feb-14 16-Feb-14 Closed
LBE-AMA-CIVIL-240 MR. GERALD AMA VAF 2 CIVIL Civil 10-Feb-14 13-Feb-14 02-Mar-14 02-Mar-14 Closed
32
LBE-SEN-
ELECT-104
MR.
FELOMINO
DAELIM
(Enginnering)
PN 1 ELECT Engineering 12-Feb-14 15-Feb-14 26-Feb-14 Info
LBE-DLM-MECH-
476
MR. GLENN
DAELIM
(Construction)
VAF 3 MECH Refractory 13-Feb-14 16-Feb-14 02-Mar-14 08-Jun-14 Closed
LBE-DLM-MECH-
477
MR. GLENN DAELIM PN 3 MECH Hvac 13-Feb-14 16-Feb-14 27-Feb-14 23-Feb-14 Closed
LBE-KCC-CIVIL-242 MR. GERALD KCC VAF 2 CIVIL Civil 15-Feb-14 18-Feb-14 01-Mar-14 21-Feb-14 Closed
33
LBE-DLM-
MECH-478
MR. SAYED
DAELIM
(Procurement)
VAF 3 MECH Piping 16-Feb-14 19-Feb-14 Open
Contractor is advised to provide and approved PCDD started in Operator building IFC drawing as per
stated in RT-SAES-T-916, Para. 4.1.1.
All IFC which Attached in RFI's and used by Construction are all improved and stamped by
RCDD.
Numerous weld defect/discontinuity observed at Liquid Furnace (Field Piping System) during or semilar
inspections: Weld joint are wrinkled and buldged to one side (up to 7mm). (01603.BEM-P-124318.03).
Misalignment or distorted due to improper welding technique. (01603.BEM.P.124318-01 TO 05). Back
welded without supporting WPS (C-016103 BEA-P-123318-03 to 07). Base Metal deeply grinded,
removed for internal alignment. On Daelim, welding and NDE team shall verify and advise appropriate
corrective and preventive action to ARCC.
Subcontractor: ARCC cute & re-aligned the fitted joints then cut and reweld the distribution
joints.
During Material receiving inspection of RFI No. MFC-DLM-EATON-EL-006 for Low Voltage MCC Panel
No. MCC-103H106 at substation G-1120, it was observed that the Bus Lean Insulator support was
broken and Panel enclosures were having deformation caused by improper handling during shipment.
This violates schedule Q attachement IV sec. 3.2.
Contractor: OSID has been prepared to inform the Vensor regarding the damaged item.
Construction follow up that Vendor will replace the insulator and waiting for feedback.
During surviellance at site, it has been noticed that there is no adequate
space between step ladder of vertical ladder and insulation rings for oil
quence tower (T-1310). The distance between them approximately is
60mm. The distance required as per standard is 230mm after insulation.
Logbook entry has been logged for root cause analysis and corrective
action prior to biginning insulation activities.
construction team.
With reference to RFI No. MFC-DLM-KCC-CI-5821 & 5822 at Cooling Tower pump (P-0901A-H)
"pocket", it was noticed that during inspection, found out that some pockets are not properly cleanedand
not ready to receive grout. In this regards, Contractor is advised to inspect it properly and see to it that
the area for inspection is ready prior to invite the PID in order not to hamper the inspection as per
schedule.
Sub-Contractor: The area to receive grout was cleaned properly prior to grouting. Inspection was
done & released. RFI shall be attached.
PN: During surveillance for electrical cable tray installation at East-West
main pipe rack, it was observed that the installations of splice plate are
closed to support and less than 300mm. As per G7C-0324-03, splice plate
on support is +- 300 is required to use of a heavy duty splice plate.
Subcontractor: The issue has been investigated & corrective action
plan preprared by Construction. NCR was issued to Daelim
Construction team.
Missing Nuts in hanging modules. It was observed in Gas Furnace Refractory that one of the double
nuts in the hanging modules are not installed in furnaces F-1130, F-1140, F-1150, F-1160 & F-1170.
This deviated vendor drawing E-11154-05-01 which requires double nut to secure the bolt-on hanging
modules.
Contractor: Nuts supplied fo module installation wee not sufficient. So Daelim will purchase more
nuts in order to complete the installation.
PN: It was observed in MCC/PIB G-1120 & 1121 that Bleed Air Outlet is located about 5m above fan
outlet centerline. This bleed carried sand being removed from the outside air. Contractor must ensure
that sand extracted from the inertial separator/filter can be blown out and not build-up in the ducting
system.
Contractor: Daelim assured that this bleed fan carries sand and other solid particles. Bleed Fan:
Static Pressure: 700 PA
During surveillance and monitoring activities at Operator Building and substation G-1121. It was noticed
that some materials are scattered around the building, such as steel structure, cement and other
materials intended for Operator building. Contractor is advised to arrange the materials accordingly with
proper protection and also proper house keeping shall be maintained in order not to damage the
materials at site.
Subcontractor: All excess materials are removed from operator building. Other materials which
are using at site were already arranged proeprly.
During surveillance and monitoring activties at operator building G-1122, it was found out that some
internal walls installation of insulation board was already started without submitting first the RFI for
proper checking as per checklist. Contractor therefore is advised to take corrective acations about the
issue for proper documentation.
Contractor: Subcontractor has started insulation work without submitting the RFI to Company
because of shop drawing was not approved by Daelim after approval of shop drawing,
subcontractor submitted the RFI for inspection
With reference to the RFI # MFC-DLM-AMA-CI-6295 (Operator Building G-1122), it was noticed in some
interior walls that during inspection, no anchorage connected to the RC wall to support vertical and
horizontal frames and some insulation board are already installed. Contarctor is advised to provide shop
drawing or details showing the anchorage to the perimeter RC wall for proper implementation.
Contractor: Subcontractor QC has provided approved shop drawings and work is implemented
as per approved drawing. Subcontractor provided anchorage braket to attain the streght vertically
and horizontally alignment. Subcontractor submitted the RFI for inspection of achorage and it is
inspected and accepted to start next activity.
During surveillance inspection at East-West side of main piperack for 24.5 kV incoming line cable tray, it
was observed that the cable tray ring was deformed. This violates schedule Q, attachment IV, sec. 3.2.
Contractor: The issue was discussed in the weekly meeting and furhter discussions with the
management on how to solve the problem as it was damaged by other Contractor.
Contractor is advised to raise RFI for any communication related work in all MFC buildings. This will
prevent reworks expecially on EMT conduits installation. Take note that EMT conduits shall not be
covered or closed without RFI, it must be exposed during RFI.
RFI's was raised unfortunately it was rejected, contractor will raised RFI again for said activities
after comes out the rev.
During surveillance inspection at site observed the following violations on field installed equipment
P2415AB & 2411 AB. *No proper protection provided to prevent contamination from blowing sand and
debris. *Lack of appropriate utility in-place for equipment such as space heaters, etc. Daelim
preservation team shall take immediate action to control such kind of violation at site. Deviation of
project requirement and procedure (RT-6-ICS, RT-55-7801 and A554-E-103-QA-GEN-PRO-039.
Installed Pumps (P-2411 A/B & 2415 A/B) are now fully protected from any foreign debris such as
sands and fulling objects by installing scaffolding and wood flanks
Reference to RFI No. MFC-DLM-KCC-CI-5928 Pedestal Rebar Installation "Hilti Anchoring" for T-
support at East & West side of dike wall, it was noticed during inspection that some "Hilti Anchoring's
depth requirements do not conformed to the latest IFC drawing wherein some depths are ranging from
110mm up to 125mm only, in which the minimum requirement is 130mm depth.
Contractor/Subcontractor is advised to check properly and see to it that the depth requirement must
meet and/or comply with the latest IFC drawing.
Subcontractor: In some areas, the depth of HILTI Anchoring can not be met as per the IFC
drawing because it touches the rebar reinforcement of the paving. Relocation of the hole has
been done in order to meet the required depth.
During valve testing, it was noted that butterfly valve (103-EBV-113051)
12"X150 Flanged face serrration damaged due to pitting. This is violation
against Sadara Spec G14-S-3230-01 Para. 2.4. Contractor shall provide
corrective and preventive action.
Page 49 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
34
LBE-DLM-
MECH-479
MR. KURIAN
DAELIM
(Construction)
VAF 3 MECH
Mechanical
(Equipment)
16-Feb-14 19-Feb-14 Open
LBE-DLM-INST-011 MR. PERVEZ DAELIM VAF 1 INST Preservation 16-Feb-14 19-Feb-14 30-Mar-14 19-Apr-14 Closed
35
LBE-DLM-
MECH-480
MR. KURIAN
DAELIM
(Construction)
VAF 3 MECH
Mechanical
(Equipment)
36
LBE-SEN-
ELECT-105
MR.
FELOMINO
SENDAN/
DAELIM
VAF 1 ELECT Electrical 18-Feb-14 21-Feb-14 04-Mar-14 30-Jul-14 Open
LBE-DLM-INST-106 MR. PERVEZ DAELIM VAF 1 INST Instrumentation 18-Feb-14 21-Feb-14 24-Feb-14 04-Mar-14 Closed
37
LBE-DLM-
MECH-481
MR. SAYED
DAELIM
(Construction)
LBE-DLM-MECH-
482
MR. GLENN
DAELIM
(Enginnering)
VAF 3 MECH Hvac 20-Feb-14 23-Feb-14 09-May-14 14-Jun-14 Closed
LBE-DLM-MECH-
483
MR. GLENN DAELIM VAF 3 MECH Hvac 20-Feb-14 23-Feb-14 07-Apr-14 Closed
LBE-DLM-MECH-
484
MR. KHAN DAELIM VAF 3 MECH Piping 20-Feb-14 23-Feb-14 22-Mar-14 23-Mar-14 Closed
49
LBE-SEN-
TELE-008
MR. RODNEY SENDAN PN 1 TELECOM
Telecommunica
tion
22-Feb-14 25-Feb-14 25-Feb-14 30-Jul-14 20-Jul-14 Closed
LBE-ASYAD-INST-
107
MR. PERVEZ ASYAD VAF 3 INST Instrumentation 22-Feb-14 25-Feb-14 25-Feb-14 04-May-14 Closed
LBE-ASYAD-INST-
108
MR. PERVEZ ASYAD VAF 3 INST Instrumentation 22-Feb-14 25-Feb-14 08-Apr-14 Closed
During site surveillance, it was observed that Contractor stored Instrument panel at substation without
inspection of material receiving and proper preservation. This violates project ITP and project
Specification A554-E-103-CM-GEN-PLN-002 & smitp-j-902-06, item no. 2.2. Schedule "Q".
Contractor: Material receiving was not done because of document are not available & lack of
coordination between QC and material department. That is why it was transferred to site. RFI
raised to Company & it was inspected and accepted.
During line inspection for package no. 1681-00-HT-017 (T) line no. P-
210602-30"-HC11, it was noted that 4 nos. of socket joints (between two
dissimilar material A182-F308-304L & LTCSA671-CC70/Nipple A333-6)
welded without approved WPS. This is violation against RT8S-6500-01,
para. 2.2. Contractor shall provide Corrective & Preventive action.
With reference to RFI # MFC-DLM-AMA-CI-6387 about Leak Test for water retaining structure
(Construction Joint of Slab & Wall) at Cooling Tower basin "Room 9" heigh of water is 150mm, it was
noticed that during inspection that some portion or areas of RC wall are found with leaks at west side
wall of cooling tower cell #9 and interior wall between 9 & 8 cell. Contractor is advised to investigate the
said leaks and take remedial action on the issue. Note: RFI was rejected.
Subcontractor: During leak test at cooling tower room 9, Amana started injection work those with
leakage area as per approved method statement and by approved material. Once injection work
is done, another RFI will be submitted for inspection.
During Daelim warehouse surveillance, it was observed that all instrument (Level transmitter)
stored outside in direct sun light and no preservation. As per project preservation plan, all
Instrument shall be kept in in-door and temperature shall be controlled to prevent the
condensation of humidity. This violates Preservation Plan, doc. no. A554-E-103-CM-GEN-PLN-
002.
All Instrument material such as transmitter and other devices for instrumentation shall be
kept indoor to avoid direct sunlight exposure, playdown personnel are now aware and
corrective action is done by means of training anf reminders at tool box meeting (daily)
During inspection at Cooling Tower Basin area (PS-V7) El-19530, west
side of the cooling tower for structural padding elevation, it is observed the
anchor bolt for column support for 2" piping were bent damage and
mismatching with the column nameplate holes. It is a violation as per A554-
E-103-QA-GEN-PRO-012 Para. 7.1.3, 7.1.4, 7.1.5. Daelim should also
attach survey reports to the mech (structural RFI) for anchor bolts syrvey
from subcontractor surveryor. Ref.: A554-E-103-QA-GEN-PRO-012. para.
7.1.14, 7.1.15.
During surveillance at East-West main pipe rack near in the Furnace Area,
it was observed the following violations:
1. The LV power cable was damaged the outer insulation and other are
twisted due to improper cable pulling activities. This violates schedule "Q"
attachment IV, sec. 3.2.
2. The cable tray splicing joint was already deflected during cable pulling
activities. This violates NEMA VE2, sec. 4.2.1.
Subcontractor: 1. It is investigated and the damage portion of the
cable will be repair and also cable. 2. Tray splicing joint, the deflected
part will be repaired as per repair procedure. NCR was issued to
Daelim Construction team.
On inspection of process condensale. Shipped tower (T1510) internals,
found that super-heated steam inlet (A2-24") pipe is not rested on the
support. A gap of approx. 15mm is having between the pipe and support.
This may have as adverse impact on the process functioning of the
equipment as the feed pipe is subjected to super heated steam flow
causing the material expansion contraction and mechanical vibration during
operation aslo full load and acting directly on one side of its bolted flange.
An Engineering/Desing solution required. Ref: 115105-D003, RT 5093-01,
Para 14 (D).
PN: For conduits (EMT) installation, Contractor is advised not to or prevent
installing it in reverse way or having a more 2 (90 deg. Bend). There is a lot
of way to avoid this type of method as much as possible not do any
installation that will need a pullbox.
Contractor Engineering will submit to company RFV.
During time of surveillance and inspection, it was observed that Contractor/Subcontractor installed
wrong tie for cable protector of tray. According to standard, all the cable shall be fasten with nylon
coated 316 SS tie but Contractor/Subcontractor installed pre-coated tie instead of nylon coated ss tie.
This violates project specification RT6E-802-01.
Subcontractor: Asyad, Daelim and Sadara PMT agreed that these cable tie are being installed
are temporary, just to continue the site work especially cable pulling when availability of SS cable
tie will be replaced.
During time of inspection, it was observed that Contractor/Subcontractor installed improper nut & bolt in
open channel tray, instead of silicon bronze, Contractor installed not dip galvanized. This violates
project specification RT6E-0802-01.
Contractor: 1. RFV was officially asubmitted on Feb 19, 2014 regarding the usage og HDG Bolts
& Nuts.
2. Contractor Receives the RFV with no comments regarding the usage of HDG on March 22,
2014.
Missing CFSD in Operator building. It was observed in Operation building G-1122 that combination
fire/smoke dampers are missing in air ducts penetrating fire rated walls electrical roo & communication
room. This deviated Company requirements as follows:
-RT52-5000-01 sec. 9.16Pro FD or CFSD at all duct penetration of fire rated walls;
-RT52-5000-01 sec. 6.2.4-Provide CFSD for duct penetration in 2 hour fire rated wall (Elec)
-RT-SAES-T-916, sec. 4.4.2. Telecommunication room shall have a minimum of one hour fire rated
walls. Provide the required FD or CFSD which ever is applicable and correctly identified in the drawings.
Contractor: Daelim Engineering dept. updated new revision of IFC in operator building G-1122
which are mentioned the CFSD or FD in Electgrical room and communication room. IFC no. A554-
E-103-HV-DWG-A30-041, Rev. 6. attached.
Incorrect VAV heater capacity. During MRI for VAV & CAV for operator building G-1122, it was observed
that VAV-002 & VAV-006 heating capacities are not compliant to equipment schedule A-554-E-103-HV-
DWG-A30-013. Design Airflow/Heater: VAV-002, 120lps/3kw but actual Airflow/Heater is 120lps/5.5kw
and VAV-006, 131lps/3.2kw but actual is 131lps/3 kw.
Daelim HVAC Engineer and Material vendor was responsed regarding raised violation, there no
problem about the heating capacities for the materials VAV-002 and VAV-006 SADARA PID
Agreed installed VAV with 5.5 KW heater & communication room which has a higher heating load.
Contractor proceeded with water filling and hydro test without closer of punch A Test package no. 1621-
01-HT-030, required PWHT has not been performed on support S13 (Dwg. No. (C016103H1A-P-131002-
02) Violating SADARA RT8S-6500-01 Para. 8.11 and ASME B31.3 Para. 345.2.2 (b) requirements.
Contractor: Company has reviewed the requirement of the PWHT for this specification line class
it was agreed and confirmed by Company that PWHT is not required for such of saddle support
pads.
Page 50 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
485
MR. GLENN DAELIM VAF 3 MECH Hvac 23-Feb-14 26-Feb-14 13-Apr-14 14-Apr-14 Closed
LBE-AMA-MECH-
486
MR. GLENN AMA VAF 3 MECH Hvac 23-Feb-14 26-Feb-14 20-Apr-14 20-Apr-14 Closed
38
LBE-DLM-
ELECT-109
MR.
FILOMENO
DAELIM
(Enginnering)
VAF 3 ELECT Engineering 23-Feb-14 26-Feb-14 25-Feb-14 Open
LBE-KCC-CIVIL-244 MR. GERALD KCC VAF 1 CIVIL Civil 23-Feb-14 26-Feb-14 26-Feb-14 01-Mar-14 Closed
51
LBE-DLM-
MECH-487
MR. GLENN
DAELIM
(Enginnering)
VAF 3 MECH Hvac 24-Feb-14 27-Feb-14 15-Jul-14 20-Jul-14 Closed
LBE-KCC-MECH-
488
MR. GLENN KCC PN 3 MECH Quality Management 24-Feb-14 27-Feb-14 04-Mar-14 10-Mar-14 Closed
39
LBE-DLM-
MECH-489
MR. SAYED
DAELIM
(Construction)
40
LBE-DLM-
MECH-490
MR. KURIAN
DAELIM
(Construction)
VAF 3 MECH
Mechanical
(Equipment)
LBE-TCC-MECH-
491
TCC VAF 3 MECH
Mechanical
(Equipment)
LBE-TCC-MECH-
492
TCC VAF 3 MECH
Mechanical
(Equipment)
LBE-ARCC-MECH-
493
MR. NASSAR ARCC VAF 3 MECH Quality Management 25-Feb-14 28-Feb-14 04-Mar-14 12-Apr-14 Closed
LBE-AMA-CIVIL-245 MR. GERALD AMA VAF 2 CIVIL Civil 25-Feb-14 28-Feb-14 29-Mar-14 03-Apr-14 Closed
LBE-ARCC-MECH-
494
MR. NASSAR DAELIM VAF 3 MECH
Coating/
Painting
27-Feb-14 02-Mar-14 13-Mar-14 12-Apr-14 Closed
LBE-TCC-MECH-
495
Coating/
Painting
27-Feb-14 02-Mar-14 04-Mar-14 12-Apr-14 Closed
LBE-DLM-ELECT-
110
MR. MARK DAELIM VAF 1 ELECT Electrical 27-Feb-14 02-Mar-14 01-Mar-14 30-Mar-14 Closed
No hose bib for AHU & ACCU. During surveillance in MCC/PIB G-1120 & G-1121, it was observed that
no hose BIBS were provided for AHU's and ACCU's. This violates Company requirement RT5S-5050-
01, section 1.5.1.11. A service water or portable water hose BIB with vaccum breaker shall be provided
within close proximity (not to exceed 3M or 10 feet) of HVAC equipment that require periodic washing.
Comply hose BIB requirement.
Contractor: Attached Reply Came from Daelim Regarding the Raised Violation of Hose BIB in
Mechanical Room.
Cleanout without access and trap without vent. It was observed in O.B G-1122 that cleanout has no
access and trap without vent. This violates plumbing code as follows:
-IPC. Sec 708.9 cleanouts on 6-inch and smaller pipes shall be provided with clearance not less than 18
inches for rodding.
-IPC sec. 708.10 Access shall be provided to all cleanouts
-IPC 901.2.1 every trap and trapped fixture shall be vented in accordance with one of the venting
method specified.
Subcontractor: Isometric Drawing was Submitted to DAELIM Engineering and was approved
wherein no cleanout provided for the fixture (Service sink) See Attached Drawing - Accepted RFI
for these issued: MFC-DLM-AMA-B-038 - Vent was already provided on the trap fixture (Service
Sink)
During site surveillance at substation G-1120, it was observed that the
cable tray installation is close to the inter-pacing relay panel tag no. IRP-
103J101 & IRP-103J102. Actual vertical distance from equipment to the
bottom of the tray is 300mm. This violates as per G7C-0321-01, para 3.12.
Contractor: It was discussed to Engineering and feedback will be
followed-up regarding the issue. -> Discussed and agreed with
Company. NCR was issued to Daelim construction team.
Inspection for the bolt torquing for internal panels for tower 1510, the subcontractor is found using
uncalibrated torque wrench. All the instruments and measuring equipment used at site should be
calibrated and coumented.
Subcontractor: Calibration Certificate provided
It has been noticed that field coating activities has been covered by unqualified coating inspector. This
is violation of Schedule Q and ITP.
Subcontractor: ARCC submitted the CV of Painting Inspector Mr. Posadas last 23 Feb. 2014
with transmittal # 1235, awaiting for Interview and approval.
During surveillance and monitoring inspection at Cooling Tower (West Side Portion), we have noticed
chipping and preparation works at six (6) pedestals and some reinforcing bars has been cut due to re-
installation of anchor bolts for the said pedestals. In this regards, Contractor was advised to investigate
this chipping and preparation works and also corrective action concerning this issue for proper
implementation.
Subcontractor: has been executed the work as approved shop drawing which is signed by
Daelim Engineer, corrective action has been taken as follows 1. Cut/Chip the concrete up to
required depth to fix the anchor bolt. 2. additonal reinforcement is approved shop drawing. 3.
contractor has submitted the RFI for Inspection and it is inspected and approved.
During pre-punching for package no. 1652-00HT-007 (T) line No. P-
172601-18"-4C01, it was noted that water filling started in the line without
internal cleaning & flushing. This violates against G4S-G421-02, para. 4.9.
Material receiving inpsection of overhead crane hoist for common
compressor having a name plate no. CR 1695 with capacity of 100/15 ton
double girder top STAHL manufactured, has damaged rolly plat form.
Which may have occurred due to improper handling and the rail on which
the crane will be mounted and rolled is corroded. Painting is required on all
surfaces. Other than trail-trolly wheel contact surface as per the
manufacturer drawing. Ref. RTBICS, para. 2.2.11, 2.4.1, A554-E-103-QA-
GEN-PRO-035, para. 8.1.9, 8.1.11, 8.2.6 & 8.1.11.
During surveillance, it is noticed that near C2 Splitter Goulds manufactured pump P2122A, P2215 A/B
were found with an oil leakand without cleaning of mud due to rain on the skid top. Preliminary
inspection of the pump and its parts show oil leak is from oil level indicator bottom. Further investigation
need to be done after complte removal of the spilled oil on skid to ensure that there is no oil from any
parts of the pump. Other corrective actions are required from Daelim. Ref. RT61CS Para. 2.5.3.b , Para
2.6.b.1 , 2.6.b.c
Subcontractor: All leak had been recrificed.
With reference ro RFI # MFC-DLM-KCC-CI-6001 & 6002 Local Platform and T-Support, it was noticed
during inspection that some pedestals for "HILTI ANCHORING" are not conform to latest IFC drawings.
In this regards, Contractor was advised to check internally/properly based on the approved DWG. The
anchoring & general cleaning of holes. Prior to invite SQIT in order not to hamper inspection schedule.
Please note that this RFI was rejected.
Subcontractor: Relocation of drilling hole was done to get the required depth.
Non-compliant inertial filter housing and bleed fan. Supplied inertial filters
manufactured by Filtrotechnical Italia (3 nos.) are not compliant to project
specifications RT5S-5035-01 sections 2.4.1.3 & 2.2.1.1 (for G-1120/E-
1121/G-1122): Filter housing is made of corten steel instead of the required
stainless steel or high density polypropylene. Bleed fans by CIMME are
manufactured and tested per ISO Standards instead of AMCA99 & AMCA
210. Submit RFV for SME approval.
Contractor: RFV was already submitted to Sadara and found
approved with comment.
Incomplete subcontractor QC coverage of UG-RTR Piping activities- it has been observed that UG-
Piping activities such as gasket verification, bolt tightening and hydrotesting are not covered by KCC
UGP QC Inspector. This violates schedule Q, sec. 5.9. Contractor's quality personnel will be dedicated
to perform and complete all quality functions as described in this schedule Q.
Subcontractor: UG-Piping Inspector was informed to be full time on site during inspection and
all related activities regarding UG-Piping. Mr. Denny villareal approved Hydrostatic testing
coordinator will take care all inspections related to UG-Piping activities such as gasket
verification, bolt tightening and hydrotesting. Mr. Rafique will take care of the laminiation.
During surveillance, it was observed during internal transportation of piping from storage yard to site
(spent caustic area) by truck, there are no means of protection such as rubber pads provided between
the coated pipes & side U-channel. This leads to friction and damage to the coating film.
Subcontractor: Construction and Piping team are advised to take special care while transporting
coated pipes to site. All repairs and damages covered during transportation and handling shall be
repaired using Sadara approved Field Tou-up Procedure. A554-E-QA-GEN-PRO-036.
during routine inspection on surface preparation of pipes weld joints it has been noticed that TCC
subcontractor using power wire brushes for surface preparation. The area of weld joint is more than 25
sq. cm., this being a violation of SADARA requirement and lat letter # MFC-T-CJ-DJ-PI-0799 which
issued by SADARA "Power wire brushes or sanding dics when used alone may not produce the required
surface profile to an unacceptable level.: SUrface preparation was done for 16 weld joints on to 30"
diameter. Weld joints found in line ID C016103W4A-P-241012-01 & C016103W4A-P-242009-01 30"
diameter.
Subcontractor: From Mar. 3, 2014 onwards TCC shall provide full-time QC for site activities. This
RFI was rejected by Sadara. On Mar. 3, 2014 TCC again done the Surface Preparation for weld
joints with bristle blast and accepted by Sadara. Note: RFI No. MFC-DLM-H-L-733, 734 are
attached.
During site testing, it was noticed that the Contractor was conducting impedance testing for transformer
without an approved procedure which is a violation as per Schedule Q Attachment IV Sec. 7.1
Contractor: Procedure will be revised as it was approved already to include impedance testing.
Page 51 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
46
LBE-SEN-
ELECT-111
MR. MARK SENDAN VAF 1 ELECT Electrical 01-Mar-14 04-Mar-14 03-Mar-14 30-Jul-14 22-Jul-14 Closed
LBE-TCC-MECH-
496
MR. NASSAR TCC VAF 4 MECH Quality Management 01-Mar-14 04-Mar-14 19-Mar-14 12-Apr-14 Closed
LBE-AMA-CIVIL-246 MR. GERALD AMA VAF 2 CIVIL Civil 02-Mar-14 05-Mar-14 02-Apr-14 24-Apr-14 Closed
LBE-AMA-CIVIL-247 MR. GERALD AMA VAF 2 CIVIL Civil 03-Mar-14 06-Mar-14 29-Mar-14 03-Apr-14 Closed
LBE-TCC-MECH-
497
MR. NASSAR TCC VAF 3 MECH Quality Management 03-Mar-14 06-Mar-14 10-Mar-14 12-Apr-14 Closed
LBE-PSCL-MECH-
498
MR. NASSAR PSCL VAF 3 MECH Tank 04-Mar-14 07-Mar-14 20-Apr-14 Closed
LBE-DLM-ELECT-
112
MR.
FELOMINO
DAELIM
(Construction)
VAF 1 ELECT Material 04-Mar-14 07-Mar-14 06-Mar-14 12-Jul-14 Closed
LBE-SEN-ELECT-
113
MR. MARK SENDAN VAF 1 ELECT Electrical 05-Mar-14 08-Mar-14 06-Mar-14 30-Mar-14 Closed
41
LBE-DLM-
ELECT-114
MR. MARK
DAELIM
(Construction)
VAF 1 ELECT Electrical 06-Mar-14 09-Mar-14 08-Mar-14 Open
42
LBE-DLM-
MECH-499
MR.
HARIKUMAR
DAELIM
(Enginnering)
PN 3 MECH Engineering 06-Mar-14 09-Mar-14
Refer to
Company
LBE
additional
comments
Info
43
LBE-DLM-
MECH-500
MR.
HARIKUMAR
DAELIM
(Construction)
VAF 3 MECH
Mechanical
(Equipment)
06-Mar-14 09-Mar-14 Open
LBE-PCMC-MECH-
501
MR. AMIN PCMC VAF 3 MECH Quality Records 06-Mar-14 09-Mar-14 08-May-14 13-May-14 Closed
LBE-KAF-MECH-
502
MR. NASSAR KAEFER VAF 3 MECH Fireproofing 06-Mar-14 09-Mar-14 09-Apr-14 08-Jun-14 Closed
DAELIM
(Construction)
VAF 1 INST Instrumentation 06-Mar-14 09-Mar-14 05-Jun-14 05-Jun-14 Closed
LBE-AMA-CIVIL-248 MR. JERRY AMA VAF 2 CIVIL Civil 08-Mar-14 11-Mar-14 29-Mar-14 01-Apr-14 Closed
During monitoring & surveillance activities at cooling tower basis "Cell #7" concerning leak test, height
of water is only 150mm from top of slab. It was noticed that some portion of Mid-Wall-6 (North side)
having visible leak. In this regards, Contractor is advised to investigate the said visible leak and take
remedial action on the issue.
Subcontractor: has been rectify the leave portion by using approved injection material, work has
been done executed and inspected by Daelim and Company Inspector. The RFI reference No is
MFC-DLM-AMA-CI-6618
It has been observed that KCC Coating Inspector not available during Inspection activities. As per
inspection and test plan and schedule Q, Coating Inspector should attend all application activities and
inspection time. Inspection level for Subcontractor is hold point for all activities.
Subcontractor:Tape wrapping and holiday test inspection is not KCC scope. This is the scope of
TCC. KCC is only prepairing the RFI.
In the absence of TCC Inspector, Daelim inspector attended the activity and performed the
inspection and was found acceptable.
During inspection time for RFI # MFC-DLM-PS-H-0075 on spent Caustic storage tank (V-500A), it has
been noticed the dimensions of Arabic letters doesn't provided in approved IFC drawing. Furthermore,
letters (Arabic & English) degree intervals doesn't meet Sadara specification (RT9S-2500-01 section 8)
The degree intervals required between every letter ( Arabic & English) is 90 deg. around the tank. The
violation also repeated in Tank V-500B. This violation has been logged for information and corrective
action.
Contractor: Drawing were Revised to mention the required dimensions & informations RFI was
raised for the activity and accepted by sadara.
During routine site visit at the east of debutanizer structure area, it was
noticed that the Contractor already pulled a cable for street lighting without
the usage of PVC bushings ar all conduit termination which is a violation as
per NEC Article 352.46.
Subcontractor: Installation done as per IFC Drawing and Conduit
Exceeded more than 150mm the same will go inside the electrical
street lighting pole.
During surveillance, it has been noticed that TCC Subcontractor Inspector unavailable at site during
surface preparation. Weld joints found in line ID C016103W4A-P-241012-01 & C016103W4A-P-242009-
01 30" diameter. Surface preparation was done for 16 weld joints in the absence of complete for
Subcontractor inspector.
Note: Subcontractor inspector name is Jishnu N.P. ; RFI # MFC-DLM-TCC-H-L-714 & MFC-DLM-TCC-H-
L-715
Subcontractor: TCC has three (3) Painting and Coating Inspectors approved by SADARA. No
more issue for Paitning shortage at TCC.
With reference to RFI # MFC-DLM-AMA-CI-6542 during inspection for metal door frame & leaf (pre-
installation), we have noticed that no "label for fire rating" both door frame & leaf. In this regard,
Contractor was advised to investigate why they delivered at site without this fire rated "labels" & not
conforming to our requirement and should take corrective action concerning this issue. Please note
counter check also some door frame and leaf (This RFI was rejected).
Subcontractor: Regarding the Lable for fere rating subcontractor already contact to vendor, as
per vendor those door cannot be fere rated due to over size, and base an approved shop drawing
its mentioned.
During surveillance, it has been observed that aluminum jacketing has been damaged for E-2050, D-
171B, D-1914, E-0235 and E-2051 during construction activities and erection of scaffolding.
Furthermore, EQ # E-2051, cladding has been damaged due to downfall of the cement on the top of
equipment during fireproofing application activities. Logbook entry has been logged for root cause
analysis and corrective action.
Contractor: all overspray were removed equipment tags area cleaned and repair was done for
damaged areas, damages was not covered due to fireproofing activities KAEEFER has verified
all stated equipments and found no damaged caused due to fireproofing activity.
During Material Receiving inspection of Panel, it was observed that 3 nos. of Instrument Cabinet I/O Grd
found damaged and not fixed properly and one panel has damage. This violation to project specification
and schedule "Q", attach. IV, Sec. 1.1. and G6A-0041-00 sec. 61.5.4.2. Contractor requested to take a
preventive action plan.
Contractor: 3 number of instrument cabinet which are having problem in inspection have been
done with RFI No. INST-022-023.
With reference to RFI # MFC-DLM-AMA-CI-6571, it was noticed that there is no anchor bolt or plate
embedded on the sliding of the pedestal. The civil dawing shall be reviewed in coordination with
mechanical installation drawing as it is always required that a plate or anchor bolt is necessary to limit
any movement during the production phase. This RFI is rejected unless design can prove that no anchor
bolt or plate is necessary.
Subcontractor has been Executed the work as per civil IFC drawing there was conflict between
mechanical and civil IFC Drawing, Subcontractor confirm with Mechanical team and rectify the
anchor bolt as per mechanical IFC Drawing, Executed work is Inspected and approved the RFI
reference No is MFC-DLM-AMA-CI-6570-0A and 6571-0B
PN: Gas Furnace: Area furnace box sleeves are not centered/defected as
per actual arrangement drawing A554-7-103-MB-DWG-MB-2-002. It is
string with radiant coil which will be cause of damage during the operation.
Daelim shall propose appropriate method to fix the discrepancies with
Engineering approved method.

