Project Quality Realization Program Project Quality Realization Project

Project Quality Realization Program

Project Quality Realization • • • Project Phases Project Scope Inspection Coverage Plan • • Mission Statement Strategies Organization Chart Manning Levels Integration of Proponent Inspection Group Quality Enhancements Contractor’s Quality Program • • • Quality Plans Inspection & Test Plans Quality Procedures Contractor Inspection Team Schedule Q requirements

Project Quality Realization • Design Phase • Scope • Specifications • Drawings • Waivers • Procurement Phase • Major Equipment • Regulated Vendor List • Purchase Orders • Vendor Inspection • EDR system

Project Quality Realization • Construction Phase – Quality Reporting • • • – – – • • LBEs, NCRs and EDRs Weekly Highlights Quality Indicators/Statistical Reports Project Quality Index Increasing visibility to quality requirements through meetings Construction Phase by segment Mechanical Completion Pre-Commissioning Startup Quality Assessments & Audits Quality Lessons Learned

Project Quality Realization – Construction Phase by segment • Mechanical Works – – • Civil Works – – • Welding Non Destructive Testing Concrete Asphalt Electrical – – – – Cable Pulling Cable Trays Substations Switchgears Transformers Panelboards Classified Areas • • Instrumentation Telecommunication Plumbing HVAC

Project Phases – Engineering Design • • • Project Feed DBSP Project Proposal Detailed Design Engineering Review of Project Proposal and Detailed Design » » » » Project Scope Job Specifications Library Drawings Mandatory Drawings Project Design Drawings Applicable Standards Equipment and Spare Parts Data Requirements • • Project Award Type of Contracts – – Engineering LSTK LSPBO

Project Phases – Procurement (Long Lead Items, RVL, RPOs, Fabrication, TPI, Delivery, Receiving Inspection – Construction • • • – – Project Packages Project Organization (SAPMT and others) Site preparation Material Receiving Construction Activities Mechanical Completion Pre-Commissioning Startup

Project Scope The $3. 2 billion Hd. GP project encompasses design, procurement and construction of a grass root gas plant and associated facilities to increase the Sales Gas delivery to the Kingdom’s Master Sales Gas System by a nominal 1, 500 MMSCFCD. The following table summarizes the main project packages, and Lump Sum Turn Key (LSTK) Contractors.

Project Scope BI/JO Package Title Contractor 3159/31590 Gas Processing Facilities JGC 3159/31591 Utilities & Offsite Facilities Technip Italy 3159/31592 Industrial Support Facilities SCE 3159/31593 Permanent Comm. GD 8516/85160 Haradh Camp J&P 3160/31600 & 3166/31660 Downstream Gas & Condensate Pipelines Technip Germany 3161/31610 Manifolds & Trans. PLs. SRB

Inspection Coverage Plan Timely Assignment of Inspection Team: q Timely assignment of SPC/PQM (Preferably at Project Proposal stage) Role: Coordinate all inspection support activities during the three phases of the project. q Timely Assignment of SAIRS Role: Saudi Aramco Inspection Representatives (SAIRs) report to PQM and manage procurement phase. q Timely mobilization of inspection team to construction site. Inspection coverage plan should be prepared in accordance with: GI-400. 001, SAEP– 1150 and Schedule Q.

Inspection Coverage Plan Mission Statement • “Implement an integrated quality system that focuses on Preventing problems, and early detection to eliminate surprises”. SAPMT mission was: • “To design and construct a world-class gas plant with highest quality in the shortest time and the most economical cost which will become the pace-setter for the industry”

Inspection Coverage Plan Strategies q The inspection team shall work as a supportive organization to SAPMT and Contractor rather than playing the traditional policeman role. q Work in prevention and/or early detection mode. Several preventive and early detection measures were taken to support this strategy. q Integrate and align the efforts of all stakeholders (Inspection Team, SAPMT, Proponent and Contractors) to work under one quality system and in one direction. q Develop and implement Quality Indices to measure the quality of all critical activities. q Increase the visibility of quality requirements through quality meetings and CEO presentations. q Effective use of previous lessons learned. q Effective use of weekly quality meetings

Inspection Coverage Plan Sample Quality Problems – Design, Procurement and Construction Phases: q The “Monitoring” Term Was Understood Differently by Each Contractor, SAPMT, and Inspection Representatives. q Each Contractor Has His Own Systems and Procedures q Sourcing Material and Equipments From Unapproved Vendors q Inspection Coverage on Worldwide Purchase Orders Were Not Properly Controlled. No Consistent Control Mechanisms Were Available Within Inspection and Contractors. q Number of Contractor Inspectors Is Much Less Than the Project Requirements.

Inspection Coverage Plan Sample QA Problems – Design, Procurement and Construction Phases q Contractor Inspectors Are Not Adequately Trained in Their Disciplines. q Contractor NDT Technician Findings Are Overridden for Schedule and Cost Purposes. q Contractor QC Personnel Are Performing Non-QC Jobs Such As Construction Foreman or Materials Procurement Supervisor. q Contractor QC Personnel Are Not Supported by Their Management. q Contractor’s Approved Organization Chart Is Disregarded. q Construction and QC End up Under the Same Management.

Inspection Coverage Plan Sample QC Problems - Construction Phase: • • • Poor handling of gaskets. Wrong class or type of gaskets High Weld Reject Rate: Improper Weld electrode Control Questionable Radiography Interpretation Large piece of equipment shipped without post weld heat treatment. It was assumed that this heat treatment could easily be performed in the field. • Concrete foundations removed because the ice used had excessive salts. • Large Tanks collapsed while under construction, due to high winds.

Project Quality Realization ü Project Phases ü Project Scope ü Inspection Coverage Plan ü ü § § • Mission Statement Strategies Organization Chart Manning Levels Integration of Proponent Inspection Group Quality Enhancements Contractor’s Quality Program • • • Quality Plans Inspection & Test Plans Quality Procedures Inspection Team Schedule Q requirements

Inspection Coverage Plan Double click to open the pdf format (in normal mode).

Inspection Coverage Plan.

Inspection Coverage Plan.

Inspection Coverage Plan.

Inspection Coverage Plan.

Inspection Coverage Plan Typical Inspection Team Organization Chart

Inspection Coverage Plan Organization Chart

Inspection Coverage Plan Relation with PMT

Inspection Coverage Plan.

Inspection Coverage Plan.

Inspection Coverage Plan Manning Levels

Inspection Coverage Plan Manning Levels Contractor QC Manpower at Peak JGC 68 Technip 61 SCE 9 J&P 14 GD 15 Technip 51 SRB 18 Total Contractor Personnel 236 S. Aramco Personnel 49

Inspection Coverage Plan Quality Enhancements : • • Schedule Q Regulated Vendor List Electronic Database of Inspection Logbook entries Peer Review of Non Destructive Testing Quality Assessment Program Process Review of critical activities 100% inspection of new construction activities

Project Quality Realization ü Project Phases ü Project Scope ü Inspection Coverage Plan ü ü ü Mission Statement Strategies Organization Chart Manning Levels Integration of Proponent Inspection Group Quality Enhancements ü Contractor’s Quality Program ü ü Quality Plans Inspection & Test Plans Quality Procedures Contractor Inspection Team • Schedule Q requirements

Project Quality Realization ü Design Phase ü Scope ü Specifications ü Drawings • Waivers • Procurement Phase • Major Equipment • Regulated Vendor List • Purchase Orders • Vendor Inspection

Project Quality Realization

Project Quality Realization

Project Quality Realization

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