PPS-GFO Thermal Site Q Audit

g Power Plant Systems Global Field Operations Thermal Site Management and Quality Audit

Project: Site Manager:

Customer: Auditor: Audit Total Rated Score = 64.56%
Audit Date: Plant Arrangement:

Total Inspections = 158

Project Implementation Model

Total of Needed Improvements = 56

Verification Manager
The Verification Manager will be responsible to inspect the stated Name of Verification Manager:
Condition for improvement after it has been corrected/reworked
to verify correctness and compliance. Company Employed BY:

Opening Meeting
Date:

The opening meeting is to discuss the Audit, areas to be audited, limitation of the auditor and review any questions the field personnel may have.

Name Title Company

Mechanical Inspector
Electrical Inspector
Project Manager
Design Coordinator
Site QA/QC Manager GE

DO NOT ALTER THIS AUDIT FORM IN ANYWAY UNLESS STATED

ALERTING MAY CAUSE INCORRECT REPORT DATA FROM EMBEDDED FORMULAS

All rows are to be addressed with data input applicable to you observations in each section audited.

You are required to input the numeric data in Boxes C, D, E & F. Only one box per line can have data input. More than one box with data will create errant scoring.

To the auditor: Ensure Audit Sections 1.0 through 11.0 not audited are left blank.
The numeric data to input is the number listed in the column header as described below in the Audit Legend.

If possible, attach digital photos to this audit to support observations.

This Audit when all open items completed and closed

is to be uploaded into Project net Folder 06.06.02.

Audit Form Legend Listed on Audit Sheets

Column Description

A Audit Item number listed in section.

B Describes the Activity or condition observed.

C Score of what was is acceptable. 1

D Score of what can improve. 1

1
E Score of what was is acceptable with comment.

F N/A: Not Applicable to the audit. Description /Activity not being performed,

not observed or not is GE's or the Company being audited contract scope. 1

G Required Corrective Action Comment / Party Responsible Party

H Target Date to Close Improvement: Unless otherwise agreed upon with the Auditor, all improvements are to be closed within 5 business days

I Issue Corrected, Inspected & Accepted by GE. The GE Site Manager per the Verification Manager is responsible for final acceptance.

J Date Closed: The date the issues was corrected and accepted by the site GE Site Manager per the GE Verification Manager.

SCORING
1 Section Audit Score is based on 100% percentile of each section with each line item rated as an equal portion of 100% of the section audited.
2 Each section is individually rated with a total rating score given to the project Audit Rating Score listed on the Audit Summary .
3 No extra credit is given. Below is a summary of color code for audit ratings. Ratings in YELLOW below 95% are considered areas of opportunity for improvement.

1 of 20
 PPS-GFO Thermal Site Q Audit

AUDIT SUMMARY

Section Title Rating Inspections Need to Improve 100.00%

1.0 Site Program - General 52.38% 21 10

2.0 Document Control 60.00% 15 6 80.00%

3.0 Nonconformance 60.00% 10 4

4.0 Material Control 76.92% 13 3 60.00%

5.0 Field Erected Tanks 0 0

6.0 Structural Steel 33.33% 12 8 40.00%

7.0 Insulation & Coatings 85.71% 7 1

8.0 NDE & Pressure Tests 57.14% 21 9 20.00%

9.0 Mechanical & Piping 76.47% 34 8

10.0 Civil 66.67% 18 6 0.00%

1 2 3 4 5 6 7 8 9 10 11 12
11 Electrical 85.71% 7 1 Series1 52.38% 60.00% 60.00% 76.92% 0.00% 33.33% 85.71% 57.14% 76.47% 66.67% 85.71% 0.00%

12 Engineering 0 0 Sections Audited

Audit Rating Score (Total I- total Imp)/Total I 64.56%
Audit Rating Comparison

Total Inspections = 158

Total of Needed Improvements = 56

total score 64.56%

Discipline Break Down Inspections Need to Improve

Site Quality 158 55

Target Closure
Section Reference ISSUE Recommended Resolution Responsible Party Date Closed
Date
1.Quality Program - General
2.Document Control
3.Nonconformance
4.Material Control
5.Field Erected Tanks
6.Structural Steel
7.Insulation & Coatings
8.NDE & Pressure Tests
9.Mechanical & Piping
10.Civil
11.Electrical

Closing Meeting
Date:

The closing meeting is to discuss the results of Audit, findings, closure dates and that is required to close findings.