Furnace pipe rack observed that weld joint were distorted and flange face
is off-set up: 10mm due to improper fabrication method and welding
technique on BFV-123501-6P007. Violation of Fabrication drawing and
procedure A554-E-103-QA-GEN-PRO-046.
It is found that PCMC Supervisor and DAELIM Inspector signed the blank report for internal cleaning
enclosed with one test package for Mar. 8, 2014 on dated Mar. 6, 2014, violating and ignoring the
inspection requirements. Daelim quality management should implement the Company standard's
minimum inspection requirements. Ref.: Sch. "Q" attac. 0, para. 3.7, 7.2, attch. IV, para. 3, 4.
Subcontractor: PCMC supervisor filled the report after confirmation, now every format fill first the
signature. We have now the quality system as per approved. Now it is made sure that all the
reports must be filled at site. Noreports will be filled-up after work completion.
During material receiving inspection of RFI No. MFC-DLM-RYD-EL-075, it was observed the following
violations:
1. LV cables are not new and these cables were taken from subcontractor. This violates as per schedule
G. para. 2.1.
2. LV cables have no markings for flame retardant in the outer sheet of the cable. This violates as per
RT7D-0430-00, para. 1.7
3. The cable reels have no stainless steel tag which is violation as per RT7D-0430-10, para. 5.3.
Contractor: Engineering/Construction was already informed with this discrepancies. As per
Engineering, RFV already submited to Company
During routine site visit, it was noticed that the Contractor installed PVC conduit for the protection of
bare copper grounding conductor for lightning protection system but uses as unapproved fittings which
is a violation as per G7-C-0311-03, section 1.4.1 at operator building G-1122.
Contractor: Subcontractor already instructed to remove the un-approved materials and replaced
with the approved one. Action has already been taken.
During routine site inpsection, it was noticed that the Contractor installed
lighting fixtures and used the channel tray as a support inside operator
building and battery room of substation G-1121. This is a violation as per
G7C-0321-01, section 1.2 and RT7C-1822-06.
Subcontractor: The installation done as per IFC drawing but the
same has been conveyed to Engineering, waiting for reply. After
Enginering decision, it will be rectified accordingly.
Contractor: Contractor submits TM/RFC to Company. RFC was
acknowledged already by the Company and approved buy SME has
comments to change the revision of RFV.
Page 52 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
58
LBE-KCC-
CIVIL-249
MR. JERRY KCC VAF 2 CIVIL Civil 09-Mar-14 12-Mar-14 29-Apr-14 Closed
50
LBE-DLM-
CIVIL-250
MR. GERALD
DAELIM
(Enginnering)
VAF 2 CIVIL Civil 09-Mar-14 12-Mar-14 02-Apr-14
Included in
the
Punchlist
22-Jul-14 Closed
51
LBE-AMA-
CIVIL-251
MR. GERALD AMA VAF 2 CIVIL Civil 09-Mar-14 12-Mar-14 29-Mar-14 25-Jul-14
Included in
the
Punchlist
22-Jul-14 Closed
LBE-DLM-ASYD-
INST-002
MR. SHABIRUL
ASYAD/
DAELIM
VAF 1 INST Instrumentation 09-Mar-14 12-Mar-14 14-Mar-14 09-Apr-14 Closed
LBE-DLM-MECH-
503
MR. GLENN
DAELIM
(Construction)
VAF 3 MECH Plumbing 09-Mar-14 12-Mar-14 01-Jun-14 21-Jun-14 Closed
47
LBE-TCC-
MECH-504
Mechanical
(Equipment)
09-Mar-14 12-Mar-14 13-Apr-14 26-Jul-14 23-Jul-14 Closed
44
LBE-DLM-
MECH-505
MR. KURIAN
DAELIM
(Procurement)
VAF 3 MECH Material 09-Mar-14 12-Mar-14 Open
LBE-TCC-MECH-
506
Mechanical
(Equipment)
45
LBE-DLM-
MECH-507
MR. KURIAN
DAELIM
(Construction)
VAF 3 MECH
Mechanical
(Equipment)
LBE-DLM-MECH-
508
MR. KURIAN
DAELIM
(Enginnering)
PN 3 MECH Engineering 10-Mar-14 13-Mar-14 12-Mar-14 03-Jun-14 Closed
LBE-AMA-CIVIL-252 MR. GERALD AMA VAF 2 CIVIL Civil 10-Mar-14 13-Mar-14 29-Mar-14 01-Apr-14 Closed
LBE-KCC-CIVIL-253 MR. GERALD KCC VAF 2 CIVIL Civil 10-Mar-14 13-Mar-14 02-Apr-14 02-Apr-14 Closed
LBE-DLM-MECH-
509
MR. KURIAN
DAELIM
(Enginnering)
PN 3 MECH Engineering 11-Mar-14 14-Mar-14 12-Mar-14 03-Jun-14 Closed
46
LBE-DLM-
MECH-510
MR. KURIAN
DAELIM
(Mat. Dept)
VAF 3 MECH Preservation 11-Mar-14 14-Mar-14 23-Mar-14 Open
47
LBE-DLM-
MECH-511
MR.
HARIKUMAR
DAELIM
(Enginnering)
VAF 3 MECH Engineering 12-Mar-14 15-Mar-14 Open
During material receiving of Back wash water pup (P 0589) by powerking
system found an instrumentation part attached to the seal reservoir is being
damaged by it support attaching it to the reservior by welding. The damage
may havehappened due to poor handling and preservation. This is violation
as per A554-E-103-QA-GEN-PRO-034, Para. 8.1.3 & A554-E-103-QA-
GEN-PRO-035, Para. 8.2.1.11 & 8.11.
PN: During surveillance at site for T-2220 Downcomers Stiffner without holes were found drilling without
proper safely measures abd with CS clamps (scaffolding clamps and pipes). This may cause
condonation of the SS stiffeness. Corrective measures required from the Contractor.
Subcontractor: Noted I will chck with equipment inspector and let you know regarding these
issue
During tray leveling inspection for the tower T1510, it is noticed that tray
no. 2with downcommer pannel (EB-102) is having a scattered corrossion
on its surface. Corrective ation is required. Ref. RTSS-5093-01, Para. 1.37,
1.3.8., RT 6-1CS.
During site surveillance, it was observed Contractor installed Channel cable tray using SS nuts and
Bolts, as per standard RTGE-0802-01 required silicon bronze nuts and bolts. This is violation against
standard RTGE-0802-01
Contractor: submitted RFV to Company for review regarding usage of HDC for channel tray as
per transmittal no. MFC-T-D-CJ-IC-1185, dated 19 Feb. 20143.
During MRI of Fire protection materials, it was observed that Stud Bolts have developed corrosion due
to damaged galvanized coating by cutting ends ad no traceability to comply specification for low alloy
carbon steel bolting G45-3251-00, sec. 1.1.1 ASTM A 193 grade B7/B16/ ASTM A 320 grade L7 and
ASTM A 194, grade 2H/4/7 plus S4, sec. 1.2 The marking shall be done by means of die stamping.
Contractor:All the rejected stud bolts which are not completed were replaced with new studs.
During pad-leveling inspection at Cooling Tower and ground flare area, the
foundation bolts for T supoort and column support of ground flare wind
fence found bented. At ground flare wind fence column no. 13 from south
to north of the east site found bented and later it was heated to make it
straight (plates available). These are violations as per ALSCC303 para.
7.5.1. A554-103-QA-GEN-PRO-001
Subcontractor: There was cicil problem, TCC construction group fix
the issue. Pictures are attached. Need hardness test.
With reference to RFI-MFC-DLM-KCC-CI-16134. Mixing, placement and
sampling inspection for Epoxy grouting of Cooling Tower Pump (P-0901B)
First part (SKID), it was noticed that the epoxy grouting procedure has not
been complied. Instead of pouring the epoxy in one (1) direction, the other
side of the pump was also poured, thus, creating a void in the middle of the
skid. The Contractor shall demonstrate further on how to totally fill the
inside of the skid prior to procceed grouting of other portion.
Subcontractor: The materials were already replaced with EP 150
which is more flowable compaired to EP 160 which was used on that
grouting. The hollow portion will be filled when the next day will be
poured.
With reference to LBE #246, dated 2 Mar 2014, during surveillance
inspection & monitoring activities, it was found out the door & frames
without fire rated labels:
a. Substation G1121 SD5 at switchgear room;
b. Substation G1121 SD6 at mechanical room;
c. Substation G1120 SD2 at Battery room;
d. substation G1120 SD4 at Switchgear room
e. Substation G1120 SD5 at Mechanical room
Regarding the Fire Rated Labels, as per vendor those door cannot be
fire rated due to over size, please see attached approved door and
frame schedule.
During surveillance& monitoring activities at substations, it was observed
that mostof the internal door & frames for substation G1120 & G1120 are
already installed without providing RFI to the Company first. This violates
(as per ITP) SMIC-M-1047. Contractor is advised to take corrective and
Subcontractor Submitted the RFI for the Door Installation and some
door already Inspected, Remaining Installed door have Comments,
Once all Comments will Rectify Sub Contractor will raise the RFI for
Inspection, Inspection Door RFI Reference is MFC-DLM-AMA-CI-6031-
During inspection at Cooling Water Tower observed that partition walls
grinder beam (intermediate) obstructed or on cross on walkway platform.
Daelim/SPIG shall redesign the structural arrangement and provide proper
access without any obstruction on walkway and re-evaluate the structural
integrity if any significant modification required.
Reference to RFI No. MFC-DLM-AMA-CI-6614-0A, during material receiving inspection for galvanized
steel angular bars for canopy substation G1120 & G1121, found that one (1) piece of delivered steel
canopy was deformed due to handling or delivery discrepancy. Contractor to replace or backload the
said material and not to install or not use at site.
Regarding Galvanized Steel cannopy which was deformed at site it is already recitified or repair.
PN: During the Tray level inspection for the internals of equipment T-1210, it is observed that Seal pan
1st tray support rig and tray # 1 is having a level difference of 14 to 15 (slop) mm toward one side of the
Tower. Engineering solution required.
Noted: Work will be done accordingly
During surveillance at site, it is noticed the pump P2320, C2701, C2711
were found without proper covering and temporary shelter protection over it
as these are critical.
After Cleaning The Pumps Fix Will be Attached
PN: During the internal tray level inspection for the Tower (T-2220) it is observed that Seal pan tray
arrangement is not as per the actual orientation shown in the provided tray arrangment drawing.
Engineering solution is required.
Noted: Work will be done accordingly
During surveillance & monitoring activities at operator building along south side "outside area" found out
some materials scattered around the building. Contractor is advised to put the materials in the
designated area with prooper handling and protection to avoid damaging the items and Contractor to
observe proper housekeeping.
Subcontractor has taken the action all scattered material already shifted from operator building
and the area is clean. It is advised to construction team that not to do same practice in future.
With reference to RFI No. MFC-DLM-KCC-CI-6108 & 6109, during material receiving inspection for
metal roofing and siding intended for truck loading shelter and lube oil shed, noticed that the materials
are not properly protected and poor preservation was observed. Contractor is advised to cover the
materials properly to protect from any damage.
Materials were already Covered and Protected
Page 53 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-ASYD-
INST-003
MR. PERVEZ
ASYAD/
DAELIM
VAF 1 INST Instrumentation 13-Mar-14 16-Mar-14 15-Mar-14 28-Apr-14 Closed
LBE-TCC-MECH-
512
MR. SAYED TCC VAF 3 MECH Piping 15-Mar-14 18-Mar-14 19-Mar-14 Closed
48
LBE-DLM-
MECH-513
MR. SAYED
DAELIM
(Mat. Dept)
VAF 3 MECH Material 17-Mar-14 20-Mar-14 Open
LBE-KCC-CIVIL-256 MR. GERALD KCC VAF 2 CIVIL Preservation 17-Mar-14 20-Mar-14 02-Apr-14 02-Apr-14 Closed
LBE-SEN-ELECT-
115
MR. MARK SENDAN PN 1 ELECT Electrical 17-Mar-14 20-Mar-14 20-Mar-14 31-May-14 Closed
LBE-DLM-MECH-
514
MR. SURESH
DAELIM
(QA/QC)
VAF 3 MECH Mechanical 18-Mar-14 21-Mar-14 28-Apr-14
Refer to
Company LBE
for further
comments
03-Jun-14 Closed
LBE-DLM-MECH-
515
MR. SURESH
DAELIM
(Mat. Dept)
VAF 3 MECH Preservation 19-Mar-14 22-Mar-14 29-Jun-14 Closed
LBE-DLM-TELE-009 MR. RODNEY
DAELIM
(Enginnering)
VAF 1 TELECOM Telecomunication 19-Mar-14 22-Mar-14 29-May-14 01-Jun-14 Closed
LBE-KCC-MECH-
516
MR. GLENN KCC VAF 3 MECH UG-RTR 19-Mar-14 22-Mar-14 26-Mar-14 13-Apr-14 Closed
58
LBE-SEN-
ELECT-116
MR. MARK SENDAN VAF 1 ELECT Electrical 20-Mar-14 23-Mar-14 30-Jul-14 22-Jul-14 Closed
49
LBE-DLM-
CIVIL-257
MR. JERRY
DAELIM
(Enginnering)
VAF 2 CIVIL Engineering 20-Mar-14 23-Mar-14 Open
LBE-DLM-CIVIL-258 MR. JERRY DAELIM VAF 2 CIVIL Civil 20-Mar-14 23-Mar-14 01-Apr-14 01-Apr-14 Closed
LBE-SEN-ELECT-
012
MR.
FELOMINO
SENDAN VAF 1 ELECT Preservation 20-Mar-14 23-Mar-14 26-Apr-14 26-Apr-14 Closed
LBE-ASYAD-INST-
004
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 20-Mar-14 23-Mar-14 03-Apr-14 08-Apr-14 Closed
LBE-KCC-CIVIL-259 MR. JERRY KCC VAF 2 CIVIL Civil 21-Mar-14 24-Mar-14 25-Mar-14 26-Mar-14 Closed
LBE-ASYAD-INST-
005
MR. PERVEZ ASYAD PN 1 INST Preservation 22-Mar-14 25-Mar-14 23-Apr-14 07-Jun-14 Closed
During inspection, it was noticed that Contractor installed JB not according to Standard & typical
drawing, JB supports weld or handrails, which is not allowed. This violates Project Specification G-6A-
0041-00, Para. 61.6.5 & typical drawing G-07C-0326. Contractor to take preventive action,
Contractor: Contractor submit RFV to company for review regarding mounting of support for FJB
on handrail as per transmittal no. MFC-T-DS-CJ-CI-1243, dated 14 Mar. 2014.
During Surviellance at TCC Site Area, It has been observed that rejected fit-up joint was welded without
joint preparation for root gap, root face & bevel angle, Line No. 24"-PR-171702-HC35 Joint No. 015.
This is Violation against A554-K-PRG-CE-SPC-DES-045 para 5.1, Contractor shall provide corrective
action & Preventive action.
TCC QC Manager and QC Supervisor Conducted one Tool Box Meeting with TCC Piping and
Welding Inspector and strictly inform to all QC Inspector 100% Fit-up Inspection and full time
monitoring for Construction Activities.
At Building G-1122 (Operator Building) the Opening for Instrumentation route in the telecom outside wall
is not allowed as per TIA/EIA 569B Para. 7.11.1 states that the telecommunication room shall be
dedicated to the telecommunications function and related support facilities, in RT-SAES-T-916 Para.
4.3.7.1 overhead routing of other utilities through the telecommunications room space shall be avoided
to prevent obstruction to communication equipment.
Engineering was informed regarding this issue including civil, violation will be updated what is the
action of contractor. RFV no. A554-RFV-103-284 was already approved by the Company
regarding this violation. Contractor request to Company to close this violation.
It was Obsereved that RTR Firewater Piping FW-071282 (HT-010) Near Sump Pit G-1121 was
damaged due to excavation this line has been leak tested and passed damaged line shall re-tested after
completion of repair to comply G4S-G423-01 Sec. 7 a new test shall be applied after repairs &
corrections have been made.
The Damaged pipe was already repair, waiting for the hydrotest before backfilling.
During Routine Site Visit, it was noticed that the cable tray (HV-27-001)
was already reflected due to installation of cable which is a violation as per
NEMA VE-2 Section 4.2.1 at E-W Piperack near battery Limit.
Contractor: Reply same with LBE No. 115 Company will inform after
discussion/rectification has been done.
PN: Contractor Shall replace all cable trays with damaged rungs acquired during cable fulling specially
by other contractor to avoid delays for the energization of electrical equipments in both substations G-
1120 & G-1121
Contractor: The issue was already addressed to Contraction as it was damaged by other
contractor during cable pulling.
WRONG PWHT CHART Recorder: During Surviellance Inspection at splitter Pipe rack area, found
contractor has been using the wrong PWHT Chart recorder, single point/channel recorder using local
PWHT, instead of Multipoint recorder., This PWHT chart are not clearly differentiate each channel/point
by use different colored inks or automatic number stamping. this is violation against RT8S-6500-01
Para. 8.16 which states that, " Multipoint chart recorders shall clearly differentiate/identify each
channel/point by use different coloroed inks or automatic numbering stamping". ISO Drawing No.
N016103V6A-CWS-093032-01, Joint No. FW-01 (PWHT Vendor: M/S AMSYCO)
Please find attached approved RFI copy and report copy which is clearly Differentiate each
channel by use of different colored inks.
Equipment and Materials Improper Preservation: During Surviellance at daelim laydown yard the
following violations. 1. All Equipment has not been displayed" maintenance Preservation Log Sheet" as
per Preservation Plan. 2. galvanized structural Materials and Coated Ladders Improperly stored on the
sand. 3. Many furnace Duct Flanges have not been protected with protected covering or tarps. (see
Attached photos), this is violation against preservation plan Document No. A554-E-103-CM-GEN-PLN-
002 Para 2.3, 2.19.16, and 2.5
with reference to RFI # MFC-DLM-AMA-CI-6392A and 6393A, Pre-Installation Inspection (Inner Wall)
Prior to Instruction of Insulation board, & Inspection of Metal Track Prior to Installa Gypsum board
(Above 1.2 Mts, Heaight) and Wall tiles, @ (Operator Building G-1122) Sample Preparation room, it was
observed that no shop DRWG, or connection details, termination for wall tiles installation, in this
regards, contractor was advised to submit/provide shop drawing & deatails for the said wall tiles
installation for (North & West Side) of Sample Preparation Room. for Proper Documentation and
Regarding the Operator Building Sample preparation room subcontractor has already submitted
the shop drawing. Shop drawing has been approved by Daelim, Please see attached Approved
Drawing.
During Valve Receiving Inspection, It has benn Observed that some
supplies are Violation DOW Spec for Tagging. According to G4R-7200-01
Each Valve Shall be tagged by vendor with a brass tag with monel wire and
crimped with each other onto the wire end to avoid loses of tags, VENDOR
NAME: 1. Bonney forged Italy, 2. Pantair Vanessa, 3. Zero Engg., All
vendors provided valve tag without the monel crimp sleeve that may cause
of lost tag.
Contractor: Company accepted Contractor's TM indicating that
stainless steel 18 gauge wire and using crimp sleeves of same base
netal of wire is acceptable. (MFC-T-CJ-DS-PI-0976)
With Reference to RFI # MFC-DLM-KCC-CI-6211 Material Receiving Inspection of Varipanel 65 (VP-65)
Metal Deck Intended for Common Compressor shelter, it was observed that during Inspection this
materials have no proper cover or protections., In this regards, contractor was advised to take corrective
action concerning this issue for proper preservation & material Handling for the said materials.
Materials were already Covered and Protected
During Site Surviellance at cooling tower piperack it was noticed that contractor use stainless steeel wire
instead of nylon coated 316 SS tie, it may damaged the outer sheath of cable, this vioaltion project
specification, RT6E-0802-01 & A554-O-PRG-IC-GEN-BOD-003., Contractor Request to take a
Preventive action.
Subcontractor: Stainless Steel wire @ Cooling tower Pipe rack was already replace with the
stainless steel Nylon Coated 316SS Tie, Cable Pulling Inspection it was Already Accepted.
Review of RFI # MFC-DLM-KCC-UG-2235, 2227 & 2228, the frequency of test and backfilling and
compaction timing are not probable due to location, please provide expalnation and timing each FDT
test result.
With Reference to the RFI # MFC-DLM-KCC-UG-2235, 2227 & 2228, The testing was done, time
to time. (See Attached RFI'S)
PN: During Surviellance at Site it was Observed that installed JB in not Protected all the JB is Un-
covered, which is not good it may caused damage of junction box will be full of from dust dust, this
Violation NEC-110-12 and G-06A-0041-00, Contractor request to take Preventive action.
It has been informed to the concerned authorities, they have started the process of covering all
the JB's which are not properly covered in uncovered state. Now, it is completed all junction and
also covered.
It was notice that during inspection at G1120 and G1124 Paving Area, the
slope design of the paving is not in accordance with the project
specification RT2S-2700 Section 8. also the actual elevation of the existing
paving is not in accordance with the design.
As discussed with Company PMT, Non-process area can be less than
1% slope
it was noticed that in the drawing of pump FDN, details (A554-E-103-CV-DWG-C30-373 Rev. 3B) the
grout specified the drawing is non-shrink grout, this is a violation of RT5S-5311-02 Section 2.3 status
"Epoxy Grout Should be used to grout all rotating equipment covered by this specification" and RT5S-
5303-01 Section 1.2
Drawing was Revised, those Epoxy grout installed at non shrink grout.
During Site Surviellance Inspection of Power Transformer Tag # TR-103 G101A & TR-103 G101B at
Substation G-1120, it was observed that the transformer main tank oil pressure gauges are having low
gas pressure. This violates as per contractor preservation plan Doc. No. A554-E-103-CM-GEN-PLN-
002. Para. 2.8 (e) & Schedule Q Attachement IV Para. 6
Power Transformer with A Tag TR-103G101A/B of Substation G-1120 were now
purged/Pressurized with Nitrogen (N2) Monitoring for the establishing of pressure shall be
observed
Page 54 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
60
LBE-AMA-
CIVIL-260
MR. GERALD AMA VAF 2 CIVIL Civil 25-Mar-14 28-Mar-14 20-Jul-14 30-Jul-14
Included in
the
Punchlist
22-Jul-14 Closed
DAELIM
(Enginnering)
VAF 1 INST Instrumentation 26-Mar-14 29-Mar-14 15-Jun-14 16-Jun-14 Closed
50
LBE-DLM-
ELECT-117
MR.
FELOMINO
DAELIM
(Construction)
51
LBE-DLM-
ELECT-118
MR. MARK
DAELIM
(Construction)
LBE-ASYAD-INST-
007
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 29-Mar-14 01-Apr-14 09-Apr-14 05-Jun-14 Closed
56
LBE-DLM-
CIVIL-261
MR. GERALD
DAELIM
(Enginnering)
VAF 2 CIVIL Civil 30-Mar-14 02-Apr-14
Included in
the
Punchlist
22-Jul-14 Closed
LBE-SEN/DLM-
ELECT-119
MR. MARK
SENDAN/
DAELIM
PN 1 ELECT Electrical 31-Mar-14 03-Apr-14 01-Apr-14 07-Apr-14 Closed
64
LBE-AMA-
MECH-517
MR. NASSAR AMA VAF 3 MECH
Coating/
Painting
31-Mar-14 03-Apr-14 05-Aug-14 22-Jul-14 Closed
LBE-DLM-ELECT-
013
MR. MARK DAELIM VAF 1 ELECT Preservation 31-Mar-14 03-Apr-14 26-Apr-14 26-Apr-14 Closed
LBE-KCC-CIVIL-262 MR. JERRY KCC VAF 2 CIVIL Civil 01-Apr-14 04-Apr-14 02-Apr-14 08-Apr-14 Closed
LBE-AMA-CIVIL-263 MR. JERRY AMA VAF 2 CIVIL Civil 01-Apr-14 04-Apr-14 28-Jun-14 30-Jun-14 Closed
LBE-AMA-CIVIL-264 MR. JERRY AMA PN 2 CIVIL Civil 01-Apr-14 04-Apr-14 05-May-14 05-May-14 Closed
52
LBE-DLM-
ELECT-120
MR. MARK
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 02-Apr-14 05-Apr-14 Open
LBE-DLM-ELECT-
121
MR. MARK
DAELIM
(QA/QC)
VAF 1 ELECT Electrical 02-Apr-14 05-Apr-14 09-Apr-14 31-May-14 Closed
LBE-SEN-ELECT-
122
MR. MARK SENDAN VAF 1 ELECT Electrical 02-Apr-14 05-Apr-14 03-Apr-14 12-Jul-14 Closed
LBE-SEN-ELECT-
123
MR.
FELOMINO
SENDAN VAF 1 ELECT Electrical 02-Apr-14 05-Apr-14 05-Apr-14 28-Jun-14 Closed
During Surviellance & Monitoring Activities at Operator Building, It has
been observed that mostly of rooms have already installed suspension
system and hangers in which some opening for internal wall and
penetrating sleeves are not yet repair of retouch. It is Violate also STD
G2S-9510-01 Section 3.4 Para 3.4.1 up to 3.4.3, in this regards contractor
was advised to take corrective action & Preventive Action concerning this
issue for proper sequencing and scheduling of works.
Subcontractor: Amana has started the rectifiation work suspension
ceiling system and openning work. Amana will submit the RFI room by
room inspection.
During Inspection at Site in PIB-1121 Operator Building it was observed that contractor Installed ^" Open
Channel tray, which is not allowed as per SADARA Specification, Contractor Shall use only 3" & 4" open
channel tray, This Violates RT6E-802-01, Contractor Request to Take a Preventive Action.
Contractor: Contractor issued RFV for 6" channel cable tray, RFV accepted by Company.
During Site Surviellance at Electrical Room Substation G-1120 it was
Observed that the cable tray Installation is closed and insufficient clearance
to the grounding Busbar, This is Violates as per G7C-0104-00 Para. 5.7
contractor: Discrepancies of Installation with regards to the standards
will address to engineering for Clarification and action. NCR issued to
The Contractor Stopped Curing of the Ditches at the west side of common compressor area without
completing the 7 day requirement specified in RT25-3001-01 Section 9. Para. 9.12 which states not less
than 7 days water curing, Please provide Corrective Action to this violation.
Subcontractor: Burlap Were already & Contineous the curing.
It was Noticed that some existing angle bars for tranch covers at North east Side of Furnace and west
side of the flare area open ditches were already corroded, please investigate the coating or the
galvanization process as the adjacent location does not show sign of corrosion of the source material,
provide corrective action and identified corroded materials.
Contractor: Regarding the corroded angle bars, Company has already issued an NCR to
Contractor/Subcontractor.
With Ref # MFC-DLM-AMA-CI-6999-0A Metal Flushing & Trim Pre-Installation inspection at south &
eastside of Sub station Building G-1120 "Roof Slab" we found out that installation of Flashing 5" & not
conform to the latest IFC Drawing (as Shown on the detail 1) Drwg # A554-E-G1120-DWG-A03-450 Rev.
3 in this regards, contractor should investigate and take corrective action concerning this issue for
proper implementation at site.
Contractor: Amana has submitted the shop drawing and approved by Daelim.
Contractor shall connect to grounding cable between the apparatus ground bus and the local ground
grid as per 67C-0104-00 Section 6.4.1, for switchgears and MCC's at S/S G-1120 & G-1121
Noted: Engineering will be Informed to attest what will be the action.
During Surviellance it has been noticed that projecting Steel Item angles
embedded plate or gravity angles open ditch was corroded due wrong paint
code system, system coating required as per SADARA Specification RT2S-
3001-01 is hot dip galvanizing in accordance with ASTM A123, Grating
angles were installed & found in two Locations right now, North East of
Furnace # 1250 & North West of Ground Flare area of Piperack, this is for
Information and Corrective Action shall be taken by Daelim/Amana
Company NCR has been issued to Contractor.
Contractor Shall Energized the Space heater for all the Switchgear at substation G-1120 & G-1121 as of
now, the space Heaters of these Switchgear are not yet energized which os a violation as per RT-6-1CS
Sectionb 2.9.C.
Controlling Temperature Inside the Two (2) Substations G-1120 & G-1121 is the main solution by
installation Air conditioning Unit (4 Nos) as per construction plans & action, also Please Attached
file for the discussion of company & Contractor top Management.
During routine site surviellance, it was noticed that the installation of
battery disconnect was located outside the battery room which is a violation
as per G7C-1816-00 Section 3.11 and NEC Article 480.5.
Contractor: Issue Will be addressed to engineering for further
assessment regarding this violation. As per Engineering team, it was
installed outside the battery room to prevent splashing of electropolyte
and same principle of 67C-1816-00, Spec. 6.2 installation.
During Site Surviellance at NS Piperack it was observed that 300mm wides cable tray has been damage
by Mechanical crane. This Violation Project Specification SCH Q" Attachment IV Para. 5 G-070-0322 -
00, Contractor Request a preventive Action.
Subcontractor: The Incharge supervisor in that particular area was already coordinate to the
TCC. After completion of job erection, they will rectify the seal cable tray damage.
Contractor: Damage cable tray already replaced and inspection has been done.
During Surviellance and Monitoring Activities at Sub-station G-1120, it was
noticed that contractor was installed "stainless" Steel Gutter & Downspot"
at west side wherein the downspot holder and gutter support are
galvanized materials, it violates STD RT20-7004-74 Section 5.2.3 Para.
5.2.3.1 States that "Fascia Trim", Flashing and Other exposed metal work
should be one of the following:
1. For all now Sxposed uses - 24 ga " Paint Grip" Galvanized Steel.
2. For all Exposed Uses - 24 ga " Stainless steel" and RT2D-7004-04
Section 3.11 Para 3.11.1, in this regards contractor must takes corrective
concerning this issue for proper implementation.
During Surviellance at Battery Room Substation, G-1120, it was observed that the Battery was
energized and the eyewash were using is temporary portable type personal eyewash. This violates as
per G7C-1816-00 Para. 6.1.1.3
Contractor: as part of safety first and during pre-commissioning stage personal eyewash has
been provided within the vianity and it will be replaced with acceptance eyewash as per
specification.
During Material Receiving Inspection, it was Noticed that one cubicle was
damaged. Contractor shall replace the damage cubicle at its components
inside motor control center MCC-103H204 at Substation G-1121.
Contractor: Contractor issue to vendor for replacment of damage part
in MCC-103H204 -> Replaced with new component
During Routine Site visit this morning, it was Noticed that there is no QC Inspector coverage for S/S G-
1121 from the main contractor which is a Violation as per Schedule Q Attachment VI, Section 1.1
Contractor: The Assign QC Contractor QC in G-1121 has been return to day shift schedule.
During routine site Inspection that the Contractor Installed clamp for EMT conduit that tdoes not comply
with NEC Requirements and not UL Listed which is a Vioaltion as per 67C-0311-06 Section 1.1
Subcontractor: The subjected matter has been informed to construction team, the same will be
replaced approved clamp.
Page 55 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
53
LBE-DLM-
ELECT-124
MR.
FILOMENO
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 02-Apr-14 05-Apr-14 Open
LBE-ASYAD/DLM-
INST-008
MR. PERVEZ
ASYAD/
DAELIM
VAF 1 INST Instrumentation 03-Apr-14 06-Apr-14 28-Apr-14 28-Apr-14 Closed
LBE-ASYAD-INST-
009
MR. PERVEZ ASYAD PN 1 INST Preservation 03-Apr-14 06-Apr-14 07-May-14 07-May-14 Closed
76
LBE-DLM-
TELE-010
MR. RODNEY
DAELIM
(Enginnering)
VAF 1 TELECOM
Telecommunica
tion
05-Apr-14 08-Apr-14 09-Apr-14 20-Jul-14 Closed
54
LBE-DLM-
MECH-518
MR. SAYED
DAELIM
(Procurement)
VAF 3 MECH Material 05-Apr-14 08-Apr-14 Open
55
LBE-ARCC-
MECH-519
MR.
HARIKUMAR
ARCC VAF 3 MECH
Mechanical
(Equipment)
05-Apr-14 08-Apr-14 12-Apr-14 Open
56
LBE-DLM-
MECH-520
MR.
HARIKUMAR
DAELIM
(Construction)
VAF 3 MECH Mechanical 05-Apr-14 08-Apr-14 Open
LBE-DLM-TELE-011 MR. RODNEY
DAELIM
(QA/QC)
VAF 1 TELECOM Telecomunication 06-Apr-14 09-Apr-14 09-Apr-14 13-May-14 Closed
80
LBE-DLM-
TELE-012
MR. RODNEY
DAELIM
(Enginnering)
VAF 1 TELECOM
Telecommunica
tion
06-Apr-14 09-Apr-14 09-Apr-14 20-Jul-14 Closed
25
LBE-DLM-
ELECT-125
MR. MARK
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 07-Apr-14 10-Apr-14 10-Apr-14 22-Jul-14 Closed
LBE-DLM-ELECT-
126
MR. MARK
DAELIM
(QA/QC)
VAF 1 ELECT Qaulity Management 07-Apr-14 10-Apr-14 12-Jul-14 Closed
57
LBE-DLM-
MECH-521
MR. SURESH
DAELIM
(Enginnering)
During surviellance at site it was observed that contractor pulled the cable in improper way cable laid on
walk way worker walk on the cable & there is no preservation of cable this Violation of Schedule Q" NEC
Article 110.12, Contractor request Preventive Action.
Subcontractor: Cable was already laid on the cable tray and some area: was already provide a
protection cover.
Contractor in advised to verified the height of lighting fixtures installed
inside the TER at G-1122 operator building, the standard states at RT-
SAES-T-916 Para. 4.4.2.12 that the lighting fixtures shall be located at the
minimum height of 2.6m from the finich floor.
Contractor already issued SQDR to addressed the sub-contractor for
verification & Rectification.
During review of material test certificate of LTCS Pipes A333 Gr. 6 (PO No.
- 100532-B-PIP-0037-01) it is observed that mill certificate does not have
the impact test details, this is violation of ASTM A333 Gr. 6 Para. 14 which
specifies all materials furnished under LTCS soecification shall be tested
for impact resistance at all temp for the respective grade.

During Surviellance at Electrical Room Substation G-1120, it was observed
that the power panel and Dry Type Teransformer was installed along with
LV Switchgear is forture space for LV Switchgear. This is Violates as per
G7C-1811-00 Para. 6.1.2 & 6.1.8
Contractor: Engineering was informed regarding this matter/Issue,
company will be informed of contractor action. -> Discussed and
agreed with Company. NCR was issued to Daelim Construction
team.
During Inspection at Operator Building G-1122 it was noticed that contractor installed the conduit &
covered by gypsum board prior to inspection of conduit installation. This is violation of Project ITP &
Schedule Q" Attach # IV Para. 3.7 & SMITP-J-106-06 Note 3
Contractor Already Provided Photos that conduits are installed as per standard, next time, work
will be inspected prior proceeding to the next work.
WRONG TEMPERATURE CHARPY TESTED PIPES: The piping Class
HC72 and HC35 used pipe Material size NPS 30" and 64" has been charpy
tested at 29C (-20F), Instead of (-45C (-50F) at manufacturer Place.
Pipe material ASTM A671 GR CC70 CL. 12, S2., This is Violation against
piping Material Specification RTIP, HC72-103 and HC35-103, common
general note P-LC04PE625, states that charpy Test shall be for -50F (-
45C). Pipe Manufacturer; SEAH Steel Corp, KOREA, MTC No. D20121-
1123-024263(1305656) Dated 21 Dec-12, D201210-1268-020252 Dated
22-OCT-14, Found Heat No. SF23532 (30"), SP36974 (64") Contractor has
confirmed to take corrective action at site, remaining available same heat
number stock pipes, carry out retest or alternative solution for this vioaltion.

Contractor is advised to follow the correct type of cable runway to be used
inside the telecom room as per I.C-038 (See Photos Attached) take note
that the (IT) is using chatworth racks therfore it is important to use a cable
runway with the same type as chatworth of equivalent.
Contractor: This Issue was already addressed to engineering &
meeting also, action of EPC will be inform to company.
During Routine site inspection, it was obeserved that the contractor already
energized the battery at substation G-1121 without the acceptance of the
cable power from the battery to the disconnect switch. The power cable do
not pass the material receiving inspection and without cable testing which
is a violation as per schedule Q" attachement IV Section 3.7
Contractor: Contractor will submit RFV to company for variation of
cable's specs, cable was tested in the drum and after cable pulling
once the RFV will be approved by the company activities which is
covered by this cable shall be closed. -> Discussed and Agreed with
Company on the installed cables
During routine site visit, it was noticed that there is neither contractor QC nor subcontractor no present
QC Witnessing the on-going battery testing at battery room in substation G-1121 which is a violation as
per schedule Q Section 1.2
Contractor: If the Activity was filling of battery QC Monitoring only. The assign QC in G-1121 at
that date was in night shift thats why one of QC Contractor was temporary assigned during testing
in G-1121, April 9, 2014 the assign QC Contractor was already shift to day shift.
Observed that ARCC is modify combustion air duct/stack without confirmed
support document or approval following discrepancy Noted: F 1240 area, *
Duct was damaged due to improper fabrication method * gas was burned
by gas cutting flame. DAELIM/ARCC shall propose appropiate corrective
action for rectifying the damaged part and replace damaged gasket *
DAELIM shall obtain proper approval for rectifying any vendor supplied
eqpt. prior to start activity by company, Violation of Sch Q and Material
management plan.
Subcontractor: ARCC to Rectify this violation as per submitted &
Approved method Statement. Attached photo of rectified conbustion
duct.
Observed the following violation discrepancy 1. Third discharge drum D-
1607 nozzle LIB 2" flange has damaged or distorted and out of squireness
due to improper material boundary. 2. Flange space seration damaged on
steam vent silencer on F-1170 (1030-SI-117) DAELIM shall verify the
extention damage and propose appropraite rectification method to
company approval.

At Telecom room building G-1120, G-1121 & G-1122 contractor is advised to provide and installed a #
5/0 AWG ground wire connected to the building ground grid with five(S) meters coiled in the TER and
/OR TR, see the Typical drawing for the location of grounding sleeve - A554-F-760-15-DWG-E64-018,
IC-038.
# 4/0 AWG was already provided for other contractor purposes & as per scope of work.
Page 56 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-AMA-CIVIL-265 MR. JERRY AMA VAF 2 CIVIL Civil 10-Apr-14 13-Apr-14 24-Apr-14 28-Apr-14 Closed
58
LBE-GACC-
MECH-522
MR. KURIAN GACC VAF 3 MECH Mechanical 10-Apr-14 13-Apr-14 18-Apr-14 Open
59
LBE-DLM-
MECH-523
MR. KURIAN
DAELIM
(Procurement)
60
LBE-DLM-
MECH-524
MR. KURIAN
DAELIM
(Enginnering)
PN 3 MECH Engineering 10-Apr-14 13-Apr-14 17-May-14 Info
61
LBE-DLM-
MECH-525
MR. KURIAN
DAELIM
(Procurement)
VAF 3 MECH Mechanical 10-Apr-14 13-Apr-14 17-May-14 Open
LBE-ASYAD-INST-
010
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 12-Apr-14 15-Apr-14 28-Apr-14 28-Apr-14 Closed
LBE-ASYAD-INST-
011
MR. PERVEZ ASYAD PN 1 INST Instrumentation 12-Apr-14 15-Apr-14 28-Apr-14 28-Apr-14 Closed
LBE-AMA-CIVIL-266 MR. GERALD AMA PN 2 CIVIL Quality Records 12-Apr-14 15-Apr-14 22-Apr-14 05-May-14 Closed
LBE-AMA-CIVIL-267 MR. GERALD AMA PN 2 CIVIL Quality Records 13-Apr-14 16-Apr-14 24-Apr-14 26-Apr-14 Closed
76
LBE-SEN-
ELECT-127
MR. MARK SENDAN VAF 1 ELECT Electrical 14-Apr-14 17-Apr-14 17-Apr-14 30-Jul-14 22-Jul-14 Closed
LBE-SEN-ELECT-
128
MR. MARK SENDAN VAF 1 ELECT Electrical 14-Apr-14 17-Apr-14 17-Apr-14 28-Jun-14 Closed
65
LBE-DLM-
ELECT-129
MR. MARK
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 15-Apr-14 18-Apr-14 18-Apr-14 24-Jul-14 Closed-
LBE-DLM-ELECT-
014
MR. MARK DAELIM VAF 1 ELECT Preservation 15-Apr-14 18-Apr-14 26-Apr-14 26-Apr-14 Closed
LBE-DLM-CIVIL-268 MR. JERRY
DAELIM
(Enginnering)
VAF 2 CIVIL Civil 16-Apr-14 19-Apr-14 28-Jun-14 29-Jun-14 Closed
LBE-AMA-CIVIL-269 MR. JERRY AMA VAF 2 CIVIL Civil 16-Apr-14 19-Apr-14 16-Jun-14 17-Jun-14 Closed
LBE-DLM-CIVIL-270 MR. JERRY
DAELIM
(Enginnering)
PN 2 CIVIL Quality Records 16-Apr-14 19-Apr-14 08-May-14 14-Jun-14 Closed
Despite of Logbook Entry # 263, the Contractor continue to utilize non-galvanized angle frames for the
sump located North of D-0950 during Inspection today of paving, this is a violation to RT2S-300-01
Para 8.2.7 which is requires that this item shall be not be dip galvanized in accordance with ASTM
A123.
The Installed non galvanized angle frames mistake done by the site foreman, subcontractor do
agree to not happen again in future, subcontractor has replace the angle frames which is hot dip
galvanized.
During Surviellance at MFC Daelim Site it is noticed/observed that the
dilution steam generator structure, Strcutural Brazing welded to the
embedded plate were half/incompletely welded is found at all the different
elevation of the dilution steam generator structure TCC has an inspection
point with Daelim with witness point as per the ITP. Hence it is violation of
ITP and Procedure. Ref.# A554-E-103-QA-GEN-PLN-021 Rev. 3 Para.
4.2, 4.11, 4.9
Subcontractor: 1. Noted I will check with structure inspector and let
you know regarding this issue.
With Reference to LBE # 250 (Dated 09,03, 2014) Subcontractor replied concerning fire rated "Labels at
door & frames, as per vendor clarification those door cannot be "fire rated" due to oversize (See
attached approved door & frame schedule) in this regards, contractor shall provide of submit shop
drawing, and details showing "CMU" size and fire rating for both exterior and interior CMU wall @ (Sub-
station G-1120 & G-1121), for Proper Documentation & Implementation @ Site.
Subcontractor is requesting to close this log book entry because its repeated.
During Routine Site Inspection, it was noticed that the contractor used hog
bolts and nuts in the installation of outdoor enclosures which is vioalation
as per A554-K-PRC-EL-GEN-PHL-005 Section 3.4.4
Subcontractor: The Subjected matter has been informed to
construction group to coordinate with engineering, the installation done
as per IFC drawing, Contractor will submit TM for the same.
During Surviellance Inspection of Electrical room Substaion G-1120, it was observed the following
Violation: 1). Power and control cable was installed in cable tray and cable dressing has completed in
vertical and horizontal capability without inspection the tray this violates as per schedule Q Attachement
Q IV. PAra. 3.7. 2). During Inspection of LV Power Cables were Installed in Cable Tray # EH-112-104,
EH-114-107 and EH-115-109, Power Cables not Properly dressed. this violates as per schedule Q
Subcontractor: 1). After Receiving asbuilt drawing from engineering subcontractor will raise RFI
for the same. 2). Subcontractor will complete the cable dressing as per ITP and RFI will raise for
the same.
During Site Surviellance it was observed that in cooling tower pipe rack JB inspection not cleared and
Contractor Claud this cable, this is not the 1st time happened, repeated violation done by contractor.
This violates Schedule Q" Attachment IV Para 3.7 and Project ITP Contractor requested to take a
Preventive Action.
RFI # MFC-DLM-ASY-INST-990A to 998A already submitted and accepted, cable installation will
not be done unless JB's are inspected & Accepted.
During Surviellance at PIB-1121 it was observed that improper installation of cable pulling at building
and worker sitting an tray and used as walkways, this vioalate Schedule Q" AVEMV-VE2 and NEC
Article 40.12, Contractor request to take a Preventive Action.
Subcontractor: Subcontractor already provided temporary access/Scaffolding planks in order not
to use the cable tray as walkway
During the Surviellance and Monitoring Activities at Operator Building (G-1122) along sample
preparation room, it was noticed that wall tiles installation has been started, wherein no RFI of shop
drawing submitted by contractor, in this regards, contractor shall be provide "Shop Drawing" Showing
Layout of Wall & Floor Tiles, for Proper Documentation and Implementation at Site.
Subcontractor: Amana has submited the shop drawing and approved by Daelim.
During Material Receiving Inspection E222313 Exchange it is noticed that
its Leg (Jointed to the foundation) is bented makes it difficult in equipment
align also the boday of the equipment is found damage (Corroded and
broken - external body part), this may have happened in trnasportation and
material handling, proper action to be taken by the contractor with the
vendor recommendation for the rectification of the equipment. Ref #. A554-
103-QA-GEN-PRO-034 Para. 8.1.3 A554-E-103-QA-GEN-PRO-035 Para.
8.2.1 & 11.8.11