Name Title Company

Mechanical Inspector
Electrical Inspector
Design Coordinator
Site QA/QC Manager GE

2 of 20
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 21 Total Deficiencies = 10

1.0 Quality Program - General

Section Score = 52.38%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected & Accepted
No. Description/Activity (1) Comment by
(1)

1.1 Not shown any evidence however verbally said.

Has the subcontractor been Pre approved?
Ther is Quality Manual in place however it has not been reviewed /
1.2 1
Is there a Quality Plan and is it being performed as written? approved by GE

1.3 1 Mech, E&I , Civil ITPs present at IFC Stage

Have the Inspection Test Plan been approved By GE and the Customer?
Procedures are available but not issued for review and approval. Procedure
Are Processes in place as stated in the subcontractor's Quality Manual
1.4 1 14 selected as example, 14.5 requies annual review of NCRs but this was
Program/ITPs?
not completed.
Ther is Quality Manual in place however it has not been reviewed /
Are subcontractors to the GE subcontractor working in accordance with the
1.5 1 approved by GE, Calibration log is not in line with project quality plan
approved Quality Manual/Plan/ITP?
requirements

1.6 Are there adequate Specifications on site to perform the work? 1

1.7 Are Procedures in place for all functions and disciplines where needed? 1

As per contract Quality Lead and 3 inspectors shall be present. Currently 3

inspectors available at site. As of 3/3 new mechanical insp. Joined the team
Does subcontractor (the non-GE installer) have a full time Quality
1.8 1 and total number reached 4. previous mech. Insp internally assinged as
representative?
quality lead. GE approval has not been granted yet. Approval will be
requested officially

1.9 Do the forms being used to control work, comply with GE Requirements? 1

Is there evidence that site staff personnel are qualified to do their work.
1.10 1 New Mechanical Inspector who joined 3/3 has TWI CSWIP 3.1 qualification.
(Check resumes or certifications.)

1.11 Is the Installer's or Customer's Site QC involved with the work? 1

1.12 Is there a Request For Information (RFI) system in place? 1 External and Internal RFI system is in place.

1.13 1 new changes has not been implemented in Org chart. It is not posted.
Is the site organization chart posted and is the correct edition?
Separate list used to track different discipline equipments. There is no
1.14 Is there an M&TE program in Place? 1
single master list to track.
PG-145 selected as example, calibration certificate reviewed and found
1.15 Are M&TE calibrated records current 1
current.
Is there evidence and out of calibrated M&TE is addressed and a corrective It is not documented how to out of calibrated Measuring device to be
1.16 1
action is in placed? handled.

1.17 Is there proof GE sub contractors have been pre qualified? 1

Is QA/QC Team independent from the personnel engaged in construction

Quality personnel involved only quality activities. However there is no
1.18 activities. (i.e. no dobule hat for single person), if yes, how this independancy 1
written reference to this.
guaranteed by Subcontracor Management.
Quality Plan describe, Project and Quality Key Performance Indicators
1.19 1 KPIs are not described for this project.
(KPIs). If yes, how monitoring and evaluation is being performed ?

Job Description for Key personnel and QA/QC Personnel available ? In JD

1.20 minimum requirements are described, if yes, how it is established. If no
without minimum requirement how personnel competency measured ?

Is there a procedure to assess and document personnel competency on an No procedure is available to document personnel competency on annual
1.21 1
annual basis? basis.
Is there an escalation process by which personnel that do not pass
1.22 1 there is no escalaltion process available, no process defined
competency are retrained etc.?
Is there a list to track Quality personnel certificates and expiration dates ? If
1.23 1 There is no list to track quality personnel certificates
yes how frequently updated, where it is described.
Does subcontractor perform internal audits ? If yes, what were the last audits
1.24 1 No internal audit performed for this project.
findings.
Acc
Needs to
Acc With N/A
Improve
Comment

Totals 8 10 3 1
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 15 Total Deficiencies = 6

2.0 Quality Program - Document Control

Section Score = 60.00%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity (1) Comment Accepted by
(1)

There is no site level document control procedure

available, however company wide document is
2.1 Does the site have a copy of the document control procedure available? 1
available. In house distribution is not described.
In house authority/responsibility not defined.