PN: During Surviellance it is Observed that P-0126B, P2320A, P2411A,
P2415A/B, P1311A/B/C, P1302A/B, 1711A, P2122B by ITT goulds found
Leaking. Leaking is from the oil drum out valve thread connections, Daelim
should take appropraite corrective action by consulting the
recommendation of vendor manufacturer.
Contractor: Vendor site visit being arranged. The expected visit date
is within 23 May 2014. -> NCR with coorective action was sent to
Company through TR no. MFC-T-DS-CJ-QA-1567 dt July 14.
During Inspection it is found that in tower (T2110 Primary Demethanizer)
for internal tray Installation flange down condencer brazing suppor for the
false down commer plate is not welded to the tower shell, also for lower
T1810, HP depropanizer bolt for tray 31 placed BW feed pipe at beneath
tray 31 is not founded welded. contractor shall take corrective action
consulting with the tower manufacturer and SME. Ref. KOCH-GLI-TSCH
Drwg. No. 115108-D000, 115111-D001.
Contractor: Contractor already discussed the issue with Company
and will submit the site work procedure for missing clips to Company.
After receiving the confirmation from Company, Contractor will do site
work.
Contractor: Contractor is now procuring the required material for T-
1810 & T-2110.
(1) T-2110 : Required Material (SA 537 Cl.1+S5, -48) is arrived at
site.
(2) T-1810 : Contractor is continuously expediting Tower fabricator to
supply the reqruied material (SA 537 Cl.1 + S5, -59 Impact Tested)
It was noticed that in the V-0555 (Sodium Hypochhlorite) tank area, the Paving Located at the sout side
has a construction joint without a TPER. TPER shall be installed as required by Document # A554-K-
PRG-CV-500-CON-001, Section 16.4, Contractor shall submit a method statement or shop drawing for
approval by company See also Doc. No. A554-K-PRG-CV=SPC-C20-047.
Contractor: Already rectified the area as per shop drawing. See attachments.
It was noticed that sometimes contractor does not have the complete drawing to verify slope during
survey. There is no assurance that the survey done by sub-contractor personnel are they updated IFC.
Please Advise surveyor to be independent from the sub-contractor survey data and must provide their
own computation to compare data with Contractor to ensure proper checking during survey work to
avoid erromous survey result (Pro-Active).
Contractor: Contractor noted the the notification, Contractor surveyor was informed to bring
drawing everytime there is on-going inspection & compare his survey report to subcontractor
surveyor for counter checking.
During routine site inspection, it was noticed that the IFC Drawings for fire
alarm System, Dont have an approval from fire department which is
vioaltion as per A554-F-PRG-SE-GEN-BOD-002 Section 1.4.
Contractor: Engineering team shall clarify the issue to Sadara
regarding the scope of work or the design issue. Government
approval is out of Contractor's work scope
During routine site visit, it was observed that the temperature inside the electrical room of substation G-
1121 was already 28.6C, which is violation as per 67C-1811-00 Section 12.3.3
Controlling Temperature Inside the Two (2) Substations G-1120 & G-1121 is the main solution by
installation Air conditioning Unit (4 Nos) as per construction plans & action, also Please Attached
file for the discussion of company & Contractor top Manageme
With Ref. to RFC (Request for Certificate # A554-RFC-149-131 Regarding Clarification for Epoxy
grouting Centrifugal Pump" for Equipment (PUMPS) pocket holes already grouted with non-shrink
cementitious grout" the response was all Non-shrink cementitious grout that was used on rotating
equipment shall be removed and replaced with epoxy grout to comply with SADARA Specification"
Please identify the pumps where Non-cementitious grout was used also, Please refer to Logbook Entry
# 258.
Contractor: Already identified the area of non-curing grout and epoxy grout.
Page 57 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-DLM-MECH-
526
MR. GLENN DAELIM PN 3 MECH Hvac 16-Apr-14 19-Apr-14 26-Apr-14 26-Apr-14 Closed
LBE-AMA-CIVIL-271 MR. GERALD AMA PN 2 CIVIL Civil 19-Apr-14 22-Apr-14 24-Apr-14 26-Apr-14 Closed
LBE-SEN-ELECT-
015
MR.
FELOMINO
SENDAN VAF 1 ELECT Preservation 22-Apr-14 25-Apr-14 01-Jun-14 02-Jun-14 Closed
LBE-ASYAD-INST-
012
MR. PERVEZ ASYAD VAF 1 INST Qaulity Management 22-Apr-14 25-Apr-14 07-Jun-14 15-Jun-14 Closed
LBE-ASYAD-INST-
013
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 22-Apr-14 25-Apr-14 07-Jun-14 15-Jun-14 Closed
LBE-KCC-CIVIL-272 MR. JERRY KCC VAF 2 CIVIL Civil 22-Apr-14 25-Apr-14 08-May-14 14-May-14 Closed
LBE-KCC-MECH-
527
MR. GLENN KCC VAF 3 MECH Plumbing 22-Apr-14 25-Apr-14 24-Apr-14 24-Apr-14 Closed
LBE-KCC-MECH-
528
MR. GLENN KCC VAF 3 MECH UG-RTR 22-Apr-14 25-Apr-14 04-May-14 04-May-14 Closed
62
LBE-KCC-
MECH-529
MR. GLENN KCC VAF 3 MECH UG-RTR 23-Apr-14 26-Apr-14 23-Jul-14 Open
63
LBE-DLM-
MECH-530
MR.
HARIKUMAR
DAELIM
(Enginnering)
VAF 3 MECH Mechanical 23-Apr-14 26-Apr-14 17-May-14 Open
LBE-AMA-MECH-
531
MR. GLENN AMA VAF 3 MECH Hvac 24-Apr-14 27-Apr-14 09-Jun-14 11-Jun-14 Closed
64
LBE-TCC-
MECH-532
MR. SAYED TCC VAF 3 MECH Piping 24-Apr-14 27-Apr-14 28-Apr-14 20-Jul-14
Daelim to
rectify all
joints
Open
69
LBE-TCC-
MECH-533
Coating/
Painting
26-Apr-14 29-Apr-14 10-May-14 20-Jul-14 26-Jul-14 Closed-
LBE-ASYAD-INST-
014
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 27-Apr-14 30-Apr-14 05-Jun-14 05-Jun-14 Closed
72
LBE-KCC-
CIVIL-273
MR. JERRY KCC VAF 1 CIVIL Civil 28-Apr-14 01-May-14 08-May-14
Included in
the
Punchlist
22-Jul-14 Closed
94
LBE-DLM-
TELE-013
MR. RODNEY
DAELIM
(Enginnering)
VAF 1 TELECOM
Telecommunica
tion
29-Apr-14 02-May-14 09-Apr-14 20-Jul-14 Closed
95
LBE-SEN-
TELE-014
MR. RODNEY SENDAN VAF 1 TELECOM
Telecommunica
tion
29-Apr-14 02-May-14 29-Apr-14 30-Jul-14 20-Jul-14 Closed
During Surviellance and Monitoring Activities at operator building (G-1122), Internal rooms it has been
observed that mostly of rooms, had been already installaed suspension system and hangers in which
some internal wall and sleeves were not properly sealed or repaired as per (SADARA Standard G2G-
4300-41 requirement) a Pro-active notification was issued to the contractror for further action.
Subcontractor: Subcontractor is requesting to close this log entry because its repeated, Please
see the log book entry # 260
During Site Surviellance Inspection at Transformer yard substation G-1120, it was observed that the
power tnasformer tag # TR=103H101A has oil leakage from grounding bushing. This violates as per
contractor preservation plan document # A554-E-103-CM-GEN-PLN-002, Para 2.8 (D) Schedule "Q"
Attachment IV Para 6.6
Transformer for G-1120 with a tag number of TR-103H101A is now rectified and re-tightened to
ensure that leaks (oil leaking) are prevented. This substation is now energized and final leak test
for installed tranformers were done.
Sub-contractor QC Manager Absence for job site from last one month & he left for annual leave without
proper notification & procedure and from last one month sub contractor don't have any QC manger, Its
violation of Schedule "Q" Attachment VI Contractor Request to take Preventive action ASAP.
Subcontractor: Subcontractor QC manager interview has been completed and safety orientation
is finished. Waiting for SADARA ID. Subcon QC Manager has been mobilized to the site on June
13, 2014.
Equipment Defeciencies the following accu deficiences were observed in G-1120.
1. 3 Nos. Pressure gauges are defective for ACCU-001 A/B/C.
2. Isolation valve of ACCU-001A has leakage hindering connection of piping to header.
3. No charging valve available for circuit 1 for each suction Line ACCU-001A/B/C.
all noted Deficiencies shall be rectified by vendor to prepare the equipment for the pre-commissioning.
Equipment Defeciences already rectified by zamil vendor.
1. Deffective pressure gauge already Replaced @ ACCU-001 A/B/C in substation G-1120
2. Isolation valve of ACCU-001A was already replaced by Zamil
3. as per Zamil Technicain Instruction charging valve shall be available to used in the compressor
portion.
Incorrect VD material observed in G-1121/G-1120 battery room exhauset ductwork that volume dampers
are made of galvanized steel, these will be exposed to corrosive environment and non-complaint to
RT5S-5051 Sec. 3.1.3 were specified for use in conveying corrosive or moisture ladder fumes or gases.
stianless steel ductwork shall be fabricated of type 316 sheets.
Contractor: Rectification for volume damper already done. Contractor applied paint coated in
coulume damper inside and outside of material to protect corrosion
127 Nos. of joints welded with wrong consumable in TCC shop 1 @ 2 for
CAO9 and CA85 line class as per specification filler material shall contain
0.5% moly (ER80S-D2, E7010-AI & E7018-A1) but TCC used ER70S2 as
per WPS-TCC-P1/P1-01, which has Molydenum 0.15% Daelim should take
appropiate corrective action.
Contractor: The same issue was not noted and raised SQDR dated
9/12/13. TCC-WPS-P1/P Rev. 2 has been approved for CA-09 & CA-
47 line class 90% joints are cut and rewelded.
It has been noticed that during material receiving Inspection, 48 PCS of
Stainless steel Themowell flanges has been coated using Modified silicons
paint at TCC without any notification to contractor & company, this is
vioaltes schedule Q" Attachment IVV, this is information & corrective action
shall be taken by contractor.
Contractor: Thermo couplers were inspected and accepted by
SARADA. RFI No. MFC-DLM-TCC-H-L-849.
UG Piping backfilled w/o stress reinforcement accepte4d & SS flange wrapping UG piping DVA line
under package No. HT-0727 has been backfilled without completing the underground piping works as
follows:
-Stress reinforcement Spot No. 65 thickness per ISO drawing N01610AAB-FW-072054-01.
-SS Flange was backfilled without wrapping for corrosion protection.
Comply Project Specification
Reply to Inspection Comments Spot # 65 has been excavated, tape wrapping and stored
reinforcement lamination done, Line # FW-072054-4"-ES17 Pipe TE 8mm, Inspection carried out
are accepted by SADARA RFI # MFC-DLM-KCC-UG-2410 Dated. 01.05.2014.
CUT FRP Piping Firewater line FW-071102-20 was cut and 2 added 2
joints to fit the PIV IP-P-1031735-004859 under test pack HT-015, this line
has been hydrostatically tested and Passed. Modified line shall be re-tested
to comply 64S-6423-01 Sec. 7 a new test shall be applied after repair and
convections have been made.
Subcontractor: This matter was already addressed to top
management, waiting for advice from Daelim.
Observed that the spent caustic unit T-0523 scrobber tower nozzle B1
observed imperfection of flange face (Serration damaged) is exceed as
permissible tolerance limit of ASME 16.47 Table: 29 Daelim QC and
Engineering team shall propose Rectification method and obtain company
approval prior to comments any activities in subjected nozzle.
Contractor: Vendor recommends to make smooth finish by sand
paper, then to use liquid paste together with gasket.
During routine site surviellance, it was observed the subcontractor store all the calibrated Instrument in
one container where no Air conditioning and temperature not maintain, Contractor shall provide proper
quarantine are for all the instrument, this is Vioaltion preservation plan A554-E-103-CM-GEN-PLN-002,
Contractor requested to take preventive action.
Subcontractor: ASYAD will provide AC for the temperature maintaining of all calibrated
instruments in the store room.
The Existing foundatrion of common piperack located at the corner of south west of spent caustic area
is lower than the open ditch elevation adjacent to it. The drained water cannot flow to the open ditch on
this area. (Near Vessel V-05 66/V-0567) contractor shall provide method statement of shop drawing to
ensure the design requiments for drainage is complied for company approval.
Contractor: New revision drawing was already issued.
Unplumbed fire monitor riser observed that fire monitor riser from FW-071275-6 to FM-0738 is out of
Plumbness. This is not complaint to installation detailed drawing A554-E-103-CN-SPC-C99 Sht 006,
Rectify Plumbness Prior conducting Hydrostatic Test.
Under ground fire water line SS riser for fire water monitor (FW-071275-6 to FM-0738 is already
rectified. Fixed the SS riser within the acceptable limit. Plumbness of the SS for water monitor
riser found satisfactory & accepted.
During site surviellance at EW piperack it was observed that instrument open channel tray damage by
mechanical crew (crane) this violate Schedule "Q" attachment IV Para 5 G-07D-0322-00, Contractor
request to take preventive action.
Contractor: The damage cable tray already replaced and inspection has been done.
The attached Drawing are locations of uneven or irrgular top surface of
foundations or paving, the contractor shall rectify the concrete curfaces to
comply with the requirements of RTS-3004-01 Section 10.
Subcontractor: KCC area shall be repaired later because the area
was temporarily used by other discipline for stacking of materials.
At Building G-1122 at Telecom room contractor is advised to follow the
requirement stated on RT-SAES-T-916 Para. 4.4.2 is locate the light
fixtures a minimum of 2.6 meters (8ft, 6 inches) above the finished floor.
Contractor: Same with LBE no. 010.
For Building G-1120, G-1122 & G-1121 at all Telecom Room, Contractor is
advised that all overhead pathways (Trays, Conduits, Trunks, ETC) Entries
into the TR shall Protrude into the room a distance of 5 centimeters (2
inches) maximum at a minimum height of eight (8) feet.
Contractor: This issue has been conveyed already to Construction
team to follow standards. Company will be informed of Contractor's
action.
Page 58 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
65
LBE-DLM-
MECH-534
MR. SAYED
DAELIM
(Procurement)
VAF 3 MECH Material 30-Apr-14 03-May-14 17-May-14 Open
LBE-KCC-CIVIL-274 MR. JERRY KCC PN 1 CIVIL Civil 01-May-14 04-May-14 14-Jun-14 17-Jun-14 Closed
LBE-AMA-CIVIL-275 MR. ENDRANO AMA PN 1 CIVIL Quality Records 01-May-14 04-May-14 08-May-14 13-May-14 Closed
66
LBE-AMA-
CIVIL-276
MR.
ENDRANO
AMA VAF 1 CIVIL Material 01-May-14 04-May-14 26-May-14 30-Apr-14 Open
67
LBE-AMA-
CIVIL-277
MR.
ENDRANO
AMA PN 2 CIVIL Civil 06-May-14 09-May-14 20-Jul-14 Info
LBE-DLM-ELECT-
130
MR.
FELOMINO
DAELIM
(Enginnering)
VAF 1 ELECT Electrical 03-May-14 06-May-14 15-May-14 14-Jun-14 Closed
68
LBE-AMA-
INST-015
MR. PERVEZ AMA VAF 2 INST Instrumentation 06-May-14 09-May-14 19-Jun-14 30-Jul-14 Open
LBE-KCC-CIVIL-278 MR. JERRY KCC VAF 2 CIVIL Civil 08-May-14 11-May-14 12-May-14 26-Jun-14 Closed
LBE-KCC-CIVIL-279 MR. JERRY KCC VAF 2 CIVIL Civil 14-May-14 17-May-14 14-Jun-14 17-Jun-14 Closed
LBE-KCC-CIVIL-280 MR. JERRY KCC PN 2 CIVIL Civil 15-May-14 18-May-14 14-Jun-14 17-Jun-14 Closed
69
LBE-DAELIM-
CIVIL-281
MR. JERRY
DAELIM
(Enginnering)
VAF 2 CIVIL Engineering 15-May-14 18-May-14 20-Jul-14 Open
70
LBE-
DLM/AMA-
MECH-535
MR.
HARIKUMAR
DAELIM
(Enginnering)
VAF 3 MECH Engineering 15-May-14 18-May-14 Open
During Leak testing of Manual Butterfly valve in NAISCO Testing Facility
Jubail, it was observed that there was contineous leak found in the 14" x
150 butterfly valve in low pressure closure test due to crack in heating
area. This is vioaltes API 598 Table 6., DAelim Should take Appropiate
action and corrective action,
Contractor: It is under process to send back to vendor shop for this
repair.
PN: Due to the change in paln for the transfer of foundations P-2417 A/B, the demolished paving shall
be returned to its original location, however there is a construction left by the demolition which make the
joint not water tight anymore, Contractor shall provide watership on the joint in accordance with Doc. No.
A554-K-PRG-CV-CON-001, Section 16.4
Contractor: The demolished paving in the particular area around the P-2417 A/B foundation.
After inspection with the Company inspector, the concreting of paving was done to its original
location/elevation as shown in the attached picture.
Subcontractor: Advised to QC Inspector to check the area before submitting RFI to Daelim or
Company.
During Surviellance and monitoring acivities at sub-sation G-1120, along
transient lips sytem, we found out that "steel door" SDG was deformed or
damaged, in this regards, contractor was revised to check or investigate
the said steel door and replace with good materials as per latest IFC
Drwg./Door Schedule.
Subcontractor: The deformed dorr "SDG" is already repaired and re-
installed at site.
PN: During surveillance and monitoring actiivities at substation G-1121,
found out that gutter support (FB.50X6) has already been installed without
submitting first the "RFI" for Material Receiving inpsection to ensure that
the material complied with Sadara standard prior to inspection. Contractor
is advised to submit material receiving inspection to counter-check by
Company Coating Inspector for proper documentation and acceptance.
Contractor: Subcontractor will raise/submit RFI for the material
receiving to check the installed gutter support randomly at G-1121 to
confirm installed gutter are meet as per Sadara standard.
During surveillance, obseerved that following discrepancies: G #1122
Operator building (Amana): * Embedded door frame for blastering door are
inclined and gaps bowing more than the acceptable limit - as per GA
drawing (A554-E-G-11-22-GWA-402302) * Welding activities carry out with
unqualified welder and WPS. Improper sequence of weld and crack - leak
of fusion-undercut . * Daelim quality team to investigate and propose
appropriate remedy action with Engineering support to fix the occured
discrepancies.
It was noticed that the Surveyor damaged the instrument survey level, SN LEICA NAK-2 5048521 with
LEICA AUTO LEVEL NAK-2 SN 5549201 during the checking of elecvation at battery limit after
founding out a difference of 1cm in the reading of location of walls of open different conneting the MFC
and Outside Battery limit. Upon investigation, it was found that the survey level SN LEICA NAK-2
5048521 this errneous reading. It was also found out that LEICA AUTO LEVEL NAK-2 SN 5549201 is
the one listed in the survey sheet. Contractor shall provide corrective action to this violation is order not
to repeat this violation.
Contractor: It was strictly advised to the Surveyor that they must be consistent. The instrument
name and serial number must be mentioned in the data sheet result. And in order to assure the
accuracy of the instrument where submitted the following calibration certificate, refer to the
attachment.
PN: During attendance of RFI # MFC-DLM-KCC-CI-7101, it was found out that the dimension of the
erected structure steel reinforcement of the Pedestal at area P-A Paving is not in accordance with the
drawing. Upon further verification of the dimension, it was clasified that the drawing utilized for
construction is superseded by a new drawing. Please advise subcontractor to utilize always updated
revised drawing in their construction to avoid rework.
Contractror: During inspection, the error of dimension to the said pedestal reinforcment was
rectified as early as commented by Company inspector. And it was advised to the Construction
team to use always the latest approved drawing.
It was noticed on site that the Structural Column for Foundation F1-025 is
clashing with the equipment E1805. The beam connecting the steel
columns therefore cannot be connected. Also the erected column (one side
only) is tilting because the equipment is inside the column vertical
alignment/plumbness. The foundation is very near the construction joint
also. Contractor to investigate and provide corrective action.
Contractor: Already Fit-025 structural colomn supports are accepted,
refer to attached drawing.
During Surviellance Inspection at Substation G-1120 & G-1121 for MV & LV Swithcgear, it was observed
that the grounding conductor was installed and undersized that actual size is 70sq. Mm and main buses
rated amper of MV switchgear is 2000 A and LV switchgear is 3200A, This is violates as per G7C-0104-
00, Para. 6.4.3.
Contractor: Contractor shall add two more 70mm grounding cable to the existing installation to
comply as per G7C-0104-00. Company will be informed once the activity is finish for the closure
of the issue.
During inspection at site at PIB G-1121, following violation has been has
been noticed during cable tray inspection. Splice over support, field
fabricated fitting used instead of factory made. Improper nut and bolts used
in tray, wrong splice plate used, slotted hole joint plate used instead of
round hole. There is no clearance between two layers of tray, provide
proper separation between tray, Contractor used 150mm open channel tray
instead of 100mm maximum allowed. This violation RTGE-0802-01, NEMA
VE2, G-07C-0321-G07C--0324.
Subcontractor: The Subcontractor wil rectify the field fabricated items
and splash plate to be repalced with Standard Materials at the earliest.
It was observed that during the removal of burlap and polythylene sheets at several location at paving
west of common compressor and spent caustic areas, the broom finish of the paving were not uniformly
rendered. Please advice the finishing in0charge to properly perform finishing in accordance with RT2S-
3001-01, Para. section 10.
Subcontractor: The mason group was informed to take good care on the finishing after the
concrete has been consolidated and leveled.
With Ref #. To RFI # MFC-DLM-AMA-CI-7467, 7468 & 7469 (Dated 27-Apr-2014) it has been observed
that some RFI's by our Sub-con (AMANA) they are submitting up to (3) times prior to Inspection, it
means the area is not ready for inspection, in this regards, contractor must see to it that the area is
completed or ready for inspection, prior to submit the RFI and also will proper coordination to
construction for proper documentation.
Page 59 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
LBE-INST-ASYAD-
016
MR. SHABIRUL ASYAD VAF 1 INST Quality Management 17-May-14 20-May-14 07-Jun-14 08-Jun-14 Closed
71
LBE-PCMC-
MECH-536
MR. SURESH PCMC VAF 3 MECH Piping 18-May-14 21-May-14 26-Jul-14 Open
90
LBE-SEN-
ELECT-131
MR.
SHAMSHER
SENDAN VAF 1 ELECT Electrical 19-May-14 22-May-14 04-Jun-14 30-Jul-14 24-Jul-14 Closed-
72
LBE-DLM-
ELECT-132
MR.
SHAMSHER
DAELIM
(Procurement)
VAF 1 ELECT Material 19-May-14 22-May-14 24-May-14 Open
73
LBE-AMA-
CIVIL-282
MR. GERALD AMA VAF 2 CIVIL Civil 20-May-14 23-May-14 Open
74
LBE-AMA-
CIVIL-283
MR. GERALD AMA VAF 2 CIVIL Civil 20-May-14 23-May-14 30-Jun-14 Open
75
LBE-TCC-
MECH-537
MR. SURESH TCC VAF 3 MECH Piping 21-May-14 24-May-14 24-Jul-14 20-Jul-14 Open
76
LBE-DLM/
SEN-ELECT-
133
MR.
SHAMSHER
DAELIM
(Construction)
PN 1 ELECT Electrical 21-May-14 24-May-14 24-May-14 Info
LBE-AMA-CIVIL-284 MR. JERRY AMA VAF 2 CIVIL Material 22-May-14 25-May-14 26-Jun-14 26-Jun-14 Closed
85
LBE-PCMC-
MECH-538
Coating/
Painting
26-May-14 29-May-14 10-Jun-14 20-Jul-14
Should
attached
copy of RFI
after
rectification
23-Jul-14 Closed
77
LBE-TCC-
MECH-539
MR. SAYED TCC VAF 3 MECH Piping 27-May-14 30-May-14 24-Jul-14 20-Jul-14 Open
LBE-TCC-MECH-
540
MR. SAYED TCC VAF 3 MECH Piping 30-May-14 02-Jun-14 10-Jun-14 16-Jun-14 Closed
During surviellance inspection in TCC area, it was observed that the pipe is
clashing with Equipment E-2331 and there is no sufficient clearance for the
application of 130mm insulation on pipe. This is violation against Sadra
spec: G4D-0142-01 & GAZ-0010-00 Para. 6.10.2. Contractor shall take
necessary action.
Subcontractor: This is Engineering issue. TCC already get JCR
approval. The pipe length will be added soon. The job alreadt
compelted.
Subcontractor: Warning letter has been issued to Personnel. Tool box meeting was conducted
regarding the matter.
During witness of Hydrotest, it was found that the check valve flabber was not removed (Pkg. No. 1147-
0-PRG-GEN-PRO-014, Para. 9.4.3. which states that "unless the check valve has a bypass valve, the
disk of the check valve shall be removed.
Subcontractor QC Inspector left the site from last week without proper notification and procedure, this is
violation of schedule Q, attachtment VI. Contractor requested to take preventive action ASAP.
Subcontractor: QC Inspector file for emergency exit due to family problem so ASYAD has no
enough time to inform the client.
During srveillance inspection at MFC site all over areas, it was observed
that, Contractor has installed the Variable height clamp type Pipe shoe;
separator barrier has not overlapped itself and overlap orientation in wrong
position, such as 2 clock, 4 clock and 10 clock position. This is violation
against G4G-1420-21, Note 3, which states that, "The separator material
shall overlap itself on the bottom center line of the pipe.
Due to lack and material traceability, in the MFC-TCC site, V# area, it was
observed that, Subcontractor TCC has wrongly assembled and welded the
ASTM A53 Gr, ERW pipes instead of Seamless pipe ASTM A106 Gr. B for
Caustic service piping line class CA09. This violation against CA-09M,
Note P-CSO1PEXS and Isometric IFC drawing. ISO drawing #
N016103V3A-CA-179013-02, J # FW 08 & 09. N016103V3A-CA-179028-
01, J # FW 01.
Subcontractor:Due to material shortage, the Construction using
ASTM A53GR GRW Pipe instead of ASTM A106 GR.B without
confirming the class required. TCC already cut-out all wrong joints and
applied PT. ISO drawing new revision.
Subcontractor: Rectification has been done. Sadara has inspected
and accepted for line #1404-00HT-001 & 1617-00-HT-001. RFI
mentioned attached, please refer to the LBE.
During inspection for surface preparation prior to primer coat for line # 1404-
00-HT-001 & 1617-00HT-001 as per request for Inspection # PCMC-H-S-
0379 & PCMC-H-S-0380, it has been observed that PCMC has applied
primer coat prior to inspection time. This is non-conformance with schedule
Q.
During surveillance at substation 1120/1121. It was found that the
grounding cables are connected to earth bar without numbered or marker.
This violation to G7C-0104-00, section 5.8 which states that " all eathing
bars including the connected cables shall be numbered or marked.
Contractor: It is already communicated to Daelim engineering to
assign & generate the tag no. of each ground bus bars.
During Material Receiving Inspection of the Thermal Fire Detector at
Daelim laydown yard, it was found that the thermal fire detection (P/N
27120) are not matching with Pusrcahse Order. Note. This is violation to
attached documents and schedule "Q", attachment III, Section 3.
Contractor: This issue will be forwarded to procurement for further
investigation regarding traceabiity of materials. This LBE will be
updated once the action of procurement is given.
PN: During Inspection of FRP cable tray at spent caustic area, it was
observed that the cable tray installation are using temporary nut-bolt for
fasteners/hold down stainless steel materials. This is violation to G7D-0323-
00, section 4.1.5 and data sheet G7D-0323-A required silicon bronze.
Contractor: For the time being that the materials which are approved
to install in FRP cable tray is notavailable, stainless steel was installed
temporarily to proceed on the next activity. Once the approved
materials arrived in the site, it will be replaced.
Contractor: Already replcaed the anules of hot dip galvanized for the location of sump in the
area.
With reference to RFI #MFC-DLM-AMA-CI-7762, Roof leak testing on roof
of substation G-1120. (GL G-11/AC), at around 2:20 pm starting spray of
water using two (2) water truck using hose, continuously after and hour
around 3:20 pm, they finshied spray of water and thats the time we found
out that there are some areas with stagnant water, 2.40 meter from the
edge of gutter and also four (4) locations at gutter connection with leaks. In
this regards, Contractor shall rectify or repair the area with stagnant water
and seal-off the gutter conncetion with leak and should take corrective
action on the issue. (RFI has been rejected).
During surveillance and monitoring activities at sum-0645 south side of
substation G1121, it was noticed that the installed ladder rung some are
preserve with corrosion. This is a violation to SADARA specification RT-
3001-01, section 8.2, Para. 8.2.7. In this regards, Contractor should
investigate these materials and take corrective action about the issue.
Contractor: Regardimg ladder Rung which is coordinated @ sump pit
#645 Company has already issued an NCR to Contractor.
RFI # MFC-DLM-AMA-CI-7767/7768 were attended and during the Inspection, it was noticed that the
angle frame of thesump for the TOTES was not hot dip galvanized upon testing into sharp object. The
QC personnel of Amana insist they have certificate but cannot provide. The coating inspector of Daelim
was called to verify the angle frame coating whether painted only or hot dip galvanized. The coating
inspector confirmed the angle frame is not hot dip galvanized. This is the third logbook entry that
galvanized paint are applied by the same subcontractor and despite repetitive violation, the same
subcontractor continues this same violation. Provide corrective action no to repeat the same violation.
Page 60 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
78
LBE-KCC-
CIVIL-285
MR. GERALD KCC VAF 2 CIVIL Civil 02-Jun-14 05-Jun-14 14-Jun-14 Open
LBE-KCC-CIVIL-286 MR. GERALD KCC VAF 2 CIVIL Civil 02-Jun-14 05-Jun-14 14-Jun-14 17-Jun-14 Closed
79
LBE-DAELIM-
CIVIL-287
MR. JERRY
DAELIM
(Enginnering)
PN 2 CIVIL Engineering 03-Jun-14 06-Jun-14 12-Jul-14 15-May-14 Info
100
LBE-IKK-
MECH-541
MR. NASSAR IKK VAF 3 MECH
Coating/
Painting
03-Jun-14 06-Jun-14 22-Jul-14 Closed
101
LBE-IKK-
MECH-542
Coating/
Painting
03-Jun-14 06-Jun-14 22-Jul-14 Closed
LBE-AMA-CIVIL-288 MR. JERRY AMA VAF 2 CIVIL Civil 04-Jun-14 07-Jun-14 28-Jun-14 29-Jun-14 Closed
80
LBE-INST-
ASYAD-017
MR. PERVEZ ASYAD PN 2 INST Instrumentation 04-Jun-14 07-Jun-14 30-Jul-14 Info
LBE-INST-ASYAD-
018
MR. PERVEZ ASYAD VAF 2 INST Instrumentation 07-Jun-14 10-Jun-14 10-Jun-14 23-Jun-14 Closed
81
LBE-KCC-
MECH-543
MR. GLENN KCC PN 3 MECH UG-RTR 08-Jun-14 11-Jun-14 23-Jul-14 Info
82
LBE-IKK-
MECH-544
Coating/
Painting
08-Jun-14 11-Jun-14 Open
LBE-ARCC-MECH-
545
MR. RAMO ARCC VAF 3 MECH Piping 08-Jun-14 11-Jun-14 15-Jun-14 15-Jun-14 Closed
105
LBE-IKK-
CIVIL-289
MR. JERRY IKK VAF 2 CIVIL Civil 08-Jun-14 11-Jun-14 22-Jul-14 Closed
83
LBE-KCC-
CIVIL-290
MR. GERALD KCC PN 2 CIVIL Civil 08-Jun-14 11-Jun-14 12-Jul-14 Info
Contractor: The previous installed gutter was already removed, and
KCC construction team was advised to purchase a new one
lgalvanized gutter as per approved drawing. And KCC will raise RFI for
material receiving inspection prior to installation.
Contractor: The mason curing group was informed to make an immediate action that the casted
deck slab must be properly covered by burlap and polythelene sheet and continouos curing will
be for 7 days.
Contractor: Discussed to civil construction and engineering action
granted that they will provide ab approved drawing on how the
proposal to be accepted by Company. An sketch is attached.
During surveillance and monitoring activities at expander building (61123),
found out that the gutter was already installed, without submitting first RFI
for material receiving inspection for proper documentation and checking.
Contractor should take corrective action on this issue and for proper
implementation. This is violation to SMIC-M-1031-1 (Metal Roofing
Receiving and Storage Inspection).
During monitoring and surviellance activities at Crack Gas Compressor' Deck slab, it was noticed that
the newly casted slab has insufficient water curing, burlaps and improper covering of polythelene sheet.
These are violations to RT2S-3001-01, section 9, para. 9.1.2 which states that water curing shall be
continues until the compressive strength has reached to 70% of the specific strength but not less than 7
days after placement. Contractor should take corrective and preventive action on the issue.
PN: It was noticed that some of pipe support, not yet erected in many
locationsare directly located in the TPER (expansion joint), please note that
the foundation/pedestals of these pipe supports are sugject to verification
by Daelim Design Engineering for proper design and possible
demobilization of paving to erect new foundation. It is recommended that
the location of these pipe support shall be identified in advance by Daelim
for proper disposition.
The following RFI's were received very late b the Company. The RFI's were submitted one (1) month
later after the activities are completed. This is a violation of schedule Q, Para. 3.
RFI No. MFC-DLM-AMA-CI-5547 17/12/13, CI-5509 15/12/13, CI-5429 09/12/13, CI-5552 18/12/13, CI-
5561 19/12/13, CI-5624 24/12/13, CI-5606 23/12/13, CI-5589 22/12/13, CI-5589 22/12/13, CI-5571
21/12/13. The RFI's were received on 29 May 2014.
Contractor: The RFIs were submitted one month later due to third party report. Subcontractor to
assure not to repeat in the future.
PN: During site surviellance at EW Pipe rack, it was observed that
Contractor installed open channel tray in improper way. Tray below the
flange and un-avoidable . This violates G-07C-0321-01, Para. 3.8 & NEMA-
VE-2 and NEC 110.12. Contractor requested to take a necessary action.
Subcontractor: Channel Cable tray will be provided with cover that
serves as cable protection and any falling debris.
Subcontractor: Contractor QC already issue the SQDR for the violation of cable pulling. Now
cable tray inspection has been done.
During site surviellance, it was observed that Contractor installed the tray and without inspection, cable
has been pulled and grounded and terminated without inspection of tray. This is repeated violation done
by Conractor. This violates project ITP and schedule Q, attachment IV, Para. 3.7. Contractor requested
to take a preventive action.
During surviellance at cooling tower room #7. floor lining , it has been
noticed that IKK subcon has applied primer coat prior to repairing the
cracks as per proper concrete repair method statement (A554-E-103-CM-
GEN-PLN-024) & Sadara Specs. (RT2S-3001-01, Section 11.1.4), Coating
applicators are just filling the cracks using MasterBrace ADH 2200 after
applied primer coat. Furthermore, lining was applied in contravention of
approved work procedure, applicator was fixed tissue mark on the dry
primer coat prior to apply second coat of Master protect 1815. This is for
During routine inspection for surface preparation at cooling tower room #06
floor, it has noticed that long cracks, width is greater than 1mm which
exceeds the limiting value in the Sarada specs (RT2S-3001-01, Section
11.1.4). Cooling applicators were just filling the cracks using Masterbrace
PN: Fire hydrant FH-0707 (under FW-HT-002) was hit by a PCMC truck
causing minor damaged and scratches on fire hydrant with condition of
buried RTR piping unknown until put to service. Ensur all fire fighting
equipment are guarded against damaged to comply LPP 103-6R8.
Temporary guards must be provided where permanent guards are still not
in place. Verify RTR UG Piping of FH-0707 to ensure no crack developed
during the impact.
Subcontractor: The area cannot be excavated for checking &
verification because it is being used as an access. KCC shall excavate
and check as soon as the area is clear.
During line checking of Test package 1504-02 HT-002 at Furnace area were observed the Globe Valve
socket weld type against the flow direction as per IFC drawing No. CO16103AFA-CF-114040-02
Rev.3F1. This vioklates G4S-7200-01, Para. 2.1.5 and and not accoradnace with G4S-727-01, Para 5.4
"Manufacturer" instruction, welding for all socket welded" Contactor shall provide necessary CAR.
It was noticed that the foundation slab of cooling tower basin have cracks
greater than .10mm which extends from the jump to the center of the
fouundation slab and some to the other side of the wall. The coating
applicators are just filling the cracks and proper method of repair as per the
approved method statement is not being complied.
Contractor: ARCC Operation group already cut and reweld JT-FW-21 & FW-22 to correct wrong
flow direction of globe valve and also NDE/PT done.
Contractor: At crack gas compounf (deck slab), the cutting of concrete
was already done and there is a small balance portion that cannot be
proceeded to cut it because the area is still use by other subcon and
work can proceed after the removal of scaffolding suport.
PN: During monitoring and surviellance activities at Crack Gas
Compressor "Deca Slab", it was noticed that after casting the slab the
control joint was not implemented after 10 days wherein the concrete was
already hardened. Contractor shall take corrective and remedial action on
this issue.
During routine inspection at cooling tower room #7 & 3, it has been
observed that IKK had no treatment expansion joint as per approved
method statement (A554-E-103-CM-GEN-PLN-024) section 3.2 of applied
only Materbrace ADH 2200.
Page 61 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
84
LBE-TCC-
MECH-546
MR. RAMO TCC VAF 3 MECH Piping 09-Jun-10 12-Jun-10 Open
85
LBE-PSCL-
MECH-547
MR. KURIAN PSCL VAF 3 MECH
Coating/
Painting
86
LBE-KCC-
CIVIL-291
MR. JERRY KCC VAF 2 CIVIL Civil 10-Jun-14 13-Jun-14 21-Jul-14 Open
LBE-ARCC-MECH-
548
MR. RAMO ARCC VAF 3 MECH Piping 12-Jun-14 15-Jun-14 16-Jun-14 07-Jul-14 Closed
87
LBE-DLM-
MECH-549
MR. SAYED
DAELIM
(Construction)
VAF 3 MECH Piping 12-Jun-14 15-Jun-14 Open
111
LBE-IKK-
CIVIL-292
MR.
BUCASAS
IKK VAF 2 CIVIL Civil 12-Jun-14 15-Jun-14 22-Jul-14 Closed
88
LBE-ASYAD-
INST-019
MR. PERVEZ ASYAD VAF 1 INST
Qaulity
Management
14-Jun-14 17-Jun-14 21-Jun-14 24-Jul-14 Open
89
LBE-AMA-
MECH-550
MR. NASSAR AMA VAF 3 MECH
Coating/
Painting
15-Jun-14 18-Jun-14 20-Jul-14 Open
90
LBE-GACC-
MECH-551
MR. RAMO GACC VAF 3 MECH Preservation 15-Jun-14 18-Jun-14 15-Jul-14 20-Jul-14 Open
95
LBE-PCMC-
MECH-552
Coating/
Painting
16-Jun-14 19-Jun-14 23-Jul-14 20-Jul-14 24-Jul-14 Closed-
91
LBE-AMA-
CIVIL-293
MR. RAHMAN AMA VAF 2 CIVIL Civil 16-Jun-14 19-Jun-14 20-Jul-14 Open
During surveillance, it was noticed that AMANA has repaired corroded hot
dip galvanized ladder rungs in Sump pit #644 without notification for
inspection for SQIT Coating, still not dry since one week due to improper
surface preparation & coating application. This is for information &
corrective action by Contractor.
During surveillance at GACC (W5) area were found the piping materials
are laying on the ground without any protection or cover end of the check
valve. This violates RT-6-1CS Material and Equipment protection and
Preservation Plan Rev. 3, Sec. 2.19, Para. 2.19.1 "All materials shall be
suitably stored and protected from the site conditions" Para. 2.19.12 )d).
Storage methods shall protect materials from infiltration of water, dust, dirt,
vermin, insect, etc. Contractor shall provide necesary CAR.
Contractror: The following LBE No. 551 has been noted and the
necessary corrective action has been taken for the same. Tool box
meeting was conducted.
During routine inspection on test package #1625-00-HT-044 (RFI No. MFC-
DLM-PCMC-H-S-S-0418) it has been noticed that applied paint didn't dry
yet. Application was done one day before inspection. Application paint not
fully dry due to improper mixing ratio. This is ofr information, corrective and
preventive action shall be taken by contractor/subcontractor to avoid
mistakes in the furture.
Subcontractor: Applied wet paint was removed and did surface
preparation and applied top coat as per Sadara requirement. RFI
(0418) was inspected and accepted by Daelim for Package No. 1625-
00HT-004.
During surveillance, it was noted that the Contractor has started external
coating Renderoc FC on west side without any RFI for cooling tower. 1.
Concrete repair work acceptance, 2. Surface preparation for concrete
coating pre-application inspection. As per ITP.
Subcontractor: Due to misunderstanding, Amana did not raised RFI
for surface preparation for Rooms # 1 & 2, effectively from 17th of
June Amana has raised RFI for surface preparation for Room # 3, 4,
5, 6, 7, 8 & 9 which are approved by Sadara Inspector.
During surveillance at Compressor area were observed the 3" CVA-237114-
02" TW-237040-01-A. This violates G4Z-0010-00, Sec. 6.10, Para. 6.10.2
"Clearance shall be maintained" and G4D-0142-01, Pipe spacing chart
Notes: 6 table.
During surviellance at site , it is observed that subcontractor erected
structural members (Column & its hanging) for Clarifier tank (V-0568)
supplied by Tsukishima Kankyo Eng. Without final chemical protective
coating (only primary coating found). In A554-E-103-MJ-REQ-MU4-115
states that it is the responsible of the Contractor to apply complete final
coat if the mechanicm is shop blasted and poured with manufacturers'
procedures. See Para. (coating 1, 2, 3).
Contractor: Required revised drawing.
During witness Hydrostatic test of test package (1504-02-HT-002) at ARCC area were found the water is
contaminated of "Deminerailzed Water" as per actual sample of DMW with attached certificate. This is
violates to General Requirements for pressure testing and Lay-up, Sec. 8.2, Para. 8.2.1 to 8.2.8.
Contractor shall provide necessary CAR.
Contractor: ARCC operation group re-test the the test pack AGES TP-1504-02-HT-002. See
attached RFI No. MFC-DLM-ARCC-PIP-0483 and Water lab test result.
During surveillance at cooling tower corridor wall near basin oom 7 and
sump area A, it was found out that some repaired concrete wall tie rod
holes, honecombs, etc are still soft until to date. This is a violation to
schedule "Q" , General requirement sec. 1.3. Contractor shall investigate
root cause and initiate corrective action.
The Contractor was reminded of the requirements of Hot weather
concreting prior to concrete placement of pavement as per RFI No. MFC-
DLM-KCC-CI-7691 (Paving area B-A Span 65 & 66). The contractor
continued to place concrete in spite of violation of RT2S-3001-01, section
5.4.8 which states: a. Shade temperature exceeds (110F) 43C at the job
site combined with a mean speed of 10 mph or over. No measure to prevent
exercise moisture loss before the final curing procedure are accompanied in the
requirement of RT2S-3001-01, Para. 5.1. The shade temperature at 10:30 AMis
44.5. No apparatus to measure the wind velocity, relative humidity, etc. to check
the rate of evaporation per table 2.1.5 of sec. 1305.
Contractor: All concrete pouring shall start now at 5:00 PM onwards
(July 21, 2014).
During Site surveillance, it was observed that ASYAD has a shortage of
QC Inspector. Contractor has 6 Inspectors while ASYAD has only 3
Inspectors and its Manpower is more than 200. This violates Schedule "Q"
Contractor is requested to take preventive action.
Contractor: Recently, ASYAD has 4 QC Inspector & waiting for
SADARA approval for 1 remaining QC Inspector. Contractor will
arrange additional QC Inspector as per Sch. "Q" within two weeks.
During field leak testing of resilient seated butterfly valves in NASICO
testing facilitiy Jubail, it is observed that there is a continues bubbles found
in 8 nos of EBV during all 7 valves all rejected. This violates API 598 Table
6 which states that "These shall be no leakage for the minimum required
test duration for all soft seated valves.
Page 62 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
92
LBE-AMA-
CIVIL-294
MR. RAHMAN AMA VAF 2 CIVIL Civil 16-Jun-14 19-Jun-14 25-Jul-14 Open
93
LBE-FCN-
CIVIL-295
MR. JERRY FCN VAF 2 CIVIL Civil 17-Jun-14 20-Jun-14 Open
94
LBE-DAELIM-
CIVIL-296
MR. JERRY
DAELIM
(Enginnering)
PN 2 CIVIL Engineering 17-Jun-14 20-Jun-14 15-Jul-14 Info
95
LBE-DAELIM-
CIVIL-297
MR. JERRY
DAELIM
(Enginnering)
PN 2 CIVIL Engineering 17-Jun-14 20-Jun-14 15-Aug-14 Info
96
LBE-AMA-
CIVIL-298
MR. GERALD AMA VAF 2 CIVIL Civil 17-Jun-14 20-Jun-14 20-Jul-14 Open
97
LBE-TCC-
CIVIL-299
MR. GERALD TCC PN 2 CIVIL Civil 17-Jun-14 20-Jun-14 20-Aug-14 Info
98
LBE-SEN-
ELECT-016
MR. PERVEZ SENDAN VAF 1 ELECT Preservation 18-Jun-14 21-Jun-14 30-Jul-14 Open
LBE-ASYAD-INST-
020
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 18-Jun-14 21-Jun-14 22-Jun-14 13-Jul-14 Closed
LBE-ASYAD-INST-
021
MR. S.KHAN ASYAD VAF 1 INST Instrumentation 18-Jun-14 21-Jun-14 20-Jun-14 23-Jun-14 Closed
LBE-KCC-CIVIL-300 MR. BUCASAS KCC VAF 2 CIVIL Civil 19-Jun-14 22-Jun-14 28-Jun-14 29-Jun-14 Closed
99
LBE-KCC-
CIVIL-301
MR. GERALD KCC VAF 2 CIVIL Civil 21-Jun-14 24-Jun-14 Open
100
LBE-AMA-
CIVIL-302
MR. GERALD AMA PN 2 CIVIL Civil 21-Jun-14 24-Jun-14 20-Jul-14 Info
LBE-DLM-INST-022 MR. S.KHAN DAELIM VAF 1 INST Instrumentation 21-Jun-14 24-Jun-14 22-Jun-14 26-Jun-14 Closed
During surveillance, it was noted that Amana is doing External Concrete
Coating for Cooling Tower west side without any QC Civil Inspector
coverage. This is a violation to Schedule "Q", attachment VI, VI-1, PQP
Personnel requirements.
It was observed that after the fireproofing of vessel using Pyrocrete 241,
the cementious fireproofing developed cracks on several locations of the
structure. Please investigate the causes and provide corrective measures
to avoid recurrence.
PN: The dowels for the arbwall at the southside and of T-1710, D-1715 and
Pumps area were not placement for foundation of adjacent piperacks.
Please investigate and verify location since the drawing shows, it crosses
the TPER by several inches only and confirm in the Enfineering to relocate
to avoid cracks in future.
PN: The evaluation of Paving in between the piperacks at North of Cooling
Tower and Southeast by Building East 6-1121 is not level with the
foundation of the piperack. The cover of the open trench in that location,
therefore, will have a different elavations. Please advise Engineering for
the remedial works on this location.
Subcontractor: Amana already assigned the inspector to monitor the
external concrete coating work at cooling tower.
Contractor: Daelim shall provide drawing regarding this issue.
During surveillance and monitoring activities at Operator building (6-1122),
it was observed that mostly of the rooms are already installed acoustical
ceiling (SMIC-M-1053), Inspection checklist for acoustic suspension ceiling
system installation inspection also check some opening on walls. In this
regards, Contractor should take corrective action concerning this issue for
Contractor: Contractor will provide the lugs instrument side after completed the work and
resubmit the RFI for inspection.
Subcontractor: ASYAD will provide additional support in between splice plate for the cable tray.
During inspection at site (cooling tower), it was noticed that Contractor terminate the cable instrument
side without lugs. This violates G-070-0401-12, Para. 5.2. Contractor is requested to take preventive
action.
During inspection of 300mm ladder cable installation at Liquid Furnace (F-1250) area, it was observed
that there were two (2) splice between support. This is violation to NEMA V-2, Section 4.3.1 which states
that to ensure no more than one splice is located between supports.
From field Junction box to cabinet not require the wire marker as per RT6E-0804-01. Note: 2 and
IFC drawing A554-E-103-IC-DWG-1D3-001, This is SPI format engineering can not change
because it is standard format.
During surveillance, it was observed that the primary instrument cable in field junction box and cabinets
has terminated without wire tag/ wire marker. This is violation to approved IFC Drawing A554-E-103-IC-
DWG-ID3-001, page 4 of 4, not-2, which states that each terminated pair shall have a printed wire
marker.
KCC grouted the anchor bolt at North south side top wall of pump sump no. 7 of cooling tower without
raising RFI's for the following inspections:
1. Surface Preparation
2. Forworks installation inspection
3. Grout sampling, testing & placement
Violation to RT2S-3050-01, section 3, schedule Q, general requirements, sections 1.1 & 1.6, attachment
IV, section 1.1.3 & 1.1.9.
Contractor: Already rectified and chipped the area of North-South side of cooling tower pump
sump, room # 7. Raised RFI for this area and inspected by Sadara representative.
Subcontractor: Amana has started the rectification work sspension
ceilling system and opening work. Amana will raise/submit RFI room
by room inspection.
PN: During surveillance at flare area, it was noticed that two (2) pedestals
was deformed or bent the acnhor bolts. Contractor should investigate and
take corrective action about the issue for proper implementation.
During site surveillance inspection at decoke area, it was observed that the
4.16 KV provision voltage motor of air compressor tag # MC-2701 and MC-
2711, were installed at site without energizing the motor space heater. This
violates as per material and Equipment Protection and Preservation Plan
doc. #RT-6-1CS, Para. 2.7.2.
PN:During surveillance & monitoring at Sub-station G-1120 & G-1121. It
was noticed that most of the doors's accessories have already been
installed but Contractor did not submit Final Acceptance Inspection (SMIC-
M-1051) ITP Checklist. Contractor shall submit RFI for proper checking of
those accessoties and proper documentation.
Subcontractor: Amana has started the door rectification work and
they will submit the RFI once the soor is totally sccepted by internal
inspector. (On-going).
With reference to RFI #MFC-DLM-KCC-CI-7890-0A & F7932, installation of
epoxy coated steel bars & embeded item/floor closure inspection (deck
slab) at area D-G common computer shelter GL 13-16/A-D, Contractor did
not submit RFI and no advice from Daelim Inspectors to Company for
proper checking of repair arrangement and diameter as per latest IFC
drawing and also this RFi was "Hold" point. This is a violation to Schedule
"Q" attachment IV, Para. 1.1.3 & 1.1.9/3.7. Contractor should take
corrective & remedial action on the issue. (RFI was rejected).
Page 63 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
126
LBE-IKK-
MECHI-553
MR. NASSAR IKK VAF 3 MECH Mechanical 21-Jun-14 24-Jun-14 26-Jul-14 Closed-
106
LBE-PCMC-
MECH-554
Coating/
Painting
21-Jun-14 24-Jun-14 23-Jul-14 20-Jul-14 24-Jul-14 Closed-
101
LBE-DLM-
ELECT-134
MR.
FELOMINO
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 22-Jun-14 25-Jun-14 25-Jun-14 Open
102
LBE-SEN-
ELECT-135
MR.
FELOMINO
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 22-Jun-14 25-Jun-14 25-Jun-14 Open
103
LBE-AMA-
CIVIL-303
MR. RAHMAN AMA PN 2 CIVIL Civil 23-Jun-14 26-Jun-14 20-Jul-14 Info
104
LBE-TCC-
CIVIL-304
MR.
BUCASAS
TCC VAF 2 CIVIL Civil 24-Jun-14 27-Jun-14 Open
146
LBE-DLM-
INST-023
MR. PERVEZ
DAELIM
(Enginnering)
PN 1 INST Engineering 23-Jun-14 26-Jun-14 22-Jun-14 16-Jul-14 Closed
107
LBE-SEN-
ELECT-017
MR. S.KHAN SENDAN VAF 2 ELECT Preservation 23-Jun-14 26-Jun-14 20-Jul-14 30-Jul-14 30-Jul-14 Closed-
108
LBE-DLM-TEL-
018
MR. S.KHAN
DAELIM
(Preservation)
VAF 1 TELECOM Preservation 23-Jun-14 26-Jun-14 20-Jul-14 30-Jul-14 Closed-
109
LBE-ARCC-
MECH-555
MR. S.KHAN ARCC VAF 3 MECH Piping 23-Jun-14 26-Jun-14 24-Jul-14 Closed-
PN: During surveillance and work monitoring, it was noted that the repair
material is not fully bonded to the surface after recommended curing time b
manufacturer. Contractor is pro-actively advised to take Pull of Test to
determine the Tensile Strength of repair material as per Approved ITP for
coating/waterproof lining. 1. Document No. A554-E-103-QA-GEN-PLN-119,
checklist no. SMIC-R-103, item no. a4, E6. 2. Concrete repair guide - ACI-
546R-04, Para no. 2.7 "In-place-tensile pull-off tests are recommended to
evaluate that bonding of repair materials is adequate. 3. Document no.
A554-K-PRG-PI-DPC-VIA-150, aProtective Coatings for Industrial concrete
structures, Para. 8.6.4.
During routine inspection at room #5, it as been observed loss of adhesion
has occurred due to poor or inadequate repair of honeycomb defect prior to
surface preparation. Consequently, coating not obtain the required
adhesion to concrete surface. Coating layers including repair materilas can
be removed easily by finger. This defect loated in the different locations
and rooms.
Subcontractor: Mid-Coat was removed and primer coat was
inspected and accepted by Daelim prior to apply mid-coat for Package
No. 1441-00-HT-002 & 1625-00-HT-016.
During routine inspection for Package # 1441-00-HT-002 & 1625-00-HT-
016, it has been noticed that PCMC has applied Mid-Coat prior to
inspection time. This is non-conformance with Schedule "Q".
During surveillance, it was noticed that after epoxy grouting on foundations
of pump 1411C located at south side of east-west piperack, pumpsump
area foundations of cooling tower 901C, 901E, 901F, 901G & 901H that
cracks developed on the surface of the foundations. Contractor shall
investigate the root cause and initiate corrective action to avoid recurrence.
Electrical cables at site are now covered & protected with end caps
after cutting activity at site. SENDAN is now aware and well-informed
of the importance of end cap protection after cutting.
During site surveillance, it was found that the electrical cables are not
protected with end caps after cutting at site near substation 1120. This is
violation to G7C-0305-02, Para. 4.4. which states that the cables shall be
carefully protected from normal field construction hazards. Cable ends shall
be sealed using heat shrinkable end caps to prevent entrance of moisture.
PN: During site surveillance at site, near caustic tank NS pipe rack D-1090,
it was observed that transmitter obstructs with the fire water pipe, no
maintenance access for Instruments. This violates G0GA-041-00 Para.
61.3.3.3. Contractor requested to take preventive action.
Subcontractor: Instrument was temporarily fixed before issuing RFI,
subcontractor will rectify and submit RFI for inspection.
Contractor: Engineering will coordinate to Riyadh Cable for
investigation on how this issue will be solved. -> TM or RFV shall be
issued. Meanwhile, we received from vendor statung that there is no
problem.
Contractor: Contractor will coordinate to Zamil for explanation in this
failed result
During surveillance inspection of Substation G-1120 & G-1121 & North
South and near cooling tower, it was observed that the LV power cables
were install underground trench for street ligting is above grand type of
cable the outer sheath of cable is color black. This violates RT70-0430-00,
Para. 37.2 and 3.8.
During winding installation resistance test of RFI #MFC-DLM-SND-EL-1610
for compressor notor #1, G-1120-ACCU-001A at Mechanical room
substation G-1120, it was observed that the test result has failed the actual
valve was 10.7 mega-ohms. This violates as per Company Pre-
commissioning Porcedure G7M-0020-08, which is the acceptable valve of
winding installation test shall be 100 me ohms.
During routine inspection at CI area, ARCC welders were found welding 2"
pipe with unapproved WPS for CA-09 / caustic line clay. 5 joints were
identified for approval of WPS. C016103C1A-CA-059703 JT. No. 10, 12,
14. C016103CIA-CA-171315-02, 07.
During site surveillance, it was found that the Fiber Optic cable end has
exposed at site for all analyzer. This is violation to RTIP-A554-R-001-IS-
SPC-EG4-508, Para. 7.6.2 which states that "all FO cable ends are to be
effectively sealed (waterproof) at all stages of use. Sealing shall be
performed immediately after a length of cable has been cut from a drum.
Exposed part of Fiber Optic cable (end part) has now covered and
protected by using tape for sealing against water. Other contractor
(WIPRO) is now well informed regaqrding protection of fiber optic
cable end.
Page 64 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
105
LBE-ARCC-
MECH-556
MR. RAMO ARCC VAF 3 MECH Piping 23-Jun-14 26-Jun-14 Open
106
LBE-GACC-
MECH-557
MR. KURIAN GACC VAF 3 MECH
Mechanical
(Equipment)
24-Jun-14 27-Jun-14 20-Jul-14 Open
107
LBE-TCC-
MECH-558
MR. SAYED TCC VAF 3 MECH Piping 25-Jun-14 28-Jun-14 24-Jul-14 20-Jul-14 Open
117
LBE-PSCL-
MECH-559
MR. NASSAR PSCL VAF 3 MECH Tank 25-Jun-14 28-Jun-14 23-Jul-14 24-Jul-14 Closed-
108
LBE-ARCC-
MECH-560
MR. RAMO ARCC VAF 3 MECH Piping 25-Jun-14 28-Jun-14 Open
109
LBE-SEN-
ELECT-136
MR. MARK SENDAN VAF 1 ELECT Electrical 25-Jun-14 28-Jun-14 27-Jun-14 30-Jul-14 Open
110
LBE-AMA-
CIVIL-137
MR. MARK AMA VAF 1 CIVIL Civil 25-Jun-14 28-Jun-14 28-Jun-14 30-Jul-14 Open
LBE-ASYAD-INST-
024
MR. PERVEZ ASYAD PN 1 INST Instrumentation 25-Jun-14 28-Jun-14 25-Jun-14 12-Jul-14 Closed
111
LBE-ASYAD-
INST-025
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 25-Jun-14 28-Jun-14 25-Jun-14 Two Weeks Open
142
LBE-ASYAD-
INST-026
MR. PERVEZ ASYAD VAF 1 INST
Qaulity
Management
25-Jun-14 28-Jun-14 26-Jun-14 19-Jul-14 22-Jul-14 Closed
LBE-ASYAD-INST-
027
MR. PERVEZ ASYAD PN 1 INST Instrumentation 26-Jun-14 29-Jun-14 17-Jul-14 12-Jul-14 Closed
LBE-ASYAD-INST-
028
MR. PERVEZ ASYAD PN 1 INST Instrumentation 26-Jun-14 29-Jun-14 01-Jul-14 12-Jul-14 Closed
112
LBE-SEN-
ELECT-138
Contractor: Conractor already provided the Gas detector blind plug.
During site surveillance at C3 Splitter pipe rack, it was noticed that Branch Cable laid in was improper
way of cable hanging on scaffolding. As observed, JB cable not protected from machines. This violates
NEC Article 110.12 and Schedule Q, Contractor requested to take a preventive action.
Contractor: Durign cable pulling, cables were hanging so that it will not be damaged and use as
walkway. Dressing is done.
PN: During site surveillance at cooling tower side filter unit, it was noticed that Level Transmitter
(Capillary type) not Preserved. Capillary hanging and kept on walk ways. This violates Project Specs
G06A--0041-00, Para. 61.3.3.3, Installation deatil G-06E-04010-01, Contractor requested to take
preventive action.
Contractor: ASYAD will rectify installation of level transmitter (capillary type) in proper ways and
inform to construction to keep away on the walkways to maintain preservation or protections.
During site surveillance (all area) at site (general), it was noticed that
Contractor installed PVC tie instead of 316 Nylon cooled ties. This violation
RT6E-0802-01, Para. Note-10, Contractor requested to take a preventive
action.
Contractor: SS 316 Nylon coated ties are not available as of now but
the material shall be ordered and as soon as it available,
Contractor/Subcontractor will change the temporary ties to SS316
Nylon coated ties.
During routine site inspection at Operator building G-1122, it was noticed
that the contractor installed felxible metallic conduit that was more than 1.8
meters in length which is a violation as per NEC, Article 348.20 (A) (2) c.
Contractor: The installation done as per IFC drawings for corrective
action and proposal, Contractor/Subcontractor will coordinate with
Engineering.
During routine site visit at Operator building 6-1122, it was found out the
Contractor used the cable tray as a support for the T-runner of the false
ceiling which is a violation as per 67C-0321-01, section 1-2.
Contractor: Construction already instructed to remove the tie wire
which connected to channel tray
During line checking and inspection at Furnace area were found the piping
flanges with spectacle blinds was installed without hole for jack screw
twelve (12) locations and EL+15400 TP (1615-01-HT-003) This violates
Project Specification for Mechanical Completion and Acceptance Rev.2
(A554-K-PRG-CM-GEN-DOC-005) Attachment 4, sec. 4, Para. 4.1.5 Install
jacking bolts on all flanges with spectacle blinds. A logbook entry was
made and informed to PMT/Contractor.
During surveillance, it is noticed that during night shifts in tower T-1710, the
subcontractor is installing tray and TSR without inspection of levelness, no
RFI's were raised for the installation levelness inspection scale pan, tray
1,2,3. Also no subcontractor QC was available during this inspection.
Daelim should ensure that concerened QC is raising RFI of the installation
of internal activities of tray with the presence and/or involvement of
subcontractor QC. It is a violation as per A554-E-103-QA-GEN-PLN-103,
Para. 3.39, 3.33 Sch. Q, attachment VI.
Contractor: Already one QC Inspector has been assigned for the night
shift and has been attending inspection in the night shift from 2nd of
July onwards. The Trays 1,2,3 have already ben completed and RFI's
for the same already been submitted. The concerned RFI nos. are
MFC-DLM-GA-ME-0060, 061, 062, 0063 & 0064. All the inspections
are now goin in line with the requirements and in the presence of QC
Inspector.
During surveillance inspection at TCC area cold box, it was fond that
triunion support directly welded to pipe is not in the center of run pipe. This
is not accordance of support standard drawing GF31P-F4-005 & DF33P-F-
3-002 which shown run pipe and triunion support pipe center are in on line.
Subcontractor: Already cut-out and refit-up. Welding RFI already
accepted.
During surveillance at Process condensatre holding tank V-1425, it has
been observed that PSCL has applied primer coat zinc richepoxy (interzinc
22) for roof top area which is not meeting with Mechanical dataa sheet. As
per Mechanical data sheet, the required paint code system is GI6S-0202-
02 (Inorganic zinc primer, epoxt mid coat and Polyurehane) and applied
paint socd system is G16S-0202-10 (Zinc rich epoxy 1 epoxy mid coat and
polyurethane finished. A log book entry was issued to require corrective
and preventive action.
Contractor: As per SADARA transmittal No. MFC-T-CJ-DC-VP-5354.
The variance is accepted.
During line checking of test package (1601-02-HT-021) at ARCC (F-1110)
were found the marking of welding joint identification and welder symbol is
away to the exact location FW-04. This violates
In addition to LBE No. 22, subcontractor failed to provide Quality Manager
while the works are on-going, aside from its lack of QC inspectors at site.
This violates schedule "Q", attachment VI. Contractor is requested to take
actiojn as soon as possible.
Contractor: For the corrective action for the same,
Contractor/Subcontractor will use unistrut channel below the cable tray
flange at both sides. Tha sample will be inspected and if it' is required
any more recrification, it will be corrdinated with the Engineering.
During routine site visit at East side of substation G-1121 & cooling tower,
it has been coticed that the aluminum and fiberglass cable trays were
deflected at the splice plates next to expansion splice plate. This is
violation as per NEMA VE-2, Section 4.2.1.
Contractor: Contractor already issue NCR to Asyad.
During inspection, it was observed that Gas detector installed without blind plug. This violates RT-61CS,
appendix 3, Contractor requested to take preventive action.
Page 65 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
113
LBE-SEN-
ELECT-139
124
LBE-PCMC-
MECH-561
Coating/
Painting
28-Jun-14 01-Jul-14 23-Jul-14 28-Jul-14 24-Jul-14 Closed-
125
LBE-TCC-
MECH-562
Coating/
Painting
29-Jun-14 02-Jul-14 23-Jul-14 20-Jul-14 24-Jul-14 Closed-
114
LBE-PCMC-
MECH-563
MR. KHAN PCMC VAF 3 MECH Piping 30-Jun-14 03-Jul-14 28-Jul-14 Open
148
LBE-IKK-
MECH-564
Coating/
Painting
30-Jun-14 03-Jul-14 22-Jul-14 Closed
127
LBE-PSCL-
MECH-565
MR.
HARIKUMAR
PSCL VAF 3 MECH Tank 30-Jun-14 03-Jul-14 15-Jul-14 26-Jul-14 Closed-
1145
LBE-GACC-
MECH-566
MR. RAMO GACC VAF 3 MECH Piping 30-Jun-14 03-Jul-14 15-Jul-14 20-Jul-14 Open
116
LBE-ARCC-
MECH-305
MR.
BUCASAS
ARCC PN 3 MECH Mechanical 30-Jun-14 03-Jul-14 Info
165
LBE-KCC-CI-
306
MR.
ENDRANO
KCC VAF 2 CIVIL Civil 02-Jul-14 05-Jul-14 Closed
130
LBE-GACC-
MECH-567
MR. RAMO GACC VAF 3 MECH Piping 03-Jul-14 06-Jul-14 15-Jul-14 25-Jul-14 26-Jul-14 Closed-
Contractor: The LBE No. 566 has been noted and the valve has been
preserved and installed to its respective line.
PN: During surveillance at North side of furnace area, it was noticed that
excessive crack appears on the surface of epoxy grouted FD Fan
foundations F-1164, F-1174, F-1244 & F-1254. This a repeated violation
and Contractor should take immediate action to resolve this issue.
Contractor is proatively advised to call for the attention of the epoxy grout
manufacturer for any recommendations/action to avoide resurrence.
During surveillance & monitoring activities at Deck Slab area D-6 common
compressor shelter GL: 1-6/A-D at elevation 27,200, noticed that newly
casted deck slabs have insufficient water curing application and some
burlap/polythylene sheets are not properly covered with some materials on
top of the slab. This is a violation of Sadara Standard RT2S-3001-01,
Section 9, Para. 9.1.2. states that "Water curing shall be continuous until
the compressive strength has reached 70% of the specific strenght but not
less than 7 days after placement. Contractor must take corrective/remedial
action on the issue for proper implementation.
During surveillance at Compressor area W5 were observed the "6-CWS
pipe spool was erected ad not maintained the clearance from concrete
foundation. This violates G4Z-0010-00, Sec. 6.10, Para. 6.10.2 "Clearance
shall be mainatined" and G4D-0142-01, Pipe Spacing Chart Notes: See
Table,. A logbook Entry was made and informed to PMT/Contractor.
Contractor shall provide necessary C.A.R.
Subcontractor: LBE No. 567 has been noted and in this 2 joints will
be cut and line shall be deducted to 50mm. It has been informed and
shown to DAELIM Construction Piping Supervisor of W5 area and
they will issue JCR and then need to be followed. TCC did this before
so needs to be closed.
During routine site visit, it was noticed that the Contractor used a HDG bolt
for the installation of enclosure at the lightning pole at the west side od
substation G-1121 which is a violation as per A554-K-PRG-EL-GEN-PHL-
005, Section 3.4.4.
Contractor: The HDG bolt of enclosure will be replaced by SS bolt.
The replacement of bolts are already in progress.
During scheduled inspection for shaft alignment for V-056 and V-0567
Flocalation mixing tank)., observed the following violation: *Tank bottom is
not rested on base structure which is showing 50mm gap between base
structure and bottom of tank. *Anchor bolt hole fabricate an improper
method and exceeded the hole size more than allowable limit. * Daelim
Engineering shall investigate and prepare appropriate corrective action to
controll the elevation variance on subjected tank.
During surveillance at GACC (W5&K1) area were found the butterfly valve
was on the ground and without any cover or protection end of the Butterfly
valve and visible the dust / grit blasting materials and foreign object. This
violates Material & Equipment Protection and Preservation Plan -3 (RT-
61CS) Sec. 2.13, Para. 2.13.1 (a) "Valves stored outdoors must be
protected from blowing sand and salt spray", Para. 2.19.12 and (d).
vermin, insect, etc. A logbook enrty was made and informed to
PMT/Contractor. Contractor shall provide necessadry C.A.R.
Subcontractor: LBE No. 566 has been noted and the valve has been
installed to its respective line. Therefore, please verify and close this
LBE.
During surveillance at MFC site during field trouch up/repair for weld joint, it
has been noticed that PCMC using an improper method for mixing (Pepsi
can); mixing ratio for two component always mixed partially. As per Sadara
spec (G1651-0101-54), partial mixing is a two-component and multi-
component coating is probihited. An immediate action be taken by Daelim.
During surveillance at MFC site during filed touch-up/Repair, it has been
noticed that TCC using improper method for mixing ratio for two-
component always mixed partially. As per Sadara specs (G16S-0101-S4),
partial mixing in two components and multi-components coating prohibited.
Immediately action shall be taken by Daelim.
Contractor: Subcontractor advised to use measuring cups while doing
partial mixing for Touch ups as per attached letter from manufacturer.
Contractor: Subcontractor advised to use measureing cupas while
doing partial mixing for Touch ups as per manufacturer letter.
Found that PCMC welders were welding 10" Pipe joint of drawing #
N016103T1A-CH-012209-01 without fit-up inspection, violating the ITP's
hold point for PCMC. Last warning letter should be issued by Daelim
Quality to welders (JCC #1318, 1391) and their welding Foreman.
Subjected joint must be cut-out or RT'd without counting it is RT
Percentatge. Daelim/PCMC QC needs to get corrective action
immediatelywith preventive measures.
AT Cooling Tower Room # 3 floor lining, it has been detected loss of
adhesion for applied top coat. Loss of adhseion (cohesion failure) was
found in between two layers. This is found defect in different locations of
the floor. Immediate action shall be taken by Daelim.
Page 66 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
117
LBE-AMA-
CIVIL-307
MR. RAHMAN AMA VAF 2 CIVIL Civil 05-Jul-14 08-Jul-14 20-Jul-14 Open
118
LBE-DLM-
MECH-568
MR. KURIAN
DAELIM
(Enginnering)
VAF 3 MECH Engineering 07-Jul-14 10-Jul-14 27-Jul-14 Open
119
LBE-DLM-
MECH-569
MR. KURIAN
DAELIM
(Enginnering)
VAF 3 MECH Engineering 07-Jul-14 10-Jul-14 21-Jul-14 Open
120
LBE-KCC-
MECH-570
MR. RAMO KCC VAF 3 MECH UG-Piping 07-Jul-14 10-Jul-14 23-Jul-14 Open
121
LBE-KCC-
CIVIL-308
MR.
BUCASAS
KCC VAF 3 CIVIL Civil 08-Jul-14 11-Jul-14 21-Jul-14 Open
122
LBE-IKK-
MECH-571
Coating/
Painting
08-Jul-14 11-Jul-14 Open
123
LBE-TCC-
MECH-572
MR. RAMO TCC VAF 3 MECH Mechanical 08-Jul-14 11-Jul-14 Open
124
LBE-KCC-
MECH-573
MR. RAMO TCC VAF 3 MECH Mechanical 08-Jul-14 11-Jul-14 Open
125
LBE-KCC-
CIVIL-309
MR.
BUCASAS
KCC VAF 3 CIVIL Civil 09-Jul-14 12-Jul-14 15-Jul-14 Open
Contractor: Materials are already approved. The old materials was
replaced by Emaco S85 instead of Emaco 301.
During surveillance, it has been noticed that IKK has applied primer coat &
using for Pump Sump A101, 02 & 03 at Cooling Tower without notifying the
Company for inspection of surface preparation prior to apply coating and
lining. As per Sch. "Q" and approved ITP, RFI notification shall be required.
During Surveillance at Cooling Water Pump area were found the peel-off
the expansion (rubber) due to excessive during bolt tihgtening at eight (8)
locations pump nozzles. This violates G8S-8005-00, Sec. 6, Para. 6.2
"Cracking in this area indicates excessive stress and will need to be
addresses before the flanged joint is re-assembled and 6.4.2.1 "Flanges
should not have to be forced into alignment, friction, load and relaxation
effects will be magnified during the preloading process if fasteners are
used to force flanges into alignment". A logbook entry was made and
informed to PMT/Contractor. Contractor shall provide necessary CAR.
Reference to PRO-ACTIVE LBE #303, dated 23 June 2014, Contractor did
not has not performed any Pull-of-Test as required before Coating for
surface soundness. This is violation to Sadara Specs A554-K-PRG-PI-SPS-
VIA-150, Para. 8.6.4. Contractor has proceeded without the required test,
coating is on ongoing in Pump basin #03 & 04 whihc has violated the same
Sadra specs.
During TSR inspection for Tray-1310, it is noticed that the tray is without
bracing for the beam support for all the tray throughtout the TSR.
Engineering clarification required with proper approved repair procedure
and its documentation for rectification.
Surveillance inspection at Cooling Tower Pump Sump #8 for moch-up
grout filling of opennings. However, it was found out that after removal of
formworks, there were portions or gap not filled with grout. Actual
measurement was checked and approximately 10cm depth or thickness of
the wall not grouted. This is a violation to Sch. "Q", section 1.2, Sadara
dcoument no. A554-E-103-CM-GEN-PLN-031. Contractor shall investigate
the root cause and initiate corrective action.
Subcontractor: After the removal of forms, the hollow portion of the
grouted area was cleaned bt removing all loose materials & laittance.
Formworks were re-installed, making sure no leakage will appear by
putting sealant on the edge. After the preparation, the area was
grouted using approved Materials masterflo 526.
During work monitoring and surveillance, it was observed that KCC begun
with the tie-rod holes repair at least side wall of cooling tower pump sump
area using not approved material EMCO 301.Clear violation to Sadara
document no. A554-E-103-WA-GEN-PLN-095, checklist SMIC-12-1003,
ite, A. ITP for repair of cooling tower. Contactor is advised to rectify and
comply as required.
Contractor : DAELIM already issued technical memorandum for repair
work of bracing to SADARA. And now we are communicating with
SADARA's welding SME, Plummer, Robert for the welding of bracing.
And we'll offcially issue the completed repair procedure after
discussion with SADARA.
Tower F1710 is found with the TSR down by 7 to 10mm down, Engineering
clarification reuired with proper rectification. All rectification and repair work
shouild be approved and documented.
Contractor: For T-1710, we already got the approval of the repair
work for leveling of TSR from SADARA. Now we are installing shim
plate and adjusting the level of TSR and internal trays at site.
During surveillance at Cooling Tower Water Pump area were found the
crack at flanges corner radius of 48"-CWS line (FRP) due of excessive
stress during bolt tightening at several location with six (6) flanges. This is
violates G8S-8005-00, Sec. 6, Para. 6.2 "Cracking in this area indicates
excessive stress and will need to be addressed before the flanged joint is a
re-assembled" and 6.4.2.1 "Flanges should not have to be forced into
alignment, Friction, load and relaxation effects will be magnified during the
preloading process if factners are used to force flanges into alignment". A
logbook entry was made and informed to PMT/Contractgor. Contractor
shall provide necessary CAR.
Subcontractor: The area was already visited by FPI representative
and assured that it is a surface crack. FPI will submit a written report
to Company to close this issue.
During surveillance at V2 Compressor area were found the serration of
raise face was damage with line number PR-250905-04-A. This is violation
to Flanged Joints - an overwiew (G4D-4250-01), Sec. 8, Para. 8.1 "The
gasket faces of flanged joints which have been opened and cleaned should
be visually inspected for corrosion (pitting and oxidation) and for defects
(such as scracthes, cracking. Finish damage, etc) & 8.2 "Flangeswith
nicks, scrathes, cuts or finish damage must be repalced". A logbook entry
was made nd informed to PMT/Copntractor. Contractor shall provide
necessary CAR.
Page 67 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
126
LBE-DLM-
MECH-574
MR. SURESH
DAELIM
(Procurement)
VAF 3 MECH Material 10-Jul-14 13-Jul-14 Open
177
LBE-ASYAD-
INST-029
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 12-Jul-14 15-Jul-14 15-Jul-14 16-Jul-14 21-Jul-14 Closed
LBE-ASYAD-
INST-030
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 12-Jul-14 15-Jul-14 16-Jul-14 16-Jul-14 Closed
127
LBE-ASYAD-
INST-031
MR. PERVEZ ASYAD VAF 1 INST Instrumentation 13-Jul-14 16-Jul-14 24-Jul-14 Open
128
LBE-AMA-
CIVIL-575
MR. NASSAR AMA VAF 3 CIVIL Civil 14-Jul-14 17-Jul-14 Open
129
LBE-DLM-
MECH-576
MR.
HARIKUMAR
DAELIM
(Procurement)
VAF 3 MECH Material 14-Jul-14 17-Jul-14 Open
130
LBE-SEN-
ELECT-140
MR. MARK SENDAN VAF 1 ELECT Preservation 14-Jul-14 17-Jul-14 17-Jul-14 30-Jul-14 Open
131
LBE-KCC-
CIVIL-310
MR.
BUCASAS
KCC VAF 2 CIVIL Material 14-Jul-14 17-Jul-14 Open
132
LBE-AMA-
CIVIL-311
MR. GERALD AMA VAF 2 CIVIL Civil 15-Jul-14 18-Jul-14 Open
133
LBE-DLM-
MECH-577
MR. S.KHAN
DAELIM
(Enginnering)
VAF 3 MECH Engineering 15-Jul-14 18-Jul-14 Open
134
LBE-IKK-
MECH-578
Coating/
Painting
During Site Surveillance at EW Pipe rack column no 58, it was noticed that
open channel tray was damaged by Electrical crew. This violates schedule
Q, attachment VI para. 5 and G078-0322. Contractor requested to take
preventive action and re-offer inspection to Company after modification.
During site surveillance, it was noticed that in Gas Furnace area Contractor installed open-channel tray
with two splice between support. This violates NEMA-VE-2 Para. 4.31, which states that "to ensure no
more than one (1) splice between the supports. Contractor requested to take preventive action.
Contractor: ASYAD already provided the support between two splice-joints for the channel cable
tray.
Please inform Contractor of applicable equipment numbers.
Contractor: Subcontractor already advised to repair the PVC
damaged. Company will be advised for the action taken.
The Contractor/Subcontractor installed the Pre-fabricated gratings cover on
ditches without the proper issuance of RFI for the Material receiving
inspection. It was also noted that there was a variance of size on the cross
bar from 10mm as per required to 8mm actual size delivered. This violates
schedule Q section 3.2 and Standard drawing. QC inspector shall initiate
the RFI in a timely manner per approved ITP. Contractor shall investigate
the root cause and initiate corrective action regarding the size variance on
cross bar gratings.
During site inspection at Gas Furnace, it was observed that Open channel
tray observed with piping and clading on going after insulation trap will be
damaged, there is no clearance between tray and pipe. This violates G07C-
0321-3. & NEMA VE-2. Contractor requested to take a preventive action.
Contractor: Rectification on going. It will be competed tomorrow, July
16, 2014.
During Line inspection in Gas Furnace area, it was observed that Pipe
used as a support to other Pipe or supportingone pipe on the top of
another pipe. This is violation against with G4Z-0010-00, Para. 9.6.6 states
that "all inside battery limit piping, supporting one pipe on the Top of
another pipe or hanging a pipe from an overhead pipe is strictly prohibited".
Line # SVH-117507-10-PU74, ISO drawing # N016103ACA-SVH-117507-
03, Support Type/No.: EPS-120. Note: This violation is aslo applicable for
all 7 Gas Furnaces SHV piping, similar type supports.
During surveillance at Cooling Tower, it has been noticed that dusting on
the concrete surface during coating application at corridor (Wall GF: 4A &
5A) middle portions, non-clean surface causes loss of adhesion between
concrete section shall be taken prior to apply final coat.
During surveillance inspection at Diedsel generator building (G-1124),
found out that gutter & support was already installed without raising RFI to
Company. This is a violation Sadara inspection checklist (SMIC-M-1031-1)
"Metal roofing/Flashing and trim material receiving inspection". Contractor
should take corrective action.
During surveillance inspection in Liquid furnace area, it was observed that,
Contractor has been procuring wrong material Flow element Vnturi and
welded with high pressure steam piping PU74. The material specification
found A 183 Grade F11, instead of A182 Grade F22. This is violation as
per PU74 Pipig Material Specfication (Base metal P22) and construction
ASME B 31.3. FE Tag Numbers: FE121552, FE223552, FE123552,
FE124552 and FE125552. Line Number SVH-122504-12 PU74 and
application each lighuid frncaces.
Contractor: New venturi flowmeter was ordered and fabrication is on-
going
During surveillance, it has been detected of Loss of adhesion for concrete
coating at Sump Pit #645. Loss of adhision was found on the wall. The
reason of failure is improper mixing ratio for repair materials during surface
preparation.
During Material Receiving inspection and pre-alignment verfication of Sump
pump (vertical 7 unit) observed that significant defirence on RPM with
Manufacturer name plate data and project data sheet. (Enbossed RPM on
motor is 3480 instead of 3560) which couild be impact on efficiency time
and dischargearation, etc. Daelim Engineering shall investigate and
propose the corrective action prior to final alignment of subject of 7 units of
pumps.
During routine visit, it was noticed that the PVC conduits installed at the
manhole at north side of substation G-1121 were already damaged due to
cable pulling of power cables and the conduits do not have PVC end bells
for the protection of the cables which is a violation as per NEC 352.46.
Page 68 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
149
LBE-ASYAD-
INST-032
MR.
SHABIRUL
ASYAD VAF 1 INST Instrumentation 17-Jul-14 20-Jul-14 26-Jul-14 27-Jul-14 Closed-
135
LBE-KCC-
CIVIL-312
MR. GERALD KCC VAF 2 CIVIL Civil 17-Jul-14 20-Jul-14 Open
136
LBE-SEN-
ELECT-141
MR.
FELOMINO
SENDAN VAF 1 ELECT Electrical 19-Jul-14 22-Jul-14 23-Jul-14 Open
137
LBE-DLM-
ELECT-142
MR.
FELOMINO
DAELIM
(Enginnering)
VAF 1 ELECT Engineering 20-Jul-14 23-Jul-14 Open
138
LBE-AMA-
CIVIL-313
MR.
BUCASAS
AMA VAF 2 CIVIL Civil 21-Jul-14 24-Jul-14 Open
139
LBE-AMA-
CIVIL-314
MR.
ENDRANO
AMA VAF 2 CIVIL Civil 22-Jul-14 25-Jul-14 Open
140
LBE-ARCC-
MECH-579
MR. NASSAR ARCC VAF 3 MECH
Coating/
Painting
141
LBE-TCC-
MECH-580
MR. RAMO TCC VAF 3 MECH Piping 21-Jul-14 24-Jul-14 Open
142
LBE-TCC-
MECH-581
Coating/
Painting
During routine inspection on package # TP-1505-01-HT-027 & TP-15015-
01-HT-028, found at F1180 Top Level, it has been noticed that much
cracking and loss of adhesion due to improper surface preparation. This is
for necessary corrective action.
During witness of Bolt Torquing and Butterfly valve, gasket verification at
Cooling Water (TCC) V6 area were found the following violation.
* Gasket missing between Butterfly Valve and Flange.
* Double nuts were installed both side.
This is violation to G4D-4250-01, Sec. 3, Para. 3.3 and G8S-8005-00, Sec.
3, Para. 3.1.1/3.1.2/3.1.3.
* Wrong color coding of Butterfly Vavle (RED)
This vis violation to RT16D-0120-01, Sec. 6, Para. 6 (a). Contractor shall
provide necessary C.A.R.
During routine inspectionm, it has been noticed that TCC coating applicator
not cleaned the pipeline surface for process line (P-172702) at dryer
Piperack prior to apply the coating. Shoes marks were detected in diferrent
locations & coating applicator was applied for final coat without cleaning
dirtied areas. Daelim inspector has witnessed this violation. This is for
necessary corrective action.
During surveillance & monitoring activities at North side of sub-station G-
1121 (Open Ditch) or SW due Type-1, found out that finishing work and
alignment of this open ditch is not properly done and poor workmanship,
especially on finishing touches. Contractor shall take remedial action on the
issue in order that the work must be acceptable. This is violation to RT2S-
3001-01, section 10 & DWG # A554-E-CV-DWG-C70-038, Rev.2.
During inspection at Cooling Tower Pump sump no. 7 with RFI No. MFC-
DLM-AMA-CI-8011, it was found out that some areas on floor slab have
surface irregularities, sharp edge projections which might damage the
tissue mat lining system installation. This is a violation to Sadara document
No. A554-K-PRG-SPC-VIA-150, section 6.1.3 the subcontractor shall
rectify the surface irregularities with approved materials prior to coating
application. The RFI is Rejected.
During site surveillance, it was noticed Contractor installed wrong bolt and
nut fasteners for Instrument channel tray. Once the correct materials are
received, Contractor needs to change correct HDG M6 bolts. Location shall
be identified properly to avoid mixing SEICO-103-6000-01-492-002 Rev.
002, MF-HW02
Subcontractor: It was tried to install but already removed. Installation
was not being continued. Correct HDG MG Bolts were installed in all
areas.
During inspection of RFI # MFC-DLM-SDN-EL-1893 for cable pulling of
Motor RTD cable was installed in the same cable tray of LV power cables.
This violates as per G7C-0302-00, Para. 3.4.2.
During surveillance inspection of LV control cables, 4Cx6mm2, 5CX2MM2,
30Cx2.5mm2 and ITRx2.5mm2 CU/XLPE/PVC, 0.6/1KV (MESC Cable)
and 2PRX2.5MM2 (Dekoron cable), for Generator panel cable (GCP-
103H101) at Substation G-1120, it was observed the following violations: 1.
LV Control has been installing at site without material receiving inspection.
This violates as per Sch. "Q", Attachment IV, Para. 3.2. 2. LV Control cable
has no marking per flame retardant in the outer sheath of the cable. This
violates as per RT70-0430-00, Para. 1.7.
Contractor: Engineering/Construction were advised on the necessary
action on or remedy for this issue.
During concrete placement, on July 16, 2014 at around 7:30 PM for (DVA
703-708) Fire wall, the forms collapsed. The side forms were removed on
July 17, 2014. It was observed that the concrete placement was more than
one (1) meter in height from the base slab, which is located at southwest
potion of fire wall. This is a violation to Sadara RT2S-3001-01, section 6.1,
Para. 6.1.2 & 6.1.3. Note that the fire wall must be monolithic or massive
concrete. Contractor shall investigate the root cause and initiate corrective
action to avoid recurrence.
Page 69 of 138
As of July 30, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF /
PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Company
comment
Approved Close
LBE by Company
STATUS
143
LBE-KCC-
CIVIL-315
MR. GERALD KCC VAF 2 CIVIL Civil 26-Jul-14 29-Jul-14 Open-
144
LBE-TCC-
MECH-582
MR. SURESH TCC VAF 3 MECH Piping 27-Jul-14 30-Jul-14 Open-
During surveillance and monitoring activities at South side of Subtation G-
1122 (Operator Bldg.) Car Park shelter foundation on 2 (two) units, found
out that Bitume coating applications are already done without RFI, which
caused improper checking of Company especially on the required
docomentations. This is a violation to schedule "Q", attachment IV, Section
1, Para. 1.1.3 & 1.1.9 and Sadara MFC inspection checklist (SMIC-H-1003)
"Surface Preparation for concrete & building painting pre-applciation
inspection. Contractor shall take remedial action on the issue in order that
the work will be accepted.
At Gas Furnace area, it was observed that Contractor has installed the
wrong type of support and welded with Run Pipe instead of "EPS-105" type
support. Reinforcing pad does not exist on installed support. As per ISO
drawing, EPS-105 Support, reinforcing pas is required. This is violation
against IFC Isometric drawing.
Page 70 of 138
As of July 09, 2014
1
LBE-AMA-
CIVIL-208
MR.
JERRY
AMA VAF 1 CIVIL Civil 20-Dec-13
2
LBE-AMA-
CIVIL-231
MR.
GERALD
AMA VAF 2 CIVIL Civil 25-Jan-14
3
LBE-AMA-
CIVIL-232
MR.
JERRY
DAELIM
(Constructio
n)
VAF 2 CIVIL Civil 28-Jan-14
4
LBE-AMA-
CIVIL-277
MR.
ENDRAN
O
AMA PN 2 CIVIL Civil 06-May-14
5
LBE-AMA-
CIVIL-282
MR.
GERALD
AMA VAF 2 CIVIL Civil 20-May-14
With reference to RFI #MFC-DLM-AMA-CI-7762, Roof leak testing on roof
of substation G-1120. (GL G-11/AC), at around 2:20 pm starting spray of
water using two (2) water truck using hose, continuously after and hour
around 3:20 pm, they finshied spray of water and thats the time we found
out that there are some areas with stagnant water, 2.40 meter from the
edge of gutter and also four (4) locations at gutter connection with leaks. In
this regards, Contractor shall rectify or repair the area with stagnant water
and seal-off the gutter conncetion with leak and should take corrective
action on the issue. (RFI has been rejected).
PN: During surveillance and monitoring actiivities at substation G-1121,
found out that gutter support (FB.50X6) has already been installed without
submitting first the "RFI" for Material Receiving inpsection to ensure that
the material complied with Sadara standard prior to inspection. Contractor
is advised to submit material receiving inspection to counter-check by
Company Coating Inspector for proper documentation and acceptance.
The Contractor did not continue the grouting of foundation of the inside
portion of the oil quench and water quence structures. Only the outside
portions wre grouted. The Contractor shall ensure that space between
plates shall also be fully filled with grout.
During surveillance & monitoring inspection at operator building along blast
type door along north side. It was found out that sub-frame of blast door
was not align properly and squareness of the said sub-frame. Contractor is
advised to submit shop drawing and details on how to rectify or repair the
squareness and alignment of sub-frame.
The Conrractor started to erect equipment/structural support without
submitting RFI at Air Cooler Structures area and Fresh Ethane Structure
area. Some deficiencies noted on the structures are the following: No
chamfer on exposed corners, chamfers were not uniformly trimmed,
blowholes and small honeycombs were not repaired, beams have irregular
shapes, some color of the repaired structures were not uniform, the top
portion of the beams were not properly cleaned prior to repair. Contractor
did not submit RFI to cover Item 3.6 of ITP SMITP-Q-001-02.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Daelim/Subcontractor Response / Reason VAF / PN S/N LBE NO. PID
SUBCON/
CONTRACTOR
Page 71 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
6
LBE-AMA-
CIVIL-283
MR.
GERALD
AMA VAF 2 CIVIL Civil 20-May-14
7
LBE-KCC-
CIVIL-285
MR.
GERALD
KCC VAF 2 CIVIL Civil 02-Jun-14
8
LBE-KCC-
CIVIL-290
MR.
GERALD
KCC PN 2 CIVIL Civil 08-Jun-14
9
LBE-KCC-
CIVIL-291
MR.
JERRY
10
LBE-AMA-
CIVIL-293
MR.
RAHMAN
AMA VAF 2 CIVIL Civil 16-Jun-14
11
LBE-AMA-
CIVIL-294
MR.
RAHMAN
During surveillance, it was noted that Amana is doing External Concrete
Coating for Cooling Tower west side without any QC Civil Inspector
coverage. This is a violation to Schedule "Q", attachment VI, VI-1, PQP
Personnel requirements.
During surveillance, it was noted that the Contractor has started external
coating Renderoc FC on west side without any RFI for cooling tower. 1.
Concrete repair work acceptance, 2. Surface preparation for concrete
coating pre-application inspection. As per ITP.
The Contractor was reminded of the requirements of Hot weather
concreting prior to concrete placement of pavement as per RFI No. MFC-
DLM-KCC-CI-7691 (Paving area B-A Span 65 & 66). The contractor
continued to place concrete in spite of violation of RT2S-3001-01, section
5.4.8 which states: a. Shade temperature exceeds (110F) 43C at the job
site combined with a mean speed of 10 mph or over. No measure to prevent
exercise moisture loss before the final curing procedure are accompanied in the
requirement of RT2S-3001-01, Para. 5.1. The shade temperature at 10:30 AM is
44.5. No apparatus to measure the wind velocity, relative humidity, etc. to check
the rate of evaporation per table 2.1.5 of sec. 1305.
(July 21, 2014).
PN: During monitoring and surviellance activities at Crack Gas
Compressor "Deca Slab", it was noticed that after casting the slab the
control joint was not implemented after 10 days wherein the concrete was
already hardened. Contractor shall take corrective and remedial action on
this issue.
During surveillance and monitoring activities at sum-0645 south side of
substation G1121, it was noticed that the installed ladder rung some are
preserve with corrosion. This is a violation to SADARA specification RT-
3001-01, section 8.2, Para. 8.2.7. In this regards, Contractor should
investigate these materials and take corrective action about the issue.
During surveillance and monitoring activities at expander building (61123),
found out that the gutter was already installed, without submitting first RFI
for material receiving inspection for proper documentation and checking.
Contractor should take corrective action on this issue and for proper
implementation. This is violation to SMIC-M-1031-1 (Metal Roofing
Receiving and Storage Inspection).
Page 72 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
12
LBE-FCN-
CIVIL-295
MR.
JERRY
FCN VAF 2 CIVIL Civil 17-Jun-14
13
LBE-AMA-
CIVIL-298
MR.
GERALD
14
LBE-TCC-
CIVIL-299
MR.
GERALD
TCC PN 2 CIVIL Civil 17-Jun-14
15
LBE-KCC-
CIVIL-301
MR.
GERALD
16
LBE-AMA-
CIVIL-302
MR.
GERALD
AMA PN 2 CIVIL Civil 21-Jun-14
PN:During surveillance & monitoring at Sub-station G-1120 & G-1121. It
was noticed that most of the doors's accessories have already been
installed but Contractor did not submit Final Acceptance Inspection (SMIC-
M-1051) ITP Checklist. Contractor shall submit RFI for proper checking of
those accessoties and proper documentation.
With reference to RFI #MFC-DLM-KCC-CI-7890-0A & F7932, installation of
epoxy coated steel bars & embeded item/floor closure inspection (deck
slab) at area D-G common computer shelter GL 13-16/A-D, Contractor did
not submit RFI and no advice from Daelim Inspectors to Company for
proper checking of repair arrangement and diameter as per latest IFC
drawing and also this RFi was "Hold" point. This is a violation to Schedule
"Q" attachment IV, Para. 1.1.3 & 1.1.9/3.7. Contractor should take
corrective & remedial action on the issue. (RFI was rejected).
PN: During surveillance at flare area, it was noticed that two (2) pedestals
was deformed or bent the acnhor bolts. Contractor should investigate and
take corrective action about the issue for proper implementation.
During surveillance and monitoring activities at Operator building (6-1122),
it was observed that mostly of the rooms are already installed acoustical
ceiling (SMIC-M-1053), Inspection checklist for acoustic suspension ceiling
system installation inspection also check some opening on walls. In this
regards, Contractor should take corrective action concerning this issue for
by room inspection.
It was observed that after the fireproofing of vessel using Pyrocrete 241,
the cementious fireproofing developed cracks on several locations of the
structure. Please investigate the causes and provide corrective measures
to avoid recurrence.
Page 73 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
17
LBE-AMA-
CIVIL-303
MR.
RAHMAN
AMA PN 2 CIVIL Civil 23-Jun-14
18
LBE-TCC-
CIVIL-304
MR.
BUCASA
S
TCC VAF 2 CIVIL Civil 24-Jun-14
19
LBE-AMA-
CIVIL-137
MR.
MARK
20
LBE-AMA-
CIVIL-307
MR.
RAHMAN
AMA VAF 2 CIVIL Civil 05-Jul-14
21
LBE-KCC-
CIVIL-308
MR.
BUCASA
S
KCC VAF 3 CIVIL Civil 08-Jul-14
Surveillance inspection at Cooling Tower Pump Sump #8 for moch-up
grout filling of opennings. However, it was found out that after removal of
formworks, there were portions or gap not filled with grout. Actual
measurement was checked and approximately 10cm depth or thickness of
the wall not grouted. This is a violation to Sch. "Q", section 1.2, Sadara
dcoument no. A554-E-103-CM-GEN-PLN-031. Contractor shall investigate
the root cause and initiate corrective action.
Reference to PRO-ACTIVE LBE #303, dated 23 June 2014, Contractor did
not has not performed any Pull-of-Test as required before Coating for
surface soundness. This is violation to Sadara Specs A554-K-PRG-PI-SPS-
VIA-150, Para. 8.6.4. Contractor has proceeded without the required test,
coating is on ongoing in Pump basin #03 & 04 whihc has violated the same
Sadra specs.
During routine site visit at Operator building 6-1122, it was found out the
Contractor used the cable tray as a support for the T-runner of the false
ceiling which is a violation as per 67C-0321-01, section 1-2.
PN: During surveillance and work monitoring, it was noted that the repair
material is not fully bonded to the surface after recommended curing time b
manufacturer. Contractor is pro-actively advised to take Pull of Test to
determine the Tensile Strength of repair material as per Approved ITP for
coating/waterproof lining. 1. Document No. A554-E-103-QA-GEN-PLN-119,
checklist no. SMIC-R-103, item no. a4, E6. 2. Concrete repair guide - ACI-
546R-04, Para no. 2.7 "In-place-tensile pull-off tests are recommended to
evaluate that bonding of repair materials is adequate. 3. Document no.
A554-K-PRG-PI-DPC-VIA-150, aProtective Coatings for Industrial concrete
structures, Para. 8.6.4.
During surveillance, it was noticed that after epoxy grouting on foundations
of pump 1411C located at south side of east-west piperack, pumpsump
area foundations of cooling tower 901C, 901E, 901F, 901G & 901H that
cracks developed on the surface of the foundations. Contractor shall
investigate the root cause and initiate corrective action to avoid recurrence.
Page 74 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
22
LBE-KCC-
CIVIL-309
MR.
BUCASA
S
23
LBE-AMA-
CIVIL-575
MR.
NASSAR
24
LBE-AMA-
CIVIL-311
MR.
GERALD
25
LBE-KCC-
CIVIL-312
MR.
GERALD
26
LBE-AMA-
CIVIL-313
MR.
BUCASA
S
27
LBE-AMA-
CIVIL-314
MR.
ENDRAN
O
During surveillance & monitoring activities at North side of sub-station G-
1121 (Open Ditch) or SW due Type-1, found out that finishing work and
alignment of this open ditch is not properly done and poor workmanship,
especially on finishing touches. Contractor shall take remedial action on the
issue in order that the work must be acceptable. This is violation to RT2S-
3001-01, section 10 & DWG # A554-E-CV-DWG-C70-038, Rev.2.
During surveillance inspection at Diedsel generator building (G-1124),
found out that gutter & support was already installed without raising RFI to
Company. This is a violation Sadara inspection checklist (SMIC-M-1031-1)
"Metal roofing/Flashing and trim material receiving inspection". Contractor
should take corrective action.
During concrete placement, on July 16, 2014 at around 7:30 PM for (DVA
703-708) Fire wall, the forms collapsed. The side forms were removed on
July 17, 2014. It was observed that the concrete placement was more than
one (1) meter in height from the base slab, which is located at southwest
potion of fire wall. This is a violation to Sadara RT2S-3001-01, section 6.1,
Para. 6.1.2 & 6.1.3. Note that the fire wall must be monolithic or massive
concrete. Contractor shall investigate the root cause and initiate corrective
action to avoid recurrence.
During inspection at Cooling Tower Pump sump no. 7 with RFI No. MFC-
DLM-AMA-CI-8011, it was found out that some areas on floor slab have
surface irregularities, sharp edge projections which might damage the
tissue mat lining system installation. This is a violation to Sadara document
No. A554-K-PRG-SPC-VIA-150, section 6.1.3 the subcontractor shall
rectify the surface irregularities with approved materials prior to coating
application. The RFI is Rejected.
During work monitoring and surveillance, it was observed that KCC begun
with the tie-rod holes repair at least side wall of cooling tower pump sump
area using not approved material EMCO 301.Clear violation to Sadara
document no. A554-E-103-WA-GEN-PLN-095, checklist SMIC-12-1003,
ite, A. ITP for repair of cooling tower. Contactor is advised to rectify and
comply as required.
During surveillance, it has been detected of Loss of adhesion for concrete
coating at Sump Pit #645. Loss of adhision was found on the wall. The
reason of failure is improper mixing ratio for repair materials during surface
preparation.
Page 75 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
28
LBE-KCC-
CIVIL-315
MR.
GERALD
During surveillance and monitoring activities at South side of Subtation G-
1122 (Operator Bldg.) Car Park shelter foundation on 2 (two) units, found
out that Bitume coating applications are already done without RFI, which
caused improper checking of Company especially on the required
docomentations. This is a violation to schedule "Q", attachment IV, Section
1, Para. 1.1.3 & 1.1.9 and Sadara MFC inspection checklist (SMIC-H-1003)
"Surface Preparation for concrete & building painting pre-applciation
inspection. Contractor shall take remedial action on the issue in order that
the work will be accepted.
Page 76 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
23-Dec-13 19-Jul-14 Open
28-Jan-14 20-Jul-14 10-Aug-14 Open
31-Jan-14 Open
09-May-14 20-Jul-14 Info
23-May-14 Open
Company
comment
Approved Close
LBE by
Company
STATUS Daelim/Subcontractor Response / Reason
Page 77 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
23-May-14 30-Jun-14 Open
11-Jun-14 12-Jul-14 Info
13-Jun-14 21-Jul-14 Open
(July 21, 2014).
Page 78 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
20-Jun-14 Open
20-Jun-14 20-Aug-14 Info
24-Jun-14 Open
by room inspection.
Page 79 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
27-Jun-14 Open
28-Jun-14 28-Jun-14 30-Jul-14 Open
Page 80 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
17-Jul-14 Open
18-Jul-14 Open
20-Jul-14 Open
24-Jul-14 Open
25-Jul-14 Open
Page 81 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
29-Jul-14 Open-
Page 82 of 138
As of July 09, 2014
1
LBE-IKK-
MECH-544
IKK VAF 3 MECH
Coating/
Painting
08-Jun-14
2
LBE-PSCL-
MECH-547
PSCL VAF 3 MECH
Coating/
Painting
10-Jun-14
3
LBE-AMA-
MECH-550
AMA VAF 3 MECH
Coating/
Painting
15-Jun-14
4
LBE-IKK-
MECH-571
IKK VAF 3 MECH
Coating/
Painting
08-Jul-14
5
LBE-IKK-
MECH-578
IKK VAF 3 MECH
Coating/
Painting
16-Jul-14
6
LBE-ARCC-
MECH-579
ARCC VAF 3 MECH
Coating/
Painting
20-Jul-14
7
LBE-TCC-
MECH-581
TCC VAF 3 MECH
Coating/
Painting
22-Jul-14
During routine inspectionm, it has been noticed that TCC coating applicator
not cleaned the pipeline surface for process line (P-172702) at dryer
Piperack prior to apply the coating. Shoes marks were detected in diferrent
locations & coating applicator was applied for final coat without cleaning
dirtied areas. Daelim inspector has witnessed this violation. This is for
necessary corrective action.
During routine inspection on package # TP-1505-01-HT-027 & TP-15015-
01-HT-028, found at F1180 Top Level, it has been noticed that much
cracking and loss of adhesion due to improper surface preparation. This is
for necessary corrective action.
During surveillance at Cooling Tower, it has been noticed that dusting on
the concrete surface during coating application at corridor (Wall GF: 4A &
5A) middle portions, non-clean surface causes loss of adhesion between
concrete section shall be taken prior to apply final coat.
During surveillance, it was noticed that AMANA has repaired corroded hot
dip galvanized ladder rungs in Sump pit #644 without notification for
inspection for SQIT Coating, still not dry since one week due to improper
surface preparation & coating application. This is for information &
corrective action by Contractor.
During surveillance, it has been noticed that IKK has applied primer coat &
using for Pump Sump A101, 02 & 03 at Cooling Tower without notifying the
Company for inspection of surface preparation prior to apply coating and
lining. As per Sch. "Q" and approved ITP, RFI notification shall be required.
During surviellance at site , it is observed that subcontractor erected
structural members (Column & its hanging) for Clarifier tank (V-0568)
supplied by Tsukishima Kankyo Eng. Without final chemical protective
coating (only primary coating found). In A554-E-103-MJ-REQ-MU4-115
states that it is the responsible of the Contractor to apply complete final
coat if the mechanicm is shop blasted and poured with manufacturers'
procedures. See Para. (coating 1, 2, 3).
Daelim/Subcontractor Response / Reason VAF / PN
During routine inspection at cooling tower room #7 & 3, it has been
observed that IKK had no treatment expansion joint as per approved
method statement (A554-E-103-CM-GEN-PLN-024) section 3.2 of applied
only Materbrace ADH 2200.
S/N LBE NO.
SUBCON/
CONTRACTOR
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Page 83 of 139
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
11-Jun-14 Open
13-Jun-14 Open
11-Jul-14 Open
19-Jul-14 Open
23-Jul-14 Open
25-Jul-14 Open
Company
comment
Approved Close
LBE by
Company
Page 84 of 139
As of July 09, 2014
1
LBE-SEN-
ELECT-105
SENDAN/
DAELIM
VAF 1 ELECT Electrical 18-Feb-14
2
LBE-DLM-
ELECT-114
DAELIM
(Constructio
n)
VAF 1 ELECT Electrical 06-Mar-14
3
LBE-DLM-
ELECT-117
DAELIM
(Constructio
n)
4
LBE-DLM-
ELECT-118
DAELIM
(Constructio
n)
5
LBE-DLM/
SEN-ELECT-
133
DAELIM
(Constructio
n)
PN 1 ELECT Electrical 21-May-14
6
LBE-SEN-
ELECT-136
SENDAN VAF 1 ELECT Electrical 25-Jun-14
7
LBE-SEN-
ELECT-138
During routine site visit at East side of substation G-1121 & cooling tower,
it has been coticed that the aluminum and fiberglass cable trays were
deflected at the splice plates next to expansion splice plate. This is
violation as per NEMA VE-2, Section 4.2.1.
During routine site inspection at Operator building G-1122, it was noticed
that the contractor installed felxible metallic conduit that was more than 1.8
meters in length which is a violation as per NEC, Article 348.20 (A) (2) c.
Engineering.
PN: During Inspection of FRP cable tray at spent caustic area, it was
observed that the cable tray installation are using temporary nut-bolt for
fasteners/hold down stainless steel materials. This is violation to G7D-0323-
00, section 4.1.5 and data sheet G7D-0323-A required silicon bronze.
During routine site surviellance, it was noticed that the installation of
battery disconnect was located outside the battery room which is a violation
as per G7C-1816-00 Section 3.11 and NEC Article 480.5.
During Site Surviellance at Electrical Room Substation G-1120 it was
Observed that the cable tray Installation is closed and insufficient clearance
to the grounding Busbar, This is Violates as per G7C-0104-00 Para. 5.7
During routine site inpsection, it was noticed that the Contractor installed
lighting fixtures and used the channel tray as a support inside operator
building and battery room of substation G-1121. This is a violation as per
G7C-0321-01, section 1.2 and RT7C-1822-06.
During surveillance at East-West main pipe rack near in the Furnace Area,
it was observed the following violations:
1. The LV power cable was damaged the outer insulation and other are
twisted due to improper cable pulling activities. This violates schedule "Q"
attachment IV, sec. 3.2.
2. The cable tray splicing joint was already deflected during cable pulling
activities. This violates NEMA VE2, sec. 4.2.1.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Daelim/Subcontractor Response / Reason VAF / PN S/N LBE NO.
SUBCON/
CONTRACTOR
Page 85 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
8
LBE-SEN-
ELECT-139
9
LBE-SEN-
ELECT-141
SENDAN VAF 1 ELECT Electrical 19-Jul-14
During inspection of RFI # MFC-DLM-SDN-EL-1893 for cable pulling of
Motor RTD cable was installed in the same cable tray of LV power cables.
This violates as per G7C-0302-00, Para. 3.4.2.
During routine site visit, it was noticed that the Contractor used a HDG bolt
for the installation of enclosure at the lightning pole at the west side od
substation G-1121 which is a violation as per A554-K-PRG-EL-GEN-PHL-
005, Section 3.4.4.
Page 86 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
21-Feb-14 04-Mar-14 30-Jul-14 Open
24-May-14 24-May-14 Info
28-Jun-14 27-Jun-14 30-Jul-14 Open
29-Jun-14 27-Jun-14 30-Jul-14 Open
Engineering.
Company
comment
Approved Close
LBE by
Company
STATUS
Page 87 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
STATUS
30-Jun-14 28-Jun-14 30-Jul-14 Open
Page 88 of 138
As of July 09, 2014
1
LBE-DLM-
MECH-359
DAELIM
(Enginnerin
g)
VAF 2 MECH Engineering 09-Oct-13
2
LBE-SEN-
ELECT-104
DAELIM
(Enginnerin
g)
PN 1 ELECT Engineering 12-Feb-14
3
LBE-DLM-
ELECT-109
DAELIM
(Enginnerin
g)
VAF 3 ELECT Engineering 23-Feb-14
4
LBE-DLM-
MECH-499
DAELIM
(Enginnerin
g)
PN 3 MECH Engineering 06-Mar-14
5
LBE-DLM-
MECH-511
DAELIM
(Enginnerin
g)
VAF 3 MECH Engineering 12-Mar-14
During inspection at Cooling Water Tower observed that partition walls
grinder beam (intermediate) obstructed or on cross on walkway platform.
Daelim/SPIG shall redesign the structural arrangement and provide proper
access without any obstruction on walkway and re-evaluate the structural
integrity if any significant modification required.
PN: Gas Furnace: Area furnace box sleeves are not centered/defected as
per actual arrangement drawing A554-7-103-MB-DWG-MB-2-002. It is
string with radiant coil which will be cause of damage during the operation.
Daelim shall propose appropriate method to fix the discrepancies with
Engineering approved method.

During site surveillance at substation G-1120, it was observed that the
cable tray installation is close to the inter-pacing relay panel tag no. IRP-
103J101 & IRP-103J102. Actual vertical distance from equipment to the
bottom of the tray is 300mm. This violates as per G7C-0321-01, para 3.12.
PN: During surveillance for electrical cable tray installation at East-West
main pipe rack, it was observed that the installations of splice plate are
closed to support and less than 300mm. As per G7C-0324-03, splice plate
on support is +- 300 is required to use of a heavy duty splice plate.
Construction team.
Found that Isometric IFC Drawings of Daelim are showing one of the notes
in the left bottom corner for "FFW" (indicates Field Fir Weld, Pipe at this
joint shall be fabricated 150mm longer) but actually on drawings it is not
marked on any required locations. Discrepancy also enquired from Daelim
Quality & Engineering Departments and Contractor also acknowledged. It
is a violation of G4D-0140-10. Daelim Quality must ensure FFW markings
on IFC drawings to avoid any discrepancy while connecting pipe joints to
the rotating equipment. Some Ref. Dwg. Nos. are 054703-02, 051703-02 &
131109-01.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
Page 89 of 142
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
6
LBE-DLM-
CIVIL-257
DAELIM
(Enginnerin
g)
VAF 2 CIVIL Engineering 20-Mar-14
7
LBE-DLM-
ELECT-120
DAELIM
(Enginnerin
g)
VAF 1 ELECT Engineering 02-Apr-14
8
LBE-DLM-
ELECT-124
DAELIM
(Enginnerin
g)
VAF 1 ELECT Engineering 02-Apr-14
9
LBE-DLM-
MECH-524
DAELIM
(Enginnerin
g)
PN 3 MECH Engineering 10-Apr-14
10
LBE-DAELIM-
CIVIL-281
DAELIM
(Enginnerin
g)
VAF 2 CIVIL Engineering 15-May-14
11
LBE-
DLM/AMA-
MECH-535
DAELIM
(Enginnerin
g)
VAF 3 MECH Engineering 15-May-14
During surveillance, obseerved that following discrepancies: G #1122
Operator building (Amana): * Embedded door frame for blastering door are
inclined and gaps bowing more than the acceptable limit - as per GA
drawing (A554-E-G-11-22-GWA-402302) * Welding activities carry out with
unqualified welder and WPS. Improper sequence of weld and crack - leak
of fusion-undercut . * Daelim quality team to investigate and propose
appropriate remedy action with Engineering support to fix the occured
discrepancies.
During Surviellance at Electrical Room Substation G-1120, it was observed
that the power panel and Dry Type Teransformer was installed along with
LV Switchgear is forture space for LV Switchgear. This is Violates as per
G7C-1811-00 Para. 6.1.2 & 6.1.8
team.
PN: During Surviellance it is Observed that P-0126B, P2320A, P2411A,
P2415A/B, P1311A/B/C, P1302A/B, 1711A, P2122B by ITT goulds found
Leaking. Leaking is from the oil drum out valve thread connections, Daelim
should take appropraite corrective action by consulting the
recommendation of vendor manufacturer.
It was noticed on site that the Structural Column for Foundation F1-025 is
clashing with the equipment E1805. The beam connecting the steel
columns therefore cannot be connected. Also the erected column (one side
only) is tilting because the equipment is inside the column vertical
alignment/plumbness. The foundation is very near the construction joint
also. Contractor to investigate and provide corrective action.
During Material Receiving Inspection, it was Noticed that one cubicle was
damaged. Contractor shall replace the damage cubicle at its components
inside motor control center MCC-103H204 at Substation G-1121.
It was notice that during inspection at G1120 and G1124 Paving Area, the
slope design of the paving is not in accordance with the project
specification RT2S-2700 Section 8. also the actual elevation of the existing
paving is not in accordance with the design.
1% slope
Page 90 of 142
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
12
LBE-DAELIM-
CIVIL-287
DAELIM
(Enginnerin
g)
PN 2 CIVIL Engineering 03-Jun-14
13
LBE-DAELIM-
CIVIL-296
DAELIM
(Enginnerin
g)
14
LBE-DAELIM-
CIVIL-297
DAELIM
(Enginnerin
g)
15
LBE-DLM-
ELECT-134
DAELIM
(Enginnerin
g)
VAF 1 ELECT Engineering 22-Jun-14
16
LBE-SEN-
ELECT-135
DAELIM
(Enginnerin
g)
VAF 1 ELECT Engineering 22-Jun-14
17
LBE-DLM-
MECH-568
DAELIM
(Enginnerin
g)
VAF 3 MECH Engineering 07-Jul-14
18
LBE-DLM-
MECH-569
DAELIM
(Enginnerin
g)
During TSR inspection for Tray-1310, it is noticed that the tray is without
bracing for the beam support for all the tray throughtout the TSR.
Engineering clarification required with proper approved repair procedure
and its documentation for rectification.
Tower F1710 is found with the TSR down by 7 to 10mm down, Engineering
clarification reuired with proper rectification. All rectification and repair work
shouild be approved and documented.
PN: The evaluation of Paving in between the piperacks at North of Cooling
Tower and Southeast by Building East 6-1121 is not level with the
foundation of the piperack. The cover of the open trench in that location,
therefore, will have a different elavations. Please advise Engineering for
the remedial works on this location.
During surveillance inspection of Substation G-1120 & G-1121 & North
South and near cooling tower, it was observed that the LV power cables
were install underground trench for street ligting is above grand type of
cable the outer sheath of cable is color black. This violates RT70-0430-00,
Para. 37.2 and 3.8.
problem.
During winding installation resistance test of RFI #MFC-DLM-SND-EL-1610
for compressor notor #1, G-1120-ACCU-001A at Mechanical room
substation G-1120, it was observed that the test result has failed the actual
valve was 10.7 mega-ohms. This violates as per Company Pre-
commissioning Porcedure G7M-0020-08, which is the acceptable valve of
winding installation test shall be 100 me ohms.
failed result
PN: It was noticed that some of pipe support, not yet erected in many
locationsare directly located in the TPER (expansion joint), please note that
the foundation/pedestals of these pipe supports are sugject to verification
by Daelim Design Engineering for proper design and possible
demobilization of paving to erect new foundation. It is recommended that
the location of these pipe support shall be identified in advance by Daelim
for proper disposition.
PN: The dowels for the arbwall at the southside and of T-1710, D-1715 and
Pumps area were not placement for foundation of adjacent piperacks.
Please investigate and verify location since the drawing shows, it crosses
the TPER by several inches only and confirm in the Enfineering to relocate
to avoid cracks in future.
Page 91 of 142
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
19
LBE-DLM-
MECH-577
DAELIM
(Enginnerin
g)
20
LBE-DLM-
ELECT-142
DAELIM
(Enginnerin
g)
VAF 1 ELECT Engineering 20-Jul-14
During surveillance inspection of LV control cables, 4Cx6mm2, 5CX2MM2,
30Cx2.5mm2 and ITRx2.5mm2 CU/XLPE/PVC, 0.6/1KV (MESC Cable)
and 2PRX2.5MM2 (Dekoron cable), for Generator panel cable (GCP-
103H101) at Substation G-1120, it was observed the following violations: 1.
LV Control has been installing at site without material receiving inspection.
This violates as per Sch. "Q", Attachment IV, Para. 3.2. 2. LV Control cable
has no marking per flame retardant in the outer sheath of the cable. This
violates as per RT70-0430-00, Para. 1.7.
During Line inspection in Gas Furnace area, it was observed that Pipe
used as a support to other Pipe or supportingone pipe on the top of
another pipe. This is violation against with G4Z-0010-00, Para. 9.6.6 states
that "all inside battery limit piping, supporting one pipe on the Top of
another pipe or hanging a pipe from an overhead pipe is strictly prohibited".
Line # SVH-117507-10-PU74, ISO drawing # N016103ACA-SVH-117507-
03, Support Type/No.: EPS-120. Note: This violation is aslo applicable for
all 7 Gas Furnaces SHV piping, similar type supports.
Page 92 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
12-Oct-13 17-May-14
Company still
awaits reply
from
Constractor
Mar.2, 2014
Open
15-Feb-14 26-Feb-14 Info
09-Mar-14
Refer to
Company LBE
additional
comments
Info
15-Mar-14 Open