Do personnel involved in document transmittals and issuances know the Site DCC is not aware that there is Document
2.2 1
procedure? Control procedure available (company wide)
Do personnel (Site Foremen, Engineers, etc.) involved in receiving document site personnel know company wide document
2.3 1
issuances know the procedure? control procedure.

Everything kept electronically and some

2.4 is the site document storage per an approved procedure? 1 document hard copy. Electronic files are kept in
HDD however there is no solution for back up.

PQP attachement received from head office, it is

Is the process/procedure in place being performed properly? (Walk a
2.5 1 not matching document data control procedure
document through the process to verify)
item 5.6
If a white paper storage process is in place, are fire extinguishers or an
2.6 1 Fire extinguisher available outside the DCC office
overhead sprinkler system in place for fire protection?
Drawing index is available however it does not
2.7 Does the site have an accurate drawing index? 1 have document number and it is not controlled
document,
Are electronic or white paper documentation transmittal forms being used and transmittal 3375 selected, and it is observed that it
2.8 1
are they available and correct? is correct and available.

2.9 Does the drawing index list current revisions matching issued drawings? 1

Are drawings stamped by set and filed orderly either electronically or white 26909-CE-A1-003 selected randomly. Hard copy
2.10 1
paper? shown for 2 transmittals.
Document Control Log is available but it does not
2.11 Is there a document transmittal to field process in place with a issue log? 1
have document control number.
26909-CE-A1-003 has 2 revisions. Rev 00 and rev
Are outdated, superceded drawings identified, marked superceded, void etc.
2.12 1 01. rev 00 has not been stamped as
and removed from the work area?
superceeded/void/etc
Were there any drawings with the wrong revision or stamped superceded,
2.13 1
observed in the offices during this audit?

company wide document control procedure states

1 year retantion after completion of project. The
2.14 Is a documentation retention system set up for archival storage? 1 storage to be performed in sinsina head office.
However there is no reference / description how
to do this.

site document control procedure not available.

Company wide document control procedure does
2.15 Are documents being controlled per the document control procedure? 1
not contain all essential ingredients to control
document
Are red marked up documents containing all needed information (date,
last issued RLM trasmitted via 3023. it has all
2.16 signature, engineering validation reference, etc…) ? Are red marked up 1
needed information
document communicted according to the defined process.
Acc
Needs to
Acc With N/A
Improve
Comment

Totals 5 6 4 1
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 10 Total Deficiencies = 4

3.0 Quality Program - Nonconformance

Section Score = 60.00%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity (1) Comment Accepted by
(1)
Is there a plan/procedure for nonconformance reporting and corrective action control of nonconforming product procedure is
3.1 on site? 1 available (procedure 13) but this procedure is not site
level document it is company level document.
Is the NCR Procedure being correctly implemented per the Quality Manual?
Site level NCR procedure is not available, company
3.2 1
wide procedure 13 is not beging followed.

Is there an NCR log and is it current? Are non conformities recorded and NCR/OBS log is available but it does not have
3.3 1
transmitted according to process defined ? document control number
Is the disposition of NCRs in accordance with the Quality Manual/Procedure'? NCR distribution not described. At site distribution
3.4 1
performed via emails.
Is there an adequate method for closing NCRs? corrective and preventing action procedure (14)
3.5 1 available. But this is not site level document. It is
company level
Are corrective actions being reviewed/inspected and verified correct to close Internal review performed but not described in
3.6 1
NCRs? procedure.
Is there documented and physical evidence the NCR and corrective action
NCR-SS/GTG1-8/0001/2019 reviewed and found
3.7 process/procedure is working? (Walk an NCR through the process to the 1
acceptable
rework to verify)
Is the disposition of NCRs in accordance with the Quality Manual ? NCR-SS/GTG1-8/0001/2019 reviewed and found
3.8 1
acceptable
Is the timeline closure recorded ?
3.9 1 NCR log does not contain timeline information

is there a target for NCR closure (number of days, milestone etc)

3.10 1 there is no recorded target for NCR closure.