Construction team.
Company
comment
Approved Close
LBE by
Company
Page 93 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
23-Mar-14 Open
05-Apr-14 Open
05-Apr-14 Open
13-Apr-14 17-May-14 Info
18-May-14 20-Jul-14 Open
18-May-14 Open
team.
1% slope
Page 94 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
06-Jun-14 12-Jul-14 15-May-14 Info
20-Jun-14 15-Aug-14 Info
problem.
failed result
Page 95 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
Company
comment
Approved Close
LBE by
Company
18-Jul-14 Open
23-Jul-14 Open
Page 96 of 142
As of July 09, 2014
1
LBE-DLM-
INST-098
DAELIM
(Enginnerin
g)
VAF 1 INST Instrumentation 26-Jan-14
2
LBE-AMA-
INST-015
AMA VAF 2 INST Instrumentation 06-May-14
3
LBE-INST-
ASYAD-017
ASYAD PN 2 INST Instrumentation 04-Jun-14
4
LBE-ASYAD-
INST-025
ASYAD VAF 1 INST Instrumentation 25-Jun-14
5
LBE-ASYAD-
INST-031
ASYAD VAF 1 INST Instrumentation 13-Jul-14
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
During Site Surveillance at EW Pipe rack column no 58, it was noticed that
open channel tray was damaged by Electrical crew. This violates schedule
Q, attachment VI para. 5 and G078-0322. Contractor requested to take
preventive action and re-offer inspection to Company after modification.
Nylon coated ties.
PN: During site surviellance at EW Pipe rack, it was observed that
Contractor installed open channel tray in improper way. Tray below the
flange and un-avoidable . This violates G-07C-0321-01, Para. 3.8 & NEMA-
VE-2 and NEC 110.12. Contractor requested to take a necessary action.
S/N LBE NO.
SUBCON/
CONTRACTOR
VAF / PN
During the time of cable tray inspection, it was observed that Contractor
installed wrong splice plate. Instead of round type connector, installed was
slotted type. This violates NEMA VEZ, project specs G-07C-301.
During site surveillance (all area) at site (general), it was noticed that
Contractor installed PVC tie instead of 316 Nylon cooled ties. This violation
RT6E-0802-01, Para. Note-10, Contractor requested to take a preventive
action.
During inspection at site at PIB G-1121, following violation has been has
been noticed during cable tray inspection. Splice over support, field
fabricated fitting used instead of factory made. Improper nut and bolts used
in tray, wrong splice plate used, slotted hole joint plate used instead of
round hole. There is no clearance between two layers of tray, provide
proper separation between tray, Contractor used 150mm open channel tray
instead of 100mm maximum allowed. This violation RTGE-0802-01, NEMA
VE2, G-07C-0321-G07C--0324.
Page 97 of 139
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
Target Date
29-Jan-14 09-Feb-14 24-Jul-14 Open
09-May-14 19-Jun-14 30-Jul-14 Open
28-Jun-14 25-Jun-14
Two
Weeks
Open
Company
comment
Approved Close
LBE by
Company
Nylon coated ties.
Page 98 of 139
As of July 09, 2014
1
LBE-DLM-
MECH-281
DAELIM
(Procureme
nt)
VAF 2 MECH Material 28-Jul-13
2
LBE-DLM-
MECH-283
DAELIM
(Procureme
nt)
VAF 2 MECH Material 01-Aug-13
3
LBE-DLM-
MECH-286
DAELIM
(Procureme
nt)
VAF 2 MECH Material 06-Aug-13
4
LBE-DLM-
INST-062
DAELIM
(Procureme
nt)
VAF 1 INST Material 05-Sep-13
5
LBE-DLM-
MECH-330
DAELIM
(Procureme
nt)
VAF 2 MECH Material 11-Sep-13
6
LBE-DLM-
MECH-338
DAELIM
(Procureme
nt)
VAF 2 MECH Material 18-Sep-13
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Daelim/Subcontractor Response / Reason S/N LBE NO.
SUBCON/
CONTRACTOR
VAF / PN
During Material Receiving inspection for Equipment (W1720) & (W1721) at
site, the Equipment W1720 found with flanges corroded, external surface
of the equipment especially place were saddle was attached and other
surface of the equipment, some internal pipes connection to the flange
were also also found corroeded. Equipment W1721 found with corroded
flanges. The equipment is also found errected without proper preservation
for corrotion deterioration. This is a violation as per A554-E-103-QA-GEN-
PRO-035, Para 8.2.1, 8.1.11, 8.1.12, RT--6-ICS, 2.19.3. These equipment
are supplied by DOOSAN Engineering.
Material Receiving inspection of the flare runner at laydown yard shown the
supports welded to the runners for attaching heat shield found bended.
This can damage the welded portion and also may have taken place during
transportation mishandled the equipment. The supplier of this equipment is
ZEECO Industries, Korea. P.O. No. is 100532-14-216-001- A01, violation
as per Ref. A554-E-103-QA-GEN-PRO-035, Para. 8.2.1, 8.1.11, 8.1.12.
site.
Material receiving inspection at Daelim laydown yard revealed cooling
tower accessories supplied bt SPIG (internal & external plates) were found
damaged. Square tubes were stocked improperly. All these accessories
are made of FRP materials without proper maintainance.
During Material Receiving inspection of Compressor, it was observed that
compressor instrument & Junction Box (JB) are not as per Standard.
Compressor C-02501 documents are not available such as FAT Report,
MTR, Calibration report. Grounding is not connected to JB Instrument and
not completed. This violates G06A-0003-17 & G06A-41-00.
ARCC shall install.
During Material receiving inspection of C3R 4th stage suction drum
(D2508) supplied by DOOSAN found corroded in the skill portion of the
equipment which require better preservation to avoid further degradation as
per A554-E-103-QA-GEN-PRO-035, Para. 8.2.5. Corrective action
required.
During material receiving inspection at site revealed that plates with plates
secondary transfer live exchanger (E1122) supplied by ALSTDM having
distorted nameplate occurred due to improper lifting or transportation
violation as per A555-E-103-QA-GEN-PRO-0353, para 8.2.1.
Page 99 of 142
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
VAF / PN
7
LBE-DLM-
MECH-403
DAELIM
(Procureme
nt)
VAF 2 MECH Material 24-Nov-13
8
LBE-DLM-
ELECT-085
DAELIM
(Mat. Dept
&
Procuremen
t)
VAF 1 ELECT
Material
(Procurement)
26-Nov-13
9
LBE-DLM-
MECH-445
DAELIM
(Procureme
nt)
VAF 3 MECH Material 05-Jan-14
10
LBE-DLM-
MECH-505
DAELIM
(Procureme
nt)
VAF 3 MECH Material 09-Mar-14
11
LBE-DLM-
MECH-513
DAELIM
(Mat. Dept)
VAF 3 MECH Material 17-Mar-14
During material receiving inspection of Valves, it has been noticed that
failure of paint bwtween prime coat and top coat. P.O. No. U31-002-A02-
42, Vendor: NEWMANS, RFI No. MFC-DLM-NEWMAN-PIP-001. No of
Valve approximately 54 nos. This violates Sadara Specification G16S-0202-
04 which mandates "each coat shall be of the correct colour, free of defects
such as but not limited to pinholes, blisters, dry spray, detrimental runs and
sags, excessive or inadequate film built, improper recoat times, foriegn
inclussion and adhesion between Coat and to the substrate shall equal the
manufacturer's limit. Contractor shall verify occured discrepancy and
propose Corrective action.
During material receiving inspection of RFI # CCHINDS-EL-024 at Daelim
Laydwon area, it was observed that the 2" Hot dip galvanized PVC coated
conduit and 2" X 3/4" reducer fittings has no labeled and not listed. This
violates as per G7C-0311-01, Para 1.2.
During inspectionof Valve leak testing at NASICO, leakage observed at
Seat of a 18 nos of butterfly valves supplied by Zero Engr. And it is beyond
the acceptable limit. Hence, valve is rejected. This violates API S98 para.
3.9.2. The Contractor shall follow up with the issue and notify the supplier
for repair or replacements.
During material receiving of Back wash water pup (P 0589) by powerking
system found an instrumentation part attached to the seal reservoir is being
damaged by it support attaching it to the reservior by welding. The damage
may havehappened due to poor handling and preservation. This is violation
as per A554-E-103-QA-GEN-PRO-034, Para. 8.1.3 & A554-E-103-QA-
GEN-PRO-035, Para. 8.2.1.11 & 8.11.
During Valve Receiving Inspection, It has benn Observed that some
supplies are Violation DOW Spec for Tagging. According to G4R-7200-01
Each Valve Shall be tagged by vendor with a brass tag with monel wire and
crimped with each other onto the wire end to avoid loses of tags, VENDOR
NAME: 1. Bonney forged Italy, 2. Pantair Vanessa, 3. Zero Engg., All
vendors provided valve tag without the monel crimp sleeve that may cause
of lost tag.
Page 100 of 142
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
VAF / PN
12
LBE-DLM-
MECH-518
DAELIM
(Procureme
nt)
VAF 3 MECH Material 05-Apr-14
13
LBE-DLM-
MECH-534
DAELIM
(Procureme
nt)
VAF 3 MECH Material 30-Apr-14
14
LBE-AMA-
CIVIL-276
AMA VAF 1 CIVIL Material 01-May-14
15
LBE-DLM-
ELECT-132
DAELIM
(Procureme
nt)
VAF 1 ELECT Material 19-May-14
16
LBE-DLM-
MECH-574
DAELIM
(Procureme
nt)
17
LBE-DLM-
MECH-576
DAELIM
(Procureme
nt)
During review of material test certificate of LTCS Pipes A333 Gr. 6 (PO No.
- 100532-B-PIP-0037-01) it is observed that mill certificate does not have
the impact test details, this is violation of ASTM A333 Gr. 6 Para. 14 which
specifies all materials furnished under LTCS soecification shall be tested
for impact resistance at all temp for the respective grade.