Acc
Needs to
Acc With N/A
Improve
Comment

Totals 2 4 4 0
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 13 Total Deficiencies = 3

4.0 Quality Program - Material Control

Section Score = 76.92%
A B C D E F G H I J
Acc Needs to Acc N/A (1) Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With Responsible Person For Corrective Action Date Inspected &
(1) Comment Accepted by
No. Description/Activity
(1)

Is there a Receiving Inspection process in place and is it being performed per

4.1 1 Material Receiveing inspection procedure is not available.
the procedure?
Is there an OS&D procedure in place?
4.2 1 OS&D procedure is not in place.

Is the lay down area adequate for equipment requirements?

4.3 1

Is there a lay down equipment location map?

4.4 1 SS-WS-001 rev0 issued for lay down equipment map.

Is Material stored on supports, out of mud and away from vehicle traffic?
4.5 1

Is there an area for QC Hold of nonconforming Equipment and Material?

4.6 1

Are QC Hold tags or another method of holding in place for control?

4.7 1 Quarantine area is present however ther is QC hold tags

Is a nonconforming Product procedure in place and is it being performed Control of non conforming product procedure (13) for
4.8 accordingly? 1 company wide is available. However it is not being followed
at site
Is there a plan for inspecting received materials and equipment? handling, storage, packing and delivery procedure (15) item
4.9 1
15.3.3. descrined receiving plan.
Does the receiving plan include climate controlled storage and control for handling, storage, packing and delivery procedure (15) item
4.10 1
instruments such as accelerometers, chart recorders, and purge gages? 15.3.7. dedescribed AC storage
Is there a plan in place for protection from inclement weather?
4.11 1 Yanbu is subjected to inclement weather

Are storage procedures adequate? (Long and short term)

4.12 1

Do pipe ends have protection in the lay down area?

4.13 1 most of the pipe ends are closed. However not all of them.

Are small items such as 2” pipe fittings being stored in bins, shelves, etc. for
4.14 1
control?
Are small items storage areas readily identified with the material
4.15 1
nomenclature for easy identification?
Are heaters used, wired and running for motors over 5 hp where required?
4.16 1

Is there a process in place to track material issued to the work areas?

4.17 1

Is there a preventive maintenance program in place and is it by the procedure

4.18 1
or manufacturer's instructions.
Is the preventative maintenance program being performed with all required
4.19 maintenance at required intervals with current documentation? 1

Are the material control (RIR forms and logs, Shipping dockets, Issuance to
4.20 field, OS&D, Maintenance, locator map, etc.) in good condition and filed in 1
an orderly manner for easily identification.
Acc
Needs to
Acc With N/A
Improve
Comment

Totals 8 3 2 7
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 12 Total Deficiencies = 8

6.0 Quality Program – Structural Steel

Section Score = 33.33%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity (1) Comment Accepted by
(1)
Do the bolts and nuts meet the specifications?
6.1 1 GE supplied material

Is an approved bolt tensioning plan in effect?

6.2 1 No bolt tension plan is developped

Does the plan have a bolt layout diagram to identify the bolts inspected?
6.3 1 No plan no layout diagram

Are inspections of being performed by certified inspectors Civil inspector is performing inspection activities,
6.4 1 he has no record of inhouse or local certification
etc.
Is there a plan in place to identify, remove and replace unacceptable bolts?
6.5 1 not available,

Are bolt torque records available?

6.6

Is a calibrated torque wrench being used to test bolts? Calibrated torque wrenches are used. 10-50Nm and
6.7 1
20-150F-Lbs
Are calibration records available for the torque wrench? Calibrated torque wrenches are used. 10-50Nm and
6.8 1
20-150F-Lbs
Are torque wrenches available?
6.9 1

Is a calibrated torque wrench being used to test bolts?

6.10 1

Are Welders qualified to AWS D1.1 (or any other local standards) ?
6.11 1 No welder qualification available as per AWS D1.1

Is a copy of the Welder's Performance Qualification Records (WPQR) on site

6.12 and are they correct? 1

Are Welding Procedure Specifications (WPS) qualified to AWS D1.1?

6.13 1 No AWS D1.1 WPS observed at site,

Are copies of the WPS with supporting Procedure Qualification records

6.14 (PQR) on site and are they correct? 1 No AWS D1.1 WPS observed at site,

Are structural pieces clearly marked with the their unique identification
6.15 number (UNID)? 1 GE scope

Are structural pieces stored properly to prevent damage?

6.16 1 GE storing structual pieces

Is the Turn of Nut method being used to tighten bolts?