During Leak testing of Manual Butterfly valve in NAISCO Testing Facility
Jubail, it was observed that there was contineous leak found in the 14" x
150 butterfly valve in low pressure closure test due to crack in heating
area. This is vioaltes API 598 Table 6., DAelim Should take Appropiate
action and corrective action,
repair.
During Material Receiving inspection and pre-alignment verfication of Sump
pump (vertical 7 unit) observed that significant defirence on RPM with
Manufacturer name plate data and project data sheet. (Enbossed RPM on
motor is 3480 instead of 3560) which couild be impact on efficiency time
and dischargearation, etc. Daelim Engineering shall investigate and
propose the corrective action prior to final alignment of subject of 7 units of
pumps.
During Surviellance and monitoring acivities at sub-sation G-1120, along
transient lips sytem, we found out that "steel door" SDG was deformed or
damaged, in this regards, contractor was revised to check or investigate
the said steel door and replace with good materials as per latest IFC
Drwg./Door Schedule.
installed at site.
During Material Receiving Inspection of the Thermal Fire Detector at
Daelim laydown yard, it was found that the thermal fire detection (P/N
27120) are not matching with Pusrcahse Order. Note. This is violation to
attached documents and schedule "Q", attachment III, Section 3.
During surveillance inspection in Liquid furnace area, it was observed that,
Contractor has been procuring wrong material Flow element Vnturi and
welded with high pressure steam piping PU74. The material specification
found A 183 Grade F11, instead of A182 Grade F22. This is violation as
per PU74 Pipig Material Specfication (Base metal P22) and construction
ASME B 31.3. FE Tag Numbers: FE121552, FE223552, FE123552,
FE124552 and FE125552. Line Number SVH-122504-12 PU74 and
application each lighuid frncaces.
going
Page 101 of 142
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
VAF / PN
18
LBE-KCC-
CIVIL-310
KCC VAF 2 CIVIL Material 14-Jul-14
The Contractor/Subcontractor installed the Pre-fabricated gratings cover on
ditches without the proper issuance of RFI for the Material receiving
inspection. It was also noted that there was a variance of size on the cross
bar from 10mm as per required to 8mm actual size delivered. This violates
schedule Q section 3.2 and Standard drawing. QC inspector shall initiate
the RFI in a timely manner per approved ITP. Contractor shall investigate
the root cause and initiate corrective action regarding the size variance on
cross bar gratings.
Page 102 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
31-Jul-13 11-Aug-13 Open
04-Aug-13 20-Jul-14 Open
09-Aug-13 20-Aug-13 Open
08-Sep-13 17-Sep-13 24-Jul-14 Open
21-Sep-13 22-Jul-14 Open
CONTRACTOR'S
CORRECTIVE ACTION PLAN
Company
comment
Approved Close
LBE by
Company
site.
ARCC shall install.
Page 103 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
27-Nov-13 14-Jul-14 Open
29-Nov-13 10-Dec-13 Open
08-Jan-14 Open
12-Mar-14 Open
20-Mar-14 Open
Page 104 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
08-Apr-14 Open
03-May-14 17-May-14 Open
04-May-14 26-May-14 30-Apr-14 Open
22-May-14 24-May-14 Open
13-Jul-14 Open
17-Jul-14 Open

repair.
installed at site.
going
Page 105 of 142
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
17-Jul-14 Open
Page 106 of 142
As of July 09, 2014
1
LBE-DLM-
MECH-296
DAELIM
(Mat. Dept)
PN 2 MECH
Mechanical
(Equipment)
17-Aug-13
2
LBE-DLM-
MECH-321
DAELIM
(Constructio
n)
VAF 2 MECH
Mechanical
(Equipment)
09-Sep-13
3
LBE-DLM-
MECH-342
DAELIM
(Constructio
n)
VAF 2 MECH
Mechanical
(Equipment)
23-Sep-13
4
LBE-DLM-
MECH-346
DAELIM
(Enginnerin
g)
VAF 2 MECH
Mechanical
(Equipment)
25-Sep-13
5
LBE-DLM-
MECH-367
DAELIM
(Constructio
n)
VAF 2 MECH
Mechanical
(Equipment)
14-Oct-13
Observed that Surface Condensater (CG Compressor #2301) pressure
parts. (Vendor clossed part) were open for easy installation which is not
designed for Contractor activities. Daelim/TCC team is not authorized to
open/relocate the PCE without proper approval, elsewhere it has be to be
designed for further Constraction. Violation of Sch. "Q" and ITP and
required corrective action.
Nov. 2013.
Observed several locations Anchor bolt holes were extended during
equipment installation due to misalignment/dimensional discrepancy with
fabrication/GA drawing and trimmed hole are extended as specifying
tolerance limit by Vendor. The anchor bolts hole shall not be
extended/reduced in diameter nor offset to facilitate modification of the
mounting plate to facilitiate alignment is not permitted unless authorized by
designated vendor. Violation of A554-E-103-QA-GEN-PLN-056. Trimmed
area shall be coated with paints material.specifications.
During surveillance inspection at furnace F-1160, Radiant crossover piping
installed on position observed that numerous discrepancies on pass 1 and
2 header lines. Example: Inclination of levelness, plumbness, dimensional
discrepancy on pipe supports and sidtoration due to improper fabrication
method etc. by Vendor JNK, Korea. Daelim/ARCC shall verify occured
discrepancy and propose corrective action in accordance with appropriate
Engineering Method.
During Material Receiving at site for inspection of Ground Flare Auxiliary
and spare parts. Supports found with bolts welded to the support, have
threads exposed without proteection. It is a violation as per RT-^-ICS,
2.19A4C.
PN: During the Material Receiving inspection for Turbo expander: Unit
counter panel (21392-3) box with the indicator with showing red color.
(Showing shock occurrence due to handling improperly) hence inspection
for damages require as per manufacturer advice if damaged imidiate
inspection request from carrier within 15 days of delivery. 2. Spare rotating
assembly is N2 purged container with O reading in the gauge and red light
indication piece no. (21392-1)
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
Page 107 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
6
LBE-DLM-
MECH-369
DAELIM
(Procureme
nt)
VAF 2 MECH
Mechanical
(Equipment)
21-Oct-13
7
LBE-DLM-
MECH-395
DAELIM
(Enginnerin
g)
VAF 2 MECH
Mechanical
(Equipment)
12-Nov-13
8
LBE-DLM-
MECH-418
DAELIM
(Enginnerin
g)
VAF 2 MECH
Mechanical
(Equipment)
10-Dec-13
9
LBE-DLM-
MECH-440
DAELIM
(Enginnerin
g)
VAF 3 MECH
Mechanical
(Equipment)
29-Dec-13
10
LBE-DLM-
MECH-451
DAELIM
(Constructio
n)
PN 3 MECH
Mechanical
(Equipment)
07-Jan-14
During routine inspection for insulation activities of Water Quence Towe (T-
1410), it has been noticed that there is no adequate distance between step
ladder of ladder cage and insulation ring (approx. 2"). As per standard
requirement the distance required is 230mm. This is for your information
and corrective action required.
PN: Received an equipment D21-24 (Reflex drum) this with three others. T-
2120 (Secondary Demethanizer) E-2121 (Interncondenser) & 2123 will be
installed one over the other vertically with T-2120 at the bottom. E-2121 &
E-2123 are yet to arrive but SME, Engineering and Vendor guidance
instruction required to whether to carry out a combined hydrotest to prove
the integrity of the bolted flange joints of these equipment. The general
arrangement drawing is also mentioning of field hydro test for about 21.047
bar.
Surveillance shown the equipment P42131 (Cold box) the nozzle "GVENTI"
found bended due to mishandling or may be during installation at site, this
is a violation as per A554-E-103-QA-GEN-PRO-034, Para. 8.1.3. and A554-
E-103-QA-GEN-PRO-035, Para. 8.2.1. & 8.1.11.8.1.1.
Installation process of Incinerator at spent caustic area noted the following
discrepancy:
* Alignment process of smelt dissolver and incinerator sole and filler plate
height exceed up to 70: as recommended by gvendor it shall be 20mm.
*Incinerator holding structure (secondary girder beam @ 23050) are
showing inclination level variance and gusset plate are slightly bend.
* Bolt length are not sufficient to engage lock nut as per vendor design.
* Daelim shall advised to re-evaluate the structural integrity and fix the
discrepancy with prior approved Method by Company.
At surveillance, it is observed that Equipment E-2303 bottom side of the
supporting leg is not painted as per the required painting specs. Also this
part is corroded which may damage the metal support. This is the improper
following of painting spec. The equipment is supplied by Doosan
Engineering with P.O. No. 100532-13-231-001.
Page 108 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
11
LBE-TCC-
MECH-461
TCC VAF 3 MECH
Mechanical
(Equipment)
19-Jan-14
12
LBE-DLM-
MECH-473
DAELIM
(Enginnerin
g)
VAF 3 MECH
Mechanical
(Equipment)
04-Feb-14
13
LBE-DLM-
MECH-479
DAELIM
(Constructio
n)
VAF 3 MECH
Mechanical
(Equipment)
16-Feb-14
14
LBE-DLM-
MECH-480
DAELIM
(Constructio
n)
VAF 3 MECH
Mechanical
(Equipment)
18-Feb-14
15
LBE-DLM-
MECH-490
DAELIM
(Constructio
n)
VAF 3 MECH
Mechanical
(Equipment)
25-Feb-14
Material receiving inpsection of overhead crane hoist for common
compressor having a name plate no. CR 1695 with capacity of 100/15 ton
double girder top STAHL manufactured, has damaged rolly plat form.
Which may have occurred due to improper handling and the rail on which
the crane will be mounted and rolled is corroded. Painting is required on all
surfaces. Other than trail-trolly wheel contact surface as per the
manufacturer drawing. Ref. RTBICS, para. 2.2.11, 2.4.1, A554-E-103-QA-
GEN-PRO-035, para. 8.1.9, 8.1.11, 8.2.6 & 8.1.11.
During inspection at Cooling Tower Basin area (PS-V7) El-19530, west
side of the cooling tower for structural padding elevation, it is observed the
anchor bolt for column support for 2" piping were bent damage and
mismatching with the column nameplate holes. It is a violation as per A554-
E-103-QA-GEN-PRO-012 Para. 7.1.3, 7.1.4, 7.1.5. Daelim should also
attach survey reports to the mech (structural RFI) for anchor bolts syrvey
from subcontractor surveryor. Ref.: A554-E-103-QA-GEN-PRO-012. para.
7.1.14, 7.1.15.
On inspection of process condensale. Shipped tower (T1510) internals,
found that super-heated steam inlet (A2-24") pipe is not rested on the
support. A gap of approx. 15mm is having between the pipe and support.
This may have as adverse impact on the process functioning of the
equipment as the feed pipe is subjected to super heated steam flow
causing the material expansion contraction and mechanical vibration during
operation aslo full load and acting directly on one side of its bolted flange.
An Engineering/Desing solution required. Ref: 115105-D003, RT 5093-01,
Para 14 (D).
During surviellance at site, it has been noticed that there is no adequate
space between step ladder of vertical ladder and insulation rings for oil
quence tower (T-1310). The distance between them approximately is
60mm. The distance required as per standard is 230mm after insulation.
Logbook entry has been logged for root cause analysis and corrective
action prior to biginning insulation activities.
construction team.
Contractor at MFC site raised RFI TCC-SS-WE-0608 for the Post welding
inspection Structural Support T--1810 but inspection showed the support
were only tack welded which made the RFI's to cancel. The Structures
attached to this were there never inspected after this and the equipment is
already been erected. The Inspector for pipe welding was on 25/12/2014.
attached,
Page 109 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
16
LBE-DLM-
MECH-500
DAELIM
(Constructio
n)
VAF 3 MECH
Mechanical
(Equipment)
06-Mar-14
17
LBE-DLM-
MECH-507
DAELIM
(Constructio
n)
VAF 3 MECH
Mechanical
(Equipment)
09-Mar-14
18
LBE-ARCC-
MECH-519
ARCC VAF 3 MECH
Mechanical
(Equipment)
05-Apr-14
19
LBE-DLM-
MECH-520
DAELIM
(Constructio
n)
VAF 3 MECH Mechanical 05-Apr-14
20
LBE-DLM-
MECH-521
DAELIM
(Enginnerin
g)
WRONG TEMPERATURE CHARPY TESTED PIPES: The piping Class
HC72 and HC35 used pipe Material size NPS 30" and 64" has been charpy
tested at 29C (-20F), Instead of (-45C (-50F) at manufacturer Place.
Pipe material ASTM A671 GR CC70 CL. 12, S2., This is Violation against
piping Material Specification RTIP, HC72-103 and HC35-103, common
general note P-LC04PE625, states that charpy Test shall be for -50F (-
45C). Pipe Manufacturer; SEAH Steel Corp, KOREA, MTC No. D20121-
1123-024263(1305656) Dated 21 Dec-12, D201210-1268-020252 Dated
22-OCT-14, Found Heat No. SF23532 (30"), SP36974 (64") Contractor has
confirmed to take corrective action at site, remaining available same heat
number stock pipes, carry out retest or alternative solution for this vioaltion.

Observed the following violation discrepancy 1. Third discharge drum D-
1607 nozzle LIB 2" flange has damaged or distorted and out of squireness
due to improper material boundary. 2. Flange space seration damaged on
steam vent silencer on F-1170 (1030-SI-117) DAELIM shall verify the
extention damage and propose appropraite rectification method to
company approval.

Observed that ARCC is modify combustion air duct/stack without confirmed
support document or approval following discrepancy Noted: F 1240 area, *
Duct was damaged due to improper fabrication method * gas was burned
by gas cutting flame. DAELIM/ARCC shall propose appropiate corrective
action for rectifying the damaged part and replace damaged gasket *
DAELIM shall obtain proper approval for rectifying any vendor supplied
eqpt. prior to start activity by company, Violation of Sch Q and Material
management plan.
duct.
During tray leveling inspection for the tower T1510, it is noticed that tray
no. 2with downcommer pannel (EB-102) is having a scattered corrossion
on its surface. Corrective ation is required. Ref. RTSS-5093-01, Para. 1.37,
1.3.8., RT 6-1CS.
Furnace pipe rack observed that weld joint were distorted and flange face
is off-set up: 10mm due to improper fabrication method and welding
technique on BFV-123501-6P007. Violation of Fabrication drawing and
procedure A554-E-103-QA-GEN-PRO-046.
Page 110 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
21
LBE-GACC-
MECH-522
GACC VAF 3 MECH Mechanical 10-Apr-14
22
LBE-DLM-
MECH-523
DAELIM
(Procureme
nt)
23
LBE-DLM-
MECH-525
DAELIM
(Procureme
nt)
24
LBE-DLM-
MECH-530
DAELIM
(Enginnerin
g)
25
LBE-GACC-
MECH-557
GACC VAF 3 MECH
Mechanical
(Equipment)
24-Jun-14
During surveillance, it is noticed that during night shifts in tower T-1710, the
subcontractor is installing tray and TSR without inspection of levelness, no
RFI's were raised for the installation levelness inspection scale pan, tray
1,2,3. Also no subcontractor QC was available during this inspection.
Daelim should ensure that concerened QC is raising RFI of the installation
of internal activities of tray with the presence and/or involvement of
subcontractor QC. It is a violation as per A554-E-103-QA-GEN-PLN-103,
Para. 3.39, 3.33 Sch. Q, attachment VI.
Inspector.
During Inspection it is found that in tower (T2110 Primary Demethanizer)
for internal tray Installation flange down condencer brazing suppor for the
false down commer plate is not welded to the tower shell, also for lower
T1810, HP depropanizer bolt for tray 31 placed BW feed pipe at beneath
tray 31 is not founded welded. contractor shall take corrective action
consulting with the tower manufacturer and SME. Ref. KOCH-GLI-TSCH
Drwg. No. 115108-D000, 115111-D001.
work.
1810 & T-2110.
site.
Observed that the spent caustic unit T-0523 scrobber tower nozzle B1
observed imperfection of flange face (Serration damaged) is exceed as
permissible tolerance limit of ASME 16.47 Table: 29 Daelim QC and
Engineering team shall propose Rectification method and obtain company
approval prior to comments any activities in subjected nozzle.
During Surviellance at MFC Daelim Site it is noticed/observed that the
dilution steam generator structure, Strcutural Brazing welded to the
embedded plate were half/incompletely welded is found at all the different
elevation of the dilution steam generator structure TCC has an inspection
point with Daelim with witness point as per the ITP. Hence it is violation of
ITP and Procedure. Ref.# A554-E-103-QA-GEN-PLN-021 Rev. 3 Para.
4.2, 4.11, 4.9
During Material Receiving Inspection E222313 Exchange it is noticed that
its Leg (Jointed to the foundation) is bented makes it difficult in equipment
align also the boday of the equipment is found damage (Corroded and
broken - external body part), this may have happened in trnasportation and
material handling, proper action to be taken by the contractor with the
vendor recommendation for the rectification of the equipment. Ref #. A554-
103-QA-GEN-PRO-034 Para. 8.1.3 A554-E-103-QA-GEN-PRO-035 Para.
8.2.1 & 11.8.11

Page 111 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
26
LBE-ARCC-
MECH-305
ARCC PN 3 MECH Mechanical 30-Jun-14
27
LBE-TCC-
MECH-572
TCC VAF 3 MECH Mechanical 08-Jul-14
28
LBE-KCC-
MECH-573
TCC VAF 3 MECH Mechanical 08-Jul-14
During surveillance at V2 Compressor area were found the serration of
raise face was damage with line number PR-250905-04-A. This is violation
to Flanged Joints - an overwiew (G4D-4250-01), Sec. 8, Para. 8.1 "The
gasket faces of flanged joints which have been opened and cleaned should
be visually inspected for corrosion (pitting and oxidation) and for defects
(such as scracthes, cracking. Finish damage, etc) & 8.2 "Flangeswith
nicks, scrathes, cuts or finish damage must be repalced". A logbook entry
was made nd informed to PMT/Copntractor. Contractor shall provide
necessary CAR.
During Surveillance at Cooling Water Pump area were found the peel-off
the expansion (rubber) due to excessive during bolt tihgtening at eight (8)
locations pump nozzles. This violates G8S-8005-00, Sec. 6, Para. 6.2
"Cracking in this area indicates excessive stress and will need to be
addresses before the flanged joint is re-assembled and 6.4.2.1 "Flanges
should not have to be forced into alignment, friction, load and relaxation
effects will be magnified during the preloading process if fasteners are
used to force flanges into alignment". A logbook entry was made and
informed to PMT/Contractor. Contractor shall provide necessary CAR.
PN: During surveillance at North side of furnace area, it was noticed that
excessive crack appears on the surface of epoxy grouted FD Fan
foundations F-1164, F-1174, F-1244 & F-1254. This a repeated violation
and Contractor should take immediate action to resolve this issue.
Contractor is proatively advised to call for the attention of the epoxy grout
manufacturer for any recommendations/action to avoide resurrence.
Page 112 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
20-Aug-13 15-Jul-14 Info
26-Sep-13 Open
28-Sep-13 09-Oct-13 Open
17-Oct-13 22-Oct-13 Open
Nov. 2013.
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
Page 113 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
24-Oct-13 04-Nov-13 Open
15-Nov-13 17-May-14 Open
13-Dec-13 17-May-14 Open
01-Jan-14 19-Mar-14 Open
10-Jan-14 Info
Page 114 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
22-Jan-14 19-Mar-14 Open
07-Feb-14 19-Apr-14 Open
19-Feb-14 Open
21-Feb-14 Open
28-Feb-14 Open
construction team.
attached,
Page 115 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
09-Mar-14 Open
12-Mar-14 Open
08-Apr-14 12-Apr-14 Open
08-Apr-14 Open
12-Apr-14 Open

duct.
Page 116 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
13-Apr-14 18-Apr-14 Open
13-Apr-14 Open
13-Apr-14 17-May-14 Open
26-Apr-14 17-May-14 Open
Inspector.
work.
1810 & T-2110.
site.

Page 117 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
03-Jul-14 Info
11-Jul-14 Open
11-Jul-14 Open
Page 118 of 138
As of July 09, 2014
1
LBE-ARCC-
MECH-436
ARCC VAF 3 MECH Piping 26-Dec-13
2
LBE-DLM-
MECH-465
DAELIM
(Constructio
n)
VAF 3 MECH Piping 23-Jan-14
3
LBE-DLM-
MECH-471
DAELIM
(Procureme
nt)
VAF 3 MECH Piping 03-Feb-14
4
LBE-DLM-
MECH-478
DAELIM
(Procureme
nt)
5
LBE-DLM-
MECH-481
DAELIM
(Constructio
n)
6
LBE-DLM-
MECH-489
DAELIM
(Constructio
n)
During pre-punching for package no. 1652-00HT-007 (T) line No. P-
172601-18"-4C01, it was noted that water filling started in the line without
internal cleaning & flushing. This violates against G4S-G421-02, para. 4.9.
During line inspection for package no. 1681-00-HT-017 (T) line no. P-
210602-30"-HC11, it was noted that 4 nos. of socket joints (between two
dissimilar material A182-F308-304L & LTCSA671-CC70/Nipple A333-6)
welded without approved WPS. This is violation against RT8S-6500-01,
para. 2.2. Contractor shall provide Corrective & Preventive action.
During valve testing, it was noted that butterfly valve (103-EBV-113051)
12"X150 Flanged face serrration damaged due to pitting. This is violation
against Sadara Spec G14-S-3230-01 Para. 2.4. Contractor shall provide
corrective and preventive action.
During Material Receiving inspection of pipe fittings under P.O. 100532-42-
K04-005-A01, it was noted that fitting internally coated with rust prevention
paint. This is violation against DOW specification G4S-0210-01 para 2.1.5
which states that "If the piping was coated with a light coating of mineral oil
to prevent corrosion, the coating shall be removed by pulling a swab
saturated in cleaning solution through the piping". Contractor shall
investigate and provide corrective and preventive action.
During surveillance, it was found that Vendor's Spools (R-2030 & R-2035)
has been cut without providing detail method of statement which WPS and
NDE to be used. This is violation against schedule "Q". Contractor needs
to provide a full detail report on the incident.
Misalignment, distortions, offset at weld joint observed at ARCC field
installaed piping system. Weld joints weredistorted, misaligned and pipe
cocked to one side after welding which is caused by
*Weld joint strength reduction factor *Detrimental strain in Equipment,
piping of components is prohibited. *Excessive piping sag/or desctruction
subject to cause of creep under condition of repeated internal cycle.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
Page 119 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
7
LBE-TCC-
MECH-532
TCC VAF 3 MECH Piping 24-Apr-14
8
LBE-PCMC-
MECH-536
PCMC VAF 3 MECH Piping 18-May-14
9
LBE-TCC-
MECH-537
TCC VAF 3 MECH Piping 21-May-14
10
LBE-TCC-
MECH-539
TCC VAF 3 MECH Piping 27-May-14
11
LBE-TCC-
MECH-546
TCC VAF 3 MECH Piping 09-Jun-10
12
LBE-DLM-
MECH-549
DAELIM
(Constructio
n)
VAF 3 MECH Piping 12-Jun-14
During field leak testing of resilient seated butterfly valves in NASICO
testing facilitiy Jubail, it is observed that there is a continues bubbles found
in 8 nos of EBV during all 7 valves all rejected. This violates API 598 Table
6 which states that "These shall be no leakage for the minimum required
test duration for all soft seated valves.
During surveillance at Compressor area were observed the 3" CVA-237114-
02" TW-237040-01-A. This violates G4Z-0010-00, Sec. 6.10, Para. 6.10.2
"Clearance shall be maintained" and G4D-0142-01, Pipe spacing chart
Notes: 6 table.
During surviellance inspection in TCC area, it was observed that the pipe is
clashing with Equipment E-2331 and there is no sufficient clearance for the
application of 130mm insulation on pipe. This is violation against Sadra
spec: G4D-0142-01 & GAZ-0010-00 Para. 6.10.2. Contractor shall take
necessary action.
compelted.
Due to lack and material traceability, in the MFC-TCC site, V# area, it was
observed that, Subcontractor TCC has wrongly assembled and welded the
ASTM A53 Gr, ERW pipes instead of Seamless pipe ASTM A106 Gr. B for
Caustic service piping line class CA09. This violation against CA-09M,
Note P-CSO1PEXS and Isometric IFC drawing. ISO drawing #
N016103V3A-CA-179013-02, J # FW 08 & 09. N016103V3A-CA-179028-
01, J # FW 01.
During srveillance inspection at MFC site all over areas, it was observed
that, Contractor has installed the Variable height clamp type Pipe shoe;
separator barrier has not overlapped itself and overlap orientation in wrong
position, such as 2 clock, 4 clock and 10 clock position. This is violation
against G4G-1420-21, Note 3, which states that, "The separator material
shall overlap itself on the bottom center line of the pipe.
127 Nos. of joints welded with wrong consumable in TCC shop 1 @ 2 for
CAO9 and CA85 line class as per specification filler material shall contain
0.5% moly (ER80S-D2, E7010-AI & E7018-A1) but TCC used ER70S2 as
per WPS-TCC-P1/P1-01, which has Molydenum 0.15% Daelim should take
appropiate corrective action.
Page 120 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
13
LBE-ARCC-
MECH-556
ARCC VAF 3 MECH Piping 23-Jun-14
14
LBE-TCC-
MECH-558
TCC VAF 3 MECH Piping 25-Jun-14
15
LBE-ARCC-
MECH-560
ARCC VAF 3 MECH Piping 25-Jun-14
16
LBE-PCMC-
MECH-563
PCMC VAF 3 MECH Piping 30-Jun-14
17
LBE-GACC-
MECH-566
GACC VAF 3 MECH Piping 30-Jun-14
During surveillance at GACC (W5&K1) area were found the butterfly valve
was on the ground and without any cover or protection end of the Butterfly
valve and visible the dust / grit blasting materials and foreign object. This
violates Material & Equipment Protection and Preservation Plan -3 (RT-
61CS) Sec. 2.13, Para. 2.13.1 (a) "Valves stored outdoors must be
protected from blowing sand and salt spray", Para. 2.19.12 and (d).
vermin, insect, etc. A logbook enrty was made and informed to
PMT/Contractor. Contractor shall provide necessadry C.A.R.
LBE.
During line checking of test package (1601-02-HT-021) at ARCC (F-1110)
were found the marking of welding joint identification and welder symbol is
away to the exact location FW-04. This violates
Found that PCMC welders were welding 10" Pipe joint of drawing #
N016103T1A-CH-012209-01 without fit-up inspection, violating the ITP's
hold point for PCMC. Last warning letter should be issued by Daelim
Quality to welders (JCC #1318, 1391) and their welding Foreman.
Subjected joint must be cut-out or RT'd without counting it is RT
Percentatge. Daelim/PCMC QC needs to get corrective action
immediatelywith preventive measures.
During surveillance inspection at TCC area cold box, it was fond that
triunion support directly welded to pipe is not in the center of run pipe. This
is not accordance of support standard drawing GF31P-F4-005 & DF33P-F-
3-002 which shown run pipe and triunion support pipe center are in on line.
accepted.
During line checking and inspection at Furnace area were found the piping
flanges with spectacle blinds was installed without hole for jack screw
twelve (12) locations and EL+15400 TP (1615-01-HT-003) This violates
Project Specification for Mechanical Completion and Acceptance Rev.2
(A554-K-PRG-CM-GEN-DOC-005) Attachment 4, sec. 4, Para. 4.1.5 Install
jacking bolts on all flanges with spectacle blinds. A logbook entry was
made and informed to PMT/Contractor.
Page 121 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
18
LBE-TCC-
MECH-580
TCC VAF 3 MECH Piping 21-Jul-14
19
LBE-TCC-
MECH-582
TCC VAF 3 MECH Piping 27-Jul-14
At Gas Furnace area, it was observed that Contractor has installed the
wrong type of support and welded with Run Pipe instead of "EPS-105" type
support. Reinforcing pad does not exist on installed support. As per ISO
drawing, EPS-105 Support, reinforcing pas is required. This is violation
against IFC Isometric drawing.
During witness of Bolt Torquing and Butterfly valve, gasket verification at
Cooling Water (TCC) V6 area were found the following violation.
* Gasket missing between Butterfly Valve and Flange.
* Double nuts were installed both side.
This is violation to G4D-4250-01, Sec. 3, Para. 3.3 and G8S-8005-00, Sec.
3, Para. 3.1.1/3.1.2/3.1.3.
* Wrong color coding of Butterfly Vavle (RED)
This vis violation to RT16D-0120-01, Sec. 6, Para. 6 (a). Contractor shall
provide necessary C.A.R.
Page 122 of 138
As of July 09, 2014
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compelted.
Page 124 of 138
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LBE.
accepted.
Page 125 of 138
As of July 09, 2014
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Open-
Page 126 of 138
As of July 09, 2014
1
LBE-DLM-
MECH-450
DAELIM
(Mat. Dept)
VAF 3 MECH Preservation 06-Jan-14
2
LBE-DLM-
MECH-510
DAELIM
(Mat. Dept)
VAF 3 MECH Preservation 11-Mar-14
3
LBE-GACC-
MECH-551
GACC VAF 3 MECH Preservation 15-Jun-14
4
LBE-SEN-
ELECT-016
SENDAN VAF 1 ELECT Preservation 18-Jun-14
5
LBE-SEN-
ELECT-017
SENDAN VAF 2 ELECT Preservation 23-Jun-14
6
LBE-DLM-TEL-
018
DAELIM
(Preservatio
n)
VAF TELECOM Preservation 23-Jun-14
Daelim/Subcontractor Response / Reason DESCRIPTION
ISSUED
DATE
During surveillance at GACC (W5) area were found the piping materials
are laying on the ground without any protection or cover end of the check
valve. This violates RT-6-1CS Material and Equipment protection and
Preservation Plan Rev. 3, Sec. 2.19, Para. 2.19.1 "All materials shall be
suitably stored and protected from the site conditions" Para. 2.19.12 )d).
vermin, insect, etc. Contractor shall provide necesary CAR.
S/N LBE NO.
SUBCON/
CONTRACTOR
VAF / PN
During site surveillance, it was found that the Fiber Optic cable end has
exposed at site for all analyzer. This is violation to RTIP-A554-R-001-IS-
SPC-EG4-508, Para. 7.6.2 which states that "all FO cable ends are to be
effectively sealed (waterproof) at all stages of use. Sealing shall be
performed immediately after a length of cable has been cut from a drum.
cable end.
During surveillance at site, it is noticed the pump P2320, C2701, C2711
were found without proper covering and temporary shelter protection over it
as these are critical.
During surveillance at MFC laydown yard shown equipment Secondary
demethanizer OUHD condenser (E-2123) were preserved in a wrong way
by keeping the equipment in direct contact with the ground. Outdoor
storage requires separation from sand/mud or areas subjected to pouring
of water. Cross-cut timber with specific dimensions may be used as
recommended in the specification. The equipment is supplied bu vendor
Fives Cryos. This activity is found to be a violation as per A554-E-103-QA-
GEN-PRO-035, para. 8.2.1, 8.2.3, 8.2.4.
During site surveillance, it was found that the electrical cables are not
protected with end caps after cutting at site near substation 1120. This is
violation to G7C-0305-02, Para. 4.4. which states that the cables shall be
carefully protected from normal field construction hazards. Cable ends shall
be sealed using heat shrinkable end caps to prevent entrance of moisture.
During site surveillance inspection at decoke area, it was observed that the
4.16 KV provision voltage motor of air compressor tag # MC-2701 and MC-
2711, were installed at site without energizing the motor space heater. This
violates as per material and Equipment Protection and Preservation Plan
doc. #RT-6-1CS, Para. 2.7.2.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
Page 127 of 138
As of July 09, 2014
Daelim/Subcontractor Response / Reason DESCRIPTION
ISSUED
DATE
S/N LBE NO.
SUBCON/
CONTRACTOR
VAF / PN
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
7
LBE-SEN-
ELECT-140
SENDAN VAF 1 ELECT Preservation 14-Jul-14
During routine visit, it was noticed that the PVC conduits installed at the
manhole at north side of substation G-1121 were already damaged due to
cable pulling of power cables and the conduits do not have PVC end bells
for the protection of the cables which is a violation as per NEC 352.46.
Page 128 of 138
As of July 09, 2014
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cable end.
Page 129 of 138
As of July 09, 2014
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Page 130 of 138
As of July 09, 2014
1
LBE-ASYAD-
INST-019
ASYAD VAF 1 INST
Qaulity
Management
14-Jun-14
During Site surveillance, it was observed that ASYAD has a shortage of
QC Inspector. Contractor has 6 Inspectors while ASYAD has only 3
Inspectors and its Manpower is more than 200. This violates Schedule "Q"
Contractor is requested to take preventive action.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
Page 131 of 138
As of July 09, 2014
Open
Page 132 of 138
As of July 09, 2014
1
LBE-DLM-
MECH-399
MR.
KURIAN
DAELIM
(Enginnerin
g)
VAF 2 MECH Structural 19-Nov-13
During surveillance above the 2nd lyre of the EW pipe rack of the east side
from column 10 onwards were found in inclined position ladder fixed as it is
fauling with the beams.
department.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
Daelim/Subcontractor Response / Reason S/N LBE NO. PID
SUBCON/
CONTRACTOR
VAF / PN
Page 133 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
22-Nov-13 03-Dec-13 Open
department.
CONTRACTOR'S CORRECTIVE
ACTION PLAN
Company
comment
Approved Close
LBE by
Company
Page 134 of 138
As of July 09, 2014
LBE-KCC-
MECH-529
MR.
GLENN
KCC VAF 3 MECH UG-RTR 23-Apr-14
LBE-KCC-
MECH-543
MR.
GLENN
KCC PN 3 MECH UG-RTR 08-Jun-14
LBE-KCC-
MECH-570
MR.
RAMO
KCC VAF 3 MECH UG-Piping 07-Jul-14
During surveillance at Cooling Tower Water Pump area were found the
crack at flanges corner radius of 48"-CWS line (FRP) due of excessive
stress during bolt tightening at several location with six (6) flanges. This is
violates G8S-8005-00, Sec. 6, Para. 6.2 "Cracking in this area indicates
excessive stress and will need to be addressed before the flanged joint is a
re-assembled" and 6.4.2.1 "Flanges should not have to be forced into
alignment, Friction, load and relaxation effects will be magnified during the
preloading process if factners are used to force flanges into alignment". A
logbook entry was made and informed to PMT/Contractgor. Contractor
shall provide necessary CAR.
CUT FRP Piping Firewater line FW-071102-20 was cut and 2 added 2
joints to fit the PIV IP-P-1031735-004859 under test pack HT-015, this line
has been hydrostatically tested and Passed. Modified line shall be re-tested
to comply 64S-6423-01 Sec. 7 a new test shall be applied after repair and
convections have been made.
PN: Fire hydrant FH-0707 (under FW-HT-002) was hit by a PCMC truck
causing minor damaged and scratches on fire hydrant with condition of
buried RTR piping unknown until put to service. Ensur all fire fighting
equipment are guarded against damaged to comply LPP 103-6R8.
Temporary guards must be provided where permanent guards are still not
in place. Verify RTR UG Piping of FH-0707 to ensure no crack developed
during the impact.
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
VAF / PN
Page 135 of 138
As of July 09, 2014
LBE
Vol No.
DISCIPLINE
Discipline
Category
(Piping/Mech)
(Refractory)
(Structural)
(Tank)
(Quality Mgt)
(Others)
DESCRIPTION
ISSUED
DATE
SUBCON/
CONTRACTOR
VAF / PN
Page 136 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
26-Apr-14 23-Jul-14 Open
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
Page 137 of 138
As of July 09, 2014
DUE DATE
Issued
corrective
action to
Company
CONTRACTOR'S
Company
comment
Approved Close
LBE by
Company
Page 138 of 138

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SUMMARY OF LBE

As of July 30, 2014

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