6.17 1 Torque technique is used no turn of nut method.

If Turn of Nut is being used. Are bolts marked to ensure the right amount of
6.18 turn is performed for the size bolt being tightened? 1 Torque technique is used no turn of nut method.

Acc
Acc Unacc With N/A
Comment
Totals 4 8 0 5
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 7 Total Deficiencies = 1

7.0 Quality Program – Insulation & Coatings

Section Score = 85.71%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity
(1) Comment Accepted by
(1)
Has the pipe to be coated/wrapped been reviewed to ensure all testing and
7.1 1 DFT gauge is not in the calibration log.
inspections have been completed?
Has the contractor brief coatings subcontractor on specification GE-26909-YGTG-M-02-1007 is followed
7.2 requirements? 1 Inspector familiar with this spec. however
not fully.
Is the base material prepped properly?
7.3 1

Are dry mill thickness tests being made as job progresses? Reports available, however reference to
7.4 1
measuring device is not present.
Are Holiday detection records kept up to date?
7.5 1

Are previsions being made to control over spray or drift? GE-26909-YGTG-M-02-1007 is followed to
7.6 1
control over spray and drift
Is there a NACE or equivalent inspector monitoring the painting and liquid
7.7 coating processes per spec? 1 No qualified inspector available at site

Are paint and liquid coatings being applied within the humidity and
Paintshop is open area, it is open to
temperature requirements?
atmospheric conditions. Currenlty
7.8 1
temperature/humidity condition is not
severe however it will change soon.

Acc
Needs to
Acc With N/A
Improve
Comment
Totals 2 1 4 1
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 21 Total Deficiencies = 9

8.0 Quality Program – NDE & Pressure Test

Section Score = 57.14%
A B C D E F G H I J
Acc Needs to Acc With N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve Comment (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity (1) (1) Accepted by
When Applicable, Audit for Compliance to EU 97/23/ec As
Code shall be Directive where applicable
All personnel trained and tested in accordance with the Quality Manual and NDE-CCS is used as NDT subcontractor,
8.1 1
applicable code? qualification records readily available.
Are NDE procedures per the applicable Code and/or GE Specifications and
NDE-CCS procedures are not available,
available for use?
8.2 1 Fugro Procedures are available, however
Fugro is not performing NDE activities.

Are NDE personnel certifications including VT in order and correct?

8.3 1

Are all NDE records current with the correct information referencing the M-3115 RFI reports randomly selected and
8.4 applicable code? 1
found they have relevant code reference.
Is NDE being performed to the code specified by the project specifications
NDT matrix (spreadsheet) was shown
and drawings?
8.5 1 however no traceability for this document
available. No signature no logo available.

Is the radiographic film and other NDE reports being review by GE’s and the
8.6 1 RT films are not reviewed by GE.
Contractor’s Quality Dept.?
Is the quality of the radiographic film free of scratches, smudges, light leaks,
8.7 1
static marks and processing abnormalities as not to interfere with
Are welds being visually inspected at fit up, during welding and after
8.8 completion for final acceptance? 1 final VT test performed with MFQ

Are calibration records available and traceable to tools and instruments that 2pcs 30 bar 2pcs 100 bar guages available.
8.9 1
require calibration There is no pressure test activitiy at site.
Are calibrations current for tools and instruments that require calibration? 6 pressure guages, 8 pressure relief valve
8.10 1 listed in the list. All have valid calibration
records

8.11 Are all checklists correct and accurate? 1 checklist MRFY-CKL-M-007 is used

8.12 Has the Hydro Procedure been reviewed and is it adequate for the test? 1 Hydrotest procedure is not available

8.13 Does the procedure include a safety review? 1 Hydrotest procedure is not available
each HT package has a drain plan which is
8.14 Is there a plan for draining water where applicable? 1 using plant drains.
8.15 Is Hydro tests being inspected and accepted by GE? 1 Each HT performed with RFI.
Do Hydro test forms reflect gage S/N, test pressures, holding times,
code part not filled, ambient temperature
8.16 applicable codes, ambient temperature and the system/section being testing? 1
not recorded.

Is Hydro tests being performed properly in accordance with the written

8.17 1 Hydrotest procedure is not available
procedure, applicable code and specifications?
 Are in service leak test being performed authorized by the customer? RFI/HT packages is used to get approval
8.18 1
and cover the activity
Is Gas piping leak test being performed is in strict compliance with a safety
8.19 1 No safety plan available in test packages
plan?
If test is observed - Is there a gauge at the high point and at the source? gauge positions are not shown in the test
8.20 1
packages
If test is observed - Is air being bled off until test medium is seen?
8.21 1
If a Test Header is used -has ASME VIII been reviewed for the testing and There is no document available for test
8.22 1
stamping of header? headers
If pneumatic test is used, is a strict safety plan in place with Site EHS?
8.23 1

Needs to Acc With

Acc N/A
Improve Comment

Totals 11 9 1 2
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 34 Total Deficiencies = 8

9.0 Quality Program – Mechanical & Piping

Section Score = 76.47 %
A B C D E F G H I J
Acc Needs to Adequate N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity (1) Comment Accepted by
When Applicable, Audit for Compliance to EU 97/23/ec As (1)
Are welding procedures (WPS) adequate with supporting WPQRs in
WPS/PQR list issued and approved D-2-0270 as 25th dec
9.1 accordance with the governing code? 1
2017

Are welder/welding operator performance records (WPQR) adequate in

9.2 accordance with the governing code? 1

Are Welder’s qualified to the process, which they are welding to?
9.3 1

Is the welder/welder operator continuity log up to date?

9.4 1 continuity records available only hard copy,

Are weld records being documented in accordance with the Quality Manual quality manual not approved and it does not have
9.5 and the applicable code? 1
information about weld records
Are hold points being identified for inspection?
9.6 1

Are welds being identified with the weld number and welder’s ID in Weld log contains welder id however weldlog form is
9.7 accordance with the applicable code? 1
not registered,
Are welding inspectors qualified to perform the necessary inspections? there are 2 CSWIP 3.1 qualified welding inspectors
9.8 1
available at site.
9.9 Are weld material issue slips being used? 1 no slips used
9.10 Is unused weld material being returned and documented? 1 no control mechanism about unsued material
Is low hydrogen welding rods being stored in holding ovens at the proper
9.11 temperature? 1

Is the welding material in the holding ovens segregated by type and

9.12 adequately identified? 1

Are welding rods holding ovens free of all other items except welding
9.13 material? 1

Are rod caddies being used to store low hydrogen rod in at welding points?
9.14 1

Are rod caddies plugged in?

9.15 1

Is welding material being controlled to the extent that there are not any rods
9.16 1
or wires lying around the site?
Does the site have a copy of the Gas turbine welding instructions?
9.17 1 not delivered to Subcontractor

Have the Gas Turbine welding instructions been reviewed and is there an
9.18 understanding of the requirements? 1 not delivered to Subcontractor

Does the site have a copy of the Steam Turbine welding instructions?
9.19 1

Have the Steam Turbine welding instructions been reviewed and is there an
9.20 1
understanding of the requirements?
 Is the Pipe material readily identified?
9.21 1

Are all piping spools being inspected for cleanliness? There is no record of cleanliness inspection.
9.22 1
Inspections not performed
Do all piping spools have end caps prior to being fit up?
9.23 1

Is piping being installed in accordance with the drawings and specifications?

9.24 1

Is Carbon Steel pipe welding and cleaning of welding being controlled as not
9.25 to allow carbon contamination of stainless steel? 1 there are different shops for CS and SS material

Are Stainless Welds being cleaned with stainless steel brushes?

9.26 1

Is non-consumable paint and coatings being removed from the weld area
9.27 prior to welding? 1

Are “As Built” drawings available for any field run pipe?
9.28 1

Are pipe supports being installed in accordance with the Drawings?

9.29 1

Are welded pipe supports being inspected in accordance with the applicable RFI-M-3050 is selected as example. RFI raised for
9.30 code? 1
inspection of welded pipe support installation
Are anchor bolts being verified for location prior to equipment installation?
9.31 1 1

Are flanges being torqued with the right gaskets?

9.32 1 no bolt torque reports

Are flanges being inspected for tightness?

9.33 1 no report for verification. ITP

Are Compression Fittings being installed per the manufacturer installation

9.34 booklet? 1

Is installation processes being perfor med in accordance with the GE

9.35 approved Quality manual? 1

Are welds being Radiograped where applicable?

9.36 1

Is equipment being set on location per design CWM and WIS installation for block 4 not performed as
9.37 1
per drawings. Correction completed after issue raised
Are rotation records available and are they correct?
9.38 1

Are alignment records available and are they correct?

9.39 1 alignment done by RFI

Is there a preventative maintenance program in place and is it being

9.40 1
performed as stated?
Is the PWHT Procedure adequate for the welds to be stressed per the
9.41 applicable code and specifications? 1

Has GE PWHT requirements been reviewed for GE piping where required?

9.42 1

Do the heat charts contain the pertinent information for adequate

9.43 identification of the welds and the heating process? 1

Are heating, soaking and relief temperatures and times within code
9.44 parameters for the metal being heat-treated? 1

Do the stress machines have calibration certifications and do they match the
9.45 S/N of the machine in use? 1

Are certification stickers attached to the machines?

9.46 1

Is loss of temperature conditions being adjusted to the proper heating,

9.47 soaking and cooling temperatures and rates where applicable? 1

Are thermocouples being attached in accordance with GE requirements

9.48 where applicable? 1
 Is GE or the controlling site QC reviewing the charts for accuracy?
9.49 1

Acc
Needs to
Acc With N/A
Improve
Comment
Totals 23 8 3 16
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 18 Total Deficiencies = 6

10.0 Quality Program – BOP Civil

Section Score = 66.67%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected &
No. Description/Activity (1) Comment Accepted by
(1)

Is the mix design been approved by A/E Engineering?

35MPa and 17Mpa type concrete is used at site for 2
10.1 1 different locations. (4 different mix design available).
MFQ26909-YGTG-D-4-0004 5 Aug 2017 approval letter.

Is work being performed in accordance with the Drawings and Specifications? site controls are in place 4/150 trucks rejected before
10.2 1
going further stages.
Are Proctors being used for soil used for fill? Troxler devices are calibrated however there is no
10.3 1 certificate in place. Troxler devices are not shown in
calibration log
Does the foundation bearing areas meet the correct density and/or RFI-C-375 & 382 selected as random example. Both
compaction? density measurement not meeting 95%. RFI-C-419
10.4 1 issued to cover 382 however no document trail
available for 375. which is GNAC foundation
compaction test for GTG2
Any contamination releases controlled and do not affect the soil? MS does not have any reference for contamination, At
10.5 1
site it is not followed.
Are pile chart with blow counts being filled out where applicable?
10.6 1

Is there a qualified Piling Procedure?

10.7 1

Are form inspections and concrete tests being performed on auger piles?
10.8 1

Is a qualified Testing Laboratory being used and are they on site during
10.9 pours? 1 Fugro-Suhaimi is 3rd party company for civil tests

Has the Concrete Batch Plant been inspected (Driver Orientation)?

initial approval inspection completed for GSI and
Suadi ready mix back 2017. however there is no
10.10 1
routine inspection for any them to verify batching
plant been calibrated and working as required.

Rebar Supplier and Fabricator qualified? Al-Fazan Building Material Company is rebar supplier
10.11 1 and it is approved 14th of May 2017 MFQ-26909-YGTG-
G-6-0199
Does the rebar meet the A/E specifications for the job?
Material develivery inspection performed for each
10.12 1 rebar delivery ticket. As an example MRFYNB-RH-GEN-
MAT-C-186 reviwed and found acceptable

Is rebar being installed in accordance with the A/E drawings (overlaps and Pre-pouring renar inspection is performed for installed
staggers)? rebars. As an example. RFI-C-3396 is performed rebar
10.13 1
inspection for exhaust frame blow foundation east and
west side at unit 7
Do the forms meet the A/E Specification?
10.14 1
 Are forms being installed in accordance with the Civil, Electrical, Mechanical
10.15 and piping drawings? 1 pre-pouring inspection covers formwork activities.

Are forms being inspected and documented prior to concrete placement?

10.16 1 pre-pouring inspection covers formwork activities.

Are truck tickets being review for the right mix design, dispatch time, water Delivery ticket 1438 selected as example, site
10.17 etc.? 1 inspection performed however there is no master list
to track values
Is control of storage of compression cylinders adequate?
10.18 1 Cylinders are stored at Fugro facilities.

Is there a cylinder break log and are the results current?

10.19 1 there is no break log available for this project

Are the same records and emphasis placed on grouting as on concrete?

10.20 1 there is no break log available for this project

Are imbeds measured for placement accuracy and tested for stability?
10.21 1 pre-pouring inspection covers imbeds

(Underground Piping) Are welding procedures (WPS) adequate?

10.22 1

(Underground Piping) Are welder/welding operator performance records

10.23 (WPQR) adequate? 1

(Underground Piping) Are Welder’s qualified to the process, which they are
10.24 welding to? 1

(Underground Piping) Is the welder/welder operator continuity log up to date?

10.25 1

(Underground Piping) Are weld records being documented in accordance with

10.26 the Quality Manual and the applicable code? 1

(Underground Piping) Are hold points being identified for inspection?

10.27 1

(Underground Piping) Are welds being identified with the weld number and
10.28 welder’s ID in accordance with the applicable code? 1

(Underground Piping) Are welding inspectors qualified to perform the

10.29 necessary inspections? 1

(Underground Piping) Is weld material being controlled as the site is clear of

10.30 rods and wire? 1

(Underground Piping) Are all piping spools being inspected for cleanliness?
10.31 1

(Underground Piping) Do all piping spools have end caps prior to being fit up?
10.32 1

(Underground Piping) Is piping being installed in accordance with the

10.33 drawings and specifications? 1

(Underground Piping) Are welds being inspected in accordance with the

10.34 Specifications and applicable Code? 1

(Underground Piping) Are piping and finished welds being wrapped and
10.35 coated per the A/E specifications? 1

(Underground Piping) Are piping and finished welds being spark (Jeep) tested
10.36 and documented? 1

(Underground Piping) Is the backfill being installed with proper material, lifts
10.37 and compaction? 1

(Underground Piping) Are hydrostatic tests being performed with calibrated

10.38 gages and documented? 1

Acc
Needs to
Acc With N/A
Improve
Comment

Totals 11 6 1 20
 This Section Audited (Y=Yes, N=No) Y To Audit Summary

Total Section Observations (C+D+E) = 7 Total Deficiencies = 1

11.0 Quality Program - Electrical

Section Score = 85.71%
A B C D E F G H I J
Acc Needs to Acc N/A Comment / Corrective Action / Target Closure Issue Corrected, Date Closed
YES (1) Improve With (1) Responsible Person For Corrective Action Date Inspected & Accepted
No. Description/Activity (1) Comment by
(1)
Is an electrical equipment and cable index prepared?
11.1 1 GE preparing Cable index

Are all cables identified for interconnecting and the required testing?
11.2 1 at this stage of the project, there is no cable pulling.

Is there a cable-landing chart available?

11.3 1 no work at the moment at site.

Are right crucibles for cad welding being used properly during installation?
11.4 1 Furseweld Catalog is being followed. In the catalog it is described.

Are personnel performing cad weld qualified? 2 technicians performing cad welding, they are experienced however there
11.5 1
is no track of profecieny
Is there a procedure for inspection of grounding and cad welds to ensure
11.6 continuity? 1 no procedure available,

Are there provisions for assuring cable will not be damaged during the pulling Z-2-0050 Cable pulling procedure contains prov isions such as using rollers
11.7 process? 1
or lubricant in conduits.
Is there a procedure for pulling cable and does it include tensioner ? Z-2-0050 Cable pulling procedure available.tensioner not used in this
11.8 1
project.
Does the cable pull procedure include the tension radius requirements for the
11.9 size cable being polled? 1 Tensioners are not used.

Are non-terminated cable ends being wrapped for protection in accordance

11.10 with the National Electrical Code or that stated in the specifications? 1 no work at the moment at site.

Are trays, raceways and conduit being installed per the drawings and A/E
11.11 Specifications? 1

Is conduit being cleaned out with the right size auger?

11.12 1 no cable pulling

Are static check outs (rotation, meggar) being performed?

11.13 1 Drum megger tests are being performed with RFI

Are pre operational checks being performed and documented?

11.14 1

Is Cathodic Protection being installed per the drawings and Specifications?

11.15 1

Is the right level of cable being installed in cable vaults and trenches?
11.16 1 no cable pulling

Are explosive proof connections being installed in asreas stated in the

11.17 specifications and on the drawings? 1 no exproof connections in scope of work

Acc
Needs to
Acc With N/A
Improve
Comment
Totals 5 1 1 10